Skoda OCTAVIA Instruction manual
Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5130.50.20 E ition 11.99
5-Spee Manual Gearbox 02C
4 Wheel Drive
The Service Manual is intended only for use within the koda Organisation;
it is not permitted to pass it onto third persons.
© 1999 KODA AUTO a. s.
Printed in CR
Service
List of Supplements to
OCTAVIA Workshop Manual Edition: 08.02
5-Speed Manual earbox 02C 4 Wheel Drive
Replaces List of Supplements - Edition: 11.00
Supple- Edition Subject Article Number
ment
11.99 Basic Edition of Workshop Manual S00.5130.50.20
1 02.00 Self-Diagnosis S00.5130.51.20
2 11.00 Modifications to 1st ear Synchromesh S00.5130.52.20
3 08.02 Rear final drive S00.5130.53.20
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Contents ⇒ next page.
The Service Manual is intended only for use within the
Skoda Organisation; it is not permitted to pass it on to
third persons.
© 2002 KODA AUTO a. s.
Printed in CR
S00.5130.53.20
Edition 02.00
S00.5130.51.20
------------
1 ------------
OCTAVIA Service
Contents
00 Technical Data Page
Identification of gearbox ............................................................................................................. 00 1
- Code letters, component assignment, transmission ratios, capacities .................................... 00-2
Overview of power flow .............................................................................................................. 00 3
- Notes on brake and performance test and on towing vehicle .................................................. 00-4
General repair information ......................................................................................................... 00 5
01 Self Diagnosis/Electrical Test Page
Testing operation of Haldex coupling ....................................................................................... 01 1
Self diagnosis .............................................................................................................................. 01 2
- Fault finding with the vehicle s stem tester V.A.G 1552 at the Haldex coupling (guide) ....... 01-4
Electrical/electronic components and fitting locations ........................................................... 01 5
- Removing and installing 4WD control unit -J492- .................................................................... 01-7
- Removing and installing pump for Haldex coupling -V181- ..................................................... 01-8
Performing self diagnosis .......................................................................................................... 01 10
- Connecting vehicle s stem tester V.A.G 1552 and selecting functions .................................... 01-10
- Interrogating fault memor ....................................................................................................... 01-12
- Fault table ................................................................................................................................. 01-13
- Erasing fault memor ............................................................................................................... 01-15
- Ending output ........................................................................................................................... 01-15
- Final control diagnosis .............................................................................................................. 01-16
- Reading measured value block ................................................................................................ 01-18
Electrical test ............................................................................................................................... 01 21
- Performing electrical test .......................................................................................................... 01-22
30 Clutch Page
Servicing clutch mechanism ......................................................................................................5
Servicing clutch release ............................................................................................................. 5
Servicing clutch ........................................................................................................................... 5
34 Shift Mechanism/Housing Page
Servicing shift mechanism ......................................................................................................... 34 1
- Fitting location of shift mechanism ........................................................................................... 34-1
- I - Assembl overview - gearshift knob and cover .................................................................... 34-3
- II - Assembl overview - gearshift lever and shift housing ....................................................... 34-5
- III - Assembl overview - shift mechanism cables .................................................................... 34-8
- Removing and installing shift mechanism ................................................................................ 34-10
- Setting shift mechanism ........................................................................................................... 34-13
Removing and installing gearbox .............................................................................................. 34 16
