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Skoda OCTAVIA Workshop Manual
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Skoda OCTAVIA Workshop Manual

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Service
Workshop Manual
OCTAVIA
Running Gear
Service Department. Technical Information
S00.5103.50.20
Edition 08.96

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Summary of Contents for Skoda OCTAVIA

  • Page 1 Service Workshop Manual OCTAVIA Running Gear Service Department. Technical Information S00.5103.50.20 Edition 08.96...
  • Page 2 The Workshop Manual is intended only for use within the ŠKODA Organisation; it is not permitted to pass it on to third parties. Printed in Czech Republic © 1996 ŠKODA, automobilová a.s.
  • Page 3 Supplement to Repair Group 40 and 42; Repair Group S00.5103.52.20 44, 45 and 48 11.97 Engine 1.9 l/81 kW TDI S00.5103.53.20 10.98 Engine 1.8 l/110 kW; Octavia Estate S00.5103.54.20 12.98 Drive shafts, vehicle measurement, Brake FN-3 S00.5103.55.20 06.99 Modifications to steering system, brakes, rear axle, S00.5103.56.20...
  • Page 5 OCTAVIA Service Table of Contents Technical Data Page Technical Data ..........................00-1 The chassis ..........................00-1 The steering system ......................... 00-5 The brake system ........................00-6 Wheels, tyres ........................... 00-8 Front wheel suspension Page Repairing the front wheel suspension ..................40-1 I - Summary of the components of the assembly carrier, anti-roll bar, track control arm ..
  • Page 6 Service OCTAVIA Repairing the rear axle (vehicles with a four-wheel drive) ............42-32 An overview of the rear axle with four-wheel drive ..............42-32 Summary of components for springs and dampers on vehicles with a four-wheel drive ..42-33 Removing and installing helical springs ................... 42-35 Removing and installing dampers ....................
  • Page 7 OCTAVIA Service Undertaking the self-diagnosis ....................45-9 Conditions for performing checking and tests ................45-9 Connecting up to the V.A.G vehicle tester 1552 and selecting a function ........ 45-9 Querying the control unit version ..................... 45-10 An overview of the functions which can be selected ..............45-12 Interrogating the fault memory ....................
  • Page 8 Service OCTAVIA Undertaking the self-diagnosis ....................45-97 Conditions for performing checking and tests ................45-97 Connecting up to the V.A.G vehicle tester 1552 and selecting a function ........ 45-97 Querying the control unit version ..................... 45-98 The automatic testing sequence ....................45-100 An overview of the functions which can be selected ..............
  • Page 9 OCTAVIA Service Electrical testing of the ABS/EDL/TCS Mark 60 ............... 45-205 Conditions for performing checking and tests ................45-205 Multiple plug connectors with contact allocation ..............45-206 Testing table ..........................45-208 The anti-lock braking system ABS/EDL/ESP MK 60 ..............45-214 Safety measures, basics concerning searching for faults and repairs ........
  • Page 10 Service OCTAVIA Repairing a rear wheel brake - four-wheel drive/disc brake ........... 46-24 Removing and installing a rear brake ..................46-24 Removing and installing brake linings ..................46-26 Adjusting the handbrake ......................46-29 Removing and installing the handbrake cable (four-wheel drive/disc brake) ....... 46-31...
  • Page 11 OCTAVIA Service A summary of components: the power-assisted steering gearing system ......48-9 Removing and installing the expansion bottle for hydraulic oil ..........48-11 Removing and installing the power-assisted steering gearing system ........48-12 Repairing the power-assisted steering gearing system (ZF) ........... 48-19 Altered track rod ends ......................
  • Page 13 Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver). Not adjustable, depending on design Adjustable Not valid for Octavia 4 x 4 Only Octavia RS (1.8 l/32 kW) Edition 11.02 ------------ 00-1 ------------...
  • Page 14 After carrying out corrections of steering geometry, inspect position of steering wheel and alter to correct position, if necessary. Only Service Mobil (Octavia 1.9 l/66 kW SLX, Octavia 1.8 l/92 kW SLX) Only Service Mobil (Octavia Estate 1.9 l/81 kW SLX) Only Service Mobil (Octavia 1.9 l/66 kW GLX...
  • Page 15 OCTAVIA Technical Data Chassis Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver). ä ä...
  • Page 16 OCTAVIA Technical Data ------------ 00-4 ------------ ------------ 00-3.1 ------------ Edition 11.00 S00.5103.59.20...
  • Page 17 Not adjustable, depending on design The individual tracking values can be ad- justed and the running direction of the rear axle can be corrected by shifting the bear- ing brackets. Only for Octavia 4x4 Edition05.04 ------------ 00-3.2 ------------ S00.5103.67.20...
  • Page 18 ♦ All petrol and diesel engines with a manual tomatic gearbox or an automatic gearbox ♦ All diesel engines over 66 kW with a ♦ Octavia 4 x 4 manual gearbox Rear axis PR No. Engine installed / gearbox design PR No.
  • Page 19 OCTAVIA Technical Data Steering Model Steering type Rack and pinion type steering system Steering gear Power-steering gear Steering-wheel turns from stop to stop 3.04 Steering-wheel diameter (mm) Total ratio of steering 15.60 Lubricant for gear racks Steering gear-flow grease TL 733 N 052 733 00 Part No.: AOF 063 000 04...
  • Page 20 20.64 20.64 20.64 ∅ Brake lining, width 32.0 Lining thickness without supporting shoe Minimum thickness without supporting shoe Models without ABS Not for taxi models (designation F4E) Models with ABS For Octavia Combi: 20.64 ------------ 00-6 ------------ Edition 05.01 S00.5103.61.20...
