Service

Workshop Manual
Octavia 1997
1.9 l/96 kW (TDI) Engine, Mechanics
Edition 04.03
Engine code

ASZ

Service Department. Technical Information

Printed in Czech Republic S00.5142.50.20

Service

The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.

Printed in Czech Republic S00.5142.50.20

Octavia 1997

1.9 l/96 kW (TDI) Engine, Mechanics

List of Supplements to Workshop Manual

Octavia 1997
1.9 l/96 kW (TDI) Engine, Mechanics
Edition 04.03
Supplement 1

Edition 04.03 09.04

Subject Basic Edition Modifications in Rep. Gr. 13, 20, 21 and 26

Article Number S00.5142.50.20 S00.5142.51.20

Edition 09.04 S00.5142.51.20

List of Supplements

Octavia 1997

1.9 l/96 kW (TDI) Engine, Mechanics

List of Supplements

Edition 09.04 S00.5142.51.20

Octavia 1997

1.9 l/96 kW (TDI) Engine, Mechanics

Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1 page 1

10 Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 page 1

13 Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 Removing and installing, tightening the timing belt ........................................... 13-2 - Summary of components ............................................................................. 13-2 - Removing and installing, tightening the timing belt .............................................. 13-2 Removing and installing sealing flange and flywheel ......................................... 13-3 Crankshaft, Piston and Conrod ..................................................................... 13-4 page page page page page page 1 1 1 2 1 1

15 Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 Repairing Valve Gear .................................................................................. 15-2 Camshaft ................................................................................................. 15-3 Valve seats, valves guides, valve stem seals .................................................... 15-4 page page page page 1 1 1 1

17 Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 Removing and installing oil pan .................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3 page page page 1 1 1

19 Cooling
Parts of cooling system - Summary of components ........................................... 19-1 Removing and installing radiator, coolant pump and coolant thermostat ................ 19-2 page page 1 1

20 Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 - Safety precautions when working on the fuel supply system ................................... 20-1 - Rules of cleanliness ................................................................................... 20-1 - Removing and installing the fuel tank with its component parts ................................ 20-1 - Removing and installing the fuel tank .............................................................. 20-1 - Removing and installing fuel filter ................................................................... 20-1 - Removing and installing fuel cooler ................................................................ 20-1 - Check the fuel delivery unit .......................................................................... 20-1 - Removing and installing the fuel delivery unit ..................................................... 20-1 - Removing and installing the fuel gauge sender . ................................................. 20-1 - Removing and installing the tandem pump ........................................................ 20-1 - Inspecting a tandem pump ........................................................................... 20-1 Servicing accelerator pedal .......................................................................... 20-2 - Removing and installing the accelerator control .................................................. 20-2 page page page page page page page page page page 1 1 1 2 4 5 6 6 8 9

page 10 page 11 page page 1 1

21 Turbocharging
Charge air system with turbocharger I ............................................................ 21-1 page 1

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- Removing and installing exhaust turbocharger with component parts ........................ 21-1 - Removing and installing parts of the charge air cooling ......................................... 21-1 - Removing and installing charge-air cooler ........................................................ 21-1 - Rules of cleanliness ................................................................................... 21-1 - Connection diagram for vacuum hoses ............................................................ 21-1 Charge air system with turbocharger II ........................................................... 21-2 - Remove exhaust turbocharger ...................................................................... 21-2 - Checking charge pressure control .................................................................. 21-2

26 Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Removing and installing front exhaust pipe with catalytic converter .......................... 26-1 - Replace connecting tube and rear silencer ....................................................... 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Exhaust gas recirculation system .................................................................. 26-2 - Testing mechanical exhaust gas recirculation valve ............................................. 26-2 page page page page page page page 1 2 3 3 4 1 2

II

Table of Contents

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00

00 Technical Data
00-1 Technical Data

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 vehicle data stickers.

Engine characteristics Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Firing order min. CN Catalytic converter Exhaust gas recirculation Turbocharging Charge air cooler l kW at rpm Nm at rpm mm mm ASZ 12.02 EU-3 1.896 96/4000 310/1900 79.5 95.5 19.0 : 1 1-3-4-2 49 yes yes yes yes

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00-1 page 2

Technical Data

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10

10 Removing and Installing Engine

10-1 Removing and Installing Engine

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 10

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Removing and Installing Engine

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10-1 page 2

Removing and Installing Engine

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13 Crankgear
13-1 Removing and installing V-ribbed belt

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 13

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Removing and installing V-ribbed belt

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13-1 page 2

Removing and installing V-ribbed belt

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13

13-2

Removing and installing, tightening the timing belt

Summary of components
Note

Before removing the timing belt, mark direction of running. Reversing the rotation direction of an already used belt may destroy it.
1 - Top toothed belt guard K when installing, correctly insert into the middle toothed belt guard 2 - 100 Nm K to release and tighten use counterholder -T10051 3 - 20 Nm + torque a further + 45 (1/8 turn) 4 - Camshaft sprocket K Mark installation position 5 - Hub K with sensor rotor for Hall sensor -G40K to release and tighten use counterholder -T10051 K to remove use extractor -T10052K removing and installing Chapter 15-2 6 - 10 Nm K insert using locking agent -D 000 600 A27 - Rear timing belt guard K to remove, unscrew coolant pump K when installing, correctly insert into the front sealing flange 8 - 25 Nm 9 - Rubber bush K replace if damaged 10 - 20 Nm + torque a further + 45 (1/8 turn) 11 12 13 14 Tensioning pulley 22 Nm Guide pulley Coolant pump K removing and installing Chapter 19-1 15 - Crankshaft toothed belt sprocket K there must not be any oil present on contact surface between timing belt sprocket and the crankshaft K can be installed only in one position

