Page 1 Service Workshop Manual Octavia III 2013 ➤ Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine CJZB CJZA Engine ID Edition 11.2014 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 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Contents 00 - Technical data ........... .
Page 4 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Separating new conrod ........... .
Page 5 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Summary of components - electric coolant pump ....... . 157 Summary of components - coolant temperature sender .
Page 6 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Injection system - Fitting location of the injection system ......234 Air filter .
Page 7: Technical Data
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 00 – Technical data Identification (SRL000738; Edition 11.2014) ⇒ “1.1 Engine number, engine data”, page 1 Engine number, engine data “The engine identification characters” and the “serial number” are located on the sticker -arrow- at the top timing belt guard.
Page 8: Safety Instructions
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 2 ⇒ “2.2 Safety measures for working on vehicles with start/stop system”, page 3...
Page 9: Safety Measures For Working On Vehicles With Start/Stop System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Caution When undertaking all assembly work, particularly in the engine compartment due to its cramped construction, please observe the following: ♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐...
Page 10: Safety Precautions During Road Tests In Which Testing And Measuring Equipment Is Used
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Safety precautions during road tests in which testing and measuring equipment is used Note the following if testers and measuring instruments must be...
Page 11: Safety Precautions When Working On The Injection System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note When the engine is warm, the cooling system is under pres‐ ♦ sure. If necessary, release pressure before beginning repair work. Secure all hose connections with hose clips, allocation ⇒...
Page 12: Safety Precautions When Working On Ignition System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Safety precautions when working on ig‐ nition system WARNING To prevent injuries to persons and/or damage to the injection and ignition system, please observe the following: Do not touch or disconnect ignition cables when the engine is running or being turned at starter speed.
Page 13: Repair Instructions
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 7 ⇒ “3.2 Foreign bodies in the engine”, page 7 ⇒ “3.3 Contact corrosion”, page 7 ⇒...
Page 14: Cable Routing And Securing
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Cable routing and securing ♦ To ensure the original installation position, e.g. lines for fuel, hydraulics, vacuum, activated charcoal filter system lines or electric cables must be marked before removal.
Page 15: General Notes On The Ignition System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Caution In case a mechanical damage to the exhaust gas turbocharger is found, for example, damage to the compressor wheel, it is not sufficient to only replace the turbocharger. In order to avoid consequential damage, perform the following tasks: ♦...
Page 16: Reduce Pressure In The High-Pressure System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Fuel hoses in the engine compartment must only be secured with spring-type clips ⇒ electronic catalogue of original parts“ETKA” . The use of clamp or screw-type clips is not per‐...
Page 17: Removing And Installing Engine
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Removing engine”, page 11 ⇒ “1.2 Securing the engine to the assembly stand”, page 21 ⇒...
Page 18 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Open cap -arrow- for coolant expansion tank. WARNING There is risk of injury due to hot steam and hot coolant. ♦ When the engine is warm, the cooling system is under overpressure.
Page 19 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screw left and right arrow -2-. – Unclip and remove the air guide on the lock carrier. – Raise holding clamp -arrow- and remove top left coolant hose from radiator.
Page 20 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unlock catch -arrow- and remove vacuum hose -1-. – Expose vacuum hose on the air guide pipe -2-. Vehicles without auxiliary heating –...
Page 21 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screws -arrows- and remove holder. Note Collect leaking coolant by placing a cloth under it. – Loosen hose clamp -1- and remove coolant hose.
Page 22 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect the plug electrical plug connection -1- at the en‐ gine control unit - J623- . Note On vehicles with an engine control unit with protective cover, first remove the protective cover ⇒...
Page 23 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew nut -arrow-, remove and expose electric cable. – Disconnect plug connections -1- and -2-. For vehicles with manual gearbox – Remove shift mechanism from gearbox ⇒ Gearbox; Rep. gr.
Page 24 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect electrical plug connection -1- at the oil level and temperature sender - G266- . – Unhook electric cable on the holder -2-.
Page 25 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release nut -arrow- on left and right for swivel hub. – Unscrew the nut -arrow- from the left track control arm - G78- if the front left vehicle level sensor is present.
Page 26 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Position adapter T10497/2 on the housing fin of the cylinder block, as shown in the illustration. – Position engine mount T10497 with bolts T10497/1 at the cyl‐...
Page 27: Securing The Engine To The Assembly Stand
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Screw out gearbox mount screws -arrows- fully. Caution There is a risk of damage from vacuum lines or electric cables. ♦ Check that all vacuum lines and electric cables between engine, gearbox, assembly bracket and body have been loosened.
Page 28: Installing Engine
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Secure engine with bolts -arrows- at engine and gearbox mount - VAS 6095- as shown in the illustration. Installing engine Work procedure Installation is performed in a similar way in the reverse order.
Page 29 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 For models with automatic gearbox – Replace the needle bearing -arrow- in the crankshaft ⇒ “3.3 Replace needle bearing for crankshaft”, page 57 –...
Page 30 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Initially insert screws -arrows- for gearbox mount by hand as far as the stop. Note The screws must not be permanently tightened until the assembly bracket is adjusted ⇒...
Page 31 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Install air filter housing ⇒ “2.2 Removing and installing air filter housing”, page 239 Caution There is a risk of destruction of control units as a result of over‐...
Page 32: Assembly Bracket
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Assembly bracket ⇒ “2.1 Unit mounting - summary of components”, page 26 ⇒ “2.2 Removing and installing engine mount”, page 28 ⇒ “2.3 Removing and installing gearbox mount”, page 28 ⇒...
Page 33 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 12 - Bolt ❑ replace after removal ❑ Tightening torque and tightening order ⇒ page 27 13 - Bolt ❑ replace after removal ❑...
Page 34: Removing And Installing Engine Mount
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing engine mount Special tools and workshop equipment required ♦ Supporting device - T30099- ♦ Surface - T30119- ♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)- ♦...
Page 35 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Surface - T30119- ♦ Hook for MP9-200 and T30099 - MP9-200/10 (10-222A/10)- ♦ Adapter - MP9-200/18 (10-222A/18)- ♦ Support - 10-222A/31-3- ♦ Clutch - T40091/3- Removing –...
Page 36 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Connect support bracket - T30099- together with the other el‐ ements, as shown in the illustration. – Attach spindle snap hook to the engine suspension eye.
Page 37: Check Assembly Bracket Setting
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Check assembly bracket setting Work procedure The following dimensions must be reached: • A distance of -a- = 10 mm must be present between engine support -1- and engine mount -2-.