  • Page 21 OCTAVIA Technical Data M = Manual gearbox A = Automatic gearbox Master brake cylinder - ∅ 23.81 Brake booster - ∅ Inch Left-hand drive with and without ABS: 10" Right-hand drive with and without ABS: 7"/8" - Tandem Front brake caliper Front brake caliper, piston - ∅...
  • Page 22 OCTAVIA Technical Data ------------ 00-6.2 ------------ Edition 05.01 S00.5103.61.20...
  • Page 23 OCTAVIA Technical Data Engine l/kW 1.9/66 TDI 1.9/81 TDI 1.8/92; 2.0/85 (82) 1.8/110 M = Manual gearbox A = Automatic gearbox Master brake cylinder - ∅ 23.81 Brake booster - ∅ Inch Left-hand drive with and without ABS: 10“ Right-hand drive with and without ABS: 7“/8“ - Tandem...
  • Page 24 OCTAVIA Technical Data Brake fluid Classification Brake fluid N 052 766 US standard FMVSS 571. 116 DOT Part No.: B 000 700 A.. (A1..M8 - Package size) Contents of brake fluid 0.49 Vehicles with rear drum brakes, without ABS 0.53 Vehicles with rear drum brakes, with ABS 0.57...
  • Page 25 205/55 R16 91 V, W J x 16 H2 205/55 R16 91 W J x 16 H2 Tyre inflation pressure Not valid for Octavia Estate RS ⇒ Inspection and Maintenance as well as sticker on vehicle Edition 11.02 ------------ ------------...
  • Page 26 OCTAVIA Technical Data Load rating-index (Last Index): 88 = 560 kg 91 = 615 kg 89 = 580 kg Speed symbol: T = 190 km/h H = 210 km/h V = 240 km/h W = 270 km/h Notes: ♦ Only use tyres of a same size and type on a vehicle, however the tread pattern and manufacturer may differ per axle.
  • Page 27 OCTAVIA Technical Data Tyre inscription Inscription e.g. 175/80 R14 88 T Meaning 175/80 Tyre width (mm)/cross section ratio of height - width (%) Tyre construction (radial) Wheel diameter (inch) Load index Speed symbol Date of manufacture DOT ... 394 K Manufactured in 39th week 1994 (K = designates decade 1990 ...
  • Page 29 OCTAVIA Front Suspension Servicing front suspension I - Removing and installing subframe, anti-roll II - Removing and installing wheel mounting, bar, track control arm ⇒ page 40-2 suspension strut, drive shaft, brake ⇒ page 40-13 ------------ 40-1 ------------ Edition 10.98...
  • Page 30 OCTAVIA Front wheel suspension I - Summary of the components of the assembly carrier, anti-roll bar, track control arm Comments: 1 - Axle guide ♦ Removing and installing ⇒ Page 40-4 ♦ If vehicles on which the universal drive shaft ♦...
  • Page 31 OCTAVIA Front wheel suspension 4 - 15 Nm and turn through a further 90° 18 - Shift rail ♦ Replace after every disassembly op- ♦ Mount the spherical head with the long eration threaded pin -A- (above) on the spring...
  • Page 32 OCTAVIA Front Suspension Removing and installing track con- trol arm Special tools, testers and aids required ♦ Removing tool MP 6-425 ♦ Supporting device MP 9-200 ♦ Torque wrench 75 ... 400 Nm, e.g. V.A.G 1576 ♦ Torquing angle wrench, e.g. V.A.G 1756 Removing Take off the wheel trim;...
  • Page 33 OCTAVIA Front Suspension Press out drive shaft. Position tool, as shown in Fig., for this step. Note: Ensure adequate clearance when pressing out the drive shaft. Unscrew hexagon bolt -3-, if fitted, at wish- bone. Unscrew hexagon bolts -1- and -2-.
  • Page 34 OCTAVIA Front Suspension Installing (applies to models fitted with manual and auto- matic gearbox) Remove any corrosion present in the thread/ spline of the outer joint. Insert wishbone and attach. Attach subframe. Moisten splines of wheel hub with oil. Insert outer joint as far as possible into the splines of the wheel hub.
  • Page 35 OCTAVIA Front Wheel Suspension The wheel bearing will be damaged if the wheel bearings are burdened through the weight of the vehicle. The working life of the wheel bearing decreases through this. Operate brake (second mechanic required). Tighten new twelve-point nut with 225 Nm and slacken half a turn.
  • Page 36 OCTAVIA Front Suspension Removing and inserting bush for track control arm Special tools, testers and aids required ♦ Thrust plate MP 3-406 ♦ Thrust plate MP 3-407 ♦ Pipe section MP 3-414 ♦ Pipe section MP 3-429 ♦ Thrust washer MP 3-456 ♦...
  • Page 37 OCTAVIA Front Suspension K Installation position for rear bush in track control arm One of the stamped arrows points towards the recess in the track control arm; kidney-shaped recess (arrow A) in bush points toward centre of vehicle. K Removing and inserting rear bush for track...
  • Page 38 OCTAVIA Front Suspension Removing and installing subframe Special tools, testers and aids required ♦ Removal tool MP 6-425 ♦ Gearbox jack with attachment, e.g. V.A.G 1383 A with V.A.G 1359/2 Removing Take off the wheel trims of the front wheels;...
  • Page 39 OCTAVIA Front Suspension Unscrew bolts -1- and -2- and take off pen- dulum support. Unscrew bolts for steering gear -5-. Unscrew nut -7- for coupling rod of anti-roll bar. Unscrew bolts -6- for exhaust system (only TDI). Position gearbox jack with attachment, e.g.
  • Page 40 OCTAVIA Front Suspension Removing and installing bonded rubber bush Special tools, testers and aids required ♦ Pressure plate MP 3-407 ♦ Pressure die MP 3-448 ♦ Counterholder MP 6-410 ♦ Removal tool MP 6-425 ♦ Assembly device MP 6-430 ♦ Workshop press, e.g. V.A.G 1290 A ♦...
