Skoda Octavia III 2013 Workshop Manual
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Skoda Octavia III 2013 Workshop Manual

Skoda Octavia III 2013 Workshop Manual

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Table of Contents

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Service
Workshop Manual
Octavia III 2013 ➤ , Octavia III 2014 ➤ ,
Rapid NH 2013 ➤ , Rapid NH 2014 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤
1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine
Engine ID
Edition 04.2020
Service Department. Technical Information
CLH
CLH
CKF
A
B
B
CXX
CXX
DBK
A
B
A
DDY
DDY
DCY
B
A
A
CKF
CRV
CUP
C
C
A
CYK
CXM
CUU
A
A
A
DGT
DJG
DFFA
E
A
CRK
CRM
CUN
B
B
A
CUU
DFS
DFS
B
A
B

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Summary of Contents for Skoda Octavia III 2013

  • Page 1 Service Workshop Manual Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 2014 ➤ , Yeti 2010 ➤ , Yeti 2011 ➤ 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine Engine ID DFFA Edition 04.2020...
  • Page 2 Service List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 21 - Turbocharging/supercharging 23 - Mixture preparation - injection...

  • Page 3: Table Of Contents

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Contents 00 - Technical data ........... .
  • Page 4 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Pistons and conrods ............
  • Page 5 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Check cooling system for leaks ..........227 Draining the cooling system .
  • Page 6 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Summary of components - injection units (injectors) ......452 Summary of components - High pressure reservoir (fuel distributor) .
  • Page 7 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing exhaust gas cleaning module ......589 Installing and removing regulated particle filter .
  • Page 8 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Contents...

  • Page 9: Technical Data

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 00 – Technical data Denomination (SRL001550; Edition 04.2020) ⇒ “1.1 Engine number, engine data”, page 1 Engine number, engine data ⇒...
  • Page 10 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 En‐ CU‐ gine codes l 1.5 0… 0… 0… … … 0… 0…...
  • Page 11 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 En‐ CU‐ gine codes Charg yes yes yes yes ye yes yes ye...

  • Page 12: Safety Instructions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Safety instructions ⇒ “2.1 Safety precautions when working on fuel supply system”, page 4 ⇒...

  • Page 13: Safety Precautions During Road Tests In Which Testing And Measuring Equipment Is Used

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Safety precautions during road tests in which testing and measuring equipment is used There is a risk of injury from unsecured testing and measuring instruments.

  • Page 14: Safety Precautions When Working On The Exhaust System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Automatic back-suction of reduction agent • After the ignition is turned off, the reduction agent is sucked back out from the dosage line to the injection valve for reduc‐...

  • Page 15: Repair Instructions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Repair instructions ⇒ “3.1 Rules of cleanliness”, page 7 ⇒ “3.2 Foreign bodies in the engine”, page 8 ⇒...

  • Page 16: Foreign Bodies In The Engine

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ When the system is opened: Avoid using compressed air. Avoid moving the vehicle.

  • Page 17: General Instructions For Charge Air System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
  • Page 18 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 sealing surfaces of the quick couplings are coated with oil ⇒ , page 474 ♦...

  • Page 19: Removing And Installing Engine

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 – Removing and installing engine Removing and installing engine ⇒ “1.1 Removing engine”, page 11 ⇒...
  • Page 20 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 CAUTION The cooling system remains pressurised while the engine is warm! Danger of scalding due to hot steam and hot coolant.
  • Page 21 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock tab -arrow-, remove vacuum hose -1-. Vehicles with SCR system – Disconnect electrical plug connector from injection valve for reduction agent - N474- -3- and pull off.
  • Page 22 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect plug -2- from the engine control unit - J623- ⇒ “7 Engine control unit”, page 527 –...
  • Page 23 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew nut -arrow-, remove and expose electric cable. Vehicles fitted with a manual gearbox –...
  • Page 24 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection -arrow- for the oil level and oil temperature transmitter - G266- .
  • Page 25 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fit radiator protection mat - VAS 531 003- to vehicle, as shown.
  • Page 26 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamp -arrow-, remove top right coolant hose from charge air cooling circuit radiator.
  • Page 27 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with double gearbox screwed connection Continuation for all vehicles – Tighten engine mount - T10497- or -T10497A- with bolt - T10497/1- with screw -1- to around 20 Nm to cylinder block.
  • Page 28 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with double gearbox screwed connection Continuation for all vehicles NOTICE Risk of damaging vacuum lines or electric cables and the engine compartment.
  • Page 29 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open cap -arrow- for coolant expansion tank. CAUTION Danger of scalding due to hot steam and hot coolant.
  • Page 30 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 31 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose the following plug connections and electric cables: 1 - for charge pressure control solenoid valve - N75-...
  • Page 32 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose bracket -3- with fuel hoses. – Unscrews screws -1- and nuts -2- (if present).
  • Page 33 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Detach the alternator lead -1- from the fuse holder. – Open the catches for cable guides on the frame side rail -arrows-.
  • Page 34 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles fitted with a manual gearbox – Separate electrical plug connection -2-. – Press back B+-pole protection -1- and unscrew B+-cable from the starter magnet switch.
  • Page 35 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with double gearbox screwed connection Vehicles with air conditioning – Remove the ribbed V-belt ⇒...
  • Page 36 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen clips -arrows-, remove noise insulation -1- for oil sump. Vehicles with four-wheel drive –...
  • Page 37 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Tighten engine mount - T10497- or -T10497A- with bolt - T10497/1- with screw -1- to around 20 Nm to cylinder block.
  • Page 38 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.1.3 Removing the engine, Rapid NH NOTICE If the stripped engine is replaced after engine removal, the tight‐...
  • Page 39 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Press release buttons on both sides of the hose -1- for crank‐...
  • Page 40 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 NOTICE Risk of defects caused by contamination ♦ Rules of cleanliness when working on the fuel supply system ⇒...
  • Page 41 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electric plug connection -1- from the starter motor. – Unlock catch -arrow-, open cover -2-.
  • Page 42 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Screw screws -2- out of the gearbox mounts by approximately 2 turns.
  • Page 43 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with dual clutch gearbox: – Remove selector lever cable from gearbox selector lever and lay to the side Shift mechanism⇒...
  • Page 44 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew nuts -arrows- and take off cover -1-. – Disconnect the electrical plug connection -arrow- for lambda probe 1 after catalytic converter - GX7- –...
  • Page 45 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection -arrow- for the oil level and oil temperature transmitter - G266- .

  • Page 46: Attach Engine Attached To Engine And Gearbox Mount

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Screw out gearbox mount screws -arrows- fully. NOTICE Risk of damaging vacuum pipes or electric cables and the en‐...

  • Page 47: Installing Engine

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installing engine ⇒ “1.3.1 Installing the engine, Octavia III, Yeti”, page 39 ⇒ “1.3.2 Installing the engine, Rapid NH”, page 43 1.3.1...
  • Page 48 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – If there are no dowel sleeves -A- are available in the cylinder block for centring the engine and gearbox, insert dowel sleeves.
  • Page 49 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Initially insert screws -arrows- for gearbox mount by hand as far as the stop.
  • Page 50 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Install fan shroud ⇒ “4.6 Removing and installing fan shroud”, page 365 –...
  • Page 51 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Tightening torques Note The function to increase oil pressure does not always have to ♦...
  • Page 52 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Screws which have been tightened firmly to a torquing angle ♦ must be replaced.
  • Page 53 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Initially insert screws -arrows- for engine mount by hand as far as the stop.
  • Page 54 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Initially insert screws -arrows- for gearbox mount -1- by hand as far as the stop.
  • Page 55 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Install the front left and right wheelhouse liner ⇒ Exterior body work ; Rep. gr. 66 ; Wheelhouse liner; Removing and installing the front wheelhouse liner .

  • Page 56: Assembly Bracket

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Assembly bracket ⇒ “2.1 Assembly overview - assembly mountings”, page 48 ⇒ “2.2 Removing and installing engine mount”, page 53 ⇒...
  • Page 57 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw ❑ Replace after disas‐ sembly ❑ Tightening sequence ⇒ page 50 2 - Engine support bracket ❑...
  • Page 58 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 14 - Gearbox mount ❑ with supporting arm 15 - Screw ❑ Replace after disassembly ❑...
  • Page 59 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.1.2 Assembly bracket, Yeti Assembly bracket 1 - 20 Nm + 90° - replace after disassembly 2 - 40 Nm + 90°...
  • Page 60 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.1.3 Summary of components - assembly bracket, Rapid NH Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 61: Removing And Installing Engine Mount

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Screw ❑ Replace after disassembly ❑ 40 Nm + 90° 11 - Screw ❑...
  • Page 62 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -1-. – Remove bracket -2- with fuel hoses.
  • Page 63 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock catches -arrows- and disconnect holder -1- with fuel hoses from the guide on the coolant expansion reservoir.

  • Page 64: Removing And Installing Pendulum Support

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Position assembly bracket to longitudinal beam • The insertion positions -arrows- must be in an axis; if required, check this with a suitable auger.

  • Page 65: Support The Engine In Its Installed Position

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.3.2 Removing and installing the pendulum support, Rapid NH Removing – Remove the sound dampening system ⇒ Body Work; Rep.
  • Page 66 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...
  • Page 67 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose vacuum hoses -arrow- at the air guide pipe. – Release hose clamps -1, 3- and remove air guide pipe -2-.

  • Page 68: Check Assembly Bracket Setting

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Check assembly bracket setting ⇒ “2.5.1 Checking setting of engine mount, Octavia IlI”, page 60 ⇒...
  • Page 69 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • A distance of -a- = 10 mm must be present between engine support -2- and engine mount -1-.
  • Page 70 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Make sure that on the gearbox side the edges of the support‐...
  • Page 71 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • Engine and gearbox held by supporting device - T30099- , supporting plate - T30099/1- and adapter - MP9-200/3 (10-222A/3)- or engine and gearbox supported by engine mount and engine/engine/gearbox jack .

  • Page 72: Engine Trim Panel

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Engine trim panel ⇒ “3.1 Removing and installing engine trim panel”, page 64...

  • Page 73: Crankshaft Group

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 13 – Crankshaft group Cylinder block (pulley end) ⇒ “1.1 Assembly overview - cylinder block (pulley end)”, page 65 ⇒...
  • Page 74 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - V-ribbed belt ❑ check for wear ❑ mark the direction of ro‐...

  • Page 75: Summary Of Components - Sealing Flange On The Belt Pulley Side

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 12 - Alternator ❑ Summary of components ⇒ Electrical system; Rep. gr. 27 ; Alternator; Summary of components -...
  • Page 76 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Sealing flange on the belt pulley side ❑ with shaft sealing ring for crankshaft ❑...

  • Page 77: Removing And Installing V-Ribbed Belt

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing V-ribbed belt ⇒ “1.3.1 Removing and installing V-ribbed belt for vehicles without air conditioning system”, page 69...
  • Page 78 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – To release the tension of the V-ribbed belt, use the ring span‐...

  • Page 79: Removing And Installing Tensioning Pulley For V-Ribbed Belt

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing tensioning pul‐ ley for V-ribbed belt Removing – Remove V-ribbed belt ⇒...

  • Page 80: Removing And Installing Bracket For Auxiliary Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installing Installation is carried out in the reverse order. When installing, observe the following:...
  • Page 81 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose bracket -1- with fuel hoses. – Unscrew screws -arrows-. – Release screw -arrow-, remove guide pulley.

  • Page 82: Removing And Installing Engine Support

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing engine support ⇒ “1.7.1 Removing and installing the engine support bracket, Oc‐...

  • Page 83: Removing And Installing The Sealing Flange On The Belt Pulley Side

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove top toothed belt guard ⇒ “2.3 Removing and installing toothed belt guard”, page 142 –...
  • Page 84 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove the toothed belt from the camshaft ⇒ “2.5 Remove the toothed belt from the camshaft”, page 159 –...
  • Page 85 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Cut off nozzle tube at the front marking (∅ of nozzle approx.
  • Page 86 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Apply sealant bead -arrow- onto the clean sealing surface of the sealing flange, as shown in the illustration.

