Octavia: Service
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Workshop Manual
OCTAVIA
Running Gear
Service Department. Technical Information
S00.5103.50.20
Edition 08.96
The Workshop Manual is intended only for use within the KODA
Organisation; it is not permitted to pass it on to third parties.
1996 KODA, automobilov a.s.
Printed in Czech Republic
Service
List of Supplements to
OCTAVIA Workshop Manual
Edition: 06.05
Chassis
Replaces List of Supplements - Edition: 05.04
Subject
Article Number
08.96
Basic Edition of Workshop Manual
S00.5103.50.20
09.96
Supplement to Basic Edition
S00.5103.51.20
03.97
Supplement to Repair Group 40 and 42; Repair Group
44, 45 and 48
S00.5103.52.20
11.97
Engine 1.9 l/81 kW TDI
S00.5103.53.20
10.98
Engine 1.8 l/110 kW; Octavia Estate
S00.5103.54.20
12.98
Drive shafts, vehicle measurement, Brake FN-3
S00.5103.55.20
06.99
Modifications to steering system, brakes, rear axle,
ABS; Engine 1.4 l/44 kW
S00.5103.56.20
11.99
4 wheel drive (4 x 4)
S00.5103.57.20
04.00
Vehicles with ABS/EDS/ESP
S00.5103.58.20
11.00
Anti-lock brake system MK60
S00.5103.59.20
10
02.01
Anti-lock brake system MK60 ESP
S00.5103.60.20
11
05.01
Mechanical brake assistant, Brake FN-3
S00.5103.61.20
12
08.01
Text modifications to Repair Group 00, 40, 42 and 45
S00.5103.62.20
13
01.02
Text modifications to Repair Group 45
S00.5103.63.20
14
06.02
Text modifications to Repair Group 00, 40, 44, 45 and
46
S00.5103.64.20
15
11.02
Engine 1.9 l/96 kW PD, Supplement to Repair Group
00, 40, 42 and 45
S00.5103.65.20
16
04.03
Text modifications to Repair Group 40, 45 and 46
S00.5103.66.20
17
05.04
Text modifications to Repair Group 00, 40 and 44
S00.5103.67.20
18
06.05
Text modifications to Repair Group 00, 40, 42 and 45
S00.5103.68.20
Supplement
Edition
19
20
Contents next page.
The Service Manual is intended only for use within the
koda Organisation; it is not permitted to pass it on
to third persons.
2005 KODA AUTO a. s.
Printed in CR
S00.5103.68.20
OCTAVIA
Service
Table of Contents
00
40
42
Technical Data
Page
Technical Data .............................................................................................................................
- The chassis ..............................................................................................................................
- The steering system .................................................................................................................
- The brake system ....................................................................................................................
- Wheels, tyres ...........................................................................................................................
00-1
00-1
00-5
00-6
00-8
Front wheel suspension
Page
Repairing the front wheel suspension ......................................................................................
- I - Summary of the components of the assembly carrier, anti-roll bar, track control arm .........
- Removing and installing the track control bar ..........................................................................
- Pressing out and pressing in the bearing for track control arm ................................................
- Removing and installing the assembly carrier .........................................................................
- Pressing out and pressing in the rubber-metal bearing ...........................................................
- II - Summary of the components of the wheel bearing, suspension strut, drive shaft, brakes ....
- Repairing a wheel bearing housing ..........................................................................................
- Checking the steering joint .......................................................................................................
- Removing and installing the steering joint ...............................................................................
- Removing and installing a suspension strut and a wheel bearing housing ..............................
- Repairing the suspension strut at the front ..............................................................................
- Checking dampers ...................................................................................................................
- Disposing of dampers ..............................................................................................................
- Removing and installing drive shafts .......................................................................................
40-1
40-2
40-4
40-8
40-10
40-12
40-13
40-16
40-19
40-20
40-21
40-25
40-28
40-31
40-34
Repairing a drive shaft ...............................................................................................................
- Repairing a drive shaft with an outer and inner constant velocity joint ....................................
- Repairing a drive shaft with an outer and inner constant velocity joint VL 3700 ......................
- Checking an outer constant velocity joint .................................................................................
- Checking an inner constant velocity joint .................................................................................
- Repairing a drive shaft with an inner tripod joint AAR 2900 and outer constant joint velocity .....
- Dismantling a tripod joint AAR 2900 and assembling it again ..................................................
- Repairing a drive shaft with an inner tripod joint AAR 2000 and outer constant velocity joint .....
- Dismantling a tripod joint AAR 2000 and assembling it again ..................................................
40-38
40-38
40-39.1
40-45
40-46
40-49
40-51
40-56
40-58
Rear wheel suspension
Page
Repairing the rear axle - drum brakes.......................................................................................
- Removing and installing the rear axle ......................................................................................
- Summary of components of the rear axle ................................................................................
- Removing and installing a rubber-metal bearing .....................................................................
- Removing and installing dampers/springs ...............................................................................
- Dismantling a damper and assembling it again .......................................................................
42-1
42-1
42-4
42-7
42-10
42-11
Repairing the rear axle - disc brakes ........................................................................................
- Removing and installing the rear axle ......................................................................................
- Summary of components of the rear axle ................................................................................
- Removing and installing a rubber-metal bearing .....................................................................
- Removing and installing dampers/springs ...............................................................................
- Dismantling a damper and assembling it again .......................................................................
42-12
42-12
42-15
42-18
42-21
42-22
Repairing the wheel bearing system ......................................................................................... 42-23
- Repairing the wheel bearing system - drum brakes ................................................................. 42-23
- Repairing the wheel bearing system - disc brakes .................................................................. 42-28
Edition 06.05
S00.5103.68.20
------------ I ------------
Service
OCTAVIA
Repairing the rear axle (vehicles with a four-wheel drive) ......................................................
- An overview of the rear axle with four-wheel drive ..................................................................
- Summary of components for springs and dampers on vehicles with a four-wheel drive .........
- Removing and installing helical springs ...................................................................................
- Removing and installing dampers ............................................................................................
42-32
42-32
42-33
42-35
42-39
Summary of components of the trailing arm and suspension arm........................................
- Pressing out and pressing in the wheel bearing ......................................................................
- Removing and installing the rubber-metal bearing for the trailing arm ....................................
- Removing and installing guide joints ........................................................................................
- Removing and installing a trailing arm .....................................................................................
- Removing and installing a suspension arm .............................................................................
42-41
42-44
42-50
42-52
42-54
42-58
A summary of components for an assembly carrier with axial drive.....................................
- Removing and installing an assembly carrier with axial drive ..................................................
- Removing and installing the rubber-metal bearing for an assembly carrier .............................
- Removing and installing the rubber-metal bearing for an axial drive .......................................
42-60
42-61
42-66
42-68
Repairing a drive shaft ............................................................................................................... 42-72
- Removing and installing drive shaft ......................................................................................... 42-72
- Repairing a drive shaft with constant velocity joint .................................................................. 42-75
44
Wheels/tyres/vehicle measurement
Page
Vehicle measurement .................................................................................................................
- Conditions for performing checking and tests ..........................................................................
- Making preparations to take measurements ............................................................................
- Designations of the various chassis available .........................................................................
- Nominal value for vehicle measurement ..................................................................................
- Checking the lateral inclination ................................................................................................
- Checking the wheel camber of the front axis, averaging if necessary .....................................
- Checking the wheel camber of the rear axis ............................................................................
- Checking the wheel camber of the rear axis, averaging/adjusting if necessary ......................
- Checking the wheel camber of the front axis, adjusting if necessary ......................................
- Checking the steering angle on the left and right .....................................................................
- Mathematical determination of the deviation of the rear axle from the direction of travel ........
44-1
44-2
44-2.1
44-2.2
44-2.2
44-2.3
44-2.4
44-2.5
44-2.5
44-2.6
44-2.6
44-2.8
Wheels and tyres......................................................................................................................... 44-3
- The disc wheel ......................................................................................................................... 44-3
- The light metal wheel ............................................................................................................... 44-4
45
The Anti-Lock Braking System
Page
The anti-lock braking (ABS) ITT Mark 20 IE ..............................................................................
- Safety measures, basics concerning searching for faults and repair
of the ABS and ABS/EDL ITT Mark 20 IE ................................................................................