  • Page 41 OCTAVIA Front Suspension II - Assembly overview of wheel mounting, suspension strut, drive shaft, brake Notes: ♦ Always replace corroded nuts and bolts. ♦ If it is necessary to move a vehicle on which 1 - Self-locking hexagon collar nut, 60 Nm the drive shaft has been removed, first of all ♦...
  • Page 42 OCTAVIA Front Suspension 4 - Drive shaft with inner CV joint 7 - Drive shaft with inner tripod joint ♦ removing and installing ⇒ page 40- ♦ removing and installing ⇒ page 40- ♦ servicing ⇒ page 40-38 ♦ servicing ⇒ page 40-49...
  • Page 43 OCTAVIA Front Wheel Suspension 9 - Brake disc (FS-III) 21 - Brake carrier (FN-3) ♦ without marking for axial run-out 22 - Brake caliper (FN-3) ♦ with a fixing hole for the wheel hub ♦ assignment ⇒ electronic catalogue of...
  • Page 44 OCTAVIA Front Suspension 31 - Self-locking hexagon collar nut, 20 Nm 35 - Self-locking hexagon collar nut + torque a further 90° (1/4 turn) ♦ up to 05.98: 50 Nm + torque a further ♦ replace each time removed 90° (1/4 turn) from 06.98: 60 Nm + torque a further...
  • Page 45 OCTAVIA Front Suspension 38 - Wheel bearing 40 - Wheel hub without pulse rotor ♦ pressing out ⇒ from page 40-16 ♦ only on models without ABS ♦ replace, is destroyed when pressed ♦ assignment ⇒ Parts List ♦ pressing in ⇒ from page 40-16 41 - Wheel hub with pulse rotor for wheel ♦...
  • Page 46 OCTAVIA Front Wheel Suspension Repairing wheel bearing housing Special tools, testers and aids required ♦ Thrust plate MP 3-406 ♦ Thrust plate MP 3-407 ♦ Thrust plunger MP 3-408 ♦ Tube section MP 3-4012 ♦ Tube section MP 3-450 ♦ Thrust plate MP 3-467 ♦...
  • Page 47 OCTAVIA Front Suspension K Pressing wheel hub out of wheel bearing K Removing and installing circlip Use commercially available circlip pliers to remove and replace circlip. Notes: ♦ Replace ♦ When inserting, ensure the circlip is correctly located. K Pressing wheel bearing out of wheel bearing...
  • Page 48 OCTAVIA Front Wheel Suspension K Pull the inner ring of the bearing off the wheel Insert washer MP 6-416 as shown. Screw cross member Kukko 18-0 into washer MP 6-416. Install pressure plate MP 3-467 onto wheel hub and pull off inner ring of bearing by turn- ing the threaded spindle.
  • Page 49 OCTAVIA Front Suspension Inspecting steering joint Inspecting axial play Pull steering link firmly down and push up again. Inspecting radial play Push wheel firmly in and out at the bottom. Notes: ♦ There must not be any perceptible or visible play present when conducting both inspections.
  • Page 50 OCTAVIA Front Suspension Removing and installing steering joint Special tools, testers and aids required ♦ Wrench socket waf 19 MP 6-423 ♦ Extraction tool MP 6-425 ♦ Wrench socket waf 21 MP 6-427 ♦ Expanding tool 3424 ♦ Torquing angle wrench, e.g. V.A.G 1756 ♦...
  • Page 51 OCTAVIA Front Suspension Removing and installing suspension strut and wheel bearing housing Special tools, testers and aids required ♦ Extractor MP 6-425 ♦ Socket wrench bit waf 21 MP 6-427 ♦ Expander 3424 ♦ Torque wrench 75 ... 400 Nm, e.g.
  • Page 52 OCTAVIA Front Wheel Suspension Use puller Matra V176 (commercial) to press ⊳ track rod off the steering arm Unplug connector -1- ABS speed sensor from the mountings. Disconnect the ABS speed sensor from the mountings -arrow-. Remove caps -2- and unscrew brake cal- ⊳...
  • Page 53 OCTAVIA Front Suspension K Separating suspension strut from wheel bearing housing Insert special tool -3424- as shown, and spread wheel bearing housing apart. Take out suspension strut. Installing Remove any corrosion present in the thread/ spline of the outer joint.
  • Page 54 OCTAVIA Front Wheel Suspension Tightening torque: Suspension strut to suspension 60 Nm strut dome Use new nuts! Coupling rod to suspension strut 90 Nm Use new nuts! Steering joint to track control arm 20 Nm + 90° Use new screws and new lock...
  • Page 55 OCTAVIA Front Suspension Servicing front suspension strut 1 - Shock absorber ♦ Always replace complete ♦ Assigning ⇒ Parts List ♦ Can be replaced individually ♦ Inspecting shock absorber ⇒ page 40-28 ♦ Disposal ⇒ page 40-31 2 - Bump stop...
  • Page 56 OCTAVIA Front Suspension K Fig. 1 Removing coil spring Clamp suspension strut mount, e.g. V.A.G 1752/2, in a vice. Clamp suspension strut at shock absorber tube in suspension strut mount. Prestress screwdriver sufficiently with tensioning device, e.g. V.A.G 1752/1, until the spring disc at the top is free.
  • Page 57 OCTAVIA Front Suspension K Fig. 4 Installing coil spring Mount pretensioned screwdriver with tension- ing device, e.g. V.A.G 1752/1, onto spring base at bottom; the end of the spring coil should be touching the stop -arrow- when this is done.
  • Page 58 OCTAVIA Front Suspension Inspecting shock absorbers K Leaks at shock absorbers A slight oil leakage (sweating) at the gasket of the piston rod is not a reason for replacing the shock absorber. If an oil stain is visible (but mat, possibly dry...