Page 38 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Connect supporting device - T30099- as shown in the illustra‐ tion. – Attach snap hook to the engine suspension eyes. – Slightly pre-tension engine/gearbox unit with the spindles, do not raise.
Page 39 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Make sure that on the gearbox side the edges of the support‐ ing arm -2- and gearbox support -1- are parallel. •...
Page 40: Crankshaft Group
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 13 – Crankshaft group Cylinder block (pulley end) ⇒ “1.1 V-ribbed belt - Summary of components”, page 34 ⇒ “1.2 Removing and installing poly V-belt”, page 37 ⇒...
Page 41 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 3 - Poly V-belt ❑ check for wear ❑ mark the direction of rotation with chalk or a felt-tip pen before removing ❑ do not kink ❑...
Page 42 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1.1.2 Summary of components - Vehicles with air conditioning 1 - Poly V-belt ❑ check for wear ❑ mark the direction of ro‐...
Page 43: Removing And Installing Poly V-Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 7 - AC generator ❑ 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 44 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 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 45: Removing And Installing Tensioning Device For V-Ribbed Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 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 46: Removing And Installing Ribbed Belt Pulley
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screws -arrows- and pull off tensioning device -1- for V-ribbed belt. Install Installation is performed in a similar way in the reverse order. Pay attention to the following points: –...
Page 47: Removing And Installing Engine Support
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Place V-ribbed belt pulley crankshaft, insert screw with the oiled thread manually until into the system. – Tighten the screw -arrow-; to do so, use the counterholder - T10475- .
Page 48 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screw -1-. – Loosen hose clamp -2- and remove coolant hose. – Unscrew screws -1- and remove the catalytic converter holder -2-.
Page 49 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screws -arrows- at holder for pre-exhaust pipe. – Remove pendulum support ⇒ “2.1 Unit mounting - summary of components”, page 26 –...
Page 50: Renewing Crankshaft Oil Seal - Belt Pulley End
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove bolts -arrows-. – Press engine/gearbox unit slightly to the left and remove en‐ gine support. Install Installation is carried out in the reverse order. When installing, observe the following: –...
Page 51 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Lift out sealing ring using the extractor hook -T20143/2- -arrow-. – Clean the contact and sealing surfaces. Note Do not oil new sealing ring.
Page 52 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Pull sealing ring -2- in to the stop using the thrust piece - T10485/1- and the belt pulley screw -1-. – Fit crankshaft toothed belt pulley onto the crankshaft.
Page 53: Cylinder Block, Gearbox End
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Cylinder block, gearbox end ⇒ “2.1 Gearbox side cylinder block - Summary of components”, page 47 ⇒ “2.2 Removing and installing flywheel”, page 48 ⇒...
Page 54: Removing And Installing Flywheel
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Sealing flange on the gearbox side - tightening torque and tight‐ ening order – Tighten screws in steps as follows: Stage Screws Tightening torque -1 …...
Page 55: Removing And Installing Sealing Flange On Gearbox Side
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing sealing flange on gearbox side Special tools and workshop equipment required ♦ Depth gauges - VAS 6082- ♦ Assembly tool - T10134- ♦...
Page 56 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 57 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note The sealing flange -1- is pressed together with the sensor rotor -2- from the crankshaft -3-. – To press out, insert 3 screws M6x35 -arrows- into the sealing flange -1- alternately by a maximum of / 2 turns each.
Page 58 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Grip assembly device - T10134- on clamping surface -A- of the threaded spindle in a vice -1-. – Push assembly cup -C- down so that it rests on the nut -B- -arrow-.
Page 59 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 • Upper edge of sealing lip support ring -1- and front edge of sealing flange -2- must align -arrows-. – Lay the sealing flange -1- with the front side on the assembly device - T10134- in such a way that the positioning pin -D- engages into the hole -3- of the sensor rotor -2-.
Page 60 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Secure the assembly device - T10134- onto the crankshaft flange -2-. Screw in Allan screws -E- into the crankshaft flange by approx. five thread turns.
Page 61 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 E - Inspect the installation position of the rotor on the crankshaft – Screw nut -B- on until it reaches end of threaded spindle.
Page 62 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Tighten nuts -B- on the assembly device - T10134- to 40 Nm. – Checking sender wheel installation position on crankshaft again ⇒ page 55 –...
Page 63: Crankshaft
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Crankshaft ⇒ “3.1 Crankshaft mass”, page 57 ⇒ “3.2 Measuring axial play of crankshaft”, page 57 ⇒ “3.3 Replace needle bearing for crankshaft”, page 57...
Page 64 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Centering mandrel -T30029 (3176)- ♦ Interior extractor -Kukko 21/2- ♦ Countersupport -Kukko 22/1- Removing – Pull out needle bearing with interior extractor -Kukko 21/2- and countersupport -Kukko 22/1- .
Page 65: Pistons And Conrods
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Pistons and conrods ⇒ “4.1 Assembly overview - piston and conrod”, page 59 ⇒ “4.2 Separating new conrod”, page 61 ⇒ “4.3 Removing and installing the piston”, page 61 ⇒...
Page 66 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 7 - Piston ❑ with combustion chamber ❑ Mark the installation position and the assignment to cylinder ⇒ page 60 ❑ installing and removing ⇒...
Page 67: Separating New Conrod
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Oil spray nozzle and pressure relief valve Screw with pressure relief valve - 27 Nm Oil spray nozzle (for cooling piston) • Fitting position: Align guide edge of the oil spray nozzle -2- to the cylinder block surface.
Page 68 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove cylinder head ⇒ “1.3 Removing and installing cylinder head”, page 69 – Remove oil sump ⇒ “1.2 Removing and installing oil sump”, page 128 , remove baffle.
Page 69: Checking Piston And Cylinder Bore
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Checking piston and cylinder bore Checking piston – Using an external micrometer, measure pistons approx. 10 mm from the lower edge of skirt, at 90° to the piston pin axis.
Page 70: Removing And Installing Oil Injection Nozzles
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Measure cylinder bore Caution There is risk of damaging the cylinder bore surface. ♦ Do not use normal workshop equipment to work on cylin‐...
Page 71 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew relief valve -1- with socket insert - T10545- . – Remove oil spray nozzles -2-. Installing Installation is performed in a similar way in the reverse order. Pay...
Page 72: Cylinder Head, Valve Gear
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 15 – Cylinder head, valve gear Cylinder head ⇒ “1.1 Summary of components - cylinder head”, page 66 ⇒ “1.2 Summary of components - camshaft housing”, page 68 ⇒...
Page 73 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 8 - Bolt ❑ Tightening torque and tightening order ⇒ page 69 9 - Bolt ❑ replace after removal ❑ Loosening order ⇒ page 72 ❑...
Page 74: Summary Of Components - Camshaft Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Summary of components - camshaft housing 1 - Fit pin 2 - Gasket ❑ With oil strainer ❑ inserted into the cylinder head ❑...
Page 75: Removing And Installing Cylinder Head
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 15 - Sealing ring ❑ For exhaust camshaft, gearbox side ❑ Renew ⇒ “3.4.3 Removing and installing the camshaft sealing ring for exhaust camshaft on the gearbox side”,...
