Cwva 1 6 Mpi Engine Eng

Service
Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
Yeti 2010 ➤
Yeti 2011 ➤
1.6/81 kW MPI engine
Engine ID
CWV
A
Edition 06.2014
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤
1.6/81 kW MPI engine - Edition 06.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 4
2.3 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 5
2.6 Safety precautions when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 6
2.7 Safety precautions during road tests in which testing and measuring equipment is used . . 6
2.8 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.9 Additional instructions when undertaking assembly work on the air-conditioning system . . 7
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Assembly of radiators and capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Remove - (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Removing - (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.4 Installing - (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.5 Installing - (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Assembly bracket - Summary of components (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Assembly bracket - Summary of components (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Removing and installing engine bracket - (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Removing and installing engine bracket - (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.5 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6 Checking the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.7 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 Cylinder block on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.3 Removing and installing tensioning device for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Removing and installing ribbed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.6 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Gearbox side cylinder block - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Removing and installing the sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . 57
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Contents i
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.1 Piston and conrod - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.1 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.2 Camshaft housing - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.4 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.5 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.2 Timing belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.3 Test timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.4 Remove the toothed belt from the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.3 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.4 Removing and installing gasket rings for camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.5 Removing and installing N205 the camshaft adjustment valve 1 . . . . . . . . . . . . . . . . . . . . 121
3.6 Removing and installing valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.1 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Oil sump and oil pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Removing and installing oil sump bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.3 Removing and installing oil sump top part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.1 Engine oil cooler - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.1 Crankcase ventilation - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.1 Summary of components - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.3 Testing oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.3 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
ii Contents
2.1 Summary of components - coolant pump/coolant thermostat . . . . . . . . . . . . . . . . . . . . . . 153

2.2 Coolant temperature sender - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.4 Removing and installing toothed belt pulley for coolant pump drive . . . . . . . . . . . . . . . . . . 159
2.5 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
2.6 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 162
2.7 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 163
3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.1 Cooling system attached to engine - Summary of components . . . . . . . . . . . . . . . . . . . . . . 165
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.1 Radiator- Summary of components (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2 Radiator - Summary of components (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.3 Fan shroud with a radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 170
4.4 Fan shroud with two radiator fans - Summary of components . . . . . . . . . . . . . . . . . . . . . . 171
4.5 Remove and install radiator (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.6 Removing and installing radiator (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.7 Removing and installing radiator cowl for radiator fan (Octavia III) . . . . . . . . . . . . . . . . . . 175
4.8 Removing and installing fan shroud for radiator fan (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.9 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.10 Removing and installing radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Fuel tank- Summary of components (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.2 Fuel tank - Summary of components (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.3 Fuel filter - Summary of components (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.4 Removing and installing fuel filter (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.5 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
1.6 Removing and installing fuel tank- (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
1.7 Removing and installing fuel tank - (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.8 Fuel delivery unit and sender for fuel gauge display - Summary of components . . . . . . . . 198
1.9 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.10 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 202
1.11 Check fuel pump - (Octavia IlI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.12 Check fuel pump - (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2 Quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.1 Separating quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3.1 Accelerator pedal module- Summary of components (Octavia III) . . . . . . . . . . . . . . . . . . . . 220
3.2 Summary of components - Accelerator pedal module (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . 221
3.3 Removing and installing accelerator pedal module (Octavia IlI) . . . . . . . . . . . . . . . . . . . . 221
3.4 Removing and installing accelerator pedal module (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4.1 Activated charcoal filter- Summary of components (Octavia III) . . . . . . . . . . . . . . . . . . . . 226
4.2 Activated charcoal filter - Summary of components (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.3 Removing and installing parts of the activated charcoal filter system - (Octavia III) . . . . . . 227
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.1 Injection system - Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.1 Air filter housing- Summary of components (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . 233
2.2 Summary of components - Air filter housing (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.3 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Contents iii
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

3.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
3.3 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 238
3.4 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.1 Fuel rail with injection valves - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.2 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
4.3 Removing and installing injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.4 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.5 Clean injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
5.1 Removing and installing intake air temperature sender G42 / manifold pressure sender G71
...................................................................... 248
6 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6.1 Lambda probe - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6.2 Removing and installing lambda probe G39 / G130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
7.1 Installing and removing engine control unit J623 without protective housing - (Octavia III)
........................................................................ 252
7.2 Removing and installing engine control unit J623 , engine control unit with protective housing
- (Octavia III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
7.3 Installing and removing engine control unit J623 without protective housing - (Yeti) . . . . . . 255
7.4 Removing and installing engine control unit J623 , engine control unit with protective housing
- (Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

1 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
1.1 Pre-exhaust pipe with catalytic converter - Summary of components . . . . . . . . . . . . . . . . 259
1.2 Middle or rear part of the exhaust system - Summary of components (Octavia III) . . . . . . 261
1.3 Middle or rear part of the exhaust system - Summary of components (Yeti) . . . . . . . . . . . . 262
1.4 Removing and installing pre-exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . 262
1.5 Removing and installing or replacing the middle and rear silencer - (Octavia III) . . . . . . . . 264
1.6 Removing and installing or replacing the middle and rear silencer - (Yeti) . . . . . . . . . . . . 266
1.7 Aligning exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.8 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.1 Ignition system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
iv Contents
00 – Technical data
1 Identification
(SRL000704; Edition 06.2014)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine characteristics”, page 1
1.1 Engine number

The “engine identification characters” and “serial number” are
shown on the crankcase narrowly above the gearbox connection.
“Engine identification characters” and “serial number” are located
on the sticker -arrow- on the upper toothed belt guard.
The “engine identification” characters are also indicated on the
vehicle data sticker.
Fitting locations for vehicle data stickers:
♦ ⇒ Maintenance ; Booklet Octavia III
♦ ⇒ Maintenance ; Booklet Yeti
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999 999 engines with the same engine
code were produced then the first digit of the six part section will
be replaced by a letter.
Vehicles with four-digit engine identification characters
♦ Starting with the letter “C”, new four digit engine codes have
been introduced.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched on the cylinder block including
the serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine - J623- control unit.
1.2 Engine characteristics

Edition 01.2014, version 1.0
Octavia III
Engine identification characters CWVA
Manufactured 02.14►
Emission standards EU5
Displacement cm 3 1598
Output kW at rpm 81/5800
Torque Nm at rpm 155/3800
Bore ∅ mm 76.5
Stroke mm 86.9
Compression 10.5
Cylinder/valves per cylinder 4/4
RON at least unleaded 95 1)
Ignition system, fuel injection Bosch ME 17
1. Identification 1

Firing order 1-3-4-2
1) At least 91 RON in exceptional cases, although engine output
is reduced.
Yeti
Manufactured 06.14►
Emission standards EU4, EU5
Capacity cm3 1598
Output kW at rpm 81/5800
Torque Nm at rpm 155/3800
Bore ∅ mm 76.5
Stroke mm 86.9
Compression ratio 10.5
Cylinder/valves per cylinder 4/4
RON at least 95 unleaded
Ignition system, fuel injection Bosch ME 17
Firing order 1-3-4-2
Volkswagen Technical Site: http://vwts.ru

огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi
2 Rep. gr.00 - Technical data

2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.2 Rules of cleanliness to observe when working on the fuel
supply system”, page 4
⇒ “2.3 General notes on the injection system”, page 4
⇒ “2.4 General notes on the ignition system”, page 5
⇒ “2.5 Safety measures to apply when working on the fuel injec‐
tion and ignition system”, page 5
⇒ “2.6 Safety precautions when working on vehicles with a start/
stop system”, page 6
⇒ “2.7 Safety precautions during road tests in which testing and
measuring equipment is used”, page 6
⇒ “2.8 Safety precautions when working on cooling system”, page
6
⇒ “2.9 Additional instructions when undertaking assembly work
on the air-conditioning system”, page 7
2.1 Safety precautions when working on

fuel supply system
♦ The fuel delivery unit is activated when the ignition is switched
on and by the door contact switch of the driver door. Before
opening the fuel system and for reasons of safety, if the battery
is not disconnected, the connector must be disconnected from
the fuel pump.
Caution
There is a risk of destruction of electronic components when

disconnecting the battery.
♦ Observe measures when disconnecting the battery.
Disconnect the battery only when the ⇒ Electrical System; Rep.

gr. 27 ; battery is disconnected .
WARNING
When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (for fuel, hydraulic fluid, the active
charcoal container-unit, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ Ensure that there is adequate free access to all moving or
hot components.
When removing and installing the delivery unit from a full or partly
filled fuel tank pay attention to the following:
2. Safety instructions 3
WARNING
The fuel system is under pressure! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully removing the hose.
♦ The extraction hose of an exhaust extraction system which is

switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
Rules of cleanliness when working on the fuel supply system
⇒ page 4 .
2.2 Rules of cleanliness to observe when

working on the fuel supply system
Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean components: Remove spare parts from their
wrapping immediately before fitting. Do not use any parts
which have been stored unwrapped.
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean
the hoses immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
2.3 General notes on the injection system

Injection system - Fitting location of the injection system
⇒ page 229 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the fault
memory. Also check the vacuum hoses and connections (un‐
metered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ Electronic catalogue of original parts
“ETKA” . The use of clamp-type or screw-type clips is not al‐
lowed.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ Certain inspections may cause the control unit to detect and
store a fault. After ending all tests and repairs, query the error
memory and remedy any errors ⇒ Vehicle diagnostic tester.

♦ After deleting the fault memory of the engine control unit the
readiness code must be re-generated.
Safety measures ⇒ page 5 .
2.4 General notes on the ignition system

Ignition system - Assembly overview ⇒ page 269 .
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ The engine control unit and further components are equipped
with self-diagnosis: Inspection ⇒ Vehicle diagnostic tester.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. After ending all tests and repairs, query the error
memory and remedy any errors ⇒ Vehicle diagnostic tester.
♦ After deleting the fault memory of the engine control unit the
Safety measures ⇒ page 5 .
Setting data, spark plugs:
2.5 Safety measures to apply when working

on the fuel injection and ignition system
WARNING
The fuel system is under pressure! Before opening the system

lay cleaning cloths around the connection point. Reduce pres‐
sure by carefully releasing the connection point.
Observe the following points to prevent injury to persons and/or

damage to the injection and ignition system:
♦ Do not touch or disconnect ignition cables when the engine is
being turned at start speed when the engine is running.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ The fuel delivery unit is activated when the ignition is switched
on and by the door contact switch of the driver door. Before
opening the fuel system and for reasons of safety, if the battery
is not disconnected, the connector must be disconnected from
the fuel delivery unit.
If the engine must be operated at start speed without the engine
starting:
– Disconnect all plug connections from the ignition coils
⇒ page 269 .
– Disconnect all plug connections from the injection valves
⇒ page 229 .
If test and measuring devices are required during test drives ob‐
serve the following safety instructions ⇒ page 6 .
2.6 Safety precautions when working on ve‐

hicles with a start/stop system
When working on vehicles with start/stop system, please observe
the following:
WARNING
There is risk of injury from automatic engine starting on vehi‐

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

which testing and measuring equipment
is used
If test and measuring devices are required during test drives ob‐
serve the following:
WARNING
There is a risk of accident from deflection and insufficient se‐

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

cooling system
WARNING
Hot steam may escape when the compensation bottle is

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

Caution
When undertaking all assembly work, particularly in the engine

compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (for fuel, hydraulic fluid, the active
charcoal container-unit, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ Secure all hose connections with hose clamps, assignment ⇒
Electronic Catalogue of Original Parts “ETKA” .
♦ Using the hose clip pliers , for example -VAS 6362- , is rec‐
ommended for assembling the spring strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection and hose).
2.9 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
In order to avoid damage to the condenser as well as to the re‐

frigerant lines and hoses, ensure that the lines and hoses are not
over-tensioned, kinked or bent.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit:
– Remove the holding clamp(s) of the refrigerant lines.
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 8
⇒ “3.2 Foreign bodies in the engine”, page 8
⇒ “3.3 Contact corrosion”, page 8
⇒ “3.4 Cable routing and securing”, page 8
⇒ “3.5 Assembly of radiators and capacitors”, page 9
3.1 Rules of cleanliness

Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean components: Remove spare parts from their
wrapping immediately before fitting. Do not use any parts
which have been stored unwrapped.
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean
the hoses immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
3.2 Foreign bodies in the engine

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

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

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

3.5 Assembly of radiators and capacitors

The radiator and capacitor may have minor indentations on the
fins, even if assembly is correct. This is not a case of damage.
The radiator and capacitor must not be replaced because of these
indentations.
3. Repair instructions 9
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Remove - (Octavia III)”, page 10
⇒ “1.2 Removing - (Yeti)”, page 18
⇒ “1.3 Securing the engine to the assembly stand”, page 25
⇒ “1.4 Installing - (Octavia III)”, page 26
⇒ “1.5 Installing - (Yeti)”, page 29
1.1 Remove - (Octavia III)

Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel - MP8-602/1-
♦ Extending the lifting device - MP9-201 (2024A)-
♦ Engine/gearbox jack - V.A.G 1383 A-
♦ Engine mount - T10497-
♦ Catch pan , e.g. -VAS 6208-
♦ Hose clip pliers, e.g. - VAS 6362-
♦ Locking pin - T10060 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Grease - G 000 100-
♦ Protective goggles
♦ Protective gloves
Work procedure
Note
♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
10 Rep. gr.10 - Removing and installing engine

– Open cap -arrow- for coolant expansion tank.
WARNING
Danger of scalding due to hot steam and hot coolant.

♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.
– Remove both wheels ⇒ Axles, steering; Rep. gr. 44 .

– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
– Drain coolant ⇒ page 148 .
Caution
There is a risk of destruction through reversing the rotation di‐

rection of an already used V-ribbed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the V-ribbed belt.
For vehicles with air conditioning
WARNING
Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning
system.
– Remove V-ribbed belt ⇒ page 47 .
– Disconnect electric plug connection -1- on the control valve for

the air conditioning system - N280- compressor.
– Release screws -arrows- for AC compressor.
Caution
Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.
– Remove AC compressor with connected refrigerant hoses and

strap up to the right side.
Continued for all vehicles
– Remove air filter housing ⇒ page 235 .
1. Removing and installing engine 11

– Raise the retaining clip -arrow- and remove the top coolant
hose from the radiator.
– Removing fan shroud ⇒ page 175 .
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Release the lug -arrow- and remove hose connection -1- for
vacuum hose -2-.
– Undo hose clamps -arrows- and remove coolant hoses from

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

– Unscrew nuts -1- for securing the exhaust pipe to the cylinder
head.
– Unscrew screws -2- for supporting the exhaust system and
strap up the exhaust system.
Note
Collect leaking coolant by placing a cloth under it.
– Loosen hose clamps -arrows- and remove coolant hoses.
WARNING
There is risk of injury from fuel.

♦ To relieve the fuel pressure, place a clean cloth around
the connection point and loosen the connection point care‐
fully before opening the fuel system.
Note
♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 4 .
– Disconnect the hose coupling on the fuel feed line -1-

⇒ page 216 .
– Disconnect the hose coupling -2- to the activated charcoal fil‐
ter ⇒ page 216 .
– Unclip the hose holder from the coolant expansion tank and
place the hoses to one side.
Note
♦ On vehicles with an engine control unit with protective cover,

first remove the protective cover ⇒ page 252 .
♦ For the following clip unclipping procedure use the removal
tool for inner door trim panel - MP8-602/1- .

– Disconnect the upper electrical plug connection -1- from the

engine control unit - J623- .
– Take electrical plug connections -2- and -3- out of the holder
and disconnect.
– Expose electric cables.
– Separate plug connection -2-.

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

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

box engine compartment upwards.

– Unscrew nut -arrow-, remove and expose electric cable.
– Disconnect plug connections -1- and -2-.

For vehicles with manual gearbox
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
34 .
– Remove slave cylinder ⇒ Gearbox; Rep. gr. 30 .
For models with automatic gearbox
– Remove selector lever linkage, remove transmission connec‐
tor and remove all mounting brackets from transmission ⇒
Transmission; Rep. gr. 34 .
– Screw out screws -arrows- on engine mount by approximately

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

mately 2 turns.

– Undo screws -1-, -2-, -3- and remove the pendulum support
-4-.
– Remove assembly carrier ⇒ Axles, steering; Rep. gr. 40 .
– Slide drive shaft off the transmission left and right ⇒ Axles,
steering; Rep. gr. 40 and secure to the bodyshell.
Note
Ensure that the surface protection of the cardan shaft is not dam‐
aged.
– Unscrew the nut -arrow- from the left track control arm - G78-
if the front left vehicle level sensor is present.
– Release nut -arrow- on left and right for swivel hub.

– Unhook swivel hub from track control arm on left and right for
swivel hub.
– Unscrew the drive shaft left and right ⇒ Axles, steering; Rep.
gr. 40 and strap up.
Note
Make sure that the surface protection of the cardan shaft is not
damaged.
– Swivel out the suspension strut outwards towards the left and
support with the extension of the lifting device -MP9-201
(2024A)- as shown.
WARNING
There is a risk of accidents caused by loose parts of the sup‐

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

– Screw swivel hub -2- right at the track control arm -1- tight
using the nut -arrow-, as shown in the illustration.
– Position adapter T10497/2 on the housing fin of the cylinder

block, as shown in the illustration.
– Position engine mount T10497 with bolts T10497/1 at the cyl‐
inder block.
– Screw the adapter T10497/2 with screw -1- to the engine
mount T10497 and secure to 20 Nm.
– Fit the adapter - T10497/3- to the engine mount - T10497- and

tighten screw -1- to 20 Nm.
– Insert engine and gearbox jack - V.A.G 1383 A- to engine
mount T10497 and raise the engine/gearbox unit somewhat.
Note
Use double ladder , -VAS 5085- for example, to release the

screws for the assembly bracket.
– Screw out engine mount screws -arrows- fully.

– Screw out gearbox mount screws -arrows- fully.
Caution
There is a risk of damage from vacuum lines or electric cables.

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

– Push the gearbox side of the engine/gearbox unit forwards
and drain it slowly and carefully.
– Remove the gearbox from the engine ⇒ gearbox; Rep. gr.
34 .
1.2 Removing - (Yeti)

♦ Removal tool for inner lining of the door panel - MP8-602/1-
♦ Extending the lifting device - MP9-201 (2024A)-
♦ Engine/gearbox jack - V.A.G 1383 A-
♦ Engine bracket - T10497-
♦ Hose clip pliers, e.g. - VAS 6362-
♦ Double ladder , e. g. -VAS 5085-
♦ Grease - G 000 100-
♦ Protective gloves
Note
♦ The engine is removed downwards together with the gearbox.

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

WARNING

overpressure.
– Remove both wheels ⇒ Axles, steering; Rep. gr. 44 .

gr. 66 .
Caution

WARNING
Risk of injury through refrigerant.

♦ Do not open the refrigerant circuit of the air conditioning
system.
– Remove plug -1- at the air conditioning unit compressor con‐

trol valve - N280- .
– Release screws -arrows- for AC compressor.
Caution
Risk of damaging refrigerant lines and hoses.

♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.
– Remove AC compressor with connected refrigerant hoses and

strap up to the right side.

– Raise the retaining clip -arrow- and remove the top coolant
hose from the radiator.
– Unlock connector from control unit for automatic gearbox -
J217- and remove it, remove control unit ⇒ Gearbox 09G;
Rep. gr. 37 .
gr. 27 .
– Release the lug -arrow- and remove hose connection -1- for
vacuum hose -2-.
– Undo hose clamps -arrows- and remove coolant hoses from

heat exchanger for heating.
Note
Collect leaking coolant by placing a cloth under it.
WARNING
There is risk of injury from fuel.

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

⇒ page 3 .
⇒ page 4 .



⇒ page 216 .
– Remove line -2- to the activated charcoal filter from solenoid

valve 1 for activated charcoal filter - N80- -1-.
– Unclip line to the activated charcoal filter from the hose bracket
at the top toothed belt guard.
– Unscrew the earth cable on the body.
– Disconnect the plug of the engine wiring harness from the en‐
gine control unit ⇒ page 255 , or ⇒ page 256 .
– Release duct for engine wiring harness -arrow- and pull out
upwards.
– Expose the plug connection -1- and disconnect it.

– Open the bracket -2- lying below the cable guide.

– Open all locking elements and fastenings for the engine wiring
harness at frame side rail -arrows-.
– Remove engine wiring harness and place on the engine.
– Disconnect all electrical lines from the gearbox, generator and
starter motor and uncover them.
shaft, if present.
head.
– Unscrew screws -2- for supporting the exhaust system and
strap up the exhaust system.
– Unscrew the nut -arrow- from the left track control arm - G78-
if the front left vehicle level sensor is present.

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

– Unhook swivel hub from track control arm on left and right for
swivel hub.
– Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
34 .
– Remove slave cylinder ⇒ Gearbox; Rep. gr. 30 .
– Unscrew drive shaft from the transmission left and right ⇒
Axles, steering; Rep. gr. 40 and attach to the bodyshell.
– Remove selector lever linkage, remove transmission connec‐
tor and remove all mounting brackets from transmission ⇒
Gearbox 09G; Rep. gr. 34 .
– Slide drive shaft off the transmission left and right ⇒ Axles,
steering; Rep. gr. 40 and secure to the bodyshell.
– Swivel out the suspension strut outwards towards the left and
support with the extension of the lifting device -MP9-201
(2024A)- as shown.
WARNING
There is a risk of accidents caused by loose parts of the sup‐

port.
♦ Secure rig pin with plug-in lock and swivel hub -arrow- with
nut -1-.
– Screw swivel hub -2- right at the track control arm -1- tight
using the nut -arrow-, as shown in the illustration.
Note
Ensure that the surface protection of the cardan shaft is not dam‐
aged.
– Undo screws -1-, -2-, -3- and remove the pendulum support
-4-.

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

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

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

block, as shown in the illustration.
– Position engine mount T10497 with bolts T10497/1 at the cyl‐
inder block.
– Screw the adapter T10497/2 with screw -1- to the engine
mount T10497 and secure to 20 Nm.
– Fit the adapter - T10497/3- to the engine mount - T10497- and

tighten screw -1- to 20 Nm.
– Insert engine and gearbox jack - V.A.G 1383 A- to engine
mount T10497 and raise the engine/gearbox unit somewhat.
Note
Use double ladder , -VAS 5085- for example, to release the

screws for the assembly bracket.

– Screw out engine mount screws -arrows- fully.
– Screw out gearbox mount screws -arrows- fully.
Caution
There is a risk of damage from vacuum lines or electric cables.

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

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

stand
♦ Lifting device - MP9-201 (2024A)-
♦ Engine and gearbox support - VAS 6095-
♦ Workshop crane , e.g. -VAS 6100-
Work procedure
• Gearbox disconnected from engine.

– Suspend lifting device - MP9-201 (2024A)- from the engine

and workshop crane - VAS 6100- as shown in the illustration.
Note
For coordination with the unit centre of gravity position the perfo‐
rated rails must be placed as shown in the illustration.
WARNING
There is a risk of accident from loose parts of the lifting device.

♦ The suspension hooks and rig pin on the lifting must be
secured using plug-in locks -arrows-.
– Lift off engine with installed engine mount T10497 with work‐
shop crane - VAS 6100- from engine/gearbox jack - V.A.G
1383 A- .
– Remove engine mount T10497 .
– Secure engine with bolts -arrows- at engine and gearbox

mount - VAS 6095- as shown in the illustration.
1.4 Installing - (Octavia III)

Installation is performed in a similar way in the reverse order. Pay
attention to the following points:
– Installing intermediate plate ⇒ page 57 .
– Clean the serration of the drive shaft and if the clutch disc has
been used clean the hub serration, remove existing corrosion
and only apply a very thin layer of grease - G 000 100- to the
serration of the drive shaft.
– Subsequently move the clutch disc up and down on the drive
shaft until the hub fits smoothly on the shaft. Always remove
excess grease.
– Check the centering of the clutch disc ⇒ Gearbox; Rep. gr.
30 .
– Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ Gearbox; Rep. gr. 30 .


– Replace the needle bearing -arrow- in the crankshaft
⇒ page 67 .
– Installing the gearbox ⇒ Gearbox; Rep. gr. 34 .
– Install gearbox support bracket.
– Take up engine/gearbox unit with the engine mount T10497 .
– Position engine/gearbox unit with the engine mount - T10497-
on the engine and gearbox jack - V.A.G 1383 A- .
Note
♦ Replace screws which have been tightened firmly to a torque‐

ing angle.
♦ Replace self-locking nuts and screws as well as gasket rings,
gaskets and O-rings.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA”
♦ All cable straps should be fastened again in the same place
when installing.
– Insert engine/gearbox unit into the body.
– Initially insert screws -arrows- for engine mount by hand as far

as the stop.

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

far as the stop.
Note
The screws must not be permanently tightened until the assembly

bracket is adjusted ⇒ page 42 .
– Remove engine mount T10497 from engine.

– Install the starter motor ⇒ Electrical System; Rep. gr. 27 .
– Install slave cylinder ⇒ Gearbox; Rep. gr. 30 .
– Install linkages with linkage support ⇒ Gearbox; Rep. gr. 34 .
– Install assembly carrier ⇒ Axles, steering; Rep. gr. 40 .
– Install selector lever linkage, attach mechatronics plug and all
holders to the gearbox ⇒ Gearbox; Rep. gr. 37 .
– Install pendulum support ⇒ page 33 .
– Installing pre-exhaust pipe ⇒ page 262 .
– Installing drive shafts ⇒ Axles, steering; Rep. gr. 40 .
– Installing nuts for steering joint/wheel bearing housing left and
right ⇒ Axles, steering; Rep. gr. 40 .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. gr.
87 .
– Install the V-ribbed belt ⇒ page 47 .
– Electrical connections and proper routing ⇒ Electrical System;
Rep. gr. 97 and ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
– Installing the engine control unit - J623- ⇒ page 252 .
– Connect coolant hoses with quick coupling ⇒ page 168 .
– Installing the front wheels ⇒ Axles, steering; Rep. gr. 44 .
– Adjust the assembly bracket ⇒ page 42 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Install air filter housing ⇒ page 235 .
Note
♦ Only re-use drained coolant if the cylinder head or cylinder

block has not been replaced.
♦ Dirty coolant must not be used again.
– Top up and bleed cooling system ⇒ page 148 .

– Interrogate all fault memories and delete all fault entries, which
are caused by removing and installing the engine ⇒ Vehicle
diagnostic tester.

