Skoda Octavia III 2013 Instruction manual

Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines
Engine ID CJSA CJSB CHH
B
Edition 01.2015
Service
Service Department. Technical Information

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
24 - Mixture preparation - injection
26 - Exhaust system
28 - Ignition system
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.
Service

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Separate engine from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Assembly bracket for vehicles with manual gearbox- Summary of components . . . . . . . . 33
3.2 Assembly bracket for vehicles with automatic gearbox - Summary of components . . . . . . 35
3.3 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.4 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.6 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.8 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 Cylinder block - Belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Removing and installing tensioner pulley for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.5 Removing and installing ribbed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2 Cylinder block - gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Sealing flange and flywheel - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3 Removing and installing the sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . 57
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.1 Crankshaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2 Assign crankshaft bearing shells to the cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Pulling out and driving in the needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 Balancing shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.1 Balancing shafts - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.2 removing and installing balancing shaft for inlet camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.3 Replace sealing ring for balancing shaft for inlet camshaft . . . . . . . . . . . . . . . . . . . . . . . . 70
4.4 removing and installing balancing shaft for exhaust camshaft . . . . . . . . . . . . . . . . . . . . . . 71
5 Pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.1 Piston and connecting rod - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.2 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.3 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.4 Separating new connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.5 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
Contents i

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1 Covers for timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.1 Covers for timing chains - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.2 Removing and installing N205 / N318 the camshaft adjustment valves . . . . . . . . . . . . . . . . 82
1.3 Removing and installing top cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.4 Removing and installing bottom cover for timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Replacing gasket ring for crankshaft -on the belt pulley side- . . . . . . . . . . . . . . . . . . . . . . 89
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.1 Camshaft timing shaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Removing and installing the camshaft timing shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.3 Balancing shaft timing chain- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.4 Removing and installing the balancing shaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.5 Check timing chain length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.1 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.3 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.4 Testinf the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1 Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.2 Oil trap and vacuum pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.3 removing and installing camshafts up to 07.2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.4 removing and installing camshafts as of 07.2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.5 Install ball for camshaft slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.6 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.7 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.8 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 159
1.3 Removing and installing oil sump bottom part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.5 Removing and installing oil sump top part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2 bracket for auxiliary units with oil filter and engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Bracket for auxiliary units with oil filter and engine oil cooler - Summary of components . . 167
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.3 Removing and installing the mechanical switch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.1 Crankcase ventilation - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4 Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.1 Oil pressure switch- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.2 Removing and installing control valve for piston cooling nozzles N522 . . . . . . . . . . . . . . 173
4.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.4 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 174
4.5 Removing and installing oil pressure switch, stage 3 F447 . . . . . . . . . . . . . . . . . . . . . . . . 175
4.6 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 176
4.7 Testing oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.8 Check oil pressure for piston cooling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
ii Contents

1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.1 Connection diagram for coolant hoses for vehicles with manual gearbox . . . . . . . . . . . . . . 179
1.2 Connection diagram for coolant hoses for vehicles with automatic transmission . . . . . . . . 181
1.3 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.4 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2 Coolant pump and positioning element for engine temperature control . . . . . . . . . . . . . . . . 188
2.1 Coolant pump and positioning element for engine temperature control - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.2 Coolant recirculation pump- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2.3 Coolant valve for gearbox N488 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.4 Coolant temperature sender - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.5 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
2.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
2.7 Removing and installing coolant recirculation pump V51 . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.8 Removing and installing coolant shut-off valve N82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.9 Removing and installing coolant valve for gearbox N488 . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.10 Removing and installing positioning element for engine temperature control N493 . . . . . . 200
2.11 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 202
2.12 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 203
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.1 Coolant pipe - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.2 Removing and installing the front coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.3 Removing and installing top coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.1 Cooler for coolant- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.2 Fan shroud with a radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 211
4.3 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.4 Fan shroud with two radiator fans - Summary of components . . . . . . . . . . . . . . . . . . . . . . 212
4.5 Installing and removing radiator fans V7 and V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.6 Removing and installing radiator fan for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.7 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
1.1 Fuel containers for vehicles with front-wheel drive - Summary of components . . . . . . . . . . 217
1.2 Fuel containers for vehicles with all-wheel drive - Summary of components . . . . . . . . . . . . 220
1.3 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.4 Removing and installing fuel tank for vehicles with front-wheel drive . . . . . . . . . . . . . . . . 222
1.5 Removing and installing fuel tank for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . 226
1.6 Fuel delivery unit/fuel gauge sender for vehicles with front-wheel drive - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.7 Fuel delivery unit/fuel gauge sender for vehicles with four-wheel drive - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.8 Removing and installing fuel delivery unit and fuel gauge sender G on vehicles with front-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.9 Removing and installing fuel delivery unit and fuel gauge sender G on vehicles with four-
wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.10 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 240
1.11 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.12 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.13 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.14 Suction spray pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2 Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
3 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
Contents iii

