Skoda OCTAVIA Instruction manual

Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5103.50.20 Edition 08.96
Running Gear

The Workshop Manual is intended only for use within the ŠKODA
Organisation; it is not permitted to pass it on to third parties.
© 1996 ŠKODA, automobilová a.s. Printed in Czech Republic

Service
List of Supplements to
OCTAVIA Workshop Manual Edition: 06.05
Chassis
Replaces List of Supplements - Edition: 05.04
Supple-
ment
Edition Subject Article Number
08.96 Basic Edition of Workshop Manual S00.5103.50.20
1 09.96 Supplement to Basic Edition S00.5103.51.20
2 03.97 Supplement to Repair Group 40 and 42; Repair Group
44, 45 and 48
S00.5103.52.20
3 11.97 Engine 1.9 l/81 kW TDI S00.5103.53.20
4 10.98 Engine 1.8 l/110 kW; Octavia Estate S00.5103.54.20
5 12.98 Drive shafts, vehicle measurement, Brake FN-3 S00.5103.55.20
6 06.99 Modifications to steering system, brakes, rear axle,
ABS; Engine 1.4 l/44 kW
S00.5103.56.20
7 11.99 4 wheel drive (4 x 4) S00.5103.57.20
8 04.00 Vehicles with ABS/EDS/ESP S00.5103.58.20
9 11.00 Anti-lock brake system MK60 S00.5103.59.20
10 02.01 Anti-lock brake system MK60 ESP S00.5103.60.20
11 05.01 Mechanical brake assistant, Brake FN-3 S00.5103.61.20
12 08.01 Text modifications to Repair Group 00, 40, 42 and 45 S00.5103.62.20
13 01.02 Text modifications to Repair Group 45 S00.5103.63.20
14 06.02 Text modifications to Repair Group 00, 40, 44, 45 and
46
S00.5103.64.20
15 11.02 Engine 1.9 l/96 kW PD, Supplement to Repair Group
00, 40, 42 and 45
S00.5103.65.20
16 04.03 Text modifications to Repair Group 40, 45 and 46 S00.5103.66.20
17 05.04 Text modifications to Repair Group 00, 40 and 44 S00.5103.67.20
18 06.05 Text modifications to Repair Group 00, 40, 42 and 45 S00.5103.68.20
19
20
Contents ⇒ next page.
The Service Manual is intended only for use within the
Škoda Organisation; it is not permitted to pass it on
to third persons.
© 2005 ŠKODA AUTO a. s.
Printed in CR
S00.5103.68.20

Edition 06.05
S00.5103.68.20
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OCTAVIA Service
Table of Contents
00 Technical Data Page
Technical Data ............................................................................................................................. 00-1
- The chassis.............................................................................................................................. 00-1
- The steering system................................................................................................................. 00-5
- The brake system .................................................................................................................... 00-6
- Wheels, tyres ........................................................................................................................... 00-8
40 Front wheel suspension Page
Repairing the front wheel suspension...................................................................................... 40-1
- I - Summary of the components of the assembly carrier, anti-roll bar, track control arm ......... 40-2
- Removing and installing the track control bar .......................................................................... 40-4
- Pressing out and pressing in the bearing for track control arm................................................ 40-8
- Removing and installing the assembly carrier ......................................................................... 40-10
- Pressing out and pressing in the rubber-metal bearing ........................................................... 40-12
- II - Summary of the components of the wheel bearing, suspension strut, drive shaft, brakes .... 40-13
- Repairing a wheel bearing housing.......................................................................................... 40-16
- Checking the steering joint....................................................................................................... 40-19
- Removing and installing the steering joint ............................................................................... 40-20
- Removing and installing a suspension strut and a wheel bearing housing.............................. 40-21
- Repairing the suspension strut at the front .............................................................................. 40-25
- Checking dampers ................................................................................................................... 40-28
- Disposing of dampers .............................................................................................................. 40-31
- Removing and installing drive shafts ....................................................................................... 40-34
Repairing a drive shaft ............................................................................................................... 40-38
- Repairing a drive shaft with an outer and inner constant velocity joint .................................... 40-38
- Repairing a drive shaft with an outer and inner constant velocity joint VL 3700 ...................... 40-39.1
- Checking an outer constant velocity joint................................................................................. 40-45
- Checking an inner constant velocity joint................................................................................. 40-46
- Repairing a drive shaft with an inner tripod joint AAR 2900 and outer constant joint velocity..... 40-49
- Dismantling a tripod joint AAR 2900 and assembling it again.................................................. 40-51
- Repairing a drive shaft with an inner tripod joint AAR 2000 and outer constant velocity joint..... 40-56
- Dismantling a tripod joint AAR 2000 and assembling it again.................................................. 40-58
42 Rear wheel suspension Page
Repairing the rear axle - drum brakes....................................................................................... 42-1
- Removing and installing the rear axle...................................................................................... 42-1
- Summary of components of the rear axle ................................................................................ 42-4
- Removing and installing a rubber-metal bearing ..................................................................... 42-7
- Removing and installing dampers/springs ............................................................................... 42-10
- Dismantling a damper and assembling it again ....................................................................... 42-11
Repairing the rear axle - disc brakes ........................................................................................ 42-12
- Removing and installing the rear axle...................................................................................... 42-12
