CJZC Engine Cylinder Head

Octavia III 2013 ➤ , Octavia III 2014 ➤
1.2/63; 77 kW TSI engine - Edition 08.2013
15 – Cylinder head, valve gear

1 Cylinder head
1.1 Summary of components - cylinder

head
Caution
The camshafts must not be removed individually.

When carrying out repairs the camshaft housing must be com‐
pletely replaced.
1 - Cylinder head gasket

❑ replace ⇒ page 64
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❑ check fitting position:
Cylinder head part num‐
ber
2 - Fitting sleeve
❑ 2 pieces
3 - Cylinder head
❑ removing and installing
⇒ page 64
❑ check for distortion
⇒ page 62
4 - Dowel pins
5 - Gasket
❑ With oil strainer
❑ inserted into the cylinder
head
6 - Gasket
❑ replace
7 - Camshaft housing
⇒ page 67
8 - Screw
❑ Tightening torque and
tightening order
⇒ page 64
9 - Screw
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ replace unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ looseningwith
order
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ page 66
❑ Tightening torque and tightening order ⇒ page 62
1. Cylinder head 61
Cylinder head - tightening torque and tightening order
Note
Replace screws which have been tightened firmly to a torquing

angle.
– Tighten screws in steps in the given sequence:

Stage Screws Tightening torque/torquing angle
1. -1 … 10- 40 Nm
2. -1 … 10- 90° (torque a further 90° (1/4 turn)
Checking cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
500 mm knife-edge straightedge - VAS 6075- and feeler
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gauge.
• Maximum permitted distortion: 0.05 mm.
1.2 Summary of components - camshaft housing
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
62 Rep. gr.15 - Cylinder head, valve gear

1 - Fit pin
2 - Gasket
❑ With oil strainer
❑ inserted into the cylinder
head
3 - Sealing ring
❑ For inlet camshaft
4 - Sealing ring
❑ For exhaust camshaft,
belt pulley side
5 - Camshaft housing
⇒ page 67
6 - Screw
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tightening order
⇒ page 64
7 - O-ring
❑ replace
8 - Inlet camshaft control valve
1 - N205-
⇒ page 105
9 - 8 Nm
10 - Gasket
❑ for cap
11 - Screw cap
12 - O-ring
❑ replace
13 - Hall sender - G40-
❑ removing and installing ⇒ page 250
14 - 8 Nm
15 - Sealing ring
❑ For exhaust camshaft, gearbox side
16 - Toothed belt pulley
❑ For coolant pump
❑ removing and installing ⇒ page 142
17 - Screw
❑ Tightening torque ⇒ page 136
18 - 8 Nm
19 - Screw cap
20 - O-ring
❑ replace Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
1. Cylinder head 63
21 - Gasket
❑ replace
Camshaft housing - tightening torque and tightening order
Note
Replace screws which have been tightened firmly to a torquing

angle.
– Tighten screws in steps in the given sequence:

Stage Screws Tightening torque/torquing angle
1. -1 … 15- 10 Nm
1.3 Removing and installing cylinder head
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Removing
Note
Fit all heat protection sleeves on again in the same place when
installing.
– Remove the camshaft housing ⇒ page 67 .

– Removing the intake manifold ⇒ page 214 .
– Disconnect electrical plug connections:
1- On the oil pressure switch for reduced oil pressure - F378-
2- On the fuel pressure sender - G247-
3- on the injection valves -N30- to -N33-
– Unscrew screw -2- and remove screw clamp.

– Unscrew screw -1- and nuts -arrows- and strap up catalytic
converter.

– Release screws -1- and remove heat shield for right drive
shaft, if present.
– Screw out the screws -arrows-, remove oil feed line -1- and oil
return pipe -2-.
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1 - for coolant temperature sender - G62-
2 - For charge pressure regulator - V465-
– Unscrew screw -1- at the engine support.
1. Cylinder head 65
– Slacken the screws for the cylinder head in the sequence

-1…10- and release them.
– Remove cylinder head and place it on a clean base (foam).
Install
Caution
Risk of damaging sealing surfaces.

♦ Carefully remove residual sealant from the cylinder head
and cylinder block.
♦ Make sure this does not cause any extended scoring or
scratching.
There is a risk of damage to the cylinder block.
♦ There must be no oil or coolant in the blind holes for the
cylinder head bolts in the cylinder block.
There is a risk of leakage on the cylinder head gasket.
♦ Carefully remove sanding and grinding residues.
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♦ Remove the new cylinder head gasket from its wrapping
immediately before fitting.
♦ To prevent the silicon layer and the area of the bead from
being damaged, handle the gasket with the utmost care.
Note
♦ Replace screws which have been tightened firmly
unless to abytorquing
authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
angle. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Replace self-locking nuts, gasket rings, gaskets and O-rings.

♦ If a replacement cylinder head must be installed, the contact
surfaces between hydraulic balancing elements, roller rocker
fingers and camshaft slideways must be oiled before the cam‐
shaft housing is installed.
♦ Secure all hose connections with hose clamps which comply
with the series design ⇒ Electronic Catalogue of Original
Parts“ETKA.”
♦ When the cylinder head or the cylinder head gasket is re‐
placed, all the coolant and engine oil must be replaced.

– Fit on cylinder head gasket -1-.

