Page 1 Service Workshop Manual Octavia III 2013 ➤ Octavia III 2014 ➤ Yeti 2010 ➤ Yeti 2011 ➤ 1.6/81 kW MPI engine Engine ID Edition 06.2014 Service Department. Technical Information...
Page 2 Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling...
Page 3: Table Of Contents
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Contents 00 - Technical data ........... .
Page 4 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Pistons and conrods ............
Page 5 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Summary of components - coolant pump/coolant thermostat ..... . 153 Coolant temperature sender - Summary of components .
Page 6 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Intake manifold ............236 Intake manifold - Summary of components .
Page 7: Technical Data
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 00 – Technical data Identification (SRL000704; Edition 06.2014) ⇒ “1.1 Engine number”, page 1 ⇒ “1.2 Engine characteristics”, page 1 Engine number The “engine identification characters”...
Page 8 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Engine identification characters CWVA Firing order 1-3-4-2 At least 91 RON in exceptional cases, although engine output is reduced.
Page 9: Safety Instructions
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 3 ⇒ “2.2 Rules of cleanliness to observe when working on the fuel supply system”, page 4...
Page 10: Rules Of Cleanliness To Observe When Working On The Fuel Supply System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 WARNING The fuel system is under pressure! Place a clean cleaning cloth around the connection point before detaching hose connec‐...
Page 11: General Notes On The Ignition System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ After deleting the fault memory of the engine control unit the readiness code must be re-generated.
Page 12: Safety Precautions When Working On Vehicles With A Start/Stop System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Safety precautions when working on ve‐ hicles with a start/stop system When working on vehicles with start/stop system, please observe...
Page 13: Additional Instructions When Undertaking Assembly Work On The Air-Conditioning System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Caution When undertaking all assembly work, particularly in the engine compartment due to its cramped construction, please observe the following: ♦...
Page 14: Repair Instructions
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 8 ⇒ “3.2 Foreign bodies in the engine”, page 8 ⇒...
Page 15: Assembly Of Radiators And Capacitors
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Assembly of radiators and capacitors The radiator and capacitor may have minor indentations on the fins, even if assembly is correct. This is not a case of damage.
Page 16: Removing And Installing Engine
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Remove - (Octavia III)”, page 10 ⇒...
Page 17 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open cap -arrow- for coolant expansion tank. WARNING Danger of scalding due to hot steam and hot coolant.
Page 18 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Raise the retaining clip -arrow- and remove the top coolant hose from the radiator. – Removing fan shroud ⇒...
Page 19 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew nuts -1- for securing the exhaust pipe to the cylinder head. – Unscrew screws -2- for supporting the exhaust system and strap up the exhaust system.
Page 20 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the upper electrical plug connection -1- from the engine control unit - J623- .
Page 21 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew nut -arrow-, remove and expose electric cable. – Disconnect plug connections -1- and -2-.
Page 22 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Undo screws -1-, -2-, -3- and remove the pendulum support -4-. For models with automatic gearbox –...
Page 23 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw swivel hub -2- right at the track control arm -1- tight using the nut -arrow-, as shown in the illustration.
Page 24: Removing - (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw out gearbox mount screws -arrows- fully. Caution There is a risk of damage from vacuum lines or electric cables.
Page 25 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open cap -arrow- for coolant expansion tank. WARNING Danger of scalding due to hot steam and hot coolant.
Page 26 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Raise the retaining clip -arrow- and remove the top coolant hose from the radiator. – Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
Page 27 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the hose coupling on the fuel feed line -1- ⇒ page 216 – Remove line -2- to the activated charcoal filter from solenoid valve 1 for activated charcoal filter - N80- -1-.
Page 28 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open all locking elements and fastenings for the engine wiring harness at frame side rail -arrows-.
Page 29 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release nut -arrow- on left and right for swivel hub. – Unhook swivel hub from track control arm on left and right for swivel hub.
Page 30 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw out screws -arrows- on engine mount by approximately 2 turns. – Screw out screws -arrows- on gearbox mount by approxi‐...
Page 31: Securing The Engine To The Assembly Stand
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw out engine mount screws -arrows- fully. – Screw out gearbox mount screws -arrows- fully.
Page 32: Installing - (Octavia Iii)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Suspend lifting device - MP9-201 (2024A)- from the engine and workshop crane - VAS 6100- as shown in the illustration.
Page 33 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 For models with automatic gearbox – Replace the needle bearing -arrow- in the crankshaft ⇒ page 67 Continued for all vehicles –...
Page 34 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Note...
Page 35: Installing - (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 After deleting the fault memory of the engine control unit the readiness code must be re-generated.
Page 36 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 For models with automatic gearbox – Replace the needle bearing -arrow- in the crankshaft ⇒ page 67 Continued for all vehicles –...
Page 37 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Note...
Page 38 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Note Only re-use drained coolant if the cylinder head or cylinder ♦ block has not been replaced.
Page 39: Assembly Bracket
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Assembly bracket ⇒ “2.1 Assembly bracket - Summary of components (Octavia III)”, page 33 ⇒ “2.2 Assembly bracket - Summary of components (Yeti)”, page ⇒...
Page 40 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 10 - Screw ❑ replace ❑ 130 Nm + torque a further 90° ( / 4 turn) 11 - Screw ❑...
Page 41: Assembly Bracket - Summary Of Components (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Installation is carried out in the reverse order. Note Replace screws of engine support. – Tighten screws in steps in the given sequence:...
Page 42 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 13 - Pendulum support ❑ removing and installing ⇒ page 36 14 - Screw ❑ replace ❑...