- Information concerning repair work on an ABS and ABS/EDL ITT Mark 20 IE ........................
- Required technical information ................................................................................................
45-1
45-1
45-1
45-3
Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE .....
- General comments ...................................................................................................................
- The ABS ITT Mark 20 IE ..........................................................................................................
- The ABS/EDL ITT Mark 20 IE ..................................................................................................
- Installed position of the ABS or ABS/EDL ITT Mark 20 IE .......................................................
45-4
45-4
45-4
45-5
45-5
Self-diagnosis..............................................................................................................................
- Function of the self-diagnostic system .....................................................................................
- Indication of faults concerning the warning lamps K47 and K14/33 ........................................
- A vehicle with ABS/EDL has no EDL function ..........................................................................
45-6
45-6
45-7
45-8
------------ II ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
Service
Undertaking the self-diagnosis..................................................................................................
- Conditions for performing checking and tests ..........................................................................
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................
- Querying the control unit version .............................................................................................
- An overview of the functions which can be selected ................................................................
- Interrogating the fault memory .................................................................................................
- The automatic testing sequence ..............................................................................................
- The fault table ..........................................................................................................................
- Deleting the fault memory ........................................................................................................
- Ending output ...........................................................................................................................
- Coding the control unit .............................................................................................................
- Reading the measuring value block .........................................................................................
- Actuator diagnosis ...................................................................................................................
- Initiating the basic setting .........................................................................................................
45-9
45-9
45-9
45-10
45-12
45-12
45-13
45-14
45-21
45-22
45-22
45-24
45-29
45-36
Electrical testing of the ABS and ABS/EDL ITT Mark 20 IE .....................................................
- Conditions for performing checking and tests ..........................................................................
- Multiple plug connectors with contact allocation ......................................................................
- An overview of the test steps ...................................................................................................
- Testing table .............................................................................................................................
45-41
45-41
45-42
45-43
45-44
Electrical/electronic components and installed locations of the ABS,
ABS/EDL ITT Mark 20 IE .............................................................................................................
- Removing and installing the hydraulic control unit and holder .................................................
- Repairing the hydraulic control unit ..........................................................................................
- Testing parts of the ABS system on the front axle/removing and installing ..............................
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes - front-wheel drive ................................................................................
- Removing and installing as well as adjusting a brake light switch up to MY 1999 ...................
- Removing and installing as well as adjusting a brake light switch as of MY 2000 ...................
45-51
45-52
45-57
45-60
45-65
45-69
45-69.1
A summary of components for the hydraulic control unit, brake booster/master
brake cylinder for vehicles with ABS, ABS/EDL ITT Mark 20 .................................................. 45-70
Self diagnosis of the ABS/EDL for a four-wheel drive vehicle with a Haldex clutch ............
- Querying the control unit version .............................................................................................
- Fault table for ABS/EDL for a four-wheel drive vehicles with a Haldex clutch .........................
- Coding the control unit .............................................................................................................
- Testing the sender for longitudinal acceleration -G251- ...........................................................
- Testing the data-bus lines ........................................................................................................
- Initiating the basic setting .........................................................................................................
- Switching off the sender for longitudinal acceleration -G251- ..................................................
- Zero balancing of the sender for longitudinal acceleration -G251- ..........................................
45-71
45-71
45-72
45-73
45-74
45-75
45-76
45-76
45-77
Electrical testing of the ABS/EDL for a four-wheel drive vehicle with a Haldex clutch........ 45-79
- Test table .................................................................................................................................. 45-79
Electrical/electronic components and fitting locations (four-wheel drive) ........................... 45-81
- Removing and installing the sender for longitudinal acceleration -G251- ................................ 45-82
- Testing parts of the ABS system on the rear axle/removing and installing (disc brakes)
S-four-wheel drive .................................................................................................................... 45-82
The anti-lock braking system ABS/EDL/ESP ITT Mark 20 IE...................................................
- Safety measures, basics concerning searching for faults and repair .......................................
- Information concerning repair work on the ABS/EDL/ESP ITT Mark 20 IE ..............................
- Required technical information ................................................................................................
45-88
45-88
45-88
45-88
Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL/ESP ITT
Mark 20 IE ....................................................................................................................................
- General comments ...................................................................................................................
- The ABS/EDL/ESP ITT Mark 20 IE ..........................................................................................
- Fitting position of the ABS/EDL/ESP ITT Mark 20 IE ...............................................................
45-89
45-89
45-90
45-90
Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP ITT Mark 20 IE .......................................
- Function of the self-diagnostic system .....................................................................................
- Indication of faults concerning the warning lamps K47, K118 and K155 .................................
- A vehicle with ABS/EDL/ESP has no EDL function ..................................................................
45-91
45-91
45-92
45-96
Edition 06.05
S00.5103.68.20
------------ III ------------
Service
OCTAVIA
Undertaking the self-diagnosis..................................................................................................
- Conditions for performing checking and tests ..........................................................................
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................
- Querying the control unit version .............................................................................................
- The automatic testing sequence ..............................................................................................
- An overview of the functions which can be selected ................................................................
- Interrogating the fault memory .................................................................................................
- The fault table ..........................................................................................................................
- Deleting the fault memory ........................................................................................................
- Ending output ...........................................................................................................................
- Coding the control unit .............................................................................................................
- Reading the measuring value block .........................................................................................
- Initiating the basic setting .........................................................................................................
- The logging-in procedure .........................................................................................................
45-97
45-97
45-97
45-98
45-100
45-100
45-101
45-102
45-113
45-114
45-114
45-116
45-124
45-131
Electrical testing of the ABS/EDL/ESP ITT Mark 20 IE.............................................................
- Conditions for performing checking and tests ..........................................................................
- Multiple plug connectors with contact allocation ......................................................................
- Testing table .............................................................................................................................
- Test steps 1 - 20 .......................................................................................................................
- Test steps 21 - 28 .....................................................................................................................
45-133
45-133
45-134
45-138
45-138
45-148
Electrical/electronic components and installed locations of the ABS/EDL/ESP ITT
Mark 20 IE ....................................................................................................................................
- Removing and installing the hydraulic control unit ABS/EDL/ESP and holder .........................
- Repairing the hydraulic control unit ABS/EDL/ESP..................................................................
- Testing parts of the ABS system on the front axle/removing and installing ..............................
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes - front-wheel drive ................................................................................
- Removing and installing parts of the ESP system ...................................................................
- Removing and installing as well as adjusting a brake light switch ...........................................
45-155
45-158
45-163
45-166
45-170
45-170
45-176
A summary of components for the hydraulic control unit, brake booster/master
brake cylinder for vehicles with ABS/EDL/ESP ITT Mark 20 ................................................... 45-177
The anti-blocking system (ABS) MK60 .....................................................................................
- Safety measures, basics concerning searching for faults and repair of the ABS
and ABS/TCS/EDL ITT MK 60 .................................................................................................
- Information concerning repair work on an ABS and ABS/TCS/EDL ITT MK 60 .......................
- Required technical information ................................................................................................
- General guidelines ...................................................................................................................
- ABS and ABS/TCS/EDL ...........................................................................................................
- Installed position of the ABS or ABS/TCS/EDL ITT MK 60 ......................................................
45-179
45-179
45-179
45-179
45-179
45-179
45-179
Self-diagnosis.............................................................................................................................. 45-180
- Function of the self-diagnostic system ..................................................................................... 45-180
- Indication of faults concerning the warning lamps K47 and K14/33 ........................................ 45-180
Undertaking the self-diagnosis..................................................................................................
- Conditions for performing checking and tests ..........................................................................
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................
- An overview of the functions which can be selected ................................................................
- The fault table ..........................................................................................................................
- Coding the control unit .............................................................................................................
- Table of codes for vehicles with Anti-Lock Brake System Mark 60 ..........................................
- Reading the measuring value block .........................................................................................
- Actuator diagnosis ...................................................................................................................
- Initiating the basic setting .........................................................................................................
45-182
45-182
45-182
45-182
45-183
45-190
45-191
45-192
45-194
45-194
Electrical/electronic components and installed location of the Mark 60 ...............................
- Removing and installing the hydraulic control unit and holder .................................................
- Repairing the hydraulic control unit ..........................................................................................
