Engine 2 0 103 KW TDI PD 2 0 100 KW TDI PD

Service
Workshop Manual
OCTAVIA II 2004 ➤
Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD
Engine ID BKD AZV BMM
Edition 02.04
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling
20 - Fuel Supply
21 - Turbocharging
23 - Fuel Formation, Injection
26 - Exhaust System
28 - Glow Plug System
OCTAVIA II 2004 ➤
Engine 2.0/103 kW TDI PD, 2.0/100 kW TDI PD - Edition 02.04
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Additional instructions when undertaking assembly work on the air-conditioning system . . 2
1.3 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Safety precautions when working on the diesel direct injection system . . . . . . . . . . . . . . . . 3
1.5 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
........................................................................ 4
1.6 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 4
1.7 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Unit mounting - tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.5 Checking and adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1 Disassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2 Removing and installing toothed belt for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Removing and installing toothed belt for engine with engine identification characters BMM
........................................................................ 38
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.1 Replacing gasket ring for crankshaft -on the belt pulley side- . . . . . . . . . . . . . . . . . . . . . . 49
2.2 Removing and installing the sealing flange -on the belt pulley side- . . . . . . . . . . . . . . . . . . 51
2.3 Replace sealing flange -on the gearbox side- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Removing and installing drive chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.4 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.5 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Summary of components for engine with engine identification characters BKD, AZV . . . . 71
1.2 Removing and installing cylinder head cover for engine with engine identification characters
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.3 Removing and installing cylinder head for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.4 Testing compression pressure for engine with engine identification characters BKD, AZV
........................................................................ 82
1.5 Summary of components for engine with engine identification characters BMM . . . . . . . . 83
Contents i
OCTAVIA II 2004 ➤
1.6 Removing and installing cylinder head cover for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.7 Removing and installing cylinder head for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.8 Testing compression pressure for engine with engine identification characters BMM . . . . 94
2 Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Inspect axial play of the camshafts for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.3 Replace gasket rings of camshafts for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.4 Removing and installing camshafts for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.5 Removing and installing roller rocker arm for engine with engine identification characters
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.6 Inspecting hydraulic supporting elements for engine with engine identification characters
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.7 Replacing valve stem seals for engine with engine identification characters BKD, AZV . . 109
2.8 Valve dimensions for engine with engine identification characters BKD, AZV . . . . . . . . . . 111
2.10 Inspect axial play of the camshaft for engine with engine identification characters BMM . . 113
2.11 Replace gasket ring of camshaft for engine with engine identification characters BMM . . 114
2.12 Removing and installing camshaft for engine with engine identification characters BMM . . 116
2.13 Checking hydraulic bucket tappets for engine with engine identification characters BMM
........................................................................ 119
2.14 Replacing valve stem seals for engine with engine identification characters BMM . . . . . . 120
2.15 Valve dimensions for engine with engine identification characters BMM . . . . . . . . . . . . . . 122
2.16 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.1 Disassembling and assembling oil filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.4 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1 Removing and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.1 Parts of the cooling system fitted to body for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1.2 Parts of the cooling system fitted to engine for engine with engine identification characters
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.3 Connection diagram for coolant hoses for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.4 Draining coolant and filling up for engine with engine identification characters BKD, AZV
........................................................................ 137
1.5 Removing and installing fan shroud for radiator fan V7 and right radiator fan V35 for engine
with engine identification characters BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.6 Removing and installing radiator for engine with engine identification characters BKD, AZV
........................................................................ 140
1.7 Parts of the cooling system fitted to body for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.8 Parts of the cooling system fitted to engine for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.9 Connection diagram for coolant hoses for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.10 Draining coolant and filling up for engine with engine identification characters BMM . . . . 145
1.11 Removing and installing fan shroud for radiator fan V7 and right radiator fan V35 for engine
with engine identification characters BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ii Contents
OCTAVIA II 2004 ➤
1.12 Removing and installing radiator for engine with engine identification characters BMM . . 148
1.13 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.14 Removing and installing coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.15 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.1 Fuel tank with component parts - Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . 153
1.2 Fuel tank with component parts for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . 155
1.3 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.4 Drain the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
1.5 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.6 Remove and install the fuel tank for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . 160
1.7 Removing and installing fuel tank for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . 162
1.8 Removing and installing the fuel delivery unit on vehicles with front-wheel drive . . . . . . . . 164
1.9 Removing and installing the fuel delivery unit on vehicles with four-wheel drive . . . . . . . . 165
1.10 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 170
1.11 Removing and installing fuel gauge sender 2 G169 on vehicles with four-wheel drive. . . . . 172
1.12 Removing and installing suction jet pump on vehicles with four-wheel drive . . . . . . . . . . . . 173
1.13 Removing and installing tandem pump, vehicles with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.14 Removing and installing tandem pump, vehicles with engine identification characters BMM
........................................................................ 175
1.15 Inspecting a tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.16 Checking fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1 Charge-air system with exhaust gas turbocharger - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . 187
1.1 Connection diagram for vacuum hoses for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.2 Connection diagram on the solenoid valve block and for vacuum connector for engines with
engine identification characters BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.3 Inspecting vacuum setting element and tension rods for charge pressure control for engines
with engine identification characters BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.4 Connection diagram for vacuum hoses for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
2 Charge-air system with exhaust gas turbocharger - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . 191
2.1 Removing and installing exhaust gas turbocharger for engine with engine identification
characters BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
2.2 Removing and installing parts of the charge air cooling for engine with engine identification
2.3 Removing and installing exhaust gas turbocharger for engine with engine identification
characters BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
2.4 Removing and installing parts of the charge air cooling for engine with engine identification
characters BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.6 Hose connections with push-fit couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.7 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

1 Repairing diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.1 Fitting locations for engine with engine identification characters BKD, AZV - Overview . . 205
1.2 Intake manifold - Summary of components for engine with engine identification characters
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Contents iii
OCTAVIA II 2004 ➤
1.3 Pre-wiring for unit injectors and glow plugs - Summary of components for engine with engine
identification characters BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
1.4 Removing and installing pre-wiring for unit injectors and glow plugs for engine with engine
1.5 Removing and installing air filter for engine with engine identification characters BKD, AZV
........................................................................ 212
1.6 Repairing the unit injectors for engine with engine identification characters BKD, AZV . . 213
1.7 Removing and installing the unit injectors for engines with engine identification characters
BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
1.8 Replacing O-rings of unit injector for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
1.9 Fitting locations for engine with engine identification characters BMM - Overview . . . . . . 219
1.10 Intake manifold - Summary of components for engine with engine identification characters
BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
1.11 Removing and installing air filter for engine with engine identification characters BMM . . 223
1.12 Repairing the unit injectors for engine with engine identification characters BMM . . . . . . 224
1.13 Removing and installing unit injectors for engine with engine identification characters BMM
........................................................................ 224
1.14 Replacing O-rings of unit injector for engine with engine identification characters BMM . . 228
1.15 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.3 Exhaust system for vehicles with four-wheel drive - Overview of components . . . . . . . . . . 236
1.4 Removing and installing pre-exhaust pipe with diesel particle filter . . . . . . . . . . . . . . . . . . 237
1.5 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
1.7 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.1 Removing and installing parts of the exhaust gas recirculation system for engine with engine
2.2 Summary of components of cooling for exhaust gas recirculation system for engine with
engine identification characters BKD, AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.3 Testing mechanical exhaust gas recirculation valve for engine with engine identification
2.4 Operation of radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2.5 Checking change-over for radiator for exhaust gas recirculation for engine with engine
2.6 Removing and installing radiator for exhaust gas recirculation for engine with engine
2.7 Removing and installing parts of the exhaust gas recirculation system for engine with engine
identification characters BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.8 Summary of components of cooling for exhaust gas recirculation system for engine with
engine identification characters BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.9 Checking change-over for radiator for exhaust gas recirculation for engine with engine
2.10 Removing and installing radiator for exhaust gas recirculation for engine with engine
2.11 Connection diagram for vacuum hoses for exhaust gas recirculation system for engine with
engine identification characters BMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.1 Removing and installing glow plugs for engine with engine identification characters BKD,
AZV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
iv Contents
OCTAVIA II 2004 ➤
1.2 Testing glow plugs for engine with engine identification characters BKD, AZV . . . . . . . . . . 253
1.3 Removing and installing glow plugs for engine with engine identification character BMM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
1.4 Testing glow plugs for engine with engine identification characters BMM . . . . . . . . . . . . . . 254
Contents v
OCTAVIA II 2004 ➤
vi Contents
OCTAVIA II 2004 ➤
00 – Technical data
1 Technical data
1.1 Engine number

The engine number (“engine identification character” and “serial
number”) is located in the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification character” and
“serial number” is affixed to the toothed belt guard.
The engine code is also indicated on the vehicle data sticker.
1.2 Engine characteristics

Engine identification characters BKD AZV BMM
Manufactured 05.04 ? 10.04 ? 12.05 ?
Exhaust limit values conforming to EU4 EU4 EU4
Displacement l 1,968 1,968 1,968
Power output kW at rpm 103/4000 100/4000 103/4000
Torque Nm at rpm 320/1750 … 2500 320/1750 … 2500 320/1750 …2500
Bore ∅ mm 81,0 81,0 81,0
Stroke mm 95,5 95,5 95,5
Number of valves per cylinder 4 4 2
Compression 18,5 : 1 18,5 : 1 18,5 : 1
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic converter yes yes yes
Exhaust gas recirculation with radiator yes yes yes
Turbocharging yes yes yes
Charge air cooler yes yes yes
Diesel particle filter no no yes
1. Technical data 1
OCTAVIA II 2004 ➤
01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions
1.1 Self-diagnosis
This repair group is no longer applicable.
For this use “Vehicle self-diagnosis”, “Measuring method” and
“Targeted fault finding” ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.
1.2 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
To avoid causing damage to the condenser and to the refrigerant

lines and hoses make sure the lines and hoses are not over-ex‐
tended, kinked or bent.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit.
– Unscrew the holding clamp(s) on the refrigerent lines
– Remove V-ribbed belt ⇒ page 23 .
– Remove AC compressor from the bracket for auxiliary units
⇒ page 23 .
– Mount the air conditioning compressor and the condenser at
the structure in such a way that the refrigerent lines and hoses
are not under tension.
2 Rep. Gr.01 - Self-diagnosis

OCTAVIA II 2004 ➤
1.3 Safety precautions when working on the

fuel supply system
WARNING
♦ On vehicles with pump injector engine, the temperature of

the fuel lines or of the fuel can be up to 100°C in an ex‐
treme case. Let the fuel cool down before opening the
lines, as otherwise there is a high risk of burning.
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
♦ The fuel pump is activated when the ignition is switched on

and by the door contact switch of the driver door. Before open‐
ing the fuel system and for reasons of safety, if the battery is
not disconnected, the connector -arrow- must be disconnected
from the fuel delivery unit.
WARNING
Please observe the following when undertaking all assembly

work, particularly in the engine compartment, due to its cram‐
ped construction.
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerent, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
When removing and installing the fuel gauge sender from a full or
partly filled fuel tank, pay attention to the following:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
1.4 Safety precautions when working on the

diesel direct injection system
If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
If the test and measuring devices are operated from the passen‐
ger seat, the passenger can be injured by the release of the
passenger airbag in the event of an accident.
1. Self diagnosis, safety measures, cleanliness regulations and directions 3

OCTAVIA II 2004 ➤
WARNING
Secure the test and measuring devices on the rear seat and
operate them there.
Observe the following points to prevent injury to persons and/or

damage to the injection and preheating system:
♦ Ignition must be switched off before disconnecting and re-
connecting the wires of the injection and preheating system as
well as of the test equipment.
♦ If the engine should be run at the starter speed without it ac‐
tually igniting, then separate the central plug connection for
the unit injector at the cylinder head.
♦ Before disconnecting the battery determine the code of the
radio fitted with anti-theft coding.
♦ Switch off the ignition before connecting or disconnecting the
battery as this could otherwise damage the diesel direct injec‐
tion system control unit.
♦ When the battery is disconnected and reconnected, carry out
rework ⇒ Electrical System ⇒ Rep. Gr. 27 .
1.5 Regulations concerning cleanliness

when working on the fuel supply/fuel in‐
jection system
Carefully observe the following “6 rules” for cleanliness when
working on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Replace imme‐
diately any hoses which have suffered damage.
1.6 Regulations concerning cleanliness

when working on the exhaust gas turbo‐
charger
Carefully observe the following “5 rules” for cleanliness when
working on the exhaust gas turbocharger:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.

OCTAVIA II 2004 ➤
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
1.7 General instructions for charge air sys‐

tem
WARNING

ped construction.
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Check air filter housing, air filter element and charge air
pipes as well as charge air hoses for soiling.
♦ Check all the air guides and the charge air cooler for for‐
eign bodies.
If foreign bodies are detected in the charge air system, the
charge-air routing must be cleaned and the charge air cooler
must be replaced.
♦ The charge-air system must be tight, check ⇒ page 202 .

♦ Always replace self-locking nuts.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before being installed. The gasket ring
and the sealing surface must be slightly oiled only for push-fit
couplings ⇒ page 202 .
♦ Observe assembly markings on the hoses and components.
♦ All hose connections of the charge air system are secured with
spring strap clamps or push-fit couplings.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Assembly of hose connections with push-fit couplings
⇒ page 202 .
♦ Before screwing on the oil feed line, fill the exhaust gas tur‐
bocharger on the connection fitting with engine oil.
1. Self diagnosis, safety measures, cleanliness regulations and directions 5

OCTAVIA II 2004 ➤
♦ after installing the exhaust gas turbocharger run the engine

approx. 1 minute in idle and do not increase speed immedi‐
ately in order to ensure the supply of oil to the exhaust gas
turbocharger.

OCTAVIA II 2004 ➤
10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing engine

Special tools and workshop equipment required
♦ Catch pan for workshop crane , e.g. -VAS 6208-
♦ Engine and gearbox jack , e.g. -V.A.G 1383 A-
♦ Engine mount -T10012-
♦ Workshop crane , e.g. -VAS 6100-
♦ Double ladder , e. g. -VAS 5085-
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
♦ Pliers for spring strap clamps
– Before removing the engine, interrogate the fault memory of
all control units ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
Note
♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be fitted again in the same location
when the engine is installed again.
♦ Leave the car key in the ignition lock so that the steering wheel
lock does not click into place.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
Caution

ped construction.
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.
Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
– Remove engine cover ⇒ page 13 .
– Before disconnecting the battery, if necessary remove the
adapter for the safety wheel bolts from the luggage compart‐
ment.
1. Removing and installing engine 7

OCTAVIA II 2004 ➤
WARNING
Observe measures when disconnecting the battery ⇒ Electri‐

cal System ⇒ Rep. Gr. 27 .
– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

trical System ⇒ Rep. Gr. 27 .
– Remove plenum chamber cover and bulkhead plenum cham‐
ber ⇒ Body Work ⇒ Rep. Gr. 66 .
– Remove air filter with air mass meter, air intake hose and suc‐
tion hose.
♦ Vehicles with engine identification characters BKD, AZV:
⇒ page 212
♦ Engine identification characters BMM: ⇒ page 223
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .
– Slacken the screw for the front right drive shaft only by maxi‐
mum 90°, otherwise the wheel bearing may be damaged.
– Remove both front wheels ⇒ Chassis ⇒ Rep. Gr. 44 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Remove the right wheelhouse liner bottom part ⇒ Body Work
⇒ Rep. Gr. 66 .
– Remove right drive shaft ⇒ Chassis ⇒ Rep. Gr. 40 .
– Remove the left drive shaft from the gearbox flange.
– Unscrew the nut from the left coupling rod -2- of the anti-roll
bar and press the coupling rod off the anti-roll bar.
– Unscrew the nuts from the left steering joint -3- and press the
steering joint out of the suspension arm.
– If present, remove coupling rod from front left vehicle level
sensor -G78- .
– Turn steering to full left lock.
– Swivel the steering joint outwards and secure the drive shaft
-1- with a band -A- in the wheel housing as shown in the illus‐
tration.
– Insert the steering joint to ensure stabilisation with a threaded
bore into the suspension arm.
WARNING
Hot steam or hot coolant may escape when the coolant ex‐
pansion reservoir is opened. Cover the cap with a cloth and
open carefully.
– Draining coolant.
⇒ page 137
8 Rep. Gr.10 - Removing and installing engine

OCTAVIA II 2004 ➤
– Detach coolant hose, fuel intake hose -2- and fuel return-flow
hose -1- from pipes at cylinder head.
Vehicles up to 08.05
– Unlatch fuse, remove fuel filter with its connected hoses up‐
wards from bracket -arrow- and lay to the side.
Vehicles as of 08.05

OCTAVIA II 2004 ➤
– Release screw -1- by one turn.

– Release screw -2- and nut -3-.
– Take out fuel filter with connected hoses and lay to the side.
Continued for all vehicles
– Remove alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
Vehicles with air conditioning
WARNING
Refrigerant circuit of the air conditioning system must not be

opened.
Note
To avoid causing damage to the AC compressor as well as to the

refrigerant lines and hoses make sure the lines and hoses are not
over-extended, kinked or bent.
– Remove AC compressor from the bracket for auxiliary units

⇒ page 23 .
– Tie up removed AC compressor with connected refrigerant
hoses to the body.
Vehicles with auxiliary heating.
– Disconnect necessary connections at the coolant pipes and at
the coolant shut-off valve of heating system -N279- .
– Only remove long exhaust pipe of auxiliary heating ⇒ Heating,
Air Conditioning ⇒ Rep. Gr. 82 .
– Remove charge air hoses and charge air pipe between engine
and charge air cooler.
♦ Engine identification characters BKD, AZV: ⇒ page 195
Caution
Shut off the openings of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.
– Remove fan shroud and radiator.

– Remove the bracket for the wiring of the oil level and oil tem‐
perature sender -G266- from the assembly carrier.

OCTAVIA II 2004 ➤
– First of all release the screw -1-.

– Then release the screws -2- and -3- and remove the pendulum
support.
Vehicles with four-wheel drive
– Remove assembly carrier without steering gear ⇒ Chassis ⇒
Rep. Gr. 40 .
– Disconnect propshaft from gearbox ⇒ Gearbox ⇒ Rep. Gr.
39 .
Caution
The decoupling element in the pre-exhaust pipe should not be

bent by more than 10° - danger of damaging it.
– Remove the pre-exhaust pipe from the exhaust turbocharger

⇒ page 232 .
– Unlatch the fuse and disconnect the front plug from the engine
control unit ⇒ page 230 .
– Release duct for engine wiring harness -arrow- and pull out
upwards.

OCTAVIA II 2004 ➤
– Open the cable guide -arrows-, remove the engine wiring har‐
ness and place down to the side.
– Release all remaining plugs at engine and gearbox and lay
aside the relevant lines.
Note
To release the plug of the engine speed sender -G28- , press the
plug together with a screwdriver and at the same time raise the
release button with a thin wire hook.
– Detach all connecting, coolant and vacuum hoses from the

engine.
Vehicles fitted with a manual gearbox
– Remove the gearshift mechanism from the gearbox ⇒ Gear‐
box ⇒ Rep. Gr. 34 .
– Remove the pressure line at the breather/slave cylinder of the
clutch control ⇒ Gearbox ⇒ Rep. Gr. 30 .
WARNING
After separating the hydraulic line, do not operate the clutch

pedal.
Vehicles with automatic gearbox

– Remove the gearshift mechanism from the gearbox ⇒ Gear‐
– Screw engine mount -T10012- to the cylinder block with nut

-2- and screw -1- to 20 Nm.
– Insert engine/gearbox jack -V.A.G 1383 A- in the engine
mount and slightly raise.
WARNING
Use double ladder to release the screws for the engine and
gearbox mounting.

OCTAVIA II 2004 ➤
– Successively release screws for engine mounting -arrows-.
– Successively release screws for gearbox mounting -arrows-.
Note
♦ Check whether all hose and line connections between engine,

gearbox and body are released.
♦ When lowering carefully guide the engine with the gearbox, in
order to avoid damage.
– Carefully lower engine with gearbox.

– Remove the gearbox from the engine ⇒ gearbox ⇒ Rep. Gr.
34 .
1.1.1 Removing and installing engine trim

panel
Removing
Vehicles with engine identification characters BKD, AZV
– Pull oil dipstick -1- out of oil dipstick guide.
– Lift the engine cover at the sides -arrows 2- and pull out to‐
wards the front -arrow 3-.
– Push the oil dipstick back into the oil dipstick guide, so that
nothing can fall into the opening.

OCTAVIA II 2004 ➤
Vehicles with engine identification characters BMM

– Pull the outer -1- and inner -2- engine cover evenly towards
the top.
Install
Note
On vehicles with engine identification characters BKD, AZV, pull

the oil dipstick out of the oil dipstick guide before installing and
push it back again into the oil dipstick guide after installing.
Caution
Before installing the engine cover, check the correct position

of the fixing elements (ball sockets). If necessary they must be
put back into their correct position. Otherwise this can lead to
damage to the engine cover.
– If necessary, press the ball sockets of the engine cover into

the correct position.
– Place the engine cover onto the fixing points and press it into
the catch.
1.2 Securing the engine to the assembly

stand
♦ Lifting device -MP 9-201 (2024A)-
♦ Engine mount -MP 1-202 (VW 540)-
♦ Hook -MP 1-202/10-
♦ Bushing -T30010 (VW 540/1B)-
♦ Assembly stand -MP 9-101-
♦ Workshop crane , e.g. -VAS 6100-
Procedure
• Separate engine from gearbox.

OCTAVIA II 2004 ➤
WARNING
Use securing pins on the hooks and rig pins to prevent release.
– Attach lifting device -MP 9-201- at engine and at workshop

crane e.g. -V.A.G 1202A- .
Belt pulley side: 2nd hole of the attachment in Position 1.
Flywheel side: 4th hole of the attachment in Position 8.
– Lift off engine with installed engine mount -T10012- with work‐
shop crane from engine and gearbox jack.
– Remove engine mount -T10012 - .
– For carrying out assembly work, attach the engine with the
engine mount -MP 1-202- , the extension -MP 1-202/10- and
the sleeves -T30010- to the assembly stand -MP 9-101- . (The
figure shows the 1.9 ltr./47kW SDI Engine; the fixing system
is identical).
1.3 Installing the engine

Installation occurs in reverse order to removal. Pay attention to
the following:
Note
♦ When performing installation work replace the self-locking

nuts.
♦ Replace screws which have been tightened to a turning angle
as well as gasket rings and seals.
♦ All cable straps should be fitted on again in the same place
when installing.
♦ Secure all hose connections with corresponding hose clips.

OCTAVIA II 2004 ➤
Caution

ped construction.
lished.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.
Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness ⇒ page 2 .
Engines for manual gearboxes
Note
♦ Clean the serration on the drive shaft and if the clutch discs
have been used clean the hub serration, remove corrosion and
only apply a very thin layer of grease -G 000 100- . Subse‐
quently move the clutch disc up and down on the drive shaft
until the hub fits smoothly on the shaft. Always remove all ex‐
cess grease.
♦ After installing the coupling, check the centering of the clutch
disc ⇒ gearbox ⇒ Rep. Gr. 30 .
♦ Check the clutch release bearing for wear. Replace release
bearing if worn ⇒ gearbox ⇒ Rep. Gr. 30 .
Engines for automatic gearbox
Note
♦ Replace the needle bearing -arrow- in the crankshaft

⇒ page 63 .
♦ Coat the drive shaft pin of the gearbox with a thin layer of high
temperature grease -G 052 133 A2- . Do not grease the ser‐
ration of the drive shaft.
Continued for all engines

– Check whether the dowel sleeves for centering the engine/
gearbox are present in the cylinder block; insert if necessary.
– Ensure that the intermediate plate has been inserted on the

sealing flange and is pushed onto the dowel sleeves
-arrows-.
– Screw on gearbox to engine ⇒ gearbox ⇒ Rep. Gr. 34 .
– Insert engine with gearbox into the body.

OCTAVIA II 2004 ➤
– Successively screw in by hand the new screws for engine

mounting -arrows-.
– Successively screw in by hand the new screws for gearbox

mounting -arrows-.
– Adjust assembly bracket ⇒ page 20 and tighten screws
⇒ page 19 .
– Remove engine mount -T10012- from engine.
– Attach propshaft to gearbox ⇒ Gearbox ⇒ Rep. Gr. 39 .
– Install assembly carrier without steering gear ⇒ Chassis ⇒
Rep. Gr. 40 .
– First tighten pendulum support with new screws -2- and -3- at
gearbox and then tighten with new screw -1- at assembly car‐
rier.
Tightening torque: ⇒ page 19

OCTAVIA II 2004 ➤
– On gearboxes with rigid shaft, replace the O-ring -1- on the

right rigid shaft and grease the serration -2- with multi-purpose
grease.
– Install the right drive shaft and attach the left drive shaft to the
gearbox flange ⇒ Chassis ⇒ Rep. Gr. 40 .
– Install pre-exhaust pipe ⇒ page 232 and align exhaust system
free of stress ⇒ page 242 .
– Connect hydraulic line to cylinder of hydraulic clutch control
and bleed clutch hydraulic ⇒ gearbox ⇒ Rep. Gr. 30 .
– Attach the shift mechanism to the gearbox and adjust ⇒ Gear‐
– Install fan shroud and radiator.
– Secure the coolant hoses to the auxiliary heating and the cool‐
ant pipes.
– Install long exhaust pipe of auxiliary heating ⇒ Heating, Air
Conditioning ⇒ Rep. Gr. 82 .
– Attach AC compressor to holder for auxiliary units
⇒ page 23 .
– Install alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install the V-ribbed belt ⇒ page 23 .
– Connect all connecting, fuel, coolant and vacuum hoses to the
engine.
– Observe the assembly instruction for hose connections with
push-fit couplings ⇒ page 202 .
– Connect electrical connections and attach cables ⇒ Current
flow diagrams and Fitting locations.
– Install battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Install bulkhead plenum chamber and plenum chamber cover
⇒ Body Work ⇒ Rep. Gr. 66 .
– Install wiper arms ⇒ Electrical System ⇒ Rep. Gr. 92 .
– Filling system with coolant ⇒ page 137 , ⇒ page 145 .
– Checking the oil level ⇒ Maintenance ; Octavia II .
– Install the noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Install the right wheelhouse liner bottom part ⇒ Body Work ⇒
Rep. Gr. 66 .
– Perform a test drive.
– Interrogate all fault memories, rectify any faults existing and
erase fault memory ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.

OCTAVIA II 2004 ➤
Note
After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.
Tightening torques
Component Nm
Screws/nuts M 9
6
M 13
7
M 20
8
M 40
10
M 70
12
Engine/gearbox connecting screws ⇒ gearbox
⇒ Rep. Gr. 34
1.4 Unit mounting - tightening torques

Unit mounting for engine
A - 20 Nm + 90° (1/4 turn) - replace
B - 40 Nm + 90° (1/4 turn) - replace
C - 60 Nm + 90° (1/4 turn) - replace
Unit mounting for gearbox

1 - 40 Nm + 90° (1/4 turn) - replace
2 - 60 Nm + 90° (1/4 turn) - replace

OCTAVIA II 2004 ➤
Pendulum support
A (strength category 8.8) - 40 Nm + torque a further 90° (1/4 turn)
- replace
A (strength category 10.9 1)) - 50 Nm + 90° (1/4 turn) - replace
B - 100 Nm + 90° (1/4 turn) - replace

Remove: First release screw -B-, then screws -A-.
Install: First tighten screws -A-, then screw -B-.
1)On manual gearbox MQ350 (02Q), only use the screws with
the strength category 10.9 if bolt-holes have been installed (e.g.
Heli-Coil) -arrow-.
1.5 Checking and adjusting the unit mount‐

ing
1.5.1 Checking the unit mounting

Check dimensions on the right hanger for engine/gearbox unit:
• Between engine bracket and engine support there must be a
distance -a- of 10...13 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- can also be checked e.g. with corresponding

round bars.
Only if there is an acoustic complaint (engine or gearbox knock

on the frame side rail when cornering) and the dimension -a- is
outside 10…13 mm:
– Adjust the unit mounting ⇒ page 20 .
1.5.2 Adjusting the unit mounting

♦ Supporting device -T30099-
♦ Supporting plate -T30099/1-
♦ Hook -MP 9-200/10 (10-222A/10)-
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.
Gr. 27 .

OCTAVIA II 2004 ➤
– Remove the cooling water tank cover ⇒ Body Work ⇒ Rep.

Gr. 66 .
– Position supporting device -T30099- and support plate -
T30099/1- and support the engine/gearbox unit in its installed
position.
– Uniformly pre-tension the engine/gearbox unit with both spin‐
dles, but do not raise.
– Release the screws -arrows- of the unit mounting at the en‐

gine.
– Slightly loosen the screws -2- of the unit mounting at the gear‐
box (less than 1 revolution).
– Successively replace all the screws of the unit mounting (as
long as it has not already been performed when installing the
engine) and screw them in loosely.

OCTAVIA II 2004 ➤
– Move the engine/gearbox unit with a tyre lever between engine

support -1- and supporting arm -3- for engine mount until the
following dimensions are set:
• Between engine bracket and engine support there must be a
distance -a- of 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- = 10 mm can be checked e.g. with suitable round

bars.
– Tighten the screws of the unit mounting for engine

⇒ page 19 .
– Make sure that on the gearbox side the edges of the support‐
ing arm -2- and gearbox support -1- are parallel.
• The dimension -x- must be the same on both mount sides.
– Tighten the screws of the unit mounting for gearbox
⇒ page 19 .
Further installation occurs in reverse order.

OCTAVIA II 2004 ➤
13 – Crankgear
1 Disassembling and assembling en‐
gine
1.1 Removing and installing V-ribbed belt
1 - Belt pulley of the crankshaft

❑ with vibration damper
❑ can be installed only in
one position
2 - Cap
❑ for belt pulley of crank‐
shaft
❑ mounted up to 05.05
3 - 10 Nm + torque a further 90°
(1/4 turn)
❑ replace
4 - Tensioning device for V-rib‐
bed belt
❑ swivel tensioning device
for V-ribbed belt with
open-end wrench to
slacken the V-ribbed
belt
❑ can be interlocked with
locating pin -T10060A-
or Allan key
5 - 23 Nm
6 - screw for guide pulley
❑ only for vehicles with en‐
gine identification char‐
acters BKD, AZV
❑ replace
❑ different screws for ve‐
hicles with small or large
engine support
❑ Tightening torque:
♦ Vehicles with small engine
support: ⇒ page 24
♦ Vehicles with large engine support: ⇒ page 25
7 - Guide pulley
❑ for toothed belt
❑ only for vehicles with engine identification characters BKD, AZV
8 - Bracket for auxiliary units
❑ order of tightening ⇒ page 24
9 - Fitting sleeve
❑ pay attention to correct fit in the holder
1. Disassembling and assembling engine 23

OCTAVIA II 2004 ➤
10 - 23 Nm
11 - AC generator
❑ removing and installing ⇒ Electrical System ⇒ Rep. Gr. 27
❑ to facilitate positioning, drive the threaded bushings for fixing screws at the generator slightly backwards
12 - 45 Nm
❑ observe the order of tightening up ⇒ page 24
13 - Fitting sleeve
❑ 2 pieces
❑ pay attention to correct fit in the holder
14 - 25 Nm
15 - AC compressor
16 - V-ribbed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ do not kink
❑ removing ⇒ page 25
❑ installing ⇒ page 26
Bolts at bracket for auxiliary units - tightening sequence

(
Tightening torque for guide pulley - vehicles with small engine

support (only for vehicles with engine identification characters
BKD, AZV)
Screw -arrow- without inside thread.
• Tightening torque: 40 Nm + torque a further 90° (1/4 turn).
24 Rep. Gr.13 - Crankgear

OCTAVIA II 2004 ➤
Tightening torque for guide pulley - vehicles with large engine

support (only for vehicles with engine identification characters
BKD, AZV)
Screw -arrow- with inside thread for engine support fixture
• Tightening torque: 90 Nm + torque a further 90° (1/4 turn).
Removing
– Unlatch fuse, remove fuel filter with its connected hoses up‐
wards from bracket -arrow- and lay to the side.
– Release screw -1- by one turn.

