2004-2012 Skoda Octavia Service & Repair Manual
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Workshop Manual
Octavia II 2004 ➤ , Octavia II 2010 ➤ ,
Superb II 2008 ➤ , Superb II 2011 ➤ ,
Yeti 2010 ➤ , Yeti 2011 ➤
2.0/103; 125 kW TDI CR Engine (1st generation)
Engine ID
CBB
B
CBD
B
CEG
A
Edition 11.2014
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
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
20 - Fuel supply system
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
Service
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . . 2
2.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Regulations concerning safety precautions when working on the fuel system . . . . . . . . . . 3
2.4 Regulations concerning cleanliness when working on the fuel supply/fuel injection system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . . 5
2.6 General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Removing and installing top engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Remove engine (Octavia II, Yeti) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Remove engine Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Installing the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.6 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.7 Checking and adjusting the assembly bracket (Octavia II, Yeti) . . . . . . . . . . . . . . . . . . . . 31
1.8 Checking and adjusting the assembly bracket Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.9 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1 Removing and installing a V-ribbed belt and a toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 40
1.1 Summary of components - V-ribbed belt drive for vehicles without air conditioning system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.2 Summary of components - V-ribbed belt drive for vehicles with air conditioning system . . 43
1.3 Removing and installing V-ribbed belt for vehicles without air conditioning system . . . . . . 45
1.4 Removing and installing V-ribbed belt for vehicles with air conditioning system . . . . . . . . 45
1.5 Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . 47
1.6 Installing and removing the vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.7 Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.8 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.9 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2 Sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.1 Summary of components - sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . . . 64
2.2 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.3 Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . . 67
2.4 Summary of components - gearbox side summary of components and flywheel . . . . . . . . 69
2.5 Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.6 Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3 Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Summary of components - Crankshaft Octavia II, Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2 Summary of components - Crankshaft Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Measuring axial play of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.4 Replacing the needle bearing for crankshaft Octavia II, Superb II . . . . . . . . . . . . . . . . . . . . 83
3.5 Replacing the drive chain sprocket Octavia II, Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.6 Replacing the crankshaft drive pinion Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.7 Assembly overview - piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
Contents i
3.8 Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.9 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.1 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.3 Summary of components - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
1.6 Removing and installing the vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.7 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.2 Replacing camshaft gasket ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.3 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.4 Measuring the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.5 Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.6 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.7 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.8 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1 Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.1 Summary of components - Parts of the lubrication system Octavia II, Yeti . . . . . . . . . . . . 135
1.2 Summary of components - Parts of the lubrication system Superb II . . . . . . . . . . . . . . . . 138
1.3 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 141
1.4 Summary of components - oil filter holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.5 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1.6 Removing and installing oil pump Octavia II, Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.7 Removing and installing oil pump Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.8 Removing and installing balancing shaft module Superb II . . . . . . . . . . . . . . . . . . . . . . . . 148
1.9 Installing new balancing shaft module Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.10 Re-installing the already used balancing shaft module Superb II . . . . . . . . . . . . . . . . . . . . 151
1.11 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.12 Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . . 153
1.13 Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.1 Connection diagram for coolant hoses for vehicles up to 08.2009 . . . . . . . . . . . . . . . . . . . . 160
1.2 Connection diagram for coolant hoses for vehicles from 08.2009 . . . . . . . . . . . . . . . . . . . . 162
1.3 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2 Coolant pump and coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.1 Summary of components - coolant pump and coolant regulator (vehicles up to 08.2009)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2.2 Summary of components - Coolant pump and 4/2 way valve with coolant regulator (vehicles
from 08.2009) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.4 Removing and installing coolant regulator - (vehicles up to 08.2009) . . . . . . . . . . . . . . . . 168
2.5 Removing and installing 4/2 way valve with coolant regulator (vehicles from 08.2009) . . . . 170
2.6 Testing coolant thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3 Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.1 Summary of components - Parts of cooling system engine side . . . . . . . . . . . . . . . . . . . . 174
3.2 Replace coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.3 Replace coolant temperature sender at radiator outlet G83 . . . . . . . . . . . . . . . . . . . . . . . . 177
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
ii Contents
3.4 Remove and install coolant recirculation pump 2 V178 . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.5 Removing and installing the front coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.6 Remove and install the left coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.7 Removing and installing the right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4 Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.1 Summary of components - Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
4.2 Removing and installing fan shroud for radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