Removing and installing bevel box ........................................................................................... 34 27
Inspecting gear oil in manual gearbox with bevel box ............................................................ 34 31
Disassembling and assembling gearbox .................................................................................. 34 32
- I - Removing and installing cover for gearbox housing and 5th gear ....................................... 34-33
- II - Removing and installing gearbox housing and shift mechanism ........................................ 34-34
- III - Removing and installing input shaft, output shaft (pinion shaft), differential
and shift forks ........................................................................................................................... 34-35
- Assembl sequence ................................................................................................................. 34-37
5⇒⇒
⇒⇒
⇒ 5 Speed Manual Gearbox 02J
Service OCTAVIA
Edition 02.00
S00.5130.51.20
------------
11 ------------
Servicing gearbox housing and clutch housing ...................................................................... 34 49
Disassembling and assembling shift mechanism at gearbox side ........................................ 34 53
Disassembling and assembling shift forks .............................................................................. 5
35 Gears/Shafts Page
Disassembling and assembling input shaft (drive pinion) ..................................................... 35 1
Setting input shaft ....................................................................................................................... 5
Disassembling and assembling output shaft (drive pinion) ................................................... 35 2
Setting output shaft .................................................................................................................... 5
Disassembling and assembling reverse idler shaft ................................................................. 5
39 Final Drive/Front and Rear Differential Page
Replacing seals for left flange shaft or right joint flange (gearbox installed) ....................... 39 1
-
-
Replacing seal for output flange of bevel box (bevel box removed) ..................................... 39 5
Disassembling and assembling differential ............................................................................. 39 6
Setting differential ....................................................................................................................... 5
Disassembling and assembling angle gear .............................................................................. 39 14
-
-
Replacing needle bearing (polygon bearing) for output shaft of right joint flange .............. 39 27
Setting shaft and head bevel gear (drive pinion set) ............................................................... 39 30
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Removing and installing cardan shaft ...................................................................................... 39 44
-
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Servicing cardan shaft ................................................................................................................ 39 53
Replacing seal for flange/cardan shaft at rear final drive (final drive removed) ................... 39 58
Replacing seals for flange shafts at rear final drive (final drive installed) ............................ 39 61
Replacing O rings in rear final drive ......................................................................................... 39 63
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Removing and installing rear final drive ................................................................................... 39 66
Inspecting gear oil in rear final drive ......................................................................................... 39 69
Inspecting oil level in Haldex coupling and changing oil ....................................................... 39 70
-
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-
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5⇒⇒
⇒⇒
⇒ 5 Speed Manual Gearbox 02J
OCTAVIA Technical Data 00
Edition 11.99
S00.5130.50.20
------------
00-1 -------------
Identification of gearbox
Assignment ⇒ page 00-2.
KLocation on gearbox
Code letters and date of manufacture (arrow 1)
Manual gearbox 02C 4 D (arrow 2)
KManual gearbox 02C 4WD arrow 2)
KCode letters and date of manufacture of gear-
box
Example: EAH 15 03 9
III I
Code letters Day Month Year (1999)
of manufacture
Additional data are related to production.
Note:
The code letters of the gearbox are also listed
in the data stickers of the vehicle.
OCTAVIA
00 Technical Data
Edition 11.00
S00.5130.52.20
Code letter, component assignment, transmission ratios, capacities
Manual gearbox 5-speed manual gearbox 02C x
Code letters EAG EWK1)
Manufactured from 05.99 08.00
to 07.00
Assignment Engine 1.9-ltr./66 kW DI 1.9-ltr./66 kW DI
ransmission ratios: Final drive 62 : 17 = 3.647 62 : 17 = 3.647
1st gear 34 : 9 = 3.778 34 : 9 = 3.778
2nd gear 33 : 16 = 2.063 33 : 16 = 2.063
3rd gear 34 : 26 = 1.308 34 : 26 = 1.308
4th gear 33 : 36 = 0.917 33 : 36 = 0.917
5th gear 33 : 46 = 0.717 33 : 46 = 0.717
Reverse 18 : 9 x 36 : 20 = 3.600 18 : 9 x 36 : 20 = 3.600
Speedo 13 : 22 = 0.591 13 : 22 = 0.591
Capacity 2.4 ltr.