– Release screw -2- and nut -3-.
– Take out fuel filter with connected hoses and lay to the side.
Note
Mark the direction of rotation with chalk or a felt-tip pen before

removing the V-ribbed belt. Reversing the rotation direction of an
already used belt may destroy it.

⇒ Rep. Gr. 66 .

OCTAVIA II 2004 ➤
– Swing the the tensioning device in

-the direction of the arrow- detension the V-ribbed belt.
– Hold the tensioning device and remove the slackened V-rib‐
bed belt.
Install
the following:
Note
Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.
Vehicles without air conditioning
– First position the V-ribbed belt on the belt pulleys of the crank‐
shaft and the generator, then release the tensioning device.
– First position the V-ribbed belt on the belt pulleys of the crank‐
shaft and AC compressor and on the belt pulley of the gener‐
ator last, then release the tensioning device.
– Check correct positioning of the ribbed V-belt on the belt pul‐
leys.
– Start engine and check ribbed V-belt run.

OCTAVIA II 2004 ➤
1.2 Removing and installing toothed belt for

engine with engine identification char‐
acters BKD, AZV
1.2.1 Summary of components - part 1
1 - Cap
❑ for belt pulley of crank‐
shaft
(1/4 turn)
❑ replace
❑ can be installed only in
one position
❑ Adjust TDC for cylinder
1 with the belt pulley of
the crankshaft fitted
⇒ page 29
4 - 10 Nm
❑ insert using locking
agent -D 000 600 A2-
5 - 40 Nm + torque a further
180° (1/2 turn)
❑ replace
❑ observe the order of
tightening up
⇒ page 30
6 - Engine support bracket
❑ from 05.05 the engine
support bracket is instal‐
led ⇒ page 30 with an‐
other support
7 - Top toothed belt guard
❑ when installing, correct‐
ly insert into the middle
part of the toothed belt guard
8 - Middle toothed belt guard
❑ to remove, remove top toothed belt guard and unscrew tensioning device for ribbed V-belt.
❑ Adjust TDC for cylinder 1 with the belt pulley of the crankshaft fitted ⇒ page 29
9 - Bottom toothed belt guard

OCTAVIA II 2004 ➤
1.2.2 Summary of components - part 2
Note

removing the toothed belt. Reversing the rotation direction of an
1 - 120 Nm + torque a further

90° (1/4 turn)
❑ replace
❑ do not oil
❑ to release and tighten
use counterholder -
T30004- or counterhold‐
er -MP 1-310 (3099)-
2 - 20 Nm
❑ self-locking, replace
3 - small guide pulley
(1/8 turn)
5 - Tensioning pulley
❑ The eccentric of the new
version has an addition‐
al hole for 6 mm hexa‐
gon socket wrench
⇒ page 29
6 - Toothed belt
❑ mark the direction of ro‐
tation with chalk or a felt-
tip pen before removing
❑ check for wear
❑ do not kink
❑ install (set the timing)
⇒ page 35
7 - 25 Nm
8 - Toothed belt sprocket of ex‐
haust camshaft
❑ Check fitting position
9 - 25 Nm
10 - Toothed belt sprocket of inlet camshaft
11 - 100 Nm
❑ to release and tighten use counterholder -T10051-
12 - 100 Nm
❑ to release and tighten use counterholder -T10051- ⇒ page 99
13 - Hub
❑ for exhaust camshaft
❑ to remove use extractor -T10052-

OCTAVIA II 2004 ➤
14 - Hub
❑ for inlet camshaft with rotor for hall sender -G40-
❑ to remove use extractor -T10052- ⇒ page 99
15 - Rear toothed belt guard
16 - Rubber grommet
❑ for the removal of the hall sender -G40- (rear toothed belt guard must not be removed)
❑ replace if damaged
17 - 10 Nm
❑ insert using locking agent -D 000 600 A2-
18 - O-ring
❑ replace
19 - Coolant pump
❑ removing and installing ⇒ page 149
20 - 15 Nm
21 - Toothed belt sprocket of crankshaft
❑ 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
22 - large guide pulley
23 - screw for guide pulley
❑ replace
❑ different screws for vehicles with small or large engine support
❑ Tightening torque:
♦ Vehicles with small engine support: ⇒ page 24
♦ Vehicles with large engine support: ⇒ page 25
Tensioning pulley
Additional hole in the eccentric of the tensioning pulley for 6 hex‐
agon socket wrench -arrow-.
Note
The tensioning pulley of the new version can be adjusted with the
special two-hole nut turner , e. g. -T10020- , or using a commercial
6 mm hexagon socket wrench.
Adjust TDC for cylinder 1 with the belt pulley of the crankshaft
fitted
– Turn the crankshaft at the central bolt in direction of rotation
of engine in such a way that the notch on the belt pulley of the
crankshaft (TDC marking for cylinder 1) -large arrow- and the
engraved arrow -small arrow- are positioned opposite each
other on the middle toothed belt guard, as shown.
Use a mirror.

OCTAVIA II 2004 ➤
Engine support bracket

For vehicles as of 05.05 the engine support -2- is installed.
Note
When removing the toothed belt it is not necessary to remove the

engine support bracket.
Tightening order for engine support
Caution
The tightening sequence and the tightening torque of the fixing

screws for the engine support must definitely be respected.
Otherwise stress of the engine support occurs, which results
in the breaking of the engine support.
1. First screw in new screws -1 … 3- by hand.

2. Then tighten the screws in the order shown -1 … 3- to 40
Nm.
3. Subsequently torque the screws in the order shown
-1 … 3- a further 180° (1/2 turn).
Note
♦ Raise or lower engine with the supporting device -T30099- .

♦ Before the engine mount is installed, all the screws of the en‐
gine support must be tightened to the specified tightening
torque.
I : Engine support for vehicles up to 05.05

lI: Engine support for vehicles as of 05.05
1.2.3 Removing toothed belt

♦ Hook -MP 9-200/10 (10-222A/10)-
♦ Rig pin -3359- or -MP 1-301- (2x)
♦ Locating pin -T10060- or -T10060A-
♦ Crankshaft arrester -T10050- or -T10100-

OCTAVIA II 2004 ➤
♦ Counterholder -T10172 - with bolts -T10172/4-

♦ Offset screwdriver -T10264-
♦ Rig tool -T10265-
⇒ Rep. Gr. 66 .
– Unscrew screws -1- and -2- and remove charge air pipe
-arrows-.
– Remove the belt pulley of the crankshaft. To do so, counter‐

hold with a ring spanner at the central bolt.
For vehicles manufactured up to 05.05:
– Observe the safety instructions when working on the fuel sup‐
ply ⇒ page 3 .
– Disconnect the fuel intake hoses and the fuel return-flow ho‐
ses from the fuel pipes on the body and on the engine.
– Unscrew bolt on filler neck -2- of windscreen washer reservoir.

– Unscrew the coolant expansion reservoir -1- and lay with con‐
nected lines to one side.

OCTAVIA II 2004 ➤
– Remove top toothed belt guard; to do so release retaining clips

-arrows-.
– Remove ribbed V-belt tensioning device -arrows-.

– Remove middle and bottom toothed belt guard.
For vehicles manufactured up to 05.05:
Gr. 66 .
– Position the supporting device -T30099- and the supporting

plate -T30099/1 - , suspend the engine/gearbox assembly on
the right lifting eye with hook -MP 9-200/10- and preload via
the spindle, do not lift.
Note
If the cylinder head must be removed, two spindles must be at‐

tached at the supporting device -T30099- ⇒ page 75 .
– Release screws -1- and -2- and remove connecting stud.

– Release screws -3 ... 6- and remove engine mounting.

OCTAVIA II 2004 ➤
– Release screws -1...3- for engine support and remove sup‐

port.
Note
To slacken the bolts for the engine support, raise engine slightly
via spindle of supporting device -T30099- .
Caution
Spin the engine at the crankshaft only in direction of rotation of

engine (in clockwise direction).
– Rotate crankshaft to TDC for cylinder 1.
• Both tooth segments -arrows- of the camshaft sprockets must

be facing up.
– Lock hubs with locking pins -3359- .
– Depending on the version, lock the toothed belt sprocket of the

crankshaft with the crankshaft arrester -T10050- or the crank‐
shaft arrester -T10100- .
Difference of the toothed belt sprocket of crankshaft:
A = original version of toothed belt sprocket with circular tooth
flank, rectangular TDC marking for cylinder 1 at tooth in 12 o'clock
position - use crankshaft arrester -T10050- .
B = new version of toothed belt sprocket with eliptical tooth flank,
triangular TDC marking for cylinder 1 at tooth opening in 1 o'clock

OCTAVIA II 2004 ➤
Note
♦ The markings on the toothed belt sprocket and on the crank‐

shaft arrester must be in line with each other -arrow-.
♦ The stud of the crankshaft arrester -arrow- must engage at the
same time in the hole of the sealing flange.
♦ The crankshaft arrester can only be fitted onto the toothed belt
sprocket from the front side of the serration.
– Mark the direction of rotation of the toothed belt with chalk or

a felt-tip pen.
– Loosen screws of toothed belt sprockets -arrows- by approx.

1 turn.
– Loosen the fixing nut -1- of the tensioning pulley.

– Turn the eccentric of the tensioning pulley with offset screw‐
driver -T10264- in anti-clockwise direction -arrow- until the
tensioning pulley can be interlocked with the rig tool -T10265- .
– Now turn the eccentric of the tensioning pulley clockwise

-arrow- as far as the stop and tighten the fixing nut -1- by hand.
– First of all take toothed belt off toothed belt sprocket of coolant
pump and then from the other toothed belt sprockets.

OCTAVIA II 2004 ➤
1.2.4 Install timing belt (set the timing)
Caution
The work procedure which is described here must be precisely

respected.
♦ If, for example, the final check is not carried out and the
rig tools are not inserted again, there is a risk that the tim‐
ing is not correctly set and the vehicle shows signs of poor
vehicle handling and idle jerking occurs.
• Interlock camshafts with locking pins -3359- or -MP 1-301- .

• Crankshaft is locked with crankshaft arrester -T10050- or
crankshaft arrester -T10100- .
• Tensioning pulley interlocked with rig tool -T10265- and fixed
with fixing nut up to right stop.
Note
♦ Always perform adjusting work on the toothed belt only on a

cold engine.
♦ When rotating the camshafts, the crankshaft must not be posi‐
tioned at TDC for any one piston. Risk of damaging valves and
pistons.
– Slightly screw in screws -arrows-.

• It must still be possible to turn the toothed belt sprockets on
the hubs, however they must not hang loose.
– Turn toothed belt sprockets clockwise in the elongated holes
as far as the stop.
– Fit toothed belt onto toothed belt sprocket of crankshaft, ten‐
sioning pulley, toothed belt sprockets, large guide pulley and,
last of all, onto the toothed belt sprocket of the coolant pump.
Adjust the tension of toothed belt as follows:
– Loosen the fixing nut of the tensioning pully and pull the rig
tool -T10265- out of the tensioning pulley.
– Pay attention to the correct fitting of the tensioning pulley in

the opening in the rear toothed belt guard -arrow-.

OCTAVIA II 2004 ➤

driver -T10264- clockwise until the pointer -2- stands in the
centre of the base plate in the gap.
Note
Ensure that the fixing nut does not turn.
– Hold the eccentric of the tensioning pulley in this position and

tighten fixing nut of tensioning pulley to 20 Nm and torque a
further 45° (1/8 turn).
Note
When tightening the fixing nut, the pointer -arrow- turns maximum
5 mm to the right from the gap of the base plate. This position
must not be corrected, because the toothed belt settles when
running-in.
– Insert counterholder -T10172- with bolts -T10172/4- , as

shown, and press in -direction of arrow-.
– Keep toothed belt sprockets with counterholder -T10172- un‐
der tension and tighten screws -arrows- of both toothed belt
sprockets to 25 Nm.
– Remove locking pins -3359- and crankshaft arrester -T10050-
or crankshaft arrester -T10100- .
Test timing:
– Turn crankshaft 2 turns in the direction of running of the engine
until the crankshaft is positioned shortly before TDC for cylin‐
der 1.
– Interlock during this motion the hub -A- in the direction of run‐
ning of the engine with locking pin -3359- .
– Check whether:
♦ the hub -B- can be interlocked with the locating pin -3359- ;
♦ the crankshaft can be arrested with the crankshaft arrester -
T10050- or crankshaft arrester -T10100- ;
♦ the pointer -2- of the tensioning pulley must be in the area
-a- of the base plate -1-.

OCTAVIA II 2004 ➤
If the hub -B- cannot be arrested:

– Loosen fixing screws -2- of toothed belt sprocket of inlet cam‐
shaft -B-.
– Fit ring spanner onto the central screw for the inlet camshaft.
– Turn the hub until the locking pin -3359- can be inserted.
– Tighten screws -2- of toothed belt sprocket of inlet camshaft
-B- to 25 Nm.
– Rotate the crankshaft 2 turns in the direction of running of the
engine until the crankshaft is positioned again on TDC for cyl‐
inder 1.
– Repeat timing test ⇒ page 36 .
If the crankshaft cannot be arrested:
– Loosen screws -1- and -2- of toothed belt sprockets -A- and
-B-.
– Rotate crankshaft in direction of rotation of engine until it can

be arrested with the crankshaft arrester .
Note
♦ The stud -arrow- must engage into the hole in the sealing
flange.
♦ If the crankshaft was turned behind the TDC for cylinder 1, turn
crankshaft back slightly and once again set to the TDC for cyl‐
inder 1 by turning in direction of rotation of engine.
– Insert counterholder -T10172- with bolts -T10172/4- , as

shown, and press in -direction of arrow-.

OCTAVIA II 2004 ➤
– Keep toothed belt sprockets with counterholder -T10172- un‐

der tension and tighten screws -1- and -2- of toothed belt
sprockets -A- and -B- to 25 Nm.
– Rotate the crankshaft 2 turns in the direction of running of the
inder 1.
Further installation
Further installation occurs in reverse order to removal. Pay at‐
tention to the following:
♦ Observe the instructions for installing the hose connections
with push-fit couplings ⇒ page 202 .
1.3 Removing and installing toothed belt for engine with engine identification
characters BMM

(1/4 turn)
❑ replace
❑ with notch, which marks
the TDC for cylinder 1
⇒ page 40
3 - Bottom toothed belt guard
❑ with notch, which marks
4 - 10 Nm
agent -D 000 600 A2-
5 - Middle toothed belt guard
❑ with arrow, which marks
⇒ page 40
❑ to remove, remove top
toothed belt guard and
unscrew tensioning de‐
vice for ribbed V-belt.
6 - Top toothed belt guard
❑ to remove, remove the
right charge air pipe
❑ when installing, careful‐
ly insert into the middle
toothed belt guard
7 - Toothed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing

OCTAVIA II 2004 ➤
❑ check for wear
❑ install (set the timing) ⇒ page 45
8 - 20 Nm + torque a further 45° (1/8 turn)
9 - Tensioning pulley
❑ The eccentric of the new version has an additional hole for 6 mm hexagon socket wrench ⇒ page 40
10 - 25 Nm
11 - Toothed belt sprocket of camshaft
❑ Mark installation position
12 - 100 Nm
13 - Hub
❑ with sensor rotor for Hall sensor -G40-
14 - 10 Nm
❑ to remove, unscrew coolant pump
❑ when installing carefully insert into the front sealing flange -belt pulley side-
16 - Rubber grommet
17 - 25 Nm
18 - O-ring
❑ replace
19 - Coolant pump
20 - 13 Nm
21 - Guide pulley
22 - Toothed belt sprocket of crankshaft
❑ 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
❑ replace
❑ do not oil
❑ to release and tighten use counterholder -T30004- or counterholder -MP 1-310 (3099)-
24 - 20 Nm
❑ self-locking, replace
25 - 10 Nm

OCTAVIA II 2004 ➤
Tensioning pulley
Additional hole in the eccentric of the tensioning pulley for 6 hex‐
agon socket wrench -arrow-.
Note
The tensioning pulley of the new version can be adjusted with the
special two-hole nut turner , e. g. -T10020- , or using a commercial
6 mm hexagon socket wrench.
Adjust TDC for cylinder 1 with the belt pulley of the crankshaft
fitted
– Turn the crankshaft at the central bolt in direction of rotation
of engine in such a way that the notch on the belt pulley of the
crankshaft (TDC marking for cylinder 1) -large arrow- and the
engraved arrow -small arrow- are positioned opposite each
other on the middle toothed belt guard, as shown.
Use a mirror.
Engine support bracket

For vehicles as of 03.07 the engine support -1- is installed.
Note
When removing the toothed belt it is necessary to remove the

engine support -1-.

OCTAVIA II 2004 ➤
Tightening order for engine support
Caution
The tightening sequence and the tightening torque of the fixing

screws for the engine support must definitely be respected.
Otherwise stress of the engine support occurs, which results
in the breaking of the engine support.
1. First screw in new screws -1...3- by hand.

2. Then tighten the screws in the order shown -1...3- to 40 Nm.
3. Subsequently torque the screws in the order shown -1…3-
a further 180° (1/2 turn).
Note
♦ Raise or lower engine with the supporting device -T30099- .

♦ Before the engine mount is installed, all the screws of the en‐
gine support must be tightened to the specified tightening
torque.
I : Engine support for vehicles up to 02.2007

lI: Engine support for vehicles as of 03.2007
1.3.1 Removing toothed belt

♦ Hook -MP 9-200/10 (10-222A/10)-
♦ Rig pin -3359- or -MP 1-301-
♦ Crankshaft arrester -T10050- or crankshaft arrester -T10100-
♦ Counterholder -T10172 - with bolts -T10172/4-
♦ Offset screwdriver -T10264-
♦ Rig tool -T10265-
♦ Locking agent -D 000 600 A2-
Note


– Remove charge air pipe to intake manifold flap motor -V157- .
ply ⇒ page 3 .

OCTAVIA II 2004 ➤
– Remove fuel feed line -2- and fuel return-flow line -1-, to do so
press in securing ring.
– Remove top toothed belt guard, to do so release retaining clips

-arrows-.
– Remove ribbed V-belt tensioning device.
⇒ Rep. Gr. 66 .
– Remove the belt pulley of the crankshaft.
– Unscrew bottom and middle toothed belt guard.
Gr. 66 .
– Position the supporting device -T30099- and the supporting

plate -T30099/1 - , suspend the engine/gearbox assembly on
the right lifting eye with hook -MP 9-200/10- and preload via
the spindle, do not lift.
Note
If the cylinder head must be removed, two spindles must be at‐

tached at the supporting device -T30099- ⇒ page 86 .
– Release screws -1- and -2- and remove connecting stud.

– Release screws -3...6- and remove engine mounting.

OCTAVIA II 2004 ➤
– Release screws -1...3- for engine support and remove sup‐

port.
Note
To release the bolts for the engine support, raise or lower the
engine slightly via the spindle of the supporting device -T30099- .
Caution


• Gear segment -arrow- must point upwards.
– Lock hub with locking pin -3359- .
– Depending on the version, lock the toothed belt sprocket of the

Difference of the toothed belt sprocket of crankshaft

OCTAVIA II 2004 ➤
Note

– Mark the direction of rotation of the toothed belt with chalk or

a felt-tip pen.
– Loosen screws -arrows- of toothed belt sprocket by approx. 1

turn.
– Loosen the fixing nut -1- of the tensioning pulley.

driver -T10264- in anti-clockwise direction -arrow- until the
tensioning pulley can be interlocked with the rig tool -T10265- .
– Now turn the eccentric of the tensioning pulley clockwise

-arrow- as far as the stop and tighten the fixing nut -1- by hand.
– First of all take the toothed belt off the toothed belt sprocket of
coolant pump and then from the other toothed belt sprockets.

OCTAVIA II 2004 ➤
1.3.2 Install timing belt (set the timing)
Caution
The work procedure which is described here must be precisely

respected.
♦ If, for example, the final check is not carried out and the
rig tools are not inserted again, there is a risk that the tim‐
ing is not correctly set and the vehicle shows signs of poor
vehicle handling and idle jerking occurs.
• Interlock camshaft with locking pin e. g. -3359- .

• Crankshaft is locked with crankshaft arrester -T10050- or
crankshaft arrester -T10100- .
• Tensioning pulley interlocked with rig tool -T10265- and fixed
with fixing nut up to right stop.
Note
♦ Always perform adjusting work on the toothed belt only on a

cold engine.
♦ When rotating the camshaft, the crankshaft must not be posi‐
tioned at TDC for any one piston. Risk of damaging valves and
pistons.
– Slightly screw in screws -arrows-.

• It must still be possible to turn the toothed belt sprocket on the
hub, however it must not hang loose.
– Turn toothed belt sprocket clockwise in the elongated holes as
far as the stop.
– Fit toothed belt onto toothed belt sprocket of crankshaft, ten‐
sioning pulley, toothed belt sprocket of camshaft and, last of
all, onto the toothed belt sprocket of the coolant pump.
Adjust the tension of toothed belt as follows:
– Loosen the fixing nut of the tensioning pully and pull the rig
tool -T10265- out of the tensioning pulley.
– Pay attention to the correct fitting of the tensioning pulley in

the opening in the rear toothed belt guard -arrow-.

OCTAVIA II 2004 ➤

driver -T10264- clockwise -arrow- in such a way until the
pointer -2- stands in the centre of the base plate in the gap.
Note
Ensure that the fixing nut does not turn.
– Hold the eccentric of the tensioning pulley in this position and

tighten fixing nut of tensioning pulley to 20 Nm and torque a
Note
When tightening the fixing nut, the pointer -arrow- turns maximum
5 mm to the right from the gap of the base plate. This position
must not be corrected, because the toothed belt settles when
running-in.
– Insert counterholder -T10172- with bolt -T10172/4- as shown

and by pressing in -direction of arrow- hold the pretension of
the toothed belt on the tension side.
– Tighten fixing screws -1- to 25 Nm.
– Remove locking pin -3359- and crankshaft arrester -T10050-
Test timing
– Turn the crankshaft 2 turns in the direction of running of the
engine until the crankshaft is positioned shortly before TDC for
cylinder 1.
– Interlock during this motion the hub in the direction of running

of the engine with locking pin -3359- .
– Check whether:
♦ the crankshaft can be arrested with the crankshaft arrester -

T10050- or crankshaft arrester -T10100- ;
♦ the pointer -2- of the tensioning pulley must be in the area
-a- of the base plate -1-.
If the crankshaft cannot be arrested:

OCTAVIA II 2004 ➤
– Loosen screws -arrows- of toothed belt sprocket.
– Rotate crankshaft in direction of rotation of engine until the

crankshaft can be arrested with the crankshaft arrester in the
hole in the sealing flange -arrow-.
Note
♦ The stud -arrow- must engage into the hole in the sealing
flange.
♦ If the crankshaft was turned behind the TDC for cylinder 1, turn
crankshaft back slightly and once again set to the TDC for cyl‐
inder 1 by turning in direction of rotation of engine.
– Tighten fixing screws -arrows- to 25 Nm.

– Remove locking pin -3359- and crankshaft arrester -T10050-
– Turn the crankshaft 2 turns in the direction of running of the
inder 1.
Further installation
Further installation occurs in reverse order to removal.

OCTAVIA II 2004 ➤
2 Removing and installing sealing

flange and flywheel
Note
Repairs to the clutch ⇒ gearbox ⇒ Rep. Gr. 30 .
1 - Gasket ring
❑ replace ⇒ page 49
❑ do not oil or grease
2 - Sealing flange -on the belt
pulley side-
❑ must be positioned on
dowel sleeves
❑ removing and installing
⇒ page 51
3 - Cylinder block
4 - The two-mass flywheel
⇒ page 59
❑ Assembly is only possi‐
ble in one position
through offset holes.
(1/4 turn)
❑ replace
6 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
❑ inserted on sealing
flange ⇒ page 49
7 - 15 Nm
❑ replace
8 - Sealing flange -on the gear‐
box side-
❑ can only be replaced
complete with gasket ring and with rotor of engine speed sender -G28-
9 - Engine speed sender -G28-
10 - 5 Nm

OCTAVIA II 2004 ➤
Installing intermediate plate

– Insert intermediate plate on sealing flange and push onto the
dowel sleeves -arrows-.
2.1 Replacing gasket ring for crankshaft -on

the belt pulley side-
♦ Counterholder -T30004 - or counterholder for toothed belt
sprocket -MP 1-310 (3099)-
♦ Gasket ring extractor -MP 1-226 (3203)-
♦ Assembly device -T10053-
Removing
• Engine installed.
– Removing timing belt.
– Remove toothed belt sprocket of crankshaft, to this end lock
the toothed belt sprocket with counterholder -T30004 - or with
counterholder for toothed belt sprocket -MP 1-310- .
2. Removing and installing sealing flange and flywheel 49

OCTAVIA II 2004 ➤
– To guide the gasket ring extractor screw in central screw for

toothed belt sprocket of crankshaft in the crankshaft up to the
stop.
– Turn inner part of gasket ring extractor -MP 1-226- two turns
(approx. 3 mm) out of the outer part and lock with knurled
screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
crankshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice and remove gasket
ring with pliers.
– Clean the contact and sealing surface.
Install
Note
Do not oil the sealing lip and the outer surface of the gasket before
the pressing in procedure.
– Remove oil residue on the crankshaft stub with a clean cloth.
– Insert guide bushing -T10053/1- on the crankshaft stub.

– Slide gasket ring over the guide bushing.

OCTAVIA II 2004 ➤
– Press in the gasket ring flush with the central screw for the
toothed belt sprocket of crankshaft and with the pressure
bushing of the assembly device -T10053- .
Note
♦ There must not be any oil present on contact surface between

toothed belt sprocket and crankshaft.
♦ Replace central screw for toothed belt sprocket of crankshaft.
♦ Do not oil central screw for toothed belt sprocket of crankshaft.
– Install toothed belt sprocket of crankshaft, to this end lock the

toothed belt sprocket with counterholder -T30004 - or with
counterholder for toothed belt sprocket -MP 1-310 (3099)- .
– Installing the timing belt.
2.2 Removing and installing the sealing

flange -on the belt pulley side-
♦ Counterholder -T30004 - or counterholder for toothed belt
sprocket -MP 1-310 (3099)-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Protective goggles and gloves
♦ Cleaning agent and grease remover e.g. -D 000 401 04-
♦ Silicone sealant -D 176 404 A2-
Removing
• Engine installed.

OCTAVIA II 2004 ➤
– Remove toothed belt sprocket of crankshaft, to this end lock

the toothed belt sprocket with counterholder -T30004 - or with
– Drain engine oil ⇒ Maintenance ; Octavia II .
– Removing the oil pan ⇒ page 127 .
– Unscrew the fixing screws of the front sealing flange and re‐
move sealing flange, if necessary release by applying slight
blows with a rubber-headed hammer.
– Drive out the gasket ring from the removed sealing flange.
Install
the following:
WARNING
Wear protective gloves when working with sealant and grease

remover!
– Clean sealing surface on sealing flange, cylinder block and on

the oil pan from gasket residues with chemical sealant remov‐
er.
– Degrease the sealing surfaces.
Note
Pay attention to the use by date on the silicone sealant.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).

OCTAVIA II 2004 ➤
– Apply silicone sealant bead -arrow- to the clean sealing sur‐

face of the sealing flange, as shown.
• Thickness of sealant bead -arrow-: 2...3 mm.
Note
♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clogg the strainer
in the oil suction pipe.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When installing the sealing flange with the gasket ring fitted
place a guide sleeve -T10053/1- on the crankshaft journal.
– Carefully push the sealing flange onto the dowel sleeves at the
cylinder block and tighten new fixing bolts by hand.
– Tighten the screws of the sealing flange alternately and cross‐
wise to 15 Nm.
– Install new gasket ring ⇒ page 49 .
– Installing the oil pan ⇒ page 127 .
– Install toothed belt sprocket of crankshaft, to this end lock the
toothed belt sprocket with counterholder -T30004 - or with
– Installing the timing belt.
– Top up with engine oil and check the oil level ⇒ Maintenance ;
Octavia II .
2.3 Replace sealing flange -on the gearbox

side-
♦ Screw M6 x 35 (3x)
♦ Screw M7 x 35 (2x)
♦ Feeler gauges
♦ Steel straightedge
2.3.1 Removing
• Gearbox removed.
– Remove the two-mass flywheel ⇒ page 59 .

OCTAVIA II 2004 ➤
– Remove the intermediate plate from the dowel sleeves and

unhook from sealing flange -arrows-.
– Position crankshaft on TDC for cylinder 1 ⇒ page 29 .
– Remove engine speed sender -G28- -1-.

– Release the fixing screws of the rear sealing flange.
– Screw 3 screws M6 x 35 mm into the threaded bores of the

sealing flange -arrows-.
– Press out sealing flange together with rotor from the crank‐
shaft by alternately screwing the screws into the sealing
flange.

OCTAVIA II 2004 ➤
2.3.2 Install
Note
♦ The sealing flange with PTFE gasket ring is provided with

sealing lip supporting ring. This supporting ring is intended as
an assembly sleeve and must not be removed before instal‐
ling.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.
♦ The rotor is given its fitting location by fixing the assembly de‐
vice -T10134- to the positioning pin.
♦ The sealing flange and gasket ring form one unit and must be
replaced together with the rotor.
♦ The rotor has an elastomer layer on its sealing surface with
the crankshaft. This layer must not be brought into contact with
dirt or grease.
♦ The assembly device -T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into
the threaded bore of the crankshaft.
A - Mounting sealing flange with rotor on the assembly device -

T10134-
A - Hexagon nut
B - Clamping surface
C - Assembly cup
D - Allan screw
E - Guide bolts (with red handle - for fuel engine)
F - Positioning pin
G - Guide bolts (with black handle - for diesel engine)
– Grip assembly device assembly device -T10134- on clamping

surface -B- of the threaded spindle in a vice.

