Inspection and Maintenance

Service
Workshop Manual
OCTAVIA II 2004 ➤
Inspection and Maintenance
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
02 - Inspection and Maintenance
OCTAVIA II 2004 ➤
Inspection and Maintenance - Edition 02.04
Contents
02 - Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Check identification of vehicle window glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Storage of ŠKODA new vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Vehicle handover from stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Additional customer information regarding inspection and maintenance . . . . . . . . . . . . . . 3
2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Pre-Delivery Inspection -PDI- (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Pre-sales Inspection - (the Czech Republic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Delivery Inspection (Export) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Engine overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Engine fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Visual inspection of engine for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Replace engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Replacing the timing belt or also the tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Inspecting timing belt for camshaft drive for wear and running (petrol engine) . . . . . . . . . . 13
3.7 Inspecting engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.8 Change engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.9 Inspecting antifreeze protection, replenishing coolant additive if necessary . . . . . . . . . . . . 15
3.10 Inspecting coolant level (volume) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.11 Ribbed V-belt: Inspect condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.12 Routing of V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.13 Replace spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.14 Replace air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.15 Replacing the fuel filter (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.16 Draining the fuel filter (diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Automatic gearbox DSG: Change the gearbox oil, replace the oil filter . . . . . . . . . . . . . . . . 24
4.2 Haldex coupling (4x4 models): Change oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Automatic 6-speed gearbox: Inspect ATF and top up if necessary . . . . . . . . . . . . . . . . . . 24
5 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Inspecting thickness of front and rear brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Inspecting brake system for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3 Changing brake fluid (every 2 years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4 Inspecting the brake fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.5 Track rod ends: Inspect play, correct attachment and joint boots . . . . . . . . . . . . . . . . . . . . 29
5.6 Inspecting tyres (including spare wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.7 Inspecting the tyre tread depth (including spare wheel) and entering . . . . . . . . . . . . . . . . 30
5.8 Tightening wheel bolts to specific torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.9 Inspecting the tyre inflation pressure (including spare wheel), if necessary correcting tyre
inflation pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.10 Tyre inspection display: Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Power windows: Inspect positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Electrical components: Check for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 Battery: Testing no-load voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4 Battery: Inspecting electrolyte level, topping up with distilled water if necessary . . . . . . . . 34
6.5 Radio: Check for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contents i
OCTAVIA II 2004 ➤
6.6 Setting clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.7 Connect diagnostic unit and interrogate fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.8 Resetting service interval display (SID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.9 Select the language in the dash panel insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.10 Changing the code of the service intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.11 Inspecting headlight beam setting and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . 35
6.12 Setting the main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.13 Adjust the fog light beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.14 Replacing the own power supply for the alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.15 Climatronic: Adjust the temperature to 22 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.16 Switch off battery transport mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1 Check underbody protection and body paintwork for damage . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Inspecting plenum chamber and water drain openings for dirt, cleaning if necessary . . . . 40
7.3 Windscreen wiper/washer system: Check for proper operation . . . . . . . . . . . . . . . . . . . . . . 41
7.4 Sun roof: Cleaning and greasing runners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.5 Door locks, locking buttons, child safety locks: Check for proper operation . . . . . . . . . . . . 44
7.6 Replace dust and pollen filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.7 Affix vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.8 Check proper operation of key switch for front passenger airbag deactivation . . . . . . . . . . 45
7.9 Mount the damping base under the vehicle identification plate . . . . . . . . . . . . . . . . . . . . . . 46
7.10 Inspecting trailer coupling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8 Exhaust-emission Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.1 Exhaust-Emission Analysis on Models with Fuel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.2 Test Values for Exhaust-Emission Analysis on Petrol Engines . . . . . . . . . . . . . . . . . . . . . . 49
8.3 Exhaust-Emission Analysis on Models with Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . 50
8.4 Test Values for Exhaust-Emission Analysis on Diesel Engines . . . . . . . . . . . . . . . . . . . . . . 51
9 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.1 Tow starting/Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.2 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9.3 Raise vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ii Contents
OCTAVIA II 2004 ➤
02 – Inspection and Maintenance

1 General points
1.1 Vehicle identification data

The vehicle identification number is attached to the right suspen‐
sion dome.
1. General points 1
OCTAVIA II 2004 ➤
The vehicle identification number can also be found bottom left of

the front window corner.
1 - Manufacturer's world code
2 - Model and version:
B - OCTAVIA II, Elegance
C - OCTAVIA II, Ambiente
D - OCTAVIA II, Classic
3 - Engine type:
A - 1.6/75 kW/petrol engine
B - 1.6/85 kW/petrol engine
C - 1.4/55 kW/petrol engine
E - 2.0 TDI/100 kW (103 kW)/diesel engine
S - 1.9 TDI/77kW/diesel engine
4 - Airbag System:
0 - no airbag
1 - 1 Front airbag
2 - 2 Front + 2 side airbags
4 - 2 Front airbags
6 - 2 front + 2 side airbags + 2 head airbags
5 - Model:
1Z - OCTAVIA II
6 - Internal code
7 - Model year:
4 - 2004
5 - 2005
8 - Manufacturing plant:
2 - Mlada Boleslav
8 - Vrchlabi
N - Mlada Boleslav
X - Poznan/PL
9 - Vehicle body number
1.1.1 Type plate

The type plate is located on the bottom of the left B pillar.
2 Rep. Gr.02 - Inspection and Maintenance

OCTAVIA II 2004 ➤
1.1.2 Vehicle data sticker

The vehicle data sticker is located at the rear left on the floor of
the boot.
1.2 Check identification of vehicle window

glazing
All windows are identified according to the digits at the end of the
vehicle identification number.
1.3 Storage of ŠKODA new vehicles

Notes for storage of new vehicles ⇒ Technical Service Hand‐
book .
1.4 Vehicle handover from stock

– Before starting a stock vehicle, carry out a Pre-sales Inspec‐
tion.
– If the vehicle has been in stock for more than 6 months, replace
the brake fluid.
– Inspect the electrolyte level of the battery and top up, if nec‐
essary.
– Before the vehicle is sold, remove the recharging table from
the battery.
– If the batteries are more than 52 weeks old or has been re‐
charged more than twice, it must be replaced with a new
battery.
1.5 Additional customer information regard‐

ing inspection and maintenance
1.5.1 Information regarding the use of vehi‐

cles under “severe conditions”:
– The service advisor should always point out to the customer
that the inspection intervals are based on normal operating
conditions.
1. General points 3
OCTAVIA II 2004 ➤
– Under “severe conditions” the inspection intervals must be

shortened.
“Severe conditions” exist, for instance, if the vehicle is operated
continuously under one or several of the conditions stated below:
♦ Towing a trailer or when fitted with a roof rack.
♦ Operated on dusty, poor, muddy roads or roads treated with
road salt.
♦ Driven for short distances and at ambient temperatures below
freezing point.
– If one or several of these “severe conditions” exists, please
advise your customer whether it is necessary to have work
carried out between the normal service intervals, such as:
♦ Changing the engine oil before the normal specified interval.
♦ Cleaning or replacing the air filter element in the air filter hous‐
ing.
1.5.2 General information:

– Inform your customer about this so that he has each inspection
carried out at the right time and none are forgetten.
– Draw the attention of your customer to the sticker affixed to
the side of the dash panel (driver's side) indicating when the
next service event is due.
– In addition, enter in the boxes provided in the pages of the
Service Schedule when the next service or other additional
operations should be carried out.
– An oil change service should be undertaken at the prescribed
interval ⇒ Chapter 02-2 .
– Advise your customer that to maintain the vehicle in a safe and
roadworthy condition and also to ensure that the warranty
terms are complied with, it is essential to have the additional
following operations carried out in addition to the annual in‐
spections:
♦ Every 2 years change the brake fluid (have this done if possi‐
ble during an inspection service).

OCTAVIA II 2004 ➤
2 Inspection
2.1 Pre-Delivery Inspection -PDI- (Export)

The operations marked with * apply to all countries; other opera‐
tions are applicable to certain countries only!
Compare as-delivered condition of vehicle with order form Chapter
♦ Engine fitted
♦ Type plate in engine compartment

♦ Vehicle data sticker (compare with stamped identification number)
♦ Colour of paintwork, badges, inscriptions
♦ Seats (cover, colour) interior trim (colour)
♦ Radio, speakers, aerial
♦ Central locking system, anti-theft alarm system
♦ Wheels, tyres
♦ Sun roof
♦ Check the vehicle log book for completion: Owner's manual and Service Schedule
(correct language and date of issue), short instructions, technical data, breakdown
assistance, if necessary code card for anti-theft wheel bolts, other instructions (Ra‐
dio, ...) - everything in the vehicle log book pouch.
♦ Other equipment (all equipment fitted in proper condition)
* Inspect for transport damage (bodywork, paintwork, upholstery, interior trim, carpeting, 02-5, 02-7
footmats, coverings, wheels and tyres)
Vehicle (exterior)
– Check that all car keys and key number fobs have been provided; check that the
sticker with the key numbers and code number for the electronic immobiliser is com‐
plete and legible
– Check proper operation of all locks (side doors, door handles, release, child safety 02-7
locks, safety lock, engine hood, protective gloves, tailgate, fuel tank cap) and keys
(including spare keys).
– Check operation of the anti-theft alarm system
Engine compartment (from above)
– Check battery no-load voltage and recharge if necessary 02-6
– Check tight connection of electric cables and plug connections (in particular battery
cables)
– Inspect engine, gearbox, cooling system, brake system and fuel system for leaks 02-3
– Check the engine oil level (to be in-between the markings on the dipstick) 02-3
– Check the brake fluid level (at MAX marking) 02-5
– Check the coolant level (in-between marking), for special equipment antifreeze down 02-3
to -35 °C
– Check the fluid level in the windshield washer reservoir (about 0.5 litre), with antifreeze
protection
Vehicle interior
– Check proper operation of seat belts, seat belt height adjuster, power windows and 02-6
sun roof
2. Inspection 5
OCTAVIA II 2004 ➤
– Check the car tool kit, spare wheel and accessories, that they have all been supplied
and are properly secured
Underside of vehicle (on lift platform)
– Inspect underbody/underbody protection for damage 02-7
– Check engine, gearbox, final drive, joint boots and brake system for leaks and dam‐ 02-3, 02-5
age.
– Check for proper routing of the brake hoses and brake lines and fuel lines, including
ventilation lines of the fuel system.
2.2 Pre-sales Inspection - (the Czech Republic)

