Page 1 Service Workshop Manual Octavia II 2004 ➤ Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine BKD AZV BMM Engine ID Edition 01.2018 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by ŠKODA AUTO A.
Page 2 Service List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 01 - Self-diagnosis 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 20 - Fuel supply system...
Page 3: Table Of Contents
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Contents 00 - Technical data ........... .
Page 4 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Summary of components for engines with code BKD, AZV ......
Page 5 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.11 Removing and installing fuel gauge sender G169 on vehicles with four-wheel drive..169 1.12 Removing and installing the suction jet pump for vehicles with four-wheel drive ..170 1.13...
Page 6 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Align exhaust system free of stress ......... . 239 Inspecting the exhaust system for leaks .
Page 7: Technical Data
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 00 – Technical data Technical data (SRL001190; Edition 01.2018) Engine number The engine number (“engine identification characters” and “serial number”) is located at the front at the engine/gearbox joint -arrow-.
Page 8: Self-Diagnosis
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 01 – Self-diagnosis Self diagnosis, safety measures, cleanliness regulations and direc‐ tions Self-diagnosis This Rep.-Gr. is deleted. For this use the “Vehicle self-diagnosis”, “Measuring method” and “Fault finding”...
Page 9: Safety Precautions When Working On Fuel Supply System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Safety precautions when working on fuel supply system WARNING ♦ On vehicles with engine with unit injectors, the tempera‐ ture of the fuel lines or of the fuel can be up to 100 °C in an extreme case.
Page 10: Regulations Concerning Cleanliness When Working On The Fuel Supply/Fuel Injection System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 WARNING Secure the test and measuring devices to the rear seat and operate from that position. Observe the following points to prevent injury to persons and/or damage to the injection and preheating system: ♦...
Page 11: General Instructions For Charge Air System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Only install clean parts: remove spare parts from their wrap‐ ping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. on a shelf or in a tool box).
Page 12 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Before screwing down the oil feed line, fill the exhaust turbo‐ charger via the connection fitting with engine oil. ♦ To ensure the oil supply to the exhaust gas turbocharger, leave the engine running for about 1 minute after installing the exhaust gas turbocharger.
Page 13: Removing And Installing Engine
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 10 – Removing and installing engine Removing and installing engine Removing engine Special tools and workshop equipment required ♦ Catch pan for workshop cranes , e.g. -VAS 6208- ♦...
Page 14 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 WARNING Observe necessary measures when disconnecting the battery ⇒ Electrical System ⇒ Rep. gr. 27 . – Disconnect the battery-earth strap with the ignition off ⇒ Elec‐...
Page 15 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Detach coolant hose, fuel intake hose -2- and fuel return-flow hose -1- from pipes at cylinder head. Vehicles up to 08.05 –...
Page 16 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Release screw -1- by one turn. – Release screw -2- and nut -3-. – Take out fuel filter with connected hoses and lay to the side.
Page 17 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – First, unscrew the screw -1-. – Then unscrew screws -2- and -3- and remove the pendulum support. Vehicles with four-wheel drive –...
Page 18 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Open the cable guides -arrows-, remove the engine wiring harness and place down to the side. – Release all remaining plugs at engine and gearbox and lay aside the relevant lines.
Page 19 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Successively release screws for engine mounting -arrows-. – Successively release screws for gearbox mounting -arrows-. Note Check whether all hose and line connections between engine, ♦...
Page 20: Securing The Engine To The Assembly Stand
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Vehicles with engine code BMM – Remove outer -1- and inner -2- engine cover by pulling evenly upwards. Installing Note On vehicles with engine code BKD, AZV, the oil dipstick must be pulled out of the dipstick guide before installation and pushed back into the oil dipstick guide after installation.
Page 21: Installing Engine
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 WARNING Use securing pins on the hooks and rig pins to prevent release. – Attach lifting device - MP 9-201- at engine and at workshop crane , e.g.
Page 22 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Observe all safety measures and notes for assembly work on the fuel supply and injection system, at the charge air system and observe as well the rules for cleanliness ⇒...
Page 23 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Successively screw in screws for gearbox mount -arrows- by hand. – Adjust assembly bracket ⇒ page 20 and tighten screws ⇒ page 19 –...
Page 24 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – For gearboxes with drive shaft, replace the O-ring -1- on the right side of the drive shaft and grease the serration -2- with universal grease.
Page 25: Unit Mounting - Tightening Torques
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Specified torques Component Screws or nuts Engine/gearbox connecting screws ⇒ gearbox ⇒ Rep. gr. 34 Unit mounting - tightening torques Unit mounting for engine A - 20 Nm + torque a further 90°...
Page 26: Checking And Adjusting The Assembly Bracket
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 On manual gearbox MQ350 (02Q), only use the screws with the strength category 10.9 if threaded inserts (e.g. Heli Coil) -arrow- have been installed.
Page 27 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Position supporting device - T30099- and base - T30099/1- and support the engine/gearbox unit in its installed position. – Uniformly pre-tension the engine/gearbox unit with both spin‐...
Page 28 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Move the engine/gearbox assembly with an assembly lever between engine support -1- and supporting arm -3- for engine mount until the following dimensions are set: •...
Page 29: Crankshaft Group
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 13 – Crankshaft group Disassembling and assembling en‐ gine Removing and installing V-ribbed belt 1 - Belt pulley - crankshaft ❑ with vibration damper ❑...
Page 30 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 10 - 23 Nm 11 - AC generator ❑ removing and installing ⇒ Electrical System ⇒ Rep. gr. 27 ❑ to facilitate positioning, push the threaded bushings of the fixing screws on the generator backwards...
Page 31 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Guide pulley tightening torque - vehicles with large engine support (only for vehicles with engine code BKD, AZV) Screw -arrow- with inside thread for fixing the engine support.
Page 32: Removing And Installing Toothed Belt For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Swing the tensioning device in -the direction of the arrow- de‐ tention the V-ribbed belt. – Hold the tensioning device and remove the de-tensioned V- ribbed belt.
Page 33 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Cap ❑ for vibration damper ❑ mounted up to 05.05 2 - 10 Nm + torque a further 90° / 4 turn) ❑...
Page 34 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - 120 Nm + torque a further 90° ( / 4 turn) ❑ replace ❑ do not oil ❑ to release and tighten use counterholder - T30004 - or counter‐...
