2 0 110 147 KW FSI Engine PDF

Service
Workshop Manual
OCTAVIA II 2004 ➤
2.0/110; 147 kW FSI Engine
Engine ID BLR BLX BLY BVX BVY BVZ BWA
Edition 02.05
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling
20 - Fuel Supply
21 - Turbocharging
24 - Fuel Formation, Injection
26 - Exhaust System
28 - Ignition system
OCTAVIA II 2004 ➤
2.0/110; 147 kW FSI Engine - Edition 02.05
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Self diagnosis, safety measures, cleanliness regulations, directions . . . . . . . . . . . . . . . . . . 5
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Release pressure in the high pressure area of the fuel system . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 7
1.5 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 8
1.6 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Additional instructions when undertaking assembly work on the air-conditioning system . . 11
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Checking and adjusting the assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Disassembling and assembling engine - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Toothed belt drive - Summary of components, engines without split toothed belt guard . . 38
1.3 Toothed belt drive - Summary of components, engines with split toothed belt guard . . . . 39
2 Disassembling and assembling engine - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.1 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2 Removing and installing the toothed belt, engines without split toothed belt guard . . . . . . 42
2.3 Removing and installing the toothed belt, engines with split toothed belt guard . . . . . . . . 52
3 Sealing flanges and flywheel/drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 65
3.4 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.5 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.6 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.2 Inspect piston, piston rings and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1 Cylinder head - Summaries of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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OCTAVIA II 2004 ➤
1.1 Summary of components - vehicles with engine identification characters BLR, BLX, BLY,
BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Summary of components - Engine identification character BWA . . . . . . . . . . . . . . . . . . . . 82
2 Cylinder head, vehicles with engine identification characters BLR, BLX, BLY, BVX, BVY,
BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.1 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.3 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4 Testinf the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3 Cylinder head, engine identification character BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.1 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.4 Testinf the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Valve gear - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.2 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.3 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.4 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5 Valve gear - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1 Replacing exhaust camshaft seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2 Removing and installing the camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.3 Removing and installing camshaft adjustment valve 1 N205 , Engine identification characters
BLR, BLX, BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4 Removing and installing camshaft adjustment valve 1 N205 , engine identification characters
BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.5 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1 Parts of the lubrication system - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.2 Balancing shaft module with oil pump - Summary of components, engine identification
characters BLR, BLX, BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.3 Balancing shaft module with oil pump - Summary of components, engine identification
characters BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.4 Oil filter holder with component parts - Summary of components, engine identification
1.5 Oil filter holder with component parts - Summary of components, engine identification
character BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2 Parts of the lubrication system - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.1 Empty oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.3 Removing and installing balancing shaft module with oil pum . . . . . . . . . . . . . . . . . . . . . . 130
2.4 Removing and installing oil filter holder, engine identification characters BLR, BLX, BLY, BVX,
BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.5 Removing and installing the oil holder, engine identification character BWA . . . . . . . . . . . . 136
2.6 Testing oil pressure and oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1 Parts of the cooling system - Summaries of components, engine identification characters
BLR, BLX, BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.1 Parts of cooling system engine side - Summary of components . . . . . . . . . . . . . . . . . . . . 141
1.2 Parts of cooling system on the side next to the body - Summary of components . . . . . . . . 142
1.3 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
1.4 Coolant regulator housing with coolant regulator, engine identification characters BLR, BLX,
BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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OCTAVIA II 2004 ➤
2 Parts of cooling system - Summaries of components, engine identification character BWA

........................................................................ 147
2.1 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.2 Parts of the cooling system fitted to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.3 Coolant after-running pump V51 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . 150
2.4 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3 Removing and installing parts of the cooling system - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . 152
3.1 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.3 Removing and installing thermostat for map-controlled engine cooling F265 , engine
identification characters BLR, BLX, BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3.4 Inspecting thermostat for map-controlled engine cooling F265 , engine identification
characters BLR, BLX, BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.5 Removing and installing coolant regulator housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4 Removing and installing parts of the cooling system - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . 161
4.1 Removing and installing fan shroud for radiator fan V7 and right radiator fan V35 . . . . . . 161
4.2 Removing and installing radiator, engine identification characters BLR, BLX, BLY, BVX, BVY,
BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.3 Removing and installing the radiator, engine identification character BWA . . . . . . . . . . . . 163
4.4 Removing and installing bottom coolant pipe, engine identification characters BLR, BLX,
BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.5 Removing and installing the coolant pipes, engine identification character BWA . . . . . . . . 165
4.6 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1 Fuel tank and fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.1 Fuel tank for vehicles with front-wheel drive - Summary of components . . . . . . . . . . . . . . 168
1.2 Fuel tank for vehicles with four-wheel drive - Summary of components . . . . . . . . . . . . . . 170
1.3 Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.4 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.5 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.6 Removing and installing the fuel delivery unit on vehicles with front-wheel drive . . . . . . . . 177
1.7 Removing and installing the fuel delivery unit on vehicles with four-wheel drive . . . . . . . . 179
1.8 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 182
1.9 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.10 Removing and installing fuel gauge sender 2 G169 for vehicles with four-wheel drive . . . . 191
1.11 Removing and installing suction jet pump for vehicles with four-wheel drive . . . . . . . . . . . . 193
2 Electronic Engine Power Control (Electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.1 Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.2 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1 Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.1 Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
1.2 Testing exhaust turbocharger pressure box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1.3 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.4 Removing and installing pressure box for exhaust turbocharger . . . . . . . . . . . . . . . . . . . . 212
1.5 Setting exhaust turbocharger pressure unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2 Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.1 Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.2 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.3 Hose connections with push-fit couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2.4 Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
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2.5 Overview plan for the exhaust turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

2.6 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
24 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

1 Fitting locations of the injection system, Engine identification characters BLR, BLX, BLY,
BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
2 Fitting locations of the injection system, engine identification character BWA . . . . . . . . . . 226
3 Injection system - Summaries of components, engine identification characters BLR, BLX,
BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.2 Suction jet pump - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.3 Fuel distributor with intake manifold flap motor V157 - Summary of components, engine
identification characters BLR, BLX, BLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
3.4 Fuel distributor with intake manifold flap motor V157 - Summary of components, engine
identification characters BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.5 High pressure pump - Summary of components, Engine identification characters BLR, BLX,
BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.6 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4 Injection system - Summary of components, engine identification character BWA . . . . . . 238
4.1 Intake manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.2 Fuel distributor - Summary of component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.3 High pressure pump - Summary of components, Engine identification character BWA . . 242
4.4 Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
5 Repairing the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.1 Remove and disassemble air filter/engine cover, engine identifcation BWA . . . . . . . . . . . . 245
5.2 Removing and installing intake manifold, engine identification characters BLR, BLX, BLY,
BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
5.3 Removing and installing fuel distributor with intake manifold flaps, engine identification
5.4 Removing and installing fuel pressure sender G247 , engine identification characters BLR,
BLX, BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
5.5 Removing and installing the intake manifold, engine identification character BWA . . . . . . 250
5.6 Removing and installing intake manifold flap motor V157 with intake manifold flap
potentiometer G336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5.7 Removing and installing the fuel distributor, engine identification character BWA . . . . . . . . 254
5.8 Removing and installing the fuel pressure sender G247 , engine identification character
BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
5.9 Removing and installing injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5.10 Replacing Teflon gasket ring at injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5.11 Removing and installing throttle valve control unit J338 , engine identification character
BWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
5.12 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
5.13 Removing and installing high pressure pump, engine identification characters BLR, BLX,
BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
5.14 Removing and installing the high pressure pump, engine identification character BWA . . 265
6 Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
6.1 Test intake manifold changeover, Engine identification characters BLR, BLX, BLY, BVX,
BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
6.2 Check double non-return valve, Engine identification character BWA . . . . . . . . . . . . . . . . 268
6.3 Check fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

1 Exhaust gas system, engine identification characters BLR, BLX, BVY, BVX - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
iv Contents
OCTAVIA II 2004 ➤
1.1 Exhaust manifold with catalytic converter - Summary of components . . . . . . . . . . . . . . . . 273

1.2 Exhaust gas system - Summary of components, vehicles with front-wheel-drive (BLR,
BVY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
1.3 Exhaust gas system - Summary of components, vehicles with four-wheel-drive (BLX,
BVX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2 Exhaust gas system, engine identification characters BLY, BVZ - Summaries of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.1 Exhaust manifold - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.2 Exhaust gas system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3 Exhaust gas system, Engine identification character BWA - Summary of components . . . . 282
3.1 Exhaust gas system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.1 Removing and installing exhaust manifold, engine identification characters BLR, BLX, BLY,
BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.2 Removing and installing front part of exhaust system, engine identification characters BLR,
BLX, BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
4.3 Removing and installing front part of exhaust system, engine identification character BWA
........................................................................ 289
4.4 Replacing middle or rear part of the exhaust system, only vehicles with front-wheel drive
........................................................................ 291
4.5 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.6 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
5 Exhaust gas recirculation system, engine identification characters BLR, BLX, BVY, BVX
........................................................................ 294
5.2 Removing and installing top connection pipe for exhaust gas recirculation . . . . . . . . . . . . 294
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
1.2 Removing and installing ignition coils with power output stages . . . . . . . . . . . . . . . . . . . . 296
Contents v
OCTAVIA II 2004 ➤
vi Contents
OCTAVIA II 2004 ➤
00 – Technical data
1 Technical data
1.1 Engine number

The engine identification characters and the engine number are
located to the left on the joint separating the engine/gearbox.
Vehicles with engine identification characters BLR, BLX, BLY,
BVX, BVY, BVZ
The engine identification character is in addition type-punched at
the cylinder head.
Vehicles with engine identification characters BWA
The engine identification character is in addition type-punched at

the cylinder head on the right and at the cylinder block.
Continued for all vehicles
The engine number consists of up to nine digits (alphanumeric).
The first part represents the “engine code” (a maximum of 3 iden‐
tification letters), the second part the “serial number”. If more than
999.999 engines with the same engine code were produced then
the first digit of the six part section will be replaced by a letter.
In addition, a sticker with the “engine identification character” and
“serial number” is affixed to the toothed belt guard.
The engine identification character is also indicated on the vehicle
data sticker.
1. Technical data 1
OCTAVIA II 2004 ➤
1.2 Engine characteristics

Identification characters BLR BLX BLY
Manufactured 11.04 ? 10.05 11.04 ? 10.05 11.04 ? 10.05
Exhaust limit values conforming to EU-4 EU-4 EU-2
Displacement cm 3 1984 1984 1984
Power output kW at rpm 110/6000 110/6000 110/5800
Torque Nm at rpm 200/3500 200/3500 200/3500
Bore ∅ mm 82,5 82,5 82,5
Stroke mm 92,8 92,8 92,8
Compression ratio 11,5:1 11,5:1 10,5:1
Cylinder/number of valves per cylinder 4/4 4/4 4/4
RON unleaded 98 1) unleaded 98 1) unleaded 95 2)
Ignition system, fuel injection Motronic MED 9.5 Motronic MED 9.5 Motronic MED 9.5
Type of fuel preparation homogeneous homogeneous/ homogeneous
stratified
Knock control 2 sensors 2 sensors 2 sensors
Lambda control 5 probes 4 probes 2 probes
Three-way catalytic converter yes yes yes
NOx storage catalytic converter no yes no
Exhaust gas recirculation yes yes no
Intake manifold change-over yes yes yes
Camshaft adjustment yes yes yes
Exhaust gas turbocharger no no no
Balancing shaft module yes yes yes
1) At least 95 RON in exceptional cases, although engine output
is reduced
is reduced
2 Rep. Gr.00 - Technical data

OCTAVIA II 2004 ➤
Identification characters BVX BVY BVZ

Manufactured 11.05 ? 11.08 11.05 ? 11.08 11.05 ? 11.08
Exhaust limit values conforming to EU-4 EU-4 EU-2
Displacement cm 3 1984 1984 1984
Power output kW at rpm 110/6000 110/6000 110/5800
Torque Nm at rpm 200/3500 200/3500 200/3500
Bore ∅ mm 82,5 82,5 82,5
Stroke mm 92,8 92,8 92,8
Compression ratio 11,5:1 11,5:1 10,5:1
Cylinder/number of valves per cylinder 4/4 4/4 4/4
RON unleaded 98 1) unleaded 98 1) unleaded 95 2)
Ignition system, fuel injection Motronic MED 9.5 Motronic MED 9.5 Motronic MED
9.5
Type of fuel preparation homogeneous/ homogeneous homogeneous
stratified
Knock control 2 sensors 2 sensors 2 sensors
Lambda control 4 probes 4 probes 2 probes
Three-way catalytic converter yes yes yes
NOx storage catalytic converter yes no no
Exhaust gas recirculation yes yes no
Intake manifold change-over yes yes yes
Camshaft adjustment yes yes yes
Exhaust gas turbocharger no no no
Balancing shaft module yes yes yes
is reduced
is reduced
1. Technical data 3
OCTAVIA II 2004 ➤
Identification characters BWA

Manufactured 10.05 ? 11.08
Exhaust limit values conforming to EU-4
Displacement cm 3 1984
Power output kW at rpm 147/5700
Torque Nm at rpm 280/2000
Bore ∅ mm 82,5
Stroke mm 92,8
Compression ratio 10,5:1
Cylinder/number of valves per cylinder 4/4
RON unleaded 98 1)
Ignition system, fuel injection Motronic MED 9.1
Type of fuel preparation homogeneous
Knock control 2 sensors
Lambda control 2 probes
Three-way catalytic converter yes
Exhaust gas recirculation no
Intake manifold change-over yes
Camshaft adjustment yes
Exhaust gas turbocharger yes
Balancing shaft module yes
is reduced
4 Rep. Gr.00 - Technical data

OCTAVIA II 2004 ➤
01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations, directions
1.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use “Vehicle self-diagnosis”, “Measuring method” and
“Targeted fault finding” ⇒ Vehicle diagnosis, testing and informa‐
tion system VAS 5051.
1.2 Safety precautions when working on the

fuel supply system
WARNING
♦ The safety measures for the pressure reduction in the high

pressure area of the fuel system must be observed
⇒ page 6 .
♦ The fuel feed line is pressurized! Wear safety goggles and
safety clothing, in order to avoid injuries and skin contact
with fuel. Place a clean cleaning cloth around the connec‐
tion point before detaching wiring. Reduce pressure by
carefully removing the wiring.
1. Self diagnosis, safety measures, cleanliness regulations, directions 5

OCTAVIA II 2004 ➤
♦ The fuel pump is activated when the ignition is switched on

and by the door contact switch of the driver door. Before open‐
ing the fuel system and for reasons of safety, if the battery is
not disconnected, the plug -arrow- must be disconnected from
the fuel pump control unit.
Caution
When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, the active
charcoal container-unit, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ In order to avoid damage to the cables, ensure that there
is adequate free access to all moving or hot components.
When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel!
♦ Wear fuel-resistant gloves!
1.3 Release pressure in the high pressure

area of the fuel system
WARNING
♦ The injection system consists of a high pressure part

(maximum 12 MPa = 120 bar) and a low pressure part
(approx. 0.6 MPa = 6 bar).
♦ Before opening the high pressure area, e.g. removing the
high pressure pump, the fuel distributor, the injection
valves, the fuel pipes or the fuel pressure sender -G247- ,
the fuel pressure in the high pressure area with a remain‐
ing pressure of approx. 0.6 MPa (6 bar) must be reduced.
The procedure for this is described below.
– Disconnect the plug from the fuel pressure regulating valve -

N276- at the high pressure pump -arrow-.
6 Rep. Gr.01 - Self-diagnosis

OCTAVIA II 2004 ➤
♦ Vehicles with engine identification characters BLR, BLX, BLY,

BVX, BVY, BVZ
♦ Vehicles with engine identification characters BWA
– Let the engine run at idling speed for approx. 10 seconds.
Note
♦ If the plug is disconnected from the fuel pressure regulating

valve -N276- at idling speed, the pressure in the high pressure
part is reduced to approx. 0.6 MPa (6 bar).
♦ After the high pressure is reduced, the high pressure system
must be opened, because the fuel pressure increases again
through the heat.
– Switch off ignition.
– For safety reasons and before opening the fuel system, dis‐
connect the plug from the fuel pump control unit -arrow-.
WARNING
The fuel lines are pressurized! Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.
Before opening the high pressure system lay cleaning cloths
around the connection point.
– Now lay a clean cleaning cloth around the connection point

and carefully open it up, in order to reduce the remaining pres‐
sure of approx 0.6 MPa (6 bar). Collect the fuel which flows
out.
Note
♦ Interrogate the fault memory of the engine control unit at the

end of the following work and delete all the fault entries.
♦ If the fault memory was erased, the readiness code must be
generated ⇒ Vehicle diagnosis, testing and information sys‐
tem VAS 5051.
1.4 Rules of cleanliness to observe when

working on the fuel supply system
Carefully observe the following five rules for cleanliness when
working on the fuel supply/injection system:

OCTAVIA II 2004 ➤
♦ Thoroughly clean the connection points and their surroundings

before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes).
♦ When the system is opened: Avoid using compressed air.
Avoid moving the vehicle.
1.5 Safety measures to apply when working

on the fuel injection and ignition system
WARNING
♦ The safety measures for the pressure reduction in the high

pressure area of the fuel system must be observed
⇒ page 6 .
♦ The fuel feed line is pressurized! Wear safety goggles and
safety clothing, in order to avoid injuries and skin contact
with fuel. Place a clean cleaning cloth around the connec‐
tion point before detaching wiring. Reduce pressure by
carefully removing the wiring.
Observe the following points to prevent injury to persons and/or

damage to the injection and ignition system:
♦ Do not touch or remove ignition leads and ignition coils with
power output stages with the engine running or at start speed.
♦ Ignition must be switched off before disconnecting and re-
connecting the cables of the fuel injection and the ignition
system as well as of the test equipment.
♦ If the engine must be operated at start speed without the en‐
gine starting, as for example, when checking the compression
pressure, open lid of fuse carrier in the engine compartment
and unplug fuse for Motronic current supply relay -J271-
⇒ Current flow diagrams and Fitting locations.

OCTAVIA II 2004 ➤
♦ The fuel pump is activated when the ignition is switched on

and by the door contact switch of the driver door. Before open‐
ing the fuel system and for reasons of safety, if the battery is
not disconnected, the plug -arrow- must be disconnected from
the fuel pump control unit.
Caution

If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger could be injured by the release of
the passenger airbag in the event of an accident.
1.6 General notes on the injection system

Repairing the ignition ⇒ page 296 .
♦ The engine control unit is equipped with self-diagnosis. Before
repairs and also for fault finding, first of all interrogate the fault
memory. Also check the vacuum hoses and connections (un‐
metered air).
♦ Fuel hoses in the engine compartment must only be secured
with spring-type clips ⇒ electronic catalogue of original parts .
The use of clamp-type or screw-type clips is not allowed.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probe.
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
♦ When opening the driver door the fuel pump is activated for 2
seconds in order to build up the pressure in the fuel system.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
Safety measures ⇒ page 8 .

OCTAVIA II 2004 ➤
1.7 General notes on the ignition system

♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.
♦ The engine control unit is equipped with self-diagnosis; in‐
spect ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnosis, testing and in‐
♦ If after fault finding, repair or inspection of components the
engine starts briefly and then stops, it is possible that the im‐
mobiliser blocks the engine control unit. Then if necessary the
control unit must be adapted ⇒ Vehicle diagnosis, testing and
Safety measures ⇒ page 8 .
Setting data, spark plugs ⇒ Maintenance ; Octavia II .
1.8 General instructions for charge air sys‐

tem
WARNING

♦ Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling
fluid and refrigerant, brake fluid, vacuum) and electrical
lines in such a way that the original line guide is re-estab‐
lished.
♦ Ensure that there is adequate free access to all moving or
hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi‐
cient to only replace the turbocharger. In order to avoid con‐
sequential damage, perform the following tasks:
♦ Clean all oil lines.
♦ Change engine oil and oil filter.
♦ Inspect the air filter housing, the air filter element and the
intake hoses for contaminations.
♦ Inspect the whole charge-air routing and the charge air
cooler for foreign bodies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
♦ The charge-air system must be tight.

OCTAVIA II 2004 ➤
♦ Always replace self-locking nuts.

♦ Hose connections and hoses for charge air system must be
free of oil and grease before being installed. The gasket ring
and the sealing surface must be slightly oiled only for push-fit
couplings ⇒ page 219 .
♦ Assembly of hose connections with push-fit couplings
⇒ page 219 .
♦ Observe markings on the hoses and components.
♦ Only install approved clamps for securing the hose connec‐
tions ⇒ Electronic Catalogue of Original Parts .
♦ Use pliers for spring strap clamps to fit the spring strap clips.
♦ Before screwing on the oil feed line, fill the exhaust gas tur‐
bocharger on the connection fitting with engine oil.
♦ After installing the turbocharger, run engine at idling speed for
about 1 minute to ensure that oil is supplied to the turbocharg‐
er.
1.9 Additional instructions when undertak‐

ing assembly work on the air-condition‐
ing system
WARNING
Do not open the refrigerant circuit of the air conditioning sys‐

tem.
Note
In order to avoid damage to the condenser as well as to the re‐

frigerant lines and hoses, ensure that the lines and hoses are not
over-tensioned, kinked or bent.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit.
– Remove the holding clamp(s) of the coolant lines.
– Remove AC compressor from the bracket ⇒ page 35 .
– Mount the AC compressor in such a way that the refrigerant
lines/hoses are not under tension.

OCTAVIA II 2004 ➤
10 – Removing and installing engine

1 Removing engine
Special tools and workshop equipment required
♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
♦ Double ladder , e. g. -VAS 5085-
♦ Engine mount -T10012-
♦ Pliers for spring strap clamps
♦ Catch pan , e.g. -VAS 6208-
♦ Grease -G 000 100-
♦ Cable strap
1.1 Removing engine

– Before removing the engine, interrogate the fault memory of
all control units ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
Note
♦ The engine is removed downwards together with the gearbox.

♦ All cable straps that have been loosened or cut open when the
engine was removed must be fitted again in the same location
when the engine is installed again.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
Caution

Observe all safety measures and notes for assembly work on the
fuel, injection and ignition system as well as the rules for cleanli‐
ness ⇒ page 5 .
WARNING
Release pressure in the high pressure area of the fuel system

⇒ page 6 .
Engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ

– Pull off the engine cover on the sides upwards.
12 Rep. Gr.10 - Removing and installing engine

OCTAVIA II 2004 ➤

– Remove engine cover ⇒ page 245 .
– Remove and disconnect the plug connection -arrow- for lamb‐
da probe upstream of catalytic converter from the bracket and
expose wiring loom.
– Before disconnecting the battery, if necessary remove the
adapter for the anti-theft wheel bolts from the luggage com‐
partment.
– Remove battery and battery tray ⇒ Electrical System; Rep.
Gr. 27 .
– Drain coolant ⇒ page 152 .
– Remove right drive shaft ⇒ Chassis; Rep. Gr. 40 .
– Unscrew the left drive shaft from the flange shaft of the gear‐
box and tie up.
– Detach coolant hoses from radiator, heat exchanger and com‐
pensation bottle.
– Pull off the engine cover on the sides upwards -arrows-.
– Detach hose -1- and plug -2- from air filter housing.
– Unscrew bolt -3-.
– Detach the air guide hose -4- from the throttle valve control
unit. To do so, open the spring strap clip with the pliers for
spring strap clips .
– Take out air filter.
– Pull off air guide hose to pre-cubic contents from lock carrier.
1. Removing engine 13
OCTAVIA II 2004 ➤
– Remove the plug connection -1- for lambda probe 2 -G108-

upstream of catalytic converter from the bracket and discon‐
nect.
– Remove the plug connection -2- for lambda probe -G39- up‐
stream of catalytic converter from the bracket and disconnect.
– Disconnect plug connection -3- for pressure sensor for brake
servo unit -G294- .
– Disconnect the plug of the engine wiring harness from the en‐
gine control unit ⇒ page 271 .
– Release duct for engine wiring harness -arrow- and pull out
upwards.
– Expose rear left engine wiring harness at the intermediate wall
for the cooling water tank.
– Open the bracket of the cable guide -arrows-.

– Take engine wiring harness for control unit -1- out of the cable
guide.
– Open the brackets -2- and -3- of the cable guide.

– Expose and disconnect the front left plug connection -1- from
the wiring loom.
– Take engine wiring harness for control unit out of the cable
guide.
– Disconnect all plug connections of engine wiring harness/body
and lay the engine wiring harness on the engine.
– Detach the protective collar from the starter.

OCTAVIA II 2004 ➤
– Unscrew the earth lead -arrow- at the frame side rail.
– Separate plug connection -4- for reversing light switch.

– Unbolt earth strap -3-.
– Detach cables -1- and -2- at starter.
– Expose the cables.
– Disconnect the vacuum hose -arrow- from the brake servo unit
at the intake manifold.
– Detach the vacuum hose -arrow- from the brake servo unit.
Vehicles fitted with an automatic gearbox 09G (AQ 250)
– Remove the selector lever control cable from the gearbox ⇒
Gearbox; Rep. Gr. 37 .
Vehicles fitted with a manual gearbox 02S (MQ 250)
– Remove the shift cable and the selector cable from the gear‐
box ⇒ Gearbox; Rep. Gr. 34 .
OCTAVIA II 2004 ➤
– Remove strut -1-.

– Remove the slave cylinder -arrows- and tie up aside, do not
open the line system.
Caution
After removing the slave cylinder, do not depress the clutch

pedal. The slave cylinder can be removed in this way.
Vehicles fitted with a manual gearbox 02Q (MQ 350)

– Remove the shift cable and the selector cable from the gear‐
box ⇒ Gearbox; Rep. Gr. 34 .
– Remove tube-hose line from the breather/slave cylinder ⇒
Gearbox; Rep. Gr. 34 .
Caution
After removing the slave cylinder, do not depress the clutch

pedal.

BVX, BVY, BVZ
– Disconnect the fuel feed line -2- (press in the securing ring).
– Unlock the plug connection at the generator -arrow-.

– Push the plug from the generator with a screwdriver.

OCTAVIA II 2004 ➤
– Mark the hoses -1- and -2- and pull off from the cables.
– Detach coolant hoses -1- and -2-.

– Detach the hose -arrow- from the activated charcoal filter.

– Pull activated charcoal filter upwards and out of the bracket.
– Slightly loosen the screws -arrows- of the assembly bracket at

the engine (less than 1 revolution).
the gearbox (less than 1 revolution):
OCTAVIA II 2004 ➤

BVX, BVY, BVZ.
♦ Vehicles with engine identification characters BWA.
– Disconnect plug connection -1-.

– Open the cable clips -2- and -3- and expose the cables.
– Unscrew the nut -1- and pull off the cable clamp at the gener‐
ator.
– Pull protective cap off the nut -2-.
– Unscrew the nut -2- and pull off the cable.
– Remove the front part of the left wheelhouse liner ⇒ Body
Work; Rep. Gr. 66 .
– Put lock carrier in service position ⇒ Body Work; Rep. Gr. 50 .

OCTAVIA II 2004 ➤
– Remove charge air hoses -arrows-.
– Unscrew the bracket for the pump for coolant after-running -

V51- -arrows- and disconnect the plug.
– Detach the coolant hoses -arrows- to the heat exchanger for

heating at the front wall.
Vehicles with air conditioning
WARNING

tem.
– Take off bracket -arrow- for refrigerant lines on the right frame
side rail.
– Remove the fan shroud with radiator fans on vehicles with en‐
gine identification characters BWA ⇒ page 161 .
– Remove V-ribbed belt ⇒ page 41 .
OCTAVIA II 2004 ➤
– Disconnect plug connection -1- for magnetic coupling at AC

compressor.
Note
In order to avoid damage to the AC compressor as well as to the

refrigerant lines and hoses, ensure that the lines and hoses are
not over-tensioned, kinked or bent.
– Release screws -arrows- for AC compressor.

BVX, BVY, BVZ
– Secure AC compressor together with the connected refriger‐
ant hoses at the bottom of the lock carrier.
– Mount the air conditioning compressor -3- as shown onto the

lock carrier -2-. To protect the radiator attach cardboard -1- to
the radiator.
Vehicles with auxiliary heating.
– Place a catch pan -VAS 6208- under the engine.
– Detach coolant hoses -1- and -2-.

– Release screw -4-, slacken the nut -3- and remove the exhaust
pipe -5- of the auxiliary heating.
BVX, BVY, BVZ

OCTAVIA II 2004 ➤
– Pull off the air guide hose -arrow- at the bottom of the pre-cubic
contents. To do so, open the spring strap clip with the pliers
for spring strap clips .
– Unscrew air guide hose at bracket and remove.
– Disconnect plug -1- at oil pressure switch -F1- .

– If present, disconnect the plug connection at oil level and oil
temperature sender -G266- to the oil pan.
– Unplug connector -1-.

– Remove the front part of the exhaust gas system
⇒ page 287 .
– Unscrew the screw for the coolant pipe and the nut for the oil
dipstick guide -arrows- from the intake manifold. Pull the oil
dipstick guide -arrow- upwards and out of the engine.
OCTAVIA II 2004 ➤
– Disconnect plug -1- from coolant temperature sender at radi‐

ator outlet -G83- .
– Expose the cable -2- behind the coolant pipe -3-.
– Remove throttle valve control unit -J338- ⇒ page 260 .
– Remove intake air temperature sender -G42- ( ⇒ page 238 ,
Pos. 23).
– Disconnect the plug from the turbocharger divert air valve -
N249- .
⇒ page 289 .
Vehicles with four-wheel drive
– Remove propshaft at angle gearbox -arrows-. The third screw

is not visible in the figure.
Note
♦ When removing the gasket ring -arrow- do not damage the

propshaft.
♦ If the gasket ring is damaged -arrow- the propshaft must be
replaced.
– Release screw -1- at gearbox.

– Unscrew the fixing nuts -3- (6 pieces) of the front part of the
exhaust system/exhaust manifold.
– Remove left strut -2- for exhaust manifold.

OCTAVIA II 2004 ➤
– First of all release the screw -1-.

– Then release the screws -2- and -3- and remove the pendulum
support.
BVX, BVY, BVZ
– Pull the plug connection -1- out of the fixture and disconnect.
– Release screws -2- -3- and -4-.
– Remove/unclamp all other necessary electrical cables from
the engine/gearbox assembly and expose them.
– Unclamp all connecting, coolant, vacuum and suction hoses
from the engine.
– Screw engine mount -T10012- to the cylinder block with nut

-2- and fixing screw -1- to approx. 20 Nm.
– Insert engine and gearbox jack -V.A.G 1383 A- at engine
mount -T10012- and slightly raise.
Note
Use double ladder -VAS 5085- to release the screws for the as‐
sembly bracket.
– Release the screws -arrows- of the assembly bracket at the

engine.
gearbox:
OCTAVIA II 2004 ➤

BVX, BVY, BVZ.
Note
♦ Check whether all hose and line connections between engine,

gearbox and body are released.
♦ When lowering carefully guide the engine/gearbox assembly,
in order to avoid damage.

BVX, BVY, BVZ
– Pull engine/gearbox unit as far forward as possible and lower
slowly downwards.
– Lower the engine/gearbox assembly with the help of a 2nd
mechanic.
– When lowering, pay particular attention to the constrictions
(“AC compressor” and “exhaust gas turbocharger”).
– First slightly lower the engine/gearbox assembly, then pull as
far forward as possible, turn to the left and lower further.

OCTAVIA II 2004 ➤
2 Securing the engine to the assembly

stand
♦ Lifting device -MP9-201 (2024A)-
♦ Engine mount -MP1-202 (VW 540)-
♦ Assembly stand -MP9-101-
♦ Workshop crane , e.g. -VAS 6100-
– Guide engine with gearbox using the engine/gearbox jack -
V.A.G 1383 A- onto a work bench.
– Lower the engine/gearbox unit in such a way that the gearbox
is positioned on the support.
– Remove engine/gearbox connecting screws.
– Press gearbox from engine.
BVX, BVY, BVZ
– Hook on the lifting device -MP9-201- as follows and raise the

engine with the workshop crane from the engine mount -
T10012- .
Belt pulley side: 4th hole of perforated bar in position 1.
Flywheel side: 3rd hole of perforated bar in position 7.
WARNING
Use securing pins on the hooks and rig pins, in order to avoid
injuries and damages to the engine.
♦ The rig positions on the supporting bracket marked 1...4 point

towards the belt pulley.
♦ The holes in the perforated bars are counted from the hook.
2. Securing the engine to the assembly stand 25

OCTAVIA II 2004 ➤
– Hook on the lifting device -MP9-201- as follows and raise the

engine with the workshop crane from the engine mount -
T10012- .
Belt pulley side: 2nd hole of perforated bar in position 1.
Flywheel side: 1st hole of perforated bar in position 8.
WARNING
Use securing pins on the hooks and rig pins, in order to avoid
injuries and damages to the engine.
♦ The rig positions on the supporting bracket marked 1...4 point

towards the belt pulley.
♦ The holes in the perforated bars are counted from the hook.
Secure the engine with engine mount -MP1-202- on the assembly
stand -MP9-101- before performing assembly work.
– Unscrew gearbox from engine.
– Screw engine mount -MP1-202- to engine and secure to the

assembly stand -MP9-101- .

OCTAVIA II 2004 ➤
3 Installing the engine
3.1 Installing the engine

Installation is carried out in the reverse order. Pay attention to the
following:
Caution

Note
♦ All cable straps should be fitted on again in the same place

when installing.
♦ Secure all hose connections with hose clamps ⇒ Electronic
Catalogue of Original Parts .
♦ When performing installation work replace the self-locking
nuts.
♦ Replace screws which have been tightened to a torquing angle
as well as gasket rings and seals.
♦ Clean the drive shaft serration and hub serration on used
clutch disc, remove corrosion and only apply a very thin layer
of grease -G 000 100- onto the serration. Subsequently move
the disc up and down on the shaft until it fits smoothly on the
shaft. Remove all excess grease.
ness ⇒ page 5 .
– Insert new dowel sleeves for centering engine/gearbox in the
cylinder block.
3. Installing the engine 27

OCTAVIA II 2004 ➤
– Ensure that the intermediate plate has been inserted on the

sealing flange and is pushed onto the dowel sleeves
-arrows-.
Vehicles fitted with a manual gearbox
– Check the centering of the clutch disc, if necessary install
clutch and clutch control ⇒ Gearbox; Rep. Gr. 30 .
– Inspect clutch release bearing for wear, replace if necessary.
– Lightly lubricate spline of input shaft with grease -G 000 100- .
– Screw on the gearbox to the engine ⇒ page 30 .
– When installing the engine/gearbox assembly, ensure clear‐
ance to the assembly carrier as well as to the radiator.