- Summary of components of the rear axle ................................................................................ 42-15
- Removing and installing a rubber-metal bearing ..................................................................... 42-18
- Removing and installing dampers/springs ............................................................................... 42-21
- Dismantling a damper and assembling it again ....................................................................... 42-22
Repairing the wheel bearing system......................................................................................... 42-23
- Repairing the wheel bearing system - drum brakes................................................................. 42-23
- Repairing the wheel bearing system - disc brakes .................................................................. 42-28

Service OCTAVIA
Edition 06.05
S00.5103.68.20
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Repairing the rear axle (vehicles with a four-wheel drive)...................................................... 42-32
- An overview of the rear axle with four-wheel drive .................................................................. 42-32
- Summary of components for springs and dampers on vehicles with a four-wheel drive ......... 42-33
- Removing and installing helical springs ................................................................................... 42-35
- Removing and installing dampers............................................................................................ 42-39
Summary of components of the trailing arm and suspension arm........................................ 42-41
- Pressing out and pressing in the wheel bearing ...................................................................... 42-44
- Removing and installing the rubber-metal bearing for the trailing arm .................................... 42-50
- Removing and installing guide joints........................................................................................ 42-52
- Removing and installing a trailing arm ..................................................................................... 42-54
- Removing and installing a suspension arm ............................................................................. 42-58
A summary of components for an assembly carrier with axial drive..................................... 42-60
- Removing and installing an assembly carrier with axial drive.................................................. 42-61
- Removing and installing the rubber-metal bearing for an assembly carrier............................. 42-66
- Removing and installing the rubber-metal bearing for an axial drive ....................................... 42-68
Repairing a drive shaft ............................................................................................................... 42-72
- Removing and installing drive shaft ......................................................................................... 42-72
- Repairing a drive shaft with constant velocity joint .................................................................. 42-75
44 Wheels/tyres/vehicle measurement Page
Vehicle measurement ................................................................................................................. 44-1
- Conditions for performing checking and tests.......................................................................... 44-2
- Making preparations to take measurements............................................................................ 44-2.1
- Designations of the various chassis available ......................................................................... 44-2.2
- Nominal value for vehicle measurement.................................................................................. 44-2.2
- Checking the lateral inclination ................................................................................................ 44-2.3
- Checking the wheel camber of the front axis, averaging if necessary ..................................... 44-2.4
- Checking the wheel camber of the rear axis............................................................................ 44-2.5
- Checking the wheel camber of the rear axis, averaging/adjusting if necessary ...................... 44-2.5
- Checking the wheel camber of the front axis, adjusting if necessary ...................................... 44-2.6
- Checking the steering angle on the left and right..................................................................... 44-2.6
- Mathematical determination of the deviation of the rear axle from the direction of travel........ 44-2.8
Wheels and tyres......................................................................................................................... 44-3
- The disc wheel ......................................................................................................................... 44-3
- The light metal wheel ............................................................................................................... 44-4
45 The Anti-Lock Braking System Page
The anti-lock braking (ABS) ITT Mark 20 IE.............................................................................. 45-1
- Safety measures, basics concerning searching for faults and repair
of the ABS and ABS/EDL ITT Mark 20 IE ................................................................................ 45-1
- Information concerning repair work on an ABS and ABS/EDL ITT Mark 20 IE ........................ 45-1
- Required technical information ................................................................................................ 45-3
Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE..... 45-4
- General comments................................................................................................................... 45-4
- The ABS ITT Mark 20 IE .......................................................................................................... 45-4
- The ABS/EDL ITT Mark 20 IE .................................................................................................. 45-5
- Installed position of the ABS or ABS/EDL ITT Mark 20 IE ....................................................... 45-5
Self-diagnosis.............................................................................................................................. 45-6
- Function of the self-diagnostic system..................................................................................... 45-6
- Indication of faults concerning the warning lamps K47 and K14/33 ........................................ 45-7
- A vehicle with ABS/EDL has no EDL function .......................................................................... 45-8

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OCTAVIA Service
Edition 06.05
