Page 1 Service Workshop Manual Octavia II 2004 ➤ Octavia II 2010 ➤ Brake systems Edition 11.2017 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
Page 2 Service List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 45 - Anti-lock brake system 46 - Brakes - mechanism 47 - Brakes - hydraulics Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety.
Page 3: Table Of Contents
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Contents 00 - Technical data ........... .
Page 4 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Disconnecting control unit from hydraulic unit - Left-hand drive ..... .
Page 5 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Setting, removing and installing the brake light switch F and brake pedal switch F47 up to MY 10.2005 ............149 Removing and installing brake light switch F and brake pedal switch F47 as of 11/2005 .
Page 6 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability with respect to the correctness of information in this document.
Page 7: Technical Data
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 00 – Technical data Brakes (SRL001140; Edition 11.2017) Brake variants and their assignment ⇒ page 1 Brake fluid ⇒ page 8 Brake inspection ⇒ page 8...
Page 8 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 valid for vehicles as of 04.2009 Engine 1.6 l/75 kW 1.6 ltr./85 1,8 ltr./112 kW TFSI kW FSI Engine code letters: BGU, BSE, BSF, CCSA, CHGA,...
Page 9 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Engine 1,8 ltr./118 kW TFSI 2.0 ltr./110 2.0 ltr./110 2,0 ltr./147 kW kW FSI kW FSI TFSI with four- wheel drive Engine code letters: BZB, CDAA...
Page 10 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Engine 1.9 ltr./77 kW 1.9 ltr./77 kW TDI- 1.9 ltr./77 kW TDI-PD TDI-PD with front-wheel-drive with four-wheel with front-wheel- and manual gearbox drive and automatic drive...
Page 11 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Engine 1.6 ltr./77 kW TDI CR 1.9 ltr./77 kW TDI- 1.9 ltr./77 kW TDI-PD with front-wheel-drive with four-wheel and automatic gear‐ drive box DSG Engine code letters:...
Page 12 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Engine 1.9 ltr./77 kW TDI-PD 2.0 ltr./100 kW TDI- 2.0 ltr./100 kW TDI- with front-wheel-drive with front-wheel- and manual gearbox drive and automatic gearbox DSG Engine code letters: BJB, BKC, BXE, BLS AZV Rear brake caliper, piston - ∅...
Page 13 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Engine 2.0 ltr./103 kW TDI-PD 2.0 ltr./103 kW TDI-PD 2.0 ltr./ with front-wheel-drive and 125 kW automatic gearbox DSG TDI-PD Engine code letters: BKD, BMM BKD, BMM Pad thickness without support‐...
Page 14: Brake Fluid
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Engine 2.0 l/81 kW TDI CR Engine code letters: CFHF Master brake cylinder - ∅ 22.2 Brake servo unit - ∅ Inch Left-hand drive: Right-hand drive: 7"/8"...
Page 15 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Note The brake regulation systems do not function when ignition is off. Test - vehicles with front-wheel-drive The brake test must be performed on a single-axle roller dyna‐...
Page 16: Anti-Lock Brake System
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 45 – Anti-lock brake system Antilock braking system (ABS) General instructions for ABS ⇒ page 10 Distinguishing features of the ABS systems ⇒ page 13 Safety precautions, basic information on fault finding and on re‐...
Page 17 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Arrangement of the ABS in right-hand drive vehicles 1 - Brake servo 2 - ABS hydraulic unit - N55- with ABS control unit - J104- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 18 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 The ABS control unit - J104- -1- and the ABS hydraulic unit - N55- -2- form a single unit. They can only be separated after the complete unit is removed.
Page 19: Distinguishing Features Of The Abs Systems
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ♦ The valve coils in the ABS control unit - J104- cannot be re‐ placed. ♦ The pressure sensor must not be modified or damaged. ♦ The pressure sensor cannot be replaced.
Page 20: Safety Precautions, Basic Information On Fault Finding And On Repairing
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ♦ XDS - Extension of the electronic differential lock. It reacts when the front inside wheel lifts during fast cornering. XDS intervenes by using braking pressure on the inside wheel, in order to prevent spinning.
Page 21: Electrical/Electronic Components And Fitting Locations Abs Mark 70 (Abs/Tcs)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Electrical/electronic components and fitting locations ABS Mark 70 (ABS/ TCS) Electrical/electronic components and fitting locations ABS Mark 70 (ABS/TCS) for vehicles up to MY 2008 ⇒ page 15...
Page 22 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 gine compartment The hydraulic unit consists of these components: ❑ ABS hydraulic pump - V64- ❑ Check ⇒ Vehicle diagnostic tester ❑ Valve block, (includes the inlet and exhaust valves) ❑...
Page 23: As Of My 2009
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Electrical/electronic components and fitting locations ABS Mark 70 (ABS/ TCS) for vehicles as of MY 2009 Note If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the ♦...
Page 24 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 4 - ABS warning light - K47- ❑ Operation: ⇒ page 29 5 - Dual circuit and hand brake system warning light - K7- ❑ Operation: ⇒...
Page 25: As Of My 2011
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Electrical/electronic components and fitting locations ABS Mark 70 (ABS/ TCS) for vehicles as of MY 2011 Note If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the ♦...
Page 26 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 4 - ABS warning light - K47- ❑ Operation: ⇒ page 29 5 - Dual circuit and hand brake system warning light - K7- ❑ Operation: ⇒...