Gear oil specification G50 SAE 75W90 (synthetic oil)
Gear oil change interval filled for life
Clutch control hydraulic
Clutch plate ∅219 mm MF2) 225 mm MF2)
Drive shaft flange ∅100 mm
Rear final drive assignment code letters END, EUN EUN
1) Gearbox with modified synchromesh for 1st gear
2) MF = wo-mass flywheel
Rear final drive 02D
Code letters END EUN
Manufactured from 05.99 10.99
to 09.99
Assignment Engine 1.9-ltr./66 kW DI
Ratio: Z2 : Z1 front/rear bevel gear 17 : 27 x 27 : 17 = 1.00
Quantity in final drive 1.0 ltr.
Gear oil specification G50 SAE 75W90 (synthetic oil)
Gear oil change interval filled for life
Quantity in Haldex clutch 0.42 ltr.
Change quantity in Haldex clutch 0.25 ltr.
Oil specification for Haldex clutch G 052 175 A1
Drive shaft flange ∅100 mm
Manual gearbox assignment code letters EAG EAG, EWK
------------
00-2 -------------
OCTAVIA Technical Data 00
Edition 11.00
S00.5130.52.20
Code letter, component assignment, transmission ratios, capacities
Manual gearbox 5-speed manual gearbox 02C x
Code letters ERW EWN1)
Manufactured from 04.00 08.00
to 07.00
Assignment Engine 2.0-ltr./85 kW 2.0-ltr./85 kW
Transmission ratios Final drive 64 15 = 4.267 64 15 = 4.267
1st gear 34 9 = 3.778 34 9 = 3.778
2nd gear 33 16 = 2.063 33 16 = 2.063
3rd gear 34 25 = 1.360 34 25 = 1.360
4th gear 35 34 = 1.029 35 34 = 1.029
5th gear 31 38 = 0.816 31 38 = 0.816
Reverse 18 9 x 36 20 = 3.600 18 9 x 36 20 = 3.600
Speedo 13 22 = 0.591 13 22 = 0.591
Capacity 2.4 ltr.
Gear oil specification G50 SAE 75W90 (synthetic oil)
Gear oil change interval filled for life
Clutch control hydraulic
Clutch plate ∅215 mm
Drive shaft flange ∅100 mm
Rear final drive assignment code letters EUL
1) Gearbox with modified synchromesh for 1st gear
Rear final drive 02D
Code letters EUL
Manufactured from 04.00
to
Assignment Engine 2.0-ltr./85 kW
Ratio Z2 Z1 front/rear bevel gear 17 27 x 27 17 = 1.00
Quantity in final drive 1.0 ltr.
Gear oil specification G50 SAE 75W90 (synthetic oil)
Gear oil change interval filled for life
Quantity in Haldex clutch 0.42 ltr.
Change quantity in Haldex clutch 0.25 ltr.
Oil specification for Haldex clutch G 052 175 A1
Drive shaft flange ∅100 mm
Manual gearbox assignment code letters ERW, EWN, FEX
------------
00-2.1 -------------
OCTAVIA
00 Technical Data
Edition 11.00
S00.5130.52.20
Code letter, component assignment, transmission ratios, capacities
Manual gearbox 5-speed manual gearbox 02C x
Code letters FEX1)
Manufactured from 0
.00
to
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Rear final drive 02D
Code letters EUL
Manufactured from 0
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00-2.2 -------------
OCTAVIA Technical Data 00
Edition 11.99
S00.5130.50.20
------------
00-
-------------
1
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Arrows point in direction of travel
T
/
I - 1st gear
II - 2nd gear
III - 3rd gear
IV - 4th gear
V - 5th gear
R - Reverse
A - Final drive
T - Speedo drive
1- Front bevel drive
2- Rear bevel drive
OCTAVIA
00 Technical Data
Edition 11.99
S00.5130.50.20
------------
-------------
Notes on brake and performance
test and on towing vehicle
Brake test on roller dynamometer
♦Use only dynamometers designed for 4WD
vehicles.
♦If a dynamometer for a 2WD vehicle is used,
1 to 2 brake tests can be performed ith the
ignition s itched on and the engine not run-
ning.
arning!
Run engine for about 5 seconds bet een the
brake test in order to build up adequate vacuum
in the brake system.