- Testing parts of the ABS system on the front axle/removing and installing ..............................
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes) - front-wheel drive ..............................................................................
45-195
45-196
45-200
45-201
45-203
A summary of components for the hydraulic control unit, brake booster/master
brake cylinder for vehicles with ABS/EDL/TCS 20 Mark 60 .................................................... 45-204
------------ IV ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
Service
Electrical testing of the ABS/EDL/TCS Mark 60 .......................................................................
- Conditions for performing checking and tests ..........................................................................
- Multiple plug connectors with contact allocation ......................................................................
- Testing table .............................................................................................................................
45-205
45-205
45-206
45-208
The anti-lock braking system ABS/EDL/ESP MK 60 ................................................................
- Safety measures, basics concerning searching for faults and repairs .....................................
- Information concerning repair work on an ABS/EDL/ESP Mark 60..........................................
- Required technical information ................................................................................................
45-214
45-214
45-214
45-214
Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP
Mark 60 MY02 .......................................................................................................................... 45-215
Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP
Mark 60 MY02 .......................................................................................................................... 45-217.1
Differences in the features of the ABS/EDL/TCS Mark 60 and the ABS/EDL/ESP Mark 60 ..... 45-218
- General comments ................................................................................................................... 45-218
- Installed position of the ABS/EDL/TCS/ESP Mark 60 .............................................................. 45-218
Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP Mark 60.................................................. 45-219
- The function ............................................................................................................................. 45-219
- Indication of faults concerning the warning lamps K47, K14/33 and K155 .............................. 45-219
46
Undertaking the self-diagnosis..................................................................................................
- Conditions for performing checking and tests ..........................................................................
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................
- Querying the control unit version .............................................................................................
- An overview of the functions which can be selected ................................................................
- The fault table ..........................................................................................................................
- Coding the control unit .............................................................................................................
- Reading the measuring value block .........................................................................................
- Initiating the basic setting .........................................................................................................
- The logging-in procedure .........................................................................................................
45-223
45-223
45-223
45-223
45-224
45-224
45-237
45-238
45-241
45-249
Electrical testing of the ABS/EDL/ESP Mark 60 .......................................................................
- Conditions for performing checking and tests ..........................................................................
- Multiple plug connectors with contact allocation ......................................................................
- Testing table .............................................................................................................................
45-250
45-250
45-251
45-254
Brakes/brake mechanics
Page
Repairing a front wheel brake ....................................................................................................
- Repairing a front wheel brake, brake calliper FS-III .................................................................
- Removing and installing brake linings or brake calliper (FS-III) ...............................................
- Repairing a front wheel brake, brake calliper FN-3 ..................................................................
- Removing and installing brake linings/brake calliper (FN-3) ....................................................
- Removing and installing brake discs (FN-3) ............................................................................
46-1
46-1
46-3
46-5
46-5.2
46-5.7
Repairing a rear wheel brake - front wheel drive/drum brake.................................................
- Removing and installing a rear brake ......................................................................................
- Resetting a brake .....................................................................................................................
- Repairing a rear wheel brake ...................................................................................................
- Removing and installing brake linings ......................................................................................
- Adjusting the handbrake (drum brake) .....................................................................................
46-6
46-6
46-7
46-8
46-10
46-12
Repairing a rear wheel brake - front wheel drive/disc brake ..................................................
- Removing and installing a rear brake ......................................................................................
- Removing and installing brake lining .......................................................................................
- Adjusting the handbrake (disc brake) ......................................................................................
46-13
46-13
46-15
46-17
Removing and installing the handbrake cable (front wheel drive/drum brake) .................... 46-17.2
Removing and installing the handbrake cable (front wheel drive/disc brake) ...................... 46-17.3
Summary of components: the handbrake cable ...................................................................... 46-18
Summary of components: foot-operated system, brake pedal .............................................. 46-19
- Disconnecting the brake pedal from the brake booster and clipping them together ................ 46-20
- Removing and installing the brake pedal ................................................................................. 46-22
Edition 06.05
S00.5103.68.20
------------ V ------------
Service
OCTAVIA
Repairing a rear wheel brake - four-wheel drive/disc brake ...................................................
- Removing and installing a rear brake ......................................................................................
- Removing and installing brake linings ......................................................................................
- Adjusting the handbrake ..........................................................................................................
46-24
46-24
46-26
46-29
Removing and installing the handbrake cable (four-wheel drive/disc brake) ....................... 46-31
47
Brakes/brake hydraulics
Page
A summary of components for the brake booster/master brake cylinder for vehicles
without ABS or ABS/EDL Mark 20 .............................................................................................
- Removing and installing the master brake cylinder .................................................................
- Checking the brake booster .....................................................................................................
- Removing and installing the brake booster ..............................................................................
- Removing and installing the vacuum pump for the brake booster ...........................................
47-1
47-2
47-4
47-4.1
47-7
Repairing a front brake calliper, brake calliper FS-III .............................................................. 47-8
- A summary of components of the brake calliper FS-III ............................................................ 47-8
- Removing and installing pistons for the front brake calliper ..................................................... 47-9
Repairing a front brake calliper, brake calliper FS-3 ............................................................... 47-10.1
- A summary of components of the brake calliper FS-3 ............................................................. 47-10.1
- Removing and installing pistons for the front brake calliper ..................................................... 47-10.2
Repairing a rear brake calliper................................................................................................... 47-11
- A summary of components of the brake calliper ...................................................................... 47-11
- Removing and installing the piston for the front brake calliper ................................................ 47-12
A summary of components of the brake force regulator ........................................................ 47-15
Checking and adjusting the brake force regulator .................................................................. 47-16
- Setting values for the load-oriented brake force regulator ....................................................... 47-17
Ventilating the brake system on vehicles with and without ABS or ABS/EDL Mark 20
and Mark 60 .................................................................................................................................
- Ventilating the brake system using a brake draining and ventilation device such
as ROMESS S15 for vehicles with Mark 20 .............................................................................
- Ventilating the brake system without the use of a brake draining and ventilation device ........
- Changing the brake fluid ..........................................................................................................
- Ventilating the brake system using a brake draining and ventilation device such a
s ROMESS S15 for vehicles with Mark 60 ...............................................................................
47-18
47-20
47-21
47-22
47-23
Tightness test of the master brake cylinder ............................................................................. 47-24
48
A summary of components: brake booster/master brake cylinder for vehicles
with ABS/EDL/ESP Mark 20 ........................................................................................................
- Removing and installing sender -1- for brake pressure -G201- and sender -2- for
brake pressure -G214- .............................................................................................................
- Removing and installing the master brake cylinder .................................................................
- Checking the brake booster .....................................................................................................
- Removing and installing the brake booster ..............................................................................
- Removing and installing the vacuum pump for the brake booster ...........................................
47-28
47-30
47-32
47-32
47-35
A summary of components: brake booster/master brake cylinder for vehicles
with ABS/EDL/TCS/ESP Mark 60................................................................................................
- Removing and installing sender -1- for brake pressure -G201- ...............................................
- Removing and installing the master brake cylinder .................................................................
- Checking the brake booster .....................................................................................................
- Removing and installing the brake booster ..............................................................................
- Removing and installing vacuum pump for the brake -V192- ..................................................
- Checking vacuum pump for the brake -V192- .........................................................................
47-36
47-37
47-37
47-37
47-37
47-38
47-39
The steering system
Page
Steering column and steering wheel with airbag.....................................................................
- Checking the steering column for damage ..............................................................................
- Removing and installing the steering column ..........................................................................
- Removing and installing the ignition lock housing with the steering column mounted in place...
48-1
48-1
48-2
48-8.3
------------ VI ------------
47-26
Edition 06.05
S00.5103.68.20
OCTAVIA
Service
A summary of components: the power-assisted steering gearing system ...........................
- Removing and installing the expansion bottle for hydraulic oil ................................................
- Removing and installing the power-assisted steering gearing system ....................................
- Repairing the power-assisted steering gearing system (ZF) ...................................................
- Altered track rod ends ..............................................................................................................
- Altered track rods .....................................................................................................................
- Disposing of a power-assisted steering gearing system ..........................................................
- Adjusting a power-assisted steering gearing system (ZF) .......................................................