  • Page 87: Cylinder Block On Gearbox Side

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Cylinder block on gearbox side ⇒ “2.1 Summary of components - cylinder block on gearbox side”, page 79 ⇒...

  • Page 88: Removing And Installing Flywheel

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 8 - Sealing flange on the gearbox side ❑ with sealing ring ❑ replace after removal ⇒...

  • Page 89: Removing And Installing Sealing Flange On Gearbox Side

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Insert counterholder - MP1-223 (3067)- into the bore on the cylinder block Pos. -B-, loosen flywheel screws.
  • Page 90 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove intermediate plate -1- from the dowel sleeves arrows -A-. – Move intermediate plate -1- upwards.
  • Page 91 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The sealing flange with PTFE sealing ring is provided with ♦ sealing lip supporting ring -2-. This support ring serves as a fitting sleeve and must not be removed prior to installation.
  • Page 92 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove the securing clip -arrow- from the new sealing flange -1-. Note Do not twist rotor or take it out of the sealing flange.
  • Page 93 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • Sealing flange must lie straight on the assembly tool. • Only 2 of the 3 knurled screws -H- can be screwed in at a time –...
  • Page 94 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Bolt assembly tool - T10134- onto crankshaft flange – Push the assembly cup -C- by hand in the -direction of the arrow- until the sealing lip supporting ring -1- rests on the crankshaft flange -2-.
  • Page 95 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Measure distance -a- between crankshaft flange -2- and rotor -1-. • Set value: Dimension -a- = 0.5 mm.
  • Page 96 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Tighten nut -B- of the assembly tool - T10134- to 40 Nm.

  • Page 97: Crankshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Crankshaft ⇒ “3.1 Summary of components - crankshaft”, page 89 ⇒ “3.2 Replace the needle bearing in the crankshaft”, page 90 ⇒...

  • Page 98: Replace The Needle Bearing In The Crankshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ different version for cylinder block and bearing cap ❑ pay attention to locating element 8 - Crankshaft ❑...

  • Page 99: Measuring Axial Play Of Crankshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Attach interior extractor to the needle bearing edge -arrow-. – Pull out the needle bearing -1- with internal extractor -A- e.g.
  • Page 100 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Work procedure – Secure the dial gauge - VAS 6079- with universal dial gauge bracket - MP3-447 (VW 387)- to the cylinder block, as shown in the illustration, and against the crankshaft.

  • Page 101: Pistons And Conrods

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Pistons and conrods ⇒ “4.1 Assembly overview - piston and conrod”, page 93 ⇒...
  • Page 102 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Axial play wear limit: 0.37 mm 5 - Pressure relief valve ❑ replace without sealant ❑...
  • Page 103 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Fitting position of piston and assignment of piston to cylinder NOTICE Risk of damaging the piston crown.

  • Page 104: Removing And Installing The Piston

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Carefully knock against the conrod bearing cap with a plastic hammer in -direction of arrow- in order to loosen it.

  • Page 105: Measure Piston Projection In Tdc

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installing Installation is carried out in the reverse order. When installing, observe the following:...

  • Page 106: Check Piston And Cylinder Bore

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Test sequence – Gauge - VAS 6079- with measuring gauge bracket - MP3-404/7 (VW382/7)- and end measuring plate -...
  • Page 107 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Using an external micrometer, measure 75-100 mm at approx. 15mm from the lower edge of skirt and 90° to the piston pin axis.
  • Page 108 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Feeler gauge – Push the piston ring into the bottom cylinder opening at right angles to the cylinder wall from above to about 15 mm from the cylinder edge.

  • Page 109: Cylinder Head, Valve Gear

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 15 – Cylinder head, valve gear Cylinder head ⇒ “1.1 Summary of components - cylinder head”, page 101 ⇒...
  • Page 110 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Cylinder block 2 - Cylinder head gasket ❑ replace after removal ⇒...
  • Page 111 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Coolant temperature transmitter - G62- ❑ Removing and installing ⇒ “2.9 Removing and installing coolant temperature transmitter G62 ”, page 305 11 - Double screw ❑...

  • Page 112: Assembly Overview - Cylinder Head Cover

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Cylinder head - tightening torque and tightening order Note Screws which have been tightened firmly to a torquing angle must be replaced.
  • Page 113 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ replace if damaged or leaking 2 - Cylinder head cover ❑...

  • Page 114: Removing And Installing Cylinder Head

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 18 - Vacuum hose 19 - Screw cap 20 - Seal ❑ for cap...
  • Page 115 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Fit all heat protection sleeves on again in the same place when ♦...
  • Page 116 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamps -1- and undo hose clamp -3-, remove coolant hoses.
  • Page 117 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release nut -2- and remove union nut -4-. – Unscrew screws -3-, -5- and remove oil return pipe.
  • Page 118 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock and disconnect connector at changeover valve for ra‐ diator of exhaust gas recirculation - N345- -1- Continued for all vehicles –...
  • Page 119 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock tab -arrow-, remove vacuum hose -1-. – Disconnect vacuum hose -2-.
  • Page 120 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release the cylinder head bolts in the sequence -1- to -10-. Note A 2nd mechanic is required for removing the cylinder head.
  • Page 121 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Pay attention to the identification of the cylinder head gasket: Part number...
  • Page 122 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Place cylinder head gasket on the dowel sleeves -arrows- in the cylinder block.
  • Page 123 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Turn the crankshaft in the direction of rotation of the engine until the stud -arrow- of the crankshaft arrester engages - T10490- during this rotary movement in the sealing flange.
  • Page 124 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 125 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove exhaust gas cleaning module ⇒ “2.3 Removing and installing exhaust gas cleaning module”, page 589 –...
  • Page 126 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -2-. – Loosen hose clamp -1-, remove coolant hose.
  • Page 127 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock tab -arrow-, remove vacuum hose -1-. – Disconnect vacuum hose -2-.
  • Page 128 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release the cylinder head bolts in the sequence -1- to -10-. Note A 2nd mechanic is required for removing the cylinder head.
  • Page 129 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Pay attention to the identification of the cylinder head gasket: Part number...
  • Page 130 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Place cylinder head gasket on the dowel sleeves -arrows- in the cylinder block.
  • Page 131 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Turn the crankshaft in the direction of rotation of the engine until the stud -arrow- of the crankshaft arrester engages - T10490- during this rotary movement in the sealing flange.

  • Page 132: Removing And Installing Cylinder Head Cover

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 374 ♦...
  • Page 133 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Press release buttons on the hose -1- for crankcase ventila‐ tion, remove hose from cylinder head cover.

  • Page 134: Removing And Installing Gasket Rings For Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Slacken the screws for the cylinder head cover in the se‐ quence -7- … -1-and remove them.

  • Page 135: Removing And Installing Camshaft Housing

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Insert sealing ring extractor - T40195- into the sealing ring -1-. – Position hammer -T10133/3- with the adapter -T10133/2- on the sealing ring extractor, as shown in the illustration, and pull out upwards.
  • Page 136 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release nut -4- and screws -2-, -3-. – Pull coolant pipe off double screw and push it downwards.
  • Page 137 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open clamp -1- and place it on the flared opening of the ex‐...
  • Page 138 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • The hub of the camshaft must be locked with the rig pin for diesel injection pump - 3359- .
  • Page 139 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Apply sealant beads -arrow- onto the clean sealing surfaces of the cylinder head as shown in the illustration.
  • Page 140 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 141 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Loosen hose clamp -2-, remove air guide pipe -1-.
  • Page 142 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -1- and nuts -2- and remove rear coolant pipe and push rear coolant pipe downwards. If necessary, secure the coolant pipe with a cable strap to the drive shaft.
  • Page 143 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the screw clamp -1- and place on the flared opening of the exhaust gas cleaning module.
  • Page 144 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • The hub of the camshaft must be locked with the rig pin for diesel injection pump - 3359- .
  • Page 145 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Apply sealant beads -arrow- onto the clean sealing surfaces of the cylinder head as shown in the illustration.

  • Page 146: Checking Compression

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The function to increase oil pressure does not always have to ♦...
  • Page 147 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection at the fuel pressure con‐ trol valve - N276- Pos. -2-.

  • Page 148: Toothed Belt Drive

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Toothed belt drive ⇒ “2.1 Summary of components - toothed belt guard”, page 140 ⇒...

  • Page 149: Summary Of Components - Toothed Belt

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Summary of components - toothed belt Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 150: Removing And Installing Toothed Belt Guard

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Do not additionally oil threads and collar ❑ 100 Nm 11 - Locating screw ❑...
  • Page 151 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Observe rules for cleanliness ⇒ “3.1 Rules of cleanliness”, page 7 Removing –...
  • Page 152 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screw -arrow-. – Open clamp -A-, pull out hose, unclip pipeline -B- and remove with the differential pressure transmitter - G505- .
  • Page 153 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release electrical plug connector from injection valve for re‐ duction agent - N474- -5- and pull off.
  • Page 154 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screw -4- for the coolant lines -3-. – Unscrew screw -6- for the coolant lines -3-.
  • Page 155 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock catches -arrows-, unhook and remove top toothed belt guard -1-. Installing Installation is performed in the reverse order, while paying atten‐...
  • Page 156 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove left screw -arrow-. – If present, unscrew screw -arrow-. – Detach measurement pipes -1- and push to the right side.
  • Page 157 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.3.4 Removing and installing bottom toothed belt guard Removing Note To simplify the production process in manufacturing plants, ♦...

  • Page 158: Removing And Installing Toothed Belt

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Unhook bottom toothed belt guard -1- upwards and remove.
  • Page 159 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove top toothed belt guard ⇒ “2.3 Removing and installing toothed belt guard”, page 142 –...
  • Page 160 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen screw -arrow- for camshaft sprocket; to do so, use counterholder - T10172- or -T10172A- with adapters - T10172/11- .
  • Page 161 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Then turn the eccentric of the tensioning pulley with the offset screwdriver - T10264- clockwise -arrow- up to the stop and tighten nut -1- by hand.
  • Page 162 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • The sheet peg -arrow- of the tensioning pulley must engage in the cast iron recess of the cylinder head.
  • Page 163 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • Lock hub of high pressure pump with rig pin - T10492- -3-.
  • Page 164 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Check whether the locking screw -1- is located between the centre elongated hole and the bottom stop -2-, where neces‐...
  • Page 165 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Make sure that the marking on the toothed belt gear is not flush with the rig pin.
  • Page 166 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • The tensioning pulley pointer -2- must be positioned in the centre between the pegs -1- and -3- of the base plate.

  • Page 167: Remove The Toothed Belt From The Camshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 NOTICE The tightening torque that is applied when loosening or tight‐ ening the central bolts on the camshaft must not be transferred to the rig pin under any circumstances.
  • Page 168 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove top toothed belt guard ⇒ “2.3 Removing and installing toothed belt guard”, page 142 –...
  • Page 169 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen screw -arrow- for camshaft sprocket; to do so, use counterholder - T10172- or -T10172A- with adapters - T10172/11- .
  • Page 170 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Then turn the eccentric of the tensioning pulley with the offset screwdriver - T10264- clockwise -arrow- up to the stop and tighten nut -1- by hand.

  • Page 171: Valve Gear

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Valve gear ⇒ “3.1 Assembly overview - valve gear”, page 163 ⇒ “3.2 Removing and installing gasket ring for camshaft”, page 166 ⇒...
  • Page 172 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw ❑ Tightening torque ⇒ “1.1 Summary of com‐ ponents - Glow plug system”, page 700...
  • Page 173 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 13 - Sealing ring ❑ If present ❑ integrated into camshaft housing Pos. -15- from 05/2015 ❑...

  • Page 174: Removing And Installing Gasket Ring For Camshaft

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ mark the fitting position for re-installation ❑ oil the contact surfaces before installing 30 - Roller rocker finger ❑...
  • Page 175 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 NOTICE ♦ If it is turned back too much, the inner pressure plate loosens -T10443- from the pressure screw.

