Engine 2.0 103 KW Tdi PD, 2.0 100 KW Tdi PD

Service
Workshop Manual
OCTAVIA II 2004
Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD
Edition 02.04
Engine code
BKD AZV
Service Department. Technical Information
Printed in Czech Republic S00.5709.00.20
Service
The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.
Printed in Czech Republic S00.5709.00.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD
List of Supplements to Workshop Manual
OCTAVIA II 2004
Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD
Edition 02.04
Supplement 1
Edition 02.04 01.05
Subject Basic Edition Supplement to engines with the engine codes AZV
Article Number S00.5709.00.20 S00.5709.01.20
Edition 01.05 S00.5709.01.20
List of Supplements
List of Supplements
Edition 01.05 S00.5709.01.20
Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1 - Engine number ......................................................................................... 00-1 - Engine characteristics ................................................................................ 00-1 page page page 1 1 1
01 Self-diagnosis
Self diagnosis, safety measures, cleanliness regulations and directions ................ 01-1 - Supplementary instructions and assembly work on vehicles with an air conditioning system ................................................................................................... 01-1 - Safety precautions when working on the fuel supply system ................................... 01-1 - Regulations concerning cleanliness when working on the fuel supply/fuel injection system 01-1 - Regulations concerning cleanliness when working on the exhaust gas turbocharger ...... 01-1 page page page page page 1 1 1 2 2
10 Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 - Removing ............................................................................................... 10-1 - Securing the engine to the assembly stand ....................................................... 10-1 - Installing ................................................................................................ 10-1 - Adjust assembly bracket ............................................................................. 10-1 - Assembly bracket ...................................................................................... 10-1 page page page page page page 1 1 4 5 8 8
13 Crankgear
Disassembling and assembling engine ........................................................... 13-1 - Removing and installing V-ribbed belt .............................................................. 13-1 - Removing and installing timing belt ................................................................. 13-1 Removing and installing sealing flanges and flywheel ........................................ 13-2 - Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-2 - Removing and installing the front sealing flange ................................................. 13-2 - Replace rear sealing flange .......................................................................... 13-2 - Removing and installing the two-mass flywheel .................................................. 13-2 - Replace needle bearing for crankshaft ............................................................ 13-2 Crankshaft, Piston and Conrod ..................................................................... 13-3 - Removing and installing crankshaft ................................................................ 13-3 - Disassembling and assembling piston and conrod .............................................. 13-3 - Checking piston projection in TDC .................................................................. 13-3 page page page page page page page 1 1 4 1 2 4 5
page 13 page 14 page page page page 1 1 2 4
15 Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 - Summary of components ............................................................................. 15-1 - removing and installing cylinder head cover ...................................................... 15-1 - Removing and installing cylinder head ............................................................. 15-1 - Removing ............................................................................................... 15-1 - Installing ................................................................................................ 15-1 - Testing the compression ............................................................................. 15-1 Repairing Valve Gear .................................................................................. 15-2 - Checking the axial play of the camshafts .......................................................... 15-2 - Replacing camshaft gasket rings ................................................................... 15-2 page page page page page page page page page 1 2 3 5 6 9 1 2 3
page 12
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Table of Contents
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD - Removing and installing camshafts ................................................................ 15-2 - Removing and installing valve lever ................................................................ 15-2 - Check hydraulic supporting elements ............................................................. 15-2 - Replacing valve stem seals .......................................................................... 15-2 - Valve dimensions ...................................................................................... 15-2 - Inspect valve guides .................................................................................. 15-2 page page page 4 8 9
page 10 page 11 page 12
17 Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 - Disassembling and assembling oil filter holder ................................................... 17-1 - Removing and installing oil pan ..................................................................... 17-1 - Removing and installing oil pump ................................................................... 17-1 - Testing oil pressure and oil pressure switch ...................................................... 17-1 page page page page page 1 3 4 6 6
19 Cooling
Removing and installing parts of the cooling system ......................................... 19-1 - Parts of the cooling system fitted to body ......................................................... 19-1 - Parts of cooling system engine side ................................................................ 19-1 - Connection diagram for coolant hoses ............................................................. 19-1 - Draining and filling up coolant ....................................................................... 19-1 - Removing and installing coolant pump ............................................................ 19-1 - Removing and installing coolant regulator ........................................................ 19-1 - Removing and installing radiator .................................................................... 19-1 - Removing and installing radiator fan -V7- and -V177- .......................................... 19-1 - Checking the coolant system for tightness ........................................................ 19-1 page page page page page page page 1 2 3 5 5 8 8
page 10 page 11 page 12
20 Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 - Fuel tank with attached parts ........................................................................ 20-1 - Removing and installing fuel filter ................................................................... 20-1 - Removing and installing fuel cooler ................................................................ 20-1 - Removing and installing the fuel tank .............................................................. 20-1 - Check the fuel delivery unit .......................................................................... 20-1 - Removing and installing the fuel delivery unit .................................................... 20-1 - Removing and installing the fuel gauge sender -G- .............................................. 20-1 - Removing and installing the tandem pump ........................................................ 20-1 - Inspecting a tandem pump ........................................................................... 20-1 Accelerator control .................................................................................... 20-2 - Accelerator pedal module - Summary of components ........................................... 20-2 - Removing and installing accelerator pedal module .............................................. 20-2 page page page page page page page page page page page page 1 1 3 3 4 5 7 8 9 1 1 1
page 10
21 Turbocharging
Charge-air system with exhaust turbocharger - Part 1 ........................................ 21-1 - Connection diagram for vacuum hoses ............................................................ 21-1 - Connection diagram for valve block ................................................................ 21-1 - Inspect vacuum setting element and tension rods for charge pressure control ............. 21-1 Charge-air system with exhaust turbocharger - Part 2 ........................................ 21-2 - Removing and installing turbocharger ............................................................. 21-2 - Removing and installing parts of the charge air cooling ......................................... 21-2 page page page page page page page 1 1 2 2 1 1 4
II
Table of Contents
Edition 01.05 S00.5709.01.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD - Removing and installing charge-air cooler ........................................................ 21-2 - Removing and installing air filter .................................................................... 21-2 page page 5 7
23 Fuel Formation, Injection

Repairing a diesel direct fuel injection system .................................................. 23-1 - Safety measures ....................................................................................... 23-1 - Overview of fitting locations .......................................................................... 23-1 - Overview of intake manifold ......................................................................... 23-1 - Repairing the unit injectors ........................................................................... 23-1 - Removing and installing the unit injectors ......................................................... 23-1 - Replace O-rings for unit injectors ................................................................... 23-1 Engine control unit ..................................................................................... 23-2 - Removing and installing engine control unit ....................................................... 23-2 page page page page page page page page page 1 1 2 3 4 5 9 1 1
26 Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Summary of components ............................................................................. 26-1 - Replacing middle or rear silencer ................................................................... 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Exhaust gas recirculation system .................................................................. 26-2 - Removing and installing parts of the exhaust gas recirculation system ...................... 26-2 - Connection diagram for exhaust gas recirculation ............................................... 26-2 - Connection diagram for valve block ................................................................ 26-2 - Test mechanical exhaust gas recirculation valve ................................................. 26-2 - Cool the exhaust gas recirculation .................................................................. 26-2 - Check exhaust gas recirculation changeover ..................................................... 26-2 - Removing and installing radiator for exhaust gas recirculation ................................ 26-2 page page page page page page page page page page page page page 1 2 2 3 4 1 2 3 3 4 4 4 5
28 Glow Plug System

Preheating ............................................................................................... 28-1 - Removing and installing glow plugs ................................................................ 28-1 page page 1 1
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Table of Contents
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IV
Table of Contents
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00
00 Technical Data
00-1 Technical Data
Engine number
The engine number (engine identification characters and serial number) is located in the front at the engine/ gearbox joint -arrow-. In addition, a sticker with the engine identification characters and serial number is affixed to the timing belt guard. The engine identification characters are also indicated on the vehicle data stickers.
Engine characteristics
Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression CN min. Firing order Catalytic converter Exhaust gas recirculation with radiator Turbocharging Charge air cooler l BKD 05.04 EU4 1,968 AZV 10.04 EU4 1,968 100/4000 320/1750 2500 81,0 95,5 4 18,5 : 1 49 1-3-4-2 yes yes yes yes
kW at 103/4000 rpm Nm at 320/1750 rpm 2500 mm mm 81,0 95,5 4 18,5 : 1 49 1-3-4-2 yes yes yes yes
Number of valves per cylinder
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Technical Data
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Technical Data
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01
01 Self-diagnosis
01-1 Self diagnosis, safety measures, cleanliness regulations and directions
Supplementary instructions and assembly work on vehicles with an air conditioning system
WARNING! Do not open the refrigerant circuit of the air conditioning system. Note In order to avoid damage to the condenser as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent. Steps which should be taken in order to remove and install the engine without opening the refrigerant circuit.
Unscrew the holding clamp(s) on the refrigerent lines Remove the V-ribbed belt Chapter 13-1. Remove the air-conditioning compressor Chapter
13-1.
Mount the air conditioning compressor and the condenser in such a way that the refrigerent lines/hoses are not under tension.
Safety precautions when working on the fuel supply system

WARNING! Please observe the following when undertaking all assembly work, particularly in the engine compartment, due to its cramped construction.
Lay lines of all kinds (e.g. for fuel, hydraulic flu-
id, cooling fluid and refrigerent, 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. When removing and installing the fuel gauge sender from a full or partly filled fuel tank, pay attention to the following:
The extraction hose of an exhaust extraction system
which is switched on, must be positioned close to the assembly opening of the fuel tank in order to extract
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Self diagnosis, safety measures, cleanliness regulations and directions
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the released fuel gases, even before the work is commenced. If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m3/h must be used.
Avoid skin contact with fuel! Wear fuel-resistant
gloves!
Regulations concerning cleanliness when working on the fuel supply/fuel injection system
Carefully observe the following 6 rules for cleanliness when working on the fuel supply/injection system:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. on a shelf or in a tool box).
When the system is open: Avoid using compressed
air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately. Replace immediately any hoses which have suffered damage.
Regulations concerning cleanliness when working on the exhaust gas turbocharger

Carefully observe the following 5 rules for cleanliness when working on the exhaust turbocharger:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. on a shelf or in a tool box).
When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
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Self diagnosis, safety measures, cleanliness regulations and directions
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10 Removing and Installing Engine

10-1 Removing and Installing Engine
Special tools, test and measuring equipment and auxiliary items required
Catch pan (e.g. -V.A.G 1306-) Engine/gearbox jack (e.g. -V.A.G 1383 A -) Engine mount -T10012 Workshop crane (e.g. -V.A.G 1202 A-) Double ladder (e. g. -VAS 5085-) Hose clamp -MP 7-602 Pliers for spring strap clips
Removing
Note
The engine is removed downwards together with the
gearbox.
All cable straps that have been loosened or cut open
when the engine was removed must be fitted again in the same location when the engine is installed again.
Collect drained coolant in a clean container for proper
disposal or reuse.
Pull oil dipstick -1- out of oil dipstick guide. Lift the engine cover at the sides -arrows 1- and pull
out towards the front -arrow 2-.
Push the oil dipstick back into the oil dipstick guide.
WARNING! Observe measures when disconnecting the battery Electrical System; Rep. Gr. 27.
Disconnect the battery-earth strap with the ignition off

Electrical System; Rep. Gr. 27.
Remove cover and intermediate wall of the plenum

chamber Body Work; Rep. Gr. 66. Chapter 21-2. Rep. Gr. 27.
Remove air filter and air guide with air mass meter Remove battery and battery tray Electrical System; Remove both front wheels Chassis; Rep. Gr. 44. Remove the middle sound dampening system
Body Work; Rep. Gr. 50.
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Removing and Installing Engine
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WARNING! Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully.
Drain coolant Chapter 19-1.

WARNING!
On vehicles with engine with unit injectors, the
temperature of the fuel lines or of the fuel can be up to 100 C in an extreme case. Let the fuel cool down before opening the lines, as otherwise there is a high risk of burning.
Wear protective gloves. Wear safety glasses.
Detach coolant hose, fuel-intake hose -2- and fuel-return hose -1- from pipes at cylinder head.
Detach fuel filter with its connected hoses upwards

from the bracket -arrow- and lay to the side. Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.
Remove the V-ribbed belt Chapter 13-1. Remove alternator Electrical System; Rep. Gr. 27.
On vehicles with air conditioning:
WARNING! Refrigerant circuit of the air conditioning system must not be opened. Note In order to avoid damage to the AC condenser as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent.
Removing AC compressor and holder for auxiliary

units Chapter 13-1.
Tie up removed AC compressor with connected refrigerant hoses to the body. Continued for all vehicles:
Remove charge air hose and charge-air pipe between

engine and charge air cooler Chapter 21-2.
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WARNING! Shut off the openings of the charge air cooler, e.g. with a clean foam piece, so that no coolant can penetrate.
Remove fan shroud and radiator Chapter 19-1. Remove the support of the allocation for the oil level/
temperature sender from the assembly carrier.
Remove the drive shaft on the right and unscrew the

drive shaft on the left from the gearbox flange Chassis; Rep. Gr. 40. Note The decoupling element in the front part of the exhaust pipe should not be bent by more than 10 - danger of damaging it.
Remove the exhaust pipe from the exhaust turbocharger Chap. 26-1.
Unlatch the fuse and and unplug the front connector

from the engine control unit Chapter. 23-2, open the cable guides -arrows-, remove the engine wiring harness and place down to the side. and lay aside the relevant lines. Note To release the plug of the engine speed sender, press the plug together with a screwdriver and at the same time raise the release button with a thin wire hook.
Release all remaining plugs at engine and gearbox
Unclamp all connecting, cooling fluid, vacuum and air

guide hoses from the engine.
Remove the gearshift mechanism from the gearbox

Gearbox 02Q or 02E; Rep. Gr. 34. clamp -MP 7-602-.
Clamp off hydraulic hose to slave cylinder with hose Pull the pressure line -1- out of the hose coupling; to
do so raise the fuse of the hose coupling -arrow-.
WARNING! After separating the hydraulic line, do not operate the clutch pedal.
Release screws -1...3- and remove pendulum support.
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Screw engine mount -T10012- to the cylinder block

with fixing nut and bolt. Tighten bolt M10x25/8.8 to a tightening torque of approx. 40 Nm. Note The pins must be screwed onto the engine mount -T10012-, as shown. The threaded bores must be positioned on the gearbox side.
Insert engine/gearbox jack (e.g. -V.A.G 1383 A -) at

the engine mount -T10012- and slightly raise. Note Use double ladder (e. g. -VAS 5085-) to release the screws for the engine/gearbox mounting.
Successively release screws for engine mounting -arrows- ...
... and gearbox mounting -arrows-.

Note
Check whether all hose and line connections between
engine, gearbox and body are released.

When lowering carefully guide the engine with the
gearbox, in order to avoid damage.
Carefully lower engine with gearbox. Remove the gearbox from the engine Manual
Gearbox 02Q; Rep. Gr. 34, Automatic Gearbox 02E; Rep. Gr. 34.
Securing the engine to the assembly stand

Lifting device -MP 9-201 Engine mount -MP 1-202 Extension -MP 1-202/10 Bushing -T30010-
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Assembly stand -MP 9-101 Workshop crane (e.g. -V.A.G 1202A-)
10
Procedure
Separate engine from gearbox.
MP 9-201
WARNING! Use securing pins on the hooks and rig pins to prevent release.
Attach lifting device -MP 9-201- at engine and at workshop crane (e.g. -V.A.G 1202A-). On the belt pulley side: 2. Hole of the extension in Position 1 On the flywheel side: 4. Hole of the extension in Position 8
12 3 4
7 5 6
Lift off engine with installed engine mount -T10012with workshop crane from engine/gearbox jack.
S10-0175
Remove engine mount -T10012-. For carrying out assembly work, attach the engine
with the engine mount -MP 1-202-, the extension -MP 1-202/10- and the sleeves -T30010 - to the assembly stand -MP 9-101-. (The figure shows the 1.9 ltr./47kW SDI Engine; the fixing system is identical).
MP 1-202
Installing
Procedure
T30010
Mount engine onto engine mount -T10012-.

Installation is performed in the reverse order. Pay attention to the following points: Note
When undertaking assembly replace self-locking nuts
S10-0123
and screws which have been tightened to a turning angle.

Always replace gasket rings and seals. All cable straps should be fitted on again in the same
place when installing.

Secure all hose connections with corresponding hose
clips. Engine with coupling for the manual gearbox 02Q Note
Clean the serration on the drive shaft and if the clutch
discs have been used clean the hub serration, remove corrosion and only apply a very thin layer of grease
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-G 000 100-. Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Always remove all excess grease.
After installing the coupling, check the centering of the
clutch disc Manual Gearbox 02Q; Rep. Gr. 30. release bearing if worn Manual Gearbox 02Q; Rep. Gr. 30.
Check the clutch release bearing for wear. Replace
Engine without coupling for the automatic gearbox 02E Note

Check needle bearing for drive shaft pin in the crank-
shaft. Replace bearing if worn Chapter 13-2.
Lubricate needle bearing and drive shaft pin with a
thin layer of grease -G 052 133 A2-. Do not grease the serration of the drive shaft. Continued for all engines:
Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; insert if necessary.
Ensure that the intermediate plate has been inserted

on the sealing flange and is pushed onto the dowel sleeves -arrows-.
Screw on gearbox to engine Gearbox 02Q or 02E;

Rep. Gr. 34.
Insert engine with gearbox into the body. First screw in successively screws for bearing at engine -arrows- ...
... and at gearbox -arrows- by hand. Use new screws

for attaching. Note Tighten screws to a final torque only when adjusting the engine and gearbox mounting.
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Remove engine mount -T10012- from engine. Tighten pendulum support with screws -1...3- at gearbox and at assembly carrier. Use new screws for attaching.
Replace the O-ring -1- on the right rigid shaft and

grease the serration -2- with universal grease.
Install the right drive shaft and screw the left drive
shaft onto the gearbox flange Chassis; Rep. Gr. 40. Chapter 26-1.
Install exhaust system and align free of stress Connect hydraulic line to cylinder of hydraulic clutch Attach shift mechanism to gearbox and adjust
Gearbox 02Q or 02E; Rep. Gr. 34. control and bleed clutch hydraulic Manual Gearbox 02Q; Rep. Gr. 30.
Install fan shroud and radiator Chapter 19-1.