After deleting the fault memory of the engine control unit the
Caution
There is a risk of destruction of control units as a result of over‐

voltage.
♦ Do not use charger for jump starting!
Tightening torques
Note
♦ Tightening torques apply only for lightly greased, oiled,

phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are allowed,
but no lubricants containing graphite.
♦ Do not use degreased parts.
Component Nm
Screws and nuts M6 9 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
Screws for assembly bracket:
♦ Assembly bracket
⇒ “2.1 Assembly bracket - Summary of components (Octavia
III)”, page 33 .
1.5 Installing - (Yeti)

– Clean the serration of the drive shaft and if the clutch disc has
been used clean the hub serration, remove existing corrosion
and only apply a very thin layer of grease - G 000 100- to the
serration of the drive shaft.
– Subsequently move the clutch disc up and down on the drive
shaft until the hub fits smoothly on the shaft. Always remove
excess grease.
– Check the centering of the clutch disc ⇒ Gearbox; Rep. gr.
30 .
– Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ Gearbox; Rep. gr. 30 .


– Replace the needle bearing -arrow- in the crankshaft
⇒ page 67 .
– Installing the gearbox ⇒ Gearbox; Rep. gr. 34 .
– Take up engine/gearbox unit with the engine mount T10497 .
– Position engine/gearbox unit with the engine mount - T10497-
on the engine and gearbox jack - V.A.G 1383 A- .
Note
♦ Replace screws which have been tightened firmly to a torquing

angle.
♦ Replace self-locking nuts and screws as well as gasket rings,
gaskets and O-rings.
Parts“ETKA.” .
♦ All cable straps should be fastened again in the same place
when installing.
– Insert engine/gearbox unit into the body.
– Initially insert screws -arrows- for engine mount by hand as far

as the stop.

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

far as the stop.
Note
The screws must not be permanently tightened until the assembly

bracket is adjusted ⇒ page 42 .
– Remove engine mount T10497 from engine.

– Install the starter motor ⇒ Electrical System; Rep. gr. 27 .
– Install slave cylinder ⇒ Gearbox; Rep. gr. 30 .
– Install linkages with linkage support ⇒ Gearbox; Rep. gr. 34 .
– Install selector lever linkage, attach mechatronics plug and all
holders to the gearbox ⇒ Gearbox; Rep. gr. 34 .
– Install pendulum support ⇒ page 33 .
– Install pre-exhaust pipe ⇒ page 262 .
– Install drive shafts ⇒ Axles, steering; Rep. gr. 40 .
– Installing nuts for steering joint/wheel bearing housing left and
right ⇒ Axles, steering; Rep. gr. 40 .
87 .
– Electrical connections and proper routing ⇒ Electrical System;
Rep. gr. 97 and ⇒ Current flow diagrams, Electrical fault find‐
ing and Fitting locations.
– Insert the plug of the engine wiring harness to the engine con‐
trol unit ⇒ page 255 , or ⇒ page 256 .
– Connect the remaining electric cables to the engine and gear‐
box.
– Installing the front wheels ⇒ Axles, steering; Rep. gr. 44 .
– Adjust the assembly bracket ⇒ page 42 .
– Connect connector to control unit for automatic gearbox -
J217- and attach the control unit ⇒ Gearbox 09G; Rep. gr.
37 .

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

block has not been replaced.
♦ Dirty coolant must not be used again.
– Top up and bleed cooling system ⇒ page 148 .

– Interrogate all fault memories and delete all fault entries, which
are caused by removing and installing the engine ⇒ Vehicle
diagnostic tester.
After deleting the fault memory of the engine control unit the
Caution
There is a risk of destruction of control units as a result of over‐

voltage.
♦ Do not use charger for jump starting!
Tightening torques
Note
♦ Tightening torques apply only for lightly greased, oiled,

phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are allowed,
but no lubricants containing graphite.
♦ Do not use degreased parts.
Component Nm
Screws and nuts M6 9 Nm
M7 15 Nm
M8 20 Nm
M10 40 Nm
M12 65 Nm
deviations:
Engine/gearbox connecting screws ⇒ Gearbox; Rep. gr. 34
Screws for assembly bracket:
III)”, page 33 .

2 Assembly bracket
⇒ “2.1 Assembly bracket - Summary of components (Octavia III)”,
page 33
⇒ “2.2 Assembly bracket - Summary of components (Yeti)”, page
35
⇒ “2.3 Removing and installing engine bracket - (Octavia IlI)”,
page 37
⇒ “2.4 Removing and installing engine bracket - (Yeti)”,
page 37
⇒ “2.5 Removing and installing gearbox mount”, page 39
⇒ “2.6 Checking the assembly bracket”, page 41
⇒ “2.7 Adjusting the unit mounting”, page 42
2.1 Assembly bracket - Summary of components (Octavia III)
1 - Screw
❑ replace
❑ order of tightening
⇒ page 34
❑ 40 Nm + torque a further
90° (1/4 turn)
2 - Engine support bracket
❑ Tightening torque and
tightening order
⇒ page 34
❑ removing and installing
⇒ page 51
3 - Engine mounting
❑ with supporting arm
⇒ page 37
4 - Screw
❑ replace
90° (1/4 turn)
5 - Screw
❑ replace
90° (1/4 turn)
6 - Screw
❑ 8 Nm
7 - Support
8 - Screw
❑ replace
90° (1/4 turn)
9 - Pendulum support
❑ removing and installing ⇒ page 34
2. Assembly bracket 33
10 - Screw
❑ replace
❑ 130 Nm + torque a further 90° (1/4 turn)
11 - Screw
❑ replace
12 - Screw
❑ replace
13 - Screw
❑ replace
14 - Screw
❑ replace
15 - Screw
❑ replace
16 - Gearbox mount
Engine support bracket - tightening torque and tightening order
Note
Replace screws of engine support.
– Tighten screws in steps in the given sequence:

Stage Screws Tightening torque/torquing angle
1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
3. -1 … 3- 90° (torque a further 90° (1/4 turn)
Removing and installing pendulum support

– Remove screw -1-.
– Remove screws -2- and -3- and remove support -4-.

Installation is carried out in the reverse order.
Note

1. -2, 3- 50 Nm
2. -1- 130 Nm
2.2 Assembly bracket - Summary of components (Yeti)
1 - Gearbox support bracket

2 - Screw
❑ Tightening torque ⇒
Gearbox; Rep. gr. 34
3 - Engine mounting
4 - Screw
❑ replace
90° (1/4 turn)
5 - Bracket for activated char‐
coal filter
6 - Screw
❑ 9 Nm
7 - Screw
❑ 9 Nm
8 - Screw
❑ replace
90° (1/4 turn)
9 - Screw
❑ replace
90° (1/4 turn)
10 - Connecting part
11 - Screw
❑ replace
90° (1/4 turn)
12 - Screw
❑ replace
13 - Pendulum support
14 - Screw
❑ replace
15 - Screw
❑ replace
16 - Screw
❑ replace
17 - Screw
❑ replace
18 - Gearbox mount
Engine support bracket - tightening torque and tightening order
Note

1. -1 … 3- 7 Nm
2. -1 … 3- 40 Nm
Removing and installing pendulum support

– Unscrew screw -1-.
– Remove screws -2- and -3- and remove support -4-.
Note

1. -2, 3- 50 Nm
2. -1- 100 Nm

2.3 Removing and installing engine bracket

- (Octavia IlI)
♦ Supporting device - T30099-
♦ Surface - T30119-
♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Unclip hose holder -2- from the coolant expansion tank.
– Unlock catches using a screwdriver -arrow- and lay coolant
expansion tank to the side.
– Remove caps of the screw connections of the front suspension
strut dome.
– Connect supporting device - T30099- as shown in the illustra‐

tion.
– Attach snap hook to the engine suspension eye, right.
– Slightly pre-tension engine/gearbox unit with the spindle, do
not raise.
– Release screws -arrows- and remove engine mount -1-.

Install
Install in the reverse order of removal. When doing this, note the
following:
– Check assembly bracket setting ⇒ page 41 .
Tightening torques
III)”, page 33
2.4 Removing and installing engine bracket

- (Yeti)

♦ Surface - T30099/1-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
66 .
– Disconnect the hose coupling on the line to the activated char‐
coal filter -1- ⇒ page 216 .
– Detach the bleeder hose -1- to intake manifold at the activated

charcoal filter.
– Unlock activated charcoal filter arrow -B- and remove the ac‐
tivated charcoal filter with bracket upwards arrow -A-.
– Unscrew bracket -3- for activated charcoal filter.

– Unscrew screw on windshield washer fluid reservoir filler neck
-2-.
– Remove plug from the coolant shortage indicator switch - F66-
at the coolant expansion tank -1- and expose electrical wiring
loom.
– Unscrew coolant expansion tank screws -1-; place coolant ex‐
pansion tank with connected hoses on the engine and attach
if necessary.
strut dome.


tion.
Note
On the Yeti, instead of base - T30119- use base - T30099/1- .
– Attach snap hook to the engine suspension eye, right.

not raise.
– Release screws -1- to -6- and remove engine mounting.

Install
Tightening torques
⇒ “2.2 Assembly bracket - Summary of components (Yeti)”,
page 35
2.5 Removing and installing gearbox mount

♦ Surface - T30099/1-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
gr. 27 .
Octavia III vehicles
– Remove engine control unit ⇒ page 252 .
– Unscrew screws -arrows- and remove holder -1-.
Note
Holders are installed differently according to build version.
– Unscrew screw -1-, unclip upwards -arrows- and push slightly

to the side.
50 .
strut dome.
– Fit support bracket - T30099- together with the other elements

according to the illustration.
Note
– Attach spindle snap hook to the engine suspension eye.

– Pre-tension engine/gearbox unit with the spindle, do not raise.

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

Install
following:
Note
Screws which have been tightened firmly to a torqueing angle

must be replaced.
Caution
There is a risk of damaging the thread in the gearbox support

bracket by positioning the bolts obliquely.
♦ Before screwing in the screws -arrows- the gearbox sup‐
port bracket and supporting arm of the gearbox mount
must be absolutely parallel to each other. If necessary,
push up gearbox at the rear using a hydraulic trolley jack.
♦ Do not remove support bracket - T30099 - until the bolts
securing the assembly mounting have been tightened to
specified torque.
– Lift gearbox with the support bracket spindle until the gearbox
support bracket is touching the supporting arm of the gearbox
mount.
– Checking the assembly bracket ⇒ page 41 .
– Disconnect support bracket - 10 - 222 A- from engine.
Tightening torques
♦ Assembly bracket Octavia III
III)”, page 33
♦ Assembly bracket Yeti
page 35
♦ Engine control unit ⇒ “7 Engine control unit”, page 252
2.6 Checking the assembly bracket

The following dimensions must be reached:
• A distance of -a- = 10 mm must be present between engine
support -1- and engine mount -2-.
• The cast edge on the engine support -2- must be parallel -b-
with the engine mount supporting arm -1-.
• The dimension -a- must be the same on the front and rear.
Note
The distance -a- = 10 mm can be checked, for example with suit‐

able round bars.
– If the measured distance is too great or too small, adjust the

assembly bracket ⇒ page 42 .
2.7 Adjusting the unit mounting

♦ Surface - T30099/1-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Work procedure
gr. 27 .
50 .
strut dome.
tion.
Note
– Attach snap hook to the engine suspension eyes.

– Slightly pre-tension engine/gearbox unit with the spindles, do
not raise.
Note
♦ Screws which have been tightened firmly to a torqueing angle

must be replaced.
♦ Screws which were already replaced when installing the en‐
gine and only tightened hand-tight do not change.
– Unscrew the screws -arrows-for the engine bracket in se‐

quence, and replace.
– Loosely insert new screws.

– Unscrew screws -arrows- for the gearbox mount in sequence,

and replace.
– Loosely insert new screws.
– Move engine/gearbox unit with an assembly lever until the fol‐

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

able round bars.
– Tighten screws for engine mount.
– Make sure that on the gearbox side the edges of the support‐
ing arm -2- and gearbox support -1- are parallel.
• Dimension -x- = dimension -x-.
– Tighten gearbox mount screws.
Tightening torques
♦ Assembly bracket Octavia III
III)”, page 33
♦ Assembly bracket Yeti
page 35
13 – Crankshaft group
1 Cylinder block on belt pulley side
⇒ “1.1 V-ribbed belt - Summary of components”, page 44
⇒ “1.2 Removing and installing V-ribbed belt”, page 47
⇒ “1.3 Removing and installing tensioning device for V-ribbed
belt”, page 49
⇒ “1.4 Removing and installing ribbed belt pulley”, page 50
⇒ “1.5 Removing and installing engine support”, page 51
⇒ “1.6 Replacing crankshaft seal on belt pulley side”, page 53
1.1 V-ribbed belt - Summary of components

⇒ “1.1.1 Summary of components - Vehicles without air condi‐
tioning”, page 44
⇒ “1.1.2 Summary of components - Vehicles with air condition‐
ing”, page 46
1.1.1 Summary of components - Vehicles without air conditioning
1 - Screw
❑ replace
❑ to release and tighten
use counterholder -
T10475-
❑ 150 Nm + torque a fur‐
ther 180° (1/2 turn)
Caution
There is a risk of destruc‐
tion of the engine.
So
♦ as not to adjust the
timing the crankshaft
must not be turned while
the screws are removed.
2 - Crankshaft V-ribbed belt

pulley
❑ with vibration damper
⇒ page 50
Caution
Risk of destruction of the
engine.
So
the ribbed belt pulley is
removed.
3 - V-ribbed belt
❑ check for wear
44 Rep. gr.13 - Crankshaft group

❑ mark the direction of ro‐
tation with chalk or a felt-tip pen before removing
❑ do not kink
❑ obieg paska wielorowkowego ⇒ page 48
❑ pay attention to the correct position on the belt pulley when installing it
4 - Screw
❑ replace
5 - Tensioning device for V-ribbed belt

❑ Swivel tensioning device for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060 A-
6 - Screw
❑ 23 Nm
7 - Alternator
❑ removing and installing ⇒ Electrical System; Rep. gr. 27
❑ depending on the model of the alternator, different separation V-ribbed belt pulleys can be fitted with
freewheel -A- and -B-. ⇒ page 45
❑ depending on the model of the belt pulley for alternator, the correct length of the V-ribbed belt must be
assigned ⇒ ETKA - Electronic Catalogue of Original Parts
Model of the V-ribbed belt pulley with freewheel
1. Cylinder block on belt pulley side 45

1.1.2 Summary of components - Vehicles with air conditioning
1 - V-ribbed belt
❑ check for wear
tation with chalk or a felt-
tip pen before removing
❑ do not kink
❑ obieg paska wielorow‐
kowego ⇒ page 49
⇒ page 47
❑ pay attention to the cor‐
rect position on the belt
pulley when installing it
2 - Screw
❑ replace
❑ to release and tighten
use counterholder -
T10475-
Caution
There is a risk of destruc‐
tion of the engine.
So
the screws are removed.
❑ 150 Nm + torque a fur‐

ther 180° (1/2 turn)
3 - Crankshaft V-ribbed belt
pulley
❑ with vibration damper
⇒ page 50
Caution
Risk of destruction of the
engine.
So
the ribbed belt pulley is
removed.
4 - Tensioning device for V-ribbed belt

❑ Swivel tensioning device for V-ribbed belt with socket insert to slacken the V-ribbed belt
❑ lock with locking pin - T10060 A-
5 - Screw
6 - Screw
❑ 23 Nm

7 - Alternator
❑ removing and installing ⇒ Electrical System; Rep. gr. 27
❑ depending on the model of the alternator, different separation V-ribbed belt pulleys can be fitted with
freewheel -A- and -B-. ⇒ page 47
❑ depending on the model of the belt pulley for alternator, the correct length of the V-ribbed belt must be
assigned ⇒ ETKA - Electronic Catalogue of Original Parts
8 - Fitting sleeve
❑ for the AC compressor
9 - AC compressor
❑ Do not unscrew or disconnect refrigerant lines
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. gr. 87
10 - Screw
❑ Tightening torques ⇒ Heating, Air Conditioning; Rep. gr. 87
Model of the V-ribbed belt pulley with freewheel
1.2 Removing and installing V-ribbed belt

⇒ “1.2.1 Removing and installing V-ribbed belt - Vehicles without
air conditioning”, page 47
⇒ “1.2.2 Removing and installing V-ribbed belt - Vehicles with air
conditioning”, page 48
1.2.1 Removing and installing V-ribbed belt -

Vehicles without air conditioning

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

– Remove the V-ribbed belt.
Install
following:
– Lay the V-ribbed belt as shown in the illustration.
1- Crankshaft V-ribbed belt pulley
2- Tensioning device for V-ribbed belt
3- AC generator
– Turn the tensioning device in an anticlockwise direction

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

Vehicles with air conditioning

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

– Remove the V-ribbed belt.
Install
following:
– Lay the V-ribbed belt as shown in the illustration:
1- Crankshaft V-ribbed belt pulley
2- Tensioning device for V-ribbed belt
3- AC generator
4- AC compressor
– Turn the tensioning device in an anticlockwise direction

-arrow- and remove locking pin - T10060 A- .
– Release pressure on tensioning device.
– Check that the V-ribbed belt is positioned correctly.
– Start end and check that the V-ribbed belt is running correctly.
1.3 Removing and installing tensioning de‐

vice for V-ribbed belt
Removing
– Removing the V-ribbed belt:
♦ Vehicles without air conditioning system ⇒ page 47 .
♦ Vehicles with air conditioning system ⇒ page 48 .

– Release screws -arrows- and pull off tensioning device -1- for
V-ribbed belt.
Install
following:
– Install the V-ribbed belt:
Vehicles without air conditioning system ⇒ page 47 .
Vehicles with air conditioning system ⇒ page 48 .
Tightening torques
♦ Screw for tensioning device
1.4 Removing and installing ribbed belt pul‐

ley
♦ Counterholder - T10475-
Removing
– Remove noise insulation ⇒ Body; Rep. gr. 66 .
– Undo screw -arrow-, use the counterholder - T10475- to do so.
– Unscrew bolt and remove V-ribbed belt pulley crankshaft.
Caution
Risk of destruction of the engine.

♦ So as not to adjust the timing the crankshaft must not be
turned while the ribbed belt pulley is removed.
Install
Note

ing angle.
♦ All contact surfaces between screws, V-ribbed belt pulley
crankshaft and crankshaft toothed belt sprocket must be free
of oil and grease.
– Place V-ribbed belt pulley crankshaft, insert screw with the

oiled thread manually until into the system.
– Tighten screw -arrow-, use the counterholder - T10475- to do
so.
Installation is carried out in the reverse order. When installing,
note the following:
Tightening torques
♦ Screw for belt pulley

1.5 Removing and installing engine support

♦ Surface - T30099/1-
♦ Adapter - MP9-200/18 (10-222A/18)-
♦ Support - 10-222A/31-3-
♦ Clutch - T40091/3-
Removing
– Remove ribbed V-belt tensioning device ⇒ page 49 .
– Expose vacuum hose on the holder -3-.
– Loosen clips -arrows- and remove toothed belt guard -1- up‐
wards.

⇒ page 216 .
ter ⇒ page 216 .
Note
Open closed lines and connections immediately with suitable

screen caps.
– Expose hoses on bracket -2- and place to one side.

– Unplug connector -1-.
– Unlock catches using a screwdriver -arrow- and lay coolant
expansion tank to the side.
– Open holding clamps on the air conditioning system pipes.
Vehicles Yeti


⇒ page 216 .
ter ⇒ page 216 .
– Loosen screw -1- but do not unscrew it.

– Release screw -2-.
– Swivel generator -3- forward in -direction of the arrow-.
– Release screws -arrows- at holder for pre-exhaust pipe.

50 .
strut dome.

tion.
Note
– Attach snap hook -MP9-200/10 (10-222A/10)- to the engine

suspension eyes.
not raise.
– Remove engine mounts ⇒ page 37 .


– Release screws -arrows-.
– Release screws -1, 2, 3-.
– Unscrew the screws -arrows- from the gearbox mount.

– Press engine/gearbox unit slightly to the left and remove en‐
gine support.
Install
following:
Tightening torques
III)”, page 33
♦ Tensioning device for V-ribbed belt
♦ Fixing screws for generator ⇒ Electrical System; Rep. gr. 27
♦ Toothed belt guard
⇒ “2.1 Summary of components - toothed belt guard”,
page 86
♦ Battery tray ⇒ Electrical system; Rep. gr. 27
♦ Wiper arms ⇒ Electrical system; Rep. gr. 96
♦ Screws for bracket for the pre-exhaust pipe
⇒ “1.1 Pre-exhaust pipe with catalytic converter - Summary of
components”, page 259
1.6 Replacing crankshaft seal on belt pulley

side
♦ Assembly device - T10485-

♦ Extractor tool - T20143-

Work procedure
– Removing toothed belt ⇒ page 102 .
– Remove crankshaft toothed belt sprocket -1- in
-direction of arrow- from the crankshaft.
Caution

♦ So as not to adjust the timing the crankshaft must not be
turned while the ribbed belt pulley is removed.
– Lift out sealing ring using the extractor hook -T20143/2-

-arrow-.
– Clean the contact and sealing surfaces.
Note
Do not oil new sealing ring.
– Push new sealing ring in -direction of the arrow- over the as‐
sembly sleeve - T10485/3- onto the assembly sleeve -
T10485/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
– Pull off assembly sleeve - T10485/3- in -direction of arrow-.

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

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

• Contact surface between crankshaft toothed belt sprocket and
crankshaft must be free of oil and grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.
– install (set the timing) ⇒ page 107 .

2 Cylinder block, gearbox end

⇒ “2.1 Gearbox side cylinder block - Summary of components”,
page 56
⇒ “2.2 Removing and installing flywheel”, page 57
⇒ “2.3 Removing and installing the sealing flange on the gearbox
side”, page 57
2.1 Gearbox side cylinder block - Summary of components
Note
For assembly work, secure the engine to the engine and gearbox support -VAS 6095- ⇒ page 25 .
1 - Screw
❑ replace
90° (1/4 turn)
2 - Flywheel
⇒ page 57
❑ can be installed only in
one position
3 - Engine speed sender -
G28-
⇒ page 272
4 - Screw
❑ 5 Nm
5 - Fit pin
❑ 2 pieces
6 - Intermediate plate
❑ do not damage/bend
during assembly work
❑ installing ⇒ page 57
7 - Screw
tightening order
⇒ page 57
8 - Sealing flange with sender
wheel and oil seal
❑ Only replace sealing
flange complete with
gasket ring and rotor
⇒ page 57

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

ening order
– Tighten screws in steps as follows:
Stage Bolts Tightening torque
1. -1 … 6- by hand as far as the stop
2. -1 … 6- tighten crosswise in steps up to 10 Nm
Installing intermediate plate

– Insert intermediate plate on sealing flange -top arrow- and
push onto the dowel sleeves -bottom arrows-.
2.2 Removing and installing flywheel

♦ Counterholder - MP1-223 (3067)-
Removing
• Gearbox removed
– Insert the counterholder - 3067- into the hole on the cylinder
block -B-.
– Loosen and remove all flywheel bolts.
Install
following:
Note

ing angle.
♦ Assembly of flywheel is only possible in one position.
– Insert the counterholder - 3067- into the hole on the cylinder

block -A-.
Tightening torques
♦ Screw for flywheel
⇒ “2.1 Gearbox side cylinder block - Summary of compo‐
nents”, page 56
2.3 Removing and installing the sealing

flange on the gearbox side
2. Cylinder block, gearbox end 57

♦ Depth gauges , e.g. -VAS 6082-

♦ Assembly tool - T10134-
♦ Fixing screw - T10340-
♦ Spark plug wrench , e.g. -3122 B-
♦ 3x screw M6x35
Work procedure
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 .
Note
For a clearer illustration, the work sequences while the engine is

removed are shown.
– Remove the flywheel ⇒ page 57 .

– Remove the intermediate plate from the dowel sleeves
-arrows, bottom- and place to one side.
Set the crankshaft to “OT”:
– Remove ignition coil with power output stage 1 ⇒ page 270 .
– Remove ignition plug cylinder 1 with spark plug socket
wrench , e. g. -3122 B- .
Set the correct position of the crankshaft for screwing in the fixing
screw.
– Carefully insert a screwdriver into the opening of the ignition

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

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

screwdriver just out at the top by approx. 35 mm in the
-direction of the arrow-.
– Unscrew locking screw for “TDC” bore at the cylinder block
⇒ page 88 .
Caution
Risk of engine damage.

If the fixing screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position.
In this case, proceed as follows:
♦ Unscrew the fixing screw.
♦ Set the correct position of the crankshaft for screwing in
the fixing screw ⇒ page 58 .
– Turn the fixing screw - T10340- up to the stop in the cylinder

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

using the fixing screw - T10340- .
– Remove sump top part ⇒ page 132 .
– Remove the engine speed sender - G28- -arrow-

⇒ page 272 .
– Undo screws -1 … 6-.

Note
The sealing flange is pressed together with the crankshaft rotor .
– To press out, insert 3 screws M6x35 -arrows- into the sealing

flange alternately by a maximum of 1/2 turns each.
– Remove sealing flange with rotor
Press in sealing flange with rotor
Note
♦ The sealing flange with PTFE gasket ring is provided with

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

A - Clamping surface
B - Nut
C - Assembly cup
D - Positioning pin
E - Hexagon socket head bolt
F - Guide bolts for diesel engines
G - Guide bolts for petrol engines
A - place sealing flange with sensor rotor onto assembly tool -

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

– Grip assembly tool - T10134- at clamping surface -A- of the

threaded spindle in a vice.
– Push assembly cup -C- down so that it rests on the nut -B-
-arrow-.
• The inner part of the assembly tool and the assembly cup must
be flush.
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not twist rotor or take it out of the sealing flange.
• Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
– Lay the front side of the sealing flange on a clean and level
surface.
– Press down sealing lips supporting ring -A- in
-direction of the arrow-, until it rests on the level surface.

• Upper edge of sealing lip support ring and front edge of sealing
flange must align -arrows-.
– Place sealing flange with the front side onto the assembly tool
- T10134- so that the positioning pin -B- sits in the hole -A- of
the sensor rotor.
• Sealing flange must lie straight on the assembly tool.
– Press the sealing flange and sealing lip supporting ring -B-
while tightening up the 3 knurled screws -A- onto the surface
of the assembly tool - T10134- to ensure that the positioning
pin can no longer slip out of the bore of the sensor rotor.
Note
When installing sealing flange, ensure that sender wheel remains

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

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

– Secure the assembly tool - T10134- to the crankshaft flange.