  • Page 59 OCTAVIA Front Suspension Inspecting shock absorber without gas pres- sure Faulty shock absorbers can be detected when driving as a result of rumbling noises - as a con- sequence of the wheel jumping - particularly on a poor road surface, and should be replaced.
  • Page 60 OCTAVIA Front Suspension Testing shock absorber with gas pressure Faulty shock absorbers with gas pressure are also recognizable from loud rumbling noises because of the wheel jumping and, in most cases, as a result of an oil loss visible on the outside.
  • Page 61 OCTAVIA Front Suspension Disposing of shock absorbers Special tools, testers and aids required ♦ Pipe cutter, e.g. Stahlwille Express 150/3 ♦ Protective goggles ♦ Oil drip tray Warning! Cover over opening and wear eye protection when releasing the gas pressure (gas pressure of new shock absorber as much as 25 bar).
  • Page 62 OCTAVIA Front Suspension Draining front shock absorber Clamp shock absorber in a vice. Use an assembly lever or a similar tool to lever off the protective cap, and take off pro- tective tube. Protective cap and protective tube are fitted only to caulked shock absorbers.
  • Page 63 OCTAVIA Front Suspension Draining rear shock absorber (gas pressure shock absorber) Clamp shock absorber vertically in a vice, with the piston rod facing down. Drill a ∅ 3 mm hole (arrow A) in the outer tube. Warning! Wear eye protection.
  • Page 64 OCTAVIA Front Suspension Removing and installing drive shafts Special tools, testers and aids required ♦ Removal tool MP 6-425 ♦ Torque wrench 75 ... 400 Nm, e.g. V.A.G 1576 ♦ Tightening angle wrench, e.g. V.A.G 1756 Removing Notes: ♦ If the twelve-point nut is slackened, do not apply a load on the wheel bearing.
  • Page 65 OCTAVIA Front Suspension Press out drive shaft. Position tool as shown in the illustration for this step. Notes: ♦ Ensure adequate clearance when pressing out the drive shaft. ♦ The drive shaft must not hang down when it is pressed out. Otherwise, the inner joint will be damaged as a result of excessive flex- ing.
  • Page 66 OCTAVIA Front Suspension Installing (models fitted with manual and automatic gearbox) Remove any corrosion present in the thread/ spline of the outer joint. Moisten contact surface of twelve-point nut and also splines and thread of outer joint with oil and screw on new twelve- point nut as far as possible.
  • Page 67 OCTAVIA Front Wheel Suspension Make sure when lowering the vehicle that the wheels do not touch the ground. The wheel bearing will be damaged if the wheel bearings are burdened through the weight of the vehicle. The working life of the wheel bearing decreases through this.
  • Page 68 OCTAVIA Front Wheel Suspension Servicing drive shaft Servicing drive shaft with outer and inner CV joint Special tools, testers and aids required ♦ Circlip pliers, e.g. VW 161 A ♦ Thrust plate MP 3-406 ♦ Thrust plate MP 3-407 ♦ Thrust plunger MP 3-448 ♦...
  • Page 69 OCTAVIA Front Suspension Grease quantities and grade of grease Grease packing of CV joints with high-temperature grease G 000 603 or G 000 633. Notes: ♦ G 000 603 - Can containing 90 g grease ♦ G 000 633 - Can containing 120 g grease ♦...
  • Page 70 OCTAVIA Front Suspension ------------ 40-38.2 ------------ Edition 03.97 S00.5103.52.20...
  • Page 71 OCTAVIA Front Wheel Suspension 5 - Joint boot for inner CV joint, ∅ 94 mm 11 - Left drive shaft (solid shaft) ♦ material: Hytrel (Polyelastomere) ♦ assignment ⇒ electronic catalogue of ♦ inspect for tears and chafing points original parts ♦...
  • Page 72 OCTAVIA Front Wheel Suspension Servicing drive shaft with outer and inner CV joint VL 3700 Special tools, testers and aids required ⇒ page 40-38 Notes: ♦ Assignment of the drive shafts ⇒ Electronic catalogue of original parts ♦ Grease joint if necessary, when replacing the joint boot.
  • Page 73 OCTAVIA Front Wheel Suspension 9 - Joint boot for inner CV joint 14 - Fillister head screw with internal ser- ration ♦ material: Arnitel (Polyelastomere) ♦ inspect for tears and chafing points ♦ replace after each disassembly ♦ fitting location for left shaft ⇒ Fig. 13 ♦...
  • Page 74 OCTAVIA Front Wheel Suspension Grease quality and grease quantity Notes: ♦ The outer joints of the drive shaft are filled with: grease for normal temperatures Part-No. G 052 738 A2 grease from the relevant repair kit High temperature grease Part No. G 052 133 A2, or Part No.
  • Page 75 OCTAVIA Front Wheel Suspension Fig. 4 Fitting position of the disc spring ⊳ and thrust ring at outer joint (gear- box side) 1 - Disc spring 2 - Thrust ring Fig. 5 Pressing in the inner CV joint ⊳ Press the joint up to the stop.
  • Page 76 OCTAVIA Front Wheel Suspension Fig. 7 Fitting position of the joint boot for ⊳ the outer joint ∅ 100 mm on the right shaft The ventilation chamber -A- must be located on the largest pipe diameter. B - Ventilation hole Fig.
  • Page 77 OCTAVIA Front Wheel Suspension Tighten the warm-type clamp by turning the spindle with a torque wrench (do not tilt the pliers during this process) A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers C - Torque wrench Fig.
  • Page 78 OCTAVIA Front Wheel Suspension Fig. 13 Fitting position of the joint boot for ⊳ the inner joint on the left and right shaft Fig. 14 Fitting position of the joint boot for ⊳ the outer joint on the left shaft Fig.