On vehicles with air conditioning:
Installing AC compressor and holder for auxiliary units

Chapter 13-1. Continued for all vehicles
Install alternator Electrical System; Rep. Gr. 27. Install the V-ribbed belt Chapter 13-1. Connect all connecting, fuel, cooling fluid, oil, vacuum
and suction hoses to the engine. When installing the air guide pipe with push-fit coupling ensure that the locking clip -arrow- interlocks behind the retaining lug -A-.
Adjust assembly bracket 10-1 page 8. Connect electrical connections and attach cables Install battery Electrical System; Rep. Gr. 27 Install intermediate wall and cover of the plenum
chamber Body Work; Rep. Gr. 66.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Install wiper arms Electrical System; Rep. Gr. 92. Install the middle sound dampening system Body
Work; Rep. Gr. 50.
Top up coolant Chapter 19-1.

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Inspect oil level Inspection and Maintenance.

Tightening torques
Component Screws and nuts M6 M7 M8 M10 M12 Engine/gearbox connecting screws Gearbox 02Q or 02E; Rep. Gr. 34 Nm 9 13 20 40 70
Adjust assembly bracket

Supporting device -T30099 Hook of -MP 9-200-
The following distances must be achieved:
Between engine support and frame side rail on right

there must be a distance -a- = 13.5 mm.
The cast iron edge on the engine support -2- must be

parallel to the supporting arm -1- (dimension -x- = dimension -x-). Note The distance -a- = 13.5 mm can be checked e.g. with suitable round bars.
Assembly bracket
Tightening torques Fig. 1: Engine assembly bracket
A - 20 Nm + 90 (1/4 turn) - replace B - 40 Nm + 90 (1/4 turn) - replace C - 60 Nm + 90 (1/4 turn) - replace Fig. 2: Gearbox assembly bracket
1 - 40 Nm + 90 (1/4 turn) - replace 2 - 60 Nm + 90 (1/4 turn) - replace
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OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD Fig. 3: Hinged bracket
10
A - 40 Nm + 90 (1/4 turn) - replace B - 100 Nm + 90 (1/4 turn) - replace
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13 Crankgear
13-1 Disassembling and assembling engine
Removing and installing V-ribbed belt

1 - Belt pulley with vibration damper can be installed only in one position 2 - Cap for belt pulley 3 - 10 Nm + torque a further 90 (1/4 turn) 4 replace Tensioning device for ribbed V-belt swivel tensioning device for V-ribbed belt with open-end wrench to slacken the Vribbed belt can be interlocked with locating bolts -T10060- or -T10060A-, or Allen key. 23 Nm 40 Nm + torque a further 90 (1/4 turn) replace Large guide pulley for toothed belt Bracket for auxiliary units order of tightening Fig. 1 in 13-1 page 2 Bushing AC generator removing and installing Electrical System; Rep. Gr. 27 to facilitate positioning, drive the threaded bushings of the retaining screws at the generator slightly backwards 45 Nm insert using locking agent -D 000 600 A2 observe the order of tightening up Fig. 1 in 13-1 page 2 Bushing 2 pieces must be inserted into the support item 8 25 Nm AC compressor V-ribbed belt mark the direction of rotation with chalk or a felt-tip pen before removing check for wear do not kink removing 13-1 page 2
56-
78-
910 -
11 -
12 -
13 14 15 -
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Disassembling and assembling engine
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installing 13-1 page 3
Fig. 1:
Bolts at bracket for auxiliary units - tightening sequence
Removing
Removing engine cover Chapter 10-1. Unlatch fuses, remove fuel filter with its connected
lines upwards from bracket -arrow- and lay to the side. Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.
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Swing the the tensioning device in -the direction of the

arrow- detension the V-ribbed belt.
Hold the tensioning device and remove the slackened

V-ribbed belt.
Installing
Installation is performed in the reverse order. Pay attention to the following points: Note Before fitting the ribbed V-belt make sure that all assemblies (generator and AC compressor) are securely mounted.
First position the ribbed V-belt on the belt pulleys of

the crankshaft and AC compressor and on the belt pulley of the generator last; then release the tensioning device.
Check correct positioning of the ribbed V-belt on the

belt pulleys.
Start engine and check ribbed V-belt run.
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Removing and installing timing belt

Summary of components - part 1
1 - Cover for belt pulley 2 - 10 Nm + torque a further 90 (1/4 turn) replace 3 - V-ribbed belt pulley with vibration damper can be installed only in one position 4 - 10 Nm insert using locking agent -D 000 600 A25 - 40 Nm + torque a further 90 (1/4 turn) replace observe the order of tightening up Fig. 2 in 13-1 page 4 6 - Engine support bracket 7 - Top toothed belt guard when installing, correctly insert into the middle toothed belt guard 8 - Middle toothed belt guard to remove, remove top toothed belt guard and unscrew tensioning device for ribbed V-belt. 9 - Bottom toothed belt guard
Fig. 2:
Tightening order for engine support
Screw in screws -13- by hand first. Tighten screws -13- and 40 + torque a further 90 (1/
4
turn).
Summary of components - part 2

Note Mark the direction of rotation with chalk or a felt-tip pen before removing the toothed belt. Reversing the rotation direction of an already used belt may destroy it.
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OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD 1 - 120 Nm + torque a further 90 (1/4 turn) replace do not lubricate to release and tighten use counterholder -T30004 - or counterholder -MP 1-3102 - 20 Nm 3 - Small guide pulley 4 - 20 Nm + torque a further + 45 (1/8 turn) 5 - Tensioning pulley The eccentric of the new version has an additional hole for 6 mm hexagon socket wrench Fig. 3 in 13-1 page 6 6 - Timing belt mark the direction of rotation with chalk or a felt-tip pen before removing check for wear do not kink removing 13-1 page 6 install (set the timing) 13-1 page 9 7 - Camshaft sprocket for exhaust camshaft Check fitting position 8 - Camshaft sprocket for inlet camshaft Check fitting position 9 - 100 Nm to release and tighten use counterholder -T10051 10 - Hub for exhaust camshaft to remove use extractor -T1005211 - Hub for inlet camshaft with rotor for hall sender -G40 to remove use extractor -T1005212 - Rear timing belt guard 13 - Feed-through replace if damaged 14 - 10 Nm insert using locking agent -D 000 600 A215 - O-ring replace 16 - Coolant pump removing and installing Chapter 19-1 17 - 13 Nm 18 - Toothed belt gear for toothed belt on the crankshaft there must not be any oil present on contact surface between timing belt sprocket and the crankshaft can be installed only in one position
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19 - Large guide pulley 20 - 40 Nm + torque a further 90 (1/4 turn) replace
Fig. 3:
Tensioning pulley
Additional hole in the eccentric of the tensioning pulley for 6 hexagon socket wrench -arrow-. Note The tensioning pulley of the new version can be adjusted with the special two-hole nut turner , e. g. -T10020-, or using a commercial 6 mm hexagon socket wrench.
Removing
Supporting device -T30099 Hook of -MP 9-200 Rig pin -3359- or -MP 1-301 - (2x) Pliers for spring strap clips Two-hole nut turner -T10020 Crankshaft arrester -T10050- or -T10100 Locating bolts -T10060- or -T10060A Counterholder -T10172- with bolts -T10172/4 Torque wrench
Remove V-ribbed belt 13-1 page 1. Remove the right sound dampening system Body
Work; Rep. Gr. 50.
Unscrew air guide pipe and remove V-ribbed belt pulley with vibration damper.
WARNING!
On vehicles with engine with unit injectors, the
temperature of the fuel lines or of the fuel can be up to 100 C in an extreme case. Let the fuel cool down before opening the lines, as otherwise there is a high risk of burning.
Wear protective gloves. Wear safety glasses.
Disconnect the fuel-intake hoses and the fuel-return

hoses from the fuel pipes on the body as well as at the engine and pull fuel filter with its attached hoses to the top out of the bracket -arrow-.
13-1 page 6
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13
Unbolt bracket -3- for fuel filter. Unscrew bolt on filler neck -2- of windscreen washer
reservoir.
Unscrew the coolant expansion bottle -1- and lay with

connected lines to one side.
Remove top toothed belt guard, to do so release retaining clips -arrows-.
Remove ribbed V-belt tensioning device. Remove middle and bottom timing belt guard. Position the supporting device -T30099- on the body,
suspend the engine on the right lifting eye with hook of -MP 9-200- and preload via the spindle, however do not lift.
Release screws -1- and -2- and remove connecting

stud.
Release screws -3...6- and remove engine console.
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13-1 page 7
13
support. Note
Release screws -1...3- for engine support and remove
To slacken the bolts for the engine support, raise engine slightly via spindle of supporting device -T30099-.
WARNING! Turn the engine only with the crankshaft in the running direction of the engine (from the side of the crankshaft toothed belt sprocket clockwise).
Rotate crankshaft to TDC of cylinder 1.

Note In the TDC position, both tooth segments of the camshaft sprockets -arrows- point upwards.
Lock hubs with locking pins -3359-. Depending on the version, lock the crankshaft timing
belt sprocket with the crankshaft arrester -T10050- or crankshaft arrester -T10100-. Version of the crankshaft timing belt sprocket: A = original version of timing belt sprocket with circular tooth flank, rectangular marking for TDC at tooth in 12 o'clock - use crankshaft arrester -T10050B = new version of timing belt sprocket with eliptical tooth flank, triangular marking for TDC at tooth opening 1 o'clock - use crankshaft arrester -T10100Note
The markings on the timing belt gear and on the
crankshaft arrester must be in line with each other -arrow-. The stud on the crankshaft arrester must engage into the hole in the sealing flange.
The crankshaft arrester can only be fitted onto the tim-
ing belt gear from the front side of the serration.
13-1 page 8
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13
Mark the direction of rotation of the timing belt with

chalk or a felt-tip pen.
Loosen bolts of camshaft sprocket -arrows- by about

2 turns.
Counterhold eccentric of tensioning pulley with twohole nut turner (e.g. -T10020-) and loosen the fixing nut -1-. After this, release the tensioning pulley by turning the eccentric anti-clockwise, until spring tension releases. Secure the loose tensioning pulley by tightening the fixing nut by hand.
Remove small toothed belt guide pulley item 3 in

13-1 page 5.
First of all take toothed belt off toothed belt sprocket of

coolant pump and then from the other belt pulleys.
Installing (set the timing)
Camshafts are interlocked with locking pins -3359-. Crankshaft is is locked with crankshaft arrester
-T10050- or crankshaft arrester -T10100-.
A13-0675
Interlock tensioning pulley in released position with

fixing nut. Note
Always perform adjusting work on the timing belt only
on a cold engine.
When rotating the camshafts, the crankshaft must not
be positioned at TDC for any one piston. Risk of damaging valves and pistons.
Pay attention to the correct fitting of the tensioning

pulley in the opening in the rear timing belt guard -arrow-.
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13-1 page 9
13
Slightly screw in screws -arrows-.
It must still be possible to turn the camshaft sprockets

on the hubs, however they must not hang loose.
Turn camshaft sprockets clockwise in the elongated

holes as far as the stop.
Fit toothed belt onto crankshaft toothed belt sprocket,

tensioning pulley, camshaft sprockets, large guide pulley and, last of all, onto the toothed belt sprocket of the coolant pump.
Install small toothed belt guide pulley item 3 in

13-1 page 5.
Loosen the fixing nut -1- of the tensioning pulley. Turn the eccentric of the tensioning pulley with twohole nut turner (e. g. -T10020-) clockwise in such a way until the pointer -2- stands in the centre of the base plate in the gap. Note Ensure that the fixing nut does not turn.
Hold the eccentric of the tensioning pulley in this position and tighten fixing nut of tensioning pulley to 20 Nm + torque a further 45 (1/8 turn). Note When tightening the fixing nut, the pointer turns -arrowmax. 5 mm to the right from the gap of the base plate. This position must not be corrected, because the toothed belt settles when running-in.
13-1 page 10
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13
Insert counterholder -T10172- with bolts -T10172/4as shown and press in -direction of arrow-.
Keep camshaft sprockets with counterholder

-T10172 - under tension and tighten screws -arrowsof both camshafts to 20 Nm + torque a further 45 (1/8 turn).
Remove locking pins -3359- and crankshaft arrester

-T10050- or crankshaft arrester -T10100 -. Test timing:
Turn crankshaft 2 turns in the direction of running of

the engine until the crankshaft is positioned shortly before TDC for cylinder 1.
Interlock during this motion the hub -A- in the direction

of running of the engine with locking pin -3359-.
Check whether:
the hub -B- can be interlocked with the locating pin
-3359-;
the crankshaft can be interlocked with the crankshaft
arrester -T10050 - or crankshaft arrester -T10100 The pointer of tensioning pulley stands in the centre or
max. 5 mm to the right from the gap of the base plate.
If the hub -B- cannot be arrested:
Loosen fixing bolts -2- of the camshaft timing gear for

inlet camshaft -B-.
Fit ring spanner onto the central screw of the inlet

camshaft.
Turn the hub until the locking pin -3359- can be inserted.
Tighten bolts -2- of camshaft sprocket for inlet camshaft -B- to 20 Nm and torque a further + 45 (1/8 turn).

-T10050- or crankshaft arrester -T10100 -.

the engine until the crankshaft is positioned in the TDC for cylinder 1.
Repeat timing test 13-1 page 11.

If the crankshaft cannot be arrested:
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13-1 page 11
13
and -B-.
Loosen bolts -1- and -2- of camshaft sprockets -A Rotate crankshaft in direction of rotation of engine until it can be arrested with the crankshaft arrester -T10050- or crankshaft arrester -T10100-. Note If the crankshaft can be turned behind the TDC for cylinder 1, turn crankshaft back slightly and once again set to the TDC for cylinder 1 by turning in direction of rotation of engine.
Insert counterholder -T10172- with bolts -T10172/4as shown and press in -direction of arrow-.
Keep camshaft sprockets with counterholder

-T10172 - under tension and tighten screws -1- und -2- of the camshaft sprockets -A- and -B- to 20 Nm + torque a further 45 1/8 turn).

-T10050- or crankshaft arrester -T10100 -.

the engine until the crankshaft is positioned in the TDC for cylinder 1.
Repeat timing test 13-1 page 11.

Proceed with installation: Further installation occurs in reverse order for removal, while paying attention to the following: Note
Replace gaskets. Secure all hose connections with corresponding hose
clips.
Install bottom and middle toothed belt guard. Screw on engine support Fig. 2 in 13-1 page 4, install and adjust engine mounting Chap. 10-1.
13-1 page 12
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13
Note The engine support must be tightened up firmly before further installation of the right engine mounting.
Install belt pulley and tensioning device for V-ribbed

belt.
Install the V-ribbed belt 13-1 page 1. Install top toothed belt guard. Install charge air pipes and charge air hoses Chap.
21-2.
Install the front right wheelhouse liner Body Work;

Rep. Gr. 66.
Install fuel filter and coolant expansion reservoir.
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13-1 page 13
13
13-1 page 14
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13
13-2
Removing and installing sealing flanges and flywheel
Note Repairing the clutch Manual Gearbox 02Q; Rep. Gr. 30. 1 - Gasket ring replace 13-2 page 2 Neither oil nor grease 2 - Front sealing flange must be positioned on dowel sleeves removing and installing 13-2 page 4 install with silicone sealant -D 176 404 A23 - Cylinder block with fitted crankshaft Replace needle bearing for crankshaft 13-2 page 14 4 - The two-mass flywheel removing and installing 13-2 page 13 Assembly is only possible in one position through offset holes. 5 - 60 Nm + torque a further 90 (1/4 turn) replace 6 - Intermediate plate must be positioned on dowel sleeves do not damage/bend during assembly work inserted on sealing flange Fig. 1 in 13-2 page 2 7 - 15 Nm replace 8 - Rear sealing flange Always replace complete with gasket ring and if possible with rotor of engine speed sender -G28 replace 13-2 page 5 9 - Engine speed sender -G2810 - 5 Nm
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13-2 page 1
13
Fig. 1: Installing intermediate plate
Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.
Replacing gasket ring for crankshaft -on the belt pulley sideSpecial tools, test and measuring equipment and auxiliary items required
Counterholder -T30004- or counterholder for timing
belt sprocket -MP 1-310 Gasket ring extractor -MP 1-226 Assembly device -T10053 Torque wrench
Removing
Engine installed. Remove the V-ribbed belt Chapter 13-1. Remove the timing belt Chapter 13-1. Remove crankshaft timing belt sprocket, to this end
lock the timing belt sprocket with counterholder or counterholder for timing belt sprocket.
T 30004
MP 1-310
S13-0166
Before inserting the gasket ring extractor, screw the

central bolt of the timing belt sprocket into the crankshaft by hand up to the stop.
13-2 page 2
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13
Turn inner part of gasket ring extractor -MP 1-226two turns (approx. 3 mm) out of the outer part and lock with knurled screw.
Oil the thread head of the gasket ring extractor, position and forcely screw into the gasket ring as far as possible.
Release knurled screw and turn the inner side against

the crankshaft until the gasket ring is pulled out.
Clamp gasket ring extractor into the vice and remove

gasket ring with pliers.
Clean the contact and sealing surface.