4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.1 Activated charcoal container system - Summary of components . . . . . . . . . . . . . . . . . . . . 257
4.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.3 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
1.3 Removing and installing, adjusting charge pressure regulator V465 . . . . . . . . . . . . . . . . 266
1.4 Adjust charge pressure regulator V465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.4 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1 Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
1.1 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.1 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3 Intake manifold and fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
3.3 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 294
3.4 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4 Injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4.1 Fuel distributor FSI- summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
4.2 Fuel distributor MPI- summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.3 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.4 Removing and installing the FSI injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.5 Removing and installing the MPI injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
4.6 Clean injection valves FSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5.1 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
5.2 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
5.3 Removing and installing fuel pressure sender for low-pressure G410 . . . . . . . . . . . . . . . . 311
6 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
6.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
6.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
7 Lambda probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
7.1 Lambda probes- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
7.2 Removing and installing Lambda probe G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
7.3 Removing and installing Lambda probe after catalytic converter G130 . . . . . . . . . . . . . . 319
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
8.1 Removing and installing engine control unit J623 (without protective housing) . . . . . . . . . . 321
8.2 Removing and installing engine control unit J623 (with protective housing) . . . . . . . . . . . . 322
8.3 Removing and installing engine noise speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
1.1 Front part of exhaust system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 326
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iv Contents

1.2 Removing and installing exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
1.3 Middle or rear part of the exhaust system - Summary of components . . . . . . . . . . . . . . . . 332
1.4 Middle or rear part of the exhaust system - Summary of components . . . . . . . . . . . . . . . . 333
1.5 Middle or rear part of the exhaust system - Summary of components . . . . . . . . . . . . . . . . 334
1.6 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
1.7 Removing and installing middle and rear part of the exhaust system . . . . . . . . . . . . . . . . 337
1.8 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.9 Align exhaust tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.10 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.1 Ignition system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 342
1.3 Remove knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
1.5 Removing and installing hall sender 3 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
1.6 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
Contents v

Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
vi Contents

00 – Technical data
1 Denomination
(SRL000767; Edition 01.2015)
1.1 Engine number, engine data
The engine number ("engine identification characters" and serial
number") is located to the left of the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification characters”
and “serial number” is affixed to the top cover for the timing chain.
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
engine. These are type-punched on the cylinder block including
the serial number.
4. The 4th digit refers to the output and torque of the engine and
depends upon the engine control unit.
The four digit engine code is on the vehicle data sticker ⇒ Main‐
tenance ; Booklet Octavia III and on the engine control unit.
Engine identification characters CJSA CJSB CHHB
Manufactured 11.12 ► 05.13 ► 05.13 ►
Exhaust limit values conforming to EU2 DDK, EU5, EU6 EU5, EU6 EU6
Capacity cm31798 1798 1984
Output kW at rpm 132/5100–6200 132/5100–6200 162/4200–6000
Torque Nm at rpm 250/1250–5000 280/1350–4500 350/1500–4000
Bore ∅ mm 82,5 82,5 82,5
Stroke mm 84,2 84,2 92,8
Compression ratio 9,6:1 9,6:1 9,6:1
Cylinder/valves per cylinder 4/4 4/4 4/4
Firing order 1–3–4–2 1–3–4–2 1–3–4–2
RON 95 1) 95 1) 95 1)
Ignition system, fuel injection FSI FSI FSI
MPI MPI MPI
Knock control yes yes yes
Lambda control yes yes yes
Three-way catalytic converter yes yes yes
Exhaust gas recirculation no no no
Exhaust temperature regulation no no no
Intake manifold change-over yes yes yes
Camshaft adjustment yes yes yes
Balancing shafts yes yes yes
Secondary air system no no no
Exhaust gas turbocharger yes yes yes
Charge air cooler yes yes yes
1) At least 91 RON in exceptional cases, although engine output
is reduced.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015

1.2 Safety instructions
1.2.1 Safety precautions when working on
fuel supply system
WARNING
Fuel under high pressure creates a risk of injury.
Leaking fuel creates a fire hazard.
♦ The fuel system is under pressure! Before opening the in‐
jection system high-pressure system, the fuel pressure
must be reduced to residual pressure ⇒ page 3 .
♦ The safety measures for the pressure reduction in the high
pressure system must be observed.
♦ To reduce the residual pressure (about 0.7 MPa or 7 bar),
the connection point must be opened »immediately« after
the pressure has been reduced. Place a cleaning cloth
around the connection point.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ 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.
♦ Take out fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Caution
There is a risk of destruction of electronic components when
disconnecting the battery.
♦ Observe notes on procedure for disconnecting the battery.
Disconnect the battery only when the ⇒ Electrical System; Rep.
gr. 27 ; battery is disconnected .
WARNING
When undertaking all assembly work, particularly in the engine
compartment due to its cramped construction, please observe
the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is adequate free access to all moving or
hot components.
♦ Clean connection points and their environment thoroughly with
engine or brake cleaner and dry the cleaned area thoroughly
before loosening.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
2 Rep. gr.00 - Technical data