Performance test on roller dynamometer
♦Use only dynamometers designed for 4WD
vehicles.
♦On dynamometers designed for 2WD vehi-
cles, the front part of the cardan shaft must
first of all be removed. Pay attention to mark-
ing hen re-assembling.
OCTAVIA Technical Data 00
Edition 11.99
S00.5130.50.20
------------
00-
-------------
Scrupulous care and cleanliness, as well as
proper tools, are an essential requirement for
carrying out proper and successful gearbox re-
pairs. The generally usual basic rules of safety
also, of course, apply to repair work.
A number of generally applicable notes for indi-
vidual repair processes - which are otherwise
listed several times at various points in the work-
shop manual - are summari ed here. They ap-
ply to this workshop manual.
♦When installing, ensure the dowel sleeves
between engine and gearbox are correctly
located.
♦When installing bearing brackets as well as
waxed components, clean the contact sur-
faces. Contact surfaces must be free of wax
and grease.
♦If the manual gearbox, bevel box or the rear
final drive is replaced, pour in gear oil up to
lower edge of filler hole.
♦For capacities and specifications for manual
gearbox with bevel box, final drive, Haldex
coupling ⇒ page 00-2.
♦Thoroughly clean connecting surfaces and
apply sealant AMV 188 200 03.
♦Apply an even film of sealant - not too thick.
♦Replace O-rings.
♦Radial shaft seals:
KLightly oil at outer diameter, pack the space
between the sealing lips (arrow) with grease.
♦Inspect gear oil level in manual gearbox with
bevel box ⇒ page 34-31.
♦Inspect gear oil level in rear final drive
⇒ page 39-69.
♦Inspect oil level in Haldex coupling ⇒ page
39-70.
OCTAVIA
00 Technical Data
Edition 11.99
S00.5130.50.20
------------
-------------
♦Replace circlips.
♦Do not over-tension circlips.
♦Circlips must be installed in the base of the
groove.
K♦Replace roll pins.
Installation position: slot longitudinal to power
flow.
♦Slacken and tighten nuts and bolts for at-
taching covers and housings diagonally
across.
♦Do not twist particularly sensitive parts - such
as clutch pressure plates - and slacken and
tighten in stages diagonally across.
♦ightening torques apply to non-oiled nuts
and bolts.
♦Always replace self-locking nuts and bolts.
♦At all bolted connections, it is important to
ensure that contact surfaces as well as nuts
and bolts are waxed, if necessary, only after
being installed.
♦Install new tapered roller bearings as sup-
plied, and do not oil additionally.
♦Insert needle bearings in gearbox with gear
oil.
♦Always replace all the tapered roller bear-
ings fitted to a shaft. Use the same makes,
if possible!
♦Heat inner races to approx. 100 °C for in-
stalling.
♦Do not mix up the outer and inner races of
bearings of the same size; bearings are
matched.
♦Position needle bearings with the inscribed
side (larger metal thickness) facing the in-
sertion drift.
OCTAVIA Technical Data 00
Edition 11.99
S00.5130.50.20
------------
00-
-------------
♦Re-gauge shims at several points with a mi-
crometer. Different tolerances make it pos-
sible to exactly gauge the required shim thick-
ness.
♦Inspect for burrs or damage.
♦Install only shims which are in proper condi-
tion.
♦Do not mix up. Assign synchroni er rings to
the same gear when re-installing.
♦Inspect for wear, replace if necessary.
♦Insert with gear oil.
♦Clean and heat on a heating plate to approx.
100 °C before pressing on.
♦The temperature can be checked with the
temperature measuring instrument (e.g.
V.A.G 1558).
OCTAVIA
S00.5130.51.20
------------
01-1 -------------
Warning!
Keep area in front of the vehicle clear. Proceed with
appropriate care when conducting the test in or-
der to avoid any damage.
l
Notes:
The Haldex coupling locks as a result of the
driven front wheels and the stationary rear
wheels. This means that the rear wheels are
also driven.