  • Page 176: Removing And Installing Camshaft Control

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing camshaft con‐ trol ⇒ “3.3.1 Removing and installing camshaft control”, page 168 ⇒...
  • Page 177 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Lock the inlet camshaft with rig pin - T10492- . Please note the...
  • Page 178 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew setting valve -2- and remove camshaft adjuster -1-. Installing NOTICE A thrust washer Pos. -20- is installed between camshaft adjust‐...
  • Page 179 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Turn the crankshaft using the screw on the toothed belt gear until the camshaft sprocket is in the “TDC” position.
  • Page 180 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 the cylinder head cover is removed: • The groove -1- on the rig pin - T10492- must line up with the camshaft housing -2-.

  • Page 181: Removing And Installing Camshaft Control Valve 1 N205

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing camshaft con‐ trol valve 1 - N205- Vehicles up to 05/2015.

  • Page 182: Removing And Installing Valve Stem Seals

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove cylinder head cover ⇒ “1.4 Removing and installing cylinder head cover”, page 124 –...
  • Page 183 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Cylinders 1, 3, 4 – Position the guide plate -VAS 5161A/31- onto the cylinder head.
  • Page 184 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Screw the detent part -VAS 5161/6- with the interlocking fork -VAS 5161/5- into the guide plate.
  • Page 185 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Re-insert the assembly cartridge into the guide plate -VAS 5161 A/31- .
  • Page 186 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Position the guide plate -VAS 5161A/31- onto the cylinder head. • Labelling -A- points to the outlet side.
  • Page 187 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Pull off valve stem seal with the valve steam seal extractor - MP1-230 (3364)- .

  • Page 188: Inlet And Exhaust Valves

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Inlet and exhaust valves ⇒ “4.1 inspecting valve guides”, page 180 ⇒ “4.2 Valve dimensions”, page 181...

  • Page 189: Valve Dimensions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Valve dimensions Note Inlet and exhaust valves must not be reworked. Only lapping-in is permitted.

  • Page 190: Lubrication

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 17 – Lubrication Sump, oil pump ⇒ “1.1 Assembly overview - pan/oil pump”, page 182 ⇒...
  • Page 191 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw ❑ self-locking ❑ Replace after disas‐ sembly ❑ 8 Nm...
  • Page 192 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 14 - Fitting sleeve 15 - Cylinder block 16 - O-ring ❑ Replace after disassembly 17 - Oil pressure control valve - N428- ❑...
  • Page 193 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ ⇒ Maintenance ; Booklet Octavia III . 1 - Oil pressure control valve - N428- ❑...
  • Page 194 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 16 - Screw ❑ for oil pan shell ❑ tightening order and tightening torque ⇒...

  • Page 195: Removing And Installing Oil Pan

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Oil sump top part - tightening torque and tightening order Note 3 bolts -9- to -11- are coated with special sealing point; note ♦...
  • Page 196 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Silicone sealant ⇒ ETKA - Electronic Catalogue of Original Parts ♦ Sealant remover Gasket Stripper (stock code GST, stock item No.
  • Page 197 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Screw out screws -arrows- of oil pan/gearbox. – Loosen screws -1- to -20- crosswise and remove.
  • Page 198 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Apply sealant bead onto the clean sealing surfaces of the oil sump, as shown in the illustration.

  • Page 199: Removing And Installing The Bottom Part Of The Oil Sump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Apply sealant bead onto the clean sealing surfaces of the oil sump, as shown in the illustration.
  • Page 200 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Protective goggles and gloves Removing – Removing the sound damper ⇒ External body repairs; Rep.
  • Page 201 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen and remove screws -1- to -20-. – Screw in the screw for the oil sump bottom part by 3 turn for the welded-on nut -arrow-.

  • Page 202: Removing And Installing Top Part Of The Oil Sump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Cut off nozzle tube at the front marking (∅ of nozzle approx.
  • Page 203 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Silicone sealant ⇒ ETKA - Electronic Catalogue of Original Parts ♦ Sealant remover Gasket Stripper (stock code GST, stock item No.
  • Page 204 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Cut off nozzle tube at the front marking (∅ of nozzle approx.
  • Page 205 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 When the sealing flange on the belt pulley side WAS replaced – Apply a silicone sealant bead -2- evenly onto the clean sealing surface of the oil sump top part -1- as shown in the illustration.

  • Page 206: Removing And Installing Oil Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing oil pump Removing Vehicles with one-part oil sump – Removing the oil pan ⇒...

  • Page 207: Removing And Installing Oil Level And Oil Temperature Sender G266

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing oil level and oil temperature sender - G266- ⇒ “1.6.1 Removing and installing oil level and oil temperature sender G266 ”, page 199...
  • Page 208 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -1- and remove oil level and oil temperature transmitter - G266- Pos. -3-.
  • Page 209 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock and disconnect electrical plug connection -3- on the oil level and oil temperature sender - G266- .

  • Page 210: Engine Oil Cooler

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Engine oil cooler Note The engine oil cooler must not be disconnected from the oil filter...

  • Page 211: Oil Filter, Oil Pressure Switch

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Oil filter, oil pressure switch ⇒ “3.1 Summary of components - oil filter housing/oil pressure switch”, page 203...
  • Page 212 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ check in ⇒ Vehicle diagnostic tester Targeted fault finding ❑ Removing and installing ⇒...

  • Page 213: Removing And Installing Oil Pressure Switch F1

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing oil pressure switch - F1- ⇒ “3.2.1 Removing and installing the oil pressure switch F1 , Oc‐...
  • Page 214 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect plug connection -arrow-. Note Place a cloth below to absorb leaking engine oil.

  • Page 215: Removing And Installing Oil Pressure Switch For Reduced Oil Pressure F378

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect plug connection -arrow-. Note Place a cloth below to absorb leaking engine oil.
  • Page 216 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect plug connection -arrow-. Note Place a cloth below to absorb leaking engine oil.

  • Page 217: Testing Oil Pressure

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect plug connection -arrow-. Note Place a cloth below to absorb leaking engine oil.
  • Page 218 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The engine oil cooler must not be disconnected from the oil ♦...
  • Page 219 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -4-. – Unscrew screws -3- and push pump for charge air cooler - V188- Pos.

  • Page 220: Removing And Installing Valve For Oil Pressure Control N428

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Place a cloth below to absorb leaking engine oil. – Unscrew screws in the order -5- … -1-, remove oil filter housing together with the engine oil cooler.
  • Page 221 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 compressor; removing and installing AC compressor and strap to the right side. – Separate electrical plug connection -1-.

  • Page 222: Oil Circuit

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Oil circuit ⇒ “4.1 Removing and installing oil flow line”, page 214 ⇒ “4.2 Removing and installing the exhaust gas turbocharger oil return line”, page 215...

  • Page 223: Removing And Installing The Exhaust Gas Turbocharger Oil Return Line

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Continued for all vehicles – Unscrew bolt -2-. – Unscrew union nut -4-.
  • Page 224 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with four-wheel drive – Remove radiator for exhaust gas recirculation ⇒ “5.3 Removing and installing radiator for exhaust gas recir‐...

  • Page 225: Cooling

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 19 – Cooling Cooling system, coolant ⇒ “1.1 Connection diagram - coolant hoses”, page 217 ⇒...
  • Page 226 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Charge air cooling circuit radiator 2 - Charge air cooler ❑ Check for leaks ⇒...
  • Page 227 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles fitted with auxiliary heating Note Blue = large coolant circuit. ♦ Red = small coolant circuit.
  • Page 228 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 16 - Coolant regulator 17 - Engine oil cooler 18 - Coolant radiator...
  • Page 229 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Charge air cooling circuit radiator 2 - Charge air cooler ❑ Check for leaks ⇒...
  • Page 230 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Charge air cooling circuit radiator 2 - Charge air cooler ❑ Check for leaks ⇒...
  • Page 231 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.1.3 Connection diagram - coolant hoses, engine codes CRKB, CRVC, CRMB, CUNA, CXXA, CXXB, DBKA, CXMA,...
  • Page 232 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 13 - Coolant connector 14 - Gearbox oil cooler ❑ Equipment variants 15 - Coolant regulator...
  • Page 233 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 14 - Coolant connector 15 - Gearbox oil cooler ❑ Equipment variants 16 - Coolant regulator...
  • Page 234 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Charge air cooling circuit radiator 2 - Charge air cooler ❑ Check for leaks ⇒...

  • Page 235: Check Cooling System For Leaks

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 22 - Non-return valve 23 - Coolant radiator ❑ Summary of components ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 338...
  • Page 236 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Use the cooling system testing device to build up pressure to 0.3 MPa (3.0 bar).
  • Page 237 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fit the cooling system testing device - V.A.G 1274 B- with adapter -V.A.G 1274/8- onto the coolant expansion tank.

  • Page 238: Draining The Cooling System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Draining the cooling system ⇒ “1.3.1 Draining the cooling system, Octavia III”, page 230 ⇒...
  • Page 239 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamp -arrow-, remove bottom right coolant hose from charge air cooling circuit radiator and allow coolant to drain.
  • Page 240 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Continued for all vehicles – Loosen hose clamp -arrow-, remove bottom coolant hose to heating backup pump - V488- , allow coolant to drain.
  • Page 241 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamp -arrow-, remove bottom left coolant hose from charge air cooling circuit radiator and allow coolant to drain.
  • Page 242 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the cap -1- of the coolant expansion reservoir. – Remove the noise insulation ⇒ General body repairs, exterior;...

  • Page 243: Filling With Coolant

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Filling with coolant ⇒ “1.4.1 Filling with coolant without the electric vacuum pump, Octavia III”, page 235...
  • Page 244 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The drained coolant must not be re-used. ♦ Observe the disposal instructions.
  • Page 245 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the valve -B-, while doing so turn the lever in the direction of flow.
  • Page 246 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fill up coolant to “max” marking. Note Hose connections and air guide pipes and hoses must be free of oil and grease before being installed.
  • Page 247 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.4.2 Filling coolant without the electric vac‐ uum pump, Yeti • The coolant has been drained ⇒...
  • Page 248 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Work procedure – Connect coolant hose -arrow- to bottom left of radiator. – Connect coolant hose -arrow- to bottom of the heating backup pump - V488- .
  • Page 249 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the valve -B-, while doing so turn the lever in the direction of flow.
  • Page 250 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fill up coolant to “max” marking. Note Hose connections and air guide pipes and hoses must be free of oil and grease before being installed.
  • Page 251 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.4.3 Filling coolant without the electric vac‐ uum pump, Rapid NH • The coolant has been drained ⇒...
  • Page 252 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Work procedure – Connect coolant hose -arrow- to bottom left of radiator. – Connect coolant hoses with hose couplings -1-, -2- to charge air cooling circuit radiator.
  • Page 253 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the valve -B-, while doing so turn the lever in the direction of flow.
  • Page 254 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fill up coolant to “max” marking. Note Hose connections and air guide pipes and hoses must be free of oil and grease before being installed.
  • Page 255 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note By using the electric vacuum pump - VAS 6096/2- , a higher vac‐...
  • Page 256 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Set up the coolant reservoir - VAS 6968- in such a way that it...
  • Page 257 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Build up a vacuum with the electric vacuum pump until the pointer on the pressure gauge is -arrow- clearly below the green area.
  • Page 258 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the stopcock -A- »slowly« to prevent the refrigerant from foaming up.

  • Page 259: Checking The Filling Quality

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • If the engine is at operating temperature, the coolant level must be at the »weld seam« -arrow-.
  • Page 260 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Check coolant level, it must be approx. 5 mm -arrow- above the max mark. If necessary, top up with coolant.