Page 76 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove camshaft housing ⇒ “1.4 Removing and installing camshaft housing”, page 73 – Removing the intake manifold ⇒ “3.2 Removing and installing intake manifold”, page 241 –...
Page 77 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Screw out the screws -arrows-, remove oil feed line -1- and oil return pipe -2-. – Disconnect electrical plug connections: 1 - for coolant temperature sender - G62- 2 - For charge pressure regulator - V465- –...
Page 78 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 79: ⇒ "1.4 Removing And Installing Camshaft Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Fit on cylinder head gasket -1-. ♦ Pay attention to centring pins in cylinder block -arrows-. ♦ Check installation position of the cylinder head gasket, identi‐...
Page 80 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove high pressure pipe -3- ⇒ “6.3 Removing and installing high pressure pipe”, page 263 – Separate electrical plug connection -1-. – Loosen hose clamp -2- and disconnect hose.
Page 81 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove connector -arrow- from manifold pressure sender - GX9- . – Disconnect electrical plug connections: 2 - For valve 1 for camshaft control - N205- .
Page 82 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 • Fixing screw - T10340- turned up to the stop in the cylinder block and tightened to 30 Nm. • Crankshaft in engine direction of rotation applied to the fixing screw - T10340- = “TDC”...
Page 83: Checking Compression
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Screw 2 threaded bolts Pos. -2- and -4-, for example , - T10288/4- into the cylinder head. – Carefully place camshaft housing -3- vertically from above on‐...
Page 84 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note Removing fuse interrupts the voltage supply of the fuel pump control unit. – Start engine and allow to run until the engine has cut out.
Page 85: Toothed Belt Drive
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Toothed belt drive ⇒ “2.1 Summary of components - toothed belt guard”, page 79 ⇒ “2.2 Summary of components - toothed belt”, page 80 ⇒...
Page 86: Summary Of Components - Toothed Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Summary of components - toothed belt 1 - Toothed belt ❑ mark the direction of ro‐ tation with chalk or a felt- tip pen before removing ❑...
Page 87: Checking Valve Timing
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 9 - O-ring ❑ replace after removal 10 - Plug ❑ 20 Nm 11 - Idler roller ❑ 45 Nm 12 - Crankshaft - toothed belt sprocket ❑...
Page 88 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Undo hose clamps -arrows-, remove air guide hose -1-. – Disconnect plug -1- at charge pressure sender - GX26- . – Unlock catch pegs -arrows- with unlocking tool - T10527- and release unlocking tool - T10527/1- , remove the air guide pipe -1-.
Page 89 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Expose wiring loom -arrows-. – Unscrew screws -1-, -3- and remove toothed belt guard -2- for coolant pump toothed belt. – Release screws -arrows- and remove cap -1-.
Page 90 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 91 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Insert camshaft clamp -T10494- to stop into camshafts and tighten bolt -arrow- by hand. If camshaft clamp - T10494- cannot be installed:...
Page 92: Remove The Toothed Belt From The Camshaft
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Using the assembly tool - T10487- in -direction of arrow- press on the toothed belt. – At the same time, insert the camshaft clamp -T10494- up to stop into the camshafts and fix with the screw.
Page 93 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Fixing screw - T10340- ♦ Counterholder - T10475- ♦ Key - T10499- ♦ Insertion tool - T10500- ♦ Camshaft clamp - T10494- ♦...
Page 94 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unlock catch pegs -arrows- with unlocking tool - T10527- and release unlocking tool - T10527/1- , remove the air guide pipe -1-.
Page 95 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Expose vacuum hose on the holder -3-. – Unscrew screw -2-. – Loosen clips -arrows- and remove toothed belt guard -1- up‐...
Page 96 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 97 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 • The crankshaft sprocket now lies on the fixing screw and the “TCD” position is set. • On both camshafts the asymmetrically arranged grooves -arrows- on the gearbox side must be above the middle of the camshaft.
Page 98 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Using the assembly tool - T10487- in -direction of arrow- press on the toothed belt. – While doing so, insert camshaft control -T10494- to stop into camshafts and tighten screw -arrow- hand-tight.
Page 99 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screw -1- using insertion tool - T10500- . – Slacken the tensioning pulley at the eccentric -2- using the wrench - T10499- .
Page 100 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 • Sheet peg -arrow- of the tensioning pulley must engage in the cast iron recess of the cylinder head. Observe sequence when fitting the toothed belt.
Page 101 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Rotate the eccentric -2- of the tensioning pulley with the wrench - T10499- in -direction of arrow- until the adjustment pointer -3- is located approx. 10 mm to the right from the ad‐...
Page 102 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Pre-tighten screws -1-, -2- to 50 Nm, to do so, use the coun‐ terholder - T10172- with adapters -T10172/1- and -T10172/2- .
Page 103 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Test timing: – Turn the crankshaft in direction of rotation of engine by 2 turns. – Turn the fixing screw - T10340- up to the stop in the cylinder block and tighten to 30 Nm.
Page 104 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew positioning screw - T10340- . – Unscrew bolt -arrow- and remove camshaft clamp -T10494- . – Pre-tighten screws -1-, -2- to final tightening torque ⇒...
Page 105: Removing And Installing Toothed Belt
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Tighten locking screw -1- to 20 Nm, to do so, use the coun‐ terholder - T10172- with the adapter -T10172/1- . Caution Risk of destruction of the engine.
Page 106 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing – Loosen hose clamps -1-, -2- and remove air guide pipes. – Expose air guide hoses at the air guide pipe. – Undo hose clamps -arrows-, remove air guide hose -1-.
Page 107 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Press release buttons and remove hose -1- to the activated charcoal filter. – Unscrew screws -arrows- and remove hose for crankcase ventilation.
Page 108 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew screws -A...D- and push thermostat cover -1- to the side. Position crankshaft to “TDC” – Remove ignition coil with power output stage 1 ⇒...
Page 109 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Turn the fixing screw - T10340- up to the stop in the cylinder block and tighten to 30 Nm. – Turn crankshaft up to the stop in direction of rotation of engine.
Page 110 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Using the assembly tool - T10487- in -direction of arrow- press on the toothed belt. – While doing so, insert camshaft control -T10494- to stop into camshafts and tighten screw -arrow- hand-tight.
Page 111 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Undo screws -1-, -2- by around one turn, to do so use the counterholder - T10172- with adapters -T10172/2- and - T10172/1- .
Page 112 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 • Fixing screw - T10340- turned up to the stop in the cylinder block and tightened to 30 Nm. • Crankshaft in engine direction of rotation applied to the fixing screw - T10340- = “TDC”...
Page 113 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Observe sequence when fitting the toothed belt. – Pull toothed belt upwards, place onto the guide pulley -1- and the tensioning pulley -2- and the camshaft sprockets -3- and -4-.
Page 114 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Turn the eccentric -2- of the tensioning pulley with the wrench -T10499- in the -direction of arrow- until the setting pointer -3- is approx. 10 mm to the right of the setting window.
