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
Service Department. Technical Information
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
Service
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
4.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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Contents i
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
4.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
1.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
characters BLR, BLX, BLY, BVX, BVY, BVZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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
OCTAVIA II 2004 ➤
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ii Contents
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
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
OCTAVIA II 2004 ➤
2.0/110; 147 kW FSI Engine - Edition 02.05
Contents iii
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Description
The 2010 SKODA Octavia Scout Download Service & Repair Manual is a comprehensive guide designed to assist owners of the 2010 SKODA Octavia Scout model in maintaining and repairing their vehicle. Whether you are a skilled mechanic or a passionate DIY enthusiast, this manual will provide you with detailed step-by-step instructions and illustrations to ensure you can tackle any service or repair task with confidence.
- Easy-to-follow instructions for routine maintenance tasks such as oil changes, filter replacements, and fluid checks.
- Detailed information on troubleshooting and diagnosing common problems, allowing you to save time and money by identifying issues before they become major concerns.
- Comprehensive repair procedures covering all major systems and components, including the engine, transmission, suspension, electrical system, and more.
- Clear and concise wiring diagrams and schematics, enabling you to easily trace and resolve electrical issues.
- Specifications, torque settings, and detailed explanations of the various systems and components, ensuring you have all the necessary information to perform repairs correctly.
- Includes download links for the manual, allowing you to access the information directly on your computer, tablet, or smartphone, making it easily portable and accessible wherever you are.
No matter your level of expertise, the 2010 SKODA Octavia Scout Download Service & Repair Manual is an invaluable resource that will empower you to maintain and repair your vehicle with confidence. Get your copy today and ensure your SKODA Octavia Scout stays in optimal condition for years to come.