♦ Open closed lines and connections immediately with suitable
screen caps.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Only install clean components: Remove spare parts from their
wrapping immediately before fitting. Do not use any parts
which have been stored unwrapped (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Avoid moving the vehicle.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel!
♦ Wear fuel-resistant gloves!
1.2.2 Reduce pressure in the high-pressure
system
Caution
The injection system consists of a high pressure part (max.
pressure of 12 MPa = 120 bar) and a low pressure part (pres‐
sure of approx. 0.7 MPa = 7 bar).
Before opening the high pressure system, e.g. removing the
high pressure pump, the fuel distributor, the injection valves,
the fuel pipes or the fuel pressure sender - G247- , the fuel
pressure in the high pressure system with a remaining pres‐
sure of approx. 0.7 MPa (7 bar) must be reduced.
– Connect the ⇒ Vehicle diagnostic tester and carry out the tar‐
geted function “remove high fuel pressure”.
• The fuel pressure drops to a predetermined value.
– Switch off ignition.
– Before opening the fuel system, disconnect the plug from the
fuel pump control unit.
– Before opening the high pressure system, lay cleaning cloths
around the connection point.
– Open fuel system carefully to reduce the residual pressure of
0.7 MPa (7 bar) and when doing so collect fuel that is flowing
out.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
1. Denomination 3

Note
♦ If the high-pressure system is not opened immediately the
pressure increases again as a result of the reheating effect.
♦ The ignition system must no longer be switched on, since oth‐
erwise the pressure will increase again.
♦ Interrogate the event memory of the engine control unit at the
end of the following work and delete all the event memory en‐
tries.
♦ The readiness code must be generated if the event memory
has been cleared ⇒ Vehicle diagnostic tester.
1.2.3 Safety measures for working on vehi‐
cles with start/stop system
When working on vehicles with start/stop system, please observe
the following:
WARNING
There is risk of injury from automatic engine starting on vehi‐
cles with start/stop system.
♦ In vehicles with an activated start-stop system (indicated
by a message in the dash panel insert), the engine can
start automatically if necessary.
♦ It is therefore necessary to ensure that the start-stop sys‐
tem is deactivated when carrying out work on the vehicle
(switch ignition off, if required switch ignition on again).
1.2.4 Safety precautions during road tests in
which testing and measuring equipment
is used
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.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
4 Rep. gr.00 - Technical data

1.2.5 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:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
Note
♦ When the engine is warm the cooling system is under pres‐
sure. If necessary, release pressure before beginning repair
work.
♦ Secure all hose connections with hose clamps, assignment ⇒
Electronic Catalogue of Original Parts “ETKA” .
♦ Hose clip pliers - VAS 6362- are recommended to install
spring-type 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).
1.2.6 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 (e.g. in tool boxes etc.).
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
1. Denomination 5

♦ 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.
1.2.7 Safety precautions when working on the
injection system
WARNING
The fuel system is under pressure! Place a clean cleaning cloth
around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully removing the hose.
The safety measures for the pressure reduction in the high
pressure system must be observed ⇒ page 3 .
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
running or being turned at starter speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure, re‐
move the fuse for the voltage supply of the injection valves and
the ignition coils from the fuse holder ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.
1.2.8 Safety precautions when working on ig‐
nition system
WARNING
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
running or being turned at starter speed.
Only disconnect/connect the lines to the injection and ignition
system and measuring device lines with the ignition off.
The fuel delivery unit is activated when the ignition is switched
on and by the door contact switch of the driver door. Therefore,
if the battery power hasn't been disconnected, for safety rea‐
sons the plug of the fuel delivery unit must be disconnected, or
the fuel pump fuse must be removed before opening the fuel
system.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
6 Rep. gr.00 - Technical data

1.2.9 General notes on the injection system
Ignition system - Assembly overview ⇒ page 341 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the event
memory. Also check the vacuum hoses and connections (un‐
metered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ Electronic catalogue of original parts
“ETKA” . The use of clamp or screw-type clips is not permis‐
sible.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety precautions when working on the injection system
⇒ page 6 .
1.2.10 General notes on the ignition system
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ The engine control unit and further components are equipped
with self-diagnosis; inspect ⇒ Vehicle diagnostic tester
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety measures ⇒ page 2 .
Setting data, spark plugs ⇒ Maintenance ; Booklet Octavia III .
1.2.11 General instructions for charge air sys‐
tem
WARNING
When undertaking all installation work, particularly in the en‐
gine compartment because of its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
1. Denomination 7