OCTAVIA II 2004 ➤
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
– Lay the front side of the sealing flange on a clean and level
surface.
– Press the sealing lip supporting ring -A- -arrows-, until it rests
on the level surface.
• The top side of the rotor and the front side of the sealing flange
must be flush.
Locating hole -B- on the rotor -C- must be flush with the marking
-A- on the sealing flange.
– Lay the sealing flange with the front side on the assembly de‐
vice -T10134- in such a way that the positioning pin -A- en‐
gages in the hole -B- of the rotor.
Note
Make sure the sealing flange lies flat on the assembly device.

OCTAVIA II 2004 ➤
– When tightening the knurled screws -B- press the sealing lip
supporting ring -A- on the surface of the assembly device -
T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly device -T10134- with sealing flange
on the crankshaft flange
• The crankshaft flange must be free of grease and oil
• Crankshaft is at TDC for cylinder 1
– Unscrew hexagon nut up to the end of the threaded spindle.
– Screw assembly device -T10134- with Allan screws -A- up to

the stop onto the crankshaft flange.
– Screw in two screws M7 x 35 mm -A- by about 3 thread turns

for the sealing flange guide into the cylinder block.
– Move the assembly cup -C- by hand in the

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Subsequently insert the guide bolt with black
handle -D- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly pushed in, then the handle has a dis‐
tance of approx. 10 mm from the assembly cup -C-. This gives
the rotor its final fitting location.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
Note
The guide bolt for petrol engines (red handle) -F- must not be fitted
into the threaded hole of the crankshaft.
C - Pressing the rotor onto the crankshaft flange

OCTAVIA II 2004 ➤
– Tighten the hexagon nut of the assembly device -T10134- us‐

ing a torque wrench with adapter. Tightening torque: 35 Nm.
Note
After tightening the nut to 35 mm there must still be a narrow air

gap between the cylinder block and the sealing flange.
D - Inspecting the fitting position of the rotor on the crankshaft
– Unscrew hexagon nut -E- up to the end of the threaded spin‐

dle.
– Release both screws -A- to the guide from the cylinder block.
– Unscrew three knurled screws -B- from the sealing flange.
– Unscrew two Allan screws and remove assembly device.
– Remove sealing lips supporting ring.
The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- of 0.5 mm between the crankshaft flange
-A- and the rotor -B-.
– Position the steel striaghtedge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 59 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing flange crosswise.
Tightening torque: 15 Nm

OCTAVIA II 2004 ➤
– Install engine speed sender -G28- -1-. Tightening torque: 5

Nm.
– Fit intermediate plate.
– Install flywheel with new screws. Tighten fixing bolts to 60 Nm
and torque a further 1/4 turn (90°).
E - Pressing down the rotor
– Screw assembly device -T 10134- with Allan screws up to the

stop onto the crankshaft flange.
– Screw in three knurled screws -B- into the flange.
– Subsequently insert the guide bolt with black handle -D- fully
into the threaded bore of the crankshaft. If the guide bolt is
correctly positioned, then the handle has a distance of approx.
10 mm from the assembly cup -C-.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup.
– Tighten the hexagon nut of the assembly device using a torque

wrench with adapter.
Tightening torque: 40 Nm
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 58 .
If the dimension -a- is again too small:
– Tighten the hexagon nut of the assembly device to 45 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 58 .
2.4 Removing and installing the two-mass

flywheel
♦ Counterholder -MP1-223 (3067)-
or
♦ Engine mount -MP 1-202 (VW 540)-

♦ Bushing -T30010 (VW 540/1B)-
♦ Flywheel lock -MP 1-504-
Removing
• Gearbox removed.

OCTAVIA II 2004 ➤
Engine installed
– Insert the counterholder -MP1-223 (3067)- into the bore hole
on the cylinder block.
• Fitting position of the counterholder:
A - for tightening
B - for slackening
Engine removed
– Position the flywheel lock -MP 1-504- on the ring gear and turn
crankshaft until it rests against the sleeve -T30010- .
Continued for all

– Rotate the secondary side -A- of the two-mass flywheel in such
a way that the screws -B- are positioned in the middle of the
holes -arrows-.
Caution
When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise it will be damaged.
– Release screws -B- and remove two-mass flywheel.

Install
the following:
Note
Use new screws for attaching.

OCTAVIA II 2004 ➤
– Rotate the secondary side -A- of the two-mass flywheel in such

a way that the screws -B- are positioned in the middle of the
holes -arrows-.
1. Screw in all the screws -B- by hand.
2. First of all tighten all the screws -B- crosswise to 60 Nm.
3. Then torque all the screws -B- crosswise a further 90° (1/4
turn.)

OCTAVIA II 2004 ➤
3 Crankshaft, Piston and Conrod
3.1 Removing and installing crankshaft
Note
The engine should be attached to the engine repair stand with the
engine holder -MP 1-202 (VW 540)- for carrying out installation
work.
1 - Bearing shell
❑ for cylinder block with lu‐
bricating groove
❑ do not mix up used bear‐
ing shells (mark)
2 - Drive chain sprocket
❑ for oil pump
⇒ page 63
3 - Bearing shell
❑ for bearing cap without
lubricating groove
❑ do not mix up used bear‐
ing shells (mark)
4 - Thrust washers
❑ for bearing 3
❑ different version for cyl‐
inder block and bearing
cap
❑ pay attention to locating
element
(1/4 turn)
❑ replace
6 - Bearing caps
❑ Bearing cap 1: belt pul‐
ley side
❑ bearing cap 3 with re‐
cesses for thrust wash‐
ers
❑ retaining lugs of the
bearing shells of the cyl‐
inder block/bearing cap must be on top of one another
7 - Needle bearing
❑ only vehicles with automatic gearbox
8 - Crankshaft
❑ with chain sprocket for oil pump drive
❑ Axial play when new: 0.07...0.17 mm; Wear limit: 0.37 mm
❑ Crankshaft bearing pins: ∅ 54.00 mm

OCTAVIA II 2004 ➤
❑ Conrod bearing: ∅ 50.90 mm
3.2 Removing and installing drive chain

sprocket
♦ Drive bushing -MP1-316 (30 - 100)-
♦ Two-arm extractor, standard commercially available
♦ Protective gloves
Removing
– Remove sealing flange - on the belt pulley side ⇒ page 51 .
– Remove chain tensioner, chain sprocket for oil pump and oil
pump chain.
– Remove drive chain sprocket of crankshaft with two-arm ex‐
tractor -2-. At the same time protect the crankshaft journal with
a suitable washer -1-.
Install
the following:
WARNING
Wear protective gloves!
– Heat up the drive chain sprocket in an oven for about 15 mi‐

nutes to 220 °C.
– Place the drive chain sprocket on the shaft end using pliers
and with drive bushing -30 - 100- slide on until the stop on the
crankshaft is reached.
• Fitting location: the broad collar of the drive chain sprocket
(45° chamfer in the hole) points to the engine.
3.3 Replace needle bearing for crankshaft

Only on vehicles fitted with automatic gearbox.
♦ Interior extractor 14...18 mm , e.g. -Kukko 21/2-
♦ Countersupport , e.g. -Kukko 22/1-
♦ Centering mandrel -T30029 (3176)-
3. Crankshaft, Piston and Conrod 63

OCTAVIA II 2004 ➤
Removing
– Pull out needle bearing with interior extractor 14...18 mm and
countersupport -A-.
Note
While doing so, insert the interior extractor behind the needle
bearing.
Install
– Insert the needle bearing with the centering pin -T30029- into
the crankshaft.
• The marked side of the needle bearing (gasket ring side)
should be legible when in its installed condition.
Depth of installation of the needle bearing:

♦ Dimension -a- 1.5...1.8 mm

OCTAVIA II 2004 ➤
3.4 Disassembling and assembling pistons and conrods
1 - Piston rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
❑ marking “TOP” faces
piston crown
❑ Inspect gap clearance
⇒ page 66
❑ Inspect end clearance
⇒ page 66
2 - Piston
❑ with combustion cham‐
ber
❑ mark installation posi‐
tion and matching cylin‐
der
❑ Installation position and
assignment of piston/
cylinder ⇒ page 67
❑ arrow on piston crown
faces towards the belt
pulley side
❑ replace piston if there is
any sign of crack forma‐
tion on the piston body
❑ Inspecting piston
⇒ page 67
❑ Piston dimension: ∅
80.96 mm
❑ use piston ring tension‐
ing strap for installing
❑ inspect piston projection
at TDC ⇒ page 68
3 - Piston pin
❑ if stiff, heat piston to 60°C
❑ use drift -222A- for removing and installing
4 - Circlip
5 - Conrod
❑ always replace as a set only
❑ mark matching cylinder -A-
❑ Fitting position: Markings -B- point towards the belt pulley side
❑ with a split bearing cap
❑ separate new conrod ⇒ page 69
6 - Bearing shell
❑ Fitting position ⇒ page 68
❑ do not mix up already used bearing shells (mark)
❑ Observe version: top bearing shell (towards the piston) must be made from a long lasting material, rec‐
ognition feature for new bearing shells: black marking on the contact surface near the separation point
❑ insert in middle ⇒ page 68
❑ check for firm seating
❑ Axial play wear limit: 0.37 mm

OCTAVIA II 2004 ➤
7 - Cylinder block
❑ Inspect cylinder ⇒ page 68
❑ Cylinder dimension: ∅ 81.01 mm
8 - Conrod bearing cap
❑ cracked cover fits only in one position at the relevant conrod
9 - Oil injection nozzle
❑ for piston cooling
10 - 25 Nm
❑ replace without sealant
11 - Conrod bolt - 30 Nm + torque a further + 90° (1/4 turn)
❑ replace
❑ Oil thread and contact surface
Inspecting piston ring gap clearance

♦ Feeler gauges
– Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder. To insert
use piston without rings.
Piston ring new Wear limit
(dimensions in mm)
1. Compression ring 0,20 … 0,40 1,00
Oil scraper ring 0,25 … 0,50 1,00
Inspect piston ring end clearance

♦ Feeler gauges

OCTAVIA II 2004 ➤
– Clean before inspecting the annular grooves of the piston.

Piston ring new Wear limit
(dimensions in mm)
Oil scraper ring 0,03 … 0,06 0,15
Inspecting pistons

♦ External micrometer
– Measure about 10 mm from the lower edge, offset at right an‐
gles to the piston pin shaft.
• Maximum deviation from specified dimension: 0,04 mm
Installation position and assignment of piston/cylinder
For engine with engine identification characters BKD, AZV
For engine with engine identification characters BKD, AZV
Pistons in cylinders 1…4:
• arrow on piston crown faces towards the belt pulley side
-arrows-.
For engine with engine identification characters BMM

Pistons in cylinders 1 and 2:
• Large recess for inlet valve points to flywheel side -arrows-.
Pistons in cylinders 3 and 4:
• Large recess for inlet valve points to belt pulley side
-arrows-.
Note
♦ For new pistons the cylinder assignment is colour-coded on

the piston crown.
♦ Piston of cylinder 1 and 2: Marking 1/2.
♦ Piston of cylinder 3 and 4: Marking 3/4.

OCTAVIA II 2004 ➤
Inspecting cylinder bore

♦ Internal precision measuring instrument
– Measure cylinder at 3 points crosswise in transverse direction
-A- and lengthwise -B-.
• Maximum deviation from specified dimension: 0.10 mm
Fitting position of the bearing shells in the conrods
– Insert bearing shell in the conrod or in the center of the conrod
bearing cap.
• Dimension -a- = 2,5 mm
3.5 Checking piston projection in TDC

♦ Measuring tool for piston projection -MP 1-107-
Test sequence
When fitting new pistons or a partial engine, check the piston pro‐
jection in TDC on all pistons.
Depending on the piston projection fit the relevant cylinder head
seal in accordance with the table below.
Piston projection over cylinder Bore marking
block - top side
mm
0,91 … 1,00 1
1,01 … 1,10 2
1,11 … 1,20 3

OCTAVIA II 2004 ➤
Identification of the cylinder head seal

♦ Part number = -arrow 1-
♦ Control code = -arrow 2- (ignore)
♦ Bores = -arrow 3-
Note
♦ Differing thicknesses of cylinder head gaskets are inserted

according to the piston projection. When replacing a gasket
use a new gasket with the same identification -arrow 3-.
♦ If different values are measured during the projection meas‐
urement of the piston, the greatest dimension applies for the
seal assignment.
Note
If different values are measured during the projection measure‐

ment of the piston, the greatest dimension applies for the seal
assignment.
3.6 Separating new conrod

It can happen that the predetermined breaking point on the new
conrod is not completely pierced. If the conrod bearing cap cannot
be lifted by hand, proceed in the following manner:
– Mark the mark assignment to cylinder of the conrod.
– Slightly tension the conrod, as shown in the illustration, in a
vice provided with aluminium protective jaws.
Note
♦ The conrod must only be slightly tensioned in order to avoid

damage on the conrod.
♦ The conrod is clamped below the broken line.
– Screw out both screws -arrows- approximately 5 turns.
– Carefully knock with a plastic hammer in -direction of arrow -

against the conrod bearing cap until it is loose.

OCTAVIA II 2004 ➤
15 – Cylinder Head, Valve Gear

1 Removing and installing cylinder
head
Note
♦ Cylinder heads with cracks between the valve seats may con‐
tinue to be used without any reduction in the life time, provided
the cracks are slight and maximum 0.5 mm wide.
♦ It is not permissible to rework the cylinder heads of diesel en‐
gines.
♦ Replace O-rings and gaskets.
♦ Replace cylinder head bolts and screws which have been
tightened to a turning angle.
♦ When installing an exchange cylinder head with the camshafts
installed, it is necessary to oil the contact surfaces between
the roller arms and the cams after installing the head.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ When replacing the cylinder head, replace all the coolant.
♦ If engine damage occurs and it is suspected that the cause of
this is oil/fuel mixing (olfactory test of the engine oil), the tan‐
dem pump must absolutely be checked for internal tightness
⇒ page 181 .
♦ Change contaminated engine oil ⇒ Maintenance ; Octavia II .
70 Rep. Gr.15 - Cylinder Head, Valve Gear

OCTAVIA II 2004 ➤
1.1 Summary of components for engine with engine identification characters

BKD, AZV

2 - Rubber grommet
3 - Pin screw - 10 Nm
4 - Hub
❑ for inlet camshaft with
rotor for hall sender -
G40-
❑ to remove use extractor
-T10052-
5 - 100 Nm
❑ to release and tighten
use counterholder -
T10051-
6 - Hub
❑ for exhaust camshaft
❑ to remove use extractor
-T10052-
7 - 10 Nm
agent -D 000 600 A2-
8 - Valve-lever shaft
❑ Mark the installation po‐
sition of the valve lever
❑ do not interchange
⇒ page 75
❑ before inserting, check
whether all the ball
studs and O-rings are
inserted in the unit injec‐
tors
❑ replace
❑ pay attention to order for slackening ⇒ page 75
❑ pay attention to order and procedure for tightening ⇒ page 78
10 - Gasket for cylinder head cover
❑ replace if damaged or leaking
❑ press onto the spacer sleeves (Position 15)
11 - Cylinder head cover
12 - Screw cap
13 - Gasket
14 - Sealing sleeve
15 - Screw with spacer sleeve, 10 Nm
❑ pay attention to sequence for loosening and tightening ⇒ page 73
1. Removing and installing cylinder head 71

OCTAVIA II 2004 ➤
16 - 20 Nm
17 - Cylinder head bolt
❑ replace
❑ pay attention to order and procedure for tightening ⇒ page 80
18 - Multipin plug connection
❑ central for pump-nozzle units
❑ when removing, disconnect plug connection from bushing by turning to the left
19 - Gasket
❑ replace
20 - Tandem pump
❑ check ⇒ page 177
21 - 20 Nm
22 - Cylinder head
❑ check for distortion ⇒ page 73
❑ after replacing fill entire system with fresh coolant ⇒ page 137
23 - Mixing tube
❑ inserted into cylinder head
❑ pull out with hook
❑ Fitting position mixing tube ⇒ page 72
24 - Cylinder head gasket
❑ Pay attention to the marking ⇒ page 73
25 - Hall sender -G40-
❑ for camshaft position
Fitting position mixing tube

The recess of the mixing tube points to the top -arrow-.

OCTAVIA II 2004 ➤
Inspecting the cylinder head for distortion

♦ Feeler gauges
♦ Knife-edge straightedge
– Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
• Maximum permissible deviation: 0.05 mm
Note
It is not permissible to rework the cylinder heads of diesel engines.
Identification of the cylinder head seal

Note
Differing thicknesses of cylinder head gaskets are inserted ac‐

cording to the piston projection. If only the gasket is replaced, then
it must be replaced with a new gasket with the same marking.
1.2 Removing and installing cylinder head

cover for engine with engine identifica‐
tion characters BKD, AZV
Removing
– Detach suction hose -3-.

OCTAVIA II 2004 ➤
– Release screws -1- and -2- and slacken bracket -3- for fuel
hoses on the left engine lifting eye.
Note
Coolant hoses as well as fuel lines remain connected.
– Remove top toothed belt guard; to do so release retaining clips

-arrows-.
– Release screws -1- and -3-.

– Remove crankcase ventilation hose -2- from charge air pipe
to turbocharger and press the charge air pipe to the rear.
Note
♦ The charge air pipe -4- remains connected to the turbocharg‐

er.
♦ In the figure, the illustration is shown from the rear with the
engine removed.
– Release the screws of the cylinder head cover in the sequence

-11...1-.
– Release screws and remove cylinder head cover with gasket.
Install
the following:
Note
Replace the gasket and the screws of the cylinder head cover in
case of damage.
– First tighten the screws of the cylinder head cover in the order
-1...11- by hand, then to 10 Nm.

OCTAVIA II 2004 ➤

for engine with engine identification
characters BKD, AZV
♦ Hook -MP 9-200/10 (10-222A/10)-
♦ Support -T10014-
♦ Counterholder -T10051 -
♦ Extractor -T10052-
♦ Rig pin -3359- or -MP 1-301- (2x)
1.3.1 Removing
– Switch off the ignition and pull out the ignition key.
– Remove air filter with air intake hose and suction hose
⇒ page 212 .
– Drain coolant ⇒ page 137 .
ply ⇒ page 3 .
– Remove fuel feed line -3- and fuel return-flow line -2-, to do so
press in securing ring.
– Extract fuel from the tandem pump ⇒ page 174 .
– Removing toothed belt ⇒ page 27 .
On vehicles up to 05.05, support the engine as described be‐
low.

OCTAVIA II 2004 ➤
– Screw the bracket -T10014 - into the threaded hole above the
coolant pump. Tighten screw for bracket to 20 Nm.
– Carefully raise the engine with the spindle -A- and through this
release the spindle -B-.
– Push the spindle -B- forwards.
– Disconnect plug -2-, unscrew screw -4- and remove front air
charge pipe with connecting hose; to do so raise retaining clips
-1- and -3-.
– Unbolt heat shield for right drive shaft -arrows-.

OCTAVIA II 2004 ➤
– Remove the pre-exhaust pipe from the exhaust turbocharger,

slacken the double clamp and push the exhaust pipe to the
rear ⇒ page 232 .
– Release screws -1- and -2- and remove support for turbo‐
charger.
Note
Collect any engine oil which flows out with a cloth.
– Remove the oil return line -3- at the cylinder block.

– Unscrew oil feed line from turbocharger, exhaust manifold and
coolant pipe and lay it to one side.
– Remove connection pipe for exhaust gas recirculation be‐
tween mechanical valve and radiator for exhaust gas recircu‐
lation ⇒ page 244 .
– Remove toothed belt sprockets of camshafts and pull off hubs
for camshafts ⇒ page 28 .
– Release screws -2...4-.

– Unscrew nut -1- for tensioning pulley.
Remove the timing belt tensioning pulley on vehicles up to
05.05.
– Screw out screw -5- and remove Hall sender -G40- from cyl‐
inder head.
– Disconnect all remaining plug connections at cylinder head
and lay aside the electrical lines.
– Unscrew fixing screws of oil dipstick guide, pull guide out of
the cylinder block and for removal pivot fowards.
– Disconnect hose from vacuum reservoir, release screw and
remove reservoir from bracket. Then remove the support.
– Separate all remaining coolant, charge air and vacuum hoses
and pipes from the cylinder.
– Remove cylinder head cover ⇒ page 73 .
– Release screws -1- -3- and -5-.

– Loosen screws -2- and -4- and release alternately in several
stages.
Note
Do not pull out screws of valve-lever shaft, so that the individual

parts on the valve-lever shaft remain attached. If necessary mark
assignment of the individual parts.
– Remove valve-lever shaft.

OCTAVIA II 2004 ➤
– Unscrew screws -6...10- of bearing frame.
– Slacken cylinder head bolts in the order shown.
Note
A second mechanic is required for the following work.
– Slightly raise the cylinder head and swivel it to the left out of
the rear toothed belt guard.
Note
♦ On vehicles as of 05.05, the timing belt tensioning pulley re‐

mains on the engine support.
♦ The cylinder head must be guided carefully in order to avoid
damage.
– Place the cylinder head down on a soft surface with the sealing
surface to the top.
1.3.2 Install
Note
♦ There must not be any oil or coolant present in the blind holes
for the cylinder head bolts.
♦ Replace cylinder head bolts.
nuts.
♦ Remove the new cylinder head seal from its wrapping imme‐
diately before fitting.
♦ Treat the seal with the utmost care. Damage to the silicone
layer and in the area of the bead results in leakages.
♦ When installing an exchange cylinder head with the camshafts
the roller arms and the cams after installing the cylinder head.
♦ The plastic base for protecting the open valves should only be
removed immediately before attaching the cylinder head.

OCTAVIA II 2004 ➤
WARNING

remover!
– Make sure that when cleaning the cylinder head and cylinder
block no impurities can get into the cylinder or into the oil and
coolant galleries.
– Carefully remove old residual sealant from the cylinder head/
cylinder block using a chemical sealant remover.
– Before fitting the cylinder head rotate the crankshaft so that all
the pistons are almost evenly at TDC.
– Pay attention to the identification of the cylinder head seal.
Note
♦ If the cylinder head gasket or cylinder head are replaced, then

install a new cylinder head gasket with the same identification
-arrow 3-.
♦ If parts of the crankshaft drive were replaced then the new
cylinder head gasket must be defined by measuring the pro‐
trusion of the pistons in TDC .
– Fit on cylinder head gasket.

• Pay attention to dowel sleeves -arrows- in cylinder block.
• Observe the installed position of the cylinder head gasket, the
marking “above” or the part number must point to the cylinder
head.
– Insert the cylinder head.

OCTAVIA II 2004 ➤
– Insert new cylinder head bolts and tighten by hand.

– Tighten the cylinder head in four stages in the indicated tight‐
ening sequence:
Stage Tighten
I – Pre-tighten with the torque wrench to 40 Nm.
II – Pre-tighten with the torque wrench to 60 Nm.
III – Using a rigid wrench torque a further 90° (1/4
turn).
IV – Using a rigid wrench torque a further 90° (1/4
turn).
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.
– Before inserting the valve-lever shaft, check whether all the

ball studs -1- and O-rings -2- are inserted in the unit injectors.
– Screw on valve-lever shaft and bearing frame as follows:

– Replace screws -1...5-.
Se‐ Tighten
quence
I – Tighten screws -2- and -4- alternately in stages,
until the valve-lever shaft is positioned on the
bearing frame.
II – Tighten screws -1-, -3- and -5- to 20 Nm + torque
III – Tighten screws -2- and -4- to 20 Nm + torque a
IV – Tighten bearing frame screws -6…10- to 20 Nm.

OCTAVIA II 2004 ➤
– Insert screws -2...5- with spread on locking agent -D 000 600

A2- and tighten to 10 Nm.
– Screw in the pin screw -1- and tighten to 10 Nm.
– Position hub onto exhaust camshaft.

– Tighten screw -1- to 100 Nm, use counterholder -T10051- to
hold.
– Fit the hub onto the inlet camshaft in the same way and tighten.
– Push camshaft sprockets onto hubs.

• Both tooth segments -arrows- of the camshaft sprockets must
be facing up.
– Slightly screw in plug -1-.
• It must still be possible to turn the camshaft sprockets on the
hubs, however they must not hang loose.
– Lock hubs with locking pins -3359- .
– Depending on the version of the toothed belt sprocket, lock the


OCTAVIA II 2004 ➤
Note

– install (set the timing) ⇒ page 35 .

– Install cylinder head cover ⇒ page 73 .
– Connect oil lines to exhaust turbocharger and install exhaust
turbocharger support.
– Install exhaust system ⇒ page 233 .
– Align exhaust system free of stress ⇒ page 242 .
Note
Change contaminated engine oil ⇒ Maintenance ; Octavia II .
– Top up coolant ⇒ page 137 .
1.4 Testing compression pressure for en‐

gine with engine identification charac‐
ters BKD, AZV
The compression pressure is tested in the “Targeted fault finding”
using the vehicle diagnosis system, measurement and informa‐
tion system -VAS 5051- under “Repair Group 15; Cylinder head/
valve gear; Subsystem, Boundary conditions; Diagnostic Object:
poor compression pressure”.

OCTAVIA II 2004 ➤

BMM
1 - Vacuum hose
❑ for connecting piece of
tandem pump / brake
booster
2 - Screw cap
3 - Connecting tube
❑ for crankcase ventila‐
tion
❑ to suction hose
4 - Screw with spacer sleeve,
10 Nm
❑ pay attention to se‐
quence for loosening
and tightening
⇒ page 84
5 - Tandem pump
⇒ page 175
6 - 20 Nm
7 - 10 Nm
8 - Coolant flange
9 - O-ring
❑ replace
10 - 10 Nm
11 - Gasket rings
❑ replace
12 - Mixing tube
❑ inserted in the head
❑ pull out with hook
13 - Cylinder head gasket
❑ Pay attention to the marking ⇒ page 73
15 - 10 Nm
❑ mount using locking agent -D 000 600 A2-
16 - 15 Nm
17 - 100 Nm
18 - Hub
❑ with sensor rotor for Hall sensor -G40-
❑ remove ⇒ page 114

OCTAVIA II 2004 ➤
19 - Cylinder head
❑ check for distortion ⇒ page 84
❑ after replacing fill entire system with fresh coolant
❑ replace
❑ pay attention to order for tightening ⇒ page 91
❑ make sure that the washers arer inserted into the cylinder head
21 - Gasket for cylinder head cover
❑ press onto the spacer sleeves (Position 4)
❑ before mounting, seal contact faces with sealing compound -D 454 300 A2- ⇒ page 84
22 - Fuel return-flow line
23 - Fuel feed line
24 - Coolant lines
25 - Cylinder head cover
Inspecting the cylinder head for distortion

♦ Feeler gauges
♦ Knife-edge straightedge
– Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
• Maximum permissible deviation: 0.05 mm
Note
It is not permissible to rework the cylinder heads of diesel engines.

cover for engine with engine identifica‐
tion characters BMM

OCTAVIA II 2004 ➤

♦ Sealing compound -D 454 300 A2-
Removing
– Pull off hose -2- for crankcase ventilation.
– Pull off the vacuum hose to the vacuum reservoir at the cylin‐
der head.
– Release fuel hoses and coolant hoses at right charge air pipe.
– Remove charge air pipe to intake manifold flap motor -V157- ,
to do so pull the retaining clips.
Note
Coolant hoses as well as fuel lines remain connected.
– Remove top toothed belt guard, to do so release retaining

clips.
– Unscrew the screws of the cylinder head cover in the se‐

quence -13...1- and remove cover.
Install
the following:
WARNING

remover!
– Clean sealing surface on bearing cap and on cylinder head

from sealant residues with chemical gasket remover.
– Apply on both edges of the bearing cap sealing surfaces and

cylinder head -arrows- at front ...

OCTAVIA II 2004 ➤
– ... and apply at rear a small amount of (∅ approx. 5 mm) seal‐

ant -D 454 300 A2- -arrows-.
Note
Replace the gasket and the screws of the cylinder head cover in
case of damage.
– Tighten the screws of the cylinder head cover in the sequence

-1…13- to 10 Nm.

characters BMM
♦ Hook -MP 9-200/10 (10-222A/10)-
♦ Support -T10014-
♦ Catch pan , e.g. -VAS 6208 -
♦ Rig pin -3359- or -MP 1-301-
♦ Workshop crane , e.g. -VAS 6100 -
♦ Lifting device -MP 9-201-
1.7.1 Removing
– Extract fuel from the tandem pump ⇒ page 175 .
– Remove air filter ⇒ page 223 .
– Remove suction hose with connection fitting ⇒ page 196 .

OCTAVIA II 2004 ➤
– Detach coolant hose between engine and radiator -arrows-.

– Remove the charge air pipe between the exhaust turbocharg‐
er and the charge air cooler ⇒ page 200 .
ply ⇒ page 3 .
– Disconnect the fuel intake hose -2- and the fuel return-flow
hose -1- from the fuel lines.
– Remove coolant hose -3-.
– Disconnect the fuel feed line.
– Remove pre-exhaust pipe with diesel particle filter
⇒ page 237 .
Note
On vehicles with four-wheel drive the pre-exhaust pipe with diesel

particle filter can remain in the engine compartment and the gear‐
box with bevel gear must not be removed.
– Disconnect electrical plug connection -5- for exhaust gas tem‐

perature sender 1 -G235- ( temperature sender upstream
turbocharger -G507- ) and expose cable.
– Disconnect plug connection at changeover valve for radiator
of exhaust gas recirculation -N345- -arrow-.

OCTAVIA II 2004 ➤
– Expose electrical wiring looms to body.
– Remove the vacuum hose -2- at the vacuum unit for charge
pressure control.
– Disconnect vacuum hose -3- at the cable for the vacuum set‐
ting element of the radiator flap for exhaust gas recirculation.
– Disconnect vacuum line at the tandem pump.
– Slacken changeover valve for radiator of exhaust gas recircu‐
lation -N345- at bracket.
– Lay changeover valve for radiator of exhaust gas recirculation
-N345- with connected hoses to the side.
– Detach oil intake hose -1- from exhaust turbocharger.
– Remove oil feed pipe.
– Pull the vacuum hose -arrow- off the brake servo unit.
– Remove coolant hose -arrow- at coolant fitting.

– Disconnect the plug from the coolant temperature sender -
G62- and detach the electrical wiring.

OCTAVIA II 2004 ➤
– Pull out release pin -Pfeil 1- and open knurled nut -arrow 2- .
– Disconnect central plug connection for unit injectors and ex‐
pose wiring loom.
– Remove plug for fuel temperature sender -G81- .
– Separate edge connector of the glow plugs.
– Unscrew fixing screws of oil dipstick guide, pull oil dipstick
guide out of the cylinder block upwards.
– Disconnect coolant hoses -1- at exhaust gas recirculation ra‐

diator.
– Remove connection pipe for exhaust gas recirculation radiator
-arrows-.
– Unscrew screw for right flange shaft -arrow 1-.

– Remove right flange shaft ⇒ Gearbox ⇒ Rep. Gr. 39 .
– Release screw -2- and hollow screw -3-.

– Turn the support for exhaust gas turbocharger by 90° and pull
it towards the bottom out of the oil return-flow line.