Page 35 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 17 - 10 Nm ❑ insert using locking agent - D 000 600 A2- 18 - O-ring ❑ replace 19 - Coolant pump ❑...
Page 36 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Engine support bracket On vehicles manufactured from 05.05, the engine support -2- is in-built. Note When removing the toothed belt, it is not necessary to remove the engine support.
Page 37 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Pressure pad - T10172 - with stud - T10172/4- ♦ Offset screwdriver - T10264- ♦ Rig tool - T10265- ♦ Pliers for spring-type clips –...
Page 38 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove top toothed belt guard; to do so, release retaining clips -arrows-. – Remove V-ribbed belt tensioning device -arrows-. – Remove middle and bottom toothed belt guard.
Page 39 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Release screws -1 ... 3- for engine support and remove sup‐ port. Note To release the screws for the engine support, lift or lower engine slightly via spindle on supporting device - T30099- .
Page 40 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note Markings on the toothed belt sprocket and on the crankshaft ♦ arrester must be in line with each other -arrow-. The pin on the crankshaft arrester -arrow- must engage into ♦...
Page 41 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.2.4 Installing toothed belt (adjusting tim‐ ings): Caution The following work sequence must be followed precisely. ♦ If a final test is omitted, for example, and the pins are not reinserted, there is a risk that the timing will not be set correctly and the vehicle will have poor driving perform‐...
Page 42 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Turn the eccentric of the tensioning pulley clockwise using an offset screwdriver - T10264- until the pointer -2- is located centrally in the gap in the base plate.
Page 43 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 If the hub -B- cannot be locked: – Loosen the fixing screws -2- for the intake camshaft toothed belt sprocket -B-. – Place a ring spanner on the central screw for the intake cam‐...
Page 44: Removing And Installing Toothed Belt For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Keep toothed belt sprockets pre-tensioned using counterhold‐ er - T10172- and tighten screws -1- and -2- for toothed belt sprockets -A- and -B- to 25 Nm.
Page 45 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ install (set the timing) ⇒ page 45 8 - 20 Nm + torque a further 45° ( / 8 turn) 9 - Tensioning pulley ❑...
Page 46 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Tensioning pulley Additional hole in the eccentric of the tensioning pulley for 6 mm hexagon socket wrench -arrow-. Note The tensioner pulley of the new version can be adjusted with the special two-hole nut turner , e.
Page 47 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Tightening order for engine support Caution The tightening sequence and the tightening torque of the fixing screws for the engine support must definitely be respected.
Page 48 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Detach fuel feed line -2- and fuel return-flow line -1-, to do so press in securing ring. – Remove top toothed belt guard, to do so release retaining clips -arrows-.
Page 49 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Release screws -1 ... 3- for engine support and remove sup‐ port. Note To release the screws for the engine support, raise or lower en‐...
Page 50 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note Markings on the toothed belt sprocket and on the crankshaft ♦ arrester must be in line with each other -arrow-. The pin on the crankshaft arrester -arrow- must engage into ♦...
Page 51 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.3.2 Installing toothed belt (adjusting tim‐ ings): Caution The following work sequence must be followed precisely. ♦ If a final test is omitted, for example, and the pins are not reinserted, there is a risk that the timing will not be set correctly and the vehicle will have poor driving perform‐...
Page 52 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Turn the eccentric of the tensioning pulley with offset screw‐ driver - T10264- clockwise -arrow- in such a way until the pointer -2- stands in the centre of the base plate in the gap.
Page 53 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Loosen screws -arrows- for toothed belt sprocket. – Rotate crankshaft in direction of engine rotation until the crank‐ shaft can be locked in the hole in the sealing flange -arrow- with the crankshaft arrester .
Page 54: Removing And Installing Sealing Flange And Flywheel
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing sealing flange and flywheel Note Repairs to the clutch ⇒ gearbox ⇒ Rep. gr. 30 . 1 - Sealing ring ❑...
Page 55: Replace Crankshaft Seal On Belt Pulley Side
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Installing intermediate plate – Insert intermediate plate on sealing flange and push onto the dowel sleeves -arrows-. Replace crankshaft seal on belt pulley...
Page 56 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – To guide the gasket ring extractor screw the central screw for crankshaft - toothed belt sprocket in the crankshaft up to the stop.
Page 57: Removing And Installing The Sealing Flange On The Belt Pulley Side
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Press in the gasket ring flush with the central screw for the toothed belt sprocket of the crankshaft and with the pressure bushing of the assembly device - T10053- .
Page 58 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove the crankshaft toothed belt sprocket; to do so, hold toothed belt sprocket with counterholder - T30004 - or lock with counterholder - MP 1-310- .
Page 59: Replace Sealing Flange On The Gearbox Side
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Apply silicone sealant bead -arrow- to the clean sealing sur‐ face of the upper part of the sealing flange, as shown.
Page 60 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove the intermediate plate from the dowel sleeves and unhook from sealing flange -arrows-. – Position crankshaft to TDC for cylinder 1 ⇒...
Page 61 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 A - Mounting sealing flange with rotor on the assembly tool - T10134- A - Hexagon nut B - Clamping surface C - Assembly cup...
Page 62 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 The locating hole -B- on the rotor -C- must be flush with the mark‐ ing -A- on the sealing flange. – Lay the sealing flange with the front side on the assembly tool - T10134- in such a way that the positioning pin -A- engages into the hole -B- of the rotor.
Page 63 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Screw in two screws M7 x 35 mm -A- by about 3 thread turns for the sealing flange guide into the cylinder block.
Page 64 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 The fitting position of the rotor on the crankshaft is accurate if there is a distance -a- of 0.5 mm between the crankshaft flange -A- and the rotor -B-.
Page 65: Removing And Installing The Two-Mass Flywheel
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Tighten the hexagon nut of the assembly tool using a torque wrench with adapter. Tightening torque: 40 Nm. – Check the fitting position of the rotor on the crankshaft again ⇒...
Page 66 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Continued for all – Rotate the secondary side -A- of the two-mass flywheel in such a way that the screws -B- are positioned in the middle of the holes -arrows-.
Page 67: Crankshaft, Piston And Conrod
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Crankshaft, Piston and Conrod Removing and installing crankshaft Note The engine should be attached to the engine repair stand with the engine holder - MP 1-202 (VW 540)- for carrying out removal and installation work.
