Skoda Octavia III 2013 Instruction manual

Workshop Manual
Octavia III 2013 ➤
Octavia III 2014 ➤
1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine
Engine ID CLH
ACLH BCKF BCKF CCRV CCUP ACRK BCRM BCUN A
Edition 07.2014
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
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug 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 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety measures for working on vehicles with start/stop system . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Rules of cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Foreign bodies in the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Cable routing and securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Assembly of radiators and capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.2 Support the engine in its installed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.3 Removing and installing engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Removing and installing pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.6 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Removing and installing a V-ribbed belt and a toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 36
1.1 V-ribbed belt - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.4 Removing and installing tensioning device for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . 40
1.5 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.6 Summary of components - toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.7 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.8 Removing and installing top toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.9 Removing and installing bottom toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.10 Remove the toothed belt from the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.11 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Summary of components - sealing flange belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 63
2.3 Summary of components - gearbox side summary of components and flywheel . . . . . . . . 64
2.4 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Summary of components - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Replace the needle bearing in the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014
Contents i

3.3 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4 Removing and installing the piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.5 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.6 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.3 Replacing gasket rings for injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.4 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.2 Replacing camshaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.3 Removing and installing N205 the camshaft adjustment valve 1 . . . . . . . . . . . . . . . . . . . . 109
2.4 Removing and installing camshaft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.5 Removing and installing the camshaft adjusting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.7 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.8 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.9 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.10 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.1 Parts of the lubrication system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 127
1.2 Removing and installing oil level and oil temperature transmitter G266 . . . . . . . . . . . . . . 129
1.3 Summary of components - oil filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
1.4 Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . . 132
1.5 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.6 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.7 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.8 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 140
1.9 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 141
1.10 Testing oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.1 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2 Coolant pump and coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.1 Summary of components - coolant pump and coolant thermostat . . . . . . . . . . . . . . . . . . . . 159
2.2 Summary of components - coolant temperature transmitter . . . . . . . . . . . . . . . . . . . . . . . . 161
2.3 Summary of components - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.5 Removing and installing coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2.6 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 165
2.7 Testing coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.8 Removing and installing coolant temperature transmitter G62 . . . . . . . . . . . . . . . . . . . . . . 166
2.9 Removing and installing charge air cooler pump V188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.10 Removing and installing the heating backup pump V488 . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Octavia III 2013 ➤ , Octavia III 2014 ➤
1.6/66; 77; 81; 2.0/105; 110; 135 kW TDI CR engine - Edition 07.2014
ii Contents

3.1 Summary of components - coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.2 Removing and installing the front top coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3 Removing and installing the front bottom coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.4 Removing and installing the front left coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.5 Removing and installing the front right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.6 Remove and install the left coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.7 Removing and installing the rear coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.8 Removing and installing the rear right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.1 Parts of the cooling system fitted to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.2 Summary of components - fan shroud and radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . 190
4.3 Summary of components- fan shroud and radiator fan V7 and radiator fan 2 V177 . . . . . . 191
4.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4.5 Removing and installing fan shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.6 Removing and installing radiator fans V7 and V177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1 Measures in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Step 1, engine started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Step 2, the engine was not started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.3 Step 3, metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . . . 200
1.4 Step 4, no metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . 201
1.5 Step 5, metal swarfs are present in the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 202
1.6 Step 6: no metal swarfs are present in the high pressure pump . . . . . . . . . . . . . . . . . . . . 202
2 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.1 Fuel tank with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 204
2.2 Fuel delivery unit - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.3 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.4 Drain fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2.5 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
2.6 Fuel hoses in the engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
2.7 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.8 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2.9 Removing and installing misfuelling protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.10 Deactivate misfuelling protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.11 Removing and installing the sender for fuel gauge display . . . . . . . . . . . . . . . . . . . . . . . . 245
2.12 Separating push-on couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.13 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.14 Removing and installing fuel pump control unit J538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
2.15 Check the suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.16 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.17 Inspecting fuel pump G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.18 Check sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.2 Removing and installing accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1 Charge-air system - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
1.1 Exhaust gas turbocharger with component parts - Summary of components . . . . . . . . . . 290
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
1.3 Replace vacuum positioning element for charge pressure regulation with position sender for
charge pressure regulator G581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.4 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
1.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
1.6 Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
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Contents iii