OCTAVIA II 2004 ➤
Note
♦ When installing the engine do not damage the gasket ring

-arrow- of the propshaft.
♦ If the gasket ring is damaged -arrow- the propshaft must be
replaced.
Note
When swiveling the unit, ensure clearance to the drive shaft.
– Align the assembly bracket free of stress through tapping

movements and attach.
Note
♦ Checking and adjusting the assembly bracket ⇒ page 31 .

♦ Tightening torques of the unit mounting ⇒ page 33 .
– Install pendulum support ⇒ page 33 .

– Install drive shafts ⇒ Chassis; Rep. Gr. 40 .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. Gr.
87 .
– Install the V-ribbed belt ⇒ page 41 .
Vehicles fitted with a manual gearbox
– Install slave cylinder ⇒ Gearbox; Rep. Gr. 30 .
– Attach shift mechanism and adjust if necessary ⇒ Gearbox;
Rep. Gr. 34 .
Vehicles with automatic gearbox
– Install the selector lever control cable and adjust ⇒ Gearbox;
Rep. Gr. 37 .
– Attach propshaft ⇒ Gearbox; Rep. Gr. 39 .
– Fit the plug of the engine wiring harness onto the engine con‐
trol unit ⇒ page 271 .
3. Installing the engine 29

OCTAVIA II 2004 ➤
– Route wiring harness to the control unit -1- below and left (in
direction of travel) from wiring harness -2-.
– Install the intermediate wall for the plenum chamber ⇒ Body
Work; Rep. Gr. 66 .
– Install exhaust system and align free of stress ⇒ page 292 .
– Install the lock carrier ⇒ Body Work; Rep. Gr. 50 .
– Install the battery tray and battery ⇒ Electrical System; Rep.
Gr. 27 .
– Top up coolant ⇒ page 152 .
– Interrogate all fault memories and delete all fault entries, which
are caused by removing and installing the engine ⇒ Vehicle
diagnosis, testing and information system VAS 5051.
After deleting the fault memory of the engine control unit the
readiness code must be re-generated.
– Perform a test drive.
– Then perform a vehicle system test and if necessary eliminate
the resulting faults.
Tightening torques
Component Nm
Screws and nuts M6 9
M7 13
M8 20
M10 40
M12 70
deviations:
Engine/gearbox connecting screws:
♦ ⇒ Manual gearbox; Rep. Gr. 34
♦ ⇒ Automatic gearbox; Rep. Gr. 37
Screws for assembly bracket ⇒ page 33

OCTAVIA II 2004 ➤
4 Assembly bracket
4.1 Checking and adjusting the assembly

bracket
4.1.1 Checking the assembly bracket

– Check dimensions on the right hanger for engine/gearbox unit:
• Between engine bracket and engine support there must be a
distance -a- of 10...13 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1- the dimension -x- must be the same
at the front and rear.
Note
The distance -a- can also be checked e.g. with corresponding

round bars.
Only if there is an acoustic complaint (engine or gearbox knock

on the frame side rail when cornering) and the dimension -a- is
outside 10…13 mm:
– Adjust the assembly bracket ⇒ page 31 .
4.1.2 Adjusting the unit mounting

♦ Supporting device -T30099-
♦ Base -T30099/1-
♦ Adapter -MP9-200/3 (10-222/3)- , only engine identification
character BWA
♦ Spindle for MP9-200 and T30099 -MP9-200/10 (10-222/10)- ,
only engine identification characters BWA
♦ Shackle -10-222 A/12- (3 pieces), only engine identification
character BWA
If a too small or a too large distance is measured, perform as
follows:
Gr. 27 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. Gr.
66 .
4. Assembly bracket 31
OCTAVIA II 2004 ➤

– Install supporting device -T30099- and support engine in fitting
position.

BVX, BVY, BVZ
– Install supporting device -T30099- with base -T30099/1- (not
shown in figure) and support engine in fitting position.
– Uniformly pre-tension the engine with both spindles, do not
raise.

engine.
the gearbox (less than 1 revolution).

OCTAVIA II 2004 ➤

BVX, BVY, BVZ.
– Successively replace all the screws (as long as it has not al‐
ready been performed when installing the engine) and insert
these loosely.
– Move the engine with a tyre lever between the supporting arm
-1- and the engine support -2- until the screws are located in
the centre of the elongated holes.
• Between engine support and frame side rail on right there must
be a distance -a- of at least 10 mm.
• The cast iron edge on the engine support -2- must be parallel
to the supporting arm -1-. The dimension -x- must be the same
at the front and rear.
Note
The distance -a- can also be checked e.g. with corresponding

round bars.
– Tighten the screws for the engine side assembly bracket

⇒ page 33 .
– Tighten the screws for the gearbox side assembly bracket
⇒ page 33 .
4.2 Assembly bracket

Unit mounting for engine
1 = 20 Nm + torque a further 90° (1/4 turn)
Replace bolts
Replace bolts
Replace bolts
Assembly bracket of gearbox 02S and 09G

A = 40 Nm + torque a further 90° (1/4 turn)
Replace bolts
B = 60 Nm + torque a further 90° (1/4 turn)
Replace bolts
4. Assembly bracket 33
OCTAVIA II 2004 ➤
Assembly bracket gearbox 02Q

Replace bolts
Replace bolts
Pendulum support
Screw -A- strength category 8.8 = 40 Nm + torque a further 90°
(1/4 turn)
Replace bolts
Screw -A- strength category 10.9 1) = 50 Nm + torque a further
90° (1/4 turn)
Replace bolts
Screw -B- = 100 Nm + torque a further 90° (1/4 turn)
Replace bolts
Remove: First release screw -B-, then screws -A-.
Install: First tighten screws -A-, then screw -B-.
1)On manual gearbox MQ350 (02Q), only use the screws with
the strength category 10.9 if threaded inserts have been installed
(e.g. HeliCoil) -arrow-.

OCTAVIA II 2004 ➤
13 – Crankgear
1 Disassembling and assembling en‐
gine - Part 1
1.1 V-ribbed belt drive - Summary of components

BVX, BVY, BVZ
1 - Crankshaft-belt pulley
❑ Contact surfaces must
be free of oil and grease.
2 - 10 Nm + torque a further 90°
(1/4 turn)
❑ replace
3 - 23 Nm
4 - Lifting eye
5 - Tensioning device for V-rib‐
bed belt
❑ swivel tensioning device
for V-ribbed belt with
open-end wrench to
slacken the V-ribbed
belt
6 - Bracket for auxiliary units
❑ observe the order of
tightening up
⇒ page 37
7 - Nut
8 - AC generator
❑ removing and installing
⇒ Electrical System;
Rep. Gr. 27
❑ to facilitate positioning
of the generator, drive
the threaded bushings
of the retaining screws
at the generator slightly
backwards
9 - 45 Nm
tightening up ⇒ page 37
❑ insert using locking agent -D 000 600 A2-
10 - Bush
❑ 2 pieces
11 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning; Rep. Gr. 87
12 - V-ribbed belt
❑ Routing of the V-ribbed belt without AC compressor ⇒ page 37
❑ Routing of the V-ribbed belt with AC compressor ⇒ page 37
1. Disassembling and assembling engine - Part 1 35

OCTAVIA II 2004 ➤
❑ check for wear
❑ do not kink
❑ removing and installing ⇒ page 41
Engine identification character BWA
1 - Bracket for auxiliary units

tightening up
⇒ page 37
2 - 23 Nm
3 - Threaded bushing
4 - AC generator
⇒ Electrical System;
Rep. Gr. 27
❑ to facilitate positioning
of the generator, drive
the threaded bushings
of the retaining screws
at the generator slightly
backwards
5 - 45 Nm
tightening up
⇒ page 37
6 - Bush
❑ 2 pieces
7 - 23 Nm
8 - AC compressor
⇒ Heating, Air Condi‐
tioning; Rep. Gr. 87
9 - V-ribbed belt
❑ Routing of the V-ribbed
belt without AC com‐
pressor ⇒ page 37
❑ Routing of the V-ribbed
belt with AC compressor
⇒ page 37
❑ check for wear
❑ do not kink
10 - Crankshaft-belt pulley
❑ Contact surfaces must be free of oil and grease.
11 - 20 Nm + torque a further 90° (1/4 turn)
❑ replace
12 - 23 Nm
13 - Tensioning device for V-ribbed belt
❑ swivel tensioning device for V-ribbed belt with open-end wrench to slacken the V-ribbed belt
36 Rep. Gr.13 - Crankgear

OCTAVIA II 2004 ➤
Tightening order of bracket for auxiliary units

– First of all tighten all screws by hand starting with the screws
-4 and 6- (fit holes).
– Then tighten all the screws in the sequence -1 to 6-.
Routing of the V-ribbed belt without AC compressor

1- Belt pulley - crankshaft
2- V-ribbed belt
3- Tensioning pulley
4- Belt pulley - AC generator
Routing of the V-ribbed belt with AC compressor

1- Belt pulley - crankshaft
2- V-ribbed belt
3- Tensioning pulley
4- Belt pulley - AC generator
5- Belt pulley - AC compressor

OCTAVIA II 2004 ➤
1.2 Toothed belt drive - Summary of components, engines without split toothed
belt guard
1 - 10 Nm
2 - Top toothed belt guard
3 - 50 Nm + torque a further
180° (1/2 turn)
❑ replace
❑ to release and tighten
use counterholder -
MP1-216 (3036)-
4 - Camshaft sprocket
❑ Installation position
fixed by woodruff key
5 - 10 Nm
❑ insert using locking
agent -D 000 600 A2-
6 - Rear toothed belt guard
7 - Woodruff key
❑ check tightness
8 - 23 Nm
9 - Semi-automatic tensioning
pulley
10 - Coolant pump
⇒ page 156
11 - O-ring
❑ replace
12 - 25 Nm
agent -D 000 600 A2-
13 - Guide pulley
14 - 15 Nm
15 - 35 Nm
16 - Guide pulley
17 - Sealing flange
18 - Diamond washer
❑ for crankshaft - toothed belt sprocket
❑ only fitted for engine identification character BWA
❑ replace
19 - Crankshaft - toothed belt sprocket
❑ there must not be any oil present on the contact surface between the toothed belt sprocket and the
crankshaft
❑ can be installed only in one position
❑ replace

OCTAVIA II 2004 ➤
❑ do not oil
❑ to release and tighten use counterholder -T30004 (3415)- or -MP1-310 (3036)-
21 - Toothed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
22 - Bottom toothed belt guard
23 - Engine support bracket
24 - 45 Nm
25 - Cover for top timing belt guard
1.3 Toothed belt drive - Summary of components, engines with split toothed
belt guard
1 - 10 Nm
2 - Top toothed belt guard
180° (1/2 turn)
❑ replace
use counterholder -
MP1-216 (3036)-
fixed by woodruff key
5 - 10 Nm
agent -D 000 600 A2-
6 - Rear toothed belt guard
7 - Woodruff key
❑ check tightness
8 - 23 Nm
9 - Semi-automatic tensioning
pulley
10 - Coolant pump
⇒ page 156
11 - O-ring
❑ replace
12 - 25 Nm
agent -D 000 600 A2-

OCTAVIA II 2004 ➤
13 - Guide pulley
14 - 15 Nm
15 - 35 Nm
16 - Guide pulley
17 - Sealing flange
18 - Diamond washer
❑ for crankshaft - toothed belt sprocket
❑ only fitted for engine identification character BWA
❑ replace
19 - Crankshaft - toothed belt sprocket
❑ there must not be any oil present on the contact surface between the toothed belt sprocket and the
crankshaft
❑ can be installed only in one position
❑ replace
❑ do not oil
❑ to release and tighten use counterholder -T30004 (3415)- or -MP1-310 (3036)-
21 - Toothed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
22 - Bottom toothed belt guard
23 - 8 Nm
❑ Fixing screws for bottom toothed belt guard
❑ 7 pieces
24 - Engine support bracket
25 - 45 Nm

OCTAVIA II 2004 ➤
2 Disassembling and assembling en‐

gine - Part 2
2.1 Removing and installing V-ribbed belt

♦ Locking pin -T10060 A-
Removing
– Remove the sound dampening system ⇒ Body Work; Rep.
Gr. 50 .
– Pull activated charcoal filter with its attached lines to the top
in -direction of arrow- out of the bracket and place to the side.
– Mark the rotation direction of the V-ribbed belt.
– Loosen the V-ribbed belt by swivelling the tensioning element

in -the direction of the arrow-.

OCTAVIA II 2004 ➤
– Interlock the tensioning element with the locking pin -T10060

A- .
– Remove the V-ribbed belt.
Installing
– Installation is carried out in the reverse order. Pay attention to
the following:
Note
♦ Pay attention to the correct position and rotation direction of

the V-ribbed belt in the belt pulley when installing it.
♦ On vehicles without air conditioning system, fit the V-ribbed
belt last on the belt pulley for AC generator ⇒ page 35 .
♦ On vehicles with air conditioning system, fit the V-ribbed belt
last on the belt pulley for AC compressor ⇒ page 35 .
Each time work has been completed:

– Start engine and check belt run.
2.2 Removing and installing the toothed

belt, engines without split toothed belt
guard
♦ Base -T30099/1-
character BWA
♦ Shackle -10-222 A/12 (10-222/12)- (3 pieces), only engine
identification character BWA
♦ Hose clamp up to ∅ 25 mm -MP7-602 (3094)- , only engine
2.2.1 Removing
Note
To remove the engine support, the engine must be raised rela‐

tively high with the supporting device -T30099- . It is necessary
to remove the drive shafts from the gearbox in order to avoid
damage to the drive shafts through the sharp bending angle.

OCTAVIA II 2004 ➤
Note
♦ Safety precautions when working on the fuel supply system

⇒ page 5 .
♦ Rules of cleanliness when working on the fuel supply system
⇒ page 7 .
– Switch off the ignition and all electrical components and take
out the ignition key.
BVX, BVY, BVZ
– Remove the hose to the activated charcoal filter -1-.

– Detach the fuel feed line -2- and the fuel return-flow line -3-.
Gr. 27 .

OCTAVIA II 2004 ➤
– Disconnect the vacuum line -1- as well as the fuel feed line
-2- (press in the securing ring). Lay the cables to the side.
and out of the bracket -arrow-.
– Unscrew bolts on filler neck for windshield washer fluid reser‐

voir -3-.
– Unbolt bracket -4- for activated charcoal filter.
WARNING
Hot steam may escape when the coolant expansion reservoir

is opened. Wear safety goggles and safety clothing, in order to
avoid eye injuries and scalding. Cover the cap with a cloth and
open carefully.
– Open the cap of the expansion reservoir -6- to reduce the

pressure in the cooling system.
– Then close the expansion reservoir again.
– Remove the coolant hose -1- from the expansion reservoir
-6-.
– Unclip the coolant hose -2- from the mounting.
– Unscrew the expansion reservoir -6- and lay with the connec‐
ted coolant hose -2- on the engine.

OCTAVIA II 2004 ➤
– Pinch off the coolant hose -arrow- with a hose clamp up to ∅

25 mm -MP7-602- .
– Disconnect the line at the coolant pipe -arrow-.
– Remove the locking pin -T10060 A- from the tensioning device
for V-ribbed belt.
66 .
– Remove intermediate wall for the plenum chamber.

position.
raise.
BVX, BVY, BVZ
– Install supporting device -T30099- with base -T30099/1 - (not

Gr. 50 .
– Remove the front part of the front right wheelhouse liner ⇒
Body Work; Rep. Gr. 66 .
– Remove cover from top timing belt guard.

OCTAVIA II 2004 ➤
– Position camshaft sprocket to TDC marking for cylinder 1 by

rotating at crankshaft.
• The marking on the camshaft sprocket must be flush with the
arrow on the timing belt guard -arrows-.
Note
The TDC marking on the timing belt guard can only be seen with
a mirror.
– Remove vibration damper/belt pulley.
– Unscrew the screws from the bottom timing belt guard

-arrows-.
Note
Do not observe the pos. -1- and -2-.
– Unscrew the bottom screw -3-.

Vehicles with front-wheel-drive

OCTAVIA II 2004 ➤
– Unscrew the fixing nuts -arrows- of the front part of the exhaust
system/exhaust manifold.

– Unscrew the hanger for the exhaust system -arrows-.

OCTAVIA II 2004 ➤
– Release screws -2- and -3- of pendulum support.

Note
The next work steps are necessary in order to lift the engine suf‐
ficiently.

⇒ page 289 .
– Unscrew the left and right drive shaft from the gearbox ⇒
Chassis; Rep. Gr. 40 .
WARNING

tem.
– Remove the pipes of the air conditioning system from the

structure -arrows-.
– Release screws -1- and -2- and remove the connecting stud.
– Release screws -3- to -6- and remove the engine mount.
Note
♦ The assembly bracket must only be removed if the engine is

supported with the supporting device -T30099- !
♦ Only release the engine support if the assembly bracket is re‐
moved.

OCTAVIA II 2004 ➤

gearbox.
Caution
Make sure that no components/hoses/lines are damaged,

overstretched or torn off when lifting the engine with the sup‐
porting device -T30099- .
– Lift up the engine with the supporting device -T30099- until the
screws -1- and -2- can be unscrewed and the engine support
can be pulled out.
– Screw the screws -1- and -2- out of the top toothed belt guard.
Note
It is possible that in the area of the left screw -2- the top timing
belt guard remains glued to the rear timing belt guard. In this case
carefully separate the parts with a screwdriver.
– Remove bottom toothed belt guard.

– Remove top timing belt guard.
To do so if necessary slightly raise engine again.
– Mark the rotation direction of the timing belt.
– Slacken tensioning pulley and take off timing belt.
– Then turn crankshaft back slightly.
2.2.2 Installing
• The engine must be not more than warm to touch.
Caution
When rotating the camshaft, the crankshaft must not be posi‐

tioned at TDC. Risk of damaging valves and piston crowns.
– Fit timing belt onto the crankshaft timing belt sprocket (pay
attention to direction of running).
– Position the bottom timing belt guard, insert lower screws with
locking agent -D 000 600 A2- and tighten.
– Install the vibration dampener/belt pulley using new screws.

OCTAVIA II 2004 ➤
Tightening torque: 10 Nm + torque a further 90°

– Unscrew first the camshaft and then the crankshaft in the di‐
rection of rotation of the engine to TDC for cylinder 1
-arrows-.
Note
a mirror.
– Fit timing belt in the sequence: tensioning pulley, camshaft

sprocket, coolant pump and last the guide pulley -arrow-.
Note
Pay attention to the correct fitting of the tensioning pulley

-arrow- in the cylinder head.
Tightening the timing belt

OCTAVIA II 2004 ➤
– Tighten the timing belt. To do this, turn the Allen key on the
eccentric to the right in the -direction of arrow-, until the notch
is above the peg (timing belt is overtensioned).
– Slacken the timing belt again.
– Now tension the timing belt, until the notch and the peg are
positioned opposite each other.
– Tighten securing nut to 23 Nm.
– Turn the crankshaft two turns in the direction of rotation of en‐
gine until the engine is again on TDC. When doing this, it is
important that the last 45° (1/8 rotation) are rotated without any
interruption.
– Once again inspect tension of toothed belt.
• Specified value: Peg and notch are positioned opposite.
– Check the TDC setting once again.
If the markings -arrows- are not aligned:
Note
a mirror.
– Loosen the tensioning pulley and tension the timing belt again.
If the markings -arrows- are aligned:
– Insert top timing belt guard and tighten screws -1-.

– Insert the screws -2- with locking agent -D 000 600 A2- and
tighten.
– Insert engine support and tighten the screws by hand.

OCTAVIA II 2004 ➤
Note
Pay attention to the various screw lengths. The screw -3- is ap‐
prox. 25 mm shorter than the screws -1- and -2-.
– Lower the engine with the supporting device -T30099- until the
bottom screw -3- can be tightened.
– Tighten all screws to 45 Nm.
– Lower the engine down to the fitting position.
– Insert top screws of bottom timing belt guard with locking agent
-D 000 600 A2- and tighten all screws of bottom timing belt
guard.
– Completely install the assembly bracket for the engine, tight‐
ening torques ⇒ page 33 .
– Tighten the assembly bracket of the engine at the engine sup‐

port -arrows-. To do so the contact surfaces with the support‐
ing device -T30099- are positioned on the support.
– Checking and adjusting the assembly bracket ⇒ page 31 .
Further installation occurs in a similar way in reverse order to re‐
moval.
2.3 Removing and installing the toothed

belt, engines with split toothed belt
guard
Note
♦ Vehicles as of 10.2007 have a new toothed belt guard.

♦ Distinguishing feature: The top toothed belt guard is without
cover ( ⇒ page 38 , Pos. 25) and the toothed belt guard is split
in the area of the engine support.
♦ Removing and installing the toothed belt; engines without split
toothed belt guard ⇒ page 42 .

♦ Base -T30099/1-
character BWA
♦ Shackle -10-222 A/12 (10-222/12)- (3 pieces), only engine

OCTAVIA II 2004 ➤
♦ Hose clamp up to ∅ 25 mm -MP7-602 (3094)- , only engine

2.3.1 Removing
Note

⇒ page 5 .
⇒ page 7 .
BVX, BVY, BVZ
– Remove the hose to the activated charcoal filter -1-.

Gr. 27 .

OCTAVIA II 2004 ➤
– Disconnect the vacuum line -1- as well as the fuel feed line
-2- (press in the securing ring). Lay the cables to the side.

voir -3-.
WARNING

open carefully.
– Open the cap of the expansion reservoir -6- to reduce the

pressure in the cooling system.
– Then close the expansion reservoir again.
– Remove the coolant hose -1- from the expansion reservoir
-6-.
– Unscrew the expansion reservoir -6- and lay with the connec‐
ted coolant hose -2- on the engine.

OCTAVIA II 2004 ➤
– Pinch off the coolant hose -arrow- with a hose clamp up to ∅

25 mm -MP7-602- .
– Disconnect the line at the coolant pipe -arrow-.
– Release screws -arrows- and remove the toothed belt guard

from the top.
66 .
BVX, BVY, BVZ
– Unscrew the tensioning element for the V-ribbed belt -B- and
attach the lifting eye -A- with 3 screws M8 x 20 to the bracket
for auxiliary units.
– Remove ribbed V-belt tensioning device -arrows-.

OCTAVIA II 2004 ➤

position.
raise.
BVX, BVY, BVZ
– Install supporting device -T30099- with base -T30099/1- (not

Gr. 50 .
– Unscrew screws -arrows- and remove the charge-air pipe with

hoses.

• The marking on the camshaft sprocket must be flush with the
arrow on the timing belt guard -arrows-.
Note
a mirror.

OCTAVIA II 2004 ➤
– Remove vibration damper/belt pulley.
Note
♦ The TDC markings must be aligned before removing the vi‐

bration damper.
♦ The crankshaft must no longer be turned until the TDC position
is marked by an auxiliary marking.
– Unscrew the bottom screws -arrows- from the bottom toothed

belt guard.
– Mark the TDC position -arrow-.
– Unscrew the bottom screw -3-.
Note
The next work step is necessary in order to lift the engine suffi‐
ciently.

OCTAVIA II 2004 ➤
– Unscrew the screws -2- and -3- of the pendulum support.
– Release screws -1- and -2- and remove the connecting stud.
– Release screws -3- to -6- and remove the engine mount.
Note
♦ The assembly bracket must only be removed if the engine is

supported with the supporting device -T30099- !
♦ Only release the engine support if the assembly bracket is re‐
moved.
Caution
Make sure that no components/hoses are damaged, over‐

stretched or torn off when lifting the engine with the supporting
device -T30099- .
– Lift up the engine with the supporting device -T30099- until

both top screws -1 and 2- of the engine support can be slack‐
ened and removed.
– Release both top screws from the bottom toothed belt guard
-arrows- and remove the toothed belt guard downwards from
the engine.
– Now remove the engine support upwards from the engine.
– Mark the rotation direction of the timing belt.
– Slacken tensioning pulley and take off timing belt.
– Then turn crankshaft back slightly.

OCTAVIA II 2004 ➤
2.3.2 Installing
• The engine must be not more than warm to touch.
Caution
When rotating the camshaft, the crankshaft must not be posi‐

tioned at TDC. Risk of damaging valves and piston crowns.
– Position the camshaft and the crankshaft on the TDC mark‐

ings.
– Fit timing belt onto the crankshaft timing belt sprocket (pay
attention to direction of running).
– Fit timing belt in the sequence: tensioning pulley, camshaft

sprocket, coolant pump and last the guide pulley -arrow-.
Note
Pay attention to the correct fitting of the tensioning pulley

-arrow- in the cylinder head.
Tightening the timing belt

OCTAVIA II 2004 ➤
– Tighten the timing belt. To do this, turn the Allen key on the
eccentric to the right in the -direction of arrow-, until the notch
is above the peg (timing belt is overtensioned).
– Slacken the timing belt again.
– Now tension the timing belt, until the notch and the peg are
positioned opposite each other.
– Tighten securing nut to 25 Nm.
– Turn the crankshaft two turns in the direction of rotation of en‐
gine until the engine is again on TDC. When doing this, it is
important that the last 45° (1/8 rotation) are rotated without any
interruption.
– Once again inspect tension of toothed belt.
• Specified value: Peg and notch are positioned opposite.
If the markings -arrows- are not aligned:

– Loosen the tensioning pulley and tension the timing belt again.
If the markings -arrows- are aligned:
– Move the engine support into its installed position.
Note
Do not fit the fixing screws of the engine support yet. The engine
support must lie “loosely” between the engine and the frame side
rail.
– Install the bottom toothed belt guard from below -arrows-.
Note
Insert the middle screws of the toothed belt guard from below with
locking agent -D 000 600 A2- .
– Install the vibration dampener/belt pulley using new screws.

Tightening torque for engine identification characters BLR,
BLX, BLY, BVX, BVY, BVZ: 10 Nm + torque a further 90°
Tightening torque for engine identification characters BWA: 20
Nm + torque a further 90°

• The markings must be aligned -arrows-.

OCTAVIA II 2004 ➤
– Tighten both top screws -arrows- of the bottom toothed belt

guard.
– Install the engine support on the cylinder block and tighten the
top screws by hand.
Note
Pay attention to the various screw lengths. The screw -3- is ap‐
prox. 25 mm shorter than the screws -1 and 2-.
– Lower the engine with the supporting device -T30099- until the
bottom screw -3- can be tightened.
– Tighten all screws to 45 Nm.
– Lower the engine down to the fitting position.
– Completely install the assembly bracket for the engine, tight‐
ening torques ⇒ page 33 .
– Tighten the assembly bracket of the engine at the engine sup‐

port -arrows-. To do so the contact surfaces with the support‐
ing device -T30099- are positioned on the support.
– Checking and adjusting the assembly bracket ⇒ page 31 .
moval.

OCTAVIA II 2004 ➤
3 Sealing flanges and flywheel/drive

plate
Note
Repairs to the clutch ⇒ Gearbox; Rep. Gr. 30 .
3.1 Summary of components

(1/4 turn)
❑ replace
2 - Crankshaft - toothed belt
sprocket
3 - Diamond washer
❑ only fitted for engine
identification character
BWA
4 - 15 Nm
5 - Gasket ring for crankshaft
on belt pulley side
❑ Do not additionally lubri‐
cate or grease sealing
lip of the gasket ring
❑ replace ⇒ page 63
6 - Sealing flange on the belt
pulley side
❑ must be positioned on
dowel sleeves
⇒ page 65
❑ remove oil pan for re‐
moving and installing
⇒ page 127
7 - Cylinder block
❑ Remove and install bal‐
ancing shaft module
with oil pump
⇒ page 130
crankshaft ⇒ page 72
❑ Disassembling and as‐
sembling pistons and conrods ⇒ page 75
❑ replace
9 - Two-mass flywheel/driver disc
❑ removing and installing the two-mass flywheel ⇒ page 69
❑ removing and installing drive plate ⇒ page 70
10 - Intermediate plate
❑ must be positioned on dowel sleeves
❑ do not damage/bend during assembly work

OCTAVIA II 2004 ➤
11 - Sealing flange on the gearbox side

❑ with integrated gasket ring
3.2 Replacing crankshaft seal on belt pulley

side
♦ Gasket ring extractor -MP1-226 (3203)-
♦ Counterholder -T30004 (3415)- or Counterholer -MP1-310
(3099)-
♦ Assembly device -T10053-
Removing
– Removing timing belt.
♦ Engines without split toothed belt guard: ⇒ page 42
♦ Engines with split toothed belt guard: ⇒ page 52
– Remove crankshaft - toothed belt sprocket. To do this, coun‐
terhold the timing belt sprocket with counterholder -T30004-
or with counterholder -MP1-310- .
Note
On vehicles with engine identification characters BWA a diamond

washer is fitted between the crankshaft - toothed belt sprocket
and the crankshaft bearing pin.
– To guide the gasket ring extractor, screw central bolt by hand

fully into the crankshaft.
– Unscrew inner part of the gasket ring extractor -MP1-226- nine
turns (approx. 20 mm) out of the outer part and lock with
knurled screw.
3. Sealing flanges and flywheel/drive plate 63

OCTAVIA II 2004 ➤
– Oil the thread head of the gasket ring extractor -MP1-226- ,

position and forcefully screw it into the gasket ring as far as
possible.
– Release knurled screw and turn the inner side against the
crankshaft until the gasket ring is pulled out.
Installing
– Remove oil residue on the crankshaft bearing pin with a clean
cloth.
– Insert guide bushing -T10053/1- on the crankshaft bearing pin.

– Slide dry gasket ring over the guide bushing onto the crank‐
shaft bearing pin.
– Push in gasket ring with assembly device -T10053- and bolt -

T10053/2- (M16 x 1.5 x 60) up to the stop.
Note
♦ On vehicles with engine identification characters BWA a dia‐

mond washer is fitted between the crankshaft - toothed belt
sprocket and the crankshaft bearing pin.
♦ There must not be any oil present on the contact surfaces be‐
tween timing belt sprocket, diamond washer and crankshaft.
♦ The central screw must be replaced.
♦ The diamond washer (only engine identification character
BWA) must be replaced.
♦ Thread and collar must be free of oil and grease.

OCTAVIA II 2004 ➤
– Install crankshaft - toothed belt sprocket and counterhold with

counterholder -T30004- or lock with counterholder -
MP1-310- .
– Tighten new central bolt to 90 Nm and torque a further 90°
(1/4 turn). Tightening may occur in successive stages.
moval.
3.3 Removing and installing the sealing

flange on the belt pulley side
♦ Counterholder -T30004 (3415)- or Counterholer -MP1-310
(3099)-
♦ Guide bushing -T10053/1-
♦ Silicone sealant -D 176 404 A2 -
♦ Cleaning and degreasing agent , e.g. -D 000 401 04-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
Removing
– Removing timing belt.
– Remove crankshaft - toothed belt sprocket. To do this, coun‐
terhold the timing belt sprocket with counterholder -T30004-
or with counterholder -MP1-310- .
Note
On vehicles with engine identification characters BWA a diamond

washer is fitted between the crankshaft - toothed belt sprocket
and the crankshaft bearing pin.
– Removing the oil pan ⇒ page 127 .

OCTAVIA II 2004 ➤
– Unscrew front sealing flange -arrows-.

– Remove sealing flange, if necessary release by applying slight
blows with a rubber-headed hammer.
– Drive out the gasket ring from the removed sealing flange.
WARNING
Wear protective gloves when working with sealant and grease

remover.
– Remove residual sealant on the sealing flange and on the cyl‐

inder head using a chemical sealant remover.
– Degrease all sealing surfaces.
Installing
– Before applying the sealant bead, cover the sealing surface of
the gasket ring with a clean cloth.
– Cut off nozzle tube at the front marking (∅ of nozzle approx.

3 mm).
– Apply a bead of sealant of approx. 2...3 mm as shown
-arrows- to the clean sealing surface of the sealing flange.
Note
♦ Pay attention to the use by date on sealant.

♦ The sealant bead must not be thicker than 2...3 mm otherwise
excess sealant may get into the oil pan and clogg the strainer
in the oil suction pipe.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When installing the sealing flange with the gasket ring fitted
use guide sleeve -T10053/1- .
♦ After installing, allow the sealant to dry for about 30 minutes.
Only then may engine oil be filled in.
– Fit sealing flange immediately and lightly tighten all bolts.

– Tighten the fixing screws of the sealing flange crosswise.
Tightening torque: 15 Nm
– Remove excess sealant. There must be no sealant on the
crankshaft bearing pin and the sealing surface of the gasket
ring.
– Install oil pan ⇒ page 127 .
– Install a new gasket ring for the crankshaft -on the belt pulley
side- ⇒ page 63 .

OCTAVIA II 2004 ➤
– Install crankshaft - toothed belt sprocket and counterhold with

counterholder -T30004- or lock with counterholder -
MP1-310- .
Note
♦ On vehicles with engine identification characters BWA a dia‐

mond washer is fitted between the crankshaft - toothed belt
sprocket and the crankshaft bearing pin.
♦ There must not be any oil present on contact surface between
toothed belt sprocket and crankshaft.
♦ The central screw must be replaced.
♦ The diamond washer (only engine identification character
BWA) must be replaced.
♦ Thread and collar must be free of oil and grease.
– Tighten new central bolt to 90 Nm and torque a further 90°

(1/4 turn). Tightening may occur in successive stages.
moval.
3.4 Replace sealing flange on the gearbox

side
Removing
– Remove the two-mass flywheel or the driver disc.
♦ Remove two-mass flywheel: ⇒ page 69
♦ Remove the driver plate: ⇒ page 70

OCTAVIA II 2004 ➤
– Unscrew sealing flange -arrows-.