4.4 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1 Measures in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.1 Step 1: The engine was not started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.2 Step 2: The engine was started with incorrect fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.3 Step 3: metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . . . 196
1.4 Step 4: No metal swarfs are present in the fuel delivery unit and the fuel tank . . . . . . . . . . 197
1.5 Step 5: Metal swarfs present in high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.6 Step 6: No metal swarfs present in high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.1 Summary of components - Fuel tank with attached parts Octavia II . . . . . . . . . . . . . . . . . . 199
2.2 Summary of components - Fuel tank with attached parts Superb II, Yeti . . . . . . . . . . . . . . 202
2.3 Summary of components - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.4 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.5 Removing and installing fuel delivery unit Octavia II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.6 Removing and installing fuel delivery unit Superb II, Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.7 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 212
2.8 Removing and installing fuel gauge sender 2 G169 with suction jet pump Superb II, Yeti
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2.9 Separating quick couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.10 Removing and installing the fuel tank Octavia II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
2.11 Removing and installing the fuel tank Superb II, Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.12 Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2.13 Summary of components - Additional pressure pump V393 . . . . . . . . . . . . . . . . . . . . . . . . 229
2.14 Removing and installing additional fuel pump V393 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3 Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.1 Assembly overview - accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.2 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1 Charge-air system - exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.1 Summary of components - exhaust gas turbocharger with component parts . . . . . . . . . . 236
1.2 Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.3 Removing and installing exhaust gas temperature sender 1 G235 ( temperature sender
upstream turbocharger G507 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.4 Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
1.5 Inspect the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.6 Replacing and adjusting the vacuum setting element for exhaust turbocharger . . . . . . . . 247
2 Charge-air system - radiator, leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.1 Summary of components - Charge air cooler Octavia II . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.2 Summary of components - Charge air cooler Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
2.3 Summary of components - Charge air cooler Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
2.4 Removing and installing charge air cooler Octavia II, Yeti . . . . . . . . . . . . . . . . . . . . . . . . . . 256
2.5 Removing and installing Charge air cooler Superb II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2.6 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.7 Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
2.8 Inspect vacuum setting element and tension rods for charge pressure control . . . . . . . . . . 262
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
Contents iii
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
1 Diesel direct injection system - fitting location, system overview . . . . . . . . . . . . . . . . . . . . 264
1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
1.2 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2 Fuel system, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.1 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
2.2 Adaptation for injector quantity adjustment (IQA code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
2.3 Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
2.4 Removing and installing high fuel pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.5 Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
2.6 Replace fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
2.7 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
2.8 Removing and installing the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
2.9 Fill the high pressure pump with fuel and discharge the fuel system . . . . . . . . . . . . . . . . . . 288
2.10 Check the low pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.11 Check the fuel flow rate of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2.12 Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.13 Check the pressure holding valve in the fuel return-flow line . . . . . . . . . . . . . . . . . . . . . . . . 293
2.14 Check the fuel return-flow line on the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3 Intake manifold, air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3.1 Summary of components - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3.2 Removing and installing the throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . 301
3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3.4 Summary of components - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
3.5 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4.1 Removing and installing engine control unit J623 Octavia II . . . . . . . . . . . . . . . . . . . . . . . . 307
4.2 Removing and installing engine control unit J623 Superb II, Yeti . . . . . . . . . . . . . . . . . . . . 308
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.1 Summary of components - Pre-exhaust pipe with diesel particle filter Octavia II, Superb II,
Yeti with engine identification characters CEGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.2 Summary of components - Pre-exhaust pipe with diesel particle filter Yeti with engine
identification characters CBDB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
1.3 Replacing the exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
1.4 Summary of components - Middle and rear part of the exhaust system Octavia II . . . . . . 316
1.5 Summary of components - Middle and rear part of the exhaust system Superb II . . . . . . 318
1.6 Summary of components - Middle and rear part of the exhaust system Yeti . . . . . . . . . . . . 319
1.7 Removing and installing pre-exhaust pipe with diesel particle filter . . . . . . . . . . . . . . . . . . 319
1.8 Replacing middle or rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
1.9 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.10 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
2.1 Summary of components - Exhaust gas recirculation with radiator . . . . . . . . . . . . . . . . . . 326
2.2 Removing and installing the exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . 328
2.3 Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . 330
2.4 Check changeover of radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . 331
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
1 Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
1.1 Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
iv Contents
00 – Technical data
1 Identification
(SRL000754; Edition 11.2014)
⇒ “1.1 Engine number”, page 1
⇒ “1.2 Engine characteristics”, page 1
1.1 Engine number
The engine number (“engine identification characters” and “serial
number”) is located in the front at the engine/gearbox joint
-arrow-.