Page 43: Removing And Installing Engine Bracket - (Octavia Ili)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing engine bracket - (Octavia IlI) Special tools and workshop equipment required ♦ Supporting device - T30099- ♦...
Page 44 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Supporting device - T30099- ♦ Surface - T30099/1- ♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)- ♦...
Page 45: Removing And Installing Gearbox Mount
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Connect supporting device - T30099- as shown in the illustra‐ tion. Note On the Yeti, instead of base - T30119- use base - T30099/1- .
Page 46 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screw -1-, unclip upwards -arrows- and push slightly to the side. – Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
Page 47: Checking The Assembly Bracket
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release screws -arrows- and remove gearbox mount -1-. Install Install in the reverse order of removal. When doing this, note the...
Page 48: Adjusting The Unit Mounting
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Adjusting the unit mounting Special tools and workshop equipment required ♦ Supporting device - T30099- ♦ Surface - T30119- ♦...
Page 49 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screws -arrows- for the gearbox mount in sequence, and replace. – Loosely insert new screws.
Page 50: Crankshaft Group
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 13 – Crankshaft group Cylinder block on belt pulley side ⇒ “1.1 V-ribbed belt - Summary of components”, page 44 ⇒...
Page 51 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ❑ mark the direction of ro‐ tation with chalk or a felt-tip pen before removing ❑ do not kink ❑...
Page 52 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1.1.2 Summary of components - Vehicles with air conditioning 1 - V-ribbed belt ❑ check for wear ❑...
Page 53: Removing And Installing V-Ribbed Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 7 - Alternator ❑ removing and installing ⇒ Electrical System; Rep. gr. 27 ❑ depending on the model of the alternator, different separation V-ribbed belt pulleys can be fitted with freewheel -A- and -B-.
Page 54 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing To release the tension of the V-ribbed belt, turn the tensioning device anticlockwise -arrow-. – Lock tensioning device with locking pin - T10060 A- .
Page 55: Removing And Installing Tensioning Device For V-Ribbed Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing To release the tension of the V-ribbed belt, turn the tensioning device anticlockwise -arrow-. – Lock tensioning device with locking pin - T10060 A- .
Page 56: Removing And Installing Ribbed Belt Pulley
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release screws -arrows- and pull off tensioning device -1- for V-ribbed belt. Install Install in the reverse order of removal. When doing this, note the following: –...
Page 57: Removing And Installing Engine Support
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing engine support Special tools and workshop equipment required ♦ Supporting device - T30099- ♦...
Page 58 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the hose coupling on the fuel feed line -1- ⇒ page 216 – Disconnect the hose coupling -2- to the activated charcoal fil‐...
Page 59: Replacing Crankshaft Seal On Belt Pulley Side
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release screws -arrows-. – Release screws -1, 2, 3-. – Unscrew the screws -arrows- from the gearbox mount.
Page 60 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Extractor tool - T20143- Work procedure – Removing toothed belt ⇒ page 102 – Remove crankshaft toothed belt sprocket -1- in -direction of arrow- from the crankshaft.
Page 61 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fit guide bushing -T10485/2- with seal -1- onto crankshaft journal. – Pull sealing ring -2- in to the stop using the thrust piece - T10485/1- and the belt pulley screw -1-.
Page 62: Cylinder Block, Gearbox End
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Cylinder block, gearbox end ⇒ “2.1 Gearbox side cylinder block - Summary of components”, page 56 ⇒...
Page 63: Removing And Installing Flywheel
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Sealing flange on the gearbox side - tightening torque and tight‐ ening order – Tighten screws in steps as follows:...
Page 64 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Depth gauges , e.g. -VAS 6082- ♦ Assembly tool - T10134- ♦ Fixing screw - T10340- ♦...
Page 65 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Turn engine shaft further in direction of arrow so that the screwdriver just out at the top by approx. 35 mm in the -direction of the arrow-.
Page 66 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Note The sealing flange is pressed together with the crankshaft rotor . – To press out, insert 3 screws M6x35 -arrows- into the sealing flange alternately by a maximum of / 2 turns each.
Page 67 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Grip assembly tool - T10134- at clamping surface -A- of the threaded spindle in a vice.
Page 68 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 • Upper edge of sealing lip support ring and front edge of sealing flange must align -arrows-.
Page 69 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Secure the assembly tool - T10134- to the crankshaft flange. Screw hexagon socket head bolts -A- into crankshaft flange (approx.
Page 70 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 E - Inspect the installation position of the rotor on the crankshaft: – Screw nut -E- on until it reaches end of threaded spindle.
Page 71 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw nut -E- onto threaded spindle by hand until it lies against assembly housing -C-.
Page 72 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Tighten nuts of the assembly tool - T10134- to 40 Nm. – Checking sender wheel installation position on crankshaft again ⇒...
Page 73: Crankshaft
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Crankshaft ⇒ “3.1 Measuring axial play of crankshaft”, page 67 ⇒ “3.2 Replace needle bearing for crankshaft”, page 67 Caution There is a risk of bearing pedestal deformation.
Page 74 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing – Remove needle bearing with internal extractor -Kukko 21/2- and countersupport -Kukko 22/1- . Install...
Page 75: Pistons And Conrods
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Pistons and conrods ⇒ “4.1 Piston and conrod - Summary of components”, page 69 ⇒ “4.2 Removing and installing the piston”, page 72 ⇒...
Page 76 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ❑ Mark assignment to the cylinder and to the conrod bearing cap in colour -B- ❑ separate new conrod ⇒...
Page 77 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fitting position of piston and assignment of piston to cylinder Caution Risk of damaging the piston crown.