Screw hexagon socket head bolts -A- into crankshaft flange
(approx. 5 full turns).
– Insert 2 screws M6x35 Pos. -A- into the cylinder block for the
sealing flange guide.
C - Bolt assembly tool - T10134- onto the crankshaft flange:

– Push the assembly cup -C- by hand in the
-direction of the arrow- until the sealing lip supporting ring
-B- rests on the crankshaft flange -A-.
– Push guide pin -F- into hole in crankshaft. This gives the rotor
its final fitting location.
Note
The guide pin for diesel engines -D- must not be inserted in threa‐
ded hole of crankshaft.
– Tighten the two hexagon socket head bolts of the assembly

tool hand-tight.
– Screw nut -E- onto threaded spindle by hand until it lies against
assembly housing -C-.
D - Press sender wheel onto crankshaft flange using assembly

device - T10134-
– Tighten nuts of the assembly tool - T10134- to 35 Nm.
• After tightening the nut to 35 mm there must still be a narrow
air gap between the cylinder block and the sealing flange.

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

– Screw nut -E- on until it reaches end of threaded spindle.
– Release both screws -A- from the cylinder block.
– Release knurled screws -B- from the sealing flange.
– Unscrew assembly tool - T10134- from the crankshaft flange,
to do so, unscrew Allan screws from the crankshaft flange.
– Remove sealing lip supporting ring.
– Mount depth gauge - VAS 6082- onto the crankshaft flange.
– Measure distance -a- between crankshaft flange -A- and rotor

-B-.
• Specified value: Dimension -a- = 0.5 mm
– If the specified value is too small, press rotor down
⇒ page 64 .
– When the specified value has been reached, perform the re‐
maining assembly ⇒ page 66 .
F - Pressing down the rotor:

– Secure assembly tool - T10134- to crankshaft flange, to do so,
tighten the Allan screws -A- until hand-tight.
– Press the assembly tool - T10134- against the sealing flange
by hand.

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

– Tighten nuts of the assembly tool - T10134- to 40 Nm.

– Checking sender wheel installation position on crankshaft
again ⇒ page 64 .
– If the setpoint value is too small, tighten the nuts on the as‐
sembly tool - T10134- to 45 Nm.
– Checking sender wheel installation position on crankshaft
again ⇒ page 64 .
Assembling
– Tighten screws for sealing flange crosswise.
– Install the engine speed sender - G28- -arrow- ⇒ page 272 .
– Undo positioning screw - T10340- and replace with a locking
screw ⇒ page 88 .
– Install sump top part ⇒ page 132 .
– Install flywheel ⇒ page 57 .
– Install ignition plug and ignition coil from cylinder 1
⇒ page 270 .
Caution

♦ To finish off the work, check to see whether the positioning
screw - T10340- was removed.
Tightening torques
♦ Sealing flange on the gearbox side
⇒ Fig. ““Sealing flange on the gearbox side - tightening torque
and tightening order”“ , page 57
♦ Engine speed sender - G28-
nents”, page 56
♦ Flywheel to crankshaft
nents”, page 56
♦ Locking screw for bore in the cylinder block
⇒ Fig. ““Unscrew locking screw TDC bore at the cylinder block
- tightening torque”“ , page 88
♦ Screw for ignition coil with power output stage
⇒ “1.1 Ignition system - Summary of components”,
page 269
♦ Spark plug
page 269

3 Crankshaft
⇒ “3.1 Measuring axial play of crankshaft”, page 67
⇒ “3.2 Replace needle bearing for crankshaft”, page 67
Caution
There is a risk of bearing pedestal deformation.

♦ The crankshaft must not be removed. Merely releasing the
crankshaft bearing cover screws will result in deforma‐
tions of the bearing seats of the cylinder block.
♦ If the bearing cap bolts are loosened, the cylinder block
must be renewed complete with the crankshaft.
♦ It is not possible to measure the radial crankshaft bearing
clearance with workshop tools.
3.1 Measuring axial play of crankshaft

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

Only for vehicles with automatic gearbox
♦ Centering mandrel -T30029 (3176)-
♦ Interior extractor -Kukko 21/2-
♦ Countersupport -Kukko 22/1-
3. Crankshaft 67
Removing
– Remove needle bearing with internal extractor -Kukko 21/2-
and countersupport -Kukko 22/1- .
Install
Note
The marked side of the needle bearing should be legible when in

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

flush with the crankshaft face.

4 Pistons and conrods

⇒ “4.1 Piston and conrod - Summary of components”,
page 69
⇒ “4.2 Removing and installing the piston”, page 72
⇒ “4.3 Checking piston and cylinder bore”, page 73
4.1 Piston and conrod - Summary of com‐

ponents
Note
Before assembly moisten all bearing and contact surfaces with

oil.
1 - Screw
❑ replace
❑ Oil thread and contact
surface
90° (1/4 turn)
2 - Conrod bearing cap
❑ as a result of the con‐
rods separated in the
cracking process, the
conrod bearing cap fits
only in one position and
only to the relevant con‐
rod
❑ Mark assignment to the
cylinder and to the con‐
rod in colour -B-
❑ Fitting position: Orienta‐
tion nubs -A- on big-end
bearing cap must be
identical on all covers
Note
The connecting rods are aligned in

the direction of the gearbox with
nubs -A- ex works. The connecting
rods can be aligned the other way
round during repair, but not all at the
same time. Orientation nubs -A- on
conrod bearing cap must be identi‐
cal on all covers
3 - Bearing shells
❑ Fitting position
⇒ page 71
❑ replace used bearing shells
❑ check for firm seating
4 - Conrod
❑ with cracked conrod bearing cap
❑ Renew as set only
4. Pistons and conrods 69

❑ Mark assignment to the cylinder and to the conrod bearing cap in colour -B-
❑ separate new conrod ⇒ page 71
❑ Fitting position: Orientation nubs -A- on big-end bearing cap must be identical on all covers
Note
The connecting rods are aligned in

the direction of the gearbox with
nubs -A- ex works. The connecting
rods can be aligned the other way
round during repair, but not all at the
same time. Orientation nubs -A- on
conrod bearing cap must be identi‐
cal on all covers
5 - Circlip
❑ 2 pieces
❑ replace
6 - Piston pin
7 - Piston
❑ Mark the installation position and the assignment to cylinder ⇒ page 71
❑ Checking piston and cylinder bore ⇒ page 73
8 - Piston rings
❑ Compression rings
❑ Measure end gap ⇒ page 73
❑ Measure vertical gap ⇒ page 73
❑ use commercially available piston ring pliers for removing and installing
❑ Fitting position: Identification “TOP” or labelled side for piston crown
❑ Offset joint 120°
9 - Piston rings
❑ Oil scraper rings
❑ carefully remove and install 3-part oil scraper rings by hand
❑ Measure end gap ⇒ page 73
❑ End clearance cannot be measured

Fitting position of piston and assignment of piston to cylinder
Caution
Risk of damaging the piston crown.

♦ For re-installation, mark the assignment in colour on the
piston crown of cylinders that have already been used.
Piston crown not by centre punch, scratch, nick or similar
mark.
• Arrow on the piston crown to the belt pulley side -arrow-.
Bearing shell installation position

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

It can happen that the predetermined breaking point on the new
conrod is not completely pierced. If the conrod bearing cap cannot
be removed by hand, proceed as follows:
– To prevent damage, tension the conrod only slightly in a vice
with protective jaws as shown.
• Tension the conrod below the dotted line.
– Unscrew screws -arrows- by approx. 5 turns.
– Knock against the conrod bearing cap carefully with a plastic

hammer -arrow- in order to loosen it.

Oil spray nozzle and pressure relief valve

1- Screw with pressure relief valve, 27 Nm
2- Oil spray nozzle (for cooling piston)
• Fitting position: Align the guide edge of the oil injection nozzle
to the area of the cylinder block being worked on.
Caution
Risk of damaging the oil injection nozzles.

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

♦ Drift - VW 222 A-
♦ Commercially available piston ring tensioning strap
Removing
• Attach engine ⇒ page 25 attached to engine and gearbox
mount - VAS 6095-
– Remove cylinder head ⇒ page 80 .
– Mark installation position and assignment of the piston to the
cylinder.
– Mark the installation position and assignment of the conrod to
the cylinder and to the conrod bearing cap Pos. -4-
⇒ page 69 .
– Remove conrod bearing cap and pull out piston with conrod
upwards.
Note
In case of tightness of the piston pin, heat piston to approximately

60 °C.
– Remove securing rings from the piston pin eye.

– Drive off piston pin with a drift - VW 222 A- .
Install
following:
Note
Replace screws which have been tightened firmly to a torqueing

angle.
– Oil the contact surfaces of the bearing shells.

– Install piston with commercially available piston ring tension‐

ing strap, check installation position ⇒ page 71 .
– Install conrod bearing cap, check installation position Pos.
-2- ⇒ page 69 .
– Install cylinder head ⇒ page 80 .
– Install sump top part ⇒ page 132
Tightening torques
♦ Conrod with conrod bearing cap
⇒ “4.1 Piston and conrod - Summary of components”,
page 69
4.3 Checking piston and cylinder bore

Inspecting pistons
– Using an external micrometer, measure pistons approx.
10 mm from the lower edge of skirt, at 90° to the piston pin
axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Piston ∅ mm
Nominal dimension without lu‐ 76.455 + 0.009
bricating coating – 0.009
Nominal dimension with lubri‐ 76.485 + 0.017
cating coating – 0.017
Measure piston ring end gap

– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder.
– Push a commercially available feeler gauge into the piston ring
opening to check the end gap.
Piston ring new Wear limit
mm mm
1. Compression ring 0.20 + 0.15 1.0
2. Compression ring 0.40 + 0.20 1.0
Oil scraper rings 3 part 0.20 + 0.50 no wear indica‐
tion possible
Measure piston ring vertical gap

– Clean before inspecting the annular groove of the piston.
Piston ring new Wear limit
mm mm
1. Compression ring 0.04 … 0.08 0.15
2. Compression ring 0.03 … 0.07 0.15
Oil scraper rings (3 part) cannot be measured

Measure cylinder bore
Caution
There is risk of damaging the cylinder bore surface.

♦ Do not use normal workshop equipment to work on cylin‐
der bore (boring, honing, grinding).
– Using the internal precision instrument - VAS 6078- , measure

crosswise at 3 points in the transverse direction -A- and lon‐
gitudinal direction -B-.
• Maximum deviation from nominal dimension: 0.08 mm.
Cylinder bore ∅ mm
Nominal dimension 76.5 + 0.015
+ 0.005
Note
Cylinder bores must not be measured when cylinder block is

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

15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Cylinder head - summary of components”, page 75
⇒ “1.2 Camshaft housing - Summary of components”,
page 77
⇒ “1.3 Removing and installing camshaft housing”, page 78
⇒ “1.4 Removing and installing the cylinder head”, page 80
⇒ “1.5 Testing the compression”, page 84
1.1 Cylinder head - summary of compo‐

nents
♦ Hairline 500 mm - VAS 6075-
Caution
The camshafts must not be removed individually.

When carrying out repairs the camshaft housing must be com‐
pletely replaced.
1. Cylinder head 75
1 - Cylinder head gasket

❑ Renew. ⇒ page 80 .
❑ check fitting position:
Cylinder head part num‐
ber
2 - Cylinder head
⇒ page 80
❑ pomiar odkształcenia
⇒ page 77
3 - Dowel pins
4 - Gasket
❑ replace
5 - Camshaft housing
⇒ page 78
6 - Screw
tightening order
⇒ page 78
7 - Screw
❑ replace
❑ loosening order
⇒ page 83
tightening order
⇒ page 76
8 - Fitting sleeve
❑ 2 pieces
Cylinder head - tightening torque and tightening order
Note

angle.

Stage Bolts Tightening torque/torqueing angle
1. -1 … 10- 40 Nm
76 Rep. gr.15 - Cylinder head, valve gear

Inspecting the cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
500 mm knife-edge straightedge - VAS 6075- and feeler
gauge.
• Max. permissible distortion: 0.05 mm.
1.2 Camshaft housing - Summary of components
1 - Fit pin
2 - Sealing ring
❑ For inlet camshaft
3 - Sealing ring
❑ for exhaust camshaft on
the belt pulley side
4 - Camshaft housing
⇒ page 78
5 - Screw
tightening order
⇒ page 78
6 - O-ring
❑ replace
7 - Inlet camshaft control valve
1 - N205-
⇒ page 121
8 - Screw
❑ 8 Nm
9 - Gasket
❑ for cap
❑ replace if damaged
10 - Screw cap
11 - O-ring
❑ replace
12 - Hall sender - G40-
13 - Screw
❑ 8 Nm
14 - Sealing ring
❑ for exhaust camshaft on the gearbox side
1. Cylinder head 77
15 - Toothed belt pulley
❑ For coolant pump drive
16 - Screw
❑ Tightening torque ⇒ page 153
17 - Screw
❑ 8 Nm
18 - Screw cap
19 - O-ring
❑ replace
20 - Gasket
❑ replace
Camshaft housing - tightening torque and tightening order
Note

angle.

1. -1 … 15- 10 Nm
1.3 Removing and installing camshaft hous‐

ing
♦ Threaded bolt , e.g. -T10288/4-
Removing
– Remove coolant pump ⇒ page 156 .
– Release fixing screws -1- and -2-.
– Remove coolant pipe -3- and place to one side.
– Remove the toothed belt from the camshafts ⇒ page 91 .
– Removing ignition coils ⇒ page 270 .

– Disconnect the plug connections:

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

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

ing angle.
♦ Replace gasket.
– “Check TDC” position of camshaft and crankshaft:
• Camshaft clamp -T10477- attached to camshaft housing with

screw -arrow-.
• Crankshaft to “TDC” position ⇒ page 88 .

• Fixing screw - T10340- turned up to the stop in the cylinder
block and tightened to 30 Nm.
– Check that all roller rocker fingers are lying flat correctly on the
end of the valve stem and are clipped into the respective bal‐
ancing element.
1. Cylinder head 79
– Fit gasket onto dowel pins -arrows-.
– Screw in 2 threaded bolts -2- and -4-, e.g. -T10288/4- , into the
cylinder head.
– Carefully place the camshaft housing -3- onto the threaded
bolt in the cylinder head.
Note
Make sure that the camshaft housing does not tilt.
– Tighten camshaft housing screws ⇒ page 78 .

note the following:
– Install ignition coils ⇒ page 270 .
– Install coolant pump ⇒ page 156 .
Tightening torques
♦ Camshaft housing screws
⇒ Fig. ““Camshaft housing - tightening torque and tightening
order”“ , page 78
♦ Screws for coolant pipe
⇒ “3 Parts of cooling system engine side”, page 165
1.4 Removing and installing the cylinder

head
Removing
Note
Fit all heat protection sleeves on again in the same place when
installing.
– Removing the intake manifold ⇒ page 237 .

– Remove the camshaft housing ⇒ page 78 .
– Remove camshaft housing gasket ring.


– Remove coolant pipe -2- and place to one side.
– Disconnect plug connection -2- from oil pressure switch - F1-

-1-.
shaft, if present.
head.
– Unscrew screws -2- for exhaust pipe supports.
– Remove exhaust pipe from cylinder head and strap up.
1. Cylinder head 81
– Disconnect plug connection -2- for coolant temperature send‐

er - G62- -1-.
– Release screw -1- on engine support.

– Undo holding clips on the wire harness from the cylinder head.

– Slacken the screws for the cylinder head in the sequence

-1…10- and release them.
– Remove cylinder head and place it on a clean base (foam).
Install
Caution
Risk of damaging sealing surfaces.

♦ Carefully remove residual sealant from the cylinder head
and cylinder block.
♦ Make sure this does not cause any extended scoring or
scratching.
There is a risk of damage to the cylinder block.
♦ There must not be any oil or coolant present in the holes
for the cylinder head bolts.
There is a risk of leakage on the cylinder head gasket.
♦ Carefully remove sanding and grinding residues.
♦ Remove the new cylinder head gasket from its wrapping
immediately before fitting.
♦ To prevent the silicon layer and the area of the bead from
being damaged, handle the gasket with the utmost care.
Note

ing angle.
♦ Replace self-locking nuts, gasket rings, gaskets and O-rings.
♦ If a replacement cylinder head must be installed, the contact
surfaces between hydraulic balancing elements, roller rocker
fingers and camshaft slideways must be oiled before the cam‐
shaft housing is installed.
Parts“ETKA.”
♦ When the cylinder head or the cylinder head gasket is re‐
placed, all the coolant and engine oil must be replaced.
1. Cylinder head 83
– Fit on cylinder head gasket -1-.

♦ Pay attention to centring pins in cylinder block -arrows-.
♦ Check installation position of the cylinder head gasket, identi‐
fication: Part number must be legible from the inlet side.
– Position piston of cylinder 1 to top dead centre if the crankshaft
was turned anticlockwise again.
– Insert the cylinder head.
– Insert cylinder head bolts and tighten hand-tight.
– Tighten cylinder head bolts ⇒ page 76 .
note the following:
– Install camshaft housing ⇒ page 78 .
– Installing the intake manifold ⇒ page 237 .
– Install pre-exhaust pipe ⇒ page 264 .
– Change engine oil.
– Replace coolant ⇒ page 148 .
Tightening torques
♦ Engine support bracket
⇒ Fig. ““Engine support bracket - tightening torque and tight‐
ening order”“ , page 34
♦ Cylinder head
⇒ “1.1 Cylinder head - summary of components”, page 75
♦ Pre-exhaust pipe
⇒ Fig. ““Installing pre-exhaust pipe- tightening torque and
tightening order”“ , page 264
⇒ “3 Parts of cooling system engine side”, page 165
♦ Drive shaft screening ⇒ Axles, steering; Rep. gr. 40 .
1.5 Testing the compression

♦ Compression tester - V.A.G 1763-
Work procedure
• Engine oil temperature at least 30 °C.
• Battery voltage at least 12.5 V.

– Unlock plug-in injection valves -1- and remove.
– Unlock and remove plug connections -1- for ignition coils with
power output stages and undo screws -2-.
– Pull out ignition coils at power output stage ⇒ page 270 .
– Pull out spark plugs with spark plug socket wrench , e. g. -3122
B- .
– Check the compression pressure using the compression test‐
er - V.A.G 1763- ; handling, ⇒ Operating Manual .
– A 2nd. mechanic depresses the accelerator pedal fully and at
the same time actuates the starter until the tester shows no
further pressure rise.
– Repeat the procedure for each cylinder.
Compression readings
Engine new 1.0 ... 1.5 MPa
(10.0…15.0 bar)
Wear limit 0.7 MPa (7.0
bar)
Maximum difference between cylinders 0.3 MPa (3.0
bar)
Install
following:
– Install spark plugs.
– Install ignition coils at power output stage ⇒ page 270 .
Because the electrical plug connections were disconnected and
the engine started, errors are stored in the engine control unit:
– Clear fault memory and re-generate the readiness code ⇒ Ve‐
hicle diagnostic tester.
Tightening torques
♦ Screw for ignition coil
page 269
♦ Spark plug
page 269
1. Cylinder head 85
2 Toothed belt drive

page 86
⇒ “2.2 Timing belt - Summary of components”, page 87
⇒ “2.3 Test timing”, page 88
⇒ “2.4 Remove the toothed belt from the camshafts”, page 91
⇒ “2.5 Removing and installing toothed belt”, page 102
2.1 Summary of components - toothed belt guard
1 - Bottom toothed belt guard

2 - Screw
❑ 8 Nm
3 - Engine support bracket
tightening order
⇒ page 34
4 - Screw
tightening order
⇒ page 34
5 - Top toothed belt guard
6 - Screw
❑ 8 Nm

2.2 Timing belt - Summary of components
1 - Toothed belt
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ removing ⇒ page 102
❑ install (set the timing)
⇒ page 107
2 - Screw
❑ Tightening torque
⇒ page 107
3 - Tensioning pulley
❑ for removing and instal‐
ling, remove engine
support ⇒ page 51
4 - Screw
❑ replace
90° (1/4 turn)
5 - Toothed belt pulley, ex‐
haust camshaft
⇒ page 91
6 - Toothed belt pulley, inlet
camshaft
❑ With camshaft control
❑ Removing and installing
camshaft control
⇒ page 116
7 - Guide bushing
8 - Screw
❑ replace
9 - O-ring
❑ replace
10 - Screw plug
❑ 20 Nm
11 - Guide pulley
❑ 40 Nm
12 - Crankshaft - toothed belt sprocket
❑ there must not be any oil present on the contact surface between the toothed belt sprocket and the
crankshaft
❑ can be installed only in one position
2. Toothed belt drive 87

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

ening torque
Note
♦ Locking screw with integrated gasket ring

♦ Replace if damaged
– Tighten bolts -arrows- to 30 Nm.
2.3 Test timing

♦ Camshaft clamp - T10477-
Work procedure
gr. 66 .
– Unscrew screws -A...D- and push thermostat cover -1- to the
side.
– Expose wiring loom -arrows-.

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

– Unscrew screw -arrow- and remove screw cap -1-.

Position crankshaft to “TDC”.
wrench , e. g. -3122 B- .
screw.


screwdriver just out at the top by approx 35 mm in the
⇒ page 88 .
Caution



Note

• On the inlet camshaft -3- the asymmetrically arranged grooves
-1-, on the gearbox side, above the camshaft centre -2-.
• On the outlet camshaft the asymmetrically arranged grooves
• The asymmetrically arranged grooves of the outlet camshaft
-1- are accessible via the recesses in the toothed belt gear for
the drive of the coolant pump -3-.
Note
The outlet camshaft has one symmetrically and one asymmetri‐

cally arranged pair of grooves. In the “TDC” position the asym‐
metrically arranged pair of grooves must by above the imaginary
horizontal centre line.
If the camshafts are not as described:

– Undo the positioning screw - T10340- and rotate crankshaft a
turn further in the running direction of the engine and set to
“TDC” again ⇒ page 89 .
If the camshafts are as described:
Note
♦ The camshaft clamp - T10477- must slide into position easily.

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

– Insert camshaft clamp -T10477- to stop into camshafts and

tighten bolt -arrow- by hand.
If camshaft clamp - T10477- cannot be installed:
– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.
– At the same time, insert the camshaft clamp -T10477- up to
stop into the camshafts and fix with the screw.
If it is not possible to insert the camshaft clamp -T10477- , the
timing is NOK:
– Remove the toothed belt from the camshafts and set the tim‐
ings ⇒ page 91 .
If it is possible to insert the camshaft clamp -T10477- , the timing
is OK:
Caution

♦ To complete the work, check to ensure that the fixing
screw - T10340- and camshaft clamp -T10477- have been
removed.
following:
Tightening torques
♦ Screw cap on the camshaft housing
page 77
♦ Screws for cover for coolant regulator
⇒ “2.1 Summary of components - coolant pump/coolant ther‐
mostat”, page 153
page 269
♦ Spark plug
page 269
♦ Noise insulation ⇒ Body Work- Assembly; Rep. gr. 66
2.4 Remove the toothed belt from the cam‐

shafts

♦ Counterholder - T10172A- with adapters -T10172/1- and -

T10172/1-
♦ Key - T10499-
♦ Camshaft fixer/locator - T10477-
♦ Torque wrench -VAS 6583- or -V.A.G 1410-
♦ Insertion tool - T10500-
Work procedure
gr. 66 .
wards.

side.



wrench , e. g. -3122 B- .
screw.


⇒ page 88 .
Caution



Note

Note


Note

hammer.

– Insert camshaft control -T10477- to stop into camshafts and

tighten screw -arrow- hand-tight.
Caution
To prevent damage to the belt, do not use sharp-edged tools!

Caution
Risk of damaging the camshafts.

♦ Do not use the camshaft fixer/locator - T10477- as a coun‐
terholder.
– Unscrew locking screw -1- on the camshaft sprocket fitting

position. Use counterholder - T10172A- with adapter -
T10172/1- to do this.
– Undo screws -1- and -2- by around one turn. Use counter‐
holder - T10172A- with adapters -T10172/2- and -T10172/1-
to do this.

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

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

ing angle.
♦ Replace the damaged O-ring of the locking screw at the tooth‐
ed belt gear of the inlet camshaft.
• Camshaft clamp - T10477- attached to camshaft housing.
Caution

♦ Do not use the camshaft clamp -T10477- as a counter‐
holder.

• Crankshaft in engine direction of rotation applied to the fixing
screw - T10340- = “TDC” position.
– Replace screws -1- and -2- and insert them loosely.

• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not tilt.

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

in the cast iron recess of the cylinder head.
Observe sequence when fitting the toothed belt.
– Pull toothed belt upwards, place onto the guide pulley -1- and
the tensioning pulley -2- and the camshaft sprockets -3- and
-4-.

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

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

To tighten, the torque wrench - VAS 6583- or torque wrench -
V.A.G 1410- must be used!
To tighten, no other torque wrench may be used!
Tighten with torque wrench VAS 6583
Caution
Only use the torque wrench together with insertion tool -

T10500- !
When setting the tightening torque on the torque wrench - VAS
6583- the actual dimension specified on the tool insert -
T10500- must be put into the torque wrench!
– Keep eccentric in this position and tighten screw -1- to 25 Nm.

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

T10500- !
Set the reduced tightening torque of 12 Nm on the torque
wrench - V.A.G 1410-
The required tightening torque of 25 Nm is achieved by the
extending the torque wrench - V.A.G 1410- around the tool in‐
sert - T10500- !
– Keep eccentric in this position and tighten screw -1- to the re‐
duced tightening torque 12 Nm. To do so, use the insertion
tool - T10500- with torque wrench - V.A.G 1410- .
Continued
Note
If the engine continued to turn or has run, there may be slight

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

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

counterholder - T10172A- with adapters -T10172/1- and -
T10172/2- .
– Unscrew positioning screw - T10340- .
– Unscrew bolt -arrow- and remove camshaft clamp -T10477- .

Checking valve timing
– Turn the crankshaft by 2 turns in direction of rotation of engine
on “TDC” for cylinder 1 ⇒ page 93 .


Note


– Rotate crankshaft a turn further in the running direction of the
engine and set to “TDC” again ⇒ page 93 .
Note

hammer.



timing is NOK:
– Remove the toothed belt from the camshafts and repeat the
timings ⇒ page 96 .
is OK:
– Pre-tighten screws -1- and -2- to the final tightening torque

⇒ page 87 , to do so use the counterholder - T10172A- with
adapters -T10172/1- and -T10172/2- .

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

terholder - T10172A- with the adapter -T10172/1- .
Caution

♦ After completing the work, check whether the positioning
screw - T10340- and camshaft clamp -T10477- are re‐
moved.
Further installation occurs in reverse order.

