Skoda Yeti (2009-2013) - Workshop Manual, Repair Manual

SKODA YETI (2009-2013) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Workshop Manual / Repair Manual, for vehicles Skoda Yeti (2009-2013).
 

INDEX:

1,6 MPI Engine
00 – Technical data
- 1 Identification
- 1.1 Engine number
- 1.2 Engine characteristics
- 2 Safety instructions
- 2.1 Safety precautions when working on fuel supply system
- 2.2 Rules of cleanliness to observe when working on the fuel supply system
- 2.3 General notes on the injection system
- 2.4 General notes on the ignition system
- 2.5 Safety measures to apply when working on the fuel injection and ignition system
- 2.6 Safety precautions when working on vehicles with a start/stop system
- 2.7 Safety precautions during road tests in which testing and measuring equipment is used
- 2.8 Safety precautions when working on cooling system
- 2.9 Additional instructions when undertaking assembly work on the air-conditioning system
- 3 Repair instructions
- 3.1 Rules of cleanliness
- 3.2 Foreign bodies in the engine
- 3.3 Contact corrosion
- 3.4 Cable routing and securing
- 3.5 Assembly of radiators and capacitors
10 – Removing and installing engine
- 1 Removing and installing engine
- 1.1 Remove - (Octavia III)
- 1.2 Removing - (Yeti)
- 1.3 Securing the engine to the assembly stand
- 1.4 Installing - (Octavia III)
- 1.5 Installing - (Yeti)
- 2 Assembly bracket
- 2.1 Assembly bracket - Summary of components (Octavia III)
- 2.2 Assembly bracket - Summary of components (Yeti)
- 2.3 Removing and installing engine bracket - (Octavia IlI)
- 2.4 Removing and installing engine bracket - (Yeti)
- 2.5 Removing and installing gearbox mount
- 2.6 Checking the assembly bracket
- 2.7 Adjusting the unit mounting
13 – Crankshaft group
- 1 Cylinder block on belt pulley side
- 1.1 V-ribbed belt - Summary of components
- 1.1.1 Summary of components - Vehicles without air conditioning
- 1.1.2 Summary of components - Vehicles with air conditioning
- 1.2 Removing and installing V-ribbed belt
- 1.2.1 Removing and installing V-ribbed belt - Vehicles without air conditioning
- 1.2.2 Removing and installing V-ribbed belt - Vehicles with air conditioning
- 1.3 Removing and installing tensioning device for V-ribbed belt
- 1.4 Removing and installing ribbed belt pulley
- 1.5 Removing and installing engine support
- 1.6 Replacing crankshaft seal on belt pulley side
- 2 Cylinder block, gearbox end
- 2.1 Gearbox side cylinder block - Summary of components
- 2.2 Removing and installing flywheel
- 2.3 Removing and installing the sealing flange on the gearbox side
- 3 Crankshaft
- 3.1 Measuring axial play of crankshaft
- 3.2 Replace needle bearing for crankshaft
- 4 Pistons and conrods
- 4.1 Piston and conrod - Summary of components
- 4.2 Removing and installing the piston
- 4.3 Checking piston and cylinder bore
15 – Cylinder head, valve gear
- 1 Cylinder head
- 1.1 Cylinder head - summary of components
- 1.2 Camshaft housing - Summary of components
- 1.3 Removing and installing camshaft housing
- 1.4 Removing and installing the cylinder head
- 1.5 Testing the compression
- 2 Toothed belt drive
- 2.1 Summary of components - toothed belt guard
- 2.2 Timing belt - Summary of components
- 2.3 Test timing
- 2.4 Remove the toothed belt from the camshafts
- 2.5 Removing and installing toothed belt
- 3 Valve gear
- 3.1 Valve gear - Summary of components
- 3.2 Measuring axial play of camshaft
- 3.3 Removing and installing camshaft control
- 3.4 Removing and installing gasket rings for camshafts
- 3.4.1 Removing and installing the inlet camshaft on the belt pulley side
- 3.4.2 Removing and installing the exhaust camshaft on the belt pulley side
- 3.4.3 Removing and installing the exhaust camshaft on the gearbox side
- 3.5 Removing and installing -N205- the camshaft adjustment valve 1
- 3.6 Removing and installing valve stem seal
- 3.6.1 Removing and installing valve stem seal with cylinder head installed
- 3.6.2 Removing and installing valve stem seal with cylinder head removed
- 4 Inlet and exhaust valves
- 4.1 Inspect valve guides
- 4.2 Testing valves
- 4.3 Valve dimensions
17 – Lubrication
- 1 Lubrication system
- 1.1 Oil sump and oil pump - Summary of components
- 1.2 Removing and installing oil sump bottom part
- 1.3 Removing and installing oil sump top part
- 1.4 Removing and installing oil pump
- 2 Engine oil cooler
- 2.1 Engine oil cooler - Summary of components
- 2.2 Removing and installing engine oil cooler
- 3 Crankcase ventilation
- 3.1 Crankcase ventilation - Summary of components
- 3.2 Removing and installing oil separator
- 4 Oil filter, oil pressure switch
- 4.1 Summary of components - oil filter/oil pressure switch
- 4.2 Removing and installing oil pressure switch -F1-
- 4.3 Testing oil pressure and oil pressure switch -F1-
- 4.4 Removing and installing oil filter housing
19 – Cooling
- 1 Cooling system, coolant
- 1.1 Connection diagram for coolant hoses
- 1.2 Draining and filling up coolant
- 1.3 Checking the coolant system for leaktightness
- 1.3.1 Checking with the cooling system testing device -V.A.G 1274-
- 1.3.2 Checking with the cooling system testing device -V.A.G 1274 B-
- 2 Coolant pump, regulation of cooling system
- 2.1 Summary of components - coolant pump/coolant thermostat
- 2.2 Coolant temperature sender - Summary of components
- 2.3 Removing and installing coolant pump
- 2.4 Removing and installing toothed belt pulley for coolant pump drive
- 2.5 Removing and installing coolant regulator
- 2.5.1 Removing and installing thermostat for small coolant circuit
- 2.5.2 Removing and installing thermostat for large coolant circuit
- 2.6 Removing and installing coolant temperature sender -G62-
- 2.7 Removing and installing coolant temperature sender at radiator outlet -G83-
- 3 Parts of cooling system engine side
- 3.1 Cooling system attached to engine - Summary of components
- 3.2 Removing and installing coolant pipes
- 4 Radiator and radiator fan
- 4.1 Radiator- Summary of components (Octavia III)
- 4.2 Radiator - Summary of components (Yeti)
- 4.3 Fan shroud with a radiator fan - Summary of components
- 4.4 Fan shroud with two radiator fans - Summary of components
- 4.5 Remove and install radiator (Octavia IlI)
- 4.6 Removing and installing radiator (Yeti)
- 4.7 Removing and installing radiator cowl for radiator fan (Octavia III)
- 4.8 Removing and installing fan shroud for radiator fan (Yeti)
- 4.9 Removing and installing radiator fan -V7-
- 4.10 Removing and installing radiator fan 2 -V177-
20 – Fuel supply system
- 1 Fuel tank and fuel delivery unit
- 1.1 Fuel tank- Summary of components (Octavia III)
- 1.2 Fuel tank - Summary of components (Yeti)
- 1.3 Fuel filter - Summary of components (Yeti)
- 1.4 Removing and installing fuel filter (Yeti)
- 1.5 Extract fuel from the fuel tank
- 1.5.1 Emptying fuel tank when fuel pump is intact
- 1.5.2 Emptying fuel tank when the fuel pump is damaged when more than 3/4 full - (Octavia III)
- 1.5.3 Emptying fuel tank when the fuel pump is damaged when more than 3/4 full - (Yeti)
- 1.5.4 Emptying fuel tank when the fuel pump is damaged when less than 3/4 full
- 1.6 Removing and installing fuel tank- (Octavia IlI)
- 1.7 Removing and installing fuel tank - (Yeti)
- 1.8 Fuel delivery unit and sender for fuel gauge display - Summary of components
- 1.9 Removing and installing fuel delivery unit
- 1.10 Removing and installing the sender for fuel gauge display -G-
- 1.11 Check fuel pump - (Octavia IlI)