Page 78: Removing And Installing The Piston
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Oil spray nozzle and pressure relief valve Screw with pressure relief valve, 27 Nm Oil spray nozzle (for cooling piston) •...
Page 79: Checking Piston And Cylinder Bore
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Install piston with commercially available piston ring tension‐ ing strap, check installation position ⇒ page 71 –...
Page 80 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Measure cylinder bore Caution There is risk of damaging the cylinder bore surface. ♦ Do not use normal workshop equipment to work on cylin‐...
Page 81: Cylinder Head, Valve Gear
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 15 – Cylinder head, valve gear Cylinder head ⇒ “1.1 Cylinder head - summary of components”, page 75 ⇒...
Page 82 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1 - Cylinder head gasket ❑ Renew. ⇒ page 80 ❑ check fitting position: Cylinder head part num‐...
Page 83: Camshaft Housing - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Inspecting the cylinder head for distortion – Inspect cylinder head at several points for distortion using a 500 mm knife-edge straightedge - VAS 6075- and feeler gauge.
Page 84: Removing And Installing Camshaft Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ❑ Renew. ⇒ page 120 15 - Toothed belt pulley ❑ For coolant pump drive ❑ removing and installing ⇒...
Page 85 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the plug connections: 2 - For valve 1 for camshaft control - N205- .
Page 86: Removing And Installing The Cylinder Head
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fit gasket onto dowel pins -arrows-. – Screw in 2 threaded bolts -2- and -4-, e.g. -T10288/4- , into the cylinder head.
Page 87 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release fixing screws -1- and -3-. – Remove coolant pipe -2- and place to one side.
Page 88 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect plug connection -2- for coolant temperature send‐ er - G62- -1-. – Release screw -1- on engine support.
Page 89 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Slacken the screws for the cylinder head in the sequence -1…10- and release them. – Remove cylinder head and place it on a clean base (foam).
Page 90: Testing The Compression
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fit on cylinder head gasket -1-. ♦ Pay attention to centring pins in cylinder block -arrows-.
Page 91 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unlock plug-in injection valves -1- and remove. – Unlock and remove plug connections -1- for ignition coils with power output stages and undo screws -2-.
Page 92: Toothed Belt Drive
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Toothed belt drive ⇒ “2.1 Summary of components - toothed belt guard”, page 86 ⇒ “2.2 Timing belt - Summary of components”, page 87 ⇒...
Page 93: Timing Belt - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Timing belt - Summary of components 1 - Toothed belt ❑ mark the direction of ro‐...
Page 94: Test Timing
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Unscrew locking screw “TDC” bore at the cylinder block - tight‐ ening torque Note Locking screw with integrated gasket ring ♦...
Page 95 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screw -arrow- and remove screw cap -1-. Position crankshaft to “TDC”. – Remove ignition coil with power output stage 1 ⇒...
Page 96 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Turn the fixing screw - T10340- up to the stop in the cylinder block and tighten to 30 Nm.
Page 97: Remove The Toothed Belt From The Camshafts
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Insert camshaft clamp -T10477- to stop into camshafts and tighten bolt -arrow- by hand. If camshaft clamp - T10477- cannot be installed: –...
Page 98 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Counterholder - T10172A- with adapters -T10172/1- and - T10172/1- ♦ Fixing screw - T10340- ♦ Key - T10499- ♦...
Page 99 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screw -arrow- and remove screw cap -1-. Position crankshaft to “TDC”. – Remove ignition coil with power output stage 1 ⇒...
Page 100 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Turn the fixing screw - T10340- up to the stop in the cylinder block and tighten to 30 Nm.
Page 101 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Insert camshaft control -T10477- to stop into camshafts and tighten screw -arrow- hand-tight. If camshaft clamp - T10477- cannot be installed:...
Page 102 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release screw -1- using insertion tool - T10500- . – Slacken the tensioning pulley at the eccentric -2- using the wrench - T10499- .
Page 103 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 • The sheet peg -arrow- of the tensioning pulley must engage in the cast iron recess of the cylinder head.
Page 104 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Rotate the eccentric -2- of the tensioning pulley with the wrench - T10499- in -direction of arrow- until the adjustment pointer -3- is located approx.
Page 105 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Pre-tighten screws -1- and -2- to 50 Nm, to do so use the counterholder - T10172A- with adapters -T10172/1- and - T10172/2- .
Page 106 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 • On the inlet camshaft -3- the asymmetrically arranged grooves -1-, on the gearbox side, above the camshaft centre -2-.
Page 107 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Using the assembly tool - T10487- in -direction of arrow- press on the toothed belt.
Page 108: Removing And Installing Toothed Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Tighten locking screw -1- to 20 Nm, to do so, use the coun‐ terholder - T10172A- with the adapter -T10172/1- .
Page 109 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Expose vacuum hose on the holder -3-. – Unscrew screw -2-. – Loosen clips -arrows- and remove toothed belt guard -1- up‐...
Page 110 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Carefully insert a screwdriver into the opening of the ignition plug, minimum length of shaft 250 mm, in -direction of arrow- so that it touches the piston head.
Page 111 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 • The crankshaft sprocket now lies on the fixing screw and the “TCD” position is set.
Page 112 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Using the assembly tool - T10487- in -direction of arrow- press on the toothed belt.
Page 113 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release screw -1- using insertion tool - T10500- . – Slacken the tensioning pulley at the eccentric -2- using the wrench - T10499- .
Page 114 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Replace screws -1- and -2- and insert them loosely. • It must still be possible to turn the camshaft sprockets on the camshafts, however they must not tilt.