OCTAVIA II 2004 ➤
– Release the screws from the support for the intake manifold
flap motor -V157- -arrows-.
For vehicles with auxiliary heating.
– Remove coolant pipes to auxiliary heating with connected
coolant hoses at cylinder block.
– Remove toothed belt sprocket of camshaft and hub
⇒ page 114 .
– Remove timing belt tensioning pulley.
– Release fixing screws for rear toothed belt guard -2- and -4-.
– Unscrew screw -3- and remove Hall sender -G40- from cylin‐
der head.
– Screw the bracket -T10014- into the threaded hole above the
coolant pump. Tighten screw for bracket to 20 Nm.
– Carefully raise the engine with the spindle -A- and through this
release the spindle -B-.
– Push the spindle -B- forwards.

OCTAVIA II 2004 ➤
– Follow the specified order for loosening cylinder head bolts.

– Slightly raise the cylinder head with lifting device -MP 9-201-
and workshop crane -VAS 6100- and laterally remove from the
engine next to the toothed belt guard.
– Place the cylinder head down on a soft surface with the sealing
surface to the top.
1.7.2 Install
Note
♦ There must not be any oil or coolant present in the blind holes
for the cylinder head bolts.
♦ Replace cylinder head bolts.
nuts.
♦ Remove the new cylinder head seal from its wrapping imme‐
diately before fitting.
♦ Treat the seal with the utmost care. Damage to the silicone
layer and in the area of the bead results in leakages.
♦ When installing an exchange cylinder head with the camshaft
bucket tappets and cam tracks after installing the cylinder
head.
♦ The plastic base for protecting the open valves should only be
removed immediately before attaching the cylinder head.
WARNING

remover!
– Make sure that when cleaning the cylinder head and cylinder
block no impurities can get into the cylinder or into the oil and
coolant galleries.
– Carefully remove old residual sealant from the cylinder head/
cylinder block using a chemical sealant remover.
– Before fitting the cylinder head rotate the crankshaft so that all
the pistons are almost evenly at TDC.

OCTAVIA II 2004 ➤
– Pay attention to the identification of the cylinder head seal.

Note
♦ If the cylinder head gasket or cylinder head are replaced, then

install a new cylinder head gasket with the same identification
-arrow 3-.
♦ If parts of the crankshaft drive were replaced then the new
cylinder head gasket must be defined by measuring the pro‐
trusion of the pistons in TDC .
– Fit on cylinder head gasket.

• Pay attention to dowel sleeves -arrows- in cylinder block.
• Observe the installed position of the cylinder head gasket, the
marking “above” or the part number must point to the cylinder
head.
– Insert the cylinder head.
– Insert new cylinder head bolts and tighten by hand.

– Tighten the cylinder head in four stages in the indicated tight‐
ening sequence:
Stage Tighten
I – Pre-tighten with the torque wrench to 35 Nm.
II – Pre-tighten with the torque wrench to 60 Nm.
III – Using a rigid wrench torque a further 90° (1/4
turn).
IV – Using a rigid wrench torque a further 90° (1/4
turn).
Note
Tightening up the cylinder head bolts after doing repair work is

not necessary.
– Screw lifting eye for engine onto the front cylinder head.
Q

OCTAVIA II 2004 ➤
– Insert screws -2- and -4- with spread on locking agent -D 000
600 A2- and tighten to 15 Nm.
– Install Hall sender -G40- , insert screws -3- with spread on
locking agent -D 000 600 A2- and tighten to 10 Nm.
– Position hub onto camshaft.

hold.
– First of all position camshaft and then also crankshaft on TDC

for cylinder 1:
• For the camshaft, the cams of cylinder 1 must be pointing up
evenly -arrows-...
• ...and depending on the version, the toothed belt sprocket of

the crankshaft must be locked with the crankshaft arrester -
T10050- or the crankshaft arrester -T10100- .

OCTAVIA II 2004 ➤
Note

♦ The crankshaft arrester can only be fitted onto the serration of
the toothed belt sprocket from the front side.
– Push toothed belt sprocket onto hub.

• The tooth segment -arrow- of the toothed belt sprocket must
be at the top.
– Interlock hub with locking pin , e. g. -3359- .
– Checking the oil level ⇒ Maintenance ; Octavia ll.
Note
Change contaminated engine oil ⇒ Maintenance ; Octavia ll.
1.8 Testing compression pressure for en‐

ters BMM
♦ Compression tester , e.g. -V.A.G 1763-
♦ Adapter , e.g. -V.A.G 1381/12-
♦ Flexible-head wrench e.g. -3220-
Test conditions
• Engine oil temperature at least 30°C
Test sequence
– Detach central plug connection for unit injectors and edge
connector for glow plugs.
– Unscrew all glow plugs with flexible-head wrench .

OCTAVIA II 2004 ➤
– Screw the adapter , e.g. -V.A.G 1381/12- , in place of the glow

plug into the relevant cylinder.
– Test compression with compression tester , e.g. -V.A.G 1763-
Note
Use of tester ⇒ Operating Instructions .
– The 2nd mechanic operates the starter until the tester no lon‐
ger indicates a pressure rise.
Compression readings
new Wear limit permissible differ‐
ence between cylin‐
ders
Overpressure Overpressure Overpressure
2.5…3.1 MPa 1.9 MPa maximum 0.5 MPa
25…31 bar 19 bar maximum 5 bar
Perform after the compression pressure test:
– Install glow plugs and tighten to 15 Nm.
– Connect central plug connection for unit injectors and edge
connector for glow plugs.
– Then interrogate the fault memory of engine control unit and
erase ⇒ Vehicle diagnosis, testing and information system
VAS 5051.

OCTAVIA II 2004 ➤
2 Repairing Valve Gear
2.1 Summary of components for engine with

engine identification characters BKD,
AZV
Note
♦ After installing the camshafts, the engine must not be cranked

or started for about 30 minutes. Roller rocker arm with hy‐
draulic valve clearance compensation must settle (otherwise
valves would strike the piston).
♦ After carrying out work on the valve gear, carefully crank en‐
gine at least 2 revolutions to ensure that no valve touches the
piston when the engine is started.
♦ Always replace gasket rings and seals.
♦ Removing and installing the tandem pump ⇒ page 174 .
1 - Bracket for cable rail - 10

Nm
2 - 20 Nm
and tightening
⇒ page 99
❑ for pump-nozzle unit
(1/4 turn)
❑ replace
and tightening
⇒ page 99
❑ replace
and tightening
⇒ page 78
6 - Washer
❑ for cylinder head screws
❑ before installing the
bearing frame, insert in‐
to the cylinder head
7 - Valve collets
8 - Valve spring retainer
9 - Valve spring
10 - Valve stem seal

OCTAVIA II 2004 ➤
11 - Valve guide
❑ not to be replaced
12 - Roller rocker arm for inlet valve
❑ do not mix up used roller rocker arms (mark)
❑ with hydraulic valve clearance compensation
❑ inspect roller bearings of roller for smooth operation and play
13 - Roller rocker arm for outlet valve
❑ do not mix up used roller rocker arms (mark)
❑ with hydraulic valve clearance compensation
❑ inspect roller bearings of roller for smooth operation and play
14 - Gasket rings
❑ Neither oil nor grease sealing lip
❑ before installing, remove oil on the camshaft journal
❑ before installing, cover the groove for the spring on the camshaft cone with suitable adhesive tape
15 - Cylinder head
❑ Valve seats must not be reworked.
16 - Inlet valves
❑ Valve dimensions ⇒ page 111
17 - Exhaust valves
18 - O-ring
❑ replace
19 - Shaft with retaining plate for roller rocker arm
❑ Outlet side
20 - 10 Nm
21 - Screw plug - 10 Nm
❑ replace
22 - Shaft for roller rocker arm
❑ Inlet side
23 - Bearing shell
❑ do not mix up used bearing shells (mark)
❑ ensure the retaining lugs are correctly located in the bearing frame and in the cylinder head
24 - Exhaust camshaft
❑ Inspecting axial play ⇒ page 98
25 - Inlet camshaft
❑ Inspecting axial play ⇒ page 98
26 - Bearing frame
2. Repairing Valve Gear 97

OCTAVIA II 2004 ➤
❑ install with silicone sealant -D 176 501 A1-
2.2 Inspect axial play of the camshafts for

acters BKD, AZV
♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Test sequence
– Perform measurement with roller rocker arms removed and
bearing frame installed
• Wear limit: maximum 0.15 mm
2.3 Replace gasket rings of camshafts for

acters BKD, AZV
♦ Insertion tool -MP 1-214 (10-203)-
♦ Gasket ring extractor -T30003 (3240)-
♦ Screw M12 x 1.5 x 65 or screw M12 x 1.5 x 75 from inserting
device -MP 1-214 (10-203)- with 10 mm spacer washer.
Removing
• Cylinder head attached at engine.
– Remove toothed belt sprockets of camshafts and pull off hubs
⇒ page 28 .

OCTAVIA II 2004 ➤
– Set the inner part of the sealing ring extractor -T30003- flush
with the outer part and interlock with the knurled screw.
forcely screw into the gasket ring for exhaust camshaft as far
as possible.
camshaft until the gasket ring is pulled out.
ring with pliers.
– Remove the gasket ring for inlet camshaft in the same way.
Install
the following:
Note
Sealing lips of the gasket rings must not be oiled or greased ad‐
ditionally.
– Remove oil residue from the camshaft stud with a clean cloth.
– Cover groove on the exhaust camshaft cone with adhesive
tape and carefully push the sealing ring onto the camshaft.
– Press in the gasket ring with the pressure plate of the insertion
tool -MP 1-214- and the screw M12 x 65 up to the stop.
– Install the gasket ring for inlet camshaft in the same way.
– Install the hubs and the camshaft sprockets ⇒ page 23 .
2.4 Removing and installing camshafts for

acters BKD, AZV
♦ Counterholder -T10051-
♦ Rig pin -3359- or rig pin -MP 1-301-
♦ Surround -T10262-
♦ Dial gauge

OCTAVIA II 2004 ➤
♦ Protective goggles
Removing
– Remove air filter with air intake hose and suction hose
⇒ page 212 .
– Remove battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Remove plenum chamber bulkhead ⇒ Body Work ⇒ Rep. Gr.
66 .
– Remove radiator for exhaust gas recirculation with radiator
flap from bracket ⇒ page 244 . The coolant hoses remain
connected.
– Remove bracket of radiator flap for exhaust gas recirculation
and bracket of exhaust gas recirculation radiator.
– Remove the toothed belts from the toothed belt sprockets of
camshafts ⇒ page 27 .
– Remove locking pins -3359- .

– Screw out screws -1- and -2- of the camshaft sprockets.
– Remove camshaft sprockets from the hubs.
– Loosen fixing screw -1- of the hub. Use counterholder -

T10051- for this purpose.
– Unscrew the fixing bolt of the hub by approx. 2 turns.

OCTAVIA II 2004 ➤
– Position the extractor -T10052- and align it with the hub bores.
– Tighten fixing screws -1-.
– Put the hub under tension by uniformly tightening the screw
-2- until the hub is released from the camshaft cone.
Note
To do so, counterhold on the hexagon of the extractor using a

wrench SW 30.
– Remove hub from cone of camshaft.

– Remove the hub of the outlet camshaft in the same way.
– Remove tandem pump ⇒ page 174 .
Note
The hoses can remain connected to the tandem pump.
– Release the counternuts -2- of the adjusting screws -1- on all

unit injectors and unscrew the adjusting screws until the rele‐
vant valve lever rests against the spring cap of the unit injector.
Note

assignment of the valve lever.

– Loosen screws -2- and -4- and release alternately in several
stages. Then remove the valve-lever shaft with the valve lev‐
ers.
– Release the top securing screws of the rear toothed belt guard.

OCTAVIA II 2004 ➤
– Pull release pin in -direction of arrow 1- and open the knurled

nut in -direction of arrow 2-.
– Disconnect central plug for unit injectors and glow plugs and
expose wiring loom.
– Disconnect plug connections -1- for the unit injectors, at the

same time press latch clips together.
– Unplug connector -1- of the glow plugs.
Caution
The disassembly/assembly of the pre-wiring must only be per‐

formed by unscrewing/screwing the clamps. Slackening the
cable duct from the clamps causes them to bend up and it can
lead to cable fracture due to high play.
– Unscrew fixing screws -2- of the stainless steel clamps (10

Nm) and lay pre-wiring aside.
– Slacken and unscrew the remaining 15 screws for the bearing
frame evenly from the outside to the inside.
– Release press-off screws SW 15 of the frame -T10262- by
turning anti-clockwise upwards up to the stop.

OCTAVIA II 2004 ➤
– Position frame -T10262- , as shown, on the bearing frame and

tighten fixing screws SW 10 to 10 Nm.
– Screw in press-off screws by hand, until these touch the cyl‐
inder head screws.
– Screw in press-off screws evenly in the order -1...4-, which is
type-punched on the screw heads, until the bearing frame is
being released from the cylinder head.
– Remove bearing frame.
Note
♦ Ensure that the bearing shells of the camshafts are not mixed
up.
♦ Mark assignment of the bearing shells for the camshafts with
waterproof marker on the reverse side.
– Take out camshafts.

Install
the following:
WARNING

remover!
– Remove residual sealant on the bearing frame and cylinder

head using a chemical sealant remover.
– Clean sealing surfaces, they must be free of oil and grease.
– Check if the crankshaft is on TDC for cylinder 1.

• Depending on the version, lock the toothed belt sprocket of the
shaft arrester -T10100- in TDC for cylinder 1.

OCTAVIA II 2004 ➤
Note

♦ Ensure that the used bearing shells of the camshafts are not
mixed up (pay attention to marking).
♦ When installing the camshafts pay attention to a correct fit of
the retaining lugs of the bearing shells in the bearing frame
and cylinder head.
– Oil contact surfaces of camshafts and bearing.
– Insert camshafts into the TDC for cylinder 1:

• The cams -1- and -2- for cylinder 1 must point upwards on both
camshafts.
• The grooves -arrows- in the camshafts also point upwards.
– Cut off nozzle tube at the front marking (∅ nozzle approx. 2

mm) and apply silicone sealant -D 176 501 A1- to the clean
sealing surface of the bearing frame -arrows-.
• Thickness of sealant bead: 2 mm.
Note
The bearing frame must be installed within 5 minutes after apply‐

ing the silicone sealant.
– Position bearing frame with inserted bearing shells on the

dowel pins of the cylinder head.

OCTAVIA II 2004 ➤
– Replace screws -1, 3, 5, 7, 9-.

– Tighten the screws -1...20- evenly in the following order from
inside to outside. Tightening torque 20 Nm.
– Insert valve-lever shaft.
– Tighten the screws -1...5- of the valve-lever shaft in the fol‐

lowing order + torque a further 90° (1/4 turn).
– Install pre-wiring for unit injectors and glow plugs
⇒ page 209 .
– Install camshaft gasket rings ⇒ page 98 .
– Install tandem pump ⇒ page 174 .
– Install hubs and toothed belt sprockets of camshafts
⇒ page 23 .
– install toothed belt and set the timing ⇒ page 27 .
– Place a dial gauge as shown onto the adjusting screw of the

unit injector.
Caution

– Turn the crankshaft in the running direction of the engine until

the roller of the roller rocker arm is on the drive cam tip.
• Roller side of roller rocker arm -arrow A- is on the highest point.
• Dial gauge -arrow B- is on the lowest point.
– Remove the dial gauge.
– Turn the adjusting screw in the roller rocker arm until one feels
a significant resistance (the unit injector is against the stop).

OCTAVIA II 2004 ➤
– Turn the adjusting screw in the opposite direction from the stop
by about 180°.
– Hold the adjusting screw in this position and tighten up the lock
nut using a torque of 30 Nm
– Install battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Attach bracket and radiator for exhaust gas recirculation with
radiator flap ⇒ page 244 .
Note

2.5 Removing and installing roller rocker

arm for engine with engine identification
characters BKD, AZV
♦ Extractor -T10133/3-
Note
♦ Replace O-rings.
♦ Do not mix up used roller rocker arms.
Remove roller rocker arm for exhaust valves

– Remove the camshafts ⇒ page 99 .
– Remove connection pipe between mechanical valve for ex‐
haust gas recirculation and flap of radiator for exhaust gas
recirculation ⇒ page 244 .
– Remove connection fittings for coolant from cylinder head
⇒ page 133 .

OCTAVIA II 2004 ➤
– Mark the assignment of the roller rocker arm when installing

again.
– Pull shaft for roller rocker arm -3- on the outlet side out of the
cylinder head with the extractor -T10133/3- and remove roller
rocker arm.
Caution
If the screw plug -5- is loosened, the shaft for the roller rocker
arms may rotate against the retaining plate. If a misshaping in
the shaft is detected during a visual inspection of the thread,
the shaft must no longer be installed, because the oil supply
holes for the roller rocker arms do no longer fit in size. This can
result in rubbing damage.
Install roller rocker arm for exhaust valves

the following:
– Lubricate roller rocker arm bearing with clean engine oil before
installing.
– Slide new O-ring onto the shaft for roller rocker arm.
– Insert shaft for roller rocker arm into the cylinder head and in‐
sert roller rocker arm simultaneously and consecutively.
– Tighten fixing screw -4- to 10 Nm.
– Replace the screw plug -5- and tighten to 10 Nm.
– Attach connection fittings for coolant to cylinder head
⇒ page 133 .
– Fit connection pipe between mechanical valve for exhaust gas
recirculation and flap of radiator for exhaust gas recirculation
⇒ page 245 .
– Install camshafts ⇒ page 99 .
Remove roller rocker arm for inlet valves
– Mark the assignment of the roller rocker arm when installing
again.
– Pull shaft for roller rocker arm on the inlet side out of the cyl‐
inder head with the extractor -T10133/3- and remove roller
rocker arm.
Install roller rocker arm for inlet valves
the following:
– Lubricate roller rocker arm bearing with clean engine oil before
installing.
– Insert shaft for roller rocker arm into the cylinder head and in‐
sert roller rocker arm simultaneously and consecutively.
• The shaft for roller rocker arm must be flush with the cylinder
head.

OCTAVIA II 2004 ➤
2.6 Inspecting hydraulic supporting ele‐

ments for engine with engine identifica‐
♦ Feeler gauges
Note
♦ The hydraulic supporting elements pressed into the roller rock‐

er arms cannot be repaired.
♦ Irregular valve noises when starting engine are normal.
Test sequence
– Start engine and allow to run until the radiator fan starts. In‐
crease speed to about 2500 rpm for 2 minutes and undertake
a test drive if necessary.
Note
If there are irregular valve noises which disappear after a long

drive but keep reappearing on short journeys then the oil retaining
valve is is defective. Fitting location: in the oil filter holder. The oil
retaining valve cannot be replaced individually.
If the valves are still loud, determine which is the faulty hydraulic
supporting element as follows:
– Turn the crankshaft until the cam of the hydraulic supporting
element to be tested is positioned on top.
♦ On vehicle with manual gearbox, push the vehicle forward in
4th gear when the ignition is switched off.
♦ On vehicle with automatic gearbox, turn the crankshaft at the
central bolt.
– Press the roller rocker arm down with a screwdriver -arrows-
and measure the play between the cams and the roller of the
roller rocker arm.
If a 0.20 mm feeler gauge can be slipped between the camshafts
and the roller of the roller rocker arm:
– Replace roller rocker arm with hydaulic valve clearance com‐
pensation; to do so remove the roller rocker arm ⇒ page 99 .
Note
♦ After installing the camshafts, the engine must not be started

for about 30 minutes. Roller rocker arm with hydraulic valve
clearance compensation must settle (otherwise valves would
strike the piston).

OCTAVIA II 2004 ➤
2.7 Replacing valve stem seals for engine

with engine identification characters
BKD, AZV
♦ Valve stem seal extractor -MP 1-230 (3364)-
♦ Valve stem seal insertion tool -MP 1-233 (3365)-
♦ Disassembly and assembly device for valve keys -VAS 5161-
♦ Guide plate for 2.0 TDI engine -VAS 5161/21-
Note
♦ With cylinder head removed:

♦ Remove glow plugs from the cylinder head ⇒ page 253 .
♦ Remove unit injectors from the cylinder head ⇒ page 213 .
♦ Position cylinder head on a suitable valve supporting plate.
Removing
Note
♦ Ensure that the bearing shells of the camshafts are not mixed
up.
♦ Mark assignment of the bearing shells for the camshafts with
– Remove bearing shells of camshafts from the cylinder head.

– Remove unit injectors ⇒ page 213 .
– Put the piston of the relevant cylinder at “bottom dead centre”.
– Position the guide plate -VAS 5161/21-1- onto the cylinder
head.
– Attach the guide plate -VAS 5161/21-1- with the knurled
screws -VAS 5161/21-4- .
– Insert the impact drift -VAS 5161/3- into the guide plate and
knock off the tightly fitted valve keys using a plastic hammer.

OCTAVIA II 2004 ➤
– Screw the adapter -VAS 5161/21-2- into the guide plate by

hand.
– Fix the detent part -VAS 5161/6- with the suspension forks -
VAS 5161/5- at the cylinder head.
– Slide the knurled spacer ring -VAS 5161/21-5- onto the as‐
sembly cartridge -VAS 5161/8- .
– Insert the assembly cartridge -VAS 5161/8- into the guide
plate -VAS 5161/21-1- .
– Connect the adapter -VAS 5161/21-2- to the compressed air
with a commercially available intermediate piece and apply
constant pressure.
• Minimum pressure: 0.6 MPa (6 bar) overpressure
– Hook the pressure fork -VAS 5161/2- onto the detent part -
VAS 5161/6- .
– Press the assembly cartridge -VAS 5161/8- downwards and
turn simultaneously the knurled screw of the assembly car‐
tridge to the right, until the tips click into the valve keys.
– Slightly move the knurled screw of the assembly cartridge
back and forward. This presses the valve keys apart and in‐
stalls them into the assembly cartridge.
– Release the pressure fork -VAS 5161/2- .
– Remove assembly cartridge -VAS 5161/8- with knurled spacer
ring -VAS 5161/21-5- , valve spring retainer and valve spring.
– Pull off valve stem seals with extractor for valve stem seal
-3364- .
Install
– Insert the supplied plastic bushings -B- on the relevant valve

stem. This will prevent any damage to the new valve stem
seals -A-.
– Insert the new valve stem seal in the insertion tool for valve
stem seal -MP 1-233- .
– Oil the sealing lip of the valve stem seal and carefully slide it
onto the plastic sleeve -B-.
– Carefully press the valve stem seal with the valve stem seal
insertion tool -MP 1-233- onto the valve guide.
– Take off plastic sleeve again -B-.
– Insert the valve spring and the valve spring retainer.

OCTAVIA II 2004 ➤
– If the valve keys were removed from the assembly cartridge -

VAS 5161/8- , first of all they must be inserted into the insertion
device for valve keys -VAS 5161/18- .
Note
The large diameter of the valve keys points to the top.
– Press the assembly cartridge from the top onto the insertion
device for valve keys -VAS 5161/18- and raise the valve keys.
– Insert the assembly cartridge -VAS 5161/8- into the guide

plate.
– Press down the pressure fork -VAS 5161/2- , turn the knurled
screw of the assembly cartridge back and forward and while
doing so pull it towards the top. Thereby the valve keys are
replaced.
– Release the pressure fork -VAS 5161/2- on tightened knurled
screw.
The valve stem seal is removed and installed on the other valves
in the same way.
– Install unit injectors ⇒ page 213 .
Note

2.8 Valve dimensions for engine with engine

identification characters BKD, AZV
Dimension Inlet valve Exhaust valve
∅a mm 29,20 25,50
∅b mm 5,975 5,965
c mm 87,80 87,50
α ∠° 45 45
Note
Valves must not be reworked. Only grinding in is permissible.

OCTAVIA II 2004 ➤

BMM
Note
♦ After installing the camshaft, the engine must not be cranked or started for about 30 minutes. The hydraulic
bucket tappets must settle (otherwise valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.
♦ Always replace gasket rings and seals.
♦ Removing and installing the tandem pump ⇒ page 174 .
1 - Cylinder head
2 - Bearing shell
❑ do not mix up already
used bearing shells
(mark)
❑ ensure the retaining
lugs are correctly loca‐
ted in the bearing caps
and in the cylinder head
3 - Camshaft
❑ Radial play wear limit:
0.11 mm
❑ Slack: maximum 0.04
mm
❑ Inspecting axial play
⇒ page 113
⇒ page 116
4 - Bearing shell
❑ do not mix up already
used bearing shells
(mark)
❑ ensure the retaining
lugs are correctly loca‐
ted in the bearing caps
and in the cylinder head
5 - Bearing caps
⇒ page 116
❑ Seal bearing caps 1 and
5 with sealant -D 454
300 A2-
❑ replace
❑ replace

OCTAVIA II 2004 ➤
❑ do not mix up (mark)
9 - Washer
❑ for cylinder head screws
❑ before installing the bearing caps, insert into the cylinder head
10 - Hydraulic bucket tappets
❑ do not mix up (mark)
❑ lay aside with contact surface facing down
❑ before installing check axial play of the camshaft ⇒ page 113
❑ oil contact surfaces
11 - Valve collets
12 - Valve spring retainer
13 - Valve spring outside
14 - Valve spring inside
15 - Valve stem seal
16 - Valve guide
17 - The unit injector
18 - Gasket ring
19 - Valve
❑ do not rework, only grinding in is permissible
2.10 Inspect axial play of the camshaft for en‐

ters BMM
♦ Dial gauge

OCTAVIA II 2004 ➤
Test sequence
– Perform measurement with the bucket tappets removed and
the first and last bearing cap fitted.
• Wear limit: maximum 0.15 mm
2.11 Replace gasket ring of camshaft for en‐

ters BMM
♦ Gasket ring extractor -T30003 (3240)-
♦ Screw M12 x 65
Removing
– Remove the locking pin - 3359- .
– Unscrew the screws of the toothed belt sprocket -arrows- and
remove the toothed belt sprocket from the hub.
– Loosen fixing bolt of the hub -1- approx. 2 turns, to do so use

the counterholder -T10051- .

OCTAVIA II 2004 ➤
– Position the extractor -T10052- and screw the screws -1- into
the hub.
– Pull off the hub, to do so counterhold the hexagonal wrench
(SW 30) of the extractor and screw in the screw -2-.
– Set the inner part of the sealing ring extractor -T30003- flush
with the outer part and interlock with the knurled screw.
forcely screw into the gasket ring of the camshaft as far as
possible.
camshaft until the gasket ring is pulled out.
ring with pliers.
Installing
the following:
Note
Sealing lip of the gasket ring must not be oiled or greased addi‐
tionally.
– Remove oil residue from the camshaft stud with a clean cloth.
– Cover slot on the camshaft cone with adhesive tape and care‐
fully push the sealing ring onto the camshaft.
– Press in the gasket ring with the pressure plate of the insertion
tool -MP 1-214- and the screw M12 x 65 up to the stop.
– Position hub onto camshaft.

OCTAVIA II 2004 ➤

counterhold.
– Push the toothed belt sprocket of the camshaft onto the hub.
• The tooth segment -arrow- of the toothed belt sprocket must
be at the top.
– Interlock hub with locking pin , e. g. -3359- .
2.12 Removing and installing camshaft for

acters BMM
♦ Sealing compound -D 454 300 A2-
Removing
– Remove tandem pump ⇒ page 174 .
Note
The hoses can remain connected to the tandem pump.
– Remove toothed belt sprocket of camshaft and pull off hub

⇒ page 114 .

OCTAVIA II 2004 ➤
– Mark the valve-lever shafts with waterproof marker to avoid

mixing them up and to avoid a basic setting of the unit injectors
-arrows-.
– First release the outer screws -1- and then the inner screws
-2- of both valve-lever shafts.
– Remove valve-lever shafts.
– First remove bearing caps -1-, -3- and -5-.

– Then release bearing caps -2- and -4- alternately and cross‐
wise.
Note
♦ Ensure that the bearing shells of the camshaft are not mixed
up.
♦ Mark assignment of the bearing shells for the camshaft with
– Take out camshafts.

Install
the following:
– Check if the crankshaft is on TDC for cylinder 1.
• Depending on the version, lock the toothed belt sprocket of the

shaft arrester -T10100- in TDC for cylinder 1.

OCTAVIA II 2004 ➤
Note

♦ Ensure that the used bearing shells of the camshaft are not
♦ When installing the camshaft pay attention to a correct fit of
the retaining lugs of the bearing shells in the bearing caps and
cylinder head.
– Oil contact surfaces of camshaft.

– Insert camshaft into the TDC for cylinder 1:
• The cams for cylinder 1 of the camshaft must point upwards
-arrows-.
– Then tighten bearing caps -2- and -4- alternately and cross‐
wise.
– Apply a thin layer of sealant -D 454 300 A2- evenly to the

sealing surfaces -1- of the edge bearing caps.
Note
Make sure no sealant penetrates into the slots -arrows- as well

as onto the other surfaces.

OCTAVIA II 2004 ➤
– Install and tighten bearing caps -1-, -3- and -5-.

• Bearing cap -5- must be aligned with outer edge of cylinder
head, if not, this can result in leaks at the tandem pump.
– Insert valve-lever shafts. Pay attention to the specified identi‐

fication -arrows- when removing.
– First tighten the inner screws -2- and then the outer screws
-1- in several stages.
– Install gasket ring for camshaft, hub and toothed belt sprocket
of camshaft ⇒ page 115 .
– Lock hub for camshaft with locking pin -3359- .
– Install tandem pump ⇒ page 174 .
– If the valve-lever shafts or ball studs were replaced, then the
unit injectors must be adjusted.
Note
♦ After installing the camshaft, the engine must not be cranked

or started for about 30 minutes. The hydraulic bucket tappets
must settle (otherwise valves would strike the pistons).
2.13 Checking hydraulic bucket tappets for

acters BMM
♦ Feeler gauges
♦ Wooden or plastic wedge
Note
♦ Hydraulic bucket tappets cannot be repaired.

♦ Irregular valve noises when starting engine are normal.
Test sequence
– Start engine and allow to run until the radiator fan starts. In‐
crease revolutions to about 2500 rpm for 2 minutes and un‐
dertake a test drive if necessary.

OCTAVIA II 2004 ➤
Note
If there are irregular valve noises which disappear after a long

drive but keep reappearing on short journeys then the oil retaining
valve is is defective. Fitting location: in the oil filter holder. The oil
retaining valve cannot be replaced individually.
If the hydraulic bucket tappets are still loud, determine the faulty
hydraulic bucket tappets as follows:
– Turn the crankshaft until the cam of the hydraulic supporting
element to be tested is positioned on top.
♦ On vehicle with manual gearbox, push the vehicle forward in
4th gear when the ignition is switched off.
♦ On vehicle with automatic gearbox, turn the crankshaft at the
central bolt.
– Determine the play between the cams and the bucket tappet:
– Press down the bucket tappet using a wooden or plastic
wedge.
If a 0.20 mm feeler gauge can be slipped between the camshaft
and the bucket tappet:
– Replace hydraulic bucket tappets ⇒ page 116 .
Note
♦ After installing the camshaft, the engine must not be cranked

or started for about 30 minutes. The hydraulic bucket tappets
must settle (otherwise valves would strike the pistons).
2.14 Replacing valve stem seals for engine

BMM
Cylinder head fitted
♦ Assembly device for valves -MP 1-213 (2036)-
♦ Extractor -MP 1-206 (3047 A)-
♦ Valve lever -MP 1-211 (VW 541/1A)-
Note
♦ With cylinder head removed:

♦ Remove glow plugs from the cylinder head ⇒ page 253 .
♦ Remove unit injectors from the cylinder head ⇒ page 224 .
♦ Position cylinder head on a suitable flat valve supporting plate.