♦ Pay attention to centring pins in cylinder block -arrows-.
♦ Check installation position of the cylinder head gasket, identi‐
fication: Part number must be legible from the inlet side.
– If the crankshaft has been turned in the meantime: Put piston
of 1st. relevant cylinder at top dead centre. Turn the crank
shaft back again slightly.
– Insert the cylinder head.
– Insert cylinder head bolts and tighten hand-tight.
– Tighten cylinder head bolts ⇒ page 62 .
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.
Continued installation is carried out in the reverse order. When

installing, note the following:
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– Install camshaft housing ⇒ page 67 .
– Installing the intake manifold ⇒ page 214 .
– Change engine oil ⇒ Maintenance ; Booklet Octavia III .
– Replace coolant ⇒ page 129 .
Tightening torques
♦ Engine support bracket ⇒ page 27
♦ Cylinder head ⇒ page 61
♦ Exhaust gas turbocharger ⇒ page 195
♦ Injection system ⇒ page 208
♦ Catalytic converter ⇒ page 244
♦ Drive shaft screening ⇒ Chassis; Rep. gr. 40
1.4 Removing and installing camshaft hous‐

ing
Removing
– Remove coolant pump ⇒ page 139 .
– Remove air filter housing ⇒ page 212 .
– Removing ignition coils ⇒ page 249 .
– Remove the toothed belt from the camshafts ⇒ page 78
– Remove high pressure pipe -3- ⇒ page 233 .
1. Cylinder head 67
– Separate electrical plug connection -1-.

– Loosen hose clamp -2- and disconnect hose.
– Separate electrical plug connection -2-.
– Release screws -arrows- and remove connection piece -1-.
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– Loosen hose clamp -2- and remove coolant hose.
– Unscrew -arrows- screws and swivel coolant lines -1- to the
right side.
– Release screws -arrows- and remove mount with heat shield

-1-.

– Disconnect electrical plug connections -arrow- at the charge

pressure sender - G42- / intake temperature sender - G71- .

2 - For valve 1 for camshaft control - N205- .
4 - For Hall sender - G40- .
– Unscrew screw -3- and expose the wiring loom and lay it to
the left-hand side.
– Pull out oil dipstick -1-.
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– Loosen the screws for the camshaft housing in the sequence
-15…1- and unscrew them.
– Carefully unscrew the camshaft housing and remove from the
bonding.
– When installing again, mark the assignment of the roller rocker
finger and the balancing elements.
– Remove the roller rocker finger together with the balancing
elements and lay aside on a clean surface.
Install
Note
♦ Replace screws which have been tightened firmly to a torquing

angle.
♦ Replace gasket with oil strainer.
– “Check TDC” position of camshaft and crankshaft:
• Attach camshaft clamp -T10494- to camshaft housing using

screw -arrow-.
Caution
Risk of damaging the valve gear.

♦ When turning, the camshafts must not be moved axially.
69
1. Cylinder head
• Fixing screw - T10340- turned up to the stop in the cylinder

block and tightened to 30 Nm.
• Crankshaft in engine direction of rotation applied to the fixing
screw - T10340- = “TDC” position.
– Check that all roller rocker fingers are lying flat correctly on the
end of the valve stem and are clipped into the respective bal‐
ancing element.
– Insert gasket with oil strainer -2- into the cylinder head -1-.
– Fit gasket onto dowel pins -arrows-.
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– Screw 2 threaded bolts -Pos. 2, 4-, for example -T10288/4- ,

into the cylinder head.
– Carefully place camshaft housing -3- vertically from above on‐
to the threaded bolts in the cylinder head.
Note
Make sure that the camshaft housing does not tilt.
– Tighten camshaft housing screws ⇒ page 64 .

Installation is carried out in the reverse order. When installing,
note the following:
– Install high pressure pipe ⇒ page 233 .
– install (set the timing) ⇒ page 78 .
– Install ignition coils ⇒ page 249 .
– Install coolant pump ⇒ page 139 .
– Electrical connections and proper routing ⇒ Current flow dia‐
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grams, Electrical fault finding and Fitting locations.
Caution
Risk of damaging valves and piston crowns after work on the

valve gear.
♦ To ensure that no valve is set during starting, turn the en‐
gine carefully by at least 2 turns.
Tightening torques
♦ Air filter ⇒ page 211
1.5 Checking compression

Special tools and workshop equipment required
♦ Spark plug wrench , e.g. -3122 B-
♦ Compression tester - V.A.G 1763-
Work procedure
• Engine oil temperature at least 30 ℃.
• Battery voltage at least 12.5 V.
– Remove fuse for fuel pump control unit from the fuse holder.
Fuse assignment ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
Note
Removing fuse interrupts the voltage supply of the fuel pump

control unit.
– Start engine and allow to run until the engine has cut out.
– Switch off ignition.
1. Cylinder head 71
– Loosen hose clamps -1- and -2- and remove air guide pipes.
– Disconnect plug -2- and remove screw -1-.

– Pull out ignition coils at power output stage.
– Unscrew spark plugs with spark plug wrench , e. g., -3122 B- .
– Check the compression pressure using the compression test‐
er - V.A.G 1763- ; handling, ⇒ Operating Manual .
– A 2nd. mechanic depresses the accelerator pedal fully and at
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the same time actuates the starter until the tester shows no
further pressure rise.
– Repeat the procedure for each cylinder.
Compression readings
New part 1.0 ... 1.5 MPa
(10.0…15.0 bar)
Wear limit 0.7 MPa
(7.0 bar)
Maximum difference between cylinders 0.3 MPa
(3.0 bar)
Assembling
Assembling is performed in the reverse order, while paying at‐
tention to the following:
– Install spark plugs, tightening torque 22 Nm.
– Install ignition coils at power output stage ⇒ page 249 .
Because the electrical plug connections were disconnected and
the engine started, errors are stored in the engine control unit:
– Delete fault memory and create readiness code ⇒ Vehicle
diagnostic tester.