Page 115 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Pre-tighten screws -1-, -2- to 50 Nm, to do so, use the coun‐ terholder - T10172- with adapters -T10172/2- and -T10172/1- .
Page 116 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Test timing: – Turn the crankshaft in direction of rotation of engine by 2 turns. – Turn the fixing screw - T10340- up to the stop in the cylinder block and tighten to 30 Nm.
Page 117 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – While doing so, insert camshaft control -T10494- to stop into camshafts and tighten screw -arrow- hand-tight. If it is not possible to insert the camshaft clamp -T10494- , the timing is NOK: –...
Page 118: Remove The Sound Dampening System ⇒ Body Work; Rep
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Tighten locking screw -1- to 20 Nm, to do so, use the coun‐ terholder - T10172- with the adapter -T10172/1- . Caution Risk of destruction of the engine.
Page 119: Valve Gear
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Valve gear ⇒ “3.1 Assembly overview - valve gear”, page 113 ⇒ “3.2 Measuring axial play of camshaft”, page 114 ⇒ “3.3 Removing and installing camshaft control”, page 114 ⇒...
Page 120: Measuring Axial Play Of Camshaft
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 10 - Hydraulic balancing element ❑ Do not interchange ❑ Oil contact surface Fitting position of the valve spring • The small ∅ -a- points to the valve spring plate.
Page 121: Removing And Installing Camshaft Oil Seal
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing camshaft oil seal ⇒ “3.4.1 Removing and installing the camshaft sealing ring on the belt pulley side”, page 115 ⇒ “3.4.2 Removing and installing the camshaft sealing ring for the exhaust camshaft”, page 116...
Page 122 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Push sealing ring -1- over the receiver tube -T10478/3- onto the guide bushing -T10478/2- . • Fitting position: Closed side of sealing ring points to the re‐...
Page 123 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew screw -2- and remove camshaft sprocket. – Remove seal -1- using extractor hook -T20143/1- . Install Note Do not oil new sealing ring.
Page 124 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Pull in -T10478/1A- with the screw -T10478/5- to the stop. – install (set the timing) ⇒ “2.4 Remove the toothed belt from the camshaft”, page 86 3.4.3...
Page 125: Removing And Installing N205 The Camshaft Adjustment Valve 1
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 126 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Spark plug wrench , e.g. -3122 B- ♦ Disassembly and assembly device for valve collets - VAS 5161A- with set - VAS 5161A/32- ♦...
Page 127 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Pull off valve stem seal with valve shaft pliers , for example - VAS 6770- . Caution There is a risk of damage when installing the valve stem seals.
Page 128 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Screw the guide plate -VAS 5161A/32- back onto the cylinder head. – Insert assembly cartridge -VAS 5161A/32-1- with sleeve -VAS 5161A/32-2- into the guide plate.
Page 129 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Screw the detent part -VAS 5161/6- with the interlocking fork -VAS 5161/5- into the guide plate. – Insert assembly cartridge -VAS 5161A/32-1- with sleeve mounted -VAS 5161/32-2- into the guide plate.
Page 130 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 If the valve collets were removed from the assembly cartridge, first of all they must be inserted into the device - VAS 5161A/ 32-3- .
Page 131: Inlet And Exhaust Valves
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Inlet and exhaust valves ⇒ “4.1 Checking valve guides”, page 125 ⇒ “4.2 Testing valves”, page 125 ⇒ “4.3 Valve dimensions”, page 125...
Page 132: Lubrication
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 17 – Lubrication Lubrication system ⇒ “1.1 Oil sump and oil pump - Summary of components”, page 126 ⇒ “1.2 Removing and installing oil sump”, page 128 ⇒...
Page 133 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 page 128 8 - Oil filter ❑ Moisten gasket with oil before installing ❑ In case of damage to the outer skin, the oil filter must be replaced ❑...
Page 134: Removing And Installing Oil Sump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Oil sump - tightening torque and tightening order – Tighten screws in steps in the given sequence: Stage Screws Tightening torque -1 … 19- by hand as far as the stop -1 …...
Page 135 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Continued for all vehicles – Remove securing bolt -arrows- for gearbox. – Disconnect connect for oil level and oil temperature sender - G266- ⇒...
Page 136 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Carefully lever off sump from cylinder block at recess -arrow- using assembly lever. – Remove sump. Loosen sump with light blows of a rubber headed hammer if necessary.
Page 137: Removing And Installing Oil Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Cut off nozzle on tube at front marking (∅ of nozzle approx. 3 mm). – Apply sealant to clean sealing surface of sump as shown.
Page 138 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew securing bolts -arrows- and remove tensioning ele‐ ment. – Remove the generator ⇒ Electrical System; Rep. gr. 27 . – Removing gasket ring for crankshaft on belt pulley side ⇒...
Page 139 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Rotate oil pump gear to a position where 2 opposing notches -arrows- are aligned vertically, as shown in the illustration. – Fit oil pump onto dowel pins.
Page 140: Removing And Installing Oil Level And Oil Temperature Sender G266
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing oil level and oil temperature sender - G266- Removing • Drain engine oil ⇒ Maintenance ; Booklet Octavia III .
Page 141: Engine Oil Cooler
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Engine oil cooler ⇒ “2.1 Summary of components - engine oil cooler”, page 135 ⇒ “2.2 Removing and installing engine oil cooler”, page 135...
Page 142 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screws -arrows- and remove engine oil cooler -1-. Install Installation is carried out in the reverse order. When installing, observe the following: –...
Page 143: Crankcase Ventilation
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Crankcase ventilation ⇒ “3.1 Summary of components - crankcase ventilation”, page 137 ⇒ “3.2 Removing and installing oil separator”, page 137 Summary of components - crankcase ventilation 1 - Hose ❑...
Page 144 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Undo screw -arrow- and place charge air cooler pump - V188- to one side. – Pull off hose -3- for crankcase ventilation.
Page 145 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Insert 2 commercially available pin bolts a few revolutions into the holes -arrows-. Note Pay attention to the use by date on sealant.
Page 146 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release the screws in the order -1...9-. Continued installation is carried out in the reverse order. When installing, note the following: – Install the noise insulation ⇒ Body Work; Rep. gr. 66 .
Page 147: Oil Filter, Oil Pressure Switch
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Oil filter, oil pressure switch ⇒ “4.1 Summary of components - oil filter/oil pressure switch”, page 141 ⇒ “4.2 Removing and installing oil pressure switch for reduced oil pressure F378 ”, page 141...
Page 148: Checking Oil Pressure And Oil Pressure Switch
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing – Pull solenoid valve 1 for activated charcoal filter - N80- -3- off the intake manifold and press downwards slightly. – Separate electrical plug connection -2-.
Page 149: Removing And Installing Oil Filter Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note Mechanical damage such as bearing damage may also be the cause of oil pressure that is too low. If no fault is found: –...
Page 150: Cooling
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 19 – Cooling Cooling system, coolant ⇒ “1.1 Coolant hose schematic diagram”, page 144 ⇒ “1.2 Draining and filling coolant”, page 147 ⇒ “1.3 Checking cooling system for leaks”, page 151 Coolant hose schematic diagram ⇒...
Page 151 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1 - Coolant expansion tank 2 - Screw cap ❑ for coolant expansion tank ❑ Check pressure relief valve ⇒ page 153 3 - Cylinder head and cylinder block ❑...