2 Charge-air system - radiator, leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
2.2 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
2.3 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1 Diesel direct injection system - fitting location, system overview . . . . . . . . . . . . . . . . . . . . 314
1.1 Installation location overview - fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
1.2 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
1.3 Filling/bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
1.4 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
2 Injection units/fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.1 Summary of components - injection units (injectors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
2.2 Fuel distributor - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
2.3 Check injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
2.4 Adjust the correction values for injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
2.5 Check injection unit return quantity with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 326
2.6 Check injection unit return flow quantity at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . 329
2.7 Carry out the vacuum test of the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
2.8 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
2.9 Removing and installing high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
2.10 Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3 High pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3.1 Summary of components - high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4.1 Removing and installing intake air temperature transmitter G42 / charge air temperature
transmitter after charge air cooler G811 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4.2 Removing and installing fuel temperature transmitter G81 . . . . . . . . . . . . . . . . . . . . . . . . 342
4.3 Removing and installing air flow mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4.4 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
4.5 Replace fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
4.6 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.7 Removing and installing differential pressure transmitter G505 . . . . . . . . . . . . . . . . . . . . 348
4.8 Removing and installing pressure sensor for exhaust gas 1 G450 . . . . . . . . . . . . . . . . . . 349
5 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
5.1 Lambda probe - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
5.2 Removing and installing Lambda probe G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
5.3 Removing and installing Lambda probe after catalytic converter G130 . . . . . . . . . . . . . . 353
6 Intake manifold, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
6.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
6.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 357
6.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
6.4 Summary of components - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
6.5 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
7.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
8 Engine noise speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
8.1 Removing and installing engine noise speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
1 Removing and installing exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
1.1 Summary of components - front, middle and rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 370
1.2 Removing and installing exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
1.3 Removing and installing the exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . 381
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iv Contents

1.4 Removing and installing rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
1.5 Replacing middle or rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
1.7 Align exhaust tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
1.8 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
2 Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
2.1 Summary of components - exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
2.2 Removing and installing exhaust gas cleaning module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
2.3 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
3 Exhaust temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3.1 Summary of components - exhaust temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . 402
3.2 Removing and installing exhaust gas temperature transmitter . . . . . . . . . . . . . . . . . . . . . . 403
4 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4.1 Exhaust gas recirculation with radiator for exhaust gas recirculation - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4.2 Control motor for exhaust gas recirculation V338 - Summary of components . . . . . . . . . . 412
4.3 Removing and installing control motor for exhaust gas recirculation V338 . . . . . . . . . . . . 413
4.4 Removing and installing control motor 2 for exhaust gas recirculation V339 . . . . . . . . . . 413
4.5 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 415
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
1.1 Summary of components - preheating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
1.2 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 423
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
1.5 Removing and installing engine speed transmitter G28 . . . . . . . . . . . . . . . . . . . . . . . . . . 424
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Contents v

Octavia III 2013 ➤ , Octavia III 2014 ➤
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vi Contents