Page 27: Electrical/Electronic Components And Fitting Locations Abs Mark 60/Mark 60 Ec (Abs/Edl/Tcs/Esp (Esc))
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Electrical/electronic components and fitting locations ABS Mark 60/Mark 60 EC (ABS/EDL/TCS/ESP (ESC)) Electrical/electronic components and fitting locations ABS Mark 60 for vehicles up to MY 2008 ⇒...
Page 28 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - ABS control unit - J104- ❑ Fitting location for left- hand drive: in right of en‐ gine compartment ❑ Fitting location for right- hand drive: in left of en‐...
Page 29 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 8 - The brake light switch - F- and brake pedal switch - F47- ❑ installed from 11/05 ❑ Fitting location: on master brake cylinder ❑ Removing and installing ⇒...
Page 30: Electrical/Electronic Components And Fitting Locations Mark 60 Ec For Vehicles As Of My 2009
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Right-hand drive as of CW 22/2008 ❑ Fitting location: at power-assisted steering - cannot be replaced individually ❑ Check ⇒ Vehicle diagnostic tester Electrical/electronic components and fitting locations Mark 60 EC for vehi‐...
Page 31 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ Brake pressure sender 1 - G201- ❑ Check ⇒ Vehicle diagnostic tester ❑ Valve block, (includes the inlet and exhaust valves) ❑ The ABS control unit - J104- and the ABS hydraulic unit - N55- must not be separated from each other ❑...
Page 32 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ Removing and installing ⇒ page 82 18 - Wheel hub with wheel bearing - front axle ❑ Sensor ring for ABS is built into the wheel hub...
Page 33: Electrical/Electronic Components And Fitting Locations Abs Mark 60 Ec/Pya For Vehicles As
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Electrical/electronic components and fitting locations ABS Mark 60 EC/PYA for vehicles as of MY 2011 Note A sensor unit for ESP (ESC) -G419- is integrated in the control unit. Depending on the equipment, the control ♦...
Page 34 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 3 - ABS warning light - K47- ❑ Operation: ⇒ page 29 4 - Dual circuit and hand brake system warning light - K7- ❑ Operation: ⇒...
Page 35: Indication Of Faults By Means Of Warning Lights
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Indication of faults by means of warn‐ ing lights Warning lights - for vehicles up to MY 2008 ⇒ page 29 Warning lights - for vehicles as of MY 2009 ⇒...
Page 36 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ABS warning light - K47- ♦ If the ABS warning light - K47- -2- does not go out after the ignition is switched on and after completion of the test se‐...
Page 37 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Warning light for traction control system - K86- ♦ If the warning light for traction control system - K86- -5- does not goes out after the ignition is switched on and after com‐...
Page 38 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Warning light for tyre pressure display - K220- ♦ Warning light for tyre pressure inspection display - K220- -3- comes on: – Carry out tyre pressure inspection.
Page 39: Warning Lights - For Vehicles As Of My 2009
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Warning lights - for vehicles as of MY 2009 ABS/TCS warning lights Posi‐ Identification tion ABS warning light - K47- Dual circuit and hand brake system warning light - K7-...
Page 40 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ABS warning light - K47- ♦ If the ABS warning light - K47- -1- does not go out after the ignition is switched on and after completion of the test se‐...
Page 41 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Warning light for traction control system - K86- ♦ If the warning light for traction control system - K86- -3- does not goes out after the ignition is switched on and after com‐...
Page 42 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ESP (ESC) and TCS warning lamp - K155- ♦ If the warning light for TCS/ ESP (ESC) - K155- -3- does not go out after the ignition is switched on and after completion of the test sequence, the causes of the fault may be: There is a fault which exclusively effects the TCS/ESP (ESC).
Page 43: Warning Lights - For Vehicles As Of My 2011
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Press the button for tyre pressure inspection - E226- -arrow- for more than 2 seconds. When the button for tyre pressure inspection - E226- is pressed the warning light for tyre pressure inspection display - K220- lights up in the dash panel insert.
Page 44 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ABS/EDL/TCS/ESP (ESC) warning lights Posi‐ Identification tion Warning light 2 for ESP (ESC) and TCS - K216- ABS warning light - K47- Dual circuit and hand brake system warning light - K7-...
Page 45 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ABS warning light - K47- ♦ If the ABS warning light - K47- -2- does not go out after the ignition is switched on and after completion of the test se‐...
Page 46 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Warning light for traction control system - K86- ♦ If the warning light for traction control system - K86- -4- does not goes out after the ignition is switched on and after com‐...
Page 47 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Press the button for tyre pressure inspection - E226- -arrow- for more than 2 seconds. When the button for tyre pressure inspection - E226- is pressed the warning light for tyre pressure inspection display - K220- lights up in the dash panel insert.
Page 48: Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder Abs Mark 70 (Abs/Tcs)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder ABS Mark 70 (ABS/TCS) Summary of components - left-hand drive ⇒ page 42 Connect the brake lines from the master brake cylinder to the hy‐...
Page 49 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - ABS control unit - J104- ❑ Removing and installing ⇒ page 45 ❑ Disconnecting the con‐ trol unit from the hy‐ draulic unit ⇒ page 51 ❑...
Page 50 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 13 - Gasket ❑ for brake servo 14 - Sealing grommet ❑ for the connection of the vaccum hose 15 - Brake servo ❑ on petrol engines, the required negative pressure is drawn from the intake manifold or it is generated with a vacuum pump ⇒...
Page 51: Connect The Brake Lines From The Master Brake Cylinder To The Hydraulic Unit - Left-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Connect the brake lines from the master brake cylinder to the hydraulic unit - left- hand drive Connect brake lines to the master brake cylinder A - from master brake cylinder (push rod piston circuit) to ABS...
