OCTAVIA Service Contents Technical Data Page Identification of gearbox ......................00-1 Code letters, component assignment, transmission ratios, capacities ........00-2 Overview of power flow ......................00-3 Notes on brake and performance test and on towing vehicle ..........00-4 General repair information ......................
OCTAVIA Technical Data Identification of gearbox Assignment ⇒ page 00-2. K Location on gearbox Code letters and date of manufacture (arrow 1) Manual gearbox 02C 4WD (arrow 2) K Manual gearbox 02C 4WD (arrow 2) K Code letters and date of manufacture of gear-...
OCTAVIA Technical Data Notes on brake and performance test and on towing vehicle Brake test on roller dynamometer ♦ Use only dynamometers designed for 4WD vehicles. ♦ If a dynamometer for a 2WD vehicle is used, 1 to 2 brake tests can be performed with the ignition switched on and the engine not run- ning.
OCTAVIA Self-Diagnosis/Electrical Test Testing operation of Haldex coupling Drive the front wheels of the vehicle onto a roller dynamometer. Warning! Keep area in front of the vehicle clear. Proceed with appropriate care when conducting the test in or- der to avoid any damage.
OCTAVIA Self-Diagnosis/Electrical Test Self-diagnosis Function The central component of the four-wheel drive is the electronically-hydraulically controlled Haldex coupling. Advantages: ♦ stepless distribution of force between front and rear wheels ♦ short response time of the Haldex coupling ♦ individual adaptation of the four-wheel drive...
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OCTAVIA Self-Diagnosis/Electrical Test Function of 4x4 control unit In view of the interlinked control units with two databus lines, always first of all interrogate the contents of all the fault memories of the control units fitted to the vehicle when beginning fault finding.
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OCTAVIA Self-Diagnosis/Electrical Test Performing self-diagnosis Note: The description which follows relates only to models fitted with the new control unit genera- tion (from 10.99) ⇒ page 01-2. Connecting vehicle system tester V.A.G 1552 and selecting functions Test requirements l Haldex coupling operating properly; testing ⇒...
→ OCTAVIA Self-Diagnosis/Electrical Test Select the 4WD control unit with the address word 22 and confirm the entry with the key 02D900554B HALDEX LSC ECC 0006 K The following readout then appears in the dis- play (example): What is displayed is: ♦...
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OCTAVIA Self-Diagnosis/Electrical Test ⇒ Final control diagnosis - → K Readout in display: 4WD coupling separated Apply handbrake. Depress the clutch pedal and engage 1st gear. Drive off slowly; only the front wheels should rotate when this is done. If a variation exists:...
OCTAVIA Self-Diagnosis/Electrical Test Reading measured value block The control unit is able to transmit a wide range of measured values. These measured values supply information regarding the operating state of the system or of the sensors connected. In many cases, the measured values transmitted can be used as an aid in fault finding and in rectifying faults.
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OCTAVIA Self-Diagnosis/Electrical Test Measured value block 001 Read measured value block 1 → not op. not op. K Readout in display: not assigned not assigned Handbrake indicator switch ♦ not op. → handbrake not applied ♦ oper. → handbrake applied If a variation exists: perform electrical test ⇒...
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OCTAVIA Self-Diagnosis/Electrical Test Test step 1 What is tested is the supply voltage of the con- trol unit -J492-. Set a measuring range of 20 V. Switch ignition on. Measure between contact 1 and contact 2 (earth) at the unplugged connector.
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OCTAVIA Self-Diagnosis/Electrical Test If the readouts are less than 300 Ω or ∞ Ω: Repair wiring according to current flow dia- gram. ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder Notes: ♦ If readout is < 300 Ω there is a short circuit to earth.
OCTAVIA Shift Mechanism/Housing Servicing shift mechanism Fitting location of shift mechanism A - Shift cable for shift movement B - Selector cable for selector movement C - Heat shield ♦ Take off before removing the shift mechanism. Arrow -A- Shift movement...
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OCTAVIA Shift Mechanism/Housing I - Assembly overview - gearshift knob Removing and installing shift mechanism and cover ⇒ page 34-3 ⇒ from page 34-10. ¡ ¢ £ II - Assembly overview - gearshift lever Setting shift mechanism ⇒ page 34-13.
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OCTAVIA Shift Mechanism/Housing Take off bracket -1- above the exhaust sys- tem -arrows-. Separate exhaust system at the double clamp -2- and remove together with catalytic converter (2nd person required). ⇒ Repair Group 26; Removing and installing parts of the exhaust system.
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⇒ OCTAVIA Shift Mechanism/Housing ⇒ K ♦ If the gearbox has been replaced, always fit ⇒ the existing speedometer sender. ⇒ ♦ If the gearbox has been replaced, ensure that the intermediate plate is correctly located. ♦ Check whether dowel sleeves for centering engine/gearbox are present in the cylinder block;...
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OCTAVIA Shift Mechanism/Housing K Fitting location of 5th speed gear The groove all round (arrow) points toward the gearbox housing. Knocking on 5th speed gear. Inspecting 5th speed synchronizer ring Before re-installing selector gear and synchronizer ring of 5th speed, press...
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OCTAVIA Shift Mechanism/Housing K Fitting location of dished washers for secur- ing bolts The outer diameter (concave side -arrows-) points toward 5th gear. Engage 2 gears before tightening the bolts attaching 5th gear synchroniser body and sliding gear (arrows) ⇒ page 34-38, Fig.