- 1.11.1 Checking fuel pressure
- 1.11.2 Testing holding pressure
- 1.11.3 Checking fuel delivery rate
- 1.12 Check fuel pump - (Yeti)
- 1.12.1 Checking fuel pressure
- 1.12.2 Testing holding pressure
- 1.12.3 Checking fuel delivery rate
- 2 Quick couplings
- 2.1 Separating quick couplings
- 3 Accelerator pedal
- 3.1 Accelerator pedal module- Summary of components (Octavia III)
- 3.2 Summary of components - Accelerator pedal module (Yeti)
- 3.3 Removing and installing accelerator pedal module (Octavia IlI)
- 3.3.1 Remove and fit on connector for accelerator pedal module (Octavia III)
- 3.4 Removing and installing accelerator pedal module (Yeti)
- 3.4.1 Remove and fit on connector for accelerator pedal module (Yeti)
- 4 Activated charcoal container system
- 4.1 Activated charcoal filter- Summary of components (Octavia III)
- 4.2 Activated charcoal filter - Summary of components (Yeti)
- 4.3 Removing and installing parts of the activated charcoal filter system - (Octavia III)
24 – Mixture preparation - injection
- 1 Injection system
- 1.1 Injection system - Fitting location of the injection system
- 1.1.1 Engine compartment - Overview of fitting locations (Octavia III)
- 1.1.2 Engine compartment - Overview of fitting locations (Yeti)
- 1.1.3 Installation location overview - engine from front
- 1.1.4 Installation location overview - engine from rear
- 2 Air filter
- 2.1 Air filter housing- Summary of components (Octavia III)
- 2.2 Summary of components - Air filter housing (Yeti)
- 2.3 Removing and installing air filter housing
- 3 Intake manifold
- 3.1 Intake manifold - Summary of components
- 3.2 Removing and installing intake manifold
- 3.3 Removing and installing the throttle valve control unit -J338-
- 3.4 Clean throttle valve control unit -J338-
- 4 Injectors
- 4.1 Fuel rail with injection valves - Summary of components
- 4.2 Removing and installing the fuel distributor
- 4.3 Removing and installing injection valves
- 4.4 Checking injectors
- 4.5 Clean injection valves
- 5 Senders and sensors
- 5.1 Removing and installing intake air temperature sender -G42-/manifold pressure sender -G71-
- 6 Lambda probe
- 6.1 Lambda probe - Summary of components
- 6.2 Removing and installing lambda probe -G39-/-G130-
- 7 Engine control unit
- 7.1 Installing and removing engine control unit -J623- without protective housing - (Octavia III)
- 7.2 Removing and installing engine control unit -J623-, engine control unit with protective housing - (Octavia III)
- 7.3 Installing and removing engine control unit -J623- without protective housing - (Yeti)
- 7.4 Removing and installing engine control unit -J623-, engine control unit with protective housing - (Yeti)
26 – Exhaust system
- 1 Removing and installing exhaust system
- 1.1 Pre-exhaust pipe with catalytic converter - Summary of components
- 1.2 Middle or rear part of the exhaust system - Summary of components (Octavia III)
- 1.3 Middle or rear part of the exhaust system - Summary of components (Yeti)
- 1.4 Removing and installing pre-exhaust pipe with catalytic converter
- 1.5 Removing and installing or replacing the middle and rear silencer - (Octavia III)
- 1.6 Removing and installing or replacing the middle and rear silencer - (Yeti)
- 1.7 Aligning exhaust system
- 1.7.1 Aligning exhaust system free of stress
- 1.7.2 Align exhaust tailpipe
- 1.8 Inspecting the exhaust system for leaktightness
28 – Ignition system
- 1 Ignition system
- 1.1 Ignition system - Summary of components
- 1.2 Removing and installing ignition coils with output stage
- 1.3 Removing and installing knock sensor 1 -G61-
- 1.4 Removing and installing Hall sender -G40-
- 1.5 Removing and installing engine speed sender -G28-
Axles and Steering
00 – Technical data
- 1 Safety instructions
- 1.1 Safety precautions when working on vehicles with start-stop system
- 1.2 Safety precautions during road tests in which testing and measuring equipment is used
- 1.3 Safety precautions when working on the assembly carrier
- 2 Accident vehicle assessment
- 2.1 Checklist for assessing the chassis of accident vehicles
- 3 Repair instructions
- 3.1 Steering gear
- 3.2 Seals and sealing rings
- 3.3 Bolts, nuts
- 3.4 Electrical components
- 3.5 Lift the wheel bearing in the unladen weight position
40 – Front suspension
- 1 Front axle
- 1.1 Overview - front axle
- 2 Front axle with aluminium assembly carrier
- 2.1 Assembly overview - subframe, aluminium subframe
- 2.1.1 Assembly overview - subframe, aluminium subframe, left-hand drive
- 2.1.2 Assembly overview - subframe, aluminium subframe, right hand drive
- 2.2 Fixing the assembly carrier and the console, aluminium assembly carrier
- 2.3 Lower the assembly carrier in the service position, aluminium assembly carrier
- 2.4 Removing and installing assembly carrier without steering gear, aluminium assembly carrier
- 2.5 Removing and installing assembly carrier with steering gear, aluminium assembly carrier
- 2.5.1 Removing and installing assembly carrier with steering gear - aluminium assembly carrier, left-hand drive
- 2.5.2 Removing and installing assembly carrier with steering gear - aluminium assembly carrier right-hand drive
- 2.6 Replacing rubber-metal bearing for pendulum support, aluminium assembly carrier
- 2.7 Removing and installing anti-roll bar, aluminium assembly carrier
- 2.7.1 Removing and installing anti-roll bars, aluminium assembly carrier, left-hand drive
- 2.7.2 Removing and installing anti-roll bars, aluminium assembly carrier, right-hand drive
- 2.8 Removing and installing coupling rods from anti-roll bars, aluminium assembly carrier
- 2.9 Removing and installing track control arm with bracket - aluminium assembly carrier
- 2.9.1 Removing and installing track control arm with bracket - aluminium assembly carrier
- 2.9.2 Removing and installing left track control arm with bearing bracket, vehicles with automatic transmission, aluminium assembly carrier
- 2.10 Replacing rubber-metal bearing for track control arm, aluminium assembly carrier
- 2.11 Replacing bracket with bearing for track control arm - aluminium assembly carrier
- 2.12 Removing and installing front left vehicle level sensor -G78-
- 2.13 Inspecting the suspension link
- 2.14 Removing and installing the suspension link
- 3 Front axle with assembly carrier made of steel sheet
- 3.1 Summary of components - assembly carrier, sheet steel assembly carrier
- 3.1.1 Assembly overview - subframe, sheet steel assembly carrier, left-hand drive
- 3.1.2 Assembly overview - subframe, sheet steel assembly carrier, right hand drive
- 3.2 Fix the assembly carrier - assembly carrier made of steel sheet
- 3.3 Lower the assembly carrier in the service position, assembly carrier made of sheet steel
- 3.4 Removing and installing assembly carrier without steering gear, sheet steel assembly carrier
- 3.5 Removing and installing assembly carrier with steering gear, sheet steel assembly carrier
- 3.5.1 Removing and installing assembly carrier with steering gear, sheet steel assembly carrier, left-hand drive
- 3.5.2 Removing and installing assembly carrier with steering gear, sheet steel assembly carrier, right-hand drive
- 3.6 Replacing rubber-metal bearing for track pendulum support, sheet steel assembly carrier
- 3.7 Removing and installing the anti-roll bar - sheet steel assembly carrier
- 3.7.1 Removing and installing the steel sheet anti-roll bar, left-hand drive.
- 3.7.2 Removing and installing the steel sheet anti-roll bar, right-hand drive.