Page 68: Removing And Installing Drive Chain Sprocket
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ Conrod bearing pin: ∅ 50.90 mm Removing and installing drive chain sprocket Special tools and workshop equipment required ♦ Drive bushing - MP1-316 (30 - 100)- ♦...
Page 69: Disassembling And Assembling Pistons And Conrods
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing – Remove needle bearing with internal extractor 14 ... 18 mm and countersupport -A-. Note Place internal extractor behind needle bearing.
Page 70 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Piston rings ❑ Offset gaps by 120°. ❑ use piston ring pliers for removing and installing ❑ marking “TOP” faces piston crown ❑...
Page 71 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 8 - Connecting rod bearing cap ❑ Check fitting position ❑ cracked cover fits only in one position at the relevant conrod 9 - Oil spray jet ❑...
Page 72 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Piston ring Wear limit (dimensions in mm) 1st compression ring 0.06 - 0.09 0.25 2nd compression ring 0.05 - 0.08 0.25 Oil scraper ring 0.03 - 0.06...
Page 73: Inspect Piston Projection At Tdc
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Checking cylinder bores Special tools and workshop equipment required ♦ Cylinder gauge – Measure cylinder at 3 points crosswise in transverse direction -A- and lengthwise -B-.
Page 74: Separating New Connecting Rod
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Identification of the cylinder head gasket ♦ Part number = -arrow 1- ♦ Control code = -arrow 2- (ignore) ♦ Bores = -arrow 3-...
Page 75: Cylinder Head, Valve Gear
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 15 – Cylinder head, valve gear Removing and installing cylinder head Note Cylinder heads with cracks between the valve seats may con‐...
Page 76 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Rear toothed belt guard 2 - Rubber bowl ❑ Replace if damaged. 3 - Pin screw, 10 Nm 4 - Hub ❑...
Page 77 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ pay attention to order for slackening ⇒ page 74 ❑ Pay attention to sequence and procedure when tightening ⇒ page 78 18 - Multipin plug connection ❑...
Page 78: Removing And Installing Cylinder Head Cover For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Special tools and workshop equipment required ♦ Feeler gauges ♦ Knife-edge straightedge – Inspect cylinder head at several points for distortion using a knife-edge straightedge and feeler gauge.
Page 79: Removing And Installing Cylinder Head For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove top toothed belt guard; to do so, release retaining clips -arrows-. – Remove screws -1- and -3-. – Remove crankcase ventilation hose -2- from charge air pipe to turbocharger and push charge air pipe to rear.
Page 80 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Locking pin - T10060- or -T10060A - ♦ Catch pan for workshop cranes , e.g. -VAS 6208- ♦ Pliers for spring-type clips ♦...
Page 81 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Disconnect connector -2-, unscrew screw -4- and remove front charge air hose together with connecting hose; do so by lifting retaining clips -1- and -3-.
Page 82 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew screws -2...4-. – Unscrew nut -1- for tensioning pulley. For vehicles up to 05.05, remove the tensioning pulley for toothed belt.
Page 83 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew the cylinder head bolts in the order shown. Note For the following working steps a 2nd mechanic is required. – Lift the cylinder head slightly and release it from the rear tooth‐...
Page 84 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Pay attention to the identification of the cylinder head seal. ♦ Part number = -arrow 1- ♦ Control code = -arrow 2- (ignore) ♦...
Page 85 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Before inserting the valve-lever shaft, check that all ball studs -1- and O-rings -2- have been inserted in the unit injectors.
Page 86 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Push camshaft sprockets onto hubs. • The two tooth segments -arrows- on the camshaft wheels must both be at the top.
Page 87: Checking The Compression Pressure For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note Markings on the toothed belt sprocket and on the crankshaft ♦ arrester must be in line with each other -arrow-. The pin on the crankshaft arrester -arrow- must engage into ♦...
Page 88 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Vacuum hose ❑ for connecting piece of tandem pump / brake booster 2 - Screw cap 3 - Connecting pipe ❑...
Page 89: Removing And Installing Cylinder Head Cover For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ After replacing, fill entire system with fresh coolant. 20 - Cylinder head screw ❑ replace ❑ pay attention to order for slackening ⇒...
Page 90 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing – Remove engine cover ⇒ page 13 – Pull off hose -2- for crankcase ventilation. – Pull off the vacuum hose to the vacuum reservoir at the cylin‐...
Page 91: Removing And Installing Cylinder Head For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – ... and at rear a small amount (∅ approx. 5 mm) of sealant - D 454 300 A2- -arrows-. Note Replace the gasket and the screws for the cylinder head cover in case of damage.
Page 92 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove coolant hose between engine and radiator -arrows-. – Remove charge air pipe between the exhaust turbocharger and the charge air cooler ⇒...
Page 93 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Place electrical wiring harnesses on the bodywork. – Remove the vacuum hose -2- at the vacuum unit for charge pressure control.
Page 94 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove the release pin -arrow 1- and open the knurled nut -arrow 2-. – Disconnect the central plug connection for unit injectors and uncover the wiring harness.
Page 95 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew the screws from the support of the intake manifold flap motor - V157- -arrows-. For vehicles with auxiliary heating: – Remove coolant pipes to auxiliary heating with connected coolant hoses at cylinder block.
Page 96 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Follow the specified order for loosening cylinder head bolts. – Slightly raise the cylinder head with lifting device - MP 9-201- and workshop crane - VAS 6100- and laterally remove from the engine next to the toothed belt guard.
Page 97 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Pay attention to the identification of the cylinder head seal. ♦ Part number = -arrow 1- ♦ Control code = -arrow 2- (ignore) ♦...
Page 98 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Insert screws -2- and -4- with applied locking agent - D 000 600 A2- and tighten to 15 Nm. – Install Hall sender - G40- , insert screws -3- with spread on locking agent - D 000 600 A2- and tighten to 10 Nm.
Page 99: Checking The Compression Pressure For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note Markings on the toothed belt sprocket and on the crankshaft ♦ arrester must be in line with each other -arrow-. The pin on the crankshaft arrester -arrow- must engage into ♦...
Page 100 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Screw the adapter e.g. -V.A.G 1381/12 - into the relevant cyl‐ inder in place of the glow plug. – Test compression pressure with compression tester , e.g. - V.A.G 1763- .
Page 101: Repairing Valve Gear
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Repairing Valve Gear Summary of components for engines with code BKD, AZV Note After installing the camshafts, the engine must not be cranked ♦...