Tightening torques
♦ Screw for toothed belt guard
page 86
♦ Rollers and toothed belt gears
page 269
♦ Spark plug
page 269
♦ Screw cap on the camshaft housing
page 77
♦ Screws for cover for coolant regulator
mostat”, page 153
♦ Noise insulation ⇒ Body Work- Assembly; Rep. gr. 66
2.5 Removing and installing toothed belt

♦ Counterholder - T10172A- with adapters -T10172/1- and -
T10172/1-
♦ Key - T10499-
♦ Camshaft fixer/locator - T10477-
♦ Torque wrench -VAS 6583- or -V.A.G 1410-
♦ Insertion tool - T10500-
Removing
gr. 66 .


wards.

side.


wrench , e. g. -3122 B- .
screw.



⇒ page 88 .
Caution


Note



Note


Note
♦ The camshaft clamp -T10477- must be inserted easily.

hammer.

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


– Remove poly V-belt pulley from crankshaft ⇒ page 50 .
– Release screws -arrows- and remove bottom toothed belt

guard.
Caution

♦ Do not use the camshaft fixer/locator - T10477- as a coun‐
terholder.
– Unscrew locking screw -1- on the camshaft sprocket fitting

position. Use counterholder - T10172A- with adapters -
T10172/1- to do so.
– Loosen screws -1- and -2- around one turn, to do so use the
T10172/1- .

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

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

rection of an already used toothed belt.
the re-installation before removing the toothed belt pulley.
– Remove timing belt.
– Remove crankshaft toothed belt sprocket -1- in

-direction of arrow- from the crankshaft.
Installing (set the timing)
Note

ing angle.
♦ Replace the damaged O-ring of the locking screw at the tooth‐
ed belt gear of the inlet camshaft.
• Camshaft clamp - T10477- attached to camshaft housing.
Caution

♦ Do not use the camshaft clamp -T10477- as a counter‐
holder.

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

– Replace screws -1- and -2- and insert them loosely.

• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not tilt.
• Sheet peg -arrow- of the tensioning pulley must engage in the

cast iron recess of the cylinder head.
– Fit crankshaft toothed belt pulley onto the crankshaft.

• Contact surface between crankshaft toothed belt sprocket and
crankshaft must be free of oil and grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.
Observe sequence when fitting the toothed belt.
If the old toothed belt is installed, pay attention to the arrow which
indicates the direction of rotation.
– Mount the toothed belt -1- onto the crankshaft toothed belt
sprocket -2-.

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

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

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

T10500- !
When setting the tightening torque on the torque wrench - VAS
6583- the actual dimension specified on the tool insert -
T10500- must be put into the torque wrench!
– Keep eccentric in this position and tighten screw -1- to 25 Nm.

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

T10500- !
Set the reduced tightening torque of 12 Nm on the torque
wrench - V.A.G 1410-
The required tightening torque of 25 Nm is achieved by the
extending the torque wrench - V.A.G 1410- around the tool in‐
sert - T10500- !
– Keep eccentric in this position and tighten screw -1- to the re‐
duced tightening torque 12 Nm. To do so, use the insertion
tool - T10500- with torque wrench - V.A.G 1410- .
Continued
Note
If the engine continued to turn or has run, there may be slight

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

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

T10172/1- .
– Install the bottom toothed belt guard -arrows-.

– Installing the V-ribbed belt pulley crankshaft ⇒ page 50 .
Checking valve timing
– Turn the crankshaft by 2 turns in direction of rotation of engine
on “TDC” for cylinder 1 ⇒ page 103 .


Note


– Rotate crankshaft a turn further in the running direction of the
engine and set to “TDC” again.
Note

hammer.



timing is NOK:
– Remove the toothed belt from the camshafts and repeat the
timings ⇒ page 91 .
is OK:
– Pre-tighten screws -1- and -2- to the final tightening torque

⇒ page 87 , to do so use the counterholder - T10172A- with
adapters -T10172/2- and -T10172/1- .

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

terholder - T10172A- with the adapter -T10172/1- .
Caution

♦ After completing the work, check whether the positioning
screw - T10340- and camshaft clamp -T10477- are re‐
moved.
Further installation occurs in reverse order.

Tightening torques
• Screw for crankshaft toothed belt sprockets
• Screws for toothed belt guard
page 86
• Rollers and toothed belt gears
• Screw for ignition coil with power output stage
page 269
• Spark plug
page 269
• Locking screw for bore in the cylinder block
• Screw cap on the camshaft housing
page 77
• Screws for cover for coolant regulator
mostat”, page 153
• Noise insulation ⇒ Body Work- Assembly; Rep. gr. 66

3 Valve gear
⇒ “3.1 Valve gear - Summary of components”, page 115
⇒ “3.2 Measuring axial play of camshaft”, page 116
⇒ “3.3 Removing and installing camshaft control”, page 116
⇒ “3.4 Removing and installing gasket rings for camshafts”, page
117
⇒ “3.5 Removing and installing N205 the camshaft adjustment
valve 1 ”, page 121
⇒ “3.6 Removing and installing valve stem seal”, page 121
3.1 Valve gear - Summary of components
1 - Inlet valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ wymiary zaworu
⇒ page 127
❑ inspecting valve guides
⇒ page 127
2 - Exhaust valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ wymiary zaworu
⇒ page 127
❑ inspecting valve guides
⇒ page 127
3 - Cylinder head
4 - Valve stem seal
5 - Valve spring
❑ Fitting position
⇒ page 116
6 - Valve spring retainer
7 - Valve collets
8 - Roller rocker arm
⇒ page 78
❑ mark the fitting position
for re-installation
❑ inspect roller bearings
for smooth operation
❑ oil the contact surfaces
before installing
9 - Locking clip
❑ for hydraulic balancing element
10 - Hydraulic balancing element
❑ do not interchange
❑ Oil contact surface
3. Valve gear 115

Fitting position of the valve spring

• The small ∅ -a- points to the valve spring plate.
• The small ∅ -b- points to the cylinder head.
3.2 Measuring axial play of camshaft

♦ Universal dial gauge holder - MP3-447 (VW 387)-
inspect camshaft, axial play
– Secure dial gauge - VAS 6079- with the universal dial gauge
bracket - VW 387- to the camshaft housing, as shown in the
illustration.
– Press the camshaft by hand against the dial gauge.
– Position dial gauge to “0”.
– Press the camshaft off the dial gauge and read the value:
Axial clearance:
• Wear limit 0.25 mm.
3.3 Removing and installing camshaft con‐

trol
Removing
– Unscrew bolt -1- and remove camshaft adjuster.
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Fit the timing belt (set timings) ⇒ page 91 .

3.4 Removing and installing gasket rings for

camshafts
⇒ “3.4.1 Removing and installing the inlet camshaft on the belt
pulley side”, page 117
⇒ “3.4.2 Removing and installing the exhaust camshaft on the belt
pulley side”, page 118
⇒ “3.4.3 Removing and installing the exhaust camshaft on the
gearbox side”, page 120
3.4.1 Removing and installing the inlet cam‐

shaft on the belt pulley side
♦ Extractor tool - T20143/1-
Removing
– Remove the toothed belt from the camshaft sprockets
⇒ page 91 .
– Unscrew bolt -1- and remove camshaft adjuster.
– Remove seal -1- using extractor hook -T20143/1- .

Install
Note
3. Valve gear 117

– Push sealing ring -1- over the receiver tube -T10478/3- onto
the guide bushing -T10478/2- .
ceiver tube.
– Disconnect receiver tube and guide bushing.
– Position guide bushing -T10478/2- with seal -1- on camshaft.
– Pull sealing ring in to the stop using the thrust piece -

T10478/1A- and the camshaft sprocket screw -1-.
3.4.2 Removing and installing the exhaust

camshaft on the belt pulley side
♦ Assembly tool - T10478- with screw -T10478/5-
Removing

– Unscrew screw -2- and remove camshaft sprocket.
– Remove seal -1- using extractor hook -T20143/1- .

Install
Note
ceiver tube.
– Position guide bushing -T10478/2- with seal -1- on camshaft.
3. Valve gear 119

– Pull in -T10478/1A- with the screw -T10478/5- to the stop.

3.4.3 Removing and installing the exhaust

camshaft on the gearbox side
Removing
– Remove the toothed belt gear for coolant pump drive
⇒ page 159 .
– Carefully fit extractor hook -T20143/1- between camshaft and
seal -1-.
– Lever out the gasket ring.
Install
Note
ceiver tube.

– Fit guide bushing -T10479/2- with sealing ring -2- centrally on‐
to the camshaft.
– Fix guide bushing with screw -1- for coolant pump driving
wheel onto the camshaft.
– Push sealing ring onto camshaft, unscrew guide bushing.
– Pull sealing ring -2- into the stop using the thrust piece -
T10479/1- and the screw -1- for coolant pump driving wheel.
– Install the toothed belt gear for coolant pump drive
⇒ page 159 .
3.5 Removing and installing - N205- the

camshaft adjustment valve 1
Removing
– Unscrew screw -2- and remove camshaft control valve 1 -
N205- .
Install
following:
Note
Renew O-ring.
Tightening torques
♦ Screw for camshaft control valve 1
page 77
3.6 Removing and installing valve stem seal

⇒ “3.6.1 Removing and installing valve stem seal with cylinder
head installed”, page 121
⇒ “3.6.2 Removing and installing valve stem seal with cylinder
head removed”, page 124
3.6.1 Removing and installing valve stem seal

with cylinder head installed
3. Valve gear 121


♦ Disassembly and assembly device for valve collets - VAS
5161- with set - VAS 5161A/32-
♦ Adapter - T40012-
♦ Valve stem seal fitting tool - MP1-233 (3365)-
♦ Valve shaft pliers , e.g. -VAS 6770-
Work procedure
– Release spark plugs with spark plug wrench , e.g. -3122 B- .
– Position piston of the relevant cylinder in “BDC”.
– Place guide plate -VAS 5161A/32- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Screw in adapter - T40012- with seal ring hand-tight into the
corresponding plug connector thread.
– Connect the adapter to the compressed air with a commer‐
cially available intermediate piece and apply constant pres‐
sure.
• Minimum pressure: 0.6 MPa (6 bar)
– Insert the impact drift -VAS 5161/3A- into the guide plate -VAS
5161A/32- and slacken the tightly fitted valve collets using a
plastic hammer.
– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/5- into the guide plate -VAS 5161A/32- .
– Insert assembly cartridge -VAS 5161/32-2- with sleeve moun‐
ted -VAS 5161/32-3- into the guide plate -VAS 5161A/32- .
– Hook the pressure fork -VAS 5161/2- onto the detent part -
VAS 5161/6- and push the assembly cartridge -
VAS 5161/32-2- downwards.
– Turn simultaneously the knurled screw of the assembly car‐
tridge -VAS 5161/32-2- to the right, until the tips click into the
valve collets.
– Turn the knurled screws to the left and the right- as a result,
the valve collets are pushed away from each other and latch
into the assembly cartridge -VAS 5161/32-2- .
– Let go of the pressure fork -VAS 5161/2- .
– Remove the assembly cartridge -VAS 5161/32-2- .
– Unscrew guide plate -VAS 5161A/32- and turn it to the side.
• T compressed air hose remains connected.
– Remove the valve spring with the valve spring retainer.

– Remove valve stem seal with valve shaft pliers , e. g. -VAS

6770- .
Caution
There is a risk of damage when installing the valve stem seals.
– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal -B-.
– Slide the valve stem seal onto the plastic bushing -A-.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve -A- again.
If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device for valve
collets -VAS 5161/32-3- .
• The large diameter of the valve collets points to the top.
– Press the assembly cartridge from the top -VAS 5161/32-2-
onto the insertion device -VAS 5161/32-3- and lift up the valve
collets.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ page 116 .
3. Valve gear 123

– Screw the guide plate -VAS 5161A/32- back onto the cylinder
head.
– Insert assembly cartridge -VAS 5161/32-2- with sleeve -VAS
5161/32-3- mounted into the guide plate -VAS 5161A/32- .
– Press down the pressure fork -VAS 5161/2- and turn the
knurled screw to the left and to the right while pulling it up‐
wards, by doing so the valve collets are inserted.
– Release the pressure fork -VAS 5161/2- on tightened knurled
screw.
– Repeat the procedure for each valve.
Install
The installation occurs in reverse order, while paying attention to
the following.
– Install spark plugs ⇒ page 269 .
– Install camshaft housing ⇒ page 78 .
3.6.2 Removing and installing valve stem seal

with cylinder head removed
♦ Disassembly and assembly device for valve collets - VAS
5161- with set - VAS 5161A/32-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve shaft pliers , e.g. -VAS 6770-
♦ Valve stem seal fitting tool - 3365-
Work procedure
– Remove cylinder head ⇒ page 80 .
– Insert the cylinder head tensioning device - VAS 6419- into the
engine and gearbox jack - VAS 6095- .
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Connect cylinder head tensioning device to compressed air.
– Adjust the air bellows with the lever -arrow- below the com‐
bustion chamber on which the valve stem seals should be
removed.
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.
– Place guide plate -VAS 5161A/32- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Insert the impact drift -VAS 5161/3A- into the guide plate -VAS
5161A/32- and slacken the tightly fitted valve collets using a
plastic hammer.

– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/5- into the guide plate -VAS 5161A/32- .
– Insert assembly cartridge -VAS 5161/32-2- with sleeve moun‐
ted -VAS 5161/32-3- into the guide plate -VAS 5161A/32- .
– Hook the pressure fork -VAS 5161/2- onto the detent part -
VAS 5161/6- and push the assembly cartridge -
VAS 5161/32-2- downwards.
– Turn simultaneously the knurled screw of the assembly car‐
tridge -VAS 5161/32-2- to the right, until the tips click into the
valve collets.
– Turn the knurled screws to the left and the right- as a result,
the valve collets are pushed away from each other and latch
into the assembly cartridge -VAS 5161/32-2- .
– Let go of the pressure fork -VAS 5161/2- .
– Remove the assembly cartridge -VAS 5161/32-2- .
– Unscrew guide plate -VAS 5161A/32- and turn it to the side.
– Remove the valve spring with the valve spring retainer.
– Remove valve stem seal with valve shaft pliers , e. g. -VAS

6770- .
Caution
Risk of damage when installing the valve stem seals.
– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal -B-.
– Slide the valve stem seal onto the plastic bushing -A-.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve -A- again.
3. Valve gear 125

If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device for valve
collets -VAS 5161/32-3- .
• The large diameter of the valve collets points to the top.
– Press the assembly cartridge from the top -VAS 5161/32-2-
onto the insertion device -VAS 5161/32-3- and lift up the valve
collets.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ page 116 .
– Screw the guide plate -VAS 5161A/32- back onto the cylinder
head.
– Insert assembly cartridge -VAS 5161/32-2- with sleeve -VAS
5161/32-3- mounted into the guide plate -VAS 5161A/32- .
– Press down the pressure fork -VAS 5161/2- and turn the
knurled screw to the left and to the right while pulling it up‐
wards, by doing so the valve collets are inserted.
– Release the pressure fork -VAS 5161/2- on tightened knurled
screw.
– Repeat the procedure for each valve.
– Install cylinder head ⇒ page 80 .

4 Inlet and exhaust valves

⇒ “4.1 Inspect valve guides”, page 127
⇒ “4.2 Testing valves”, page 127
⇒ “4.3 Valve dimensions”, page 127
4.1 Inspect valve guides

♦ Universal dial gauge holder - MP3-447 (VW 387)-
Test sequence
– Insert valve into guide. The end of valve stem must be flush
with guide. Because of the different stem diameters only use
inlet valve in inlet guide or outlet valve in outlet guide.
– Determine valve rock.
• Wear limit: 0.5 mm.
– If the wear limit is exceeded, repeat measurement with new
valves.
– If the wear limit is again exceeded, replace cylinder head.
Note
The valve guides cannot be replaced.
4.2 Testing valves

– Check valves on the shank and seat surface for scoring.
– If scoring is clearly visible, change valve.
4.3 Valve dimensions
Note
Inlet and exhaust valves must not be reworked. Only grinding in

is permissible.
Dimension Inlet valve Exhaust valve

∅a mm 29.5 27.0
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30
4. Inlet and exhaust valves 127

17 – Lubrication
1 Lubrication system
⇒ “1.1 Oil sump and oil pump - Summary of components”,
page 128
⇒ “1.2 Removing and installing oil sump bottom part”, page 129
⇒ “1.3 Removing and installing oil sump top part”, page 132
⇒ “1.4 Removing and installing oil pump”, page 135
1.1 Oil sump and oil pump - Summary of components
Note
♦ If considerable quantities of metal swarf or abrasion is found when carrying out an engine repair, this can
be subject to damage to the crankshaft and conrod bearings. In order to prevent consequential damage,
the following tasks must be performed after the repair: Clean oil channels carefully; change oil injection
nozzles, engine oil cooler and oil filter.
♦ Oil spray nozzle and pressure relief valve ⇒ page 72 .
1 - Dipstick
❑ Oil quantity
♦ ⇒ Maintenance ; Booklet
Octavia III
Yeti
2 - O-ring
❑ replace
❑ oil before the assembly
3 - Vent valve
❑ Check fitting position
4 - Screw cap
5 - Oil separator
⇒ page 140
6 - Screw
tightening order
⇒ page 140
7 - Oil pressure switch - F1-
❑ 0.03 ... 0.06 MPa (0.3…
0.6 bar)
❑ Checking oil pressure
switch ⇒ page 144 .
❑ 20 Nm
128 Rep. gr.17 - Lubrication

8 - Connector
9 - Baffle
10 - Sump top part
11 - Oil filter
❑ Moisten gasket with oil before installing
❑ In case of damage to the outer skin, the oil filter must be replaced
❑ 20 Nm
12 - Sump bottom part
13 - Screw
❑ Tightening torque and tightening order ⇒ page 132
14 - Sealing ring
❑ replace
15 - Oil drain plug
❑ 30 Nm
16 - Screw
❑ replace
17 - Suction line
18 - Screw
❑ 8 Nm
19 - Screw
❑ replace
❑ Tightening torques ⇒ page 136
20 - Screw
❑ for the tensioning device
21 - Sealing ring
❑ for oil pump drive
22 - Screw
❑ replace
23 - Oil pump
24 - Gasket
❑ replace
❑ Observe positioning of runners
1.2 Removing and installing oil sump bot‐

tom part
♦ Socket insert - T10058-
1. Lubrication system 129

♦ Sealant remover gasket stripper (bearing code GST, bearing

article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning and degreasing agent , e.g. -D 009 401 04-
♦ Protective goggles and gloves
♦ Silicone sealant ⇒ Electronic Catalogue of Original Parts“ET‐
KA”
Removing
– Drain engine oil.
– Loosen the screws in the sequence -19…1- and unscrew
them.
Note
When hardened, the sealant has a high adhesive strength.

– At the point identified by an -arrow-, carefully lever out the oil

sump bottom part using a screwdriver.
– Remove lower part of oil sump. If necessary, undo the oil pan
by applying slight blows with a rubber-headed hammer.
Install
WARNING
Wear protective gloves when working with sealant and grease

remover!
– Remove the remaining sealant on the cylinder block and on

the oil pan with chemical sealant remover.
– Degrease the sealing surfaces.
Note
♦ Pay attention to the use by date on sealant.

♦ The oil pan must be installed within 5 minutes after applying
the sealant.
♦ The oil pan can be better and more securely installed if 2 M6
threaded pins are screwed on the sump top part for the inser‐
tion.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).
Caution
Risk of blockage of the lubrication system through excess seal‐

ant.
♦ Do not apply a thicker sealant bead than indicated.
– Apply sealant to clean sealing surface of sump as shown.

The sealant bead must be:
♦ be 2...3 mm thick
♦ Run bead along inner side of bolt holes -arrows-
Note
♦ Take particular care when applying sealant bead in the area

of the sealing flange.
♦ After applying the sealant, the oil sump bottom part must be
installed within 5 minutes.
– Position oil sump bottom part and tighten screws.

Oil sump bottom part - tightening torque and tightening order

– Tighten screws gradually in the given sequence:
1. -1…19- by hand as far as the stop
2. -1…19- 12 Nm
Note
After installing the lower part of the oil pan, allow the sealant to
dry for about 30 minutes. Only then may engine oil be filled in.
– Fill with engine oil and check the oil level.

1.3 Removing and installing oil sump top

part
♦ Silicone sealant ⇒ ETKA - Electronic catalogue of original
parts
Removing
Note
Sump top part can also be removed without removing the sump
top part.

Note
♦ The refrigerant lines are not opened.

♦ Prevent damage to condenser and refrigerant lines and hoses.
♦ Do NOT stretch, kink or bend lines and hoses.
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.

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


– Loosen the screws in the sequence -19…1- and unscrew
them.
– Loosing oil sump top part carefully from the bonding.
– Remove baffle.
Install
Note

angle.
– Check oil channels in the oil sump top part and in the cylinder
block for contamination.
WARNING

remover!

Note
♦ Pay attention to the use by date on sealant.

♦ The oil pan must be installed within 5 minutes after applying
the sealant.
♦ The oil pan can be better and more securely installed if 2 M6
threaded pins are screwed on the flange of the cylinder block
for the insertion.

2 mm).
Caution
Risk of blockage of the lubrication system through excess seal‐

ant.

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

the oil sump top part, as shown in the illustration.
• Thickness of sealant bead: 2 … 3 mm.
Note
After applying the sealant, the oil sump top part must be installed
within 5 minutes.
– Check firm seating of the fit pin -2- in the cylinder block.
– Position the gasket -1- at the cylinder block.
– Position oil sump top part and tighten screws.

Oil sump top part - tightening torque and tightening order
Note

angle.
– Tighten screws gradually in the given sequence:

1. -1...19- by hand as far as the stop
1. -1…19- 8 Nm
2. -1…19- 90° (torque a further 90° (1/4 turn)

note the following:
Only vehicles with air conditioner
87 .
– Fill with engine oil and check the oil level.
1.4 Removing and installing oil pump

Removing
– Removing toothed belt ⇒ page 102 .
– Unscrew the fixing screws -arrows- and remove the tensioning
device for Poly V-belt ⇒ page 49 .
– Remove alternator ⇒ Electrical System; Rep. gr. 27 .
– Removing gasket ring for crankshaft on belt pulley side
⇒ page 53 .

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

– Pull oil pump off dowel pins on cylinder block in a straight line.
– Remove gasket -1- from dowel pins -arrows-.

Install
– Fit new gasket -1- onto dowel pins -arrows-.
– Rotate oil pump gear to a position where 2 opposing notches

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

– Tighten the new fixing screws -1- und -2- in the specified order:
1. -1- 5 Nm
2. -2- 10 Nm
3. -1- 8 Nm
4. -2- 20 Nm
5. -1- and -2- 90° (torque a further 90° (1/4 turn)
– Install the new gasket ring for the crankshaft on the belt pulley
side ⇒ page 53 .
– Install sump top part ⇒ page 132 .
– Install alternator ⇒ Electrical System; Rep. gr. 27 .
– Fit tensioning device for poly V-belt with new fixing screws
-arrows- and tighten to 20 Nm + 90° (1/4 turn) ⇒ page 49 .

2 Engine oil cooler

⇒ “2.1 Engine oil cooler - Summary of components”, page 138
⇒ “2.2 Removing and installing engine oil cooler”, page 138
2.1 Engine oil cooler - Summary of components
1 - Engine oil cooler

⇒ page 138
❑ fill with fresh coolant af‐
ter replacing
2 - Screw
❑ replace
90° (1/4 turn)
3 - Gasket rings
❑ replace
2.2 Removing and installing engine oil cool‐

er
Removing

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

Install
following:
– Insert new O-rings.
– Top up coolant ⇒ page 150 .
Tightening torques
♦ Screw for engine oil cooler
⇒ “2.1 Engine oil cooler - Summary of components”,
page 138
2. Engine oil cooler 139

3 Crankcase ventilation
⇒ “3.1 Crankcase ventilation - Summary of components”,
page 140
⇒ “3.2 Removing and installing oil separator”, page 140
3.1 Crankcase ventilation - Summary of components
1 - Screw
❑ replace
❑ 9 Nm
2 - Oil separator
⇒ page 140
3 - O-ring
❑ replace
❑ oil before the assembly
4 - Inlet connections
❑ Check fitting position
5 - Hose
❑ for crankcase ventila‐
tion
3.2 Removing and installing oil separator

♦ Silicone sealant ⇒ Electronic Catalogue of Original Parts“ET‐
KA”
Removing

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

– Loosen oil separator carefully from the bonding.
Install
following:
WARNING

remover!

Caution
There is a risk of contamination of the lubrication system.

♦ Cover opened engine parts.
Note
Pay attention to the use by date on sealant.

1.5 mm).
Caution
There is risk of blockage of the lubrication system through ex‐

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

the oil separator, as shown in the illustration.
• Thickness of sealant bead: 1.5 mm.
Note
After applying the sealant, the oil separator must be installed

within 5 minutes.
3. Crankcase ventilation 141

– Position oil separator and tighten screws.

– Tighten screws in the sequence -1 … 9-.
note the following:
– Install the noise insulation ⇒ Body Work; Rep. gr. 66 .
Tightening torques
♦ Screws for oil separator
⇒ “3.1 Crankcase ventilation - Summary of components”, page
140

4 Oil filter, oil pressure switch

⇒ “4.1 Summary of components - oil filter/oil pressure switch”,
page 143
⇒ “4.2 Removing and installing oil pressure switch F1 ”,
page 143
⇒ “4.3 Testing oil pressure and oil pressure switch F1 ”,
page 144
⇒ “4.4 Removing and installing oil filter housing”, page 145
4.1 Summary of components - oil filter/oil pressure switch
1 - Oil filter
⇒ page 145
❑ Before installing, lightly
coat sealing ring with
clean engine oil
❑ pay attention to note
⇒ page 128
❑ Change interval
Octavia III
Yeti
❑ 20 Nm
❑ Switching pressure
0.03 ... 0.06 MPa (0.3…
0.6 bar)
❑ Checking oil pressure
switch ⇒ page 144 .
⇒ page 143
❑ 20 Nm
3 - Sealing ring
❑ replace
4.2 Removing and installing oil pressure

switch - F1-
♦ Flexible-head wrench SW 24 - T40175-
4. Oil filter, oil pressure switch 143

Removing
Caution
The alternator must be covered with a cloth in order to avoid

damage due to spilled engine oil.
– Screw out oil pressure switch - F1- -1-.

Install
following:
Note
♦ Renew seal.
♦ To prevent larger oil leaks, the new oil pressure switch - F1-
can be inserted into the bore.
– Checking the oil level.