- 3.8 Removing and installing coupling rod from anti-roll bar, sheet steel assembly carrier
- 3.9 Removing and installing the track control arm, sheet steel assembly carrier
- 3.9.1 Removing and installing the track control arm, sheet steel assembly carrier
- 3.9.2 Removing and installing left track control arm, sheet steel assembly carrier vehicles with an automatic gearbox
- 3.10 Replacing rubber-metal bearing for track control arm - assembly carrier made of steel sheet
- 3.10.1 Replacing the rubber-metal bearing for track control arm, front bearing
- 3.10.2 Replacing the rubber-metal bearing for rear track control arm, rear bearing
- 3.11 Inspecting the suspension link
- 3.12 Removing and installing the suspension link
- 4 Summary of components of wheel suspension
- 4.1 Summary of components - wheel suspension
- 4.2 Removing and installing the suspension strut
- 4.3 Repairing suspension strut
- 4.4 Inspect shock absorber
- 4.4.1 Leaks on the shock absorber
- 4.4.2 Noises on the shock absorber
- 4.4.3 Inspecting the removed shock absorber without gas pressure
- 4.4.4 Inspecting the removed shock absorber with gas pressure
- 4.5 Disposing of the shock absorber
- 4.5.1 Degas front gas-filled shock absorber, and empty.
- 4.5.2 Degas rear gas-filled shock absorber, and empty.
- 5 Wheel bearing
- 5.1 Summary of components - Wheel bearing
- 5.2 Removing and installing the wheel hub with wheel bearing
- 5.3 Removing and installing wheel bearing housing
- 6 Drive shaft
- 6.1 Overview - drive shaft
- 6.2 Overview of joints, distinguish the diameter as specified and grease quantity
- 6.3 Summary of components - cardan shaft
- 6.3.1 Summary of components - Cardan shaft CV joint VL100
- 6.3.2 Summary of components - Cardan shaft CV joint VL107
- 6.3.3 Summary of components - cardan shaft, tripod joint AAR2600i
- 6.4 Removing and installing cardan shaft
- 6.4.1 Removing and installing cardan shaft, CV joint VL100 and VL107
- 6.4.2 Removing and installing cardan shaft with wedge -T10161, inserted in gearbox, tripod joint AAR2600i-
- 6.4.3 PTO shaft with extractor for drive shafts -T10382-, inserted in the gearbox, removing and installing tripod joint AAR2600i
- 6.4.4 Push the cardan shaft out of the wheel hub.
- 6.5 Loosen and tighten cardan shaft screwed connection
- 6.6 Removing and installing heat shield for cardan shaft
- 6.6.1 Removing and installing the heat shield for cardan shaft, heat shield fastened with plate
- 6.6.2 Removing and installing heat shield for propshaft, protective cover secured with 2 pipe nuts
- 6.6.3 Removing and installing heat shield for propshaft, protective cover secured with 3 pipe nuts
- 6.7 Disassembling and assembling cardan shaft
- 6.7.1 Remove inner joint VL100
- 6.7.2 Remove inner joint VL107
- 6.7.3 Remove inner joint AAR2600i
- 6.7.4 Install inner joint VL100
- 6.7.5 Install inner joint VL107
- 6.7.6 Install inner joint AAR2600i
- 6.7.7 Removing outer CV joint
- 6.7.8 Installing the outer CV joint
- 6.8 Inspecting outer CV joint
- 6.9 Inspecting inner CV joint
42 – Rear suspension
- 1 Rear axle
- 1.1 Overview - rear axle
- 1.1.1 Overview - rear axle, vehicles with front-wheel drive
- 1.1.2 Overview - rear axle, vehicles with four-wheel drive
- 1.2 Removing and installing rear suspension
- 1.2.1 Removing and installing rear axle, vehicles with front wheel drive to CW 21/2010
- 1.2.2 Removing and installing rear axle, vehicles with front-wheel drive from CW 22/2010
- 1.2.3 Removing and installing the rear axle, vehicles with four-wheel drive
- 2 Subframe, control arm, tie rod, rear vehicle level encoder -G76-
- 2.1 Summary of components- assembly carrier
- 2.1.1 Overview of components - assembly carrier, control arm, tie rod, vehicles with front wheel drive to CW 21/2010
- 2.1.2 Overview of components - assembly carrier, control arm, tie rod, vehicles with front wheel drive from CW 22/2010
- 2.1.3 Summary of components: Assembly carrier, suspension arm, track rod for rear axle, vehicles with four-wheel drive
- 2.1.4 Summary of components: assembly carrier, final drive, vehicles with four-wheel drive
- 2.2 Summary of components - vehicle level sender rear
- 2.3 Removing and installing vehicle level rear encoder -G76-
- 2.4 Repairing assembly carrier
- 2.4.1 Removing and installing rubber-metal bearings at the front, vehicles with front-wheel drive up to CW 21/2010
- 2.4.2 Removing and installing bonded rubber bush at front, vehicles with four-wheel drive
- 2.4.3 Removing and installing rubber metal rear bearings, vehicles with front-wheel drive to CW 21/2010
- 2.4.4 Removing and installing bonded rubber rear bearings, four-wheel drive vehicles
- 2.5 Removing and installing top suspension arm
- 2.5.1 Removing and installing top suspension arm, vehicles with front-wheel drive
- 2.5.2 Removing and installing top suspension arm, vehicles with four-wheel drive
- 2.6 Removing and installing bottom suspension arm
- 2.6.1 Removing and installing bottom suspension arm, vehicles with front-wheel drive
- 2.6.2 Removing and installing bottom suspension arm, vehicles with four-wheel drive
- 2.7 Removing and installing track rod for rear axle
- 2.7.1 Removing and installing track rod for rear axle, vehicles with front-wheel drive
- 2.7.2 Removing and installing track rod for rear axle, vehicles with four-wheel drive
- 2.8 Removing and installing bracket for the speed sensor cable
- 3 Anti-roll bar
- 3.1 Summary of components - anti-roll bar
- 3.1.1 Summary of components - anti-roll bar, vehicles with front wheel drive up to CW 21/2010
- 3.1.2 Summary of components - anti-roll bar, vehicles with front-wheel drive, from CW 22/2010
- 3.1.3 Summary of components - anti-roll bar, vehicles with four-wheel drive
- 3.2 Removing and installing the anti-roll bar
- 3.2.1 Removing and installing anti-roll bar, vehicles with front wheel drive up to CW 21/2010
- 3.2.2 Removing and installing anti-roll bars, vehicles with front-wheel drive from CW 22/2010
- 3.2.3 Removing and installing the anti-roll bar, vehicles with all-wheel drive
- 3.3 Removing and installing coupling rod
- 4 Suspension strut/shock absorber, spring
- 4.1 Summary of components - Suspension strut/shock absorber, spring
- 4.1.1 Summary of components - strut / shock absorber, spring, vehicles with front wheel drive
- 4.1.2 Summary of components - strut / shock absorber, spring, vehicles with all-wheel drive
- 4.2 Removing and installing shock absorber
- 4.3 Repairing shock absorber
- 4.4 Removing and installing spring
- 4.5 Inspect shock absorber
- 4.5.1 Inspecting the removed shock absorber without gas pressure
- 4.5.2 Inspecting the removed shock absorber with gas pressure
- 4.6 Degas rear gas-filled shock absorber, and empty.
