Service Workshop Manual Octavia II 2004 ➤ Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) CLC CLC CFH CFH Engine ID A B C F Edition 01.2011 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Service Department. Technical Information Service List of Workshop Manual Repair Groups Repair Group 00 - Technic al data 01 - Self-diagnosis 10 - Removing and installing engine 13 - Cranks haft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 20 - Fuel supply system 21 - Turbocharging/supercharging 23 - Mixture preparation - injection 26 - Exhaust system 28 - Glow plug system Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 ŠKODA AUTO a. s. D3E802A90C1 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 Contents 00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1. 1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 01 - S elf-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2 1. 1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2 Supplementary instructions and assembly work on vehicles with an air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 Regulations concerning safety precautions when working on the fuel system . . . . . . . . . . 3 1. 4 Regulations concerning cleanliness when working on the fuel supply/fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.5 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 5 1.6 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.1 Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.4 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.5 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.6 Adjusting the unit mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1 Removing and installing a V-ribbed belt and a toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 24 1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted 1.2 Removing aunnleds si nausthtaorlisliendg by V ŠK-rOibDAb eAUdT Ob eA.l tS .f oŠKr OvDeAh AiUcTleOs A .w S.i tdhoeosu nto ta giura rcaontened oirt iaoccneipnt gan ys lyiasbitlietym . . . . . . 27 1.3 Removing anwdi thin resstpaecllti tno gth eV c-orrriebcbtneesds obf einlfot rmfoarti ovn einh thicisl edosc uwmeitnht. Caoipry rcigohtn bdy iŠtiKoOnDiAn AgU sTOy sAt. eSm.� . . . . . . . . 27 1.4 Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 1.5 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 29 1.6 Timing belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.7 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2 Removing and installing sealing flange and two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . 45 2.1 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 2.2 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 47 2.3 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.4 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.1 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3.2 Replace needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 3.3 Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 3.4 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 3.5 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 1 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 1.1 Cylinder head cover - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 1.3 Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 1.4 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 i Contents Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 1.6 Removing and installing the vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 1.7 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 2.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 2.2 Replacing camshaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 2.4 Measuring the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 2.5 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 2.6 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 2.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 2.8 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 96 1.1 Removing and installing parts of the lubrication system - Summary of components . . . . . . 96 1.2 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 97 1.3 Oil filter with engine oil cooler - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . 98 1.4 Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . . 99 1.5 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 1.6 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 1.7 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 1.8 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 1.9 Testing oil pressure switch F1 and oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 1.1 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 1.2 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 1.3 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 1.4 Remove and install coolant recirculation pump 2 V178 . . . . . . . . . . . . . . . . . . . . . . . . . . 117 1.5 Replace coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 1.6 Replace coolant temperature sender at radiator outlet G83 . . . . . . . . . . . . . . . . . . . . . . . . 119 2 Coolant pump and 4/2 way valve with coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . 121 2.1 Coolant pump and 4/2 way valve with coolant regulator - Summary of components . . . . . . 121 2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 2.3 Removing and installing 4/2 way valve with coolant regulator . . . . . . . . . . . . . . . . . . . . . . 122 2.4 Testing coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 3 Radiator and fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 3.1 Radiator with a radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 3.2 Radiator with two radiator fans - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 127 3.3 Removing and installing fan shroud and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 3.4 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 3.5 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 134 1.1 Behaviour in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 1.2 Summary of components of fuel tank with attached parts - Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 1.3 Summary of components of fuel tank with attached parts - Vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 1.4 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 1.5ProtecEtedx btrya cocpty rfiughet.l C forpoyming tfohr epr ifvuatee lo rt aconmkm e r c.i a.l p. u.r p.o s.e .s ,. i n. p.a r.t o. r .i n. w.h .o le. , .i s. n .o t. p .e r.m .it te. d. . . . . . . . . . . . . . . . . . . . . . . 