  • Page 79 OCTAVIA Front Suspension Inspecting outer CV joint The joint should be disassembled to replace the grease if the grease is extremely dirty or if the running surfaces of the balls need to be in- spected for signs of wear and damage.
  • Page 80 OCTAVIA Front Wheel Suspension Installing Press the required grease quantity into the joint part ⇒ page 40-62; grease quality and grease quantity Insert the cage and hub in the joint body. Note: The cage must be inserted in the correct posi- tion.
  • Page 81 OCTAVIA Front Suspension Tilt the ball hub out of the ball cage over the ball track (arrow). Inspect the joint body, ball hub, ball cage and balls for pitting and signs of rubbing. Note: Excessive torsional play in the joint is notice- able from load change jolts.
  • Page 82 OCTAVIA Front Wheel Suspension Swivel in the ball hub. To do so swivel the hub ⊳ out of the cage until the balls are at bearing track distance -arrow-. Lock the hub with the balls into position by ⊳ exerting considerable pressure on the cage -arrow-.
  • Page 83 OCTAVIA Front Wheel Suspension Servicing drive shaft with tripod joint AAR 2900 and CV joint Special tools, testers and aids required ♦ Thrust plate MP 3-406 ♦ Thrust plunger MP 3-448 ♦ Tube section MP 3-4012 ♦ Tensioning pliers, e.g. V.A.G 1275, V.A.G 1682...
  • Page 84 OCTAVIA Front Wheel Suspension 6 - Fillister head screw with internal ser- ration ♦ replace after each diassembly ♦ initially tighten to 10 Nm, subsequently tighten crosswise to final torques M 8 = 40 Nm M10 = 70 Nm ♦ assignment ⇒ electronic catalogue of...
  • Page 85 OCTAVIA Front Wheel Suspension 17 - Thrust ring 19 - Outer CV joint ♦ fitting location ⇒ page 40-41, Fig. 4 ♦ must be replaced completely ♦ removing ⇒ page 40-40, Fig. 1 18 - Circlip ♦ installing: drive onto the shaft with a ♦...
  • Page 86 OCTAVIA Front Suspension Take O-ring -arrow- out of groove. Mark fitting location of parts 1 ... 3. 1 - Joint 2 - Tripod star 3 - Drive shaft Notes: ♦ If parts 1 ... 3 are not marked and are not re-...
  • Page 87 OCTAVIA Front Suspension Insert drive shaft into press. Hold drive shaft tight and press out the tri- pod star. Pull joint together with joint boot off the drive shaft. Clean drive shaft and joint. Assembling Fit small hose strap for joint boot onto the drive shaft.
  • Page 88 OCTAVIA Front Wheel Suspension Insert rectangular seal -A- from repair kit into ⊳ the groove -arrow-. Notes: ♦ A direct sealing between tripod joint (joint part) and joint flange (gearbox side) occurs through the shape of the rectangular section of the seal.
  • Page 89 OCTAVIA Front Wheel Suspension Tighten warm-type clamp (drive shaft side) with tensioning pliers e.g. V.A.G 1275. Cover tripod joint with cardboard disk -A- and adhesive tape -B-. Notes: ♦ After repairing, the tripod joint is covered with a clean cut cardboard disk -A- and adhesive tape -B-.
  • Page 90 OCTAVIA Front Wheel Suspension Servicing drive shaft with inner tri- pod joint AAR 2000 and outer CV joint Special tools, testers and aids required ♦ Thrust plate MP 3-406 ♦ Thrust plate MP ♦ Thrust ♦ ♦ Thrust ♦ ♦...
  • Page 91 OCTAVIA Front Wheel Suspension 5 - Joint part ♦ grease ⇒ page 40-62 ♦ assignment ⇒ electronic catalogue of original parts 6 - Tripod spider with rollers ♦ chamfer -arrow- points toward the drive shaft serration. 7 - Circlip ♦ replace ♦...
  • Page 92 OCTAVIA Front Wheel Suspension Disassembling and assembling tri- pod joint AAR 2000 Special tools, testers and aids required ⇒ page 40-56 Grease quality and grease quantity ⇒ page 40-62 Disassembling Open warm-type clamp on joint part. Push back joint boot.
  • Page 93 OCTAVIA Front Suspension Take O-ring seal -arrow- out of groove. Mark fitting location of parts 1 ... 3. 1 - Joint 2 - Tripod star 3 - Drive shaft Notes: ♦ If parts 1 ... 3 are not marked and are not re-...
  • Page 94 OCTAVIA Front Suspension Insert drive shaft into press. Hold drive shaft tight and press out the tri- pod star. Remove tripod star with rollers and place on a clean surface. Pull joint off the drive shaft. Pull joint boot off the drive shaft.
  • Page 95 OCTAVIA Front Wheel Suspension Press high temperature grease from the ⊳ repair kit evenly in the tripod joint (tripod spider side) -arrow A- and in the rear of the tripod joint -arrow B-. Grease quality and grease quantity ⇒ page 40-62 Assembling the joint boot.
  • Page 96 OCTAVIA Front Wheel Suspension Grease quantity Outer CV joint Total grease Inner CV joint Total grease of which ∅ mm ∅ mm Joint Joint Distribute evenly into the boot joint 94 (joint) 100 (joint) 108 (tripod) 124 (tripod) 100 (joint) Valid for all vehicle, except engines 1.9 l/74 kW PD and 1.9 l/96 kW PD.
  • Page 97 OCTAVIA Rear Suspension Servicing rear suspension - drum brakes Removing and installing rear sus- pension Special tools, testers and aids required ♦ Tester for brake pressure regulator, e.g. V.A.G 1310 ♦ Gearbox jack with attachment, e.g. V.A.G 1383 A with V.A.G 1359/2 ♦...