Install
Note
♦ Do not additionally lubricate or grease sealing lip of the gasket

ring!
♦ The sealing flange is seated on the dowel pins.
– Clean the sealing surfaces. They must be free of oil and

grease.
– Remove oil residue on the crankshaft bearing pin with a clean
cloth.
Sealing flange with supporting sleeve
– Install sealing flange.
Note
♦ To install, use the supplied supporting sleeve.

♦ The supporting sleeve must not be removed until after pushing
the sealing flange onto the crankshaft bearing pin.
Sealing flange without supporting sleeve

– Fit together assembly sleeves -T10122/1- and -T10122/2 - .
– Push the assembly sleeves onto the sealing flange -A- as

shown.
– Separate the assembly sleeves.
– Position the sealing flange -A- with the assembly sleeve -

T10122/2- on the crankshaft and push the sealing flange onto
the crankshaft bearing pin.
Complete installation

OCTAVIA II 2004 ➤
– Tighten fixing screws to 15 Nm -arrows-.

moval.
3.5 Removing and installing the two-mass

flywheel
♦ Counterholder -MP1-223 (3067)-
or
♦ Engine mount -MP1-202 (VW 540)-

♦ Bushing -T30010 (VW 540/1B)-
♦ Flywheel lock -MP1-504 -
Removing
• Gearbox is removed.
– Remove the clutch ⇒ Gearbox; Rep. Gr. 30 .
Engine installed
– Insert the counterholder -MP1-223 (3067)- into the bore hole
on the cylinder block.
• Fitting position of the tool:
A - for tightening
B - for slackening

OCTAVIA II 2004 ➤
Engine removed
– Position the flywheel lock -MP1-504- on the starter ring gear
and turn crankshaft until it rests against the sleeve -T30010 - .
Continued for all engines

– Rotate the secondary side -A- of the two-mass flywheel in such
a way that the screws -B- are positioned in the middle of the
holes -arrows-.
Caution
When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise it will be damaged.
– Release screws -B- and remove two-mass flywheel.

Installing
Installation is performed in the reverse order, pay attention to the
following points:
Note
Use new screws for attaching.
– Rotate the secondary side -A- of the two-mass flywheel in such

a way that the screws -B- are positioned in the middle of the
holes -arrows-.
1. Screw in all the screws -B- by hand.
2. First of all tighten all the screws -B- crosswise to 60 Nm.
3. Then torque all the screws -B- crosswise a further 90° (1/4
turn.)
3.6 Removing and installing drive plate

♦ Flywheel lock -MP1-221 (VW 558)-
♦ Depth gauge
♦ Hexagonal screw -M8 × 45-
♦ Two hexagon nuts -M10 -

OCTAVIA II 2004 ➤
Remove the driver plate

– Remove the gearbox ⇒ Gearbox; Rep. Gr. 37 .
– Attach counterholder -MP1-221- with hexagon bolt -M8 × 45-
to the drive plate. Insert two hexagon nuts -M10- between the
counterholder and the driver disc.
Fitting position of the tool:
-A- for slackening
-B- - for tightening
Installing the drive plate
– Only insert the drive plate using the washer with recesses
-1- (without spacer washer -2-).
– Insert new bolts -3- and tighten to 30 Nm.
– Check dimension -a- in three points and determine the mean

value.
Specified value: 19.5…21.1 mm
Note
The measurement is made through the hole of the drive plate to

the milled surface of the cylinder block.
If the measurement is less than the specification:
– Remove driver disc again and use compensating washer -2-.

Insert screws -3- again and tighten to 30 Nm.
– Tighten screws -3- to 60 Nm and torque a further 90° (1/4 turn)
(the tightening may occur in several stages).

OCTAVIA II 2004 ➤
4 Crankshaft
Note
If considerable quantities of metal swarf or abrasion is found in the oil or in the engine when carrying out repairs,
this can be subject to damage to the crankshaft and conrod bearings. In order to avoid consequential damage,
perform the following tasks when carrying out repairs:
– Carefully clean the oil galleries.

– Replace oil spray jets.
– Replace oil cooler.
– Replace oil filter element.
♦ Before removing the crankshaft, ensure a suitable place is
available for placing it down so that the sensor rotor (Pos. 4)
does not rest on anything or get damaged.
♦ Secure the engine with engine mount -MP1-202- on the as‐
sembly stand -MP9-101- before performing assembly work.

(1/4 turn)
❑ replace
❑ tighten thread
2 - Bearing caps
❑ Bearing cap 1: belt pul‐
ley side
❑ retaining lugs of the
bearing shells of the cyl‐
inder block/bearing cap
must be on top of one
another
(1/4 turn)
❑ replace
4 - Rotor
❑ for engine speed sender
-G28-
❑ replace sensor rotor
each time the bolts are
slackened
❑ assembly only possible
in one position -holes
offset-
⇒ page 73
5 - Crankshaft
❑ Axial play when new:
0.07…0.23 mm
Wear limit: 0.30 mm
❑ Crankshaft bearing

OCTAVIA II 2004 ➤
pins: ∅ 54.00 mm
❑ Conrod bearing: ∅ 47.80 mm
6 - Thrust washers
❑ for bearing 3
7 - Bearing shells for cylinder block
❑ with lubricating groove
❑ do not mix up used bearing shells (mark)
❑ Identification ⇒ page 74
8 - Bearing shell for bearing cap
❑ without lubricating groove
❑ do not mix up used bearing shells (mark)
❑ Identification ⇒ page 74
Removing and installing sensor rotor
Note
Before removing the crankshaft, ensure a suitable place is avail‐

able for placing it down so that the sensor rotor does not rest on
anything or get damaged.
– Always replace the sensor rotor -2- each time the bolts -1- are
slackened.
Note
♦ After the sensor rotor is screwed on once again, the attach‐

ment points of the recess head screws are misshapened in
such a way that the bolt heads rest against the crankshaft
-3- -arrows- and the sensor rotor is positioned loosely below
the screws.
♦ It is only possible to install the sensor rotor in one position, the
holes are offset.
4. Crankshaft 73
OCTAVIA II 2004 ➤
Assign the crankshaft bearing shells to the cylinder block

The upper bearing shells are allocated to the cylinder block with
the right thickness at the works. Coloured points on the bearing
shell are used to mark the bearing shell thickness.
The bearing shell is to be used at the location which is marked
with letters, on the lower sealing surface of the cylinder block.
Letter on the cylinder block Colour of the support
B = blue
G = yellow
W = white
Note
♦ The -arrow- shows the direction of travel.

♦ If the coloured points are no longer legible, use the blue bear‐
ing shell.
♦ The bottom crankshaft bearing shells are always supplied as
replacement parts with the colour coding “yellow”.

OCTAVIA II 2004 ➤
5 Pistons and conrods
1 - Conrod bolt, 30 Nm + torque

a further + 90° (1/4 turn)
❑ replace
❑ Oil thread and contact
surface
2 - Pressure valve, 27 Nm
❑ Opening pressure:
0.13…0.16 MPa (1.3…
1.6 bar)
3 - Oil injection nozzle
❑ for piston cooling
4 - Conrod bearing cap
❑ Check fitting position
❑ as a result of the con‐
rods separated in the
cracking process, the
cover fits only in one po‐
sition and only to the rel‐
evant conrod
❑ mark assignment to cyl‐
inder -B-
❑ Fitting position: Mark‐
ings -A- point towards
the belt pulley side
5 - Bearing shell
❑ check fitting position
⇒ page 76
❑ do not mix up used bear‐
ing shells
6 - Conrod
❑ with a split bearing cap
❑ separate new conrod
⇒ page 77
❑ replace as a set only
❑ mark assignment to cylinder -B-
❑ Fitting position: Markings -A- point towards the belt pulley side
❑ Axial play when new: 0.10…0.35 mm
Wear limit: 0.4 mm
7 - Circlip
8 - Piston pin
❑ if stiff, heat piston to approx. 60°C
❑ use drift -VW 222 A- for removing and installing
9 - Piston
❑ pay attention to different versions according to engine identification characters, part number
❑ mark installation position and matching cylinder
❑ arrow on the piston crown faces towards the belt pulley side
5. Pistons and conrods 75

OCTAVIA II 2004 ➤
❑ use piston ring tensioning strap for installing
❑ check ⇒ page 77
❑ inspect cylinder bore ⇒ page 77
❑ Piston ∅: 82.465 mm (nominal dimension)
❑ Cylinder ∅: 82.51 mm (nominal dimension)
10 - Piston rings
❑ Offset joint 120°
❑ use piston ring pliers for removing and installing
❑ Markings face piston crown
❑ Vehicles with engine code BWA: 2-part oil scraper ring
❑ Inspect gap clearance ⇒ page 76
❑ Inspect end clearance ⇒ page 76
Bearing shell installation position

Bearing shell -1- with oil drilling -arrow- for conrod.
Bearing shell -2- without oil drilling for conrod bearing cap.
– Insert bearing shells in the conrod and in the conrod bearing
cap centred.
The dimension -a- must be the same on the right and left.
5.2 Inspect piston, piston rings and cylinder

bore
Inspecting piston ring gap clearance

♦ Feeler gauge
– Insert ring at right angles from above down into the lower cyl‐
inder opening, about 15 mm away from edge of cylinder.
Piston ring Gap clearance
New Wear limit
Gasket rings mm 0,20…0,40 0,8
Oil scraper ring mm 0,25…0,50 0,8
Inspect piston ring end clearance

♦ Feeler gauge

OCTAVIA II 2004 ➤
– Clean before inspecting the annular grooves of the piston.

Piston ring End clearance
New Wear limit
Gasket rings mm 0,06…0,09 0,20
Oil scraper ring mm 0,03…0,06 0,15
Inspecting pistons

♦ External micrometer 75...100 mm
– Measure about 10 mm from the lower edge and vertically off‐
set to piston pin axis.
• Deviations from specified dimension: max.: 0.04 mm
Inspecting cylinder bore

♦ Internal precision measuring instrument 50...100 mm
– Measure at 3 points crosswise in a transverse direction -A- and
lengthwise -B-.
• Deviations from specified dimension: max.: 0.08 mm
Note
Do not measure the cylinder bore if the cylinder block is fixed to

the assembly stand -MP1-202 - with the engine mount -
MP9-101- , as this may result in incorrect measurements.
5.3 Separating new conrod

It can happen that on a new conrod, the provided separation point
is not completely cracked. If the conrod bearing cap cannot be
removed by hand, proceed in the following manner:
– Mark the assignment of the conrod to the cylinder.
5. Pistons and conrods 77

OCTAVIA II 2004 ➤
– Slightly tension the conrod, as shown in the illustration, in a

vice provided with aluminium protective jaws.
Note
♦ Only tension the conrod slightly in order to avoid damage.

♦ The conrod is clamped below the broken line.
– Unscrew both screws -arrows- by approx. 5 turns.
– Knock against the conrod bearing cap with a plastic hammer

in -direction of arrow- in order to loosen it.

OCTAVIA II 2004 ➤
15 – Cylinder Head, Valve Gear

1 Cylinder head - Summaries of com‐
ponents
Testing compression pressure ⇒ page 92 .
Removing and installing toothed belt:
♦ Engines without split toothed belt guard ⇒ page 42 .
♦ Engines with split toothed belt guard ⇒ page 52 .
Note
♦ If a replacement cylinder head is installed, it is necessary to

oil all the contact surfaces between supporting elements, roller
rocker arms and cam tracks of the camshafts before installing
the cylinder head cover.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ Replace cylinder head bolts.
♦ If the cylinder head is replaced, the system must also be com‐
pletely filled with fresh coolant.
1. Cylinder head - Summaries of components 79

OCTAVIA II 2004 ➤
1.1 Summary of components - vehicles with engine identification characters

BLR, BLX, BLY, BVX, BVY, BVZ
1 - Cylinder head bolt

❑ replace
❑ pay attention to se‐
quence for loosening
and tightening
⇒ page 85
❑ Tightening torque:
⇒ page 91
2 - 10 Nm
3 - Cylinder head cover
❑ order of tightening
⇒ page 81
4 - Gasket
❑ replace if damaged or
leaking
5 - Gasket for cylinder head
cover
leaking
6 - Support
7 - Oil-filling cover
8 - 4 Nm
9 - Camshaft adjustment valve
1 -N205-
⇒ page 115
10 - Gasket
❑ replace
11 - Wiring harness bracket
12 - Housing
13 - Gasket
❑ replace
14 - Lifting eye
15 - 25 Nm
16 - Pin screw, 10 Nm
❑ for the intake manifold
17 - Separation plate
18 - Cylinder head gasket
❑ replace
❑ Replace cylinder head gasket ⇒ page 85
❑ Observe fitting position: Part number points to cylinder head
19 - Hall sender -G40-
20 - Sealing ring
❑ replace if damaged
80 Rep. Gr.15 - Cylinder Head, Valve Gear

OCTAVIA II 2004 ➤
❑ for the tensioning roller
22 - Cylinder head
❑ Inspecting the cylinder head for distortion ⇒ page 81
❑ for exhaust manifold
❑ grease with hot bolt paste -G 052 112 A3-
24 - Support
Tightening sequence of cylinder head cover
Inspecting the cylinder head for distortion

– Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
• max. permissible distortion: 0.05 mm
If this value is exceeded, the cylinder head must be replaced.
Reworking of the sealing surface is not allowed.

OCTAVIA II 2004 ➤
1.2 Summary of components - Engine identification character BWA
1 - 10 Nm
2 - Cylinder head cover
❑ order of tightening
⇒ page 81
3 - Gasket
leaking
4 - Valve housing
5 - Oil-filling cover
6 - Gasket
leaking
7 - 4 Nm
8 - Gasket for cylinder head
cover
leaking
9 - Vacuum pump
10 - Camshaft adjustment
valve 1 -N205-
⇒ page 116
11 - Sealing ring
❑ replace
12 - Cable strap
13 - Sealing ring
leaking
14 - Housing
15 - Gasket
❑ replace
16 - Spherical head, 3.5 Nm
❑ for engine cover
17 - Left lifting eye
18 - 25 Nm
❑ for the intake manifold
21 - Cylinder head gasket
❑ replace
❑ Replace cylinder head gasket ⇒ page 95
❑ Observe fitting position: Part number points to cylinder head
22 - Right lifting eye

OCTAVIA II 2004 ➤

24 - Sealing ring
❑ for the tensioning roller
26 - Cylinder head
❑ Inspecting the cylinder head for distortion ⇒ page 81
❑ for exhaust manifold
❑ grease with hot bolt paste -G 052 112 A3-
28 - Washer
29 - Cylinder head bolt
❑ replace
❑ pay attention to sequence for loosening and tightening ⇒ page 95
❑ Tightening torque: ⇒ page 100

OCTAVIA II 2004 ➤
2 Cylinder head, vehicles with engine

identification characters BLR, BLX,
BLY, BVX, BVY, BVZ
2.1 Removing and installing cylinder head

cover
Removing
– Detach the vacuum reservoir from the intake manifold.
– Remove the vacuum line -1- from the vacuum reservoir and
push the vacuum reservoir to the side.
– Screw out screws -arrows-.

OCTAVIA II 2004 ➤
– Remove ignition coils with power output stages -2-

⇒ page 296 .
– Detach the hoses -1- of the crankcase ventilation from the cyl‐
inder head cover.
– Unscrew the fixing screws of the cylinder head cover from the
outside to the inside.
– Remove cylinder head cover.
Installing
following:
Note
Replace the gasket for the cylinder head cover when damaged.
– Tighten the fixing screws of the cylinder head cover in several

stages from the inside to the outside to 10 Nm.
♦ Tightening sequence of cylinder head cover:

– Ensure that the top toothed belt guard is fitted correctly.

♦ Socket insert -T10070-
♦ Extractor -T40039-
2.2.1 Removing
Caution
When loosening the cylinder head screws, the engine must be

not more than warm to touch otherwise the cylinder head can
get distorted.
2. Cylinder head, vehicles with engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ 85
OCTAVIA II 2004 ➤
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
♦ In case of contaminated engine oil, engine oil has to be
changed ⇒ Maintenance ; Octavia II .
– Observe all safety measures and notes for assembly work on

the fuel, injection and ignition system as well as the rules for
cleanliness ⇒ page 5 .
WARNING

⇒ page 6 .
– Disconnect the battery-earth strap when the ignition and the

electrical consumers are switched off ⇒ Electrical System;
Rep. Gr. 27 .
– Remove cylinder head cover ⇒ page 84 .
– Detach hose -1- and plug -2- from air filter housing.
– Detach the air guide hose -4- from the throttle valve control
unit. To do so, open the spring strap clip with the pliers for
spring strap clips .
– Take out air filter.
– Mark the fuel feed line and the fuel return-flow line.
– Detach the hose -1- to the activated charcoal filter.


OCTAVIA II 2004 ➤
– Detach the coolant fitting -arrow- at the coolant flange of the

cylinder head.

voir -3-.
– Detach the coolant hoses -1- and -2- at the expansion reser‐
voir -6-.
– Unscrew the coolant expansion reservoir -6-.
OCTAVIA II 2004 ➤
– Disconnect the plug -arrow- from the hall sender -G40- .

– Removing the intake manifold ⇒ page 246 .
– Removing the toothed belt:

– Disconnect plug connections -1-, -3- and -4-.
66 .
– Remove the intermediate wall for cooling water tank

-arrows-.
– Remove the plug connection -1- for lambda probe 2 -G108-

upstream of catalytic converter from the bracket and discon‐
nect.
– Remove the plug connection -2- for lambda probe -G39- up‐
stream of catalytic converter from the bracket and disconnect.

OCTAVIA II 2004 ➤
– Detach the coolant hoses -1- and -2- to the heat exchanger for
heating at the front wall.
– Detach coolant hoses at throttle valve support and at exhaust
gas recirculation valve.
– Remove/unclamp all necessary electrical cables from the cyl‐
inder head.
– Release screws -2- and -3- and remove left strut for exhaust
manifold.
– Release screw -1- of right strut for exhaust manifold.
– Release screws -arrows- and remove right strut for exhaust

manifold.
OCTAVIA II 2004 ➤

– Unscrew nut -4- and push cable guide for wiring harness of
lambda probe -5- upwards.
– Release screw -1-, screws -3-, screws -6- and screw -7-.
– Remove right strut -2- for exhaust manifold.
Note
The decoupling elements in the front part of the exhaust system

should not be bent by more than 10° - danger of damaging them.
– Unscrew the screws of the cylinder head cover from the out‐
side to the inside.
– Release the cylinder head screws in the order shown.
Note
Check whether all hose and line connections to engine, gearbox

and body are released.
– Remove cylinder head.

OCTAVIA II 2004 ➤
2.2.2 Installing
Note

nuts.
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new cylinder head seal with the utmost care. Dam‐
age to the silicone layer and in the surrounding area result in
leakages.
♦ There must not be any oil or coolant present in the threaded
holes for the cylinder head bolts.
– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
WARNING

remover.
– When conducting repairs sealant residues should be removed

from the contact surface of the cylinder head/cylinder block
using a chemical cleaner.
– If the crankshaft was rotated in the meantime: Position piston
for cylinder 1 to top dead centre and turn back crankshaft
slightly.
– Fit on new cylinder head gasket. The legend (part number)
must be legible on the inlet side.
– Pay attention to centring pins in cylinder block -arrows-.
– Insert the cylinder head.
– Insert cylinder head bolts and tighten by hand.
OCTAVIA II 2004 ➤
– Tighten cylinder head bolts in the tightening order shown as

follows:
Stage Tighten
1 – Tighten with the torque wrench to 40 Nm.
2 – Using a rigid wrench torque a further 90° (1/4 turn).

moval. Pay attention to the following:
– Observe the tightening sequence of cylinder head cover
⇒ page 84 .
Tightening torques ⇒ page 80 .
– Pour in new coolant ⇒ page 152 .
– Carry out work after reattaching the battery ⇒ Electrical Sys‐
tem; Rep. Gr. 27 .
2.3 Testing the compression

♦ Spark plug wrench , e.g. -3122 B-
♦ Adapter , e.g. -V.A.G 1381/5A-
♦ Compression tester , e.g. -V.A.G 1763-
Test condition
• Engine oil temperature must be at least 30°C.
• Voltage supply o.k.
Test sequence
– Remove the ignition coils with the power output stages and the
spark plugs ⇒ page 296 .
– Open lid of fuse carrier in the engine compartment and unplug
the fuse for Motronic current supply relay -J271- ⇒ Current flow
diagrams and Fitting locations.
Note
Removing the fuse interrupts the voltage supply of the injection

valves and the ignitions coils.
– Check the compression pressure with the compression tester

-V.A.G 1763- and the adapter -V.A.G 1381/5A- .
Note
Use of tester ⇒ Operating Instructions .
– Arrange for the starter to be actuated by a second mechanic.

– Operate starter until the tester no longer indicates a pressure
rise.

OCTAVIA II 2004 ➤
Compression readings:
Engine identification charac‐ new Wear limit mx. difference
ters between the cylinders
BLR, BLX, BVX, BVY 1.3…1.6 MPa 0.8 MPa 0.3 MPa
(13.0…16.0 bar) (8.0 bar) (3.0 bar)
BLY, BVZ, BWA 1.1…1.4 MPa 0.7 MPa 0.3 MPa
(11.0…14.0 bar) (7.0 bar) (3.0 bar)
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 93 .
Installation occurs in reverse order to removal. Pay attention to
the following:
– Install spark plugs ⇒ page 296 .
– Delete the contents of the fault memory for the engine control
unit at the end of the work as error messages were stored due
to disconnecting the plugs ⇒ Vehicle diagnosis, testing and
Note
After deleting the fault memory of the engine control unit the read‐
iness code must be re-generated.
2.4 Testinf the combustion chamber for

tightness
♦ Pressure hose -MP1-210 (VW 653/3)- (replace gasket ring
with a spark plug gasket ring)
♦ Spark plug wrench
Test sequence
– Unscrew the spark plugs.
– Position piston of the relevant cylinder to dead centre.
– Screw the pressure hose MP 1-210 into the spark plug thread.
– Connect pressure hose to compressed air.
– With the assistance of a second mechanic, lock the screw at
the crankshaft on TDC position in order to avoid the displace‐
ment of the piston after pressure build-up.
– Build up a pressure of approx. 0.3 MPa (3 bar) in the com‐
bustion chamber.
– Determine how the pressure escapes:
1- Via the inlet valve(s) – the pressure enters the throttle valve.
2- Via the outlet valve(s) – the pressure enters the exhaust
system.
3- Via the piston rings – the pressure enters the engine block.
OCTAVIA II 2004 ➤
3 Cylinder head, engine identification

character BWA

cover
Removing
– Remove ignition coils with a power output stage
⇒ page 296 .
– Detach the line -1- from the cylinder head cover.

– Remove the valve housing from the cylinder head cover
-arrows-.
– Unscrew the line for the crankcase ventilation with heat shield
from the exhaust turbocharger -1-.
– Open the spring strap clamp -2- and detach the hose to the
exhaust turbocharger from the cylinder head cover.
– Unscrew the fixing screws of the cylinder head cover from the
outside to the inside.
Installing
following:
Note
Replace the gasket for the cylinder head cover when damaged.
– Tighten the fixing screws of the cylinder head cover in several

stages from the inside to the outside to 10 Nm.

OCTAVIA II 2004 ➤
♦ Tightening sequence of cylinder head cover:

– Ensure that the top toothed belt guard is fitted correctly.

♦ Lifting device -MP 9-201 (2024 A)-
♦ Workshop crane , e.g. VAS 6100
♦ Support -T10014-
3.2.1 Removing
Caution
When loosening the cylinder head screws, the engine must be

not more than warm to touch otherwise the cylinder head can
get distorted.
Note
♦ All cable straps which are detached or cut open when remov‐
ing, should be fitted on again in the same place when installing.
♦ In case of contaminated engine oil, engine oil has to be
changed ⇒ Maintenance ; Octavia II .
– Observe all safety measures and notes for assembly work on

WARNING

⇒ page 6 .
3. Cylinder head, engine identification character BWA 95

OCTAVIA II 2004 ➤

Note
The removal of the cylinder head is performed when the engine

and the gearbox are once again screwed to their positions.
– Tighten the old screws -arrows- of the assembly bracket at the

engine to 60 Nm.
– Tighten the old screws -arrows- of the assembly bracket at the

gearbox to 60 Nm.
– Remove supporting device -T30099- .
⇒ page 289 .
– Release the quick couplings, unscrew the screws -arrows- and

remove the air guide pipe.
– Remove/unclamp all necessary cables from the exhaust tur‐
bocharger.
– Remove the connecting pipe of the exhaust turbocharger/cyl‐

inder head cover -1-.
– Release the screw -2- of the oil feed line and the screws -3-
and -4- of the coolant feed line.

OCTAVIA II 2004 ➤
– Remove the oil return-flow line -arrows- at the exhaust gas

turbocharger.
– Release the screws -1- and -2- and remove the support for
exhaust gas turbocharger.
– Disconnect plugs -1- and -2-.

– Open the spring strap clamps -3- and -5- and detach the cool‐
ant hoses.
– Remove the coolant pipe with the heat shield ⇒ page 148 .


OCTAVIA II 2004 ➤
– Unscrew cable clip -arrow- and lay the cable harness to the
side.
– Unscrew the coolant flange with the coolant hoses connected

-arrows-.
– Unscrew the screws for the coolant lines of the auxiliary heat‐
ing at the cylinder block and at the cylinder head.
– Pull the locking pin -T10060 A- out of the tensioning device for
V-ribbed belt.
– Remove cylinder head cover ⇒ page 94 .
For the further procedure it is necessary to disconnect several
plug connections. The fitting locations of the plug connections can
be found ⇒ page 226 .
Disconnect the following plug connections:
♦ at fuel pressure regulating valve -N276- of high pressure pump
♦ at activated charcoal filter system solenoid valve 1 -N80-
♦ at Intake manifold flap motor -V157-
♦ at intake air temperature sender -G42-
♦ on the throttle valve control unit -J338-
♦ Disconnect and unhook plug connection of injection valves
♦ Disconnect and unhook plug connection for Hall sender -G40-
and fuel pressure sender -G247-
♦ Unclip wiring loom of ignition coils/exhaust turbocharger and
lay to the side
– Detach the pipe -3- at the oil filter holder and remove it up‐
wards.

OCTAVIA II 2004 ➤
– Open warm-type clamp -1- and detach the hose -2- from the
intake manifold.
– Detach the vacuum line -3- from the vacuum pump.
– Slacken all cylinder head bolts in the order shown. Unscrew

cylinder head bolts up to 2 pieces.
Note
♦ To secure the cylinder head these 2 screws must remain

screwed in.
♦ If all bolts are released, the cylinder head tilts towards the front
wall.
– Install the holder -T10014- with 2 small and large washers

each on the cylinder head, as shown in the fig.
1- Washer ∅ 8, small
2- Washer ∅ 8, large The outside diameter of the washer must
be larger than the hole in the holder.
3- Screw M8 x 30
– Hang the lifting device -MP9-201- in the holder -T10014- and
in the front left lifting eye at the cylinder head.
– Unscrew nut -2- from rubber-metal bearing -1-.

OCTAVIA II 2004 ➤
– Hook the lifting device -MP9-201- in the workshop crane and

slightly raise the cylinder head.
Note
Check whether all hose and line connections to engine, gearbox

and body are released.
– Unscrew the last two cylinder head screws.
– Lift off the cylinder head from the cylinder block with the work‐
shop crane . At the same time guide the rubber-metal bearing
-1- out of the intake manifold support -3-.
3.2.2 Installing
Note

nuts.
♦ Remove the new cylinder head gasket from its wrapping im‐
mediately before fitting.
♦ Treat the new cylinder head seal with the utmost care. Dam‐
age to the silicone layer and in the surrounding area result in
leakages.
♦ There must not be any oil or coolant present in the threaded
holes for the cylinder head bolts.
– Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder or into the oil
and coolant galleries.
WARNING

remover.

OCTAVIA II 2004 ➤
– When conducting repairs sealant residues should be removed

from the contact surface of the cylinder head/cylinder block
using a chemical cleaner.
– If the crankshaft was rotated in the meantime: Position piston
for cylinder 1 to top dead centre and turn back crankshaft
slightly.
– Fit on new cylinder head gasket. The legend (part number)
must be legible on the inlet side.
– Pay attention to centring pins in cylinder block -arrows-.
– Fit the cylinder head on the cylinder block with the workshop
crane . At the same time guide the rubber-metal bearing -1-
into the intake manifold support -3-.
– Insert cylinder head bolts and tighten by hand.
– Tighten cylinder head bolts in the tightening order shown as

follows:
Stage Tighten
1 – Tighten with the torque wrench to 40 Nm.

⇒ page 94 .
– Pour in new coolant ⇒ page 152 .
tem; Rep. Gr. 27 .
3.3 Testing the compression

– Testing compression pressure ⇒ page 92 .

OCTAVIA II 2004 ➤
3.4 Testinf the combustion chamber for

tightness
Work procedure ⇒ page 93 .

OCTAVIA II 2004 ➤
4 Valve gear - part 1
Note
♦ Cylinder heads with cracks between the valve seats or between a valve seat ring and the spark plug thread
may continue to be used without any reduction in life provided these are slight initial cracks which are not
more than 0.3 mm wide, or cracks exist only at the first 4 turns of the spark plug thread.
♦ Cylinder head and ladder frame must always be replaced together.
♦ After installing the camshafts, the engine must not be started for about 30 minutes. The hydraulic clearance
compensation elements must settle (otherwise valves would strike the pistons).
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.
♦ Always replace seals and gasket rings.
180° (1/2 turn)
❑ replace
use counterholder -
MP1-216 (3036)-
fixed by a parallel key
3 - Gasket ring for exhaust
camshaft
4 - Cylinder head
❑ Do not re-mill valve
seats, only grinding in
with grinding paste in
the valve seats is per‐
missible.
5 - Valve guide
6 - Valve stem seal
7 - Valve spring
8 - Valve spring retainer above
9 - Collets
10 - Supporting element
❑ do not interchange
❑ oil contact surface
11 - Parallel key
❑ check tightness
12 - Exhaust camshaft
❑ Slack: max. 0.035 mm
4. Valve gear - part 1 103

OCTAVIA II 2004 ➤
13 - Ladder frame
❑ with integrated camshaft bearings
❑ cleaning and reworking sealing surface not permissible
❑ remove old sealant residues
❑ replace
15 - Camshaft adjuster
❑ replace
❑ to release and tighten use camshaft fixer/locator -T10252- and socket insert -T40080-
17 - Inlet camshaft
❑ Slack: max. 0.035 mm
18 - Chain tensioner
❑ secure with 2 mm socket wrench before removing
19 - Drive chain
❑ check for wear
20 - 10 Nm
21 - 10 Nm
23 - O-ring
❑ replace
24 - Exhaust valve
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ page 105
❑ inspecting valve guides ⇒ page 105
25 - Inlet valve
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ page 105
❑ inspecting valve guides ⇒ page 105
26 - Screw cap
❑ replace
❑ installing: Plunge into the middle of the cover using a screwdriver and lever out.
❑ installing: Use no sealant, press in with pressure plate -T10174- up to the stop.

OCTAVIA II 2004 ➤
4.2 Valve dimensions

Inlet and exhaust valves must not be reworked. Only grinding in
with grinding paste is permissible.
Dimension Inlet valve Exhaust valve
∅a mm 33,75…33,95 27,90…28,10
∅b mm 5,973…5,987 5,958…5,972
c mm 103,97 101,87
α ∠° 45 45
4.3 Inspect valve guides

♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Dial gauge
– Insert valve into guide. The end of valve stem must be flush
with guide. Because of the different stem diameters only use
inlet valve in inlet guide or outlet valve in outlet guide.
– Determine valve rock.
• Wear limit: 0.8 mm
Note
♦ If the wear limit is exceeded, repeat measurement with new

valves. If the wear limit is again exceeded, replace cylinder
head. The valve guides cannot be replaced.
♦ If the valve is replaced when carrying out repair work, use a
new valve for the measurement.
4.4 Replacing valve stem seals

(with cylinder head installed)
♦ Valve supporting plate -MP1-218-
♦ Extractor -MP1-230 (3364)-
♦ Valve stem seal insertion tool -MP1-233 (3365)-
♦ Adapter -T40012-
♦ Disassembly and assembly device for valve collets -VAS
5161-
♦ Guide plate -VAS 5161/19- , -VAS 5161/19A- or -VAS
5161/19B-
♦ Spark plug wrench , e.g. -3122 B-

OCTAVIA II 2004 ➤
4.4.1 Removing
Note
With cylinder head removed, use valve supporting plate -

MP1-218- .
– Remove cylinder head cover:

BVX, BVY, BVZ ⇒ page 84 .
⇒ page 94 .
– Unscrew the spark plugs.
– Remove the camshafts ⇒ page 116 .
– Remove roller rocker arm and place on a clean surface. Make
sure the roller rocker arms are not interchanged.
Note
♦ Only vehicles with engine identification characters BLR, BLX,

BVX, BVY:
♦ In order to change the valve stem seals of the outlet valves of
cylinder 3 and 4, remove additionally the exhaust gas recircu‐
lation valve -N18- ⇒ page 294 .
– Tighten the guide plate -VAS 5161/19- , -VAS 5161/19A- or -

VAS 5161/19B- with the knurled screws -VAS 5161/12- as
shown.
– Put the piston of the relevant cylinder at “bottom dead centre”.
– Screw adapter -T40012- into the spark plug thread and apply
compressed air of at least 0.6 MPa (6 bar).
– If valve collets are tight, knock off using the impact drift -VAS
5161/3- and a plastic hammer.

OCTAVIA II 2004 ➤
– Screw the detent part -VAS 5161/6- with the interlocking fork
-VAS 5161/5- into the guide plate -VAS 5161/19- , -VAS
5161/19A- or -VAS 5161/19B- .
– Insert the assembly cartridge -VAS 5161/8- into the guide
plate -VAS 5161/19- , -VAS 5161/19A- or -VAS 5161/19B- .
– Hook the pressure fork -VAS 5161/2- onto the detent part -
VAS 5161/6- .
Note
On the outlet side the pressure fork -VAS 5161/2- must be hooked
on as shown.
– Press down the assembly cartridge -VAS 5161/8- . Turn si‐

multaneously the knurled screw of the assembly cartridge -
VAS 5161/8- to the right, until the tips click into the valve
collets.
– Slightly move the knurled screw of the ssembly cartridge back
and forward. This presses the valve collets apart and installs
them into the assembly cartridge.
– Release the pressure fork -VAS 5161/2- .
– Remove assembly cartridge -VAS 5161/8- .
– Unscrew guide plate -VAS 5161/19- , -VAS 5161/19A- or -VAS
5161/19B-
– Pull off valve stem seals with the extractor -MP1-230 - .