2 Toothed belt drive
2.1 Summary of components - toothed belt guard
1 - Bottom toothed belt guard

2 - 8 Nm
3 - Engine support bracket
tightening order
⇒ page 27
4 - Screw
tightening order
⇒ page 27
5 - Top toothed belt guard
6 - 8 Nm
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2. Toothed belt drive 73

2.2 Summary of components - toothed belt
1 - Toothed belt
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ removing ⇒ page 87
❑ install (set the timing)
⇒ page 83
2 - 25 Nm
❑ When setting the tight‐
ening torque on the tor‐
que wrench - VAS 6583-
the actual dimension
specified on the tool in‐
sert - T10500- must be
put into the torque
wrench!
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3 - Tensioning roller
❑ for removing and instal‐
ling, remove engine
support ⇒ page 38
4 - 50 Nm + torque a further 90°
(1/4 turn)
❑ replace
5 - Toothed belt pulley, ex‐
haust camshaft
⇒ page 78
6 - Toothed belt pulley, inlet
camshaft
❑ With camshaft control
❑ Removing andProtected
installing
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
camshaft control with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ page 100
7 - Guide sleeve
8 - 50 Nm + torque a further 135° (3/4 turn)
❑ replace
9 - O-ring
❑ replace
10 - Screw plug, 20 Nm
11 - Guide pulley, 45 Nm
12 - Crankshaft - toothed belt sprocket
❑ there must not be any oil present on the contact surface between the toothed belt sprocket and the
crankshaft
❑ can be installed only in one position

Unscrew locking screw “TDC” bore at the cylinder block - tight‐

ening torque
Note
Replace the O-ring if it is damaged.
– Tighten bolts -arrows- to 30 Nm.
2.3 Checking valve timing

♦ Fixing screw - T10340-
♦ Camshaft clamp - T10494-
Work procedure
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– Loosen hose clamps -1, 2- and remove air guide pipe.
– Expose air guide hoses at the air guide pipe.
– Disconnect plug connection -1-.

– Unlock catches -arrows- and remove air guide pipe.

– Press release buttons and remove hose -1- to the activated

charcoal filter.
– Unscrew screws -arrows- and remove hose for crankcase
ventilation.
– Expose wiring loom -arrows-.

– Unscrew screws -1, 3- and remove toothed belt guard -2- for
coolant pump toothed belt.
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– Release screws -arrows- and remove cap -1-.
– Drain coolant ⇒ page 129 .
– Unscrew screws -A...D- and push thermostat cover -1- to the
side.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .

Turn crankshaft as follows onto “TDC”:

– Unscrew locking screw “TDC” bore at the cylinder block.
– Turn the fixing screw - T10340- up to the stop in the cylinder
block and tighten to 30 Nm.
– Turn the crankshaft in direction of rotation of engine to the
stop.
• The crankshaft cheek must now be resting on the fixing screw.
Note
The crankshaft is only locked in direction of rotation of engine

using the fixing screw - T10340- .
Caution
Risk of engine damage.

If the fixing screw - T10340- cannot be screwed in up to the
stop, the crankshaft is not in the correct position.
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In this case, proceed as follows:
♦ Unscrew the fixing screw.
♦ Turn crankshaft 90° (1/4 turn) in direction of rotation of en‐
gine.
♦ Turn the fixing screw - T10340- up to the stop in the cyl‐
inder block and tighten to 30 Nm.
♦ Turn the crankshaft further in direction of rotation of engine
to the stop.
• On both camshafts the asymmetrically arranged grooves

-arrows- on the gearbox side must now be at the top, as shown
in the illustration.
• On the exhaust camshaft -A-, the grooves -top arrows- are
accessible through the recesses in the coolant pump driving
wheel.
• On the inlet camshaft -E- the grooves -bottom arrow- are
above the camshaft centre.
If the camshafts are not as described:
– Remove fixing screw - T10340- and turn crankshaft another
turn, set back to “TDC”.
Note
♦ The camshaft clamp - T10494- must slide into position easily.

♦ The camshaft clamp must not be positioned using any kind of
hammer.
If the camshafts are as described:

– Insert camshaft clamp -T10494- to stop into camshafts and

tighten bolt -arrow- by hand.
If it is not possible to insert the camshaft clamp -T10494- , the
timing is NOK:
– Set timing, remove the toothed belt from the camshaft
⇒ page 78 .
If it is possible to insert the camshaft clamp -T10494- , the timing
is OK:
– Valve timing is OK.
Caution
There is a risk of destruction of the engine.