In addition, a sticker with the “engine identification characters”
and “serial number” is affixed to the timing belt guard.
The engine identification characters are also indicated on the ve‐
hicle data sticker.
♦ The engine identification characters have 4 digits starting with
the letter “C”.
♦ The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en‐
gine. They are type-punched in the cylinder block including the
serial number.
♦ The 4th digit refers to the output and torque of the engine and
depends upon the engine control unit.
1.2 Engine characteristics
Engine identification characters CBBB CBDB CEGA
Manufactured
Superb II 08.2008 ► 05.2010 - - - - - -
Octavia II - - - - - - 06.2008 ► 02.2013
Yeti - - - 05.2009 ► 11.2009 10.2009 ► 05.2010
Exhaust limit values conforming to EU5 EU5 EU5
Displacement l 1,968 1,968 1,968
Power output kW at rpm 125/4200 103/4200 125/4200
Torque Nm at rpm 350/1750…2500 320/1750…2500 350/1750…2500
Bore ∅ mm 81,0 81,0 81,0
Stroke mm 95,5 95,5 95,5
Cylinder / valves per cylinder 4/4 4/4 4/4
Compression ratio 16,5 : 1 16,5 : 1 16,5 : 1
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Catalytic converter yes yes yes
Exhaust gas recirculation with radiator yes yes yes
Turbocharging yes yes yes
Charge air cooler yes yes yes
Diesel particle filter yes yes yes
Balancing shaft module yes no no
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
1. Identification 1
2 Self diagnosis, safety measures,
cleanliness regulations and direc‐
tions
⇒ “2.1 Self-diagnosis”, page 2
⇒ “2.2 Supplementary instructions and assembly work on vehi‐
cles with an air conditioning system”, page 2
⇒ “2.3 Regulations concerning safety precautions when working
on the fuel system”, page 3
⇒ “2.4 Regulations concerning cleanliness when working on the
fuel supply/fuel injection system”, page 4
⇒ “2.5 Regulations concerning cleanliness when working on the
exhaust gas turbocharger”, page 5
⇒ “2.6 General instructions for charge air system”, page 5
2.1 Self-diagnosis
This Rep.-Gr. is deleted.
For this use the “Vehicle self-diagnosis”, “Measuring method” and
“Fault finding” ⇒ Vehicle diagnostic tester.
2.2 Supplementary instructions and assem‐
bly work on vehicles with an air condi‐
tioning 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:
– Unscrew the holding clamp(s) on the refrigerant lines
– Remove V-ribbed belt
⇒ “1.4 Removing and installing V-ribbed belt for vehicles with
air conditioning system”, page 45 .
– Remove AC compressor from the bracket for auxiliary units
⇒ “1.2 Summary of components - V-ribbed belt drive for vehi‐
cles with air conditioning system”, page 43 .
– Mount the air conditioning compressor and the condenser in
such a way that the refrigerant lines/hoses are not under ten‐
sion.
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
2 Rep. gr.00 - Technical data
2.3 Regulations concerning safety precau‐
tions when working on the fuel system
WARNING
When undertaking all assembly work, particularly in the engine
compartment due to its cramped construction, please observe
the following:
♦ Lay lines of all kinds in such a way that the original line
guide is re-established.
♦ Ensure that there is adequate free access to all moving or
hot components.
♦ The fuel or the fuel lines in the fuel system can become
very hot (risk of scalding)!
♦ The fuel system is under pressure!