OCTAVIA II 2004 ➤
– If the extractor -MP1-230- cannot be used because of cram‐

ped working conditions, drive out the tensioning pin -arrow-
with a drift and remove the fitting adapter.
– Position the lower part of the extractor -MP1-230 - on the valve

stem seal.
– Insert the drift -1- into the hole in the lower part of the extractor.
– Position an assembly lever on the assembly device and pull
out the valve stem seal -arrow-.
4.4.2 Installing
– To avoid damaging the new valve stem seals insert plastic
bushing -A- on the valve stem seals -B-.
– Oil the sealing lip of the valve stem seal -B-, insert into the
insertion tool for valve steam seal -MP1-233- and carefully
push onto the valve guide.
– Remove plastic bushing -A-.
– Insert the valve spring and the valve spring retainer.
– Install the disassembly and assembly device -VAS 5161- as
shown.
Inlet side

OCTAVIA II 2004 ➤
Outlet side
Note
♦ If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device -VAS
5161/18- .
♦ Press assembly cartridge -VAS 5161/8- from the top onto the
insertion device and lift up the valve collets.
– Press down the assembly cartridge -VAS 5161/8- with the

pressure fork -VAS 5161/2- , turn the knurled screw of the as‐
sembly cartridge back and forward and while doing so pull it
towards the top.
– Release the pressure fork on tightened knurled screw -VAS
5161/2- of the assembly cartridge -VAS 5161/8- .
– Remove the disassembly and assembly device for valve keys
-VAS 5161- as shown.
moval.

OCTAVIA II 2004 ➤
5 Valve gear - part 2
5.1 Replacing exhaust camshaft seal

♦ Gasket ring extractor -MP1-215 (2085)-
♦ Adapter -MP1-215/2 (2085/2)-
♦ Thrust piece -T10353-
♦ Two-arm extractor -T40001- with claw -T40001/6- and claw -
T40001/7 -
Removing
– Slacken screw from camshaft sprocket. Use counterholder -
MP1-216- for this purpose.
– Release screw from camshaft sprocket approx. 10 mm

-arrow-.
– Detach camshaft sprocket with extractor -T40001- , claw -
T40001/6- and claw -T40001/7- .
– Remove the fixing screw and the screw for camshaft sprocket.
– Screw in the adapter -2085/2- by hand up to the stop in the
crankshaft to guide the gasket ring extractor.
– Turn inner part of gasket ring extractor -MP1-215- two turns
(approx. 3 mm) out of the outer part and lock with knurled
screw.

OCTAVIA II 2004 ➤
– Oil the thread head of the gasket ring extractor -MP1-215- ,

position and forcefully screw it into the gasket ring as far as
possible.
– Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
– Clamp gasket ring extractor into the vice at the flats. Remove
gasket ring with pliers.
Install
Note
Do not oil the sealing lip of the gasket ring.
– Remove oil residue on the camshaft stud with a clean cloth.

– Cover the slot on the exhaust camshaft cone with adhesive
tape and carefully push the dry gasket ring onto the camshaft.
– Press in the gasket ring with the pressure bushing -T10071- ,

the thrust piece -T10353- and a washer -arrow- up to the stop.
Use the screw -T10071/4- for this purpose.
Note
♦ When rotating the camshaft, the pistons must not be posi‐

tioned at TDC. Risk of damaging valves and pistons.
♦ Ensure that the parallel key is correctly positioned.
– Insert parallel key into camshaft.
♦ Observe the fitting position of the camshaft sprocket: The

small stay on the camshaft sprocket points outwards
-arrows- and the TDC marking is visible on the cylinder 1.
– Install camshaft timing gear. Hold the camshaft sprocket tight

with the counterholder -MP1-216- for tightening the new
screw.
Tightening torque: 50 Nm + torque a further 180° (1/2 turn).
moval.

OCTAVIA II 2004 ➤
5.2 Removing and installing the camshaft

adjuster
♦ Hose clamps up to 25 mm -MP7-602 (3094)- , only engine
♦ Two-hole nut turner -T10020-
♦ Camshaft fixer/locator -T10252-
♦ 2 mm socket wrench
5.2.1 Removing
WARNING

⇒ page 6 .
– Remove cylinder head cover:
BVX, BVY, BVZ ⇒ page 84 .
⇒ page 94 .
– Remove ignition coils with a power output stage
⇒ page 296 .
– Remove high pressure pump -1- ⇒ page 265 .
– Unlock the connector -3- and pull out.
– Disconnect the coolant hose with the hose clamp -MP7-602-
and remove it from the coolant pipe -4-.
– Remove coolant pipe -4- from engine.
– Unhook the wiring loom from the holders -5-.
– Remove the cover -2- from the camshaft adjuster.
Vehicles with engine identification characters BLR, BLX, BVX,
BVY
– Remove connection pipe of exhaust gas recirculation
⇒ page 294 .
BVX, BVY, BVZ
– Remove the high pressure pump ⇒ page 262 .

OCTAVIA II 2004 ➤
– Remove the cover -A- from the camshaft adjuster -arrows-.


rotating at crankshaft:
The recesses -arrows- must now point vertically opposite each
other.
– Position camshaft fixer/locator -T10252- as shown and attach

-arrows-.
– Release the fixing screw from the camshaft adjuster with the
socket insert -T40080- .
– Press together the chain tensioner -arrow A- and secure with

a 2 mm box spanner -arrow B-.
– Release the fixing screws from the camshaft adjuster and re‐
move the adjuster with the chain.

OCTAVIA II 2004 ➤
5.2.2 Installing
• The camshafts are fixed with the camshaft fixer/locator -
T10252- .
• Chain tensioner tightened and/or locked
– Place the chain on the camshaft adjuster.
– Hold the camshaft adjuster in front of the exhaust camshaft in

such a way that the notch -A- and the pin -B- are opposite one
another
– Put the chain into this position, first at the top -arrow- onto the
chain sprocket of the inlet camshaft.
– Slowly turn the inlet camshaft with the two-hole nut turner -
T10020- slightly in -direction of arrow A- until the camshaft
adjuster fits onto the camshaft.
Note
If the pin does not fit into the notch: Remove chain from camshaft
adjuster and position again on the camshaft adjuster offset by a
chain link.
– Tighten the new fixing screw for the camshaft adjuster to 20

Nm + torque a further 45° (1/8 turn). Use the socket insert -
T40080 - for this purpose.

OCTAVIA II 2004 ➤
– Remove box spanner -arrow B-.

Note
If the camshaft fixer/locator -T10252- cannot be removed, insert

puller -T10055 - into the centre and pull off the camshaft fixer/
locator -T10252 - .

⇒ page 80 .
5.3 Removing and installing camshaft ad‐

justment valve 1 -N205- , Engine identi‐
fication characters BLR, BLX, BLY,
BVX, BVY, BVZ
♦ TORX bit assortment , e. g. -V.A.G 1766-
♦ Attachment ratchet 1/4" , e.g. -VAS 6234-
Removing
Note
Always replace seals and gasket rings.

– Release the screws -arrows- and pull the camshaft adjustment
valve 1 -N205- out of the housing.
Installing
Note
♦ The camshaft adjustment valve 1 -N205 - as well as the hous‐

ing must be free of dirt and contaminations.
♦ Remove the new camshaft adjustment valve 1 -N205- from the
wrapping before installing.
Caution
♦ The camshaft adjustment valve 1 -N205 - must not be

subject to impacts or vibrations.
– Moisten gasket ring with engine oil.

– Carefully insert the camshaft adjustment valve 1 -N205 - into
the housing and press it in fully by hand and without tilting it.
– Tighten screws to 4 Nm.
moval.

OCTAVIA II 2004 ➤
5.4 Removing and installing camshaft ad‐

justment valve 1 -N205- , engine identi‐
fication characters BWA
♦ TORX bit assortment , e. g. -V.A.G 1766-
♦ Attachment ratchet 1/4" , e.g. -VAS 6234-
Removing
– Loosen the wiring loom -2- from the bracket.
Note
Do not pull out camshaft adjustment valve 1 -N205- at connector.
– Release the screws -arrows- and pull the camshaft adjustment

valve 1 -N205- out of the housing.
Installing
Note
♦ The camshaft adjustment valve 1 -N205 - as well as the hous‐

ing must be free of dirt and contaminations.
♦ Remove the new camshaft adjustment valve 1 -N205- from the
wrapping before installing.
Caution
♦ The camshaft adjustment valve 1 -N205 - must not be

subject to impacts or vibrations.
– Moisten gasket ring with engine oil.

– Carefully insert the camshaft adjustment valve 1 -N205 - into
the housing and press it in fully by hand and without tilting it.
– Tighten screws to 4 Nm.
moval.
5.5 Removing and installing camshafts

♦ Thrust piece -T10174-

OCTAVIA II 2004 ➤
♦ Sealant -D 154 103 A1-

5.5.1 Removing
Note
♦ The sealing surfaces at the bottom of the ladder frame and at

the top of cylinder head must not be machined.
♦ The camshaft bearings are integrated in the cylinder head and
in the ladder frame. Before removing the ladder frame, it is
necessary to slacken the toothed belt.
♦ If the ladder frame has been detached, it is necessary to re‐
place the seal of the camshaft and the end cover.
– Remove camshaft adjuster ⇒ page 112 .

– Unscrew camshaft fixer/locator -T10252- .
– Take toothed belt off camshaft sprocket.
– Slacken screw from camshaft sprocket. Use counterholder -
MP1-216- for this purpose.
– Release screw from camshaft sprocket approx. 10 mm

-arrow-.
– Detach camshaft sprocket with extractor -T40001- , claw -
T40001/6- and claw -T40001/7- .
– Remove the fixing screw and the screw for camshaft sprocket.
– Remove rear toothed belt guard from cylinder head.
– Release the screws of the ladder frame evenly from the out‐
side to the inside and remove the ladder frame.
– Carefully lift out camshafts and place down on a clean surface.
WARNING

remover.

OCTAVIA II 2004 ➤
– Remove the old sealant from the grooves of the ladder frame
as well as from all the sealing surfaces of the ladder frame and
the cylinder head with a chemical sealant remover.
Ensure that no dirt and sealant residues get into the cylinder
head.
– Degrease the sealing surfaces.
5.5.2 Installing
Note
♦ The sealing surfaces must be free of oil and grease.

♦ The pistons must not be positioned at top dead centre.
♦ Ensure that all roller rocker arms are correctly positioned on
the valve stem ends.
– Oil the contact surfaces of the camshaft.

– Carefully insert the camshafts into the camshaft bearings of
the cylinder head. The recesses -arrows- must be seated ver‐
tically opposite each other.
– Apply an even, slightly raised bead of sealant -D 154 103 A1-

into the clean grooves of the ladder frame.
Note

♦ The sealant must not be applied too thick. Wipe off any excess
sealant with a non-fluffing cleaning cloth.
♦ The ladder frame should be fitted on and bolted without any
interruption as the sealant immediately begins hardening as
soon as the sealing surfaces come into contact.

BVY

OCTAVIA II 2004 ➤
– Position the ladder frame in such a way -arrow- that it does not
touch the exhaust gas recirculation valve -N18- .
– Tighten the new screws slightly in several stages from the in‐
side to the outside.
– Tighten the screws in the order shown from the inside to the
outside to 8 Nm.
– Then torque the screws a further 90° (1/4 turn) in the order
shown.
– Drive in the cap ( ⇒ page 103 , Pos. 26) with the thrust piece
-T10174- up to the stop.
– Install a new camshaft gasket ring ⇒ page 110 .
– Install rear toothed belt guard.
– Insert parallel key into camshaft.
– Install camshaft timing gear. Hold the camshaft sprocket tight

with the counterholder -MP1-216- for tightening the new
screw.
Tightening torque: 50 Nm + torque a further 180° (1/2 turn).
Note
♦ When rotating the camshaft, the pistons must not be posi‐

tioned at TDC. Risk of damaging valves and pistons.
♦ Ensure that the parallel key is correctly positioned.

moval.

OCTAVIA II 2004 ➤
17 – Lubrication
1 Parts of the lubrication system - Part
1
Note
♦ If considerable quantities of metal swarf or abrasion is found

in the engine oil when carrying out engine repairs, carefully
clean the oil galleries in order to avoid consequential damage
and additionally replace the oil cooler, the oil spray jets and
the oil filter insert.
♦ The oil level must not be above the max. marking - risk of
damage to catalytic converter!
Inspecting oil pressure ⇒ page 137 .

Check the oil level, amount of oil and oil specification ⇒ Mainte‐
nance ; Octavia II
1 - 15 Nm
2 - Dipstick
❑ oil level must not exceed
max. marking!
3 - Filler funnel
❑ to remove from bottom
to top carefully press off
from guide tube
4 - Guide tube
❑ Engine identification
characters BLR, BLX,
BLY:
replace
⇒ page 130
6 - Balancing shaft module with
oil pump
❑ with pressure relief
valve 0.12 MPa (12 bar)
❑ Summary of compo‐
nents ⇒ page 122
⇒ page 130
BLY:
If the balancing shaft
module with oil pump
was removed, always re‐
place the intermediate
plate.
120 Rep. Gr.17 - Lubrication

OCTAVIA II 2004 ➤

❑ replace
❑ pay attention to the different screw lengths ⇒ page 130
8 - 15 Nm
9 - 8 Nm
❑ only fitted for engine identification character BWA (attachment charge air pipe)
10 - Oil pan
❑ clean sealing surface before installing
❑ if the oil pan was removed, always replace the intermediate plate (Pos. 5)
11 - 15 Nm
12 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
13 - Sprocket
❑ for oil pump
14 - 10 Nm
❑ not for engine identification characters BLY, BVZ
15 - Protective cap
16 - Oil level and oil temperature sender -G266 -
17 - Sealing ring
❑ replace
❑ oil before assembly
19 - Chain cover
20 - Chain
21 - Sealing flange on the belt pulley side
❑ must be positioned on dowel sleeves
❑ remove oil pan for removing and installing ⇒ page 127
❑ replace the gasket ring for the crankshaft - on the belt pulley side ⇒ page 63
1. Parts of the lubrication system - Part 1 121

OCTAVIA II 2004 ➤
1.2 Balancing shaft module with oil pump - Summary of components, engine
identification characters BLR, BLX, BLY, BVX, BVY, BVZ
1 - Chain cover
2 - Chain
❑ mark running direction
(installed position) with
colour before removing
3 - Fitting sleeve
4 - Balancing shaft module
⇒ page 130
❑ before installing, check
whether both dowel
sleeves (Pos. 3) for cen‐
tering are present
5 - 3 Nm
agent
6 - Cover
❑ prevents the foaming of
engine oil
7 - Oil return fittings
❑ with gasket
8 - 9 Nm
9 - Oil suction pipe
❑ Clean strainer if dirty
10 - 8 Nm
11 - O-ring
❑ replace
90° (1/4 turn)
❑ replace
❑ pay attention to the different screw lengths ⇒ page 132
13 - O-ring
❑ replace
14 - Screw plug, 15 Nm + torque a further 90° (1/4 turn)
❑ replace
15 - Fitting sleeve
16 - Outer rotor
❑ Check contact surfaces for scoring
❑ Marking must be visible
17 - Inner rotor
18 - Oil pump cover
19 - Sprocket
❑ for oil pump

OCTAVIA II 2004 ➤

❑ replace
21 - Chain tensioner with tensioning rail
❑ for installing, tension and lock ⇒ page 134
22 - 15 Nm
1.3 Balancing shaft module with oil pump - Summary of components, engine
identification characters BWA
1 - Chain cover
2 - Chain
❑ mark running direction
(installed position) with
colour before removing
3 - Fitting sleeve
5 - Balancing shaft module with
oil pump
⇒ page 130
❑ before installing, check
whether both dowel
sleeves (Pos. 3) for cen‐
tering are present
6 - 9 Nm
7 - Cover
❑ prevents the foaming of
engine oil
8 - 40 Nm
9 - 8 Nm
10 - Oil suction pipe
11 - O-ring
❑ replace
90° (1/4 turn)
❑ replace
❑ pay attention to the dif‐
ferent screw lengths
⇒ page 132
13 - O-ring
❑ replace
14 - Screw plug, 15 Nm + torque a further 90° (1/4 turn)
❑ replace
15 - Outer rotor
❑ Marking must be visible

OCTAVIA II 2004 ➤
16 - Inner rotor
17 - Oil pump cover
18 - Sprocket
❑ for oil pump
❑ replace
20 - Chain tensioner with tensioning rail
❑ for installing, tension and lock ⇒ page 134
21 - 15 Nm
1.4 Oil filter holder with component parts - Summary of components, engine
identification characters BLR, BLX, BLY, BVX, BVY, BVZ
1 - Pipe
❑ for crankcase ventila‐
tion
2 - Spring strap clamp
3 - Oil filter holder
❑ with pressure relief
valve approx. 0.4 MPa
(4 bar)
❑ do not release screw
plug for pressure relief
valve
⇒ page 135
4 - Gasket
❑ replace
5 - Oil cooler
❑ pay attention to the
notes ⇒ page 120
❑ ensure clearance to sur‐
rounding components
❑ connection diagram for
coolant hoses
⇒ page 144
6 - 25 Nm
7 - Oil pressure switch -F1- , 20
Nm
❑ 0.14 MPa (1.4 bar) black
❑ up to 05.2005 one-pin
with earth lead, then
two-pin
(1/4 turn)
❑ replace

OCTAVIA II 2004 ➤
9 - Sealing ring
❑ replace
10 - Dust cap
11 - Oil filter housing, 25 Nm
❑ removing and installing with oil filter wrench
❑ empty ⇒ page 127
12 - Oil filter element
❑ empty oil filter housing ⇒ page 127 before removing
❑ replace
14 - Baffle
15 - Gasket
❑ replace
1.5 Oil filter holder with component parts - Summary of components, engine
1 - Pipe
❑ for crankcase ventila‐
tion
2 - Oil pressure switch -F1 - ,
20 Nm
❑ 0.14 MPa (1.4 bar) black
❑ two-pin
3 - Support
4 - 25 Nm
5 - Oil cooler
❑ pay attention to the
notes ⇒ page 120
❑ ensure clearance to sur‐
rounding components
coolant hoses
⇒ page 151
6 - Gasket
❑ replace
(1/4 turn)
❑ replace
8 - Sealing ring
❑ replace
9 - Dust cap
10 - Oil filter housing, 25 Nm
with oil filter wrench
❑ empty ⇒ page 127

OCTAVIA II 2004 ➤
11 - Oil filter element

❑ empty oil filter housing ⇒ page 127 before removing
12 - Baffle
13 - Gasket
❑ replace
❑ with pressure relief valve approx. 0.4 MPa (4 bar)

OCTAVIA II 2004 ➤
2 Parts of the lubrication system - Part

2
2.1 Empty oil filter housing

♦ Oil drainage adapter -T40057-
Note
When screwing in the oil drainage adapter -T40057 - the valve is

opened in the oil filter housing. When releasing the oil drainage
adapter -T40057- the valve is closed again.
– Release dust cap -arrow- from oil filter housing.
– Hold the hose from the oil drainage adapter -T40057- in the
drip tray and screw the oil drainage adapter -T40057 - into the
oil filter housing.
– Let the engine oil drain.
2.2 Removing and installing oil pan

♦ Flexible-head wrench SW 10 , e.g. -3185 -
♦ Socket insert SW 5 , e.g. -3249- or socket insert -T10058-
♦ Silicone sealant -D 176 404 A2-
Removing
Gr. 50 .

OCTAVIA II 2004 ➤
– Drain engine oil.
Note
Please observe the disposal instructions!

– Release screws -arrows-, separate the quick couplings and
remove the charge air pipe.
– Release screws -1- from bracket for pump for coolant after-
running -V51- .
– Release screw -2- from charge air pipe.
– Unscrew oil return-flow line -arrows-.

– Disconnect the plug from the oil level and oil temperature
sender -G266- where it is mounted.

OCTAVIA II 2004 ➤
– Release fixing screws of gearbox/oil pan -arrows-.

– Unscrew oil pan screws -1- to -20-.
Note
Slacken the oil pan bolts at flywheel side -12- and -13- with the
flexible-head wrench SW 10 -3185- and unscrew them with the
socket insert -T10058- .
– Remove oil pan. If necessary, loosen the oil pan by applying

slight blows with a rubber-headed hammer.
Vehicles with engine identification characters BLR, BLX, BLY
– Remove balancing shaft module with oil pump and the inter‐
mediate plate ⇒ page 130 .
Install
Note
♦ Always replace the intermediate plate after removing the oil

pan.
♦ The oil pan must be immediately installed and tightened at the
new intermediate plate after installing the balanching shaft
module with oil pump.
WARNING

remover.
– Clean the sealing surface of the oil pan. It must be free of oil
and grease.
– Install balancing shaft module with oil pump ⇒ page 130 .
Vehicles with engine identification characters BVX, BVY, BVZ,
BWA
WARNING

remover.
– Clean sealing surface on cylinder block and on the oil pan and
remove sealant residues with chemical sealant remover.
– Degrease the sealing surfaces.
Note

♦ The oil pan must be installed immediately and tightened after
applying the sealant.

OCTAVIA II 2004 ➤

3 mm).
– Apply the silicone sealant to the clean sealing surface of the
oil pan, as shown. The sealant bead must be:
♦ be 2...3 mm thick
♦ run past the area around the bolt holes on the inside
-arrows-
Note
The sealant bead must not be thicker otherwise excess sealant

may get into the oil pan and block the strainer in the oil pump
suction pipe.
– Afterwards position the oil pan immediately and tighten the

screws as follows:
1 - Tighten screws -1- to -20- only very slightly diagonally across.
2 - Tighten the bolts of oil pan/gearbox -arrows- slightly.
3 - Tighten screws -1- to -20- slightly diagonally across.
4 - Tighten the bolts of the oil pan/gearbox -arrows- to a torque of
40 Nm.
5 - Tighten bolts -1- to -20- crosswise to 15 Nm.
Note
♦ If the oil pan is installed on an engine with a removed gearbox,

the oil pan must be flush with the cylinder block.
♦ After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.

moval.
2.3 Removing and installing balancing shaft

module with oil pum
♦ Rig pin -T10027A-
♦ Silicone sealant -D 176 404 A2-
2.3.1 Removing

OCTAVIA II 2004 ➤
– Remove chain guard. Release catch pegs if necessary

through the openings -arrows- using a small screwdriver.
– Release the screw from the chain sprocket of the oil pump.
While doing so counterhold on the central screw of the crank‐
shaft.
Caution
The chain sprocket for driving the balancing shafts must not be
loosened!
– Release the tension of the chain rail with a screwdriver

-arrow- and interlock it with a socket wrench -1-, wrench size
3 mm.
– Remove the chain sprocket of the oil pump and remove the
chain from the chain sprocket of the balancing shaft.

OCTAVIA II 2004 ➤
– Release the screws -arrows- of the balancing shaft module

from the outside to the inside and remove the balancing shaft
module.
– Remove the intermediate plate.
2.3.2 Installing and setting

• Chain tensioner tightened and locked ⇒ page 134
Note
♦ Always replace the intermediate plate.

♦ The balancing shaft module with intermediate plate and the oil
pan must be installed immediately after applying the silicone
sealant and tightened.
WARNING

remover.
– Remove sealant residues from sealing surface on cylinder

block with chemical sealant remover.
– Degrease the sealing surface.
3 mm).
– Apply the silicone sealant to the clean sealing surface of the
new intermediate plate, as shown.
The following points must be observed:
♦ The sealant bead must point to the cylinder block. The oil pan
side of the intermediate plate must be provided with a seal.
♦ The sealant bead must be 2...3 mm thick.
♦ The sealant bead must run past on the inside in the area of
the bolt holes -arrows-.
Note
The sealant bead must not be thicker otherwise excess sealant

may get into the oil pan and block the strainer in the oil pump
suction pipe.

OCTAVIA II 2004 ➤
– Fit the intermediate plate on the dowel sleeves -arrows- of the

balancing shaft module, as shown.
Vehicles with engine identification characters BVX, BVY, BVZ,
BWA
– Fit the intermediate plate on the dowel sleeves -arrows- of the

balancing shaft module, as shown.
– Install the balancing shaft module with the oil pump and the
intermediate plate. Replace O-ring of screw plug.
BVX, BVY, BVZ ⇒ page 122 , Pos. 13.
♦ Engine identification characters BWA ⇒ page 123 , Pos. 13.
– Tighten the new fixing screws -arrows- from the inside to the
outside to 15 Nm + 90° (1/4 turn).
Screw assignment

BVX, BVY, BVZ
A - Screw M7 x 40
B - Screw M7 x 55
C - Screw M7 x 90
D - Screw M7 x 115
E - Screw plug with O-ring. Replace O-ring.

A - Screw M7 x 40
B - Screw M7 x 70
C - Screw M7 x 90
D - Screw M7 x 55
E - Screw plug with O-ring. Replace O-ring.

OCTAVIA II 2004 ➤
– Position crankshaft on TDC cylinder 1.
– Turn the chain sprocket of the balancing shaft in such a way

that the marking -arrow- is positioned opposite the locating
hole. Interlock the chain sprocket in this position with the rig
pin -T10027A- . Fit the chain onto the chain sprocket of the
balancing shaft.
– Install the chain sprocket of the oil pump and tighten the screw
by hand.
Note
The chain sprocket of the oil pump only fits in one position. To
install, only the oil pump must be turned.
– Remove the rig pin -T10027A- and the socket wrench -1-.
Tighten the screw from the chain sprocket of the oil pump.
While doing so counterhold on the central screw of the crank‐
shaft.
Tightening torque: 20 Nm + torque a further 90° (1/4 turn)
– Afterwards install the oil pan ⇒ page 127 .
2.3.3 Tighten and lock chain tensioner

– Push in piston by hand -arrow-.

OCTAVIA II 2004 ➤
– Push chain rail in the -direction of the arrow- and interlock with
a socket wrench -1-, wrench size 3 mm.
2.4 Removing and installing oil filter holder,

engine identification characters BLR,
BLX, BLY, BVX, BVY, BVZ
Removing
– Remove bottom coolant pipe ⇒ page 164 .
– Remove oil cooler -arrows-.
– On vehicles up to 05.2005 detach the earth lead for the oil

pressure switch.
– Release screws -1- and -2- and remove the oil filter holder.
Install
– Replace gaskets ( ⇒ page 124 , Pos. 4) and ( ⇒ page 124 ,
Pos. 15).
– Insert baffle ( ⇒ page 124 , Pos. 14).

OCTAVIA II 2004 ➤
– Install oil filter holder, tighten screws -1- and -2- evenly to 15
Nm + torque a further 90° (1/4 turn).
Note
On vehicles until 05.2005 the earth cable for the oil pressure
switch must be fastened with the screw -2- and a cable strap at
the guide tube for the oil dipstick.
– Install oil cooler -arrows-.

moval.
2.5 Removing and installing the oil holder,

engine identification character BWA
Removing
– Remove coolant pipes ⇒ page 165 .
– Remove oil cooler. To this end release bolts -A- and -B-.

OCTAVIA II 2004 ➤
– Disconnect plug -A- from oil pressure switch.

– Release fixing screws -arrows- and remove the oil filter holder.
Install
– Replace gaskets ( ⇒ page 125 , Pos. 6) and ( ⇒ page 125 ,
Pos. 13).
– Insert baffle ( ⇒ page 125 , Pos. 12).
– Install oil filter holder, tighten screws -arrows- evenly to 15 Nm

+ torque a further 90° (1/4 turn).
– Install the oil cooler with the holder for the coolant pipes.
moval.
2.6 Testing oil pressure and oil pressure

switch -F1-
Note
1-pin and 2-pin versions of the oil pressure switch -F1- are moun‐
ted. Before inspecting, check which oil pressure switch is moun‐
ted.
2.6.1 Checking oil pressure and 1-pin oil pres‐

sure switch
♦ Oil pressure tester , e. g. -V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527 B-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
♦ Vehicle diagnosis, measurement and information system -
VAS 5051B-
Conditions
• Engine oil level o.k., test ⇒ Maintenance ; Octavia II
• Coolant temperature at least 80°C (radiator fan must have run
at least once)
Note
Functional test and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams and Fitting locations, ⇒ Vehicle

OCTAVIA II 2004 ➤
Test sequence
Gr. 50 .
– Remove oil pressure switch -F1- and screw into the tester.
– Screw the testing device into the oil filter holder instead of the
oil pressure switch.
– Connect brown cable of tester to earth (-).
– Connect the voltage tester -V.A.G 1527 B- with auxiliary ca‐
bles out of the measuring tool set -V.A.G 1594 C- on plus (+)
terminal of the battery and oil pressure switch.
The LED must not light up.
– If the LED lights up, replace the oil pressure switch -F1- .
If the LED does not light up:
– Start the engine and increase the engine speed.
Given an oil pressure of 0.12...0.16 MPa (1.2...1.6 bar) the
LED must light up, otherwise replace the oil pressure switch.
– Increase engine speed further.
At 2000 rpm and 80°C oil temperature, the oil pressure should
be 0.27...0.45 MPa (2.7...4.5 bar).
At a higher engine speed the oil pressure must not be greater than
0.7 MPa (7.0 bar).
– Check the strainer in the oil suction pipe ( ⇒ page 122 , Pos.
9) for contamination.
Note
Also mechanical damage, e.g. bearing damage can be the cause

of a too low oil pressure.
If no fault is found:
– Replace balancing shaft module with oil pump ⇒ page 130 .
If the specified pressure is exceeded:
– Inspect oil galleries.
– Replace the oil filter with the pressure relief valve as required.
2.6.2 Checking oil pressure and 2-pin oil pres‐

sure switch
♦ Oil pressure tester , e. g. -V.A.G 1342-
♦ Adapter for measuring method / DSO (2-pin) -VAS 5256-
♦ Hand multimeter , e.g. -V.A.G 1526 D-
VAS 5051B-
Conditions
• Engine oil level o.k., test ⇒ Maintenance ; Octavia II

OCTAVIA II 2004 ➤
• Coolant temperature at least 80°C (radiator fan must have run

at least once)
Note
Functional test and repair of the visual and acoustic oil pressure
display ⇒ Current flow diagrams and Fitting locations, ⇒ Vehicle
Test sequence
Gr. 50 .
– Remove oil pressure switch -F1- and screw into the tester.
– Screw the testing device into the oil filter holder instead of the
oil pressure switch.
– Fit the adapter -VAS 5256- on the oil pressure switch.
– Connect the hand-held multimeter , e.g. -V.A.G 1526 D- , to
the adapter -VAS 5256- and perform conductivity testing:
At a pressure below 0.12 MPa (1.2 bar) the oil pressure switch
must be open.
– If the oil pressure switch is closed, replace the oil pressure
switch.
If the oil pressure switch is open:
– Start the engine and increase the engine speed.
Given an oil pressure of 0.12...0.16 MPa (1.2...1.6 bar) the oil
pressure switch must close, otherwise replace the oil pressure
switch.
– Increase engine speed further.
At 2000 rpm and 80°C oil temperature, the oil pressure should
be 0.27...0.45 MPa (2.7...4.5 bar).
At a higher engine speed the oil pressure must not be greater than
0.7 MPa (7.0 bar).
– Check the strainer in the oil suction pipe ( ⇒ page 122 , Pos.
9) for contamination.
Note
Also mechanical damage, e.g. bearing damage can be the cause

of a too low oil pressure.
– Replace balancing shaft module with oil pump ⇒ page 130 .
– Inspect oil galleries.
– Replace the oil filter with the pressure relief valve as required.