Page 52 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 The control unit is bolted to the hydraulic unit and is located on the right of the engine compartment. WARNING The brake lines around the hydraulic unit must not be bent! –...
Page 53 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Continued for all vehicles: – Release the plug at the control unit, to do so pull the lever -1- downwards in -direction of arrow 1-. The lever -2- is re‐...
Page 54 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Pull hydraulic unit with control unit upwards and out of the rubber bearings in -direction of arrow-. – Unscrew the bracket from the hydraulic unit.
Page 55 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Connect the plug -3- to the control unit against the -direction of arrow 3-. – Push the lever -2- against the -direction of arrow 2-.
Page 56 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Screw for hydraulic unit to bracket 8 Nm Brake lines to ABS unit: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm Protected by copyright.
Page 57: Disconnecting Control Unit From Hydraulic Unit - Left-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Disconnecting control unit from hydraul‐ ic unit - Left-hand drive ♦ In the case of a malfunction of the ABS control unit - J104- , the control unit must be disconnected from the ABS hydraulic unit - N55- and replaced individually.
Page 58 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Detach the control unit without tilting from the hydraulic unit -arrow-. – Carefully pull off all gasket rings from the valve domes of the hydraulic unit.
Page 59 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Summary of components - right-hand drive Note If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the ♦...
Page 60: Connecting The Brake Lines From The Master Brake Cylinder To The Hydraulic Unit - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 5 - Brake line, 14 Nm ❑ to front left brake caliper ❑ Distinguishing feature for vehicles up to CW 21/2008: pipe screw with thread M12 x 1 ❑...
Page 61 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Connect brake lines to the hydraulic unit. A - from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - Distinguishing feature for vehicles up to CW 21/2008: pipe screw...
Page 62 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Attach the bleeder hose of the bleeding bottle onto the vent valves of the front left and rear left brake caliper and open vent valves.
Page 63 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unlock plug on control unit, in -direction of arrow 1-. – Disconnect the plug from the control unit in -direction of arrow 2-. – Pull hydraulic unit with control unit upwards and out of the rubber bearings.
Page 64 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Screw for hydraulic unit to bracket 8 Nm Brake lines to ABS unit: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm Protected by copyright.
Page 65: Separating The Control Unit From The Hydraulic Unit - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Separating the control unit from the hy‐ draulic unit - Right-hand drive ♦ In the case of a malfunction of the ABS control unit - J104- , the control unit must be disconnected from the ABS hydraulic unit - N55- and replaced individually.
Page 66: Attaching Control Unit To Hydraulic Unit - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Detach the control unit without tilting from the hydraulic unit -arrow-. – Carefully pull off all gasket rings from the valve domes of the hydraulic unit.
Page 67: Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder Abs Mark 60/Mark 60 Ec (Abs/Edl/Tcs/Esp (Esc))
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Hydraulic control unit, brake servo unit/master brake cylinder ABS Mark 60/Mark 60 EC (ABS/EDL/TCS/ESP (ESC)) Summary of components ABS Mark 60 - for left-hand drive up to MY 2008 ⇒...
Page 68 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - ABS control unit - J104- ❑ with ABS hydraulic unit - N55- ❑ The ABS control unit - J104- and the ABS hy‐ draulic unit - N55- must not be separated on ve‐...
Page 69 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 11 - Gasket ❑ for brake servo 12 - Sealing grommet ❑ for the connection of the vaccum hose 13 - Brake servo ❑ on petrol engines, the required negative pressure is drawn from the intake manifold or it is generated with a vacuum pump ⇒...
Page 70: Summary Of Components Abs Mark 60 Ec - For Left-Hand Drive As Of My 2009
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Summary of components ABS Mark 60 EC - for left-hand drive as of MY 2009 Note Vehicles up to CW 21/2008 are fitted with the control unit for ABS Mark 60.
Page 71 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ Distinguishing feature: ∅ 5,25 mm and pipe screw with thread M12 x 1 6 - Brake line, 14 Nm ❑ to rear left brake caliper ❑...
Page 72: Connecting The Brake Lines From The Master Brake Cylinder To The Abs Hydraulic Unit - Left
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 21 - Brake fluid reservoir 22 - Screw cap 23 - Heat protection plate 24 - Self-locking nut, 8 Nm 25 - Self-locking nut; 20 Nm...
Page 73: Removing And Installing Abs Control Unit J104 Abs Hydraulic Unit N55 - Left -Hand Drive Vehicles
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Connect brake lines to the hydraulic unit. A - from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - Distinguishing feature: ∅ 6.5 mm and pipe screw with long thread M12 x 1 B - from master brake cylinder (floating piston circuit) to ABS hy‐...
Page 74 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Remove intake manifold flap motor - V157- ⇒ Engine; Rep. gr. 23 (except vehicles with engine identification characters BJB). 2.0 ltr. diesel engine: – Remove bulkhead plenum chamber ⇒ Body Work; Rep. gr.
Page 75 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Mark both brake lines from the master brake cylinder -A- and -B- and unscrew from the hydraulic unit. – Close the brake lines and threaded holes immediately with plugs from the repair kit -1H0 698 311 A- .
Page 76 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Connect the plug to the control unit against the -direction of arrow 2- and lock. – Remove the plugs consecutively from the brake lines and the ABS control unit.
Page 77 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Screw for hydraulic unit to bracket 8 Nm Brake lines to ABS unit: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm Protected by copyright.