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Undertaking the self-diagnosis.................................................................................................. 45-9
- Conditions for performing checking and tests.......................................................................... 45-9
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-9
- Querying the control unit version ............................................................................................. 45-10
- An overview of the functions which can be selected................................................................ 45-12
- Interrogating the fault memory ................................................................................................. 45-12
- The automatic testing sequence .............................................................................................. 45-13
- The fault table .......................................................................................................................... 45-14
- Deleting the fault memory ........................................................................................................ 45-21
- Ending output........................................................................................................................... 45-22
- Coding the control unit ............................................................................................................. 45-22
- Reading the measuring value block......................................................................................... 45-24
- Actuator diagnosis ................................................................................................................... 45-29
- Initiating the basic setting......................................................................................................... 45-36
Electrical testing of the ABS and ABS/EDL ITT Mark 20 IE..................................................... 45-41
- Conditions for performing checking and tests.......................................................................... 45-41
- Multiple plug connectors with contact allocation ...................................................................... 45-42
- An overview of the test steps ................................................................................................... 45-43
- Testing table ............................................................................................................................. 45-44
Electrical/electronic components and installed locations of the ABS,
ABS/EDL ITT Mark 20 IE ............................................................................................................. 45-51
- Removing and installing the hydraulic control unit and holder................................................. 45-52
- Repairing the hydraulic control unit.......................................................................................... 45-57
- Testing parts of the ABS system on the front axle/removing and installing.............................. 45-60
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes - front-wheel drive................................................................................ 45-65
- Removing and installing as well as adjusting a brake light switch up to MY 1999................... 45-69
- Removing and installing as well as adjusting a brake light switch as of MY 2000................... 45-69.1
A summary of components for the hydraulic control unit, brake booster/master
brake cylinder for vehicles with ABS, ABS/EDL ITT Mark 20.................................................. 45-70
Self diagnosis of the ABS/EDL for a four-wheel drive vehicle with a Haldex clutch............ 45-71
- Querying the control unit version ............................................................................................. 45-71
- Fault table for ABS/EDL for a four-wheel drive vehicles with a Haldex clutch ......................... 45-72
- Coding the control unit ............................................................................................................. 45-73
- Testing the sender for longitudinal acceleration -G251-........................................................... 45-74
- Testing the data-bus lines ........................................................................................................ 45-75
- Initiating the basic setting......................................................................................................... 45-76
- Switching off the sender for longitudinal acceleration -G251-.................................................. 45-76
- Zero balancing of the sender for longitudinal acceleration -G251- .......................................... 45-77
Electrical testing of the ABS/EDL for a four-wheel drive vehicle with a Haldex clutch........ 45-79
- Test table.................................................................................................................................. 45-79
Electrical/electronic components and fitting locations (four-wheel drive) ........................... 45-81
- Removing and installing the sender for longitudinal acceleration -G251-................................ 45-82
- Testing parts of the ABS system on the rear axle/removing and installing (disc brakes)
S-four-wheel drive.................................................................................................................... 45-82
The anti-lock braking system ABS/EDL/ESP ITT Mark 20 IE................................................... 45-88
- Safety measures, basics concerning searching for faults and repair....................................... 45-88
- Information concerning repair work on the ABS/EDL/ESP ITT Mark 20 IE.............................. 45-88
- Required technical information ................................................................................................ 45-88
Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL/ESP ITT
Mark 20 IE .................................................................................................................................... 45-89
- General comments................................................................................................................... 45-89
- The ABS/EDL/ESP ITT Mark 20 IE .......................................................................................... 45-90
- Fitting position of the ABS/EDL/ESP ITT Mark 20 IE............................................................... 45-90
Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP ITT Mark 20 IE....................................... 45-91
- Function of the self-diagnostic system..................................................................................... 45-91
- Indication of faults concerning the warning lamps K47, K118 and K155 ................................. 45-92