OCTAVIA II 2004 ➤
Removing
Note
♦ Ensure that the used bearing shells of the camshaft are not
♦ When installing the camshaft, ensure it is correctly located in
the retaining lugs of the bearing shells in the bearing caps and
in the cylinder head.
♦ Ensure that the bucket tappets are not mixed up, for this step
mark the assignment with waterproof marker on the reverse
side.
– Remove bearing shells of camshaft from the cylinder head.

– Remove bucket tappets and lay aside with the contact surface
facing down. Make sure the tappets are not interchanged.
– Position piston of the relevant cylinder to top dead centre
(TDC).
– Insert the assembly device for valves -MP 1-213- and adjust
bearing to the stud bolt height.
– Remove valve springs with valve lever -MP 1-211- .
Note
The valves rest on the piston crown.
– Use pulling device -MP 1-206- to pull off valve stem seals.
Install

OCTAVIA II 2004 ➤
– Insert the supplied plastic bushings -A- on the relevant valve

stem. This will prevent any damage to the new valve stem
seals -B -.
– Insert the new valve stem seal in the insertion tool -MP 1-306- .
– Oil the sealing lip of the valve stem seal and carefully slide into
the valve guide.
– Remove plastic sleeve.
– Reinstall valve springs and secure with collets.
– Insert bucket tappets.
Note
♦ After installing the camsaft, the engine must not be started for
about 30 minutes. The hydraulic bucket tappets must settle
(otherwise valves would strike the pistons).
2.15 Valve dimensions for engine with engine

identification characters BMM
Dimension Inlet valve Exhaust valve
∅a mm 35,95 31,45
∅b mm 6,980 6,965
c mm 89,45 89,05
α ∠° 45 45
Note
Valves must not be reworked by grinding. Only grinding in with

grinding paste is permissible.
2.16 Inspect valve guides

♦ Dial gauge

OCTAVIA II 2004 ➤
Test sequence
Note
If the valves are replaced when carrying out repair work, use new
valves for the measurement.
– Insert valve into valve guide. End of valve stem must be flush
with guide.
• Valve rock: maximum 1.3 mm
Note
If the wear limit is exceeded, repeat measurement with new

valves. If the wear limit is again exceeded, replace cylinder head.
The valve guides cannot be replaced.

OCTAVIA II 2004 ➤
17 – Lubrication
1 Removing and installing parts of the
lubrication system
Note
♦ If engine damage occurs and it is suspected that the cause of

this is oil/fuel mixing (olfactory test of the engine oil), the tan‐
dem pump must absolutely be checked for internal tightness
⇒ page 181 .
♦ If considerable quantities of metal swarf as well as abrasion is
found in the engine oil when carrying out engine repairs, care‐
fully clean the oil galleries in order to avoid consequential
damage and additionally replace the oil cooler as well as the
oil filter element.
♦ The oil level must not be above the MAX. marking on the oil
dipstick - risk of damage to catalytic converter!
Check the engine oil, amount of oil and oil specification ⇒ Main‐
tenance ; Octavia II .
1 - 15 Nm
2 - 15 Nm
3 - Bracket at top
❑ for cable to oil level and
oil temperature sender -
G266-
❑ pay attention to different
version
4 - Drive chain sprocket
❑ for oil pump
⇒ page 63
5 - Dipstick
❑ The oil level must not
exceed the MAX. mark‐
ing
6 - Hopper
❑ Remove for extracting
oil
7 - Guide tube
8 - Oil injection nozzle
❑ for piston cooling
❑ Pay attention to part
number (right-angle
bend)
9 - Pressure relief valve, 27 Nm
❑ opens at an overpres‐
sure of 0.25 to 0.32 MPa
(2.5 to 3.2 bar)
❑ replace without sealant
124 Rep. Gr.17 - Lubrication

OCTAVIA II 2004 ➤
10 - O-ring
❑ replace
11 - Intake manifold
❑ Clean strainer if dirty
12 - Baffle
13 - Oil pan
14 - Drain plug, 30 Nm
❑ with gasket
❑ replace
15 - 10 Nm
❑ replace
16 - Oil level and oil temperature sender -G266-
❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
17 - O-ring
❑ replace
18 - Oil pump
❑ with pressure relief valve 1.2 MPa (12 bar)
❑ before installing, check whether both dowel sleeves are present
❑ if there is any scoring on the contact surfaces of the gears, replace
❑ Tighening torque of oil pump cover at oil pump housing: 10 Nm
19 - Oil pump sprocket
❑ Fits onto oil pump shaft in one position only
20 - Bracket at bottom
❑ For cable to oil level/oil temperature sender
21 - 15 Nm
❑ replace
23 - Oil pump chain
❑ before removing mark running direction
❑ check for wear
24 - Sealing flange -on the belt pulley side-
❑ replace the gasket ring for the crankshaft - on the belt pulley side ⇒ page 49
25 - Chain tensioner
❑ do not disassemble
❑ Replace chain tensioner if spring is broken.
❑ When installing, hook on the spring and pretension
❑ tighten to 16 Nm
1. Removing and installing parts of the lubrication system 125

OCTAVIA II 2004 ➤
1.1 Disassembling and assembling oil filter holder
1 - Screw plug - 25 Nm
2 - Gasket
❑ replace
3 - Oil cooler
❑ pay attention to the in‐
formation regarding a
necessary replacement
❑ connection diagram for
coolant hoses
⇒ page 131
4 - Gasket
❑ replace
❑ Fitting position
⇒ page 127
(1/4 turn)
❑ replace
❑ tighten crosswise
6 - Oil filter holder
❑ with oil retaining valve
❑ the oil retaining valve
cannot be replaced indi‐
vidually
7 - Gasket ring
❑ replace
8 - Oil pressure switch -F1- - 20
Nm
❑ 0.07 MPa (0.7 bar)
switch
9 - Screw cap - 25 Nm
❑ loosen and tighten up with the oil filter spanner , e.g. -3417-
10 - O-ring
❑ replace
11 - Oil filter element
❑ pull off from cap (Position 9)
❑ replace O-rings if oil filter element is changed (Position 10)
❑ pay attention to change intervals ⇒ Maintenance ; Octavia II
12 - Oil feed line
❑ to exhaust gas turbocharger
❑ Observe the mounting sequence:
– Screw on the union nuts first of all by hand.
– Then tighten the union nuts to 22 Nm.
– Subsequently secure the oil feed line in the brackets.
13 - Connection fittings - 35 Nm

OCTAVIA II 2004 ➤
Fitting position of gasket for oil cooler

– Place the gasket -2- in such a way that it can be pressed onto
all the lugs of the oil cooler -1-.
• The oil duct -arrow- must not be covered from the gasket.
1.2 Removing and installing oil pan

♦ Socket insert -T10058-
Removing
– Remove the right wheelhouse liner ⇒ Body Work ⇒ Rep. Gr.
66 .
Vehicles with engine identification characters BKD, AZV
– Unscrew screws -1- and -2- and remove charge air pipe
-arrows-.
– Unplug connector -arrow- at oil level/temperature sender -

G266- .
– Drain engine oil ⇒ Maintenance ; Octavia II .

OCTAVIA II 2004 ➤
– Unscrew the bolts of oil pan/gearbox -arrows-.

– Loosen bolts -1...20- crosswise and release.
– Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
Install
the following:
WARNING

remover!
– Remove residual sealant from the sealing surfaces on the cyl‐

inder block and on the oil pan with chemical sealant remover.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.
3 mm).
– Apply silicone sealant bead -arrow- to the clean sealing sur‐

face of the oil pan, as shown.
• Thickness of sealant bead: 2…3 mm
Note
♦ The sealant bead must not be thicker than 3 mm otherwise

excess sealant may get into the oil pan and clogg the strainer
in the oil suction pipe.
♦ Take particular care when applying the sealant bead in the
area of the sealing flange at the rear -arrows-.
♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant.
– Fit on oil pan immediately and tighten the bolts as follows:

– First of all pre-tighten bolts -1...20- crosswise to 5 Nm.
– Tighten the bolts of the oil pan/gearbox -arrows- to a torque of
40 Nm.
– Tighten screws -1...20- crosswise to 15 Nm.
Note
♦ When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.
♦ After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
– Fill with engine oil and check the oil level ⇒ Maintenance ;
Octavia II .

OCTAVIA II 2004 ➤
1.3 Removing and installing oil pump

Removing
– Remove baffle ( ⇒ page 124 ; Position 12).
– Release screw -2-.
– Pull the chain sprocket off the oil pump shaft.
– Release screws -1- and -3- and remove oil pump.
Install
the following:
– Insert top dowel sleeves into the oil pump.
♦ Installed position of the oil pump shaft/chain sprocket: Chain
sprocket fits onto the shaft in one position only.
♦ Replace the sprocket screw for the oil pump.
1.4 Testing oil pressure and oil pressure

switch
♦ Oil pressure tester , e. g. -V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Test conditions
• Oil level o.k.
• Engine oil temperature approx. 80°C.
Note
Functional test and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams and Fitting locations, ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
Test preparations
– Remove the air intake hose between the lock carrier and the
air filter.
– Disconnect plug -arrow- at oil pressure switch -F1- and un‐
screw oil pressure switch -F1- .

OCTAVIA II 2004 ➤
– Screw the connection of the oil pressure tester -V.A.G 1342-

into the hole for the oil pressure switch.
– Screw oil pressure switch -2- into the oil pressure tester.
Testing oil pressure switch
– Connect brown cable -1- of oil pressure tester to earth (-).
– Unclamp the voltage tester with its auxiliary cables out of the
measuring tool set on the oil pressure switch and plus (+) ter‐
minal on the battery.
• The LED should not light up.
If the LED lights up:
– Replace oil pressure switch.
If the LED does not light up:
– Start engine.
Note
Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch can
already be exceeded when starting up.
• At 0.055...0.085 MPa (0.55...0.85 bar) the LED should light up.

If the LED does not light up:
– Replace oil pressure switch.
Testing oil pressure
– Start engine.
• Oil pressure when engine idling: at least 0.08 MPa (0.8 bar)
• Oil pressure at a speed of 2000 rpm: at least 0.2 MPa (2.0 bar)
If the specified values are not reached: Oil pump defective.
– Replace oil pump ⇒ page 129 .
• Oil pressure at a higher engine speed: maximum 0.7 MPa (7.0
bar)
If the specified value is exceeded: Pressure relief valve defective.
– Replace oil filter holder ⇒ page 126 .

OCTAVIA II 2004 ➤
19 – Cooling
cooling system
WARNING
open carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.
1. Removing and installing parts of the cooling system 131

OCTAVIA II 2004 ➤
1.1 Parts of the cooling system fitted to body for engine with engine identifica‐
1 - Radiator
⇒ page 140
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 137
2 - O-ring
3 - Top coolant hose
❑ To connection fitting at
cylinder head
coolant hoses
⇒ page 135
4 - Screw cap
❑ Test pressure
0.14...0.16 MPa
(1.4...1.6 bar)
5 - Connector
6 - 3 Nm
7 - Coolant expansion reser‐
voir
8 - Bottom coolant hose
❑ to connection fitting at
coolant regulator at cyl‐
inder block
coolant hoses
⇒ page 135
9 - 5 Nm
10 - 5 Nm
11 - Right radiator fan -V35-
12 - Radiator fan -V7-
❑ with radiator fan control unit -J293-
13 - Connector
14 - Fan shroud
132 Rep. Gr.19 - Cooling

OCTAVIA II 2004 ➤
1.2 Parts of the cooling system fitted to engine for engine with engine identifi‐
cation characters BKD, AZV
1 - Radiator for exhaust gas re‐

circulation
⇒ page 244
2 - to heat exchanger
❑ Coolant feed line
coolant hoses
⇒ page 135
3 - Hose
❑ to flap of radiator for ex‐
haust gas recirculation
4 - 10 Nm
5 - The coolant pipe at the rear
6 - Retaining clip
❑ check tightness
7 - O-ring
❑ replace
8 - Coolant temperature send‐
er -G62-
❑ with coolant tempera‐
ture gauge sensor -G2-
9 - Hose
❑ to radiator for exhaust
gas recirculation
coolant hoses
⇒ page 135
10 - Connection fittings
❑ at cylinder head
❑ with coolant tempera‐
ture sender -G62-
11 - from heat exchanger
❑ Coolant return-flow line
❑ connection diagram for coolant hoses ⇒ page 135
12 - 40 Nm
13 - Hose
❑ to cylinder head
14 - Hose
❑ to rear pipe
15 - small distributor part
16 - Hose
❑ to the distributor parts
17 - Hose
❑ To connection fitting at cylinder head

OCTAVIA II 2004 ➤
18 - Hose
❑ towards top radiator
19 - Distributor part
20 - 15 Nm
21 - Hose
❑ from oil cooler
22 - to bottom of coolant expansion reservoir
23 - Coolant pipe
24 - Hose
❑ to bottom radiator
25 - Coolant temperature sender at radiator outlet -G83-
❑ with coolant regulator
❑ with coolant temperature sender at radiator outlet -G83-
27 - Coolant regulator
❑ check: heat up regulator in a water bath
Start of opening approx. 87 °C
Full opening: approx. 102 °C
Stroke: minimum 7 mm
28 - Hose
❑ to oil cooler - connection from cylinder block
29 - Oil cooler
30 - Coolant pump
❑ check smooth operation
31 - to top of coolant expansion reservoir
32 - Top coolant pipe
❑ bolted to intake manifold
33 - Hose
❑ from the flap of the radiator for exhaust gas recirculation to the top coolant pipe (Position 32)
34 - Radiator flap for exhaust gas recirculation

OCTAVIA II 2004 ➤
1.3 Connection diagram for coolant hoses for engine with engine identification
characters BKD, AZV
Vehicles without auxiliary heating.
1 - Radiator
⇒ page 140
ant ⇒ page 137
2 - Oil cooler
ant ⇒ page 137
⇒ page 124
⇒ page 150
4 - Coolant pump
⇒ page 149
5 - Cylinder head/cylinder
block
ant ⇒ page 137
voir
❑ with cap
❑ Testing the pressure re‐
lief valve in the cap
⇒ page 152
circulation
ant ⇒ page 137
8 - Heat exchanger for heating
9 - Radiator flap for exhaust gas recirculation
10 - ATF radiator
❑ for models with an automatic gearbox

OCTAVIA II 2004 ➤

voir
❑ with cap
⇒ page 152
2 - Cylinder block
ant ⇒ page 137
3 - Radiator flap for exhaust
gas recirculation
circulation
ant ⇒ page 137
⇒ page 244
5 - Cylinder head
ant ⇒ page 137
6 - Non-return valve
❑ The arrow on the non-
return valve must point
to the radiator for ex‐
haust gas recirculation.
❑ integrated into the cool‐
ant hose
❑ not visible from the out‐
side
9 - During operation of the auxiliary heater -N279-
10 - ATF radiator
❑ for models with an automatic gearbox
12 - Oil cooler
13 - Radiator
15 - Coolant pump/coolant regulator
16 - Auxiliary heating

OCTAVIA II 2004 ➤
1.4 Draining coolant and filling up for engine

BKD, AZV
♦ Refractomer -T10007-
Draining
Note
Collect drained coolant in a clean container for proper disposal or

reuse.
WARNING
open carefully.
– Open the cap of the coolant expansion reservoir.

– Place a catch pan under the engine.
– Remove right connecting hose, to do so raise the retaining
clips-arrows-.
WARNING
Shut off the opening of the charge air cooler, e.g. with a clean
– Remove the coolant hose from the radiator; to do so pull the

retaining clip -arrow-.
– Remove the air intake hose between the lock carrier and the
air filter.

OCTAVIA II 2004 ➤
– Remove rear coolant hose on the oil cooler -arrow- and drain
residual coolant.
– Remove the coolant hoses on the pipes of the auxiliary heating
and drain the remaining coolant.
Filling up
Note
Replace O-rings.
– Connect coolant hose at bottom of radiator -arrow-.
– Connect coolant hose at rear of oil cooler -arrow-.

– Place the coolant hoses onto the pipes of the auxiliary heating
and secure with spring strap clamps.
Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Octavia II .
– In a clean reservoir mix water and coolant additive in the cor‐
rect mixing ratio ⇒ Maintenance ; Octavia II .

OCTAVIA II 2004 ➤
– Top up coolant through the connection of the coolant expan‐

sion reservoir, until the MAX. marking of the coolant level is
reached.
– Switch off the heating and air-conditioning system.
– Start engine and run for maximum 2 minutes at approx. 1500
rpm. While doing so, fill with coolant up to the MAX. marking
in the coolant expansion reservoir.
– Tighten cap at coolant expansion reservoir.
Vehicles without auxiliary heating.
– Run engine until fan starts.
Caution
The auxiliary heating must only be switched on, if the refriger‐

ant circuit is filled up -as described below-.
– Connect vehicle diagnosis, measurement and information

system -VAS 5051- .
– Start the engine and maintain the engine revolutions for about
3 minutes at about 2000 r.p.m.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”, “18 - Auxiliary heating system” and “03 - Ac‐
tuator diagnosis”.
– Press the right button on the display so often until the coolant
shut-off valve of heating system -N279- is shown.
– Perform self-diagnosis for the coolant shut-off valve of heating
system -N279- and maintain the eingine speed at approx.
2000 rpm for about 1 minute.
– Check coolant level when the expansion reservoir is closed.

• When engine is at operating temperature the coolant level
must be at the MAX. marking, when engine is cold between
the MIN. and MAX. markings.
WARNING
Hot steam may escape when the compensation bottle is

opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.
– If necessary, top up with coolant.

Further assembly is carried out in the reverse order.

OCTAVIA II 2004 ➤
1.5 Removing and installing fan shroud for

radiator fan -V7- and right radiator fan -
V35- for engine with engine identifica‐
Removing
– Remove air filter with air intake hose from lock carrier
⇒ page 212 .
– Disconnect plug -2- at charge pressure sender -G31- / intake
air temperature sender -G42- .
– Release screw -4-.
– Remove charge air pipe with connecting hose; to do so raise
the retaining clips -1- and -3-.
– Disconnect plug connection -1-.

– Screw out screws -arrows- and take out fan shroud down‐
wards.
Install
the following:
♦ Tightening torques: ⇒ page 132
1.6 Removing and installing radiator for en‐

ters BKD, AZV
Removing
Note

reuse.

OCTAVIA II 2004 ➤
WARNING
open carefully.

– Remove fan shroud for radiator fan -V7- and right radiator fan
-V35- ⇒ page 140 .
– Remove connecting hose for right charge air pipe; to do so
raise the retaining clips.
WARNING
Shut off the opening of the charge air cooler, e.g. with a clean

– Remove the bottom coolant hose from the radiator; to do so
pull the retaining clip -arrow-.
– Pull off coolant hose at top of radiator -arrow-.
– Screw out screws -arrows- and remove the radiator upwards.

Install
the following:
– If a new radiator is installed, the old (drained) coolant must not
be reused.

OCTAVIA II 2004 ➤
1.7 Parts of the cooling system fitted to body for engine with engine identifica‐
tion characters BMM
1 - Radiator fan -V7-

❑ with radiator fan control
unit -J293-
⇒ page 148
2 - 5 Nm
3 - Fan shroud
❑ To connection fitting at
cylinder head
coolant hoses
⇒ page 145
5 - O-ring
6 - Radiator
⇒ page 148
ant ⇒ page 145
7 - 5 Nm
8 - O-ring
❑ to connection fitting with
coolant regulator at cyl‐
inder block
coolant hoses
⇒ page 145
10 - 5 Nm
11 - 5 Nm
12 - Right radiator fan -V35-

OCTAVIA II 2004 ➤
1.8 Parts of the cooling system fitted to engine for engine with engine identifi‐
cation characters BMM
1 - to top of coolant expansion

reservoir
coolant hoses
⇒ page 145
2 - Top coolant pipe
❑ screwed onto the cylin‐
der head cover
3 - O-ring
❑ replace
4 - Retaining clip
❑ check tightness
5 - Coolant temperature send‐
er -G62-
6 - to radiator for exhaust gas
recirculation
coolant hoses
⇒ page 145
❑ for cylinder head
8 - 10 Nm
9 - towards top radiator
coolant hoses
⇒ page 145
10 - from heat exchanger
❑ Coolant return-flow line
coolant hoses
⇒ page 145
11 - 40 Nm
12 - Distributor part
13 - from distributor part of top coolant hose
14 - 15 Nm
15 - from bottom of coolant expansion reservoir
16 - Coolant pipe
17 - Gasket ring
❑ replace
19 - 15 Nm
20 - to bottom radiator

OCTAVIA II 2004 ➤
❑ with coolant regulator
❑ check: heat up regulator in a water bath
Start of opening approx. 87 °C
Full opening: approx. 102 °C
Stroke: minimum 7 mm
23 - The coolant pipes at the rear

❑ Vehicles with auxiliary heating.
24 - from radiator for exhaust gas recirculation
25 - to heat exchanger
26 - Coolant pump
❑ check smooth operation
27 - Oil cooler

OCTAVIA II 2004 ➤
1.9 Connection diagram for coolant hoses for engine with engine identification
characters BMM

voir
❑ with cap
⇒ page 152
circulation
ant ⇒ page 137
⇒ page 145
ant ⇒ page 145
4 - ATF radiator
❑ for models with an auto‐
matic gearbox
ant ⇒ page 145
5 - Cylinder head/cylinder
block
ant ⇒ page 145
7 - Oil cooler
ant ⇒ page 145
8 - Radiator
10 - Coolant pump/coolant regulator
11 - Auxiliary heating
1.10 Draining coolant and filling up for engine

BMM

OCTAVIA II 2004 ➤

♦ Refractomer -T10007-
Draining
Note

reuse.
WARNING
open carefully.

– Remove the coolant hose from the radiator; to do so pull the
retaining clip -arrow-.
– Remove rear coolant hose on the oil cooler -arrow- and drain
residual coolant.
Filling up
Note
Replace O-rings.

OCTAVIA II 2004 ➤
– Connect coolant hose at bottom of radiator -arrow-.
– Connect coolant hose at rear of radiator -arrow-.

Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Octavia II .
– In a clean reservoir mix water and coolant additive in the cor‐
rect mixing ratio ⇒ Maintenance ; Octavia II .
– Top up coolant through the connection of the coolant expan‐

sion reservoir, until the MAX. marking of the coolant level is
reached.
– Switch off the heating and air-conditioning system.
– Start engine and run for maximum 2 minutes at approx. 1500
rpm. While doing so, fill with coolant up to the MAX. marking
in the coolant expansion reservoir.
– Tighten cap at coolant expansion reservoir.
– Check coolant level when the expansion reservoir is closed.

• When engine is at operating temperature the coolant level
must be at the MAX. marking, when engine is cold between
the MIN. and MAX. markings.
WARNING
Hot steam may escape when the compensation bottle is

opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.
– If necessary, top up with coolant.

Further assembly is carried out in the reverse order.

OCTAVIA II 2004 ➤
1.11 Removing and installing fan shroud for

radiator fan -V7- and right radiator fan -
V35- for engine with engine identifica‐
tion characters BMM
– Remove air filter with air intake hose from lock carrier
⇒ page 223 .
– Remove left connecting hose, to do so raise the retaining
clips-arrows-.
– Disconnect plug connection -1-.

– Screw out screws -arrows- and take out fan shroud down‐
wards.
Install
the following:
1.12 Removing and installing radiator for en‐

ters BMM
Removing
Note

reuse.
– Remove fan shroud for radiator fan -V7- and right radiator fan
-V35- ⇒ page 148 .

OCTAVIA II 2004 ➤
– Detach coolant hose between engine and radiator -arrows-.
– Screw out screws -arrows- and take out radiator downwards.

Install
the following:
– If a new radiator is installed, the old (drained) coolant must not
be reused.
1.13 Removing and installing coolant pump

Removing
– Unscrew fixing bolts -1- of the coolant pump and remove the
coolant pump -2-.
– Remove O-ring -3-.
Install
the following:
Note
Replace O-ring.
– Clean sealing surface for O-ring, if necessary smoothen.

– Moisten new O-ring -3- with coolant.
– Attach the coolant pump -2-.
• Fitting position: Plug in housing points down.
– Tighten screws -1- of coolant pump to 15 Nm.

OCTAVIA II 2004 ➤
1.14 Removing and installing coolant regula‐

tor
Removing
– Disconnect battery ⇒ Electrical System ⇒ Rep. Gr. 27 .
Note

– Unscrew AC generator ⇒ Electrical System ⇒ Rep. Gr. 27

and lay to the right upwards. The hoses remain connected.
– Remove coolant hose -2- from connection fittings.
– Disconnect plug -1- at the coolant temperature sender at ra‐
diator outlet -G83- .
– Unscrew screws -arrows- and remove connection fittings.

OCTAVIA II 2004 ➤
– Turn coolant thermostat -1- approx. 90° (1/4 turn) anti-clock‐

wise -arrow- and remove from connection fitting.
– Remove O-ring -2-.
Install
the following:
Note
Replace O-ring.
– Clean sealing surface for O-ring, if necessary smoothen.

– Insert the coolant regulator with the new O-ring.
• Fitting position: the coolant regulator clamp must stand hori‐
zonally.
– Moisten O-ring with coolant.
– Fit connection fitting onto cylinder block, tighten screws to 15
Nm and connect hose of radiator.
– Install alternator ⇒ Electrical System ⇒ Rep. Gr. 27 .
– Carry out work after reconnecting the battery ⇒ Electrical
System ⇒ Rep. Gr. 27 .
1.15 Checking the coolant system for leak‐

tightness
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter , e.g. -V.A.G 1274/8-
♦ Adapter , e.g. -V.A.G 1274/9-
Test condition
• Engine must be warm.
Test sequence
WARNING
open carefully.

OCTAVIA II 2004 ➤
– Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/8- on the coolant expansion reservoir.
– Generate an overpressure of approx. 0.1 MPar (1.0 bar) for
testing the cooling system.
If the pressure drops:
– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/9- on the coolant expansion reservoir.
– Generate an overpressure for testing the pressure relief valve.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve does not open:
– Replace cap.

OCTAVIA II 2004 ➤
20 – Fuel Supply
fuel supply system
Note
♦ Fuel lines are secured with quick-release couplings.

♦ Fuel hoses must be secured only with spring strap clips. The
use of clamp-type or screw-type clips is not allowed.
♦ Use pliers for spring strap clips to fit the spring strap clips.
Observe safety measures ⇒ page 3 .

Observe rules for cleanliness ⇒ page 4 .
1.1 Fuel tank with component parts - Vehicles with front-wheel drive
1 - Mounting part
2 - Screw cap
❑ replace the O-ring if it is
damaged
3 - Earth connection
4 - 11 Nm
5 - Support
6 - Fuel tank
❑ during removal, support
using the engine and
gearbox jack , e.g. -
V.A.G 1383 A-
⇒ page 160
7 - 25 Nm
❑ replace
8 - Circlip
9 - Tensioning strap
10 - Heat shield
11 - Fuel cooler
⇒ page 160
12 - to fuel filter
13 - 20 Nm
14 - Gasket ring
❑ replace
❑ to be inserted dry into
the opening of the fuel
tank
❑ only moisten the inner seal of the flange with fuel for fitting purposes
1. Removing and installing parts of the fuel supply system 153

OCTAVIA II 2004 ➤
15 - Fuel delivery unit

❑ with sender for fuel gauge display
❑ note the installed position of the fuel tank ⇒ page 154
❑ removing and installing the sender for fuel gauge display ⇒ page 170
16 - Lock ring - 110 Nm
❑ use wrench -T30101 (3087)- for removing and installing
❑ from fuel cooler
❑ clipped in place on fuel tank
❑ blue
18 - Fuel feed line
❑ to fuel filter
❑ clipped in place on fuel tank
❑ black
19 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. Gr. 55
Fitting location of the fuel delivery unit

Marking -3- on the flange of the fuel delivery unit points against
the direction of travel.
Note
The fuel delivery unit can only be installed in this position.
Blue or blue marked fuel return-flow line -1-.

Black fuel feed line -2-.
Note
After installing the fuel delivery unit, check whether the fuel feed
line and the fuel return-flow line are still clipped in place on the
fuel tank.
154 Rep. Gr.20 - Fuel Supply

OCTAVIA II 2004 ➤
1.2 Fuel tank with component parts for vehicles with four-wheel drive

❑ from fuel cooler
❑ clipped in place on fuel
tank
❑ blue (blue marking)
2 - Fuel feed line
❑ to fuel filter
❑ clipped in place on fuel
tank
❑ black
3 - Gasket ring
❑ replace
❑ to be inserted dry into
the opening of the fuel
tank
❑ only moisten from the in‐
side the seal of the
flange with fuel for fitting
purposes
4 - Fuel delivery unit
❑ with sender for fuel
gauge display -G-
⇒ page 165
❑ note the installed posi‐
tion of the fuel tank
⇒ page 156
❑ Removing and installing
the sender for fuel gauge display -G- ⇒ page 170
5 - Lock ring, 110 Nm
❑ use wrench -T30101 (3087)- for removing and installing
6 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. Gr. 55
7 - Screw cap
8 - Mounting part
9 - Earth connection
10 - 10 Nm
11 - Suction spray pump
❑ connected to fuel gauge sender 2 -G169-

OCTAVIA II 2004 ➤
12 - Fuel level sender 2 -G169-

❑ note the installed position of the fuel tank ⇒ page 156
13 - Fuel tank
❑ during removal, support using the engine and gearbox jack , e.g. -V.A.G 1383 A-
14 - Tensioning strap
15 - 25 Nm
❑ replace
16 - Heat shield
17 - Fuel cooler
18 - to fuel filter
19 - 20 Nm
Fitting position of the fuel delivery unit (with sender for fuel gauge
display -G- ) and with fuel gauge sender 2 -G169-
Markings on the flanges must be aligned with markings on the
fuel tank -arrows-.
Note
Markings on the fuel tank are hardly visible.