Page 102 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 11 - Valve guide ❑ not to be replaced ❑ Check ⇒ page 121 12 - Valve lever for inlet valve ❑ do not mix up used valve levers (mark) ❑...
Page 103: Checking The Axial Play Of The Camshafts For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ install with silicone sealant - D 176 501 A1- Checking the axial play of the camshafts for engines with code BKD, AZV Special tools and workshop equipment required ♦...
Page 104: Removing And Installing Camshafts For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Position the inner part of the sealing ring extractor - T30003- so that it is flush with the outer part, and lock with the knurled screw.
Page 105 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Cleaning and degreasing agent, e.g. - D 000 401 04- ♦ Protective goggles ♦ Protective gloves Removing • Cylinder head fitted on engine.
Page 106 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Position the extractor - T10052- and align it with the hub bores. – Tighten fixing screws -1-. – Put the hub under tension by uniformly tightening the screw -2- until the hub is released from the camshaft cone.
Page 107 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Pull the release mandrel in -arrow direction 1- and open the knurled nut in -arrow direction 2-. – Disconnect the central plug connection for unit injectors and glow plugs and uncover the wiring harness.
Page 108 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Place frame -T10262- on the bearing bush as shown and tighten fixing screws SW 10 to 10 Nm. – Screw in the jacking screws by hand until they touch the cyl‐...
Page 109 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note Markings on the toothed belt sprocket and on the crankshaft ♦ arrester must be in line with each other -arrow-. The pin on the crankshaft arrester -arrow- must engage into ♦...
Page 110 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Replace screws -1, 3, 5, 7, 9-. – Tighten screws -1 ... 20- evenly and in the specified order from inside to outside. Tightening torque 20 Nm.
Page 111: Removing And Installing Valve Levers For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Turn the adjusting screw in the opposite direction from the stop by about 180° – Firmly hold the adjusting screw in this position and tighten the locknut to 30 Nm.
Page 112 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Mark assignment of valve levers to aid reinstallation – Remove screws -4- and -5-. – Extract pin -3- on the outlet side of the valve levers using ex‐...
Page 113: Checking The Hydraulic Supporting Elements For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Checking the hydraulic supporting ele‐ ments for engines with code BKD, AZV Special tools and workshop equipment required ♦ Feeler gauges Note The hydraulic supporting elements pressed into the valve lev‐...
Page 114: Replacing Valve Stem Seals For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Replacing valve stem seals for engines with code BKD, AZV • Cylinder head fitted on engine. Special tools and workshop equipment required ♦...
Page 115 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Screw the adapter - VAS 5161/21-2- into the guide plate by hand. – Attach the detent part - VAS 5161/6- to the cylinder head using the support fork - VAS 5161/5- .
Page 116: Valve Dimensions For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – If the valve collets were removed from the assembly cartridge - VAS 5161/8- , they must first be inserted into the insertion device for valve collets -VAS 5161/18- .
Page 117: Summary Of Components For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Summary of components for engines with code BMM Note After installing the camshaft, the engine must not be cranked or started for about 30 minutes. The hydraulic ♦...
Page 118: Checking The Axial Play Of The Camshaft For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ Pay attention to sequence for loosening and tightening ⇒ page 115 9 - Washer ❑ for cylinder head screws ❑ before installing the bearing caps, insert into the cylinder head 10 - Hydraulic bucket tappets ❑...
Page 119: Replacing The Sealing Ring For Camshaft For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 2.11 Replacing the sealing ring for camshaft for engines with code BMM Special tools and workshop equipment required ♦ Insertion tool - MP 1-214 (10-203)- ♦...
Page 120 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Oil the thread head of the gasket ring extractor, position and forcibly screw into the gasket ring of the camshaft as far as possible.
Page 121: Removing And Installing The Camshaft For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Push camshaft sprocket onto the hub. • The tooth segment -arrow- of the toothed belt sprocket must be at the top.
Page 122 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – First remove bearing caps -1-, -3- and -5-. – Then release bearing caps -2- and -4- alternately and cross‐ wise. Note Ensure that the bearing shells of the camshaft are not mixed ♦...
Page 123 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Oil contact surfaces of camshaft. – Insert camshaft into the TDC for cylinder 1: • The cams for cylinder 1 on the camshaft must point upwards -arrows-.
Page 124: Checking The Hydraulic Bucket Tappets For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Insert valve-lever shafts. While doing so, pay attention to the markings -arrows- made when removing. – First tighten the inner -2- and then the outer screws -1- in sev‐...
Page 125: Replacing Valve Stem Seals For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ For vehicles with manual transmission, push the vehicle for‐ ward with the 4th gear engaged and the ignition switched off. ♦ For vehicles with automatic transmission, turn the crankshaft at the central screw.
Page 126 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove bearing shells of camshaft from the cylinder head. – Remove bucket tappets and lay aside with the contact surface facing down. Make sure that you do not mix up the tappets.
Page 127: Valve Dimensions For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 2.15 Valve dimensions for engines with code Dimension Inlet valve Exhaust valve ∅ a 35.95 31.45 ∅ b 6.980 6.965 89.45 89.05 α...
Page 128: Lubrication
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 17 – Lubrication Removing and installing parts of the lubrication system Note If the engine is damaged and there is a suspicion that this ♦...
Page 129 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 10 - O-ring ❑ replace 11 - Intake manifold ❑ Clean strainer if dirty 12 - Baffle 13 - Oil pan ❑ Removing and installing ⇒...
Page 130: Disassembling And Assembling The Oil Filter Holder
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Disassembling and assembling the oil filter holder 1 - Screw plug - 25 Nm 2 - Gasket ❑ replace 3 - Engine oil cooler ❑...
Page 131: Removing And Installing Oil Pan
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 13 - Connecting piece - 35 Nm Fitting position of gasket for engine oil cooler – Place the gasket -2- in such a way that it can be pressed onto all the lugs of the engine oil cooler -1-.
Page 132 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew the bolts of oil pan/gearbox -arrows-. – Loosen bolts -1...20- crosswise and release. – Remove oil pan, if necessary release by applying slight blows with a rubber-headed hammer.
Page 133: Removing And Installing Oil Pump
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing oil pump Removing – Removing the oil pan ⇒ page 125 – Remove baffle ( ⇒ page 122 ; Pos. 12).