  • Page 261: Checking The Electric Vacuum Pump Vas 6096/2

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Checking the electric vacuum pump - VAS 6096/2- Note In order to ensure correct filling of the cooling system, a check must be carried out before using the cooling system filling device - VAS 6096- and the electric vacuum pump - VAS 6096/2- .
  • Page 262 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The cooling system is first flushed with approx. 12 litres of dis‐...
  • Page 263 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 7 - Vane pump ❑ Shutoff pressure: approx. 0.15 MPa (1.5 bar) 8 - Valve block ❑...
  • Page 264 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect the discharge hose -arrow- to the quick coupling -B- on the valve block.
  • Page 265 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect the discharge hose -arrow- from the quick coupling -B- on the valve block.
  • Page 266 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Guide the bleeder hose -8- for ejector into a container. – Connect the vacuum hose -6- to the suction spray pump -7-.
  • Page 267 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • The pump -VAS 531 007- must be switched on. – »Slowly« open the shut-off tap -A- to avoid coolant foaming.
  • Page 268 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect the bleeder hose -2- for the coolant expansion res‐ ervoir to the flushing hose -1-.
  • Page 269 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 A non-return valve -1- is installed in the bleeder hose of the charge air cooler.
  • Page 270 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close the bleeder hoses with hose clamps at the points indi‐ cated.
  • Page 271 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close the bleeder hoses with hose clamps at the points indi‐ cated.
  • Page 272 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close the bleeder hoses with hose clamps at the points indi‐ cated.
  • Page 273 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Repeat flushing steps 1-4 times, but always only pump approx. 1 litre of distilled water ⇒...
  • Page 274 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Check the inspection glass: if you can see the coolant coming out in the inspection glass, close the shut-off tap -A-.
  • Page 275 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close the bleeder hoses with hose clamps at the points indi‐ cated.
  • Page 276 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close the bleeder hoses with hose clamps at the points indi‐ cated.
  • Page 277 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Disconnect the coolant flushing and charge unit - VAS 531 007- : – Open the shut-off tap -B- and leave open to dissipate the pres‐...
  • Page 278 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Use the adapter for extraction, Pos. -14-, to extract coolant ⇒ Item 14 (page 255) –...
  • Page 279 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect vehicle diagnostic tester . – Switch on the ignition and select the following options on the vehicle diagnostic tester : ♦...
  • Page 280 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note If the coolant stays in the inspection glass for a long time, it may discolour. The inspection glass must ♦...

  • Page 281: Flushing Cooling System, Quick Start Guide

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Flushing cooling system, quick start guide Note The Quick Start Guide lists the main steps in the workflow. These can be printed and scraped during the workflow.
  • Page 282 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Hoses for charge air cooler 2 - Vent hose for cooler for...

  • Page 283: Coolant Pump, Regulation Of Cooling System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Coolant pump, regulation of cooling system ⇒ “2.1 Summary of components - coolant pump/thermostat”, page ⇒...
  • Page 284 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - O-rings ❑ Replace after disas‐ sembly ❑ Moisten with coolant 2 - Connection fitting 3 - O-ring ❑...
  • Page 285 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 17 - Coolant regulator housing 18 - O-ring ❑ Replace after disassembly ❑ Moisten with coolant 19 - Coolant regulator ❑...
  • Page 286 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Coolant regulator ❑ Removing and installing ⇒ “2.6 Removing and installing coolant regulator”, page 300 11 - O-ring ❑...

  • Page 287: Summary Of Components - Electric Coolant Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Summary of components - electric cool‐ ant pump ⇒ “2.2.1 Pump for charge air cooler V188 , heating backup pump V488 , variant 1”, page 279...
  • Page 288 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.2.2 Charge air cooler pump - V188- , variant 2 1 - Retaining clip 2 - Screw ❑...
  • Page 289 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.2.3 Heating backup pump - V488- , variant 2 1 - Screw ❑ 1.5 Nm...
  • Page 290 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.2.4 Charge air cooler pump - V188- , variant 3 1 - Screw ❑...
  • Page 291 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.2.5 Heating backup pump - V488- , variant 3 1 - Screw ❑ 40 Nm...

  • Page 292: Summary Of Components - Coolant Temperature Transmitter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.2.6 Charge air cooler pump - V188- , variant 4 1 - Screw ❑...

  • Page 293: Removing And Installing Electric Coolant Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Coolant temperature trans‐ mitter - G62- ❑ Removing and installing ⇒ “2.9 Removing and in‐...
  • Page 294 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Hose binding claw - VAS 6362- ♦ Catch pan , e.g. -VAS 6208- Vehicles with charge air cooler pump - V188- variant 1 ⇒...
  • Page 295 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with charge air cooler pump - V188- variant 2 – Separate electrical plug connection -3-.
  • Page 296 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the heating backup pump - V488- has to be removed ⇒ page 288...
  • Page 297 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose wiring loom. – Release and disconnect electrical plug connection -6-. – Unscrew bolt -2-.
  • Page 298 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the heating backup pump - V488- has to be removed – Disconnect electrical plug connection -arrow- on the oil level and temperature sender - G266- and pull off.
  • Page 299 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release and disconnect electrical plug connection -6-. – Unscrew bolt -2-. – Lay heating backup pump - V488- -5- to the side.
  • Page 300 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the charge air cooler pump - V188- has to be removed from the mounting bracket for reasons of space ⇒...
  • Page 301 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the charge air cooler pump - V188- has to be removed – Place a catch pan for workshop crane - VAS 6208- under‐...
  • Page 302 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Sound damper - overview of components ⇒ External body‐ work; Rep. gr. 66 ; Sound damper; Removing and installing sound damper , possibly.
  • Page 303 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Pull the heating backup pump - V488- -4- out of the mounting bracket -3-.
  • Page 304 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the heating backup pump - V488- has been removed from the bracket –...
  • Page 305 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the charge air cooler pump - V188- has to be removed from the engine for reasons of space –...

  • Page 306: Removing And Installing Coolant Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the heating backup pump - V488- has to be removed from the support –...
  • Page 307 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Continued for all vehicles – Remove the toothed belt from the camshaft ⇒ “2.5 Remove the toothed belt from the camshaft”, page 159 –...

  • Page 308: Removing And Installing Coolant Regulator

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing coolant regula‐ ⇒ “2.6.1 Removing and installing coolant thermostat, Octavia III, Yeti, variant 1”, page 300...
  • Page 309 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Insert coolant regulator -2- into the coolant regulator housing. • The retaining lugs must engage in the guides -arrows-.
  • Page 310 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release top hose clamp -arrow-. – Detach coolant hose -2- from the coolant thermostat housing -1-.
  • Page 311 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Remove connection fitting -1-. – Remove thermostat. Installing Installation is carried out in the reverse order.

  • Page 312: Testing The Coolant Regulator

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock catch peg in direction of arrow -B- (from the top using a screwdriver).

  • Page 313: Removing And Installing Coolant Temperature Transmitter G62

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection -2-, expose electric ca‐ ble. – Unscrew screw -3- and remove coolant valve for cylinder head - N489- Pos.
  • Page 314 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose electric wiring loom -1-. – Release nut -4- and screws -2-, -3-.
  • Page 315 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.9.2 Removing and installing the coolant temperature transmitter - G62- , Rapid Removing Test condition •...
  • Page 316 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -1-. – Unscrew double screw -2-, remove coolant temperature trans‐...

  • Page 317: Coolant Pipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Coolant pipes ⇒ “3.1 Summary of components - coolant pipe”, page 309 ⇒ “3.2 Removing and installing coolant pipes”, page 312 Summary of components - coolant pipe ⇒...
  • Page 318 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9 - Screw ❑ 23 Nm 10 - Nut ❑ 10 Nm 11 - The coolant pipe at the rear ❑...
  • Page 319 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.1.2 Summary of components - coolant pipes, Rapid NH Note The arrows on the coolant pipes and the coolant hose ends must face each other.

  • Page 320: Removing And Installing Coolant Pipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 14 - Left coolant pipe ❑ Removing and installing ⇒ “3.2.10 Removing and installing the left coolant pipes, Rapid NH”, page 328 15 - Nut ❑...
  • Page 321 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fit radiator protection mat - VAS 531 003- to vehicle, as shown.
  • Page 322 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove screws -2-. Note The number of connected coolant hoses is different, depending on build version.
  • Page 323 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Fit radiator protection mat - VAS 531 003- to vehicle, as shown.
  • Page 324 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew bolt -1-. – Loosen hose clamps -arrows- and disconnect coolant hoses.
  • Page 325 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 For vehicles with engine identification characters CLHA, CLHB, CKFB, CKFC, CUPA, CRVC, CYKA –...
  • Page 326 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamp -1-, remove coolant hose. – Release screw -4-. – Pull off coolant pipe bottom front -3- and remove, do not dam‐...
  • Page 327 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise hose clamp -4-, remove coolant hose. – Unscrew screws -arrows-. – Pull off locking clip -2-, pull off coolant thermostat housing -3- from bottom front -1- and remove.
  • Page 328 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamp -1-, remove coolant hose. – Release screw -4-. – Pull off coolant pipe bottom front -3- and remove, do not dam‐...
  • Page 329 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove air filter ⇒ “4.2 Removing and installing air filter housing”, page 476 –...
  • Page 330 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.2.6 Removing and installing the front left coolant pipe, Octavia III, Yeti Special tools and workshop equipment required ♦...
  • Page 331 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamp -1-, remove coolant connection fittings. – Release screw -2-.
  • Page 332 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.2.7 Removing and installing the front left coolant pipe, Rapid NH Special tools and workshop equipment required ♦...
  • Page 333 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamp -1-, remove coolant connection fittings. – Release screw -2-.
  • Page 334 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove AC compressor with connected refrigerant hoses from the holder ⇒ Heating, Air Conditioning; Rep. gr. 87 ; AC compressor;...
  • Page 335 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Drain coolant ⇒ “1.4 Filling with coolant”, page 235 – Remove air guide pipe ⇒...
  • Page 336 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Expose electric wiring loom -1-. – Release nut -4- and screws -2- and -3-.
  • Page 337 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove air filter housing ⇒ “4.2 Removing and installing air filter housing”, page 476 –...
  • Page 338 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Hose binding claw - VAS 6362- Removing – Remove the sound dampening system ⇒ General body re‐...
  • Page 339 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamp-4-, remove coolant hose, allow coolant to drain. – Loosen hose clamps -1-, remove coolant hoses.
  • Page 340 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Loosen hose clamp -2-, remove air guide pipe -1-.
  • Page 341 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamps -arrows- and disconnect coolant hoses. – Unscrew screws -1- and nuts -2- and remove rear coolant pipe.
  • Page 342 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Drain coolant ⇒ “1.4 Filling with coolant”, page 235 – Remove rear coolant pipe ⇒...
  • Page 343 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Press heat protection sleeve to the side, disconnect electrical plug connection -5-.
  • Page 344 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamp -1-, remove coolant hose. – Unscrew double screw -2- and screw -3-, remove rear right coolant pipe.
  • Page 345 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing Note Fit all heat protection sleeves on again in the same place when installing.

  • Page 346: Coolers, Radiator, Radiator Fan

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Coolers, radiator, radiator fan ⇒ “4.1 Assembly overview - radiator/radiator fan”, page 338 ⇒...
  • Page 347 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Coolant radiator ❑ Removing and installing ⇒ “4.4 Removing and in‐...
  • Page 348 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Moisten with coolant 4.1.2 Overview of components - Radiator, Oc‐ tavia III, Variant 2...
  • Page 349 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - O-ring ❑ Replace hose if damaged Pos. -11- ⇒ Item 11 (page 341) ❑...
  • Page 350 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Coolant hose ❑ to remove, raise the holding clamps ❑ Connect ⇒...
  • Page 351 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Connect ⇒ “4.1.6 Quick couplings of the coolant hoses”, page 346 4.1.4...
  • Page 352 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Air guide (air guide duct) 11 - Air guide (air guide duct) ❑...
  • Page 353 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Condenser (radiator) ❑ installing and removing ⇒ Heating, Air Condi‐ tioning; Rep. gr. 87 ;...
  • Page 354 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 14 - Coolant hose ❑ for coolant circuit for charge air cooler ❑ to remove, raise the holding clamps ❑...

  • Page 355: Summary Of Components - Fan Shroud And Radiator Fan

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Summary of components - fan shroud and radiator fan ⇒ “4.2.1 Summary of components - fan shroud with radiator fan V7 , variant 1”, page 347...
  • Page 356 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.2.2 Summary of components - fan shroud with radiator fan - V7- , variant 2 1 - Bolt ❑...
  • Page 357 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.2.3 Summary of components - fan shroud with radiator fan - V7- and radiator...
  • Page 358 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.2.4 Summary of components - fan shroud with radiator fan - V7- and radiator...