OCTAVIA II 2004 ➤
1.3 Removing and installing fuel filter

Fuel filter type one and two
Note
Before disconnecting the fuel hoses, mark assignment to the pipe supports.
1 - Fuel intake hose

❑ from fuel tank
❑ white or white marking
2 - 9 Nm
3 - Return-flow hose
❑ to fuel cooler
❑ blue or blue marking
4 - Drain plug
❑ release and drain
(catch) approx. 0.1 litre
fluid using the hand vac‐
uum pump , e. g. -
V.A.G 1390- or -VAS
5226- , and ventilation
reservoir , e.g. -V.A.G
1390/1-
5 - Gasket ring
❑ replace
❑ to the tandem pump
❑ white marking
7 - Fuel filter - top part
8 - Retaining clip
9 - Fuel temperature sender -
G81-
❑ from the tandem pump
❑ blue marking
❑ with connection fitting
for fuel temperature sender -G81-
11 - Fuel filter element
❑ pay attention to change intervals ⇒ Maintenance ; Octavia ll.
12 - Fuel filter with integrated bracket - bottom part.
❑ mounted as of 08.05
13 - Fuel filter - bottom part
14 - Support

OCTAVIA II 2004 ➤
Fuel filter type three and four
Note
Before disconnecting the fuel hoses, mark assignment to the pipe supports.

❑ from fuel tank
❑ white marking
❑ to fuel cooler
❑ blue marking
❑ to the tandem pump
❑ white marking
4 - Screw
❑ for type 3 (left illustra‐
tion): 9 Nm
❑ for type 4 (right illustra‐
tion): 5 Nm
5 - Retaining clip
6 - Fuel temperature sender -
G81-
7 - Gasket ring
❑ replace
❑ blue marking
❑ with connection fitting
for fuel temperature
sender -G81-
9 - Fuel filter - top part
❑ with integrated preheat‐
ing valve
10 - Filter insert
❑ pay attention to change intervals ⇒ Maintenance ; Octavia ll.
❑ Pay attention to the part number
11 - Fuel filter with integrated bracket - bottom part.
1.4 Drain the fuel tank

♦ Hose adapter , e.g. -V.A.G 1318-16-
♦ Adapter , e.g. -V.A.G 1318-17-
♦ Battery
♦ Fuel tank

OCTAVIA II 2004 ➤
Note
If there are functional problems of the fuel delivery unit suction off
fuel with fuel extraction device, e.g. -VAS 5190- .
Procedure
Note
♦ Safety precautions when working on the fuel supply system

⇒ page 3 .
♦ Observe the regulations concerning cleanliness when working
on the fuel supply/injection system ⇒ page 4 .
– Removing rear seat bench ⇒ Body Work ⇒ Rep. Gr. 72 .
– Remove the cover from the fuel delivery unit.
Note
For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must be disconnected additionally.
– Unplug the 5-pin connector -1- and the black fuel feed line
-2-.
Note
♦ On vehicles with four-wheel drive, the location of the plug and

the fuel lines is different.
♦ Press in the securing ring in order to unlock the line.
– Connect the adapter -V.A.G 1318/16- and -V.A.G 1318/17-

and fit this “drain pipe” onto the feed support of the fuel delivery
unit.
– Hold the “drain pipe” in a suitable fuel tank.
– Connect the battery and the contacts of the fuel pump with
adapter cables -A- from the adapter cable set -V.A.G 1594/C-
as follows:
Battery positive (+) to contact -1- of the fuel pump
Battery minus (-) to contact -5- of the fuel pump
The fuel pump runs and delivers fuel.
WARNING
In order to prevent an overflow of fuel in case of a too small

fuel tank, the fuel pump must not run unattended.

OCTAVIA II 2004 ➤
1.5 Removing and installing fuel cooler

Removing
Note
♦ The fuel cooler is located at the fuel return-flow line to the fuel
tank. It is attached to the underfloor of the vehicle body.
⇒ page 3 .
♦ Observe rules for cleanliness ⇒ page 4 .
– Removing the right underfloor trim panel.
– Separate fuel lines at fuel cooler.
– Unscrew fixing nuts for fuel cooler -arrows- and remove fuel
cooler.
Install
the following:
– Tighten fixing nuts for the fuel cooler to 15 Nm.
1.6 Remove and install the fuel tank for ve‐

hicles with front-wheel drive
Removing
Note

⇒ page 3 .
– Drain the fuel tank ⇒ page 158 .

OCTAVIA II 2004 ➤
– Unclip retaining catches -arrows- of cover for the fuel delivery

unit and remove cover.
Note
dosing pump -V54- must also be disconnected.
– Unplug connector -arrow-.

– Remove right rear wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew fuel filler cap from fuel filler neck.
– Seal the filler neck with a clean foam piece in order to avoid
any foreign bodies from entering.
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .

OCTAVIA II 2004 ➤
– Unscrew screws -1- for filler neck on the body.

– Unclip the wiring loom from the holder -2- at the top and bottom
of the filler neck.
– Remove rear tunnel bridge ⇒ page 232 .
– Slacken front double clamp at exhaust pipe and push to the
rear.
– Push out all suspensions of the middle and rear part of the
exhaust system from the retaining straps.
– Slightly lower the middle and rear part of the exhaust system
and tie with wire to the body.
– Disconnect the fuel feed line and the fuel return-flow line on
the front right of the fuel tank.
Note
♦ For vehicles with auxiliary heating, the fuel line for the dosing
pump -V54- must also be disconnected.
♦ Press down the securing rings in order to unlock the connec‐
tions of the fuel lines.
– Unscrew tensioning strap.

– Support fuel tank using the engine and gearbox jack -V.A.G
1383 A- .
– Unscrew securing bolts.
– Lower the fuel tank.
Install
the following:
♦ Lay the fuel lines avoiding any kinks.
♦ Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
♦ Make sure the fuel line connections fit tightly.
♦ Check fuel feed line and the fuel return-flow line at fuel tank
for firm seating.
♦ Check earth connection of fuel tank/body at filler neck.
1.7 Removing and installing fuel tank for ve‐

hicles with four-wheel drive
Removing
Note

⇒ page 3 .

OCTAVIA II 2004 ➤
– Drain the fuel tank ⇒ page 158 .

– Remove the cover from the fuel delivery unit and from the fuel
gauge sender 2 -G169- .
Note
– Remove the plug from the fuel delivery unit and from the fuel
gauge sender 2 -G169- -arrows-.
– Remove right rear wheel ⇒ Chassis ⇒ Rep. Gr. 44 .
– Open the fuel tank cap and clean around the fuel filler neck.
– Unscrew fuel filler cap from fuel filler neck.
– Seal the filler neck with a clean foam piece in order to avoid
any foreign bodies from entering.
– Remove the rear right wheelhouse liner ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Unscrew screws -1- for filler neck on the body.

– Unclip the wiring loom from the holder -2- at the top and bottom
of the filler neck.
– Remove middle and rear part of the exhaust system
⇒ page 236 .
– Remove propshaft ⇒ Gearbox ⇒ Rep. Gr. 39 .
– Disconnect plug from four-wheel drive control unit -J492-

-arrow-.
– Disconnect the fuel feed line and the fuel return-flow line on
the front right of the fuel tank.
Note
♦ For vehicles with auxiliary heating, the fuel line for the dosing
pump -V54- must also be disconnected.
♦ Press down the securing rings in order to unlock the connec‐
tions of the fuel lines.
– Unscrew the straps.

– Support fuel tank using the engine and gearbox jack -V.A.G
1383 A- .
– Unscrew securing bolts.
– Lower the fuel tank.
Install

OCTAVIA II 2004 ➤
– Attach line for four-wheel drive control unit -J492- to the fuel
tank -arrows-. Support the fuel tank using the engine and
gearbox jack .
– Raise fuel tank in its installation position and install.
– Connect the plug to the four-wheel drive control unit -J492-

-arrow-.
the following:
♦ Lay the fuel lines avoiding any kinks.
♦ Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
♦ Make sure the fuel line connections fit tightly.
♦ Check fuel feed line and the fuel return-flow line at fuel tank
for firm seating.
♦ Check earth connection of fuel tank/body at filler neck.
1.8 Removing and installing the fuel delivery

unit on vehicles with front-wheel drive
♦ Wrench for the lock ring -T30101 (3087)-
Condition
• The fuel tank must not be more than 3/4 full.
Removing
Note
♦ If necessary, drain the fuel tank ⇒ page 158 .

⇒ page 3 .
Note

OCTAVIA II 2004 ➤
– Disconnect the plug as well as the black fuel feed line -2- and
the blue fuel return-flow line -1- from the flange.
Note
♦ Press in securing ring in order to unlock the lines.

♦ For vehicles with auxiliary heating the suction hose for the
dosing pump -V54- must be pulled out additionally (open lower
clamp).
– Open lock ring with the wrench -T30101- .
Note
When removing the fuel delivery unit, ensure that the float arm of
the sender for the fuel gauge display -G- is not bent.
– Pull the fuel delivery unit and the gasket ring out of the opening
of the fuel tank.
Note
You must empty the old fuel delivery unit before disposing of it if
you wish to replace it.
Install
the following:
Note
♦ Insert new dry gasket ring into the opening of the fuel tank.
♦ The gasket must only be moistened from inside with fuel be‐
fore assembly of the fuel delivery unit.
♦ Do not bend the sender for fuel gauge display when installing
it.
♦ Observe the fitting location of the fuel delivery unit. Marking
-3- on the flange must point against the direction of travel. The
fuel delivery unit can only be installed in this position.
♦ Do not mix-up the fuel feed line and the fuel return-flow line.
♦ Tighten the lock ring to 110 Nm.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the fuel
feed line and the fuel return-flow line are clipped in place on
the fuel tank.
1.9 Removing and installing the fuel delivery

unit on vehicles with four-wheel drive
♦ Wrench for the lock ring -T30101 (3087)-

OCTAVIA II 2004 ➤
Condition
Removing
Note
♦ If necessary, drain the fuel tank ⇒ page 158 .

⇒ page 3 .
Note
♦ For vehicles with auxiliary heating, the plug connection for the
♦ Two types of fuel delivery units are installed in the vehicles,
which can be recognized on the different flanges.
Fuel delivery unit type 1

Note

clamp).

– Pull out closing flange and gasket ring of the fuel delivery unit
from the opening of the fuel tank and place to the side with the
connected lines.

OCTAVIA II 2004 ➤
– Separate through the opening of the fuel tank the jetstream

line -1- to the suction jet pump, to do so press the release
button.
– Unhook the fuel delivery line -2- at the fuel delivery unit, to do
so pull the catch to the top -arrow-.
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old fuel delivery unit before disposing of
it if you wish to replace it.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Note

clamp).

OCTAVIA II 2004 ➤
– Slightly raise the closing flange and check if the spring -2- is
still fastened on the flange -1-.
If the spring -2- lies loose on the guide pipe -3-, hold the spring
with the fingers when removing the closing flange.
– Pull out closing flange and gasket ring of the fuel delivery unit
from the opening of the fuel tank and place to the side with the
connected lines.
– Separate through the opening of the fuel tank the jetstream

line -1- to the suction jet pump, to do so press the release
button.
– Pull off the fuel delivery line -2- from the fuel delivery unit.
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old fuel delivery unit before disposing of
it if you wish to replace it.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
the following:
– Insert the fuel delivery unit into the fuel tank with the closing
flange placed to the side. Thus, do not bend the float arm of
the fuel gauge sender unit -G- .
– Attach fuel delivery line and jetstream line.
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.

OCTAVIA II 2004 ➤
– Insert the spring -2- into the guide bore -arrow- and place the
guide -1- of the closing flange onto the guide -3- at the fuel
delivery unit.
• The spring -2- must be fastened to the retaining lugs -1- of the
closing flange.
– First of all guide the guide pipe -3- into the guide bore -4-.
– Then lower the closing flange in such a way that the guide pipe
-6- locks into the guide bore -5-.
Note
Pay attention that the electrical lines -1- and the fuel feed line
-3- are positioned as shown in the illustration so that they do not
block the float arm -2-.
Continued for the fuel delivery unit type 1 and type 2

– Press the closing flange to the bottom and move the closing
flange into the fitting position.
Further information:

OCTAVIA II 2004 ➤
Fuel delivery unit - type 1
Fuel delivery unit - type 2

♦ Observe the fitting location of the fuel delivery unit. The tabs
-2- on the closing flange must be between the tongues -1- and
-3- at the fuel tank. The -thick arrow- points in the direction of
travel.
♦ Tighten lock ring to 110 Nm.
♦ Do not mix-up the fuel feed line and the fuel return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the fuel
feed line and the fuel return-flow line are still clipped in place
on the fuel tank.
1.10 Removing and installing the sender for

fuel gauge display -G-
Note
In the vehicles there are 2 types of senders for the fuel gauge
display -G- installed.
Sender for fuel gauge display -G- type 1

Removing
– Remove fuel delivery unit.
♦ Vehicles with front-wheel-drive: ⇒ page 164
♦ Vehicles with four-wheel drive: ⇒ page 165

OCTAVIA II 2004 ➤
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
– Raise catches -4- and -5- with a screwdriver and remove the
sender for fuel gauge display -G- from the bottom -arrow-.
Install
– Insert the sender for the fuel gauge display -G- in the guides
at the fuel delivery unit and press upwards until it latches into
position.
– Connect the lines and check the connector for secure catch.
– Install fuel delivery unit.
Sender for fuel gauge display -G- type 2
Removing
– Remove fuel delivery unit.
– Unlock the catches -arrows- using a screwdriver and pull out

the sender for fuel gauge display -G- towards the top.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the lines and check the connector for secure catch.
– Insert the sender for fuel gauge display -G- in the guides at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Install fuel delivery unit.

OCTAVIA II 2004 ➤
1.11 Removing and installing fuel gauge

sender 2 -G169- on vehicles with four-
wheel drive.
Note
♦ Empty the fuel tank if necessary ⇒ page 158 .

⇒ page 3 .
♦ Make sure that the sender for fuel gauge display is not bent.
Removing
– Remove left cover and disconnect plug connection for fuel
gauge sender 2 -G169- .
– Slightly pull fuel gauge sender 2 -G169- out of the opening of

the fuel tank to the top, release catches -arrows- and discon‐
nect suction jet pump.
Install
the following:
WARNING
When installing do not bend the swivel arm of the fuel gauge
sender 2 -G169- .
– Insert fuel gauge sender 2 -G169- into the fuel tank.

OCTAVIA II 2004 ➤
– Position inner suction jet pump in fuel tank onto fuel gauge
sender 2 -G169- and press in until the catches -arrows- latch
into position.
– Insert new dry gasket ring of the flange into the opening of the
fuel tank and only moisten the inside (towards flange) with fuel.
– Check the installation position ⇒ page 156 and insert the
flange of the fuel gauge sender 2 -G169- into the opening of
the fuel tank.
– Check correct seating of the gasket ring.
– Tighten lock ring with wrench -T30101- to 110 Nm.

– Connect plug and install left cover.
1.12 Removing and installing suction jet

pump on vehicles with four-wheel drive
Note
♦ On vehicles with four-wheel drive, the fuel tank consists of a

left and right chamber. In order to pump the fuel out of the left
chamber -3- of the fuel tank into the right chamber to the hous‐
ing of the delivery unit -2-, a suction jet pump -1- is required.
♦ The version of the fuel tank requires that the fuel is pumped
from the area of the fuel gauge sender 2 -G169- with a suction
jet pump to the fuel delivery unit.
♦ A check is only to be carried out, if the engine stops because
of fuel shortage, although the fuel gauge still indicates a fuel
tank which is 1/4 full.
Procedure
– Remove fuel delivery unit ⇒ page 164 .
– Remove fuel gauge sender 2 -G169- ⇒ page 172 .
– Now the suction jet pump can be pulled out from the side of
the fuel gauge sender 2 -G169- (left vehicle side).
– Check, if the fuel lines on the suction jet pump are placed on
firmly and not damaged.
– Check the suction jet pump additionally for possible contami‐
nation.

OCTAVIA II 2004 ➤
1.13 Removing and installing tandem pump,

vehicles with engine identification char‐
acters BKD, AZV
♦ Diesel extractor , e.g. -VAS 5226-
Removing
WARNING
Under no circumstances must the tandem pump be disassem‐

bled, otherwise it can lead to malfunction of the vacuum part.
This will result in a failure of the brake booster.
Caution
Observe instructions for installing again a used tandem pump

⇒ page 181 .
Note

⇒ page 3 .

– Disconnect the fuel intake hose -1- (marked in white) and the
fuel return-flow hose -2- (marked in blue) from the fuel filter.
– Connect diesel extractor -VAS 5226- at fuel return-flow hose
-2-.
– Apply compressed air to diesel extractor -VAS 5226- .
– Operate diesel extractor -VAS 5226- until no more fuel comes
out of the fuel return-flow hose.
– Unplug connector -2- from air mass meter -G70- .

– Disconnect ventilation hose -1-, suction hose -3- and air guide
hose -5-.
– Release screw -4- and remove air filter housing.

OCTAVIA II 2004 ➤
– Separate vacuum line -1- for brake servo unit from tandem
pump -4-.
– Disconnect the fuel intake hose -2- (marked in white) and the
fuel return-flow hose -3- (marked in blue) from the tandem
pump -4-.
– Release fixing screws -arrows- and remove tandem pump
-4- from cylinder head.
Install
the following:
Note
♦ Ensure that the driver of the tandem pump is correctly seated

in the camshaft.
♦ Always replace the tandem pump seals.
– Install tandem pump and tighten the fixing screws -arrows- to

20 Nm.
– Connect fuel intake hose -1- (marked in white) to fuel filter.

– Connect diesel extractor -VAS 5226- to return-flow hose -2-.
– Operate diesel extractor -VAS 5226- until fuel flows out of the
fuel return-flow hose.
– Connect fuel return-flow hose -2- (marked in blue) to fuel filter.
1.14 Removing and installing tandem pump,

vehicles with engine identification char‐
acters BMM
♦ Diesel extractor , e.g. -VAS 5226-
Removing
WARNING
Under no circumstances must the tandem pump be disassem‐

bled, otherwise it can lead to malfunction of the vacuum part.
This will result in a failure of the brake booster.
Caution
Observe instructions for installing again a used tandem pump

⇒ page 181 .

OCTAVIA II 2004 ➤
Note

⇒ page 3 .

– Remove fuel intake hose -2- (marked in white) from the tan‐
dem pump.
– Remove fuel return-flow hose -1- (marked in blue) from the
fuel line.
– Connect diesel extractor -VAS 5226- to fuel return-flow hose.

– Apply compressed air to diesel extractor -VAS 5226- .
– Operate diesel extractor -VAS 5226- until no more fuel comes
out of the fuel return-flow hose.
– Disconnect the vacuum hose to the brake servo unit at the

tandem pump -arrow-.
– Pull out the central plug for the unit injectors.

OCTAVIA II 2004 ➤
– Release screws -arrows-.

– Remove tandem pump -4- from cylinder head.
Install
the following:
Note
♦ Ensure that the driver of the tandem pump is correctly seated

in the camshaft.
♦ Always replace the tandem pump seals.
– Install tandem pump and tighten the top fixing screws (M8) to
20 Nm.
– Tighten bottom fixing screws (M6) to 8 Nm.
– Connect the fuel intake hose and the vacuum hose at the tan‐
dem pump.
– Connect diesel extractor -VAS 5226- to fuel return-flow hose.

– Operate diesel extractor -VAS 5226- until fuel flows out of the
fuel return-flow hose.
– Connect the fuel return flow hose (marked in blue) to the fuel
line.
– Connect central plug for unit injectors.
1.15 Inspecting a tandem pump
1.15.1 Checking feed pressure of tandem

pump, vehicles with engine identification
characters BKD, AZV
♦ Tandem pump testing device , e.g. -VAS 5187- with hollow
screw -VAS 5187/1A-
♦ Hose clamps -MP 7-602 (3094)-
Test conditions
• Coolant temperature must be at least 85°C.
• Unit injectors O.K.
• The fuel filter and fuel lines must not be blocked.

OCTAVIA II 2004 ➤
Procedure
Note

⇒ page 3 .

– Unplug connector -2- from air mass meter -G70- .
– Disconnect ventilation hose -1-, suction hose -3- and air guide
hose -5-.
– Release screw -4- and remove air filter housing.
– Release screw plug -arrow-.

OCTAVIA II 2004 ➤
– Connect tandem pump testing device -VAS 5187- with hollow

screw -VAS 5187/1A- , as shown.
– Install air filter and connect suction and air guide hose.
– Connect air mass meter -G70- .
– Start engine and engine speed must increase to 4000 rpm.
– Observe the pressure displayed on the tandem pump testing
device .
• Specified value: at least 1.05 MPa (10.5 bar).
If the specified value is not reached:
– Press together fuel return-flow line between tandem pump and
fuel filter with hose clamp -MP 7-602 - .
– Start engine and engine speed must increase to 4000 rpm.
device .
• Specified value: at least 1.05 MPa (10.5 bar)
If the specified value is now reached:
Pressure loss at the unit injectors.
– Replace O-rings for unit injectors ⇒ page 218 .
– Replace tandem pump ⇒ page 174 .
Note
After removing the tandem pump tester tighten the screw plug to
25 Nm. Always replace the gasket ring.
1.15.2 Checking feed pressure of tandem

pump, vehicles with engine identification
characters BMM
♦ Tandem pump testing device , e.g. -VAS 5187- with hollow
screw -VAS 5187/1A-
♦ Hose clamps -MP 7-602 (3094)-
Test conditions
• Coolant temperature must be at least 85°C.
• Unit injectors O.K.
• The fuel filter and fuel lines must not be blocked.
Procedure
Note

⇒ page 3 .

OCTAVIA II 2004 ➤

– Release screw plug -arrow-.
– Connect tandem pump testing device -VAS 5187- with hollow

screw -VAS 5187/1A- , as shown.
– Install air filter and connect suction and air guide hose.
– Connect air mass meter -G70- .
– Start engine and run in idle.
device .
– Engine speed must increase to 4000 rpm.
device .
– Press together fuel return-flow line between tandem pump and
fuel filter with hose clamp -MP 7-602 - .
device .
If the specified value is now reached:
Pressure loss at the unit injectors.
– Replace O-rings for unit injectors ⇒ page 228 .
– Replace tandem pump ⇒ page 175 .
Note
After removing the tandem pump tester tighten the screw plug to
25 Nm. Always replace the gasket ring.

OCTAVIA II 2004 ➤
1.15.3 Checking the tandem pump for tight‐

ness (internal)
Note
After re-installing an already used tandem pump e.g. after chang‐

ing or repairing the cylinder head and/or after changing an engine
without component parts, the tandem pump must be absolutely
checked for internal tightness between fuel and oil part. In case
of leakage fuel and oil can be mixed, which can cause an engine
damage.

♦ Tester , e. g. -V.A.G 1687-
Procedure
– Disconnect the fuel intake hose (white marking) and the fuel
return-flow hose (blue marking) from the tandem pump.
– Close fuel return-flow connection at tandem pump with a plug.
Secure plugs with spring strap clips.
Prepare tester -V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
– Connect test connection -5- with a commercially available
connection for compressed air und a piece of fuel hose to the
connection of the fuel feed line for the tandem pump. Secure
connection with spring strap clips.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect the pneumatic hose -1- (pneumatic support) at tester.
Note
If there is water in the transparent water drain reservoir, drain

water via the drain plug -6-.
– Open valve -3-.

– Set the pressure to 0.1 MPa (1.0 bar) with the pressure control
valve -2-.
WARNING
The maximum test pressure is 0.13 MPa (1.3 bar) and it must
not be exceeded.

OCTAVIA II 2004 ➤
– Open valve -4- and wait until the test circuit is filled up. If nec‐
essary readjust pressure to 0.1 MPa (1.0 bar).
– Close the valve -3- to maintain the pressure and observe the
drop in pressure for 1 minute.
If the pressure does not drop, the tandem pump can still be used.
In case of drop in pressure the tandem pump must be re‐
placed.
1.16 Checking fuel delivery unit

♦ Remote control , e.g. -V.A.G 1348/3A-
♦ Adapter , e.g. -V.A.G 1318/16-
♦ Adapter , e.g. -V.A.G 1318/17-
♦ Measuring glass

OCTAVIA II 2004 ➤
Checking the function and supply voltage

Test conditions
• Battery voltage at least 11.5 volts
• Fuses o.k. (No. 27)
• All electrical components such as lights and rear window heat‐
er must be switched off.
Test sequence
– Switch on ignition.
• The fuel pump must be heard to start running.
– Switch off ignition.
If the fuel pump does not run:
– Continuing searching for faults using a multimeter ⇒ Current
flow diagrams and Fitting locations.
Check fuel flow rate
Test conditions
• Battery voltage at least 11.5 volts
• Fuel temperature 15…30 °C
• Fuel tank at least 1/4 full.
Test sequence
Note

⇒ page 3 .
– Unscrew the cap from the filler neck.
– Unclip retaining catches -arrows- of cover for the fuel delivery

unit and remove cover.
Note

OCTAVIA II 2004 ➤
– Unplug connector -arrow-.
Note
On vehicles with four-wheel drive, the location of the plug and the
fuel lines is different.
– Connect remote control -V.A.G 1348/3A- with connection lines

from measuring tool set to contact -1- of the fuel pump and to
battery positive terminal.
– Use connection lines from the measuring tool set to connect
the contacts -5- to the plug and to the fuel pump.
– Pull off the fuel feed line from the flange of the fuel delivery
unit.
– Connect adapter -V.A.G 1318/17- and adapter -
V.A.G 1318/16- , fit onto the feed support and hold in a
measuring glass.
– Activate the remote control -V.A.G 1348/3A- for 30 seconds.
– Measure the battery voltage.
– Compare the fuel rate with the specified value.
Note
♦ The amount of the fuel pumped is dependent on the voltage.

♦ The diagram refers to the voltage which exists at the fuel
pump.
♦ The voltage at the fuel pump is about 2 volts less than the
battery voltage.
If the fuel flow rate is not reached:

– Remove the fuel delivery unit and check whether the pump
strainer is not clogged up.
If no fault was detected until now:
– Replace fuel delivery unit.

OCTAVIA II 2004 ➤
2 Accelerator control
2.1 Accelerator pedal module - Summary of components
1 - Connector
❑ black
❑ 6-pin
2 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ for vehicles with auto‐
matic gearbox with kick-
down-force element
❑ not adjustable
❑ -A- are openings for re‐
lease tool -T10238- or -
T10240-
⇒ page 185
❑ adapt this for a replace‐
ment engine control unit
⇒ Vehicle diagnosis,
testing and information
system VAS 5051
3 - 10 Nm
4 - Cap
2.2 Removing and installing accelerator

pedal module
♦ Release tool -T10238- (for left-hand drive vehicle)
♦ Release tool -T10240- (for right-hand drive vehicle)
2. Accelerator control 185

OCTAVIA II 2004 ➤
Removing
– Remove cover for the steering column -arrows-.
– Lever out the cap ( ⇒ page 185 , position 4) with a screwdriver.
– Unscrew the fixing screw ( ⇒ page 185 , position 3).
– Push the release tool -T10238- (on right-hand drive vehicles

release tool -T10240- ), as shown up to the stop into the pro‐
vided openings and remove the accelerator pedal module.
– Unplug connector from accelerator pedal module. To do so
press down securing element from connector.
Install
– Fit connector -2- onto the accelerator pedal module -5-.

The locking of the connector must be audible.
– Push accelerator pedal module onto the fixing bolts -6-.
– Insert centering pin -7- in the hole on the vehicle floor.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install cover for steering column.
– If the accelerator pedal module was replaced, the engine con‐
trol unit has to be adapted ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
– If the accelerator pedal module was replaced on vehicles with
an automatic gearbox, the kick-down function must be initial‐
ised ⇒ Vehicle diagnosis, testing and information system VAS
5051.

OCTAVIA II 2004 ➤
21 – Turbocharging
1 Charge-air system with exhaust gas
turbocharger - Part 1
Note
♦ Observe rules for cleanliness ⇒ page 4 .

♦ The charge-air system must be tight.
♦ Replace the gaskets, the sealing rings and the self-locking
nuts.
1.1 Connection diagram for vacuum hoses for engine with engine identification
characters BKD, AZV
1 - Mechanical exhaust gas re‐

circulation valve
2 - Vacuum reservoir
3 - to vacuum setting element
of charge pressure control
4 - to the vacuum setting ele‐
ment of the radiator flap for ex‐
5 - Solenoid valve block
❑ Component parts of the
valve block are:
♦ Changeover valve for radi‐
ator of exhaust gas recircu‐
lation -N345-
♦ Exhaust gas return valve -
N18-
♦ Solenoid valve for charge
pressure control -N75-
❑ Connection diagram
⇒ page 188
6 - Vacuum line
to the valve block
7 - Tandem pump
8 - Air filter
1. Charge-air system with exhaust gas turbocharger - Part 1 187

OCTAVIA II 2004 ➤
1.2 Connection diagram on the solenoid

valve block and for vacuum connector
for engines with engine identification
characters BKD, AZV
Connection diagram on the solenoid valve block
P1 - Vacuum line from the tandem pump
P2 - to mechanical exhaust gas recirculation valve
P3 - to the vacuum setting element of the radiator flap for exhaust
gas recirculation
P4 - Air admission hose to air filter
P5 - to vacuum reservoir
P6 - to vacuum setting element of charge pressure control
Note
The vacuum connection marked with -arrow- is not used and is

closed.
Connection diagram for vacuum connector
Note
The illustration shows the side of the hose connection.
1 - Vacuum line from the tandem pump

2 - to mechanical exhaust gas recirculation valve
3 - to the vacuum setting element of the radiator flap for exhaust
gas recirculation
4 - Ventilation hose to air filter
5 - to vacuum reservoir
6 - to vacuum setting element of charge pressure control
1.3 Inspecting vacuum setting element and

tension rods for charge pressure control
for engines with engine identification
characters BKD, AZV
♦ Hand vacuum pump , e.g. -VAS 6213-
Faults at tension rods or at vacuum setting element of charge
pressure control lead to the following faults:
♦ Specified values for charge pressure are not reached.
♦ Poor performance.
♦ Irregular performance in the partial load region.
♦ Engine jerking in change-overs.
188 Rep. Gr.21 - Turbocharging

OCTAVIA II 2004 ➤
Test sequence
• Vacuum piping for tightness and completeness checked
⇒ page 187 .
• Charge-air system for tightness checked ⇒ page 202 .
– Connect the connecting hose -2- to the vacuum setting ele‐
ment and to the hand vacuum pump -VAS 6213- .
– Position the sliding ring -1- of the hand vacuum pump -VAS
6213- in the -direction of arrow- for “vacuum”.
Note
A second mechanic is required for the additional test.
– Generate vacuum with the hand vacuum pump -VAS 6213-

and observe the movement of the tension rod of exhaust
turbocharger.
Note
For the inspection use a mirror.
Nominal values:
• At a vacuum of 0.05...0.120 bar (0.005…0.012 MPa) the ten‐
sion rod must move up.
• At a vacuum of 0.550...0.620 bar (0.055…0.062 MPa) the ten‐
sion rod must lie at the top against the stop.
– Remove the connecting hose from the hand vacuum pump -
VAS 6213- and at the same time observe the tension rod
movement over the entire adjustment range.
• The tension rod must move without jolting over the entire ad‐
justment range.
If the specified values are not achieved or the tension rod only
moves in jolts:
– Replace exhaust turbocharger ⇒ page 191 .
Note
♦ If in case of doubt, the measuring accuracy of the vacuum at

the hand vacuum pump -VAS 6213- is not adequate, a turbo‐
charger tester can be used, e.g. -V.A.G 1397 A- for a more
precise measurement.
♦ Connection of the turbocharger tester : ⇒ Operating instruc‐
tions .