Tightening torques
♦ Oil pressure switch
page 143
4.3 Testing oil pressure and oil pressure

switch - F1-
♦ Oil pressure tester - V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Checking the oil level.
• Oil level o.k.
• Engine oil temperature at least 80 °C (radiator fan must have
run once).
Testing oil pressure
– Remove oil pressure switch - F1- ⇒ page 143 .

– Screw the oil pressure tester - V.A.G 1342- into the hole for
the oil pressure switch on the cylinder head.
– Screw in the oil pressure switch - F1- into the hole on the oil
testing device - V.A.G 1342- .
– Start engine.
• Oil pressure in idle: at least 0.1 MPa (1 bar)
• Oil pressure at 3000 rpm: at least 0.25 MPa (2.5 bar)
• Oil pressure at 4500 rpm: at least 0.3 MPa (3 bar)
Note
♦ Mechanical damage such as bearing damage or camshaft ad‐

justment may also be the cause of oil pressure that is too low.
♦ The oil pressure must not be greater than 0.5 MPa (5 bar).
Otherwise, the fault lies in the control circuit of the pump.
Test oil pressure switch - F1-

– Switch off engine.
– Connect brown cable of tester to earth (-).

– Connect the voltage tester - V.A.G 1527B- with auxiliary ca‐
bles from the measuring tool set - V.A.G 1594C- to the battery
plus (+) and oil pressure switch - F1- .
• The LED must not light up.
If the LED lights up:
– Replace oil pressure switch - F1- .
If the LED does not light up:
– Start engine and increase engine speed.
• Start engine, at an overpressure of 0.03 .... 0.06 MPa
(0.3...0.6 bar) the LED must light up, otherwise renew oil pres‐
sure switch ⇒ page 143 .
– Install the oil pressure switch - F1- ⇒ page 143 .
4.4 Removing and installing oil filter housing

♦ Oil filter tool - 3417-
Removing
4. Oil filter, oil pressure switch 145

– Remove oil filter -arrow- with oil filter tool - 3417- .

Install
following:
– Moisten gasket of oil filter with engine oil
– Tighten oil filter with oil filter wrench - 3417- .
– Top up with engine oil.
Tightening torques
♦ Oil filter
page 143

19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Connection diagram for coolant hoses”, page 147
⇒ “1.2 Draining and filling up coolant”, page 148
⇒ “1.3 Checking the coolant system for leaktightness”,
page 150
1.1 Connection diagram for coolant hoses
Note
♦ Brown = heating coolant circuit

♦ Yellow = heating coolant circuit ATF gearbox oil (only on ve‐
hicles with automatic gearbox)
♦ The arrows point in the coolant flow direction.
1 - Coolant radiator
ter replacing
2 - Cylinder head and cylinder
block
ter replacing
3 - Coolant expansion tank
4 - Screw cap
❑ for coolant expansion
tank
❑ Check pressure relief
valve ⇒ page 152
5 - Coolant temperature send‐
er - G62-
6 - Heat exchanger of heating
system
ter replacing
7 - Coolant pump
❑ with thermostat housing
8 - ATF radiator
❑ only for vehicles with au‐
tomatic gearbox
9 - Engine oil cooler
10 - Coolant temperature
sender at radiator outlet - G83-
1. Cooling system, coolant 147

1.2 Draining and filling up coolant

♦ Refractometer
♦ Pliers for spring strap clamps
♦ Cooling system charge unit e.g. -VAS 6096-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
Draining
Note

disposal.
♦ Observe the disposal instructions.

– Place catch pan - VAS 6208- underneath.
– Remove plug -2- at the coolant temperature sender - G83-

-3-.
– Raise holding clamp -1-, remove bottom left coolant hose from
radiator fan for coolant, allow coolant to drain.
Filling up
Choose the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts “ETKA” .
– In a clean reservoir mix drinking water and coolant additive in
the specified mixing ratio.
– Connect coolant hose with quick coupling to radiator bottom
left ⇒ page 168 .
148 Rep. gr.19 - Cooling

– Fill up the coolant reservoir of the -VAS 6096- with at least 10

litres of pre-mixed coolant mixed to the correct ratio:
– Screw the adapter for the cooling system testing device , e.g.
-V.A.G 1274/8- onto the coolant expansion tank.
– Connect the cooling system charge unit - VAS 6096- with the
adapter -V.A.G 1274/8- .
– Lead the air hose -1- into a small container -2-.
Note
A small amount of coolant, which is entrained with the exhaust

air, must be collected.
– Close the valves -A- and -B-, while doing so turn the lever at
right angles to the direction of flow.
– Connect hose -3- to compressed air.
• Pressure: 0.6 -1 MPa (6…10 bar) overpressure.
– Open the valve -B-, while doing so turn the lever in the direction
of flow.
• Vacuum is generated in the cooling system by the suction jet
pump. The display instrument pointer must be in the green
area.
– In addition, briefly open the valve -A- by turning the lever in the
direction of flow, so that the hose of the coolant expansion
bottle of the -VAS 6096- is filled with coolant.
– Close the valve -A- again.
– Leave the valve -B- open a further 2 minutes.
• A vacuum pump is created in the cooling system by the vac‐
uum pump; the display instrument pointer must remain in the
green area.
– Close the valve -B-.
• The display instrument pointer must remain unaffected in the
green area. The vacuum in the cooling system is now sufficient
for subsequent filling.
Note
♦ If the pointer is below the green area, repeat the process.

♦ If the vacuum drops, check the cooling system for leak points.
– Disconnect pneumatic hose.

– Open valve -A-.
• The vacuum pump in the cooling system draws the coolant out
of the coolant reservoir -VAS 6096- and fills the cooling sys‐
tem.
– Remove the cooling system charge unit - VAS 6096- from the
coolant expansion tank.

– Fill up coolant up to “Max” marking.

– Set temperature to “HI”.
– Switch off AC compressor. Press AC button to do so.
• The LED in the button must not illuminate.
– Start engine and run for not more than 2 minutes at 1500 rpm.
– With the engine running, fill coolant up to the overflow hole on
the coolant expansion tank.
– Tighten cap for coolant expansion tank tighten until it clicks
into place.
– Run engine at idling speed until the two large coolant hoses
at the radiator are hot.
– Switch off engine and allow it to cool down.
– Check coolant level.

• If the engine is cold the coolant level must be between the
“Min” and “Max” marking.
• When the engine is at operating temperature the coolant level
may be at the “Max” marking.
– If necessary, top up with coolant.
1.3 Checking the coolant system for leak‐

tightness
⇒ “1.3.1 Checking with the cooling system testing device V.A.G
1274 ”, page 150
⇒ “1.3.2 Checking with the cooling system testing device V.A.G
1274 B ”, page 151
1.3.1 Checking with the cooling system test‐

ing device - V.A.G 1274-
♦ Cooling system testing device , e.g. -V.A.G 1274-
Test condition
• Engine is at operating temperature.
Test sequence
WARNING
Hot steam may escape when the coolant expansion reservoir

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

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

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

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

ing device - V.A.G 1274 B-
♦ Cooling system testing device , e.g. -V.A.G 1274 B-
Work procedure
• Engine must be warm.

WARNING

overpressure.
– Fit the cooling system testing device - V.A.G 1274 B- with

adapter -V.A.G 1274/8- onto the coolant expansion tank.
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0.1 MPa (1.0 bar).
WARNING
Risk of scalding!
♦ Before the cooling system testing device - V.A.G 1274 B-
is separated from the connecting hose or the connecting
piece - V.A.G 1274 B/1- , the existing pressure must ab‐
solutely be released.
♦ For this step, press the pressure relief valve on the cooling
system testing device - V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value »0«.
– If the pressure drops determine leak positions and repair.
Check pressure relief valve in cap.

– Fit the cooling system testing device - V.A.G 1274 B- with
adapter -V.A.G 1274/9- onto the cap.
– Build up overpressure using hand pump on cooling system
tester.
♦ The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Summary of components - coolant pump/coolant thermo‐
stat”, page 153
⇒ “2.2 Coolant temperature sender - Summary of components”,
page 155
⇒ “2.3 Removing and installing coolant pump”, page 156
⇒ “2.4 Removing and installing toothed belt pulley for coolant
pump drive”, page 159
⇒ “2.5 Removing and installing coolant regulator”, page 160
⇒ “2.6 Removing and installing coolant temperature sender G62
”, page 162
⇒ “2.7 Removing and installing coolant temperature sender at
radiator outlet G83 ”, page 163
2.1 Summary of components - coolant pump/coolant thermostat
1 - Coolant regulator housing

⇒ page 161
❑ Observe tightening se‐
quence when tightening
to coolant pump
⇒ page 156 .
2 - Coolant regulator
❑ For large coolant circuit
(cylinder block circuit)
❑ Start of opening approx.
87 °C
❑ different versions ⇒
Electronic Catalogue of
Original Parts“ETKA”
⇒ page 161
3 - Gasket
❑ replace
❑ Observe proper seating
of gasket
❑ before installing, slightly
moisten with coolant
4 - Coolant pump
⇒ page 156
❑ Replace toothed belt
when changing coolant
pump
5 - Screw
❑ order of tightening
⇒ page 155
❑ 8 Nm
6 - Gasket
❑ replace
2. Coolant pump, regulation of cooling system 153

❑ Observe proper seating of gasket
❑ before installing, slightly moisten with coolant
7 - Toothed belt guard
❑ For coolant pump toothed belt
8 - Screw
❑ replace
20 Nm + torque a further 90° (1/4 turn)
9 - Toothed belt
❑ Replace when changing coolant pump
10 - Toothed belt pulley
11 - Screw
8 Nm
12 - Screw
❑ order of tightening ⇒ page 155
7 Nm
13 - Screw cap
❑ for coolant regulator
14 - Gasket
❑ replace
❑ before installing, slightly moisten with coolant
15 - Coolant regulator
❑ For small coolant circuit (cylinder head circuit)
❑ Start of opening approx. 80 ℃
❑ Fitting position ⇒ page 154
16 - Screw
Installation position of thermostat for large coolant circuit

• Must be fitted with the centring pin into guide -arrow- on cool‐
ant pump housing.

Tightening sequence thermostat housing at coolant pump - tight‐

ening torque and tightening sequence
Note
Self-cutting screws must be positioned by hand in such a way that

they find the old thread turn. Then tighten the screw to torque.
– Tighten screws in the sequence -A…F- to 8 Nm.
Tightening sequence cover for coolant thermostat at the coolant

thermostat housing - Tightening torque
Note
Self-cutting screws must be positioned by hand in such a way that

they find the old thread turn. Then tighten the screw to torque.
– Tighten cover screws -1- in the sequence -A…D- to 7 Nm.
2.2 Coolant temperature sender - Summary of components

1 - Screw
❑ 8 Nm
2 - Support ring
3 - O-ring
❑ replace
er - G62-
⇒ page 162
5 - O-ring
❑ replace
er at radiator outlet - G83-
⇒ page 163
7 - Retaining clip
❑ check tightness
2.3 Removing and installing coolant pump

Removing

– Undo screws -2- for coolant pipe -3- and press the pipe to one
side.

– Loosen the screws in the sequence -5- to -1- and unscrew

them.
– Remove coolant pump with toothed belt.
– Remove thermostat housing when coolant pump is being re‐
placed ⇒ page 160 .
Install
Note
♦ Replace gaskets -arrows-.

♦ Remove toothed belt when coolant pump is being replaced.
♦ Secure hose connections with hose clamps which comply with
the series design ⇒ Electronic Catalogue of Original Parts“ET‐
KA” .

– Ensure proper seating of gaskets -arrows-.

– Moisten gasket for coolant pump with coolant.
Caution
Always adhere to the sequence of work steps given below

when installing the coolant pump.
This ensures that the toothed belt is correctly tensioned.
The following work steps must be carried out with the aid of a
2nd mechanic.
• Used toothed belts must always be replaced with new ones

when the coolant pump is being replaced.
– Set cylinder 1 to TDC ⇒ page 88 .
– Fit toothed belt centrally onto camshaft sprocket and coolant
pump toothed belt pulley .
– Mount coolant pump on cylinder head with securing bolts.
– Initially tighten screws in the specified order:

1. -1 … 5- by hand as far as the stop
2. -1 … 5- 10 Nm
– Loosen all screws by 1 turn.

– Fit torque wrench e. g. -VAS 6583- with hexagon socket SW10

insert Pos. -6- in hexagon socket head to the coolant pump.
– Pre-tension coolant pump with torque wrench, e.g. -VAS
6583- , to 30 Nm in a clockwise direction.
Note
♦ Do not support torque wrench with the other hand.

♦ In order to avoid the belt tension being too high the torque
wrench must not be »put under excessive pressure«.
– Keep coolant pump pretensioned.

– At the same time, have a second mechanic pre-tighten the
fixing screws on the coolant pump clockwise in sequence from
right to left, beginning with screw -2-, -1- and -5- »3rd Pre‐
tighten stage« to 10 Nm.
– Then tighten the fixing screws to the »4th. stage«.
3. -2, 1, 5- 10 Nm
4. -3, 4, 5, 1, 2- 12 Nm
note the following:
Tightening torques
⇒ “3.2 Removing and installing coolant pipes”, page 165
Component Tightening torque
Thermostat housing to coolant 7 Nm
pump
Coolant pump 12 Nm
Toothed belt guard 8 Nm
2.4 Removing and installing toothed belt

pulley for coolant pump drive
♦ Counterholder - T10172A- with adapters -T10172/2-
Removing
– Loosen screw -1-. Use counterholder - T10172A- with adapter
-T10172/2- to do so.
– Undo screw, remove toothed belt gear for coolant pump drive
-2-.
Install
following:

– Set the toothed belt gear for the coolant pump drive onto the
camshaft so that the asymmetric grooves -1- and -2- in the
camshaft are positioned exactly in the middle of the recesses
-arrows- in the toothed belt gear.
• Grooves -1- and -2- in the camshaft are arranged asymmetri‐
cally.
• The recesses -arrows- in the toothed belt gear for the coolant
pump drive are also arranged symmetrically.
Tightening torques
♦ Screw for belt pulley
mostat”, page 153
2.5 Removing and installing coolant regula‐

tor
⇒ “2.5.1 Removing and installing thermostat for small coolant cir‐
cuit”, page 160
⇒ “2.5.2 Removing and installing thermostat for large coolant cir‐
cuit”, page 161
2.5.1 Removing and installing thermostat for

small coolant circuit
♦ Key - T10508-
Removing
– Loosen hose clamp -4- and remove coolant hose -3-.
– Undo screws -a- and remove cover -2- from thermostat hous‐
ing -1-.

– Remove thermostat with spanner - T10508- .

– Light press the wrench - T10508- down, while doing so, turn
in the -direction of the arrow-.
Install
– Insert thermostat. Fit the centring pin in into the

guide-arrow-.
– Install thermostat with spanner - T10508- .

– Light press the wrench - T10508- down, while doing so, turn
in the -direction of the arrow- as far as it can go.
following:
Note
Replace gasket.
– Moisten gasket with coolant.

Tightening torques
♦ Thermostat cover screws on thermostat housing ⇒ page 153
2.5.2 Removing and installing thermostat for

large coolant circuit
Removing

– Release the screws in the order -F…A-.

– Remove coolant pump from coolant pump housing.
– Remove thermostat -2- from coolant pump -1-.

Install
following:
Note
Replace gasket.
– Moisten gasket with coolant.
– Fit thermostat housing to coolant pump.

• The centring bolts on the thermostat must be inserted into the
guides -arrows- on the coolant pump.
– Tighten screws for thermostat housing ⇒ page 155 .
Tightening torques
♦ Screws for thermostat housing
⇒ Fig. ““Tightening sequence thermostat housing at coolant
pump - tightening torque and tightening sequence”“ ,
page 155
2.6 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.
– Briefly open the cap -arrow- for the coolant expansion reser‐
voir in order to remove the remaining pressure in the coolant
system, then close until it clicks into place.
– Disconnect plug connection from coolant temperature sender
- G62-
Note
Place a cloth below to absorb leaking coolant.

– Undo screw -1- and remove coolant temperature sender -

G62- Pos. -2-.
Note
♦ If the O-ring -3- with support ring -4- remains in the cylinder
head, lift out the O-ring with support ring using a wire.
♦ Insert new coolant temperature sender - G62- immediately in‐
to cylinder head in order to avoid loss of coolant.
Install
following:
Note
Renew O-ring.
– Check coolant level ⇒ page 150 .

Tightening torques
♦ Screw of sender
⇒ “2.2 Coolant temperature sender - Summary of compo‐
nents”, page 155
2.7 Removing and installing coolant temper‐

ature sender at radiator outlet - G83-
Removing
• Engine cold.
– Briefly open the cap -arrow- for the coolant expansion reser‐
voir in order to remove the remaining pressure in the coolant
system, then close until it clicks into place.

Note
Place a cloth below to absorb leaking coolant.
– Pull off holding clamp -3- and take coolant temperature sender
on radiator outlet - G83- out of connection piece.
Install
following:
Note
♦ Renew O-ring.
♦ Insert new coolant temperature sender - G83- into the con‐
nection piece immediately in order to avoid loss of coolant.
– Remove front noise insulation ⇒ Body Work; Rep. gr. 66 .


3 Parts of cooling system engine side

⇒ “3.1 Cooling system attached to engine - Summary of compo‐
nents”, page 165
⇒ “3.2 Removing and installing coolant pipes”, page 165
3.1 Cooling system attached to engine - Summary of components
1 - Coolant hose
2 - Screw
❑ 8 Nm
3 - Coolant pipe
4 - Coolant hose
5 - Screw
❑ 8 Nm
6 - Coolant hose
7 - Coolant pipe
❑ When removing using a
screwdriver, carefully
lever out of the catch
8 - Screw
❑ 20 Nm
9 - Screw
❑ 8 Nm
10 - Coolant hose
Note
The arrows which are on the coolant pipes and the coolant hose
ends must stand opposite to each other.
3.2 Removing and installing coolant pipes

♦ Hose clamps up to 25 mm - MP7-602 (3094)-
3. Parts of cooling system engine side 165

Removing
WARNING

overpressure.

– Disconnect coolant hoses with hose clamps -MP7-602
(3094)- .

– Remove coolant pipe -2-.

– Remove coolant pipe -3-.
Install
following:
Note
Secure all hose connections with hose clamps which comply with
the series design ⇒ Electronic Catalogue of Original Parts“ET‐
KA.” .

Tightening torques
♦ Coolant pipes at engine
⇒ “3.1 Cooling system attached to engine - Summary of com‐
ponents”, page 165

4 Radiator and radiator fan

⇒ “4.1 Radiator- Summary of components (Octavia III)”,
page 167
⇒ “4.2 Radiator - Summary of components (Yeti)”, page 168
⇒ “4.3 Fan shroud with a radiator fan - Summary of components”,
page 170
⇒ “4.4 Fan shroud with two radiator fans - Summary of compo‐
nents”, page 171
⇒ “4.5 Remove and install radiator (Octavia IlI)”, page 171
⇒ “4.6 Removing and installing radiator (Yeti) ”, page 173
⇒ “4.7 Removing and installing radiator cowl for radiator fan (Oc‐
tavia III)”, page 175
⇒ “4.8 Removing and installing fan shroud for radiator fan (Yeti)”,
page 176
⇒ “4.9 Removing and installing radiator fan V7 ”, page 177
⇒ “4.10 Removing and installing radiator fan 2 V177 ”,
page 178
4.1 Radiator- Summary of components (Octavia III)
⇒ page 171
ter replacing
2 - Coolant hose
❑ to remove, raise holding
clamps
❑ connect ⇒ page 168
3 - O-ring
❑ replace
4 - Coolant hose
clamps
5 - O-ring
❑ replace
6 - Condenser
⇒ Heating, Air Condi‐
tioning; Rep. gr. 87
7 - Top radiator bearing
❑ If the fuse latches break,
you will not need to re‐
place the top radiator
bearing. The fuse is re‐
placed by a special
screw ⇒ Electronic
Catalogue of Original
Parts“ETKA” .
4. Radiator and radiator fan 167

8 - Bottom radiator bearing
Note
Connect coolant hose with quick coupling

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
plug-in connector is fully engaged.
4.2 Radiator - Summary of components (Yeti)
1 - Coolant hose
clamps
2 - O-ring
❑ replace
⇒ page 173
ter replacing
4 - Screw cap
5 - Connector
6 - Screw
❑ 2 Nm
7 - Expansion reservoir
❑ Sprawdzenie szczelno‐
ści układu chłodzenia
⇒ page 150
8 - Top radiator bearing
9 - Screw
❑ 5 Nm
10 - Bottom radiator bearing
11 - Nut
❑ 5 Nm
12 - Fan shroud
⇒ page 176
13 - Screw
❑ 5 Nm

14 - Radiator fan - V177-

16 - Coolant hose
❑ to remove, raise holding clamps
17 - Retaining clip
18 - Thermoswitch
19 - O-ring
❑ replace
Note
Connect coolant hose with quick coupling

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Press coolant hose onto connection -1- until there is an audible
click.
– Press coolant hose down again and check by pulling that the
plug-in connector is fully engaged.

4.3 Fan shroud with a radiator fan - Summary of components
1 - Screw
❑ 5 Nm
2 - Fan shroud
⇒ page 175
⇒ page 177

4.4 Fan shroud with two radiator fans - Summary of components
1 - Screw
❑ 5 Nm
2 - Fan shroud
⇒ page 175
3 - Screw
❑ 5 Nm
⇒ page 177
⇒ page 178
4.5 Remove and install radiator (Octavia IlI)

WARNING
There is risk of injury from radiator fans starting up automati‐

cally.
♦ Before carrying out work in the fan shroud area, discon‐
nect the electrical plug connections.
Removing
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .

– Raise the retaining clips -arrow- and remove the top coolant
hoses from the radiator.
– Press the catches for the top radiator bearing -arrows- at the
same time, e.g. with screwdrivers, and unclip the bearing on
both sides.
– Partially tilt cooler into the engine compartment.
Note
If the fuse latches break, you will not need to replace the top ra‐
diator bearing -1- . The fuse is replaced by a special screw -3- ⇒
Electronic Catalogue of Original Parts“ETKA” .

– Unlock the left and right catches from the cooler -1- arrow
-A- and raise the condenser.
– Press the radiator downwards until the radiator bearing de‐
flects at the bottom, to do so, unhook the condenser -2- from
the radiator -1-.
– Strap capacitor to the lock support.
– Remove the radiator downwards out of the vehicle.
Install
following:
Note
♦ When there is light pressure on the fins ⇒ page 9 .

♦ Replace O-rings.
– Install front bumper ⇒ Body Work; Rep. gr. 63 .

– Install fan shroud ⇒ page 175 .
– Replenish coolant ⇒ page 148 .
Note
If the radiator has been replaced, all the coolant must be changed.
4.6 Removing and installing radiator (Yeti)

WARNING

cally.
Removing

– Raise the retaining clips -arrow- and remove the top coolant
hoses from the radiator.
– Remove front bumper ⇒ Body Work; Rep. gr. 63 .
– Partially tilt cooler into the engine compartment.
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or
bent.
– Unscrew fixing screws at condenser -arrows-.


– Unscrew screws for radiator bearing -arrows-.

– Swivel the radiator slightly backwards.
– Strap capacitor to the lock support.
– Unhook radiator upwards and remove downwards.
Install
Note
♦ When there is light pressure on the fins ⇒ page 9 .

♦ Replace O-rings.
– Install front bumper ⇒ Body Work; Rep. gr. 63 .

Note
If the radiator has been replaced, all the coolant must be changed.
Tightening torques
♦ Screws for radiator bearing
4.7 Removing and installing radiator cowl

for radiator fan (Octavia III)
Note
The removal and installation of the fan shroud with two radiator
fans is similar to the removal and installation of the radiator cowl
with one radiator fan.
WARNING

cally.
overpressure.

Removing
– Disconnect the electrical plug connection -1- for radiator fan,
to do so, move the fuse upwards arrow -A- and also press the
release buttons upwards.
– Press the locking lugs for the fan shroud at the same time ar‐
row -B- and prise out fan shroud in direction of arrow -C-.
– Remove the fan shroud downwards out of the vehicle.
Install
4.8 Removing and installing fan shroud for

radiator fan (Yeti)
Note
The removal and installation of the fan shroud with two radiator
fans is similar to the removal and installation of the radiator cowl
with one radiator fan.
WARNING

cally.
overpressure.

Removing
– Unscrew the bottom securing bolts-arrows- below of the fan
shroud.
gr. 66 .
– Disconnect the plug connection -1- for the radiator fan and re‐
move the bottom fixing screws -arrows- on the radiator cowl.
– Remove the fan shroud downwards out of the vehicle.
Install
Tightening torques
♦ Fan shroud at radiator
4.9 Removing and installing radiator fan -

V7-
WARNING

cally.
Removing
Note
All cable straps should be fastened again in the same place when
installing.

– Release screws -arrows- and remove radiator fan - V7- .
Install
following:
Tightening torques
♦ Fan screw
⇒ “4.3 Fan shroud with a radiator fan - Summary of compo‐
nents”, page 170

4.10 Removing and installing radiator fan 2 -

V177-
WARNING

cally.
Removing
Note
installing.