- A vehicle with ABS/EDL/ESP has no EDL function.................................................................. 45-96

Service OCTAVIA
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Edition 06.05
S00.5103.68.20
Undertaking the self-diagnosis.................................................................................................. 45-97
- Conditions for performing checking and tests.......................................................................... 45-97
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-97
- Querying the control unit version ............................................................................................. 45-98
- The automatic testing sequence .............................................................................................. 45-100
- An overview of the functions which can be selected................................................................ 45-100
- Interrogating the fault memory ................................................................................................. 45-101
- The fault table .......................................................................................................................... 45-102
- Deleting the fault memory ........................................................................................................ 45-113
- Ending output........................................................................................................................... 45-114
- Coding the control unit ............................................................................................................. 45-114
- Reading the measuring value block......................................................................................... 45-116
- Initiating the basic setting......................................................................................................... 45-124
- The logging-in procedure ......................................................................................................... 45-131
Electrical testing of the ABS/EDL/ESP ITT Mark 20 IE............................................................. 45-133
- Conditions for performing checking and tests.......................................................................... 45-133
- Multiple plug connectors with contact allocation ...................................................................... 45-134
- Testing table ............................................................................................................................. 45-138
- Test steps 1 - 20....................................................................................................................... 45-138
- Test steps 21 - 28..................................................................................................................... 45-148
Electrical/electronic components and installed locations of the ABS/EDL/ESP ITT
Mark 20 IE .................................................................................................................................... 45-155
- Removing and installing the hydraulic control unit ABS/EDL/ESP and holder......................... 45-158
- Repairing the hydraulic control unit ABS/EDL/ESP.................................................................. 45-163
- Testing parts of the ABS system on the front axle/removing and installing.............................. 45-166
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes - front-wheel drive................................................................................ 45-170
- Removing and installing parts of the ESP system ................................................................... 45-170
- Removing and installing as well as adjusting a brake light switch ........................................... 45-176
A summary of components for the hydraulic control unit, brake booster/master
brake cylinder for vehicles with ABS/EDL/ESP ITT Mark 20................................................... 45-177
The anti-blocking system (ABS) MK60 ..................................................................................... 45-179
- Safety measures, basics concerning searching for faults and repair of the ABS
and ABS/TCS/EDL ITT MK 60 ................................................................................................. 45-179
- Information concerning repair work on an ABS and ABS/TCS/EDL ITT MK 60....................... 45-179
- Required technical information ................................................................................................ 45-179
- General guidelines ................................................................................................................... 45-179
- ABS and ABS/TCS/EDL........................................................................................................... 45-179
- Installed position of the ABS or ABS/TCS/EDL ITT MK 60 ...................................................... 45-179
Self-diagnosis.............................................................................................................................. 45-180
- Function of the self-diagnostic system..................................................................................... 45-180
- Indication of faults concerning the warning lamps K47 and K14/33 ........................................ 45-180
Undertaking the self-diagnosis.................................................................................................. 45-182
- Conditions for performing checking and tests.......................................................................... 45-182
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-182
- An overview of the functions which can be selected................................................................ 45-182
- The fault table .......................................................................................................................... 45-183
- Coding the control unit ............................................................................................................. 45-190
- Table of codes for vehicles with Anti-Lock Brake System Mark 60 .......................................... 45-191
- Reading the measuring value block......................................................................................... 45-192
- Actuator diagnosis ................................................................................................................... 45-194
- Initiating the basic setting......................................................................................................... 45-194
Electrical/electronic components and installed location of the Mark 60............................... 45-195
- Removing and installing the hydraulic control unit and holder................................................. 45-196