♦ To complete the work, check to ensure that the fixing
screw - T10340- and camshaft clamp -T10494- have been
removed.
Installation is performed in a similar way in the reverse order. Pay
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attention to the following points:
Note
♦ Replace screws which have been tightened firmly
with respect to theto a torquing
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
angle.
♦ Renew O-ring of locking screw if damaged.
Tightening torques
♦ Toothed belt guard ⇒ page 73
♦ Summary of components - toothed belt ⇒ page 74
♦ Locking screw for bore in the cylinder block ⇒ page 75
♦ Camshaft housing ⇒ page 62
♦ Coolant pump ⇒ page 136
♦ Charge-air system ⇒ page 202
♦ Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .
2.4 Remove the toothed belt from the cam‐

shaft
♦ Counterholder - T10172- with adapters -T10172/1- and -
T10172/2-
♦ Counterholder - T10475-
♦ Key - T10499-
♦ Insertion tool - T10500-
♦ Assembly tool - T10487-

Work procedure

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– Press release buttons, pull off hose -1-.

ventilation.




side.
– Remove noise insulation ⇒ Body; Rep. gr. 66 .
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– Turn crankshaft up to the stop in direction of rotation of engine.
Note

Caution

♦ Turn crankshaft 90° in direction of rotation of engine.
to the stop.


wheel.
Note
The camshafts have one symmetrically and one asymmetrically

arranged pair of grooves. In the “TDC” position the asymmetrically
arranged pair of grooves must by above the imaginary horizontal
centre line.

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Note
♦ The camshaft clamp -T10494- must be inserted easily.

hammer.
If camshaft clamp - T10494- cannot be installed:
Caution
To prevent damage to the belt, do not use sharp-edged tools!
– Using the assembly tool - T10487- into-direction
with respect ofofarrow-
the correctness press
information in this document. Copyright by ŠKODA AUTO A. S.�
on the toothed belt.

– While doing so, insert camshaft control -T10494- to stop into

camshafts and tighten screw -arrow- hand-tight.
– Expose vacuum hose on the holder -3-.
– Release screw -2-.

– Loosen clips -arrows- and remove toothed belt guard -1- up‐
wards.
Caution
Risk of damaging the camshaft.
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♦ Do not use the camshaft fixer/locator - T10494- as a coun‐
terholder.
– Unscrew locking screw -1- on the camshaft sprocket fitting

position. Use counterholder - T10172- with adapter -
T10172/1- to do this.
– Loosen screws -1, 2- by approximately one turn. Use coun‐

terholder - T10172- with adapters -T10172/2- and -T10172/1-
to do this.

– Release screw -1- using insertion tool - T10500- .

– Slacken the tensioning pulley at the eccentric -2- using the
wrench - T10499- .
– Remove the toothed belt from the camshaft sprockets.
Installing (set the timing)
Note

angle.
• Attach camshaft clamp -T10494- to camshaft housing.
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Caution
Risk of damaging the camshafts.

♦ Do not use the camshaft clamp -T10494- as a counter‐
holder.

screw - T10340- = “TDC” position. unless
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Replace screws -1, 2- and insert them loosely.

• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not tilt.

• Sheet peg -arrow- of the tensioning pulley must engage in the

cast iron recess of the cylinder head.
Observe sequence when fitting the toothed belt.
– Pull toothed belt upwards, then fit the tensioning pulley -2- and
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camshaft sprockets -3- and -4- onto the guide roller -1-.
– Rotate the eccentric -2- of the tensioning pulley with the

wrench - T10499- in -direction of arrow- until the adjustment
pointer -3- is located approx. 10 mm to the right from the ad‐
justment window.
– Push eccentric so far back that the adjustment pointer is posi‐
tioned exactly in the adjustment window.
Caution
The torque wrench - VAS 6583- must be used for tightening!

When setting the tightening torque on the torque wrench - VAS
6583- the actual dimension specified on the tool insert -
T10500- must be put into the torque wrench!
– Keep eccentric in this position and tighten screw -1- to 25 Nm.

Use tool insert - T10500- with torque wrench - VAS 6583- to
do this ⇒ page 74 .
withNote
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
If the engine continued to turn or has run, there may be slight

deviations of the adjustment pointer -3- setting in the adjustment
window. This has no influence on the toothed belt tensioning.

– Initially tighten screws -1, 2- to 50 Nm. To do so, use counter‐

holder - T10172- with adapters -T10172/1- and -T10172/2- .
– Unscrew fixing screw - T10340- .
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– Unscrew bolt -arrow- and remove camshaft clamp -T10494- .

Test timing:
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the crankshaft further in direction of rotation of engine to
the stop.
Note

Note

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hammer.
– Insert camshaft control -T10494- to stop into camshafts and

tighten screw -arrow- hand-tight.
timing is NOK:
– Repeat control time settings.
If it is possible to insert the camshaft clamp -T10494- , the timing
is OK:

– Tighten screws -1, 2- to the end stop tightening torque

⇒ page 74 . To do so, use counterholder - T10172- with adapt‐
ers -T10172/1- and -T10172/2- .
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– Tighten locking screw -1- to the 20 Nm. To do so use coun‐
terholder - T10172- with adapter -T10172/1- .
Caution

♦ To complete the work, checkProtected
to ensure that the
by copyright. fixing
Copying for private or commercial purposes, in part or in whole, is not permitted
screw - T10340- and camshaft clamp
unless -T10494-
authorised by ŠKODA have
AUTObeen
A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
removed. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Further assembling occurs in reverse order.