- 5 Wheel bearing, trailing arm
- 5.1 Summary of components - wheel bearing housing, trailing arm
- 5.1.1 Summary of components: wheel-bearing housing, trailing arm, vehicles with front-wheel drive
- 5.1.2 Summary of components: wheel-bearing housing, trailing arm, vehicles with four-wheel drive
- 5.2 Removing and installing wheel bearing housing
- 5.2.1 Removing and installing wheel bearing housing, vehicles with front-wheel drive
- 5.2.2 Removing and installing the wheel bearing housing, vehicles with four-wheel drive
- 5.3 Removing and installing wheel-bearing unit
- 5.3.1 Removing and installing the wheel-bearing unit, vehicles with front-wheel drive
- 5.3.2 Removing and installing wheel-bearing unit, vehicles with four-wheel drive
- 5.4 Replacing the rubber-metal bearing for wheel-bearing housing
- 5.4.1 Replacing the rubber-metal bearing for wheel-bearing housing, vehicles with front-wheel drive
- 5.4.2 Replacing the rubber-metal bearing for wheel-bearing housing, vehicles with four-wheel drive
- 5.5 Removing and installing trailing arm with bracket
- 5.6 Repairing trailing arm
- 6 Drive shaft
- 6.1 Summary of components - cardan shaft
- 6.2 Designation, distinguish the diameter as specified and grease quantity for joints
- 6.3 Removing and installing cardan shaft
- 6.3.1 Removing and installing cardan shaft
- 6.3.2 Push the cardan shaft out of the wheel hub.
- 6.4 Disassembling and assembling cardan shaft
- 6.4.1 Removing and installing the outer CV joint
- 6.4.2 Removing and installing the inner CV joint
- 6.5 Loosen and tighten cardan shaft screwed connection
- 6.6 Check outer joint
- 6.7 Checking the inner joint
44 – Wheels, tyres, vehicle geometry
- 1 Wheels, Tyres
- 1.1 Wheel change
- 1.1.1 Rotating wheels
- 1.1.2 Wheel change, protecting wheel centring seat against corrosion
- 1.1.3 Wheel replacement, assembly conditions
- 1.1.4 Wheel change, installation instructions for wheel change
- 1.1.5 Wheel change, wheel installation
- 1.1.6 Wheel change, position of anti-theft wheel bolts for steel wheels
- 1.2 Tightening torque of the wheel screws
- 1.3 Disposing of tyre sealant
- 1.4 Vehicles with breakdown set
- 2 Chassis - Specified values
- 2.1 Nominal values front axle
- 2.2 Nominal values rear axle
- 2.3 Finding and interpreting chassis PR numbers
- 3 Axle alignment
- 3.1 General points
- 3.2 Measurement preliminaries
- 3.3 Axle alignment
- 3.4 Overview of the work sequence for the axle alignment
- 3.5 Check transversal inclination of the vehicle “straight-ahead position”
- 3.6 Adjusting camber at front wheels
- 3.6.1 Adjust the camber on the front axle - aluminium assembly carrier
- 3.6.2 Adjusting the camber on the front axle - assembly carrier made of steel sheet
- 3.7 Adjust the camber on the rear axle
- 3.8 Adjust the track on the rear axle
- 3.9 Adjust the track on the front axle
- 3.10 Check position of steering wheel, align if necessary
48 – Steering
- 1 Steering column
- 1.1 Summary of components - steering column
- 1.1.1 Summary of components of steering column - left-hand drive without knee airbag
- 1.1.2 Summary of components of steering column - left-hand drive with knee airbag
- 1.1.3 Summary of components of steering column - right-hand drive without knee airbag
- 1.1.4 Summary of components of steering column - right-hand drive with knee airbag
- 1.2 Check the steering column for damage
- 1.3 Observe handling and transportation of the steering column
- 1.4 Removing and installing steering column
- 1.4.1 Removing and installing steering column, left-hand drive
- 1.4.2 Removing and installing steering column, right-hand drive
- 1.5 Removing and installing holder for steering column and frequency link, right-hand drive
- 2 Steering gear
- 2.1 Summary of components - steering gear
- 2.1.1 Summary of components - steering gear, left-hand drive, aluminium assembly carrier
- 2.1.2 Summary of components - steering gear, right-hand drive, aluminium assembly carrier
- 2.1.3 Summary of components - steering gear, left-hand drive, sheet steel assembly carrier
- 2.1.4 Summary of components - steering gear, right-hand drive, sheet steel assembly carrier
- 2.2 Removing and installing steering gear
- 2.2.1 Removing and installing steering gear, left-hand drive, aluminium assembly carrier
- 2.2.2 Removing and installing steering gear, right-hand drive, aluminium assembly carrier
- 2.2.3 Removing and installing steering gear, left-hand drive, sheet steel assembly carrier
- 2.2.4 Removing and installing steering gear, right-hand drive, sheet steel assembly carrier
- 2.3 Removing and installing bellows
- 2.4 Removing and installing track rod
- 2.5 Removing and installing track rod ends
- 2.6 Repairing steering box
Brake System
00 – Technical data
- 1 Safety instructions
- 1.1 Safety precautions when working on vehicles with a start/stop system
- 1.2 Safety precautions during road tests in which testing and measuring equipment is used
- 2 Denomination
- 2.1 PR number assignment – brake
- 3 Technical data
- 3.1 Technical data for brakes
- 3.1.1 Brake master cylinder and brake servo
- 3.1.2 Front brakes
- 3.1.3 Rear brake
- 3.1.4 Brake fluid
- 4 Brake inspection
- 4.1 General points
- 4.2 Checking vehicles with front-wheel drive
- 4.3 Testing vehicles with four-wheel drive
45 – Anti-lock brake system
- 1 General points
- 1.1 Repair instructions for repair work on ABS
- 1.2 Distinguishing features of the ABS systems
- 1.3 Indication of faults by means of warning lights
- 1.3.1 Indicates faults by means of warning lights, vehicles up to CW 21/2010
- 1.3.2 Faults indicated by warning lights; vehicles from CW 22/2010
- 2 Installation location overview
- 2.1 Installation location overview - ABS
- 2.1.1 Installation location overview - ABS, ABS Mark 70 (ABS/TCS) up to CW 21/2010
- 2.1.2 Installation location overview - ABS, ABS Mark 70 (ABS/TCS) up to CW 22/2010
- 2.2 ABS/ESP installation location overview
- 2.2.1 Installation location overview - ABS/ESP Mark 60 EC (ABS/EDL/TCS/ESP) up to CW 21/2010
- 2.2.2 Installation location overview - ABS/ESP Mark 60 EC (ABS/EDL/TCS/ESP) up to CW 22/2010
- 3 Control unit and hydraulic unit
- 3.1 Exploded view – control unit and hydraulic unit
- 3.1.1 Summary of components - control unit and hydraulic unit, Mark 60 EC, left-hand drive vehicles
- 3.1.2 Summary of components – control unit and hydraulic unit, Mark 60 EC, right-hand drive vehicles
- 3.1.3 Summary of components - control unit and hydraulic unit, Mark 70, left-hand drive vehicles
- 3.1.4 Summary of components – control unit and hydraulic unit, Mark 70, right-hand drive vehicles
- 3.2 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-
- 3.2.1 Removing and installing the ABS control unit -J104-/ABS hydraulic unit -N55-, Mark 60 EC, left-hand drive vehicles
- 3.2.2 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-, Mark 60 EC, right-hand drive vehicles
- 3.2.3 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-, Mark 70, left-hand drive vehicles
- 3.2.4 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-, Mark 70, right-hand drive vehicles
- 3.3 Disconnecting the control unit from the hydraulic unit
- 3.3.1 Disconnecting the control unit from the hydraulic unit, Mark 60 EC
- 3.3.2 Disconnecting the control unit from the hydraulic unit, Mark 70 EC
- 3.4 Fitting the control unit to the hydraulic unit
- 3.4.1 Fitting the control unit to the hydraulic unit, Mark 60 EC