00 – Technical data
1 Identification
(SRL000718; Edition 07.2014)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data
The engine number (“engine identification characters” and “serial
number”) is located at the engine/gearbox joint -arrow-.
In addition, a sticker with the “engine identification characters”
and “serial number” is affixed to the timing belt guard.
The engine identification characters are also indicated on the ve‐
hicle data sticker.
♦ The engine identification characters have 4 digits starting with
the letter “C”.
♦ 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 in the cylinder block including the
serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine control unit.
Engine identifi‐
cation charac‐
ters
CLHB CLHA CKFB CKFC CRVC CUPA CRKB CRMB CUNA
Manufactured 05.13 ► 11.12 ► 11.12 ► 11.12 ► 05.13 ► 05.13 ► 11.13 ► 08.14 ► 08.14 ►
Exhaust limit
values con‐
forming to
EU5 EU5 EU5 EU5 EU4 EU5 EU6 EU6 EU6
Ca‐
pacity l 1,598 1,598 1,968 1,968 1,968 1,968 1,598 1,968 1,968
Out‐
put kW at rpm 66/275 0…
4800
77/300
0…
4000
105/35
00…
4000
110/350
0…4000 105/350 0…4000 135/350 0…4000 81/3250 …4000 110/40 00 135/35 00…
4000
Tor‐
que Nm at rpm 230/14 00…
2700
250/15
00…
2750
320/17
50…
3000
320/175
0…3000 320/175 0…3000 380/175 0…3250 250/150 0…3000 340/17 50…
3000
380/17
50…
3000
Bore ∅ mm 79,5 79,5 81,0 81,0 81,0 81,0 79,5 81,0 81,0
Stroke mm 80,5 80,5 95,5 95,5 95,5 95,5 80,5 95,5 95,5
Cylinder/
valves per cyl‐
inder
4/4 4/4 4/4 4/4 4/4 4/4 4/4 4/4 4/4
Compression
ratio 16,2 16,2 16,2 16,2 16,2 15,8 16,2 16,2 15,8
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic con‐
verter yes yes yes yes yes yes yes yes yes
Exhaust gas
recirculation
with radiator
yes yes yes yes yes yes yes yes yes
Turbocharging yes yes yes yes yes yes yes yes yes
Charge air
cooler yes yes yes yes yes yes yes yes yes
Octavia III 2013 ➤ , Octavia III 2014 ➤
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1. Identification 1
Volkswagen Technical Site: http://vwts.ru http://vwts.info
огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

Engine identifi‐
cation charac‐
ters
CLHB CLHA CKFB CKFC CRVC CUPA CRKB CRMB CUNA
Diesel particle
filter yes yes yes yes no yes yes yes yes
Balancing
shafts no no no no no yes no no yes
Octavia III 2013 ➤ , Octavia III 2014 ➤
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2 Rep. gr.00 - Technical data

2 Safety instructions
⇒ “2.1 Safety precautions when working on fuel supply system”,
page 3
⇒ “2.2 Safety measures for working on vehicles with start/stop
system”, page 5
2.1 Safety precautions when working on
fuel supply system
WARNING
♦ The fuel or the fuel lines in the fuel system can become
very hot (risk of scalding)!
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
For reasons of safety, the power supply to the fuel pump must
be interrupted before the fuel system is opened. The fuel pump
would otherwise be activated when the driver's door is opened.
One of the following options must be used to interrupt the cur‐
rent supply:
♦ Disconnect battery
or
♦ Take out fuse for fuel pump control unit - J538-
or
♦ Disconnect the plug on the flange of the fuel delivery unit.
Caution
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 (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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2. Safety instructions 3

Caution
♦ Do not remove fuel hoses from the fuel filter.
♦ Pay attention to the notes
⇒ “2.6 Fuel hoses in the engine compartment”,
page 222 .
♦ Do not lever the connection fittings.
♦ This leads to leaks and damage to the fuel filter top part.
♦ Ensure that no diesel fuel gets onto other components in
the engine compartment. If this happens, clean affected
components immediately!
Caution
♦ Because of insufficient lubrication by diesel fuel, misfuel‐
ling can cause irreversible damage to high pressure com‐
ponents, particularly the high pressure pump. Damage in
the form of engine seizure and clogging by particles can
be expected. These particles create a risk of further dam‐
age in the pressure control valve and injectors.
Caution
In order to avoid the high pressure pump to run dry and to ach‐
ieve a quick engine start after parts are replaced, the following
points must be observed.
♦ If parts of the fuel system have been removed or replaced,
to bleed the fuel system it is necessary to perform the fuel
system filling/bleeding process
⇒ “1.3 Filling/bleeding the fuel system”, page 321 .
♦ If the fuel pump, fuel line or fuel filter have been removed
or replaced, the fuel system filling/bleeding process must
be performed
⇒ “1.3 Filling/bleeding the fuel system”, page 321 .
♦ If the high pressure pump is removed or replaced, the in‐
itial fuel filling of the high pressure pump must be carried
out before the first engine start
⇒ “1.3 Filling/bleeding the fuel system”, page 321 .
♦ If the high pressure system was opened, it must be
checked for tightness
⇒ “1.4 Check the fuel system for tightness”, page 322 .
When removing and installing the fuel gauge transmitter or the
fuel delivery unit from a full or partly filled fuel tank, pay attention
to the following points:
♦ 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!
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4 Rep. gr.00 - Technical data