Tightening torques
♦ Toothed belt guard ⇒ page 73
♦ Summary of components - toothed belt ⇒ page 74
♦ Locking screw for bore in the cylinder block ⇒ page 75
♦ Camshaft housing ⇒ page 62
♦ Coolant pump ⇒ page 136
♦ Charge-air system ⇒ page 202
♦ Noise insulation ⇒ Body work; Rep. gr. 66
2.5 Removing and installing toothed belt

♦ Counterholder - T10172- with adapters -T10172/1- and -
T10172/2-

♦ Counterholder - T10475-
♦ Key - T10499-
♦ Insertion tool - T10500-
Removing
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– Press release buttons and remove hose -1- to the activated

charcoal filter.
ventilation.



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side.
– Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .


– Turn crankshaft up to the stop in direction of rotation of engine.
Note

Caution

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♦ Turn crankshaft 90° in direction of rotation of engine.
to the stop.


wheel.
Note
The camshafts have one symmetrically and one asymmetrically

arranged pair of grooves. In the “TDC” position the asymmetrically
arranged pair of grooves must by above the imaginary horizontal
centre line.

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Note

hammer.
If camshaft clamp - T10494- cannot be installed:

Caution
To prevent damage to the belt, do not use sharp-edged tools!
– Using the assembly tool - T10487- in -direction of arrow- press

on the toothed belt.

– While doing so, insert camshaft control -T10494- to stop into

camshafts and tighten screw -arrow- hand-tight.
– Remove crankshaft-belt pulley ⇒ page 37 .
– Release screws -arrows- and remove bottom toothed belt

guard.
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– Expose vacuum hose on the holder -3-.
– Release screw -2-.
– Loosen clips -arrows- and remove toothed belt guard -1- up‐
wards.
Caution
There is a risk of damage to the camshaft.

♦ Do not use the camshaft fixer/locator - T10494- as a coun‐
terholder.
– Unscrew locking screw -1- on the camshaft sprocket fitting

position. Use counterholder - T10172- with adapters -
T10172/1- to do so.

– Loosen screws -1, 2- by approximately one turn. To do so, use

counterholder - T10172- with adapters -T10172/2- and -
T10172/1- .
– Release screw -1- using insertion tool - T10500- .

– Slacken the tensioning pulley at the eccentric -2- using the
wrench - T10499- .
Caution
There is a risk of destruction through reversing the rotation di‐
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rection of an already used toothed belt.
♦ Mark the direction of rotation with chalk or a felt-tip pen for
the re-installation before removing the toothed belt pulley.
– Remove timing belt.
– Remove crankshaft toothed belt pulley -1- -arrow-.

Installing (set the timing)
Note

angle.
• Camshaft clamp - T10494- attached to camshaft housing.
Caution
Risk of damaging the camshafts.

♦ Do not use the camshaft clamp -T10494- asauthorised
unless a counter‐
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
holder. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�


screw - T10340- = “TDC” position.
– Replace screws -1, 2- and insert them loosely.

• It must still be possible to turn the camshaft sprockets on the
camshafts, however they must not tilt.
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• The sheet peg -arrow- of the tensioning pulley must engage
in the cast iron recess of the cylinder head.
– Fit crankshaft toothed
with respect to thebelt pulley
correctness onto thein crankshaft.
of information this document. Copyright by ŠKODA AUTO A. S.�
• The contact surface between the V-ribbed belt pulley and the
crankshaft toothed belt pulley must be free of oil and grease.
• Milled surface -arrow- on the crankshaft toothed belt must be
positioned on the crankshaft stub.
Observe sequence when fitting the toothed belt.

– Pull toothed belt upwards, then fit the tensioning pulley -2- and
camshaft sprockets -3- and -4- onto the guide roller -1-.
– Rotate the eccentric -2- of the tensioning pulley with the

wrench -T10499- in -direction of arrow- until the adjustment
pointer -3- is located approx. 10 mm to the right from the ad‐
justment window.
– Push eccentric so far back that the adjustment pointer is posi‐
tioned exactly in the adjustment window.
Caution
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The torque wrench - VAS 6583- must be used for tightening!
When setting the tightening torque on the torque wrench - VAS
6583- the actual
unless dimension
authorised by ŠKODA AUTO specified
A. S. ŠKODAon AUTO the
A. S.tool insert
does not - or accept any liability
guarantee
T10500- must be put
with respect into
to the the torque
correctness wrench!
of information in this document. Copyright by ŠKODA AUTO A. S.�
– Keep eccentric in this position and tighten screw -1- to 25 Nm.

Use tool insert - T10500- with torque wrench - VAS 6583- to
do this ⇒ page 74 .
Note
If the engine continued to turn or has run, there may be slight

deviations of the adjustment pointer -3- setting in the adjustment
window. This has no influence on the toothed belt tensioning.
– Initially tighten screws -1, 2- to 50 Nm. To do so, use counter‐

holder - T10172- with adapters -T10172/2- and -T10172/1- .

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– Install the bottom toothed belt guard -arrows-.
– Install crankshaft belt pulley ⇒ page 37 .

Test timing:
– Turn the crankshaft in direction of rotation of engine by 2 turns.
– Turn the crankshaft further in direction of rotation of engine to
the stop.
Note

Note

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hammer.
– Insert camshaft control -T10494- to stop into camshafts and

tighten screw -arrow- hand-tight.
timing is NOK:
– Repeat control time settings.
If it is possible to insert the camshaft
unless authorised byclamp -T10494-
ŠKODA AUTO , theAUTO
A. S. ŠKODA timing
A. S. does not guarantee or accept any liability
is OK: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Tighten screws -1, 2- to the end stop tightening torque

⇒ page 74 . To do so, use counterholder - T10172- with adapt‐
ers -T10172/2- and -T10172/1- .
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– Tighten locking screw -1- to the 20 Nm. To do so use coun‐
terholder - T10172- with adapter -T10172/1- .
Caution

♦ To complete the work, check to ensure that the fixing
screw - T10340- and camshaft clamp -T10494- have been
removed.
Further assembling occurs in reverse order.