OCTAVIA II 2004 ➤
19 – Cooling
1 Parts of the cooling system - Sum‐
maries of components, engine iden‐
tification characters BLR, BLX, BLY,
BVX, BVY, BVZ
WARNING

open carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ The hose connections are secured with spring-type clips. In
the event of repairs only use spring-type clips ⇒ electronic
catalogue of original parts .
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection).
♦ The arrows which are on the coolant pipes and the coolant
hose ends must stand opposite to each other.
140 Rep. Gr.19 - Cooling

OCTAVIA II 2004 ➤
1.1 Parts of cooling system engine side - Summary of components

2 - Connecting hose
3 - O-ring
❑ replace
4 - Coolant temperature send‐
er -G62-
5 - Retaining clip
6 - Coolant connection fitting
7 - towards top radiator/top
heat exchanger
coolant hoses
⇒ page 144
8 - 10 Nm
9 - Throttle valve control unit -
J338-
❑ only for engine identifi‐
cation characters BLR,
BLX, BLY coolant-heat‐
ed
coolant hoses
⇒ page 144
10 - 15 Nm
11 - Top coolant pipe
12 - Connecting hose
13 - to oil cooler
coolant hoses
⇒ page 144
14 - Coolant pipe below
15 - 15 Nm
16 - to the expansion reservoir
❑ connection diagram for coolant hoses ⇒ page 144
17 - 10 Nm
18 - to bottom radiator
19 - 15 Nm
20 - Coolant regulator housing
❑ for engine identification characters BLR, BLX, BLY:
♦ with thermostat for map-controlled engine cooling -F265-
♦ Summary of components ⇒ page 146
♦ removing and installing ⇒ page 156
♦ check ⇒ page 158
1. Parts of the cooling system - Summaries of components, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ 141
OCTAVIA II 2004 ➤
❑ for engine identification characters BVX, BVY, BVZ
♦ with coolant regulator
♦ Check coolant regulator: opening start at 87°C.
21 - Coolant pump
22 - 15 Nm
23 - to bottom heat exchanger
24 - to coolant hose at top radiator
25 - Exhaust gas return valve -N18-
❑ only for engine identification characters BLR, BLX, BVX, BVY
❑ coolant-heated
1.2 Parts of cooling system on the side next to the body - Summary of compo‐
nents
1 - Top coolant hose

❑ to coolant connection fit‐
ting at cylinder head
2 - O-ring
3 - Radiator
⇒ page 162
❑ after replacing fill entire
system with fresh cool‐
ant
4 - Gasket
5 - Screw cap
❑ Testing the pressure re‐
lief valve in the cap
⇒ page 166
6 - Connector
7 - 2 Nm
8 - Expansion reservoir
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling sys‐
tem for tightness
⇒ page 166
9 - Support
❑ for radiator
10 - 5 Nm
11 - Spacer
❑ for holder for refrigerant

OCTAVIA II 2004 ➤
lines
12 - Rubber bearing
❑ 2 pieces
❑ insert into lock carrier
13 - 10 Nm
14 - Fan shroud
15 - 5 Nm
16 - Right radiator fan -V35-
17 - Connector
18 - Connector
19 - Radiator fan -V7-
❑ with radiator fan control unit -J293-
20 - 5 Nm
21 - Support
❑ for intake air duct from lock carrier to pre-cubic contents
22 - Bottom coolant hose
❑ to coolant regulator housing
23 - Retaining clip
24 - Coolant temperature sender at radiator outlet -G83-
25 - O-ring
❑ replace
OCTAVIA II 2004 ➤
1.3 Connection diagram for coolant hoses

Vehicles without auxiliary heating.
2 - Exhaust gas return valve -
N18-
BLX, BVX, BVY
3 - Heat exchanger
4 - Gearbox oil cooler
❑ only on vehicles with au‐
tomatic gearbox
5 - Engine oil cooler
6 - Throttle valve control unit -
J338-
BLX, BLY coolant-heat‐
ed
7 - Intake manifold
8 - Radiator
BLY: with thermostat for
map-controlled engine
cooling -F265-
⇒ page 146
characters BVX, BVY,
BVZ: with coolant regu‐
lator
10 - Coolant pump
⇒ page 156
11 - Cylinder head/cylinder block
❑ fill with fresh coolant after replacing

OCTAVIA II 2004 ➤
1 - Radiator
2 - Auxiliary heating
BLY: with thermostat for
map-controlled engine
cooling -F265-
⇒ page 146
characters BVX, BVY,
BVZ: with coolant regu‐
lator
4 - Coolant pump
5 - Cylinder head/cylinder
block
N18-
BLX, BVX, BVY
8 - Non-return valve
❑ integrated into the cool‐
ant hose
❑ not always visible from
the outside
9 - Heat exchanger
10 - Coolant shut-off valve of
heating system -N279-
❑ integrated into the cool‐
ant hose
❑ not always visible from the outside
12 - Coolant hose
❑ only on vehicles with automatic gearbox
13 - Gearbox oil cooler
❑ only on vehicles with automatic gearbox
15 - Throttle valve control unit -J338-
❑ only for engine identification characters BLR, BLX, BLY coolant-heated
16 - Intake manifold
OCTAVIA II 2004 ➤
1.4 Coolant regulator housing with coolant regulator, engine identification char‐
acters BLR, BLX, BLY
1 - O-ring
❑ replace
❑ with thermostat for map-
controlled engine cool‐
ing -F265-
⇒ page 159
3 - O-ring
❑ replace
4 - Coolant pipe below
⇒ page 164
5 - 10 Nm
6 - 15 Nm
7 - Sealing ring
❑ replace
8 - Heating resistor
❑ Resistance at 25°C:
14..16 Ω
9 - Connector
10 - Thermostat for map-con‐
trolled engine cooling -F265-
⇒ page 156
❑ Start of opening approx.
105°C
❑ Opening stroke: 8 mm

OCTAVIA II 2004 ➤
2 Parts of cooling system - Summaries

of components, engine identification
character BWA
WARNING

open carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ The hose connections are secured with spring-type clips. In
the event of repairs only use spring-type clips ⇒ electronic
catalogue of original parts .
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
marking on the coolant connection).
♦ The arrows which are on the coolant pipes and the coolant
hose ends must stand opposite to each other.
2. Parts of cooling system - Summaries of components, engine identification character BWA 147
OCTAVIA II 2004 ➤
2.1 Parts of cooling system engine side
1 - 40 Nm
2 - 30 Nm
3 - Heat shield
4 - Spherical head, 3.5 Nm
5 - Coolant pipe
6 - Connecting hose
7 - Retaining clip
er -G62-
9 - O-ring
❑ replace
11 - Connecting piece
13 - Coolant pipe
⇒ page 165
15 - 5 Nm
17 - Coolant pipe
⇒ page 165
18 - Support
19 - 5 Nm
21 - Connection fitting with connecting hose
22 - 15 Nm
❑ with coolant regulator
❑ Check coolant regulator: opening start at 87°C.
24 - Coolant pump
25 - 15 Nm
26 - 8 Nm
28 - 3.5 Nm
❑ for ball head
29 - 6 Nm
❑ for coolant pipe

OCTAVIA II 2004 ➤

31 - 10 Nm
2.2 Parts of the cooling system fitted to body
1 - Top coolant hose

❑ to coolant connection fit‐
ting at cylinder head
coolant hoses
⇒ page 151
2 - O-ring
3 - Radiator
⇒ page 163
❑ after replacing fill entire
system with fresh cool‐
ant
4 - Screw cap
⇒ page 166
5 - Connector
❑ for coolant shortage
G32-
6 - 3 Nm
❑ with coolant shortage
G32-
❑ Check the cooling sys‐
tem for tightness
⇒ page 166
8 - 5 Nm
9 - 5 Nm
10 - Bottom coolant hose
11 - Right radiator fan -V35-
12 - Connector
13 - Connector
14 - Radiator fan -V7-
❑ with radiator fan control unit -J293-
15 - Fan shroud
OCTAVIA II 2004 ➤
2.3 Coolant after-running pump -V51- - Summary of components
1 - 5 Nm
2 - Coolant pipe
4 - Coolant line
❑ to exhaust gas turbo‐
charger
5 - Coolant hose
6 - Support
7 - 40 Nm
8 - Coolant hose
❑ to radiator inlet
9 - Pump for coolant after-run‐
ning -V51-
❑ the function can be
checked in the actuator
diagnosis ⇒ Vehicle di‐
agnosis, testing and in‐
formation system VAS
5051
10 - 8 Nm
11 - 5 Nm

OCTAVIA II 2004 ➤
2.4 Connection diagram for coolant hoses
1 - Radiator
⇒ page 163
❑ fill with fresh coolant af‐
ter replacing
2 - Pump for coolant after-run‐
ning -V51-
❑ with coolant regulator
4 - Auxiliary heating
❑ only for vehicles with
special equipment
5 - Coolant pump
⇒ page 156
6 - Cylinder head/cylinder
block
ter replacing
7 - Exhaust gas turbocharger
⇒ page 204
❑ with cap
⇒ page 166
9 - Heat exchanger for heating
ter replacing
OCTAVIA II 2004 ➤
3 Removing and installing parts of the

cooling system - Part 1
3.1 Draining and filling up coolant

♦ antifreeze tester
Draining
Note
♦ Collect drained coolant in a clean container for reuse or proper

disposal.
♦ Please observe the disposal instructions.
WARNING

open carefully.
– Open the cap of the expansion reservoir.

Gr. 50 .
– Place a catch pan under the radiator.
BVX, BVY, BVZ
– Open the spring strap clip -arrow- with the pliers for spring
strap clips and push back.
– Remove the coolant hose from the support.

OCTAVIA II 2004 ➤
– Disconnect plug -1- at oil pressure switch -F1- .

– Remove bottom coolant hose at radiator -2- and allow remain‐
ing coolant to drain.
– Unlock the quick coupling -arrow- and detach the coolant hose
from the radiator.
– Open spring strap clamp -arrow- and detach coolant hose from
oil cooler.
Filling up
Select the appropriate coolant additive from the ⇒ Electronic
Catalogue of Original Parts or from the list of allowed coolant ad‐
ditives ⇒ Maintenance ; Octavia II .
– In a clean reservoir mix water and antifreeze agent in the
specified mixing ratio ⇒ Maintenance ; Octavia II .
BVX, BVY, BVZ
– Fit the coolant hose onto the coolant fitting and fasten with the
spring strap clamp -arrow-.
3. Removing and installing parts of the cooling system - Part 1 153

OCTAVIA II 2004 ➤
– Attach bottom coolant hose to coolant pipe -2-.

– Fit the plug -1- on the oil pressure switch -F1- .
– Fit the quick coupling -arrow- on the support of the radiator.
– Mount coolant hose onto oil cooler and fasten with spring strap
clamp -arrow-.
– Install the noise insulation ⇒ Body Work; Rep. Gr. 50 .

OCTAVIA II 2004 ➤
– Fill up the coolant slowly up to the top marking of the criss-

crossed field (max.) on the expansion reservoir.
– Seal expansion reservoir.
– Switch off the heating and air-conditioning system.
Vehicles with coolant shut-off valve of heating system -N279-
l. vehicles without auxiliary heating
Note
This procedure also applies to vehicles with auxiliary heating,

which have no coolant shut-off valve of heating system -N279- .
– Start the engine and maintain the engine speed for about 3
minutes at approx. 2000 r.p.m.
– Run engine until radiator fan -V7- starts.
2nd Vehicles with auxiliary heating.
Caution
The auxiliary heating must only be switched on, if the refriger‐

ant circuit is filled up -as described below-.
– Connect vehicle diagnosis, measurement and information

system -VAS 5051B- .
– Start the engine and maintain the engine speed for about 3
minutes at approx. 2000 r.p.m.
– On the display press consecutively the buttons for “Vehicle
self-diagnosis”,“18 - Auxiliary heating system” and “03 - Ac‐
tuator diagnosis”.
– Press the right arrow on the display so often until the coolant
shut-off valve of heating system - N279- is shown.
– Perform self-diagnosis for the coolant shut-off valve of heating
system -N279- and maintain the eingine speed at approx.
2000 rpm for about 1 minute.
– Continue to run engine until radiator fan -V7- starts.
– Check coolant level when the expansion reservoir is closed.

• When engine is at operating temperature the coolant level
must be at the max. marking, when engine is cold between the
min. and the max. markings.
WARNING
Hot steam may escape when the compensation bottle is

opened. Wear safety goggles and safety clothing, in order to
open carefully.
– Top up coolant if necessary.

OCTAVIA II 2004 ➤
3.2 Removing and installing coolant pump

Removing
WARNING

open carefully.

– Release the fixing screws -1- of the coolant pump and remove
the coolant pump -2-.
– Remove O-ring -3-.
Install
following:
– Replace O-ring.
– Clean sealing surface for O-ring and smoothen.
– Moisten the new O-ring -3- with coolant.

– Attach the coolant pump -2-.
• Fitting position: Plug in housing points down.
– Tighten screws -1- of coolant pump to 15 Nm.
– Installing the timing belt:
3.3 Removing and installing thermostat for

map-controlled engine cooling -F265- ,
BLX, BLY
Removing
Note
If it is intended to remove the thermostat for map-controlled en‐

gine cooling -F265 - with the coolant regulator housing, first of all
the coolant pipe must be removed ⇒ page 164 .
– Disconnect the battery-earth strap when the ignition and the

electrical consumers are switched off ⇒ Electrical System;
Rep. Gr. 27 .

OCTAVIA II 2004 ➤
– Remove engine cover.

in -direction of arrow- out of the bracket and place to the side.
– Remove alternator ⇒ Electrical System; Rep. Gr. 27 .
– Remove the tensioning device for V-ribbed belt -1- with the
lifting eye -2-.
WARNING

tem.
– Disconnect plug connection -1- for magnetic coupling at AC

compressor.
Note
In order to avoid damage to the AC compressor as well as to the

– Release screws -arrows- for AC compressor.

– Secure AC compressor together with the connected refriger‐
ant hoses at the bottom of the bumper.
– Remove coolant hose -2-. To this end pull out retaining clips
-1-.

OCTAVIA II 2004 ➤
– Release screws -1- to -6- and remove bracket for auxiliary

units.

– Remove thermostat for map-controlled engine cooling -F265-
-arrows-.
Install
following:
– Replace O-ring.
– Clean sealing surface for O-ring or smoothen.
– Moisten new O-ring with coolant.
– Install the bracket for auxiliary units ⇒ page 35 .
– Install alternator ⇒ Electrical System; Rep. Gr. 27 .
– Install AC compressor ⇒ Heating, Air Conditioning; Rep. Gr.
87 .
– Install the V-ribbed belt ⇒ page 41 .
tem; Rep. Gr. 27 .
3.4 Inspecting thermostat for map-control‐

led engine cooling -F265- , engine iden‐
tification characters BLR, BLX, BLY
Test sequence
– Remove thermostat for map-controlled engine cooling -F265-
⇒ page 156 .

OCTAVIA II 2004 ➤
– Check thermostat when cold.

The large valve disc -arrow- must provide a proper seal to the
connection flange over the entire circumference.
If the seal is not in order:
– Replace thermostat for map-controlled engine cooling -F265- .
If the seal is in order:
– Connect the contacts of the thermostat for map-controlled en‐

gine cooling -F265- to the battery with the adapter cables from
the measuring tool set -V.A.G 1594 C- . Use pliers to carefully
place it vertically up to the flange in a bowl filled with boiling
coolant (mixing ratio: 50% G12).
WARNING
The metal parts of the thermostat must not be touched other‐

wise they heat up. Risk of burning!
The resistance heater now additionally heats up the wax in the

thermostat.
– Observe whether the minimum stroke of -a- 8 mm is reached
after 10 minutes.
If thestroke of 8 mm is reached:
– Separate the voltage supply to the battery.
Note
This test must not be carried out on air. Otherwise there is a risk
of damaging the expansion element!
If the minimum stroke is not reached:

– Replace thermostat for map-controlled engine cooling -F265- .
3.5 Removing and installing coolant regula‐

tor housing
Removing
– Remove alternator ⇒ Electrical System; Rep. Gr. 27 .
BVX, BVY, BVZ
– Remove coolant pipe ⇒ page 164 .
– Remove coolant pipes ⇒ page 165 .

OCTAVIA II 2004 ➤

– Remove coolant hose -2- from coolant regulator housing. To
this end pull out retaining clips -1-.
– Disconnect the plug -arrow- from the thermostat for map-con‐

trolled engine cooling -F265- .
– Release screws -arrows- and remove the coolant regulator

housing.
Install
– Clean sealing surface for O-ring.
– Replace O-ring and moisten with coolant.
– Position the coolant regulator housing at the cylinder block and
tighten the screws evenly to 15 Nm.
– Further installation occurs in a similar way in reverse order to
removal.

OCTAVIA II 2004 ➤

cooling system - Part 2
4.1 Removing and installing fan shroud for

radiator fan -V7- and right radiator fan -
V35 -
♦ Hose clamps -T30096 (3093)-
♦ Catch pan , e.g. -VAS 6208- , only engine identification char‐
acter BWA
Removing
Gr. 50 .
– Screw out screws -arrows- and remove the air intake connec‐
tion -2-.
– Pinch off the coolant feed hose with the hose clamp -T30096- .
– Place the catch pan underneath and separate the quick cou‐
pling -1-.
Note
If the service position is required for the following work, the quick
coupling of the coolant feed hose must not be disconnected.
– Unscrew the top fixing screws -top arrows- of the fan shroud.
BVX, BVY, BVZ

OCTAVIA II 2004 ➤
– Remove the bottom air guide hose at the pre-cubic contents.

To do so open spring strap clip -arrow- and push back.
– Unscrew air guide hose at bracket -arrow- and remove.
– Unhook the bottom coolant hose (not shown in the figure) from
the holder -2-.
– Disconnect plug connection -1-.
– Release the bottom fixing screws -bottom arrows- of the fan
shroud.
– Remove fan shroud.
BVX, BVY, BVZ: downwards
♦ Engine identification characters BWA: upwards
Install
Installation occurs in reverse order to removal.
4.2 Removing and installing radiator, en‐

gine identification characters BLR, BLX,
BLY, BVX, BVY, BVZ
Removing

OCTAVIA II 2004 ➤
– Unlock the connector -1- and pull out.

– Disconnect coolant fitting at top and bottom radiator.
– Remove fan shroud with radiator fans ⇒ page 161 .
– Unscrew screws ( ⇒ page 142 , Pos. 10) from right and left
radiator bearing at lock carrier.
WARNING

tem.
Caution
In order to avoid damage to the condenser as well as to the

Note
For the following work, a second mechanic is required to hold the

radiator.
– Unhook the radiator upwards out of the lower bearings and

swivel it backwards.
– Screw out the fixing screws -1- of the condenser.

– Remove radiator downwards.
Vehicles without air conditioning
– Unscrew screws ( ⇒ page 142 , Pos. 10) from right and left
radiator bearing at lock carrier.
– Press the radiator upwards and out of the rubber bearings.
– Swivel the radiator to the bottom slightly backwards and re‐
move it downwards.
Install
following:
– If a new radiator is installed, the old (drained) coolant must not
be reused.
4.3 Removing and installing the radiator,

engine identification character BWA

OCTAVIA II 2004 ➤
Removing
– Remove the coolant hoses from the radiator.
– Remove the charge air hoses -arrows- from the charge air
cooler.
– Release screws -arrows- from radiator.

– Lift the radiator out of the mounts in the charge air cooler and
pull it slightly backwards.
– Remove radiator downwards.
Install
following:
– If a new radiator is installed, the old (drained) coolant must not
be reused.
4.4 Removing and installing bottom coolant

pipe, engine identification characters
Removing
– Pull the plug -1- out of the fixture and expose the cable.
– Slacken all electrical lines from the intake manifold support.
– Unscrew screws -2- to -4- and remove the intake manifold
support.

OCTAVIA II 2004 ➤
– Detach coolant hose -arrow- from coolant pipe.

– Detach coolant hose to expansion reservoir from coolant pipe.
– Detach coolant hose -1- from coolant pipe.

– Release screws -2- and -3- and remove the coolant pipe.
Install
following:
– Replace the O-ring for the pipe in the coolant regulator hous‐
ing.
4.5 Removing and installing the coolant

pipes, engine identification character
BWA
Removing
– Disconnect plug from charge pressure sender -G31- -3-.
– Release screws -2- and -4-.
– Slacken the clamp -1-, separate the quick coupling at the
charge air cooler and remove the charge air pipe with the hose
downwards.

OCTAVIA II 2004 ➤
– Disconnect the plug connections -arrows-.
– Detach the coolant hoses from the coolant pipes -arrows-.
– Detach the hose -A- and release the screw -B-. Remove the
front coolant pipe.
– Pull the plug -A- out of the holder.

– Open the spring strap clamp -B- and pull off the coolant hose.
– Cut through cable straps -arrow-.
– Release screws -C-. Remove the rear coolant pipe.
Install
Installation is carried out in the reverse order.
– Tighten the screws of the coolant pipes to 5 Nm.
4.6 Checking the coolant system for leak‐

tightness
♦ Coolant system tester , e.g. -V.A.G 1274-
♦ Adapter , e.g. -V.A.G 1274/8-
♦ Adapter , e.g. -V.A.G 1274/9-

OCTAVIA II 2004 ➤
Test condition
• Engine must be warm.
Test sequence
WARNING

open carefully.
– Open the cap of the expansion reservoir.

– Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/8- on the coolant expansion reservoir.
– Using the hand pump of the testing device generate a pressure
of approx. 0.1 MPa (1.0 bar).
If the pressure drops:
– Search position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/9- on the cap.
– Operate the handpump.
• The pressure relief valve should open at a pressure of 0.14 ...
0.16 MPa (1.4 ... 1.6 bar).

OCTAVIA II 2004 ➤
20 – Fuel Supply
1 Fuel tank and fuel delivery unit
Note
♦ Fuel hoses at the engine must only be secured with spring-

type clips ⇒ electronic catalogue of original parts .
1.1 Fuel tank for vehicles with front-wheel drive - Summary of components
1 - Mounting part
2 - Screw cap
3 - Earth connection
❑ check for firm seating
4 - 11 Nm
5 - Cable guide
6 - 25 Nm
❑ replace
7 - Fuel tank
⇒ page 174
8 - Circlip
9 - Bracket for the exhaust sys‐
tem
10 - Tensioning strap
11 - Shield
12 - Feed line
❑ to high pressure pump
13 - Fuel filter
❑ Fitting position: arrow
points in direction of flow
14 - Vent line
❑ clipped in place on the
side of the fuel tank
15 - Sealing ring
❑ replace
❑ to be inserted dry into the opening of the fuel tank
❑ only moisten the inner seal of the flange with fuel for fitting purposes
16 - Fuel delivery unit
168 Rep. Gr.20 - Fuel Supply

OCTAVIA II 2004 ➤
❑ inspecting fuel pump ⇒ page 183
❑ note the installed position of the fuel tank ⇒ page 169
❑ with sender for fuel gauge display -G -
❑ Removing and installing the sender for fuel gauge display -G- ⇒ page 182
17 - Lock ring, 110 Nm
❑ use wrench -T30101 (3087)- for removing and installing
18 - Feed line
❑ black
❑ clipped in place on the side of the fuel tank
19 - Return-flow line
❑ blue
20 - Fuel pump control unit -J538 -
❑ after replacing, adapt the engine control unit -J623 - to the fuel pump control unit -J538- ⇒ Vehicle di‐
agnosis, testing and information system VAS 5051.
❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
21 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work; Rep. Gr. 55
Fitting location of the fuel delivery unit

The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-.
Note
♦ The -arrow- shows the direction of travel.

♦ The fuel delivery unit can only be installed in this position.
1. Fuel tank and fuel delivery unit 169

OCTAVIA II 2004 ➤
1.2 Fuel tank for vehicles with four-wheel drive - Summary of components
1 - Feed line
❑ black
2 - Return-flow line
❑ blue
3 - Sealing ring
❑ replace
❑ to be inserted dry into
the opening of the fuel
tank
❑ only moisten the inner
seal of the flange with
fuel for fitting purposes
4 - Fuel delivery unit
⇒ page 179
❑ inspecting fuel pump
⇒ page 183
❑ note the installed posi‐
tion of the fuel tank
⇒ page 171
❑ with sender for fuel
gauge display -G -
❑ Removing and installing
the sender for fuel
gauge display -G-
⇒ page 182
5 - Lock ring, 110 Nm
❑ use wrench -T30101
(3087)- for removing
and installing
6 - Fuel pump control unit -J538 -
❑ after replacing, adapt the engine control unit -J623 - to the fuel pump control unit -J538- ⇒ Vehicle di‐
❑ check ⇒ Vehicle diagnosis, testing and information system VAS 5051
7 - Screw cap
8 - Mounting part
9 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work; Rep. Gr. 55
10 - Earth connection

OCTAVIA II 2004 ➤
11 - 11 Nm
12 - Tank ventilation
13 - Connector
❑ for fuel gauge sender 2 -G169-
14 - Fuel gauge sender 2 -G169-
15 - Suction spray pump
❑ clipped in place on fuel gauge sender 2 -G169-
16 - Tank ventilation
17 - Vent line
18 - Fuel tank
❑ during removal, support using the engine and gearbox jack , e.g. -V.A.G 1383 A-
19 - Tensioning strap
20 - 25 Nm
❑ replace
21 - 25 Nm
❑ replace
22 - Shield
❑ riveted together with hanger of exhaust system
23 - 3 Nm
24 - Fuel filter
❑ Fitting position ⇒ page 172
25 - Vent line
Fitting position of the flange of the fuel delivery unit (with the
sender for fuel gauge display -G- ) and the fuel gauge sender 2 -
G169-
The markings on the flanges must be aligned with markings on
the fuel tank -arrows-.
Note
The arrows on the fuel tank are hardly visible due to the floor
panel.

OCTAVIA II 2004 ➤
1.3 Fuel filter - Summary of components
1 - Fuel filter
❑ with installed pressure
limiting valve for fuel re‐
turn-flow
Opening pressure:
0.60…0.68 MPa (6.0…
6.8 bar)
❑ do not interchange con‐
nections
❑ Fitting position
⇒ page 172
2 - Fuel feed line
❑ black
❑ from fuel tank
❑ press in securing ring in
order to unlock
3 - Fuel return-flow line
❑ blue
❑ to fuel tank
order to unlock
4 - Fuel feed line
❑ black
❑ to the engine
order to unlock
5 - 3 Nm
6 - Support
❑ for fuel filter
❑ attached to the fuel tank
Fitting position of the fuel filter

The pin -2- at the filter housing must engage in the recess -1- of
the bracket.
The direction of flow is marked by arrows.
1.4 Extract fuel from the fuel tank

♦ Hose adapter , e.g. -V.A.G 1318/16-
♦ Adapter , e.g. -V.A.G 1318/17-

OCTAVIA II 2004 ➤
♦ Battery
♦ Fuel tank
Work procedure
Note

⇒ page 5 .
⇒ page 7 .
– Removing rear seat bench ⇒ Body Work; Rep. Gr. 72 .
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
Note
For vehicles with auxiliary heating, the plug connection for the
dosing pump -V54- must be disconnected additionally.
– Unplug the 5-pin plug -1- from the black feed line -2-.
Note
Press in securing ring in order to unlock the lines.

OCTAVIA II 2004 ➤
– Connect the adapter -V.A.G 1318/16- and -V.A.G 1318/17-

and connect the “suction line” thus prepared to the feed sup‐
port of the fuel pump.
– Keep “suction line” in a suitable fuel tank.
– Connect the battery and the contacts of the fuel pump with
adapter cables -A- from the adapter cable set -V.A.G 1594/C-
as follows:
Battery positive (+) to contact -1- of the fuel pump
Battery minus (-) to contact -5- of the fuel pump
The fuel pump runs and suctions off fuel.
WARNING
In order to prevent an overflow of fuel in case of a too small

fuel tank, the fuel pump must not run unattended.
1.5 Removing and installing the fuel tank

♦ Engine/gearbox jack , e.g. -V.A.G 1383 A-
1.5.1 Removing
• The fuel tank must not be more than 1/4 full.
Note
♦ If necessary, extract fuel from the fuel tank ⇒ page 172 .

⇒ page 5 .
⇒ page 7 .
– Unclip the cover -1- with the fuel pump control unit -J538-
-2-.
Note

OCTAVIA II 2004 ➤
– Unplug the 5-pin plug -1- from the fuel pump.

– Remove the cover of the fuel gauge sender 2 -G169 - (in the
figure on the right) and unplug the plug -right arrows-.
– Remove propshaft ⇒ Gearbox; Rep. Gr. 39 .
– Clean around the fuel filler neck.
– Unscrew right rear wheel.
– Remove the rear right wheelhouse liner ⇒ Body Work; Rep.
Gr. 66 .
– Unscrew screws -1- for filler neck on the body.

– Unclip the electrical cable from the bracket -2- at the top and
bottom of the filler neck.
– Disconnect vent line -1- (white) and fuel feed line -2- (black)
at the connection point.
Note
♦ For vehicles with auxiliary heating, the fuel line of the dosing
pump -V54- must also be disconnected.
♦ Press in the securing ring in order to unlock the line.

OCTAVIA II 2004 ➤
– Disconnect plug -arrow- at four-wheel drive control unit -

J492- .
– Support fuel tank using the engine/gearbox jack -V.A.G 1383

A- . Unscrew the straps and fixing screws.
– Remove front part of exhaust gas system ⇒ page 291 , except
vehicles with engine identification characters BWA.
– Release fixing screws -2- and -4- and remove the tensioning
strap.
– Support fuel tank using the engine/gearbox jack -V.A.G 1383
A- .
– Release fixing screws -1- and -3-.
– Slightly lower the fuel tank.
Note
The filler neck must be “extracted” between structure and rear

axle Lift down the fuel tank, with a 2nd mechanic, from engine and
gearbox jack -V.A.G 1383 A- .
1.5.2 Install
– Clip the cable for the four-wheel drive control unit -J492- into
the brackets -arrows- at the fuel tank.
– Check both earth connections for corrosion, if necessary re‐
move corrosion.

OCTAVIA II 2004 ➤
– Check fitting position of the earth lead -1-.

• The plug -1- must tightly fit on the plate ring -2-.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
– Guide the filler neck between rear axle and structure with the
assistance of a 2nd mechanic. Then position the fuel tank onto
the engine and gearbox jack -V.A.G 1383 A- .
– Fit the plug -arrow- on the four-wheel drive control unit -J492- .
Further installation occurs in reverse order. Pay attention to the
following:
♦ Lay the vent and fuel lines without any kinks.
♦ Do not mix-up the feed line and the return-flow line (the return-
flow line is blue, the feed line is black).
♦ Make sure the line connections fit tightly.
♦ Check earth connection of fuel tank/body at filler neck.
♦ After installing the fuel tank, check whether the lines are still
clipped in place on the fuel tank.
1.6 Removing and installing the fuel delivery

unit on vehicles with front-wheel drive
♦ Key -T30101 (3087)-
♦ Protective gloves
Removing
Note

⇒ page 5 .
⇒ page 7 .

OCTAVIA II 2004 ➤
– Unclip cover -4- with fuel pump control unit -J538- -1-.
Note
– Unplug the 5-pin plug, the black feed line -1- and the blue re‐
turn-flow line -2-.
Note
♦ Press in securing ring in order to unlock the lines.

♦ For vehicles with auxiliary heating the suction line for the dos‐
ing pump -V54- must be pulled out additionally (open lower
clamp).
– Unlock lock ring with the wrench -T30101 - .
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
Installation occurs in reverse order. Pay attention to the following:
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Insert the fuel delivery unit into the fuel tank in such a way that
the float arm of the sender for the fuel gauge display -G- is not
bent.

OCTAVIA II 2004 ➤
Note
♦ Pay attention to installed position of flange of fuel delivery unit:

The peg -2- on the fuel delivery unit must be between the pegs
-1- and -3-. -Arrow- points in direction of travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange the black feed line with the blue return-flow
line (arrows on the flange of the fuel delivery unit).
♦ Make sure the line connections and the 5-pin plug fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
and return-flow lines are also clipped on the fuel tank.
– Press the closing flange downwards, install the lock ring and
connect the fuel lines.
– Clip on cover -4- with fuel pump control unit -J538- -1-.
The arrow -2- on the cover points in direction of travel.
1.7 Removing and installing the fuel delivery

unit on vehicles with four-wheel drive
♦ Wrench for the lock ring -T30101 (3087)-
♦ Protective gloves
Removing
Note

⇒ page 5 .
⇒ page 7 .
– Switch off ignition and withdraw ignition key.

– Remove the cover from the fuel delivery unit.

OCTAVIA II 2004 ➤
Note
– Disconnect the plug, the black feed line -1- and the blue return-
flow line -2- from the flange.
Note
♦ Press in securing ring in order to unlock the lines.

♦ For vehicles with auxiliary heating the suction line for the dos‐
ing pump -V54- must be pulled out additionally (open lower
clamp).
– Open lock ring with the wrench -T30101 - .

– Pull out closing flange and gasket ring of the fuel delivery unit
from the opening of the fuel tank and place to the side with the
connected lines.

OCTAVIA II 2004 ➤
– Separate through the opening of the fuel tank the fuel line
-1- to the suction jet pump, to do so press the release button.
– Unhook the fuel delivery line -2- at the fuel delivery unit, to do
so pull the fixing clamp upwards -arrow-.
Note
♦ You must wear protective gloves for removing the fuel delivery
unit.
♦ Take the fuel delivery unit out of the fuel tank in such a way
that the electrical cables and the fuel hoses are not damaged
and that the float arm of the sender for the fuel gauge display
-G- is not bent.
♦ You must empty the old delivery unit before disposing of it if
you wish to replace the fuel delivery unit.
– Pull the fuel delivery unit out of the opening of the fuel tank.
Install
The installation of the fuel delivery unit occurs in the reverse or‐
der. Pay attention to the following:
– Insert the fuel delivery unit into the fuel tank with the closing
flange placed to the side. Thus, do not bend the float arm of
the fuel gauge sender unit -G- .
– Install the fuel delivery unit and the fuel line.
– Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the
closing flange.
– Slide the spring -2- into the opening of the guide -arrow- and
fit the guide -1- of the closing flange into the guide -3- on the
fuel delivery unit.
– Press the closing flange down and adjust it in the installation
position.
Further information:

OCTAVIA II 2004 ➤
♦ Observe the fitting location of the fuel delivery unit. The peg
-2- on the closing flange must be between the tongues -1- and
-3- at the fuel tank. The -thick arrow- points in the direction of
travel.
♦ Tighten the lock ring to 110 Nm.
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel lines fit tightly.
♦ After installing the fuel delivery unit, check whether the feed
line and the return-flow line are still clipped in place on the fuel
tank.
1.8 Removing and installing the sender for

fuel gauge display -G-
Note
There are two types of senders for the fuel gauge display -G- in‐
stalled in the vehicles.
Fuel gauge sender -G- type 1

Removing
– Remove fuel delivery unit:
♦ Vehicles with front-wheel drive ⇒ page 177 .
♦ Vehicles with four-wheel drive ⇒ page 179 .
– Unlatch and disconnect the plug connection of the lines -1-
(brown), -2- (blue) and -3- (black).
– Raise catches -4- and -5- with a screwdriver and remove the
sender for fuel gauge display -G- from the bottom -arrow-.
Install
– Insert the sender for the fuel gauge display -G- in the guides
at the fuel delivery unit and press upwards until it latches into
position.
– Connect the cables and check the plugs for secure catch.
– Install fuel delivery unit:
Fuel gauge sender -G- type 2
Removing
– Remove fuel delivery unit:

OCTAVIA II 2004 ➤
– Unlock the catches -arrows- using a screwdriver and pull out

the sender for fuel gauge display -G- towards the top.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the cables and check the plugs for secure catch.
– Insert the sender for fuel gauge display -G- in the guide at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Install fuel delivery unit:
1.9 Testing fuel pump

♦ Key -T30101 (3087)-
♦ Pressure gauge , e.g. -V.A.G 1318-
♦ Adapter , e.g. -V.A.G 1318/1-
♦ Adapter , e.g. -V.A.G 1318/11-
♦ Hose adapter , e.g. -V.A.G 1318/16-
♦ Adapter set , e.g. -V.A.G 1318/17-
♦ Double connection piece , e.g. -V.A.G 1318/23-
♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable , e.g.
-V.A.G 1348/3-3-
♦ Voltage tester , e. g. -V.A.G 1527 B-
VAS 5051B-
♦ Measuring vessel

OCTAVIA II 2004 ➤
1.9.1 Inspecting proper operation and power

supply
Test condition
• Battery voltage at least 11.5 V.
• Fuel pump fuse O.K. ⇒ Current flow diagrams and Fitting lo‐
cations.
• Fuel pump control unit -J538- O.K.
• Fuel pressure sender for low pressure -G410- (if present) O.K.
Test sequence
Note
The fuel pump is tested with the actuator diagnosis ⇒ Vehicle di‐
– Connect vehicle diagnosis, measurement and information

system -VAS 5051 B- .
– Switch on ignition.
– Select the function “Vehicle self-diagnosis” and further select
the function “Actuator diagnosis” and activate the fuel pump.
• The fuel pump must now run slowly to the maximum speed.
Note
The fuel pump runs very quietly.