Page 78: Disconnecting Control Unit From Hydraulic Unit - Left-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Disconnecting control unit from hydraul‐ ic unit - Left-hand drive ♦ In the case of a malfunction of the ABS control unit - J104- , the control unit must be disconnected from the ABS hydraulic unit - N55- and replaced individually.
Page 79: Attaching Control Unit To Hydraulic Unit - Left-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Attaching control unit to hydraulic unit - Left-hand drive WARNING Strong vibrations (e.g. fall, knock) can destroy the control unit. The control unit must no longer be used.
Page 80 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Brake line ❑ from master brake cylin‐ der (floating piston cir‐ cuit) to ABS hydraulic unit ❑ Distinguishing feature: ∅ 6,5 mm and pipe screw with thread M 12 ×...
Page 81: Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ Fitting the control unit to the hydraulic unit ⇒ page 80 7 - Screw, 2 Nm + 0.8 Nm ❑ Replacing 8 - Rubber bearing ❑...
Page 82: Removing And Installing Abs Control Unit J104 / Abs Hydraulic Unit N55 - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Connect brake lines to the ABS hydraulic unit A - from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - Distinguishing feature: ∅ 6,5 mm and pipe screw with thread M 12 ×...
Page 83 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Remove battery ⇒ Electrical System; Rep. gr. 27 . – Position brake pedal load , e.g. -V.A.G 1869/2- . – Attach the bleeder hose of the bleeding bottle onto the vent valves of the front left and rear left brake caliper and open vent valves.
Page 84 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Release the plug at the ABS control unit -in direction of arrow 1-. – Disconnect the plug from the control unit in -direction of arrow 2-.
Page 85: Separating The Control Unit From The Hydraulic Unit - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Screw in screw -3- and tighten to the recommended tightening torque. – Connect the plug to the control unit against the -direction of arrow 2- and lock.
Page 86: Attaching Control Unit To Hydraulic Unit - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Note The hydraulic pump - V64- and ABS hydraulic unit - N55- must ♦ not be separated from each other. On a disconnected ABS control unit - J104- , the printed circuit ♦...
Page 87 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Push all the gasket rings -A- a little over the valve domes. – Position the control unit without tilting it onto the hydraulic unit. Thus the gasket rings are brought into their end position.
Page 88: Removing And Installing Parts Of The Abs System On The Front And Rear Axle
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and Installing parts of the ABS System on the front and rear axle Remove and install parts of the ABS system on the front axle ⇒...
Page 89 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Separate plug connection -1- of ABS speed sensor/wheel speed sensor cable. – Release screw -2- from the wheel-bearing housing. – Take the ABS-speed sensor out of the wheel bearing housing.
Page 90 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Tightening torque: ABS speed sensor in wheel-bearing housing 8 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 91: Removing And Installing Parts Of The Abs System On The Rear Axle (Front-Wheel Drive)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing parts of the ABS system on the rear axle (front- wheel drive) 1 - ABS wheel speed sensor ❑ clean the inner surface of the hole before insert‐...
Page 92 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Separate plug connection -1- of ABS speed sensor/wheel speed sensor cable. – Release screw -2- from the wheel-bearing housing. – Take the ABS-speed sensor out of the wheel bearing housing.
Page 93 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Tightening torque: ABS speed sensor in wheel-bearing housing 8 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 94: Removing And Installing Parts Of The Abs System On The Rear Axle (Four-Wheel Drive)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing parts of the ABS system on the rear axle (four- wheel drive) 1 - ABS wheel speed sensor ❑ clean the inner surface of the hole before insert‐...
Page 95 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Separate plug connection -1- of ABS speed sensor/wheel speed sensor cable. – Release screw -2- from the wheel-bearing housing. – Take the ABS-speed sensor out of the wheel bearing housing.
Page 96 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Tightening torque: ABS speed sensor in wheel-bearing housing 8 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 97: Removing And Installing Parts Of The Esp (Esc) System
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing parts of the ESP (ESC) system Remove and install sensor unit for ESP (ESC) - G419- ⇒ page 91 Removing and installing steering angle sender - G85- ⇒...
Page 98 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Tightening torque: Fixing nuts ESP (ESC) sensor unit - G419- 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 99: Removing And Installing Steering Angle Sender G85
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 For vehicles as of CW 22/2008: As of CW 22/2008 the sensor unit for ESP (ESC) -G419- (in‐ cludes: lateral acceleration sender - G200- , yaw rate sender -...
Page 100: Brakes - Mechanism
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 46 – Brakes - mechanism Repairing front wheel brake Changing the brake pads of the front brake - Mounting instruc‐ tions ⇒ page 94 Repairing front wheel brake, floating caliper disc brake FS-IIl ⇒...
Page 101: Repairing Front Wheel Brake, Floating Caliper Disc Brake Fs-Iil
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing front wheel brake, floating caliper disc brake FS-IIl Note Observe the instructions for changing the pad ⇒ page 94 ♦ Brake inspection ⇒ page 8 ♦...
Page 102: Removing And Installing Brake Pads, Floating Caliper Disc Brake Fs-Iii
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 7 - Guide bolt, 30 Nm 8 - Cap ❑ remove 9 - Brake hose with banjo union and hollow screw, 35 Nm 10 - Guide bolt, 30 Nm 11 - Cap ❑...
Page 103 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Remove caps -arrows-. – Loosen and remove the two guide bolts -arrows- from the brake caliper. – Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose.
Page 104 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – First, position the brake caliper with the brake pads at the bot‐ tom -arrow- of the brake carrier. – Screw the brake caliper with both guide bolts to the brake car‐...