The Haldex coupling is able to briefly absorb
the speed differences without locking only at
engine speeds which are just above idling speed
and when first gear is engaged. The vehicle is
not pushed out of the dynamometer.
OCTAVIA
01 Self-Diagnosis/Electrical Test
Edition 02.00
S00.5130.51.20
------------
01-2 -------------
Self-diagnosis
Function
The central component of the four-wheel drive
is the electronically-hydraulically controlled
Haldex coupling.
Advantages:
♦stepless distribution of force between front
and rear wheels
♦short response time of the Haldex coupling
♦individual adaptation of the four-wheel drive
to all driving situations
Overview of control units
A distinction is made between two types of con-
trol units for four-wheel drive -J4 2-.
♦Up to 0 . none of the control units has a
diagnostic capability. On such models, per-
form the electrical test in full when dealing
with complaints ⇒ page 01-21.
♦From 10. all of the control units have a
diagnostic capability. This new generation of
control units with modified software is rec-
ognizable only from the part number of the
control unit.
Assignment of control units
⇒Parts List
OCTAVIA Self-Diagnosis/Electrical Test 01
Edition 11.00
S00.5130.52.20
------------
01-3 -------------
Function of 4x4 control unit
In view of the interlinked control units with two
databus lines, always first of all interrogate the
contents of all the fault memories of the control
units fitted to the vehicle when beginning fault
finding.
This is done by selecting the Automatic test
sequence which is activated with the key func-
tion .
The aim here is to check whether any fault which
may have an effect on the Haldex clutch, is
stored.
Self-diagnosis relates to the electrical/electronic
part of the Haldex clutch, in other words only
faults which can be detected through the elec-
trical connection to the control unit (e.g. supply
voltage) are displayed.
The control unit detects faults when driving and
stores them in a fault memory ⇒ Fault table,
from page 1-13. This information is also re-
tained even if there is no battery voltage.
Faults which occur only temporarily (sporadi-
cally), are also shown in the display, with the
addition /SP. The cause of a sporadic fault may
be, for example, a loose contact or a brief open
circuit in the wiring. If, however, the fault no
longer occurs during 1 engine starts and start-
ing-off operations in the case of faults relating
to the databus system, or 5 engine starts and
starting-off operations in the case of other faults,
the fault is then deleted in the fault memory, with
the exception of the fault Control unit defec-
tive.
The stored faults can be read with the fault
reader V.A.S 5 51, V.A.G 1552 or with vehicle
system tester V.A.G 1551 ⇒ page 1-12.
After rectifying all the faults, it is then necessary
to erase the fault memory ⇒ page 1-15.
Notes:
♦The description which follows relates only to
the vehicle system tester V.A.G 1552 using
the up-to-date programme card.
♦If fault reader V.A. 5051 or V.A.G 1551 with
integrated printer is used, the readouts which
appear in the display may differ slightly.
OCTAVIA
01 Self-Diagnosis/Electrical Test
Edition 02.00
S00.5130.51.20
------------
-------------
Fault finding
t
system tester .A.G 1552 at
Haldex coupling (guide)
Connect vehicle system tester
V.A.G 1552
↓
Select address word 22 - 4WD electronics
↓
Interro ate fault memory
↓
Rectify fault accordin to fault table No fault reco nized
Read measured value block Perform final control dia no-
sis
Replace component 1. Conduct a road test at a speed of more than
20 km/h
2. Once a ain interro ate fault memory
3. If No fault reco nized is a ain displayed
Perform electrical test of Haldex couplin
Replace component
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
↓
- Connect vehicle system tester V.A.G 1552 and once a ain interro ate the fault memory.
- Erase fault memory.
- Conduct the road test at a speed of more than 20 km/h.
- After the road test, once a ain interro ate the fault memory. If after completin repairs and the
road test no fault reco nized appears in the display of the vehicle system tester V.A.G 1552, the
self-dia nosis is ended.
↓
↓
↓
↓
↓
↓
↓
↓
↓
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