Page 115 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Pull toothed belt upwards, place onto the guide pulley -1- and the tensioning pulley -2- and the camshaft sprockets -3- and -4-.
Page 116 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Turn the eccentric -2- of the tensioning pulley with the wrench -T10499- in the -direction of arrow- until the setting pointer -3- is approx.
Page 117 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Pre-tighten screws -1- and -2- to 50 Nm, to do so use the counterholder - T10172A- with adapters -T10172/2- and - T10172/1- .
Page 118 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 • On the inlet camshaft -3- the asymmetrically arranged grooves -1-, on the gearbox side, above the camshaft centre -2-.
Page 119 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Using the assembly tool - T10487- in -direction of arrow- press on the toothed belt.
Page 120 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Tighten locking screw -1- to 20 Nm, to do so, use the coun‐ terholder - T10172A- with the adapter -T10172/1- .
Page 121: Valve Gear
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Valve gear ⇒ “3.1 Valve gear - Summary of components”, page 115 ⇒ “3.2 Measuring axial play of camshaft”, page 116 ⇒...
Page 122: Measuring Axial Play Of Camshaft
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fitting position of the valve spring • The small ∅ -a- points to the valve spring plate.
Page 123: Removing And Installing Gasket Rings For Camshafts
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing gasket rings for camshafts ⇒ “3.4.1 Removing and installing the inlet camshaft on the belt pulley side”, page 117...
Page 124 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Push sealing ring -1- over the receiver tube -T10478/3- onto the guide bushing -T10478/2- .
Page 125 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screw -2- and remove camshaft sprocket. – Remove seal -1- using extractor hook -T20143/1- .
Page 126 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Pull in -T10478/1A- with the screw -T10478/5- to the stop. – Fit the timing belt (set timings) ⇒...
Page 127: Removing And Installing N205 The Camshaft Adjustment Valve
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fit guide bushing -T10479/2- with sealing ring -2- centrally on‐ to the camshaft. – Fix guide bushing with screw -1- for coolant pump driving wheel onto the camshaft.
Page 128 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Spark plug wrench , e.g. -3122 B- ♦ Disassembly and assembly device for valve collets - VAS 5161- with set - VAS 5161A/32- ♦...
Page 129 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Remove valve stem seal with valve shaft pliers , e. g. -VAS 6770- . Caution There is a risk of damage when installing the valve stem seals.
Page 130 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw the guide plate -VAS 5161A/32- back onto the cylinder head. – Insert assembly cartridge -VAS 5161/32-2- with sleeve -VAS 5161/32-3- mounted into the guide plate -VAS 5161A/32- .
Page 131 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw the detent part -VAS 5161/6- with the interlocking fork -VAS 5161/5- into the guide plate -VAS 5161A/32- .
Page 132 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 If the valve collets were removed from the assembly cartridge, first of all they must be inserted into the insertion device for valve collets -VAS 5161/32-3- .
Page 133: Inlet And Exhaust Valves
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Inlet and exhaust valves ⇒ “4.1 Inspect valve guides”, page 127 ⇒ “4.2 Testing valves”, page 127 ⇒...
Page 134: Lubrication
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 17 – Lubrication Lubrication system ⇒ “1.1 Oil sump and oil pump - Summary of components”, page 128 ⇒...
Page 135: Removing And Installing Oil Sump Bottom Part
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 8 - Connector 9 - Baffle 10 - Sump top part ❑ removing and installing ⇒ page 132 11 - Oil filter ❑...
Page 136 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Sealant remover gasket stripper (bearing code GST, bearing article no. R 34402), manufacturer Retech s.r.o.
Page 137 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – At the point identified by an -arrow-, carefully lever out the oil sump bottom part using a screwdriver.
Page 138: Removing And Installing Oil Sump Top Part
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Oil sump bottom part - tightening torque and tightening order – Tighten screws gradually in the given sequence:...
Page 139 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Continued for all vehicles – Loosen the screws in the sequence -19…1- and unscrew them. – Loosing oil sump top part carefully from the bonding.
Page 140 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Apply sealant bead -arrow- onto the clean sealing surface of the oil sump top part, as shown in the illustration.
Page 141: Removing And Installing Oil Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Oil sump top part - tightening torque and tightening order Note Replace screws which have been tightened firmly to a torqueing angle.
Page 142 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew oil pump securing bolts -1- and -2-. – Pull oil pump off dowel pins on cylinder block in a straight line.
Page 143 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Tighten the new fixing screws -1- und -2- in the specified order: Stage Bolts Tightening torque/torqueing angle...
Page 144: Engine Oil Cooler
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Engine oil cooler ⇒ “2.1 Engine oil cooler - Summary of components”, page 138 ⇒ “2.2 Removing and installing engine oil cooler”, page 138...
Page 145 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release screws -arrows- and remove engine oil cooler -1-. Install Install in the reverse order of removal. When doing this, note the following: –...
Page 146: Crankcase Ventilation
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Crankcase ventilation ⇒ “3.1 Crankcase ventilation - Summary of components”, page 140 ⇒ “3.2 Removing and installing oil separator”, page 140...
Page 147 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Loosen the screws in the sequence -9…1- and unscrew them. – Loosen oil separator carefully from the bonding.
Page 148 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Position oil separator and tighten screws. – Tighten screws in the sequence -1 … 9-.
Page 149: Oil Filter, Oil Pressure Switch
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Oil filter, oil pressure switch ⇒ “4.1 Summary of components - oil filter/oil pressure switch”, page 143 ⇒...
