Skoda Octavia III 2013 Instruction manual

Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
1.2/63; 77 kW TSI engine
Engine ID CJZB CJZA
Edition 11.2014
Service
Service Department. Technical Information
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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
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety measures for working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . 3
2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 4
2.4 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Assembly of radiators and capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Additional instructions when undertaking assembly work on the air-conditioning system . . 8
3.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.8 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.9 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.10 Reduce pressure in the high-pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Unit mounting - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Removing and installing gearbox mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Check assembly bracket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.5 Adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.3 Removing and installing tensioning device for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Removing and installing ribbed belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.6 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Gearbox side cylinder block - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Crankshaft mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.1 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014
Contents i
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4.2 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.5 Removing and installing oil injection nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Summary of components - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.2 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.4 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.3 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.5 Removing and installing N205 the camshaft adjustment valve 1 . . . . . . . . . . . . . . . . . . . . 119
3.6 Removing and installing valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.1 Oil sump and oil pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 134
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Summary of components - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3 Crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.1 Summary of components - crankcase ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.1 Summary of components - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.2 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 141
4.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 Summary of components - coolant pump/coolant thermostat . . . . . . . . . . . . . . . . . . . . . . 154
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 11.2014
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2.2 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.3 Summary of components - coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
2.5 Removing and installing toothed belt pulley for coolant pump . . . . . . . . . . . . . . . . . . . . . . 162
2.6 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 167
2.9 Removing and installing coolant temperature sender at radiator outlet G83 . . . . . . . . . . 168
3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.1 Radiator version 1 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.2 Radiator version 2 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.3 Radiator version 3 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.4 Fan shroud with a radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 178
4.5 Fan shroud with two radiator fans - Summary of components . . . . . . . . . . . . . . . . . . . . . . 179
4.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.7 Removing and installing fan shroud for radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.8 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.9 Removing and installing radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.1 Fuel tank - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.2 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.3 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.4 Summary of components - fuel delivery unit and sender for fuel gauge display . . . . . . . . 200
1.5 Fuel delivery unit with sender for fuel gauge display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.6 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 204
1.7 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.8 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2 Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3 Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
3.3 Disconnect connector for accelerator pedal module and fit on . . . . . . . . . . . . . . . . . . . . . . 216
4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.2 Removing and installing activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.3 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.1 Summary of components - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
1.3 Removing and installing charge pressure regulator V465 . . . . . . . . . . . . . . . . . . . . . . . . . . 227
2 Charge-air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.1 Summary of components - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.2 Removing and installing charge pressure sender GX26 . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.4 Checking the charge-air system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
24 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
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Contents iii
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1.1 Injection system - Fitting location of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
3.3 Removing and installing the throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . 244
3.4 Clean throttle valve control unit GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.2 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.3 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.4 Clean injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5.1 Removing and installing intake manifold pressure sender GX9 . . . . . . . . . . . . . . . . . . . . 257
5.2 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
5.3 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
6.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
6.3 Removing and installing high pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.1 Summary of components - lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.2 Removing and installing lambda probe GX10 / GX7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
8 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
8.1 Removing and installing engine control unit J623 without protective housing . . . . . . . . . . 268
8.2 Removing and installing engine control unit J623 , engine control unit with protective
housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1 Removing and installing exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
1.1 Catalytic converter and component parts - Summary of components . . . . . . . . . . . . . . . . 272
1.2 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.3 Removing and installing catalytic converter with pre-exhaust pipe . . . . . . . . . . . . . . . . . . 275
1.4 Removing and installing or replacing the middle and rear silencer . . . . . . . . . . . . . . . . . . 277
1.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.6 Align exhaust tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
1.7 Inspecting the exhaust system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.2 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 282
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
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iv Contents
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00 – Technical data
1 Identification
(SRL000738; Edition 11.2014)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data
“The engine identification characters” and the “serial number” are
located on the sticker -arrow- at the top timing belt guard.
The “engine identification characters” and “serial numbers” are
also indicated on the engine above the engine connection with
the gearbox, on the vehicle data sticker and on the engine control
unit.
♦ Starting with the letter “C”, new four digit engine codes have
been introduced.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched on the cylinder block including
the serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine - J623- control unit.
Note
Fitting locations of vehicle data sticker ⇒ Maintenance ; Booklet
Octavia III .