– Disconnect plug connection -arrow-.
– Unscrew screws -2- and radiator fan 2 - V177- .
Install
following:
Tightening torques
♦ Fan screw
⇒ “4.4 Fan shroud with two radiator fans - Summary of com‐
ponents”, page 171

20 – Fuel supply system

1 Fuel tank and fuel delivery unit
⇒ “1.1 Fuel tank- Summary of components (Octavia III)”,
page 179
⇒ “1.2 Fuel tank - Summary of components (Yeti)”, page 182
⇒ “1.3 Fuel filter - Summary of components (Yeti)”, page 184
⇒ “1.4 Removing and installing fuel filter (Yeti)”, page 184
⇒ “1.5 Extract fuel from the fuel tank”, page 185
⇒ “1.6 Removing and installing fuel tank- (Octavia IlI)”,
page 191
⇒ “1.7 Removing and installing fuel tank - (Yeti)”, page 195
⇒ “1.8 Fuel delivery unit and sender for fuel gauge display - Sum‐
mary of components”, page 198
⇒ “1.9 Removing and installing fuel delivery unit”, page 199
⇒ “1.10 Removing and installing the sender for fuel gauge display
G ”, page 202
⇒ “1.11 Check fuel pump - (Octavia IlI)”, page 203
⇒ “1.12 Check fuel pump - (Yeti)”, page 207
Note
♦ Fuel hoses ion the engine must only be secured with spring-
type clips ⇒ Electronic catalogue of original parts “ETKA” .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Fuel hoses can be connected further with push-fit couplings
⇒ page 216 .
1.1 Fuel tank- Summary of components (Octavia III)
1. Fuel tank and fuel delivery unit 179

1 - Screw cap
❑ screw in until there is an
audible click
❑ with securing suspen‐
ded to prevent any loss
at tank fuel filler flap
2 - Earth connection
❑ for fuel filler neck
❑ for discharging the elec‐
trostatic charge
⇒ page 181
3 - Screw
❑ replace
❑ 8 Nm
4 - Lock ring
❑ loosen and tighten up
with spanner -T30101
(3087)-
❑ 110 Nm
5 - Sealing ring
❑ replace
❑ install when dry
6 - Fuel delivery unit
❑ with integrated fuel filter,
the fuel filter cannot be
replaced individually
❑ with sender for fuel
gauge display - G-
⇒ page 199
❑ sprawdzenie pompy
paliwa ⇒ page 203
❑ Connect fuel lines ⇒ page 181
❑ Removing and installing fuel gauge sender - G- ⇒ page 202 .
7 - Fuel tank
8 - Heat shield
❑ for fuel tank
9 - Circlip
10 - Tensioning strap
❑ Mark installation position before installation
❑ pay attention to correct position
11 - Screw
❑ replace
12 - Fuel feed line

❑ to the engine
❑ pushed into the fuel tank
❑ do not kink
180 Rep. gr.20 - Fuel supply system

❑ disconnect and connect ⇒ page 216
Earth connection for fuel filler neck

– Connect earth connection as shown in the illustration.
– Ensure proper seating of plug connection.
♦ Plug -2- of the earth connection on the threaded ring -3- of the
fuel filler neck.
– Unhook contact peg -1- of the earth connection in the securing
bore on the fuel tank -4- and press in the distance sleeve -5-.
WARNING
Risk of explosion from electrostatic charge.

♦ After installing, use an ohmmeter to test the electrical con‐
nection of the plate ring on the fuel filler neck at a bare
point on the body.
♦ Specified value approximately 0 Ω.
Fitting location of the fuel delivery unit

• The marking -2- at the fuel delivery unit closing flange -1- must
be located against arrow -3- at the fuel tank.
Connect the fuel line to the fuel delivery unit.

1.2 Fuel tank - Summary of components (Yeti)
1 - Screw cap
❑ screw in until there is an
audible click
❑ with securing suspen‐
ded to prevent any loss
at tank fuel filler flap
2 - Earth connection
❑ for fuel filler neck
3 - Screw
❑ replace
❑ 11 Nm
4 - Adapter cable
5 - Screw
❑ replace
❑ 25 Nm
6 - Fuel tank
⇒ page 195
7 - Circlip
8 - Bracket for the exhaust sys‐
tem
9 - Tensioning strap
❑ Mark installation posi‐
tion before installation
❑ pay attention to correct
position
10 - Heat shield
❑ for fuel tank
11 - Fuel feed line
❑ to the engine
❑ do not kink
12 - Fuel filter
❑ with built-in fuel pressure sender
❑ schemat montażowy ⇒ page 184
13 - Vent line
14 - Sealing ring
❑ replace
❑ with sender for fuel gauge display - G-

❑ sprawdzenie pompy paliwa ⇒ page 207
❑ Removing and installing fuel gauge sender - G- ⇒ page 202 .
16 - Lock ring
❑ loosen and tighten up with spanner -T30101 (3087)-
❑ 110 Nm
17 - Fuel feed line
❑ Black
18 - Fuel return-flow line
❑ Blue
19 - Fuel tank lid unit
❑ Removing and installing ⇒ Body Work; Rep. gr. 55
Fitting location of the fuel delivery unit

• The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-.
• The -arrow- shows the direction of travel.
• Blue return-flow line -1- on the connection with the marking
-R-.
• Connect black feed line -2- to connection with marking -V-.

1.3 Fuel filter - Summary of components (Yeti)
1 - Fuel filter
❑ with integrated pressure
regulator
❑ Opening pressure: 0.4
MPa (4 bar)
❑ The direction of flow is
indicated with an arrow -
do not switch connec‐
tions
⇒ page 184
2 - Fuel feed line
❑ Black
❑ from fuel tank
❑ disconnect and connect
⇒ page 216
3 - Fuel return-flow line
❑ Blue
❑ to fuel tank
⇒ page 216
4 - Fuel feed line
❑ Black
❑ to the engine
⇒ page 216
5 - Screw
❑ 3 Nm
6 - Support
❑ for fuel filter
❑ attached to the fuel tank
1.4 Removing and installing fuel filter (Yeti)
Note
Observe safety measures and rules of cleanliness when working

on the fuel supply ⇒ page 3 .
Removing
– Place a catch pan under the fuel filter.
WARNING
The fuel system is under pressure! Before opening the system

lay cleaning cloths around the connection point. Reduce pres‐
sure by carefully releasing the connection point.

– Pull off fuel hoses -1-, -2- and -3- ⇒ page 216 .
– Remove fuel filter.
Install
The direction of flow is marked by arrows on the filter housing.
Fitting position
• Pin -2- at filter housing must engage in the recess of the guide
-1- at the filter holder.
Tightening torques
♦ Fixing screw
⇒ “1.3 Fuel filter - Summary of components (Yeti)”, page 184
1.5 Extract fuel from the fuel tank

⇒ “1.5.1 Emptying fuel tank when fuel pump is intact”,
page 185
⇒ “1.5.2 Emptying fuel tank when the fuel pump is damaged when
more than 3/4 full - (Octavia III)”, page 188
more than 3/4 full - (Yeti)”, page 190
less than 3/4 full”, page 191
1.5.1 Emptying fuel tank when fuel pump is

intact
♦ Fuel extraction device , e. g. -VAS 5190-
♦ Adapter for fuel extraction - VAS 5190 /3-
♦ Disassembly wedge - 3409-
♦ Remote control - V.A.G 1348/3A-
♦ Adapter - VAS 5565-
Note
If the fuel extraction device - VAS 5190- is still fitted with an ex‐
traction hose with a fixed tip, replace it by the version with a screw-
type tip.

– Unscrew tip -1- from extraction hose of fuel extraction unit -

VAS 5190- .
– Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐
tion adapter set - VAS 5190 /10- onto extraction hose.
Note

⇒ page 3 .
⇒ page 4 .
– Switch off ignition.


⇒ page 216 .
Vehicles Yeti

⇒ page 216 .

– Connect the fuel extraction device - VAS 5190- with the adapt‐
er for the fuel extraction - VAS 5190 /3- to the fuel feed line.
Caution
Secure the earth cable of the fuel extraction device to a bare

metal part of the body.

– Removing rear seat bench ⇒ Body Work; Rep. gr. 72 .
Vehicles Yeti
– Remove rear seat bench with brackets ⇒ Body Work; Rep.
gr. 72 .
– Remove floor covering under the rear seats.
– Unclip the cover -1- using the disassembly wedge - 3409- .

– Unlock electrical plug connection -2- from closing flange, and

remove.
Vehicles Yeti
– Unlock electrical plug connection -arrow- from closing flange,

and remove.
– Open shut-off valve at the fuel extraction device - VAS 5190-
until the fuel tank is empty.

– Connect adapter - VAS 5565- to fuel delivery unit -1-.

– Connect remote control - V.A.G 1348/3A- to adapter -
VAS 5565- and to battery positive terminal in engine compart‐
ment.
– Connection -5- (yellow) from the adapter - VAS 5565- with
adapter cable -3- from the measuring tool set , e. g. -V.A.G
1594 C- , to the battery minus pole terminal.
Note
This step is only intended to ensure that the fuel pump runs when
the engine is switched off.
– Open tank flap unit -2-.

– Clean the area around the fuel filler neck.
– Unscrew the cap -1- for the fuel filler neck.
– Operate the remote control - V.A.G 1348/3A- and the shut-off
cock on the fuel extraction device - VAS 5190- until the fuel
tank is emptied.
Caution
The fuel pump must not run »dry«.
1.5.2 Emptying fuel tank when the fuel pump

is damaged when more than 3/4 full -
(Octavia III)
Note

⇒ page 3 .
⇒ page 4 .

– In distance -a- from the end of the extraction hose make a

marking -arrow- on the hose.
– Use insulating tape for this purpose.
Rear axle Distance a in mm

Vehicles with torsion beam rear axle 1,010 mm
– Open tank flap unit -2-.

Caution

– Push the extraction hose of the fuel extraction device as far

into the fuel tank holder as necessary until the previously ap‐
plied marking -arrow- terminates with the filler neck -2-.
– Drain the fuel tank through the filler neck as much as possible.
Note
♦ In the fuel tank there is a flap -1- on the lower end of the filler
neck, which must not be damaged by the extraction hose of
the fuel extraction device . Therefore, the hose must only be
pushed in up to the previously made marking -arrow-.
♦ If the extraction hose becomes stuck to the check valve while
being pulled out, do not pull the extraction hose violently.
♦ If this is the case, remove the fuel delivery unit and hold the
check valve open by hand. Make sure that your arm does not
come in contact with fuel.
– Carefully pull out the extraction hose.
Note
When no more fuel is extracted, the tank is emptied just enough

for the sender flange to be opened without danger.


is damaged when more than 3/4 full -
(Yeti)
Note

⇒ page 3 .
⇒ page 4 .
– Remove cone of valve -2- from the cylinder end piece -1- of
the fuel extraction device , e.g. -VAS 5190- .
– Make a mark -arrow- on hose with insulating tape at distance
-a- = 1,180 mm from end of extraction hose.
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew the cap from the fuel filler neck.
Caution

– Screw the cylinder end piece -1- of the fuel extraction device
onto the filler tube of the fuel tank.

– Push the extraction hose of the fuel extraction device as far

into the fuel tank holder as necessary until the previously ap‐
plied marking -arrow- terminates with the cylinder end piece
-1-.
Note
A ball valve -2- is located at the bottom of the filler neck in the fuel
tank; it must not be damaged by the extraction hose -3-. There‐
fore, the hose must only be pushed in up to the previously made
marking -arrow-.
– Drain the fuel tank through the filler neck as much as possible.
– Carefully pull out the extraction hose.
Note
When no more fuel is extracted, the tank is emptied just enough

for the sender flange to be opened without danger.

is damaged when less than 3/4 full
Note

⇒ page 3 .
⇒ page 4 .
– Remove fuel delivery unit ⇒ page 199 .
Caution

– Insert suction hose of fuel extractor - VAS 5190- as far as

possible into fuel tank.
– Extract fuel using the fuel extraction device - VAS 5190- .
If fuel tank needs only to be emptied, re-install the fuel delivery
unit ⇒ page 199 .
1.6 Removing and installing fuel tank- (Oc‐

tavia IlI)
♦ Engine and gearbox jack , e.g. -V.A.G 1383A-
♦ Body saw , e. g. -V.A.G 1523 A - or grinder

Caution
The fuel tank must be empty for weight reasons when removing
it, if necessary suction the fuel out of the fuel tank
⇒ page 185 .
Removing
Note

⇒ page 3 .
⇒ page 4 .
– Switch off the ignition and all electrical components and take
out the ignition key.
– Unclip cover -1- for closing flange from holder catches
-arrows- using the disassembly wedge - 3409- .

remove.
– Open tank flap.

Note
Close the opening of the fuel filler neck with a clean cloth so that
no dirt can penetrate.
– Remove rear wheel on the right ⇒ Axles, steering; Rep. gr.

44 .
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
gr. 66 .
– Remove right rear wheel brake calliper and place to the side
⇒ Brake systems; Rep. gr. 46 .
– Disconnect the plug connection at the ABS speed sensor and
undo the line from the brackets at the rear axle ⇒ Brake sys‐
tems; Rep. gr. 45 .
– Remove the vent lines -1- and -2- from the activated charcoal
filter, do so by disconnecting the push-fit couplings
⇒ page 216 .
– Loosen ventilation lines from fasteners on the holder
-arrows-.
– Loosen ventilation line -1- from fastener on the holder

-arrow-.
– Disconnect the exhaust pipe with body saw , e. g. -V.A.G 1523
A - or grinder, and remove the middle- and rear part of the
exhaust system separately ⇒ page 264 .
– Unscrew screws -1- -2- for fuel filler neck.
WARNING
Risk of injury caused by fuel which is under high pressure.

Lay a clean cloth around the connection point and carefully
slacken the connection point in order to relieve the pressure in
the fuel system.
– Unclip hand-brake cables from the holders.

– Disconnect vent line -3- and fuel line -2- ⇒ page 216 .
Note
Fuel line -1- is not assembled.
WARNING
Risk of accident from fuel tank weight.

The fuel tank must be empty for removal.

– Remove holder for exhaust system retaining strap -arrow-.
– Unscrew fixing screws -3- and remove tensioning strap -7-.
– Support the fuel tank using the engine and gearbox jack -
V.A.G 1383A- .

– Release fixing screws -2-, -4- and -6-.

– Remove retaining nuts for heat shield of fuel tank and remove
protection plate.
– Slightly lower the fuel tank using the engine and gearbox jack
- V.A.G 1383A- .
Note
♦ The aid of a 2nd mechanic is required to remove the fuel tank.

♦ Make sure that the individual cables are not damaged.
– With the aid of a second mechanic, turn the fuel tank to one
side, and lower.
– Pull the filler tube through between the rear axle and body‐
shell.
Install
– Check both earth connections for corrosion, if necessary re‐
move corrosion.
– Check the fitting position of the earth lead ⇒ page 181 .
Note
♦ The aid of a 2nd mechanic is required to install the fuel tank. .

– With the aid of a second mechanic, pull the filler tube through
between the rear axle and bodyshell and support fuel tank with
the Engine and gearbox jack - V.A.G 1383A- .
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
♦ Vent and fuel lines must be laid without any kinks.
♦ Do not mix-up the feed line and the air bleed valve (the air
bleed valve is white, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.
Tightening torques
♦ Fuel tank
⇒ “1.1 Fuel tank- Summary of components (Octavia III)”, page
179
1.7 Removing and installing fuel tank - (Yeti)

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

Caution
The fuel tank must be empty for weight reasons when removing
it, if necessary suction the fuel out of the fuel tank
⇒ page 185 .
Removing
Note

⇒ page 3 .
⇒ page 4 .
gr. 72 .
– Unclip cover -1- for closing flange from holder catches
-arrows- using the disassembly wedge - 3409- .
– Unlock and disconnect the connectors -1- from the fuel deliv‐
ery unit.
– Open the fuel tank cap.
44 .
gr. 66 .

– Unscrew screws -1- for fuel filler neck.
WARNING

the fuel system.
– Disconnect push-fit couplings on the ventilation line -1- (white)

and fuel feed line -2- (black) ⇒ page 216 .
– Remove middle and rear silencer ⇒ page 266 .
WARNING
Risk of accident from fuel tank weight.

The fuel tank must be empty for removal.
– Release fixing screws -2- and -4- and remove the tensioning
strap.
– Remove retaining nuts for heat shield of fuel tank and remove
protection plate.
– Support the fuel tank using the engine and gearbox jack -
V.A.G 1383A- .
– Slightly lower the fuel tank using the engine and gearbox jack
- V.A.G 1383A- .
Note
♦ The aid of a 2nd mechanic is required to remove the fuel tank.

– With the aid of a second mechanic, turn the fuel tank to one
side, and lower.
– Pull the filler tube through between the rear axle and body‐
shell.
Install
Note
♦ The aid of a 2nd mechanic is required to install the fuel tank. .

– Check both earth connections for corrosion, if necessary re‐

move corrosion.

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

– With the aid of a second mechanic, pull the filler tube through
between the rear axle and bodyshell and support fuel tank with
the Engine and gearbox jack - V.A.G 1383A- .
Further installation occurs in reverse order. However, pay atten‐
tion to the following:
♦ Vent and fuel lines must be laid without any kinks.
♦ Do not mix-up the feed line and the air bleed valve (the air
bleed valve is white, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ After installing the fuel tank, check whether the lines are also
clipped in place on the fuel tank.
Tightening torques
♦ Fuel tank
⇒ “1.2 Fuel tank - Summary of components (Yeti)”, page 182
1.8 Fuel delivery unit and sender for fuel gauge display - Summary of compo‐
nents

❑ on Octavia III vehicles
with a built-in fuel filter,
the fuel filter cannot be
replaced separately ⇒
Original Parts “ETKA”
❑ Checking electric fuel
pump ⇒ Vehicle diag‐
nostic tester
⇒ page 199
❑ Fill the vehicle with at
least 5 litres of fuel after
installing
2 - Sealing ring
❑ replace
3 - Lock ring
❑ loosen and/or tighten
using wrench - T30101
(3087)-
❑ 110 Nm
4 - Connector
❑ for Fuel pump for prede‐
livery system - G6- and
fuel gauge sender - G-
❑ Ensure safe locking by
pulling
5 - Fuel feed line
❑ to the engine
❑ do not kink
⇒ page 216

6 - Fuel gauge sender - G-

Note
The fuel delivery unit on the Yeti is also equipped with a fuel re‐
turn-flow line ⇒ Electronic Catalogue of Original Parts “ETKA” .
1.9 Removing and installing fuel delivery

unit
♦ Key - T30101 (3087)-
Removing
• The fuel tank must not be more than 3/4 full.
Note
♦ If necessary, extract fuel from the fuel tank ⇒ page 185 .

♦ Observe the safety instructions before starting fitting work
⇒ page 3 .
⇒ page 4 .
Vehicles Yeti
gr. 72 .
– Unclip cover -1- from the retaining tabs -arrows- with the dis‐
assembly wedge - 3409- .


remove.
Vehicles Yeti
– Unlock electrical plug connection -arrow- from closing flange,

and remove.
WARNING

the fuel system.
– Disconnect fuel lines from closing flange. Unlock the quick

coupling and disconnect ⇒ page 216 .
Note
Ensure that the fuel delivery unit is not damaged when loosening
the lock ring of the holder on the flange.
– Open lock ring with the wrench - T30101 (3087)- .
Note
Remove fuel delivery unit from the fuel tank so that the electric
lines and fuel hoses are not damaged and the float arm of the
sender for fuel gauge display - G- is not bent.

– Pull the fuel delivery unit -2- out of the opening of the fuel tank.
– Remove sealing ring -1- from fuel tank opening.
WARNING
Beware of fuel flowing out of the fuel pump that is still full -
accident hazard.
Put cleaning cloths underneath fuel delivery unit to collect fuel.
Note
You must empty the old fuel delivery unit before disposing of it if
you wish to replace it.
Install
Installation is carried out in the reverse order. Pay attention to the
following:
– Insert the new dry gasket ring for the flange into the opening
of the fuel tank and moisten only from the inside with fuel for
installing the closing flange.
– Insert the fuel delivery unit into the fuel tank in such a way that
the float arm of the sender for the fuel gauge display - G- is
not bent.
Caution
Risk of leakage.
The gasket ring must not get damaged when inserting the
closing flange.
• The lug -2- on the closing flange of the fuel delivery unit must
be positioned between tabs -3- and -4- and the marking must
face the opening -arrow- of the sealing ring on the fuel tank.
• Press down the closing flange of the fuel delivery unit down‐
wards against the spring force and bring it into the installation
position.

– Insert lock ring and tighten using the wrench - T30101 (3087)- .
Fitting position of the fuel delivery unit on the Octavia III

• The marking -2- at the fuel delivery unit closing flange -1- must
be located against arrow -3- at the fuel tank.
Fitting position of the fuel delivery unit on the Yeti

• The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-.
• Blue return-flow line -1- on the connection with the marking
-R-.
• Connect black feed line -2- to connection with marking -V-.
– Connect fuel line ⇒ page 216 .
After installing the fuel delivery unit, refuel with at least 5 litres of
fuel.
1.10 Removing and installing the sender for

fuel gauge display - G-
Removing
Note
♦ Observe safety instructions ⇒ page 3 .

♦ Observe rules for cleanliness ⇒ page 4 .
– Remove fuel delivery unit ⇒ page 199 .

– Unlock the catches -arrows- using a screwdriver and pull out

the sender for fuel gauge display - G- towards the top.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
Installation is carried out in the reverse order. Pay attention to the
following:
– Connect the wiring and check correct installation of the plug.
– Insert the sender for fuel gauge display - G- into the lines at
the fuel delivery unit and press downwards until it latches into
position.
– Install fuel delivery unit ⇒ page 199 .
1.11 Check fuel pump - (Octavia IlI)

⇒ “1.11.1 Checking fuel pressure”, page 203
⇒ “1.11.2 Testing holding pressure”, page 204
⇒ “1.11.3 Checking fuel delivery rate”, page 205
♦ Pressure gauge , e.g. -VAS 6550-
♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.
-V.A.G 1348/3-3 -
♦ Multimeter e. g. -V.A.G 1715-
♦ Auxiliary measuring set - V.A.G 1594/C-
♦ Measuring vessel
1.11.1 Checking fuel pressure
Note

⇒ page 3 .
⇒ page 4 .


⇒ page 216 .
– Connect pressure tester - VAS 6550- to fuel supply line with
adapter - VAS 6550/2- .
– Install adapter - VAS 6550/1- and keep in a fuel-resistant

measuring vessel.
Caution
Risk of fuel dripping out.

♦ Make sure that the shut-off tap -C- is closed.
♦ Lever points in the direction of flow.
– Open shut-off taps -A- and -B- .

– Switch on ignition until bubble-free fuel flows out.
– Close shut-off tap -B- to will build fuel pressure.
– Read off fuel pressure on pressure gauge.
• Specified value: 0.4 MPa (4 bar).
1.11.2 Testing holding pressure
Note

⇒ page 3 .
⇒ page 4 .
– Check leaktightness and while doing so observe pressure

drop at pressure gauge - VAS 6550- .
• The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure falls below 0.3 MPa (3.0 bar)
• Check line connections between pressure gauge - VAS 6550-
and fuel feed line for leaktightness.
• Inspect pressure measuring device - VAS 6550- for leaks.
• Check fuel lines and its connections for tightness.

If no fault is found:
♦ Non-return valve in the fuel delivery unit is leaking:
– Replace fuel delivery unit ⇒ page 199 .
Assembly is carried out in the reverse order. When installing, ob‐
serve the following:
• The ignition must be switched off.
Note
Reduce fuel pressure before removing the pressure gauge, while

doing so open the shut-off tap -C- and let the fuel drain into the
measuring vessel.
1.11.3 Checking fuel delivery rate
Note

⇒ page 3 .
⇒ page 4 .

⇒ page 216 .
– Connect the pressure gauge - VAS 6550- with the adapter -
VAS 6550/2- to the fuel feed line.

– Install adapter - VAS 6550/1- and keep in a fuel-resistant

measuring vessel.
Caution


• The levers are housed in the flow direction.
– Loosen catch pegs -arrows- of the cover -1- with disassembly

wedge - 3409- and remove the cover.

remove.

– Connect remote control - V.A.G 1348/3A- with adapter line -

V.A.G 1348/3-3- and with the line from the measuring tool set
- V.A.G 1594/C- to contact -1-.
– Mask second plug contact of the adapter - V.A.G 1348/3-3-
with short-circuit proof tape -arrow-.
– Connect contact -5- with line of auxiliary measuring set - V.A.G
1594/C- to body mass -A-.
– Connect alligator clips to the positive terminal “+” -B- of the
battery.
Note
Primary pressure must be built up against which the fuel pump

must work when the fuel delivery flow in the fuel line is being
measured. This primary pressure is set as follows using pressure
gauge VAS 6550:
– Activate remote control - V.A.G 1348/3A- . While doing this,

slowly close the shut-off tap -B- until the pressure gauge dis‐
plays a pressure of 0.4 MPa (4 bar). Now do not make any
further changes to the position of the shut-off cock.
– Empty measuring glass.
– Activate remote control for 15 seconds.
– Compare fuel quantity delivered with minimum flow quantity in

the diagram cm3/15s.
Note
Voltage at the fuel pump when engine is not running and pump is
approximately 2 volts less than battery voltage.
If the minimum fuel delivery volume is not reached, it can be

caused by the following faults:
♦ Fuel lines squashed.
♦ The fuel filter is clogged.
♦ The fuel pressure sender is defective.
♦ Fuel delivery unit defective.
1.12 Check fuel pump - (Yeti)

⇒ “1.12.1 Checking fuel pressure”, page 208
⇒ “1.12.2 Testing holding pressure”, page 210
⇒ “1.12.3 Checking fuel delivery rate”, page 212
♦ Pressure gauge , e.g. -VAS 6550-

♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.

-V.A.G 1348/3-3 -
♦ Multimeter e. g. -V.A.G 1715-
♦ Auxiliary measuring set - V.A.G 1594/C-
♦ Measuring vessel
1.12.1 Checking fuel pressure
Note

⇒ page 3 .
⇒ page 4 .

⇒ page 216 .
– Connect adapter - VAS 6550/1- and keep in a measuring ves‐

sel.
Caution



– Switch on ignition until bubble-free fuel flows out.
– Close shut-off tap -B- to will build fuel pressure.
– Read off fuel pressure on pressure gauge.
• Specified value: 0.4 MPa (4 bar).
If fuel line is o.k.:
– Test holding pressure ⇒ page 210 .
If fuel pressure is too high:
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is found:
– Replace fuel filter. The pressure limiting valve in the fuel filter
is faulty.
If fuel pressure is too low:
– Check the fuel pressure before the fuel filter, to do so proceed
as follows:
– Disconnect fuel feed line -arrow- at fuel filter.
– Connect the pressure gauge -VAS 6550- with adapters -VAS

6550/1- and -VAS 6550/2- between the fuel filter and fuel feed
line.
– Make sure that drain tap is closed and cut-off taps are open.
– Start engine and run in idle.

– Slowly close the shutoff cock -A-.
Note
The pressure must rise to at least 0.7 MPa (7.0 bar).
– If the 0.7 MPa (7.0 bar) is reached, immediately open the shut-
off cock again.
If pressure has risen:
Fuel pump O.K., pressure limiting valve in the fuel filter defective,
replace the fuel filter ⇒ page 184 .
If pressure does not rise:
– Fuel pump defective, replace fuel delivery unit ⇒ page 199 .
1.12.2 Testing holding pressure
Note

⇒ page 3 .
⇒ page 4 .

gr. 72 .
– First of all check the plug -arrow- for firm seating.
Note
To do so, pull on the plug without pressing the catch. If the plug
was not correctly plugged in, it may have caused a fault.
– Disconnect the plug -arrow- from the fuel delivery unit.

– Check contacts on plug and on fuel delivery unit for damage.