Tightening torques
• V-ribbed belt - Summary of components ⇒ page 33
• Toothed belt guard ⇒ page 73
• Summary of components - toothed belt ⇒ page 74
• Locking screw for bore in the cylinder block ⇒ page 75
• Camshaft housing ⇒ page 62
• Exhaust gas turbocharger ⇒ page 195

• Coolant pump ⇒ page 136
• Charge-air system ⇒ page 202
• Remove the sound dampening system ⇒ Body Work; Rep.
gr. 66 .

3 Valve gear
3.1 Assembly overview - valve gear
1 - Inlet valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ Valve dimensions
⇒ page 111
❑ inspecting valve guides
⇒ page 111
2 - Exhaust valve
❑ do not rework, only
grinding in is permissi‐
ble
❑ Valve dimensions
cardiagn.com
⇒ page 111
❑ inspecting valve guides
⇒ page 111
3 - Cylinder head
4 - Valve stem seal
5 - Valve spring
❑ Fitting position
⇒ page 100
6 - Valve spring plate
7 - Valve collets
8 - Roller rocker finger
❑ removingProtected
and installing
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
⇒ page 67 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ mark the fitting position
for re-installation
❑ inspect roller bearings
for smooth operation
❑ oil the contact surfaces
before installing
9 - Locking clip
❑ for hydraulic balancing element
10 - Hydraulic balancing element
❑ Do not interchange
❑ Oil contact surface
3. Valve gear 99
Fitting position of the valve spring

• The small ∅ -a- points to the valve spring plate.
• The small ∅ -b- points to the cylinder head.
3.2 Measuring axial play of camshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Checking camshaft axial clearance
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– Secure dial gauge - VAS 6079- with the universal dial gauge
bracket - VW 387- to the camshaft housing, as shown in the
illustration.
– Press the camshaft by hand against the dial gauge.
– Position dial gauge to “0”.
– Press the camshaft off the dial gauge and read the value:
Axial clearance:
• Wear limit 0.25 mm.
3.3 Removing and installing camshaft con‐

trol
Removing
– Remove the toothed belt from the camshafts ⇒ page 78 .
Install
Installation is carried out in the reverse order.
Tightening torques
• V-ribbed belt ⇒ page 33 .
• Toothed belt guard ⇒ page 73 .
• Parts of cooling system on the side next the engine
⇒ page 149 .
• Check assembly bracket setting ⇒ page 30 .
3.4 Removing and installing camshaft oil

seal
3.4.1 Removing and installing the camshaft

sealing ring on the belt pulley side
Special tools
Protected and workshop
by copyright. equipment
Copying for private required
or commercial purposes, in part or in whole, is not permitted


♦ Puller hooks - T20143/1-
Removing
– Remove the toothed belt from the camshaft sprockets
⇒ page 78 .
– Unscrew screw -1- and remove camshaft sprocket.
– Remove seal -1- using extractor hook -T20143/1- .
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Install
Note
Do not oil new sealing ring.
– Push sealing ring -1- over the receiver tube -T10478/3- onto
the guide bushing -T10478/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
– Disconnect receiver tube and guide bushing.
3. Valve gear 101

– Place guide bushing -T10478/2- with sealing ring -1- onto the
camshaft.
– Pull sealing ring in to the stop using the thrust piece -T10478/1-
and the camshaft sprocket screw -1-.
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sealing ring for the exhaust camshaft
♦ Assembly device - T10478- with screw -T10478/5-
Removing
– Remove the toothed belt from the camshafts ⇒ page 78 .
– Unscrew screw -2- and remove camshaft sprocket.

– Remove seal -1- using extractor hook -T20143/1- .

Install
Note
the guide bushing -T10478/2- .
• Fitting position: Closed side of sealing ring points to the re‐
ceiver tube.
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– Position guide bushing -T10478/2- with seal -1- on camshaft.
– Pull in -T10478/1- with the screw -T10478/5- to the stop.

3. Valve gear 103


sealing ring for exhaust camshaft on the
gearbox side
Removing
– Remove toothed belt pulley for coolant pump ⇒ page 142 .
– Carefully fit extractor hook -T20143/1- between camshaft and
seal -1-.
– Lever out sealing ring.
Install
Note
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the guide bushing
Protected -T10479/2-
by copyright. . or commercial purposes, in part or in whole, is not permitted
Copying for private
• Fitting position: Closed
with respect to side ofofinformation
the correctness sealingin ring pointsCopyright
this document. to the byre‐
ŠKODA AUTO A. S.�
ceiver tube.
– Fit guide bushing -T10479/2- with sealing ring -2- centrally on‐
to the camshaft.
– Fix guide bushing with screw -1- for coolant pump driving
wheel onto the camshaft.
– Push sealing ring onto camshaft, unscrew guide bushing.