Page 105 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Guide bolt on brake carrier 30 Nm Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 106: Removing And Installing Brake Caliper, Floating Caliper Disc Brake Fs-Iii
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing brake caliper, floating caliper disc brake FS-III Special tools and workshop equipment required ♦ Brake pedal load e.g. -V.A.G 1869/2- Removing: This procedure applies only to exchanging or the following repair work on the brake caliper.
Page 107 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Screw the brake caliper with both guide bolts to the brake car‐ rier. • The bolt of the brake caliper must be located behind the guide of the brake carrier! –...
Page 108 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Guide bolt on brake carrier 30 Nm Brake hose to brake caliper 35 Nm Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 109: Repairing Front Wheel Brake, Brake Caliper Fn3
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing front wheel brake, brake caliper FN3 Note Observe the instructions for changing the pad ⇒ page 94 ♦ Brake inspection ⇒ page 8 ♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to ♦...
Page 110: Removing And Installing Brake Pads, Brake Calliper Fn3
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ repairing ⇒ page 155 7 - Guide bolt, 30 Nm 8 - Cap ❑ remove 9 - Brake hose with banjo union and hollow screw, 35 Nm 10 - Screw, 190 Nm ❑...
Page 111 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Disconnect the plug connection -1- for the brake pad wear in‐ dicator. – Remove caps -arrows-. – Loosen and remove the two guide bolts -arrows- from the brake caliper.
Page 112 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Screw the brake caliper with both guide bolts to the brake car‐ rier. – Insert both caps. – Insert retaining spring in brake caliper. – Mount the plug connection of the brake pad wear indicator.
Page 113 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Guide bolt on brake carrier 30 Nm Brake hose to brake caliper 35 Nm Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 114: Removing And Installing Brake Caliper, Brake Caliper Fn3
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing brake caliper, brake caliper FN3 Special tools and workshop equipment required ♦ Brake pedal load e.g. -V.A.G 1869/2- Removing: Note This procedure applies only to exchanging or the following repair work on the brake caliper.
Page 115 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Note Observe the instructions for changing the pad ⇒ page 94 ♦ Firmly depress brake pedal several times with vehicle station‐ ♦ ary so that the brake pads are properly seated in their normal operating position.
Page 116 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Guide bolt on brake carrier 30 Nm Brake hose to brake caliper 35 Nm Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 117: Repairing Rear Brake
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing rear brake Changing the brake pads of the rear brake - Mounting instructions ⇒ page 111 Repairing rear brake CII 41 (vehicles with front and four-wheel drive) ⇒...
Page 118: Repairing Rear Brake Cii 41 (Vehicles With Front And Four-Wheel Drive)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing rear brake CII 41 (vehicles with front and four-wheel drive) Note Observe the instructions for changing the pad ⇒ page 111 ♦ Brake inspection ⇒ page 8 ♦...
Page 119 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 8 - ABS speed sensor (vehicles with four-wheel drive) 9 - Wheel hub with wheel bearing (vehicles with four-wheel drive) 10 - Screw (vehicles with four-wheel drive) ❑...
Page 120: Removing And Installing Brake Pads Cii 41
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 21 - Hose clamp 22 - Brake line, 14 Nm 23 - Hand-brake cable ❑ Setting the hand-brake ⇒ page 132 24 - Self-locking screw, 35 Nm ❑...
Page 121 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Screw in the piston by turning the knurled wheel clockwise on the resetting tool - T10165- , during this procedure do not damage the protective cap.
Page 122 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake calliper to brake carrier 35 Nm ♦ Use new self-locking screws! Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 123: Removing And Installing Brake Caliper Cii 41
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing brake caliper CII 41 Special tools and workshop equipment required ♦ Brake pedal load e.g. -V.A.G 1869/2- Removing: This procedure applies only to exchanging or the following repair work on the brake caliper.
Page 124 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake calliper to brake carrier 35 Nm ♦ Use new self-locking screws! Brake line to brake calliper 12 Nm Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 125: Repairing Rear Brake Ci 38 (Vehicles With Front-Wheel Drive)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing rear brake CI 38 (vehicles with front-wheel drive) Note Brake inspection ⇒ page 8 ♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to ♦...
Page 126: Removing And Installing Brake Pads Ci 38
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 14 - Brake caliper ❑ do not unscrew the brake hose when replacing the brake pad ❑ Removing and installing ⇒ page 123 ❑ repairing ⇒ page 159 ❑...
Page 127 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Screw in the piston by turning the knurled wheel clockwise on the resetting tool - T10165- , during this procedure do not damage the protective cap.
Page 128 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake calliper to brake carrier 35 Nm ♦ Use new self-locking screws! Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 129: Removing And Installing Brake Caliper Ci 38
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing brake caliper CI Special tools and workshop equipment required ♦ Brake pedal load e.g. -V.A.G 1869/2- ♦ Bleeding bottle (commercially available) Removing: This procedure applies only to exchanging or the following repair work on the brake caliper.
Page 130 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake calliper to brake carrier 35 Nm ♦ Use new self-locking screws! Brake line to brake calliper 12 Nm Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 131: Repairing Rear Brake Bosch Biriii (Vehicles With Front And Four-Wheel Drive)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing rear brake Bosch BIRIII (vehicles with front and four-wheel drive) Note Brake inspection ⇒ page 8 ♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to ♦...
Page 132: Removing And Installing Brake Pads Bosch Biriii
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 10 - Wheel hub with wheel bearing (vehicles with four-wheel drive) ❑ Assignment ⇒ Electronic Catalogue of Original parts 11 - Tighten screw 70 Nm + 90° (vehicles with four-wheel drive) ❑...