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 passen‐
ger seat, the passenger can be injured by the release of the
passenger airbag in the event of an accident.
WARNING
Secure the diagnostic device to the rear seat and operate from
that position.
Observe the following points to prevent injury to persons and/or
damage to the injection and preheating system:
♦ People, who have a heart pacemaker implant, should not bend
over the engine compartment when the engine is running, as
the injection units generate an output high voltage pulse.
♦ No fuel lines must be opened when the engine is running.
♦ Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
♦ Do not carry out engine wash unless the ignition is switched
off.
♦ If the engine must be operated at starter speed, without it
starting, unplug the connector -2- at the fuel pressure regulat‐
ing valve - N276- -Pos. 1-.
♦ Before disconnecting the battery determine the code of the
radio fitted with anti-theft coding.
♦ Always switch off the ignition before disconnecting and re-
connecting the battery. Otherwise the engine control unit may
be damaged.
♦ After connecting the battery, carry out certain additional oper‐
ations ⇒ Electrical System; Rep. gr. 27 .
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 instructions:
WARNING
Risk of injury from automatic engine start on vehicles 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.
♦ You must therefore ensure that the start/stop system is
deactivated (switch off the ignition, switch the ignition on
again if necessary) when working on the vehicle.
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2. Safety instructions 5

3 Repair instructions
⇒ “3.1 Rules of cleanliness”, page 6
⇒ “3.2 Foreign bodies in the engine”, page 7
⇒ “3.3 Contact corrosion”, page 7
⇒ “3.4 Cable routing and securing”, page 7
⇒ “3.5 Assembly of radiators and capacitors”, page 7
⇒ “3.6 Supplementary instructions and assembly work on vehi‐
cles with an air conditioning system”, page 7
⇒ “3.7 General instructions for charge air system”, page 8
3.1 Rules of cleanliness
⇒ “3.1.1 Regulations concerning cleanliness when working on the
fuel supply/fuel injection system”, page 6
⇒ “3.1.2 Regulations concerning cleanliness when working on the
exhaust gas turbocharger”, page 6
3.1.1 Regulations concerning cleanliness
when working on the fuel supply/fuel in‐
jection system
When working on the fuel supply and injection system, pay careful
attention to the following “6 rules” for cleanliness:
♦ 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 components: Remove spare parts from their
wrapping immediately before fitting. Do not use any parts
which have been stored unwrapped (e.g. on a shelf or in a tool
box).
♦ When the system is open: Avoid using compressed air when‐
ever possible. Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Contaminated
hoses must be replaced.
3.1.2 Regulations concerning cleanliness
when working on the exhaust gas turbo‐
charger
Carefully observe the following “5 rules” for cleanliness when
working on the exhaust gas turbocharger:
♦ 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 components: Remove spare parts from their
wrapping immediately before fitting. Do not use any parts
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6 Rep. gr.00 - Technical data

which have been stored unwrapped (e.g. on a shelf or in a tool
box).
♦ When the system is open: Avoid using compressed air when‐
ever possible. Avoid moving the vehicle.
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
ETKA .
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 Supplementary instructions and assem‐
bly work on vehicles with an air condi‐
tioning 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:
– Unscrew the holding clamp(s) on the refrigerent lines.
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3. Repair instructions 7