Page 150: Testing Oil Pressure And Oil Pressure Switch F1
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing – Separate plug connection -2-. Caution The alternator must be covered with a cloth in order to avoid damage due to spilled engine oil.
Page 151: Removing And Installing Oil Filter Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Screw the oil pressure tester - V.A.G 1342- into the hole for the oil pressure switch on the cylinder head.
Page 152 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Remove oil filter -arrow- with oil filter tool - 3417- . Install Install in the reverse order of removal. When doing this, note the following: –...
Page 153: Cooling
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 19 – Cooling Cooling system, coolant ⇒ “1.1 Connection diagram for coolant hoses”, page 147 ⇒ “1.2 Draining and filling up coolant”, page 148 ⇒...
Page 154: Draining And Filling Up Coolant
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Draining and filling up coolant Special tools and workshop equipment required ♦ Refractometer ♦ Catch pan , e.g. -VAS 6208- ♦...
Page 155 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fill up the coolant reservoir of the -VAS 6096- with at least 10 litres of pre-mixed coolant mixed to the correct ratio: –...
Page 156: Checking The Coolant System For Leaktightness
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fill up coolant up to “Max” marking. – Install the noise insulation ⇒ Body Work; Rep. gr. 66 .
Page 157 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open cap -arrow- for coolant expansion tank. – Position the cooling system testing device - V.A.G 1274- with adapter - V.A.G 1274/8 - on the coolant expansion reservoir.
Page 158 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open cap -arrow- for coolant expansion tank. WARNING Danger of scalding due to hot steam and hot coolant.
Page 159: Coolant Pump, Regulation Of Cooling System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Coolant pump, regulation of cooling system ⇒ “2.1 Summary of components - coolant pump/coolant thermo‐ stat”, page 153 ⇒...
Page 160 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ❑ Observe proper seating of gasket ❑ before installing, slightly moisten with coolant 7 - Toothed belt guard ❑...
Page 161: Coolant Temperature Sender - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Tightening sequence thermostat housing at coolant pump - tight‐ ening torque and tightening sequence Note Self-cutting screws must be positioned by hand in such a way that they find the old thread turn.
Page 162: Removing And Installing Coolant Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1 - Screw ❑ 8 Nm 2 - Support ring 3 - O-ring ❑ replace 4 - Coolant temperature send‐...
Page 163 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Undo screws -2- for coolant pipe -3- and press the pipe to one side. – Expose wiring loom -arrows-.
Page 164 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Ensure proper seating of gaskets -arrows-. – Moisten gasket for coolant pump with coolant. Caution Always adhere to the sequence of work steps given below when installing the coolant pump.
Page 165: Removing And Installing Toothed Belt Pulley For Coolant Pump Drive
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Fit torque wrench e. g. -VAS 6583- with hexagon socket SW10 insert Pos. -6- in hexagon socket head to the coolant pump.
Page 166: Removing And Installing Coolant Regulator
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Set the toothed belt gear for the coolant pump drive onto the camshaft so that the asymmetric grooves -1- and -2- in the camshaft are positioned exactly in the middle of the recesses -arrows- in the toothed belt gear.
Page 167 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Remove thermostat with spanner - T10508- . – Light press the wrench - T10508- down, while doing so, turn in the -direction of the arrow-.
Page 168: Removing And Installing Coolant Temperature Sender G62
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release the screws in the order -F…A-. – Remove coolant pump from coolant pump housing.
Page 169: Removing And Installing Coolant Temperature Sender At Radiator Outlet G83
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Undo screw -1- and remove coolant temperature sender - G62- Pos. -2-. Note If the O-ring -3- with support ring -4- remains in the cylinder ♦...
Page 170 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Separate plug connection -2-. Note Place a cloth below to absorb leaking coolant. – Pull off holding clamp -3- and take coolant temperature sender on radiator outlet - G83- out of connection piece.
Page 171: Parts Of Cooling System Engine Side
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Parts of cooling system engine side ⇒ “3.1 Cooling system attached to engine - Summary of compo‐...
Page 172 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing WARNING Danger of scalding due to hot steam and hot coolant. ♦ When the engine is warm, the cooling system is under overpressure.
Page 173: Radiator And Radiator Fan
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Radiator and radiator fan ⇒ “4.1 Radiator- Summary of components (Octavia III)”, page 167 ⇒ “4.2 Radiator - Summary of components (Yeti)”, page 168 ⇒...
Page 174: Radiator - Summary Of Components (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 8 - Bottom radiator bearing Note The arrows which are on the coolant pipes and the coolant hose ends must stand opposite to each other.
Page 175 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 14 - Radiator fan - V177- ❑ removing and installing ⇒ page 178 15 - Radiator fan - V7- ❑...
Page 176: Fan Shroud With A Radiator Fan - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fan shroud with a radiator fan - Summary of components 1 - Screw ❑ 5 Nm 2 - Fan shroud ❑...
Page 177: Fan Shroud With Two Radiator Fans - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fan shroud with two radiator fans - Summary of components 1 - Screw ❑ 5 Nm 2 - Fan shroud ❑...
Page 178 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Raise the retaining clips -arrow- and remove the top coolant hoses from the radiator. – Press the catches for the top radiator bearing -arrows- at the same time, e.g.
Page 179: Removing And Installing Radiator (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unlock the left and right catches from the cooler -1- arrow -A- and raise the condenser.
Page 180 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Raise the retaining clips -arrow- and remove the top coolant hoses from the radiator. – Remove front bumper ⇒ Body Work; Rep. gr. 63 .