16 - 120 Nm + torque a further 90 (1/4 turn) K replace K do not oil K to release and tighten use counterholder -T30004 17 - 13 Nm
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18 - Bottom toothed belt guard 19 - Belt pulley with vibration damper K Assembly only possible in one position - holes offset K with notch for TDC of cyl. 1. 20 - 10 Nm + torque a further 90 (1/4 turn) K replace 21 - Cap 22 - Timing belt K mark the direction of rotation with chalk or a felt-tip pen before removing K check for wear K do not kink K removing and installing (setting the timing) 13-2 page 2 23 - Middle toothed belt guard K with notch for TDC of cyl. 1 or with marked arrow

Removing and installing, tightening the timing belt

Note

The adjusting work at the timing belt must only be carried out when engine is cold.
Special tools, test and measuring equipment and auxiliary items required
Torque wrench Rig pin -MP 1-301- or - 3359 Supporting device -MP 9-200- with adapter

-MP 9-200/3 Crankshaft arrester -T10050 Wrench for tensioning pulleys (e.g. -Matra V 159-,

-T10020-, -Hazet 2587 - or -Stahlwille 127-17-)

Removing

Remove the V-ribbed belt Chapter 13-1. Remove ribbed V-belt tensioning device. Remove the front right wheelhouse liner Body
Work; Rep. Gr. 66.

WARNING!

Fuel feed line is pressurized. Place cleaning cloths around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.

2 1

Remove the fuel filterm, disconnect the fuel-intake

hose -1- and the fuel-return hose -2- from the pipes.

Remove top charge air pipe Chapter 21-1. Remove coolant expansion reservoir and place down
to the front with coolant hoses connected.
S10-0164

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Removing and installing, tightening the timing belt

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Remove power-steering reservoir, do not detach hoses however, and place down to the side.

Fit on supporting device -MP 9-200- in combination

with adapter -MP 9-200/3-.

MP 9-200/3

MP 9-200

Removing engine mounting Chapter 10-1. Remove top toothed belt guard. Remove belt pulley with vibration damper. Remove middle and bottom timing belt guard. Position crankshaft on TDC cylinder 1.

S34-0536

Note

Rotate crankshaft until the marking on the top of the timing belt sprocket and the arrow on the rear timing belt guard are positioned opposite the lugs on the hub of the sense rotor -arrows-.

Lock hub with locking pin -MP 1-301- or - 3359-. Insert

locking pin through the left slot into the hole at the cylinder head.

Secure the timing belt sprocket-crankshaft with the

crankshaft arrester -T10050 -. Insert the crankshaft arrester from the front side of the timing belt sprocket into the gearing. Note

The markings on the timing belt gear and on the crankshaft arrester must be in line with each other. The pin on the crankshaft arrester must engage into the opening in the sealing flange.

Mark the direction of rotation of the timing belt with

chalk or a felt-tip pen.

Slacken bolts of camshaft sprocket -arrows-.

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Counterhold eccentric of tensioning pulley with twohole nut turner (e.g. -T10020-) and loosen the fixing nut -1-. After this, release the tensioning pulley by turning the eccentric anti-clockwise, until spring tension releases. Secure the loose tensioning pulley by tightening the fixing nut by hand.

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Remove toothed belt guide pulley item 13 in 13-2

page 1.

First of all take toothed belt off toothed belt sprocket of

coolant pump and then from the other belt pulleys.

Installing and tensioning

Note
The adjusting work at the timing belt must only be car-

ried out when engine is cold.

When rotating the camshaft, the crankshaft must not

be positioned at TDC for any one piston. Risk of damaging valves and pistons.

Interlock camshaft with locking pin e. g. -3359- or

-MP 1-301-.

Interlock the crankshaft with the crankshaft arrester

-T10050-.

Interlock tensioning pulley in released position with

fixing nut.

Pay attention to correct fitting of the tensioning pulley

in the rear timing belt guard -arrow-.

Slightly screw in screws -arrows-. It must still be possible to turn the camshaft sprocket
on the hub, however it must not hang loose.

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Removing and installing, tightening the timing belt

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Turn camshaft sprocket clockwise in the elongated

holes as far as the stop.

Fit toothed belt onto crankshaft toothed belt sprocket,

tensioning pulley, camshaft and, last of all, onto the toothed belt sprocket of the coolant pump.

Install toothed belt guide pulley item 13 in 13-2

page 1.

Loosen the fixing nut -1- of the tensioning pulley. Turn the eccentric of the tensioning pulley with twohole nut turner (e. g. -T10020-) clockwise in such a way until the pointer -2- stands in the centre of the base plate in the gap. Note

Ensure that the fixing nut does not turn.

Hold the eccentric of the tensioning pulley in this position and tighten fixing nut to 20 Nm + torque a further 45 (1/8 turn). Note

When tightening the fixing nut, the pointer turns -arrowmax. 5 mm to the right from the gap of the base plate. This position must not be corrected, because the toothed belt settles when running-in.

Tighten bolts of camshaft sprocket to 20 Nm + torque

a further 45 (1/8 turn).

Remove locking pin -3359- and crankshaft arrester

-T10050-. Test timing:

Turn crankshaft 2 turns in the direction of running of

the engine until the crankshaft is positioned shortly before TDC for cylinder 1.

Interlock during this motion the hub in the direction of

running of the engine with locking pin -3359- .

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Check whether:
the crankshaft can be interlocked with the crankshaft

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1.9 l/96 kW (TDI) Engine, Mechanics

arrester -T10050 -;
Pointer of tensioning pulley stands in the centre or

max. 5 mm to the right from the gap of the base plate. If the crankshaft cannot be arrested:

Slacken bolts of camshaft sprocket -arrows-.

Rotate crankshaft in direction of rotation of engine until it can be arrested with the crankshaft arrester -T10050-. Note

If the crankshaft can be turned behind the TDC for cylinder 1, turn crankshaft back slightly and once again set to the TDC for cylinder 1 by turning in direction of rotation of engine.