Compare as-delivered condition of vehicle with order form Chapter
♦ Engine fitted
♦ Type plate in engine compartment

♦ Vehicle data sticker (compare with stamped identification number)
♦ Colour of paintwork, badges, inscriptions
♦ Seats (cover, colour) interior trim (colour)
♦ Radio, speakers, aerial
♦ Central locking system, anti-theft alarm system
♦ Wheels, tyres
♦ Sun roof
♦ Check the vehicle log book for completion: Owner's manual and Service Schedule
assistance, list of Dealers in the the Czech Republic, other instructions (Radio, ...) -
everything in the vehicle log book pouch.
♦ Other equipment (all equipment fitted in proper condition)
♦ Vehicles in stock for more than 6 months: Change brake fluid 02-5
Inspections and operations to be completed

Vehicle (exterior)
– Check plastic and rubber parts for cleanliness and damage
– Inspect bodywork and paintwork for damage 02-7
– Check identification of vehicle window glazing 02-1
– Check that all car keys and key number fobs have been provided; check that the
sticker with the key numbers and code number for the electronic immobiliser is com‐
plete and legible
– Inspect proper operation of door handles outside, door locks, child safety locks, door 02-7
contact switches and all locks and keys (including spare keys), doors, boot lid/tailgate,
fuel filler cap, bonnet lock
– Check the wheel bolts for the specified torque (steel and light alloy wheels 120 Nm), 02-5
fit wheel caps
– Check the tyre inflation pressure (including spare wheel or emergency wheel), if nec‐ 02-5
essary correct the tyre inflation pressure, fit valve caps
– Fit roof aerial
– Mount the damping base under the vehicle identification plate 02-7

OCTAVIA II 2004 ➤

– Check battery no-load voltage; recharge if necessary 02-6
cables)
– Inspect engine, gearbox, cooling system, brake system and fuel system for leaks 02-3, 02-5
– Check the brake fluid level (at “MAX” marking) 02-5
– Check the coolant level (in-between markings) 02-3
– Fill up liquid in washer reservoir and ensure that there is antifreeze protection if there
is any risk of frost
– Check the function of all washer nozzles (windscreen, headlights) and adjust if nec‐ 02-7
essary
– Select a language (on vehicles with an informatioin display) 02-6
– Check proper operation of key switch for airbag “ON/OFF” and position to “ON” 02-7
– Switch off battery transport mode 02-6
Vehicle interior
– Inspect all switches, all electrical components, all gauges/indicators and controls 02-6
– Inspect upholstery, interior trim, carpeting and footmats for cleanliness and damage
– Set the temperature to 22 °C (Climatronic) 02-6
– Inspect proper operation of radio, set clock 02-6
– Reset service interval display 02-6
– Power windows: Inspecting positioning 02-6
– Fit net in luggage compartment (if available)
– Inspect proper operation of seat belts and seat belt height adjustment, power windows
and sun roof
– Check the car tool kit, spare wheel and accessories, that they have all been supplied
and are properly secured
– Fit enclosed carpets in the vehicle
– Inspect underbody (underbody protection for damage) 02-7
– Inspect for leaks and damage: Engine, gearbox, final drive, steering, brake system, 02-3, 02-5
axles, joint boots. Check proper routing of the brake hoses and brake lines, fuel lines
including ventilation of the fuel system
– Inspect tyres and wheels for damage 02-5
Concluding operations
– Perform a test drive 02-9
– Interrogate fault memory of all systems, if necessary erase 02-6
– Remove protective covering
– Remove recharging table (if affixed)
– Complete the service schedule, affix the vehicle data sticker in the Service Schedule 02-7
to the floor of the luggage compartment next to the spare wheel, complete the “Next
Service Date” sticker and affix to the side of the dash panel on the driver's side, hand
the card “Škoda Assistance” to the customer
– Final inspection to ensure proper condition for handover to the customer
2.3 Delivery Inspection (Export)

Inspections and operations to be completed Chapter
Vehicle (exterior)
– Check plastic and rubber parts for cleanliness and damage
2. Inspection 7
OCTAVIA II 2004 ➤
– Inspect bodywork and paintwork for damage

– Check identification of window glazing 02-1
– Check the function of all locks (side doors, door grip, unlocking, child safety locks, 02-7
bonnet lock, glove compartment, tailgate, fuel tank lid) and all other keys (including
the spare key).
– Tighten the wheel bolts to the specified torque, attach the wheel caps 02-5
– Check the tyre inflation pressure (including spare wheel), if necessary correct the tyre 02-5
inflation pressure, fit valve caps
– Vehicles in stock for more than 6 months: Change brake fluid 02-5
– Fit roof aerial
– Mount the damping base under the vehicle identification plate 02-7
– Check battery no-load voltage and recharge if necessary 02-6
cables)
– Check the brake fluid level (at “MAX” marking) 02-5
– Check the coolant level (in-between marking), for special equipment antifreeze down 02-3
to -35 °C
– Fill up liquid in washer reservoir and ensure that there is antifreeze protection if there
is any risk of frost
– Check windscreen wiper and washer system, the washer nozzle adjustment and the 02-7
resting position of the windscreen wipers
Vehicle interior
– Switch off battery transport mode 02-6
– Inspect upholstery, upholstery, carpeting, footmats and coverings for cleanliness and
damage
– Inspect all switches, all electrical components, all gauges/indicators and controls 02-6
– Check proper operation of key switch for airbag “ON/OFF” and position to “ON” 02-7
– Set the temperature to 22 °C (Climatronic) 02-6
– Radio: Inspect for proper operation, store stations, set clock. 02-6
– Fit net in luggage compartment (if available)
– Select a language (on vehicles with an information in display) - LHD vehicles 02-6
– Adjust the power window lifter 02-6
– Check the vehicle log book for completion: Owner's manual and Service Schedule
assistance, other instructions (Radio, ...) - everything in a leather bag.
– Inspect underbody (underbody protection for damage) 02-7
– Inspect for leaks and damage: Engine, gearbox, final drive, steering, brake system, 02-3, 02-5
axles, joint boots. Check proper routing of the brake hoses and brake lines, fuel lines
including ventilation of the fuel system
– Inspect tyres and wheels for damage 02-5
Concluding operations
– Perform a test drive 02-9
– Complete the service schedule, affix the vehicle data sticker in the Service Schedule 02-7
to the floor of the luggage compartment next to the spare wheel, complete the “Next
Service” sticker and affix to the side of the dash panel on the driver's side
– Remove recharging table (if affixed)

OCTAVIA II 2004 ➤
– Fit enclosed carpets in the vehicle

– Remove protective covering
– Final inspection to ensure proper condition for handover to customer
2.4 Oil change

Work involved Chapter
– Change engine oil 02-3
– Replace engine oil filter

– Check the brake lining thickness 02-5
– Drain away water from the fuel filter (diesel engine with diesel fuel operation, which 02-3
does not comply with standard DIN EN 590)
After each oil change
– Complete “Next Service” sticker (max. 1 year or 15 000 km) and affix sticker to the
side of the dash panel (on the driver's side)
– Complete and attach service mirror tag to the interior rear-view mirror
– Hand customer the completed and signed form
2.5 Inspection Service

Chapter
Every 2 years 02-5
– Change brake fluid
Every 90 000 km 02-3
– Replace the fuel filter (diesel engine with diesel fuel operation according to DIN
EN 590)
– Clean air filter housing and replace air filter element (or 6 years) 1)
Every 120 000 km 02-3
– Replace the toothed belt and the tensioning pulley for camshaft drive (PD Diesel
engine).
Every 180.000 km 02-3
– Replace the toothed belt - 2.0/110 kW FSI Engine
Exhaust-emission analysis (EEA): Expiry date - see EEA tag on the vehicle identifi‐
cation plate (only valid for some countries)
At each inspection - check the 'use by date' of the first aid kit
Recommendation: Replace the windscreen wiper blades twice a year
1) If the air filter housing was opened before 90 000 km or 6 years, the change interval for 90 000 km or 4 years applies
After each inspection service