  • Page 359: Summary Of Components - Radiator Blind

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Summary of components - radiator blind ⇒ “4.3.1 Summary of components - radiator blind”, page 351 ⇒...
  • Page 360 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Wiring loom placement on the frame of the radiator blind – Wiring loom -2- for the control motor for radiator blind - V544- is attached in the retaining tab in the frame of the radiator blind -1- -arrows-.

  • Page 361: Removing And Installing Radiator

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Arrangement of the fins 1 - Left flaps 2 - Right flaps Šipka - Control flap Removing and installing radiator ⇒...
  • Page 362 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Detach coolant hose -2-. – Unlock catches -arrows-, remove top part-1- of air guide.
  • Page 363 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Raise holding clamps -1-, -2- and remove coolant hoses from charge air circuit cooler.
  • Page 364 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock the latches left and right -arrow A- and raise the con‐...
  • Page 365 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with radiator variant 3 – Unlock catches on the radiator -1- for the charge air circuit arrows -A- –...
  • Page 366 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove top and bottom part of the air guide duct Pos. -4- and ⇒...
  • Page 367 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew fixing screws -1-. – Remove radiator -2- downwards. Installing Installation is carried out in the reverse order. However, pay at‐...
  • Page 368 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Drain coolant ⇒ “1.4 Filling with coolant”, page 235 – Remove the front bumper ⇒ General body repairs, exterior;...
  • Page 369 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Slide a wide cross-head screwdriver into the left lock of the radiator for charge air cooler -1- at the front and rear.

  • Page 370: Removing And Installing Charge Air Cooling Circuit

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Insert the charge air cooler -2- into the right support. – Lock the charge air cooler -2- to the supports of the radiator -1-.
  • Page 371 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove radiator ⇒ “4.4.2 Removing and installing radiator, Yeti”, page 357 – Release clamps -1-.
  • Page 372 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove screws -1-. • Assistance of a second mechanic is required. – Disconnect additional radiator -3- from condenser -2-.

  • Page 373: Removing And Installing Fan Shroud

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing fan shroud ⇒ “4.6.1 Removing and installing fan shroud, Octavia III”, page 365 ⇒...
  • Page 374 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electric plug connection -1- for radiator fan. – To do so, slide the securing mechanism in direction of arrow -A- and then push the release downwards.
  • Page 375 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ⇒ “4.1.1 Summary of components - air filter housing, Octavia III, Yeti”, page 473 –...
  • Page 376 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screw -2-, remove air guide duct -1-. – Disconnect the electrical plug connection -1- of the bottom ra‐...

  • Page 377: Removing And Installing Radiator Fan V7

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing radiator fan - ⇒ “4.7.1 Removing and installing radiator fans V7 and V177 ”, page 369 4.7.1...

  • Page 378: Removing And Installing The Radiator Blind Control Motor V544

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Disassembly tool for door panel - T10236- ♦ Disassembly wedge - 3409- Removing –...
  • Page 379 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Put the flaps of the radiator blind to “open”, as shown in the illustration.
  • Page 380 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Mark the fitting position of the connecting bridge -1-. – Use the plug -5- as reference point.
  • Page 381 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Bring connecting bridge -1- to correct fitting position. To do this, use the mark prepared earlier or use the plug -5- as reference point.

  • Page 382: Turbocharging/Supercharging

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 21 – Turbocharging/supercharging Exhaust gas turbocharger ⇒ “1.1 Summary of components - exhaust gas turbocharger”, page 374 ⇒...
  • Page 383 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - hollow bolt ❑ 30 Nm 2 - Oil feed line ❑ check continuity ❑...
  • Page 384 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 17 - Heat shield 18 - Exhaust gas turbocharger ❑ Removing and installing ⇒...
  • Page 385 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.1.2 Overview of components - Exhaust gas turbocharger with attachments, vehicles with emission standard EU4...
  • Page 386 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 13 - Seal ❑ Replace after disassembly 14 - Connecting pipe ❑ to radiator for exhaust gas recirculation 15 - Nut ❑...
  • Page 387 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Exhaust gas turbocharger - tightening torque and tightening order – Tighten bolts step by step in the given sequence:...
  • Page 388 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - hollow bolt ❑ 30 Nm 2 - Sealing rings ❑ replace 3 - Oil feed line ❑...
  • Page 389 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 19 - Screw ❑ 8 Nm 20 - Heat shield 21 - Circlip ❑...

  • Page 390: Removing And Installing Exhaust Gas Turbocharger

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing exhaust gas turbocharger ⇒ “1.2.1 Removing and installing exhaust gas turbocharger, Oc‐...
  • Page 391 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Continued for all vehicles – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...
  • Page 392 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vehicles with water pipe above the exhaust gas cleaner – Open hose clamp -1-, remove coolant hose.
  • Page 393 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release nut -2- and remove union nut -4-. – Unscrew screws -3-, -5-, remove oil return-flow line.
  • Page 394 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 395 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – When installing the coolant pipe -1-, ensure that the guide -2- is seated correctly in the holder.
  • Page 396 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ ⇒ “4.1 Summary of components - exhaust temperature regu‐ lation”, page 647 ♦...
  • Page 397 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...
  • Page 398 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows- and remove heat shield -1-. – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 399 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew nuts -arrows- and detach the exhaust gas turbo‐ charger with exhaust manifold -1- from the cylinder head, and remove from the top.
  • Page 400 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The function to increase oil pressure does not always have to ♦...
  • Page 401 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Observe rules for cleanliness ♦ ⇒ “3.1 Rules of cleanliness”, page 7 Observe general instructions for charge-air system ♦...
  • Page 402 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove the vacuum hose -2- from the vacuum unit for charge pressure control.
  • Page 403 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew nuts -arrows- and detach the exhaust gas turbo‐ charger with exhaust manifold from the cylinder head and remove downwards.
  • Page 404 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note The function to increase oil pressure does not always have to ♦...
  • Page 405 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Observe rules for cleanliness ♦ ⇒ “3.1 Rules of cleanliness”, page 7 Observe general instructions for charge-air system ♦...
  • Page 406 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows- and remove container with pre-cubic contents -1-. – Disconnect electrical plug connections and expose wiring loom.
  • Page 407 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -1- … -4- and remove bracket for exhaust gas cleaning module.
  • Page 408 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew nuts -arrows- and remove the exhaust gas turbo‐ charger with exhaust manifold from the cylinder head.

  • Page 409: Replacing Exhaust Gas Turbocharger Pressure Box

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 410 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Version 1 – Disconnect the electrical plug connection -3- from the position transmitter for charge pressure regulator - G581- .
  • Page 411 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Version 1 – Hook the control rod into the adjuster lever. – Position pressure box and screw in screws -1- by hand until it stops.
  • Page 412 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – 3Put the sliding ring -1- of the hand vacuum pump - VAS 6213- in position -A- for “vacuum”.
  • Page 413 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Version 2 – Slide the pressure box in the -direction of arrow- until a voltage of 0.75 ±...
  • Page 414 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Voltage not OK. Note Variant 1 is shown. – Release screws -1-. – Adjust the voltage value ⇒...

  • Page 415: Removing And Installing The Exhaust Gas Turbocharger Connection Fitting

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release and disconnect the electrical plug connection -2- from the position sender for charge pressure regulator - G581- .
  • Page 416 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Hose binding claw - VAS 6362- – If present, detach vacuum hose -arrow-.

  • Page 417: Charge-Air System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Charge-air system ⇒ “2.1 Summary of components - charge air system”, page 409 ⇒...
  • Page 418 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Check for leaks ⇒ “2.3 Checking the charge-air system for leak-tightness”, page 411 12 - Screw ❑...

  • Page 419: Removing And Installing Charge Pressure Sender G31

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing charge pres‐ sure sender - G31- Removing – Remove engine cover ⇒...
  • Page 420 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect vacuum hoses on the air guide pipe -arrows-. – Loosen hose clamps -1-, -2-, and remove air guide pipe.
  • Page 421 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew pressure control valve -2- fully and close the valves -3- and -4-.
  • Page 422 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect the pneumatic hose -1- (pneumatic support) to tester for charge air system.
  • Page 423 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Hose binding claw Preparing the adapter - V.A.G 1687/15- – Shorten the adapter - V.A.G 1687/15- to 70 mm.
  • Page 424 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect adapter - V.A.G 1687/11- with -V.A.G 1687/15- and -V.A.G 1687/19- to the exhaust gas turbocharger.
  • Page 425 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect the pneumatic hose -1- (pneumatic support) to tester for charge air system.

  • Page 426: Installing And Removing The Air Guide Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Read off the turbocharger tester - V.A.G 1397A- – The pressure must stay at 0.05 MPa (0.5 bar).

  • Page 427: Leak Testing The Charge Air Cooler

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Remove air guide pipe -1-. Installing Installation is carried out in the reverse order. When installing,...
  • Page 428 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Connect tester for charge air systems - V.A.G 1687- – Remove engine cover ⇒...
  • Page 429 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Prepare tester for charge air system - V.A.G 1687- as follows: – Pull the pressure control valve -2- upwards and unscrews completely, then close valves -3- and -4-.
  • Page 430 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Clean Y distributor - VAS 691 005/1- Note After completing the leakage test, the Y distributor - VAS 691 005/1- must be cleaned to remove any moisture that has got in.

  • Page 431: Mixture Preparation - Injection

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 23 – Mixture preparation - injection Injection system ⇒ “1.1 Schematic overview - fuel system”, page 423 ⇒...
  • Page 432 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Injection units ❑ Summary of compo‐ nents ⇒ “3.1 Summary of com‐...
  • Page 433 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.1.2 Schematic overview - fuel system, Del‐ phi, Octavia III Note Injection system assignment ♦...
  • Page 434 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Removal and installation ⇒ “6.1 Removing and installing the fuel pressure regulating valve N276 ”, page 496 6 - High pressure pump ❑...
  • Page 435 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Fuel filter ❑ ⇒ Rep. gr. 20 ; Fuel fil‐ ter; Summary of compo‐...

  • Page 436: Installation Location Overview - Fuel Injection System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installation location overview - fuel in‐ jection system ⇒ “1.2.1 Installation location overview in engine compartment, Octavia III, Yeti”, page 428...
  • Page 437 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Coolant valve for cylinder head - N489- ❑ Fitting location ⇒ page 431 2 - Injection units ♦...
  • Page 438 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 12 - Intake air temperature sender - G42- ❑ Summary of components ⇒ “5.1 Assembly overview - intake manifold”, page 481 13 - Fuel pressure regulating valve - N276- ❑...
  • Page 439 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Accelerator pedal module - GX2- The accelerator pedal module - GX2- consists of: ♦...
  • Page 440 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Faults can be detected by the control unit as checking and ♦...
  • Page 441 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9 - Air mass meter - G70- ❑ Fitting location ⇒ “4.1 Assembly overview - air filter housing”, page 473 10 - NOx sender control unit - J583- ❑...
  • Page 442 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 21 - High pressure pump ❑ with fuel dosage valve - N290- (do not remove valve) ❑...
  • Page 443 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Changeover valve for radiator of exhaust gas recirculation - N345- ♦ Summary of components ⇒...
  • Page 444 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Pressure sensor for the brake servo unit - G294- ❑ provides signals to the ABS control unit - J104-...
  • Page 445 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Fitting location of gearbox neutral position transmitter - G701- ♦ On front of manual gearbox -arrow-.
  • Page 446 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Differential pressure trans‐ mitter - G505- ❑ its use depends on ex‐...
  • Page 447 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 6 - Injection valve for cylinder 4 - N33- ❑ ⇒ “3.1 Summary of components - injection units (injectors)”, page 452 ❑...
  • Page 448 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.2.4 Installation overview - engine from front 1 - Oil pressure control valve - N428- ❑...
  • Page 449 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.2.5 Installation location overview - engine from rear, vehicles without SCR sys‐ Note The summary of components only applies to vehicles with engine identification characters CLHA, CLHB, CRKB, CKFB, CKFC, CUPA, CRMB, CUNA, CXXA, CXXB, DBKA, CYKA, CXMA, DDYB, DDYA, DCYA.
  • Page 450 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 7 - Exhaust gas temperature sender 4 - G648- ❑ Depending on vehicle ❑...
  • Page 451 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 5 - NOx sender control unit - GX30- consists of NOx sender - G295- and NOx transmitter control unit - J583- ❑...