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Removing and installing, tightening the timing belt

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13

Tighten bolts -arrows- of camshaft sprocket to 20 Nm

+ torque a further 45 (1/8 turn).

Remove locking pin -3359- and crankshaft arrester

-T10050-.

Turn crankshaft 2 turns in the direction of running of

the engine until the crankshaft is on TDC.

Repeat timing test.

Proceed with installation: Further installation occurs in reverse order for removal, while paying attention to the following: Note
Replace gaskets. Pay attention to different hose connections. Secure all

hose connections depending on the version with hose clips or retaining clips.

Install bottom and middle toothed belt guard. Install belt pulley with vibration damper. Install engine support. Screw in screws -1 ... 3- by
hand first and then tighten to 45 Nm. Note

The engine support must be tightened up firmly before further installation of the engine mounting.

Install top toothed belt guard. Install and adjust the engine mounting Chap. 10-1. Install tensioning device for V-ribbed belt. Tighten
bolts to 25 Nm.

Install the V-ribbed belt Chapter 13-1. Install charge air pipes and charge air hoses Chap.
21-2.

Install fuel filter, coolant expansion reservoir and power-steering reservoir.

Install the front right wheelhouse liner Body Work;

Rep. Gr. 66.

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13-2 page 8

Removing and installing, tightening the timing belt

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13

13-3

Removing and installing sealing flange and flywheel

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 13

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Removing and installing sealing flange and flywheel

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13-3 page 2

Removing and installing sealing flange and flywheel

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13

13-4

Crankshaft, Piston and Conrod

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 13

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Crankshaft, Piston and Conrod

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13-4 page 2

Crankshaft, Piston and Conrod

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15

15 Cylinder Head, Valve Gear

15-1 Removing and installing cylinder head

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 15

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Removing and installing cylinder head

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15-1 page 2

Removing and installing cylinder head

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15

15-2

Repairing Valve Gear

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 15

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Repairing Valve Gear

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15-2 page 2

Repairing Valve Gear

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15

15-3

Camshaft

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 15

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Camshaft

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15-3 page 2

Camshaft

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15

15-4

Valve seats, valves guides, valve stem seals

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 15

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Valve seats, valves guides, valve stem seals

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15-4 page 2

Valve seats, valves guides, valve stem seals

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17

17 Lubrication
17-1 Removing and installing parts of the lubrication system

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 17

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Removing and installing parts of the lubrication system

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17-1 page 2

Removing and installing parts of the lubrication system

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17

17-2

Removing and installing oil pan

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 17

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Removing and installing oil pan

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17-2 page 2

Removing and installing oil pan

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17

17-3

Testing oil pressure and oil pressure switch

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 17

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Testing oil pressure and oil pressure switch

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17-3 page 2

Testing oil pressure and oil pressure switch

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19 Cooling
19-1 Parts of cooling system Summary of components

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 19

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Parts of cooling system - Summary of components

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19-1 page 2

Parts of cooling system - Summary of components

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19-2

Removing and installing radiator, coolant pump and coolant thermostat

1.9 l/74 kW (TDI) Engine, Mechanics; Rep. Gr. 19

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Removing and installing radiator, coolant pump and coolant thermostat

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19-2 page 2

Removing and installing radiator, coolant pump and coolant thermostat

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20

20 Fuel Supply
20-1 Removing and installing parts of the fuel supply system

Safety precautions when working on the fuel supply 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 (e.g. for fuel, hydraulic fluid, the active charcoal container-unit, cooling fluid and refrigerent, brake fluid, vacuum) and electrical lines 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.
When removing and installing the fuel gauge sender from a full or partly filled fuel tank, pay attention to the following:
The extraction hose of an exhaust extraction system

which is switched on, must be positioned close to the assembly opening of the fuel tank in order to extract the released fuel gases, 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 above 15 m3/h must be used.
Avoid skin contact with fuel! Wear fuel-resistant

gloves!

Rules of cleanliness
When working on the fuel supply/fuel injection system, pay careful attention to the following 6 rules for cleanliness.
Thoroughly clean the connection points and their sur-

roundings before releasing.

Place removed parts on a clean surface and cover. Do

not use fuzzy cloths!

Carefully cover or close opened components if the re-

pair is not completed immediately.

Only install clean parts: Remove spare parts from

their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped, e.g. on a shelf or in a tool box.

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When the system is open: Avoid using compressed

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air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant

hoses. If this is the case clean the hoses immediately. Immediately replace contaminated hoses.

Removing and installing the fuel tank with its component parts
1 - Fuel tank K when removing support, for example with the engine/ gearbox jack -V.A.G 1383 AK removing and installing 20-1 page 4 2 - Gasket ring K to be inserted dry into the opening of the fuel tank K replace if damaged K only moisten the seal of the flange with fuel for fitting purposes 3 - Fuel delivery unit K with sender for fuel gauge display K Removing and installing the fuel delivery unit 20-1 page 8 K Fitting position Fig. 1 in 20-1 page 3 K check 20-1 page 6 K Clean strainer if dirty K removing and installing fuel gauge sensor 20-1 page 9 4 - Union nut, 80 Nm K use wrench -MP 1-227- for removing and installing 5 - Feed line K to fuel filter K clipped in place on fuel tank K check for firm seating K black 6 - Return-flow line K from fuel cooler K clipped in place on fuel tank K check for firm seating K blue 7 - Overflow hose 8 - O-ring K replace if damaged 9 - Gravity valve K to remove, unclip valve and lift up and out of the filler neck K inspect valve for blockage, valve in a vertical position: open, valve tilted 45: closed 10 - Fuel filler cap 11 - Fuel tank lid unit K with rubber bowl

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Removing and installing parts of the fuel supply system