OCTAVIA II 2004 ➤
1.4 Connection diagram for vacuum hoses for engine with engine identification
characters BMM
1 - Exhaust gas turbocharger

2 - Charge air cooler
3 - Inlet hose
5 - Brake servo unit
6 - Solenoid valve for charge
pressure control -N75-
7 - Air filter
8 - Changeover valve for radi‐
ator of exhaust gas recircula‐
tion -N345-
9 - Tandem pump
10 - Cylinder head
11 - Intake manifold
13 - Exhaust pipe
14 - Vacuum setting element
❑ the radiator flap for ex‐
❑ always replace together
with radiator for exhaust
gas recirculation
15 - electrical exhaust gas re‐
circulation valve -N18- with
EGR potentiometer -G212-
and EGR control motor -V338-
❑ white connection points
to charge pressure con‐
trol solenoid valve (Po‐
sition 6) and to vacuum reservoir
❑ for charge pressure control
❑ part of turbocharger, cannot be replaced separately

OCTAVIA II 2004 ➤
2 Charge-air system with exhaust gas

turbocharger - Part 2
2.1 Removing and installing exhaust gas turbocharger for engine with engine
1 - Gasket
❑ replace
2 - to flap of radiator for ex‐
3 - 25 Nm
❑ replace
❑ Coat stud bolts with hot
bolt paste -G 052 112
A3-
4 - Connecting tube
❑ to flap of radiator for ex‐
5 - Support
❑ for oil feed line
6 - 10 Nm
7 - Oil feed line
❑ Check oil feed line for
continuity before instal‐
ling.
❑ Fill the exhaust turbo‐
charger with engine oil
through the connection
fitting of the oil feed line
before installing
8 - Union nut - 22 Nm
9 - Connection fitting - 30 Nm
10 - Gasket ring
❑ replace
11 - Gasket
❑ replace
12 - Exhaust gas turbocharger
❑ can only be replaced complete with exhaust manifold and vacuum setting element of charge pressure
control
❑ Check vacuum setting element ⇒ page 188
13 - Support
❑ between turbocharger and the cylinder block
14 - 40 Nm
❑ first tighten all screws by hand

OCTAVIA II 2004 ➤
15 - Oil return line

❑ in the cylinder block
16 - Connection fittings - 40 Nm
17 - 17 Nm
18 - 20 Nm
❑ first tighten all screws by hand
19 - Heat shield
20 - 22 Nm

Caution
In case of mechanical damage to the exhaust turbocharger,

e.g. damage of the compressor wheel, it is not sufficient to only
replace the exhaust turbocharger. In order to prevent conse‐
quential damage to the engine, perform the following tasks:
eign bodies.
must be replaced.
Removing
Gr. 66 .
– Remove bulkhead plenum chamber -arrows-.
⇒ Rep. Gr. 66 .
– Release the screws of the coolant pipes for the auxiliary heat‐
ing and swivel the coolant pipes to the left.
Note
The figure shows the removed engine from a rear view.

OCTAVIA II 2004 ➤

– Release the vacuum lines at the rear of the charge air pipe
and detach hose to vacuum setting element of charge pres‐
sure control.
– Detach hose -2- to crankcase vemtilation from charge air pipe.
– Release spring strap clip -4- with pliers for spring strap clips
and remove charge air pipe from exhaust turbocharger.
– Unscrew fixing screws of right charge air pipe and remove

connecting hose from exhaust turbocharger; to do so slightly
raise the retaining clip -arrow-.
– Remove pre-exhaust pipe ⇒ page 233 .
– Release screws -1- and -2- and remove turbocharger support.

– Remove the oil return line -3- from the cylinder block.
– Unscrew oil feed line from exhaust turbocharger and exhaust

manifold -arrows- and furthermore from coolant pipe and from
oil filter holder and lay it to one side.

OCTAVIA II 2004 ➤
– Remove connection pipe for exhaust gas recirculation

-arrows- and heat shield for exhaust manifold.
– Unscrew nuts -arrows- and remove exhaust manifold with ex‐

haust turbocharger downwards.
Install
the following:
Note

nuts.
♦ Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
free of oil and grease before being installed.
– Install pre-exhaust pipe ⇒ page 233 .

Note
after installing the exhaust turbocharger run the engine approx. 1

minute in idle and do not increase speed immediately in order to
ensure the supply of oil to the turbocharger.

OCTAVIA II 2004 ➤
2.2 Removing and installing parts of the charge air cooling for engine with en‐
gine identification characters BKD, AZV
Note
♦ Before testing or repairing check all hoses and lines for tight connection and leaktightness.
♦ Hose connections and hoses for charge air system must be free of oil and grease before being installed.
1 - 7 Nm
2 - Support
⇒ page 200
4 - top seal
❑ placed onto charge air
cooler
5 - bottom seal
cooler
6 - Connecting hose
7 - to exhaust gas turbocharger
8 - Charge air pipe
9 - to induction pipe
10 - 15 Nm
11 - 3 Nm
12 - Charge pressure sender -
G31- / Intake air temperature
sender -G42-

OCTAVIA II 2004 ➤
2.3 Removing and installing exhaust gas turbocharger for engine with engine
identification characters BMM
1 - 10 Nm
2 - Support
3 - Heat shield
4 - Oil feed hose
❑ to connection fitting of
oil feed line for exhaust
turbocharger
❑ Check oil feed line for
continuity before instal‐
ling.
❑ Fill the exhaust turbo‐
charger with engine oil
through the connection
fitting of the oil feed line
before installing
❑ for charge pressure
control
❑ part of turbocharger,
cannot be replaced sep‐
arately
6 - Vacuum hose
7 - Gasket
❑ replace
8 - for diesel particle filter
9 - Clamp - 7 Nm
❑ for exhaust gas turbo‐
charger and diesel par‐
ticle filter
❑ replace
10 - Exhaust turbocharger with exhaust manifold
❑ can only be replaced as one part
11 - 25 Nm
❑ replace
12 - 25 Nm
13 - Gasket
❑ replace
14 - Connecting tube
❑ for exhaust gas recirculation
15 - 25 Nm
❑ replace
16 - 15 Nm
17 - O-ring
❑ replace

OCTAVIA II 2004 ➤
18 - Hollow screw - 60 Nm
19 - Support
❑ for exhaust gas turbocharger
❑ for oil return-flow line
20 - Exhaust gas temperature sender 1 -G235- ( Temperature sender upstream turbocharger -G507- )
❑ 45 Nm
❑ the thread of new temperature senders must be coated with assembly paste
❑ grease only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender.
21 - Heat shield
22 - Supports
❑ for suction hose at exhaust gas turbocharger
23 - 9 Nm
24 - 10 Nm

♦ Set of tools SW 17 -T10395-
Caution
In case of mechanical damage to the exhaust turbocharger,

e.g. damage of the compressor wheel, it is not sufficient to only
replace the exhaust turbocharger. In order to prevent conse‐
quential damage to the engine, perform the following tasks:
eign bodies.
must be replaced.
Removing

OCTAVIA II 2004 ➤
– Disconnect electrical plug connection -5- to exhaust gas tem‐

perature sender 1 -G235- ( temperature sender upstream
turbocharger -G507- ) and expose cable.
⇒ page 237 .
– Disconnect plug at air mass meter -G70- ⇒ page 219 .
– Remove connection pipe and suction hose ⇒ page 223 .
– Remove support for suction hose at exhaust gas turbocharger
⇒ page 196 .
– Remove vacuum line to vacuum setting element (Position 5).
– Detach oil feed hose (Position 4).
– Pull out connecting hose from the turbocharger ⇒ page 200 .
– Remove connection pipe to exhaust gas recirculation radiator
⇒ page 250 .
– Remove exhaust gas temperature sender 1 -G235- ( temper‐

ature sender upstream turbocharger -G507- ) -arrow- using a
key from the set of tools SW 17 -T10395- .
– Remove right flange shaft for angle gearbox ⇒ Gearbox ⇒
Rep. Gr. 39 .


OCTAVIA II 2004 ➤
– Remove heat shield at exhaust manifold -arrows-.

– Unscrew bracket for diesel particle filter.
– Unscrew nuts -arrows- and remove exhaust manifold with ex‐

haust turbocharger downwards.
Install
the following:
Note

nuts.
♦ Fill exhaust turbocharger with engine oil through the connec‐
tion fitting of the oil feed line.
free of oil and grease before being installed.

Note
after installing the exhaust turbocharger run the engine approx. 1

minute in idle and do not increase speed immediately in order to
ensure the supply of oil to the turbocharger.

OCTAVIA II 2004 ➤
2.4 Removing and installing parts of the charge air cooling for engine with en‐
gine identification characters BMM
Note
♦ Before testing or repairing check all hoses and lines for tight connection and leaktightness.
♦ Hose connections and hoses for charge air system must be free of oil and grease before being installed.
1 - 5 Nm
2 - Support
⇒ page 200
4 - top seal
cooler
5 - 3 Nm
6 - Charge pressure sender -
G31- / Intake air temperature
sender -G42-
7 - O-ring
8 - Support
9 - 5 Nm
10 - Connecting hose
11 - Charge air pipe
❑ for intake manifold flap
motor -V157-
13 - 8 Nm
❑ from exhaust turbo‐
charger
15 - bottom seal
cooler
2.5 Removing and installing charge air cool‐

er
Removing
– Removing coolant cooler.

OCTAVIA II 2004 ➤
– Remove front bumper ⇒ Body Work ⇒ Rep. Gr. 63 .

– Remove connecting hoses from charge air cooler, if it is not
yet performed.
– Release the screws of the brackets for charge air cooler.
⇒ page 195 , Position 1
♦ Vehicles with engine identification characters BMM:
⇒ page 200 , Position 1
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Caution
To avoid causing damage to the condenser and to the refrig‐

erant lines and hoses make sure the lines and hoses are not
over-extended, kinked or bent.
Note
For the following work, a second mechanic is required to hold the

charge-air cooler.
– Swivel the charge air cooler towards the rear, remove the lat‐
eral bearings and unhook out of the lower bearings.
– Release the securing bolts -arrows- of the condenser.
– Remove charge air cooler downwards.
Install
the following:
Note
Replace O-rings.


OCTAVIA II 2004 ➤
2.6 Hose connections with push-fit cou‐

plings
Caution
The gasket ring for the push-fit coupling can be damaged, if

the locking clip is in the lock position during the assembly. This
could result in a leakage. Observe the assembly instruction.
Removing
– Release push-fit coupling by pulling the locking clip -arrow-.
Disconnect hose/pipe without auxiliary tool.
Install
– When replacing the gasket ring, place the gasket ring in the
groove of the charge air hose. Make sure that the gasket ring
is fully seated all round in the groove and not twisted.
– Oil the sealing surface and the gasket ring.
– Put the locking clip into the release position -1-.

– Push the charge air hose up to the stop into the coupling.
– Put the locking clip into the lock position -2- and then press
down once again the charge air hose.
– Check for correct seating and the correct locking in place of
the push-fit coupling by pulling on the hose.
2.7 Checking the charge-air system for

leaktightness
♦ Charge-air system testing device , e. g. -V.A.G 1687-
♦ Adapter , e.g. -V.A.G 1687/10-

OCTAVIA II 2004 ➤
Test sequence
– Remove the suction hose -1- from the air filter.
– Fit adapter -1687/10- into the suction hose -1- and secure with
a clamp.
Prepare tester for charge air system -V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect the tester for charge air system -V.A.G 1687- , as

shown, at the adapter -1687/10- .

OCTAVIA II 2004 ➤
– Connect the pneumatic hose -1- (pneumatic support) at tester.
Note
If there is water in the transparent water drain reservoir, drain

water via the drain plug -6-.
– Open valve -3-.

– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
Caution
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device , e.g. -V.A.G 1842- ,
to check the charge-air system for leak points.
Note
♦ Minor leaks are permissible on the suction side of the turbo‐

charger, because the suction hose is not designed for over‐
pressure.
♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ operating
instructions .
♦ In case of a leak point, observe the instructions for charge air
system ⇒ page 5 during the installation.
♦ Before removing the adapter, depressurize the test circuit by
detaching the coupling from the adapter -1687/10- .

OCTAVIA II 2004 ➤
23 – Fuel Formation, Injection

1 Repairing diesel direct injection sys‐
tem
The control unit is equipped with a fault memory. Before repairs,
setting operations and fault finding, interrogate the fault memory
and execute a self-diagnosis ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
Note
♦ Faults can be detected by the control unit as checking and

adjustment work is being undertaken and then saved. It is
therefore absolutely necessary to delete the fault memory af‐
ter completing all checking and adjustment work ⇒ Vehicle
diagnosis, testing and information system VAS 5051
♦ Safety precautions when working on the diesel direct injection
system ⇒ page 3 .
1.1 Fitting locations for engine with engine identification characters BKD, AZV
- Overview
Note
♦ Some components are fitted under the engine cover.

♦ Remove engine cover ⇒ page 13 .
1. Repairing diesel direct injection system 205

OCTAVIA II 2004 ➤
Components A through G are not represented in the overview

figure.
A - Warning light for engine

electronics -K149-
❑ in the dash panel insert
B - Accelerator pedal position
sender -G79- with accelerator
pedal position sender 2 -G185-
❑ in footwell on the accel‐
erator pedal
C - Brake light switch -F- and
brake pedal switch -F63-
❑ in footwell on the brake
pedal
D - Fuel pump relay -J17-
❑ on relay carrier
E - Clutch position sender -
G476-
❑ on clutch main cylinder
F - 6-pin relay carrier
❑ with automatic glow pe‐
riod control unit -J179-
❑ below E-box in the en‐
gine compartment
G - Relay and fuse carrier
❑ with relay for voltage
supply terminal 30 -
J317-
supply terminal 15 -
J329-
❑ E-box in the engine
compartment
1 - Unit injectors and glow
plugs
❑ Unit injector valve of cylinder 1 -N240-
❑ Removing and installing unit injectors ⇒ page 213
❑ Glow plug 1 -Q10-
❑ Removing and installing glow plugs ⇒ page 253
2 - Diesel direct injection system control unit -J248-
❑ with altitude sender -F96-
3 - Flap of radiator for exhaust gas recirculation
❑ Central plug connection for unit injectors and glow plugs
206 Rep. Gr.23 - Fuel Formation, Injection

OCTAVIA II 2004 ➤
5 - Solenoid valve block

❑ Component parts of the valve block are:
♦ Changeover valve for radiator of exhaust gas recirculation -N345-
♦ Exhaust gas return valve -N18-
♦ Solenoid valve for charge pressure control -N75-
6 - Air mass meter -G70-
7 - Coolant temperature sender -G62-
8 - Tandem pump
9 - Fuel temperature sender -G81-
11 - Charge pressure sender -G31- with intake air temperature sender -G42-
12 - Intake manifold flap motor -V157-
13 - Mechanical exhaust gas recirculation valve
15 - 3-pin plug connection
❑ for hall sender -G40-

OCTAVIA II 2004 ➤
1.2 Intake manifold - Summary of components for engine with engine identifi‐
cation characters BKD, AZV
1 - Induction pipe
2 - 22 Nm
3 - Lifting eye
4 - Gasket
❑ replace
5 - 22 Nm
6 - Support
❑ for wiring loom
7 - from radiator for exhaust
gas recirculation
8 - 10 Nm
9 - Connecting tube
❑ for exhaust gas recircu‐
lation
10 - Gasket
❑ replace
11 - Intake manifold flap motor
-V157-
❑ The intake manifold flap
is closed for about 3
seconds after switching
off the engine and then
opens again. This re‐
duces the switch-off im‐
pact.
12 - O-ring
❑ replace
13 - Mechanical exhaust gas
recirculation valve
❑ with vacuum setting ele‐
ment
14 - 3 Nm

OCTAVIA II 2004 ➤
1.3 Pre-wiring for unit injectors and glow plugs - Summary of components for
engine with engine identification characters BKD, AZV
1 - Glow plug connector

2 - Stainless steel clamps
❑ do not bend up
3 - Fixing screw
❑ tighten to 10 Nm
4 - Adapter ring
❑ when assembling pay
attention to correct posi‐
tion ⇒ page 209
5 - Central plug
❑ when assembling pay
attention to correct posi‐
tion ⇒ page 209
6 - Connector
❑ 2-pin
❑ for pump-nozzle unit
7 - Cable guide
❑ only disassemble/as‐
semble together with
stainless steel clamps
(Pos. 2)
1.4 Removing and installing pre-wiring for

unit injectors and glow plugs for engine
BKD, AZV
♦ Key -T10310-

OCTAVIA II 2004 ➤
Removing
Caution
The disassembly and assembly of the pre-wiring must only be

performed by unscrewing and screwing the clamps. Slacken‐
ing the cable guide from the clamps causes them to bend up
and it can lead to cable fracture due to high play. This applies
also when changing the unit injectors, as well as all work which
does not require the complete removal of the pre-wiring.
– Disconnect central plug conection at cylinder head. To do so,
pull release pin in -direction of arrow 1- and open the knurled
nut in -direction of arrow 2-.
– Position wrench -T10310- at adapter ring and slacken by a 90°

turn (1/4 turn) in -direction of arrow-.
– Pull the locking clip -1- slightly upwards using a screwdriver

and press through central plug -2- to the inside.

OCTAVIA II 2004 ➤

– Unplug connector of the glow plugs -1-. Unscrew fixing screws

-2- of stainless steel clamps and remove complete pre-wiring.
Install
the following:
– Position pre-wiring and tighten fixing screws to 10 Nm.
– Guide the central plug through the opening in the bearing

frame. To do so pay attention to the correct seating of the
locking clip -arrows-.
– Position adapter ring (colour marked “long” leg -arrow- points

to 12 o'clock).

OCTAVIA II 2004 ➤
– Position wrench -T10310- at adapter ring and interlock by a

90° turn (1/4 turn) opposite the -direction of arrow-.
Note
After correct assembly of the adapter ring the colour marked

“short” leg points to 12 o'clock.
– Position central plug connection at cylinder head and lock.

1.5 Removing and installing air filter for engine with engine identification char‐
acters BKD, AZV
1 - Inlet hose
❑ to exhaust gas turbo‐
charger
3 - O-ring
4 - 2 Nm
5 - Air filter top part
❑ If during repairs the air
filter housing is opened
(except for air filter ele‐
ment change), it should
be entered in the Serv‐
ice Schedule (change
interval for air filter ele‐
ment is shortened).
6 - Ventilation hose
❑ to solenoid valve block
7 - Air filter element
8 - Air intake hose
❑ to the lock carrier
9 - Air filter bottom part
❑ with supports for drain
pipe
10 - 8 Nm
11 - Drain pipe
❑ Vehicles 12.04 ?

OCTAVIA II 2004 ➤
1.6 Repairing the unit injectors for engine with engine identification characters
BKD, AZV
Note
Observe rules for cleanliness ⇒ page 2 .

(3/4 turn)
❑ replace
Note
⇒ page 213
(1/4 turn)
❑ replace
4 - Adjusting screw
❑ replace
❑ Grease the contact sur‐
face of the unit injector
to the ball pin using
grease -G 000 100-
5 - Counternut - 30 Nm
⇒ page 213
❑ When installing, oil the
O-rings and the lines in
the cylinder head
7 - O-ring
8 - O-ring
9 - Cylinder head
1.7 Removing and installing the unit injec‐

tors for engines with engine identifica‐
♦ Valve lever -MP1-211 (VW 541/1A)-
♦ Assembly device for valves -MP1-213 (2036)-
♦ Retaining plates -MP1-213/1 (2036/1)-
♦ Striking hammer -T10133/3-

OCTAVIA II 2004 ➤
♦ Socket insert -T10054- (XZN 6, total length at least 75 mm)
♦ Counterholder -T10172 - or -MP 1-216-
♦ Dial gauge
1.7.1 Removing
– Release the counternuts -2- of the adjusting screws -1- on all
unit injectors and unscrew the adjusting screws until the rele‐
vant valve lever rests against the spring cap of the unit injector.
Note

assignment of the valve lever.

– Loosen screws -2- and -4-, release alternatively in several
stages and remove valve-lever shaft.


OCTAVIA II 2004 ➤
– Unplug connector -1- of the glow plugs.
Caution
To remove and install the unit injectors, the screws for the re‐
taining clips must be loosened or tightened. If the electrical
wiring loom is loosened from the retaining clips, they can be
bent and it can lead to cable fracture due to high play.
– Release screws -2- at the retaining clips and lay the complete
electrical wiring set to the side.
– Screw out screws -arrows- with socket insert -T10054- and

pull out of holes.
– Always pull the ball pin -1- out of the relevant unit injector.
– Insert extractor -T10163- into the holes for the screws on the
unit injector.
– Tighten spindle -A- moderately against the unit injector. Tight‐
en counternut -B- by hand.
– With careful knocks on the striking hammer -T10133/3- pull
the unit injector out of the cylinder head seat upwards.
Note
Do not interchange the unit injectors, if necessary mark the as‐

signment to each cylinder.

OCTAVIA II 2004 ➤
1.7.2 Install
Caution
• For any work procedure involving an adjustment of the unit

injector via the adjusting screw, it is necessary to replace
the adjusting screw in the valve lever and the ball pin of
the unit injector, otherwise this can lead to considerable
wear of these components.
• The fixing screws of the unit injectors must definitely be
replaced as well.
Note
♦ When installing, oil the O-rings and the lines in the cylinder
head.
♦ New unit injectors are supplied with new O-rings.
♦ If the old unit injectors are installed again, all O-rings must be
replaced ⇒ page 218 .
♦ Grease the contact surfaces of the ball pin and the adjusting
screw using Grease - G 000 100- .
– Before installing the unit injector check the correct position of

both O-rings.
• The O-rings must not be twisted.
• The white marked O-ring is located in the bottom groove of the
unit injector.
– Oil O-rings and shank of the unit injector.
– Check seat of unit injector in cylinder head for any dirt or for‐
eign bodies (swarfs/carbon deposits etc..) and if necessary
clean with compressed air.
– Insert the unit injector with the greatest of care into the cylinder
head seat.
– Fit assembly device for valves -2036- with the retaining plates
-2036/1- , as shown, onto the bearing frame of the cylinder
head.
Note
If the fixing plates -2036/1- cannot be fitted due to the exhaust

gas recirculation radiator, place large body washers underneath.

OCTAVIA II 2004 ➤
– Position new fixing screws using socket insert -T10054- and

carefully screw in without using force up to the stop -arrow-.
Caution
If the unit injector is pulled down by the fixing screws, there is

the risk that the unit injector is pulled skewed into its seat. This
can result in poor vehicle handling and starting problems. For
this reason the unit injector must be pressed into its seat and
must only then be screwed on.
– Position valve lever -VW 541/1 A- with pressure plate -VW

541/5- .
– Carefully press the unit injector into its seat with the valve lever
and hold with a force.
– Screw in fixing screws of the unit injector carefully and without
using force up to the stop.
– Tighten screws of unit injector -arrows- alternatively as follows

with a socket insert -T10054- :
Stage Tighten
I – Tighten with the torque wrench to 3 Nm.
II – Using a rigid wrench torque a further 270° (3/4
turn).
Note
The torquing angle of 270° must absolutely be carried out in one

working step!
– Before inserting the valve-lever shaft, check whether all the

ball pins -1- and O-rings -2- are inserted in the unit injectors.

OCTAVIA II 2004 ➤
– Screw on valve-lever shaft with new screws as follows:

Se‐ Tighten
quence
I – Tighten screws -2- and -4- alternatively in several
stages, until the valve-lever shaft rests on the
bearing frame.
II – Tighten screws -1-, -3- and -5- to 20 Nm and tor‐
que a further 90° (1/4 turn).
III – Tighten screws -2- and -4- to 20 Nm and torque
– Place a dial gauge, as shown, onto the adjusting screw of the

unit injector.
Caution


the roller of the roller rocker arm is on the drive cam tip.
• Roller side of roller rocker arm -arrow A- is on the highest point.
• Dial gauge -arrow B- is on the lowest point.
– Turn the adjusting screw in the roller rocker arm until one feels
a significant resistance (the unit injector is against the stop).
by about 180°.
– Hold the adjusting screw in this position and tighten up the lock
nut using a torque of 30 Nm
– Mount plug for unit injectors and for glow plugs.
– Fasten retaining clips.
1.8 Replacing O-rings of unit injector for en‐

ters BKD, AZV
♦ Assembly sleeve -T10164/1-
♦ Assembly sleeve -T10164/2-
Removing
– Remove unit injector ⇒ page 213 .
– Lever off the old O-rings from the unit injector with extreme
care.
– Make sure that no burr arises at the base of the O-rings.

OCTAVIA II 2004 ➤
Install
Note
♦ Always use the assembly sleeves to install the O-rings. If they

are not used, the O-rings can be damaged.
♦ Observe the correct allocation of the O-rings to the channels.
♦ When installing, slide on the O-rings, do not roll. They must
not be turned inwards on the seat of the unit injector.
– Clean the contact surfaces for the O-rings at the unit injector
with great care.
– Insert the assembly sleeve -T10164/1- on the unit injector up
to the stop.
– Carefully slide the top, thicker O-ring onto the assembly sleeve
and insert it in the groove of the unit injector.
– Remove assembly sleeve.

to the stop.
– Carefully slide the lower, white marked O-ring onto the as‐
sembly sleeve and insert it in the groove of the unit injector.
– Install unit injector ⇒ page 213 .
1.9 Fitting locations for engine with engine identification characters BMM -
Overview
Note
♦ Some components are fitted under the engine cover.

♦ Remove engine cover ⇒ page 13 .

OCTAVIA II 2004 ➤
Components A through G are not represented in the overview

figure.
A - Warning light for engine

electronics -K149-
❑ in the dash panel insert
B - Accelerator pedal position
sender -G79- with accelerator
pedal position sender 2 -G185-
❑ in footwell on the accel‐
erator pedal
C - Brake light switch -F- and
brake pedal switch -F63-
❑ in footwell on the brake
pedal
D - Fuel pump relay -J17-
❑ on relay carrier
E - Clutch position sender -
G476-
❑ on clutch main cylinder
F - Automatic glow period con‐
trol unit -J179-
❑ below E-box in the en‐
gine compartment
G - Relay and fuse carrier
supply tml. 30 -J317-
supply tml. 15 -J329-
❑ E-box in the engine
compartment
1 - Intake manifold flap motor -
V157-
2 - Exhaust gas temperature
sender 3 -G495- ( Tempera‐
ture sender downstream particle filter -G527- )
3 - lambda probe -G39- with heating for lambda probe -Z19-
4 - electrical exhaust gas recirculation valve -N18- with EGR potentiometer -G212- and EGR control motor -
V338-
5 - Diesel direct injection system control unit -J248-
6 - Exhaust gas temperature sender 2 -G448- ( Temperature sender upstream particle filter -G506- )
7 - Pressure sensor 1 for exhaust gas -G450-
8 - Exhaust gas temperature sender 1 -G235- ( Temperature sender upstream turbocharger -G507- )
9 - The unit injectors
❑ Removing and installing unit injectors ⇒ page 213

OCTAVIA II 2004 ➤
10 - Changeover valve for radiator of exhaust gas recirculation -N345-

11 - Coolant temperature sender -G62-
12 - Solenoid valve for charge pressure control -N75-
13 - Plug connection
❑ left on partition panel
❑ Summary of components ⇒ page 221
15 - Tandem pump
❑ central for pump-nozzle units
18 - Fuel temperature sender -G81-
19 - Glow plugs
20 - 3-pin plug connection
for hall sender -G40-

22 - Glow plugs
23 - Charge pressure sender -G31- with intake air temperature sender -G42-
Summary of components of plug connections on the partition wall

1 - Solenoid valve for charge pressure control -N75-
2 - Plug connection (orange) for exhaust gas temperature sender
3 -G495- ( temperature sender downstream particle filter -G527- )
3 - Plug connection for exhaust gas temperature sender 2 -G448-
( temperature sender upstream particle filter -G506- )
4 - Plug connection for lambda probe -G39- with heating for lamb‐
da probe -Z19-
5 - Plug connection for exhaust gas temperature sender 1 -G235-
( temperature sender upstream turbocharger -G507- )

OCTAVIA II 2004 ➤
1.10 Intake manifold - Summary of components for engine with engine identifi‐
cation characters BMM
1 - Gasket
❑ replace
2 - Intake manifold
3 - Gasket ring
❑ replace
4 - Supports
V157-
pact.
6 - from charge-air cooler
7 - 10 Nm
8 - electrical exhaust gas recir‐
culation valve -N18- with EGR
potentiometer -G212- and
EGR control motor -V338-
❑ before installing, check
sealing surfaces at in‐
take manifold for dirt
and clean as required
❑ After replacing, adapt
new part as follows:
– Switch ignition on and
off and wait 1 minute for
the afterrun of the con‐
trol units.
– Start engine and run in

idle for at least 1 minute.
– Interrogate the fault memory ⇒ Vehicle diagnosis, testing and information system VAS 5051.
• No fault must be stored in the fault memory.

– If a fault occurs, erase the fault memory and repeat the entire work procedure.
9 - Gasket
❑ replace
10 - Radiator
11 - 22 Nm
12 - Support
13 - 22 Nm

OCTAVIA II 2004 ➤
1.11 Removing and installing air filter for engine with engine identification char‐
acters BMM
1 - Inlet hose
❑ to exhaust gas turbo‐
charger
3 - O-ring
4 - Vacuum hose
❑ To the solenoid valve for
charge pressure limita‐
tion -N75-
5 - 2 Nm
6 - Air filter top part
❑ If during repairs the air
filter housing is opened
(except for air filter ele‐
ment change), it should
be entered in the Serv‐
ice Schedule (change
interval for air filter ele‐
ment is shortened).
7 - Air intake connection
❑ screwed onto lock carri‐
er
8 - 2 Nm
9 - Air intake hose
10 - Drain pipe
11 - Air filter bottom part
❑ with supports for drain
pipe
12 - 8 Nm
13 - Air filter element
14 - 2 Nm
❑ from cylinder head cover
❑ for crankcase ventilation

OCTAVIA II 2004 ➤
1.12 Repairing the unit injectors for engine with engine identification characters
BMM
♦ Always replace gasket rings and O-rings.

(1/4 turn)
❑ replace
❑ with valve levers
3 - Counternut, 30 Nm
4 - Adjusting screw
❑ replace
face of the unit injector
to the ball pin using
grease -G 000 100-
5 - Ball pin
❑ replace
❑ Check ball pins for wear
marks and replace if
necessary
face to the adjusting
screw using grease -G
000 100-
⇒ page 224
7 - O-ring
8 - O-ring
9 - O-ring
10 - Heat-protection seal
❑ replace
11 - Circlip
12 - Cylinder head
13 - Clamping pad
❑ replace
1.13 Removing and installing unit injectors

characters BMM

OCTAVIA II 2004 ➤

♦ Dial gauge
1.13.1 Removing
– Remove top toothed belt guard and cylinder head cover
⇒ page 84 .
– Release the counternuts -2- of the adjusting screws on all unit
injectors and unscrew the adjusting screws until the relevant
valve lever rests against the spring cap of the unit injector.
– Screw out the fixing screws -2- for the valve-lever shaft from
the outside to the inside and remove the valve-lever shaft.
– Set the camshaft in such a way that the cam for cylinder 2
-arrow- is positioned as shown. All clamping pads can be re‐
moved in this position.
– Disconnect plug for unit injector. Support the opposite side of
the connector with your finger in order to avoid twisting the
connector.
– Screw out fixing screw -3- of the clamping pad (top illustration)
and remove the pad in the direction towards the camshaft.
– Insert extractor -T10055- in direction of the camshaft instead

of the clamping pad in the slot of the unit injector.
– Remove the unit injector through careful movements of the
sleeve at the nut -direction of arrow-.
Note
Do not interchange the unit injectors, if necessary mark the as‐

signment to each cylinder.