Page 181: Removing And Installing Radiator Cowl For Radiator Fan (Octavia Iii)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screws for radiator bearing -arrows-. – Swivel the radiator slightly backwards. – Strap capacitor to the lock support.
Page 182: Removing And Installing Fan Shroud For Radiator Fan (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing – Disconnect the electrical plug connection -1- for radiator fan, to do so, move the fuse upwards arrow -A- and also press the release buttons upwards.
Page 183: Removing And Installing Radiator Fan V7
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing – Unscrew the bottom securing bolts-arrows- below of the fan shroud. – Remove the sound dampening system ⇒ Body Work; Rep.
Page 184: Removing And Installing Radiator Fan 2 V177
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 4.10 Removing and installing radiator fan 2 - V177- WARNING There is risk of injury from radiator fans starting up automati‐...
Page 185: Fuel Supply System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 20 – Fuel supply system Fuel tank and fuel delivery unit ⇒ “1.1 Fuel tank- Summary of components (Octavia III)”, page 179 ⇒...
Page 186 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1 - Screw cap ❑ screw in until there is an audible click ❑ with securing suspen‐...
Page 187 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ❑ disconnect and connect ⇒ page 216 Earth connection for fuel filler neck – Connect earth connection as shown in the illustration.
Page 188: Fuel Tank - Summary Of Components (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fuel tank - Summary of components (Yeti) 1 - Screw cap ❑ screw in until there is an audible click ❑...
Page 189 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ❑ removing and installing ⇒ page 199 ❑ sprawdzenie pompy paliwa ⇒ page 207 ❑ Fitting position ⇒...
Page 190: Fuel Filter - Summary Of Components (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fuel filter - Summary of components (Yeti) 1 - Fuel filter ❑ with integrated pressure regulator ❑...
Page 191: Extract Fuel From The Fuel Tank
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Pull off fuel hoses -1-, -2- and -3- ⇒ page 216 – Unscrew screw -4-.
Page 192 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew tip -1- from extraction hose of fuel extraction unit - VAS 5190- . – Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐...
Page 193 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Connect the fuel extraction device - VAS 5190- with the adapt‐ er for the fuel extraction - VAS 5190 /3- to the fuel feed line.
Page 194 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Connect adapter - VAS 5565- to fuel delivery unit -1-. – Connect remote control - V.A.G 1348/3A- to adapter - VAS 5565- and to battery positive terminal in engine compart‐...
Page 195 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – In distance -a- from the end of the extraction hose make a marking -arrow- on the hose.
Page 196 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1.5.3 Emptying fuel tank when the fuel pump is damaged when more than / 4 full -...
Page 197: Removing And Installing Fuel Tank- (Octavia Ili)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Push the extraction hose of the fuel extraction device as far into the fuel tank holder as necessary until the previously ap‐...
Page 198 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Protective goggles Caution The fuel tank must be empty for weight reasons when removing it, if necessary suction the fuel out of the fuel tank ⇒...
Page 199 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew the cap -1- for the fuel filler neck. Note Close the opening of the fuel filler neck with a clean cloth so that no dirt can penetrate.
Page 200 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect vent line -3- and fuel line -2- ⇒ page 216 Note Fuel line -1- is not assembled.
Page 201: Removing And Installing Fuel Tank - (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Release fixing screws -2-, -4- and -6-. – Remove retaining nuts for heat shield of fuel tank and remove protection plate.
Page 202 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Caution The fuel tank must be empty for weight reasons when removing it, if necessary suction the fuel out of the fuel tank ⇒...
Page 203 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew screws -1- for fuel filler neck. WARNING Risk of injury caused by fuel which is under high pressure.
Page 204: Fuel Delivery Unit And Sender For Fuel Gauge Display - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Check the fitting position of the earth lead -1-. – With the aid of a second mechanic, pull the filler tube through between the rear axle and bodyshell and support fuel tank with the Engine and gearbox jack - V.A.G 1383A- .
Page 205: Removing And Installing Fuel Delivery Unit
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 6 - Fuel gauge sender - G- ❑ removing and installing ⇒ page 202 Note The fuel delivery unit on the Yeti is also equipped with a fuel re‐...
Page 206 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unlock electrical plug connection -2- from closing flange, and remove. Vehicles Yeti – Unlock electrical plug connection -arrow- from closing flange, and remove.
Page 207 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Pull the fuel delivery unit -2- out of the opening of the fuel tank. – Remove sealing ring -1- from fuel tank opening.
Page 208: Removing And Installing The Sender For Fuel Gauge Display G
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Insert lock ring and tighten using the wrench - T30101 (3087)- . Fitting position of the fuel delivery unit on the Octavia III •...
Page 209: Check Fuel Pump - (Octavia Ili)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unlock the catches -arrows- using a screwdriver and pull out the sender for fuel gauge display - G- towards the top.
Page 210 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the hose coupling on the fuel feed line -1- ⇒ page 216 – Connect pressure tester - VAS 6550- to fuel supply line with adapter - VAS 6550/2- .
Page 211 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 If no fault is found: ♦ Non-return valve in the fuel delivery unit is leaking: – Replace fuel delivery unit ⇒...
Page 212 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Install adapter - VAS 6550/1- and keep in a fuel-resistant measuring vessel. Caution Risk of fuel dripping out.
Page 213: Check Fuel Pump - (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Connect remote control - V.A.G 1348/3A- with adapter line - V.A.G 1348/3-3- and with the line from the measuring tool set - V.A.G 1594/C- to contact -1-.
Page 214 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 ♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g. -V.A.G 1348/3-3 - ♦ Multimeter e. g. -V.A.G 1715- ♦...