- Repairing the hydraulic control unit.......................................................................................... 45-200
- Testing parts of the ABS system on the front axle/removing and installing.............................. 45-201
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes) - front-wheel drive .............................................................................. 45-203
A summary of components for the hydraulic control unit, brake booster/master
brake cylinder for vehicles with ABS/EDL/TCS 20 Mark 60 .................................................... 45-204

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OCTAVIA Service
Edition 06.05
S00.5103.68.20
Electrical testing of the ABS/EDL/TCS Mark 60 ....................................................................... 45-205
- Conditions for performing checking and tests.......................................................................... 45-205
- Multiple plug connectors with contact allocation ...................................................................... 45-206
- Testing table ............................................................................................................................. 45-208
The anti-lock braking system ABS/EDL/ESP MK 60 ................................................................ 45-214
- Safety measures, basics concerning searching for faults and repairs..................................... 45-214
- Information concerning repair work on an ABS/EDL/ESP Mark 60.......................................... 45-214
- Required technical information ................................................................................................ 45-214
Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP
Mark 60 äMY02 .......................................................................................................................... 45-215
Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP
Mark 60 MY02 ä.......................................................................................................................... 45-217.1
Differences in the features of the ABS/EDL/TCS Mark 60 and the ABS/EDL/ESP Mark 60..... 45-218
- General comments................................................................................................................... 45-218
- Installed position of the ABS/EDL/TCS/ESP Mark 60.............................................................. 45-218
Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP Mark 60.................................................. 45-219
- The function ............................................................................................................................. 45-219
- Indication of faults concerning the warning lamps K47, K14/33 and K155 .............................. 45-219
Undertaking the self-diagnosis.................................................................................................. 45-223
- Conditions for performing checking and tests.......................................................................... 45-223
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-223
- Querying the control unit version ............................................................................................. 45-223
- An overview of the functions which can be selected................................................................ 45-224
- The fault table .......................................................................................................................... 45-224
- Coding the control unit ............................................................................................................. 45-237
- Reading the measuring value block......................................................................................... 45-238
- Initiating the basic setting......................................................................................................... 45-241
- The logging-in procedure ......................................................................................................... 45-249
Electrical testing of the ABS/EDL/ESP Mark 60 ....................................................................... 45-250
- Conditions for performing checking and tests.......................................................................... 45-250
- Multiple plug connectors with contact allocation ...................................................................... 45-251
- Testing table ............................................................................................................................. 45-254
46 Brakes/brake mechanics Page
Repairing a front wheel brake.................................................................................................... 46-1
- Repairing a front wheel brake, brake calliper FS-III................................................................. 46-1
- Removing and installing brake linings or brake calliper (FS-III)............................................... 46-3
- Repairing a front wheel brake, brake calliper FN-3.................................................................. 46-5
- Removing and installing brake linings/brake calliper (FN-3).................................................... 46-5.2
- Removing and installing brake discs (FN-3) ............................................................................ 46-5.7
Repairing a rear wheel brake - front wheel drive/drum brake................................................. 46-6
- Removing and installing a rear brake ...................................................................................... 46-6
- Resetting a brake..................................................................................................................... 46-7
- Repairing a rear wheel brake................................................................................................... 46-8
- Removing and installing brake linings...................................................................................... 46-10
- Adjusting the handbrake (drum brake)..................................................................................... 46-12
Repairing a rear wheel brake - front wheel drive/disc brake .................................................. 46-13
- Removing and installing a rear brake ...................................................................................... 46-13
- Removing and installing brake lining ....................................................................................... 46-15
- Adjusting the handbrake (disc brake) ...................................................................................... 46-17
Removing and installing the handbrake cable (front wheel drive/drum brake).................... 46-17.2