Installing
Note Do not oil the sealing lip and the outer surface of the gasket before the pressing in procedure.
MP 1-226
S13-0078
Remove oil residue on the crankshaft stub with a

clean cloth.
Insert guide bushing -T10053/1- on the crankshaft

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

Replace central screw for crankshaft toothed belt
gear.
Do not oil the central screw for the timing belt sprocket
crankshaft.
Install crankshaft timing belt sprocket, to this end lock

the timing belt sprocket with counterholder.
Install the timing belt (set the timing) Chapter 13-1. Install the V-ribbed belt Chapter 13-1.
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13-2 page 3
13
Removing and installing the front sealing flange

Counterholder -T30004- or counterholder for timing
belt sprocket -MP 1-310 Assembly device -T10053 Torque wrench Flat scraper Hand-held power drill with plastic brush insert Protective goggles Silicone sealant -D176 404 A2-
Removing
Engine installed. Remove the V-ribbed belt Chapter 13-1 Remove the timing belt Chapter 13-1 Remove crankshaft timing belt sprocket, to this end
lock the timing belt sprocket with counterholder or counterholder for timing belt sprocket.
T 30004
Drain engine oil Inspection and Maintenance. Removing oil pan Chapter 17-1. Unscrew the fixing screws of the front sealing flange
and remove sealing flange, if necessary release by applying slight blows with a rubber-headed hammer.
Installing
Installation is performed in the reverse order. Pay attention to the following points:
MP 1-310
Carefully remove the remaining sealant on the cylinder block.

S13-0166
WARNING! Wear safety glasses.
Remove the remaining sealant on the sealing flange

and on the oil pan using a device such as a rotating plastic brush.
Clean sealing surfaces, they must be free of oil and

grease. Note Pay attention to the 'use by date' on the silicone sealant.
13-2 page 4
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13
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
Apply silicone sealant bead -arrow- to the clean sealing surface of the upper part of the sealing flange, as shown.
Thickness of sealant bead -arrow-: 2 ... 3 mm.

Note
The sealant bead must not be thicker than 3 mm oth-
erwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.
The sealing flange must be installed within 5 minutes
after applying the silicone sealant.

When installing the sealing flange with the gasket ring
fitted place a guide sleeve -T10053/1- on the crankshaft journal.
Carefully push the sealing flange onto the dowel

sleeves at the cylinder block and tighten new fixing bolts by hand.
Tighten the screws of the sealing flange alternately

and crosswise.
Installing oil pan Chapter 17-1. Install crankshaft timing belt sprocket, to this end lock
the timing belt sprocket with counterholder or counterholder for timing belt sprocket.
Install the timing belt (set the timing) Chapter 13-1. Install the V-ribbed belt Chapter 13-1. Fill with engine oil and check the oil level Inspection
and Maintenance.
Replace rear sealing flange

Assembly device -T10134 Depth gauge Screw M6x35 (3x) Screw M7x35 (2x) Torque wrench
Removing
Gearbox removed. Remove the two-mass flywheel 13-2 page 13. Remove the intermediate plate from the dowel
sleeves and unhook from sealing flange -arrows-.
Position engine to TDC of cylinder 1 Chapter 13-1.
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13-2 page 5
13
Remove engine speed sender -G28- -position 1-. Removing oil pan Chapter 17-1. Release the fixing screws of the rear sealing flange.
Note Sealing flange and rotor are pressed together with three M6 x 35 mm screws from the crankshaft.
To this end screw 3 screws M6 x 35 alternately by

max. 1/2 turn into the sealing flange.
Remove gasket ring together with rotor.

Installing
Note
The sealing flange with PTFE gasket ring is provided
with sealing lip supporting ring. This supporting ring is intended as an assembly sleeve and must not be removed before installing.
Do not separate or turn the sealing flange and rotor af-
ter removing them from the spare part package.

The rotor is given its fitting location by fixing the as-
sembly device -T10134- to the positioning pin.

The sealing flange and gasket ring form one unit and
must be replaced together with the rotor.

The assembly device -T10134- is given its fitting loca-
tion to the crankshaft by means of a guide bolt, which is guided into a hole of the crankshaft. Assembly device -T10134ABCDEFGClamping surface Hexagon nut Assembly cup Positioning pin Allen screw Guide bolt for diesel engines (red handle) Guide bolt for petrol engines (black handle)
A - Mounting the sealing flange with gasket ring and rotor on the assembly device -T10134-:
Screw the hexagon nut -B- right up to the clamping

surface -A- of the threaded spindle.
13-2 page 6
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13
Grip assembly device assembly device -T10134- on

clamping surfaces -A- of the threaded spindle in a vice.
Push assembly cup -C- down so that it rests on the

hexagon nut -B- -arrowNote The inner part of the assembly device and assembly cup must be at the same level.
Remove the securing clip -arrow- from the new sealing flange. Note Do not remove or turn the rotor from the sealing flange.
The locating hole -A- on the rotor -C- must be flush

with the marking -B- on the sealing flange.
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13
level surface.
Lay the front side of the sealing flange on a clean and Press down sealing lips supporting ring -A- in -direction of the arrow-, until it rests on the level surface.
The top side of the rotor and the front side of the sealing flange must be flush -arrows-.
Lay the sealing flange with the front side on theassembly device -T10134- in such a way that the positioning pin -B- engages in the hole -A- of the rotor. Note Make sure the sealing flange lies flat on the assembly device.
13-2 page 8
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13
When tightening the three knurled screws -A- press

the sealing flange and sealing lip supporting ring -Bon the surface of the assembly device -T10134- in such a way that the positioning pin cannot slide out of the rotor hole. Note Make sure the rotor remains fixed in the assembly device while mounting the sealing flange.
B - Mounting the assembly device -T10134- with sealing flange on the crankshaft flange
The crankshaft flange must be free of grease and oil. The engine is at TDC for cylinder 1
Screw in hexagon nut -B- up to the end of the threaded spindle.
Press the threaded spindle of the assembly device

-T10134 - in -direction of the arrow- until the hexagon nut -B- rests on the assembly cup.
Align the flattened side of the assembly cup with the

cylinder block on the oil pan side.
Attach assembly device -T10134- to the crankshaft

flange, to this end screw in Allan screws -A- with approximately 5 thread turns onto the crankshaft flange.
Edition 01.05 S00.5709.01.20
13-2 page 9
13
into the cylinder block.
Screw 2 screws M7 x 35 -A- for guide of sealing flange
C - Screwing the assembly device -T10134- onto the crankshaft flange:
Push the assembly cup -A- by hand in the -direction of

the arrow- until the sealing lips supporting ring -Brests on the crankshaft flange -A-.
Push guide bolt for diesel engines (red handle) -Dinto the hole of the crankshaft. This gives the rotor its final fitting location. Note The guide bolt for petrol engines (black handle) -F- must not be fitted into the threaded hole of the crankshaft.
Tighten the 2 Allan screws of the assembly device by

hand.
Screw in hexagon nut -E- by hand onto the threaded

spindle until it rests against the assembly cup -C-. D - Pressing the rotor with assembly device - T10134onto the crankshaft flange
Tighten the hexagon nut of the assembly device

-T10134 - to 35 Nm. Note After tightening the hexagon nut to 35 mm there must still be a narrow air gap between the cylinder block and the sealing flange.
13-2 page 10
Edition 01.05 S00.5709.01.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD E - Inspecting the fitting position of the rotor on the crankshaft:
13
Screw in hexagon nut -E- up to the end of the threaded spindle.
Release 2 screws -A- from the cylinder block. Release the 3 knurled screws -B- from the sealing
flange.
Remove assembly device -T10134-. Remove sealing lips supporting ring.
The fitting position of the rotor on the crankshaft is accurate if there is a distance -a- of 0.5 mm between the crankshaft flange -A- and the rotor -B-.
Position the caliper gauge onto the crankshaft flange. Measure distance -a- between crankshaft flange and
rotor. If the dimension -a- is too small:
Press down rotor 13-2 page 12.

If the dimension -a- is correct:
Proceed with installation 13-2 page 13.
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13-2 page 11
13
F - Pressing down the rotor:
Attach assembly device -T10134- -A- to crankshaft

flange, to do so tighten the Allen screws by hand.
Slide assembly device -T10134- by hand towards the

sealing flange.
Screw in hexagon nut -E- by hand onto the threaded

spindle until it rests against the assembly cup -C-.

-T10134 - to 40 Nm.
Again inspect the fitting position of the rotor on the

crankshaft 13-2 page 11. If the dimension -a- is again too small:

-T10134 - to 45 Nm.
Again inspect the fitting position of the rotor on the

crankshaft 13-2 page 11.
13-2 page 12
Edition 01.05 S00.5709.01.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD complete installation:
13
Tighten the new fixing screws of the sealing flange

crosswise.
Screw on engine speed sender -G28- -position 1-. Installing oil pan Chapter 17-1. Insert intermediate plate on sealing flange and push
onto the dowel sleeves -arrows-.
Install the two-mass flywheel 13-2 page 13.
Removing and installing the two-mass flywheel

Flywheel lock -MP 1-504-.
Removing
Secure two-mass flywheel by inserting the flywheel

lock -MP 1-504- into the serration and turn sufficiently until it touches the bushing -T30010-.
MP 1-202
Mark installation position of two-mass flywheel on

crankshaft.
T30010
T30010 MP 1-504
S13-0191
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13-2 page 13
13
Note
To avoid destroying the two-mass flywheel during removal, the screws -B- must not be unscrewed with a compressed air or an impact screwdriver. They must only be unscrewed by hand. Ensure that no screw head touches the two-mass flywheel, otherwise the flywheel may be damaged at the following turning of the screw.
Rotate two-mass flywheel -A- in such a way that the

screws are positioned in the middle of the holes -arrows-.
Screw out the screws.

Installing
Use new screws for attaching. Install the flywheel in the location marked when re-
moving.
Replace needle bearing for crankshaft

Centering mandrel -T30029 Special tool Kukko 21/21 (or 21/2) and Kukko 22/1
Pull out needle bearing with interior extractor

-Kukko 21/1 (oder 21/2)- and support -Kukko 22/1Note The side with the marking on the needle bearing must point outwards after driving in.
Carefully insert new needle bearing with centering

mandrel - T30029- into the crankshaft.
13-2 page 14
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13
13-3
Crankshaft, Piston and Conrod
Removing and installing crankshaft

Note The engine should be attached to the engine repair stand with the engine holder -MP 1-202- for carrying out removal and installation work. 1 - 65 Nm + torque a further 90 (1/4 turn) replace 2 - Bearing caps Bearing cap 1: on the belt pulley side bearing cap 3 with recesses for thrust washers retaining lugs of the bearing shells of the cylinder block/ bearing cap must be on top of one another 3 - Bearing shell 3 for cylinder block with lubricating groove for bearing cap without lubricating groove do not mix up used bearing shells (mark) 4 - Thrust washers for bearing cap 3 different version for cylinder block and bearing cap pay attention to locating element 5 - Crankshaft with chain sprocket for oil pump drive Axial play when new: 0.07... 0.17 mm, wear limit: 0.37 mm Crankshaft bearing journal: 54.00 mm Conrod bearing journal: 50.90 mm 6 - Bearing shells 1, 2, 4 and 5 for cylinder block with lubricating groove for bearing cap without lubricating groove do not mix up used bearing shells (mark)
Edition 02.04 S00.5709.00.20
13-3 page 1
13
Disassembling and assembling piston and conrod

1 - Piston rings Offset joint 120 use piston ring pliers for removing and installing marking TOP must face towards piston crown inspect gap clearance Fig. 1 in 13-3 page 3 inspect end clearance Fig. 2 in 13-3 page 3 2 - Piston with combustion chamber mark installation position and matching cylinder Installation position and assignment of piston/cylinder Fig. 4 in 13-3 page 4 arrow on piston crown faces towards the belt pulley side replace piston if there is any sign of crack formation on the piston body Inspecting pistons Fig. 3 in 13-3 page 3 Piston dimenston: 80.96 mm use piston ring tensioning strap for installing inspect piston projection at TDC 13-3 page 4 3 - Piston pin if stiff, heat piston to approx. 60C use drift -MP 3-400- for removing and installing 4 - Circlip 5 - Conrod always replace as a set only mark matching cylinder -A Fitting position: Markings -B- point towards the belt pulley side with a split bearing cap 6 - Bearing shell Fitting position Fig. 6 in 13-3 page 4 do not mix up used bearing shells (mark) Pay attention to version: top bearing shell (towards the piston) must be made from a long lasting material, recognition feature for new bearing shells: black marking on the contact surface near the separation point insert in middle Fig. 6 in 13-3 page 4 check for firm seating axial play wear limit: 0.37 mm 7 - Cylinder block Inspect cylinder Fig. 5 in 13-3 page 4 Cylinder dimension: 81.01 mm 8 - Conrod bearing cap Check fitting position cracked cover fits only in one position at the relevant conrod.
13-3 page 2
Edition 02.04 S00.5709.00.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD 9 - Oil injection nozzle for cooling pistons 10 - 25 Nm replace without sealant 11 - Conrod bolt - 30 Nm + torque a further + 90 (1/4 turn) replace oil thread and head contact surface
13
Fig. 1:
Inspecting piston ring gap clearance
Feeler gauge
Insert ring at right angles from above down into lower

cylinder opening, about 15 mm away from edge of cylinder. To insert use piston without rings. Piston ring (dimensions in mm) 1. Compression ring 2. Compression ring Oil scraper ring Fig. 2: new Wear limit
0.25 0.40 0.25 0.40 0.25 0.50
1.00 1.00 1.00
Inspect piston ring end clearance
Feeler gauge
Clean before inspecting the annular grooves of the

piston. Piston ring (dimensions in mm) 1. Compression ring 2. Compression ring Oil scraper ring Fig. 3: new Wear limit
V13 - 0687
0.06 0.09 0.05 0.08 0.03 0.06
0.25 0.25 0.15
Inspecting pistons
External micrometer
Measure about 10 mm from the lower edge, offset at

right angles to the piston pin shaft.
Max. deviation from specified dimension: 0.04 mm.

Edition 02.04 S00.5709.00.20 Crankshaft, Piston and Conrod
13-3 page 3
13
Fig. 4:
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD Installation position and assignment of piston/cylinder
Pistons in cylinders 1...4:
arrow on piston crown faces towards the belt pulley

side -arrows-.
Fig. 5:
Inspecting cylinder bore
Internal precision measuring instrument
Measure at 3 points crosswise in a transverse direction -A- and lengthwise -B-.
Max. deviation from specified dimension: 0.10 mm.
Fig. 6:
Fitting position of the bearing shells in the conrods
Insert bearing shell in the conrod or in the center of the

conrod bearing cap.
Dimension -a- = 2.5 mm
Checking piston projection in TDC

Measuring tool for piston projection -MP 1-107-
13-3 page 4
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13
Test sequence
When fitting new pistons or a partial engine, check the piston projection in TDC on all pistons. Depending on the piston projection fit the relevant cylinder head seal in accordance with the table below. Piston projection over cylinder block - top side mm 0.91 1.00 1.01 1.10 1.11 1.20 Bore marking
1 2 3
Cylinder head gasket identification

Spare parts No. = -arrow 1 Control code = -arrow 2- (ignore) Bores = -arrow 3-
Note If different values are measured during the projection measurement of the piston, the greatest dimension applies for the seal assignment.
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13-3 page 5
13
13-3 page 6
Edition 02.04 S00.5709.00.20
15
15 Cylinder Head, Valve Gear

15-1
Note
Cylinder heads with cracks between the valve seats
Removing and installing cylinder head
may continue to be used without any reduction in the life time provided the cracks are slight and max. 0.5 mm wide.
It is not permissible to rework the cylinder heads of
diesel engines.
Replace O-rings and gasket rings. Replace cylinder head bolts and screws which have
been tightened to a turning angle.