Page 152 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1.1.2 For vehicles as of 06.2013 Note ♦ Red = small coolant circuit. Blue = large coolant circuit. ♦ Green = charge-air coolant circuit ♦...
Page 153: Draining And Filling Coolant
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 17 - Auxiliary heating ❑ for vehicles with auxiliary heating only Draining and filling coolant Special tools and workshop equipment required ♦ Refractometer ♦...
Page 154 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect electrical plug connection -2- at the coolant tem‐ perature sender at the radiator outlet - G83- -3-. – Raise holding clamp -1-, remove bottom left coolant hose from radiator fan for coolant, allow coolant to drain.
Page 155 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Connect coolant hose bottom right to charge air circuit cooler -2-. Continued for all vehicles – Fill up the coolant -VAS 6096- with at least 10 litres of pre- mixed coolant mixed to the correct ratio ⇒...
Page 156 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Open the valve -B-, while doing so turn the lever in the direction of flow. • Vacuum is generated in the cooling system by the suction jet pump.
Page 157: Checking Cooling System For Leaks
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Check coolant level. • If the engine is cold the coolant level must be between the “Min” and “Max” marking. • When the engine is at operating temperature the coolant level may be at the “Max”...
Page 158 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Position the cooling system testing device - V.A.G 1274- with adapter - V.A.G 1274/8 - on the coolant expansion reservoir. – Using the hand pump of the testing device generate an over‐...
Page 159 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Fit the cooling system testing device - V.A.G 1274 B- with adapter -V.A.G 1274/8- onto the coolant expansion tank. – Using the hand pump of the testing device generate an over‐...
Page 160: Coolant Pump, Regulation Of Cooling System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Coolant pump, regulation of cooling system ⇒ “2.1 Summary of components - coolant pump/coolant thermo‐ stat”, page 154 ⇒ “2.2 Summary of components - electric coolant pump”, page 157 ⇒...
Page 161 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1 - Thermostat housing ❑ installing and removing ⇒ “2.7.2 Removing and installing thermostat for large coolant circuit”, page 167 ❑ Observe tightening se‐...
Page 162 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ❑ installing and removing ⇒ “2.5 Removing and installing toothed belt pulley for coolant pump”, page 162 11 - Bolt ❑ 8 Nm 12 - Bolt ❑...
Page 163: Summary Of Components - Electric Coolant Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Tightening sequence cover for coolant thermostat at the coolant thermostat housing - Tightening torque Note Self-cutting screws must be positioned by hand in such a way that they find the old thread turn.
Page 164: Summary Of Components - Coolant Temperature Sender
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Summary of components - coolant temperature sender 1 - O-ring ❑ replace after removal 2 - Coolant temperature send‐ er at radiator outlet - G83- ❑...
Page 165 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Loosen hose clamps -1-, -2- and remove air guide pipes. – Expose air guide hoses at the air guide pipe. – Undo hose clamps -arrows-, remove air guide hose -1-.
Page 166 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Press release buttons on the hose -1- to pull off the activated charcoal filter. – Unscrew screws -arrows- and remove hose for crankcase ventilation.
Page 167 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 168: Removing And Installing Toothed Belt Pulley For Coolant Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Fit torque wrench, e. g. - VAS 6583- with hexagon socket SW10 insert -Pos. 6- to the coolant pump. – Preload coolant pump with a 10 mm hexagon socket insert -6- with extension and torque wrench e.g.
Page 169: Removing And Installing Electric Coolant Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Loosen screw -1-. Use counterholder - T10172- with adapter -T10172/2- to do so. – Unscrew screw, remove toothed belt pulley-2-. Install Installation is carried out in the reverse order. When installing, observe the following: –...
Page 170: Removing And Installing Thermostat
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing – Open cap -arrow- for coolant expansion tank. WARNING There is risk of injury due to hot steam and hot coolant. ♦ When the engine is warm, the cooling system is under overpressure.
Page 171 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Release tool - T10527/1- Removing – Drain coolant ⇒ “1.2 Draining and filling coolant”, page 147 – Expose air guide hoses at the air guide pipe.
Page 172 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Loosen hose clamp -4- and remove coolant hose -3-. – Screw out screws -arrows- and remove cover -2- from ther‐ mostat housing -1-.
Page 173: Removing And Installing Coolant Temperature Sender G62
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 2.7.2 Removing and installing thermostat for large coolant circuit Removing – Remove coolant pump ⇒ “2.4 Removing and installing coolant pump”, page 158 –...
Page 174: Removing And Installing Coolant Temperature Sender At Radiator Outlet G83
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Briefly open the cap -arrow- for the coolant expansion reser‐ voir in order to remove the remaining pressure in the coolant system, then close until it clicks into place.
Page 175 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Separate electrical plug connection -2-. Note Place a cloth below to catch any leaking coolant. – Pull off holding clamp -3- and take coolant temperature sender on radiator outlet - G83- out of connection piece.
Page 176: Parts Of Cooling System Engine Side
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Parts of cooling system engine side ⇒ “3.1 Summary of components”, page 170 ⇒ “3.2 Removing and installing coolant pipe”, page 170 Summary of components 1 - Coolant hose ❑...
Page 177 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing WARNING Danger of scalding due to hot steam and hot coolant. ♦ When the engine is warm, the cooling system is under overpressure.
Page 178 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Using the screwdriver in the direction of arrow -2- carefully press and at the same time raise the coolant pipe -4- in direc‐...
Page 179: Radiator And Radiator Fan
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Radiator and radiator fan ⇒ “4.1 Radiator version 1 - Summary of components”, page 173 ⇒ “4.2 Radiator version 2 - Summary of components”, page 175 ⇒...
Page 180 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ❑ connect ⇒ page 174 10 - Top radiator bearing ❑ If the fuse latches break, you will not need to replace the top radiator bearing.
Page 181: Radiator Version 2 - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Radiator version 2 - Summary of components 1 - Coolant hose ❑ to remove, raise the holding clamps ❑ connect ⇒ page 176 2 - O-ring ❑...
Page 182: Radiator Version 3 - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note The arrows which are on the coolant pipes and the coolant hose ends must stand opposite to each other. Connect coolant hose with quick coupling –...
Page 183 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 11 - Bottom radiator bearing 12 - O-ring ❑ replace after removal 13 - Coolant hose ❑ to remove, raise holding clamps ❑ connect ⇒...
Page 184: Fan Shroud With A Radiator Fan - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Fan shroud with a radiator fan - Summary of components 1 - Bolt ❑ 5 Nm 2 - Fan shroud ❑ installing and removing ⇒...
Page 185: Fan Shroud With Two Radiator Fans - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Fan shroud with two radiator fans - Summary of components 1 - Bolt ❑ 5 Nm 2 - Fan shroud ❑ installing and removing ⇒...
Page 186 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note Depending on the vehicle version, 3 radiator versions are in‐ ♦ stalled. Coolant radiator and charge air circulation cooler are removed ♦...
Page 187 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Raise holding clamp -arrow- and remove top left coolant hose from radiator. – Press the catches for the top radiator bearing -arrows- at the same time, e..g with screwdrivers, and unclip the bearing on...