– Connect test instrument adapter -VAS 5565- to connector and

fuel delivery unit.
– Connect the remote control -V.A.G 1348/3A- to the test instru‐
ment adapter -VAS 5565- and to Battery Plus (+).
Fuel pressure O.K. and pressure gauge -VAS 6550- connected

in the engine compartment ⇒ page 208 .
– Activate the remote control with short pauses in between until
an pressure of 0.4 MPa (4 bar) is built up.
Note
Lower pressure which has become too high by carefully opening

the shut-off valve.
– Observe pressure drop at pressure gauge.

minutes.
If the pressure falls below 0.3 MPa (3.0 bar):
– After pressure has built up, cut-off tap -B- of pressure tester -
VAS 6550- immediately. Lever is then at right angle to direc‐
tion of flow.
If the pressure does not drop now:
The leakage is on the engine side.
If the pressure again drops:
The leakage on the fuel tank side.
– Proceed as follows to check pressure retention valve at fuel
delivery unit:


line.
– After pressure has built up, cut-off tap -A- of pressure tester -
VAS 6550- immediately. Lever is then at right angle to direc‐
tion of flow.
– Observe pressure drop at pressure gauge.
minutes.
If pressure drops:
– Replace fuel delivery unit, non-return valve faulty
⇒ page 199 .
1.12.3 Checking fuel delivery rate
Note

⇒ page 3 .
⇒ page 4 .

gr. 72 .


– First of all check the plug -arrow- for firm seating.
Note
To do so, pull on the plug without pressing the catch. If the plug
was not correctly plugged in, it may have caused a fault.
– Disconnect the plug -arrow- from the fuel delivery unit.

– Check contacts on plug and on fuel delivery unit for damage.
– Connect test instrument adapter -VAS 5565- to connector and

fuel delivery unit.
– Connect the remote control -V.A.G 1348/3A- to the test instru‐
ment adapter -VAS 5565- and to Battery Plus (+).
Note
♦ This step is only intended to ensure that the fuel delivery unit
runs when the engine is switched off.
♦ The fuel flow rate is measured at 0.4 MPa (4 bar) - this is why
first of all you need to check that the value is correct
⇒ page 208 .
WARNING
Fuel supply line is pressurised! Wear safety goggles and safety

gloves, in order to avoid injuries and skin contact. Place clean‐
ing cloths around the connection point before detaching hose
connections. Then reduce the pressure by carefully removing
the hose.


⇒ page 216 .
– Connect adapter - VAS 6550/1- and keep in a measuring ves‐

sel.
WARNING
Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety gloves, in order to avoid inju‐
ries and skin contact. Hold the container in front of the free
connection to the pressure gauge - VAS 6550- .
– Activate remote control -V.A.G 1348/3A- . While doing this,

slowly close the shut-off cock -arrow- until the pressure gauge
displays 0.4 MPa (4 bar) overpressure. From this point on do
not move position of shut-off tap.
– Empty measuring glass.
Note
The fuel flow rate of the fuel pump is dependent on the battery
voltage. For this reason, the battery voltage must be measured
when measuring the flow.
– Attach the Multimeter -V.A.G 1715- to terminals -1- and -5- of

the test instrument adapter -VAS 5565-
– Activate remote control -V.A.G 1348/3A- for 15 seconds while
measuring the battery voltage.


Note
Voltage at the fuel pump when engine is not running and pump is
approximately 2 volts less than battery voltage.
If the minimum fuel delivery volume is not reached:

– Check the feed line to the filter for possible restrictions (kinks)
or blocking.
If the fuel line is O.K.:
– Take fuel tank cap off fuel filler neck and repeat the test.
If the fuel flow rate is now reached:
– Check the ventilation of the fuel tank.
If the minimum fuel delivery volume is still not reached:
– Check the fuel flow rate before the fuel filter.

line.
If the minimum fuel flow rate is now reached:
– Replace fuel filter.
If the minimum fuel delivery volume is still not reached:
– Remove fuel delivery unit and inspect filter strainer for soiling
⇒ page 199 .
If no fault was detected:
– Replace fuel delivery unit ⇒ page 199 .


2 Quick couplings
⇒ “2.1 Separating quick couplings”, page 216
2.1 Separating quick couplings

♦ Lever - T10468-
Note
♦ The quick couplings of fuel, vacuum and ventilation lines are

colour marked. Either the colour point at the quick coupling or
the release button has the corresponding colour.
♦ Observe safety measures ⇒ page 3 .
Quick coupling Colour coding at the quick cou‐

pling
Fuel feed black
line
Vent line White, beige
Vacuum line green
WARNING
The fuel feed line is pressurized! Wear safety goggles and

safety clothing, in order to avoid injuries and skin contact with
fuel. Place cleaning cloths around the connection point before
detaching hose connections. Reduce pressure by carefully re‐
moving the hose.
Variant 1
Quick coupling with release buttons -arrows- on right and left.

The separation point -1- in the engine compartment must be held.

– Insert the lever - T10468- between the heat shield and the stop
-arrow- of the fuel feed line -2- and hold it.
Continued for all separation points
Note
When the push-fit coupling is fitted with a plastic circlip, leave it

inserted when removing and installing the quick release.
– Press the push-fit coupling -1- in direction of arrow -A-.

– Press the release buttons and remove the push-fit coupling
-1- from the fuel line -2- in direction of the arrow -B-.
Pay attention to the assignment of the colours when installing
⇒ page 216 .
– Check the quick coupling for firm seating by pulling in the op‐
posite direction!
Variant 2
Push-on coupling with pull-release mechanism -arrow-
2. Quick couplings 217

– Press the push-fit coupling -1- in direction of arrow -A-.

– Pull pull-release mechanism -2- in direction of arrow -B-.
– Remove the push-fit coupling -1- from the fuel line -3- in di‐
rection of the arrow -B-.
⇒ page 216 .
posite direction!
Variant 3
Quick coupling with front release button -arrow-.
– Press the release button -arrow- and detach the quick cou‐
pling.
⇒ page 216 .
posite direction!
Variant 4
– Press the push-fit coupling in direction of arrow -A-.
– Press release buttons -arrows- and pull push-on coupling off.
⇒ page 216 .
posite direction!
Variant 5
– Press release buttons -arrows- and pull push-on coupling off.
⇒ page 216 .
posite direction!

Variant 6
– Press push-on coupling -1- in -direction of arrow- and hold
pressed.
– Press release buttons -arrows- and detach quick coupling.
⇒ page 216 .
– Check the quick couplings for firm seating by pulling in the
opposite direction!
Variant 7
Quick coupling -1- with release buttons -arrows- right and left.
– Press push-on coupling -1- in direction of arrow -A- and hold
pressed.
– Press the release buttons -2- in direction of arrow -B- and re‐
move the push-fit coupling -1-.
⇒ page 216 .
– Check the quick couplings for firm seating by pulling in the
opposite direction!
2. Quick couplings 219

3 Accelerator pedal
⇒ “3.1 Accelerator pedal module- Summary of components (Oc‐
⇒ “3.2 Summary of components - Accelerator pedal module (Ye‐
ti)”, page 221
⇒ “3.3 Removing and installing accelerator pedal module (Octavia
IlI)”, page 221
⇒ “3.4 Removing and installing accelerator pedal module (Yeti)”,
page 223
3.1 Accelerator pedal module- Summary of components (Octavia III)
1 - Screw
❑ 6 Nm
2 - Connector
❑ Ensure safe locking by
pulling
3 - Accelerator pedal module
❑ with accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ After replacing in vehi‐
cles with automatic
gearbox, a the engine
control unit

3.2 Summary of components - Accelerator pedal module (Yeti)
1 - Connector
2 - Accelerator pedal module
❑ with accelerator pedal
position sender - G79-
and accelerator pedal
position sender 2 -
G185-
❑ After replacing in vehi‐
cles with automatic
gearbox, a the engine
control unit
❑ -A- Openings for the un‐
locking tool
3 - Screw
❑ 10 Nm
4 - Cap
3.3 Removing and installing accelerator

pedal module (Octavia IlI)
⇒ “3.3.1 Remove and fit on connector for accelerator pedal mod‐
ule (Octavia III)”, page 222
Removing
– Tilt cover for underbody -1- in -direction of arrow-.
3. Accelerator pedal 221

– Disconnect plug connection -2- at the accelerator pedal mod‐

ule ⇒ page 222 .
– Remove accelerator module -3- from the uptake.
Install
On vehicles with automatic transmission, adapt the engine control
unit after replacing the gas pedal module.
Tightening torques
♦ Screw for gas pedal module.
⇒ “3.1 Accelerator pedal module- Summary of components
(Octavia III)”, page 220
3.3.1 Remove and fit on connector for accel‐

erator pedal module (Octavia III)
Note
The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.
Disconnect connector 1K0 973 706

– Slightly press the piston slide valve -A- (grey) in direction of
arrow -1- and push it up to the stop in direction of arrow -2-.
– Hold the piston slide valve in this position and disconnect the
socket housing -B- towards the top in direction of arrow -3-.
The piston slide valve -A- remains in the bottom position.
Fit on connector 1K0 973 706

– Push the socket housing -B- down in -direction of arrow- until
the housing can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.
– For safety reasons, check the connector for secure catch by
tightening it in the opposite direction.


– Pull piston slide valve -A- (red) upwards in direction of arrow
-1- up to the stop.
– Press the piston slide valve in direction of arrow -2- and dis‐
connect the socket housing -B- in direction of arrow -3-.
The piston slide valve -A- remains in the top position.

– Push the socket housing -B- down in direction of arrow -1- up
to the stop.
– Lightly press the piston slide valve in direction of arrow -2- and
slide in the direction of arrow -3-.
The piston slide valve -A- can only be pushed downwards if
the socket housing was pushed downwards »up to the stop«.
3.4 Removing and installing accelerator

pedal module (Yeti)
⇒ “3.4.1 Remove and fit on connector for accelerator pedal mod‐
ule (Yeti)”, page 224
♦ Release tool - T10238- (for left-hand drive vehicle)
♦ Release tool - T10240- (for right-hand drive vehicle)
Removing
– Remove steering column cover -arrows-.
– Lever out the cap Pos. 4 ⇒ page 221 with a screwdriver.
– Release fixing screw Pos. 3 ⇒ page 221 .

– Push the release tool - T10238- (for right-hand drive vehicles

release tool - T10240- ) up to the stop into the provided open‐
ings and remove the accelerator pedal module.
– Disconnect connector from accelerator pedal module
⇒ page 224 .
Install
– Fit the plug -2- onto the accelerator pedal module -5-
⇒ page 224 .
Note
The plug must lock audibly.
– Push accelerator pedal module onto the fixing bolts -6-.

– Insert the centering pin -7- into the hole in the underbody.
– Screw on accelerator pedal module with screw -3- and fit on
cap -4-.
– Re-install steering column trim panel.
Note
On vehicles with automatic transmission, adapt the engine control

unit after replacing the gas pedal module.
Tightening torques
♦ Screw for gas pedal module.
⇒ “3.2 Summary of components - Accelerator pedal module
(Yeti)”, page 221
3.4.1 Remove and fit on connector for accel‐

erator pedal module (Yeti)
Note
The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.

– Slightly press the piston slide valve -A- (grey) in direction of
arrow -1- and push it up to the stop in direction of arrow -2-.
– Hold the piston slide valve in this position and disconnect the
socket housing -B- towards the top in direction of arrow -3-.
The piston slide valve -A- remains in the bottom position.


– Push the socket housing -B- down in -direction of arrow- until
the housing can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.

– Pull piston slide valve -A- (red) upwards in direction of arrow
-1- up to the stop.
– Press the piston slide valve in direction of arrow -2- and dis‐
connect the socket housing -B- in direction of arrow -3-.
The piston slide valve -A- remains in the top position.

– Push the socket housing -B- down in direction of arrow -1- up
to the stop.
– Lightly press the piston slide valve in direction of arrow -2- and
slide in the direction of arrow -3-.
The piston slide valve -A- can only be pushed downwards if
the socket housing was pushed downwards »up to the stop«.

4 Activated charcoal container system

⇒ “4.1 Activated charcoal filter- Summary of components (Octavia
III) ”, page 226
⇒ “4.2 Activated charcoal filter - Summary of components (Yeti)”,
page 227
⇒ “4.3 Removing and installing parts of the activated charcoal
filter system - (Octavia III)”, page 227
4.1 Activated charcoal filter- Summary of components (Octavia III)
1 - Vent line
❑ For solenoid valve 1 for
activated charcoal filter -
N80-
⇒ page 216
2 - Screw
❑ 20 Nm
3 - Activated charcoal filter
❑ Installation location in
wheelhouse under the
wheelhouse liner
⇒ page 227
4 - Vent line
❑ to fuel tank
⇒ page 216

4.2 Activated charcoal filter - Summary of components (Yeti)
1 - Activated charcoal filter

❑ Fitting location in right-
hand engine compart‐
ment
❑ if the catch peg is un‐
locked, the activated
charcoal filter can be re‐
moved from the holder
2 - Pressure holding valve with
connection hose
3 - Screw
❑ 8 Nm
4 - Vent line
❑ to fuel tank
⇒ page 216
5 - Nut
❑ 8 Nm
6 - Support
❑ for activated charcoal fil‐
ter
7 - Electrical solenoid valve 1
for Activated charcoal filter sol‐
enoid valve - N80-
❑ Valve closed when igni‐
tion is switched off
❑ valve is actuated
(pulsed) by engine con‐
trol unit when engine is
warm
8 - Connecting hose
❑ To intake manifold
9 - Air admission fitting
4.3 Removing and installing parts of the ac‐

tivated charcoal filter system - (Octavia
III)
– Observe safety instructions ⇒ page 3 .
– Observe rules for cleanliness ⇒ page 4 .
44 .
gr. 66 .
– Disconnect the vent lines -1- and -2- on the activated charcoal
filter ⇒ page 216 .
4. Activated charcoal container system 227

– Loosen ventilation lines from fasteners on the holder

-arrows-.

– Pull out catch -3- using a screwdriver and pull the activated
charcoal filter -2- down out of the lock -arrow-.
Install

24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Injection system - Fitting location of the injection system”,
page 229
1.1 Injection system - Fitting location of the

injection system
⇒ “1.1.1 Engine compartment - Overview of fitting locations (Oc‐
⇒ “1.1.2 Engine compartment - Overview of fitting locations (Ye‐
ti)”, page 230
⇒ “1.1.3 Installation location overview - engine from front”,
page 231
⇒ “1.1.4 Installation location overview - engine from rear”,
page 232
1.1.1 Engine compartment - Overview of fitting locations (Octavia III)

1 - N205-
❑ schemat montażowy
⇒ page 77
2 - lambda probe - G39- and
heating for lambda probe -
Z19-
⇒ page 249
3 - Lambda probe downstream
of catalytic converter - G130-
and heater of lambda probe 1
downstream of catalytic con‐
verter - Z29-
⇒ page 249
4 - Hall sender - G40- (cam‐
shaft position sensor)
⇒ page 269
5 - Engine control unit - J623-
⇒ page 252
⇒ page 163
7 - intake air temperature
sender - G42- / intake manifold
pressure sender - G71-
⇒ page 236
1. Injection system 229

8 - Throttle valve module - J338-

❑ with throttle valve drive - G186- , throttle valve drive angle sender 1 - G187- and throttle valve drive angle
sender 2 - G188- .
9 - Ignition coils with a power output stage
♦ Ignition coil 1 with output stage - N70-
10 - Activated charcoal filter solenoid valve 1 - N80-
1.1.2 Engine compartment - Overview of fitting locations (Yeti)

1 - N205-
⇒ page 77
2 - lambda probe - G39- and
Z19-
⇒ page 249
3 - Lambda probe downstream
of catalytic converter - G130-
and heater of lambda probe 1
downstream of catalytic con‐
verter - Z29-
⇒ page 249
4 - Engine control unit - J623-
⇒ page 252
5 - Hall sender - G40- (cam‐
shaft position sensor)
⇒ page 269
⇒ page 163
7 - intake air temperature
sender - G42- / intake manifold
pressure sender - G71-
⇒ page 236
8 - Throttle valve module -
J338-
❑ with throttle valve drive - G186- , throttle valve drive angle sender 1 - G187- and throttle valve drive angle
sender 2 - G188- .
230 Rep. gr.24 - Mixture preparation - injection

9 - Ignition coils with a power output stage

10 - Activated charcoal filter solenoid valve 1 - N80-
1.1.3 Installation location overview - engine from front

Installation location overview - engine from front
1 - Knock sensor 1 - G61-

⇒ page 269
⇒ page 143
3 - Solenoid valve 1 for activa‐
ted charcoal filter - N80-
4 - Injectors
♦ Injector, cylinder 1 - N30-
⇒ page 241
5 - Engine speed sender -
G28-
⇒ page 269
1. Injection system 231

1.1.4 Installation location overview - engine from rear

er - G62-
⇒ page 162

2 Air filter
⇒ “2.1 Air filter housing- Summary of components (Octavia III)”,
page 233
⇒ “2.2 Summary of components - Air filter housing (Yeti)”,
page 234
⇒ “2.3 Removing and installing air filter housing”, page 235
2.1 Air filter housing- Summary of components (Octavia III)
1 - Air guide lower part

❑ on the lock support
2 - Screw
❑ 2 Nm
3 - Cover
❑ for air guide
4 - Screw
❑ 2 Nm
5 - Rubber bearing
position
6 - Air filter lower part
❑ remove mechanical for‐
eign particles
7 - Air filter element
❑ Change intervals
Octavia III
8 - Screw
❑ 2 Nm
9 - Hose
tion
10 - Air filter top part
11 - Sealing ring
position
12 - Hose clamp
13 - Air guide hose
14 - air guide pipe top
15 - O-ring
16 - Water drain hose
❑ clean
2. Air filter 233

2.2 Summary of components - Air filter housing (Yeti)
1 - Air guide lower part

2 - Screw
❑ 2 Nm
3 - Rubber bearing
position
4 - Air filter lower part
❑ remove mechanical for‐
eign particles
5 - Air filter element
❑ Change intervals
Yeti
6 - Screw
❑ 2 Nm
7 - Hose
tion
8 - Air filter upper part
9 - Sealing ring
position
10 - Hose clamp
11 - Air guide hose
12 - air guide pipe top
13 - Screw
❑ 2 Nm

2.3 Removing and installing air filter hous‐

ing
Remove air filter housing
– Detach air guide hose -2- from air filter housing.
– Detach air guide hose -4- from air filter housing.
– Loosen hose clamp -3- and remove air guide hose.
– Raise air filter housing -1- upwards from the ball pin, and re‐
move.
Removing air guide - Octavia III
– Loosen hose clamp -1- and remove air guide hose.
– Release screw left and right arrow -2-.

– Unclip and remove the air guide on the lock carrier.
Install
Note
♦ If the air filter is heavily soiled or wet, dirt particles or moisture

can enter components and distort the measured values. This
leads to loss of power as a smaller injection quantity is calcu‐
lated.
♦ It is imperative for the air filter housing to be clean.
♦ Hose connections and air guide pipes and hoses must be free
of oil and grease before being installed.
♦ Use a silicone-free lubricant to assemble the air guide hoses.
Parts“ETKA.” .
♦ When blowing out the air filter housing using compressed air,
cover critical air-carrying components such as air ducts, etc.
with a clean cloth. This will prevent any malfunctions.
♦ Observe disposal regulations!
– Remove mechanical foreign particles from the top and bottom

parts of the air filter housing.
– Clean the water drain with compressed air.
Tightening torques
• Air filter housing Octavia- Summary of components
⇒ “2.1 Air filter housing- Summary of components (Octavia
III)”, page 233
• Air filter housing Yeti- Summary of components
⇒ “2.2 Summary of components - Air filter housing (Yeti)”,
page 234
2. Air filter 235

3 Intake manifold
⇒ “3.1 Intake manifold - Summary of components”, page 236
⇒ “3.2 Removing and installing intake manifold”, page 237
⇒ “3.3 Removing and installing the throttle valve control unit J338
”, page 238
⇒ “3.4 Clean throttle valve control unit J338 ”, page 239
3.1 Intake manifold - Summary of components
1 - Intake manifold
⇒ page 237
2 - Sealing ring
❑ replace
3 - Sealing ring
❑ replace
4 - Intake manifold pressure
sender - G71- with intake air
temperature sender - G42- .
⇒ page 248
❑ Repair solution when
the lug is damaged
⇒ page 248
5 - Screw
❑ 10 Nm
6 - Sealing ring
❑ replace
7 - Throttle valve module -
J338-
❑ czyszczenie
⇒ page 239
⇒ page 238
❑ in case of replacement,
erase initialisation val‐
ues and adapt the en‐
gine control unit - J623-
⇒ Vehicle diagnostic
tester.
8 - Screw
❑ 7 Nm
9 - Screw
❑ 7 Nm
10 - Fuel rail with injectors
11 - Sealing ring
❑ replace

3.2 Removing and installing intake manifold

Removing
Caution
Risk of malfunctions caused by soiling.
– Unlock connector -2- for throttle valve control unit - J338- and
remove.
– Remove connector for manifold pressure sender - G71- with
intake manifold pressure sender - G42- .
– Unlock the safety mechanism of the quick coupling -arrow-

and remove the underpressure from the intake manifold.

– Unlock the connector -4- from the solenoid valve 1 for activa‐
ted charcoal filter - N80- and remove.
– Unclip line to the activated charcoal filter from the mounting
brackets -arrow- and place to the side.
– Carefully remove the line to the activated charcoal filter from
the intake manifold.
– Remove fuel distributor with injector valves and lay to side
⇒ page 242 .
Note
♦ The fuel line does not need to be disconnected.

♦ Do not remove injectors from fuel rail.
3. Intake manifold 237

– Remove electric harness -1- to the brackets -arrows-.
– Raise intake manifold and remove the wire harness -arrow-

from the bottom part of the intake manifold.
– Remove intake manifold -1-.
If the intake manifold should be replaced, remove the throttle
valve control unit - J338- ⇒ page 238 .
Install
– Observe proper seating of gaskets.
Note
Replace gaskets and O-rings.

Tightening torques
♦ Intake manifold - Summary of components
3.3 Removing and installing the throttle

valve control unit - J338-
Removing


– Unscrew screws -arrows- and remove throttle valve control
unit - J338- -1-.
Install
following:
– After replacing the throttle valve control unit - J338- , this part
must be re-adapted to the engine control unit - J623- ⇒ Vehicle
diagnostic tester.
Tightening torques
♦ Screw for throttle flap control unit
3.4 Clean throttle valve control unit - J338-
Note
♦ Observe safety measures ⇒ page 3 .

♦ Observe rules for cleanliness ⇒ page 4 .
♦ If a new engine control unit - J623- is installed the throttle valve
module must be adjusted. Adaptation is only allowed to be
made with a new or cleaned throttle valve module.
♦ Soiling and carbonisation in the limit stop can lead to incorrect
adjustment values.
♦ The throttle valve support must not be scratched when clean‐
ing.

♦ Commercially available Acetone
♦ Paint brush
Work procedure
– Remove throttle valve module - J338- ⇒ page 238 .
– Open throttle valve by hand and lock in open position using
wood or a plastic wedge -arrow-.
WARNING
Acetone is easily inflammable.

♦ Accident prevention regulations and the safety instruc‐
tions must be observed when handling easily inflammable
fluids.
♦ Compressed air must not be used for cleaning throttle
valve.
♦ To avoid injury from metal shavings and to avoid skin con‐
tact, wear eye protection and protective clothing.
3. Intake manifold 239

– Thoroughly clean the throttle valve housing using commer‐

cially available Acetone and a paint brush, particularly in the
area -arrows- of the closed throttle valve.
– Wipe the throttle valve support with a lint-free cloth.
– Allow Acetone to dry off completely.
– Install throttle valve module - J338- ⇒ page 238 .
– Erase initialisation values and adapt the engine control unit -
J623- to the throttle valve control unit - J338- ⇒ Vehicle diag‐
nostic tester.

4 Injectors
⇒ “4.1 Fuel rail with injection valves - Summary of components”,
page 241
⇒ “4.2 Removing and installing the fuel distributor”, page 242
⇒ “4.3 Removing and installing injection valves”, page 243
⇒ “4.4 Checking injectors”, page 244
⇒ “4.5 Clean injection valves”, page 246
4.1 Fuel rail with injection valves - Summary of components
1 - Feed line
❑ from fuel filter
❑ Black with white marks.
❑ secure with spring strap
clamps
2 - Fuel rail with injectors
⇒ page 242
❑ Checking the tightness
and injection rate of the
injection valves
⇒ page 244
3 - Screw
❑ 7 Nm
4 - Injector
❑ Injector, cylinder 1 -
N30-
N31-
N32-
N33-
⇒ page 243
❑ Checking the tightness
and injection rate of the
injection valves
⇒ page 244
5 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine oil
6 - Retaining clip
❑ check tightness on the injection valve and fuel distributor
4. Injectors 241
4.2 Removing and installing the fuel distrib‐

utor
Removing
Caution
Risk of malfunctions caused by soiling.

♦ Safety precautions when working on the fuel supply sys‐
tem ⇒ page 3 .
♦ Rules of cleanliness when working on the fuel supply sys‐
tem ⇒ page 4 .
Removing
WARNING
The fuel feed line is pressurized! Wear safety goggles and

safety gloves, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
hose connections. Then reduce the pressure by carefully re‐
moving the hose.

⇒ page 216 .
– Open the clamp for the fuel feed line on the coolant expansion
tank -2- and remove the fuel feed line.
Vehicles Yeti


⇒ page 216 .
– Open the clamp for the fuel feed line -3- on the coolant ex‐
pansion tank -1- and remove the fuel feed line.
– Seal line so that fuel system is not contaminated by dirt.
– Unscrew bolts -3- from the intake manifold.

– Pull fuel rail -2- with injection valves -4- out of the intake mani‐
fold.
Install
following:
– Replace gasket rings.
– Before installing, lightly coat seals with clean engine oil.
– Ensure proper seating of gasket rings.
– Press fuel distributor down firmly in the area of the securing
mechanism and tighten screws by 2 turns.
– Tighten screws crosswise uniformly.
Tightening torques
♦ Screws fuel distributor
⇒ “4.1 Fuel rail with injection valves - Summary of compo‐
nents”, page 241
4.3 Removing and installing injection valves

Removing
– Remove fuel distributor ⇒ page 242 .
4. Injectors 243
– Carefully remove retaining clip -6- of injector to be removed.