When installing an exchange cylinder head with the
camshaft installed, it is necessary to oil the contact surfaces between the valve levers and the cams after installing the cylinder head.
Do not remove the plastic bases supplied as a protec-
tion for the open valves until just before fitting on the cylinder head.
If the cylinder head is replaced, replace all the coolant
Chapter 19-1. nance.
Change dirty engine oil Inspection and Mainte-
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15
Summary of components
1 - Rear timing belt guard 2 - Rubber feed-through replace if damaged 3 - Pin screw - 15 Nm 4 - Hub for inlet camshaft with rotor for hall sender -G40 to remove use extractor -T100525 - 100 Nm to release and tighten use counterholder -T10051 6 - Hub for exhaust camshaft to remove use extractor -T100527 - 10 Nm insert using locking agent -D 000 600 A28 - Valve-lever shaft Mark the installation position of the valve lever do not interchange removing and installing 15-1 page 5 Before inserting, check whether all the ball studs and O-rings are inserted in the unit injectors. 9 - 20 Nm + torque a further 90 (1/4 turn) pay attention to order for slackening 15-1 page 6 pay attention to order and procedure for tightening 15-1 page 9 10 - Gasket for cylinder head cover replace if damaged or leaking press onto the spacer sleeves item 15 11 - Cylinder head cover removing and installing 15-1 page 3 12 - Cap 13 - Gasket replace if damaged or leaking 14 - Sealing sleeve 15 - 10 Nm pay attention to sequence for loosening and tightening 15-1 page 3 16 - 20 Nm 17 - Cylinder head bolt replace pay attention to order for slackening 15-1 page 6 pay attention to order and procedure for tightening 15-1 page 10 18 - 20 Nm 19 - Tandem pump removing and installing Chapter 20-1
15-1 page 2
Edition 01.05 S00.5709.01.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD 20 - Gasket replace 21 - Cylinder head removing 15-1 page 6 check for distortion Fig. 1 in 15-1 page 3 installing 15-1 page 9 after replacing, replace all the coolant Chapter 19-1 22 - Cylinder head gasket replace 15-1 page 6 Pay attention to the marking Fig. 2 in 15-1 page 3 23 - Hall sender -G40 for camshaft position
15
Fig. 1:
Inspecting the cylinder head for distortion
Inspect cylinder head at several points for distortion

using a knife-edge straightedge and feeler gauge.
Max. permissible distortion: 0.1 mm.

Note It is not permissible to rework the cylinder heads of diesel engines.
Fig. 2:
Cylinder head gasket identification
Note Differing thicknesses of cylinder head gaskets are inserted according to the piston projection. If only the gasket is replaced, then it must be replaced with a new gasket with the same marking.
removing and installing cylinder head cover

Torque wrench
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15-1 page 3
15
Removing
Removing engine cover Chapter 10-1. Detach the air guide hose -3-.
Unscrew screws -1- and -2- and slacken bracket -3for fuel hoses on the left engine lifting eye. Note Coolant hoses as well as fuel lines remain connected.
Remove top toothed belt guard, to do so release retaining clips -arrows-.
15-1 page 4
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15
Release screws -1- and -3-. Remove crankcase ventilation hose -2- from air guide
to turbocharger and press the air guide to the rear. Note
Air guide pipe -Position 4- remains connected to the
turbocharger.
In the fig., the illustration is shown from the rear with
the engine removed.
Release the cylinder head bolts in the order -11...1-. Release screws and remove cylinder head cover with
gasket.
Installing
Installation is performed in the reverse order. Pay attention to the following points: Note Replace gasket for cylinder head cover and bolts of cylinder head cover if damaged.
First tighten the cylinder head bolts in the order

-1...11-, then to 10 Nm.

Supporting device -T30099 Hook of -MP 9-200- (with spindle) Bracket -T10014 Catch pan (e.g. -V.A.G 1306-) Pliers for spring strap clips Pressure pad -T10051 Extractor -T10052 Rig pin -3359- or -MP 1-301 - (2x) Two-hole nut turner -T10020 Crankshaft arrester -T10050- or crankshaft arrester
-T10100 Locating bolts -T10060- or -T10060A -
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15
Removing
WARNING!
Observe measures when disconnecting the battery Electrical System; Rep. Gr. 27.
Disconnect the earth strap from the battery with the ignition off.
Removing engine cover Chapter 10-1. Remove air filter, charge air pipes and charge air hoses Chap. 21-2.
Remove the middle sound dampening system

Body Work; Rep. Gr. 50. gine.
Position drip tray (e.g. -V.A.G 1306-) under the en-
Drain coolant Chapter 19-1. Remove fuel feed line -3- and fuel feed line -2-, to do
so pull latch clips.
Use hand vacuum pump to extract the fuel at the return-flow hose of the tandem pump Chap. 20-1.

from the bracket -arrow- and lay to the side.
Remove the V-ribbed belt Chapter 13-1. Unscrew the right air guide pipe between the charge
air cooler and the exhaust turbocharger and remove the V-ribbed belt pulley with the vibration damper.
15-1 page 6
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15
Release screws -4- and remove front air guide pipe

with air guide hose; to do so raise the retaining clips -1- and -3-.
Remove the exhaust pipe from the exhaust turbocharger, slacken the clamping sleeve and push the exhaust pipe to the rear Chapter 26-1.
Release screws -1- and -2- and remove support for

turbocharger. Note Collect any engine oil which flows out with a cloth.
Remove the oil return line -3- at the cylinder block. Unscrew oil feed line from turbocharger, exhaust
manifold and from coolant pipe and lay it to one side.
Remove connection pipe of exhaust gas recirculation

between mechanical valve and exhaust gas recirculation radiator Chapter 26-2.
Remove the timing belt Chapter 13-1. Remove camshaft sprockets and pull off hubs for
camshafts Chap. 13-1.
Remove toothed belt tensioning pulley. Release screws -2...4-. Unscrew pin screw -1- with two M8 nuts tightened up
opposite one another.
Screw out screw -5- and remove Hall sender -G40from cylinder head.
Disconnect all remaining plug connections at cylinder

head and lay aside the electrical lines.
Unscrew fixing screws of oil dipstick guide, pull guide

out of the cylinder block and for removal pivot fowards.
Disconnect hose of vacuum reservoir, unscrew screw

and remove reservoir from bracket. Then remove the support.
Separate all remaining coolant, charge air and vacuum hoses and pipes from the cylinder.
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15
Screw the bracket -T10014- into the threaded hole

above the coolant pump. Tighten screw for bracket to 20 Nm.
Support engine from underneath. Offset hook of -MP 9-200- for supporting device
-T30099- from the right lifting eye of the engine into the lug of the bracket -T10014- and preload engine via the spindle, do not lift.
Remove cylinder head cover 15-1 page 3.
Release screws -1- -3- and -5-. Loosen screws -2- and -4- and release alternately in
several stages. Note Do not pull out screws of the valve-lever shaft, so that the individual parts on the valve-lever shaft remain attached. If necessary mark assignment of the individual parts.
Remove valve-lever shaft. Unscrew inner screws of bearing frame -610-.
15-1 page 8
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15
Follow the specified order for loosening cylinder head

bolts.
Raise cylinder head.
Installing
Note
Carefully remove residual sealant from the cylinder
head and cylinder block. Make sure this does not cause any extended scoring or scratching.
There must not be any oil or coolant present in the
blind holes for the cylinder head bolts.

Replace cylinder head bolts. When undertaking assembly replace self-locking nuts
and screws as well as gasket rings and gaskets which have been tightened to a turning angle.
Remove the new cylinder head seal from its wrapping
immediately before fitting.

Treat the seal with the utmost care. Damage to the sil-
icone layer and in the area of the bead results in leakages.

When installing an exchange cylinder head with the
camshaft installed, it is necessary to oil the contact surfaces between the valve levers and the cams after installing the cylinder head.
The plastic base for protecting the open valves should
only be removed immediately before attaching the cylinder head.

clips.
Before fitting the cylinder head rotate the crankshaft

so that all the pistons are almost evenly at TDC of cylinder 1.
Pay attention to the identification of the cylinder head

seal.
Note
If the cylinder head gasket or cylinder head are re-
placed, install a new cylinder head gasket with the same identification marking.
If parts of the crankshaft drive were replaced then the
new cylinder head gasket must be defined by measuring the protrusion of the pistons in TDC .
Fit on cylinder head gasket. Pay attention to dowel sleeves -arrows- in cylinder
block.
Note the installed position of the cylinder head gasket,

the marking above or the spare part number must point to the cylinder head.
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Insert the cylinder head. Insert cylinder head bolts and tighten by hand. Tighten the cylinder head in four stages in the indicated tightening sequence: Stage I II III IV Tighten
Pre-tighten with the torque

wrench to 40 Nm.

wrench to 60 Nm.
Using a rigid wrench torque a further 90 (1/4 turn).
Note Tightening up the cylinder head bolts after doing repair work is not necessary.
Before inserting the valve-lever shaft, check whether

all the ball studs -1- and O-rings -2- are inserted in the unit injectors.
Screw on valve-lever shaft and bearing frame as follows: Sequence: I Tighten
Tighten screws -2- and -4alternately in stages, until the valve-lever shaft is positioned on the bearing frame.
II
Tighten screws -1-, -3- and

-5- to 20 Nm + torque a further 90 (1/4 turn).
III
Tighten screws -2- and -4to 20 Nm + torque a further 90 (1/4 turn).
IV
Tighten screws -610- of

the bearing frame to 20 Nm.
15-1 page 10
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Insert screws -2...5- with spread on locking agent

-D 000 600 A2- and tighten to 10 Nm.
Screw in the pin screw -1- and tighten to 15 Nm.
Position hub onto exhaust camshaft. Tighten screw -1- to 100 Nm, use counterholder
-T10051- to hold.
Fit the hub onto the inlet camshaft in the same way.
Push camshaft sprockets onto hubs. Slightly screw in plug -1-. Interlock hubs with locking pins e. g. -3359-. The tooth segments -arrowsof the camshaft sprockets must be positioned at the top.
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Position the crankshaft through rotating in the running

direction of the engine on TDC for cylinder 1 and interlock with crankshaft arrester -T10050- or crankshaft arrester -T10100-. Version of the crankshaft timing belt sprocket: A = original version of timing belt sprocket with circular tooth flank, rectangular marking for TDC at tooth in 12 o'clock - use crankshaft arrester -T10050B = new version of timing belt sprocket with eliptical tooth flank, triangular marking for TDC at tooth opening 1 o'clock - use crankshaft arrester -T10100Note
The markings on the timing belt gear and on the
crankshaft arrester must be in line with each other -arrow-. The stud on the crankshaft arrester must engage into the hole in the sealing flange.
The crankshaft arrester can only be fitted onto the tim-
ing belt gear from the front side of the serration.
Install the timing belt (set the timing and check)

Chapter 13-1.
Install cylinder head cover 15-1 page 5.

Further installation occurs in reverse order, while paying attention to the following:
Connect oil lines to exhaust turbocharger and install

exhaust turbocharger support.
Install exhaust system and align free of stress

Chapter 26-1.

Note Change dirty engine oil Inspection and Maintenance.
Top up or replace coolant Chapter 19-1. Connect battery Electrical System; Rep. Gr. 27.
Testing the compression

Compression pressure is tested through the fault finding program of the vehicle diagnosis, measurement and information system -VAS 5051 A- under Repair Group 15; Cylinder head/valve gear; Particular System, Boundary conditions; Diagnostic Object: poor compression pressure.
15-1 page 12
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15
15-2
Note
Repairing Valve Gear
After installing the camshafts, the engine must not be
started for about 30 minutes. The valve levers with hydraulic valve clearance compensation must settle (otherwise valves would strike the piston).
After carrying out work on the valve gear, carefully
crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started.
Always replace gasket rings and seals. Removing and installing tandem pump Chapter 20-
1. 1 - Bracket for cable rail - 10 Nm 2 - 20 Nm pay attention to sequence for loosening and tightening 15-2 page 4 3 - Valve-lever shaft for pump-nozzle units 4 - 20 Nm + torque a further 90 (1/4 turn) replace pay attention to sequence for loosening and tightening 15-2 page 4 5 - Cylinder head bolt replace Pay attention to tightening and release sequence Chapter 15-1 6 - Washer for cylinder head screws before installing the bearing frame, insert into the cylinder head 7 - Valve collets 8 - Valve spring retainer 9 - Valve spring 10 - Valve stem seal replace 15-2 page 10 11 - Valve guide check 15-2 page 12 12 - Valve lever for inlet valve do not mix up used valve levers (mark) with hydraulic valve clearance compensation inspect roller bearings of roller for smooth operation and play removing and installing 15-2 page 8 13 - Valve lever for exhaust valve do not mix up used valve levers (mark) with hydraulic valve clearance compensation inspect roller bearings of roller for smooth operation and play removing and installing 15-2 page 8
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15
14 - Gasket rings Neither grease nor oil sealing lip before installing, remove oil from the camshaft journal before installing, cover the slot for the spring on the camshaft cone with suitable adhesive tape removing and installing 15-2 page 3 15 - Cylinder head Valve seats must not be reworked. 16 - Inlet valves Valve dimensions 15-2 page 11 17 - Exhaust valves Valve dimensions 15-2 page 11 18 - O-ring replace 19 - Valve lever stud for exhaust valves removing and installing 15-2 page 8 20 - 10 Nm 21 - Screw plug - 10 Nm replace insert using locking agent -D 000 600 A222 - Valve lever stud for inlet valves removing and installing 15-2 page 8 23 - Bearing shell do not mix up used bearing shells (mark) ensure the retaining lugs are correctly located in the bearing frame and in the cylinder head 24 - Exhaust and inlet camshaft inspecting axial play 15-2 page 2 removing and installing 15-2 page 4 25 - Inlet camshaft inspecting axial play 15-2 page 2 removing and installing 15-2 page 4 26 - Bearing frame pay attention to sequence for loosening and tightening 15-2 page 4 install with silicone sealant -D 176 501 A1-
Checking the axial play of the camshafts

Universal dial gauge holder -MP 3-447 Dial gauge
Test sequence
Perform measurement with valve levers removed and

bearing frame installed
Wear limit: max. 0,15 mm
15-2 page 2
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15
Replacing camshaft gasket rings

Insertion tool -MP 1-214 Gasket ring extractor -T30003 Pressure pad -T10051 Extractor -T10052 Torque wrench Screw M12x60
Removing
Cylinder head attached at engine. Remove the timing belt Chapter 13-1. Remove camshaft sprockets and pull off hubs
Chap. 13-1.
Set the inner part of the sealing ring extractor

-T30003- flush with the outer part and interlock with the knurled screw.
Oil the thread head of the gasket ring extractor, position and forcely screw into the gasket ring of the exhaust camshaft as far as possible.
Release knurled screw and turn the inner side against

the camshaft until the gasket ring is pulled out.
Clamp gasket ring extractor into the vice and remove

gasket ring with pliers.
Clean the contact and sealing surface. Remove the gasket ring of the inlet camshaft in the
same way.
Installing
Installation is performed in the reverse order. Pay attention to the following points: Note The sealing lips of the gasket rings must not be oiled or greased additionally.
Remove oil residue from the camshaft stud with a

clean cloth.
Cover slot on the exhaust camshaft cone with adhesive tape and carefully push the sealing ring onto the camshaft.
Push on the sealing ring with the pressure plate of

theinsertion tool -MP 1-214- and press in with screw M12x60 up to the stop.
Install the gasket ring of the inlet camshaft in the same

way.
Install the hubs and the camshaft sprockets Chap.

13-1.
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15
Install the timing belt (set the timing) Chapter 13-1.
Removing and installing camshafts

Pressure pad -T10051 Extractor -T10052 Rig pin -3359- or rig pin -MP 1-301 Torque wrench Silicone sealant -D 176 501 A1-
Removing
Cylinder head attached at engine. Remove cover and intermediate wall of the plenum
Remove air filter, air mass meter and intake hose to

exhaust turbocharger Chapter 21-2.
Remove battery Electrical System; Rep. Gr. 27 Exhaust gas recirculation radiator, flap and bracket of
exhaust gas recirculation radiator Chapter 26-2. Chapter 13-1. Chap. 13-1.
Remove the timing belt from the camshaft sprockets Remove camshaft sprockets and pull off hubs Remove cylinder head cover Chapter 15-1. Remove tandem pump Chap. 20-1.
Note The hoses can remain connected to the tandem pump.
Release the counternuts -2- of the adjusting screws

-1- on all unit injectors and unscrew the adjusting screws until the relevant valve lever rests against the tappet spring of the unit injector.
several stages. Then remove the valve-lever shaft with the valve levers. Note Do not pull out screws of the valve-lever shaft, so that the individual parts on the shaft remain attached. If necessary mark assignment of the individual parts.
15-2 page 4
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Separate central plug connection for unit injectors and

for glow plugs.
Unplug plug -1- for the unit injectors; to do so press

latch clips.
Unplug connector -2- for glow plugs. Slacken cable rail from the fixtures and place down to
the side.
Slacken the remaining 15 screws evenly from the outside to the inside and remove bearing frame.
Release press-off screws SW 15 of the frame

-T10262- by hand and by turning anti-clockwise until the stop is upwards.
Position frame -T10262- on the bearing frame according to the illustration and tighten fixing screws SW10 to 10 Nm.
Screw in press-off screws by hand, until these touch

the cylinder head screws.
Screw in press-off screws evenly in the order -1...4-,

which is type-punched on the screw heads, until the bearing frame is being released from the cylinder head. Note
Ensure that the bearing shells of the camshafts are
2
not mixed up.

Mark assignment of the bearing shells for the cam-
shafts with waterproof marker on the reverse side.
Take out camshafts.

Installing
Remove the remaining sealant at the bearing frame

and at the cylinder head using a device such as a rotating plastic brush.
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15
grease.
Clean sealing surfaces, they must be free of oil and Check if the crankshaft is on TDC of cylinder 1. Depending on the version, lock the crankshaft timing
belt sprocket with the crankshaft arrester -T10050- or crankshaft arrester -T10100 -. Version of the crankshaft timing belt sprocket: A = original version of timing belt sprocket with circular tooth flank, rectangular marking for TDC at tooth in 12 o'clock - use crankshaft arrester -T10050B = new version of timing belt sprocket with eliptical tooth flank, triangular marking for TDC at tooth opening 1 o'clock - use crankshaft arrester -T10100Note
Ensure that the used bearing shells of the camshafts
are not mixed up (pay attention to marking).