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12 - Earth connection 13 - O-ring K replace if damaged 14 - Vent valve K to remove, unclip valve at side and take out of filler neck. K before installing, unscrew fuel filler cap item 10 K check Fig. 2 in 20-1 page 4 15 - 10 Nm 16 - Vent line K black K clipped in place on the side of the fuel tank K check for firm seating K secure with spring strap clamps 17 - Circlip K removing: turn to the left K Installing: tighten to 2 Nm 18 - Heat shield K for fuel tank 19 - Cover K for fuel tank K not fitted to all vehicles 20 - 25 Nm 21 - Tensioning strap K pay attention to different lengths 22 - Fuel cooler K removing and installing 20-1 page 6 23 - to fuel filter 24 - 20 Nm

Fig. 1:

Fitting position of the fuel delivery unit

The marking on flange -1- must be aligned with the marking on the fuel tank -2-. Note

After installing the fuel delivery unit, check whether the feed and return-flow lines are still clipped in place on the fuel tank.

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Fig. 2: Inspect vent valve

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Lever in off position: closed Lever pushed in -direction of arrow-: open Note

Before installing the vent valve, unscrew fuel filler cap.

Removing and installing the fuel tank

Special tools, test and measuring equipment and auxiliary items required
Engine/gearbox jack (e.g. -V.A.G 1383 A-) Torque wrench

Removing
Note
The fuel tank must not be more than 1/4 full. Observe the safety instructions before starting fitting

work 20-1 page 1.

Disconnect the battery-earth strap with the ignition off. Remove the rear right wheelhouse liner Body
Work; Rep. Gr. 66.

Remove filler flap unit with rubber bowl Body Work;

Rep. Gr. 55.

Unscrew the securing bolt on the fuel filler neck. Unscrew the straps. Support the fuel tank with engine/
gearbox jack -V.A.G 1383 A- when removing.

Lower engine/gearbox jack -V.A.G 1383 A- in such a

way that the feed and return line and the connector on the delivery unit and on the fuel gauge sender can be pulled out.

Unclip the feed and return line on the fuel tank. Lower the fuel tank.
Installing
Installation is carried out in the reverse order. Pay attention to the following:
Lay the ventilation hoses avoiding any kinks. Lay the fuel hoses avoiding any kinks. Secure fuel hoses with spring collar clamps. Do not mix-up the feed and return line (the return line

is blue, the feed line is black).

Clip the feed and return line onto the fuel tank.

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Removing and installing parts of the fuel supply system

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Removing and installing fuel filter

The fuel flow direction is indicated with arrows on the hoses, on the glow valve and the fuel filter. 1 - Return-flow hose K to fuel cooler K blue marking 2 - Intake hose K from fuel tank K white marking 3 - Retaining clip K replace if damaged 4 - Preheating valve K Fitting position: Arrow points to fuel tank K if the filter is replaced remove retaining clip and preheating valve with the fuel lines connected K Temperature less than + 15C: access to filter open K Temperature above + 31C: access to filter closed 5 - O-ring K replace 6 - Return-flow hose K from the tandem pump K blue marking 7 - Fuel hose 8 - Fuel temperature sender -G819 - Non-return valve K only vehicles 03.02 K Fitting position: arrow points to tandem pump 10 - Intake hose K to the tandem pump K white marking 11 - Fuel filter K fill with diesel fuel before fitting K do not interchange connections K replace if damaged 12 - Gasket K replace if damaged 13 - Drain plug K to ventilate remove the retaining clip of the preheating valve and remove preheating valve with the fuel lines connected K release and drain approx. 0.1 litre fluid (catch)

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Removing and installing fuel cooler
Special tools, test and measuring equipment and auxiliary items required
Torque wrench

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1.9 l/96 kW (TDI) Engine, Mechanics

Removing
Observe rules for cleanliness 20-1 page 1. Note

The fuel cooler is located at the return-flow line to the fuel tank. It is attached to the underfloor of the vehicle body.

Removing cover -A-. Separate fuel line at fuel cooler. Unscrew fixing nuts -arrows-.
Installing
Installation is carried out in the reverse order. Pay attention to the following:
Tighten nuts of the fuel cooler to 20 Nm.

Check the fuel delivery unit

Special tools, test and measuring equipment and auxiliary items required
Remote control, e.g. -V.A.G 1348/3A Pressure gauge appliance, e.g. -V.A.G 1318 Adapter, e.g. -V.A.G 1318/1 Adapter, e.g. -V.A.G 1318/11 Adapter, e.g. -V.A.G 1318/17 Adapter, e.g. -V.A.G 1318/23 Measuring vessel

Inspecting proper operation and power supply Test conditions

Battery voltage at least 11.5 V. Fuses o.k. (No. 28). All electrical components such as lights and rear window heater must be switched off.

8 5 1 2 24 3 4 31 32 33 34 35 36 37 6 7 9 10 11 38 39 40 41 42 43 44

12 13 14 15

16 17 18 19

20 21 22 23

Test sequence

25 26 27 28 29 30

Fold rear seat forwards. Remove the trim panel of the fuel delivery unit. Switch on ignition. The fuel delivery unit must be
heard to start running.

Switch off ignition.

S97-0319

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If the fuel delivery unit does not run:

Continuing searching for faults using a multimeter

(e.g. -V.A.G 1715-) Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.

Inspecting fuel flow rate Test conditions

Supply voltage is o.k. Battery voltage at least 11.5 V. Fuel temperature 15...30 C. Fuel tank at least 1/4 full.

Test sequence

Unscrew the fuel tank cap from the filler neck. Fold rear seat forwards. Remove the trim panel of the fuel delivery unit. Unplug 4-pin plug from fuel delivery unit. Connect remote control -V.A.G 1348/3A- with connection lines from measuring tool set to contact -1- of the fuel delivery unit and to battery +. connect the contacts -4- to the plug and to the fuel delivery unit.