– Pull off injector from fuel rail.
Install
– Replace gasket rings.
– Before installing, lightly coat seals with clean engine oil.
– Ensure proper seating of gasket rings.
– Make sure the injection valves -4- are seated correctly in the
fuel distributor -2-.
– Pay attention to the correct seating and fitting position of the
holding clamps -6-.
– Install fuel distributor ⇒ page 242 .
4.4 Checking injectors

♦ Remote control for V.A.G 1348 - V.A.G 1348/3A-
♦ Adapter cable - V.A.G 1348/3-2-
♦ Injection rate tester - V.A.G 1602-
♦ Adapter - VAS 5565-
Test conditions
• Fuel pressure OK ⇒ page 203 .
• Engine and fuel temperature: approx. 20 °C.
Note

⇒ page 3 .
⇒ page 4 .
– Remove fuel distributor together with the injection valves

⇒ page 242 .
Do not disconnect fuel hoses.
Injectors are not being removed from fuel rail.
– Remove 4 measuring glasses from the injection rate tester -
V.A.G 1602- .
Vehicles Yeti
gr. 72 .


– Unclip the cover -1- using the disassembly wedge - 3409- .
– Release electrical plug connection -2- from the closing flange

of the fuel delivery unit, and remove.
– Connect adapter - VAS 5565- to fuel delivery unit -1-.

– Connect remote control - V.A.G 1348/3A- to adapter -
VAS 5565- and to battery positive terminal in engine compart‐
ment.
– Connection -5- (yellow) from the adapter - VAS 5565- with
adapter cable -3- from the measuring tool set , e. g. -V.A.G
1594 C- , to the battery minus pole terminal.
Note
This step is only intended to ensure that the fuel pump runs when
the engine is switched off.
Testing injection rate
4. Injectors 245
– Connect a contact from the injection valve to be tested on the

engine mass using adapter cables from the measuring tool set
- V.A.G 1594C- .
– Connect second contact of the injection valve with adapter line
- V.A.G 1348/3-2- to the remote control to the V.A.G 1348 -
V.A.G 1348/3A- .
– Connect crocodile clip to positive battery pole in engine com‐
partment.
– Place measuring glass of the injection rate tester - V.A.G
1602- underneath the injection valve to be tested.
– Control fuel delivery unit.
– Press the remote control to the V.A.G 1348 - V.A.G 1348/3A-
for controlling the injection valve to be tested for 30 seconds.
– Switch off the fuel pump.
– Repeat test at the other injectors.
– After all the injectors have been operated, place the measuring
glasses on a flat surface and compare the individual quantities
of fuel injected.
Specified value: 84 … 99 ml per valve.
If the measurement obtained for one or several injection valves
is below or above the specification:
– Replace the faulty injector ⇒ page 243 .
Testing for leaks
– Place measuring glasses from the injection rate tester - V.A.G
1602- underneath the injection valves.
– Control fuel delivery unit.
No more than 2 drops/min must escape from each injector.
– Switch off the fuel pump.
If the fuel loss is greater than this:
– Replace the faulty injector ⇒ page 243 .
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Replace the O-rings on all the injectors and moisten lightly with
clean engine oil.
– Fit fuel rail with secured injectors onto intake manifold and
tighten evenly ⇒ page 241 .
4.5 Clean injection valves

♦ Ultrasonic cleaning device - VAS 6418-
♦ Feeder plate for injection units - VAS 6418/1-
♦ Cleaning fluid ⇒ Electronic Catalogue of Original Parts“ETKA”

Note
♦ The ultrasound device must be filled with cleaning agent up to

the top edge of the holes.
♦ Observe the safety and operating instructions of the ultra‐
sound device.
– Remove injection valves ⇒ page 243 .

– Insert injectors -1- into the feeder plate for injection units - VAS
6418/1- -2-.
– Immerse injectors with the feeder plate for injection units - VAS
6418/1- into the cleaning fluid - VAS 6418/2- .
– On the rotating head -4-, set a temperature of 50 °C.
– On the rotating head -5-, set a cleaning time of 30 minutes.
– Switch on ultrasound device using the button -3-.
Note
♦ Once the cleaning temperature has reached 50 °C the set time

begins to elapse.
♦ After cleaning, replace O-rings on each injection valve.
4. Injectors 247
5 Senders and sensors

⇒ “5.1 Removing and installing intake air temperature sender
G42 / manifold pressure sender G71 ”, page 248
5.1 Removing and installing intake air tem‐

perature sender - G42- / manifold pres‐
sure sender - G71-
Removing
– Unlock connector on the manifold pressure sender - G71- with
intake air temperature sender - G42- -2- and remove.
– Remove intake manifold pressure sender - G71- with intake
air temperature sender - G42- -2-, to do so, undo the lug
-arrow-.
Note
The intake manifold pressure sender - G71- with intake air tem‐
perature sender - G42- -2- can also be screwed with the intake
manifold -1-. In this case, the bolts must be removed from the
holes -3-.
Install
following:
Note
♦ Renew O-ring.
♦ If the retaining tabs break during removal, fixing screws can
be attached to the sender as a replacement ⇒ Electronic
Catalogue of Original Parts“ETKA” .
Pay attention to the correct seating and safe catching of the intake
manifold pressure sender - G71- with intake air temperature
sender - G42- at the intake manifold.
Tightening torques
Component Nm
intake air temperature sender/intake 3 Nm
manifold pressure sender

6 Lambda probe
⇒ “6.1 Lambda probe - Summary of components”, page 249
⇒ “6.2 Removing and installing lambda probe G39 / G130 ”, page
250
6.1 Lambda probe - Summary of compo‐

nents
Note
♦ New lambda probes are coated with assembly paste. This

paste must not come into contact with the slots of the lambda
probe body.
♦ For a re-used lambda probe, only coat the thread with hot bolt
paste. This paste must not come into contact with the slots of
the lambda probe body. Hot bolt paste ⇒ Electronic Catalogue
of Original Parts“ETKA”
♦ The electrical cable wire connection of the lambda probe must
be secured again at the same points during installation. Con‐
tact between the electrical cable connection and the exhaust
pipe must be prevented.
6. Lambda probe 249

1 - Lambda probe after catalyt‐

ic converter - G130- with heat‐
ing for lambda probe 1 after
catalytic converter - Z29-
⇒ page 250
❑ 55 Nm
2 - Connector
❑ for lambda probe - G39-
with heating for lambda
probe - Z19-
3 - Connector
❑ for lambda probe after
catalytic converter -
G130- with heating for
lambda probe 1 after
catalytic converter -
Z29-
4 - lambda probe - G39- with
Z19-
⇒ page 250
❑ 55 Nm
6.2 Removing and installing lambda probe -

G39- / -G130-
♦ Ring spanner set for lambda probe - 3337-
Removing
– Disconnect electrical plug connections:
1- for lambda probe downstream of catalytic converter - G130-
and heater of lambda probe 1 downstream of catalytic con‐
verter - Z29-
2- for lambda probe - G39- and heating for lambda probe - Z19-

– Unscrew respective lambda probe using a spanner from the

lambda probe ring spanner set - 3337- .
1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39-
Install
following:
Note
♦ New lambda probes are coated with assembly paste. This

paste must not come into contact with the slots of the lambda
probe body.
♦ For a re-used lambda probe, only coat the thread with hot bolt
paste. This paste must not come into contact with the slots of
the lambda probe body. Hot bolt paste ⇒ Electronic Catalogue
of Original Parts“ETKA”
♦ The electrical cable wire connection of the lambda probe must
be secured again at the same points during installation. Con‐
tact between the electrical cable connection and the exhaust
pipe must be prevented.
Tightening torques
♦ Lambda probe
⇒ “6.1 Lambda probe - Summary of components”, page 249
6. Lambda probe 251

7 Engine control unit

⇒ “7.1 Installing and removing engine control unit J623 without
protective housing - (Octavia III)”, page 252
⇒ “7.2 Removing and installing engine control unit J623 , engine
control unit with protective housing - (Octavia III)”, page 252
⇒ “7.3 Installing and removing engine control unit J623 without
protective housing - (Yeti)”, page 255
⇒ “7.4 Removing and installing engine control unit J623 , engine
control unit with protective housing - (Yeti)”, page 256
7.1 Installing and removing engine control

unit - J623- without protective housing -
(Octavia III)
Removing
Note
If the engine control unit is replaced, the vehicle diagnosis, meas‐

urement and information systems ⇒ Vehicle diagnostic tester
must be connected and the “Replace control unit” function run
WARNING
If the engine control unit touches the plus pole of the battery,
this will destroy it.
– Unlock catch in -direction of the arrow- and remove the engine

control unit -1-.
– Unlock plug connections for engine control unit - J623- and
pull off.
Install
following:
After installing a new engine control unit, the following work step
must be performed:
– Connect the Vehicle diagnosis, measurement and information
system ⇒ Vehicle diagnostic tester.
– Activate the engine control unit in mode “Software version
management” or “Targeted functions” under Replace engine
control unit .
7.2 Removing and installing engine control

unit - J623- , engine control unit with
protective housing - (Octavia III)
Removing
♦ commercially available miniature grinder
♦ Hot-air blower , e. g. -VAS 1978/14A- with push-on nozzle from
the wiring harness repair set - VAS 1978 B-

Removing
Note
If the engine control unit is replaced, the vehicle diagnosis, meas‐

urement and information systems ⇒ Vehicle diagnostic tester
must be connected and the “Replace control unit” function run
Unscrew shear bolts -arrows- to remove the protective housing

-1- as follows:
– In the shear bolt head -1-, using a miniature grinder -2-, make
a slot for a screwdriver.
Note
♦ The threads of the pull-off screws are equipped with safety

agent. Warming the pull-off screw when grinding a slot for a
screwdriver makes it easier to undo it afterwards.
♦ If the pull-off screws still cannot be undone, warm the, up with
a hot air blower.
Undoing pull-off screws with a hot air blower
– Set the temperature adjustment potentiometer -2- to maximum

heating performance and set the air flow two stage switch
-3- to position 3.
WARNING
Risk of burns from hot air blower.

♦ Only warm up the pull-off screws with a hot air blower.
♦ By warming the pull-off screws, the cover plate and parts
in its vicinity are heated up strongly too. Where necessary,
protect these parts by a piece of sheet covering.
7. Engine control unit 253

– Heat the shear bolt head -1- for approximately 20 to 30 sec‐

onds.
Continued for slackened screws
– Release shear bolt -1- using the screwdriver -2-.
– Remove protective housing -1-.
WARNING
If the engine control unit touches the plus pole of the battery,
this will destroy it.

– Unlock catch in -direction of the arrow- and remove the engine

control unit -1-.
pull off.
Install
following:
– It is imperative for the protective housing to be put back in
place on the engine control unit - J623- .
– Clean the threaded holes for the shear bolts to remove safety
agent residues. Cleaning can be done using a tapper.
– Use new shear bolts.
must be performed:
– Activate the engine control unit in mode “Software version
management” or “Targeted functions” under Replace engine
control unit .
7.3 Installing and removing engine control

unit - J623- without protective housing -
(Yeti)
Note
♦ In order to unplug the plugs from the engine control unit, the
control unit must always be removed.
♦ If the engine control unit is replaced, the vehicle diagnosis,
measurement and information systems ⇒ Vehicle diagnostic
tester must be connected and the “Replace control unit” func‐
tion run
Removing
66 .
– Remove bulkhead plenum chamber -arrows-.

– Open retaining clip -arrow- and remove engine control unit -

J623- .
pull off.
Install
must be performed:
– Activate the engine control unit in operating mode “Software
version management” or “Targeted functions” under Replace
engine control unit .
7.4 Removing and installing engine control

unit - J623- , engine control unit with
protective housing - (Yeti)
♦ commercially available miniature grinder
♦ Hot-air blower , e. g. -VAS 1978/14A- with push-on nozzle from
the wiring harness repair set - VAS 1978 B-
Note
♦ In order to unplug the plugs from the engine control unit, the
control unit must always be removed.
♦ If the engine control unit is replaced, the vehicle diagnosis,
measurement and information systems ⇒ Vehicle diagnostic
tester must be connected and the “Replace control unit” func‐
tion run
Removing
66 .
– Remove bulkhead plenum chamber -arrows-.

– Open retaining clip -arrow- and remove engine control unit -

J623- .
– Cut with min-grinder a slot for the screwdriver in the heads of

the pull-off screws -3- and -4-.
Rebore a slit for the screwdriver with mini-grinder -2- into the
screw -1-.
Note
♦ The threads of the pull-off screws are equipped with safety

agent. Warming the pull-off screw when grinding a slot for a
screwdriver makes it easier to undo it afterwards.
♦ If the pull-off screws still cannot be undone, warm the, up with
a hot air blower.
Undoing pull-off screws with a hot air blower
– Set the temperature adjustment potentiometer -2- to maximum

heating performance and set the air flow two stage switch
-3- to position 3.
WARNING
Risk of burns from hot air blower.

♦ Only warm up the pull-off screws with a hot air blower.
♦ By warming the pull-off screws, the cover plate and parts
in its vicinity are heated up strongly too. Where necessary,
protect these parts by a piece of sheet covering.

– Heat the shear bolt head -1- for approximately 20 to 30 sec‐

onds.
Continued for slackened screws
– Release shear bolt -1- using the screwdriver -2-.
– Unscrew the screws and remove the protective cover for the
plug connections -2- and -5-.
pull off.
Install
– It is imperative for the protective housing to be put back in
place on the engine control unit - J623- .
– Clean the threaded holes for the shear bolts to remove safety
agent residues. Cleaning can be done using a tapper.
– Use new shear bolts.
must be performed:
– Activate the engine control unit in operating mode “Software
version management” or “Targeted functions” under Replace
engine control unit .

26 – Exhaust system
1 Removing and installing exhaust sys‐
tem
⇒ “1.2 Middle or rear part of the exhaust system - Summary of
components (Octavia III)”, page 261
components (Yeti)”, page 262
⇒ “1.4 Removing and installing pre-exhaust pipe with catalytic
converter”, page 262
⇒ “1.5 Removing and installing or replacing the middle and rear
silencer - (Octavia III)”, page 264
⇒ “1.6 Removing and installing or replacing the middle and rear
silencer - (Yeti)”, page 266
⇒ “1.7 Aligning exhaust system”, page 267
⇒ “1.8 Inspecting the exhaust system for leaktightness”,
page 268
1.1 Pre-exhaust pipe with catalytic converter - Summary of components
1. Removing and installing exhaust system 259

1 - Clamping sleeve
❑ before tightening, align
exhaust system free of
stress ⇒ page 267
❑ Fitting position and
tightening torque
⇒ page 261
❑ Tighten bolted connec‐
tions evenly
2 - Exhaust pipe with catalytic
converter
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Do not load decoupler
with tensile stress
❑ Do not damage wire
mesh on decoupling el‐
ement
❑ protect catalytic con‐
verter against shocks
and blows
⇒ page 262
❑ Remove the protection
for the decoupling ele‐
ment on the spare part
as late as possible
❑ ustawienie układu wy‐
dechowego bez naprę‐
żeń ⇒ page 267
3 - Nuts
tightening order
⇒ page 264
4 - Gasket
❑ replace
5 - Nuts
6 - Screw
7 - Support
8 - Support
9 - Support
10 - Screw
❑ 20 Nm
260 Rep. gr.26 - Exhaust system

Installation position of front clamp

– Install clamping sleeve in the position shown.
• Angle -α- = approximately 20°.
• Bolted connection to the right.
• Nuts upwards.
– Tighten bolted connections of clamping sleeve evenly to 30
Nm.
1.2 Middle or rear part of the exhaust system - Summary of components (Oc‐
tavia III)
1 - Retaining strap
❑ Observe part number ⇒
ETKA - Electronic Cata‐
logue of Original Parts
2 - Support
3 - Screw
❑ 20 Nm
4 - Support
5 - Retaining strap
6 - Middle and rear silencer
❑ for first version a build‐
ing unit, replace individ‐
ually when carrying out
repairs ⇒ page 264
żeń ⇒ page 267
7 - Retaining strap
8 - Support
❑ Observe part number ⇒ ETKA - Electronic Catalogue of Original Parts

1.3 Middle or rear part of the exhaust system - Summary of components (Yeti)
1 - Retaining strap
2 - Screw
❑ 20 Nm
3 - Middle and rear silencer
❑ for first version a build‐
ing unit, replace individ‐
ually when carrying out
repairs ⇒ page 266
żeń ⇒ page 267
4 - Retaining strap
5 - Support
1.4 Removing and installing pre-exhaust

pipe with catalytic converter
♦ Hot bolt paste ⇒ Electronic Catalogue of Original Parts“ETKA”
Removing
Note
installing.

– Take electrical plug connections -1- and -2- out of the holder
and disconnect.
– Release the electrical cable from the clips and place down to
the side.
– Remove plastic cover for floor tunnel ⇒ Rep. gr. 50 .
– Remove tunnel bridge ⇒ Rep. gr. 50 .
shaft, if present.
– Unscrew securing nuts-1- for securing the exhaust pipe to the

cylinder head.
– Unscrew nuts -3- for securing the exhaust pipe to the mounting
bracket.
– Unscrew nuts -2- for securing the mounting bracket to the cyl‐
inder head.
– Remove pre-exhaust pipe from the coat bolts on the cylinder
head.

– Loosen the clamping sleeve -arrow- and slide it backwards.
Note
♦ The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - risk of damage.
♦ Do not bend the decoupling element by pulling it.
♦ Do not damage the wire mesh of the decoupling element.
– Remove the pre-exhaust pipe from the rear.

Install
following:
Note
♦ Replace the gasket and the self-locking nuts.

♦ Coat the coat bolts and screws on the pre-exhaust pipe with
hot bolt paste ⇒ Electronic Catalogue of Original Parts “ET‐
KA” .
– Align exhaust system free of stress ⇒ page 267 .
Installing pre-exhaust pipe- tightening torque and tightening order

1. – Fit pre-exhaust pipe onto the
coat bolts on the cylinder
head and at the same time fit
to the bracket
2. – Loosely tighten the nuts -1-, • It must still be pos‐
nuts -3- and screws -2- by sible to move the
hand pre-exhaust pipe
and the brackets
3. – Tighten nuts -1-. 20 Nm

4. – Tighten nuts -3-. 20 Nm
5. – Tighten nuts -2- for securing 20 Nm
the mounting bracket to the
cylinder head.
1.5 Removing and installing or replacing the

middle and rear silencer - (Octavia III)
♦ The rear axle is not removed when replacing the middle or rear
silencer.
♦ For individually replacing the middle silencer, a separation
point is provided in the connecting pipe.
♦ The separation point is marked by indentation on the circum‐
ference of the exhaust pipe.
– When present, remove the underbody rear left trim panel ⇒
Body; Rep. gr. 66 .

– Remove rear tunnel bridge arrows ⇒ Body; Rep. gr. 66 .

– Loosen the clamping sleeve -arrow- and slide it forwards.
– Use body saw to separate exhaust pipe at right angles at the

separation point -arrow-.
WARNING
Risk of accident from silencer weight.

♦ A second mechanic is required for removing the silencer.
– Undo screws -2- and remove rear silencer -1-.

– Undo screw -3- and remove middle silencer -1-.
Install
following:
– Position clamping sleeve centrally to the side markers during

installation -arrows-.

Installation position of rear clamp

• Nuts upwards.
• 30 Nm
– Installing front clamping sleeve ⇒ page 261 .
– Align exhaust system in cold condition free of stress
⇒ page 267 .
Tightening torques
• Middle and rear silencer
components (Octavia III)”, page 261
• Front clamping sleeve
• Remove the tunnel bridge and underbody cover ⇒ Body Work;
Rep. gr. 66
1.6 Removing and installing or replacing the

middle and rear silencer - (Yeti)
♦ For individually replacing the middle silencer, a separation
point is provided in the connecting pipe.
♦ The separation point is marked by indentation on the circum‐
ference of the exhaust pipe.
– Remove rear tunnel bridge arrows ⇒ Body; Rep. gr. 66 .
– Loosen the clamping sleeve -arrow- and slide it forwards.
WARNING
Risk of accident from silencer weight.

♦ A second mechanic is required for removing the silencer.

– Separate exhaust pipe at right angles at the separation point

arrow -2- with body saw.
– Remove screws for suspensions and remove parts of the ex‐
haust system.
Install
– When installing clamping sleeve -4- position on the side mark‐

ings arrow -1- and arrow -3-.
Installation position of rear clamp

• Nuts upwards.
• 30 Nm
– Installing front clamping sleeve ⇒ page 261 .
– Align exhaust system in cold condition free of stress
⇒ page 267 .
Tightening torques
• Middle and rear silencer
components (Yeti)”, page 262
• Front clamping sleeve
• Remove the tunnel bridge and underbody cover ⇒ Body Work;
Rep. gr. 66
1.7 Aligning exhaust system

⇒ “1.7.1 Aligning exhaust system free of stress”, page 267
⇒ “1.7.2 Align exhaust tailpipe”, page 268
1.7.1 Aligning exhaust system free of stress

• The exhaust system is aligned when cold.

– Loosen bolted connections on clamping sleeve -arrow-.
– Push the rear silencer so far forward until the pre-tensioning

on the retaining strap on the exhaust pipe is -a- = 5 mm.
– Installing the clamping sleeve ⇒ page 261 .
Tightening torques
Pre-exhaust pipe
1.7.2 Align exhaust tailpipe

Work procedure
– Align rear silencer in such a way that there is an equal distance
-a- between bumper opening and exhaust tailpipe.
– For centring the exhaust tailpipes, loosen the suspension of
the rear silencer.
1.8 Inspecting the exhaust system for leak‐

tightness
Work procedure
– Start engine and run in idle.
– Close off exhaust tailpipes for the duration of the leak test,
using cloths or plugs.
– Check connection points on exhaust manifold for leak-tight‐
ness by listening:
– Eliminate any leak found.

28 – Ignition system
1 Ignition system
⇒ “1.1 Ignition system - Summary of components”, page 269
⇒ “1.2 Removing and installing ignition coils with output stage”,
page 270
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 271
⇒ “1.4 Removing and installing Hall sender G40 ”, page 271
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
272
1.1 Ignition system - Summary of components
1 - Screw
❑ the tightening torque in‐
fluences the knock sen‐
sor function
❑ 20 Nm
2 - Knock sensor 1 - G61-
⇒ page 271
3 - Spark plug
❑ use spark plug wrench
e.g. -3122 B- for remov‐
ing and installing
❑ Change interval
Octavia III
Yeti
Original Parts “ETKA”
❑ 22 Nm
4 - Ignition coil with a power
output stage
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
⇒ page 270
5 - Screw
❑ 8 Nm
1. Ignition system 269

6 - Screw
❑ 8 Nm
7 - Hall sender - G40-
8 - O-ring
9 - Screw
❑ 5 Nm
10 - Engine speed sender - G28-
11 - Sealing flange on the gearbox side
12 - Rotor
❑ for engine speed sender - G28-
❑ cannot be removed separately, only with sealing flange Pos. -11-
13 - Screw
14 - Screw
❑ replace
1.2 Removing and installing ignition coils

with output stage
Removing
– Press extractor -T10530- up to the stop into the bore of the

ignition coils -1-.
– Tighten the nut -2- in -direction of arrow- so that the extractor
-T10530- stays firm in the bore of the ignition coil.
270 Rep. gr.28 - Ignition system

– Remove ignition coil with extractor -T10530- in

-direction of arrow- out of the camshaft housing.
– Undo nuts from the extractor -T10530- and remove from the
bore of the ignition coil.
– Using the extractor -T10530- remove the other ignition coils
out of the camshaft housing in sequence.
Install
following:
– Place the ignition coils loosely into the spark plug shaft.
– Align the ignition coils so that the fixing screws can be screwed
in.
– Press ignition coils onto the spark plugs evenly by hand (do
not use an impact tool).
Tightening torques
♦ Screw for ignition coil
1.3 Removing and installing knock sensor 1

- G61-
Removing
– Release connector -2- and pull off.

– Undo screw -arrow- and remove knock sensor 1 - G61- -1-
from engine.
Install
following:
Tightening torques
♦ Screw for knock sensor
1.4 Removing and installing Hall sender -

G40-
Removing
– Unscrew plug -arrow-.
– Remove hall sender - G40- -1-.
Install
– Installation is carried out in the reverse order.
Tightening torques
♦ Screw for hall sender
1. Ignition system 271

1.5 Removing and installing engine speed

sender - G28-
♦ Socket insert 4 mm - T10370-
Removing
– Undo screw -arrow- with socket insert - T10370- .

– Remove engine speed sender - G28- -1-.
Install
Caution
Carefully insert engine speed sender - G28- into the bore.

This prevents the engine speed sensor - G28- from falling be‐
tween the engine and gearbox.
following:
Tightening torques
Screw for engine speed sender
272 Rep. gr.28 - Ignition system

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Service

Service Department. Technical Information

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

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2.1 Summary of components - coolant pump/coolant thermostat . . . . . . . . . . . . . . . . . . . . . . 153

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

1.1 Engine number

1.2 Engine characteristics

Engine identification characters CWVA

Volkswagen Technical Site: http://vwts.ru

2 Rep. gr.00 - Technical data

2.1 Safety precautions when working on

There is a risk of destruction of electronic components when

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

When undertaking all assembly work, particularly in the engine

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

♦ The extraction hose of an exhaust extraction system which is

2.2 Rules of cleanliness to observe when

2.3 General notes on the injection system

4 Rep. gr.00 - Technical data

2.4 General notes on the ignition system

2.5 Safety measures to apply when working

The fuel system is under pressure! Before opening the system

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

2.6 Safety precautions when working on ve‐

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

2.7 Safety precautions during road tests in

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

2.8 Safety precautions when working on

Hot steam may escape when the compensation bottle is

6 Rep. gr.00 - Technical data

When undertaking all assembly work, particularly in the engine

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

2.9 Additional instructions when undertak‐

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

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

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

3.1 Rules of cleanliness

3.2 Foreign bodies in the engine

3.3 Contact corrosion

3.4 Cable routing and securing

8 Rep. gr.00 - Technical data

3.5 Assembly of radiators and capacitors

10 – Removing and installing engine

1.1 Remove - (Octavia III)

♦ The engine is removed downwards together with the gearbox.

10 Rep. gr.10 - Removing and installing engine

– Open cap -arrow- for coolant expansion tank.

Danger of scalding due to hot steam and hot coolant.

– Remove both wheels ⇒ Axles, steering; Rep. gr. 44 .

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

For vehicles with air conditioning

Risk of injury through refrigerant.

– Remove V-ribbed belt ⇒ page 47 .

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

Risk of damaging refrigerant lines and hoses.

– Remove AC compressor with connected refrigerant hoses and

1. Removing and installing engine 11