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OCTAVIA Shift Mechanism/Housing 13 - Guide sleeve with O-ring ♦ O-ring attached to guide sleeve. If da- maged, replace guide sleeve ♦ With seal ♦ Knocking out seal Fig. 3 ♦ Knocking in seal Fig. 4 ♦ Remove guide sleeve in order to re-...
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OCTAVIA Gears/Shafts Disassembling and assembling input shaft ⇒ ⇒ Notes: ♦ Pay attention to technical data when install- ing new gears page 00-2. ♦ Disassembling and assembling input shaft: 5-Speed Manual Gearbox 02J; Repair Group 35; Disassembling and assembling input shaft Edition 11.99...
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OCTAVIA Gears/Shafts Disassembling and assembling output shaft (drive pinion) ♦ Disassembling and assembling output shaft: Notes: 5-Speed Manual Gearbox 02J; Repair ♦ Pay attention to the technical data when in- Group 35; Disassembling and assembling stalling new gears or a new output shaft output shaft page 00-2.
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OCTAVIA Final Drive/Differential Replacing seals for flange shafts (gearbox installed) Pay attention to the general repair informa- tion ⇒ page 00-5. Replacing seal for left flange shaft Special tools, testers and aids required ♦ Assembly device MP 9-501 ♦ Extraction hook MP 3-419/37 ♦...
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OCTAVIA Final Drive/Differential Installing Installation is performed in the reverse order; pay attention to the following points: Knock in new seal as far as the stop; do not twist seal during this step. Pack space between sealing lip and dust lip half-full with grease G 052 128 A1.
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OCTAVIA Final Drive/Differential Place drip tray below. Disconnect oil return-flow line for turbo- charger from engine -arrow-. ⇒ 1.9-ltr./66 kW (TDI) Engine, Mechanical Components; Repair Group 21; Charge air system for turbocharger Use V.A.G 1669 or commercially available 6 mm wrench socket to remove screw for joint flange of right output shaft.
OCTAVIA Final Drive/Differential Disassembling and assembling bevel box Assembly overview Removal and installation sequence ⇒ page 1 - End cap 39-17 ♦ Is destroyed when removed ♦ Always replace If these parts are replaced, it is necessary to carry out setting operations ⇒ page 39-17.
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OCTAVIA Final Drive/Differential 4 - Conical bolt, 25 Nm 17 - Head bevel gear with input shaft ♦ For output shaft (item 8) or for flange ♦ Is matched with the shaft bevel gear shaft (item 5), respectively, to the dif-...
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OCTAVIA Final Drive/Differential K Now, install the assembly device T10047 as fol- lows: Position the two parts of the device so that the markings A are pointing toward each other. The shoulders (arrows) must be positioned below the bearing. Now, bolt together the two halves as far as the stop.
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OCTAVIA Final Drive/Differential Recommended sequence for re- setting drive pinion set If it is necessary to set the shaft bevel gear and head bevel gear, observe the following sequence to ensure a rational workflow: 1. Setting shaft bevel gear (S and S Determine thickness of shim S...
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OCTAVIA Final Drive/Differential Re-determining shim S when re- placing output flange This setting is only necessary if the output flange is replaced. The purpose of the setting is to cre- ate the preload of the taper roller bearings for the shaft bevel gear.
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OCTAVIA Final Drive/Differential Insert shaft bevel gear. Insert inner race of small taper roller bear- ing and output flange and fit on hexagon nut. A - Screw in M 10 hexagon bolt as a counter- support. B - Wrench socket Tighten hexagon nut to 20 Nm, turn back hexagon bolt -A- or turn out fully.
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OCTAVIA Final Drive/Differential Remove drive pinion housing together with shaft bevel gear. Install calculated size of shim S Performing inspection measurement - in- specting dimension R Insert universal gauge and measure dimension R. If the correct sized of shims have been selected, the dial gauge must indicate the figure of the variation r...
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OCTAVIA Final Drive/Differential Setting preload of taper roller bearings for head bevel gear (friction torque) The shaft bevel gear is removed. Insert an 1.2 mm shim (Part No. 113 517 211 A) into the seat of the outer race for the small taper roller bearing (S side).
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OCTAVIA Final Drive/Differential Determining thickness of shim S (setting torsional backlash) Drive pinion housing together with shaft bevel gear and S installed. Head bevel gear of input shaft installed on the side with S (example: 1.85 mm). Friction tot. torques for bearings of head bevel gear of input shaft and shaft bevel gear must be correct.
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OCTAVIA Final Drive/Differential Determining thickness of shim S = Shim inserted (S tot. Average torsional backlash + Lift (constant figure) Lift = 0.20 mm Example: Shim inserted (S 1.85 mm tot. Average torsional backlash 1.25 mm 0.60 mm + Lift (constant figure) 0.20 mm...
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OCTAVIA Final Drive/Differential Take pendulum support off the subframe (arrows - A -). Carefully push engine/gearbox forward and at the same time move the pendulum sup- port up in front of the subframe -arrow-. Secure the pendulum support to the sub- frame with bolt -1- (M8x80 mm) and nut -2-.
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OCTAVIA Final Drive/Differential Notes: If rumbling noises occur when driving, it is then necessary to carry out the following steps: ♦ Unbolt propshaft with flexible joint from flange of Haldex clutch and bolt on again re-posi- tioned by one hole.
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¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § OCTAVIA Final Drive/Differential Lightly oil outer diameter of new seal and between the sealing lips with high-perform- ance oil for the Haldex coupling G 052 175 A1 before installing. Knock in the new seal until flush.
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OCTAVIA Final Drive/Differential ¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § If the final drive is to be replaced or clamped in the repair stand, the cross member -A- must be unscrewed. Installation is carried out in the reverse order.
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