Use connection lines from the measuring tool set to Pull off the fuel feed line at the fuel filter and gather residual fuel in a cloth.

WARNING!

The fuel feed line is pressurized! Place a clean cleaning cloth around the connection point before detaching hose connections. Reduce pressure by carefully releasing the connection point.

Connect pressure gauge -V.A.G 1318- with adapter

-V.A.G 1318/23- and -V.A.G 1318/17- to the fuel feed line.

Connect hose -V.A.G 1318/1- to adapter

-V.A.G 1318/11- of the pressure gauge and hold in the measuring vessel.

Open shut-off cock of the pressure measuring device.

The lever points in the direction of flow -A-.

Activate remote control -V.A.G 1348/3A-. Slowly

close the shut-off cock until the manometer displays 3.5 MPa overpressure (0.35 bar). Now do not change the position of the shut-off cock.

Empty measuring vessel. Activate remote control for 30 seconds.

Specified volume: 660 ml/30 seconds. If the minimum flow rate is not reached:
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Check the fuel lines for possible diameter restrictions
(kinks) or blocking.

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Remove the fuel delivery unit and check whether the

pump strainer is not clogged up. If no fault was detected until now:

Replace the fuel delivery unit.

Removing and installing the fuel delivery unit

Special tools, test and measuring equipment and auxiliary items required
Wrench for the lock ring -T30101 Fuel extraction device (e.g. -VAS 5190-) Torque wrench

Condition

The fuel tank must not be more than 3/4 full.

Removing
Note
Empty the fuel tank if necessary using the fuel extrac-

tion device -VAS 5190-.

Observe all safety measures Chapter 01-1 before

beginning the assembly work.

Observe the cleanliness regulations Chapter 01-1.

Disconnect the battery-earth strap with the ignition off

Electrical System; Rep. Gr. 27.

Fold rear seat forwards. Remove the trim panel of the fuel delivery unit.
WARNING!

The fuel system is under pressure! Place a clean cleaning cloth around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.
Note

Press together the bottom securing ring on the rear side of the angular connection in order to unlock the fuel lines.

Pull out the connector as well as the fuel lines -1 and

2- from the flange of the fuel delivery unit.

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Loosen union nut with wrench -MP 1-227-. Pull the fuel delivery unit and the gasket ring out of the
opening of the fuel tank. Note

You must empty the old delivery unit before disposing of it if you wish to replace it.

Installing

The installation of the fuel delivery unit occurs in reverse order. Pay attention to the following: Note
Do not bend the fuel gauge sender when installing it. Insert dry gasket ring into the opening of the fuel tank. The gasket must only be moistened from inside with

fuel before assembly of the fuel delivery unit.

Pay attention to installation position of flange of fuel

delivery unit. Marking on the flange -arrow- must point against the direction of travel. The flange of the fuel delivery unit can only be installed in this position.
Do not interchange the feed and return lines. Make sure the fuel lines fit tightly. After installing the fuel delivery unit, check whether

the feed and return-flow lines are correctly clipped in place on the fuel tank.

Undertake the work operation Procedure after interrupting the power supply Vehicle Diagnosis, Measuring and Information System VAS 5051.

Removing and installing the fuel gauge sender

Removing

Removing fuel delivery unit 20-1 page 8. Unlatch and disconnect the line contact studs -3- and
-4-.

Raise catches -1- and -2- with a screwdriver and remove the fuel gauge sender towards the bottom -arrow-.

Installing

Insert the fuel gauge sender in the fuel delivery unit

guides and press upwards until the catches latch into position.

Install the fuel delivery unit 20-1 page 8.

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20
Removing and installing the tandem pump
Special tools, test and measuring equipment and auxiliary items required
Torque wrench Hand vacuum pump (e.g. -V.A.G 1390-) Ventilation reservoir (e.g. -V.A.G 1390/1-) Pliers for spring strap clips

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Removing

Separate feed hose -1- (marked in white) and returnflow hose -2- (marked in blue) from the fuel filter.

Connect hand vacuum pump -V.A.G 1390- with ventilation reservoir -V.A.G 1390/1- to return-flow hose.

Operate hand vacuum pump until no more fuel comes

out of the return-flow hose. Ensure that no fuel is drawn into the hand vacuum pump.

Unscrew the charge air pipe and put to one side. Separate vacuum line -1- for brake servo unit from
tandem pump -4-.

Separate central plug connection for unit injectors. Remove feed hose -2- (marked in white) at the tandem pump -4-.

Unscrew securing bolts -arrows-. Remove tandem pump -4- from cylinder head. Pull tandem pump -4- upwards, separate return-flow
hose -3- (marked in blue) and remove tandem pump -4-.

Installing
Installation is performed in the reverse order. Pay attention to the following points: Note
Ensure the tandem pump coupling is correctly insert-

ed into the camshaft.

Always replace the tandem pump seals.

Connect return-flow hose -3- (marked in blue) to the

return-flow coupling of the tandem pump.

Install tandem pump and tighten the top fixing screws

to 20 Nm.

Tighten the bottom fixing screws to 10 Nm. Connect the feed hose -2- (marked in white) to the
feed connection and the vacuum line -1- of the brake servo unit to the tandem pump -4-.

Connect the central plug connection for the unit injector.

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Install the charge air pipe. Connect feed hose -1- (marked in white) to fuel filter. Connect the hand vacuum pump -V.A.G 1390- with
the ventilation reservoir -V.A.G 1390/1- to the return flow hose -2- (blue marking) of the fuel filter.

Operate hand vacuum pump until fuel flows out of the

return-flow hose. Ensure that no fuel is drawn into the hand vacuum pump.

Connect return-flow hose -2- (marked in blue) to fuel

filter.