When installing the camshafts pay attention to a cor-
rect fit of the retaining lugs of the bearing shells in the bearing frame and cylinder head.
Oil contact surfaces of the camshafts and the bearing. Insert camshafts into the TDC for cylinder 1: For both camshafts the cams -1- and -2- for cylinder 1
must point upwards.
Slots -arrows- in the camshafts also point upwards.
15-2 page 6
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15
Cut off nozzle tube at the front marking ( nozzle approx. 2 mm) and apply silicone sealant -D 176 501 A1- to the clean sealing surface of the bearing frame -arrows-.
Thickness of sealant bead: 2 mm.

Note The bearing frame must be installed within 5 minutes after applying the silicone sealant.
Position bearing frame with inserted bearing shells on

the dowel pins of the cylinder head.
Tighten the screws -120- evenly in the following order from inside to outside. Tightening torque 20 Nm.
Tighten the screws -15- of the valve-lever shaft in

the following order + torque a further 90 (1/4 turn).
Insert the cable rail in the bracket, connect plug for

unit injectors, plug for glow plugs and the central plug connection for unit injectors and for glow plugs.
Install camshaft gasket rings 15-2 page 3. Install tandem pump Chap. 20-1. Install the hubs and the camshaft sprockets Chap.
13-1.
Installing the toothed belt and setting the timing

Chapter 13-1.
Adjust unit injectors Chap. 23-1. Install cylinder head cover Chapter 15-1.
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15
Install battery Electrical System; Rep. Gr. 27

Note
Removing and installing valve lever

Extractor -T10133/3-
Note
Replace O-rings. Do not mix up used valve levers.
Remove valve levers for exhaust valves
Remove the camshafts 15-2 page 4. Drain coolant Chapter 19-1. Remove connection pipe between exhaust gas recirculation mechanical valve and flap of exhaust gas recirculation radiator Chapter 26-2.
Remove connection fittings for coolant from cylinder

head Chapter 19-1. ing again.
Mark the assignment of the valve levers when install Release screws -4- and -5-. Pull out the stud -3- of the valve levers on the exhaust
side with extractor -T10133/3- from the cylinder head and remove the valve levers.
Install valve levers for exhaust valves

Lubricate valve lever bearing. Push valve lever stud into the cylinder head and insert
the valve levers simultaneously and consecutively.
Tighten fixing screw item 20 in 15-2 page 2 to 10

Nm.
Replace the screw plug item 21 in 15-2 page 2

and tighten to 10 Nm.
Remove connection fittings for coolant on cylinder

head Chapter 19-1.
15-2 page 8
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15
Install connection pipe between exhaust gas recirculation mechanical valve and flap of exhaust gas recirculation radiator Chapter 26-2.
Install camshafts 15-2 page 4. Top up coolant Chapter 19-1.

Remove valve levers for inlet valves
Remove the camshafts 15-2 page 4. Mark the assignment of the valve levers when installing again.
Pull out the stud of the valve levers on the inlet side
with extractor -T10133/3- from the cylinder head and remove the valve levers.
Install valve levers for inlet valves

Lubricate valve lever bearing. Push valve lever stud into the cylinder head and insert
the valve levers simultaneously and consecutively.
Install camshafts 15-2 page 4.
Check hydraulic supporting elements

Feeler gauge
Note
The hydraulic supporting elements pressed into the
valve levers cannot be repaired.

Irregular valve noises when starting engine are nor-
mal.
Test sequence
Start engine and allow to run until the radiator fan

starts. Increase revolutions to about 2500 rpm for 2 minutes and undertake a test drive if necessary. Note If there are irregular valve noises which disappear after a long drive but keep reappearing on short journeys then the oil retaining valve is is defective. Fitting location: In the oil filter holder. The oil retaining valve cannot be replaced individually. If the valves are still loud, determine which is the faulty hydraulic supporting element as follows:
Remove cylinder head cover.
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15
Turn the crankshaft until the cam of the hydraulic supporting element to be tested is positioned on top, while doing so push the vehicle forward in 4th gear when ignition is switched off.
Press the valve lever down with a screwdriver -arrows- and measure the play between the cams and the roller of the valve lever. If a 0.20 mm feeler gauge can be slipped between the camshafts and the roller of the valve lever:
Replace valve lever with hydaulic valve clearance

compensation; to do so remove the valve lever 15-2 page 4. Note
Replacing valve stem seals

Cylinder head attached at engine.
Valve lever -MP 1-211 Pressure plate -MP 1-211/6 Assembly device -MP 1-213 Extractor for valve stem seal -MP 1-230 Insertion tool -MP 1-233-
Note
With cylinder head removed: Removing glow plugs from the cylinder head Chap.
28-1.
Remove unit injectors from the cylinder head Chap.
23-1.
Lay the cylinder on a suitable level valve supporting
plate.
Removing
Remove the camshafts 15-2 page 4. Remove unit injectors Chap. 23-1.
15-2 page 10
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15
Note
Ensure that the used bearing shells of the camshafts
are not mixed up (mark).

When installing the camshafts pay attention to a cor-
rect fit of the retaining lugs of the bearing shells in the bearing frame and cylinder head.
Remove bearing shells of camshafts from the cylinder

head.
Fold down valve lever to the side. Position piston of the relevant cylinder to dead centre. Insert the assembly device -MP 1-213- and adjust
bearing to the stay bolt height.
Remove valve springs with valve lever -MP 1-211with thrust piece -MP 1-211/6-. Note The valves rest on the piston crown.
Use pulling device -MP 1-230 - to pull off valve stem

seals.
Installing
Insert the supplied plastic bushings -A- on the relevant

valve stem. This will prevent any damage to the new valve stem seals -B-.
Insert the new valve stem seal in the insertion tool

- MP 1-233-.
Oil the sealing lip of the valve stem seal and carefully
slide into the valve guide.
Remove plastic sleeve. Reinstall valve springs and secure with collets. Install camshafts 15-2 page 5.
Note
Valve dimensions
Dimension a b c mm mm mm Inlet valve 29,20 5,975 87,80 45 Exhaust valve 25,50 5,965 87,50 45
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15
Note
Valves must not be reworked. Only grinding in is permissible.
Inspect valve guides

Universal dial gauge holder -MP 3-447 Dial gauge
Test sequence
Insert valve into valve guide. The end of valve stem

must be flush with guide. Valve rock: max. 1.3 mm Note
If the wear limit is exceeded, repeat measurement
with new valves. If the wear limit is again exceeded, replace cylinder head. The valve guides cannot be replaced.
If the valves are replaced when carrying out repair
work, use new valves for the measurement.
15-2 page 12
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17
17 Lubrication
17-1 Removing and installing parts of the lubrication system
Note
If considerable quantities of metal swarf or abrasion is
found in the engine oil when carrying out engine repairs, carefully clean the oil galleries and additionally replace the oil cooler and the oil filter einsert.
The oil level must not be above the max. marking! -
risk of damage to catalytic converter! Check the engine oil condition, oil level and oil specification Inspection and Maintenance. 1 - 15 Nm 2 - Bracket for cable of oil level/temperature sender -G266 pay attention to different version 3 - Dipstick oil level must not exceed max. marking 4 - Filler funnel Remove for extracting oil 5 - Guide tube 6 - Fitting sleeve 2 pieces 7 - Oil pump with pressure relief valve 1.2 MPa (12 bar) removing and installing 17-1 page 6 Before installing, check whether both dowel sleeves item 6 for centering oil pump/cylinder block are present if there is any scoring on contact surfaces of gears, replace Tighening torque of oil pump cover at oil pump housing: 10 Nm 8 - Suction line Clean strainer if dirty 9 - O-ring replace 10 - Oil pan removing and installing 17-1 page 4 install with silicone sealant -D 176 404 A2Edition 01.05 S00.5709.01.20 Removing and installing parts of the lubrication system
17-1 page 1
17
11 - Gasket ring replace 12 - Oil drain plug - 30 Nm Cut open gasket ring if leaking and replace 13 - 10 Nm replace 14 - Oil level/temperature sender -G266 Test Electrical System; Rep. Gr. 90 15 - O-ring replace 16 - Baffle 17 - Oil pump sprocket Fits onto oil pump shaft in one position only 18 - Oil pump chain before removing mark running direction check for wear 19 - 20 Nm + torque a further 90 (1/4 turn) replace 20 - Front sealing flange install with silicone sealant -D 176 404 A2 replace sealing ring for crankshaft at belt pulley side Chapter 13-2 21 - Chain tensioner do not disassemble Replace chain tensioner if spring is broken. Check fitting position When installing, hook on the spring and pretension Tighten to 16 Nm
17-1 page 2
Removing and installing parts of the lubrication system
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17
Disassembling and assembling oil filter holder

1 - Screw plug - 25 Nm 2 - Gasket replace 3 - Oil cooler pay attention to the necessary replacement Connection diagram of coolant hoses Chap. 19-1. 4 - Gasket replace Fitting position Fig. 1 in 17-1 page 4 5 - 15 Nm + torque a further 90 (1/4 turn) replace Tighten crosswise Oil filter holder with oil retaining valve the oil retaining valve cannot be replaced individually Gasket ring replace Oil pressure switch -F1- - 20 Nm 0.07 MPa (0.7 bar) switch check 17-1 page 6 Cap - 25 Nm loosen and tighten up with the oil filter spanner e.g. -3417O-ring replace Oil filter element remove from the cap item 9 Replace O-rings item 10 if oil filter element is replaced Check fitting position Observe the servicing intervals Inspection and Maintenance Oil feed line to turbocharger Observe the mounting sequence: Screw on the union nuts first of all by hand.
6-
78-
9-
10 11 -
12 -
Then tighten the union nuts to 22 Nm. Subsequently secure the oil feed line in the brackets.
13 - Connection fitting - 35 Nm
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17
Fig. 1:
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD Fitting position of gasket for oil cooler
Place the gasket -2- in such a way that it can be

pressed onto all the lugs of the oil cooler -1-.
The oil duct -arrow- must not be covered from the gasket.
Removing and installing oil pan

Socket insert -T10058- or Socket insert SW 5 (e. g.
-3249-)
Torque wrench Hand-held power drill with plastic brush insert Silicone sealant -D 176 404 A2-
Removing
Remove the middle sound dampening system

Body Work; Rep. Gr. 50. clips.
Remove right air guide pipe, to do so pull the retaining Unplug connector at oil level/temperature sender
-G266 -.
Drain engine oil Inspection and Maintenance. Unscrew the bolts of oil pan/gearbox -arrows-. Loosen bolts -1 ... 20- crosswise and release. Remove oil pan, if necessary release by applying slight blows with a rubber-headed hammer. Note
Both rear oil pan bolts -1- and -2- are accessible through the recess -arrow- at the flywheel -3-, turn the flywheel appropriately to allow this.
Installing
17-1 page 4
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17
Remove the remaining sealant on the oil pan and on

the cylinder block using a device such as a rotating plastic brush.
Clean sealing surfaces, they must be free of oil and

grease.
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
Apply silicone sealant bead -D 176 404 A2- -arrow- to

the clean sealing surface of the oil pan, as shown.
Thickness of sealant bead: 2 ... 3 mm.

Note
The sealant bead must not be thicker than 3 mm oth-
erwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.
Take particular care when applying the sealant bead
in the area of the sealing flange at the rear -arrows-.

The oil pan must be installed within 5 minutes after ap-
plying the silicone sealant -D 176 404 A2-.
Fit on the oil pan immediately and tighten the bolts as

follows:
Pre-tighten bolts -1 ... 20- crosswise to 5 Nm. Tighten the bolts of the oil pan/gearbox -arrows- to a
torque of 45 Nm.
Tighten bolts -1 ... 20- crosswise to 15 Nm.

Note
When installing the oil pan with the engine removed,
ensure that the oil pan is flush with the cylinder block at the flywheel side.
After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled in.
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17-1 page 5
17
and Maintenance.
Fill with engine oil and check the oil level Inspection
Removing and installing oil pump

Removing
Remove oil pan 17-1 page 4 and baffle item 16

in 17-1 page 2.
Release screw -2-. Pull the chain sprocket off the oil pump shaft. Release screws -1- and -3- and remove oil pump.
Installing
Insert top dowel sleeves item 6 in 17-1 page 1 into

the oil pump.
Installed position of the oil pump shaft/chain sprocket:

Chain sprocket fits onto the shaft in one position only
Installing the oil pan 17-1 page 4.
Testing oil pressure and oil pressure switch

Oil pressure tester (e.g. -V.A.G 1342 -) Diode test lamp (e.g. -V.A.G 1527 B -) Measuring tool set -V.A.G 1594 C-
Test conditions
Oil level is OK. Engine oil temperature approx. 80 C.

Preparations
Removing engine cover Chapter 10-1. Remove air guide to air filter. Disconnect plug -arrow- at oil pressure switch -F1and unscrew oil pressure switch -F1-.
17-1 page 6
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Screw the oil pressure tester (e. g. -V.A.G 1342 -) into

the hole for the oil pressure switch.
Screw oil pressure switch -2- into oil pressure tester

(e. g. -V.A.G 1342-).
Testing oil pressure switch
Connect brown cable -1- of oil pressure tester to earth

(-).
Unclamp the diode test lamp with its auxiliary cables

out of the measuring tool set on the oil pressure switch and plus (+) terminal on the battery.
The LED should not light up.

If the LED lights up:
Replace oil pressure switch. Start engine.

Note Observe the testing equipment and the LED while actuating the starter since the switching point of the oil pressure switch can already be exceeded when starting up.
At 0.055... 0.085 MPa (0.55 ... 0.85 bar) the LED must
come on at an overpressure. If the LED does not light up:
Replace oil pressure switch.

Testing oil pressure
Start engine. Oil pressure when engine idling: min. 0,08 MPa (0,8
bar)
Oil pressure at 2000 rpm: min. 0,2 MPa (2,0 bar)

If the specified values are not reached: Oil pump defective.
Replace oil pump 17-1 page 6. Oil pressure at a higher engine speed: max. 0.7 MPa
(7.0 bar). If the specified pressure is exceeded: Pressure relief valve defective.
Replace oil filter holder 17-1 page 3.
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17-1 page 8
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19
19 Cooling
19-1 Removing and installing parts of the cooling system
WARNING! Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully. Note
When the engine is warm the cooling system is under
pressure. If necessary reduce pressure before repairs.

clips.
Use pliers for spring strap clips to fit the spring strap
clips.
Always replace seals and gasket rings.
Edition 01.05 S00.5709.01.20
Removing and installing parts of the cooling system
19-1 page 1
19
Parts of the cooling system fitted to body

1 - Radiator removing and installing 19-1 page 10 after replacing fill entire system with fresh coolant 19-1 page 5 2 - O-ring replace if damaged 3 - Top coolant hose To connection fitting at cylinder head connection diagram for coolant hoses 19-1 page 5 4 - Cap Test pressure 1.4 ... 1.6 bar check 19-1 page 12 5 - Connector 6 - 5 Nm 7 - Expansion reservoir 8 - Bottom coolant hose to connection fitting at coolant regulator at block connection diagram for coolant hoses 19-1 page 5 9 - 10 Nm 10 - 5 Nm 11 - Radiator fan 2 -V177 removing and installing 19-1 page 11 12 - Radiator fan -V7 with radiator fan control unit -J293 removing and installing 19-1 page 11 13 - Connector 14 - Fan shroud
19-1 page 2
G12
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19
Parts of cooling system engine side

1 - Exhaust gas recirculation radiator removing and installing Chapter 26-2 2 - to heat exchanger Feed line connection diagram for coolant hoses 19-1 page 5 3 - Hose to flap of exhaust gas recirculation radiator 4 - 10 Nm 5 - The coolant pipe at the rear 6 - Retaining clip check tightness 7 - O-ring replace 8 - Sender for coolant temperature -G62 with coolant temperature gauge sensor -G29 - Hose To connection fitting at cylinder head connection diagram for coolant hoses 19-1 page 5 10 - Connection fittings for cylinder head with coolant temperature sender - G6211 - from heat exchanger Return-flow line connection diagram for coolant hoses 19-1 page 5 12 - 40 Nm 13 - Hose to cylinder head 14 - Hose to rear pipe 15 - Small distributor part 16 - Hose to the distributor parts 17 - Hose To connection fitting at cylinder head 18 - Hose towards top radiator 19 - Distributor part 20 - 15 Nm 21 - Hose from oil cooler 22 - to bottom compensation bottle connection diagram for coolant hoses 19-1 page 5 23 - Coolant pipe
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19
24 - Hose to bottom radiator 25 - Coolant temperature sender radiator outlet-G8326 - Connection fittings for coolant regulator with sender for coolant temperature radiator outlet -G8327 - Coolant regulator removing and installing 19-1 page 8 test: heat up regulator in a water bath Start of opening approx. 87 C Full opening approx. 102 C Stroke min. 8 mm 28 - Hose to oil cooler - connection from block 29 - Oil cooler removing and installing Chapter 17-1 30 - Coolant pump check smooth operation Check fitting position removing and installing 19-1 page 8 31 - to the compensation bottle above connection diagram for coolant hoses item 30 32 - Top coolant pipe bolted to intake manifold 33 - Hose from the flap of the exhaust gas recirculation radiator 34 - Flap of the exhaust gas recirculation radiator removing and installing Chapter 26-2
19-1 page 4
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19
Connection diagram for coolant hoses

1 - Radiator removing and installing 19-1 page 10 fill with fresh coolant after replacing 19-1 page 5 2 - Oil cooler fill with fresh coolant after replacing 19-1 page 5 removing and installing Chapter 17-1 3 - Coolant regulator removing and installing 19-1 page 8 4 - Coolant pump removing and installing 19-1 page 8 5 - Cylinder head/cylinder block fill with fresh coolant after replacing 19-1 page 5 6 - Expansion reservoir with cap Testing the pressure relief valve in the cap 19-1 page 12 7 - Exhaust gas recirculation radiator fill with fresh coolant after replacing 19-1 page 5 removing and installing Chapter 26-2 8 - Heat exchanger for heating fill with fresh coolant after replacing 19-1 page 5 9 - Flap of the exhaust gas recirculation radiator 10 - ATF radiator For models with an automatic gearbox fill with fresh coolant after replacing 19-1 page 5
Draining and filling up coolant

Catch pan (e.g. -V.A.G 1306-) Pliers for spring strap clips Refractomer -T10007-
Draining
Note Collect drained coolant in a clean container for proper disposal or reuse.
Edition 01.05 S00.5709.01.20 Removing and installing parts of the cooling system
19-1 page 5
19
Open the cap of the coolant expansion reservoir. Remove the sound dampening system in the middle
Body Work; Rep. Gr. 50. gine.
Position drip tray (e.g. -V.A.G 1306-) under the en Remove right air guide hose, to do so raise the retaining clips-arrows-.
WARNING! Shut off the opening of the charge air cooler, e.g. with a clean foam piece, so that no coolant can penetrate.
Remove the coolant hose from the radiator; to do so

pull the retaining clip -arrow-.
Removing engine cover Chapter 10-1. Remove the air guide between the lock carrier and the
air filter.
Remove top coolant hose on the oil cooler -arrow- and

drain residual coolant.
Filling up
Note Replace O-rings.
19-1 page 6
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19
Connect coolant hose at bottom of radiator -arrow-.
Connect coolant hose at top of oil cooler -arrow-.