Work involved Chapter
– Visual inspection of engine and parts in the engine compartment for leaks and 02-3
damage - every 60 000 km or 4 years
– Change the engine oil, replace the oil filter 02-3
– Inspecting brake system for leaks and damage - every 60 000 km or 4 years 02-5
– Check the brake lining thickness 02-5
2. Inspection 9
OCTAVIA II 2004 ➤
– Inspecting gearbox, final drive and joint boots for leaks and damage - every 60 02-5
000 km or 4 years
– Inspecting axle joints and and joint boots for leaks and damage - every 60 000 02-5
km or 4 years
– Inspecting play, correct attachment and joint boots on the track rod ends - every 02-5
60 000 km or 4 years
– Check the tyre inflation pressure (including spare wheel), correct if necessary 02-5
– Inspect the tyre wear pattern (including spare wheel) 02-5
– Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., 02-5
RL..., SP...)
– Inspecting exhaust system for leaks, damage and attachment - every 60 000 km
or 4 years
– Check brake fluid, if necessary top up - every 60 000 km or 4 years 02-5
– Check the battery 02-6
– Drain away water from the fuel filter (diesel engine with diesel fuel operation ac‐ 02-3
cording to DIN EN 590) - every 60 000 km or 4 years
– Check the anti-freeze in the cooling system and record ...... °C, check for leaks, 02-3
top up coolant if necessary - every 60 000 km or 4 years
– Lubricate flap lock for engine bonnet - every 60 000 km or 4 years
– Inspect operation of all switches, all electrical components, controls and gauges/ 02-6
indicators for proper operation - every 60 000 km or 4 years
– Check the windscreen wiper system and the condition of the wiper blades - every 02-7
60 000 km or 4 years
– Inspect and set windscreen wiper system, if necessary top up with washer fluid - 02-7
every 60 000 km or 4 years
– Inspect plenum chamber for dirt, clean if necessary 02-7
– Inspect operation of tilting roof and grease the runners 02-7
– Check headlights, adjust if necessary - every 60 000 km or 4 years 02-6
– Inspect trailer coupling ( with removable ball head - manufacturer Profsvar) 02-7
– Check the underbody protection and body paintwork 02-7
– Replace the fuel filter - diesel engine with diesel fuel operation, which does not 02-3
comply with standard DIN EN 590
– Replace dust and pollen filter 02-7
– V-ribbed belt - inspect condition and for vehicles without tensioning pulley also 02-3
the tension - every 60.000 km or 4 years
– Check ATF, if necessary top up - every 60 000 km or 4 years: Automatic 6-speed 02-4
gearbox
– Change oil: Haldex coupling (4x4 models) 02-4
– Change the oil, replace the filter: Automatic gearbox DSG 02-4
– Replace spark plugs - every 60 000 km or 4 years 02-3
– Inspect the toothed belt for the camshaft drive on petrol engines: Inspect every 02-3
90 000 km, then every 30 000 km
– Replace the own power supply of the alarm system - every 6 years
– Replace filling for tyre repair set (if available), check the "use by date" - every 4
years
– Enter the next service date on the “Next Service” sticker and affix sticker to the
side of the dash panel (on the driver's side), that is according to the indicator or
the time and kilometer schedule (also the date for changing the brake fluid)
– Conduct a test drive - every 60 000 km or 4 years 02-9
– Complete and attach service mirror tag to the interior rear-view mirror
– Hand customer the completed and signed form

OCTAVIA II 2004 ➤
3 Engines
3.1 Engine overview

Engine identifica‐ BCA BGU BLF BJB4) BKD4) AZV
tion characters
Emission standard EU-4 EU-4/ 2 DDK EU-4 EU-3 EU-4 EU-4
Manufacturing
(from...through)
Displacement in li‐ 1,4 1,6 1,6 1,9 2,0 2,0
tres
Output (kW at 55 / 5000 75 / 5600 85 / 6000 77 / 4000 103 / 4000 100 / 4000
rpm)
Max. torque (Nm 126 / 3300 148 / 3800 155 / 4000 250 / 1900 320 / 1750 - 320 / 1750 -
at rpm) 2500 2500
Bore (∅ mm) 76,5 81 76,5 82,5 81 81
Stroke (mm) 75,6 77,4 86,9 79,5 95,5 95,5
Compression 10,5 10,5 12 19 18 18,5
Hydraulic valve - X X X X X
clearance com‐
pensation
Mixture formation Bosch Mo‐ Simos 7.1 Bosch Mo‐ Bosch EDC Bosch EDC Bosch EDC
tronic ME tronic MED 16 16 16
7.5.10 9.5.10
Fuel RON (mini‐ 952) 952) 983) - - -
mum)
Fuel CN (mini‐ - - - 49 49 49
mum)
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Exhaust gas recir‐ X X X X X X
culation
Ignition system/ Bosch Mo‐ Simos 7.1 Bosch Mo‐ Bosch EDC Bosch EDC Bosch EDC
fuel injection tronic ME tronic MED 16 16 16
7.5.10 9.5.10
Self-diagnosis X X X X X X
Catalytic converter X X X X X X
Turbocharging - - - X X X
Charge air cooler - - - X X X
Lambda probe X X X - - -
2) Regular grade petrol (min. 91 RON) can be used although engine power output is slightly reduced.
3) Regular grade petrol (min. 95 RON) can be used although engine power output is slightly reduced.
4) PD diesel engine (TDI diesel engine with unit injector)
3.2 Engine fitted

The engine identification characters and serial number are loca‐
ted at the engine/gearbox joint.
In addition, a sticker with the engine identification characters and
serial number is affixed to the timing belt guard.
3. Engines 11
OCTAVIA II 2004 ➤
Engine with identification characters BCA.
Engine with identification characters BGU and BLF.
Engine with identification characters BJB and BKD and AZV.
3.3 Visual inspection of engine for leaks and

damage
– Inspect engine for leaks and damage.
– Inspect all lines, hoses and connections of the fuel system and
of the cooling and heating system for leaks, chafing points,
porous and brittle joints.
– Inspect gearbox or final drive for leaks (e.g. drain plug, drive
shafts, shift linkage etc.).
– Inspect steering, sealing boots of track rod ends as well as
steering boots for damage and correct installation.
– Inspect boots of steering joints for damage, leaks and correct
installation.
3.4 Replace engine oil filter
3.4.1 Vehicles with petrol engine

Special tools and workshop equipment required

OCTAVIA II 2004 ➤
♦ Oil filter wrench

– Loosen oil filter and remove.
– Clean sealing surface at engine.
– Oil rubber seal slightly.
– Screw in new filter and tighten by hand.
– After filling with oil, run engine until it is at operating tempera‐
ture and inspect for leaks.
3.4.2 Vehicles with diesel engine

♦ Oil filter wrench -3417- or wrench 36
– Release cap -1-.
– Replace O-rings -2- as well as the oil filter element -3-.
– Tighten cap -1-.
Tightening torque of the cap: 25 Nm
3.5 Replacing the timing belt or also the ten‐

sioning roller
– Removing and installing the timing belt and also the tensioning
roller as required ⇒ Rep. Gr. 13 ; Engine ...
3.6 Inspecting timing belt for camshaft drive

for wear and running (petrol engine)
Check timing belt for:
♦ Tears or splits -A-, cross-sectional fractures
♦ Lateral catches -B-
♦ Fraying or chunking -C-
♦ Crack in the base tooth -D-
♦ Separation of layers (timing belt housing, cords)
♦ Traces of oil and grease
Note
The timing belt must most definitely be replaced if any shortcom‐

ings are found. This will help prevent any failures or operational
problems. Replacing the timing belt is a repair measure.
3. Engines 13
OCTAVIA II 2004 ➤
3.7 Inspecting engine oil level
Note
♦ The oil level must not, under any circumstances, be above the
area -a- - danger of damage to the catalytic converter.
♦ The vehicle must be standing on level ground when measuring
the oil level. Wait a few minutes after switching off the engine
to allow the oil to flow back into the oil pan.
– Withdraw dipstick, wipe off with a clean cloth and re-insert

dipstick fully.
– Withdraw dipstick once again and read off oil level.
The oil level in area -a-
– The oil must not be topped up.
The oil level in area -b-
– The oil can be topped up. It is possible that the oil level will rise
to the area -a-.
The oil level in area -c-
– The oil must be topped up. It is sufficient when the oil level
rises to the area -b-.
3.8 Change engine oil
Note
♦ The engine oil should always be changed, if possible, when

the engine is at normal operating temperature.
♦ If the engine oil is drained, replace the seal of the oil drain plug.
♦ It is absolutely necessary to observe the oil disposal instruc‐
tions!
♦ It is not permitted to clean and re-use the oil filter!
– Remove oil filler cap.

– Remove the noise insulation.
– Screw out the oil drain plug and collect the flowing out oil in a
suitable vessel.
– Clean oil drain plug, screw in with a new seal and tighten to
the specified tightening torque:
Engine-oil pan: 30 Nm
– Pour in oil as stated in the specifications ⇒ page 15 .
3.8.1 Engine oil capacities

Engine Approximative oil capacity with
oil filter change
1.4 ltr./55 kW 3.2 ltr.
1.6 ltr./75 kW 4.5 ltr.
1.6 ltr./85 kW 3.2 ltr.

OCTAVIA II 2004 ➤
Engine Approximative oil capacity with

oil filter change
1.9 litre/77 kW 4.3 ltr.
2.0 ltr./100 kW 3.8 ltr.
2.0 ltr./103 kW 3.8 ltr.
The engine is factory-filled with quality multigrade oil, which can
also be used as an all-season oil, except in extremely cold climatic
zones.
– Close the oil filler opening again.
– Start engine and check for leaks.
– Check the engine oil level again and top up with oil if neces‐
sary.
– Wait at least 3 minutes after topping up the oil again before
inspecting the oil level again.
– Install the noise insulation.
Note
The oil level must not be above the -max- marking to avoid dam‐
age to the catalytic converter. See Inspecting engine oil level.
3.8.2 Engine oil specification

Vehicles with fixed service intervals (QG0, QG2)
Denomination Oil specification for Oil specification for
petrol engines diesel engines
Multigrade high-lu‐ VW 500 00 VW 505 01
bricity oils:
VW 502 00
Multigrade oils VW 501 01 ACEA B35), or B45)
ACEA A25), or A35)
5) Such oils must only be used once for topping up if no approved engine oil is
available.
Vehicles with variable service intervals (QG1)

Oil specification
Fuel engines VW 503 00
Diesel engines VW 506 01
3.9 Inspecting antifreeze protection, replen‐

ishing coolant additive if necessary
WARNING
♦ Coolant additives are toxic!

♦ Do not inhale coolant vapours, do not swallow coolant,
avoid contact with skin and eyes; hazardous if consumed!
3. Engines 15
OCTAVIA II 2004 ➤
Note
♦ Collect drained coolant for proper disposal.

♦ Observe the disposal instructions for the drained coolant.

♦ Refractometer, e.g. -T10007-
3.9.1 Inspecting antifreeze protection of the

coolant
– Extract a small quantity of coolant with the pipette and place
on the measuring glass. Hold unit against a light source and
read off the temperature down to which antifreeze protection
exists on the scale for ethylene glycol.
Note
♦ Antifreeze protection must be ensured down to about -25°C.