Caution
In case a mechanical damage to the exhaust gas turbocharger
is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
♦ The charge-air system must be tight.
♦ Renew self-locking nuts.
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
♦ Only use approved clamps for securing the hose connections
⇒ Electronic Catalogue of Original Parts“ETKA” .
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Before connecting the oil feed line, fill the exhaust turbocharg‐
er via the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
1.2.12 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
To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
Steps which should be taken in order to remove and install the
engine without opening the refrigerant circuit:
– Remove the holding clamp(s) of the refrigerant lines.
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
8 Rep. gr.00 - Technical data

1.3 Repair instructions
1.3.1 Cleanliness rules
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 (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean
the hoses immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
1.3.2 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- .
1.3.3 Contact corrosion
The use of unsuitable connection elements causes contact cor‐
rosion (screws, nuts, washers, …).
This is why only connection elements with a special surface coat‐
ings are fitted.
Therefore, the rubber or plastic parts and the adhesives are made
from electrically non-conductive materials.
If there is a question mark about the suitability of parts, generally
use new parts ⇒ Electronic Catalogue of Original Parts “ETKA” .
1.3.4 Cable routing and securing
♦ To ensure the original installation position, lines such as fuel,
hydraulics, vacuum, activated charcoal filter system lines or
electric cables must be marked before removal. Make sketch‐
es or take photographs if necessary.
♦ Sufficient clearance from all moving or hot components must
be ensured in the engine compartment due to its cramped
construction. This prevents damage to lines.
1.3.5 Assembly of radiators and capacitors
The radiator, capacitor and charge air cooler may have minor in‐
dentations on the fins, even if assembly is correct. This is not a
case of damage. Radiator, capacitors or charge air cooler must
not be replaced because of these indentations.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
1. Denomination 9

10 – Removing and installing engine
1 Removing and installing engine trim
panel
⇒ “1.1 Removing and installing engine trim panel”, page 10
1.1 Removing and installing engine trim
panel
Removing
– Carefully pull the engine cover off the retaining bolts one after
another -arrows-. Do not pull engine cover off in jerks or on
one side.
Install
– To avoid damage, do not strike the engine cover with the fist
or a tool.
– Position the engine cover paying attention to the oil fill sup‐
ports and dipstick.
– Press the engine trim panel into the rubber sleeves, first left,
then right.
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
10 Rep. gr.10 - Removing and installing engine

2 Removing and installing engine
⇒ “2.1 Removing engine”, page 11
⇒ “2.2 Separate engine from gearbox”, page 22
⇒ “2.3 Securing the engine to the assembly stand”, page 27
⇒ “2.4 Installing engine”, page 28
2.1 Removing engine
Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel - MP8-602/1-
♦ Supporting device - MP9-200 (10-222A)-
♦ Hook - MP9-200/10-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Catch pan , e.g. -VAS 6208-
♦ Hose strap pliers , e.g. -VAS 6362-
♦ Screw plug set for engine , e.g. -VAS 6122-
♦ Engine bracket - T10359-
♦ Bolt - T10359/2-
♦ Adapter - T10359/3-
♦ Protective goggles
♦ 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.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
Caution
When undertaking all installation work, particularly in the en‐
gine compartment due to its cramped construction, please
observe the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines/wiring, ensure sufficient clear‐
ance to all moving or hot components.
Work procedure
Observe all safety measures and notes for assembly work on the
fuel system, on the injection and ignition system and the charge
air system as well as rules for cleanliness ⇒ page 9 .
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
2. Removing and installing engine 11

– Drain coolant ⇒ page 182 .
– Remove the assembly carrier ⇒ Chassis; Rep. gr. 40 .
– Remove the front left and right wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Remove engine cover ⇒ page 10 .
– Remove air guide and air filter housing ⇒ page 288 .
– Undo screws on air guide right and left -arrow-.
– Unclip and remove the air guide pipe bottom - 1 -.
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Disconnect vacuum hose -2-.
– Press the unlocking tool on the vacuum hose -1- and remove
the hose from the vacuum pump.
Note
Place a cloth under heating heat exchanger to absorb escaping
coolant.
– Raise holding clamps -arrows- and remove coolant hoses
from heat exchanger for heating.
– Hold the coolant hoses downwards and allow the coolant to
drain.
Vehicles with auxiliary heating
– Undo hose clamp -1-, raise holding clamps -arrows- and re‐
move the coolant hoses.
Continued for all vehicles
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.8/132 kW TSI; 2.0/162 kW TSI engines - Edition 01.2015
12 Rep. gr.10 - Removing and installing engine