Page 134 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Screw the connection of the oil pressure tester - V.A.G 1342- into the hole for the oil pressure switch. – Screw the oil pressure switch -2- into the oil pressure tester.
Page 135: Cooling
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 19 – Cooling Removing and installing parts of the cooling system WARNING When opening the coolant expansion reservoir, hot steam or hot coolant may escape. Cover the cap with a cloth and open carefully.
Page 136 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Radiator ❑ Removing and installing ⇒ page 138 ❑ After replacing, fill with fresh coolant ⇒ page 135 2 - O-ring ❑...
Page 137: Parts Of The Cooling System Engine Side For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Parts of the cooling system engine side for engines with code BKD, AZV 1 - Radiator for exhaust gas re‐ circulation ❑ Removing and installing ⇒...
Page 138 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 19 - Distributor part 20 - 15 Nm 21 - Hose ❑ from the engine oil cooler 22 - to the coolant expansion reservoir ❑...
Page 139: Connection Diagram For Coolant Hoses For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Connection diagram for coolant hoses for engines with code BKD, AZV Vehicles without auxiliary heating. 1 - Radiator ❑ Removing and installing ⇒...
Page 140 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Coolant expansion tank ❑ with cap ❑ Check the overpressure valve in the screw cap ⇒ page 149 2 - Cylinder block ❑...
Page 141: Draining And Topping Up Coolant For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Draining and topping up coolant for en‐ gines with code BKD, AZV Special tools and workshop equipment required ♦ Catch pan for workshop cranes , e.g. -VAS 6208- ♦...
Page 142 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Detach the rear coolant hose on the engine oil cooler -arrow- and drain residual coolant. Vehicles with auxiliary heating – Remove the coolant hoses on the pipes of the auxiliary heating and drain residual coolant.
Page 143: Removing And Installing
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Top up coolant through the neck of the expansion reservoir, until it reaches the max. marking. – Switch off the heater unit and air conditioning unit.
Page 144: Removing And Installing Radiators For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove the air filter with air guide hose from the lock carrier ⇒ page 208 – Remove noise insulation ⇒ Body Work ⇒ Rep. gr. 50 .
Page 145: Parts Of The Cooling System Fitted To Body For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 WARNING Shut off the opening of the charge air cooler, e.g. with a clean foam piece, so that no coolant can penetrate.
Page 146 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Radiator fan - V7- ❑ with radiator fan control unit - J293- ❑ Removing and installing ⇒ page 145 2 - 5 Nm...
Page 147: Parts Of The Cooling System Engine Side For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Parts of the cooling system engine side for engines with code BMM 1 - to the coolant expansion tank at the top ❑...
Page 148 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 21 - Connection fitting ❑ with coolant regulator 22 - Coolant regulator ❑ Removing and installing ⇒ page 147 ❑ check: heat up regulator in a water bath Start of opening approx.
Page 149: Connection Diagram For Coolant Hoses For Engines With Code Bud
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Connection diagram for coolant hoses for engines with code BUD 1 - Coolant expansion tank ❑ with cap ❑ Check the overpressure valve in the screw cap ⇒...
Page 150 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Draining Note Collect drained coolant in a clean container for proper disposal or reuse. WARNING When opening the coolant expansion reservoir, hot steam or hot coolant may escape.
Page 151: Fan Shroud For Radiator Fans V7 And V35 For Engines With Code Bmm Removing And Installing
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Connect coolant hose at rear of radiator -arrow-. Select the appropriate coolant additive from the ⇒ Electronic Catalogue of Original Parts or from the list of allowed coolant ad‐...
Page 152: Removing And Installing The Radiator For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove connecting hose on left; to do so, slightly lift retaining clips -arrows-. – Disconnect plug connection -1-. – Remove screws -arrows- and take out fan shroud downwards.
Page 153: Removing And Installing Coolant Pump
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew screws -arrows- and remove radiator downwards. Installing Installation occurs in reverse order to removal. Pay attention to the following: ♦ Tightening torques: ⇒...
Page 154: Check Cooling System For Leaks
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove V-ribbed belt ⇒ page 23 Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.
Page 155 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Test condition • Engine must be warm. Test sequence WARNING When opening the coolant expansion reservoir, hot steam or hot coolant may escape. Cover the cap with a cloth and open carefully.
Page 156: Fuel Supply System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 20 – Fuel supply system Removing and installing parts of the fuel supply system Note Fuel lines are secured with quick-release couplings.
Page 157 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 the opening of the fuel tank ❑ only moisten the inner seal of the flange with fuel for fitting purposes 15 - Fuel pump ❑...
Page 158: Fuel Tank With Attached Parts For Vehicles With Four-Wheel Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Fuel tank with attached parts for vehicles with four-wheel drive 1 - Fuel return-flow line ❑ from fuel cooler ❑ clipped in place on fuel tank ❑...
Page 159 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 the fuel gauge sender - ⇒ page 167 5 - Lock ring, 110 Nm ❑ use wrench - T30101 (3087)- for removing and installing ❑...
Page 160: Removing And Installing Fuel Filter
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing fuel filter Fuel filter type one and two Note Before disconnecting the fuel hoses, mark assignment to the supports.
Page 161: Extract Fuel From The Fuel Tank
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Fuel filter type three and four Note Before disconnecting the fuel hoses, mark assignment to the supports. 1 - Fuel intake hose ❑...
Page 162 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note If there are functional problems of the fuel delivery unit suction off fuel with fuel extraction device, e.g. -VAS 5190- .
Page 163: Removing And Installing Fuel Cooler
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing fuel cooler Removing Note The fuel cooler is located on the fuel return-flow line to the fuel ♦ tank. It is attached to the underfloor of the vehicle body.
Page 164 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unclip retaining catches -arrows- of cover for the fuel delivery unit and remove cover. Note On vehicles with auxiliary heating, the plug connection for the dosing pump - V54- must also be disconnected.
Page 165: Removing And Installing Fuel Tank For Vehicles With Four-Wheel Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove screws -1- for filler neck on the body. – Unclip the wiring loom from the holder -2- at the top and bottom of the filler neck.
Page 166 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Drain the fuel tank ⇒ page 155 – Removing rear seat bench ⇒ Body Work ⇒ Rep. gr. 72 . – Remove the covers from the fuel delivery unit and from the fuel gauge sender 2 - G169- .
Page 167: Removing And Installing The Fuel Delivery Unit On Vehicles With Front-Wheel Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Attach line for four-wheel drive control unit - J492- to the fuel tank -arrows-. To do so, support the fuel tank with the engine/ gearbox jack .