- 3.4.2 Fitting the control unit to the hydraulic unit, Mark 70
- 3.5 Connecting brake lines to hydraulic unit
- 3.5.1 Connecting the brake lines to the hydraulic unit, Mark 60 EC, left-hand drive vehicles
- 3.5.2 Connecting the brake lines to the hydraulic unit, Mark 60 EC, right-hand drive vehicles
- 3.5.3 Connecting the brake lines to the hydraulic unit, Mark 70, left-hand drive vehicles
- 3.5.4 Connecting the brake lines to the hydraulic unit, Mark 70, right-hand drive vehicles
- 4 Sender
- 4.1 Assembly overview - speed sensor on front axle
- 4.2 Assembly overview - speed sensor on rear axle
- 4.2.1 Summary of components - speed sensors on rear axle, vehicles with front-wheel drive
- 4.2.2 Summary of components - speed sensors on rear axle, vehicles with four-wheel drive
- 4.3 Removing and installing front speed sensors -G45-/-G47-
- 4.4 Removing and installing the rear speed sensors -G44-/-G46-
- 4.4.1 Removing and installing rear speed sensors -G44-/-G46-, vehicles with front-wheel drive
- 4.4.2 Removing and installing rear speed sensors -G44-/-G46-, vehicles with four-wheel drive
46 – Brakes - mechanism
- 1 Front brakes
- 1.1 Assembly overview - front brakes
- 1.1.1 Summary of components - front brakes, FS-III brake
- 1.1.2 Summary of components - front brakes, FN3 brake
- 1.2 Removing and installing brake linings
- 1.2.1 Changing the brake pads of the front brake - Mounting instructions
- 1.2.2 Removing and installing brake pads, FS-III brake
- 1.2.3 Removing and installing brake pads – FN3 brake
- 1.3 Removing and installing brake caliper
- 1.3.1 Removing and installing brake caliper, FS-III brake
- 1.3.2 Removing and installing brake caliper, FN3 brake
- 2 Rear brakes
- 2.1 Assembly overview - rear brakes
- 2.1.1 Summary of components - rear brakes, FN CII 41 brake
- 2.1.2 Summary of components - rear brakes, Bosch BIRIII brake
- 2.1.3 Summary of components - rear brakes, CI 38 brake
- 2.2 Removing and installing brake linings
- 2.2.1 Changing the brake pads of the rear brake - Mounting instructions
- 2.2.2 Removing and installing brake linings, CII 41 brake
- 2.2.3 Removing and installing brake pads, Bosch BIRIII brake
- 2.2.4 Removing and installing brake linings, CI 38 brake
- 2.3 Removing and installing brake caliper
- 2.3.1 Removing and installing brake caliper, CII 41 brake
- 2.3.2 Removing and installing brake caliper, Bosch BIRIII brake
- 2.3.3 Removing and installing brake caliper, CI 38 brake
- 3 Handbrake
- 3.1 Assembly overview - parking brake
- 3.2 Adjusting parking brake
- 3.3 Removing and installing the rear handbrake cable
- 4 Brake pedal
- 4.1 Assembly overview - brake pedal
- 4.1.1 Summary of components - brake pedal, left-hand drive
- 4.1.2 Summary of components - brake pedal, right-hand drive
- 4.2 Removing and installing bearing bracket
- 4.2.1 Removing and installing bushing, left-hand drive vehicles
- 4.2.2 Removing and installing bearing bracket, right-hand drive vehicles
- 4.3 Removing and installing brake light switch
- 4.3.1 Removing and installing brake light switch -F- and brake pedal switch -F47-, left-hand drive vehicles
- 4.3.2 Removing and installing brake light switch -F- and brake pedal switch -F47-, right-hand drive vehicles
- 4.4 Separating brake pedal from brake servo
- 4.5 Removing and installing brake pedal
- 4.5.1 Removing and installing the brake pedal, left-hand drive vehicles
- 4.5.2 Removing and installing the brake pedal, right-hand drive vehicles
47 – Brakes - hydraulics
- 1 Front brake calipers
- 1.1 Exploded view - front brake caliper
- 1.1.1 Summary of components - front brake caliper, FS-III brake
- 1.1.2 Summary of components - front brake caliper, FN3 brake
- 1.2 Removing and installing brake caliper piston
- 1.2.1 Removing and installing brake caliper piston, FS-III brake
- 1.2.2 Removing and installing brake caliper piston, FN3 brake
- 2 Rear brake caliper
- 2.1 Assembly overview - rear brake caliper
- 2.1.1 Summary of components - rear brake caliper, CII 41 brake
- 2.1.2 Summary of components - rear brake caliper, Bosch BIRIII brake
- 2.1.3 Summary of components - rear brake caliper, CI 38 brake
- 2.2 Removing and installing brake caliper piston
- 2.2.1 Removing and installing brake caliper piston, CII 41 brake
- 2.2.2 Removing and installing brake caliper piston, Bosch BIRIII brake
- 2.2.3 Removing and installing brake caliper piston, CI 38 brake
- 3 Brake servo unit and master brake cylinder
- 3.1 Summary of components - brake servo unit and master brake cylinder
- 3.1.1 Summary of components - brake servo unit/master brake cylinder, left-hand drive vehicles
- 3.1.2 Summary of components - brake servo unit/master brake cylinder, right-hand drive vehicles
- 3.2 Removing and installing brake servo
- 3.2.1 Removing and installing brake servo unit, left-hand drive vehicles
- 3.2.2 Removing and installing brake servo unit - right-hand drive
- 3.3 Removing and installing brake master cylinder
- 3.3.1 Removing and installing master brake cylinder, left-hand drive vehicles
- 3.3.2 Removing and installing master brake cylinder, right-hand drive vehicles
- 3.4 Check the operation of the brake servo unit
- 3.5 Checking the master brake cylinder for tightness
- 3.6 Fitting position of the cap from the brake fluid reservoir
- 4 Vacuum system
- 4.1 Exploded view – vacuum pump
- 4.1.1 Summary of components - vacuum pump, vehicles with petrol engines
- 4.1.2 Summary of components - vacuum pump, vehicles with diesel engines
- 4.2 Checking the non-return valve
- 4.3 Vacuum sensor -G608-, vehicles with four-wheel and left-hand drive
- 5 Brake lines
- 5.1 Repairing brake lines
- 5.1.1 Assembly overview - Flaring tool
- 5.1.2 Work instruction
- 6 Hydraulic system
- 6.1 General notes on brake fluid
- 6.2 Prebleeding the hydraulic system
- 6.3 Bleeding hydraulic system following standard procedure
- 6.4 Subsequent bleeding of hydraulic system
- 6.5 Testing leak-tightness
Electrical System- General notes
27 – Starter, current supply, CCS
- 1 Battery
- 1.1 Basics about batteries
- 1.2 Battery types
- 1.2.1 Batteries with a magic eye
- 1.2.2 Fleece batteries (AGM batteries)
- 1.3 Warning instructions and safety precautions when working on the battery
- 1.4 Screwed connections of battery poles
- 1.5 No-load voltage measurement - Demonstration vehicles and stock vehicles
- 2 Checking the battery
- 2.1 Visual inspection of the battery
- 2.2 Check battery with a magic eye
- 2.2.1 “Checking the two-coloured” indicator of the magic eye
- 2.2.2 “Checking the three-coloured” indicator of the magic eye
- 2.3 Checking fleece battery (AGM)
- 2.4 Checking battery with battery tester with printer -VAS 6161- or with battery tester with printer -VAS 5097 A-
- 2.5 Check current drain when charging
- 3 Charge battery
- 3.1 Charging battery
- 3.2 Severely discharged batteries
- 4 Cruise control system (CCS)
- 4.1 General description
- 4.2 Activate/deactivate cruise control system
92 – Windscreen wash/wipe system
- 1 Repairing washer fluid level pipes
- 1.1 Repair solution for plain ended pipe
- 1.2 Repair solution for corrugated pipe
- 1.2.1 Repairing corrugated washer fluid level pipes - vehicles up to 12.2010
- 1.2.2 Repairing corrugated washer fluid level pipes - vehicles as of 01.2011
- 2 Washer fluid lines
- 2.1 Connections of washer fluid level pipes
94 – Lights, bulbs, switches - exterior