– Remove V-ribbed belt
⇒ “1.2 Removing and installing poly V-belt”, page 38 .
– Remove AC compressor from the bracket for auxiliary units
⇒ “1.1 V-ribbed belt - Summary of components”, page 36 .
– Mount the air conditioning compressor and the condenser in
such a way that the refrigerent lines/hoses are not under ten‐
sion.
3.7 General instructions for charge air sys‐
tem
Caution
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 (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.
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.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all the air guides and the charge air cooler for for‐
eign 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, check
⇒ “2.3 Checking the charge-air system for leaktightness”, page
311 .
♦ Replace the gaskets, the gasket rings and the self-locking
nuts.
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed. The gasket
ring and the sealing surface must be slightly oiled only for
push-fit couplings
⇒ “1.6 Hose connections with screw clamps”, page 308 .
♦ Observe assembly markings on the hoses and components.
♦ All hose connections of the charge air system are secured with
spring strap clamps or push-fit couplings.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ ETKA - Electronic Catalogue of Original Parts .
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8 Rep. gr.00 - Technical data

♦ Hose clip pliers are recommended to install spring-type clips.
♦ Install hose connections with screw clamps
⇒ “1.6 Hose connections with screw clamps”, page 308 .
♦ Before screwing down the oil feed line, fill the exhaust turbo‐
charger 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.
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3. Repair instructions 9

10 – Removing and installing engine
1 Removing and installing engine
⇒ “1.1 Removing and installing engine trim panel”, page 10
⇒ “1.2 Removing engine”, page 10
⇒ “1.3 Securing the engine to the assembly stand”, page 23
⇒ “1.4 Installing engine”, page 25
1.1 Removing and installing engine trim
panel
Caution
When removing and installing the engine trim panel, where
applicable, prevent a collision with the fuel return-flow line or
prevent coming into contact with the lines by accident. In un‐
favourable situations, the outlets on the injectors may break
off. This can cause leaks in the fuel system.
The brackets of the engine cover on the cylinder head cover
can break off when they are incorrectly removed.
♦ It is therefore necessary to remove the engine cover ac‐
cording to the following instruction.
– 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.
– First press the engine cover into the rubber grommets on the
left side, then into the rubber grommets on the right side.
1.2 Removing engine
Special tools and workshop equipment required
♦ Removal tool for inner lining of the door panel - MP8-602/1-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Double ladder
♦ Screw plug set for engine - VAS 6122-
♦ Catch pan , e.g. -VAS 6208-
♦ Hose clip pliers - VAS 6362-
♦ Locking pin - T10060 A-
♦ Engine mount - T10497- with bolts -T10497/1-
♦ Protective goggles
♦ Protective gloves
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10 Rep. gr.10 - Removing and installing engine

Work procedure
Note
♦ If the stripped engine is replaced after engine removal, the
tightening of the injection unit clamping claws on the new strip‐
ped engine must be checked. Specified torque: Position -8-
⇒ “2.1 Summary of components - injection units (injectors)”,
page 323 .
♦ The engine is removed downwards together with the gearbox.
♦ Fit all cable straps on again in the same place when installing.
♦ Fit all heat protection sleeves on again in the same place when
installing.
WARNING
Danger of scalding due to hot steam and hot coolant.
♦ When the engine is warm, the cooling system is under
overpressure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with a cloth and opening it carefully.
– Remove assembly bracket -9- without steering gear ⇒ Chas‐
sis; Rep. gr. 40 .
– Remove the front left and right wheelhouse liner ⇒ Body Work;
Rep. gr. 66 .
– Drain coolant ⇒ “1.2 Draining and filling coolant”, page 151 .
– Remove engine cover
⇒ “1.1 Removing and installing engine trim panel”, page 10 .
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1. Removing and installing engine 11

– Unscrew screws -1-, -3-.
– Unlock catch -arrows-, remove cover-2-.
– Expose coolant hose -2-.
– Unlock catches -arrows-, remove top part-1- of air guide.
– Disconnect the plug connection -2- at the air mass meter -
G70- .
– Disconnect vacuum hose -4-.
– Loosen hose clamp -3-, remove air guide hose.
– Remove radiator air filter housing -1-.
– Release screw left and right -arrow-.
– Unclip and remove bottom part -1- of air guide.
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12 Rep. gr.10 - Removing and installing engine