Select the appropriate coolant additive from the electronic original spare parts catalogue koda or from the list of allowed coolant additives Inspection and Maintenance; Rep. Gr. 02.
First of all prepare required quantity of coolant mixed

to the correct ratio in a suitable vessel Inspection and Maintenance; Rep. Gr. 02.
Top up coolant through the connection of the expansion reservoir, until the maximum marking of the coolant level is reached.
Start engine, run for not more than 2 minutes at approx. 1500 rpm and while doing so top up coolant in the expansion reservoir.
Tighten cap at expansion reservoir. Run engine until fan starts.

Check the level of coolant and top up if necessary. When engine is at operating temperature the coolant
level must be at the maximum marking, when engine is cold between the minimum and the maximum markings.
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19
Removing and installing coolant pump

Removing
Drain coolant 19-1 page 5. Remove the V-ribbed belt Chapter 13-1. Remove tensioning device for V-ribbed belt at middle
toothed belt guard Chapter 13-1 Chapter 13-1.
Remove the timing belt from the camshaft sprockets Unscrew fixing bolts -1- of the coolant pump and remove the coolant pump -2-.
Remove O-ring -3-.

Installing
Installation is performed in the reverse order. Pay attention to the following points: Note Replace O-ring.
Clean sealing surface for O-ring or smoothen. Moisten new O-ring -3- with coolant. Attach the coolant pump -2-. Fitting position: Plug in housing points down.
Tighten screws -1- of coolant pump to 15 Nm. Install the timing belt (set the timing) Chapter 13-1. Install the V-ribbed belt Chapter 13-1. Filling system with coolant 19-1 page 6.
Removing and installing coolant regulator

Catch pan (e.g. -V.A.G 1306-) Pliers for spring strap clips
Removing
19-1 page 8
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19
Drain coolant 19-1 page 5.

WARNING! Observe measures when disconnecting the battery Electrical System; Rep. Gr. 27.
Disconnect the earth strap from the battery with the ignition off.

from the bracket -arrow- and lay to the side.
Remove the V-ribbed belt Chapter 13-1.

Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.
Unscrew AC generator and lay to the right upwards.

The hoses remain connected.
Remove coolant hose -2- from connection fittings. Disconnect plug -1- at the coolant temperature sender
radiator outlet -G83-.
Unscrew screws -arrows- and remove connection fittings.
Turn coolant thermostat -1- approx. 90 (1/4 turn) anticlockwise -arrow- and remove from connection fittings.
Remove O-ring -2-.

Installing
Installation is performed in the reverse order. Pay attention to the following points: Note Replace O-ring.
Clean sealing surface for O-ring or smoothen. Insert coolant regulator with new O-ring. Fitting position: the clamp of the coolant thermostat
must be positioned vertically.
Moisten O-ring with coolant. Fit connection fitting onto cylinder block, tighten
screws to 15 Nm and connect hose of radiator.
Install alternator Electrical System; Rep. Gr. 27. Install the V-ribbed belt Chapter 13-1.
Edition 01.05 S00.5709.01.20 Removing and installing parts of the cooling system
19-1 page 9
19
Filling system with coolant 19-1 page 6. Connect battery Electrical System; Rep. Gr. 27.
Removing and installing radiator

Catch pan (e.g. -V.A.G 1306-) Pliers for spring strap clips
Removing
Open the cap of the coolant expansion reservoir. Remove air filter and air guide to lock carrier
Chapter 21-2.
Remove the sound dampening system in the middle

Body Work; Rep. Gr. 50.
Disconnect plug -2- at charge pressure sender -G31-/

intake air temperature sender -G42-.
Release screw -4-. Remove front air guide pipe with air guide hose; to do
so raise the retaining clips -1- and -3-.
Remove right air guide hose, to do so raise the retaining clips.
WARNING! Shut off the opening of the charge air cooler, e.g. with a clean foam piece, so that no coolant can penetrate.
Place a catch pan -V.A.G 1306- under the engine. Remove the bottom coolant hose from the radiator; to
do so pull the retaining clip -arrow-.
19-1 page 10
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Separate plug connection -1-. Screw out screws -arrows- and take out fan shroud
downwards.
Remove coolant hose at top of radiator -arrow-.
Screw out screws -arrows- on the radiator reverse

side and remove radiator toward top.
Installing
Always replace gasket rings and O-rings. Secure all hose connections with corresponding hose
clips.
Filling system with coolant 19-1 page 6.
Removing and installing radiator fan -V7- and -V177Removing
Fan shroud removed.
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19
Separate plug connection -1- and expose cables. Unscrew the nuts -arrows- and remove the fan.
Installing
Installation is carried out in the reverse order.
Checking the coolant system for tightness

Coolant system tester (e. g. -V.A.G 1274 -) Adapter (e.g. -V.A.G 1274/8-) Adapter (e.g. -V.A.G 1274/9-)
Test condition
Engine must be warm.

Test sequence
Open the cap of the coolant expansion reservoir. Position coolant system tester (e.g. -V.A.G 1274 -)
with adapter (e.g. -V.A.G 1274/8-) on the compensation bottle.
Generate an overpressure of approx. 1.0 bar for testing the cooling system. If the pressure drops:
Determine position of the leak and repair.

Testing the pressure relief valve in the cap
Position coolant system tester (e.g. -V.A.G 1274 -)

with adapter (e.g. -V.A.G 1274/9-) on the cap.
Generate an overpressure for testing the pressure relief valve.
The pressure relief valve should open at a pressure of

0.14 ... 0.16 MPa (1.4 ... 1.6 bar). If the pressure relief valve does not open:
Replace cap.
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20
20 Fuel Supply
20-1 Removing and installing parts of the fuel supply system
Note
Fuel lines are secured with quick-release fittings. Fuel hoses must be secured only with spring strap
clips. The use of clamp-type or screw-type clips is not allowed.

Use pliers for spring strap clips to fit the spring strap
clips. Observe the safety precautions Chapter 01-1. Observe the cleanliness regulations Chapter 01-1.
Fuel tank with attached parts

1 - Mounting part 2 - Fuel filler cap replace O-ring if damaged 3 - Earth connection 4 - 11 Nm 5 - Bracket 6 - Fuel tank when removing support, for example with the engine/ gearbox jack -V.A.G 1383 A removing and installing 20-1 page 4 7 - 25 Nm 8 - Circlip 9 - Tensioning strap Check fitting position 10 - Heat shield 11 - Fuel cooler removing and installing 20-1 page 3 12 - to fuel filter 13 - 20 Nm 14 - Gasket ring to be inserted dry into the opening of the fuel tank replace if damaged Moisten the fuel delivery unit with fuel only from inside when installing the flange. 15 - Fuel delivery unit with sender for fuel gauge display removing and installing 20-1 page 7
Edition 01.05 S00.5709.01.20 Removing and installing parts of the fuel supply system
20-1 page 1
20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD note the installed position of the fuel tank Fig. 1 in 20-1 page 2 inspecting fuel pump 20-1 page 5 Clean strainer if dirty removing and installing fuel gauge sensor 20-1 page 8 Lock ring - 145 Nm use wrench -T30101- for removing and installing check for firm seating Return-flow line from fuel cooler clipped in place on fuel tank check for firm seating blue Feed line to fuel filter clipped in place on fuel tank check for firm seating black Fuel tank lid unit with rubber bowl removing and installing Body Work; Rep. Gr. 55
16 -
17 -
18 -
19 -
Fig. 1:
Fitting position of the flange of the fuel delivery unit/fuel gauge sender
Marking -3- on the flange points against the direction of travel. Note The fuel delivery unit can only be installed in this position. Blue or blue marked return-flow line -1-. Black feed line -2-. Note After installing the flange of the fuel delivery unit, check whether the feed and return-flow lines are still clipped in place on the fuel tank.
20-1 page 2
Removing and installing parts of the fuel supply system
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20
Removing and installing fuel filter

The fuel flow direction is indicated with arrows on the hoses and on the fuel filter. 1 - Intake hose from fuel tank white or white marking 2 - 8 Nm 3 - Return-flow hose to fuel cooler blue or blue marking 4 - Drain plug unscrew and drain (catch) approx. 0.1 litre fluid using the hand vacuum pump with adapter e. g. -V.A.G 1390and ventilation reservoir -V.A.G 1390/15 - Gasket ring replace 6 - Intake hose to the tandem pump white marking 7 - Fuel filter - top part 8 - Retaining clip replace if damaged 9 - Fuel temperature sender -G8110 - Return-flow hose from the tandem pump blue marking with connection fitting for fuel temperature sender -G8111 - Fuel filter element pay attention to change intervals 12 - Fuel filter - bottom part 13 - Bracket
Removing and installing fuel cooler

Torque wrench
Note The fuel cooler is located at the return-flow line to the fuel tank. It is attached to the underfloor of the vehicle body.
Observe the cleanliness regulations Chapter 01-1.
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20
Removing
Removing the right underfloor trim panel. Separate fuel lines at fuel cooler. Unscrew fixing nuts for fuel cooler -arrows- and remove fuel cooler.
Installing
The installation occurs in reverse order: Tighten fixing nuts for the fuel cooler to 15 Nm.
Removing and installing the fuel tank

Engine/gearbox jack (e.g. -V.A.G 1383 A-) Torque wrench
Removing
Note Observe all safety measures Chapter 01-1 before beginning the assembly work.

Drain the fuel tank. Take out mounting part for fuel-tank lid unit and remove fuel-tank lid unit Body Work; Rep. Gr. 55.
Removing rear seat bench Body Work;

Rep. Gr. 72.
Remove the trim panel of the fuel delivery unit. Unlock connector and pull off from flange of the fuel
delivery unit.
Unscrew right rear wheel Chassis; Rep. Gr. 44. Remove the rear right wheelhouse liner Body
Work; Rep. Gr. 66.
Unscrew fixing bolts on filler neck -arrows-. Remove the rear tunnel bridge Chapter 26-1. Slacken front clamping sleeve at exhaust sleeve and
push clamping sleeve to the rear.
Push out all suspensions of rear muffler from the retaining straps.
Slightly lower the exhaust pipe and tie with wire to

body.
Disconnect the feed and return line on the front right

of the fuel tank.
20-1 page 4
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20
Note Press down the securing rings in order to unlock the connections of the fuel lines.
Unscrew tensioning strap and fixing screws. Support

the fuel tank with engine/gearbox jack -V.A.G 1383 Awhen removing.
Lower the fuel tank.

Installing
Installation is carried out in the reverse order. Pay attention to the following:
Lay the vent and fuel hoses without any kinks. Do not mix-up the feed and return line (the return line
is blue, the feed line is black).

Make sure the line connections fit tightly. Check feed, return and ventilation line at fuel tank for
firm seating.
Check earth connection of fuel tank/body at filler neck.
Check the fuel delivery unit

Remote control, e.g. -V.A.G 1348/3A Pressure gauge appliance, e.g. -V.A.G 1318 Adapter, e.g. -V.A.G 1318/1 Adapter, e.g. -V.A.G 1318/11 Adapter, e.g. -V.A.G 1318/17 Adapter, e.g. -V.A.G 1318/23 Measuring vessel
Inspecting proper operation and power supply Test conditions
Battery voltage at least 11.5 V. Fuses o.k. (No. 27). All electrical components such as lights and rear window heater must be switched off.
Test sequence

Rep. Gr. 72.
Remove the trim panel of the fuel delivery unit. Switch on ignition. The fuel delivery unit must be
heard to start running.
Switch off ignition.

If the fuel delivery unit does not run:
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20
Continuing searching for faults using a multimeter
(e.g. -V.A.G 1715-) Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Inspecting fuel flow rate Test conditions
Supply voltage is o.k. Battery voltage at least 11.5 V. Fuel temperature 15...30 C. Fuel tank at least 1/4 full.
Test sequence
Unscrew the fuel tank cap from the filler neck. Removing rear seat bench Body Work;
Rep. Gr. 72.
Remove the trim panel of the fuel delivery unit. Unplug 4-pin plug from fuel delivery unit. Connect remote control -V.A.G 1348/3A- with connection lines from measuring tool set to contact -1- of the fuel delivery unit and to battery +.
Use connection lines from the measuring tool set to

connect the contacts -4- to the plug and to the fuel delivery unit.
WARNING! The fuel feed line is pressurized! Place a clean cleaning cloth around the connection point before detaching hose connections. Reduce pressure by carefully releasing the connection point.
Pull off the fuel feed line at the fuel filter and gather residual fuel in a cloth.
Connect pressure gauge -V.A.G 1318- with adapter

-V.A.G 1318/23- and -V.A.G 1318/17- to the fuel feed line.
Connect hose -V.A.G 1318/1- to adapter

-V.A.G 1318/11- of the pressure gauge and hold in the measuring vessel.
Open shut-off cock of the pressure measuring device.

The lever points in the direction of flow -A-.
Activate remote control -V.A.G 1348/3A-. Slowly

close the shut-off cock until the manometer displays 3.5 MPa overpressure (0.35 bar). Slowly close the shut-off cock until the manometer displays 3.5 MPa overpressure (0.35 bar).
Empty measuring vessel. Activate remote control for 30 seconds.

Specified volume: 660 ml/30 seconds. If the minimum flow rate is not reached:
20-1 page 6
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20
Check the fuel lines for possible diameter restrictions

(kinks) or blocking.
Remove the fuel delivery unit and check whether the

pump strainer is not clogged up. If no fault was detected until now:
Replace the fuel delivery unit.
Removing and installing the fuel delivery unit

Wrench for the lock ring -T30101 Fuel extraction device (e.g. -VAS 5190-) Torque wrench
Condition
The fuel tank must not be more than 3/4 full.

Removing
Note
Empty the fuel tank if necessary using the fuel extrac-
tion device -VAS 5190-.

Observe all safety measures Chapter 01-1 before
beginning the assembly work.

Observe the cleanliness regulations Chapter 01-1.


Rep. Gr. 72.
Remove the trim panel of the fuel delivery unit.

WARNING! The fuel system is under pressure! Place a clean cleaning cloth around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose. Note Press together the bottom securing ring on the rear side of the angular connection in order to unlock the fuel lines.
Pull out the connector as well as the fuel lines -1 and

2- from the flange of the fuel delivery unit.
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20
Unlock lock ring with wrench -T30101-. Pull the fuel delivery unit and the gasket ring out of the
opening of the fuel tank. Note You must empty the old delivery unit before disposing of it if you wish to replace it.
Installing
The installation of the fuel delivery unit occurs in reverse order. Pay attention to the following: Note
Do not bend the fuel gauge sender when installing it. Insert dry gasket ring into the opening of the fuel tank. The gasket must only be moistened from inside with
fuel before assembly of the fuel delivery unit.