142 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 1.6 Removing and installing the fuel delivery unit on vehicles with front-wheel drive . . . . . . . . 143 with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� 1.7 Removing and installing the fuel delivery unit on vehicles with four-wheel drive . . . . . . . . 145 1.8 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 148 ii Contents Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 1.9 Removing and installing fuel gauge sender 2 G169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 1.10 Removing and installing suction jet pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 1.11 Remove and install the fuel tank for vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . 151 1.12 Removing and installing fuel tank for vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . 153 1.13 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 1.14 Removing and installing additional fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 2 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 2.3 Disconnect connector for accelerator pedal module and fit on . . . . . . . . . . . . . . . . . . . . . . 164 21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 1 Charge-air system - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 1.1 Exhaust gas turbocharger with component parts - Summary of components . . . . . . . . . . 165 1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 1.3 Removing and installing exhaust gas temperature sender 1 G235 ( temperature sender upstream turbocharger G507 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 1.4 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 1.5 Inspect the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 2 Charge-air system - radiator, leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 2.2 Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 2.4 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 1 Diesel direct injection system - fitting locations, system overview . . . . . . . . . . . . . . . . . . . . 181 1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 1.2 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 2 Fuel system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 2.1 High pressure pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 2.2 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 2.3 Filling and bleeding the high pressure pump/fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . 189 2.4 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 2.5 Injection units (solenoid injectors) - Summary of components . . . . . . . . . . . . . . . . . . . . . . 191 2.6 Adaptation for injector quantity adjustment (IQA code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 2.7 Always search for injection units in open state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 2.8 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 2.9 Installing the high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 2.10 Removing and installing fuel high pressure reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 2.11 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted 2.12 Check the low pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability 2.13 Check fuel pressurweit hr eregspuelcat ttoi nthge cvoarrelvctene sNs 2of7 in6fo r m a.t io. n. i n. th. is. d.o .c u.m .e n.t .. C .o p.y .ri g.h t. b.y .Š K. O. D.A . A .U T. O. A. . .S ..� . . . . . . . 205 2.14 Replace fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 3 Intake manifold, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 3.1 Intake manifold with component parts - Summary of components . . . . . . . . . . . . . . . . . . . . 208 3.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 209 3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 3.4 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 3.5 Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 4.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218 iii Contents Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 1.1 Pre-exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 1.2 Middle or rear part of the exhaust system - Summary of components . . . . . . . . . . . . . . . . 222 1.3 Replacing differential pressure sender G505 (for engine with engine identification characters CFHC, CFHF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 1.4 Removing and installing pre-exhaust pipe with diesel particle filter (for engine with identifica tion characters CFHC, CFHF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 1.5 Removing and installing pre-exhaust pipe (for engines with engine identification characters CLCA, C LCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 1.6 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 1.7 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 1.8 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 2.1 Exhaust gas recirculation with radiator - Summary of components . . . . . . . . . . . . . . . . . . 233 2.2 Removin g and installing radiator for exhaust gas recirculation with exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 2.3 Checking change-over flap for radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . 236 28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238 1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� iv Contents Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 00 – Technical data 1 Technical data 1.1 Engine number The engine number („engine identification characters“ and „serial number“) is located in the front at the engine/gearbox joint -arrow-. In addition, a sticker with the „engine identification characters“ and „serial number“ is affixed to the timing belt guard. The engine identification characters are also indicated on the ve‐ hicle data sticker. ♦ The engine identification characters have 4 digits starting with the letter „C“. ♦ The first 3 digits of the engine identification characters refer to the displacement and the mechanical construction of the en‐ gine. They are type-punched in the cylinder block including the serial number. ♦ The 4th digit refers to the output and torque of the engine and depends upon the engine control unit. 1.2 Engine characteristics Engine identification CLCA CLCB CFHC CFHF characters Manu‐ 03.2010 ► 03.2010 ► 05.2010 ► 01.2011► factured Exhaust limit values con‐ EU-4 / BS-4 EU-4 / BS-4 EU5 EU5 forming to Dis‐ l 1,968 1,968 1,968 1,968 place‐ ment Power kW at rp m 81/4200 103/4200 103/4200 81/4200 output Torque Nm at rp m 250/1500...2500 320/1750...2500 320/1750 … 2500 280/1750 … 2750 Bore ∅ mm 81 81 81 81 Stroke m m 95,5 95,5 95,5 95,5 Cylinder / valves per cyl‐ 4/4 4/4 4/4 4/4 inder Compression ratio 16,5 16,5 16,0 16,0 Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 Catalytic yes yes yes yes convert‐ er Exhaust gas recirculati on yes yes yes yes with radiator Turbo‐ yes Protected by copyyrieghst. Copying for private or comymeesrcial purposes, in part or in wyhoeles, is not permitted charging unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liabi lity with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Charge air cooler yes yes yes yes Diesel particle filter no yes yes yes 1 1. Technical data Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 01 – Self-diagnosis 1 Self diagnosis, safety measures, cleanliness regulations and direc‐ tions 1.1 Self-diagnosis This Rep.-Gr. is deleted. For this use the „Vehicle self-diagnosis“, „Measuring method“ and „Fault finding“ ⇒ Vehicle diagnostic, testing and information sys‐ tem VAS 5051. 1.2 Supplementary instructions and assem‐ bly work on vehicles with an air condi‐ tioning system WARNING Do not open the refrigerant circuit of the air conditioning sys‐ tem. Note In order to avoid damag e to the condenser as well as to the re‐ frigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent. Steps which should be taken in order to remove and install the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted engine without opening the refrigerant circuit: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� – Unscrew the holding clamp(s) on the refrigerent lines – Remove V-ribbed belt ⇒ page 27 . – Remove AC compressor from the bracket for auxiliary units ⇒ page 24 . – Mount the air conditioning compressor and the condenser in such a way that the refrigerent lines/hoses are not under ten‐ sion. 2 Rep. gr.01 - Self-diagnosis Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 1.3 Regulations concerning safety precau‐ tions when working on the fuel system WARNING When undertaking all assembly work, particularly in the engine compartment due to its cramped construction, please observe the following: ♦ L ay lines of all kinds in such a way that the original line guide is re-established. ♦ E nsure that there is adequate free access to all moving or hot components. ♦ T he fuel or the fuel lines in the fuel system can become very hot (risk of burning)! ♦ T he fuel system is under pressure! ♦ Wear safety goggles and safety clothing, in order to avoid injuries and skin contact with fuel. ♦ Place cleaning cloths around the connection point before detaching cable connections. Reduce pressure by care‐ fully removing the wiring. For reasons of safety the current supply to the fuel pump must be interrupted before opening the fuel system. Otherwise the fuel p ump is activated when opening the driver's door. One of the following options must be used to interrupt the current sup‐ ply: ♦ Disconnect battery or ♦ Take out fuse for fuel pump relay -J17- or Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted ♦ Disconnect the pluugnl eossn a utthhoeri sfelad nbyg ŠeK OoDfA t hAUeT Ofu Ae. lS .d ŠeKlOivDeA rAyU TuOn Ait. S. does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.� Caution In order to avoid the high pressure pump to run dry and to ach‐ ieve a quick engine start after parts are replaced, the following points must be observed: ♦ If the fuel system was opened, starting with the fuel tank through to the high pressure pump, the ventilation of the fuel system must be carried out before starting the engine. For this purpose, switch on the ignition and only switch it off once the fuel pump has come to a standstill. Repeat this procedure at least »5 times«. ♦ If the high pressure pump is removed or replaced, the in‐ itial fuel filling of the high pressure pump must be carried out before the first engine start ⇒ page 189 . ♦ If the high pressure system was opened, it must be checked for tightness ⇒ page 190 . When removing and installing the fuel gauge sender or the fuel delivery unit from a full or partly filled fuel tank, pay attention to the following points: ♦ The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the assembly open‐ 3 1. Self diagnosis, safety measures, cleanliness regulations and directions Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/81; 103 kW TDI CR Engine (2nd generation) - Edition 01.2011 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! 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. WARNING Secure the diagnostic device to the rear seat and operate from that position. Observe the following points to prevent injury to persons and/or damage to the injection and preheating system: ♦ People, who have a heart pacemaker implant, should not bend over the engine compartment when the engine is running, as the injection units (solenoid valve injectors) generate an output high voltage pulse. ♦ No fuel lines must be opened when the engine is running. ♦ Disconnect and connect wi res of the preheating and injection system as well as measuring device wires when the ignition is switched off. ♦ Do not carry out engine wash unless the ignition is switched off. ♦ If the engine must be operated, without it starting, unplug the connector -arrow- at the fu el pressure regulating valve - N276- . ♦ Switch off the ignition before disconnecting and connecting the battery, as this may damage the 4AV control unit. ♦ After connecting the battery , carry out certain additional oper‐ ations ⇒ Electrical System ⇒ Rep. gr. 27 . 1.4 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: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability ♦ Thoroughly clean the connection points and thewirit hs ruesrpreocut tno dthien cgorsrectness of information in this document. Copyright by ŠKODA AUTO A. S.� 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 etc...). 4 Rep. gr.01 - Self-diagnosis