Engine codes CJZA CJZB
Manufactured 01.2013 ► 11.2012 ►
Emission standards EU5 EU5
Capacity cm31197 1197
Output kW at rpm 77/4500-5500 63/4300-5300
Torque Nm at rpm 175/1400-4000 160/1400-3500
Bore ∅ mm 71.0 71.0
Stroke mm 75.6 75.6
Compression ratio 10.5 10.5
Cylinder/valves per cylinder 4 / 4 4 / 4
RON min. 95 unleaded 95 unleaded
Ignition system, fuel injection Motronic MED17 Motronic MED17
Firing order 1-3-4-2 1-3-4-2
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1. Identification 1
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2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 2
⇒ “2.2 Safety measures for working on vehicles with start/stop
system”, page 3
⇒ “2.3 Safety precautions during road tests in which testing and
measuring equipment is used”, page 4
⇒ “2.4 Safety precautions when working on cooling system”, page
4
⇒ “2.5 Safety precautions when working on the injection system”,
page 5
⇒ “2.6 Safety precautions when working on ignition system”, page
6
2.1 Safety precautions when working on
fuel supply system
WARNING
Fuel under high pressure creates a risk of injury.
Leaking fuel creates a fire hazard.
♦ The fuel system is under pressure! Before opening the
high-pressure system, the fuel pressure must be reduced
to residual pressure
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .
♦ The safety measures for the pressure reduction in the high
pressure system must be observed.
♦ To reduce the residual pressure (about 0.7 MPa or 7 bar),
the connection point must be opened »immediately« after
the pressure has been reduced. Place a cleaning cloth
around the connection point.
♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Fuel pump is activated by switching on ignition and via driver
door contact switch. Before opening the fuel system and for
reasons of safety, if the battery is not disconnected, the con‐
nector must be disconnected from the fuel pump.
♦ Take out fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
Caution
There is a risk of destruction of electronic components when
disconnecting the battery.
♦ Observe notes on procedure for disconnecting the battery.
Disconnect the battery only when the ⇒ Electrical System; Rep.
gr. 27 battery is disconnected.
Octavia III 2013 ➤ , Octavia III 2014 ➤
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2 Rep. gr.00 - Technical data
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Caution
When undertaking all assembly work, particularly in the engine
compartment due to its cramped construction, please observe
the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ Ensure that there is adequate free access to all moving or
hot components.
♦ Clean connection points and their environment thoroughly with
engine or brake cleaner and dry the cleaned area thoroughly
before loosening.
♦ Open closed lines and connections immediately with suitable
screen caps.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths!
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Avoid moving the vehicle.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Prevent skin contact with fuel!
♦ Wear fuel-resistant gloves!
2.2 Safety measures for working on vehi‐
cles with start/stop system
When working on vehicles with start/stop system, please observe
the following:
WARNING
There is risk of injury from automatic engine starting on vehi‐
cles with start/stop system.
♦ In vehicles with an activated start-stop system (indicated
by a message in the dash panel insert), the engine can
start automatically if necessary.
♦ It is therefore necessary to ensure that the start-stop sys‐
tem is deactivated when carrying out work on the vehicle
(switch ignition off, if required switch ignition on again).
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2. Safety instructions 3
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2.3 Safety precautions during road tests in
which testing and measuring equipment
is used
Note the following if testers and measuring instruments must be
used during a road test:
WARNING
There is a risk of accident from deflection and insufficient se‐
curing of testers and measuring instruments.
There is also a hazard from the release of the passenger airbag
in the event of an accident.
• Using testers and measuring instruments during driving
operation creates a risk of deflection.
• Increased risk of injury from unsecured testers and meas‐
uring instruments must be prevented.
♦ Testers and measuring instruments must always be se‐
cured on the rear seat using a seat belt and by a 2nd
person on the rear seat.
2.4 Safety precautions when working on
cooling system
WARNING
Steam may escape when expansion tank is opened.
♦ Wear eye protection and protective clothing to avoid eye
injuries and scalding.
♦ Cover cap with cloth and open carefully.
Caution
When undertaking all assembly work, particularly in the engine
compartment due to its cramped construction, please observe
the following:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
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Note
♦ When the engine is warm, the cooling system is under pres‐
sure. If necessary, release pressure before beginning repair
work.
♦ Secure all hose connections with hose clips, allocation ⇒
electronic parts catalogue “ETKA” .
♦ Hose clip pliers - VAS 6362- are recommended to install
spring-type clips.
♦ Renew gaskets and seals.
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection and hose).
2.5 Safety precautions when working on the
injection system
WARNING
The fuel system is under pressure! Place a clean cleaning cloth
around the connection point before detaching hose connec‐
tions. Reduce pressure by carefully removing the hose.
The safety measures for the pressure reduction in the high
pressure system must be observed
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
♦ Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without it starting,
as for example, when checking the compression pressure, re‐
move the fuse for the voltage supply of the injection valves and
the ignition coils from the fuse holder ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.
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2. Safety instructions 5
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2.6 Safety precautions when working on ig‐
nition system
WARNING
To prevent injuries to persons and/or damage to the injection
and ignition system, please observe the following:
Do not touch or disconnect ignition cables when the engine is
running or being turned at starter speed.
Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
Fuel pump is activated by switching on ignition and via driver
door contact switch. Therefore, if the battery power hasn't been
disconnected, for safety reasons the plug of the fuel delivery
unit must be disconnected, or the fuel pump fuse must be re‐
moved before opening the fuel system.
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3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 7
⇒ “3.2 Foreign bodies in the engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Cable routing and securing”, page 8
⇒ “3.5 Assembly of radiators and capacitors”, page 8
⇒ “3.6 Additional instructions when undertaking assembly work
on the air-conditioning system”, page 8
⇒ “3.7 General instructions for charge air system”, page 8
⇒ “3.8 General notes on the ignition system”, page 9
⇒ “3.9 General notes on the injection system”, page 9
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10
3.1 Rules of cleanliness
Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before fitting. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes etc.).
♦ When the system is open: Do not work with compressed air.
Do not move vehicle.
♦ Ensure that no fuel runs onto the fuel hoses. If happens, clean
the hoses immediately.
♦ Protect electrical plug connections from dirt and moisture and
only connect them when dry.
3.2 Foreign bodies in the engine
To prevent the penetration of foreign bodies, open channels of
the inlet connection and exhaust tract must be sealed with suita‐
ble plugs during assembly works on the engine, for example from
the screw plug set for engine - VAS 6122- .
3.3 Contact corrosion
The use of unsuitable connection elements causes contact cor‐
rosion (screws, nuts, washers, ...).
This is why only connection elements with a special surface coat‐
ings are fitted.
Therefore, the rubber or plastic parts and the adhesives are made
from electrically non-conductive materials.
If you have any doubts about the suitability of parts, please use
new parts in general ⇒ Electronic Catalogue of Original Parts“ET‐
KA” .
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3.4 Cable routing and securing
♦ To ensure the original installation position, e.g. lines for fuel,
hydraulics, vacuum, activated charcoal filter system lines or
electric cables must be marked before removal. Make sketch‐
es or take photographs if necessary.
♦ Sufficient clearance from all moving or hot components must
be ensured in the engine compartment due to its cramped
construction. This prevents damage to lines.
3.5 Assembly of radiators and capacitors
The radiator, capacitor and charge air cooler may have minor in‐
dentations on the fins, even if assembly is correct. This is not a
case of damage. Radiator, capacitors or charge air cooler must
not be replaced because of these indentations.
3.6 Additional instructions when undertak‐
ing assembly work on the air-condition‐
ing system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐
tem.
Note
To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
Steps which should be taken in order to remove and install the
engine without opening the refrigerant circuit:
– Remove the holding clamp(s) of the refrigerant lines.
– Remove AC compressor ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.
3.7 General instructions for charge air sys‐
tem
Caution
When undertaking all assembly work, particularly in the engine
compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds (for example, for fuel, hydraulic fluid,
cooling fluid and refrigerant, brake fluid, vacuum) and
electrical lines in such a way that the original line guide is
re-established.
♦ Ensure that there is adequate free access to all moving or
hot components.
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Caution
In case a mechanical damage to the exhaust gas turbocharger
is found, for example, damage to the compressor wheel, it is
not sufficient to only replace the turbocharger. In order to avoid
consequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
♦ The charge-air system must be tight.
♦ Renew self-locking nuts.
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.
♦ Only use approved clamps for securing the hose connections
⇒ Electronic Catalogue of Original Parts“ETKA” .
♦ Spring-type clip pliers are recommended for installation of
spring-type clips.
♦ Before connecting the oil feed line, fill the exhaust turbocharg‐
er via the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
3.8 General notes on the ignition system
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the engine control unit.
♦ The engine control unit and further components are equipped
with self-diagnosis; inspect ⇒ Vehicle diagnostic tester
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety measures
⇒ “2.6 Safety precautions when working on ignition system”, page
6 .
Setting data, spark plugs ⇒ Maintenance ; Booklet Octavia III .
3.9 General notes on the injection system
Repairing ignition ⇒ “1 Ignition system”, page 281 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the event
memory. Also check the vacuum hoses and connections (un‐
metered air).
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♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ electronic catalogue of original
parts“ETKA” . The use of clamp or screw-type clips is not per‐
missible.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the event
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnostic tester.
Safety precautions when working on the injection system
⇒ “2.5 Safety precautions when working on the injection system”,
page 5 .
3.10 Reduce pressure in the high-pressure
system
Caution
The injection system consists of a high pressure part (max.
pressure of 12 MPa = 120 bar) and a low pressure part (pres‐
sure of approx. 0.7 MPa = 7 bar).