♦ Down to about -35 °C in countries with an arctic climate.
♦ If a greater antifreeze concentration is required for climatic
reasons, the concentration may be increased up to 60 % (i.e.
antifreeze protection down to approx -40 °C). Any further in‐
crease in concentration increase would reduce the antifreeze
protection and impair cooling efficiency.
3.9.2 Replenishing coolant additive
Note
♦ The vehicles are filled with coolant additive G12 PLUS which
has a lilac colour and conforms with the standard TL VW 774
F.
♦ Coolant additive G12 PLUS must only be mixed with coolant
additives G12 and G11.
♦ Coolant additive G12 PLUS is recommended for use on all
vehicles when changing the coolant.
If the vehicle is filled with the recommended coolant and the an‐
tifreeze protection is not adequate, drain part of the coolant from
the cooling system.
– After this, fill the cooling system with concentrated coolant ad‐
ditive.

OCTAVIA II 2004 ➤
– Perform a test drive and again check the coolant antifreeze

protection.
3.9.3 Quantities of coolant in the cooling sys‐

tem
Engine Amount (I)
1.4 ltr./55 kW 6,7
1.6 ltr./75 kW 7,7
1.6 ltr./85 kW 6,9
1.9 litre/77 kW 7,7
2.0 ltr./100 kW 8,2
2.0 ltr./103 kW 8,2
3. Engines 17
OCTAVIA II 2004 ➤
3.10 Inspecting coolant level (volume)

– The coolant expansion reservoir is located on the left-hand
side of the engine compartment.
– Inspect coolant level only when the engine is not running.
Specified coolant level for the Inspection Service -arrow-:
• Engine cold: between“MAX” and “MIN” marking.
• Engine warm: slightly above the “MAX” marking.
WARNING
♦ Coolant additives are toxic!

♦ Do not inhale coolant vapours, do not swallow coolant,
avoid contact with skin and eyes; hazardous if consumed!
Note
♦ The cooling system is filled all year round with a mixture of

water and antifreeze/anti-corrosion agent. Coolant additives
prevent damage from frost and corrosion and the accumula‐
tion of lime scale while also raising the boiling point of the
coolant. For these reasons the cooling system must always be
filled all year round with radiator antifreeze and anti-corrosion
agent offering these properties.
♦ The vehicles are filled with coolant additive G12 PLUS which
has a lilac colour and conforms with the standard TL VW 774
F.
♦ Coolant additive G12 PLUS must only be mixed with coolant
additives G12 and G11.
♦ Coolant additive G12 PLUS is recommended for use on all
vehicles when changing the coolant.
Do not use coolant additives that have not been recommended

by ŠKODA AUTO a.s.
Other coolant additives may specifically impair the provided cor‐
rosion protection.
The resulting corrosion damage may lead to a loss of coolant and
subsequently cause major engine damage.
Coolant additives conforming to the standard TL VW 774F (G12
PLUS) prevent frost and corrosion damage, as well as the for‐
mation of scale, and also increase the boiling point of the coolant.
For these reasons you must use coolant additives 12 months a
year.
The higher boiling temperature of the coolant contributes to the
engine's reliability when the engine is stressed, especially in
countries with a tropical climate.
3.10.1 Coolant additives G12 PLUS - an over‐

view
Coolant additives from the ŠKODA Genuine Parts List which
comply with the standard TL VW 774 F:
Coolant additive Manufacturer
Havoline XLC+B (VL 02) ARTECO

OCTAVIA II 2004 ➤
Coolant additive Manufacturer

Glysantin G 30-81 BASF AG
Frostox SF D12 PLUS HENKEL HÄRTOL GmbH
Note
The listed G12 PLUS coolant additives may be intermixed.
3.11 Ribbed V-belt: Inspect condition

♦ Wrench socket
3.11.1 Perform the following procedure:

– Raise vehicle.
– Remove right noise insulation.
– Remove cap for screw of v-ribbed belt pulley - if present.
– Use a socket wrench to crank the engine at vibration damper/
belt pulley -2-.
– Inspect V-ribbed belt from below for:
♦ Splits in the carcass (initial splits, splits in core, splits across

carcass).
♦ Separation of layers (top layer, cords).
♦ Sections of carcass broken out.
♦ Fraying of cords.
♦ Wear to sides (abrasion of material, frayed sides, hardening
of sides, glazed and hardened surfaces).
♦ Traces of oil and grease.
♦ Correct tension.
Note
It is essential to replace the V-ribbed belt if defects are found. This

will help avoid any failures or operational problems. Replacing the
ribbed V-belt is a repair measure.
3. Engines 19
OCTAVIA II 2004 ➤
3.12 Routing of V-ribbed belt

1.4 litre/55 kW (BCA) with air-conditioning
1- Crankshaft
2- Tensioning pulley
3- AC generator
4- V-ribbed belt
5- AC compressor
1.6 litre/75 kW (BGU) with air-conditioning
1.6 litre/85 kW (BLF) without air-conditioning

1- Coolant pump
3- AC generator
4- V-ribbed belt
5- Crankshaft
1.6 litre/85 kW (BLF) with air-conditioning

1- Coolant pump
2- Guide pulley
3- AC generator
5- AC compressor
6- Crankshaft

OCTAVIA II 2004 ➤
1.9 ltr./77 kW (BJB) and 2.0 ltr./103 kW (BKD) and 2.0 ltr./100 kW
(AZV) without air-conditioning
1.9 ltr./77 kW (BJB) and 2.0 ltr./103 kW (BKD) and 2.0 ltr./100 kW
(AZV) with air-conditioning
3.13 Replace spark plugs
Note
♦ To replace the spark plugs use the special spark plug wrench.
♦ Observe the disposal instructions for the spark plugs.
♦ Change interval: every 60 000 km, or 4 years.
♦ Tightening torque: 30 Nm.
♦ Use assembly tool -T10029- for unplugging the spark plug
connector (not applicable to cable with fixture).
Engine fitted Spark plug man‐ Parts No. Electrode spacing

ufacturer's desig‐
nation
1.4 ltr./55 kW NGK BKUR 101 000 033 AA 1+0.1 mm6)
6ET-10
1.6 ltr./75 kW NGK BKUR 101 000 033 AA 1±0.1 mm6)
6ET-10
1.6 ltr./85 kW Bosch FGR 101 000 068 AA 1,35±0.05 mm6)
6HQE0
6) Distance between earth electrode and spark plug insulator.
3.14 Replace air filter element

– Remove the filter housing cover.
– Release the air guide hose.
– Open the filter housing.
– Replace the filter element and clean the filter housing.
3. Engines 21
OCTAVIA II 2004 ➤
– Close filter housing and check correct fitting.
3.15 Replacing the fuel filter (diesel engine)
Note
♦ Make sure no diesel fuel comes into contact with the coolant
hoses. If necessary clean the hoses immediately!
♦ It is absolutely necessary to observe the oil disposal instruc‐
tions!
♦ Observe the disposal instructions!
– Release screw from drain pipe -1-.

– Connect drain tank e.g -V.A.G 1390/1- to outlet
– Use hand vacuum pump e.g. -V.A.G 1390- to extract approx.
100 ml of diesel fuel.
– Replace gasket ring and screw the screw into the drain pipe.
– Remove screws -arrows- and take off fuel filter - top part.
– Take filter element -1- out of the filter housing -4-.

– Replace gaskets -2- and -3-.
Note
Observe the disposal instructions!
– Install new filter element.

OCTAVIA II 2004 ➤
– Fit on fuel filter - top part and install screws -arrows-.
3.16 Draining the fuel filter (diesel engine)

– Release screw from drain pipe -1-.
– Connect drain tank e.g -V.A.G 1390/1- to outlet
– Use hand vacuum pump e.g. -V.A.G 1390- to extract approx.
100 ml of diesel fuel.
– Replace gasket ring and screw the screw into the drain pipe.
3. Engines 23
OCTAVIA II 2004 ➤
4 Gearbox
4.1 Automatic gearbox DSG: Change the

gearbox oil, replace the oil filter
The subject is revised.
4.2 Haldex coupling (4x4 models): Change

oil:
The subject is revised.
4.3 Automatic 6-speed gearbox: Inspect

ATF and top up if necessary
⇒ Automatic 6-speed gearbox ; Rep. Gr. 37

OCTAVIA II 2004 ➤
5 Chassis
5.1 Inspecting thickness of front and rear

brake pads/linings
5.1.1 Front disc brake pads
Note
For a better assessment of the residual pad thickness remove

wheels.
– Mark the position of the wheel.

– Release the wheel bolts and remove wheel.
The wear limit -a- is reached at a pad thickness of 7.5 mm, in‐
cluding backing plate.
If the thickness of the pad is less than 7.5 mm including backing
plate, always replace the brake pads on both sides (repair meas‐
ure)
– Fit on wheels in the marked position and tighten the wheel
bolts to 120 Nm.
Note
After replacing the brake pads depress brake pedal firmly several
times when the vehicle is stationary to ensure the brake pads are
properly seated in their normal operating position.
5.1.2 Rear disc brake pads
Note
For a better assessment of the residual pad thickness remove

wheels.
– Mark the position of the wheel.