- Checking the hydraulic fluid level on a power-assisted steering system and topping it
up where necessary .................................................................................................................
- Emptying a power-assisted steering system, filling and ventilating .........................................
- Checking a power-assisted steering system for leaks .............................................................
- Noises on a power-assisted steering system ...........................................................................
48-9
48-11
48-12
48-19
48-23.1
48-23.2
48-24
48-25
A summary of components: the vane pump ............................................................................
- A summary of components for vane pumps which are mounted above and below .................
- Pressure switch for the power-assisted steering system .........................................................
- Checking the delivery pressure of the vane pump ...................................................................
48-33
48-33
48-34
48-35
Removing and installing the vane pump ..................................................................................
- Vehicles with the vane pump mounted above ..........................................................................
- Vehicles with the vane pump mounted below ..........................................................................
- Disposing of a vane pump .......................................................................................................
48-37
48-37.1
48-41
48-45
Edition 06.05
S00.5103.68.20
48-26
48-28
48-30
48-31
------------ VII ------------
OCTAVIA
00
Technical Data
Technical Data
Chassis
Nominal values front axle
Spring strut axle (Front and 4 Wheel Drive)
Standard
suspension7)
Chassis
G06
G12
G13
G14
G15
Overall track2)
G20
G30
G31
G32
G33
1GA
1GG
1GE
1GH
Sport suspension
G35
G85
Rough road
suspension
G04
G07
G34
G39
G40
1GB
1GW
Explanation concerning this PR No. see page 00-4
0 10'
0 10'
0 10'
Track for 15" (mm)2) wheels
Measuring point: 196 mm from wheel centre
0 1.1
0 1.1
0 1.2
0 1.2
0 1.2
Track for 17"8) (mm)2) wheels
Measuring point: 225 mm from wheel centre
0 1.3
- 1 30' 20'
- 1 31' 20'
- 1 27' 20'
- 6 35'
- 6 40'
- 6 35'
40
39 45'
40 45'
14"7)
Track for
wheels
Measuring point: 184 mm from wheel centre
(mm)2)
Track for 16"7) (mm)2) wheels
Measuring point: 209 mm from wheel centre
Toe difference angle on turns
of 20 of inside wheels1)
Toe difference angle on turns
at full lock of inside wheel1)
Max. wheel lock angle1)
Continued table page 00-2
01
01
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir
for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver).
1)
2)
7)
8)
Not adjustable, depending on design
Adjustable
Not valid for Octavia 4 x 4
Only Octavia RS (1.8 l/32 kW)
Edition 11.02
S00.5103.65.20
------------ 00-1 ------------
00
OCTAVIA
Technical Data
Continuation of table Nominal values of front axle of page 00-1
Spring strut axle (Front and 4-Wheel Drive)
Camber3)
Standard suspension7)
Sport suspension
Rough road suspension
-30 30
-33 30
-16 30
-0 25 30
4)6)
-0 28 305)
Max. difference between
left and right side
Caster angle1)
30
30
7 40 308)
7 50 308)
7 15 308)
7 40 +30, -609)
7 50 +30, -609)
7 15 +30, -609)
8 23 304)
8 305)6)
Max. difference of caster
angle between left and
right side
30
30
Comment:
Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for the
windscreen wiper washer system, spare wheels, tool kit, jack and without driver).
1)
Not adjustable, depending on design
3)
The camber can be changed marginally, by moving the assembly carrier.
Pay attention to: Always replace the screws and washers of the assembly carrier!
After carrying out corrections of steering geometry, inspect position of steering wheel and alter to correct position,
if necessary.
4)
Only Service Mobil (Octavia 1.9 l/66 kW SLX, Octavia 1.8 l/92 kW SLX)
5)
Only Service Mobil (Octavia Estate 1.9 l/81 kW SLX)
6)
Only Service Mobil (Octavia 1.9 l/66 kW GLX
7)
Not valid for Octavia 4 x 4
8)
up to MY 2000
9)
as of MY 2001
------------ 00-2 ------------
Edition 06.05
S00.5103.68.20
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OCTAVIA
00
Technical Data
Chassis
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir
for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver).
Edition 11.02
S00.5103.65.20
------------
------------
00
------------ 00-3.1
00-4 -----------------------
Technical Data
OCTAVIA
Edition 11.00
S00.5103.59.20
OCTAVIA
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Comment: Technical data applies for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver).
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S00.5103.67.20
------------ 00-3.2 ------------
00
OCTAVIA
Technical data
Chassis designations with PR numbers
A variety of chassis can be installed depending
on the engine used and the equipment fitted.
These all designated with a PR number.
The chassis which is installed in the vehicle is
documented by the PR number for the front axle
recorded on the vehicle data carrier.
The vehicle data carrier is located at the rear on
the left of the base of the luggage compartment
and in the service plan.
K Example of a vehicle data carrier
This example shows that the vehicle is fitted with
a standard chassis 1GA -arrow-.
The table below shows a listing of the various
chassis PR numbers which are decisive for the
allocation of nominal values to the vehicle
Page 00-1
PR No.
Engine installed / gearbox design
Front axis
PR No.
1GA
All petrol engines up to 74 kW with a
manual gearbox
1GE
1GG
All petrol engines up to 74 kW with an automatic gearbox
All diesel engines over 66 kW with a
manual gearbox
1GB
Rear axis
PR No.
Engine installed / gearbox design
1JD
Only a sedan
All petrol and diesel engines with a manual
or an automatic gearbox other than the
1.8-ltr./110 kW engine
1JH
Only estate cars
All petrol and diesel engines with a manual
or an automatic gearbox other than the
1.6-ltr./55 kW engine
------------ 00-4 ------------
Engine installed / gearbox design
All petrol engines up to 74 kW with a
manual or an automatic gearbox
All diesel engines over 66 kW with a
manual gearbox
All petrol and diesel engines with a manual
or an automatic gearbox
Octavia 4 x 4
PR No.
Engine installed / gearbox design
1JB
All petrol and diesel engines with a manual
or an automatic gearbox
1JW
Octavia 4 x 4
Edition 06.02
S00.5103.64.20
OCTAVIA
00
Technical Data
Steering
Model
All
Steering type
Rack and pinion type steering system
Steering gear
Power-steering gear
Steering-wheel turns from stop to stop
3.04
Steering-wheel diameter (mm)
370
Total ratio of steering
Lubricant for gear racks
15.60
Steering gear-flow grease
TL 733
N 052 733 00
Part No.: AOF 063 000 04
(e.g. DEA ORNA F6 EPO)
Filling weight (g)
23...27
Maximum clearance between pressure plate and cover
(mm)
0.05...0.1
Authorised axial force for the displacement of the gear
rack (N)
250
Rotating force of the track rods from rest position (N)
Hydraulic oil designation
1...3.5
Hydraulic oil
TL 52 146
N 052 146 00
Part No.: G 002 000
(e.g. PENTOSIN CHF 11S)
Hydraulic oil amount in the system (l)
Edition 06.05
S00.5103.68.20
0.7...0.9 l
------------ 00-5 ------------
00
OCTAVIA
Technical Data
Brakes
Engine
l/kW
Brake master cylinder
mm
S = (Manual) shift gearbox
A = Automatic gearbox
Brake servo unit
Inch
Front disc brakes
Front brake calliper
Front brake caliper, piston
Front brake disc
1.4/44; 1.4/55
S
1.6/55
1.6/74;1.6/75
LHD models with and without ABS: 10
RHD models with and without ABS: 7/8 tandem
FS-III 3)
mm
54.0
256.0
Brake disc, minimum thickness
mm
19.0
Minimum thickness without
supporting plate
mm
2.0
Pad thickness with supporting plate
23.81
mm
Brake disc, thickness
1.9/50 SDI
mm
22.0
mm
19.5
Rear disc brakes
Rear brake caliper, piston
Rear brake disc
Brake disc, thickness
mm
mm
mm
239.0
7.0
2.0
mm
Minimum thickness without
supporting plate
mm
mm
Brake disc, minimum thickness
Pad thickness with supporting plate
41.0
9.0
17.0
Rear drum brakes
Brake drum
mm
230.0
Brake drum - maximum diameter
mm
mm
20.64
20.64
Wheel brake cylinder2)
mm
20.64
20.64
Brake lining, width
mm
32.0
Minimum thickness without
supporting shoe
mm
2.5
Wheel brake cylinder1)
Lining thickness without supporting
shoe
1)
2)
Models without ABS
Models with ABS
------------ 00-6 ------------
mm
231.0
20.64
19.05
19.054)
20.64
20.64
20.64
5.5
3)
4)
Not for taxi models (designation F4E)
For Octavia Combi: 20.64
Edition 05.01
S00.5103.61.20
!"