Removing and installing the handbrake cable (front wheel drive/disc brake)...................... 46-17.3
Summary of components: the handbrake cable...................................................................... 46-18
Summary of components: foot-operated system, brake pedal .............................................. 46-19
- Disconnecting the brake pedal from the brake booster and clipping them together ................ 46-20
- Removing and installing the brake pedal ................................................................................. 46-22

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Edition 06.05
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Repairing a rear wheel brake - four-wheel drive/disc brake ................................................... 46-24
- Removing and installing a rear brake ...................................................................................... 46-24
- Removing and installing brake linings...................................................................................... 46-26
- Adjusting the handbrake .......................................................................................................... 46-29
Removing and installing the handbrake cable (four-wheel drive/disc brake)....................... 46-31
47 Brakes/brake hydraulics Page
A summary of components for the brake booster/master brake cylinder for vehicles
without ABS or ABS/EDL Mark 20 ............................................................................................. 47-1
- Removing and installing the master brake cylinder ................................................................. 47-2
- Checking the brake booster ..................................................................................................... 47-4
- Removing and installing the brake booster.............................................................................. 47-4.1
- Removing and installing the vacuum pump for the brake booster ........................................... 47-7
Repairing a front brake calliper, brake calliper FS-III .............................................................. 47-8
- A summary of components of the brake calliper FS-III ............................................................ 47-8
- Removing and installing pistons for the front brake calliper..................................................... 47-9
Repairing a front brake calliper, brake calliper FS-3 ............................................................... 47-10.1
- A summary of components of the brake calliper FS-3 ............................................................. 47-10.1
- Removing and installing pistons for the front brake calliper..................................................... 47-10.2
Repairing a rear brake calliper................................................................................................... 47-11
- A summary of components of the brake calliper ...................................................................... 47-11
- Removing and installing the piston for the front brake calliper ................................................ 47-12
A summary of components of the brake force regulator ........................................................ 47-15
Checking and adjusting the brake force regulator .................................................................. 47-16
- Setting values for the load-oriented brake force regulator ....................................................... 47-17
Ventilating the brake system on vehicles with and without ABS or ABS/EDL Mark 20
and Mark 60 ................................................................................................................................. 47-18
- Ventilating the brake system using a brake draining and ventilation device such
as ROMESS S15 for vehicles with Mark 20............................................................................. 47-20
- Ventilating the brake system without the use of a brake draining and ventilation device ........ 47-21
- Changing the brake fluid .......................................................................................................... 47-22
- Ventilating the brake system using a brake draining and ventilation device such a
s ROMESS S15 for vehicles with Mark 60............................................................................... 47-23
Tightness test of the master brake cylinder............................................................................. 47-24
A summary of components: brake booster/master brake cylinder for vehicles
with ABS/EDL/ESP Mark 20........................................................................................................ 47-26
- Removing and installing sender -1- for brake pressure -G201- and sender -2- for
brake pressure -G214-............................................................................................................. 47-28
- Removing and installing the master brake cylinder ................................................................. 47-30
- Checking the brake booster ..................................................................................................... 47-32
- Removing and installing the brake booster.............................................................................. 47-32
- Removing and installing the vacuum pump for the brake booster ........................................... 47-35
A summary of components: brake booster/master brake cylinder for vehicles
with ABS/EDL/TCS/ESP Mark 60................................................................................................ 47-36
- Removing and installing sender -1- for brake pressure -G201- ............................................... 47-37
- Removing and installing the master brake cylinder ................................................................. 47-37
- Checking the brake booster ..................................................................................................... 47-37
- Removing and installing the brake booster.............................................................................. 47-37
- Removing and installing vacuum pump for the brake -V192- .................................................. 47-38
- Checking vacuum pump for the brake -V192- ......................................................................... 47-39
48 The steering system Page
Steering column and steering wheel with airbag..................................................................... 48-1
- Checking the steering column for damage .............................................................................. 48-1
- Removing and installing the steering column .......................................................................... 48-2
- Removing and installing the ignition lock housing with the steering column mounted in place... 48-8.3