– Release the wheel bolts and remove wheel.
5. Chassis 25
OCTAVIA II 2004 ➤
The wear limit -a- is reached at a pad thickness of 7.5 mm, in‐
cluding backing plate.
If the thickness of the pad is less than 7.5 mm including backing
plate, always replace the brake pads on both sides (repair meas‐
ure)
– Fit on wheels in the marked position and tighten the wheel
bolts to 120 Nm.
Note
After replacing the brake pads depress brake pedal firmly several
times when the vehicle is stationary to ensure the brake pads are
properly seated in their normal operating position.
5.2 Inspecting brake system for leaks and

damage
– Inspect master brake cylinder, brake servo unit (for ABS: hy‐
draulic unit), brake pressure regulator, brake calipers for leaks
and damage.
– Inspect brake hoses for twisting.
– Ensure that the brake hoses do not touch any parts of the ve‐
hicle when the steering is turned to full left or full right lock.
– Inspect the brake hoses for porous and brittle points. Inspect
the brake hoses and brake lines for chafing points.
– Inspect the brake connections and attachment to ensure they
are correctly fitted, free of leaks and corrosion.
WARNING
Any defects found must be rectified (repair measure).
5.3 Changing brake fluid (every 2 years)

♦ Extraction device
♦ Brake pedal support, e.g. -V.A.G 1869/2-
Use only fresh genuine brake fluid FMVSS 571.116 DOT 4 .
WARNING
♦ Brake fluid must never come into contact with fluids con‐
taining mineral oils (oil, petrol, cleaning agent). Mineral
oils damage the gaskets and boots of the brake system.
♦ Brake fluid is toxic. Because of its caustic effect brake fluid
must not come into contact with paint.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air . Therefore it should always be stored in
airtight containers.
♦ Wash any parts stained with brake fluid with large volumes
of water.
♦ Observe the disposal instructions!

OCTAVIA II 2004 ➤
– Unscrew cap -1- from the brake fluid reservoir

– Remove strainer and clean.
– Use extraction device -1- to extract as much brake fluid as

possible from the brake fluid reservoir.
WARNING
Drained (used) brake fluid must never be used again.
– Insert strainer and fill new brake fluid into the brake fluid res‐
ervoir.
Vehicles fitted with a manual gearbox
– Fit hose of extraction device -Arrow- onto the bleeder screw

of the slave cylinder -1-.
– Open the bleeder screw and by depressing the clutch pedal
allow approx. 0.1 litre of brake fluid to flow out.
– Secure the clutch with the brake pedal depressor, e.g. -V.A.G
1869/2- in bottom position.
– Tighten bleeder screw and remove hose.
– Put the clutch pedal in home position.
All vehicles
Sequence: Wheel brake cylin‐ Quantity of brake fluid that
der, brale caliper, clutch slave must flow out of the wheel
cylinder brake cylinders or brake cali‐
pers and clutch slave cylinder:
Rear right 0.2 ltr.
Rear left 0.2 ltr.
Front right 0.2 ltr.
Front left 0.2 ltr.
Note
When changing the brake fluid it is necessary to replenish the

brake fluid reservoir with brake fluid.
5. Chassis 27
OCTAVIA II 2004 ➤
– Fit hose of extraction device -1- onto the bleeder screw of the
rear right wheel. 7)
7) On vehicles with right-hand steering: fit hose of extraction device onto the
bleeder screw of the rear left wheel.
– Open the bleeder screw and by depressing the brake pedal

allow approx. 0.2 litres of brake fluid to flow out.
– Secure the clutch with the brake pedal depressor, e.g. -V.A.G
1869/2- in bottom position.
– Tighten bleeder screw and remove hose.
– Put the brake pedal in home position.
– Repeat the procedure for all wheels in the following sequence:
rear left, front right and front left. 8)
8) For right-hand drive vehicles the following sequence applies: rear right, front
left and front right.
– Fill brake fluid into the brake fluid reservoir up to the specified
level.
– Inspect pedal position and idle travel at brake pedal. Idle trav‐
el: max. 1/3 of pedal travel.
Vehicles with ABS or ABS/EDL:
A road test on such models must be carried out after bleeding the
brake system. While doing so perform at least one ABS adjust‐
ment!
5.4 Inspecting the brake fluid level

Use only fresh genuine brake fluid FMVSS 571.116 DOT 4 .
WARNING
♦ Brake fluid is toxic. Because of its caustic effect brake fluid

must not come into contact with paint.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air . Therefore it should always be stored in
airtight containers.
Note
The brake fluid must not be above the “MAX” marking to prevent
fluid flowing out of the reservoir.
5.4.1 Delivery Inspection

The brake fluid level during the delivery inspection should be at
the “MAX” marking.
5.4.2 Inspection Service:

– The brake fluid level (volume) must always be assessed on
the basis of the brake pad wear. When driving a slight drop in
the brake fluid level occurs as a result of wear-and-tear and
the automatic slack adjustment of the brake pads.
– If the fluid brake level is on the “MIN” marking or slightly above,
it is not necessary to top up the brake fluid if the brake pads
have practically reached their wear limit.

OCTAVIA II 2004 ➤
– If the brake pads are new or far off the brake wear limit, the
brake fluid level must be between the “MIN” and “MAX” mark‐
ings.
– If the brake fluid level has dropped below the “MIN” marking,
it is necessary to inspect the brake system before topping up
the brake fluid ⇒ page 26 ; carry out repair measures if nec‐
essary.
5.5 Track rod ends: Inspect play, correct at‐

tachment and joint boots
– Raise vehicle (wheel clear of the ground) and inspect play by
moving the track rods and wheels. Clearance: There must not
be any play present.
– Inspect attachment.
– Inspect seals for damage and correct installation.
5.6 Inspecting tyres (including spare wheel)
Note
Only tyres of the same type may be fitted to the vehicle. Tyres of
the same brand and tread pattern must always be fitted to wheels
on the same axle!
WARNING
Tyres that are more than 6 years old must only be used in case
of emergency and while driving very carefully.
5.6.1 Delivery Inspection:

– Inspect the tyre tread and side wall for damage, if necessary
remove any foreign bodies from the tyres, such as nails or
glass splinters.
5.6.2 Inspection Service:

– Inspect the tyre tread and side wall for damage, if necessary
remove any foreign bodies from the tyres, such as nails or
glass splinters.
– Inspect tyres for scrubbing, tread worn down on one side, po‐
rous side walls, cuts and punctures. Any defects found must
be advised to the customer and the customer's attention must
be drawn to any necessary repair measures!
5.6.3 Inspecting tyre wear

– The wear pattern on the front tyres makes it possible to assess
whether it is necessary to inspect the wheel toe and camber:
♦ The formation of ridges on the tyre tread is an indication of
wheel toe errors.
♦ Tread worn on one side is usually attributable to camber er‐
rors.
5. Chassis 29
OCTAVIA II 2004 ➤
– If such signs of wear are found, determine the cause by check‐

ing the chassis alignment (repair measure).
5.7 Inspecting the tyre tread depth (includ‐

ing spare wheel) and entering
This value may differ in individual countries as a result of differing
statutory requirements.
If the tyre tread depth is close to the legal minimum, in other words
if no further tread exists at the points around the circumference
of the tyre at which the 1.6 mm high wear indicators are posi‐
tioned, the customer should be informed of the necessary repair
measures.
5.8 Tightening wheel bolts to specific torque

♦ Torque wrench
Tightening torque for steel and light alloy wheels 120 Nm.
5.9 Inspecting the tyre inflation pressure (in‐

cluding spare wheel), if necessary cor‐
recting tyre inflation pressure
♦ Tyre inflation pressure tester
Note
♦ The tyre inflation pressures are indicated on a sticker,which is

affixed to the inside of the fuel filler flap.
♦ The tyre inflation pressures indicated on the sticker apply only
to the tyres when cold. Do not reduce the higher inflation pres‐
sure of warm tyres.
♦ If winter tyres are fitted, the relevant tyre inflation pressure
should be increased by 0.2 bar/20 kPa.
5.9.1 Tyre inflation pressure table

Engine Tyres Tyre inflation pressure (kPa/bar)
half load full load
front rear front rear
1.6 ltr./75 kW 195/65 R15 210/2,1 210/2,1 230/2,3 330/3,3
1.6 ltr./85 kW 205/60 R15 200/2,0 240/2,4 320/3,2
1.9 ltr./77 kW 205/55 R16 210/2,1 200/2,0 310/3,1
225/45 R17
1.4 ltr./55 kW 195/65 R15 200/2,0 200/2,0 230/2,3 330/3,3
205/60 R15 320/3,2
205/55 R16 300/3,0
225/45 R17
2.0 ltr./103 kW 195/65 R15 220/2,2 230/2,3 250/2,5 340/3,4
(2.0 ltr./100 kW) 205/60 R15 240/2,4 320/3,2
205/55 R16 220/2,2 230/2,3 310/3,1
225/45 R17 210/2,1 240/2,4 300/3,0

OCTAVIA II 2004 ➤
Engine Tyres Tyre inflation pressure (kPa/bar)

half load full load
front rear front rear
2.0 ltr./110 kW 195/65 R15 220/2,2 220/2,2 230/2,3 330/3,3
205/60 R15 210/2,1 240/2,4 320/3,2
205/55 R16 220/2,2 230/2,3 300/3,0
225/45 R17 240/2,4
5.10 Tyre inspection display: Perform basic

setting
Note
♦ The basic setting of the tyre inspection display should always

be performed, after the tyre inflation pressure values have
been corrected first of all to the correct values.
♦ If no pressure loss and no tyre damage is discovered after a
tyre pressure warning, this erroneous warning can be elimi‐
nated by a basic setting.
The tyre inspection display operates via the ABS sensors, which
compare the wheel rotations and through this also the wheel cir‐
cumferences. In case of a change in the wheel circumference, the
warning light in the dash panel insert lights up.
The tyre circumference can change, if
• the tyre inflation pressure is too low
• the tyre structure is damaged
• the vehicle is loaded on one side
• the wheels on an axle are heavily loaded (e.g when operating
a trailor, on steep gradients).
• snow chains are mounted
• an emergency wheel is mounted
• a wheel is changed on an axle.
A basic setting is required at each pressure change, at each tyre
change (also change from front to rear) and after working on the
chassis in the workshop, which has an influence on the tyre in‐
spection display.
The tyre inspection display has a warning light in the dash panel
insert.
♦ Constant lighting in combination with a warning tone means
that a pressure loss was detected. In this case, the inflation
pressure in all the tyres has to be inspected and a basic setting
is performed.
♦ Flashing light means a system failure or a new basic setting
has not yet been performed ⇒ Vehicle Diagnosis, Measure‐
ment and Information System VAS 5051, “Self-diagnosis”,
“Targeted fault finding” .
5.10.1 Perform basic setting

– Switch on ignition.
5. Chassis 31
OCTAVIA II 2004 ➤
– Press button of tyre inspection display -arrow- for more than 2

seconds.
The warning light for the tyre inflation display in the dash panel
insert lights up as long as the button is pressed.
Performing the basic setting is confirmed by an informative tone.
When starting the ignition again, no more warning will appear.