Before opening the high pressure system, e.g. removing the
high pressure pump, the fuel distributor, the injection valves,
the fuel pipes or the fuel pressure sender - G247- , the fuel
pressure in the high pressure system with a remaining pres‐
sure of approx. 0.7 MPa (7 bar) must be reduced.
– Connect the ⇒ Vehicle diagnostic tester and carry out the tar‐
geted function “remove high fuel pressure”.
• The fuel pressure drops to a predetermined value.
– Switch off ignition.
– Before opening the fuel system, disconnect the plug from the
fuel pump control unit.
– Before opening the high pressure system, lay cleaning cloths
around the connection point.
– Open fuel system carefully to reduce the residual pressure of
0.7 MPa (7 bar) and when doing so collect fuel that is flowing
out.
Note
♦ If the high-pressure system is not opened immediately the
pressure increases again as a result of the reheating effect.
♦ The ignition system must no longer be switched on, since oth‐
erwise the pressure will increase again.
♦ Interrogate the event memory of the engine control unit at the
end of the following work and delete all the event memory en‐
tries.
♦ The readiness code must be generated if the event memory
has been cleared ⇒ Vehicle diagnostic tester.
Octavia III 2013 ➤ , Octavia III 2014 ➤
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10 Rep. gr.00 - Technical data
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10 – Removing and installing engine
1 Removing and installing engine
⇒ “1.1 Removing engine”, page 11
⇒ “1.2 Securing the engine to the assembly stand”, page 21
⇒ “1.3 Installing engine”, page 22
1.1 Removing engine
Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel - MP8-602/1-
♦ Extension - 2024 A /1- of lifting device - MP9-201 (2024A)-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Engine bracket - T10497-
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Hose clip pliers, e.g. - VAS 6362-
♦ Locking pin - T10060 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Grease - G 000 100-
♦ Protective goggles
♦ Protective gloves
Work procedure
Note
♦ The engine is removed downwards together with the gearbox.
♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
WARNING
There is risk of injury from high fuel pressure.
♦ Before opening the high-pressure system, the fuel pres‐
sure must be reduced to residual pressure.
– Reduce the fuel pressure in the high pressure system
⇒ “3.10 Reduce pressure in the high-pressure system”,
page 10 .
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– Open cap -arrow- for coolant expansion tank.
WARNING
There is risk of injury due to hot steam and hot coolant.
♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.
– Remove both front wheels ⇒ Chassis; Rep. gr. 44 .
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
– Remove the front left and right wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Disconnect electrical plug connection -2- at the coolant tem‐
perature sender at the radiator outlet - G83- -3-.
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 .
Caution
There is a risk of destruction through reversing the rotation di‐
rection of an already used V-ribbed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the V-ribbed belt.
Vehicles with air conditioning
WARNING
Risk of injury through refrigerant.
♦ Do not open the refrigerant circuit of the air conditioning
system.
– Remove V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 37 .
– Disconnect electric plug connection -1- on the control valve for
the air conditioning system - N280- compressor.
– Release screws -arrows- for AC compressor.
Caution
Risk of damaging refrigerant lines and hoses.
♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.
– Remove AC compressor with connected refrigerant hoses and
strap up to the right side.
Continued for all vehicles
– Loosen hose clamp -1- and remove air guide hose.
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– Release screw left and right arrow -2-.
– Unclip and remove the air guide on the lock carrier.
– Raise holding clamp -arrow- and remove top left coolant hose
from radiator.
Note
Depending on the vehicle version, 3 radiator versions are instal‐
led.
♦ Radiator Version 1
⇒ “4.1 Radiator version 1 - Summary of components”,
page 173 .
♦ Radiator Version 2
⇒ “4.2 Radiator version 2 - Summary of components”,
page 175 .
♦ Radiator Version 3
⇒ “4.3 Radiator version 3 - Summary of components”,
page 176 .
Vehicles with radiator version 1
– Raise holding clamp -arrow- and disconnect coolant hose right
above radiator for charge air circuit.
Vehicles with radiator versions 2 and 3:
– Raise holding clamps -1- and remove coolant hose from
charge air circuit cooler.
Continued for all vehicles
– Removing fan shroud
⇒ “4.7 Removing and installing fan shroud for radiator fan”,
page 182 .
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
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– Unlock catch -arrow- and remove vacuum hose -1-.
– Expose vacuum hose on the air guide pipe -2-.
Vehicles without auxiliary heating
– Raise holding clamps -arrows- and remove coolant hoses
from heat exchanger for heating.
Vehicles with auxiliary heating
– Loosen holding clamp and holding clamps and pull off both
coolant hoses -arrows-.
Continued for all vehicles
– Unscrew screw -2- and remove screw clamp.
– Unscrew screws -1- and nuts -arrows-, strap up catalytic con‐
verter.
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