#$%&'
OCTAVIA
M = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
Brake booster -
Front brake caliper
mm
Inch
Front brake caliper, piston -
mm
Brake disc, thickness
mm
Front brake disc -
00
Technical Data
23.81
Left-hand drive with and without ABS: 10"
Right-hand drive with and without ABS: 7"/8" - Tandem
54.0
54.0
54.0
mm
312,0
280,0
288,0
Brake disc, minimum thickness
mm
23,0
19,0
23,0
Minimum thickness without
supporting plate
mm
2,0
2,0
2,0
Rear brake caliper, piston -
mm
38,0
41,0
41,0
Brake disc, thickness
mm
Pad thickness with supporting
plate
Rear brake disc -
mm
25,0
22,0
19,5
19,5
25,0
19,5
mm
256,0
239,0
232,0
Brake disc, minimum thickness
mm
mm
20,0
17,37
7,0
17,37
7,0
17,0
Minimum thickness without
supporting plate
mm
2,0
2,0
2,0
Brake drum -
mm
Pad thickness with supporting
plate
Brake drum - maximum diameter
Wheel brake cylinder1) -
Wheel brake cylinder2) -
Pad thickness
Pad thickness without supporting
plate
Minimum thickness without
supporting plate
1)
Vehicles without ABS
Edition 11.02
S00.5103.65.20
22,0
9,0
9,0
mm
mm
mm
mm
mm
2)
Vehicles with ABS
------------
------------
00
------------ 00-6.2 ------------
Technical Data
OCTAVIA
Edition 05.01
S00.5103.61.20
OCTAVIA
00
Technical Data
Engine
l/kW
M = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
mm
Brake booster -
Inch
1.9/66 TDI
1.9/81 TDI
1.8/92; 2.0/85 (82)
1.8/110
M
23.81
Left-hand drive with and without ABS: 10
Right-hand drive with and without ABS: 7/8 - Tandem
Front brake disc
Front brake caliper
FN-III3)5)
FN-34)
Front brake caliper, piston -
mm
54.0
54.0
Front brake disc -
mm
280.0
288.0
Brake disc, thickness
mm
22.0
25.0
Brake disc, minimum thickness
mm
19.0
23.0
Pad thickness with supporting plate
mm
19.5
19.5
Minimum thickness without supporting plate
mm
2.0
2.0
Rear disc brake
38.08)
41.09)
Rear brake caliper, piston -
mm
Rear brake disc -
mm
Brake disc, thickness
mm
9.0
Brake disc, minimum thickness
mm
7.0
Pad thickness with supporting plate
mm
17.0
Minimum thickness without supporting plate
mm
2.0
232.06)
239.07)
232.0
239.07)
Drum brake
Brake drum -
Brake drum - maximum diameter
1)
mm
230.0
mm
231.0
Wheel brake cylinder -
mm
20.64
Wheel brake cylinder2) -
mm
20.64
20.64
Pad thickness, width
mm
32.0
Pad thickness without supporting
plate
mm
5.5
Minimum thickness without supporting plate
mm
2.5
1)
Vehicles without ABS
2)
Vehicles with ABS
3)
Not valid for Taxi vehicles (identification
F4E)
4)
For Taxi vehicles (F4E) also 1.9/66; 2.0/85;
1.9/81
Edition 06.05
S00.5103.68.20
5)
For Taxi vehicles (F4E) also 1.4/44; 1.4/55;
1.6/55; 1.6/74; 1.6/75; 1.9/50
6)
Vehicles with ESP
7)
Four-wheel drive vehicles
8)
up to 07.98
9)
as of 08.98
------------ 00-7 ------------
00
OCTAVIA
Technical Data
Brake fluid
Classification
Brake fluid
N 052 766
US standard FMVSS 571. 116 DOT4)
Part No.: B 000 700 A..
(A1......M8 - Package size)
Contents of brake fluid
Brake fluid change
0.49
0.53
0.57
Vehicles with rear drum brakes, without ABS
Vehicles with rear drum brakes, with ABS
Vehicles with rear disc brakes, with ABS
every 2 years
Wheels, Tyres
Rims:
Bolt-hole circle diameter: 100 mm
Center hole diameter: 57 mm
5-hole fixing
Engine
Tyre size1)
Light alloy rim
1.4 l/44 kW
175/80 R14 88 T, H
1.4 l/55 kW
195/65 R15 91 T, H, V
6J x 15 H2
1.6 l/55 kW
205/60 R15 91 H
61/2J x 15 H2
1.9 l/50 kW
Steel rim
6J x 14 H2
Offset
(mm)
38
6J x 15 H2
Snow chains
Permitted
yes
no
43
205/55 R16 91 H
6 /2J x 16 H2
42
205/55 R16 91 W
51/2J x 16 H2
36
38
1.6 l/74 kW
175/80 R14 88 H
1.6 l/75 kW
195/65 R15 91 H, V
6J x 15 H2
205/60 R15 91 H
61/2J x 15 H2
43
205/55 R16 91 H
61/2J x 16 H2
42
36
38
2.0 l/85 kW
6J x 14 H2
6J x 15 H2
205/55 R16 91 W
5 /2J x 16 H2
195/65 R15 91 H, V
6J x 15 H2
205/60 R15 91 H
61/2J x 15 H2
43
205/55 R16 91 H
61/2J x 16 H2
42
205/55 R16 91 W
51/2J x 16 H2
36
6J x 15 H2
Continued table page 00-9
1)
Tyre inflation pressure
Inspection and Maintenance;
as well as sticker on vehicle
------------ 00-8 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
00
Technical Data
1,8 l/92 kW
1,8 l/110 kW
195/65 R15 91 H, V
205/60 R15 91 H, V
195/65 R15 91 V
6J x 15 H2
205/55 R16 91 W
J x 16 H2
205/55 R16 91 W
5 1/2 J x 16 H2
205/55 R16 91 W
205/55 R16 91 W
W2)
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
1,9 l/74 kW PDi 195/65 R15 91 V
205/60 R15 91 V
205/55 R16 91 V
205/55 R16 91 W
1,9 l/81 kW TDI 195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H, V, W
205/55 R16 91 W
1,9 l/96 kW PDi 195/65 R15 91 V
205/60 R15 91 V
205/55 R16 91 V, W
205/55 R16 91 W
Tyre inflation pressure
Inspection and Maintenance as well as
sticker on vehicle
1/
2
1/
2
J x 15 H2
1/
2
6J x 15 H2
6
1/
2
J x 16 H2
J x 16 H2
1/
2
J x 16 H2
J x 16 H2
1/
2
J x 16 H2
J x 16 H2
1/
2
36
36
J x 16 H2
2)
43
42
X
-
X
-
38
43
36
43
36
43
36
43
36
J x 16 H2
38
6J x 15 H2
6 1/2 J x 15 H2
6J x 15 H2
1/
2
42
6J x 15 H2
6 1/2 J x 15 H2
6J x 15 H2
1/
2
6J x 15 H2
6 1/2 J x 15 H2
6
6J x 15 H2
1/
2
36
6J x 15 H2
6 1/2 J x 15 H2
1/
2
7J x 17 H2
6 1/2 J x 16 H2
J x 16 H2
42
6 1/2 J x 16 H2
43
6J x 15 H2
J x 16 H2
38
5 1/2 J x 16 H2
205/55 R16 91 V, W
1,9 l/66 kW TDI 195/65 R15 91 T, H, V
Edition 11.02
S00.5103.65.20
1/
2
6J x 15 H2
J x 15 H2
205/50 R17 89
1)
1/
2
205/55 R16 91 H, V, W
205/60 R15 91 V
1,8 l/132 kW
6J x 15 H2
no
38
42
38
42
38
42
38
42
X
-
X
-
X
-
X
-
X
-
X
-
X
-
Not valid for Octavia Estate RS
------------
------------
00
Load rating-index (Last Index):
Speed symbol:
OCTAVIA
Technical Data
88 = 560 kg
89 = 580 kg
T = 190 km/h
V = 240 km/h
91 = 615 kg
H = 210 km/h
W = 270 km/h
Notes:
Only use tyres of a same size and type on a vehicle, however the tread pattern and manufacturer may differ per axle.