- 1 Gas discharge lamps
- 1.1 Use and safety instructions for gas discharge lamps
96 – Lights, bulbs, switches - interior
- 1 12V power sockets, cigarette lighter
- 1.1 Removing and installing the 12 V power socket/cigarette lighter in the centre console
97 – Wiring
- 1 Vehicle diagnosis, measurement and information systems
- 1.1 Safety instructions
- 1.2 Connect vehicle diagnosis, measurement and information system VAS 505x
- 2 Wiring loom repair
- 2.1 General instructions for the repair on the vehicle electrics
- 2.2 General instructions for wiring loom and plug repair
- 2.3 Tool descriptions
- 2.3.1 Stop plier with insert
- 2.3.2 Release tools for contacts
- 2.3.3 Assembly tools for single cable seals
- 2.3.4 Wire stripper -VAS 1978/3-
- 2.3.6 Crimping pliers -VAS 1978/1A-
- 2.4 Repair of airbag and belt tensioner cables
- 2.5 Repair of CAN bus lines
- 2.6 Repairing wires with a cross-section of up to 0.35 mm2
- 2.7 Line break with single repair point
- 2.8 Line break with two repair points
- 3 Repairing socket housings and connectors
- 3.1 Notes on repairing socket housings and connectors
- 3.2 Repairing contacts in socket housings
- 3.3 Assembly of single cable seals
- 4 Unlocking and disassembling socket housings
- 4.1 Notes on unlocking and disassembling socket housings
- 4.2 Secondary lock
- 4.3 Primary lock
- 4.3.1 Round plug connector systems
- 4.3.2 Flat plug connector systems
- 4.3.3 Special connector systems
- 5 Repairing optical fibres
- 5.1 General points
- 5.2 Preparing optical fibres
- 5.3 Removing and installing optical fibre in the housing
- 6 Contact surface cleaning set -VAS 6410-
- 6.1 Use contact surface cleaning set -VAS 6410-
- 6.2 Repairing the cable eyes
- 6.3 Repairing screwed connections
- 6.4 Cleaning the battery pole terminals and battery poles
- 6.5 Preserving
- 7 Replace the lambda probe
- 7.1 Replace the LSF lambda probe (4-pole)
- 7.2 Replace the LSU lambda probe (6-pole)
- 7.3 Protective pipe variants of the unit lambda probes
Gearbox 0A4
00 – Technical data
- 1 Identification
- 1.1 Identification of the gearbox
- 1.2 Identification characters, aggregate assignment, ratios, filling capacities (Octavia II)
- 1.3 Identification characters, aggregate assignment, ratios, filling capacities (Octavia III)
- 1.4 Identification characters, aggregate assignment, ratios, filling capacities (Superb II)
- 1.5 Identification characters, aggregate assignment, ratios, filling capacities (Yeti)
- 2 Overview of Transmission System
- 2.1 Designation of components and transmission ratio
- 3 General repair information
- 3.1 Notes
- 3.2 Contact corrosion
- 3.3 Safety measures for working on vehicles with start/stop system
- 3.4 Safety precautions during road tests in which testing and measuring equipment is used
- 3.5 Components
30 – Clutch
- 1 Clutch control
- 1.1 Summary of components - Foot controls
- 1.1.1 Summary of components - Foot controls - Octavia ll
- 1.1.2 Summary of components - Foot controls - Superb II
- 1.1.3 Summary of components - Foot controls - Yeti
- 1.1.4 Summary of components - Foot controls - Octavia III
- 1.2 Removing and installing holder for knee airbag with crash strut for clutch pedal (Yeti)
- 1.3 Removing and installing bearing bush
- 1.4 Removing and installing over-centre helper spring (Octavia II)
- 1.5 Removing and installing over-centre helper spring (Octavia III)
- 1.6 Removing and installing over-centre helper spring (Superb II)
- 1.7 Removing and installing over-centre helper spring (Yeti)
- 1.8 Removing and installing tension spring and over-centre helper spring (Octavia III)
- 1.9 Removing and installing clutch pedal (Octavia II)
- 1.10 Removing and installing clutch pedal (Octavia IlI)
- 1.11 Removing and installing clutch pedal (Superb II)
- 1.12 Removing and installing clutch pedal (Yeti)
- 1.13 Removing and installing bearing bracket for clutch pedal (Octavia II)
- 1.14 Removing and installing bearing bracket for clutch pedal (Octavia III)
- 1.15 Removing and installing bearing bracket for clutch pedal (Superb II)
- 1.16 Removing and installing bearing block for clutch pedal (Yeti)
- 1.17 Removing and installing master cylinder (Octavia II)
- 1.18 Removing and installing master cylinder (Octavia IIl)
- 1.19 Removing and installing master cylinder (Superb II)
- 1.20 Removing and installing master cylinder (Yeti)
- 1.21 Removing and installing clutch position sender -G476- (Octavia II)
- 1.22 Removing and installing clutch position sender -G476- (Octavia IIl)
- 1.23 Removing and installing clutch position sender -G476- (Superb II)
- 1.24 Removing and installing clutch position sender -G476- (Yeti)
- 1.25 Summary of components - Hydraulics (Octavia II, Superb II and Yeti)
- 1.26 Summary of components - Hydraulics (Octavia III)
- 1.27 Check hydraulic clutch control
- 1.28 Removing and installing slave cylinder (Octavia II)
- 1.28.1 Removing
- 1.28.2 Install
- 1.29 Removing and installing master cylinder (Octavia III)
- 1.30 Removing and installing slave cylinder (Superb II)
- 1.30.1 Removing
- 1.30.2 Install
- 1.31 Removing and installing slave cylinder (Yeti)
- 1.31.1 Removing
- 1.31.2 Install
- 1.32 Removing and installing cables for clutch control (Octavia III)
- 1.33 Bleeding the clutch control (Octavia II, Superb II) and Yeti)
- 1.34 Bleeding the clutch control (Octavia III)
- 2 Repairing clutch control
- 2.1 Assembly overview - clutch release mechanism
- 2.2 Remove and install the clutch release lever together with the release bearing and guide bushing
- 3 Repairing clutch
- 3.1 Summary of components - Repairing the clutch make “Sachs”
- 3.2 Removing and installing clutch make “Sachs”
- 3.2.1 Removing
- 3.2.2 Install
- 3.3 Summary of components - Repairing the clutch make “LuK”
- 3.4 Removing and installing clutch make “Luk”
- 3.4.1 Removing
- 3.4.2 Install
- 3.5 Fault finding power transmission - problems with the clutch and clutch control
34 – Controls, housing
- 1 Shift mechanism
- 1.1 Fitting location of shift mechanism
- 1.2 Summary of components (Octavia ll)
- 1.3 Summary of components (Octavia III)
- 1.4 Summary of components (Superb II)
- 1.5 Summary of components (Yeti)
- 1.6 Summary of components - gearshift knob with shift lever collar (Octavia II)
- 1.7 Summary of components - gearshift knob with shift lever collar (Octavia III)
- 1.8 Summary of components - gearshift knob with shift lever collar (Superb II)
- 1.9 Summary of components - Gearshift knob with shift lever collar (Yeti)
- 1.10 Removing and installing gearshift knob with shift lever collar (Octavia II)
- 1.11 Removing and installing gearshift knob with shift lever collar (Octavia IIl)
- 1.12 Removing and installing gearshift knob with shift lever collar (Superb II)
- 1.13 Removing and installing gearshift knob with shift lever collar (Yeti)
- 1.14 Summary of components - Gearshift mechanism up to 10.06
- 1.15 Summary of components - Gearshift mechanism as of 11.06
- 1.16 Disassembling and assembling the gearshift mechanism
- 1.16.1 Dismantling
- 1.16.2 Assembling together
- 1.17 Summary of components - Control cables up to 10.06
- 1.18 Summary of components - Control cables as of 11.06
- 1.19 Plastic relay lever
- 1.20 Remove and install shift mechanism (Octavia II, Octavia III)
- 1.20.1 Removing
- 1.20.2 Install
- 1.21 Removing and installing shift mechanism (Superb II)
- 1.21.1 Removing
- 1.21.2 Install