Interrogate the fault memory Vehicle Diagnosis,

Measuring and Information System VAS 5051. Note

Faults are stored as a result of separating the central plug connection for the unit injector. Interrogate the fault memory and delete it as required.

Inspecting a tandem pump

Special tools, test and measuring equipment and auxiliary items required
Pressure gauge appliance (e.g. -VAS 5187-) Torque wrench Pliers for spring strap clips

Test conditions

Coolant temperature must be at least 85 C. Unit injectors O.K. Fuel filter and fuel line must not be blocked. The non-return valve in the fuel-intake hose must be O.K. (only vehicles 03.02).

Fuel gauge sender must be in proper order.

Procedure

Unscrew the charge air pipe and put to one side. Unscrew screw plug -arrow-.

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Connect pressure gauge appliance -VAS 5187- as
shown.

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1.9 l/96 kW (TDI) Engine, Mechanics

Tighten up the charge air pipe. Engine speed must increase to 1500 rpm. Note the pressure shown on the manometer. Specified value: min. 0.35 MPa (3.5 bar). If the specified value is not reached:

Replace tandem pump 20-1 page 10.

Note

After removing the pressure gauge appliance reinstall the plug and tighten to 25 Nm. Always replace the gasket ring.

20-1 page 12

Removing and installing parts of the fuel supply system

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20-2

Servicing accelerator pedal

Removing and installing the accelerator control

1 - Bracket K removing and installing Chassis; Rep. Gr. 46 2 - Connector K black, 6 pin 3 - 10 Nm 4 - Sender for accelerator pedal position -G79K Before removal, remove lower part of the dash panel insert on the driver's side Body Work; Rep. Gr. 70. 5 - Bracket K for footwell cover K clipped in place at accelerator pedal position sender

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20-2 page 2

Servicing accelerator pedal

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21 Turbocharging
21-1 Charge air system with turbocharger I

Removing and installing exhaust turbocharger with component parts

Observe rules for cleanliness 21-1 page 4. Note
The hose connections are secured with clamps. The charge-air system must be tight. Always replace self-locking nuts.

1 - Oil feed line K before connecting fill the exhaust turbocharger on the connection fitting item 4 with clean engine oil. 2 - Union nut, 22 Nm 3 - 22 Nm 4 - Connection fitting, 30 Nm K replace K Coat thread and ball sealing surface with -G 052 112 A35 - 10 Nm 6 - Hollow screw, 25 Nm 7 - Gasket ring K replace 8 - Intake manifold 9 - Gasket K replace K Check fitting position 10 - Washer 11 - 25 Nm K replace K Coat stud bolts with -G 052 112 A312 - Support K Exhaust turbocharger - cylinder block 13 - 40 Nm K tighten all bolts first of all by hand 14 - Connecting tube K Between turbocharger and air filter 15 - Intermediate flange 16 - Exhaust turbocharger K Can only be replaced complete with exhaust manifold K removing and installing Chapter 21-2 K Inspecting charge pressure control Chapter 21-2 K Charge pressure control valve and vacuum setting element for charge pressure control valve are parts of the turbocharger and cannot be replaced separately

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17 18 19 20 21 -

22 23 24 25 26 -

K After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharger Gasket K replace Connection fitting, 40 Nm Oil return line K to cylinder block 17 Nm Vacuum line K To the solenoid valve for charge pressure limitation -N75K Connection diagram for vacuum hoses 21-1 page 5 20 Nm K tighten all bolts first of all by hand 20 Nm K replace Shield Front exhaust pipe Bracket K for oil feed line item 1 K Before installing attach the oil feed line

21-1 page 2

Charge air system with turbocharger I

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Removing and installing parts of the charge air cooling

Note
The hose connections are secured with clamps. The charge-air system must be tight. Remove oil and grease from the charge pressure hoses and charge pressure pipes and from their connections

before installing.
1 - 5 Nm 2 - O-ring K replace if damaged 3 - Top charge-air pipe 4 - Charge air connection hose K to connection fitting 5 - Rubber bowl 6 - Charge air connection hose K from turbocharger 7 - 10 Nm 8 - Bottom charge air pipe 9 - Charge air connection hose 10 - Bracket 11 - Air deflector 12 - Charge air cooler 13 - Intake manifold pressure sender -G71- with intake manifold temperature sender -G72-

Removing and installing charge-air cooler

Special tools, test and measuring equipment and auxiliary items required
Torque wrench Pliers for spring strap clips

Removing

Remove the right sound dampening system Body

Work; Rep. Gr. 50.

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Disconnect plug from intake manifold temperature
sender -G72-.

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1.9 l/96 kW (TDI) Engine, Mechanics

Separate top charge air connection pipe item 3 in

21-1 page 3.

Separate bottom charge air connection pipe item 8

in 21-1 page 3.

Unscrew bolts attaching item 7 in 21-1 page 3

charge air cooler and take out cooler.

Installing
Installation is carried out in the reverse order.

Rules of cleanliness
Carefully observe the following 5 rules for cleanliness when working on the exhaust turbocharger:
Thoroughly clean the connection points and their sur-

roundings before releasing.

Place removed parts on a clean surface and cover. Do

not use fuzzy cloths!

Carefully cover or close opened components if the re-

pair is not completed immediately.

Only install clean parts. Do not remove new parts from

their wrapping until just before installing.

When the system is open: Do not work with com-

pressed air, do not move the vehicle.