Page 133 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing: When removing mark the brake pads you intend to keep using. Fit in same position when installing, or braking will be uneven! – Remove wheels.
Page 134 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Make sure that the brake pads are located in the pad retaining plates -arrows-. – Secure the brake caliper using new self-locking screws. ♦ There are four self-locking screws in the repair set, which must be fitted.
Page 135 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake calliper to brake carrier 35 Nm ♦ Use new self-locking screws! Wheel bolts 120 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 136: Removing And Installing Brake Caliper Bosch Biriii
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 2.10 Removing and installing brake caliper Bosch BIRIII Special tools and workshop equipment required ♦ Brake pedal load , e.g. -V.A.G 1869/2- Removing: This procedure applies only to exchanging or the following repair work on the brake caliper.
Page 137 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake calliper to brake carrier 35 Nm ♦ Use new self-locking screws! Hollow screw for brake line to brake caliper 35 Nm Wheel bolts 120 Nm Protected by copyright.
Page 138: Handbrake
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Handbrake Handbrake lever - Summary of components ⇒ page 132 Setting the hand-brake ⇒ page 132 Removing and installing the hand-brake cable ⇒ page 133 Handbrake lever - Summary of components 1 - Handbrake lever ❑...
Page 139: Removing And Installing The Hand-Brake Cable
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Tighten adjusting nut -arrow-, … – ... So that the levers -1- rise from the stop -2- on the brake calipers. – The distance -a- to the stop -2- on the left and right brake cal‐...
Page 140 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 For the version with the spring bushing – Slacken the spring bushing -1- for the hand-brake cable from the bracket on the brake caliper. Continued for all versions –...
Page 141: Brake Pedal - Left-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Brake pedal - left-hand drive Summary of components of brake pedal ⇒ page 135 Separating the brake pedal from the brake servo unit and clipping onto the brake servo unit ⇒...
Page 142 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Bearing bracket ❑ Removing and installing ⇒ page 138 ❑ up to 05/2007 ❑ Assignment ⇒ Electron‐ ic Catalogue of Original parts 2 - Self-locking nut, 25 Nm...
Page 143: Separating The Brake Pedal From The Brake Servo Unit And Clipping Onto Brake Servo Unit
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Separating the brake pedal from the brake servo unit and clipping onto brake servo unit Special tools and workshop equipment required ♦ Release tool - T10159A- Separate: –...
Page 144: Removing And Installing Bearing Bracket
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew the nut -1-, while doing so counterhold the screw of the brake pedal -4-. – Remove the screw of the brake pedal -4- towards the left.
Page 145: Removing And Installing Brake Light Switch F And Brake Pedal Switch F47 As Of 11/2005
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 The removal and installation of the brake light switch must only be performed when the tappet is pressed otherwise the locking mechanism of the brake light switch will be damaged.
Page 146 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Disconnect plug connection -1- from brake pedal switch -F47- -3-. – Unscrew the screw -2- from the master brake cylinder. – Take switch -3- out of the lock -4-.
Page 147 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Tightening torque: Brake light switch -F- and brake pedal switch -F47- to brake cylinder 5 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 148 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Inspection: ⇒ Vehicle diagnostic tester Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability...
Page 149: Brake Pedal - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Brake pedal - right-hand drive Summary of components of brake pedal ⇒ page 143 Separating the brake pedal from the brake servo unit and clipping onto the brake servo unit ⇒...
Page 150 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Brake servo ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 2 - Screw ❑ up to 01.2007 3 - Cable support ❑ up to 01.2007 4 - Nut, 12 Nm ❑...
Page 151: Separating The Brake Pedal From The Brake Servo Unit And Clipping Onto Brake Servo Unit
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Summary of components of brake pedal as of 02/2007(with brake light switch - F- and brake pedal switch - F47- at brake cylinder) Grease all bearing surfaces with polycarbamide grease - G 052 142 A2- before assembly.
Page 152: Removing And Installing Brake Pedal
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 For all vehicles – Press the brake pedal towards the brake servo unit and hold it in position. – Insert release tool - T10159A- and pull it in the direction of the driver's seat while counterholding the brake pedal (the pedal must not move backwards during this operation).
Page 153: Removing And Installing Bearing Bracket
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Insert the brake pedal -3- into the bearing bracket -2-. – Insert the screw of the brake pedal -4- from the left. – Screw on the new nut -1- and tighten together with the screw ⇒...
Page 154 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew screws -1- from the right bracket. – Unscrew nut -2- from the left bracket. – Remove bracket. Installing – Insert bracket. – Screw on nut -2- for the left bracket and tighten to tightening torque.
Page 155: Setting, Removing And Installing The Brake Light Switch F And Brake Pedal Switch F47 Up To My 10.2005
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Setting, removing and installing the brake light switch - F- and brake pedal switch - F47- up to MY 10.2005 Note Switch ⇒ Item 6 (page 144) mounted up to 10/2005.
Page 156 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew the screw -2- from the master brake cylinder. – Take switch -3- out of the lock -4-. Installing: Installation is carried out in the reverse order.
Page 157 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Tightening torque: Brake light switch -F- and brake pedal switch -F47- to brake cylinder 5 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 158 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Inspection: ⇒ Vehicle diagnostic tester Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability...
Page 159: Brakes - Hydraulics
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 47 – Brakes - hydraulics Repairing front brake caliper Repairing the brake caliper FS-III ⇒ page 153 Removing and installing the piston of the brake caliper for the FS- III brake ⇒...