- 1.22 Removing and installing shift mechanism (Yeti)
- 1.22.1 Removing
- 1.22.2 Install
- 1.23 Removing and installing shift cable and selector cable
- 1.23.1 Removing
- 1.23.2 Install
- 1.24 Setting the clutch control (Octavia II, Superb II and Yeti)
- 1.24.1 Operation
- 1.25 Setting shift mechanism (Octavia IlI)
- 1.25.1 Check function
- 2 Removing and installing the gearbox
- 2.1 Remove gearbox (Octavia II and Octavia III)
- 2.1.1 Transporting the gearbox
- 2.2 Install gearbox (Octavia II and Octavia III)
- 2.2.1 Tightening torques
- 2.3 Remove gearbox (Superb II)
- 2.3.1 Transporting the gearbox
- 2.4 Install gearbox (Superb II)
- 2.4.1 Tightening torques
- 2.5 Removing gearbox (Yeti)
- 2.5.1 Transporting the gearbox
- 2.6 Installing gearbox (Yeti)
- 2.6.1 Tightening torques
- 3 Check gear oil level
- 3.1 Draining out gear oil
- 3.2 Pour in gear oil
- 4 Disassembling and assembling the gearbox
- 4.1 Gearbox - Summary of components
- 4.2 Summary of components
- 4.3 Removing and installing gearbox housing cover and 5th gear
- 4.4 Removing and installing gearbox housing and shift mechanism
- 4.5 Removing and installing the drive shaft, output shaft, differential gear and shift forks
- 4.6 Mounting sequence - Removing and installing gearbox housing cover and 5th gear
- 4.6.1 Removing gearbox housing cover and 5th gear
- 4.6.2 Mount 5th gear and cover for gearbox housing
- 4.7 Mounting sequence - completely disassembling and assembling the gearbox
- 4.7.1 Disassembling gearbox
- 4.7.2 Assembling gearbox
- 4.7.3 Install 5th gear
- 5 Repairing gearbox housing and clutch housing
- 6 Repairing the shift mechanism on the gearbox
- 7 Disassembling and assembling the gearshift forks
35 – Gears, shafts
- 1 Drive shaft
- 1.1 Disassembling and assembling the drive shaft
- 1.2 Setting drive shaft
- 1.2.1 Determine the adjusting washer
- 1.2.2 Control measurement
- 2 Output shaft
- 2.1 Disassembling and assembling the output shaft
- 2.2 Setting output shaft
- 2.2.1 Determine the adjusting washer
- 3 Reverse shaft
- 3.1 Disassembling and assembling the reverse shaft
39 – Final drive - differential
- 1 Replacing gasket rings for flange shafts with gearbox installed
- 1.1 Replacing the left flange shaft gasket ring
- 1.1.1 Removing
- 1.1.2 Install
- 1.2 Difference between the gasket rings with right flange
- 1.3 Replace gasket ring in separated version for right flange shaft
- 1.3.1 Removing
- 1.3.2 Install
- 1.4 Replace gasket ring in single version (together with bushing) for right flange shaft
- 1.4.1 Removing
- 1.4.2 Install
- 2 Differential gear
- 2.1 Disassembling and assembling differential gear
- 2.2 Adjusting the differential gear
- 2.2.1 Determine the adjusting washer
- 3 Setting overview
Gearbox 0AJ
00 – Technical data
- 1 Identification of the gearbox
- 1.1 Location on the gearbox
- 1.2 Identification characters, aggregate assignment, ratios, capacities
- 1.2.1 Identification characters, aggregate assignment, ratios, filling capacities (Octavia II)
- 1.2.2 Identification characters, aggregate assignment, ratios, filling capacities (Octavia III)
- 1.2.3 Identification characters, aggregate assignment, ratios, filling capacities (Superb II)
- 1.2.4 Identification characters, aggregate assignment, ratios, filling capacities (Yeti)
- 2 Transmission System - Overview
- 2.1 Designation of components and transmission ratio
- 3 General repair information
- 3.1 Components
30 – Clutch
- 1 Repairing clutch control
- 1.1 Overview
- 1.2 Summary of components - Foot controls
- 1.2.1 Summary of components - Foot controls (Octavia II, Superb II and Yeti)
- 1.2.2 Summary of components - Foot controls (Octavia III)
- 1.3 Summary of components - Hydraulics
- 1.3.1 Summary of components - Hydraulics - Left-hand drive (Octavia II, Superb II and Yeti)
- 1.3.2 Summary of components - Hydraulics - Right-hand drive (Octavia II, Superb II and Yeti)
- 1.3.3 Summary of components - Hydraulics (Octavia III)
- 1.4 Removing and installing holder for knee airbag with crash strut for clutch pedal (Yeti)
- 1.5 Removing and installing bearing bush (Octavia III)
- 1.6 Removing and installing the over-centre helper spring
- 1.6.1 Removing and installing over-centre helper spring (Octavia II)
- 1.6.2 Removing and installing over-centre helper spring (Octavia III)
- 1.6.3 Removing and installing over-centre helper spring (Superb II)
- 1.6.4 Removing and installing over-centre helper spring (Yeti)
- 1.7 Removing and installing tension spring and over-centre helper spring (Octavia III)
- 1.8 Removing and installing the clutch pedal
- 1.8.1 Removing and installing clutch pedal (Octavia II)
- 1.8.2 Removing and installing clutch pedal (Octavia IlI)
- 1.8.3 Removing and installing clutch pedal (Superb II)
- 1.8.4 Removing and installing clutch pedal (Yeti)
- 1.9 Removing and installing bearing block for clutch pedal
- 1.9.1 Removing and installing bearing bracket for clutch pedal (Octavia II)
- 1.9.2 Removing and installing bearing bracket for clutch pedal (Octavia III)
- 1.9.3 Removing and installing bearing bracket for clutch pedal (Superb II)
- 1.9.4 Removing and installing bearing block for clutch pedal (Yeti)
- 1.10 Removing and installing the master cylinder
- 1.10.1 Removing and installing master cylinder (Octavia II)
- 1.10.2 Removing and installing master cylinder (Octavia IIl)
- 1.10.3 Removing and installing master cylinder (Superb II)
- 1.10.4 Removing and installing master cylinder (Yeti)
- 1.11 Removing and installing clutch position sender
- 1.11.1 Removing and installing clutch position sender -G476- (Octavia II)
- 1.11.2 Removing and installing clutch position sender -G476- (Octavia IIl)
- 1.11.3 Removing and installing clutch position sender -G476- (Superb II)
- 1.11.4 Removing and installing clutch position sender -G476- (Yeti)
- 1.12 Check hydraulic clutch control
- 1.13 Removing and installing the slave cylinder
- 1.13.1 Removing and installing slave cylinder (Octavia II)
- 1.13.2 Removing and installing master cylinder (Octavia III)
- 1.13.3 Removing and installing slave cylinder (Superb II)
- 1.13.4 Removing and installing slave cylinder (Yeti)
- 1.14 Removing and installing cables for clutch control (Octavia III)
- 1.15 Bleeding the clutch control
- 1.15.1 Bleeding the clutch control (Octavia II, Superb II) and Yeti)
- 1.15.2 Bleeding the clutch control (Octavia III)
- 2 Clutch release mechanism
- 2.1 Assembly overview - clutch release mechanism
- 2.2 Repairing clutch control
- 3 Repairing clutch
- 3.1 Summary of components - repairing the clutch
- 3.2 Removing and installing clutch
- 3.3 Fault finding power transmission - problems with the clutch and clutch control
34 – Controls, housing
- 1 Repairing shift mechanism
- 1.1 Fitting location of shift mechanism
- 1.2 Summary of components for clutch
- 1.3 Summary of components - Gearshift knob with shift lever collar
- 1.3.1 Summary of components - gearshift knob with collar (Octavia II)
- 1.3.2 Summary of components - gearshift knob with shift lever collar (Octavia III)
- 1.3.3 Summary of components - gearshift knob with collar (Superb II)
- 1.3.4 Summary of components - Gearshift knob with collar (Yeti)
- 1.4 Summary of components - Gearshift mechanism
- 1.5 Summary of components - Control cables
- 1.6 Removing and installing gearshift knob with shift lever collar
- 1.6.1 Removing and installing gearshift knob with collar (Octavia II)