  • Page 452: Filling/Bleeding The Fuel System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Electrical connectors on the bulkhead, variant 2 Solenoid valve for charge pressure control - N75-...

  • Page 453: Check The Fuel System For Tightness

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Afterwards, carry out a test drive with at least one full load acceleration.

  • Page 454: Vacuum System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Vacuum system ⇒ “2.1 Connection diagram - Vacuum system”, page 446 ⇒ “2.2 Checking the vacuum system”, page 448 ⇒...
  • Page 455 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9 - Vent line 10 - To air filter housing 11 - To vacuum pump ❑...

  • Page 456: Checking The Vacuum System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 6 - Solenoid valve for charge pressure control - N75- 7 - Vent line...
  • Page 457 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock tab -arrow-, remove vacuum hose -1-. – Unscrew screw -3-, remove vacuum hose -2-.
  • Page 458 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -3-. – Unscrew screws -arrows- and remove exhaust gas recircula‐...
  • Page 459 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew bolt -1-. – Unclip vacuum line -2- from clip -3- and cylinder block.

  • Page 460: Injection Units / High Pressure Accumulators (Fuel Distributors)

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Injection units / high pressure accu‐ mulators (fuel distributors) ⇒ “3.1 Summary of components - injection units (injectors)”, page ⇒...
  • Page 461 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Sealing ring ❑ in the cylinder head cov‐ ❑ replace after removal ⇒...

  • Page 462: Summary Of Components - High Pressure Reservoir (Fuel Distributor)

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installation position of the clamping claw, variant 1 • One clamping claw has 2 injection units.
  • Page 463 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Fuel pressure transmitter - G247- ❑ Removing and installing ⇒ “6.3 Removing and in‐...

  • Page 464: Adjust The Correction Values For Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 11 - Screw ❑ 8 Nm Adjust the correction values for injection units ♦...

  • Page 465: Check Injection Unit Return Quantity With Engine Running

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Check injection unit return quantity with engine running Injection system assignment ⇒ page 1 ⇒...
  • Page 466 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 NOTICE There is a risk of malfunctions caused by soiling. ♦ Observe rules for cleanliness ⇒...
  • Page 467 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.5.2 Checking the return flow of the injection units when the engine is running, vehi‐...

  • Page 468: Check Injection Unit Return Flow Quantity At Starter Speed

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Speed Measured time Limit (max.) for injection Matches the VAS 6684 unit scale...
  • Page 469 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 NOTICE There is a risk of malfunctions caused by soiling.
  • Page 470 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.6.2 Checking the return flow of the injection units with starter speed, vehicles with...

  • Page 471: Checking The Injection Units In Open State

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close fuel drain hose -arrow- with the hose clamp up to ∅...

  • Page 472: Removing And Installing The Injection Units

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Note Pay attention to cleanliness, no dirt must get into the fuel sys‐...
  • Page 473 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Extractor - T10055- ♦ Assembly sleeve - T10377- ♦ Puller - T10415- , for Bosch injection system ♦...
  • Page 474 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connections -arrows- from the in‐ jection units. Note Each clamping claw secures 2 injection valves and can only be removed when both injection units are »removed«.
  • Page 475 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 For vehicles with Bosch injection system, assignment ⇒ page 1 – Unscrew bolt -1-.

  • Page 476: Removing And Installing High Pressure Lines

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Replace the sealing ring for the injection unit, using the as‐ sembly sleeve - T10377- .
  • Page 477 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew bolt -1-. NOTICE Avoid risk of malfunctions caused by contamination. – Observe rules for cleanliness ⇒...

  • Page 478: Removing And Installing High Pressure Reservoir (Fuel Distributor)

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Suction off dirt from the sealing cone on the fuel high pressure reservoir.
  • Page 479 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connections: for coolant valve for cylinder head - N489-...
  • Page 480 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connections: 1 - for fuel pressure sender - G247- 3 - for fuel pressure regulating valve - N276- –...

  • Page 481: Air Filter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Air filter ⇒ “4.1 Assembly overview - air filter housing”, page 473 ⇒ “4.2 Removing and installing air filter housing”, page 476 Assembly overview - air filter housing ⇒...
  • Page 482 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ ⇒ Maintenance ; Booklet Octavia III ♦ ⇒ Maintenance ; Booklet Yeti 17 - Insert ❑...
  • Page 483 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.1.2 Summary of components - air filter housing, Rapid NH 1 - Drain pipe ❑...

  • Page 484: Removing And Installing Air Filter Housing

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Removing and installing ⇒ Electrical System; Rep. gr. 27 20 - Screw ❑...
  • Page 485 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect the plug connection -2- at the air mass meter - G70- .
  • Page 486 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.2.2 Removing and installing air filter hous‐ ing, Yeti Removing – Release and take off cover -1- at the catches -arrows-.
  • Page 487 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release the securing tab -arrow- and remove the air filter from the compensating tank upwards.
  • Page 488 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.2.3 Removing and installing the air filter housing, Rapid NH Removing – Unscrew screw -2-, unlock catches arrows -A-.

  • Page 489: Intake Manifold

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Intake manifold ⇒ “5.1 Assembly overview - intake manifold”, page 481 ⇒ “5.2 Removing and installing intake manifold”, page 483 ⇒...
  • Page 490 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 12 - Screw ❑ Replace after disassembly ❑ Tightening torque and tightening order ⇒...

  • Page 491: Removing And Installing Intake Manifold

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Intake manifold with charge air cooler - tightening torque and tightening order – Tighten screws successively.
  • Page 492 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Radiator protection mat , e.g. -VAS 531 003- Removal – Remove front top coolant pipe ⇒...
  • Page 493 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamp -2-. – Unscrew screws -1-, remove connection fittings with throttle valve control unit - J338- .
  • Page 494 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove screws -10- … -1- with the Polydrive socket XZN 10 - T10501- , remove the intake manifold with charge air cooler.
  • Page 495 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Tighten screws -1- … -10- as per the tightening torques and - sequence ⇒...
  • Page 496 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove front top coolant pipe ⇒ “3.2.2 Removing and installing the top front coolant pipes, Rapid NH”, page 314...
  • Page 497 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -2-. – Loosen hose clamp -1-, remove coolant hose.
  • Page 498 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove screws -10- … -1- with the Polydrive socket XZN 10 - T10501- , remove the intake manifold with charge air cooler.

  • Page 499: Removing And Installing The Throttle Valve Control Unit J338

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Tighten screws -1- … -10- as per the tightening torques and - sequence ⇒...
  • Page 500 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...
  • Page 501 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connections: 2 - Intake air temperature sender - G42- 3 - Throttle valve control unit - J338- –...
  • Page 502 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Loosen hose clamp -2-, remove air guide pipe -1-.
  • Page 503 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connections: 2 - Intake air temperature sender - G42- 3 - Throttle valve control unit - J338- –...

  • Page 504: Senders And Sensors

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Senders and sensors ⇒ “6.1 Removing and installing the fuel pressure regulating valve N276 ”, page 496...
  • Page 505 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Version 2 – Removing and installing, Variant 2 ⇒ “6.1.3 Removing and installing the fuel pressure regulating valve N276 , Variant 2”, page 500...
  • Page 506 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release and pull off electrical plug connection -arrow- from fuel pressure sender - G247- .
  • Page 507 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows- and pull back the cable. – Unlock and remove electrical plug connection -2- from Hall sender - G40- .
  • Page 508 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -2-. – Loosen union nuts -1- - to do so, counterhold hex on the high pressure accumulator (fuel distributor).
  • Page 509 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Removing – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...
  • Page 510 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew the fuel pressure regulating valve - N276- -2- from the high pressure accumulator (fuel distributor) -1-.

  • Page 511: Check Fuel Pressure Regulating Valve N276

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Align the fuel pressure regulating valve - N276- -1- with suit‐ able workshop equipment.

  • Page 512: Removing And Installing Fuel Pressure Sender G247

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen hose clamp -arrow- and remove fuel return-flow hose from the high pressure reservoir.
  • Page 513 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing Note Safety precautions when working on the fuel supply system ♦ ⇒ “2 Safety instructions”, page 4 Observe rules for cleanliness ♦...

  • Page 514: Removing And Installing Air Flow Mass Meter G70

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect plug connection -arrow-. – Unscrew the fuel pressure sender - G247- with the socket in‐...
  • Page 515 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -6-. – Disconnect vacuum hoses on the air guide pipe -arrows-.
  • Page 516 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – To install, position the air mass meter - G70- Pos. -2- and turn in the direction of arrow -A-.
  • Page 517 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows-. – Detach air flow mass meter - G70- -2- from the air filter housing -1-.

  • Page 518: Removing And Installing Differential Pressure Transmitter G505

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing differential pressure transmitter - G505- ⇒ “6.5.1 Removing and installing differential pressure transmitter G505 , variant 1”, page 510...
  • Page 519 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the differential pressure transmitter - G505- and pressure sen‐ sor 1 for exhaust gas - G450- have to be removed from the cylinder head cover –...
  • Page 520 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 6.5.2 Removing and installing differential pressure transmitter - G505- , variant 2 If the differential pressure transmitter - G505- has to be removed ⇒...
  • Page 521 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open heat protection sleeve -4-. – Release and disconnect electrical plug connection -3-.
  • Page 522 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 If the differential pressure transmitter - G505- has to be removed from the cylinder head cover –...

  • Page 523: Removing And Installing Pressure Sensor For Exhaust Gas 1 G450

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open heat protection sleeve -1-. – Separate electrical plug connection -4-. – Unscrew screw -3- and remove differential pressure transmit‐...

  • Page 524: Removing And Installing Intake Air Temperature Sender G42

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open heat protection sleeve -1-. – Separate electrical plug connection -8-. – Unscrew screw -2- and press the differential pressure trans‐...

  • Page 525: Removing And Installing Nox Transmitter 2 G687

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -2-. – Unscrew intake air temperature sender - G42- .
  • Page 526 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove the NOx encoder 2 - G687- -arrow-. Installing Installation is carried out in the reverse order. When installing, observe the following: –...

  • Page 527: Removing And Installing Charge Air Temperature Transmitter After Charge Air Cooler G811

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing charge air tem‐ perature transmitter after charge air cooler - G811- Removing –...

  • Page 528: Removing And Installing Nox Transmitter Control Unit Gx30

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Replace the gasket ring -3-. – Check the correct fit of the seal ring -2-.
  • Page 529 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Lambda probe open ring spanner set - 3337- ♦ Tool insert SW 22 , e.g. -V.A.G 1332/12- Removing –...
  • Page 530 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Use this wrench from the ring wrench set for Lambda probe - 3337/7- .
  • Page 531 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing bracket for the NOx sender control unit - J583- – Remove NOx encoder control unit - J583- from bracket ⇒...
  • Page 532 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removal options Removing NOx sender - G295- on exhaust gas cleaning module ⇒ page 524...
  • Page 533 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release and pull off the electrical plug connection -2-. – Unclip NOx sender control unit - J583- -1- -arrows-.
  • Page 534 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Hose binding claw - VAS 6362- – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...

  • Page 535: Engine Control Unit

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Engine control unit ⇒ “7.1 Removing and installing engine control unit J623 ”,...
  • Page 536 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 7.1.2 Removing and installing engine control unit - J623- , engine control unit with...
  • Page 537 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Heat the shear screw head -1- for approximately 20 to 30 sec‐...
  • Page 538 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock catch in -direction of the arrow- and remove the engine control unit -1-.
  • Page 539 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open retaining clip -arrow- and remove the engine control unit - J623- .
  • Page 540 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew shear screw -1- with a screwdriver -2-. – Remove the protective covers for plug connections -2- and -5-.
  • Page 541 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection -1- on the charge pres‐ sure control solenoid valve - N75- Pos. -2-.
  • Page 542 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection -1- on the charge pres‐ sure control solenoid valve - N75- Pos. -2-.
  • Page 543 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Undoing pull-off screws with a hot air blower – Set the temperature adjustment potentiometer -2- to maximum heating performance and set the air flow two stage switch -3- to position 3.
  • Page 544 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Insert the engine control unit - J623- into the catch -2- of the bracket holder.