Page 188: Removing And Installing Fan Shroud For Radiator Fan
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Press left and right radiator locking lugs simultaneously -arrow- and remove coolant radiator from the charge air circuit radiator. Vehicles with radiator versions 2 and 3: –...
Page 189 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 WARNING There is risk of injury from radiator fans starting up automati‐ cally. ♦ Before carrying out work in the fan shroud area, discon‐...
Page 190: Removing And Installing Radiator Fan V7
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove plug -1- for radiator fan, for this purpose slide screw clamp backwards arrow -A- and press release button down. – Press locking lugs for fan shroud left and right simultaneously -arrow B- and remove fan shroud upwards from the radiator.
Page 191: Removing And Installing Radiator Fan 2 V177
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect electrical plug connections. – Release screws -arrows- and remove radiator fan - V7- . Install Installation is performed in a similar way in the reverse order. Pay attention to the following points: –...
Page 192: Fuel Supply System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 20 – Fuel supply system Fuel tank and fuel delivery unit ⇒ “1.1 Fuel tank - Summary of components”, page 186 ⇒ “1.2 Extract fuel from the fuel tank”, page 189 ⇒...
Page 193 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1 - Screw cap ❑ screw in until there is an audible click ❑ with securing suspen‐ ded to prevent any loss at tank fuel filler flap 2 - Earth connection ❑...
Page 194 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 12 - Mounting bracket ❑ For fuel pump control unit -J538- ❑ Removing and installing fuel pump control unit -J538- ⇒ “1.8 Removing and installing fuel pump control unit J538 ”, page 210 13 - Support ❑...
Page 195: Extract Fuel From The Fuel Tank
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Fitting location of the fuel delivery unit • The marking -2- at the fuel delivery unit closing flange -1- must be located against arrow -3- at the fuel tank.
Page 196 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew tip -1- from extraction hose of fuel extraction unit - VAS 5190- . – Screw fuel extraction adapter - VAS 5190 /2- from fuel extrac‐...
Page 197 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unclip the cover -1- using the removal wedge - 3409- . Vehicles with auxiliary heating – Disconnect the plug connection of the dosing pump - V54- -2-.
Page 198 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1.2.2 Emptying fuel tank when the fuel pump is damaged when more than / 4 full Special tools and workshop equipment required ♦ Fuel extraction device , e. g. -VAS 5190-...
Page 199 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Push the extraction hose of the fuel extraction device as far into the fuel tank holder as necessary until the previously ap‐...
Page 200 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unclip sealing grommet -1- downwards from the cover -2-. – Guide the cover -2- backward at the electric wiring loom -3-. – Unlock electrical plug connection -1- from closing flange, and remove.
Page 201: Removing And Installing The Fuel Tank
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Open locking ring using union nut wrench - T30101 (3087)- . – Carefully lift out fuel delivery unit flange -3-. – Remove gasket -1- and raise the fuel delivery unit flange slightly higher.
Page 202 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing Note Safety precautions when working on the fuel supply system ♦ ⇒ “2.1 Safety precautions when working on fuel supply sys‐ tem”, page 2 Rules of cleanliness when working on the fuel supply system ♦...
Page 203 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 204 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect vent line -3- and fuel line -2- ⇒ “2 Separating push-on couplings”, page 211 Note For vehicles with auxiliary heating, the fuel line -1- for the dosing pump - V54- must also be disconnected ⇒...
Page 205 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release fixing screws -2-, -4- and -6-. – Remove securing nuts for heat shield of fuel tank and remove protection plate. – Slightly lower the fuel tank using the engine and gearbox jack - V.A.G 1383A- .
Page 206: Summary Of Components - Fuel Delivery Unit And Sender For Fuel Gauge Display
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Summary of components - fuel delivery unit and sender for fuel gauge dis‐ play 1 - Fuel delivery unit ❑ with integrated fuel filter,...
Page 207: Fuel Delivery Unit With Sender For Fuel Gauge Display
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Fuel delivery unit with sender for fuel gauge display Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Key - T30101 (3087)- Removing •...
Page 208 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove fuel line -1- from closing flange ⇒ “2 Separating push-on couplings”, page 211 Vehicles with auxiliary heating – Loosen hose clamp, fuel line -2- to the dosing pump for the auxiliary heating from the closing flange.
Page 209 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove sealing ring -1- from fuel tank opening. WARNING Beware of fuel flowing out of the fuel pump that is still full - accident hazard.
Page 210: Removing And Installing The Sender For Fuel Gauge Display G
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Insert lock ring and tighten using the wrench - T30101 (3087)- . – Connect fuel line ⇒ “2 Separating push-on couplings”, page 211 Vehicles with auxiliary heating –...
Page 211: Checking Fuel Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unlock the catch on the uptake clamps -3- and -4-; at the same time, pull the sender for fuel gauge display -G- -2- upwards.
Page 212 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Insert hose line - VAS 6550/1- and keep in the fuel-resistant measuring vessel. Caution Risk of fuel dripping out. ♦ Make sure that the shut-off tap -C- is closed.
Page 213 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Renew fuel delivery unit ⇒ “1.5 Fuel delivery unit with sender for fuel gauge display”, page 201 Assembly is carried out in the reverse order. When installing, ob‐...
Page 214 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove the fuel feed line -2- ⇒ “2 Separating push-on couplings”, page 211 and catch the fuel which flows out with a cleaning cloth.
Page 215 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect plug connection -1- at the closing flange. – 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 216: Removing And Installing Fuel Pump Control Unit J538
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 217: Separating Push-On Couplings
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Separating push-on couplings Special tools and workshop equipment required ♦ Lever - T10468- Note The quick couplings of fuel, vacuum and ventilation lines are ♦...
Page 218 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 The coupling point -1- in the engine compartment must be held. – Insert the lever - T10468- between the heat shield and the stop -arrow- of the fuel line -2- and hold it.
Page 219 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Press the push-fit coupling -1- in direction of arrow -A-. – Pull pull-release mechanism -2- in direction of arrow -B-. – Remove the push-fit coupling -1- from the fuel line -3- in di‐...
Page 220 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 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 221: Accelerator Pedal
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Accelerator pedal ⇒ “3.1 Assembly overview - accelerator module”, page 215 ⇒ “3.2 Removing and installing accelerator module”, page 216 ⇒ “3.3 Disconnect connector for accelerator pedal module and fit on”, page 216...
Page 222: Removing And Installing Accelerator Module
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing accelerator module Removing – Tilt the cover for underbody -1- towards the front in -direction of arrow-. – Disconnect plug connection -2- at the accelerator pedal mod‐...
Page 223 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 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 224: Activated Charcoal Filter System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Activated charcoal filter system ⇒ “4.1 Assembly overview - activated charcoal filter system”, page ⇒ “4.2 Removing and installing activated charcoal filter”, page 218 ⇒...