It is exceptionally allowed to use a different tyre temporarily in the event of a breakdown. Take into account a change
in driving and braking behaviour.
Wheel bolts with spherical collar and a thread of M14 x 1,5 - torque: 120 Nm
Only use authorized on the relevant vehicle.
When replacing rims always use wheel bolts to these rims (different length and spherical cap shape).
Also observe the national legislation.
Caution!
Tyres that are more than 6 years old must only be used in case of emergency and while driving
very carefully.
------------ 00-10 ------------
Edition 11.02
S00.5103.65.20
OCTAVIA
00
Technical Data
Tyre inscription
Inscription e.g. 175/80 R14 88 T
175/80
R
14
88
T
Date of manufacture
DOT ... 394 K
DOT ... 0300
Edition 11.00
S00.5103.59.20
Meaning
Tyre width (mm)/cross section ratio of height - width (%)
Tyre construction (radial)
Wheel diameter (inch)
Load index
Speed symbol
Manufactured in 39th week 1994
(K = designates decade 1990 ... 1999)
Manufactured in 3rd week 2000
(03 = 3rd calendar week, 00 = year 2000)
------------
------------
OCTAVIA
40
Front Suspension
Servicing front suspension
I - Removing and installing subframe, anti-roll
bar, track control arm page 40-2
Edition 10.98
S00.5103.54.20
II - Removing and installing wheel mounting,
suspension strut, drive shaft, brake
page 40-13
------------ 40-1 ------------
40
Front wheel suspension
OCTAVIA
I - Summary of the components of the assembly carrier, anti-roll bar, track control arm
Comments:
If vehicles on which the universal drive shaft
has been removed have to be moved then
an outer joint must be fitted instead of the
universal drive shaft which should be tightened to 50 Nm otherwise the wheel bearing
will be damaged.
It is not allowed to do welding and straightening work on weight carrying and wheel
guiding components of the wheel suspension system.
1 - Axle guide
Removing and installing Page 40-4
Elongated holes only serve to adjust
the wheel camber!
2 - 15 Nm and turn through a further 90
3 - Shift rail
Shift rails on a given axle must be of
the same design
Allocation spare parts catalogue
Self-locking nuts must always be replaced.
Corroded bolts/nuts must always be replaced.
------------ 40-2 ------------
Edition 06.02
S00.5103.64.20
OCTAVIA
40
Front wheel suspension
4 - 15 Nm and turn through a further 90
Replace after every disassembly operation
5 - Shift rail
Only for anti-roll bars with a diameter
of 23 mm
Replace with a steel unit
Shift rails on a given axle must be of
the same design
Allocation spare parts catalogue
6 - Bearing at the front for the axle guide
Pressing out and pressing in Page
40-8
7 - 70 Nm and turn through a further 90
Replace after every disassembly operation
8 - Rocking pier
9 - 40 Nm and turn through a further 90
Replace after every disassembly operation
18 - Shift rail
Mount the spherical head with the long
threaded pin -A- (above) on the spring
plate
Mount the spherical head with the
short threaded pin -B- (below) on the
anti-roll bar
Allocation spare parts catalogue
19 - 90 Nm
Replace after every disassembly operation
20 - Metal - rubber bearing
Pressing out and pressing in Page
40-12
21 - Nut, self-locking
Replace after every disassembly operation
22 - 100 Nm and turn through a further 90
Replace after every disassembly operation
10 - 40 Nm and turn through a further 90
Replace after every disassembly operation
23 - Bearing behind for the axle guide
Installed location Page 40-9
Pressing out and pressing in Page
40-9
11 - 20 Nm and turn through a further 90
Replace after every disassembly operation
24 - 100 Nm and turn through a further 90
Replace after every disassembly operation
12 - Assembly carrier
Removing and installing Page
40-10
The undertaking of repairs on the
thread of the front axle guide screw
connection is not allowed!
25 - 70 Nm and turn through a further 90
Replace after every disassembly operation
13 - 15 Nm and turn through a further 90
Replace after every disassembly operation
14 - Anti-roll bar
The assembly carrier must be lowered
in order to remove and install this
15 - Rubber bearing
16 - 25 Nm
17 - Clamp
26 - Securing plate
Replace after every disassembly operation
27 - 20 Nm and turn through a further 90
Replace after every disassembly operation
28 - Axle joint
Checking Page 40-19
Check the rubber bellows for damage
and replace the axle joint as necessary
Removing and installing only in connection with the wheel bearing housing Page 40-20
Mark the installed location before removing and place in the middle of the
elongated hole when replacing the
axle guide; also check the tracking
29 - 20 Nm and turn through a further 90
Replace after every disassembly operation
Edition 06.02
S00.5103.64.20
------------
------------
40
OCTAVIA
Front Suspension
Removing and installing track control arm
Special tools, testers and aids required
Removing tool MP 6-425
Supporting device MP 9-200
Torque wrench 75 ... 400 Nm,
e.g. V.A.G 1576
Torquing angle wrench, e.g. V.A.G 1756
Removing
-
Take off the wheel trim; pull off cap on lightalloy wheels (hook included in tool kit).
Jack up vehicle until no weight is pressing
on the front suspension.
Slacken twelve-point nut.
Raise vehicle and take off wheel.
Unscrew twelve-point nut.
- Remove noise insulation panel.
Engine, Mechanical Components; Repair
Group 10; Removing and installing engine
Only for models with automatic gearbox:
K-
Insert supporting device MP 9-200 and take
up weight of engine/gearbox in this position.
All models:
Note:
Mark installation position of the bolts -1- otherwise the axle geometry must be checked.
K-
------------ 40-4 ------------
Unscrew bolts -1-.
Edition 10.98
S00.5103.54.20
OCTAVIA
40
Front Suspension
K-
Press out drive shaft. Position tool, as shown
in Fig., for this step.
Note:
Ensure adequate clearance when pressing out
the drive shaft.
K-
Unscrew hexagon bolt -3-, if fitted, at wishbone.
Unscrew hexagon bolts -1- and -2-.
Take out wishbone.
Only for models with automatic gearbox
-
Unscrew hexagon bolts -4- for pendulum
support.
Unscrew bolts + washers -5- and -6- for
subframe.
Note:
Pull out bolt -1- by pushing subframe slightly
down and take out wishbone.
Edition 02.01
S00.5103.60.20
------------ 40-5 ------------
40
Front Suspension
OCTAVIA
Installing
(applies to models fitted with manual and automatic gearbox)
Remove any corrosion present in the thread/
spline of the outer joint.
-
Insert wishbone and attach.
Attach subframe.
Moisten splines of wheel hub with oil.
Insert outer joint as far as possible into the
splines of the wheel hub.
Attach steering joint and wishbone with new
bolts onto old impression.
-
Bolt pendulum support to gearbox.
Bolt coupling rod, as appropriate, to wishbone.
Moisten contact surface of twelve-point
nut and also splines and thread of outer
joint with oil and screw on twelve-point
nut as far as possible.
Pull outer joint sufficiently far into the wheel
hub until it is making contact in the wheel
bearing.
- Install noise insulation.
Engine, Mechanical Components; Repair
Group 10; Removing and installing engine
-
Fit on wheel.
Lower vehicle; when doing this, ensure that
the wheels do not yet touch the ground.
Tightening torques:
------------
------------
Subframe to body
Use new bolts!
100 Nm + 90
Steering joint to wishbone
Use new bolts and new
locking plate!
20 Nm + 90
Pendulum support to gearbox
Use new bolts!
40 Nm + 90
Coupling rod to wishbone
Use new bolt!
15 Nm + 90
Edition 02.01
S00.5103.60.20
OCTAVIA
40
Front Wheel Suspension
The wheel bearing will be damaged if the wheel
bearings are burdened through the weight of the
vehicle. The working life of the wheel bearing
decreases through this.
-
Operate brake (second mechanic required).