Page 160: Removing And Installing The Piston Of The Brake Caliper Of The Fs-Iii Brake
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing the piston of the brake caliper of the FS-III brake Special tools and workshop equipment required ♦ Disassembly wedge - 3409- ♦ Piston jig - T10145- Removing: –...
Page 161: Repairing Brake Caliper Fn3
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Insert inner sealing lip of the protective cap with disassembly wedge - 3409- in the groove of the cylinder. To do so hold the piston in front of the brake caliper.
Page 162: Removing And Installing Piston Of Brake Caliper Fn3
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Cover caps ❑ insert in bushing 2 - Guide bolt, 30 Nm 3 - Bushing ❑ insert into the brake cal‐ iper housing 4 - Dust cap ❑...
Page 163 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Insert wooden plate so that the piston is not damaged. – Lever off protective cap with disassembly wedge - 3409- from the brake caliper. – Remove gasket ring with disassembly wedge - 3409- .
Page 164 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Press the protective cap with the assembly tool -1- and the piston jig -2- onto the brake caliper in such a way that it is resting all around the brake caliper.
Page 165: Repairing Rear Brake Caliper
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Repairing rear brake caliper Repairing brake caliper CII 41 ⇒ page 159 Repairing brake caliper CI 38 ⇒ page 161 Removing and installing the brake caliper piston CII 41 or CI 38 ⇒...
Page 166 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Brake caliper with lever for the handbrake cable ❑ replace brake caliper if the lever for the hand‐ brake cable is not sealed ❑ pre-bleed brake caliper after undertaking re‐...
Page 167: Repairing Brake Caliper Ci 38
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 11 - Sealing ring ❑ Removing and installing ⇒ page 162 Repairing brake caliper CI 38 Note Brake inspection ⇒ page 8 ♦ Install the complete repair set when undertaklng repairs.
Page 168: Removing And Installing The Brake Caliper Piston Cii 41 Or Ci 38
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ Removing and installing ⇒ page 162 9 - Piston with automatic adjusting device ❑ Removing and installing ⇒ page 162 ❑ thinly coat piston with assembly paste - G 052 150 A2- before fitting 10 - Sealing ring ❑...
Page 169: Repairing The Brake Caliper Bosch Biriii
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 To do so hold the piston in front of the brake caliper. Caution Use the resetting tool - T10165- to adjust the piston. The automatic adjustment in the brake caliper is destroyed when adjusting the piston with a resetting tool e.g.
Page 170: Removing And Installing The Brake Caliper Piston Bosch Biriii
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Brake caliper with lever for the handbrake cable ❑ replace brake caliper if the lever for the hand‐ brake cable is not sealed ❑ pre-bleed brake caliper after undertaking re‐...
Page 171 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing: Insert the resetting tool - T10165- in such a way that the collar is resting on the piston. – Release the piston by turning the knurled wheel of the reset‐...
Page 172: Pre-Bleeding The Brake Caliper
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Insert the resetting tool - T10165- in such a way that the collar is resting on the brake caliper. – Screw the piston by turning the knurled wheel of the resetting tool - T10165- to the right into the brake caliper.
Page 173: Checking The Master Brake Cylinder For Tightness
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Checking the master brake cylinder for tightness Special tools and workshop equipment required ♦ Brake system tester e. g. -V.A.G 1310 A- ♦ Adapter M 10 e.g. -V.A.G 1310/6- Test requirements: •...
Page 174: Bleeding Brake System
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Bleeding brake system Bleeding the brake system with the brake filling and bleeding de‐ vice ⇒ page 168 Bleeding the brake system without using the brake filling and bleeding device ⇒...
Page 175 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Connect the thread plug -1- of the brake filling and bleeding device e.g. -VAS 5234- to the brake fluid reservoir. – Switch on the brake filling and bleeding device e.g. -VAS 5234- and activate the system with a brake fluid pressure of 0.2 MPa...
Page 176 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Fit the hose of the bleeding bottle -1- onto the vent valve. Note Use the tool set for brake bleeding - VAS 6564- to loosen and ♦...
Page 177: Bleeding The Brake System Of Air Without Using The Brake Filling And Bleeding Device
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Continued for all vehicles – Disconnect the brake filling and bleeding device . – Disconnect the brake filling and bleeding device from the brake fluid reservoir.
Page 178: Change Brake Fluid
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Fit the hose of the bleeding bottle -1- onto the corresponding bleeder valve. – Press brake pedal and then loosen the bleeder valve. By doing so, the procedure for bleeding the brakes is performed.
Page 179: Summary Of Components: Brake Servo Unit/Master Brake Cylinder
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Summary of Components: brake ser‐ vo unit/master brake cylinder Summary of components - left-hand drive ⇒ page 173 Summary of components - right-hand drive ⇒ page 176 Fitting position of the cap from the brake fluid reservoir ⇒...
Page 180 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Foot controls ❑ different versions ❑ Assignment ⇒ Electron‐ ic Catalogue of Original parts 2 - Self-locking nut, 25 Nm ❑ replace after each re‐...
Page 181 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ if there are faults replace completely ❑ Removing and installing ⇒ page 186 ❑ Assignment ⇒ Electronic Catalogue of Original Parts 11 - Brake light switch -F- and brake pedal switch -F47- ❑...
Page 182: Summary Of Components - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Summary of components - right-hand drive Note The master brake cylinder and the brake servo unit can be replaced independently of one another. 1 - Screw cap –...