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Connection diagram for vacuum hoses

1 - Vacuum setting element K For intake manifold flap 2 - Changeover valve for intake manifold flap -N2393 - Distributor part 4 - Vacuum reservoir 5 - To air filter 6 - Solenoid valve for charge pressure control -N75K Inspecting charge pressure control Chapter 21-2 7 - Vacuum setting element K Boost-pressure control K Component part of the exhaust turbocharger cannot be replaced separately 8 - Exhaust gas recirculation valve -N189 - Mechanical exhaust gas recirculation valve 10 - Tandem pump 11 - Brake servo unit 12 - Distributor part K With non-return valve for brake servo unit

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21-1 page 6

Charge air system with turbocharger I

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21-2

Charge air system with turbocharger II

Remove exhaust turbocharger

Special tools, test and measuring equipment and auxiliary items required Torque wrench Pliers for spring strap clips

Removing

Remove engine cover -arrows-. Remove top connection pipe and charge air connection hose Chapter 21-1.

Remove the intake manifold Chapter 21-1. Remove the noise insulation. Remove connecting hoses -1- and -2-. Remove oil return-flow line -5-. Unscrew bolts -3- and -4- from support and take out support. for charge pressure control.

S10-0165

2 4 3

Remove the vacuum hose -7- from the vacuum unit Remove front exhaust pipe -6- from turbocharger and
place down to the side Chapter 26-1.

Remove connection pipes for inlet connection - exhaust manifold for exhaust gas recirculation Chapter 26-2.

7 6

5
S21-0022

Remove the oil feed line for the exhaust turbocharger

Chapter 21-1.

Unbolt exhaust manifold from cylinder head. Lift turbocharger up and out.
Installing
Installation occurs in reverse order. Pay attention to the following: Note Tightening torques Chapter 21-1. After installing the exhaust turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the exhaust turbocharger.

Checking charge pressure control

Special tools, test and measuring equipment and auxiliary items required Hand vacuum pump (e.g. -V.A.G 1390-) Hand multimeter (e.g. -V.A.G 1715-)

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Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3CAdapter cable set (e.g. -V.A.G 1594 C-) Test box -V.A.G 1598/31-

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Test conditions

No fault in the fault memory 1.9-ltr./96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 01

No leaks on the intake and exhaust side No fault on the engine/fuel injection system Engine oil temperature at least 80C
Test sequence
If test and measuring devices are required during test drives observe 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 equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.

The charge pressure is measured with vehicle system

tester - V.A.G 1552- when the engine is idling and during a road test.

Connect up the Vehicle system tester -V.A.G 1552and select the address word 01 Engine electronics (the engine must be idling at the time) 1.9 ltr./96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 01.

Select function
group 0 1
1.

0 4 for Basic setting and display Basic setting 11 1400 rpm OFF -> 99 %

Readout on display: Note After selecting display group 011, the idling speed is increased by the engine control unit in display block 1 to 13801420 rpm. The display in display field 2 must switch between off and on every 10 seconds. The following readouts must fluctuate in display fields 3 and 4: Display field 2: off. Specification in display field 3: Atmospheric pressure in mbar Specification in display field 4: 98100 % Display field 2: on.

982 mbar

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Specification in display field 3: Atmospheric pressure in mbar +100250 mbar Specification in display field 4: 02 % Continue the test as follows:
Press.

Select function

0 8 for Read measured value

block and display group 0 1 1 .

Accelerate vehicle in 2nd gear from about 1000 rpm to

3200 rpm. While doing so the accelerator pedal must be fully pressed down.

At about 3000 rpm read off the value indicated in display block. Specification in display field 3: 21002600 mbar If the specified value is not reached:

Reading measured value block 11 ->

Conduct an actuator diagnosis for the charge pres-

sure control solenoid valve -N75- 1.9 ltr./96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 01.

Charge pressure control solenoid valve must operate for this test. While doing so the linkage of the charge pressure control vacuum unit at the bottom of the turbocharger must move back and forward. This linkage must move at least 34 times as long as a vacuum is present in the vacuum system. If the linkage moves and the nominal charge pressure is not reached:

Replace turbocharger.
If the linkage does not move because the charge pressure control solenoid valve is not operating:

Test charge pressure control solenoid valve -N75 1.9 ltr./96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 23.

Inspect vacuum hoses Chapter 21-1.

If the linkage does not move although the charge pressure control solenoid valve is operating:

Connect hand vacuum pump to charge pressure control valve and inspect linkage for unobstructed movement. If the linkage only moves with difficulty or does not move at all:

V.A.G 1390

Replace turbocharger.

N21-0078

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Charge air system with turbocharger II

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26 Exhaust System
26-1
Note
Always replace gaskets and self-locking nuts. The decoupling element in the front part of the exhaust pipe should not be bent by more than 10 - danger of dam-

Removing and installing parts of the exhaust system

aging it.
After performing installation work on the exhaust system, make sure the exhaust system is not mounted under ten-

sion and has adequate clearance from the vehicle body. If necessary slacken the clamping sleeve (s) and collar clamp and align the silencer and exhaust pipe so as to create adequate clearance between these components and the vehicle body, and that the weight of the exhaust system is evenly distributed over the hangers.
1 - Tunnel bridge K with hole for aligning exhaust system 26-1 page 3 2 - Connecting tube K if factory-fitted the connecting tube and the rear silencer form a building unit, when carrying out repairs both components are replaced individually K Separation point 26-1 page 3 K when installing align free of stress 26-1 page 3 3 - Hanger K Fitting position Fig. 1 in 26-1 page 2 4 - 25 Nm 5 - Hanger 6 - 25 Nm K replace 7 - Exhaust turbocharger K with exhaust manifold K removing and installing Chapter 21-2 8 - Gasket K replace 9 - 25 Nm K replace K Coat stud bolts of exhaust turbocharger with hot bolt paste -G 052 112 A3- before installing. 10 - Front exhaust pipe K with oxidation catalytic converter K protect against shocks and blows K with decoupling element K do not twist decoupling element more than 10 - risk of damage K removing and installing 26-1 page 2 K Align exhaust system free of stress 26-1 page 3

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11 - Clamping sleeve - front K Align exhaust system free of stress before tightening 26-1 page 3 K Fitting position: horizontal in vehicle, bolted connection points to the left K Tighten bolted connections evenly 12 - 40 Nm 13 - Retaining strap 14 - Rear silencer K if factory-fitted the rear silencer and the connecting tube form a building unit, when carrying out repairs both components are replaced individually K Separation point 26-1 page 3 K when installing align free of stress 26-1 page 3 15 - Clamping sleeve - rear K for individual replacement of the rear silencer or connecting tube K Align exhaust system free of stress before tightening 26-1 page 3 K Fitting position: horizontal in vehicle, bolted connection points to the front K Tighten bolted connections evenly

Fig. 1:

Installed position of the hanger

The angled side -arrow- at the base of the hanger points in direction of travel.