♦ Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
♦ Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care‐
fully removing the wiring.
For reasons of safety the current supply to the fuel pump must
be interrupted before opening the fuel system. Otherwise the
fuel pump is activated when opening the driver's door. One of
the following options must be used to interrupt the current sup‐
ply:
♦ Disconnect battery
or
♦ Take out fuse for fuel pump relay - J17-
or
♦ Pull connector off fuel delivery unit flange.
Caution
In order to avoid the high pressure pump to run dry and to ach‐
ieve a quick engine start after parts are replaced, the following
points must be observed:
♦ If parts of the fuel system were removed or replaced, it is
necessary to initiate the basic setting “check fuel pump” in
order to vent the fuel system ⇒ Vehicle diagnostic tester.
♦ If the fuel pump, fuel line or fuel filter were removed or
replaced, the basic setting “check fuel pump must be ini‐
tiated” »once« before the first engine start.
♦ If the fuel pump was removed, the basic setting “test of
fuel pump” must be initiated »3 times« before the first en‐
gine start.
♦ If the high pressure pump was replaced, the high pres‐
sure-pump must be filled with fuel before the first engine
start
⇒ “2.9 Fill the high pressure pump with fuel and discharge
the fuel system”, page 288 .
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
2. Self diagnosis, safety measures, cleanliness regulations and directions 3
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 m
3
/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
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 passen‐
ger seat, the passenger could be injured by the release of the
passenger airbag in the event of an accident.
WARNING
Secure the diagnostic device to the rear seat and operate from
that position.
Observe the following points to prevent injury to persons and/or
damage to the injection and preheating system:
♦ People, who have a heart pacemaker implant, should not bend
over the engine compartment when the engine is running, as
the injection units generate an output high voltage pulse.
♦ No fuel lines must be opened when the engine is running.
♦ Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
♦ Do not carry out engine wash unless the ignition is switched
off.
♦ If the engine must be operated, without it starting, unplug the
connector -arrow- at the fuel pressure regulating valve -
N276- .
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the control unit.
♦ After connecting the battery, carry out certain additional oper‐
ations ⇒ Electrical System; Rep. gr. 27 .
2.4 Regulations concerning cleanliness
when working on the fuel supply/fuel in‐
jection system
Carefully observe the following “rules” for cleanliness when work‐
ing on the fuel supply/injection system:
♦ Thoroughly clean the connection points and their surroundings
before releasing.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths!
♦ Carefully cover or close opened components if the repair is not
completed immediately.
Octavia II 2004 ➤ , Octavia II 2010 ➤ , Superb II 2008 ➤ , Superb II 20 ...
2.0/103; 125 kW TDI CR Engine (1st generation) - Edition 11.2014
4 Rep. gr.00 - Technical data
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The 2004-2012 Skoda Octavia Service & Repair Manual is the ultimate guide for all Skoda Octavia owners and enthusiasts. With this comprehensive manual, you will have the detailed information and step-by-step instructions required to service and repair your vehicle to perfection.
Whether you are a DIY enthusiast or a professional mechanic, this manual is an essential resource. It covers every aspect of the Skoda Octavia from 2004 to 2012, including both petrol and diesel models, ensuring that no matter which variant you own, you have all the information at your fingertips.
Inside this manual, you will discover extensive details on engine maintenance and repair, transmission systems, suspension, brakes, electrical systems, and much more. It features easy-to-follow diagrams, illustrations, and photographs to provide clear guidance through each process.
Highlights of the 2004-2012 Skoda Octavia Service & Repair Manual:
- Comprehensive coverage of all Skoda Octavia models from 2004 to 2012
- Step-by-step instructions for servicing and repairing your vehicle
- Detailed information on engine maintenance and repair
- Guidance on transmission systems, suspension, and brakes
- Electrical system troubleshooting and repair advice
Whether you need to change the oil, replace a part, or diagnose an electrical issue, this manual will provide the answers you’re looking for. It is a reliable and invaluable resource that will save you time and money by empowering you to perform repairs and maintenance tasks on your own.
Get the 2004-2012 Skoda Octavia Service & Repair Manual today and take the first step towards becoming a Skoda Octavia expert!