Page 225: Checking The Fuel Tank Venting
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove the rear right wheelhouse liner ⇒ Body Work; Rep. gr. 66 . – Disconnect the vent lines -1- and -2- on the activated charcoal filter ⇒...
Page 226 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Connect the hand vacuum pump -V.A.S 6213- with adapter - VAS 6550/3-2 - to the vent line as shown. – Put the change-over ring -1- of the hand vacuum pump -V.A.S 6213- in position -A- for vacuum –...
Page 227: Turbocharging/Supercharging
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 21 – Turbocharging/supercharging Exhaust gas turbocharger ⇒ “1.1 Summary of components - exhaust gas turbocharger ”, page 221 ⇒ “1.2 Removing and installing exhaust gas turbocharger”, page 223 ⇒...
Page 228 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 12 - Release handle 13 - Locking clip 14 - Charge pressure regulator - V465- ❑ installing and removing ⇒ “1.3 Removing and installing charge pressure regulator V465 ”, page 227 1.1.2...
Page 229: Removing And Installing Exhaust Gas Turbocharger
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 17 - Bolt ❑ 8 Nm 18 - O-ring ❑ replace after removal ❑ wet with engine oil 19 - Bolt ❑ 9 Nm...
Page 230 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Release screws -1- and remove heat shield for right drive shaft, if present. – Screw out the screws -arrows-, remove oil feed line -1- and oil return pipe -2-.
Page 231 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Undo hose clamps -arrows-, remove air guide hose -1-. – Disconnect plug -1- at charge pressure sender - GX26- . – Unlock catch pegs -arrows- with unlocking tool - T10527- and release unlocking tool - T10527/1- , remove the air guide pipe -1-.
Page 232 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect plug connection -2-. – Release screws -arrows- and remove connection piece -1-. – Loosen hose clamp -2- and remove coolant hose.
Page 233: Removing And Installing Charge Pressure Regulator V465
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Push screwdriver -2- into the recess -arrow- of the exhaust gas turbocharger and lever out the sealing ring -1-. Note Replace gaskets, O-rings and securing nuts for cylinder head.
Page 234: Charge-Air System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Charge-air system ⇒ “2.1 Summary of components - charge air system”, page 228 ⇒ “2.2 Removing and installing charge pressure sender GX26 ”, page 229 ⇒...
Page 235: Removing And Installing Charge Pressure Sender Gx26
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 11 - Intake manifold pressure sender - GX9- ❑ comprises: Intake air temperature sender 2 - G299- Intake manifold pressure sender - G71- ❑...
Page 236: Removing And Installing Charge Air Cooler
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Intake air temperature transmitter - G42- Removing – Separate electrical plug connection -1-. – Release catches -arrows- and remove the charge pressure sender - GX26- .
Page 237 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Open the clamp -1- and push hose -arrow- to the side. – Loosen hose clamps -1- and remove coolant hoses. – Release screws -arrows- and remove charge air cooler.
Page 238: Checking The Charge-Air System For Leak Tightness
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Tighten screws -arrows- from centre to outside crosswise. – Attach hose clamps -1-. Note When there is light pressure on the fins ⇒...
Page 239 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Prepare tester for charge air system - V.A.G 1687- as follows: – Unscrew pressure control valve -2- fully and close the valves -3- and -4-.
Page 240: Mixture Preparation - Injection
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 24 – Mixture preparation - injection Injection system ⇒ “1.1 Injection system - Fitting location of the injection system”, page 234 Injection system - Fitting location of the injection system ⇒...
Page 241 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 5 - Engine control unit - J623- ❑ installing and removing ⇒ “8 Engine control unit”, page 268 6 - Coolant temperature sender at radiator outlet - G83- ❑...
Page 242 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1.1.2 Installation overview - engine from front 1 - Knock sensor 1 - G61- ❑ Summary of compo‐ nents ⇒ “1.1 Assembly over‐...
Page 243 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 1.1.3 Installation overview - engine from rear 1 - Oil level and oil temperature sender - G266- ❑ installing and removing ⇒ “1.4 Removing and in‐...
Page 244: Air Filter
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Air filter ⇒ “2.1 Assembly overview - air filter housing”, page 238 ⇒ “2.2 Removing and installing air filter housing”, page 239 Assembly overview - air filter housing 1 - Air guide lower part ❑...
Page 245: Removing And Installing Air Filter Housing
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing air filter hous‐ Removing – Pull off air guide hose -2-. – Pull off -1- air filter housing upwards from the ball pin.
Page 246: Intake Manifold
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Intake manifold ⇒ “3.1 Assembly overview - intake manifold”, page 240 ⇒ “3.2 Removing and installing intake manifold”, page 241 ⇒ “3.3 Removing and installing the throttle valve control unit GX3 ”, page 244...
Page 247: Removing And Installing Intake Manifold
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 10 - Inlet connections 11 - O-ring ❑ replace after removal 12 - Air guide pipe 13 - O-ring ❑ replace after removal 14 - Bolt ❑...
Page 248 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ♦ Release tool - T10527- ♦ Release tool - T10527/1- Removing – Remove air filter housing ⇒ “2.2 Removing and installing air filter housing”, page 239 –...
Page 249 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Undo hose clamps -arrows-, remove air guide hose -1-. – Disconnect plug -1- at charge pressure sender - GX26- . – Unlock catch pegs -arrows- with unlocking tool - T10527- and release unlocking tool - T10527/1- , remove the air guide pipe -1-.
Page 250: Removing And Installing The Throttle Valve Control Unit Gx3
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Disconnect electrical plug connections: 1 - For solenoid valve 1 for activated charcoal filter - N80- 3 - for throttle valve control unit - GX3- 4 - Intake manifold pressure sender - GX9- –...
Page 251 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Special tools and workshop equipment required ♦ Release tool - T10527- ♦ Release tool - T10527/1- Removing – Expose air guide hoses at the charge air pipe.
Page 252: Clean Throttle Valve Control Unit Gx3
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Separate electrical plug connection -3-. – Unscrew the screws -arrows- and remove throttle valve control unit - GX3- -1- with adapter -2-.
Page 253 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – 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 254: Injectors
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Injectors ⇒ “4.1 Assembly overview - fuel rail with injectors”, page 248 ⇒ “4.2 Removing and installing the fuel distributor”, page 249 ⇒ “4.3 Removing and installing injectors”, page 250 ⇒...
Page 255: Removing And Installing The Fuel Distributor
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 6 - O-ring ❑ replace after removal ❑ Moisten with engine oil 7 - Distance ring ❑ replace if damaged 8 - Injector ❑...
Page 256: Removing And Installing Injectors
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Separate electrical plug connection -1-. Note Place a cloth below to absorb leaking fuel. – Release the screws -arrows- and disconnect the fuel distribu‐...
Page 257 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove fuel distributor ⇒ “4.2 Removing and installing the fuel distributor”, page 249 – Remove O-ring -4- from injector -2-. – Disconnect the electrical plug connections from affected in‐...
Page 258 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Gently apply a few knocks to the impact sleeve to loosen the injector. Note Use a torque wrench to pull out the injector.
Page 259 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Install – Clean hole in the cylinder head using a nylon cylinder brush - T10133/4- . Note Replace combustion chamber sealing ring and O-ring.