Tighten new twelve-point nut with 225 Nm
and slacken half a turn.
Turn wheel hub at least 90
Tighten twelve-point nut:
Tightening torque:
50 Nm and torque a further 60
Note:
K It is recommended to use the torque wrench
V.A.G 1756 for tightening the twelve-point nut.
Edition 11.02
S00.5103.65.20
------------ 40-7 ------------
40
OCTAVIA
Front Suspension
Removing and inserting bush for
track control arm
Special tools, testers and aids required
Thrust plate MP 3-406
Thrust plate MP 3-407
Pipe section MP 3-414
Pipe section MP 3-429
Thrust washer MP 3-456
Assembly device MP 5-402
Assembly device MP 6-401
Plunger MP 6-405
Base MP 6-407
Extraction tube MP 6-408
Workshop pressing tool, e.g. V.A.G 1290 A
Acid-free lubricant, e.g. G 294 421
K Pressing out front bush for track control arm
K Inserting front bush for track control arm
-
Insert bush into pipe section MP 3-414.
Note:
Use acid-free lubricant, e.g. G 294 421, for inserting the bush. On no account use grease or
soapsuds.
------------ 40-8 ------------
Edition 12.98
S00.5103.55.20
OCTAVIA
40
Front Suspension
K Installation position for rear bush in track
control arm
One of the stamped arrows points towards the
recess in the track control arm; kidney-shaped
recess (arrow A) in bush points toward centre
of vehicle.
K Removing and inserting rear bush for track
control arm
Pay attention to installation position when inserting Fig. V40-1010.
Edition 10.98
S00.5103.54.20
------------
------------
40
OCTAVIA
Front Suspension
Removing and installing subframe
Special tools, testers and aids required
Removal tool MP 6-425
Gearbox jack with attachment,
e.g. V.A.G 1383 A with V.A.G 1359/2
Removing
-
Take off the wheel trims of the front wheels;
remove caps on light-alloy wheels (hook included in tool kit).
Jack up vehicle sufficiently so that there is
no load pressing on the front suspension.
Slacken twelve-point nut on left and right.
Raise vehicle and take off wheels.
Unscrew twelve-point nut on left and right.
- Remove noise insulation panel.
Engine, Mechanical Components; Repair
Group 10; Removing and installing engine
Note:
Mark installation position of bolts -1- otherwise
the axle geometry must be checked.
K-
Unscrew bolts -1-.
K-
Press out drive shaft on left and right. Position tool as shown in illustration for this step.
Note:
Ensure adequate clearance when pressing out
the drive shafts.
------------ 40-10 ------------
Separate track control arm on left and right
from steering joint.
Swivel wheel bearing housing and steering
joint out and support.
Edition 10.98
S00.5103.54.20
OCTAVIA
40
Front Suspension
K-
Unscrew bolts -1- and -2- and take off pendulum support.
Unscrew bolts for steering gear -5-.
Unscrew nut -7- for coupling rod of anti-roll
bar.
Unscrew bolts -6- for exhaust system
(only TDI).
Position gearbox jack with attachment, e.g.
V.A.G 1383 A with V.A.G 1359/2, below
subframe.
Unscrew bolts -3- and -4- for subframe.
Lower subframe with gearbox jack.
Note:
Ensure that the steering gear detaches from the
subframe.
-
Support steering gear; take up weight with
tensioning strap if necessary.
Installing
Before fitting on the bolts for the subframe, position steering gear on subframe and then insert bolts for steering gear.
K
The threaded sleeve -1- should be located
in the hole of the subframe.
The remaining installation is carried out in the
reverse order.
Tightening torques page 40-2.
After installing, carry out a road test in order to
check the position of the steering wheel.
If the steering wheel is not properly centred, it is
then necessary to check the axle alignment.
Edition 10.98
S00.5103.54.20
------------ 40-11 ------------
40
Front Suspension
OCTAVIA
Removing and installing bonded
rubber bush
Special tools, testers and aids required
Pressure plate MP 3-407
Pressure die MP 3-448
Counterholder MP 6-410
Removal tool MP 6-425
Assembly device MP 6-430
Workshop press, e.g. V.A.G 1290 A
Gearbox lift with attachment,
e.g. V.A.G 1383 A with V.A.G 1359/2
Acid-free lubricant, e.g. G 294 421 A1
It is possible to remove and install the bonded
rubber bush after removing the subframe.
-
Removing and installing subframe
page 40-10.
K Pressing out bonded rubber bush
K Pressing in bonded rubber bush
Note:
Coat bonded rubber bush in subframe with acidfree lubricant, e.g. G 294 421 A1, before pressing in. On no account use grease or soap suds.
------------ 40-12 ------------
Edition 11.99
S00.5103.57.20
OCTAVIA
40
Front Suspension
II - Assembly overview of wheel mounting, suspension strut, drive shaft, brake
Notes:
If it is necessary to move a vehicle on which
the drive shaft has been removed, first of all
install an outer joint in place of the drive shaft
and tighten to 50 Nm otherwise the wheel
bearing will be damaged.
It is not permitted to carry out any welding
and straightening work on load-bearing and
wheel-locating components of the front suspension.
Always replace self-locking nuts.
Edition 05.01
S00.5103.61.20
Always replace corroded nuts and bolts.
1 - Self-locking hexagon collar nut, 60 Nm
replace each time removed
2 - Stop
3 - Suspension strut
removing and installing page
40-21
servicing page 40-25
assignment Parts List
------------ 40-13 ------------
40
Front Suspension
OCTAVIA
4 - Drive shaft with inner CV joint
removing and installing page 4034
servicing page 40-38
7 - Drive shaft with inner tripod joint
removing and installing page 4034
servicing page 40-49
5 - Base plate
8 - Machine bolt with internally serrated
head
replace each time removed
tighten initially to 10 Nm, then diagonally across to final torque
M8 = 40 Nm
M10 = 70 Nm
assignment Parts List
6 - Machine bolt with internally serrated
head
replace each time removed
tighten initially to 10 Nm, then diagonally across to final torque
M8 = 40 Nm
M10 = 70 Nm
assignment Parts List
------------ 40-14 ------------
Edition 05.01
S00.5103.61.20
OCTAVIA
40
Front Wheel Suspension
9 - Brake disc (FS-III)
without marking for axial run-out
with a fixing hole for the wheel hub
assignment electronic catalogue of
original parts
10 - Wheel bolt, 120 Nm
11 - Twelve-point nut, self-locking
loosen and tighten page 40-6
replace after each disassembly
21 - Brake carrier (FN-3)
22 - Brake caliper (FN-3)
For vehicles with engine as of 96 kW
do not release brake hose when working on the front wheel suspension
tie up with wire or anything similar
removing and installing brake pads
Repair Group 46
repairing Repair Group 47
12 - Screw, 4 Nm
23 - Guide bolts (FN-3), 28 Nm
removing and installing
page 46-5.2
13 - Brake pads (FS-III)
removing and installing
page 46-3
24 - Cap (FN-3)
14 - Brake caliper (FS-III)
For vehicles with engine up to 92 kW.