– Pull sealing ring -2- into the stop using the thrust piece -
T10479/1- and the screw -1- for coolant pump driving wheel.
– Install toothed belt pulley for coolant pump ⇒ page 142 .
3.5 Removing and installing camshaft con‐

trol valve 1 - N205-
Removing
– Unscrew screw -2- and remove camshaft control valve 1 -
N205- .
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Install
Installation is carried out in the reverse order. When installing,
observe the following:
Note
Renew O-ring.
Tightening torques
Component Nm
Screw for camshaft control valve 1 8 Nm
3.6 Removing and installing valve stem seal
3.6.1 Removing and installing valve stem seal

with cylinder head installed
♦ Spark plug wrench , e.g. -3122 B-
♦ Disassembly and assembly device for valve collets - VAS
5161- with set - VAS 5161/32-32-
♦ Adapter - T40012-
♦ Valve stem seal fitting tool - MP1-233 (3365)-
♦ Valve shaft pliers , e.g. -VAS 6770-
Work procedure
– Release spark plugs with spark plug wrench , e.g. -3122 B- .
3. Valve gear 105


– Put the piston of the relevant cylinder at “bottom dead centre”.
– Place guide plate -VAS 5161/32-1- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Screw the adapter - T40012- with sealing ring into the relevant
spark plug thread by hand.
– Connect the adapter to the compressed air with a commer‐
cially available intermediate piece and apply constant pres‐
sure.
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• Minimum pressure: 0.6 MPa (6 bar)
– Insert the impact drift -VAS 5161/3A- into the guide plate and
knock off the tightly fitted valve collets using a plastic hammer.
– Screw the detent part -VAS 5161/6- with the interlocking

Protected by copyright.fork
Copying for private or commercial purposes, in part or in whole, is not permitted
-VAS 5161/5- into the guide plate. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Insert assembly cartridge -VAS 5161/32-2- with sleeve moun‐
ted -VAS 5161/32-3- into the guide plate.
– Hook the pressure fork -VAS 5161/2- onto the detent part and
push the assembly cartridge downwards.
– Turn simultaneously the knurled screw of the assembly car‐
tridge to the right, until the tips click into the valve collets.
– Rotate the knurled screw to the left and to the right, by doing
so the valve collets are pressed apart and are installed in the
assembly cartridge.
– Release the pressure fork.
– Remove assembly cartridge.
– Unscrew guide plate and turn it to the side.
• T compressed air hose remains connected.
– Remove the valve spring with the valve spring retainer.

– Pull off valve stem seal with valve shaft pliers , for example -
VAS 6770- .
Caution
There is a risk of damage when installing the valve stem seals.
– Fit the plastic bushing -A-, which is attached to the new valve
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stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve.
If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device.
• The large diameter of the valve collets points to the top.
– Press the assembly cartridgeProtected
from the top onto
by copyright. the
Copying for insertion
private or commercial purposes, in part or in whole, is not permitted
device and lift up the valve collets.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ page 100 .
3. Valve gear 107

– Screw the guide plate -VAS 5161/32-1- back onto the cylinder
head.
– Insert assembly cartridge -VAS 5161/32-2- with sleeve -VAS
5161/32-3- mounted into the guide plate.
– Press down the pressure fork and turn the knurled screw to
the left and to the right while pulling it upwards, by doing so
the valve collets are inserted.
– Release the pressure fork on tightened knurled screw.
– Repeat the procedure for each valve.
Assembling
Assembly is carried out in the reverse order. When installing, ob‐
serve the following.
– Install spark plugs ⇒ Maintenance ; Booklet Octavia III .
– Install camshaft housing ⇒ page 67 .
3.6.2 Removing and installing valve stem seal

with cylinder head removed
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♦ Disassembly and assembly device for valve collets - VAS
5161- with set - VAS 5161/32-32-
♦ Engine and gearbox support - VAS 6095-
♦ Cylinder head tensioning device - VAS 6419-
♦ Valve shaft pliers , e.g. -VAS 6770-
♦ Valve stem seal fitting tool - 3365-
Work procedure
– Remove cylinder head ⇒ page 64 .
– Insert the cylinder head tensioning device - VAS 6419- into the
engine and gearbox jack - VAS 6095- .
– Tension the cylinder head in the cylinder head tensioning de‐
vice, as shown in the illustration.
– Connect cylinder head tensioning device to compressed air.
– Adjust the air bellows with bythe
unless authorised lever
ŠKODA -arrow-
AUTO below
A. S. ŠKODA AUTO the com‐
A. S. does not guarantee or accept any liability
bustion chamberwith onrespect
which the valve stem seals should be
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
removed.
– Allow just enough air to flow into the air bag so that it applied
to the valve disc.
– Place guide plate -VAS 5161/32-1- on the cylinder head and

screw on using the knurled screws -VAS 5161/12- .
– Insert the impact drift -VAS 5161/3A- into the guide plate and
knock off the tightly fitted valve collets using a plastic hammer.

– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/5- into the guide plate.
– Insert assembly cartridge -VAS 5161/32-2- with sleeve moun‐
ted -VAS 5161/32-3- into the guide plate.
– Hook the pressure fork -VAS 5161/2- onto the detent part and
push the assembly cartridge downwards.
– Turn simultaneously the knurled screw of the assembly car‐
tridge to the right, until the tips click into the valve collets.
– Rotate the knurled screw to the left and to the right, by doing
so the valve collets are pressed apart and are installed in the
assembly cartridge.
– Release the pressure fork.
– Remove assembly cartridge.
– Unscrew guide plate and turn it to the side.
– Remove the valve spring with the valve spring retainer.
– Pull off valve stem seal with valve shaft pliers , for example -
VAS 6770- .
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Caution
Risk of damage when installing the valve stem seals.
– Fit the plastic bushing -A-, which is attached to the new valve
stem seals -B-, onto the valve stem.
– Lightly oil sealing lip of the valve stem seal.
– Slide the valve stem seal onto the plastic bushing.
– Carefully press the valve stem seal with the valve stem seal
insertion tool - 3365- onto the valve guide.
– Remove plastic sleeve.
3. Valve gear 109

If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device.
• The large diameter of the valve collets points to the top.
– Press the assembly cartridge from the top onto the insertion
device and lift up the valve collets.
– Insert the valve spring and the valve spring retainer, installa‐
tion position of valve spring ⇒ page 100 .
– Screw the guide plate -VAS 5161/32-1- back onto the cylinder
head.
– Insert assembly cartridge -VAS 5161/32-2- with sleeve -VAS
5161/32-3- mounted into the guide plate.
– Press down the pressure fork and turn the knurled screw to
the left and to the right while pulling it upwards, by doing so
the valve collets are inserted.
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– Release the pressure fork on tightened knurled screw.
– Repeat the procedure for each valve.
– Install cylinder head ⇒ page 64 .

4 Inlet and exhaust valves
4.1 Checking valve guides

♦ Universal dial gauge bracket - MP3-447 (VW 387)-
♦ Dial gauge , e.g. -VAS 6079-
Test procedure
– Insert valve into guide. The end of the valve stem must be flush
with the guide. On account of differing stem diameters, only
use inlet valve in inlet valve guide and exhaust valve in exhaust
valve guide.
– Determine valve rock.
• Wear limit: 0.5 mm.
– If the wear limit is exceeded, repeat measurement with new
valves.
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– If the wear limit is again exceeded, replace cylinder head.
Note
The valve guides cannot be changed.
4.2 Testing valves

– Check valves on the shank and seat surface for scoring.
– If scoring is clearly visible, change valve.
4.3 Valve dimensions
Note
Inlet and exhaust
withvalves
respect tomust not beof reworked.
the correctness Only
information in this lapping-in
document. Copyright by ŠKODA AUTO A. S.�
is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 26.5 23.5
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30
4. Inlet and exhaust valves 111

CJZC Engine Cylinder Head

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Octavia III 2013 ➤ , Octavia III 2014 ➤

1.2/63; 77 kW TSI engine - Edition 08.2013

15 – Cylinder head, valve gear

1.1 Summary of components - cylinder

The camshafts must not be removed individually.

1 - Cylinder head gasket

Cylinder head - tightening torque and tightening order

Replace screws which have been tightened firmly to a torquing

– Tighten screws in steps in the given sequence:

Checking cylinder head for distortion

1.2 Summary of components - camshaft housing

62 Rep. gr.15 - Cylinder head, valve gear

Camshaft housing - tightening torque and tightening order

Replace screws which have been tightened firmly to a torquing

– Tighten screws in steps in the given sequence:

1.3 Removing and installing cylinder head

– Remove the camshaft housing ⇒ page 67 .

– Unscrew screw -2- and remove screw clamp.

64 Rep. gr.15 - Cylinder head, valve gear

– Disconnect electrical plug connections:

– Unscrew screw -1- at the engine support.

– Slacken the screws for the cylinder head in the sequence

Risk of damaging sealing surfaces.

♦ Replace self-locking nuts, gasket rings, gaskets and O-rings.

66 Rep. gr.15 - Cylinder head, valve gear

– Fit on cylinder head gasket -1-.

Tightening up the cylinder head bolts after doing repair work is

Continued installation is carried out in the reverse order. When

1.4 Removing and installing camshaft hous‐

– Separate electrical plug connection -1-.

– Release screws -arrows- and remove connection piece -1-.

– Release screws -arrows- and remove mount with heat shield

68 Rep. gr.15 - Cylinder head, valve gear

– Disconnect electrical plug connections -arrow- at the charge

– Disconnect electrical plug connections:

♦ Replace screws which have been tightened firmly to a torquing

– “Check TDC” position of camshaft and crankshaft:

• Attach camshaft clamp -T10494- to camshaft housing using

Risk of damaging the valve gear.

• Fixing screw - T10340- turned up to the stop in the cylinder

70 Rep. gr.15 - Cylinder head, valve gear

– Screw 2 threaded bolts -Pos. 2, 4-, for example -T10288/4- ,

Make sure that the camshaft housing does not tilt.

– Tighten camshaft housing screws ⇒ page 64 .

Risk of damaging valves and piston crowns after work on the

1.5 Checking compression

Removing fuse interrupts the voltage supply of the fuel pump

– Disconnect plug -2- and remove screw -1-.

72 Rep. gr.15 - Cylinder head, valve gear

2 Toothed belt drive

2.1 Summary of components - toothed belt guard

1 - Bottom toothed belt guard

2. Toothed belt drive 73

2.2 Summary of components - toothed belt

74 Rep. gr.15 - Cylinder head, valve gear

Unscrew locking screw “TDC” bore at the cylinder block - tight‐

Replace the O-ring if it is damaged.

– Tighten bolts -arrows- to 30 Nm.

2.3 Checking valve timing