Pay attention to installation position of flange of fuel
delivery unit. Marking on the flange -3- must point against the direction of travel. The flange of the fuel delivery unit can only be installed in this position.
Do not interchange the feed and return lines. Make sure the fuel lines fit tightly. After installing the fuel delivery unit, check whether
the feed and return-flow lines are correctly clipped in place on the fuel tank.
Undertake the work operation Procedure after interrupting the power supply Vehicle Diagnosis, Measuring and Information System VAS 5051.
Removing and installing the fuel gauge sender -GRemoving
Removing fuel delivery unit 20-1 page 7. Unlatch and disconnect the line contact studs -1 ... 3-.
Note When installing, observe the routing of the line connections.
Raise catches -4- and -5- with a screwdriver and remove the fuel gauge sender -G- from the bottom -arrow-.
3 2 1
Installing
Insert the fuel gauge sender -G- in the fuel delivery

unit guides and press upwards until the catches latch into position.
Install the fuel delivery unit 20-1 page 7.
S20-0162
20-1 page 8
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20
Removing and installing the tandem pump

Torque wrench Hand vacuum pump (e.g. -V.A.G 1390-) Ventilation reservoir (e.g. -V.A.G 1390/1-) Pliers for spring strap clips
Removing
Separate feed hose -1- (marked in white) and returnflow hose -2- (marked in blue) from the fuel filter.
Connect hand vacuum pump e.g.-V.A.G 1390- with

ventilation reservoir -V.A.G 1390/1- to return-flow hose -2-.
Operate hand vacuum pump until no more fuel comes

out of the return-flow hose. Ensure that no fuel is drawn into the hand vacuum pump.
Unplug connector -2- from the air mass meter -G70-. Detach vent hose -1-, intake hose -3- and air guide
-5-.
Screw out screw -4- and remove air filter housing. Separate central plug connection for unit injectors and
for glow plugs.
Separate vacuum line -1- for brake servo unit from

tandem pump -4-.
Separate feed hose -2- (marked in white) and returnflow hose -3- (marked in blue) from the tandem pump -4-.
Unscrew fixing screws -arrows- and remove tandem

pump -4- from cylinder head.
Installing
Ensure the tandem pump coupling is correctly insert-
ed into the camshaft.

Always replace the tandem pump seals.
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20
rows- to 40 Nm.
Install tandem pump and tighten fixing screws -ar Connect return-flow hose -3- (marked in blue) to the
return-flow coupling of the tandem pump.
Connect the feed hose -2- (marked in white) to the

feed connection and the vacuum line -1- of the brake servo unit to the tandem pump -4-.
Connect central plug connection for unit injectors and

for glow plugs.
Install air filter and connect intake air hose and air
guide.
Connect the hand vacuum pump -V.A.G 1390- with

the ventilation reservoir -V.A.G 1390/1- to the return flow hose -2- (blue marking) of the fuel filter.
Operate hand vacuum pump until fuel flows out of the

return-flow hose. Ensure that no fuel is drawn into the hand vacuum pump.
Connect return-flow hose -2- (marked in blue) to fuel

filter.
Interrogate the fault memory Vehicle Diagnosis,

Measuring and Information System VAS 5051. Note Faults are stored as a result of separating the central plug connection for the unit injector. Interrogate the fault memory and delete it as required.
Inspecting a tandem pump

Pressure gauge appliance (e.g. -VAS 5187-) Torque wrench Pliers for spring strap clips Hose clamp -MP 7-602-
Test conditions
Coolant temperature must be at least 85 C. Unit injectors O.K. Fuel filter and fuel line must not be blocked.
Procedure
Unplug connector -2- from the air mass meter -G70-. Detach vent hose -1-, intake hose -3- and air guide
-5-.
Screw out screw -4- and remove air filter housing.
20-1 page 10
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20
Unscrew screw plug -arrow-.
Connect pressure gauge appliance -VAS 5187- as

shown.
Install air filter and connect intake air hose and air
guide.
Start engine and engine speed must increase to 4000

rpm.
Note the pressure shown on the manometer.

Specified value: min. 1,05 MPa (10,5 bar) If the specified value is not reached:
Unclamp return-flow line between tandem pump and

fuel filter with hose clamp -MP 7-602-.
Start engine and engine speed must increase to 4000

rpm.
Note the pressure shown on the manometer.

Specified value: min. 1,05 MPa (10,5 bar) If the specified value is now reached: Pressure loss at the unit injectors.
Replace O-rings for unit injectors Chapter 23-1.

If the specified value is not reached:
Replace tandem pump 20-1 page 9.

Note After removing the pressure gauge appliance tighten the plug to 25 Nm. Always replace the gasket ring.
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20-1 page 12
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20-2
Accelerator control
Accelerator pedal module - Summary of components

1 - Connector black 6-pin 2 - Accelerator pedal module with Accelerator pedal position sender -G79- and accelerator pedal position sender 2 -G185 with kick-down-force element not adjustable to remove, release with -T10238-, or -T10240 removing and installing 20-2 page 1 3 - 10 Nm 4 - Cap
Removing and installing accelerator pedal module

Release tool -T10238- or -T10240-
T10238
Removing
Remove cover in the footwell. Disconnect connector at accelerator pedal module. Pull out cap at top of module. Unscrew the fixing screw. Insert release tool -T10238- (on vehicles with righthand steering release tool -T10240-) in the corresponding openings up to the stop.
Accelerator control
S20-0175
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20-2 page 1
20
Remove accelerator pedal module.
Installing
Installation is carried out in the reverse order. Pay attention to the following:
Insert cable line -1- and connector -2- on the accelerator pedal module.
Push accelerator pedal module onto fixing bolts -6-. Insert centering pin -7- in the opening in the vehicle
floor.
Screw on accelerator pedal module with fixing screws

-3-, tighten to 10 Nm and push on cap -4-.
Install cover in the footwell.
20-2 page 2
Accelerator control
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21
21 Turbocharging
21-1 Charge-air system with exhaust turbocharger Part 1
Note
Observe rules for cleanliness. Secure all hose connections with corresponding hose
clips.
The charge-air system must be tight. Replace the gaskets, the sealing rings and the self-
locking nuts.
Connection diagram for vacuum hoses

1 - Mechanical exhaust gas recirculation valve 2 - Vacuum reservoir 3 - To vacuum setting element of charge pressure control 4 - To vacuum setting element of radiator for exhaust gas recirculation 5 - Valve block Component parts of the valve block are: Changeover valve of radiator for exhaust gas recirculation -N345 Exhaust gas recirculation solenoid valve -N18 Solenoid valve for charge pressure control -N75 Connection diagram 21-1 page 2 6 - Vacuum line from the tandem pump to the valve block 7 - Tandem pump 8 - Air filter
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Charge-air system with exhaust turbocharger - Part 1
21-1 page 1
21
Connection diagram for valve block

P1 - Vacuum line from the tandem pump P2 - To mechanical exhaust gas recirculation valve P3 - To vacuum setting element of radiator for exhaust gas recirculation P4 - Ventilation hose to air filter P5 - To vacuum reservoir P6 - To vacuum setting element of charge pressure control Note The vacuum connection marked with -arrow- is not used and is closed.
Inspect vacuum setting element and tension rods for charge pressure control
Hand vacuum pump with accessories (e.g.
-V.A.G 1390 -)
Turbocharger tester (e. g. -V.A.G 1397 A -)
Faults at tension rods or at vacuum setting element of charge pressure control lead to the following faults:
Specified values for charge pressure are not reached. Poor performance. Irregular performance in the partial load region. Engine jerk in change-over.
Check vacuum piping for tightness and completeness

21-1 page 1.
II
Test sequence
Removing engine cover Chapter 10-1. Connect hand vacuum pump (e. g. -V.A.G 1390-) and
turbocharger tester (e.g. -V.A.G 1397 A-) with auxiliary hoses as shown. Fit test hose onto the connection fitting -I- and put the band switch of the unit into the position -I- (absolute pressure).
Generate vacuum with hand vacuum pump. Read off vacuum value at turbocharger tester
-V.A.G 1397 A- and at the same time observe tension rod of exhaust turbocharger. Note For the inspection use a mirror.
Specified value at 50 120 mbar: The tension rod

must move up.
Specified value at 550 620 mbar: The tension rod

must be positioned at the top up to the stop.
21-1 page 2
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21
Note The absolute pressure indicated on the turbocharger tester -V.A.G 1397 A- must decrease to the stated specified values.
Ventilate hand vacuum pump. Tension rod must move down.

Note Check tension rod movement over the entire adjustment range: Tension rod must move without jolting. If the specified values are not achieved or the tension rod moves with jolt:
Replace turbocharger Chap. 21-2.
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21-1 page 4
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21-2
Removing and installing turbocharger

1 - Gasket replace 2 - to flap of exhaust gas recirculation radiator 3 - 25 Nm replace Coat stud bolts with hot bolt paste -G 052 112 A3 4 - Connecting tube to flap of exhaust gas recirculation radiator 5 - Bracket for oil feed line 6 - 10 Nm 7 - Oil feed line Check oil feed line for continuity before installing. Fill the exhaust turbocharger with oil through the connection fitting of the oil feed line before installing 8 - Union nut - 22 Nm 9 - Connection fitting - 30 Nm 10 - Gasket ring replace 11 - Gasket replace Check fitting position 12 - Exhaust turbocharger can only be replaced complete with exhaust manifold and vacuum setting element of charge pressure control removing 21-2 page 2 installing 21-2 page 3 13 - Support between turbocharger and the cylinder block 14 - 40 Nm tighten all bolts first of all by hand 15 - Oil return line to cylinder block 16 - Connection fitting - 40 Nm 17 - 17 Nm 18 - 20 Nm tighten all bolts first of all by hand 19 - Shield 20 - 22 Nm
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21-2 page 1
21
Pliers for spring strap clips
Removing
Removing engine cover Chapter 10-1. Remove the middle sound dampening system
Body Work; Rep. Gr. 50. Note The fig. shows the removed engine from a rear view.
Release screws -1- and -3-. Release the vacuum lines at the rear of the air guide
pipe and detach hose to vacuum setting element of charge pressure control.
Detach hose -2- to crankcase vemtilation from air

guide pipe.
Release spring strap clip -4- with pliers for spring strap
clips and remove air guide pipe from exhaust turbocharger.
Unscrew fixing screws of right air guide pipe and remove air guide hose from exhaust turbocharger; to do so slightly raise the retaining clip -arrow-.
Remove the exhaust pipe Chap. 26-1.
Release screws -1- and -2- and remove support for

turbocharger.
Remove the oil return line -3- from the cylinder block.
21-2 page 2
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21
Unscrew oil feed line from exhaust turbocharger and

from exhaust manifold -arrows- and furthermore from coolant pipe and from oil filter holder and lay it to one side.
Remove connection pipe for exhaust gas recirculation

-arrows- and shield for exhaust manifold.
Unscrew nuts -arrows- and remove exhaust manifold

with exhaust turbocharger downwards.
Installing
Replace the gaskets, the sealing rings and the self-
locking nuts.
Fill exhaust turbocharger with engine oil through the
connection fitting of the oil feed line.

Hose connections and hoses for charge air system
must be free of oil and grease before being installed.

clips.
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21
Chapter 26-1.
Install exhaust system and align free of stress When installing the air guide with push-fit coupling ensure that the locking clip -arrow- interlocks behind the retaining lug -A-.

Note after installing the exhaust turbocharger run the engine approx. 1 minute in idle and do not increase speed immediately in order to ensure the supply of oil to the turbocharger.
Removing and installing parts of the charge air cooling

Note
Before testing or repairing check all hoses and lines
for tight connection and leaktightness.

Hose connections and hoses for charge air system
must be free of oil and grease before being installed.

clips.
21-2 page 4
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21
1 - 8 Nm 2 - Bracket Check fitting position 3 - Charge air cooler removing and installing 21-2 page 5 4 - Air guide hose 5 - to turbocharger 6 - Air guide pipe 7 - to induction pipe 8 - 15 Nm 9 - 3 Nm 10 - Charge pressure sender -G31-/Intake air temperature sender -G42-
Removing and installing charge-air cooler

Removing
Removing coolant cooler Chapter 19-1. Remove front bumper Body Work; Rep. Gr. 63. Unscrew the air guide on the left and right of the
charge air cooler.
WARNING! Refrigerant circuit of the air conditioning system must not be opened. Note To avoid damaging the condenser, wiring and air conditioning hoses make sure the lines and hoses are not excessively expanded, buckled or bent.
Edition 01.05 S00.5709.01.20 Charge-air system with exhaust turbocharger - Part 2
21-2 page 5
21
Screw out the fixing screws -2- of the condenser. Release screws item 1 in 21-2 page 5 at charge
air cooler.
Swivel the charge air cooler backwards, unhook upwards and remove downwards.
Installing
Install front bumper Body Work; Rep. Gr. 63.

Note Replace O-rings.
When installing the air guide with push-fit coupling ensure that the locking clip -arrow- interlocks behind the retaining lug -A-.
Install the coolant cooler Chapter 19-1.
21-2 page 6
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Removing and installing air filter

1 - Air intake hose to turbocharger 2 - Air mass meter -G703 - O-ring replace if damaged 4 - 8 Nm 5 - Top part of air filter if during repairs the air filter housing is opened (except for air filter element change), it should be entered in the Service Schedule (change interval for air filter element is shortened) 6 - Ventilation hose to valve block 7 - Air filter element 8 - Air deflector to the lock carrier 9 - Bottom part of air filter with supports for drain pipe 10 - 10 Nm 11 - Drain pipe Vehicles 12.04
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21-2 page 8
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23
23 Fuel Formation, Injection

23-1 Repairing a diesel direct fuel injection system
The control unit is equipped with a fault memory. Before repairs, setting operations and fault finding, interrogate the fault memory and execute a self-diagnosis Vehicle Diagnosis, Measuring and Information System VAS 5051. Note Faults can be detected by the control unit as checking and adjustment work is being undertaken and then saved. It is therefore absolutely necessary to delete the fault memory after completing all checking and adjustment work Vehicle Diagnosis, Measuring and Information System VAS 5051
Safety measures
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring devices are operated from the passenger seat, the passenger can be injured by the release of the passenger airbag in the event of an accident.
WARNING! Secure the diagnostic device to the rear seat and operate from that position. Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Disconnect and connect wires of the preheating and
injection system and measuring device wires when the ignition is switched off.
If the engine should be run at the starter speed without
it actually igniting, then separate the central plug connection for the unit injector at the cylinder head.
Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.

Switch off the ignition before connecting or discon-
necting the battery as this could otherwise damage the diesel direct injection system control unit.
When the battery is disconnected and reconnected,
carry out rework Electrical System; Rep. Gr. 27.
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Repairing a diesel direct fuel injection system
23-1 page 1
23
Overview of fitting locations
Note
Some components are fitted under the engine cover. Removing Chapter 10-1. Components A through G are not represented in the overview figure. A - Warning light for engine electronics -K149 on the dash panel insert B - Accelerator pedal position sender -G79- with accelerator pedal position sender 2 -G185 in footwell on the accelerator pedal C - Brake light switch -F- and Brake pedal switch -F63 in footwell on the brake pedal D - Fuel pump relay -J17 on relay carrier E - Clutch position sender -G476 on clutch main cylinder F - 6-pin relay carrier with automatic glow period control unit -J179 below E-box in the engine compartment G - Relay and fuse carrier with voltage supply relay terminal 30 -J317 with voltage supply relay terminal 15 -J329 E-box in the engine compartment 1 - Unit injectors and glow plugs Unit injector solenoid valve No.1 cyl. -N240 Unit injector solenoid valve No. 2 cyl. -N241 Unit injector solenoid valve No. 3 cyl. -N242 Unit injector solenoid valve No. 4 cyl. -N243 Removing and installing the unit injectors 23-1 page 5 Glow plug 1 -Q10 Glow plug 2 -Q11 Glow plug 3 -Q12 Glow plug 4 -Q13 Removing and installing glow plugs Chap. 28-1 2 - Diesel direct injection system control unit -J248 with altitude sender -F96 removing and installing Chapter 23-2 3 - Flap of radiator for exhaust gas recirculation 4 - Multipin plug connection Central plug connection for unit injectors and glow plugs
23-1 page 2
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OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD 5 - Valve block Component parts of the valve block are: Changeover valve for radiator, exhaust gas recirculation -N345 Exhaust gas recirculation valve -N18 Solenoid valve for charge pressure control -N756 - Air mass meter -G707 - Sender for coolant temperature -G628 - Tandem pump 9 - Fuel temperature sender - G8110 - Engine speed sender -G2811 - Charge pressure sender -G31- with intake air temperature sender -G4212 - Intake manifold flap motor -V15713 - Mechanical exhaust gas recirculation valve 14 - Coolant temperature sender-cooler outlet -G8315 - 3-pin plug connection for hall sender -G4016 - Hall sender -G40 for camshaft position
23
Overview of intake manifold

12345678910 11 12 13 14 15 16 17 22 Nm Lifting eye 22 Nm Gasket replace 10 Nm Pipes for fuel and coolant Intake manifold Bracket for wiring loom 22 Nm O-ring replace 22 Nm Connecting tube for exhaust gas recirculation Gasket replace Mechanical exhaust gas recirculation valve 10 Nm Air guide pipe Gasket ring replace
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23
18 - Intake manifold flap motor -V157 The intake manifold flap is closed for about 3 seconds after switching off the engine and then opens again. This reduces the switch-off impact. 19 - O-ring replace 20 - 10 Nm 21 - Vacuum hose in valve block
Repairing the unit injectors

Note Observe the cleanliness regulations Chapter 01-1. 1 - 8 Nm + torque a further + 180 (1/2 turn) replace 2 - Valve-lever shaft removing and installing 23-1 page 5 3 - 20 Nm + torque a further 90 (1/4 turn) replace 4 - Adjusting screw replace Grease the contact surfaces of the unit injector to ball pins using grease -G 000 1005 - Lock nut - 30 Nm 6 - Unit injector removing and installing 23-1 page 5 When installing, oil the Orings and the lines in the cylinder head 7 - O-ring replace 23-1 page 9 8 - O-ring replace 23-1 page 9 9 - Cylinder head
23-1 page 4
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23
Removing and installing the unit injectors