OCTAVIA II 2004 ➤
6 Electrical System
6.1 Power windows: Inspect positioning

If the battery is diconnected the power windows forget their cur‐
rent position.
Test conditions:
• All car doors closed
The inspection procedure is carried out from the outside
Close window with the car key using the convenience closing
system.
– Turn car key into close position and hold until all the windows
are closed.
– After closing the windows hold the key in the close position for
approximately another 3 seconds.
6.2 Electrical components: Check for proper

operation
– Inspect lighting, headlights, headlight beam control, fog lights,
turn signal lights, hazard warning light system, tail lights, rear
fog lights, reversing lights, brake lights, parking light control for
brightness and proper operation.
– Inspect interior lights, illuminated storage compartment, illu‐
minated ashtray for proper operation.
– Airbag warning lamps: Check operation ⇒ Chapter 02-7 .
– Inspect warning buzzer, onboard computer, all switches in the
centre console as well as in the dash panel insert and horn for
proper operation.
– Inspect power windows, exterior mirrors (heated and electri‐
cally adjustable), central locking system and convenience
closing system for proper operation
– Inspect heating of front seats for proper operation.
– Inspect radio for proper reception and absence of interference,
also inspect speakers ⇒ page 34 .
6.3 Battery: Testing no-load voltage

♦ Digital multimeter
Prior to the measurement the vehicle must have been in the no-
load state for at least two hours (no engine starts, no charging or
discharging of battery).
The following procedure applies to measuring the battery voltage
in the no-load state (after at least two hours):
– With the battery installed measure the voltage between the
terminals (ignition switched off).
If the tester indicates a voltage of 12.5 Volts or more, the battery
is O.K.
If the voltage is less than 12.5 volts determine the cause (repair
measure).
6. Electrical System 33
OCTAVIA II 2004 ➤
6.4 Battery: Inspecting electrolyte level, top‐

ping up with distilled water if necessary
– Inspect electrolyte level:
WARNING
When working on the battery wear proper protection and ob‐

serve safety precautions.
– The electrolyte level must be between the “MIN” and “MAX”

markings.
Note
There are no “MIN”- and “MAX” markings available on the Battery

⇒ Electrical system; Rep. Gr. 27 .
6.5 Radio: Check for proper operation

Precise information on how to operate the radio should be ob‐
tained from the operating instructions before inspecting proper
operation of the radio set.
– Switch radio set on and off.
– Operate the volume control.
– Carry out station programming.
– Inspect station search 9)
.
– Inspect cassette or CD player (insert cassette or CD and play)
9)
.
– Activate anti-theft code of radio 9)
.
9) These functions are model specific and are not present on all types of radio
sets. For operation refer to Radio Operating Instructions.
6.6 Setting clock

A rotary knob is provided next to the speedometer for setting the
time. The hours (h) are set by turning the knob -arrow- to the left,
and the minutes (min) are set by turning the knob to the right:
– By briefly turning the knob the time is advanced by one hour
or one minute. It is possible to move the hours or minutes back
or forward continuously by holding the knob in the left or right
position respectively.
6.7 Connect diagnostic unit and interrogate

fault memory
These tasks are carried out using the vehicle diagnostic, meas‐
uring and information system -VAS 5051- together with the diag‐
nostic cable -VAS 5051/6A- , or with the diagnostic cable -VAS
5051/5A- .

OCTAVIA II 2004 ➤
Connect the diagnostic unit -1- to the diagnostic connector

-arrow-.
6.8 Resetting service interval display (SID)

5051/5A- .
6.9 Select the language in the dash panel

insert.
– Hold the button -1- for longer than 1 second.
– With the button -1- select the function “Setup (setting)” and
confirm by briefly pressing the button -2-.
– With the button -1- select the function “Language (language)”
and confirm by briefly pressing the button -2-.
– With the button -1- select the desired language and confirm by
briefly pressing the button -2-.
– Switch off ignition.
6.10 Changing the code of the service inter‐

vals
5051/5A- .
6.11 Inspecting headlight beam setting and

adjusting if necessary
♦ Headlight beam setting device
In principle the following inspection and setting description ap‐
plies for all countries. However, comply with national guidelines
and legislation of the relevant country. ⇒ Operating instructions
for the headlight beam setting device
Test and setting conditions
• Tyre inflation pressure o.k.
• Lenses must neither be damaged nor soiled.
• Reflectors and bulbs o.k.
OCTAVIA II 2004 ➤
• Vehicle load must be achieved.

Load: With an individual or 75 kg on the driver's seat in an other‐
wise unladen vehicle (dead weight).
The unladen weight is the weight of the vehicle with full fuel tank
(at least 90 %) including the weight of all the operational equip‐
ment elements (e.g. spare wheel, tool kit, jack etc.).
The vehicle must have rolled a few metres or have been de‐
pressed a few times at the front and rear to allow the springs to
settle.
• Both the vehicel and headlight beam setting device must be
on a level flat surface.
• Align the vehicle and headlight beam setting device in accord‐
ance with the device manufaturer's indications.
• Check the control system of vehicles equipped with headlight
beam control by repeatedly turning the thumbwheel in the
dash panel. Then turn the thumbwheel to basic position.
• Set the inclination value.
Inclination value:
The inclination value is marked in “%” at the top of the headlight
housing, next to the adjusting bolts. The main headlights must be
set to this value. The percentage value applies up to 10 metres
projection distance. This will be 10 cm for an inclination value of
e.g. 1.0 %.
6.11.1 Inspecting headlight beam setting and

adjusting if necessary
Main headlights:
– Check whether the horizontal light/dark limit touches the sep‐
aration mark -1- on the test surface when the low beam light
is on .
– Check whether the kink -2- between the left horizontal part and
the ascending right part of the light/dark limit intersects with
the central mark -3- on the vertical line. The light core of the
light beam must be located to the right of the vertical line.

OCTAVIA II 2004 ➤
Note
♦ To easily determine the kink -2- alternately cover and uncover

the left half of the headlight (in the driving direction) a few
times. After this, check the low beam once again.
♦ Once the low beam light has been correctly set the centre of
the light beam of the main beam must be positioned on the
central mark -3-.
♦ The adjustment foreseen for the new control screen also ap‐
plies for the previous one, which has a 15° adjusting line. To
avoid incorrect settings disregard the 15° adjusting line.
Other additional headlights:

Additionally fitted headlights must be inspected or set in compli‐
ance with the relevant applicable directives.
6.12 Setting the main beam
Note
The headlight adjusting device is used to set up the headlight.

The specified values ⇒ page 35 .
6.12.1 Left low beam (right low beam in mirror

image)
1 - Adjust the low beam (adjustment for height)
2 - Adjust the low beam (adjustment from side to side)
– Adjust with relevant thumbwheel.
6.12.2 Right main beam (left main beam in mir‐

ror image)
1 - Adjust the main beam (adjustment from side to side)
2 - Adjust the main beam (adjustment for height)
Note
The illustrated headlight is removed from the vehicle for the pur‐
pose of clear presentation. For the headlight setting it must not
be removed.
6.13 Adjust the fog light beam

Inclination value:
The inclination is -2.2%.
Right fog light (left fog light in mirror image)
OCTAVIA II 2004 ➤
– Remove the cover next to the fog light ⇒ Body Work; Rep. Gr.
63 .
– Align the fog light by turning the screw -1-.
6.14 Replacing the own power supply for the

alarm system
– Replacing the alarm of the alarm system ⇒ Electrical System;
Rep. Gr. 94.
6.15 Climatronic: Adjust the temperature to

22 °C
Note
♦ The fastest way to obtain a comfortable climate (temperature)

in the vehicle, is by adjusting the temperature to 22 °C.
♦ Hence if personal health conditions demand, only a regulation
in the adjustment is necessary.
– Check if the displays (displays) indicate 22 °C.
If adjustment of temperature is necessary, proceed as follows:
– By turning the regulators -1- and -2- adjust the temperature to
22 °C for both halves of the vehicle.
– Press key -3- for automatic operation. On the button -3- the
warning light comes on.
6.16 Switch off battery transport mode

– Connect the vehicle diagnostic, measuring and information
system -VAS 5051- together with the diagnostic cable -VAS
5051/6A- , or with the diagnostic cable -VAS 5051/5A- .

OCTAVIA II 2004 ➤

-arrow-.
– Select function “vehicle self diagnosis”.
– Select function “collective services”.
– Select function “switch off transport mode”.
– Select function “skip” and then “end”.
– Switch off the vehicle diagnostic, measuring and information
system -VAS 5051- together with the diagnostic cable -VAS
5051/6A- , or with the diagnostic cable -VAS 5051/5A- .
OCTAVIA II 2004 ➤
7 Body
7.1 Check underbody protection and body

paintwork for damage
The inspection of the underbody sealant and paintwork should
cover the following points:
1) undamaged layer of PVC Plastisol
– Vehicle floor
– Wings and wheel housings
– Sills
2) undamaged paintwork
– all body joints
– surround of windscreen
– surround of rear window
– flange of inner surfaces of engine hood
– horizontal and vertical painted surfaces
– Connection of the roof in the region of the tailgate
It is essential to rectify any defects found!
The materials and the corresponding work instructions are listed
in the ⇒ Technical Service Handbook, Technology of paint re‐
pairs, chemical materials .
7.2 Inspecting plenum chamber and water

drain openings for dirt, cleaning if nec‐
essary
Carry out a visual inspection for soiling through the cover of the
plenum chamber -arrows-. Remove the cover if it is necessary to
clean the plenum chamber (repair measure).
Note
The water drain openings must not be blocked with wax or un‐
derbody sealant.