Page 215 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open shut-off taps -A- and -B- . – Switch on ignition until bubble-free fuel flows out.
Page 216 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Slowly close the shutoff cock -A-. Note The pressure must rise to at least 0.7 MPa (7.0 bar).
Page 217 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Connect test instrument adapter -VAS 5565- to connector and fuel delivery unit. – Connect the remote control -V.A.G 1348/3A- to the test instru‐...
Page 218 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect fuel feed line -arrow- at fuel filter. – Connect the pressure gauge -VAS 6550- with adapters -VAS 6550/1- and -VAS 6550/2- between the fuel filter and fuel feed line.
Page 219 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Loosen catch pegs -arrows- of the cover -1- with disassembly wedge - 3409- and remove the cover.
Page 220 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the hose coupling on the fuel feed line -1- ⇒ page 216 – Connect pressure tester - VAS 6550- to fuel supply line with adapter - VAS 6550/2- .
Page 221 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Compare fuel quantity delivered with minimum flow quantity in the diagram cm /15s. Note Voltage at the fuel pump when engine is not running and pump is approximately 2 volts less than battery voltage.
Page 222: Quick Couplings
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Quick couplings ⇒ “2.1 Separating quick couplings”, page 216 Separating quick couplings Special tools and workshop equipment required ♦...
Page 223 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 The separation point -1- in the engine compartment must be held. – Insert the lever - T10468- between the heat shield and the stop -arrow- of the fuel feed line -2- and hold it.
Page 224 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Press the push-fit coupling -1- in direction of arrow -A-. – Pull pull-release mechanism -2- in direction of arrow -B-.
Page 225 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Variant 6 Quick coupling with release buttons -arrows- on right and left. – Press push-on coupling -1- in -direction of arrow- and hold pressed.
Page 226: Accelerator Pedal
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Accelerator pedal ⇒ “3.1 Accelerator pedal module- Summary of components (Oc‐ tavia III)”, page 220 ⇒ “3.2 Summary of components - Accelerator pedal module (Ye‐...
Page 227: Summary Of Components - Accelerator Pedal Module (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Summary of components - Accelerator pedal module (Yeti) 1 - Connector 2 - Accelerator pedal module ❑...
Page 228 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect plug connection -2- at the accelerator pedal mod‐ ⇒ page 222 – Release screw -1-.
Page 229: Removing And Installing Accelerator Pedal Module (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Disconnect connector 8K0 973 706 – Pull piston slide valve -A- (red) upwards in direction of arrow -1- up to the stop.
Page 230 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Push the release tool - T10238- (for right-hand drive vehicles release tool - T10240- ) up to the stop into the provided open‐...
Page 231 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Fit on connector 1K0 973 706 – Push the socket housing -B- down in -direction of arrow- until the housing can be heard to lock in place.
Page 232: Activated Charcoal Container System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Activated charcoal container system ⇒ “4.1 Activated charcoal filter- Summary of components (Octavia III) ”, page 226 ⇒...
Page 233: Activated Charcoal Filter - Summary Of Components (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Activated charcoal filter - Summary of components (Yeti) 1 - Activated charcoal filter ❑ Fitting location in right- hand engine compart‐...
Page 234 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Loosen ventilation lines from fasteners on the holder -arrows-. – Release screw -1-. – Pull out catch -3- using a screwdriver and pull the activated charcoal filter -2- down out of the lock -arrow-.
Page 235: Mixture Preparation - Injection
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 24 – Mixture preparation - injection Injection system ⇒ “1.1 Injection system - Fitting location of the injection system”,...
Page 236 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 8 - Throttle valve module - J338- ❑ with throttle valve drive - G186- , throttle valve drive angle sender 1 - G187- and throttle valve drive angle sender 2 - G188- .
Page 237 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 9 - Ignition coils with a power output stage ♦ Ignition coil 1 with output stage - N70- ♦...
Page 238 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1.1.4 Installation location overview - engine from rear 1 - Coolant temperature send‐ er - G62- ❑...
Page 239: Air Filter
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Air filter ⇒ “2.1 Air filter housing- Summary of components (Octavia III)”, page 233 ⇒ “2.2 Summary of components - Air filter housing (Yeti)”, page 234 ⇒...
Page 240: Summary Of Components - Air Filter Housing (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Summary of components - Air filter housing (Yeti) 1 - Air guide lower part ❑ on the lock support 2 - Screw ❑...
Page 241: Removing And Installing Air Filter Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing air filter hous‐ Remove air filter housing – Detach air guide hose -2- from air filter housing.
Page 242: Intake Manifold
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Intake manifold ⇒ “3.1 Intake manifold - Summary of components”, page 236 ⇒ “3.2 Removing and installing intake manifold”, page 237 ⇒...
Page 243: Removing And Installing Intake Manifold
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing intake manifold Removing – Remove air filter housing ⇒ page 235 – Remove noise insulation ⇒ Body; Rep. gr. 66 .
Page 244: Removing And Installing The Throttle Valve Control Unit J338
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Remove electric harness -1- to the brackets -arrows-. – Release screws -arrows-. – Raise intake manifold and remove the wire harness -arrow- from the bottom part of the intake manifold.
Page 245: Clean Throttle Valve Control Unit J338
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Separate plug connection -2-. – Unscrew screws -arrows- and remove throttle valve control unit - J338- -1-.
Page 246 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Thoroughly clean the throttle valve housing using commer‐ cially available Acetone and a paint brush, particularly in the area -arrows- of the closed throttle valve.