  • Page 98 OCTAVIA Rear Suspension Detach handbrake cables -1- from hand- brake lever. Pull handbrake cables out of the guide tubes. Unclip brake cables -arrows-. Detach clips -2- from brake hose fixture and Separate brake lines. Note: Seal lines with plugs. Unplug connectors of wheel speed sensors.
  • Page 99 OCTAVIA Rear Suspension Continued for all models: Support rear axle with gearbox lifter and adap- ter, e.g. V.A.G 1383 A with V.A.G 1359/2. Unscrew hexagon bolts -1- of the bonded rubber bush and lower rear axle. Installing Before inserting the rear axle, grease the kid- ney-shaped cavities of the bonded rubber bushes with assembly paste G 052 150 A2.
  • Page 100 OCTAVIA Rear Wheel Suspension Summary of components of rear axle 3 - Brake drum Notes: ♦ reset brake before removing the brake ♦ Welding and straightening on axle body and drum ⇒ page 42-24, Fig. 1 axle studs not allowed.
  • Page 101 OCTAVIA Rear Suspension rear ♦ After installing, inspect total wheel toe ♦ Replace each time removed of rear axle, and align if necessary ♦ Do not slacken if possible for remov- ing rear axle ♦ Only on models with ABS ♦...
  • Page 102 OCTAVIA Rear Suspension ♦ Can be replaced individually ♦ Replace each time removed ♦ Removing and installing ♦ If thread of welded nut is damaged, ⇒ page 42-10 thread can be repaired with Heli-Coil ♦ Assigning ⇒ Parts List threaded insert. Pay attention to ♦...
  • Page 103 OCTAVIA Rear Suspension 34 - Brake line 36 - Stone chip guard 35 - Axle stub 37 - Element for attaching stone chip guard ♦ No straightening work permitted! ♦ Included in parts supplied with stone ♦ It is not permitted to re-tap thread.
  • Page 104 OCTAVIA Rear Suspension Note: Place a soft block of wood of about 10 cm be- tween axle beam and body in order to be able to fit on the special tool. 5-401 5-401 ⇒ Note: ♦ It is essential to install the bonded rubber...
  • Page 105 OCTAVIA Rear Suspension ⇒ Note: When tightening the hexagon bolt of the bonded rubber bush, the axle beam must be in horizon- tal position (unladen weight condition). Note: When installing the handbrake cables, pay at- tention to Fitting location ⇒ page 46-18.
  • Page 106 OCTAVIA Rear Suspension testers and aids ♦ Gearbox lifter with adapter, e.g. V.A.G 1383 A with V.A.G 1359/2 Notes: ♦ It is not necessary to take out the coil spring in order to remove the shock absorber. ♦ It is not necessary to take out the shock ab- sorber in order to remove the coil spring.
  • Page 107 OCTAVIA Rear Suspension Disassembling and assembling shock absorber 1 - Shock absorber ♦ Can be replaced individually ♦ Removing and installing ⇒ page 42-10 ♦ Assigning ⇒ Parts List ♦ Disposing ⇒ page 40-31 ♦ Inspecting shock absorber ⇒ page 40-28...
  • Page 108 OCTAVIA Rear Suspension Servicing rear suspension - disc brakes Removing and installing rear sus- pension Special tools, testers and aids required ♦ Gearbox jack with attachment, e.g. V.A.G 1383 A with V.A.G 1359/2 ♦ Brake filling and bleeding appliance, e.g. ROMESS S 15 ♦...
  • Page 109 OCTAVIA Rear Suspension Note: Seal lines with plugs. Edition 06.99 ------------ ------------ S00.5103.56.20...
  • Page 110 OCTAVIA Rear Suspension Installing Notes: ♦ When tightening the hexagon bolt of the bonded rubber bush, the axle beam must be in the horizontal position (unladen weight condition). ♦ When installing the handbrake cables, pay attention to Fitting location ⇒ page 46-18.
  • Page 111 OCTAVIA Rear Wheel Suspension Summary of components of rear axle 3 - Brake disc Notes: ♦ Welding and straightening on axle body and 4 - Cap axle studs not allowed. ♦ replace after each removal ♦ Always replace the self-locking nuts and ♦...
  • Page 112 OCTAVIA Rear Suspension , 30 Nm and torque a f 45° ♦ Only on models with ABS ♦ Replace each time removed ♦ Wheel bearing and wheel hub are in- stalled together in a housing ♦ This wheel bearing/wheel hub unit re- quires no maintenance and is free of play.
  • Page 113 OCTAVIA Rear Suspension ♦ Replace each time removed ♦ Replace each time removed ♦ thread attention to i ♦ ♦ thread can repaired rear threaded attention to ⇒ vehicle ♦ thread and load ♦ at not more than connection on each ♦...
  • Page 114 OCTAVIA Rear Suspension K i . rear 1 - Shock absorber 2 - Track control arm α - approx. 104° testers and aids ♦ Universal tool MP 3-419 ♦ Thrust piece MP 5-400/1 ♦ Thrust piece MP 5-400/2 ♦ Supporting tube MP 5-400/3 ♦...
  • Page 115 OCTAVIA Rear Suspension Note: Place a soft block of wood of about 10 cm be- tween axle beam and body in order to be able to fit on the special tool. 5-401 5-401 ⇒ Note: ♦ It is essential to install the bonded rubber...
  • Page 116 OCTAVIA Rear Suspension ⇒ Note: When tightening the hexagon bolt of the bonded rubber bush, the axle beam must be in horizon- tal position (unladen weight condition). Note: When installing the handbrake cables, pay at- tention to Fitting location ⇒ page 46-18.
  • Page 117 OCTAVIA Rear Suspension testers and aids ♦ Gearbox lifter with adapter, e.g. V.A.G 1383 A with V.A.G 1359/2 Notes: ♦ It is not necessary to take out the coil spring in order to remove the shock absorber. ♦ It is not necessary to take out the shock ab- sorber in order to remove the coil spring.