Page 260 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Note When sliding on the injector the combustion chamber sealing ring is widened. It must therefore be reduced in width again in two steps, as described below.
Page 261: Clean Injection Valves
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Pull support ring -5- and distance ring -3- onto the injector -2-. – Before installing injector -2-, moisten new O-ring -4- with clean engine oil.
Page 262 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Remove injection valves ⇒ “4.3 Removing and installing injectors”, page 250 – Insert injectors -1- into the feeder plate for injection units - VAS 6418/1- Pos.
Page 263: Senders And Sensors
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Senders and sensors ⇒ “5.1 Removing and installing intake manifold pressure sender GX9 ”, page 257 ⇒ “5.2 Removing and installing fuel pressure sender G247 ”, page ⇒...
Page 264: Check Fuel Pressure Sender G247
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing – Separate electrical plug connection -1-. Note Place a cloth below to absorb leaking fuel. – Undo the fuel pressure sender - G247- -2- with the Polydrive socket width across flats 27 - T40218- .
Page 265 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Moisten the sealing cone of the adapter -VAS 6394/3- with clean engine oil and screw it into the fuel distributor with 22 Nm.
Page 266 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Switch on the tester -VAS 6394/1- , for this step, briefly press the button -A-. Note If the button -A- is pressed for 2 seconds, the illumination is ♦...
Page 267: High Pressure Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 High pressure pump ⇒ “6.1 Summary of components - high pressure pump”, page 261 ⇒ “6.2 Removing and installing the high pressure pump”, page 262 ⇒...
Page 268: Removing And Installing The High Pressure Pump
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing the high pres‐ sure pump Removing • Engine cold. WARNING Risk of injury caused by fuel which is under high pressure.
Page 269: Removing And Installing High Pressure Pipe
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Insert the oiled roller tappet -1- into the camshaft housing. Note Renew O-ring. – Turn crankshaft in direction of engine rotation until the roller tappet is at the lowest point.
Page 270 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Caution Risk of malfunctions caused by soiling. ♦ ⇒ “3.1 Rules of cleanliness”, page 7 Note Place a cloth below to absorb leaking fuel.
Page 271: Lambda Probe
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Lambda probe ⇒ “7.1 Summary of components - lambda probe”, page 265 ⇒ “7.2 Removing and installing lambda probe GX10 / GX7 ”, page...
Page 272: Removing And Installing Lambda Probe Gx10 / Gx7
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 GX10 / GX7 ”, page 266 ❑ 55 Nm Removing and installing lambda probe - GX10- / -GX7- The Lambda probe 1 in front of catalytic converter - GX10- com‐...
Page 273 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew respective lambda probe using a spanner from the lambda probe ring spanner set - 3337- . Lambda probe 1 after catalytic converter - GX7-...
Page 274: Engine Control Unit
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Engine control unit ⇒ “8.1 Removing and installing engine control unit J623 without protective housing”, page 268 ⇒ “8.2 Removing and installing engine control unit J623 , engine control unit with protective housing”, page 268...
Page 275 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing Note If the engine control unit is replaced, the vehicle diagnosis tester must be connected ⇒ Vehicle diagnostic tester and the function “replace engine control unit”...
Page 276 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Heat the shear bolt head -1- for approximately 20 to 30 sec‐ onds. Continued for slackened screws: – Release shear bolt -1- using the screwdriver -2-.
Page 277 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unlock the 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 278: Exhaust System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 26 – Exhaust system Removing and installing exhaust sys‐ ⇒ “1.1 Catalytic converter and component parts - Summary of components”, page 272 ⇒ “1.2 Middle and rear silencer - Summary of components”, page ⇒...
Page 279 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 ❑ Do not damage wire mesh on decoupling element ❑ protect catalytic converter against shocks and blows ❑ installing and removing ⇒ “1.3 Removing and installing catalytic converter with pre-exhaust pipe”, page 275 ❑...
Page 280: Middle And Rear Silencer - Summary Of Components
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Middle and rear silencer - Summary of components 1 - Retaining strap ❑ replace if damaged 2 - Hanger ❑ replace if damaged 3 - Rear silencer ❑...
Page 281: Removing And Installing Catalytic Converter With Pre-Exhaust Pipe
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Installation position of rear clamp – Install clamping sleeve in the position shown. • Angle -α- = approximately 20°. • Nuts upwards. •...
Page 282 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Unscrew screw -2- and remove screw clamp. – Unscrew screws -1- and nuts -arrows-. – Release screws -arrows- of the holder. – Remove the tunnel bridge ⇒ Body Work - Assembly work;...
Page 283: Removing And Installing Or Replacing The Middle And Rear Silencer
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Loosen the clamping sleeve -arrow- and slide it backwards. – Remove catalytic converter backwards. Note The decoupling element in the pre-exhaust pipe should not be ♦...
Page 284 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – When present, remove the underbody rear left trim panel ⇒ Body Work- Assembly work; Rep. gr. 66 . – Remove the rear tunnel bridge ⇒ Body Work - Assembly work;...
Page 285: Aligning Exhaust System Free Of Stress
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Position clamping sleeve centrally to the side markers during installation -arrows-. – Install rear clamping sleeve ⇒ page 275 – Installing front clamping sleeve ⇒...
Page 286: Inspecting The Exhaust System For Leak Tightness
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Inspecting the exhaust system for leak tightness Work procedure – Start engine and run at idling speed. – Close off exhaust tailpipes for the duration of the leak test, using cloths or plugs.
Page 287: Ignition System
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 28 – Ignition system Ignition system ⇒ “1.1 Assembly overview - ignition system”, page 281 ⇒ “1.2 Removing and installing ignition coils with output stage”, page 282 ⇒...
Page 288: Removing And Installing Ignition Coils With Output Stage
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 7 - Hall sender - G40- ❑ installing and removing ⇒ “1.4 Removing and installing Hall sender G40 ”, page 284 8 - O-ring 9 - Rotor ❑...
Page 289: Removing And Installing Knock Sensor 1 G61
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Press extractor -T10530- into the bore of the ignition coil -1- as far as the stop. – Tighten nuts -2- in -direction of arrow-.
Page 290: Removing And Installing Hall Sender G40
Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 Removing and installing Hall sender - G40- Removing – Loosen hose clamps -1- and -2- and remove air guide pipes. – Separate electrical plug connection -1-.
Page 291 Octavia III 2013 ➤ , Octavia III 2014 ➤ 1.2/63; 77 kW TSI engine - Edition 11.2014 – Separate electrical plug connection -1-. – Unscrew screw -2- and pull out engine speed sender - G28- . Install Caution Carefully insert engine speed sender - G28- into the bore.

This manual is also suitable for:

Octavia iii 2014

Skoda Octavia III 2013 Workshop Manual

Table of Contents

Technical Data

Removing and Installing Engine

Crankshaft Group

Cylinder Head, Valve Gear

2.4 Remove the Toothed Belt from the Cam- Shaft

Lubrication

Cooling

2 Coolant Pump, Regulation of Cooling System

Fuel Supply System

Turbocharging/Supercharging

Mixture Preparation - Injection

Exhaust System

Ignition System

Quick Links

Chapters

Need help?

Questions and answers

Related Manuals for Skoda Octavia III 2013

Summary of Contents for Skoda Octavia III 2013

This manual is also suitable for:

Table of Contents