Page 168: Removing And Installing The Fuel Delivery Unit On Vehicles With Four-Wheel Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Disconnect the plug as well as the black fuel feed line -2- and the blue fuel return-flow line -1- from the flange.
Page 169 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Protective gloves Condition • The fuel tank must not be more than / 3 full. Removing Note Drain the fuel tank ⇒...
Page 170 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Through the opening of the fuel tank, disconnect the fuel line -1- to the vacuum pump by pressing the release button.
Page 171 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Slightly raise the closing flange and check if the spring -2- is still fastened on the flange -1-. If the spring -2- lies loose on the guide pipe -3-, hold the spring with the fingers when removing the closing flange.
Page 172 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Slide the spring -2- into the guide bore -arrow- and fit the cable -1- of the closing flange on the cable -3- of the fuel delivery unit.
Page 173: Removing And Installing The Fuel Gauge Sender G
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Fuel delivery unit type one Fuel delivery unit type two ♦ Observe the fitting location of the fuel delivery unit. The peg -2- at the closing flange must be located between the pegs -1- and -3-.
Page 174 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unlatch and disconnect the plug connection of the lines -1- (brown), -2- (blue) and -3- (black). – Raise securing tabs -4- and -5- with a screwdriver and remove the fuel gauge sender - - downwards -arrow-.
Page 175: Removing And Installing Fuel Gauge Sender G169 On Vehicles With Four-Wheel Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.11 Removing and installing fuel gauge sender - G169- on vehicles with four- wheel drive. • The fuel tank must not be more than / 2 full.
Page 176: Removing And Installing The Suction Jet Pump For Vehicles With Four-Wheel Drive
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Place suction jet pump inside in the fuel tank on the fuel dis‐ penser 2 - G169- and push to the stop until the retaining slats -arrows- engage.
Page 177: Removing And Installing Tandem Pump, Vehicles With Engine Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.13 Removing and installing tandem pump, vehicles with engine code BKD, AZV Special tools and workshop equipment required ♦ Diesel extractor , e. g. -VAS 5226- ♦...
Page 178: Removing And Installing Tandem Pump, Vehicles With Engine Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Separate vacuum line -1- for brake servo unit from tandem pump -4-. – Detach fuel intake hose -2- (marked in white) and fuel return- flow hose -3- (marked in blue) from the tandem pump -4-.
Page 179 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Note Safety precautions when working on the fuel supply system ♦ ⇒ page 3 Observe the regulations concerning cleanliness when working ♦...
Page 180: Inspecting A Tandem Pump
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew screws -arrows-. – Remove tandem pump -4- from cylinder head. Installing Installation occurs in reverse order to removal. Pay attention to...
Page 181 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Work procedure Note Safety precautions when working on the fuel supply system ♦ ⇒ page 3 Observe the regulations concerning cleanliness when working ♦...
Page 182 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Connect tester for tandem pump - VAS 5187 - with hollow screw -VAS 5187/1A- as shown. – Install air filter and intake hose and air guide hose.
Page 183 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove air filter ⇒ page 220 – Release screw plug -arrow-. – Connect tester for tandem pump - VAS 5187 - with hollow screw -VAS 5187/1A- as shown.
Page 184 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.15.3 Check tightness (internally) of tandem pump Note After re-installing a used tandem pump e.g. after changing or re‐ pairing a cylinder head and/or after changing a hopper motor the tandem pump must absolutely be checked for internal tightness between fuel and oil side.
Page 185: Inspecting Fuel Pump
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Open valve -4- and wait until the test circuit is filled. If neces‐ sary, re-adjust the pressure to 0.1 MPa (1.0 bar).
Page 186 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Checking the function and supply voltage Test conditions • Battery voltage at least 11.5 V • Fuses OK (No. 27). • All electrical consumers such as the lights and rear window heater must be switched off.
Page 187 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unplug connector -arrow-. Note On vehicles with four-wheel drive, the position of the plugs and the fuel lines is different. – Connect remote control - V.A.G 1348/3A- with connection lines from measuring tool set to contact -1- of the fuel pump and to battery positive terminal.
Page 188: Accelerator Control
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Accelerator control Assembly overview - accelerator module 1 - Connector ❑ black ❑ 6-pin 2 - Accelerator pedal module ❑ with accelerator pedal...
Page 189 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing – Remove steering column trim panel -arrows-. – Lever out the cap ( ⇒ page 182 Pos. 4) with a screwdriver.
Page 190: Turbocharging/Supercharging
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 21 – Turbocharging/supercharging Charge-air system with exhaust gas turbocharger - Part 1 Note Observe rules for cleanliness ⇒ page 4 ♦ Secure all hose connections with corresponding hose clips.
Page 191: Connection Diagram For Valve Block And Vacuum Sockets For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Connection diagram for valve block and vacuum sockets for engines with code BKD, AZV Connection diagram for valve block P1 - Vacuum line from the tandem pump P2 - To mechanical exhaust gas recirculation valve P3 - To vacuum setting element of radiator for exhaust gas recir‐...
Page 192: Connection Diagram For Vacuum Hoses For Engines With Code Bud
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove engine cover ⇒ page 13 – Connect the connecting hose -2- to the vacuum setting ele‐ ment and to the hand vacuum pump - VAS 6213- .
Page 193 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - Exhaust gas turbocharger 2 - Charge air cooler 3 - intake hose 4 - Non-return valve 5 - Brake servo...
Page 194: Charge-Air System With Exhaust Gas Turbocharger - Part 2
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Charge-air system with exhaust gas turbocharger - Part 2 Removing and installing exhaust gas turbochargers for engines with code BKD, AZV 1 - Gasket ❑...
Page 195 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 15 - Oil return-flow line ❑ in the cylinder block 16 - Connecting piece - 40 Nm 17 - 17 Nm 18 - 20 Nm ❑...
Page 196 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove screws -1- and -3-. – Unlock the vacuum lines at the rear of the charge air pipe and disconnect the hose to the vacuum actuator of the charge boost pressure control.
Page 197: Removing And Installing Charge Air Cooling Parts For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove the connection pipe for exhaust gas recirculation -arrows- and heat shield for exhaust manifold. – Unscrew nuts -arrows- and remove exhaust manifold with ex‐...