  • Page 118 OCTAVIA Rear Suspension Disassembling and assembling shock absorber 1 - Shock absorber ♦ Can be replaced individually ♦ Removing and installing ⇒ page 42-21 ♦ Assigning ⇒ Parts List ♦ Disposing ⇒ page 40-31 ♦ Inspecting shock absorber ⇒ page 40-28...
  • Page 119 OCTAVIA Rear Wheel Suspension Repairing the wheel bearing Repairing the wheel bearing, vehicles with front-wheel-drive vehicles - drum brakes 1 - Screw, 4 Nm 2 - Brake drum ♦ reset brake before removing the brake drum ⇒ Fig. 1 3 - Cap ♦...
  • Page 120 OCTAVIA Rear Suspension 6 - Wheel hub with wheel bearing without pulse rotor ♦ Only on models without ABS ♦ Wheel bearing and wheel hub are in- stalled together in a housing ♦ This wheel bearing/wheel hub unit re- quires no maintenance and is free of play.
  • Page 121 OCTAVIA Rear Suspension K Fig. 2 Pressing off cap Detach cap from its seat by striking with light blows on the claw. K Fig. 3 Pressing off cap ------------ ------------ Edition 10.98 S00.5103.54.20...
  • Page 122 OCTAVIA Rear Suspension K Fig. 4 Pulling wheel hub and wheel bear- ing off axle end Use a commercially available puller, e.g. Kukko 20/2. K Fig. 5 Pulling bearing inner race off axle Use a commercially available puller, e.g. Kukko 204/1.
  • Page 123 OCTAVIA Rear Suspension ⇒ Notes: ♦ Replace cap each ♦ Edition 04.00 ------------ ------------ S00.5103.58.20...
  • Page 124 OCTAVIA Rear Wheel Suspension Repairing the wheel bearing - Disc brake 4 - Brake disc ♦ assignment ⇒ electronic catalogue of original parts 5 - Cap ♦ replace after each removal ♦ pressing off ⇒ Fig. 1 and 2 ♦ inserting ⇒ Fig. 8 6 - Self-locking twelve-point nut, 70 Nm and tighten a further 40°...
  • Page 125 OCTAVIA Rear Suspension K Fig. 1 Pressing off cap Detach cap from the seat by applying light blows to the claw. K Fig. 2 Pressing off cap ------------ 42-29 ------------ Edition 09.96 S00.5103.51.20...
  • Page 126 OCTAVIA Rear Wheel Suspension Fig. 6 Removing the brake caliper ⊳ Unscrew screws -A-, remove brake caliper and tie up with wire to the body. Note: Do not unscrew the brake hose to remove the brake caliper. Unscrew the fixing screws of the brake disc and remove brake disc.
  • Page 127 OCTAVIA Rear Suspension Use special tool MP 5-403. Fit wheel hub and wheel bearing as far as possible onto axle stud. Screw on special tool MP 5-403 and pull on wheel hub and wheel bearing as far as the stop.
  • Page 128 OCTAVIA Rear Suspension Servicing rear suspension (4x4 models) Overview of rear suspension for 4x4 models 2 - Final drive Notes: ♦ Removing and installing ♦ Always replace self-locking nuts and bolts. ⇒ 5-Speed Manual Gearbox 02C 4x4; Repair ♦ Always replace nuts and bolts which have signs of Group 39;...
  • Page 129 OCTAVIA Rear Wheel Suspension 3 - Cross member 10 - Spacer ♦ only on vehicles with rough road sus- 4 - Clamp pension ♦ on vehicles without spacer this must 5 - Anti-roll bar not be installed subsequently ♦ if necessary eliminate paint damage ♦...
  • Page 130 OCTAVIA Rear Wheel Suspension 11 - Stop buffer with positioning pin ♦ as of 08.99 ♦ the correct fitting position is deter- mined by the positioning pin ♦ the positioning pin must be removed on the bottom side when used for vehicles manufactured before 08.99...
  • Page 131 OCTAVIA Rear Suspension Removing and installing coil springs Special tools, testers and aids required ♦ Spring tensioning device, e.g. V.A.G 1752/1 ♦ Spring retainer set, e.g. V.A.G 1752/15 The spring retainer set consists of: ♦ Spring retainer, e.g. V.A.G 1752/15 L. U.
  • Page 132 OCTAVIA Rear Suspension Position spring retainer, e.g. V.A.G 1752/15 L. O. onto the topmost accessible spring coil. Insert the spring tensioning device, e.g. V.A.G 1752/1. Note: Do not use an impact screwdriver or similar for tensioning the coil spring. Turn the shaft of the spring tensioning de-...
  • Page 133 OCTAVIA Rear Suspension nspect spring retainers are positioned at spring just position, necessary. Notes: ♦ Do not use an impact screwdriver or similar for tensioning or coil ♦ It is essential to end t tensioning device once spring coils II - B Edition 11.99...
  • Page 134 OCTAVIA Rear Suspension K Models without stop on bump stop: The start of the spring coil -3- must be in the 9 o’clock (9:00) position. 1 - Coil spring 2 - Bump stop without stop for coil spring F - Direction of travel Notes: ♦...
  • Page 135 OCTAVIA Rear Suspension Removal and installation of the right coil spring is similar to the procedure for the left coil spring ⇒ page 42-35. In place of the special tools ♦ Spring retainer, e.g. V.A.G 1752/15 L. U. (left bottom) ♦...
  • Page 136 OCTAVIA Rear Suspension ------------ ------------ Edition 11.99 S00.5103.57.20...
  • Page 137 OCTAVIA Rear Wheel Suspension Summary of components - trailing arm and suspension arm 1 - Fillister head screw with internal ser- Notes: ration, 40 Nm ♦ Never load the wheel-bearing, if the drive ♦ replace after each removal shaft was removed! ♦...