The fuel pump does not run:
– Disconnect plug from fuel pump control unit -J538- .

OCTAVIA II 2004 ➤
– Testing the voltage supply with the voltage tester -V.A.G 1527
B- between contact -1- and -6-.
• The LED must light up.
The LED does not light up:
– Determine and remove open circuit in the wiring according to
the current flow diagram ⇒ Current flow diagrams and Fitting
locations.
The LED lights up (power supply O.°K.):
– Remove fuel delivery unit ⇒ page 177 .
– Check whether the electric wiring between the flange and fuel
pump is connected.
If there is no open circuit in the wiring, the fuel pump is defective:
– Replace fuel delivery unit ⇒ page 177 .
1.9.2 Check fuel pressure
Note

⇒ page 5 .
⇒ page 7 .
– Remove the fuel feed line -2- (press in the securing ring) and
catch the fuel which flows out with a cleaning cloth.

OCTAVIA II 2004 ➤
– Install the pressure gauge -V.A.G 1318- with the adapter -

V.A.G 1318/1- and the adapter set -V.A.G 1318/17- instead of
the fuel feed line.
– Open shut-off cock of the pressure gauge. The lever then
points in position -A-.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
Specified value: 0.35...0.5 MPa (3.5...5.0 bar).
If fuel line is o.k.:
– Test holding pressure ⇒ page 187 .
– Check the return line between the fuel filter and fuel pump for
kinks and blockages.
If no fault is detected, the pressure limiting valve in the fuel filter
is defective:
– Replace fuel filter.
– Check the fuel pressure before the fuel filter. For this step
connect the pressure gauge -V.A.G 1318- with the adapter set
-V.A.G 1318/17- between the fuel filter and the fuel feed line.
– Open shut-off cock of the pressure gauge. Lever points in di‐
rection of flow.
– Start engine and run in idle.
Caution
The shut-off cock must only be closed slowly. At a fuel pressure

of 0.8 MPa (8 bar), the shut-off cock must be immediately
opened, in order to avoid a damage of the pressure gauge.
– Slowly close the shutoff cock of the pressure measuring de‐

vice. The pressure must rise to at least 0.6 MPa (6.0 bar). If
the 0.6 MPa is achieved, immediately open the shut-off cock
again!
If the pressure has risen, the fuel pump is O.K., the pressure lim‐
iting valve in the fuel filter is defective:
If the pressure has not risen, the fuel pump is defective:

OCTAVIA II 2004 ➤
1.9.3 Test holding pressure

• Fuel pressure O.K. and pressure gauge -V.A.G 1318- con‐
nected in the engine compartment ⇒ page 185 .
– Read off fuel pressure on the pressure gauge. Specified value:
0.35...0.5 MPa (3.5...5.0 bar).
– Observe pressure drop at pressure gauge.
The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure still drops:
– Immediately close the shutoff cock of the pressure measuring

device. The lever then points in the position -B-.
If the pressure again drops:
– Check the low pressure pipe to the high pressure pump for
tightness.
– Replace high pressure pump ⇒ page 262 .
Now the pressure does no longer drop:
– Check the fuel line to the fuel filter for tightness.
If the fuel line is not found to be faulty:
– Check the non-return valve in the fuel delivery unit. For this
step connect the pressure measuring device -V.A.G 1318-
with the adapter -V.A.G 1318/17- between the fuel filter and
the fuel feed line.
– Open shut-off cock of the pressure gauge. Lever points in di‐
rection of flow.
– Read off fuel pressure on the pressure gauge.
Specified value: 0.35 ... 0.5 MPa (3.5 ... 5.0 bar)

OCTAVIA II 2004 ➤
– Immediately close the shut-off cock of the pressure measuring

device after the pressure has built up.
– Observe pressure drop at pressure gauge.
The pressure must not drop below 0.3 MPa (3.0 bar) after 10
minutes.
If the pressure drops, the non-return valve in the fuel pump is
defective:
If the pressure does not drop, the pressure limiting valve in the
fuel filter is defective:
1.9.4 Check fuel flow rate
Note

⇒ page 5 .
⇒ page 7 .
– Disconnect plug from fuel pump control unit -J538- -2-.
Note
– Remove cover -1-.

OCTAVIA II 2004 ➤
– Connect the remote control -V.A.G 1348/3A- with adapter ca‐

bles at contact -1(+)- of fuel pump and at contact -1(+)- of 10-
pin plug.
– Connect the contact -6(-)- of the 10-pin plug with the contact
-5(-)- of the fuel pump using an adapter cable from the adapter
cable set -V.A.G 1594 C- .
– Take cap off fuel filler neck.
– Disconnect the fuel feed line -2- (press in the securing ring)
and catch the fuel which flows out with a cleaning cloth.
– Connect the pressure gauge -V.A.G 1318- with the double

connection piece -V.A.G 1318/23- and the adapter set -V.A.G
1318/17- to the fuel feed line.
– Fit the hose adapter -V.A.G 1318/16- onto the adapter -V.A.G
1318/11- of the pressure measuring device and hold it in a
measuring vessel.
– Close the shut-off cock of the pressure measuring device. The
lever then points in the position -B-.
WARNING
Danger of liquid spraying out when opening the shut-off valve.

Wear safety goggles and safety clothing, in order to avoid in‐
juries and skin contact. Hold the container in front of the free
connection to the pressure gauge.
– Open shut-off cock of the pressure gauge. The lever then

points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A- . While doing so,
slowly close the shut-off cock until the pressure gauge dis‐
plays 0.4 MPa (4 bar) pressure. Now do not make any further
changes to the position of the shut-off cock.
– Empty measuring vessel.
– The fuel flow rate of the fuel pump is dependent on the battery
voltage. Therefore connect the multimeter -V.A.G 1715- with
adapter cables from the measuring tool set -V.A.G 1594 C- to
the vehicle battery.
– Activate remote control for 30 seconds while measuring the
battery voltage.

OCTAVIA II 2004 ➤
– Compare the delivered fuel rate with the specified value.

*) minimum flow rate 1 cm3/30 s
**) Voltage at the fuel pump when engine is not running and pump
is operating (approx. 2 volts less than battery voltage)
Read out examples:
During the test a voltage of 12.5 V was measured on the battery.
As the voltage on the fuel pump is approx. 2V less than the battery
voltage, a minimum flow rate of approx. 580 cm3/30 s is obtained.
If the minimum delivery volume is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.
– Disconnect the feed hose -1- from the fuel filter inlet.
– Connect pressure gauge -V.A.G 1318- with the adapter set -
V.A.G 1318/17- to the hose.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
If the minimum flow rate is again not reached:
– Remove fuel delivery unit and inspect the filter strainer for
soiling.
If you have still not found any fault up to this stage:
If the required fuel delivery volume has been achieved, but a fault
is still suspected in the fuel supply system (e.g. intermittent break‐
down of the fuel supply).
– Check power consumption of the fuel pump ⇒ page 190 .
1.9.5 Check power consumption

– Fold up rear seat.
– Unclip cover -4- with fuel pump control unit -J538- -1-.

OCTAVIA II 2004 ➤
– Connect the current probe -A- of the vehicle diagnosis, meas‐

urement and information system -VAS 5051 B- on the line
-B- to contact -1- of the 5-pin plug.
– Measure voltage consumption of the fuel pump.
Specified value: max. 9 A
Note
If the failure in the fuel supply is occasional the test may be per‐
formed during a test drive. The assistance of a 2nd person is
required.
If the power consumption is exceeded, the fuel pump is defective:

1.10 Removing and installing fuel gauge

sender 2 -G169- for vehicles with four-
wheel drive
♦ Key -T30101 (3087)-
Note

⇒ page 5 .
⇒ page 7 .
♦ Make sure that the float arm of the fuel gauge sender 2 -G169-
is not bent.
Removing
– Remove the left cover in direction of travel from the sender for
the fuel gauge display 2 -G169- .
– Disconnect the plug from the fuel gauge sender 2 -G169- and
remove the plug connection for the four-wheel drive control
unit -J492- from the bracket in the flange.

OCTAVIA II 2004 ➤
– Unlock lock ring with the wrench -T30101 - .
– Pull the fuel gauge sender 2 -G169- a little upwards and slack‐
en -arrows-.
– Remove gasket ring.
Install
Caution
When installing do not bend the float arm of the fuel gauge
sender 2 -G169- .
– Insert the fuel gauge sender 2 -G169- into the fuel tank.
– Position the suction jet pump in the inside of the fuel tank onto
the sender. The catches must click audibly.
– Insert new dry gasket ring of the flange into the opening of the
fuel tank and only now moisten the inside (towards flange) with
fuel.
– Pay attention to the fitting location of the fuel gauge sender 2
-G169 - ⇒ page 171 .
– Check correct seating of the gasket ring.
– Slacken the lock ring with the wrench -T30101 - .
– Fit on the plug and insert the plug connection into the bracket
on the flange.
– Install cover.
– Install rear seat bench ⇒ Body Work; Rep. Gr. 72 .

OCTAVIA II 2004 ➤
1.11 Removing and installing suction jet

pump for vehicles with four-wheel drive
Note
♦ The fuel tank for four-wheel drive vehicles consists of a left

and right chamber. In order to pump the fuel out of the left
chamber -3- of the fuel tank into the right chamber to the hous‐
ing of the delivery unit -2-, a suction jet pump -1- is required.
♦ On vehicles with four-wheel drive, the version of the fuel tank
makes is possible that the fuel is pumped from the area of the
fuel gauge sender 2 -G169- with a suction jet pump to the fuel
delivery unit.
♦ A check is only to be carried out, if the engine stops because
of fuel shortage, although the fuel gauge still indicates a fuel
tank which is 1/4 full.
Work procedure
– Remove fuel delivery unit ⇒ page 177 .
– Remove fuel gauge sender 2 -G169- ⇒ page 191 .
– Now the suction jet pump can be pulled out from the side of
the fuel gauge sender 2 -G169- (left vehicle side).
– Check, if the fuel lines on the suction jet pump are placed on
firmly and not damaged.
– Check the suction jet pump additionally for possible contami‐
nation.

OCTAVIA II 2004 ➤
2 Electronic Engine Power Control

(Electronic throttle)
2.1 Accelerator pedal module - Summary of components
1 - Connector
❑ black, 6 pin
❑ disconnect and fit on
⇒ page 196
2 - Accelerator pedal position
sender -G79- with accelerator
pedal position sender 2 -G185-
❑ not adjustable
❑ the accelerator pedal
sender transmits the
driver's instructions to
the engine control unit
❑ -A- openings for the re‐
lease tool
⇒ page 194
❑ when replacing, the en‐
gine control unit must be
adapted ⇒ Vehicle diag‐
nosis, testing and infor‐
mation system VAS
5051 on vehicles with
automatic gearbox
3 - 10 Nm
4 - Cap
2.2 Removing and installing accelerator

pedal module
♦ Release tool -T10238- (for left-hand drive vehicle)
♦ Release tool -T10240- (for right-hand drive vehicle)

OCTAVIA II 2004 ➤
Removing
– Remove steering column cover -arrows-.
– Lever out the cap ( ⇒ page 194 , Pos. 4) with a screwdriver.
– Release fixing screw ( ⇒ page 194 , Pos. 3).
– Push the release tool -T10238- (on right-hand drive vehicles

release tool -T10240- ) as shown up to the stop into the pro‐
vided openings and remove the accelerator pedal module.
– Disconnect connector from accelerator pedal module. To do
so press down securing element from connector.
Installing
– Fit the connector -2- onto the accelerator pedal module -5-.
The plug must lock audibly.
– Push accelerator pedal module onto the fixing bolts -6-.
– Insert centering pin -7- in the hole on the vehicle floor.
– Fasten accelerator pedal module with screw -3- (10 Nm) and
fit on cap -4-.
– Re-install the cover for the steering column.
– If the accelerator pedal module was replaced, the engine con‐
trol unit has to be adapted ⇒ Vehicle diagnosis, testing and
If the accelerator pedal module was replaced on vehicles with
an automatic gearbox, the kick-down function must be initial‐
ised ⇒ Vehicle diagnosis, testing and information system VAS
5051.
2. Electronic Engine Power Control (Electronic throttle) 195

OCTAVIA II 2004 ➤
2.2.1 Disconnect connector for accelerator

pedal module and fit on
Note
The plugs for the accelerator pedal module which are inserted,
must be disconnected and fit on in a different manner.
Disconnect connector 1K0 973 706

– Slightly press the piston slide valve -A- (grey) in
-direction of arrow 1- and push it up to the stop in
-direction of arrow 2-.
– Hold the piston slide valve in this position and disconnect the
socket housing -B- in -direction of arrow 3-.
The piston slide valve -A- is pushed into the bottom position.
Fit on connector 1K0 973 706

– Push the socket housing -B- in -direction of arrow- until the
piston slide valve can be heard to lock in place.
The piston slide valve -A- moves automatically upwards.
Note
For safety reasons, check the connector for secure catch by tight‐
ening it in the opposite direction.
Disconnect connector 8K0 973 706

– Pull piston slide valve -A- (red) in -direction of arrow 1- up to
the stop.
– Press the piston slide valve in -direction of arrow 2- and dis‐
connect the socket housing -B- in -direction of arrow 3-.
The piston slide valve -A- remains in the top position.
Fit on connector 8K0 973 706

– Push the socket housing -B- up to the stop in
-direction of arrow 1-.
– Slightly press the piston slide valve in -direction of arrow 2-
and push it in -direction of arrow 3-.
The piston slide valve -A- can only be pushed down if the
socket housing was pushed up to the stop.
Note
For safety reasons, check the connector for secure catch by tight‐
ening it in the opposite direction.

OCTAVIA II 2004 ➤
3 Activated charcoal container system
Note
♦ The hose connections are secured with spring strap clips or clamp-type clips.
♦ Always replace clamp-type clips with spring-type clips.
♦ Use pliers for spring strap clips to fit the spring strap clips.
♦ Safety precautions when working on the fuel supply system ⇒ page 5 .
♦ Rules of cleanliness when working on the fuel supply system ⇒ page 7 .
1 - Activated charcoal filter

❑ Fitting position: in right
of engine compartment
❑ as of 01.2005 with ven‐
tilation fitting instead of
sealing grommet (Pos.
9)
2 - Pressure holding valve with
connection hose
3 - Connecting hose
❑ from fuel tank
4 - 10 Nm
5 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
❑ Valve closed when igni‐
tion is switched off
❑ valve is actuated
(pulsed) by engine con‐
trol unit when engine is
warm
6 - Connecting hose
❑ To intake manifold
7 - Support
❑ for activated charcoal fil‐
ter
8 - Air admission hose
❑ up to 12.2004
9 - Sealing grommet
❑ up to 12.2004
3.2 Checking the fuel tank venting

♦ Hand vacuum pump , e.g. -VAS 6213-
3. Activated charcoal container system 197

OCTAVIA II 2004 ➤
♦ Adapter set , e.g. -V.A.G 1318/17A-

♦ Adapter , e.g. -V.A.G 1318/20-1-
Note
The adapter set -V.A.G 1318/17A- replaces the adapter set -

V.A.G 1318/17- .
Test condition
• The ignition must be switched off.
Test sequence
– Detach vent line -1-. To do so press in the securing ring.
– Connect the hand vacuum pump -VAS 6213- to the vent line
-1- as shown in the figure.
– Position the sliding ring -2- of the hand vacuum pump -VAS
6213- in the -direction of arrow- for “vacuum”.
– Operate the hand vacuum pump -VAS 6213- several times.
• No vacuum should build up.
If a vacuum builds up.
– Check the air admission hose or air admission fitting -arrow-

on the activated charcoal filter for dirt and clean as required.
If no vacuum builds up:
– Shut off air admission hose or air admission fitting -arrow- on
and once again operate the hand vacuum pump several times.
• A vacuum should build up.
– Replace activated charcoal filter.

OCTAVIA II 2004 ➤
21 – Turbocharging
1 Exhaust gas turbocharger
Note
Observe the general notes for assembly work on the charge air
system with exhaust gas turbocharger ⇒ page 10 .
1.1 Exhaust turbocharger - Summary of components
Part I ⇒ page 200

Part II ⇒ page 201
Part III ⇒ page 202
1. Exhaust gas turbocharger 199

OCTAVIA II 2004 ➤
1.1.1 Part I
1 - Gasket
❑ replace
2 - 20 Nm
❑ replace
❑ Coat pin screws of ex‐
haust manifold with hot
bolt paste -G 052 112
A3-
3 - 35 Nm
4 - Sealing ring
❑ replace
5 - 9 Nm
6 - Coolant return-flow line
⇒ page 204
8 - Support
9 - 30 Nm
❑ Coat bolt with hot bolt
paste -G 052 112 A3-
10 - 30 Nm
❑ Coat bolt with hot bolt
paste -G 052 112 A3-
11 - Support
12 - 23 Nm
13 - 30 Nm
❑ do not slacken for the re‐
moval of the exhaust
turbocharger
❑ replace
❑ Coat pin screws of exhaust manifold with hot bolt paste -G 052 112 A3-
14 - Clamping strip
200 Rep. Gr.21 - Turbocharging

OCTAVIA II 2004 ➤
1.1.2 Part II
1 - Sealing ring
❑ replace
2 - 30 Nm
3 - Oil feed line
❑ with heat protective cov‐
er
⇒ page 204
5 - 9 Nm
6 - 30 Nm
7 - Sealing ring
❑ replace
8 - 35 Nm
9 - Sealing ring
❑ replace
10 - Coolant feed line
11 - 23 Nm
12 - 35 Nm
13 - 9 Nm
14 - Sealing ring
❑ replace
15 - Gasket
❑ replace
16 - Oil return-flow line
17 - 9 Nm
18 - Gasket
❑ replace

OCTAVIA II 2004 ➤
1.1.3 Part III

⇒ page 204
2 - Gasket
❑ replace
3 - 9 Nm
4 - Line for crankcase ventila‐
tion
5 - Shield
6 - Connecting hose
❑ with heat protective cov‐
er
7 - Pressure box
⇒ page 212
❑ adjust ⇒ page 213
8 - Connecting piece
9 - Sealing ring
❑ replace
10 - Hose
11 - Hose
12 - 3 Nm
13 - Solenoid valve for charge
pressure control -N75 -
14 - 8 Nm
15 - Sealing ring
❑ replace
16 - Supports
17 - Locking clip
18 - 7 Nm
19 - Hose
20 - 7 Nm
21 - Support
22 - 7 Nm
23 - Turbocharger divert air valve -N249-
❑ check fitting position ⇒ page 203
24 - Sealing ring
❑ replace

OCTAVIA II 2004 ➤
Fitting position turbocharger divert air valve -N249-

– Check fitting position -arrows-.
1.2 Testing exhaust turbocharger pressure

box
♦ Hand vacuum pump -VAS 6213-
Test condition
• Engine oil temperature at least 60 °C
• The hose for the exhaust turbocharger above the charge pres‐
sure control solenoid valve -N75- must have access to the
pressure unit.
• charge pressure control solenoid valve -N75- o.k.
• The exhaust gas system must be tight.
Work procedure
– Start the engine and observe the actuation linkage -A- of the
pressure unit at the exhaust turbocharger with a mirror.
– Now bring the engine with a second mechanic up to high rev‐
olutions by spontaneously pressing on the accelerator pedal.
• Now the linkage -A- must move.
If the linkage does not move:

OCTAVIA II 2004 ➤
– Connect the hand vacuum pump -VAS 6213- to the pressure

unit -arrow-.
– Put the switch-over ring -1- of the hand vacuum pump -VAS
6213- in position -B- for “pressure”.
– Operate the hand vacuum pump -VAS 6213- several times
and at the same time observe the linkage.
• Now the linkage -A- must move slowly and be positioned at

the end stop at approx. 0.070 MPa (700 mbar).
Note
♦ If it is not possible to build up pressure using the hand vacuum

pump -VAS 6213- or the pressure drops immediately: Replace
pressure unit ⇒ page 212 .
♦ If the pressure box is o.k. and the linkage -A- does not move:
Check the bypass flap lever for smooth operation. If the lever
is sluggish or blocked: Replace exhaust gas turbocharger
⇒ page 204 .
1.3 Removing and installing exhaust gas

turbocharger
♦ Tensioning strap -T10038-

OCTAVIA II 2004 ➤
Caution

Removing
– Detach charge air hose -arrow- from charge air cooler.
– Release screws -arrows-, unlock the top quick coupling and

remove the charge air pipe.

OCTAVIA II 2004 ➤
– Disconnect plugs -1- and -2-.

expose wiring loom.
66 .
– Disconnect the plug -1- from the ignition coils and place the
wiring harness to the side.

OCTAVIA II 2004 ➤
– Disconnect the coolant line -arrow- to the expansion reservoir.
– Detach coolant hose -1- and -2-.

– Unscrew coolant line -3-.
– Remove shield with coolant pipe -arrows-.
– Pull off the thin coolant hose at the top from the upper coolant
hose -arrow-.

OCTAVIA II 2004 ➤
– Remove the valve housing from the cylinder head cover

-arrows-.
– Release the screws -1- of the line for the crankcase ventilation
from the exhaust turbocharger.
– Open warm-type clamp -2-. Disconnect the line of the crank‐
case ventilation from the cylinder head cover and remove.
– Detach the activated charcoal filter system line -3- to the ex‐
haust gas turbocharger from the cylinder head cover.
– Remove oil feed line -4- from exhaust gas turbocharger.
– Release both top fixing nuts -arrows- of the front part of the
exhaust gas system/exhaust gas turbocharger.
– Unbolt heat shield for right drive shaft -arrows-.

OCTAVIA II 2004 ➤
– Release both bottom fixing nuts -arrows- of the front part of

the exhaust gas system/exhaust gas turbocharger.
– Separate exhaust system at the clamping sleeve -arrow-.

– Pull off the front part of the exhaust gas system and push it
slightly back.
Note
The front part of the exhaust gas system is not removed and the
lambda probe connector is not disconnected.
– Remove pipe -1-.

– Release the screws -3- and -4- of the coolant feed line.

OCTAVIA II 2004 ➤
– Remove the oil return-flow line -arrows- at the exhaust gas

turbocharger.
– Release the screws -1- and -2- and remove the support for
exhaust gas turbocharger.
Note
The following steps are necessary in order to have more space

between the cylinder head and the bulkhead.
– Pull the engine with the tensioning strap -T10038- up to the

steering gear.

OCTAVIA II 2004 ➤
– Separate the coolant pipe -arrow-.
Note
It is not necessary to detach the nuts of the clamping strip.
– Unscrew the nuts -arrows-.

OCTAVIA II 2004 ➤
– Remove the exhaust gas turbocharger/exhaust manifold -2-

between the coolant hoses -3- and the cylinder head cover
-1- inclined to the top left.
Install
Caution


following:
♦ Gaskets, gasket rings and self-locking nuts must be replaced.
♦ Fill the exhaust turbocharger with engine oil at the connection
fitting for the oil feed line.
♦ After installing the exhaust turbocharger, run engine at idling
speed for about 1 minute to ensure that oil is supplied to the
exhaust turbocharger.
♦ The coolant return flow line ( ⇒ page 200 , Pos. 6) must be
installed together with the exhaust turbocharger.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before being assembled. The gasket ring
and the sealing surface must be slightly oiled only for push-fit
couplings ⇒ page 219 .
♦ Secure all hose connections with hose clamps ⇒ Electronic
Catalogue of Original Parts .
♦ For this step, observe the assembly instruction for hose con‐
nections with push-fit couplings ⇒ page 219 .
– Install exhaust system and align free of stress ⇒ page 292 .
– Install pendulum support ⇒ page 33 .
1.4 Removing and installing pressure box

for exhaust turbocharger
Removing
– Remove exhaust turbocharger ⇒ page 204 .
– Slacken the lock washer above the linkage of the pressure unit
at the exhaust turbocharger.

OCTAVIA II 2004 ➤
– Release counternut -2 -.
– Separate the linkage from the exhaust turbocharger -3-.
– Remove the pressure unit at the exhaust turbocharger
-arrows-.
Install
following points:
– Install pressure unit -1- with 10 Nm at exhaust turbocharger
-arrows-.
– Setting exhaust turbocharger pressure unit ⇒ page 213 .
• The counternut of the linkage must be secured with seal paint
⇒ electronic catalogue of original parts .
– Install exhaust turbocharger ⇒ page 204 .
1.5 Setting exhaust turbocharger pressure

unit
♦ Universal dial gauge holder -MP3-447 (VW 387)-
♦ Hand vacuum pump , e.g. -VAS 6213-
♦ Pressure control valve , e.g. -VAS 6342-
♦ Turbocharger tester , e.g. - V.A.G 1397 A-
♦ Dial gauge , e.g. -VAS 6341/1-
♦ 30 mm extension , e.g. -VAS 6341/3-
♦ Flat button , e.g. -VAS 6341/4-
Note
♦ The pressure unit must only be set if the linkage was detached.
♦ The setting is performed on a removed exhaust turbocharger.
– Remove exhaust turbocharger ⇒ page 204 .

– Detach the hose -arrow- from the pressure unit at the exhaust
turbocharger.
– Slacken the lock washer above the linkage of the pressure unit
at the exhaust turbocharger.

OCTAVIA II 2004 ➤
– Release counternut -2 -.
– Pre-set the bypass flap -1- above the linkage of the pressure
unit -arrow- in such a way that the bypass flap can still be
turned manually in its position.
– Tighten the counternut by hand.
– Fit together the hand vacuum pump -VAS 6213- , the turbo‐
charger tester -V.A.G 1397 A- with connection II and the
pressure control valve -VAS 6342- as shown in the figure.
– Connect the pressure control valve -VAS 6342- at lever -1-.
– Push the switch-over ring -2- of the hand vacuum pump -VAS
6213- in the -direction of arrow- to the manometer.
– Switch on the turbocharger tester -V.A.G 1397 A- and position
the sliding switch to position II.

OCTAVIA II 2004 ➤
– Attach universal dial gauge holder -MP3-447- to exhaust tur‐

bocharger -arrow-.
– Attach the dial gauge -VAS 6341/1- with 30 mm extension -
VAS 6341/3- and flat button -VAS 6341/4- at the universal dial
gauge holder -MP3-447- .
– At 0°MPa (0°bar) set the dial gauge -VAS 6341/1- to 1 mm
preload.
– Turn the readout of the dial gauge -VAS 6341/1- to 0 (zero).
– Test the smooth operation of the dial gauge.
– Operate the hand vacuum pump -VAS 6213- until the turbo‐
charger tester -V.A.G 1397 A- displays 0.035 MPa ±
0.0005 MPa (0.35 bar ± 0.005 bar).
– The dial gauge must indicate 4.1...4.3 mm, otherwise turn the
linkage of the pressure unit until the value is indicated.
– Tighten the counternut by hand.
– Repeat measurement.
Note
The mm details relate to the read off value (containing 1 mm pre‐

load).
– Release the pressure via the pressure control valve -VAS

6342- to 0 MPa (0 bar).
– Position dial gauge -VAS 6341/1- to 0 (zero).
Note
♦ Observe the sequence of the following measurements.

♦ In-between the pressure must not be released to 0 MPa
(0 bar).
charger tester -V.A.G 1397 A- displays 0.035 MPa ±
0.0005 MPa (350 mbar ± 5 mbar).
– Read off value on the dial gauge -VAS 6341/1- (value 1) and
note.
charger tester -V.A.G 1397 A- displays 0.065°MPa to 0.070
MPa (650 mbar to 700 mbar).
– Release the pressure via the pressure control valve -VAS
6342- to 0.035 MPa ± 0.0005 MPa (350 mbar ± 5 mbar).
– Read off value on the dial gauge -VAS 6341/1- (value 2) and
note.
– Add value 1 and 2 together and divide by 2.
• The result (mean value) must be 5 ± 0.25 mm.
If the result (mean value) is not 5 ± 0.25 mm:
– Adjust the setting, tighten the counternut by hand and repeat
measurement.
If the result (mean value) is 5 ± 0.25 mm:
– Tighten counternut to 5 Nm and secure with seal paint ⇒ elec‐
tronic catalogue of original parts .

OCTAVIA II 2004 ➤
– Attach the lock washer above the linkage of the pressure unit
to the exhaust turbocharger. Check the lock washer for secure
catch.

OCTAVIA II 2004 ➤
2 Charge air system with exhaust gas

turbocharger
– Observe the general notes for assembly work on the charge
air system with exhaust gas turbocharger ⇒ page 10 .
2.1 Charge air cooling - Summary of components
1 - 7 Nm
2 - Bearings
❑ for charge air cooler
3 - Charge air cooler
❑ with top and bottom seal
fitted
⇒ page 217
4 - Charge air pipe
5 - 8 Nm
6 - from exhaust turbocharger
7 - Charge air hose
8 - to throttle valve control unit
-J338-
9 - Clamp
10 - Charge air hose
11 - 8 Nm
12 - Charge air pipe
13 - Charge air hose
14 - Charge pressure sender -
G31-
15 - 5 Nm
2.2 Removing and installing charge air cool‐

er
Removing
– Remove radiator ⇒ page 163 .
2. Charge air system with exhaust gas turbocharger 217

OCTAVIA II 2004 ➤
– Remove the charge air hoses on the left and right -arrows-
from the charge air cooler.
– Unscrew fixing screws for charge air cooler on right and left
( ⇒ page 217 , Pos. 1).
WARNING

tem.
Caution
In order to avoid damage to the condenser as well as to the

Note
For the following operations a second mechanic is required to

hold the charge air cooler.
– Unhook the charge-air cooler upwards out of the lower bear‐

ings and swivel it backwards.
– Unscrew the side screw -1- on the bottom right for attaching
the coolant lines on the charge-air cooler.
– Screw out the fixing screws -1- of the condenser.

– Remove charge air cooler downwards.
Install
following points:
– For this step, observe the assembly instruction for hose con‐
nections with push-fit couplings ⇒ page 219 .

OCTAVIA II 2004 ➤
2.3 Hose connections with push-fit cou‐

plings
Caution
The gasket ring for the push-fit coupling can be damaged, if

the locking clip is in the lock position during the assembly. This
could result in a leakage. Observe the assembly instruction.
Removing
– Release push-fit coupling by pulling the locking clip -arrow-.
Disconnect hose/pipe without auxiliary tool.
Install
– When replacing the gasket ring, place the gasket ring in the
groove of the charge air hose. Make sure that the gasket ring
is fully seated all around in the groove and not twisted.
– Oil the sealing surface and the gasket ring.
– Put the locking clip into the release position -1-.

– Insert the charge air hose up to the stop into the coupling.
– Put the locking clip into the lock position -2- and then press
down once again the charge air hose.
– Check for correct seating and the correct locking in place of
the push-fit coupling by pulling on the hose.

OCTAVIA II 2004 ➤
2.4 Hose connections with screw clamps
Note
♦ Connections, charge air pipes and hoses of charge air system

must be free of oil and grease before being installed.
♦ Only install approved screw clamps for securing the hose con‐
nections ⇒ Electronic Catalogue of Original Parts .
♦ In order to secure the charge air hoses on their connection
fittings, the endless screws must be sprayed with rust solvent
if the screw clamps have been used beforehand.
♦ After a repair, check all the charge air pipes, charge air hoses
and vacuum lines for tight connection and leaktightness.
Caution
The screw clamps -A- on the charge air hoses must definitely
be precisely tightened in accordance with the specifications
⇒ page 220 .
♦ A too low or on the contrary, a too high torque of the screw
clamps, may result in the charge air hose slipping off the
fluted pipe or the charge air pipe while driving.
Tightening torques of screw clamps

1- Screw clamp -a- = 12 mm: 5.5 Nm
2- Screw clamp -b- = 9 mm: 3 Nm

OCTAVIA II 2004 ➤
2.5 Overview plan for the exhaust turbocharging
1 - Pressure box
pressure control -N75 -
3 - Turbocharger divert air
valve -N249-
5 - Brake servo unit
7 - Coolant flange
8 - Vacuum pump
solenoid valve 1 -N80-
12 - Double non-return valve
13 - Charge air cooler
14 - Throttle valve control unit
-J338-
15 - Pressure control valve
16 - to the activated charcoal
filter system
17 - Air mass meter -G70-
2.6 Checking the charge-air system for

leaktightness
♦ Charge-air system testing device , e. g. -V.A.G 1687-
♦ Adapter , e.g. -V.A.G 1687/5-
♦ Ultrasonic measuring device e. g. -V.A.G 1842-
Gr. 50 .

OCTAVIA II 2004 ➤
– Release the clasp -A- and pull off the hose -B- from the charge
air pipe.
– Mount the adapter -V.A.G 1687/5- onto the charge air hose
-A- and turn it to approx. 90° -B-.
Prepare tester for charge air system -V.A.G 1687- as follows:
– Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
– Connect tester for charge air system -V.A.G 1687- , as shown.

OCTAVIA II 2004 ➤
– Connect the pneumatic hose -1- (pneumatic support) at tester

for charge air system -V.A.G 1687- .
Note
If there is water in the inspection glass, drain water via the drain
plug -6-.
– Open valve -3-.