Page 247: Injectors
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Injectors ⇒ “4.1 Fuel rail with injection valves - Summary of components”, page 241 ⇒ “4.2 Removing and installing the fuel distributor”, page 242 ⇒...
Page 248: Removing And Installing The Fuel Distributor
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing the fuel distrib‐ utor Removing Caution Risk of malfunctions caused by soiling. ♦ Safety precautions when working on the fuel supply sys‐...
Page 249: Removing And Installing Injection Valves
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Disconnect the hose coupling on the fuel feed line -1- ⇒ page 216 Continued for all vehicles –...
Page 250: Checking Injectors
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Carefully remove retaining clip -6- of injector to be removed. – Pull off injector from fuel rail.
Page 251 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Continued for all vehicles – Unclip the cover -1- using the disassembly wedge - 3409- .
Page 252: Clean Injection Valves
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Connect a contact from the injection valve to be tested on the engine mass using adapter cables from the measuring tool set - V.A.G 1594C- .
Page 253 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Note The ultrasound device must be filled with cleaning agent up to ♦ the top edge of the holes.
Page 254: Senders And Sensors
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Senders and sensors ⇒ “5.1 Removing and installing intake air temperature sender G42 / manifold pressure sender G71 ”, page 248 Removing and installing intake air tem‐...
Page 255: Lambda Probe
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Lambda probe ⇒ “6.1 Lambda probe - Summary of components”, page 249 ⇒ “6.2 Removing and installing lambda probe G39 / G130 ”, page Lambda probe - Summary of compo‐...
Page 256: Removing And Installing Lambda Probe G39 / G130
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1 - Lambda probe after catalyt‐ ic converter - G130- with heat‐ ing for lambda probe 1 after catalytic converter - Z29- ❑...
Page 257 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unscrew respective lambda probe using a spanner from the lambda probe ring spanner set - 3337- .
Page 258: Engine Control Unit
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Engine control unit ⇒ “7.1 Installing and removing engine control unit J623 without protective housing - (Octavia III)”, page 252 ⇒...
Page 259 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing Note If the engine control unit is replaced, the vehicle diagnosis, meas‐ urement and information systems ⇒ Vehicle diagnostic tester must be connected and the “Replace control unit”...
Page 260 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Heat the shear bolt head -1- for approximately 20 to 30 sec‐ onds. Continued for slackened screws –...
Page 261: Installing And Removing Engine Control Unit J623 Without Protective Housing - (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Unlock catch in -direction of the arrow- and remove the engine control unit -1-. – Unlock plug connections for engine control unit - J623- and pull off.
Page 262 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open retaining clip -arrow- and remove engine control unit - J623- . – Unlock plug connections for engine control unit - J623- and pull off.
Page 263 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Open retaining clip -arrow- and remove engine control unit - J623- . – Cut with min-grinder a slot for the screwdriver in the heads of the pull-off screws -3- and -4-.
Page 264 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Heat the shear bolt head -1- for approximately 20 to 30 sec‐ onds. Continued for slackened screws –...
Page 265: Exhaust System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 26 – Exhaust system Removing and installing exhaust sys‐ ⇒ “1.1 Pre-exhaust pipe with catalytic converter - Summary of components”, page 259...
Page 266 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 1 - Clamping sleeve ❑ before tightening, align exhaust system free of stress ⇒ page 267 ❑...
Page 267: Middle Or Rear Part Of The Exhaust System - Summary Of Components (Octavia Iii)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Installation position of front clamp – Install clamping sleeve in the position shown. • Angle -α- = approximately 20°.
Page 268: Middle Or Rear Part Of The Exhaust System - Summary Of Components (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Middle or rear part of the exhaust system - Summary of components (Yeti) 1 - Retaining strap ❑...
Page 269 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Take electrical plug connections -1- and -2- out of the holder and disconnect. – Release the electrical cable from the clips and place down to the side.
Page 270: Removing And Installing Or Replacing The Middle And Rear Silencer - (Octavia Iii)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Loosen the clamping sleeve -arrow- and slide it backwards. Note The decoupling element in the pre-exhaust pipe should not be ♦...
Page 271 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Remove rear tunnel bridge arrows ⇒ Body; Rep. gr. 66 . – Loosen the clamping sleeve -arrow- and slide it forwards.
Page 272: Removing And Installing Or Replacing The Middle And Rear Silencer - (Yeti)
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Installation position of rear clamp – Install clamping sleeve in the position shown. • Angle -α- = approximately 20°.
Page 273: Aligning Exhaust System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Separate exhaust pipe at right angles at the separation point arrow -2- with body saw.
Page 274: Inspecting The Exhaust System For Leaktightness
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Loosen bolted connections on clamping sleeve -arrow-. – Push the rear silencer so far forward until the pre-tensioning on the retaining strap on the exhaust pipe is -a- = 5 mm.
Page 275: Ignition System
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 28 – Ignition system Ignition system ⇒ “1.1 Ignition system - Summary of components”, page 269 ⇒...
Page 276: Removing And Installing Ignition Coils With Output Stage
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 6 - Screw ❑ 8 Nm 7 - Hall sender - G40- ❑ removing and installing ⇒...
Page 277: Removing And Installing Knock Sensor 1 G61
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 – Remove ignition coil with extractor -T10530- in -direction of arrow- out of the camshaft housing.
Page 278: Removing And Installing Engine Speed Sender G28
Octavia III 2013 ➤ , Octavia III 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/81 kW MPI engine - Edition 06.2014 Removing and installing engine speed sender - G28- Special tools and workshop equipment required ♦ Socket insert 4 mm - T10370- Removing –...

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