Page 183: Fitting Position Of The Cap From The Brake Fluid Reservoir
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 ❑ Assignment ⇒ Electronic Catalogue of Original Parts 9 - Brake light switch -F- and brake pedal switch -F47- ❑ mounted as of 11.2005 ❑ Fitting location: on master brake cylinder ❑...
Page 184: Vacuum Pump For Brake Servo Unit (Vehicles With Diesel Engines)
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Vacuum pump for brake servo unit (ve‐ hicles with diesel engines) Vacuum pump for engines TDI PD: 1 - Tandem pump (vacuum pump and fuel pump)
Page 185: With Respect To The Correctness Of Information In This Document. Copyright By Škoda Auto A. S
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew brake vacuum pump - V192- -1- from bracket -2- -arrows-. Installing: Installation is carried out in the reverse order. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 186 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake vacuum pump - V192- to support 8 Nm Support to automatic gearbox 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 187: Checking The Non-Return Valve
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Checking the non-return valve ♦ The non-return valve must let the air pass through in the di‐ rection of the arrow -A-. ♦ Non-return valve must remain closed in opposite direction.
Page 188 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Place brake servo vacuum gauge - VAS 6721- between them -see following illustrations-. Posi‐ Com‐ Meaning tion po‐ nent Cut- In direction of vacuum hose, non-return valve and,...
Page 189 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Open locking valve -A-. – Close cut-off valves -B+C-. – Start warm engine (> 60°C), press accelerator briefly (engine speed greater than 2000/min). – Read indicated measured value.
Page 190 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Open cut-off valve -C- to evacuate brake servo. – Switch off engine. – Read and make a note of measured value shown. A vacuum decrease of 400 mbar in 12 hours is permissible.
Page 191: Removing And Installing The Pressure Sensor For The Brake Servo Unit G294
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing the pressure sensor for the brake servo unit -G294- Removing: – Disconnect the plug from the pressure sensor for the brake servo unit -G294- .
Page 192: Master Brake Cylinder
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Master brake cylinder Remove and install master brake cylinder - left-hand drive ⇒ page 186 Remove and install master brake cylinder - right-hand drive ⇒ page 189...
Page 193 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew the brake lines -1- at the master brake cylinder, close the brake lines with the screw plugs from the repair kit - 1H0 698 311 A- .
Page 194 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake master cylinder to brake servo 25 Nm ♦ Use new nuts! Brake lines to master brake cylinder 14 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 195: Removing And Installing Master Brake Cylinder - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing master brake cylinder - right-hand drive Special tools and workshop equipment required ♦ Repair kit - 1H0 698 311 A- ♦ Brake filling and bleeding device , e. g. -VAS 5234- Removing: –...
Page 196 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew the brake lines -1- at the master brake cylinder, close the brake lines with the screw plugs from the repair kit - 1H0 698 311 A- .
Page 197 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake master cylinder to brake servo 50 Nm ♦ Use new nuts! Brake lines to master brake cylinder 14 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 198: Brake Servo
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Brake servo Functional test ⇒ page 192 Remove and install brake servo unit - left-hand drive ⇒ page 192 Remove and install brake servo unit - right-hand drive ⇒...
Page 199 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew nuts -1- from brake servo unit. – Carefully remove the brake servo unit from the vehicle. Installing: – Installation is carried out in the reverse order.
Page 200 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake servo unit to foot controls 25 Nm ♦ Use new nuts! Brake master cylinder to brake servo 25 Nm ♦ Use new nuts!
Page 201: Removing And Installing Brake Servo Unit - Right-Hand Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Removing and installing brake servo unit - right-hand drive Special tools and workshop equipment required ♦ Brake filling and bleeding device , e. g. -VAS 5234- ♦...
Page 202 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Remove bulkhead plenum chamber ⇒ Body; Rep. gr. 66 . – Remove vacuum hose from the brake servo unit. Vehicles with diesel engines TDI PD with DPF Remove diesel particle filter ⇒...
Page 203 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Unscrew the screws -1- of the brake servo unit and remove. Vehicles with diesel engines TDI CR – Remove cover for timing belt. – Attach the engine on the right to the supporting device - T30099- .
Page 204 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Specified torques: Brake master cylinder to brake servo 50 Nm ♦ Use new nuts! Screw for brake servo unit to foot controls 25 Nm Brake lines to master brake cylinder 14 Nm Protected by copyright.
Page 205: Brake Line
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Brake line Repairing brake line ⇒ page 199 Flaring tool - Summary of components ⇒ page 201 Work instruction ⇒ page 201 Repairing brake lines Using the brake line flaring tool - VAS 6056- , the brake lines can be crimped with a pipe outside diameter of 5 mm, without dam‐...
Page 206 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 1 - Flaring tool - VAS 6056/1- ❑ The flaring chucks - VAS 6056/6- are inclu‐ ded in the flaring tool - VAS 6056/1- 2 - Pipe cutter - VAS 6056/2-...
Page 207: Flaring Tool - Summary Of Components
Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 Flaring tool - summary of components 1 - Flaring tool upper part ❑ unscrew for changing the flaring chucks 2 - Attachment for door handle ❑ must be unscrewed to...
Page 208 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Cut through the brake line in a suitable location (straight, freely accessible piece) with the pipe cutter -2-. – Remove the part to be replaced.
Page 209 Octavia II 2004 ➤ , Octavia II 2010 ➤ Brake systems - Edition 11.2017 – Turn the spindle in the flaring tool up to the stop. – Turn back the spindle once again. – Loosen the Allan screws crosswise. – Take the brake line out of the flaring tool, clean and check the brake line as well as the flaring head.

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