OCTAVIA II 2004 ➤
7.3 Windscreen wiper/washer system:

Check for proper operation
7.3.1 Inspecting setting of nozzles of wind‐

screen washer system, adjusting noz‐
zles if necessary:
The windscreen washer system is set by the manufacturer and
can be subsequently altered -arrow-.
– The water spray should strike the windscreen in a cone-sha‐
ped pattern.
Note
If the spray flows out unevenly, adjust the washer nozzle.
7.3.2 Fluid in windscreen washer fluid reser‐

voir
The windscreen washer fluid reservoir must be filled up to the
brim.
Note
♦ If it is necessary to add fluid, always mix windscreen cleaner

to the water (in summer) or antifreeze agent (in the winter).
♦ If the vehicle is fitted with a headlight washing system and the
headlights have plastic lenses (out of polycarbonate), one
must only use fluids which do not damage the polycarbonate.
7.3.3 Windscreen wiper arms: Inspecting park

position, adjusting if necessary
– Adjust windscreen wiper arms according to the markings on
the windscreen -arrows- .
Tightening torque for the windscreen wiper nut is 20 Nm.
7.3.4 Replacing the windscreen wiper blades

The windscreen wiper arms cannot be folded away from the wind‐
screen in the rest position. Therefore the windscreen wiper arms
must be put in the service position before changing the wiper
blades.
7. Body 41
OCTAVIA II 2004 ➤
7.3.5 Service position for changing the wiper

blades
– Close the bonnet.
– Switch ignition on and off.
– Move the windscreen wiper lever into position -4- within 20
seconds, the windscreen wiper arms move into the service
position.
7.3.6 Replacing the wiper blade

– Fold away windscreen wiper arm from the windscreen and
align the wiper blade horizontally.
– Remove wiper blade in direction of arrow.
7.3.7 Attaching the wiper blade

– Push the wiper blade onto the windscreen wiper arm and turn
the wiper blade in vertical position.
– Check whether the wiper blade is correctly attached.
– Fold back the windscreen wiper arms onto the windscreen and
switch on the ignition, the windscreen wiper arms move back
into the rest position.
Note
♦ The ignition must not be switched on, if the windscreen wiper

arms are folded away. The windscreen wiper arms would
move back into the rest position and could damage the paint‐
work on the bonnet.
♦ There is a risk of damage to the windscreen by the windscreen
wiper arm, if the windscreen wiper is improperly handled.

OCTAVIA II 2004 ➤
7.3.8 Wiper arm of rear window: Inspecting

and adjusting park position
– Adjust the windscreen wiper arm at a distance -a- of approx.
35 mm from the lower edge of the rear window.
The specified tightening torque for the windscreen wiper nut is 8
Nm.
– Inspect setting of nozzle, if necessary adjust with a tool, e.g.
with a needle.
The spray should strike the rear window as shown in the illustra‐
tion when the vehicle is stationary.
Note
If the spray flows out unevenly, or if it cannot be adjusted, replace

the wash nozzle (repair measure).
7.3.9 Replacing the rear window wiper blade

7.3.10 Removing the wiper blade
– Fold away windscreen wiper arm from the windscreen and
align the wiper blade horizontally.
– Hold the windscreen wiper arm in the top part with one hand.
– Unlock button -1- with the second hand in direction of arrow
and remove the wiper blade.
7.3.11 Attaching the wiper blade

– Push the wiper blade onto the windscreen wiper arm and un‐
lock the button -1-.
– Check whether the wiper blade is correctly attached.
Note
♦ The ignition must not be switched on, if the windscreen wiper

arms are folded away. The windscreen wiper arms would
move back into the rest position and could damage the paint‐
work on the bonnet.
♦ There is a risk of damage to the windscreen by the windscreen
wiper arm, if the windscreen wiper is improperly handled.
7.4 Sun roof: Cleaning and greasing run‐

ners
– Carry out a visual inspection of the sun roof for leaks and cor‐
rosion damage
7. Body 43
OCTAVIA II 2004 ➤
– Clean the runners -1- and grease with lubricant -G 052 778- .
– Inspect proper operation of the sun roof, pay attention to pos‐
sible abrasive residue.
7.5 Door locks, locking buttons, child safety

locks: Check for proper operation
7.5.1 Door locks and locking buttons:

– Unlock and lock the driver and front passenger doors. Check
whether the locking buttons move up and down when this is
done.
– Press down the locking button on the front passenger door and
on the rear doors and close the doors. The doors must be
locked.
The safety knob on the driver's door must not be pressed in as
long as the door is open.
7.5.2 Child safety locks (rear doors):

The rear doors are additionally equipped with a child safety lock.
– Insert car key in the lock.
– The child safety lock is activated when the key is turned to the
left in -the direction of the arrow-. The inner door opening lever
is blocked. The door can only be opened from the outside.
7.6 Replace dust and pollen filter
7.6.1 Removing:
– Remove the cover below the glove compartment ⇒ Body
Work; Rep. Gr. 70 .

OCTAVIA II 2004 ➤
– Press back the catch of the filter -arrow-.
– Remove filter element -1-.
7.6.2 Installing:
Installation is carried out in the reverse order.
7.7 Affix vehicle data sticker

– Stick the vehicle data sticker to the floor of the luggage com‐
partment inside the vehicle next to the spare wheel -arrow-.
7.8 Check proper operation of key switch for

front passenger airbag deactivation
7. Body 45
OCTAVIA II 2004 ➤
– Turn the key switch for the front passenger airbag with the
ignition key into the position -2- “OFF”.
When the ignition is switched on, the warning lamp in the centre
console must light up.
– Turn the key switch for the front passenger airbag with the
ignition key into the position -1- “ON”.
When the ignition is switched on, the warning lamp in the centre
console must go out after a few seconds.
WARNING
The key switch for the front passenger airbag must only be
operated when the ignition is switched off. Non compliance
may result in a fault at the airbag system (risk from the following
airbag deployment).
7.9 Mount the damping base under the ve‐

hicle identification plate
– Degrease with loctite e.g. D 009 401 04 the surface under the
vehicle identification plate before affixing the damping base.
Remove the adhesive foil from the damping base immediately
before assembly.
7.10 Inspecting trailer coupling device
7.10.1 Inspecting condition of the support for

the trailer coupling device
– Inspecting condition of the support shaft (contamination,
grease).
Clean the non treated and contaminated support shaft and treat
with -G 052 778 A2- .
– Check proper operation of the cap for the support shaft.
Replace the defective or damaged cap for the support shaft.
7.10.2 Inspect the condition of the trailer arm

– Inspect the rotation of the operating lever in open condition.
If the operating lever is difficult to turn or does not turn at all, the
jamming eccentric in the trailer arm housing must be cleaned and
treated with -G 052 778 A2- . If there is no improvement, the trailer
arm must be sent for repair to the manufacturer or replaced with
a new one.
– Inspect the rotation of the operating lever in closed condition.
If the operating lever can be turned more than 5°, the trailer cou‐
pling device is defective and must not be operated. Send the
trailer arm for repair to the manufacturer or replace it with a new
one.
– Check the turning of the key in the lock.
If the catch bolt in the operating lever is difficult to move or does
not move at all, it can be caused by the following:
♦ Lock defective: Replace bolt with lock

OCTAVIA II 2004 ➤
♦ Operating lever is bent: Repair at the manufacturer or replace

trailer arm
♦ the bolt is jamming: clean, treat with -G 052 778 A2- and bring
into motion. If this does not help, send it for repair to the man‐
ufacturer or replace it with a new one.
Note
When applying the loctite -G 052 778 A2- ensure that it penetrates
into the gaps between the lock bolt and the operating lever and
the eccentric and the trailer arm housing.
7.10.3 Check proper function of the trailer cou‐

pling device
– Insert the trailer arm into the support shaft.
– Close lock and withdraw key.
– Inspect proper closing by turning the operating lever "down‐
wards".
7. Body 47
OCTAVIA II 2004 ➤
8 Exhaust-emission Analysis
Note
The exhaust-emission analysis must be carried out according to

the relevant national legislation of the particular country.
8.1 Exhaust-Emission Analysis on Models

with Fuel Engines
Note
Perform the following visual inspections as well as comply with

the setting conditions below before performing the exhaust-emis‐
sion analysis:
Visual inspection
♦ Lambda probes are connected
♦ All vacuum hoses are connected
♦ All wires of the activated charcoal filter system are connected
♦ All the electrical wires of the ignition and injection system are
connected
♦ Hose for crankcase ventilation is connected
♦ The exhaust system must be undamaged and tight
♦ Catalyst must be undamaged
• Perfect operation of the engine
• Perfect operation of the ignition system
• Intake system tight
• All electrical components are switched off (radiator fan must
not run during the test)
Note
♦ If any shortcomings are noticed they must be repaired.

♦ The idling speed, ignition point and CO content are only meas‐
ured as they cannot be adjusted.
♦ The CO content is set to nominal value by the lambda control.
Faults in the lambda control are detected by the self-diagnosis
and stored in the fault memory.
♦ When interrogating the fault memory (engine electronics) all
detected faults must be repaired and the fault memory must
be erased.
♦ To prevent injury to persons and/or damage to the ignition and
injection system make sure the ignition is switched off when
disconnecting and connecting the wires of the ignition system.
Connect the test equipment to the vehicle

To prevent industrial accidents or avoid causing damage to the
ignition system, pay attention to the following:

OCTAVIA II 2004 ➤
♦ Disconnect and connect wires of the ignition system (including

high-voltage wires) when the ignition is switched off.
– Connect the tester in compliance with the operating instruc‐
tions.
-arrow-.
Note
The exhaust gas probe must be fully inserted into the exhaust
tailpipe (do not insert into the suction tube)!
– Start engine and run in idle.