Page 198 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - 7 Nm 2 - Mounting bracket ❑ Check fitting position 3 - Charge air cooler ❑ Removing and installing ⇒ page 197 4 - top seal ❑...
Page 199: Removing And Installing The Exhaust Gas Turbocharger For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing the exhaust gas turbocharger for engines with code 1 - 10 Nm 2 - Mounting bracket 3 - Heat shield 4 - Oil supply hose ❑...
Page 200 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 18 - Hollow screw - 60 Nm 19 - Countersupport ❑ for exhaust gas turbocharger ❑ for oil return-flow line 20 - Exhaust gas temperature sender 1 - G235- ( Temperature sender upstream of turbocharger - G507- ) ❑...
Page 201 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Disconnect plug connection -5- for exhaust gas temperature sender 1 - G235- ( temperature sender upstream turbocharger - G507- ) and expose cable.
Page 202: Removing And Installing Charge Air Cooling Parts For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Remove left heat shield at exhaust manifold -arrows-. – Unscrew holder for diesel particle filter. – Unscrew nuts -arrows- and remove exhaust manifold with ex‐...
Page 203: Removing And Installing Charge Air Cooler
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - 5 Nm 2 - Mounting bracket ❑ Check fitting position 3 - Charge air cooler ❑ Removing and installing ⇒ page 197 4 - top seal ❑...
Page 204: Hose Connections With Quick Couplings
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 WARNING Do not open the refrigerant circuit of the air conditioning sys‐ tem. Caution To avoid causing damage to the condenser and to the refrig‐...
Page 205: Checking The Charge-Air System For Leak-Tightness
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing – Release push-fit coupling by pulling the locking clip -arrow-. Disconnect hose/pipe without auxiliary tool. Installing – When replacing the sealing ring, place the sealing ring in the groove of the charge air hose.
Page 206 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Test sequence – Remove intake hose -1- from air filter. – Fit adapter - 1687/10- into the intake hose -1- and secure with a clamp.
Page 207 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Connect the pneumatic hose -1- (pneumatic support) at tester. Note If there is water in the transparent drain container, drain water via the drain plug -6-.
Page 208: Mixture Preparation - Injection
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 23 – Mixture preparation - injection Repairing Diesel Direct Injection sys‐ The control unit is equipped with event memory. Before repairs, setting operations and fault finding, query the event memory and run self-diagnosis ⇒...
Page 209 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 A - Warning light for engine electronics - K149- ❑ in the dash panel insert B - Accelerator pedal position sender - G79- with accelerator...
Page 210 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Exhaust gas recirculation valve - N18- ♦ Solenoid valve for charge pressure control - N75- 6 - Air mass meter - G70-...
Page 211: Intake Manifold - Summary Of Components For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Intake manifold - summary of components for engines with code BKD, AZV 1 - Intake manifold 2 - 22 Nm 3 - Shackle 4 - Gasket ❑...
Page 212: Wiring Harness For Unit Injectors And Glow Plugs - Summary Of Components For Engines With
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Wiring harness for unit injectors and glow plugs - summary of components for engines with code BKD, AZV 1 - Glow plug connectors 2 - Stainless steel clamps ❑...
Page 213 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Switch off ignition and pull out ignition key. – Remove cylinder head cover ⇒ page 72 – Disconnect central plug connection on cylinder head. To do so, pull the release mandrel in -arrow direction 1- and open the knurled nut in -arrow direction 2-.
Page 214: Removing And Installing The Air Filter For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unplug connector of the glow plugs -1-. Fixing screws -2-, un‐ screw the stainless steel clamps and remove the entire wiring harness.
Page 215 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - intake hose ❑ to exhaust gas turbo‐ charger 2 - Air mass meter - G70- 3 - O-ring ❑ Replace if damaged.
Page 216: Repairing Unit Injectors For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Repairing unit injectors for engines with code BKD, AZV Note Observe rules for cleanliness ⇒ page 2 1 - 3 Nm + torque a further 270°...
Page 217 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Extractor - T10163- ♦ Plug insert - T10054- (XZN 6, total length at least 75 mm) ♦ Counterholder - T10172 - or -MP 1-216- ♦...
Page 218 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unplug connector -1- from the glow plugs. Caution To remove and install the unit injectors, the screws for retaining clips must be loosened or tightened if necessary. If the wiring harness is removed from the retaining clips, the clips will be bent apart and the increased play can lead to a cable break.
Page 219 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.7.2 Installing Caution • For any work requiring adjustment of the unit injector using the adjusting screw, the adjusting screw in the valve lever and the ball stud in the unit injector will need to be re‐...
Page 220 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Insert new fixing screws and carefully screw in without a lot of force using the plug insert - T10054- as far as the stop -arrow-.
Page 221: Replacing The O-Rings Of The Unit Injector For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Screw on the valve-lever shaft with new screws as follows: Se‐ Apply quence – Alternately tighten screws -2- and -4- in stages until the valve-lever shaft is resting on the bearing bush.
Page 222: Installation Locations For Engines With Code Bmm - Overview
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Installing Note Always use the assembly sleeves to install the O-rings. If not ♦ used, the O-rings may be damaged. Pay attention to the correct assignment of the O-rings to the ♦...
Page 223 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 A - Warning light for engine electronics - K149- ❑ in the dash panel insert B - Accelerator pedal position sender - G79- with accelerator...
Page 224 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 compartment 1 - Intake manifold flap motor - V157- 2 - Exhaust gas temperature sender 3 - G495- ( Temperature sender downstream particle filter - G527 - )
Page 225: Intake Manifold - Summary Of Components For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Summary of components - plug on the front wall 1 - Solenoid valve for charge pressure control - N75- 2 - Plug (orange) for exhaust gas temperature sender 3 - G495- ( temperature sender downstream particle filter - G527- ) 3 - Plug for exhaust gas temperature sender 2 - G448- ( temper‐...
Page 226: Removing And Installing The Air Filter For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 • There must be no faults stored in the fault memory. – If a fault is stored, clear fault memory and repeat the entire procedure.
Page 227: Repairing Unit Injectors For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.12 Repairing unit injectors for engines with code BMM ♦ Always replace gasket rings and O-rings. 1 - 20 Nm + torque a further 90°...
Page 228 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.13.1 Removing – Remove top toothed belt guard and cylinder head cover ⇒ page 83 – Undo the locknuts -2- of the adjusting screws for all unit injec‐...