  • Page 545: High Pressure Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 High pressure pump ⇒ “8.1 Summary of components - high pressure pump”, page 537 ⇒...

  • Page 546: Removing And Installing The High Pressure Pump

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9 - High pressure line ❑ between the high pressure accumulator and high pressure pump ❑...
  • Page 547 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Suspend extractor -T10489- at the hub by turning to the right. – Remove the hub of the high pressure pump.
  • Page 548 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Mount the toothed belt pulley onto the hub. • There must not be any oil present between the counterholder and the toothed belt pulley –...

  • Page 549: Lambda Probe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Lambda probe ⇒ “9.1 Summary of components - lambda probe”, page 541 ⇒ “9.2 Removing and installing Lambda probe”, page 544...
  • Page 550 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 5 - Screw ❑ 8 Nm 6 - Differential pressure transmitter - G505- ❑...
  • Page 551 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9.1.2 Overview of components - Lambda probe, Octavia III with SCR system 1 - Exhaust gas temperature transmitter 4 - G648- ❑...

  • Page 552: Removing And Installing Lambda Probe 1

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Removing and installing ⇒ “6.5 Removing and installing differential pressure transmitter G505 ”, page 510 10 - Screw ❑...
  • Page 553 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove lambda probe 1 in front of the catalytic converter - GX10- -3-.
  • Page 554 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...
  • Page 555 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew lambda probe 1 in front of the catalytic converter - GX10- -arrow- with socket insert SW 22 - T10491- .
  • Page 556 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Take the electrical plug connection -arrow- for Lambda probe 1 after catalytic converter - GX7- out of its bracket and dis‐...
  • Page 557 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9.2.4 Removing and installing lambda probe 1 after catalytic converter - GX7- , Rapid...
  • Page 558 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew the lambda probe 1 after catalytic converter - GX7- -arrow- with a socket wrench from the socket insert for lambda probe - 3337- .

  • Page 559: Engine Noise Speaker

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Engine noise speaker ⇒ “10.1 Removing and installing engine noise speaker”, page 551 10.1...

  • Page 560: Exhaust System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 26 – Exhaust system Exhaust pipes/silencers ⇒ “1.1 Assembly overview - silencers”, page 552 ⇒...
  • Page 561 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly ❑ Note installation posi‐ tion ⇒...
  • Page 562 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Nut ❑ 20 Nm 11 - Rear tunnel bridge 12 - Front tunnel bridge 13 - Middle and rear part of the exhaust system ❑...
  • Page 563 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly ❑ Note installation posi‐ tion ⇒...
  • Page 564 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 11 - Rear tunnel bridge 12 - Front tunnel bridge 13 - Middle and rear part of the exhaust system ❑...
  • Page 565 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly ❑ Note installation posi‐ tion ⇒...
  • Page 566 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 10 - Shackle ❑ replace if damaged 11 - Nut ❑ 20 Nm...
  • Page 567 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly ❑ Note installation posi‐ tion ⇒...
  • Page 568 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Separation point ⇒ “1.3 Separating exhaust pipes/silencers”, page 567 13 - Middle and rear part of the exhaust system ❑...
  • Page 569 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 6 - Exhaust pipe ❑ Vehicles with NOx encoder 2 - J881- ⇒ “1.8.2 Overview of components - exhaust front pipe, vehicles with NOx encoder 2 G687 ”, page 577 ❑...
  • Page 570 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly ❑ Note installation posi‐ tion ⇒...
  • Page 571 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.1.7 Overview of components - sound damp‐ er, engine code CXMA Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 572: Removing And Installing Pre-Exhaust Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Removing and installing ⇒ “1.4 Removing and installing rear silencer”, page 568 9 - Nut ❑...
  • Page 573 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical connector -2- from the injection valve for reduction agent - N474- .
  • Page 574 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove screws -1-. – Loosen screw -2- and remove clamp. – Remove pre-exhaust pipe.

  • Page 575: Separating Exhaust Pipes/Silencers

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.2.2 Removing and installing pre-exhaust pipe, Rapid NH Removing – Separate electrical plug connection -1-.

  • Page 576: Removing And Installing Rear Silencer

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Protective goggles Note For vehicles with torsion beam rear axle, a separation point is ♦...
  • Page 577 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Vehicles with separation point: loosen clamping sleeve -arrow- and press forwards. – Unscrew screws -arrows-, remove rear silencer.
  • Page 578 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen the clamping sleeve -2- and slide it forwards. CAUTION Risk of accident from weight of the rear silencer.
  • Page 579 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Loosen clamping sleeve -arrow- and press forwards. – Screw out screw -4- and remove rear silencer.
  • Page 580 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screw -2-, remove middle silencer -1-. Installing Installation is carried out in the reverse order. When installing, observe the following: –...

  • Page 581: Align Exhaust System Free Of Stress

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.4.4 Removing and installing rear silencer , engine identification characters CXMA – Vehicles without separation point: replace middle or rear si‐...

  • Page 582: Inspecting The Exhaust System For Leaks

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Push the rear silencer so far forward until the pre-tensioning on the retaining strap on the exhaust pipe is -a- = 5 mm.

  • Page 583: Summary Of Components - Pre-Exhaust Pipe

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installation dimension for vehicles with marking on the exhaust pipe. 1 - Clamping sleeve...
  • Page 584 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw clamp ❑ Replace after disas‐ sembly ❑ Note the fitting position;...
  • Page 585 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installation position of gasket between exhaust gas cleaning mod‐ ule and pre-exhaust pipe •...

  • Page 586: Align Exhaust Tailpipes

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ⇒ “1.7 Installation posi‐ tion of clamping sleeve”, page 574 ❑ Tighten screwed connections uniformly ⇒...

  • Page 587: Cleansing Exhaust Emissions

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Cleansing exhaust emissions ⇒ “2.1 Summary of components - exhaust gas cleaning”, page 579 ⇒...
  • Page 588 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Particle filter or catalytic converter, vehicles with EU4 emission standard ❑...
  • Page 589 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Exhaust pipe ❑ Removing and installing ⇒ “1.2 Removing and in‐...
  • Page 590 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Tightening torque and tightening order ⇒ page 596 12 - Screw ❑ Tightening torque and tightening order ⇒...
  • Page 591 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 25 - Screw ❑ Replace after disassembly ❑ Tightening torque and tightening order: ♦...
  • Page 592 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw ❑ Tightening torque and tightening order ⇒ page 588 2 - Mounting bracket ❑...
  • Page 593 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 2.1.4 Overview of components - emission control, vehicles with regulated particu‐ late filter...
  • Page 594 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 13 - Seal ❑ Replace after disassembly 14 - Mounting bracket ❑ Filter for exhaust gas recirculation ❑...

  • Page 595: Removing And Installing Catalytic Converter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Bracket -2- for filter for exhaust gas recirculation– tightening tor‐ ques and tightening order –...
  • Page 596 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – If installed, unscrew the screws -arrows- of the coolant line and pull the coolant line forwards slightly.

  • Page 597: Removing And Installing Exhaust Gas Cleaning Module

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing exhaust gas cleaning module ⇒ “2.3.1 Removing and installing exhaust gas cleaning module, Octavia III”, page 589...
  • Page 598 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Drain coolant ⇒ “1.4 Filling with coolant”, page 235 – Remove rear coolant pipe ⇒...
  • Page 599 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screw -arrow-. – Open clamp -A-, pull out hose, unclip pipeline -B- and remove with the differential pressure transmitter - G505- .
  • Page 600 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock locks using a screwdriver -arrow- and lay coolant ex‐ pansion tank to the side.
  • Page 601 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open hose clamp -1-, remove coolant hose. – Unscrew screws -2- and -3- and swivel coolant line to the side.
  • Page 602 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screw -arrow-. Note The feet of the assembly aid - T10511- are supported on the screw heads of the cylinder head cover.
  • Page 603 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open clamp -1- and position it on the flared opening of the exhaust gas cleaning module.
  • Page 604 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Bring retaining straps to the functional dimension using the calibration tool - T10512- as follows.
  • Page 605 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew balancing element (left-hand thread) -1- on the cyl‐ inder head using socket insert SW 8 - 3247- in -arrow direction- as far as the stop, then rotate a further 90°.
  • Page 606 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connect coolant hose, fit hose clamp -1-. – Screw in screws -2- and -3- and tighten to 10 Nm.
  • Page 607 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Function of the balancing element Special tools and workshop equipment required ♦ Socket insert SW 8 - 3247- ♦...
  • Page 608 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open heat protection sleeve -1-. – Take electrical plug connection -5- out of the holder, discon‐...
  • Page 609 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew nut -1- and screws -3-, disconnect adapter -2- for coolant hoses from the heat exchanger for heating and put to the side.
  • Page 610 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open the screw clamp -1- and place on the flared opening of the exhaust gas cleaning module.
  • Page 611 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Bring retaining straps to the functional dimension using the calibration tool - T10512- as follows.
  • Page 612 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew balancing element (left-hand thread) -1- on the cyl‐ inder head using socket insert SW 8 - 3247- in -arrow direction- as far as the stop, then rotate a further 90°.

  • Page 613: Installing And Removing Regulated Particle Filter

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Continued tightening order Stage Screw Measure Screw -5- insert and lock by pressing...
  • Page 614 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove the sound dampening system ⇒ Body Work; Rep. gr. 50 .
  • Page 615 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew bolt -3-. – Mark the installation position and assignment of the hoses to the pipes.
  • Page 616 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew the fixing nuts -1-, undo the screws -2- by a quarter turn.
  • Page 617 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -2- and -3- and remove filter for exhaust gas recirculation -1-.

  • Page 618: Removing And Installing The Exhaust Flap Control Unit J883

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Tightening sequence for particle filter Stage Screw Measure Clamping Position via the sealing flange, lock...
  • Page 619 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Mount new exhaust flap control unit - J883- . When doing so, ensure that the driver of the control unit -1- engages into the tab of the exhaust flap -2-.

  • Page 620: Scr System (Selective Catalytic Reduction)

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 SCR system (Selective Catalytic Re‐ duction) ⇒ “3.1 Summary of components - reduction agent tank”, page 612 ⇒...
  • Page 621 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Reduction agent tank ❑ with: ♦ Feed unit ♦ Temperature transmitter for reduction agent - G685- ♦...
  • Page 622 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Mounting bracket ❑ at fuel tank filler tube 2 - Sealing grommet ❑...
  • Page 623 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw ❑ 8 Nm 2 - Screw cap 3 - Control unit for reduction agent heater - J891- ❑...

  • Page 624: Summary Of Components - Delivery Line For Reduction Agent

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Disconnect coupling ⇒ page 619 11 - Nut ❑ 2 Nm 12 - Bottom cover 13 - Electrical plug connection ❑...
  • Page 625 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Reduction agent tank ❑ Summary of compo‐ nents ⇒ “3.1 Summary of com‐...
  • Page 626 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.2.2 Summary of components - delivery line for reduction agent, Yeti Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 627: Summary Of Components - Delivery Module For Reduction Agent

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9 - Reduction catalytic converter 10 - NOx transmitter 2 - G687- ❑ with control unit for NOx transmitter 2 - J881- ❑...

  • Page 628: Removing And Installing Reduction Agent Tank

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Delivery module for reduc‐ tion agent ❑ Removing and installing ⇒ “3.6 Removing and in‐...
  • Page 629 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing CAUTION Leaking reduction agent represents danger. ♦ Note the safety precautions for handling reduction agent ⇒...
  • Page 630 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unclip, release and pull off electrical plug connection -3-. – Release and pull off reduction agent line -4-. Disconnect re‐...
  • Page 631 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows- of the reduction agent tank -1-. Note To provide a clearer illustration, the engine and gearbox jack that is placed underneath is not shown.
  • Page 632 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Observe rules for cleanliness ⇒ “3 Repair instructions”, page 7 – Empty the reduction agent tank ⇒ Maintenance ; Booklet Yeti .
  • Page 633 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Position the engine and gearbox jack - VAS 6931- for support below the reduction agent tank -1- with soft foam underlay in between.