OCTAVIA II 2004 ➤
1.13.2 Install
Caution
• For any work procedure involving an adjustment of the unit

injector via the adjusting screw, it is necessary to replace
the adjusting screw in the valve lever and the ball pin of
the unit injector, otherwise this can lead to considerable
wear of these components.
• The fixing screws of the unit injectors must definitely be
replaced as well.
Note
♦ Grease the contact surfaces of the ball pin and the adjusting
screw using Grease - G 000 100- .
♦ New unit injectors are supplied with O-rings and heat-protec‐
tion seal.
♦ If the old unit injectors are installed again, all O-rings must be
replaced ⇒ page 228 .
– Before installing the unit injector check the correct position of

the three O-rings, the heat shield ring and the circlip.
Note
The O-rings must not be twisted.
– Oil the O-rings and place the unit injector with the greatest of
care into the cylinder head.
– Slide the unit injector into the cylinder head seat up to the stop
by exerting a uniform pressure.
– Place the clamping pad in the side slot of the unit injector.
Note
If the unit injector is not perpendicular to the clamping pad the

fixing screw may loosen and cause damage to the unit injector or
cylinder head.
– Align the unit injector as follows:

– Screw the new fixing screw in the clamping pad until the unit
injector can still easily be turned.
– Set the unit injector at a right angle to the bearing shell of the
camshaft.

OCTAVIA II 2004 ➤
– Using a caliper gauge, check dimension -a- from the outer side
of the cylinder head to the cylinder surface of the unit injector.
Cylinder Dimension -a-
1 333,0 ±0.8 mm
2 245,0 ±0.8 mm
3 153,6 ±0.8 mm
4 65,6 ±0.8 mm
– Adjust the unit injector as required, tighten the fixing screw
using a torque of 12 Nm and then turn through a further 270°
(3/4 turn). Tightening may occur in successive stages.
– Mount the valve-lever shaft and tighten up the new fixing

screws as follows:
– First tighten the inside -2- then the two outside -1- screws by
hand. In the same sequence tighten to 20 Nm and turn a fur‐
ther 90° (1/4 turn).
– Place a dial gauge on the adjusting screw of the unit injector.
Caution


the roller of the valve lever is on the drive cam tip.
♦ Roller side -arrow A- is on the highest point.
♦ Dial gauge -arrow B- is on the lowest point.
– Turn the setting screw in the valve lever until one feels a sig‐
nificant resistance (the unit injector is against the stop).
by approx. 180°.
– Firmly hold the adjusting screw in this position and tighten up
the lock nut using a torque of 30 Nm.
– Fit on the plug for the unit injector and install the cylinder head
cover and the top toothed belt guard.

OCTAVIA II 2004 ➤
1.14 Replacing O-rings of unit injector for en‐

ters BMM
♦ Assembling sleeves -T10056-
Removing
– Lever off the O-rings from the grooves of the unit injector with
extreme care.
– Make sure, above all, that the contact surfaces in the grooves
for the O-rings are not damaged.
Install
Note
♦ Always use the assembly sleeves to install the O-rings. If they

are not used there is a risk that the O-rings may become dam‐
aged.
♦ Observe the correct allocation of the O-rings to the grooves:
The ring thickness reduces in the direction of the injection
nozzle.
♦ Avoid rolling the O-rings when sliding them on. The O-rings
must not be turned inwards on the groove of the unit injector.
– Remove the heat-protection seal along with the circlip.

– Clean the contact surfaces for the O-rings in the grooves of
the unit injector with great care.
to the stop.
– Carefully slide the upper, thicker O-ring onto the assembly
sleeve and in the groove of the unit injector.

to the stop.
– Carefully slide the middle, thinner O-ring onto the assembly
sleeve and in the groove of the unit injector.

OCTAVIA II 2004 ➤

to the stop.
– Carefully slide the lower O-ring onto the assembly sleeve and
insert it in the groove of the unit injector.
– Slide on a new heat-protection seal together with the circlip.
1.15 Removing and installing engine speed

sender -G28-
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094)-
♦ Assembly tool -T10118-
Removing
– Press together the coolant hoses at the oil cooler with one
hose clamp each and remove the coolant hoses.
– Remove the oil filter holder ⇒ page 126 .
– Remove the plug -arrow- on the engine speed sender -G28-
with the assembly tool -T10118- and expose the electrical line.
Note
To unlock the plug without using the assembly tool -T10118- , the
unlock button must be pressed at the plug using the screwdriver
and at the same time raise the unlock button with a thin wire hook.
– Unscrew the fixing screw -2- of the engine speed sender -G28-
-1-.
Install
the following:
– Install the oil filter holder ⇒ page 126 .
Tightening torque
Component Nm
Engine speed sender -G28- on the flange 5

OCTAVIA II 2004 ➤
2 Engine control unit
2.1 Removing and installing engine control

unit
Note
If the engine control unit should be replaced, connect vehicle di‐

agnosis, measurement and information system -VAS 5051- and
in the guided fault detection system carry out “replace engine
control unit”.

♦ Body saw e.g. -V.A.G 1523 A-
Removing
Gr. 66 .
– Remove windscreen wiper and washer system ⇒ Electrical
System ⇒ Rep. Gr. 92 .
Vehicles with protective cover
– Cut with body saw -1- a slot for the cross-head screwdriver in
the heads of the pull-off screws -2-.
Note
♦ It must be sawed twice with the body saw, so that the slot is
wide enough, in order to be able to unscrew the screws with
a suitable screwdriver.
♦ The pull-off screws until are inserted with locking agent.
– Unscrew bolts -2-.

OCTAVIA II 2004 ➤
– Lift locking tab of protective cover with cross-head screwdriv‐

er.
– Push the protective cover in the -direction of the arrow- out of
the bracket for engine control unit.
– Disconnect front plug -1- and remove from engine control unit.
– Lever off retaining bracket -2- slightly.

– Push engine control unit out of the bracket -arrow-.
– Disconnect rear plug and remove from engine control unit.
Install
Note
For vehicles with protective cover, the metal swarfs must be suc‐
tioned out of the plenum chamber before installing the engine
control unit.
– Connect rear plug to engine control unit and lock.
– Push engine control unit into the bracket and lock the retaining
bracket -2-.
– Connect front plug to engine control unit and lock.
For vehicles with protective cover
– Fasten protective cover with new pull-off screws (before tight‐
ening align the protective cover in such a way that it does not
come into contact with the surrounding components)
– Install windscreen wiper and washer system ⇒ Electrical Sys‐
tem ⇒ Rep. Gr. 92 .
2. Engine control unit 231

OCTAVIA II 2004 ➤
26 – Exhaust System
exhaust system
Note
♦ The decoupling element in the pre-exhaust pipe should not be

♦ Replace the gaskets and the self-locking nuts.
♦ When performing installation work on the exhaust system,
make sure the exhaust system is not mounted under tension
and has adequate clearance from the vehicle body. If neces‐
sary slacken the double clamp and collar clamp and align the
silencer and exhaust pipe so as to create adequate clearance
between these components and the vehicle body, and that the
weight of the exhaust system is evenly distributed over the
hangers.
232 Rep. Gr.26 - Exhaust System

OCTAVIA II 2004 ➤

BKD, AZV
1 - Rear tunnel bridge

2 - Middle part of exhaust sys‐
tem
❑ for first equipment build‐
ing unit with rear part of
exhaust gas system, re‐
place individually when
carrying out repairs
❑ Separation point
⇒ page 241
❑ Align exhaust system
free of stress
⇒ page 242
3 - Retaining strap
❑ Pay attention to the part
number
4 - Hanger
5 - 23 Nm
6 - Hanger
7 - Clamp - 7 Nm
❑ replace
8 - Gasket
9 - Pre-exhaust pipe
❑ with catalytic converter
❑ protect against shocks
and blows
❑ with decoupling element
❑ do not twist decoupling
element more than 10° -
risk of damage
❑ Align exhaust system free of stress ⇒ page 242
10 - Support
11 - 40 Nm
12 - Front double clamp
❑ align exhaust system free of stress before tightening ⇒ page 242
❑ Tighten bolted connections evenly
13 - 23 Nm
14 - Front tunnel bridge
15 - 20 Nm
16 - Rear double clamp
❑ Check fitting position: ⇒ page 241
17 - Rear part of exhaust system
❑ for first equipment building unit with middle part of exhaust gas system, replace individually when carrying
out repairs
1. Removing and installing parts of the exhaust system 233

OCTAVIA II 2004 ➤
❑ Separation point ⇒ page 241
18 - Hanger

BMM
1 - Pressure sensor 1 for ex‐

haust gas -G450-
2 - Support
❑ for control line
3 - Pressure line - 45 Nm
4 - 10 Nm
5 - Lambda probe -G39- - 50
Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3- ;
the hot bolt paste -G 052
112 A3- must not get in‐
to the slot of the probe
body
ture sender upstream particle
filter -G506- )
❑ 45 Nm
❑ the thread of new tem‐
perature senders must
be coated with assem‐
bly paste
❑ grease only the thread
with hot bolt paste -G
052 112 A3- for re-used
temperature sender.
7 - Pre-exhaust pipe with die‐
sel particle filter
8 - Exhaust gas temperature sender 3 -G495- ( Temperature sender downstream particle filter -G527- )
❑ 45 Nm
9 - Identification
❑ for front double clamp
10 - to middle part of exhaust system
11 - 23 Nm
12 - Hanger

OCTAVIA II 2004 ➤

14 - 20 Nm
15 - Hanger
16 - Rear part of exhaust system
❑ for first equipment building unit with middle part of exhaust gas system, replace individually when carrying
out repairs
17 - 23 Nm
19 - Retaining strap
21 - Hanger
22 - Middle part of exhaust system
❑ for first equipment building unit with rear part of exhaust gas system, replace individually when carrying
out repairs
23 - Rear double clamp
❑ Check fitting position: ⇒ page 241
24 - from exhaust turbocharger
25 - Clamp - 7 Nm
❑ replace
26 - Gasket
❑ replace
27 - 23 Nm
28 - Support
❑ screwed onto the cylinder block
29 - 8 Nm

OCTAVIA II 2004 ➤
1.3 Exhaust system for vehicles with four-wheel drive - Overview of compo‐
nents
1 - Pressure sensor 1 for ex‐

haust gas -G450-
2 - Support
❑ for pressure line
3 - Pressure line - 45 Nm
4 - 10 Nm
5 - Lambda probe -G39- , 50
Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3- ;
the hot bolt paste -G 052
112 A3- must not get in‐
to the slot of the probe
body
ture sender upstream particle
filter -G506- )
❑ 45 Nm
❑ the thread of new tem‐
perature senders must
be coated with assem‐
bly paste
❑ grease only the thread
with hot bolt paste -G
052 112 A3- for re-used
temperature sender.
7 - Pre-exhaust pipe with die‐
sel particle filter
8 - Exhaust gas temperature sender 3 -G495- ( Temperature sender downstream particle filter -G527- )
❑ 45 Nm
9 - Identification
❑ for double clamp

OCTAVIA II 2004 ➤
11 - 23 Nm
12 - 20 Nm
14 - 23 Nm
15 - Hanger
16 - Middle and rear part of the exhaust system
❑ replace complete when carrying out repairs
17 - Hanger
19 - Retaining strap
20 - Hanger
21 - from exhaust turbocharger
22 - Clamp - 7 Nm
❑ replace
23 - Gasket
❑ replace
24 - 23 Nm
25 - Support
❑ screwed onto the cylinder block
26 - 8 Nm
1.4 Removing and installing pre-exhaust

pipe with diesel particle filter
♦ Ratchet ring wrench -T10384- (for vehicles with four-wheel
drive)
♦ Ring spanner set for lambda probe
♦ Hot screw paste -G 052 112 A3-
Removing

OCTAVIA II 2004 ➤
– Release fuel hoses and coolant hoses at right charge air pipe.
– Removing right charge air pipe.
– Remove intake manifold flap motor -V157- ⇒ page 249 .
– Disconnect plug -1- and remove electrical exhaust gas recir‐

culation valve -N18- -arrows- ⇒ page 249 .
– Disconnect the following plug connections and expose the ca‐

bles.
♦ Position 2: Exhaust gas temperature sender 3 -G495- ( Tem‐
perature sender downstream particle filter -G527- )
♦ Position 3: Exhaust gas temperature sender 2 -G448- ( Tem‐
perature sender upstream particle filter -G506- )
♦ Position 4: lambda probe -G39-
– Remove right front wheel.
⇒ Rep. Gr. 66 .
– Disconnect plug from oil level and oil temperature sender -
G266- ⇒ page 124 .
– Remove heat shield for drive shaft from the engine (if present).
– Unscrew the drive shaft to the right of the gearbox flange.
– Remove front tunnel bridge.
Vehicles with front-wheel-drive

OCTAVIA II 2004 ➤
– Unscrew lambda probe -3-.

– Remove exhaust gas temperature sender 2 -G448- ( temper‐
ature sender upstream particle filter -G506- ) -5-.
– Unbolt bracket -2- for pressure lines.
– Unbolt pressure line -4- at diesel particle filter.
– Remove clamp -1- for diesel particle filter.
– Unscrew exhaust gas temperature sender 3 -G495- ( temper‐

ature sender downstream particle filter -G527- ) -1- from ex‐
haust pipe downstream diesel particle filter.
– Unscrew pressure line -2- for exhaust gas pressure sensor 1
-G450- .
– Disconnect plug -arrow- and remove exhaust gas pressure

sensor 1 -G450 - with pressure lines.

OCTAVIA II 2004 ➤
– Release screws -arrows- at holder for diesel particle filter.

– Slacken nuts of front double clamp.
– Unscrew hanger of exhaust system -arrows-.
Note
♦ A second mechanic is required for the following work.

♦ When removing the diesel particle filter slightly raise the heat
shield so that it is not damaged.
– Take out the pre-exhaust pipe with diesel particle filter by turn‐
ing clockwise 180°; to do so slightly press the engine/gearbox
assembly towards the front.
– Remove assembly carrier with steering ⇒ Chassis ⇒ Rep.
Gr. 40 .
– Remove propshaft from gearbox ⇒ Gearbox ⇒ Rep. Gr. 39
and tie to the left on the body.
– Remove clamp -1- for diesel particle filter.
– Disconnect plug -arrow- and unscrew pressure sensor 1 for

exhaust gas -G450 - with pressure hoses.

OCTAVIA II 2004 ➤
– Release nuts -1- using the ratchet ring wrench -T10384- .

– Slacken nuts of double clamp.
Note
♦ A second mechanic is required for the following work.

– Press engine/gearbox assembly towards the front and remove

the pre-exhaust pipe with diesel particle filter downwards.
When doing this, ensure that the pressure sensor 1 for exhaust
gas -G450 - with connected lines and the electrical lines are
not damaged.
Install
the following:
Note
♦ Replace clamp, gaskets and the self-locking nuts.

♦ All cable straps which are detached when removing, should
be fitted on again in the same place when installing.

– After replacing the diesel particle filter, an adaption must be
performed in the function “Targeted functions” ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051.
1.5 Replacing middle or rear part of the ex‐

haust system
♦ Body saw , e.g. -V.A.G 1523 A- or chain pipe cutter , e.g. -VAS
6254-
♦ Protective goggles
Procedure
♦ For separating the middle or rear part of the exhaust system,
a separation point is provided in the connecting pipe, which is
marked with a recess.
WARNING
In order to avoid injuries because of metal swarfs, wear safety

goggles and safety clothing.

OCTAVIA II 2004 ➤
– Separate exhaust pipe at right angles at the separation point

-arrow 2- with a body saw .
– When installing, position rear double clamp -4- at the side
markings -arrow 1- and -arrow 3-.
– Rotate the rear double clamp -4- in such a way that the ends
of the screws are as far upwards as possible.
– Align rear part of exhaust system horizontally and tighten rear
double clamp to 23 Nm.
1.6 Aligning exhaust system free of stress

• The exhaust gas system must be cold for aligning.
– Slacken front double clamp -1- and align to main catalytic con‐
verter -2- (-arrow- points in direction of travel).
-a- = 5 mm
The fixing screws must be on the right. They must not protrude
beyond the bottom edge of the double clamp.
– Tighten the front nut by hand.
Vehicles with front-wheel-drive
– Push the exhaust system so far forward until the initial load on
the rear retaining strap at the middle part of the exhaust sys‐
tem -a- = 9...11 mm.
– Push the exhaust system so far forward until the initial load on
the rear retaining strap at the middle part of the exhaust sys‐
tem -a- = 7...9 mm.
– Tighten the nuts of the front double clamp evenly to 23 Nm.
Align exhaust tailpipes

OCTAVIA II 2004 ➤
– Align rear part of exhaust system:

• an equal distance between bumper opening and tailpipe -a-.
• The distance -b- from the bumper opening to the tailpipes is
parallel.
For aligning, loosen the hangers of the exhaust gas system.
1.7 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.
– Seal off tail pipe for the duration of the leak check (e.g. with
cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold,
exhaust gas turbocharger/pre-exhaust pipe etc. for leaktight‐
ness by listening.
– Eliminate any leak found.

OCTAVIA II 2004 ➤
2 Exhaust gas recirculation system
2.1 Removing and installing parts of the ex‐

haust gas recirculation system for en‐
ters BKD, AZV
Note
♦ The exhaust gas recirculation system is actuated by the diesel

direct injection system control unit -J248- via the electro-pneu‐
matic EGR valve -N18- in the solenoid valve block to the
mechanical exhaust gas recirculation valve.
♦ The mechanical exhaust gas recirculation valve with conically
shaped valve tappet makes it possible to achieve different
opening cross-sections at different valve strokes.
♦ Any desired valve plunger position is possible as a result of
the pulsed operation.
♦ The exhaust gas recirculation switches off at idling speed after
about two minutes.
♦ When taking longer measurements, restart the engine or in‐
crease engine speed briefly to more than 1500 rpm. After this
repeat the measurement.
♦ Replace self-locking nuts.

OCTAVIA II 2004 ➤
1 - 22 Nm
2 - Lifting eye
3 - 22 Nm
4 - Gasket
❑ replace
5 - 10 Nm
6 - Pipes
❑ for fuel and coolant
7 - Intake manifold
8 - Support
❑ for wiring loom
9 - 22 Nm
10 - O-ring
❑ replace
11 - 22 Nm
❑ for exhaust gas recircu‐
lation
13 - Gasket
❑ replace
14 - mechanical exhaust gas
recirculation valve
15 - 10 Nm
17 - Gasket ring
❑ replace
18 - Intake manifold flap motor
-V157-
❑ The intake manifold flap is closed for about 3 seconds after switching off the engine and then opens
again. This reduces the switch-off impact.
19 - O-ring
❑ replace
20 - 10 Nm
21 - Vacuum hose
❑ in the valve block
2.2 Summary of components of cooling for exhaust gas recirculation system for
engine with engine identification characters BKD, AZV
♦ Connection diagram for vacuum hoses ⇒ page 187
2. Exhaust gas recirculation system 245

OCTAVIA II 2004 ➤
♦ Connection diagram on the solenoid valve block and for vac‐

uum connector ⇒ page 188
1 - 22 Nm
2 - Connecting tube
3 - Gasket
❑ replace
4 - Radiator flap for exhaust
gas recirculation
❑ with vacuum setting ele‐
ment
❑ when actuating it guides
the exhaust via the radi‐
ator for exhaust gas re‐
circulation
5 - to the mechanical EGR
valve
❑ ⇒ page 244 , position 14
circulation
⇒ page 247
7 - Support
❑ for radiator flap for ex‐
and exhaust gas recir‐
culation radiator
8 - 10 Nm
9 - Support
❑ for engine cover
10 - from exhaust manifold
12 - 25 Nm
2.3 Testing mechanical exhaust gas recir‐

culation valve for engine with engine
♦ Hand vacuum pump , e.g. -VAS 6213-
Test sequence

OCTAVIA II 2004 ➤
– Disconnect the vacuum hose from the mechanical exhaust

gas recirculation valve -2-.
– Connect hand vacuum pump -VAS 6213- to valve.
– Generate vacuum.
– Detach hose of hand vacuum pump from exhaust gas recir‐
culation valve.
• Closing of the valve should be clearly audible.
2.4 Operation of radiator for exhaust gas re‐

circulation
The exhaust gas recirculation system is equipped with a radiator,
through which the coolant flows, in order to improve the emission
levels.
The exhaust gas which flows back into the combustion chamber
is guided under certain conditions via this radiator. In this way the
exhaust gas temperature can be decreased, which in turn de‐
creases the combustion chamber temperature and improves the
emission levels.
Switching on and off the radiator for exhaust gas recirculation is
controlled by the engine control unit via the changeover valve for
radiator of exhaust gas recirculation -N345- . The electro-pneu‐
matic changeover valve opens and closes the vacuum supply to
the vacuum setting element of the radiator flap.
2.5 Checking change-over for radiator for

exhaust gas recirculation for engine with
AZV
♦ Hand vacuum pump , e.g. -VAS 6213 -
Test sequence
– Detach vacuum hose from vacuum setting element -2- from
radiator flap for exhaust gas recirculation.
– Connect hand vacuum pump -VAS 6213- to vacuum setting
element.
– Generate vacuum.
• Tension rod of vacuum setting element for radiator flap for ex‐
haust gas recirculation must move without jolting.
If the tension rod does not move or it only moves with a sudden
motion:
♦ Vacuum setting element defective
♦ Resistance in radiator flap for exhaust gas recirculation
– Replace radiator flap for exhaust gas recirculation
⇒ page 247 .
2.6 Removing and installing radiator for ex‐

haust gas recirculation for engine with
OCTAVIA II 2004 ➤

AZV
♦ Hose clamps -MP 7-602 (3094)-
Removing
Gr. 66 .
– Remove suction hose between air filter and exhaust gas tur‐
bocharger ⇒ page 212 .
– Press together the coolant hoses at the radiator flap housing

for exhaust gas recirculation and at the exhaust gas recircu‐
lation radiator with the hose clamps -MP 7-602- .
– Disconnect coolant hoses -1- from the radiator flap housing for
exhaust gas recirculation.
– Disconnect coolant hoses -2- und -3- from radiator for exhaust
gas recirculation.
– Detach vacuum hose -4- from vacuum setting element of ra‐
diator flap for exhaust gas recirculation.

– Release screws -1, 3, 4, 5- and remove radiator for exhaust
gas recirculation.
Install
the following:
Note

nuts.

OCTAVIA II 2004 ➤
2.7 Removing and installing parts of the ex‐

haust gas recirculation system for en‐
ters BMM
Note
♦ The actuation of the exhaust gas recirculation system is per‐

formed by the diesel direct injection system control unit -J248-
for the electrical EGR valve -N18- with EGR potentiometer -
G212- and EGR control motor -V338- .
♦ The mechanical exhaust gas recirculation valve with conically
shaped valve tappet makes it possible to achieve different
opening cross-sections at different valve strokes.
♦ Always replace self-locking nuts.
1 - Gasket
❑ replace
2 - Intake manifold
3 - Gasket ring
❑ replace
4 - Supports
V157-
pact.
6 - from charge-air cooler
7 - 10 Nm
8 - electrical exhaust gas recir‐
culation valve -N18- with EGR
potentiometer -G212- and
EGR control motor -V338-
❑ before installing, check
sealing surfaces at in‐
take manifold for dirt
and clean as required
❑ After replacing, adapt
new part as follows:
– Switch ignition on and
off and wait 1 minute for
the afterrun of the con‐
trol units.
– Start engine and run in

idle for at least 1 minute.
– Interrogate the fault memory ⇒ Vehicle diagnosis, testing and information system VAS 5051.
• No fault must be stored in the fault memory.

– If a fault occurs, erase the fault memory and repeat the entire work procedure.

OCTAVIA II 2004 ➤
9 - Gasket
❑ replace
10 - Radiator
11 - 22 Nm
12 - Support
13 - 22 Nm
2.8 Summary of components of cooling for exhaust gas recirculation system for
engine with engine identification characters BMM
1 - Coolant hose
❑ to connection fitting
coolant hoses
⇒ page 131
2 - Gasket
❑ replace
3 - 22 Nm
4 - Connecting tube
5 - From exhaust manifold
6 - 25 Nm
❑ replace
7 - to connection of electrical
exhaust gas recirculation valve
-N18-
circulation
⇒ page 251
9 - 10 Nm
10 - Coolant hose
❑ from the coolant pipe at
the rear
coolant hoses
⇒ page 131
12 - Changeover valve for ra‐
diator of exhaust gas recircu‐
lation -N345-
❑ the radiator flap for exhaust gas recirculation
❑ always replace together with radiator for exhaust gas recirculation
❑ Connection diagram ⇒ page 252

OCTAVIA II 2004 ➤
2.9 Checking change-over for radiator for

exhaust gas recirculation for engine with
engine identification characters BMM
♦ Hand vacuum pump -VAS 6213-
Procedure
Note
The vacuum setting element for change-over flap is accessible

from below.
– Pull the vacuum hose off the vacuum unit.

– Connect the hand vacuum pump to the vacuum unit.
– Operate the hand vacuum pump.
• The linkage of the change-over for radiator for exhaust gas
recirculation must move -arrows-.
If the linkage does not move or only moves with a sudden motion:
♦ Vacuum unit is defective.
♦ Change-over flap for radiator for exhaust gas recirculation is
sluggish.
– Replace radiator for exhaust gas recirculation ⇒ page 251 .
2.10 Removing and installing radiator for ex‐

haust gas recirculation for engine with
engine identification characters BMM
⇒ page 237 .
– Remove right flange shaft for angle gearbox ⇒ Gearbox ⇒
Rep. Gr. 39 .
– Detach coolant hoses from radiator for exhaust gas recircula‐
tion.

OCTAVIA II 2004 ➤
– Unscrew connection pipe for exhaust gas recirculation radiator

-arrows-.

– Unbolt bracket -2- for diesel particle filter.

– Disconnect the vacuum line -1- and remove.
– Release screws -arrows- and remove radiator for exhaust gas
recirculation.
Install
the following:
Note
♦ Replace the gaskets and the self-locking nuts.

2.11 Connection diagram for vacuum hoses

for exhaust gas recirculation system for
acters BMM
Summary of components ⇒ page 190

OCTAVIA II 2004 ➤
28 – Glow Plug System

1 Glow Plug System
1.1 Removing and installing glow plugs for

acters BKD, AZV
♦ Socket insert 8 mm
Removing
– Unplug connector of glow plugs.
– Remove glow plugs with socket insert -arrow-.
Install
the following:
1.2 Testing glow plugs for engine with en‐

gine identification characters BKD, AZV
Checking the glow plugs occurs in the “guided fault detection
system” using the vehicle diagnosis system, measurement and
information system -VAS 5051- .
1.3 Removing and installing glow plugs for

acter BMM
♦ Flexible-head wrench e.g. -3220-
Removing
1. Glow Plug System 253

OCTAVIA II 2004 ➤
– Unplug connector of the glow plugs -arrows-.

– Remove glow plugs using flexible-head wrench , e.g. -3220- .
Install
the following:
1.4 Testing glow plugs for engine with en‐

gine identification characters BMM
♦ Handheld multimeter -V.A.G 1526 B-
Test conditions
• Ignition off.
Test sequence
– Separate connector of the glow plugs.
– Connect handheld multimeter -V.A.G 1526 B- for resistance
measurement between contact and glow plug housing.
• Nominal resistance value: less than 1 Ω
If the nominal resistance value is exceeded (greater than 1 Ω),
the glow plug is defective.
– Replace defective glow plug ⇒ page 253 .
– Check glow plugs one after the other in all cylinders.
– Re-insert pulled out plugs of glow plugs.
254 Rep. Gr.28 - Glow Plug System

Engine 2 0 103 KW TDI PD 2 0 100 KW TDI PD

Uploaded by

Copyright:

Available Formats

Engine 2 0 103 KW TDI PD 2 0 100 KW TDI PD

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine 2 0 103 KW TDI PD 2 0 100 KW TDI PD

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

1.1 Engine number

1.2 Engine characteristics

1.2 Additional instructions when undertak‐

Do not open the refrigerant circuit of the air conditioning sys‐

To avoid causing damage to the condenser and to the refrigerant

Steps which should be taken in order to remove and install the

2 Rep. Gr.01 - Self-diagnosis

1.3 Safety precautions when working on the

♦ On vehicles with pump injector engine, the temperature of

♦ The fuel pump is activated when the ignition is switched on

Please observe the following when undertaking all assembly

1.4 Safety precautions when working on the

1. Self diagnosis, safety measures, cleanliness regulations and directions 3

Observe the following points to prevent injury to persons and/or

1.5 Regulations concerning cleanliness

1.6 Regulations concerning cleanliness

4 Rep. Gr.01 - Self-diagnosis

1.7 General instructions for charge air sys‐

Please observe the following when undertaking all assembly

In case a mechanical damage to the exhaust gas turbocharger

♦ The charge-air system must be tight, check ⇒ page 202 .

1. Self diagnosis, safety measures, cleanliness regulations and directions 5

♦ after installing the exhaust gas turbocharger run the engine

6 Rep. Gr.01 - Self-diagnosis

10 – Removing and installing engine

1.1 Removing engine

♦ The engine is removed downwards together with the gearbox.

Please observe the following when undertaking all assembly

1. Removing and installing engine 7

Observe measures when disconnecting the battery ⇒ Electri‐

– Disconnect the battery-earth strap with the ignition off ⇒ Elec‐

8 Rep. Gr.10 - Removing and installing engine

1. Removing and installing engine 9

– Release screw -1- by one turn.

Refrigerant circuit of the air conditioning system must not be

To avoid causing damage to the AC compressor as well as to the

– Remove AC compressor from the bracket for auxiliary units

– Remove fan shroud and radiator.

10 Rep. Gr.10 - Removing and installing engine

– First of all release the screw -1-.

The decoupling element in the pre-exhaust pipe should not be

– Remove the pre-exhaust pipe from the exhaust turbocharger

1. Removing and installing engine 11

– Detach all connecting, coolant and vacuum hoses from the

After separating the hydraulic line, do not operate the clutch

Vehicles with automatic gearbox

– Screw engine mount -T10012- to the cylinder block with nut

12 Rep. Gr.10 - Removing and installing engine

– Successively release screws for engine mounting -arrows-.

– Successively release screws for gearbox mounting -arrows-.