Universal dial gauge holder -MP 3-447 Extractor - part -T10133/3 Extractor -T10163 Dial gauge Torque wrench
Removing
Remove upper timing belt cover and cylinder head

cover Chapter 15-1.
Turn the crankshaft until the cam pair of the relevant

unit injector to be removed points uniformly upwards.
Release the counternuts -2- of the adjusting screws

-1- on all unit injectors.
Unscrew the adjusting screws until the relevant valve

lever always rests against the tappet spring of the unit injector.
several stages and remove valve-lever shaft. Note Do not pull out screws of valve-lever shaft, so that the individual parts on the valve-lever shaft remain attached. If necessary mark assignment of the valve lever.
Separate plug connections -1- for the unit injectors; at

the same time press latch clips.
Separate plug connections -2- for glow plugs.
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23-1 page 5
23
to one side.
Release cable rail -1- from the clips -arrows- and lay it
Screw out screws -arrows- and pull out of holes.
Always pull the ball pin -1- out of the relevant unit injector.
23-1 page 6
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23
Insert extractor -T10163- into the holes for the screws

on the unit injector.
Tighten spindle -A- moderately against the unit injector. Tighten counternut -B- by hand.
With careful knocks -T10133/3- pull the unit injector

out of the cylinder head seat upwards. Note Do not interchange the unit injectors, if necessary mark the assignment to each cylinder.
Installing
Note
Replace the screws of the unit injectors. When installing, oil the O-rings and the lines in the cyl-
inder head.
New unit injectors are supplied with new O-rings. When installing a new unit injector, the corresponding
adjusting screw in the valve lever must also be replaced

If the old unit injectors are installed again, all O-rings
must be replaced 23-1 page 9.
For any work procedure involving an adjustment of the
unit injector it is necessary to clean the adjusting screw in the valve lever and also the ball pin of the unit injector and to check them for traces of wear. If there is any wear replace the ball pin and the adjusting screw.
Grease the contact surfaces of the ball pin and the ad-
justing screw using Grease -G 000 100-.
Before installing the unit injector check the correct position of both O-rings.
The O-rings must not be twisted. The white marked O-ring is located in the bottom slot
of the unit injector.
Oil the O-rings as well as the lines in the cylinder head

and place the unit injector with the greatest of care into the cylinder head seat.
Screw on the unit injector with new screws -arrowsand tighten slightly by hand.
Push the unit injector into the cylinder head seat up to

the stop by exerting a uniform pressure on the spring cap.
Tighten the new screws as follows:
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23
Stage I II III Tighten

wrench to 3 Nm.
Before inserting the valve-lever shaft, check whether

all the ball pins -1- and O-rings -2- are inserted in the unit injectors.
Screw on valve-lever shaft with new screws as follows: Sequence I Tighten
Tighten screws -2- and -4alternately in several stages, until the valve-lever shaft rests on the bushing.
II
Tighten screws -1-, -3- and

-5- to 20 Nm + torque a further 90 (1/4 turn).
III
Tighten screws -2- and -4to 20 Nm + torque a further 90 (1/4 turn).
Position a dial gauge on the adjusting screw of the unit

injector as shown in the fig.
Turn the crankshaft in the running direction of the engine until the roller of the valve lever is on the drive cam tip.
Roller side of valve lever -arrow A- is on the highest

point.
Dial gauge -arrow B- is on the lowest point.
23-1 page 8
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23
Remove the dial gauge. Turn the adjusting screw in the valve lever until one
feels a significant resistance (the unit injector is against the stop).
Turn the adjusting screw in the opposite direction from

the stop by about 225 .
Hold the adjusting screw in this position and tighten up

the lock nut using a torque of 30 Nm Further installation occurs in reverse order, while paying attention to the following:
Connect plug connections for unit injectors and for

glow plugs.
Install cylinder head cover and fit upper timing belt

cover Chapter 15-1.
Replace O-rings for unit injectors

Assembly sleeve -T10164/1 Assembly sleeve -T10164/2-
Removing
Remove unit injector 23-1 page 5. Lever off the old O-rings from the unit injector with extreme care.
Make sure that no burr arises at the base of the Orings.
Installing
Note
Always use the assembly sleeves to install the O-
rings. If they are not used, the O-rings can be damaged.

Observe the correct allocation of the O-rings to the
channels.
When installing, slide on the O-rings, do not roll. They
must not be turned inwards on the seat of the unit injector.
Clean the seating surfaces for the O-rings in the unit

injector with great care.
Insert the assembling sleeve -T10164/1- on the unit

injector up to the stop.
Carefully slide the top, thicker O-ring onto the assembling sleeve and into the groove of the unit injector.
Remove assembly sleeve.
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23-1 page 9
23
injector up to the stop.
Insert the assembling sleeve -T10164/2- on the unit Carefully slide the lower, white marked O-ring onto the
assembling sleeve and in the groove of the unit injector.
Remove assembly sleeve. Install the unit injector 23-1 page 5.
23-1 page 10
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23
23-2
Engine control unit
Removing and installing engine control unit

Note
In order to be able to unplug the connector from the
control unit, the control unit must always be removed.

The learning values are erased when the plug is re-
moved from the engine control unit, the fault memory contents are however retained. Special tools, test and measuring equipment and auxiliary items required
Body saw (e.g. -V.A.G 1523 A-)
Removing
When replacing the engine control unit, in the guided

fault detection system the diagnostic field replace engine control unit must be selected Vehicle Diagnosis, Measuring and Information System VAS 5051.
Switch off ignition. Remove the cooling water tank cover Body Work;
Rep. Gr. 66.
Remove the intermediate wall for cooling water tank

-arrows-.
Removing windscreen wiper and washer system

Electrical System; Rep. Gr. 92. For vehicles with protective cover
Cut with body saw -1- a slot for the cross-head screwdriver in the heads of the pull-off screws -2-.
Screw out the screws.
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Engine control unit
23-2 page 1
23
screwdriver.
Lift locking tab of protective cover with cross-head Push the protective cover in the -direction of the arrow- out of the bracket for engine control unit. For all vehicles
Unlock retaining bracket -2-. Push out engine control unit with connectors in the -direction of the arrow-. Unlock connector at engine control unit and unplug.
Installing
Note For vehicles with protective cover, the metal swarfs must be suctioned out of the plenum chamber before installing the engine control unit.
Connect both connectors and lock. Push engine control unit into the bracket and lock with
retaining bracket -2-.
After installation of the new control unit, activate the

engine control unit in the guided fault detection system in the diagnostic field replace engine control unit Vehicle Diagnosis, Measuring and Information System VAS 5051.
After installing the original control unit interrogate the
fault memory and erase any faults present Vehicle Diagnosis, Measuring and Information System VAS 5051.
For vehicles with protective cover
Fasten protective cover with new pull-off screws (before tightening align the protective cover in such a way that it does not come into contact with the surrounding components)
23-2 page 2
Engine control unit
Edition 01.05 S00.5709.01.20
OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD For all vehicles
23
Installing windscreen wiper and washer system

Install intermediate wall and cover of the plenum

Edition 01.05 S00.5709.01.20
Engine control unit
23-2 page 3
23
23-2 page 4
Engine control unit
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26
26 Exhaust System
26-1 Removing and installing parts of the exhaust system
Note
The decoupling element in the front part of the ex-
haust pipe should not be bent by more than 10 - danger of damaging it.
Replace the gaskets and the self-locking nuts. After performing installation work on the exhaust sys-
tem, make sure the exhaust system is not mounted under tension and has adequate clearance from the vehicle body. If necessary slacken the double clamp and collar clamp and align the silencer and exhaust pipe so as to create adequate clearance between these components and the vehicle body, and that the weight of the exhaust system is evenly distributed over the hangers.
Edition 02.04 S00.5709.00.20
Removing and installing parts of the exhaust system
26-1 page 1
26
Summary of components
1 - Rear tunnel bridge 2 - The middle silencer for first equipment building unit with rear silencer, replace individually when carrying out repairs Separation point 26-1 page 2 Align exhaust system free of stress 26-1 page 3 3 - Retaining strap replace if damaged pay attention to the spare part number 4 - Hanger 5 - 23 Nm 6 - Clamp - 7 Nm 7 - Gasket 8 - Front exhaust pipe with catalytic converter protect against shocks and blows with decoupling element do not twist decoupling element more than 10 - risk of damage Align exhaust system free of stress 26-1 page 3 9 - Support 10 - 40 Nm 11 - Double clamp Align exhaust system free of stress before tightening 26-1 page 3 Tighten bolted connections evenly 12 - 25 Nm 13 - Front tunnel bridge 14 - Rear silencer for first equipment building unit with middle silencer, replace individually when carrying out repairs Separation point 26-1 page 2 Align exhaust system free of stress 26-1 page 3
Replacing middle or rear silencer

For separating the middle or rear silencer, a separa-
tion point is provided in the connecting pipe, which is marked with a recess. Special tools, test and measuring equipment and auxiliary items required
Body saw (e.g. - V.A.G 1523 A-) Protective goggles
26-1 page 2
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26
Procedure
Use body saw (e. g. -V.A.G 1523 A -) to separate exhaust pipe at right angles at separation point -arrow 2-.
When installing, position double clamp -4- at the side

markings -arrow 1- and -arrow 3-.
Install double clamps in such a way that the ends of

the screws do not protrude beyond the bottom edge of the double clamp.
bolted connection points to the right. Align exhaust system free of stress 26-1 page 3.
Aligning exhaust system free of stress

The exhaust system is aligned when cold.
Slacken bolted connections of double clamp
item 11 in 26-1 page 2 between front and middle silencer. mension -a- = 9 11 mm is achieved between hanger/body and hanger/middle silencer.
Push the exhaust system so far forward until the di-
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26
Install double clamps in such a way that the ends of

the screws do not protrude beyond the bottom edge of the double clamp.
bolted connection points to the right. Tighten bolted connections of the double clamp evenly to 25 Nm.
Align tail pipe
Align rear muffler in such a way that there is an equal

distance -a- and -b- between bumper opening and tailpipe.
For aligning the tail pipe, if necessary loosen hanger

on the rear silencer.
Checking the exhaust system for leaks

Start engine and run in idle. Seal off tail pipe for the duration of the leak check (e.g.
with cloth or plug).
Inspect connection points of cylinder head/exhaust

manifold, exhaust turbocharger/catalytic converter etc. for leaks by listening.
Eliminate any leak found.
26-1 page 4
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26
26-2
Note
Exhaust gas recirculation system
The exhaust gas recirculation system is operated by
the diesel direct injection system control unit -J248 via the EGR valve -N18- to the mechanical exhaust gas recirculation valve.
The mechanical exhaust gas recirculation valve with
conically shaped valve tappet makes it possible to achieve different opening cross-sections at different valve strokes.
Any desired valve plunger position is possible as a re-
sult of the pulsed operation.

The exhaust gas recirculation switches off at idling
speed after about two minutes.

When taking longer measurements, restart the engine
or increase engine speed briefly to more than 1500 rpm. After this repeat the measurement.
clips.
Replace self-locking nuts.
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26
Removing and installing parts of the exhaust gas recirculation system

1 - 22 Nm 2 - Connecting tube 3 - Gasket replace 4 - Flap of radiator check 26-2 page 4 when actuating it guides the exhaust via the radiator for exhaust gas recirculation Connection diagram 26-2 page 3 5 - to mechanical exhaust gas recirculation valve Connection diagram 26-2 page 3 6 - Radiator for exhaust gas recirculation removing and installing 26-2 page 5 7 - Bracket of flap for radiator and of radiator for exhaust gas recirculation 8 - 10 Nm 9 - Bracket for engine cover 10 - From exhaust manifold 11 - Connecting tube 12 - 25 Nm
26-2 page 2
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26
Connection diagram for exhaust gas recirculation

1 - Mechanical exhaust gas recirculation valve check 26-2 page 4 2 - Vacuum reservoir 3 - To vacuum setting element of charge pressure control 4 - To vacuum setting element of radiator for exhaust gas recirculation 5 - Valve block Component parts of the valve block are: Changeover valve for radiator, exhaust gas recirculation -N345 Exhaust gas recirculation valve -N18 Solenoid valve for charge pressure control -N75 Connection diagram 26-2 page 3 6 - Vacuum line from the tandem pump to the valve block 7 - Tandem pump 8 - Air filter
Connection diagram for valve block

P1 - Vacuum line from the tandem pump P2 - To mechanical exhaust gas recirculation valve P3 - To vacuum setting element of radiator for exhaust gas recirculation P4 - Ventilation hose to air filter P5 - To vacuum reservoir P6 - To vacuum setting element of charge pressure control Note The vacuum connection marked with -arrow- is not used and is closed.
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Test mechanical exhaust gas recirculation valve

-V.A.G 1390 -)
Test sequence
Removing engine cover Chapter 10-1. Disconnect the vacuum hose from the mechanical exhaust gas recirculation valve.
Connect hand vacuum pump -V.A.G 1390- to valve. Generate vacuum. Detach hose of hand vacuum pump from exhaust gas
recirculation valve.
Closing of the valve should be clearly audible.
Cool the exhaust gas recirculation

Operation
The exhaust gas recirculation system is equipped with a radiator, through which the coolant flows, in order to improve the emission levels. The exhaust gas which flows back into the combustion chamber is guided under certain conditions via this radiator. So the exhaust gas temperature can be decreased, which decreases the combustion chamber temperature again and through this the emission levels are improved. The engine control unit determines when the path via the radiator for the exhaust gas recirculation is selected. This procedure is controlled via the changeover valve of the radiator for the exhaust gas recirculation -N345-, which operates the radiator flap for the exhaust gas recirculation with the vacuum setting element.
Check exhaust gas recirculation changeover

-V.A.G 1390 -)
Test sequence
Detach vacuum hose from vacuum setting element -1from radiator flap for exhaust gas recirculation.
Connect hand vacuum pump -V.A.G 1390- to vacuum

setting element.
Generate vacuum.
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26
Tension rod of vacuum setting element for radiator

flap for exhaust gas recirculation must move. If the tension rod does not move or it only moves with a sudden motion:
Vacuum setting element defective Resistance in radiator flap for exhaust gas recircula-
tion
Removing and installing radiator for exhaust gas recirculation

Pliers for spring strap clips
Removing
Drain coolant Chapter 19-1. Remove air guide between air filter and exhaust turbocharger Chapter 21-1.
Disconnect coolant hoses -1- from the radiator flap

housing for exhaust gas recirculation.
Disconnect coolant hoses -2- und -3- from radiator for

exhaust gas recirculation.
Detach vacuum hose -4- from vacuum setting element

of flap for exhaust gas recirculation.
Release screws -2- and -6-. Release screws -1-, -3-, -4- und -5- and remove radiator for exhaust gas recirculation.
Installing
Replace the gaskets, the sealing rings and the self-
locking nuts.
clips.
Top up coolant Chapter 19-1.
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26
26-2 page 6
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28
28 Glow Plug System

28-1 Preheating
Removing and installing glow plugs

Socket insert (SW 8)
Removing
Switch off ignition. Remove cylinder head cover Chapter 15-1. Unplug connector of glow plugs. Remove glow plugs with socket insert -arrows-.
Installing
Install glow plugs and tighten to 10 Nm. Install cylinder head cover Chapter 15-1.
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Preheating
28-1 page 1
28
28-1 page 2
Preheating
Edition 02.04 S00.5709.00.20

Engine 2.0 103 KW Tdi PD, 2.0 100 KW Tdi PD

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Engine 2.0 103 KW Tdi PD, 2.0 100 KW Tdi PD

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Service

Service Department. Technical Information

Printed in Czech Republic S00.5709.00.20

Printed in Czech Republic S00.5709.00.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

List of Supplements to Workshop Manual

Edition 02.04 01.05

Article Number S00.5709.00.20 S00.5709.01.20

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

10 Removing and Installing Engine

page 13 page 14 page page page page 1 1 2 4

15 Cylinder Head, Valve Gear

Edition 01.05 S00.5709.01.20

page 10 page 11 page 12

page 10 page 11 page 12

Edition 01.05 S00.5709.01.20

23 Fuel Formation, Injection

28 Glow Plug System

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Number of valves per cylinder

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Safety precautions when working on the fuel supply system

Edition 02.04 S00.5709.00.20

Self diagnosis, safety measures, cleanliness regulations and directions

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

roundings before releasing.

not use fuzzy cloths!

pair is not completed immediately.

air. Avoid moving the vehicle.

Regulations concerning cleanliness when working on the exhaust gas turbocharger

roundings before releasing.

not use fuzzy cloths!

pair is not completed immediately.

air. Avoid moving the vehicle.

Self diagnosis, safety measures, cleanliness regulations and directions

Edition 02.04 S00.5709.00.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

10 Removing and Installing Engine

Disconnect the battery-earth strap with the ignition off

Remove cover and intermediate wall of the plenum

Edition 01.05 S00.5709.01.20

Removing and Installing Engine

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Drain coolant Chapter 19-1.

Detach fuel filter with its connected hoses upwards

Removing AC compressor and holder for auxiliary

Remove charge air hose and charge-air pipe between

Removing and Installing Engine

Edition 01.05 S00.5709.01.20

OCTAVIA II 2004 Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD

Remove the drive shaft on the right and unscrew the

Unlatch the fuse and and unplug the front connector

Release all remaining plugs at engine and gearbox