Removing and installing front exhaust pipe with catalytic converter

Special tools, test and measuring equipment and auxiliary items required
Torque wrench Hot screw paste -G 052 112 A3-

Removing
Note
Avoid large deflections at twist decoupling element,

max. deflection 10 .
Always replace self-locking nuts.

Remove the sound dampening system in the middle

Body Work; Rep. Gr. 50.

Unscrew hanger from assembly carrier -arrows-.

26-1 page 2

Removing and installing parts of the exhaust system

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Unscrew nuts at flange of exhaust turbocharger -arrows-.

Slacken bolted connections on front clamping sleeve

and push clamping sleeve to the rear.

Remove front exhaust pipe.

Installing
Installation is performed in the reverse order. Pay attention to the following points:

Coat stud bolts of exhaust turbocharger with hot bolt

paste -G 052 112 A3- before installing.

Align exhaust system free of stress 26-1 page 3.

Replace connecting tube and rear silencer

Special tools, test and measuring equipment and auxiliary items required
Torque wrench Body saw (e.g. -V.A.G 1523-)

A separation point is provided for repair purposes for replacing the connecting tube or rear silencer.

Use body saw (e. g. -V.A.G 1523-) to separate exhaust pipe at right angles at separation point -arrow 2-.

When installing, position clamping sleeve -4- at the

side markings -arrow 1- and -arrow 3-. Installation position of clamping sleeve: horizontal in vehicle, screws point to the front

Align exhaust system free of stress 26-1 page 3.

Aligning exhaust system free of stress

Special tools, test and measuring equipment and auxiliary items required
Torque wrench

Procedure

II Y

The exhaust system is aligned when cold. Shop-make screw in accordance with stated dimensions from an M10 or M14 bolt for aligning the exhaust system. Size of bolt Dimension -xDimension -yDimension -zI - M14 6 mm 25 mm 10 mm II - M10 4 mm 25 mm ---

S26-0104

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Note

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The use of the screw (M10 or M14) depends on the diameter of the rear hole in the tunnel bridge 26-1 page 4, illus. S26-0180.
A second mechanic is required for aligning the ex-

haust system.

Slacken bolted connections at front clamping sleeve

(between catalytic converter and connecting tube).

Insert shop-made screw through rear hole -arrow- of

tunnel bridge, the flat point points toward the hanger pin of the exhaust system. Note

The exhaust system is pretensioned in the direction of travel when the shop-make screw is inserted.

Align the connecting tube and rear silencer horizontally. The hanger pin at the exhaust system must be parallel to the tunnel bridge (dimension -X- on left and right identical). Note

On vehicles with fitted repair-rear clamping sleeve inspect additionally the horizontal position of the rear silencer at its tail pipes.

Fit the front clamping sleeve with a distance of approx.

5 mm from the marking A -arrow 1- in the horizontal position and tighten screws uniformly to 40 Nm. Note

Marking S does not apply for this engine.

Checking the exhaust system for leaks

Start engine and run in idle. Seal off tail pipes for the duration of the leak check
(e.g. with cloth or plugs).

Check the connection points for leaks by listening:

Cylinderhead/exhaust manifold, exhaust manifold/exhaust pipe with catalytic converter, etc.

Eliminate any leak found.

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Removing and installing parts of the exhaust system

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26-2
Note

Exhaust gas recirculation system

The exhaust gas recirculation system is operated by the diesel direct injection system control unit -J248via the EGR valve -N18- to the mechanical exhaust gas recirculation valve. Test exhaust gas recirculation and EGR valve -N18 1.9 ltr./96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 01. The mechanical exhaust gas recirculation valve with cone-shaped valve plunger makes it possible to achieve different opening cross-sections at different valve strokes. Connection diagram for vacuum hoses Chap. 21-1. 1 - Intake manifold 2 - O-ring s replace 3 - Vacuum setting element 4 - 5 Nm 5 - Mechanical exhaust gas recirculation valve s part of inlet connection s always replace complete with inlet connection s check 26-2 page 2 6 - Inlet connection s with mechanical exhaust gas recirculation valve and intake manifold flap 7 - 10 Nm 8 - Gasket s replace 9 - 25 Nm 10 - Connecting tube 11 - Gasket s replace

Edition 04.03 S00.5142.50.20

Exhaust gas recirculation system

26-2 page 1

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Testing mechanical exhaust gas recirculation valve
Special tools, test and measuring equipment and auxiliary items required Hand vacuum pump (e.g. -V.A.G 1390-)

Octavia 1997

1.9 l/96 kW (TDI) Engine, Mechanics

Test sequence

Remove engine cover -arrows-. Disconnect vacuum hose on mechanical exhaust-gas

recirculation valve.
S10-0165

Connect hand vacuum pump to valve and operate

pump. Diaphragm must move in the direction of the pressure connection -arrow-.

V.A.G 1390

Detach hose of hand vacuum pump from mechanical

exhaust gas recirculation valve. Diaphragm must move back to its original position against the -direction of the arrow-.

S13-0161

26-2 page 2

Exhaust gas recirculation system

Edition 04.03 S00.5142.50.20