– Set the pressure to 0.05 MPa (0.5 bar) with the pressure con‐
trol valve -2-.
Caution
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
– Open valve -4- and wait until the test circuit is filled. If neces‐
sary regulate the pressure to 0.05 MPa (0.5 bar).
– Listen to, touch or use commercially available leak search
spray or the ultrasonic measuring device -V.A.G 1842- to
check the charge-air system for leak points.
Note
♦ A small amount of air escapes via the valves into the engine.
For this reason no pressure test is possible.
♦ Use of ultrasonic measuring device -V.A.G 1842- ⇒ operating
instructions .
♦ Before removing the adapter, depressurize the test circuit by
detaching the coupling from the adapter -V.A.G 1687/5- .
♦ Hose connections and hoses of the charge air system must
be free of oil and grease before being installed.

OCTAVIA II 2004 ➤
24 – Fuel Formation, Injection

1 Fitting locations of the injection sys‐
tem, Engine identification characters
1 - Solenoid valve 1 for activa‐

ted charcoal filter -N80-
2 - Motronic control unit -J220-
⇒ page 271
3 - Exhaust gas recirculation
valve -N18- with exhaust gas
recirculation potentiometer -
G212-
❑ not fitted for engine
identification characters
BLY, BVZ
4 - Camshaft adjustment valve
1 -N205-
5 - 6-pin plug
❑ for lambda probe -G39-
and heating for lambda
probe -Z19- (black)
❑ for lambda probe 2 -
G108- and heating for
lambda probe 2 -Z28-
(brown), not fitted for en‐
gine identification char‐
acters BLY, BVZ
er -G62-
7 - Fuel pressure regulating
valve -N276-
8 - High pressure pump
❑ Summary of compo‐
nents and removing and
installing ⇒ page 236
er at radiator outlet -G83-
10 - Intake air temperature sender 2 -G299-
11 - Intake manifold pressure sender -G71- with intake air temperature sender -G42-
❑ with throttle valve drive -G186 - , throttle valve drive angle sender 1 -G187- and throttle valve drive angle
sender 2 -G188- .
❑ after replacing, the engine control unit must be adapted ⇒ Vehicle diagnosis, testing and information
system VAS 5051
224 Rep. Gr.24 - Fuel Formation, Injection

OCTAVIA II 2004 ➤
13 - 8-pin plug connection for injection valves

14 - Vacuum pump
15 - Ignition coils with a power output stage
❑ Ignition coil 1 with a power output stage -N70-
16 - Fuel pressure sender -G247-
17 - Valve for variable intake manifold changeover -N156-
18 - Right engine front side (in the direction of travel)
❑ Fuel pressure sender for low pressure -G410-
❑ Valve for variable intake manifold changeover -N156-
❑ 3-pin plug connection of engine speed sender -G28-
❑ Thermostat for map-controlled engine cooling -F265-
❑ 3-pin plug connection for knock sensor 1 -G61-
1. Fitting locations of the injection system, Engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ 225
OCTAVIA II 2004 ➤
2 Fitting locations of the injection sys‐

tem, engine identification character
BWA

Components A to F are not shown on the figure.

pressure control -N75-
❑ fitted directly at the ex‐
haust turbocharger
⇒ page 230
2 - Turbocharger divert air
valve -N249-
❑ fitted directly at the ex‐
haust turbocharger
⇒ page 230
3 - Motronic control unit -J220-
⇒ page 271
4 - Ignition coils with a power
output stage
⇒ page 296
❑ Ignition coil 1 with a
power output stage -
N70-
N127-
N291-
N292-
❑ the ignition coils must be
pulled out of the cylinder
head with the extractor -
T40039 -
5 - lambda probe -G39- and
heating for lambda probe -Z19-
6 - Fuel pressure sender for low pressure -G410-
❑ Tightening torque: 15 Nm
7 - Control valve for fuel pressure -N276-
8 - Camshaft adjustment valve 1 -N205-
9 - Coolant temperature sender -G62-
❑ ⇒ page 228
10 - 6-pin plug
❑ for lambda probe -G39- and heating for lambda probe -Z19- (black) ⇒ page 229

OCTAVIA II 2004 ➤

12 - Intake manifold flap motor -V157- with intake manifold flap potentiometer -G336-
❑ after replacing the fuel distributor the intake manifold flap potentiometer -G336- must be adapted again
to the Motronic control unit -J220- ⇒ Vehicle diagnosis, testing and information system VAS 5051
13 - Engine speed sender -G28 -
❑ ⇒ page 229
14 - Solenoid valve 1 for activated charcoal filter -N80-
15 - Plug connection for Hall sender -G40- and fuel pressure sender -G247 -
❑ ⇒ page 229
16 - Charge pressure sender -G31-
❑ ⇒ page 230
17 - Plug for the injection valves
❑ ⇒ page 229
18 - Throttle valve control unit -J338- , throttle valve drive for electronic power control -G186-
❑ Angle sender 1 for throttle valve drive for electronic power control -G187- and angle sender 2 for throttle
valve drive for electronic power control -G188-
❑ in case of replacement, erase initialisation values and adapt the engine control unit to the throttle valve
control unit ⇒ Vehicle diagnosis, testing and information system VAS 5051
❑ ⇒ page 229
20 - Intake air temperature sender -G42-
❑ ⇒ page 230
21 - Fuel pressure sender -G247 -
❑ ⇒ page 228
22 - Hall sender -G40- (camshaft position sensor)
❑ Plug connection ⇒ page 228
A - Air mass meter -G70-
❑ in air filter top part ⇒ page 228
B - 3-pin plug connection for knock sensor 1 -G61-
❑ ⇒ page 229
C - 3-pin plug connection for knock sensor 2 -G66-
❑ ⇒ page 229
D - Knock sensor 1 -G61-
❑ for cylinder 1 and 2
the tightening torque influences the knock sensor function
❑ ⇒ page 229
E - Knock sensor 2 -G66-
❑ for cylinder 3 and 4
the tightening torque influences the knock sensor function
❑ ⇒ page 229
F - Oil pressure switch -F1 -
❑ ⇒ page 229
2. Fitting locations of the injection system, engine identification character BWA 227
OCTAVIA II 2004 ➤
Coolant temperature sender -G62- -1-
Fuel pressure sender -G247 - -1-

Hall sender -G40- -1-
Air mass meter -G70- -1-

OCTAVIA II 2004 ➤
Plug connection -1- of lambda probe -G39- and heating for lamb‐
da probe -Z19-
Coolant temperature sender at radiator outlet -G83-

1 - Coolant temperature sender at radiator outlet -G83- , in front
of the coolant regulator housing
Plug connections
1 - 3-pin plug connection (green) for knock sensor 1 -G61-
2 - 3-pin plug connection (brown) for knock sensor 2 -G66-
3 - Oil pressure switch -F1 -
4 - Engine speed sender -G28-
5 - 3-pin plug connection (green) for engine speed sender -G28-
Fitting locations below the intake manifold

1 - Knock sensor 1 -G61-
3 - Oil pressure switch -F1 -
4 - 3-pin plug connection (brown) for knock sensor 2 -G66-
5 - 3-pin plug connection (green) for engine speed sender -G28-
6 - Plug connection for Hall sender -G40- and fuel pressure send‐
er -G247 -
7 - 8-pin plug connection for injection valves
2. Fitting locations of the injection system, engine identification character BWA 229
OCTAVIA II 2004 ➤
Sender
2 - Charge pressure sender -G31-
Components at exhaust turbocharger

1 - Tighten turbocharger divert air valve -N249- to 7 Nm. Check
fitting position ⇒ page 230 .
2 - Tighten charge pressure control solenoid valve -N75- to 3 Nm.
Fitting location of the turbocharger divert air valve -N249-

-arrows-

OCTAVIA II 2004 ➤
3 Injection system - Summaries of

components, engine identification
characters BLR, BLX, BLY, BVX,
BVY, BVZ
3.1 Intake manifold - Summary of components
1 - Vacuum hose
2 - Vacuum reservoir
3 - 5 Nm
BLX, BVX, BVY
4 - Top connection pipe
❑ for exhaust gas recircu‐
lation
BLX, BVX, BVY
5 - Vacuum hose
❑ with non-return valve
6 - Crankcase ventilation hose
7 - Sealing ring
BLX, BVX, BVY
8 - Cable strap
9 - 8 Nm
10 - Throttle valve control unit
-J338-
❑ with throttle valve drive
for electronic power
control -G186- , angle
sensor 1 for throttle
valve drive for electronic
power control -G187-
and angle sensor 2 for
throttle valve drive for
electronic power control -G188-
❑ when replacing, adapt the engine control unit ⇒ Vehicle diagnosis, testing and information system VAS
5051
❑ Clean throttle valve control unit ⇒ page 261
11 - Connection for suction jet pump
12 - Sealing ring
3. Injection system - Summaries of components, engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ 231
OCTAVIA II 2004 ➤
13 - Intake manifold pressure sender -G71- with intake air temperature sender -G42-
14 - 3 Nm
15 - O-ring
❑ replace
16 - 10 Nm
17 - Rubber-metal bearing, 3 Nm
18 - Intake manifold support
19 - 25 Nm
20 - 40 Nm
21 - Sealing ring
22 - Sealing ring
23 - Switching roller
24 - 7 Nm
25 - Cover
26 - Valve for variable intake manifold changeover -N156-
27 - Vacuum setting element
29 - Connection for activated charcoal filter system solenoid valve 1 -N80-

OCTAVIA II 2004 ➤
3.2 Suction jet pump - Summary of components
1 - to the connection of the

brake servo unit
2 - Pressure sensor for the
brake servo unit -G294-
3 - Sealing ring
4 - Connecting hose
❑ Vehicles with automatic
gearbox have an addi‐
tional connection for the
brake vacuum pump -
V192-
5 - Hose
❑ to suction hose
7 - Suction spray pump
8 - Hose
❑ To intake manifold
9 - Gasket
OCTAVIA II 2004 ➤
3.3 Fuel distributor with intake manifold flap motor -V157- - Summary of com‐
ponents, engine identification characters BLR, BLX, BLY
1 - Fuel pressure sender for

low pressure -G410 - , 15 Nm
2 - Low pressure pipe
Note
❑ do not install under ten‐

sion
❑ Tighten union nut to 22
Nm
3 - 10 Nm
4 - Gasket
❑ replace
5 - Fuel distributor
❑ with intake manifold flap
motor -V157- with intake
manifold flap potentiom‐
eter -G336-
❑ when replacing, adapt
⇒ Vehicle diagnosis,
testing and information
system VAS 5051
⇒ page 247
6 - CLIC-hose clamps
❑ fasten with pliers für
CLIC-hose clamps , e.
g. -V.A.G 1723-
7 - Coupling piece
8 - High pressure pipe
sion
9 - Hollow screw, 15 Nm
❑ with conical seal seating
❑ replace
❑ pay attention to cleanliness
10 - 10 Nm
11 - Cable rail
❑ with plug for the injection valves
12 - Pressure limiting valve, 30 Nm
13 - Fuel pressure sender -G247- , 22 Nm
❑ Moisten thread and sealing cone with clean engine oil

OCTAVIA II 2004 ➤
14 - 10 Nm
15 - Cable strap
16 - Injection valve for cylinder 1 -N30- to injection valve for cylinder 4 -N33-
3.4 Fuel distributor with intake manifold flap motor -V157- - Summary of com‐
ponents, engine identification characters BVX, BVY, BVZ
Note

sion
Nm
2 - 10 Nm
3 - Gasket
❑ replace
motor -V157- with intake
manifold flap potentiom‐
eter -G336-
system VAS 5051
⇒ page 247
5 - CLIC-hose clamps
❑ fasten with pliers für
CLIC-hose clamps , e.
g. -V.A.G 1723-
6 - Coupling piece
sion
8 - Hollow screw with conical
seal seating, 15 Nm
❑ replace
9 - 10 Nm
10 - 10 Nm
11 - Cable rail
❑ with plug for the injection valves
OCTAVIA II 2004 ➤
12 - Pressure limiting valve, 30 Nm

14 - Cable strap
15 - Injection valve for cylinder 1 -N30- to injection valve for cylinder 4 -N33-
3.5 High pressure pump - Summary of components, Engine identification char‐

acters BLR, BLX, BLY, BVX, BVY, BVZ
1 - Tappet
2 - Sealing ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
❑ with fuel pressure regu‐
lating valve -N276 -
Caution
Do not loosen the threa‐
ded neck for low pres‐
sure and high pressure
connections - risk of
damage to the high pres‐
sure pump!

⇒ page 262
4 - Dust cap for vent valve
5 - 10 Nm
❑ counterhold the threa‐
ded connection fitting on
the high pressure pump
for loosening
❑ replace
❑ pay attention to cleanli‐
ness
❑ Observe the safety measures for reducing pressure in the high pressure area ⇒ page 6
❑ before installing, check that the threaded neck on the high pressure pump has a tightening torque of 40
Nm

OCTAVIA II 2004 ➤
❑ counterhold the threaded connection fitting on the high pressure pump for loosening
❑ replace
❑ before installing, check that the threaded neck on the high pressure pump has a tightening torque of 30
Nm
3.6 Air filter - Summary of components

The positions 21 to 28 are only present on vehicles with “cold
weather equipment”.
1 - Air filter cover

2 - 2 Nm
3 - 8 Nm
4 - 2 Nm
5 - Support
6 - to connection for suction jet
pump
8 - Air intake hose
9 - O-ring
❑ replace
10 - Intake air temperature
sender 2 -G299-
11 - Filter element
12 - Air filter housing
13 - Pre-cubic contents
14 - 20 Nm
15 - Intake air duct
16 - Snap nut
17 - Air duct
❑ to the lock carrier
18 - 2 Nm
19 - Air catcher
20 - Slider
21 - Induction pipe
22 - Grommet
23 - Bushing
24 - 8 Nm
26 - Air guide hose
27 - Regulator box
28 - 2 Nm
OCTAVIA II 2004 ➤
4 Injection system - Summary of com‐

ponents, engine identification char‐
acter BWA
4.1 Intake manifold - Summary of components
1 - 10 Nm
2 - Bushing
3 - 3 Nm
5 - Gasket
❑ replace
6 - Intake manifold
❑ with intake manifold
flaps
⇒ page 250
7 - Coupling rod
8 - Intake manifold flap motor -
V157-
potentiometer -G336 -
⇒ page 253
9 - 7 Nm
10 - to the activated charcoal
filter system
11 - Hose
solenoid valve 1 -N80-
13 - Hose
14 - Double non-return valve
15 - Intake manifold support
16 - 25 Nm
17 - 10 Nm
18 - Rubber-metal bearing, 8 Nm
❑ with throttle valve drive for electronic power control -G186- , angle sensor 1 for throttle valve drive for
electronic power control -G187- and angle sensor 2 for throttle valve drive for electronic power control -
G188-
❑ in case of replacement, erase initialisation values and adapt the engine control unit to the throttle valve
control unit ⇒ Vehicle diagnosis, testing and information system VAS 5051

OCTAVIA II 2004 ➤
20 - 7 Nm
21 - Sealing ring
22 - 5 Nm
24 - 10 Nm
4.2 Fuel distributor - Summary of component

Vehicles up to 03.2006
1 - Injection valve for cylinder 1

-N30- to injection valve for cyl‐
inder 4 -N33-
⇒ page 256
2 - 5 Nm
❑ the fuel distributor must
be removed together
with the intake manifold
⇒ page 254
4 - Plate nut
5 - Pressure limiting valve, 30
Nm
Note

sion
Nm
7 - Support
sion
❑ Tighten union nut at fuel
distributor to 33 Nm
❑ Tighten the union nut on
the high pressure pump
to 27 Nm.
9 - 3 Nm
10 - Connector
❑ for injection valves
11 - Connector
❑ for fuel pressure sender -G247- and Hall sender -G40-
12 - Connector
4. Injection system - Summary of components, engine identification character BWA 239

OCTAVIA II 2004 ➤
13 - Cable rail
14 - Retaining clip
❑ hang at bottom right on sleeve of intake manifold
15 - Connector
❑ for hall sender -G40-
16 - Connector
❑ for fuel pressure sender -G247-
17 - 5 Nm
Vehicles as of 04.2006
1 - Injection valve for cylinder 1

-N30- to injection valve for cyl‐
inder 4 -N33-
⇒ page 256
2 - 5 Nm
❑ the fuel distributor must
be removed together
with the intake manifold
⇒ page 254
4 - Low pressure fuel hose
❑ to high pressure pump
5 - Pressure limiting valve, 30
Nm
6 - Plate nut
Note

sion
Nm
8 - Support
Note

sion
❑ Tighten the union nuts on the fuel distributor and on the high pressure pump to 27 Nm

OCTAVIA II 2004 ➤
10 - 3 Nm
11 - Connector
12 - Connector
❑ for fuel pressure sender -G247- and Hall sender -G40-
13 - Connector
14 - Cable rail
15 - Retaining clip
❑ hang at bottom right on sleeve of intake manifold
16 - Connector
❑ for hall sender -G40-
17 - Connector
❑ for fuel pressure sender -G247-
18 - 5 Nm
20 - Screw neck, 30 Nm

OCTAVIA II 2004 ➤
4.3 High pressure pump - Summary of components, Engine identification char‐

acter BWA
Note
As of 04.2006, the pipe with hollow screw of the low-pressure line on the high pressure pump was changed to
the hose connection with spring strap clamp.
1 - Tappet
2 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
❑ with fuel pressure regu‐
lating valve -N276 -
⇒ page 265
4 - 10 Nm
5 - Union nut, 27 Nm
Note
❑ do not install high pres‐

sure pipe under tension
❑ Observe the safety
measures for reducing
pressure in the high
pressure area ⇒ page 6
❑ Vehicles as of 04.2006
❑ only replace if it was de‐
tached
❑ When replacing the
screw neck, absolutely
leave the old gasket ring
in the high pressure
pump. Before the first in‐
stallation it is crimped at
the supplier and cannot be removed. Thus, the new screw neck has a “biting edge” for sealing.
8 - Low pressure fuel hose
❑ Vehicles as of 04.2006
❑ secure with spring strap clip
❑ Vehicles up to 03.2006
❑ counterhold the threaded neck on the high pressure pump for loosening
❑ replace

OCTAVIA II 2004 ➤

❑ before installing, check that the threaded connection piece on the high pressure pump has a tightening
torque of 30 Nm
11 - Threaded neck, 30 Nm
❑ only replace if it was detached
❑ When replacing the threaded neck, absolutely leave the old gasket ring in the high pressure pump. Before
the first installation it is crimped at the supplier and cannot be removed. Thus, the new screw neck has
a “biting edge” for sealing.
❑ for high pressure pipe
Caution
Do not loosen the screw
neck for high pressure
pipe - risk of damage to
the high pressure pump!
13 - Fuel pressure sender for low pressure -G410 - , 15 Nm

14 - Sealing ring
❑ replace

OCTAVIA II 2004 ➤
4.4 Air filter - Summary of components
1 - Air mass meter -G70-

2 - 3 Nm
3 - Air filter top part/engine cov‐
er
❑ observe the mounting
sequence when remov‐
ing ⇒ page 245
❑ disassembling
⇒ page 245
5 - Intake air duct
6 - Filter element
7 - 1.5 Nm
8 - Air filter bottom part
❑ observe the mounting
sequence when remov‐
ing ⇒ page 245
❑ disassembling
⇒ page 245
9 - 3 Nm
10 - Heat shield
11 - Rubber sleeve
❑ Observe assembly
marking
12 - Air intake hose
❑ Observe assembly
marking
13 - O-ring

OCTAVIA II 2004 ➤
5 Repairing the injection system
5.1 Remove and disassemble air filter/en‐

gine cover, engine identifcation BWA
Removing
– Remove intake hose -1-.
– Release the screws -3- and detach the hose.
Caution
Observe the sequence when removing the engine cover.
– Pull the engine cover in sequence from -arrow 1- to

-arrow 4- upwards with a sudden motion. Remove engine cov‐
er.
Dismantling
– Remove intake air duct -arrow-.
5. Repairing the injection system 245

OCTAVIA II 2004 ➤
– Separate engine cover. Pay attention to the catches

-arrows-.
5.2 Removing and installing intake mani‐

fold, engine identification characters
♦ Hose clamps up to ∅ 25 mm -MP7-602 (3094) -
♦ Pliers für CLIC-hose clamps , e. g. -V.A.G 1723-
Note
♦ Observe all safety measures and notes for assembly work on

♦ Use the explosion signs, which are illustrated on the previous
pages ⇒ page 231 .
Removing
– Detach vacuum lines -1- and -3- from vacuum reservoir.
– Disconnect the plug and the vacuum line -2- from the activated
charcoal filter system solenoid valve 1 -N80- .
BVY
– Remove connection pipe of exhaust gas recirculation
⇒ page 294 .
– Pull out oil dipstick.
– Pinch off the coolant hoses with the hose clamps -MP7-602-
at the throttle valve support. Open the spring strap clamps with
the pliers for spring strap clamps and disconnect the hoses.
– Disconnect all plug connections on the intake manifold.

OCTAVIA II 2004 ➤
– Detach the hose -1- of the crankcase ventilation from the cyl‐
inder head cover.
– Open the CLIC hose clamps -arrows- between intake manifold
and fuel distributor.
Note
Use pliers for hose clamps -V.A.G 1723- to fit the hose clamps.
– Unscrew fixing nuts -arrows-.

– Remove intake manifold upwards.
Install
following.
– Replace gasket for intake manifold.
5.3 Removing and installing fuel distributor

with intake manifold flaps, engine iden‐
tification characters BLR, BLX, BLY,
BVX, BVY, BVZ
Removing
WARNING

⇒ page 6 .

– Remove fuel hoses.

OCTAVIA II 2004 ➤
– Disconnect the plug connections at the fuel distributor

-arrows-.
– Remove pipe for crankcase ventilation -A-.
– Pull off the oil dipstick with guide tube -B- from the engine.
Note
When loosening the fuel pipes, counterhold the corresponding

screw neck.
– Unscrew screws -1- to -5- and remove the fuel pipes.
– Release the fixing screws -arrows- of the fuel distributor.

– Carefully disconnect the fuel distributor with intake manifold
flaps from the injection valves.
Install
following:
♦ The plugs must be placed onto the injection valves before in‐
stalling.
♦ If an injection valve was pulled out of the cylinder head during
removal of the fuel distributor, the Teflon gasket ring must be
replaced ⇒ page 258 .
♦ Replace O-rings between injection valves and fuel distributor
and moisten lightly with clean engine oil.
♦ If the fuel distributor was replaced, the intake manifold flap
potentiometer -G336- must be adapted to the engine control
unit ⇒ Vehicle diagnosis, testing and information system VAS
5051.
♦ Fit fuel distributor onto the cylinder head and press evenly onto
the injection valves.

OCTAVIA II 2004 ➤
– Tighten the fixing screws -arrows- of the fuel distributor to 10

Nm.
Note
Before installing the fuel pipes, check the tightening torque of the
corresponding screw neck.
♦ High pressure connection piece in the high pressure pump: 40

Nm
♦ Low pressure connection piece in the high pressure pump: 30
Nm
♦ Pressure limiting valve in fuel distributor: 30 Nm
– Install the fuel pipes with new hollow screws and first of all
tighten all the screws by hand.
– Tighten fixing screws of the high pressure pump to 10 Nm.
– Now tighten the screws/union nut -1- to -5- in the following

sequence:
1 - Fixing screws -1- to 10°Nm
2 - Hollow screw -2- to 15 Nm
5 - Union nut -5- to 22 Nm
5.4 Removing and installing fuel pressure

sender -G247- , engine identification
characters BLR, BLX, BLY, BVX, BVY,
BVZ
♦ Open ring spanner with 3/8" drive, wrench size 27mm , com‐
mercially available
♦ Assembly tool -T10118-
Removing
Note

⇒ page 5 .
⇒ page 7 .
WARNING

⇒ page 6 .

OCTAVIA II 2004 ➤
– Disconnect the hoses and the plug from the vacuum reservoir
-A- and remove the reservoir.
– Release the plug from the fuel pressure sender -G247- with
the assembly tool -T10118- and disconnect -arrow-.
– First of all position the open ring spanner -A- on the fuel pres‐
sure sender -G247- . Then insert an extension in the open ring
spanner.
– Unscrew the fuel pressure sender -G247- .
Install
following:
– Moisten thread and sealing cone of fuel pressure sender -
G247- with clean engine oil.
Tightening torque: 22 Nm.
5.5 Removing and installing the intake

manifold, engine identification character
BWA
Note
♦ Observe all safety measures and notes for assembly work on

♦ Use the explosion signs, which are illustrated on the previous
pages ⇒ page 238 .

OCTAVIA II 2004 ➤
Removing
WARNING

⇒ page 6 .
– Open warm-type clamp -1- and detach the hose -2- from the
intake manifold.
– Disconnect the pipe/hose connections -arrows-.

– Mark the cables and remove the spring strap clamps -1- and
-2-.
– Pull off the cables (collect fuel which flows out).
– Detach the pipe -3- at the oil filter holder and remove it up‐
wards.
– Unscrew the fuel pipe -4- from the support -3-. While doing so,
counterhold supports -3-.
– Release hollow screw -2- on the high pressure pump. While
doing so, counterhold supports -1-.

OCTAVIA II 2004 ➤
– Open the spring strap clamp -1- and pull off the fuel hose.
– Remove the intake manifold support -right arrows- e.g. with

the tool XZN 10 (length 120 mm), commercially available.
– Disconnect the plug -left arrow- from the fuel pressure sender
-G247- .
– Release all screws and nuts from the intake manifold.
– Carefully pull off the intake manifold with fuel distributor from
the cylinder head.
Note
♦ If one or several injection valves should remain stuck in the

intake manifold, the plug connections on the injection valves
must be removed.
♦ If injection valves in the intake manifold are stuck, the com‐
bustion chamber gasket ring (Teflon gasket ring) and the O-
ring must be replaced ⇒ page 258 for these injection valves.
– Remove fuel distributor ⇒ page 254 .

Install
following.
– If necessary install injection valves ⇒ page 256 .
– Replace gasket for intake manifold.
– Fit the plugs -arrows- on the injection valves.

– Position the cable rail -2- with the left mount in front of the
threaded pin -1-.
– Fit the intake manifold approx. 1 cm onto the threaded pins
-1- and -4-.
– Push the cable rail -2- onto the three sleeves of the intake
manifold.
Note
Check if the cable rail has been pushed onto the sleeve of the
threaded pin -1-.
– Push the intake manifold up to the stop onto the threaded pins
-1- and -4-.
– Fasten the clip -3- on the right sleeve of the intake manifold
(at threaded pin -4-).

OCTAVIA II 2004 ➤
– Install the pipe -3- and fit on the oil filter holder.
– Installing the intake manifold ⇒ page 238 .
Note
corresponding screw neck on the high pressure pump.
♦ High pressure connection piece: 40 Nm

♦ Low pressure connection piece (vehicles up to 03.2006): 30
Nm
– Install fuel pipes on high pressure pump ⇒ page 242 (replace
hollow screw).
If the intake manifold flap motor -V157- or the intake manifold was
replaced, the potentiometer for intake manifold flap -G336- must
be adapted to the engine control unit ⇒ Vehicle diagnosis, testing
and information system VAS 5051.
5.6 Removing and installing intake manifold

flap motor -V157- with intake manifold
flap potentiometer -G336-
♦ Commercially available 1/4" bit reverse ratchet
♦ Bit insert T30
Removing
– Remove engine cover/air filter ⇒ page 245 .
– Detach vacuum lines -arrows-.
– Disconnect following plugs:
Note
Plugs which are difficult to reach can be more easily opened using
the assembly tool -T10118- .
♦ Plug for intake manifold flap motor -V157-

♦ Plug for activated charcoal filter solenoid valve 1 -N80-
♦ Plug for intake manifold pressure sender -G71-
♦ Plug for throttle valve control unit -J338 -
♦ Plug for fuel pressure sender for low pressure -G410-

OCTAVIA II 2004 ➤
– In addition, disconnect plug connections -arrows-.

– Release the cable clip -A- and lay the complete cable harness
to the side.
– Unscrew the bracket for the plugs -arrows- from the coolant
pipe.
Note
The nut -left arrow- must only be loosened until the bracket can
be swiveled to the side.
– Lever off the coupling rod -arrow- from the intake manifold flap
motor -V157- .
– Screw out the screws -1- and -2- “from above” with 1/4" bit
reverse ratchet and bit insert T30 .
– Remove the intake manifold flap motor -V157- from the intake
manifold.
Install
following points:
– Position screws -1- and -2- by hand in order to avoid damage

to the thread.
If the intake manifold flap motor -V157- or the intake manifold was
replaced, the potentiometer for intake manifold flap -G336- must
be adapted to the engine control unit ⇒ Vehicle diagnosis, testing
and information system VAS 5051.
5.7 Removing and installing the fuel distrib‐

utor, engine identification character
BWA
Removing

OCTAVIA II 2004 ➤
– Unscrew bolts -1-.

– Lever off the fuel distributor -arrows- from both studs -2-.
– Unscrew both bottom screws -arrows-.

– Detach hose connection -6- from intake manifold.
– Release the screw -1- and unscrew the union nut -4-. While
doing so, counterhold the pressure limiting valve.
– Unscrew union nut -5-.
Note
During this procedure, counterhold the screw neck on vehicles as

of 04.2006.
– Carefully lever off the linkage -3- from the intake manifold flap
motor -V157- .
– Release screws -2- and remove the intake manifold flap motor
-V157- .
– Pull the fuel distributor out of the mounts -7- of the intake
manifold.
Install
Installation is carried out in the reverse order.
♦ Before installing the low pressure pipe, check that the pres‐
sure limiting valve in the fuel distributor has a tightening torque
of 30 Nm.
♦ On vehicles as of 04.2006, check that the screw neck in the
fuel distributor has a tightening torque of 30 Nm before instal‐
ling the high pressure pipe.
♦ Tightening torques: ⇒ page 239
5.8 Removing and installing the fuel pres‐

sure sender -G247- , engine identifica‐
tion character BWA
♦ Socket wrench insert 27 mm , e.g. -VAS 5301/7-
Note
ness ⇒ page 5 .

OCTAVIA II 2004 ➤
Removing
WARNING

⇒ page 6 .
– Release the screw -5- and the nut -2-.

– Pull off the coolant pipe -5- from the threaded pin -3-.
– Unscrew threaded pin -3-.
– Pull off the filler funnel -1- ( ⇒ page 120 , Pos. 3) to the top
from the guide tube ( ⇒ page 120 , Pos. 4).
Note
If there is any resistance press off with suitable tool from below.
– Release the plug from the fuel pressure sender -G247- with
the assembly tool -T10118- .
– Screw out the fuel pressure sender -G247- with the socket
wrench insert 27 mm .
Install
– Moisten sealing cone of fuel pressure sender -G247- with
clean engine oil.
Moisten thread and sealing cone of fuel pressure sender -G247-
with clean engine oil.
Tightening torque: 22 Nm.
5.9 Removing and installing injection valves

♦ Set of tools -T10133-

OCTAVIA II 2004 ➤
Injection valve - Individual parts

1 - Replace radial balancing element if damaged.
2 - Replacing the combustion chamber gasket ring (Teflon gasket
ring).
Caution
♦ When installing, the combustion chamber gasket ring

(Teflon gasket ring) must not be greased ot treated with a
lubricant.
3 - Groove on injection valve

4 - Supporting washer, replace
5 - O-ring, replace. Before fitting moisten lightly with clean engine
oil.
6 - Supporting ring
Removing
– Removing the intake manifold.
BVX, BVY, BVZ: ⇒ page 246
♦ Engine identification character BWA: ⇒ page 250
– Break off the plastic catch pegs -1- of the radial balancing el‐
ement with a screwdriver and pull off the supporting ring -2-
from the injection valve.
Note
♦ For the metal version of the radial balancing element, bend the
catch peg to the inside.
♦ The radial balancing element must be replaced when installing
the injection valve again.
– Screw the striking hammer -T10133/3- with the extractor -

T10133/2A- . Then insert the extractor -T10133/2A- into the
groove on the injection valve and carefully knock out the in‐
jection valve.
Install
Caution
When installing, the combustion chamber gasket ring (Teflon

gasket ring) must not be greased ot treated with a lubricant.
Note
An open inlet valve can possibly prevent a cleaning. In this case

it will be necessary to rotate the engine on the crankshaft with a
wrench by hand.

OCTAVIA II 2004 ➤
– Thoroughly clean the holes of the high pressure injection

valves in the cylinder head with the nylon brush -T10133/4- .
– Replace the O-ring and the Teflon gasket ring of the injection
valve ⇒ page 258 .
Note
The injection valve must insert easily, if necessary wait until the
gasket ring has been drawn together sufficiently.
– Insert the injection valve with the drift pin -T10133/9 - up to the
stop into the hole in the cylinder head.
– Pay attention to the correct position of the injection valves in

the cylinder head -arrow-.
– If the injection valves were replaced, erase the learned values
and re-adapt the engine control unit ⇒ Vehicle diagnosis, test‐
ing and information system VAS 5051.
5.10 Replacing Teflon gasket ring at injection

valve
Precondition
• Injection valve removed ⇒ page 256
♦ Set of tools -T10133-
Caution
The Teflon gasket ring must not be oiled.

OCTAVIA II 2004 ➤
– Carefully clean the injection valve in the area of the gasket ring
-arrow-. Remove the existing deposits (carbon deposits) with
a wire brush.
– Carefully cut open the gasket ring with a knife.
– Clean the gasket ring nut.
– Fit a new gasket ring onto the assembly cone -T10133/5 - .

Push the gasket ring with the assembly sleeve -T10133/6 - as
far as possible onto the assembly cone -T10133/5- .
– Turn the assembly sleeve -T10133/6- around and push the

gasket ring up to the end onto the assembly cone -T10133/5
-.
– Position the assembly cone -T10133/5 - onto the injection

valve and push the gasket ring with the assembly sleeve -
T10133/6- onto the injection valve.
– Remove the assembly cone -T10133/5- and push the gasket
ring with the assembly sleeve -T10133/6- into the groove.