- 1.6.2 Removing and installing gearshift knob with shift lever collar (Octavia IIl)
- 1.6.3 Removing and installing gearshift knob with collar (Superb II)
- 1.6.4 Removing and installing gearshift knob with collar (Yeti)
- 1.7 Removing and installing selector mechanism
- 1.7.1 Remove and install shift mechanism (Octavia II, Octavia III)
- 1.7.2 Removing and installing shift mechanism (Superb II)
- 1.7.3 Removing and installing shift mechanism (Yeti)
- 1.8 Disassembling and assembling shift mechanism housing
- 1.9 Removing and installing the cable lock from the relay lever
- 1.10 Removing and installing shift cable and selector cable
- 1.11 Setting the shift mechanism
- 1.11.1 Setting the clutch control (Octavia II, Superb II and Yeti)
- 1.11.2 Setting shift mechanism (Octavia IlI)
- 2 Removing and installing the gearbox
- 2.1 Removing the gearbox
- 2.1.1 Remove gearbox (Octavia II and Octavia III)
- 2.1.2 Remove gearbox (Superb II)
- 2.1.3 Removing gearbox (Yeti)
- 2.2 Installing the gearbox
- 2.3 Tightening torques
- 2.3.1 Tightening torques (Octavia II and Octavia III)
- 2.3.2 Tightening torques (Superb II)
- 2.3.3 Tightening torques (Yeti)
- 2.4 Transporting the gearbox
- 3 Gear oil
- 3.1 Check gear oil level
- 4 Disassembling and assembling the gearbox
- 4.1 Schematic overview - Gearbox
- 4.2 Summary of components of gearbox
- 4.3 Summary of components- Gearbox housing cover and 5th/6th gear
- 4.4 Summary of components - Clutch housing
- 4.5 Summary of components - Shafts, differential gear and gearshift forks
- 4.6 Summary of components - Gearshift unit
- 4.7 Assembly overview - shift forks
- 4.8 Repairing gearshift forks‎
- 4.9 Repairing gearshift unit
- 4.10 Disassembling and assembling the gearbox
- 5 Gearbox housing, clutch housing
- 5.1 Summary of components - Gearbox housing,clutch housing
- 5.2 Summary of components- Gearbox housing cover
- 5.3 Repairing gearbox housing cover
35 – Gears, shafts
- 1 Drive shaft
- 1.1 Summary of components - Drive shaft
- 1.2 Disassembling and assembling the drive shaft
- 1.3 Replace gasket ring for drive shaft
- 2 Output shaft
- 2.1 Summary of components - Output shaft
- 2.2 Disassembling and assembling the output shaft
39 – Final drive - differential
- 1 Replacing the flange shaft gasket rings (gearbox assembled)
- 1.1 Replacing the left flange shaft gasket ring
- 1.2 Replacing the right flange shaft seal ring
- 2 Differential gear
- 2.1 Summary of components - Differential
- 2.1.1 Differential gear - Summary of components (Octavia II, Superb II and Yeti) .
- 2.1.2 Differential gear - Summary of components (Octavia III)
- 2.2 Disassembling and assembling differential gear
- 2.3 Adjusting the differential gear
Gearbox 02Q anf 0FB
00 – Technical data
- 1 Identification of the gearbox
- 1.1 Location on the gearbox
- 1.2 Identification characters, aggregate assignment, ratios, filling capacities (Octavia II)
- 1.3 Identification characters. aggregate assignment. ratios. filling capacities (Octavia III)
- 1.4 Identification characters. aggregate assignment. ratios. filling capacities (Superb II)
- 1.5 Identification characters. aggregate assignment. ratios. filling capacities (Yeti)
- 2 Transmission System - Overview
- 2.1 Front-wheel-drive
- 2.2 Four-wheel drive
- 3 General repair information
- 3.1 Notes
- 3.2 Contact corrosion
- 3.3 Safety measures for working on vehicles with start/stop system
- 3.4 Safety precautions during road tests in which testing and measuring equipment is used
- 3.5 Components
30 – Clutch
- 1 Repairing clutch control
- 1.1 Overview
- 1.2 Summary of components - Foot controls (Octavia II. Superb II and Yeti)
- 1.3 Summary of components - Foot controls (Octavia III)
- 1.4 Removing and installing holder for knee airbag with crash strut for clutch pedal (Yeti)
- 1.5 Removing and installing bearing bush (Octavia III)
- 1.6 Removing and installing over-centre helper spring (Octavia II)
- 1.7 Removing and installing over-centre helper spring (Octavia III)
- 1.8 Removing and installing over-centre helper spring (Superb II)
- 1.9 Removing and installing over-centre helper spring (Yeti)
- 1.10 Removing and installing tension spring and over-centre helper spring (Octavia III)
- 1.11 Removing and installing clutch pedal (Octavia II. Superb II. Yeti)
- 1.12 Removing and installing clutch pedal (Octavia IlI)
- 1.13 Removing and installing bearing bracket for clutch pedal (Octavia II)
- 1.14 Removing and installing bearing bracket for clutch pedal (Octavia III)
- 1.15 Removing and installing bearing bracket for clutch pedal (Superb II)
- 1.16 Removing and installing bearing block for clutch pedal (Yeti)
- 1.17 Removing and installing master cylinder (Octavia II. Superb II. Yeti)
- 1.18 Removing and installing master cylinder (Octavia IIl)
- 1.19 Removing and installing clutch position sender -G476- (Octavia II)
- 1.20 Removing and installing clutch position sender -G476- (Octavia IIl)
- 1.21 Removing and installing clutch position sender -G476- (Superb II)
- 1.22 Removing and installing clutch position sender -G476- (Yeti)
- 1.23 Summary of components - Hydraulic (Octavia II and Superb II)
- 1.24 Summary of components - Hydraulics (Octavia III)
- 1.25 Summary of components - Hydraulic (Yeti)
- 1.26 Check hydraulic clutch control
- 1.27 Removing and installing cables for clutch control (Octavia III)
- 1.28 Bleed the clutch control
- 2 Repairing clutch control
- 2.1 Summary of components - Front-wheel-drive
- 2.2 Summary of components - Four-wheel drive
- 2.3 Remove and install slave cylinder with clutch release bearing
- 2.4 Replace gasket ring for drive shaft
- 3 Repairing clutch
- 3.1 Distinguished based on coupling manufacturer
- 3.2 Summary of components - Repairing the clutch make Sachs
- 3.3 Removing and installing clutch make Sachs
- 3.4 Summary of components - Repairing the clutch make LuK
- 3.5 Removing and installing clutch make LuK
- 3.6 Fault finding power transmission - problems with the clutch and clutch control
34 – Controls, housing
- 1 Repairing shift mechanism
- 1.1 Fitting location of shift mechanism
- 1.2 Summary of components (Octavia ll)
- 1.3 Summary of components (Octavia III)
- 1.4 Summary of components (Superb II)
- 1.5 Summary of components (Yeti)
- 1.6 Summary of components - gearshift knob with shift lever collar (Octavia II)
- 1.7 Summary of components - gearshift knob with shift lever collar (Octavia III)
- 1.8 Summary of components - gearshift knob with shift lever collar (Superb II)
- 1.9 Summary of components - Gearshift knob with shift lever collar (Yeti)
- 1.10 Removing and installing gearshift knob with shift lever collar (Octavia II)
- 1.11 Removing and installing gearshift knob with shift lever collar (Octavia IIl)
- 1.12 Removing and installing gearshift knob and shift lever collar (Superb II)
- 1.13 Removing and installing gearshift knob with shift lever collar (Yeti)
- 1.14 Summary of components - Gearshift mechanism (Octavia II up to 10.06)
- 1.15 Summary of components - Gearshift mechanism (Octavia II as of 11.06)
- 1.16 Summary of components - Gearshift mechanism (Octavia III)
- 1.17 Summary of components - Gearshift mechanism (Superb II)
- 1.18 Summary of components - Gearshift mechanism (Yeti)
- 1.19 Disassembling and assembling the gearshift mechanism (as of 11.2006)
- 1.19.1 Dismantling
- 1.19.2 Assembling together
- 1.20 Summary of components