– Measure idle speed and CO content.
8.2 Test Values for Exhaust-Emission Anal‐

ysis on Petrol Engines
The values are valid for the date of issuing of this workshop man‐
ual.
Engine identification Engine identification Engine identification
characters BGU characters BCA characters BLF
Oil temperature min. 80 °C min. 80 °C min. 80 °C
Catalyst warming-up time 2 min at 2500 rpm 2 min at 2500 rpm 2 min at 2500 rpm
Idling speed (1/min) 600 - 800 650 - 850 600 - 800
CO content at idle speed (measured 0,0 … 0,5 % 0,0 … 0,5 % 0,0 … 0,5 %
after catalyst)
Increased idling speed (rpm) 2400 - 2600 2400 - 2600 3900 - 4100
Lambda value at 2850 - 2900 rpm 0,97 - 1,03 0,97 - 1,03 0,97 - 1,03
CO content at 2850 - 2900 rpm 0,3 % 0,3 % 0,3 %
Speed for control loop test (rpm) 500 - 900 550 - 950 500 - 900
Lambda probe version Wide band probe Wide band probe Jump probe (lambda)
(lambda) (lambda)
Voltage jump (V) - - -
DELTA-lambda 0,03 0,03 0,03
Test speed Idling speed Idling speed Idling speed
Note
All tubes and plug connections, which had been removed or dis‐
connected for the test and adjustment, must be correctly re-
inserted or connected.
8. Exhaust-emission Analysis 49
OCTAVIA II 2004 ➤
Technical data of the spark plugs ⇒ Chapter 02-3 .
8.3 Exhaust-Emission Analysis on Models

with Diesel Engines
Note
♦ When possible the test should be carried out immediately after

the road test and also outdoors. If specific reasons prevent this
(weather conditions, excessive noise in residential areas) the
test may also be performed in the workshop.
♦ Secure the engine bonnet in the first stop while measuring to
reduce the noise.
Visual inspection
♦ Hose for crankcase ventilation is connected
♦ Fuel system and injection pump must be tight
♦ The exhaust system must be undamaged and tight
♦ All vacuum hoses are connected
• Engine oil temperature at least 80 °C
• All electrical components disconnected
• No fault stored in the fault memory ⇒ Chapter 02-6, connect
diagnostic unit and interrogate fault memory
Note
Correct detected faults before measuring (repair measure).
Connect the test equipment

– Connect the tester in compliance with the operating instruc‐
tions.
– Start engine, warm up to normal temperature and run in idle.
– Perform the exhaust-emission analysis.
Note
♦ Activate and inspect auxiliary equipment such as e.g. power

steering, automatic gearbox or air conditioning system. Check
whether the engine continues to run perfectly under this load.
♦ All tubes and plug connections, which had been removed or
disconnected for the test and adjustment, must be correctly
re-inserted or connected.

OCTAVIA II 2004 ➤
8.4 Test Values for Exhaust-Emission Anal‐

ysis on Diesel Engines
The values are valid for the date of issuing of this workshop man‐
ual.
Engine identification Engine identification Engine identification
characters BJB characters BKD characters AZV
Oil temperature min. 80 °C min. 80 °C min. 80 °C
Idling speed (1/min) 800 - 1000 760 - 960 760 - 960
Cutoff speed (1/min) 4650 - 5050 4800 - 5200 4800 - 5200
Soot emission max. opacity value (1/ 0,8 0,7 1,0
m)
Probe no. 1 1 1
Measurement mode B B B
Measurement time slice 0.5 s 0.5 s 0.5 s
10) From an engine oil temperature of min. 60°C warm up the engine to min. 80°
C with 10 free accelerations up to cutoff speed.
11) After the process - free acceleration.
If the actual values differ from the nominal values: Repair and
again perform an exhaust-emission analysis.
8. Exhaust-emission Analysis 51
OCTAVIA II 2004 ➤
9 Miscellaneous
9.1 Tow starting/Towing
Note
♦ A towing rope or towing bar must only be fitted to the appro‐

priate towing lugs.
♦ The towing rope must be elastic to protect the vehicle. There‐
fore only use synthetic ropes or ropes manufactured in an
equally elastic material. However, it is safer to use a towing
bar!
♦ Make sure no unauthorised traction forces or no jolting loads
are exerted. During towing manoeuvres away from hardened
road surfaces there is a risk of overloading and damaging of
the fastening parts.
♦ Before starting the engine by towing, first use the battery of
another vehicle as a start aid.
– Remove right cover in bumper ⇒ Body work; Rep. Gr. 50 .

Front: Install towing lug -1- in the opening on the right side of the
front bumper.
Note
Screw in the towing lug -1- by hand by turning it to the left in

-the direction of the arrow- up to the stop.
Rear: The towing lug is located below the rear right part of the
bumper.
Note
♦ Comply with the legal regulations on towing.

♦ Both drivers must be familiar with the specificities of the towing
process.
♦ When using a towing rope the driver of the towing vehicle must
press the clutch very smoothly when driving off and changing
gear.
♦ The driver of the towed vehicle must make sure that the rope
is kept taut.
♦ The ignition must be switched on to ensure the steering wheel
does not lock and that the turn signals, horn, windscreen wip‐
ers and windscreen washer system can be activated.
♦ As the brake servo unit only operates with the engine running,
the brake pedal must be pressed much harder when the en‐
gine is switched off.
♦ On vehicles with power steering the steering is much harder
when the engine is switched off.
♦ If there is no lubricant in the gearbox or automatic gearbox the
vehicle must only be towed with the drive wheels raised.

OCTAVIA II 2004 ➤
9.1.1 When towing vehicles with a manual

gearbox pay attention to the following:
– Before towing engage 2nd or 3rd gear.
– As soon as the engine starts, press clutch and remove gear to
avoid driving into the towing vehicle.
Note
Do not start the engine of vehicles fitted with an exhaust catalyst

by towing over a long distance as unburnt fuel may get into the
catalyst and burn there. This may result in overheating and hence
in the destruction of the catalyst.
9.2 Road test

The following must be assessed within the scope of a test drive
according to the vehicle equipment and the available possibilities
(city/country, weather)
– Inspect engine for performance, misfiring, idling behaviour,
acceleration and starting behaviour.
– Foot and handbrake: Functional test (jerking, squeaking, pull‐
ing to one side) ABS operation. Brake pedal-idle travel: max.
1/ of the idle travel.
3
– Inspect the lever position and smooth operation of the gear‐
shifts.
– Inspect the driving behaviour of the clutch as well as the pedal
force and smell.
– Inspect automatic gearbox: Selector lever position, selector
lever lock, shifting behaviour, display indication in dash panel
insert.
– Inspect steering clearance of the vehicle standing on its
wheels, with engine running by turning the steering wheel one
way and then the other (wheels straight ahead). There must
be no play on the steering.
– Inspecting the sun roof operation.
– Pay attention to pulling and to the straigt ahead position of the
steering wheel during driving.
– Inspect the imbalance of the wheels, drive shafts and prop‐
shafts.
– Inspecting functions: Heating, air conditioning, ventilation, in‐
struments and warning lights, mirror adjustment.
– Inspect engine, gearbox, axles, steering, brakes, clutch, body‐
work for abnormal noises.
9. Miscellaneous 53
OCTAVIA II 2004 ➤
9.3 Raise vehicle
9.3.1 Using a lift platform and a workshop jack

The vehicle must only be raised with a workshop jack -2- at the
indicated jacking points -1-.
The jacking points are located directly under the recesses on the
pillar. The recessess are only visible after opening the doors.
WARNING
♦ Under no circumstances may the arms of the lift platform

or jack be positioned under the engine, the gearbox, the
front or rear axles.
♦ Never start the engine or engage a gear when the vehicle
is raised, while even one driving wheel is still in contact
with the ground.
♦ Secure the vehicle on the lift platform before its centre of
gravity shifts considerably because of successive disas‐
sembly operations.

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Service

Service Department. Technical Information

02 - Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6.6 Setting clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

02 – Inspection and Maintenance

1.1 Vehicle identification data

The vehicle identification number can also be found bottom left of

1.1.1 Type plate

2 Rep. Gr.02 - Inspection and Maintenance

1.1.2 Vehicle data sticker

1.2 Check identification of vehicle window

1.3 Storage of ŠKODA new vehicles

1.4 Vehicle handover from stock

1.5 Additional customer information regard‐

1.5.1 Information regarding the use of vehi‐

– Under “severe conditions” the inspection intervals must be

1.5.2 General information:

4 Rep. Gr.02 - Inspection and Maintenance

2.1 Pre-Delivery Inspection -PDI- (Export)

♦ Type plate in engine compartment

♦ Colour of paintwork, badges, inscriptions

♦ Seats (cover, colour) interior trim (colour)

♦ Radio, speakers, aerial

♦ Central locking system, anti-theft alarm system

♦ Other equipment (all equipment fitted in proper condition)

2.2 Pre-sales Inspection - (the Czech Republic)

♦ Type plate in engine compartment

♦ Colour of paintwork, badges, inscriptions

♦ Seats (cover, colour) interior trim (colour)

♦ Radio, speakers, aerial

♦ Central locking system, anti-theft alarm system

♦ Other equipment (all equipment fitted in proper condition)

Inspections and operations to be completed

6 Rep. Gr.02 - Inspection and Maintenance

Engine compartment (from above)

2.3 Delivery Inspection (Export)

– Inspect bodywork and paintwork for damage

8 Rep. Gr.02 - Inspection and Maintenance

– Fit enclosed carpets in the vehicle

2.4 Oil change

– Replace engine oil filter

2.5 Inspection Service

After each inspection service

10 Rep. Gr.02 - Inspection and Maintenance

3.1 Engine overview

3.2 Engine fitted

Engine with identification characters BCA.

Engine with identification characters BGU and BLF.

Engine with identification characters BJB and BKD and AZV.

3.3 Visual inspection of engine for leaks and

3.4 Replace engine oil filter

3.4.1 Vehicles with petrol engine

12 Rep. Gr.02 - Inspection and Maintenance

♦ Oil filter wrench

3.4.2 Vehicles with diesel engine

3.5 Replacing the timing belt or also the ten‐

3.6 Inspecting timing belt for camshaft drive

The timing belt must most definitely be replaced if any shortcom‐