  • Page 634: Removing And Installing Delivery Line For Reduction Agent

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing delivery line for reduction agent ⇒ “3.5.1 Removing and installing the front part of the delivery line for reduction agent, Octavia III”, page 626...
  • Page 635 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect the fuel lines -1- and -2- on the underbody. – Separated fuel lines on the underbody ⇒ Rep. gr. 20 ; Quick couplings;...
  • Page 636 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Separate electrical plug connection -1-. – Remove coolant hoses, opening the mounting brackets to do –...
  • Page 637 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Continued for all vehicles – Unclip shielding -1- from the threaded bolts on the body -arrow-.
  • Page 638 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installation position of the lines at the shielding Line guide for the delivery line for reduction agent...
  • Page 639 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Installation position of the fuel lines at the underfloor 2 - Fuel return-flow line...
  • Page 640 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unclip, release and pull off electrical plug connection -3-. – Release and pull off reduction agent line -4-. Disconnect re‐...
  • Page 641 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Close all open lines and connections with clean plugs from the screw plug set for engine - VAS 6122- .

  • Page 642: Removing And Installing The Delivery Module For Reduction Agent

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Connection the delivery line -6- and the electrical wiring -1-. Secure both lines to the mountings.
  • Page 643 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Clean the area around the delivery module -5-. – Unscrew screws -arrows-.

  • Page 644: Removing And Installing The Injection Valve For Reduction Agent N474

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 order of Labelling of screws on Position of the screw Tightening torque tightening...
  • Page 645 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unclip, release and pull out the connector -3-. – Expose electric wiring harness.
  • Page 646 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 3.7.2 Removing and installing the injection valve for reduction agent - N474- , Yeti...

  • Page 647: Removing And Installing The Control Unit For Reduction Agent Heater J891

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing the control unit for reduction agent heater - J891- ⇒ “3.8.1 Removing and installing the control unit for reduction agent heat J891 , Octavia III”, page 639...

  • Page 648: Summary Of Components - Injection Valve For Reduction Agent

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unlock and unplug the electrical connectors -1-. – Unlock the catch in -direction of arrow- and remove the mount‐...
  • Page 649 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Injection valve for reduction agent - N474- ❑ Removing and installing ⇒...

  • Page 650: Removing And Installing The Filler Tube For Reduction Agent Tank

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Variants of the screw clamps Screw clamp, one-piece O-ring Screw, 5 Nm Clamp, two-piece with eye...
  • Page 651 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove fuel tank lid unit -2- ⇒ General body repairs, exterior; Rep. gr. 55 ; Fuel tank lid unit; installing and removing fuel tank lid unit .

  • Page 652: Disconnect Delivery Line For Reduction Agent

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Detach the filler pipe by turning it in -arrow- and remove from the mount -3-.
  • Page 653 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Lock Note Note the different designs of the securing clip. ♦ Assignment is based on the type of quick coupling.

  • Page 654: Adjusting The Learnt Value For The Scr System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Disconnect delivery line for reduction agent, version 3 – Clean the area around the lock with water.

  • Page 655: Exhaust Temperature Regulation

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Exhaust temperature regulation ⇒ “4.1 Summary of components - exhaust temperature regula‐ tion”, page 647 ⇒...
  • Page 656 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Lambda probe 1 after cata‐ lytic converter - GX7- ❑ consists of: lambda...
  • Page 657 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 7 - Mounting bracket 8 - Exhaust gas pressure sensor 1 - G450- ❑...
  • Page 658 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.1.2 Overview of components - exhaust gas temperature control, Octavia III with SCR system Note Malfunction caused by loose exhaust gas temperature transmitter.
  • Page 659 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 6 - Mounting bracket ❑ for differential pressure transmitter 7 - Exhaust gas pressure sensor 1 - G450- ❑...
  • Page 660 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - NOx transmitter 2 - G687- ❑ with control unit for NOx transmitter 2 - J881- ❑...

  • Page 661: Removing And Installing The Exhaust Gas Temperature Transmitter 1 G235

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ❑ Coat threads with hot bolt paste; hot bolt paste ⇒ ETKA - Electronic Catalogue of Original Parts ❑...
  • Page 662 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Take electrical plug connection-1 - out of the holder, discon‐ nect and expose electric wiring loom.
  • Page 663 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove engine cover ⇒ “3.1 Removing and installing engine trim panel”, page 64 –...

  • Page 664: Removing And Installing The Exhaust Gas Temperature Transmitter 2 G448

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing the exhaust gas temperature transmitter 2 - G448- ⇒ “4.3.1 Removing and installing the exhaust gas temperature transmitter 2 G448 , Octavia III, Yeti”, page 656...
  • Page 665 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 • The angled shaft -1- must point vertically upwards. – Electrical connections and proper routing ⇒ Electrical System;...
  • Page 666 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – For reasons of space, it may be necessary to loosen and rotate the clamp -1-.
  • Page 667 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Observe the fitting position of exhaust temperature sender. – The exhaust gas temperature sender must be installed as shown.
  • Page 668 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Open heat protection sleeve -1-. – Disconnect electrical plug connections -3, 4, 6- and expose electric cable.

  • Page 669: Removing And Installing The Exhaust Gas Temperature Transmitter 3 G495

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew exhaust temperature sender 2 - G448- -arrow-. – Use a suitable tool from the list of tools.
  • Page 670 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Tool kit - T10395B- or -T10395A- or -T10395- + - T10395/8../10- ♦ Ring insertion tool, open, SW 17 , e.g. -V.A.G 1331/10- ♦...
  • Page 671 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew exhaust gas temperature sender 3 - G495- -2-. – Use a suitable tool from the list of tools.
  • Page 672 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Fitting location ⇒ “4.1 Summary of components - exhaust temperature regula‐ tion”, page 647 –...
  • Page 673 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 4.4.3 Removing and installing exhaust gas temperature transmitter 3 - G495- , Rap‐...

  • Page 674: Removing And Installing The Exhaust Gas Temperature Transmitter 4 G648

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew exhaust gas temperature sender 3 - G495- -2-. – Use a suitable tool from the list of tools.
  • Page 675 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing Note When removing, the electric cable must be not cut off, since doing so would mean that fault diagnosis would no longer be possible.
  • Page 676 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Tool kit - T10395B- or -T10395A- or -T10395- + - T10395/8../10- ♦ Ring insertion tool, open, SW 17 , e.g. -V.A.G 1331/10- ♦...
  • Page 677 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew exhaust gas temperature sender 4 - G648- -1-. – Use a suitable tool from the list of tools.

  • Page 678: Exhaust Gas Recirculation

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Exhaust gas recirculation ⇒ “5.1 Summary of components - Exhaust gas recirculation”, page 670 ⇒...
  • Page 679 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Radiator for exhaust gas re‐ circulation ❑ Removing and installing ⇒ “5.3 Removing and in‐...
  • Page 680 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 9 - Screw ❑ 9 Nm 10 - Seal ❑ Replace after disassembly...
  • Page 681 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Radiator for exhaust gas re‐ circulation ❑ Removing and installing ⇒ “5.3 Removing and in‐...
  • Page 682 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 13 - Seal ❑ Replace after disassembly Installation position of air guide hose at radiator for exhaust gas...
  • Page 683 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly 2 - Connecting pipe ❑ to exhaust manifold 3 - Nut ❑...
  • Page 684 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 17 - Radiator for exhaust gas recirculation ❑ Removing and installing ⇒ “5.3 Removing and installing radiator for exhaust gas recirculation”, page 680 ❑...
  • Page 685 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Seal ❑ Replace after disas‐ sembly 2 - Exhaust gas recirculation...

  • Page 686: Summary Of Components - Exhaust Gas Recirculation 1 Gx5

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 12 - Connection fitting 13 - Screw ❑ 9 Nm 14 - O-ring ❑...
  • Page 687 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Coolant hose 2 - Spring clip 3 - Exhaust gas recirculation...

  • Page 688: Removing And Installing Radiator For Exhaust Gas Recirculation

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1 - Screw ❑ 9 Nm 2 - Coolant hose 3 - Exhaust gas recirculation...
  • Page 689 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing – Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .
  • Page 690 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Turn radiator for exhaust gas recirculation counter downwards in the -direction of arrow-.
  • Page 691 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Position radiator -1- for exhaust gas recirculation on the ex‐ haust gas cleaning module with gasket and gripper clamp.
  • Page 692 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – If a vacuum hose is installed: disconnect it -arrow- and move it clear.
  • Page 693 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Press heat protection sleeve to the side, disconnect electrical plug connection -5-.
  • Page 694 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Tighten the fixing screws -3- and -7-. – Ensure that the air guide hose fitting is free of tension.
  • Page 695 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Release screws -arrows- and remove heat shield for right drive shaft. – Unscrew screws -1- and nuts -2- and remove rear coolant pipe and push rear coolant pipe downwards.
  • Page 696 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove selector lever cable -1- from gearbox selector lever. – Unscrew screws -2- and push selector lever cable with cable support bracket to left side.
  • Page 697 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Put connector -1- in position for and tighten screws -1-, -3-. – Bring screw clamp -3- to installation position ⇒...
  • Page 698 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Drain coolant ⇒ “1.4 Filling with coolant”, page 235 – Loosen hose clamp -1- and disconnect hose. Unscrew the nuts -arrows-.

  • Page 699: Removing And Installing Exhaust Gas Recirculation Valve 1 Gx5

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -arrows- and carefully remove the radiator for exhaust gas recirculation -A- through the vehicle tunnel.
  • Page 700 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing Note Observe rules for cleanliness. – Remove the throttle valve control unit - J338- ⇒...

  • Page 701: Removing And Installing Exhaust Gas Recirculation Valve 2 Gx6

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing Note Observe rules for cleanliness. – Remove the throttle valve control unit - J338- ⇒...
  • Page 702 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 ♦ Control engine 2 for exhaust gas recirculation - V339- ♦ Exhaust gas recirculation potentiometer 2 - G466-...
  • Page 703 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew screws -3- and -7- and remove connecting pipe. Continued for all vehicles –...
  • Page 704 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Position engine support bracket - T10533- and secure with nut -1- and screw -2-, as shown.

  • Page 705: Removing And Installing Temperature Sensor For Exhaust Gas Recirculation G98

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 Removing and installing temperature sensor for exhaust gas recirculation - G98- ⇒ “5.6.1 Removing and installing the temperature sensor for ex‐...
  • Page 706 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Unscrew the temperature sensor for exhaust gas recirculation - G98- -1- using a suitable tool from the tool set.

  • Page 707: Test Air-Tightness Of The Radiator For Exhaust Gas Recirculation

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Remove from bracket, unlock and disconnect electrical plug connection -1-. – Expose electric cable -2-.

  • Page 708: Glow Plug System

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 28 – Glow plug system Glow plug system ⇒ “1.1 Summary of components - Glow plug system”, page 700 ⇒...

  • Page 709: Removing And Installing Glow Plugs

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 6 - Sealing flange on the gearbox side ❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange on gearbox side”, page 81 7 - Rotor ❑...
  • Page 710 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Position pliers - 3314- using the pliers groove arrow -A- on the support sleeve collar arrow -B-, as shown.

  • Page 711: Removing And Installing Automatic Glow Period Control Unit J179

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Place the glow plug connectors -1- back onto the glow plugs -arrows-.

  • Page 712: Removing And Installing Hall Sender G40

    Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 1.3.2 Removing and installing automatic glow period control unit - J179- , Rapid NH Removing –...
  • Page 713 Octavia III 2013 ➤ , Octavia III 2014 ➤ , Rapid NH 2013 ➤ , Rapid NH 20 ... 1.6/66;77;81;85;2.0/105;110;135 kW TDI CR engine - Edition 04.2020 – Disconnect electrical plug connection -1- using the assembly tool - T10118- .

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