OCTAVIA II 2004 ➤
– Press the calibration sleeve -T10133/7- with a slight rotary

movement (approx. 180°) up to the stop onto the injection
valve.
– Pull off the calibration sleeve -T10133/7- in reverse rotary
movement.
– Press the calibration sleeve -T10133/8- with a slight rotary

movement (approx. 180°) up to the stop onto the injection
valve.
– Pull off the calibration sleeve -T10133/8- in reverse rotary
movement.
– Replace the O-ring at the injection valve and the supporting
washer.
– Place the injection valve again with the supporting ring -1- and
clip on the radial balancing element -2- at the supporting ring.
5.11 Removing and installing throttle valve

control unit -J338 - , engine identification
character BWA
Removing

OCTAVIA II 2004 ➤
– Disconnect plug from charge pressure sender -G31- -3-.

– Slacken the clamp -1-, separate the quick coupling at the
charge air cooler and remove the charge air pipe with the hose
downwards.
– Release the screw -5- and the nut -2-.

– Pull off the coolant pipe from the threaded pin -3-.
– Unscrew threaded pin -3-.
– Pull off the filler funnel -1- ( ⇒ page 120 , Pos. 3) to the top
from the guide tube ( ⇒ page 120 , Pos. 4).
Note
If there is any resistance press off with suitable tool from below.
– Disconnect the plug connection on the throttle valve control

unit.
– Release the 4 screws of the throttle valve control unit -J338 -
and remove the throttle valve control unit.
Install
following:
♦ In case of replacement of the throttle valve control unit, erase
initialisation values and adapt the engine control unit to the
throttle valve control unit ⇒ Vehicle diagnosis, testing and in‐
5.12 Clean throttle valve control unit -J338-

BVX, BVY, BVZ
Note
If a new engine control unit is fitted, the throttle valve control unit
must be adapted. The adaptation must only be carried out with a
new or cleaned throttle valve control unit, because dirt/carbon
deposits in the end stop of the throttle valve can lead to incorrect
adaptation values.
– Slacken the air filter housing and pull off the intake hose from
the throttle valve support.

OCTAVIA II 2004 ➤

– Disconnect the coolant hoses on the throttle valve control unit
with the hose clamps up to ∅ 25 mm -MP7-602- .
– Detach the coolant hoses from the throttle valve control unit.
– Remove the throttle valve control unit.
♦ Vehicles with engine identification character BWA:
⇒ page 260
Note
The throttle valve support must not be scratched when cleaning.
– Open the throttle valve manually and block it in the opened

position with a suitable object -arrow-.
WARNING
Acetone is easily inflammable. Observe the accident preven‐

tion regulations and the safety instructions when handling
easily inflammable fluids. Do not use compressed air when
cleaning the throttle valve. Wear safety goggles and safety
clothing, in order to avoid injuries and skin contact with fuel.
– Thoroughly clean the throttle valve support, in particular the

area of the closed throttle valve -arrows-, with commercially
available acetone and a paint brush.
– Wipe the throttle valve support with a fluffy cloth.
– Let the acetone dry off completely and re-install the cleaned
throttle valve control unit.
– Adapt the engine control unit to the throttle valve control unit
⇒ Vehicle diagnosis, testing and information system VAS
5051.
5.13 Removing and installing high pressure

pump, engine identification characters
Note
♦ The high pressure pump must not be disassembled!

⇒ page 5 .
⇒ page 7 .

OCTAVIA II 2004 ➤
Removing
WARNING

⇒ page 6 .

– Remove the high pressure pipe and the low pressure pipe.
When loosening the connections, counterhold the correspond‐
ing screw neck.
– Release screws -arrows- from cable clip.

OCTAVIA II 2004 ➤
– Remove high pressure pump -arrows-.

– Take the tappet ( ⇒ page 236 , Pos. 1) out of the housing.
Install
Note
♦ The high pressure pump must be positioned with inserted fix‐

ing screws.
♦ The sealing area of the fuel pipes and the connection fittings
must not be damaged.
♦ The hollow screws for the fuel pipes must be replaced.
♦ The fuel pipes must be installed stress free.
– Replace the gasket ring of the high pressure pump and mois‐
ten it lightly with clean engine oil.
– Check the tappet ( ⇒ page 236 , Pos. 1) for damage and insert
it into the cylinder head.
– Carefully position the high pressure pump at the cylinder head
and tighten the screws only by hand.
Note
corresponding screw neck.
♦ High pressure connection piece in the high pressure pump: 40

Nm
♦ Low pressure connection piece in the high pressure pump: 30
Nm
♦ Pressure limiting valve in fuel distributor: 30 Nm
– Install the fuel pipes with new hollow screws. Tighten the
screws only by hand.
– Tighten fixing screws of the high pressure pump to 10 Nm.
– Now tighten the screws/union nut -1- to -5- in the following

sequence:
1 - Fixing screws -1- to 10°Nm
5 - Union nut -5- to 22 Nm
– Installing the intake manifold ⇒ page 246 .

OCTAVIA II 2004 ➤
5.14 Removing and installing the high pres‐

sure pump, engine identification charac‐
ter BWA
Note
♦ The high pressure pump must not be disassembled!

♦ Observe the safety instructions before starting fitting work
⇒ page 5 .
♦ Observe the rules for cleanliness ⇒ page 7 .
Removing
WARNING

⇒ page 6 .

– Release hollow screw -2- on the high pressure pump. While
– Open the spring strap clamp -1- and pull off the fuel hose.
– Unscrew the fuel pipe -3- from the connection piece -2-. While

OCTAVIA II 2004 ➤

– Release screws -arrows- and carefully pull out the high pres‐
sure pump.
Note
Under some circumstances the tappet ( ⇒ page 242 , Pos. 1) can

remain stuck in the cylinder head.
Install
Note
♦ The sealing area of the fuel pipes and the connection fittings
must not be damaged.
♦ The hollow screw for the fuel pipe (vehicles up to 03.2006)
must be replaced.
♦ Install fuel pipes not under tension.
– Replace the O-ring of the high pressure pump and moisten it

lightly with clean engine oil.
– Check the tappet ( ⇒ page 242 , Pos. 1) for damage and insert
it into the cylinder head.
– Carefully position the high pressure pump at the cylinder head

and tighten the screws -arrows- by hand.
Note
corresponding screw necks on the high pressure pump.
♦ High pressure connection piece: 40 Nm

♦ Low pressure connection piece (vehicles up to 03.2006): 30
Nm
– Screw on the fuel pipes by hand.
– Now tighten all the screws and the fuel pipes to the required
tightening torque ⇒ page 242 .
Further assembly occurs in reverse order.

OCTAVIA II 2004 ➤
6 Testing components
6.1 Test intake manifold changeover, En‐

gine identification characters BLR, BLX,
BLY, BVX, BVY, BVZ
♦ Hand vacuum pump , e.g. -V.A.G 1390- or -VAS 6213-
Note
ness ⇒ page 5 .
The test should only be carried out if there is a problem with a

poor torque. I.e. if insufficient elasticity or poor pulling power ex‐
ists.
Test condition
• The valve for variable intake manifold changeover -N156- was
checked with the ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
Test sequence
If the valve for variable intake manifold changeover -N156- is o.k.,
perform the following work procedure:
– Remove cover at vacuum setting element.
– The engine speed can suddenly be increased by a 2nd person
(high acceleration). Observe vacuum setting element for in‐
take manifold changeover.
• The adjustment rod must move in the -direction of the arrow-.
If the switch-over does not function as indicated:
– Check the vacuum system for tightness including the vacuum
reservoir on the intake manifold.
– Check smooth operation of changeover mechanism. To this
end activate the linkage by hand.
– Inspect vacuum lines to see that they are connected properly.
– Check vacuum hoses for porosity.
– Detach the vacuum hose to the variable intake manifold

changeover positioning element -arrow- at the variable intake
manifold changeover valve -N156- -2-.
– Connect the hand vacuum pump -VAS 6213- to the variable
intake manifold changeover positioning element.
6. Testing components 267

OCTAVIA II 2004 ➤

• The vacuum setting element must move -arrows-.
If the vacuum setting element does not move:
– Replace vacuum setting element.
6.2 Check double non-return valve, Engine

♦ Hand vacuum pump , e.g. -V.A.G 1390- or -VAS 6213-
– Disconnect the plug from the activated charcoal filter system
solenoid valve 1 -N80- and the fuel pressure sender for low
pressure -G410- -arrows-.
– Pull off the activated charcoal filter system solenoid valve 1 -
N80- -B- from the hose -A-.
– Connect the hand vacuum pump -VAS 6213- to the hose for
double non-return valve -arrow-.
• A vacuum should build up.
– Replace double non-return valve.
6.3 Check fuel pressure sender -G247-

♦ Pressure sensor tester , e.g. -VAS 6394-
♦ Test adapter -VAS 5570-
Work procedure
– Remove fuel pressure sender -G247- .
♦ Engine identification character BWA: ⇒ page 255

OCTAVIA II 2004 ➤
– Release the screw plug -2- and screw the fuel pressure sender
-G247- into the tester -VAS 6394/1- . Tightening torque 22 Nm.
– Moisten the sealing cone of the adapter -VAS 6294/2- with

clean engine oil and screw it into the fuel distributor. Tightening
torque: 22 Nm.
– Connect the pressure line of the tester -VAS 6394/1- to the

adapter -VAS 6394/2- -arrow-.
– Use the test adapter -VAS 5570- to connect the fuel pressure
sender and the plug of the fuel pressure sender .
6. Testing components 269

OCTAVIA II 2004 ➤
– Switch on the tester -VAS 6394/1- , for this step, briefly press
the button -A- once.
Note
♦ If the button -A- is pressed for 2 seconds, the illumination is

switched on for 20 seconds.
♦ If the tester -VAS 6394/1- does not indicate 0 MPa (0 bar),
carry out a zero point of the balance by means of the ⇒ op‐
erating instructions .
– Connect the vehicle diagnosis, measurement and information

system to the diagnostic connection.
– Switch on ignition.
– On the display of the vehicle diagnosis, measurement and in‐
formation system press consecutively the following buttons:
Vehicle self-diagnosis
Self-diagnosis ?
01 - Engine Electronics ?
011 - Measured values ?
– Select measured value block 1 4 0 and confirm with Q .

In the display field 3, the fuel pressure (actual value) is shown,
measured by the fuel pressure sender -G247- .
– Start engine.
– Compare the displayed pressure of the tester -VAS 6394/1-
with the actual value displayed on the vehicle diagnosis sys‐
tem, measurement and information system .
• The pressures may deviate maximum 0.5 MPa (5 bar) from
one another.
– If the deviation is greater than 0.5 MPa (5 bar), replace the fuel
pressure sender -G247- .
WARNING
The tester -VAS 6394- is under high fuel pressure! Disconnect

the plug from the fuel pressure sender -G247- while the engine
is running. Thereby the fuel pressure is reduced to approx. 0.6
MPa (6 bar). Switch off ignition. Place a cleaning cloth around
the fuel pressure sender -G247- , then reduce the remaining
pressure by carefully loosening the fuel pressure sender -
G247- .
– Repeat the test with the new fuel pressure sender -G247- and
compare both measured values.
If the measured values do not correspond again:
– Perform a cable testing ⇒ Vehicle diagnosis, testing and in‐

OCTAVIA II 2004 ➤
7 Engine control unit
7.1 Removing and installing engine control

unit
♦ Body saw, e.g. -V.A.G 1523 A-
Note
♦ If the engine control unit is replaced, connect the vehicle di‐

agnosis, measurement and information system -VAS 5051B-
and carry out the function “replace engine control unit”.
♦ If the engine control unit is replaced on vehicles with engine
identification characters BLR, BLX, BLY, BVX, BVY, BVZ, the
throttle valve control unit -J338- must be cleaned
⇒ page 261 before the adaptation.
Removing
66 .
– Removing windscreen wiper and washer system ⇒ Electrical
System; Rep. Gr. 92 .
Vehicles with protective cover
– Cut with body saw -1- a slot for the cross-head screwdriver in
the heads of the pull-off screws -2-.
Note
♦ It must be sawed 2x with the body saw, so that the slot is wide
enough, in order to be able to unscrew the screws with a suit‐
able screwdriver.
♦ The pull-off screws until are inserted with locking agent.
– Screw out the screws.
7. Engine control unit 271

OCTAVIA II 2004 ➤
– Lift locking tab of protective cover with a cross-head screw‐

driver.
– Push the protective cover in the -direction of the arrow- out of
the bracket for engine control unit.
– Unlock the front plug -1- at the engine control unit and discon‐
nect.
– Lever off lock -2- slightly.
– Push engine control unit out of the bracket -arrow-.
– Unlock the rear plug at the engine control unit and disconnect.
Install
Note
For vehicles with protective cover, the metal swarfs must be suc‐
tioned out of the plenum chamber before installing the engine
control unit.
– Connect the rear plug to the engine control unit and lock.
– Slide the engine control unit onto the retaining bracket.
– Press locking mechanism -2- in direction of engine control unit.

– Connect the front plug -1- at the engine control unit and lock.
Vehicles with protective cover
– Fasten protective cover with new pull-off screws.
– Tighten pull-off screws evenly until the screw heads are pulled
off.
– Installing windscreen wiper and washer system ⇒ Electrical
System; Rep. Gr. 92 .
– Install the intermediate wall and cooling water tank cover ⇒

OCTAVIA II 2004 ➤
26 – Exhaust System
1 Exhaust gas system, engine identifi‐
cation characters BLR, BLX, BVY,
BVX - Summary of components
Engine identification characters BLR, BVY: only vehicles with
front-wheel drive
Engine identification characters BLX, BVX: only vehicles with
four-wheel drive
1.1 Exhaust manifold with catalytic converter - Summary of components

The Positions -1- to -4- are not fitted for engine identification char‐
acters BVY.
1 - Clamp
2 - 10 Nm
3 - Cable guide
❑ for lambda probe
4 - Lambda probe 2 -G108- , 55
Nm
❑ upstream of catalytic
converter, left exhaust
pipe
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3- ;
the hot bolt paste -G 052
112 A3- must not get in‐
to the slots of the probe
body
❑ Colour of the plug:
brown
5 - Heat shield
6 - 10 Nm
7 - Lambda probe -G39- , 55
Nm
❑ upstream of catalytic
converter, right exhaust
pipe
thread with hot bolt paste -G 052 112 A3- ; the hot bolt paste -G 052 112 A3- must not get into the slots
of the probe body
❑ Colour of the plug: black
1. Exhaust gas system, engine identification characters BLR, BLX, BVY, BVX - Summary of components 273
OCTAVIA II 2004 ➤
8 - Cable strap
9 - 40 Nm
10 - 23 Nm
11 - Support for exhaust manifold
❑ right
12 - Strut
❑ between the flanges
13 - Gasket
❑ replace
14 - Support for exhaust manifold
❑ left
15 - 25 Nm
16 - Exhaust manifold with catalytic converter
❑ Coat pin screws of exhaust manifold with hot bolt paste -G 052 112 A3-
17 - 25 Nm
❑ replace
❑ Coat stud bolts in the cylinder head with hot bolt paste -G 052 112 A3-
18 - Gasket
❑ replace
19 - Bottom connection pipe
❑ of exhaust gas recirculation system
20 - Support
❑ for cable guide clamp
274 Rep. Gr.26 - Exhaust System

OCTAVIA II 2004 ➤
1.2 Exhaust gas system - Summary of components, vehicles with front-wheel-

drive (BLR, BVY)
1 - 25 Nm
❑ replace
A3-
2 - Lambda probe downstream
of catalytic converter -G130- ,
55 Nm
paste -G 052 112 A3- ;
body
3 - Lambda probe 2 down‐
stream of catalytic converter -
G131- , 55 Nm
brown
paste -G 052 112 A3- ;
body
4 - Front part of exhaust system
❑ with catalytic converter
❑ protect against shocks and blows
❑ with decoupling element
❑ do not twist decoupling element more than 10° - risk of damage
❑ Align exhaust system free of stress ⇒ page 292
5 - Lambda probe 3 downstream of catalytic converter -G287- , 55 Nm
❑ only coat the thread with hot bolt paste -G 052 112 A3- ; the paste must not get into the slots of the probe
body
6 - Retaining strap
OCTAVIA II 2004 ➤
7 - Rear tunnel bridge

8 - 20 Nm
9 - Rear part of exhaust system
❑ for first equipment building unit with the middle part of the exhaust gas system, replace individually when
carrying out repairs
❑ Separate the exhaust system ⇒ page 291
10 - Hanger
11 - 23 Nm
12 - Rear clamping sleeve
❑ for individually replacing the front and rear silencer
❑ Tighten screwed connections uniformly
13 - 23 Nm
14 - 20 Nm
15 - Front tunnel bridge
16 - Middle part of exhaust system
❑ for first equipment building unit with the rear part of the exhaust gas system, replace individually when
17 - Front clamping sleeve
❑ align exhaust system free of stress before tightening ⇒ page 292
18 - 23 Nm
19 - Hanger
20 - Hanger
21 - Gasket
❑ replace

OCTAVIA II 2004 ➤
1.3 Exhaust gas system - Summary of components, vehicles with four-wheel-

drive (BLX, BVX)
1 - 25 Nm
❑ replace
A3-
2 - Lambda probe downstream
of catalytic converter -G130- ,
55 Nm
paste -G 052 112 A3- ;
body
3 - Lambda probe 2 down‐
stream of catalytic converter -
G131- , 55 Nm
brown
paste -G 052 112 A3- ;
body
4 - Exhaust gas temperature sender 1 -G235- , 45 Nm
❑ the thread of new senders must be coated with assembly paste
❑ grease only the thread with hot bolt paste -G 052 112 A3- for re-used sender
5 - Front part of exhaust system
❑ with NOx storage catalytic converter
❑ protect against shocks and blows
❑ do not twist decoupling element more than 10° - risk of damage
6 - NOx sender -G295- , 55 Nm
❑ the thread of new senders must be coated with assembly paste
❑ grease only the thread with hot bolt paste -G 052 112 A3- for re-used sender
OCTAVIA II 2004 ➤
8 - Hanger
9 - 23 Nm
10 - 20 Nm
12 - Retaining strap
15 - 23 Nm
16 - Hanger
17 - Hanger
18 - Gasket
❑ replace

OCTAVIA II 2004 ➤
2 Exhaust gas system, engine identifi‐

cation characters BLY, BVZ - Sum‐
maries of components
Only vehicles with front-wheel-drive
2.1 Exhaust manifold - Summary of components
1 - Gasket
❑ replace
2 - Exhaust manifold
A3-
⇒ page 284
3 - Heat shield
4 - 10 Nm
5 - 40 Nm
6 - 25 Nm
7 - Support for exhaust mani‐
fold
❑ right
8 - Strut
❑ between the flanges
9 - Gasket
❑ replace
10 - Support for exhaust mani‐
fold
❑ left
11 - 25 Nm
❑ replace
❑ Coat stud bolts in the
cylinder head with hot
A3-
2. Exhaust gas system, engine identification characters BLY, BVZ - Summaries of components 279
OCTAVIA II 2004 ➤
2.2 Exhaust gas system - Summary of components
1 - 25 Nm
❑ replace
A3-
Nm
brown
paste -G 052 112 A3- ;
body
3 - Front part of exhaust sys‐
tem
❑ protect against shocks
and blows
❑ do not twist decoupling
element more than 10° -
risk of damage
⇒ page 287
❑ Align exhaust system
free of stress
⇒ page 292
4 - Lambda probe downstream of catalytic converter -G130- , 55 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3- ; the hot bolt paste -
G 052 112 A3- must not get into the slots of the probe body
5 - Retaining strap
7 - 20 Nm
9 - Hanger

OCTAVIA II 2004 ➤
10 - 23 Nm
❑ for individually replacing the middle and rear part of the exhaust system
12 - 23 Nm
13 - 20 Nm
17 - 23 Nm
18 - Hanger
19 - Hanger
20 - Gasket
❑ replace
2. Exhaust gas system, engine identification characters BLY, BVZ - Summaries of components 281
OCTAVIA II 2004 ➤
3 Exhaust gas system, Engine identifi‐

cation character BWA - Summary of
components
3.1 Exhaust gas system - Summary of components
1 - Gasket
❑ replace
Nm
paste -G 052 112 A3- ;
body
3 - 40 Nm
❑ replace
A3-
4 - Front part of exhaust sys‐
tem
❑ protect against shocks
and blows
❑ do not twist decoupling
element more than 10° -
risk of damage
⇒ page 289
❑ Align exhaust system
free of stress
⇒ page 292
5 - Lambda probe downstream of catalytic converter -G130- , 55 Nm
❑ the thread of new lambda probes must be coated with assembly paste
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3- ; the hot bolt paste -
G 052 112 A3- must not get into the slots of the probe body

OCTAVIA II 2004 ➤
7 - 23 Nm
8 - Hanger
10 - Retaining strap
12 - Hanger
13 - 23 Nm
❑ for individually replacing the middle and rear part of the exhaust system
17 - Hanger
3. Exhaust gas system, Engine identification character BWA - Summary of components 283
OCTAVIA II 2004 ➤

exhaust system
Note
♦ Vehicles with the engine identification characters BLY and

BVZ omply with exhaust emission standard EU 2. On these
vehicles, certain exhaust gas relevant components are not fit‐
ted, such as exhaust gas recirculation system, NOx-sensor
control unit -J583- , lambda probe 2 -G108 - and lambda probe
2 downstream of catalytic converter -G131- . Observe this
during the installation.
♦ Replace the gaskets and the self-locking nuts.
♦ After performing installation work on the exhaust system,
make sure the exhaust system is not mounted under tension
and has adequate clearance from the vehicle body. If neces‐
sary, slacken the clamping sleeve and align the front and
middle part of the exhaust system so as to create adequate
clearance to the vehicle body and that the weight of the ex‐
haust system is evenly distributed over the hangers.
4.1 Removing and installing exhaust mani‐

fold, engine identification characters
♦ Ring spanner set for lambda probe
♦ Hot screw paste -G 052 112 A3-
Note
♦ The following work sequence describes the removal of all

parts, which could be fitted.
♦ Fewer parts must be removed depending upon engine version
or type of drive.
4.1.1 Removing
The exhaust manifold is removed towards the top.
Gr. 50 .
⇒ page 287 .
– Unscrew screws -1- to -3- of supports for exhaust manifold.

OCTAVIA II 2004 ➤
– Remove engine cover upwards -arrows-.
– Remove the plug connections -1- and -2- for lambda probes
from the bracket and disconnect.
– Unclip hose -1- and disconnect plug -2-.

– Remove the plenum chamber cover ⇒ Body Work; Rep. Gr.
50 66.
– Remove the intermediate wall for cooling water tank

-arrows-.
4. Removing and installing parts of the exhaust system 285

OCTAVIA II 2004 ➤
– Unscrew nuts -1- and remove cable guide -2-.
– Unscrew screws -1- to -3- and remove the bottom connection

pipe.
– Remove the top connection pipe ⇒ page 294 .
– Expose the electrical wiring of the lambda probe upstream of

catalytic converter -arrows-.
– Remove lambda probe upstream of catalytic converter -1-.
– Unscrew screws -2- and -3- and lay exhaust gas recirculation
valve -1- to the side.
Note
The coolant hoses of the exhaust gas recirculation valve remain

connected.

OCTAVIA II 2004 ➤
– Remove heat shield at exhaust manifold. To do so release

screws -1- and pull off heat shield -arrows-.
– Remove exhaust manifold -arrow- and take it out to the top.

If the lambda probes should be removed, use for this step the ring
spanner set for lambda probe .
4.1.2 Install
following:
– All cable straps should be fitted on again in the same place
when installing.
– When performing installation work replace the self-locking
nuts.
– Replace all the gaskets.
– The thread of the lambda probe must be greased with hot
screw paste -G 052 112 A3- . The paste must not come into
contact with the slots of the probe body.
4.2 Removing and installing front part of ex‐

haust system, engine identification char‐
acters BLR, BLX, BLY, BVX, BVY, BVZ
Removing
Note
♦ The following work sequence describes the removal of all

parts, which could be fitted.
♦ Fewer parts must be removed depending upon engine version
or type of drive.

OCTAVIA II 2004 ➤
– Remove trim panel for base of vehicle on right -arrows-.
– Disconnect the plug -1- from the NOx-sensor control unit -

J583- .
– Remove the bracket -3- from the base of the vehicle.
– Disconnect the plug -2- for the exhaust gas temperature send‐
er 1 -G235- and expose the cable.
– Disconnect the plug (black) -4- for right lambda probe down‐
stream of catalytic converter -G130- and expose the cable.
– Disconnect the plug (brown) -5- for left lambda probe down‐
stream of catalytic converter -G131- and expose the cable.
– Remove the NOx-sensor control unit -J583- -arrows- and ex‐
pose the cable with the control unit.
– Remove front tunnel bridge -arrows-.
Note


OCTAVIA II 2004 ➤
– Remove rear tunnel bridge -3-.

– Slacken the nuts -1- at the clamping sleeve -2-.
– Push the clamping sleeve -2- so far backward until it is no lon‐
ger connected to the front part of the exhaust system.
– Remove the front part of the exhaust system.
If the lambda probes should be removed, use for this step the ring
spanner set for lambda probe .
Install
following:
– Replace the gaskets and the self-locking nuts.
– Align exhaust system free of stress ⇒ page 292 .
– Coat stud bolts of exhaust manifold with hot bolt paste -G 052
112 A3- .
4.3 Removing and installing front part of ex‐

haust system, engine identification char‐
acter BWA
Removing
expose wiring loom.

OCTAVIA II 2004 ➤
– Release both top fixing nuts -arrows- of the front part of the
exhaust gas system/exhaust gas turbocharger.
– Remove trim panel for base of vehicle on right -arrows-.
– Unclip cable -arrow-, detach bracket -1- and disconnect plug

connection -2- for lambda probe upstream of catalytic con‐
verter -G130- .
Note

– Separate exhaust system at the clamping sleeve -2-.

OCTAVIA II 2004 ➤
– Remove front tunnel bridge -arrows-.
– Release both bottom fixing nuts -arrows- of the front part of

the exhaust gas system/exhaust gas turbocharger.
– Remove the front part of the exhaust system.
Install
following:
– Replace the gaskets and the self-locking nuts.
– Align exhaust system free of stress ⇒ page 292 .
– Coat stud bolts of exhaust manifold with hot bolt paste -G 052
112 A3- .
4.4 Replacing middle or rear part of the ex‐

haust system, only vehicles with front-
wheel drive
♦ Body saw e.g. -V.A.G 1523 A-
♦ Protective goggles
Note
♦ For individually replacing the middle or rear part of the exhaust

system, a separation point is provided in the connecting pipe.
♦ The separation point is marked by indentations on the circum‐
ference of the exhaust pipe.

OCTAVIA II 2004 ➤
WARNING
In order to avoid injuries because of metal swarfs, wear safety

goggles and safety clothing.
– Separate exhaust pipe at right angles at the separation point

-arrow 2-.
– When installing, position rear clamping sleeve -4- at the side
markings -arrow 1- and -arrow 3-.
– Turn the rear clamping sleeve -4- in such a way that the ends
of the screws are as far upwards as possible.
– Align rear part of exhaust system horizontally and tighten rear
clamping sleeve -4- to 23 Nm.
– Align exhaust system in cold condition free of stress
⇒ page 292 .
4.5 Aligning exhaust system free of stress

• The exhaust gas system must be cold for aligning.
– Slacken front clamping sleeve -1- and the front part of the ex‐
haust system -2- (-arrow- points in direction of travel).
-a- = 5 mm
The fixing screws must be on the right. They must not protrude
beyond the bottom edge of the clamping sleeve.
– Tighten the front nut by hand.
– Push the exhaust system so far forward until the

-dimension a- on the retaining strap at the front silencer is 9 ...
11 mm.

OCTAVIA II 2004 ➤
– Push the exhaust system so far forward until the

-dimension a- on the retaining strap at the front silencer is 7 ...
9 mm.
– Tighten bolts of the front clamping sleeve evenly to 23 Nm.
Align exhaust tailpipes
– Align rear part of exhaust system in such a way that there is

an equal distance -a- on the left and right between bumper
opening and exhaust tailpipes.
At the same time there must be an equal distance -b- from the
bumper opening to the exhaust tailpipes.
For aligning, if necessary the hangers of the exhaust system must
be loosened.
4.6 Inspecting the exhaust system for leak‐

tightness
– Seal off exhaust tailpipes for the duration of the leak check
(e.g. with cloth or plug).
– All connection points (cylinder head/exhaust manifold, ex‐
haust manifold/front part of exhaust system etc.) should be
checked for tightness by listening and visual inspection.
– Eliminate any leak found.

OCTAVIA II 2004 ➤
5 Exhaust gas recirculation system,

BLX, BVY, BVX
1 - 10 Nm
❑ pay attention to different
lengths compared to
Pos. 4
2 - Top connection pipe
⇒ page 294
3 - Gasket
❑ replace
4 - 10 Nm
❑ pay attention to different
lengths compared to
Pos. 1
5 - Support
6 - 15 Nm
N18-
❑ with EGR potentiometer
-G212-
system VAS 5051
8 - Bottom connection pipe
9 - 15 Nm
10 - from exhaust manifold
11 - 25 Nm
12 - 10 Nm
13 - To intake manifold
5.2 Removing and installing top connection

pipe for exhaust gas recirculation
Removing
– Remove engine cover.

OCTAVIA II 2004 ➤
– Remove the vacuum line -1- from the vacuum reservoir and
push the vacuum reservoir to the side.
– Unhook coolant hose from bracket -2-.

– Unscrew bracket -3- from top connection pipe at housing with
camshaft adjustment valve.
– Remove bracket -1- from housing with camshaft adjustment
valve.
– Remove the hose for crankcase ventilation -1-.

– Remove lifting eye -2-. To this end release screw -3-.
– Unscrew screws -2- from top connection pipe at intake mani‐

fold -1-.
– Unscrew screws -4- from top connection pipe at exhaust gas
recirculation valve -N18- -3-.
– Pull out the connecting pipe upwards to the front.
Install
5. Exhaust gas recirculation system, engine identification characters BLR, BLX, BVY, BVX 295
OCTAVIA II 2004 ➤
28 – Ignition system
1 Ignition system

❑ contacts gold-plated
2 - Ignition coil with power out‐
put stage -(N70, N127, N291,
N292)-
⇒ page 296
❑ for engine identification
characters BWA Knock
sensor 2 -G66- with wir‐
ing loom and plug con‐
nection, as Pos. 1
4 - 20 Nm
❑ the tightening torque in‐
fluences the knock sen‐
sor function
5 - Spark plug, 25 Nm
❑ Type and electrode
spacing ⇒ Mainte‐
nance ; Octavia II
❑ use spark plug wrench
e.g. -3122 B- for remov‐
ing and installing
6 - 10 Nm
7 - Engine speed sender -G28-
8 - O-ring
❑ replace
1.2 Removing and installing ignition coils

with power output stages
296 Rep. Gr.28 - Ignition system

OCTAVIA II 2004 ➤
Removing
BVX, BVY, BVZ
Note
♦ For detaching the ignition plugs position the puller -T40039 -

on the upper thickest rib -arrow- of the ignition coil with power
output stage.
♦ If the lower ribs are used, they can be damaged.
– Pull all ignition coils with the extractor -T40039- first of all only
approx. 30 mm out of the spark plug shaft.
– Disconnect the plugs and then pull all the plugs simultaneously
from the ignition coils -arrows-.
Installing
– Insert all ignition coils loosely into the spark plug shaft.
1. Ignition system 297

OCTAVIA II 2004 ➤
– Fit all plugs simultaneously onto the ignition coils.

– Align the ignition coils to the recesses in the cylinder head
cover.
– Press the ignition coils evenly with the hand onto the spark
plugs.
298 Rep. Gr.28 - Ignition system

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2 Parts of cooling system - Summaries of components, engine identification character BWA

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

2.5 Overview plan for the exhaust turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

24 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

1.1 Exhaust manifold with catalytic converter - Summary of components . . . . . . . . . . . . . . . . 273

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

1.1 Engine number

The engine identification character is in addition type-punched at

1.2 Engine characteristics

2 Rep. Gr.00 - Technical data

Identification characters BVX BVY BVZ

Identification characters BWA

4 Rep. Gr.00 - Technical data

1.2 Safety precautions when working on the

♦ The safety measures for the pressure reduction in the high

1. Self diagnosis, safety measures, cleanliness regulations, directions 5

♦ The fuel pump is activated when the ignition is switched on

When undertaking all installation work, particularly in the en‐

1.3 Release pressure in the high pressure

♦ The injection system consists of a high pressure part

– Disconnect the plug from the fuel pressure regulating valve -

6 Rep. Gr.01 - Self-diagnosis

♦ Vehicles with engine identification characters BLR, BLX, BLY,

♦ If the plug is disconnected from the fuel pressure regulating

– Switch off ignition.

– Now lay a clean cleaning cloth around the connection point

♦ Interrogate the fault memory of the engine control unit at the

1.4 Rules of cleanliness to observe when

1. Self diagnosis, safety measures, cleanliness regulations, directions 7

♦ Thoroughly clean the connection points and their surroundings

1.5 Safety measures to apply when working

♦ The safety measures for the pressure reduction in the high

Observe the following points to prevent injury to persons and/or

8 Rep. Gr.01 - Self-diagnosis

♦ The fuel pump is activated when the ignition is switched on

When undertaking all installation work, particularly in the en‐

1.6 General notes on the injection system

1. Self diagnosis, safety measures, cleanliness regulations, directions 9

1.7 General notes on the ignition system

1.8 General instructions for charge air sys‐

When undertaking all installation work, particularly in the en‐

In case a mechanical damage to the exhaust gas turbocharger

♦ The charge-air system must be tight.

10 Rep. Gr.01 - Self-diagnosis

♦ Always replace self-locking nuts.

1.9 Additional instructions when undertak‐

Do not open the refrigerant circuit of the air conditioning sys‐

In order to avoid damage to the condenser as well as to the re‐

Steps which should be taken in order to remove and install the

1. Self diagnosis, safety measures, cleanliness regulations, directions 11

10 – Removing and installing engine

1.1 Removing engine

♦ The engine is removed downwards together with the gearbox.

When undertaking all installation work, particularly in the en‐

Release pressure in the high pressure area of the fuel system

Engine identification characters BLR, BLX, BLY, BVX, BVY, BVZ

12 Rep. Gr.10 - Removing and installing engine

Vehicles with engine identification characters BWA