Page 229 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.13.2 Installing Caution • For any work requiring adjustment of the unit injector using the adjusting screw, the adjusting screw in the valve lever and the ball stud in the unit injector will need to be re‐...
Page 230 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Using a caliper gauge, check dimension -a- from the outer side of the cylinder head to the cylinder surface of the unit injector.
Page 231: Replacing The O-Rings Of The Unit Injector For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1.14 Replacing the O-rings of the unit injector for engines with code BMM Special tools and workshop equipment required ♦ Assembling sleeves - T10056- Removing –...
Page 232: Removing And Installing The Engine Speed Sender G28
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Insert the assembly sleeve - T10056/3- on the unit injector up to the stop. – Carefully slide the lower O-ring onto the assembly sleeve and insert it in the groove of the unit injector.
Page 233: Engine Control Unit
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Engine control unit Removing and installing engine control unit Note If the engine control unit should be replaced, connect vehicle di‐ agnosis, measurement and information system - VAS 5051- and in the guided fault detection system carry out “replace engine...
Page 234 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Lift locking tab of protective cover with a cross-head screw‐ driver. – Push the protective cover in the -direction of the arrow- out of the bracket for engine control unit.
Page 235: Exhaust System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 26 – Exhaust system Removing and installing parts of the exhaust system Note The decoupling element in the pre-exhaust pipe should not be ♦...
Page 236 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ Installing the exhaust system without tension ⇒ page 239 10 - Countersupport 11 - 40 Nm 12 - Front clamping sleeve ❑...
Page 237: Summary Of Components For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Summary of components for engines with code BMM 1 - Exhaust gas pressure sen‐ sor 1 - G450- 2 - Mounting bracket ❑...
Page 238 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ❑ Separation point ⇒ page 238 ❑ Installing the exhaust system without tension ⇒ page 239 17 - 23 Nm 18 - Front clamping sleeve ❑...
Page 239: Exhaust System For Vehicles With Four-Wheel Drive - Summary Of Components
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Exhaust system for vehicles with four-wheel drive - Summary of compo‐ nents 1 - Exhaust gas pressure sen‐ sor 1 - G450- 2 - Mounting bracket ❑...
Page 240: Removing And Installing Pre-Exhaust Pipe With Diesel Particle Filter
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 11 - 23 Nm 12 - 20 Nm 13 - Front tunnel bridge 14 - 23 Nm 15 - Shackle 16 - Middle and rear part of the exhaust system ❑...
Page 241 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Release fuel hoses and coolant hoses at right charge air pipe. – Remove right charge air pipe. – Check intake manifold flap motor - V157- ⇒...
Page 242 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew lambda probe -3-. – Remove exhaust gas temperature sender 2 - G448- ( temper‐ ature sender upstream particle filter - G506- ) -5-.
Page 243 Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Release screws -arrows- at holder for diesel particle filter. – Slacken nuts of front clamping sleeve. – Unscrew hanger of exhaust system -arrows-.
Page 244: Replacing Middle Or Rear Part Of The Exhaust System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Release nuts -1- using the ratchet ring wrench - T10384- . – Slacken nuts of clamping sleeve. Note For the following working steps a 2nd mechanic is required.
Page 245: Align Exhaust System Free Of Stress
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Separate exhaust pipe with body saw at right angles at the separation point -arrow 2-. – When installing, position rear clamping sleeve -4- at the side markings -arrow 1- and -arrow 3-.
Page 246: Inspecting The Exhaust System For Leaks
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Align rear part of exhaust system: • There must be an equal distance -a- between bumper opening and exhaust tailpipe. •...
Page 247: Exhaust Gas Recirculation System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Exhaust gas recirculation system Removing and installing exhaust gas re‐ circulation system parts for engines with code BKD, AZV Note The exhaust gas recirculation system is operated by the en‐...
Page 248: Summary Of Components - Radiator For Exhaust Gas Recirculation System For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 1 - 22 Nm 2 - Shackle 3 - 22 Nm 4 - Gasket ❑ replace 5 - 10 Nm 6 - Pipes ❑...
Page 249: Checking The Mechanical Exhaust Gas Recirculation Valve For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 ♦ Connection diagram for valve block and vacuum sockets ⇒ page 185 1 - 22 Nm 2 - Connecting pipe 3 - Gasket ❑...
Page 250: Function Of The Exhaust Gas Recirculation Radiator
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Disconnect vacuum hose from mechanical exhaust gas recir‐ culation valve -2-. – Connect hand vacuum pump - VAS 6213- to valve.
Page 251: Removing And Installing The Radiator For Exhaust Gas Recirculation For Engines With Code Bkd, Azv
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing the radiator for exhaust gas recirculation for engines with code BKD, AZV Special tools and workshop equipment required ♦ Hose clamp - MP 7-602 (3094)- ♦...
Page 252: Removing And Installing The Exhaust Gas Recirculation System For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Removing and installing the exhaust gas recirculation system for engines with code BMM Note The exhaust gas recirculation system is controlled by the die‐...
Page 253: Summary Of Components - Radiator For Exhaust Gas Recirculation System For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 9 - Gasket ❑ replace 10 - Radiator ❑ for exhaust gas recirculation 11 - 22 Nm 12 - Mounting bracket 13 - 22 Nm...
Page 254: Checking The Change-Over For Exhaust Gas Recirculation Radiator For Engines With Code
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 Checking the change-over for exhaust gas recirculation radiator for engines with code BMM Special tools and workshop equipment required ♦ Hand vacuum pump - VAS 6213-...
Page 255: Connection Diagram For Exhaust Recirculation Vacuum Hoses For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unscrew connection pipe for exhaust gas recirculation radiator -arrows-. – Unscrew screw -2- and hollow screw -3-. – Rotate the turbocharger support 90° and pull it down and out of the oil return line.
Page 256: Glow Plug System
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 28 – Glow plug system Glow Plug System Removing and installing the glow plugs for engines with code BKD, AZV Special tools and workshop equipment required ♦...
Page 257: Checking The Glow Plugs For Engines With Code Bmm
Octavia II 2004 ➤ , Octavia II 2010 ➤ 2.0/100; 103 kW TDI PD Engine - Edition 01.2018 – Unplug connector of the glow plugs -arrows-. – Remove the glow plugs using a flexible-head wrench e.g. -3220- . Installing Installation occurs in reverse order to removal. Pay attention to the following: –...

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