  • Page 138 OCTAVIA Rear Wheel Suspension 3 - Assembly carrier 6 - Tighten screw 70 Nm and 90° ♦ removing and installing ♦ M 12 x 1.5 x 75 ⇒ page 42-61 ♦ replace after each removal 4 - Drive shaft with inner CV joint 7 - Top suspension arm ♦...
  • Page 139 OCTAVIA Rear Wheel Suspension 10 - Brake carrier with brake caliper 24 - Rubber metal bearing ♦ repairing ⇒ page 46-24 ♦ for trailing arm ♦ removing and installing brake pads ♦ removing and installing ⇒ page 46-26 ⇒ page 42-50...
  • Page 140 OCTAVIA Rear Suspension testers and aids ♦ Gearbox lift with attachment, e.g. V.A.G 1383 A with V.A.G 1359/2 ♦ Foot pump with high-pressure hose, e.g. V.A.G 1389 A/1 (Paschke) ♦ Hydraulic removal and insertion device for wheel bearings, e.g. V.A.G 1459 B (Paschke) with the following individual tools: ♦...
  • Page 141 OCTAVIA Rear Suspension Note: Top bolt attaching brake carrier is concealed. ⇒ Edition 11.99 ------------ ------------ S00.5103.57.20...
  • Page 142 OCTAVIA Rear Suspension Note: Place gearbox lift with attachment below, e.g. V.A.G 1383/A with V.A.G 1359/2 (risk of acci- dent from parts dropping off when wheel hub pressed out). ------------ ------------ Edition 11.99 S00.5103.57.20...
  • Page 143 OCTAVIA Rear Suspension Edition 11.99 ------------ ------------ S00.5103.57.20...
  • Page 144 OCTAVIA Rear Suspension Notes: ♦ Replace circlip each time removed. ♦ When inserting circlip, ensure it is correctly installed. Note: The collar -arrow- of the thrust piece -4- must be pointing toward the special nut -3-. ------------ ------------ Edition 11.99...
  • Page 145 OCTAVIA Rear Wheel Suspension Build up pressure by pumping with the foot pump. Check if all tools are correctly centered, if necessary correct position. Then press in wheel hub by pumping with the foot pump. Further installation occurs in reverse order.
  • Page 146 OCTAVIA Rear Suspension testers and aids ♦ Assembly device MP 5-401 ♦ Assembly device MP 5-402 ♦ Assembly device T10030 ♦ Assembly device T30016 Raise vehicle. Take off wheel. Remove coil spring -1- ⇒ page 42-35. Unbolt bracket for brake line -2- from trailing arm.
  • Page 147 OCTAVIA Rear Suspension ⇒ ⇒ Edition 11.99 ------------ ------------ S00.5103.57.20...
  • Page 148 OCTAVIA Rear Wheel Suspension Removing and installing the guide joint Special tools, testers and aids required ♦ Assembly device MP 5-401 ♦ Assembly device MP 5-402 ♦ Assembly device T10030 ♦ Assembly device T30017 Caution! If the top and bottom guide joint must be replaced, first of all the helical spring must be removed.
  • Page 149 OCTAVIA Rear Wheel Suspension Press down the bottom suspension arm only so far, that the assembly device can be mounted. Position the special tools as shown. ⊳ Pull out the guide joint by turning the spin- dle. Installing bottom guide joint Before positioning, the pressure plate ⊳...
  • Page 150 OCTAVIA Rear Wheel Suspension Removing top guide joint Caution! If the top and bottom guide joint must be replaced, first of all the helical spring must be removed. Raise the vehicle. Remove the wheel. Unscrew screws -A-, remove brake caliper ⊳...
  • Page 151 OCTAVIA Rear Wheel Suspension Press down the extension only so far ⊳ -arrow 1-, that the top suspension arm can be removed upwards -arrow 2-. Note: If the extension is pushed so far downwards, the drive shaft can be damaged.
  • Page 152 OCTAVIA Rear Wheel Suspension Position the special tools as shown. ⊳ Press in the guide joint -1- by turning the spindle until the marking on the pressure plate T10030/1A reaches the support on the trailing arm. Slacken special tools, do not remove.
  • Page 153 OCTAVIA Rear Suspension ⇒ ⇒ Edition 11.99 ------------ ------------ S00.5103.57.20...
  • Page 154 OCTAVIA Rear Suspension Note: Top bolt attaching brake carrier is concealed. ------------ ------------ Edition 11.99 S00.5103.57.20...
  • Page 155 OCTAVIA Rear Suspension Position Notes: ♦ If the trailing arm is replaced, use the exist- ing track control arm. ♦ The installation position of the bearing bracket must then be set as described on page 42-57. installation position to trailing ⇒...
  • Page 156 OCTAVIA Rear Wheel Suspension Tightening torques: Brake carrier with brake calliper to 65 Nm trailing arm Bracket to trailing arm 90 Nm Bracket to body 75 Nm Suspension arm to trailing arm 70 Nm + 90° Use new screws and nuts!
  • Page 157 OCTAVIA Rear Wheel Suspension Fit socket nut with two extensions onto the ⊳ wheel bolt. Press extension slightly upwards -arrow- and pull out screw -2-. 1 - Screw for top suspension arm - do not slacken! 3 - Trailing arm...
  • Page 158 OCTAVIA Rear Wheel Suspension Removing top suspension arm Caution! If the top and bottom suspension arm must be replaced, first of all the helical spring must be removed. Raise the vehicle. Remove the wheel. Unscrew screw -1- from the assembly car- ⊳...
  • Page 159 OCTAVIA Rear Wheel Suspension Press down the extension only so far ⊳ -arrow 1-, that the top suspension arm can be removed upwards -arrow 2-. Note: If the extension is pushed too far downwards, the drive shaft can be damaged.