do not release brake hose when working on the front wheel suspension
tie up with wire or anything similar
repairing page 47-8
15 - Guide bolts (FS-III), 28 Nm
removing and installing from page
46-3
25 - Bolt with safety collar (FN-3), 125 Nm
clean ribbing on underside
26 - Wheel bearing housing
For vehicles with engine as of 96 kW
removing and installing
page 40-21
repairing from page 40-16
before pressing in wheel bearing coat
evenly the entire wheel bearing seat
in the wheel bearing housing with G
052 723 A2
16 - Cap (FS-III)
27 - Cover plate
17 - Brake disc (FN-3)
with marking for axial run-out
with 5 fixing holes for the wheel hub
removing and installing from page
46-5.7
assignment electronic catalogue of
original parts
18 - Wheel hub with pulse rotor for speed
sensor
with marking for minimum axial runout
only on vehicles with ABS
pressing out page 40-16 and futher
pressing in page 40-16 and further
removing inner ring of bearing page
40-16 and further
inspecting lateral run-out of pulse rotor page 45-61
assignment electronic catalogue of
original parts
28 - Self-locking nut, 45 Nm
replace after each disassembly
29 - Steering joint
inspecting page 40-19
inspecting rubber bellows for damage,
if necessary replace steering joint
removing and installing
page 40-20
30 - Wheel bearing housing
For vehicles with engine up to 92 kW
removing and installing
page 40-21
repairing from page 40-16
before pressing in wheel bearing coat
evenly the entire wheel bearing seat
in the wheel bearing housing with G
052 723 A2
19 - Brake pads (FN-3)
removing and installing
page 46-5.2
20 - Retaining spring (FN-3)
Edition 06.05
S00.5103.68.20
------------ 40-15 ------------
40
31 - Self-locking hexagon collar nut, 20 Nm
+ torque a further 90 (1/4 turn)
replace each time removed
32 - Hexagon bolt
replace each time removed
33 - Hexagon socket bolt, 10 Nm
34 - ABS wheel speed sensor
only on models with ABS
insert with lubricating paste G 000 650
(e.g. Wolfrakote Top Paste)
------------ 40-15.1 ------------
Front Suspension
OCTAVIA
35 - Self-locking hexagon collar nut
up to 05.98: 50 Nm + torque a further
90 (1/4 turn)
from 06.98: 60 Nm + torque a further
90 (1/4 turn)
torque not less than 90
torquing angle tolerance 90 to 120
replace each time removed
36 - Track rod with track rod end
removing and installing page 4022
37 - Hexagon bolt, 10 Nm
Edition 05.01
S00.5103.61.20
OCTAVIA
38 - Wheel bearing
pressing out from page 40-16
replace, is destroyed when pressed
out
pressing in from page 40-16
replacement part only available as kit
wheel bearing with assembly parts
(items 11, 39, 38, 28, 31 and 35)
39 - Circlip
ensure properly installed from page
40-16
replace each time removed
Edition 05.01
S00.5103.61.20
40
Front Suspension
40 - Wheel hub without pulse rotor
only on models without ABS
assignment Parts List
41 - Wheel hub with pulse rotor for wheel
speed sensor
without marking for minimum axial
runout
only on models with ABS
pressing out from page 40-16
pressing in from page 40-16
pulling off bearing inner race from
page 40-16
inspecting lateral runout of pulse rotor page 45-61
assignment Parts List
------------ 40-15.2 ------------
40
OCTAVIA
Front Wheel Suspension
Repairing wheel bearing housing
Special tools, testers and aids required
Thrust plate MP 3-406
Thrust plate MP 3-407
Thrust plunger MP 3-408
Tube section MP 3-4012
Tube section MP 3-450
Thrust plate MP 3-467
Ring wrench WAF 46 MP 6-413
Assembly device MP 6-414/1
Washer MP 6-415
Washer MP 6-416
Thrust plate MP 6-418
Tube MP 6-419
Pressure pipe MP 6-420
Extractor MP 6-425
Socket wrench insert WAF 21 MP 6-427
Spreader 3424
Extractor Kukko V 176
Workshop press, e.g. V.A.G 1290 A
Torque wrench, e.g. V.A.G 1756
Cross member Kukko 18-0
Grease G 052 723 A2 (Molykote)
The repair of the wheel bearing housing by
pressing out and in the wheel hub and the wheel
bearing is only possible after removing the suspension strut and wheel bearing housing.
-
------------ 40-16 ------------
Removing and installing suspension strut
and wheel bearing housing page 40-21.
Edition 04.03
S00.5103.66.20
OCTAVIA
40
Front Suspension
K Pressing wheel hub out of wheel bearing
K Removing and installing circlip
-
Use commercially available circlip pliers to
remove and replace circlip.
Notes:
Replace
When inserting, ensure the circlip is correctly
located.
K Pressing wheel bearing out of wheel bearing
housing
Edition 03.97
S00.5103.52.20
------------ 40-17 ------------
40
Front Wheel Suspension
OCTAVIA
K Pull the inner ring of the bearing off the wheel
hub
-
Insert washer MP 6-416 as shown.
Screw cross member Kukko 18-0 into washer
MP 6-416.
Install pressure plate MP 3-467 onto wheel
hub and pull off inner ring of bearing by turning the threaded spindle.
K Press wheel bearing into wheel bearing housing
A - wheel bearing
Before pressing in wheel bearing coat evenly
the entire wheel bearing seat in the wheel
bearing housing with G 052 723 A2.
Note:
After pressing in the wheel hub, the circlip must
be inserted page 40-17.
K Press wheel hub into wheel bearing
Note:
When pressing in the wheel hub, make sure
the washer MP 6-415 is supported at the inner ring of the bearing.
Observe assignment of wheel hub with wheel
bearing housing and wheel hub for vehicles
with engine as of 110 kW (Brake FN-3)
Spare Part catalogue.
Wheel hubs with a 3 mm wide ink jet mark
for marking of minimum axial run-out can also
be combined with brake discs without marking of maximum axial run-out.
The reduction of the entire axial run-out for
Brake FN-3 is then not effective.
------------
------------
Edition 04.03
S00.5103.66.20
OCTAVIA
40
Front Suspension
Inspecting steering joint
Inspecting axial play
K-
Pull steering link firmly down and push up
again.
Inspecting radial play
K-
Push wheel firmly in and out at the bottom.
Notes:
There must not be any perceptible or visible
play present when conducting both
inspections.
Observe steering joint when carrying out the
inspections.
Allow for any wheel bearing play which is
present or play in the top suspension strut
bush.
Inspect rubber boot for damage; replace
steering joint if necessary.
Edition 09.96
S00.5103.51.20
------------ 40-19 ------------
40
OCTAVIA
Front Suspension
Removing and installing steering
joint
Special tools, testers and aids required
Wrench socket waf 19 MP 6-423
Extraction tool MP 6-425
Wrench socket waf 21 MP 6-427
Expanding tool 3424
Torquing angle wrench, e.g. V.A.G 1756
Puller, Matra V176
Removing
It is only possible to remove the steering joint
after removing the suspension strut and wheel
bearing housing.
-
Removing and installing suspension strut
and wheel bearing housing page 40-21.
K-
Position special tools as shown in illustration, and slacken hexagon nut.
A - Torx T 30
K-
Position puller as shown in illustration, and
press out steering joint.
Installing
Installation is carried out in the reverse order.
Note:
Tightening torque:
Steering joint to wheel bearing housing:
20 Nm + torque a further 90.
------------ 40-20 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
40
Front Suspension
Removing and installing
suspension strut and wheel
bearing housing
Special tools, testers and aids required
Extractor MP 6-425
Socket wrench bit waf 21 MP 6-427
Expander 3424
Torque wrench 75 ... 400 Nm,
e.g. V.A.G 1576
Torquing angle wrench, e.g. V.A.G 1756
Puller Matra V176
Removing
-
Take off wheel trim; pull off cap of light alloy
wheels (hook for pulling off cap in tool kit).
Raise vehicle sufficiently so that no load is
acting on the front suspension.
Slacken twelve-point nut.
Take off wheel and raise vehicle.
Note:
Mark fitting location of the bolts -1- otherwise
the suspension geometry has to be inspected.
K-
Unscrew bolts -1-.
K-
Press out drive shaft. Position tool as shown
in illustration for this step.
Note:
Ensure adequate clearance when pressing out
the drive shaft.
Edition 03.97
S00.5103.52.20
------------ 40-21 ------------
40
------------ 40-22 ------------
Front Wheel Suspension
OCTAVIA
Use puller Matra V176 (commercial) to press
track rod off the steering arm
Unplug connector -1- ABS speed sensor
from the mountings.
Disconnect the ABS speed sensor from the
mountings -arrow-.
Remove caps -2- and unscrew brake calliper. Secure the brake caliper with wire to
the body.
Remove the brake disc (brake disc is fixed
with one screws to the wheel hub).
If necessary remove the coupling rod from
the suspension rod.
Unscrew the suspension strut on the body
using the socket wrench insert -MP 6-427
Remove suspension strut with wheel-bearing housing.
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Suspension
K Separating suspension strut from wheel
bearing housing
Installing
Remove any corrosion present in the thread/
spline of the outer joint.
Note:
Tighten FN-3 brakes to wheel bearing housing
with a torque of 125 Nm.
Edition 02.01
S00.5103.60.20
!"
#
$
!"
Moisten contact surface of twelve-point
nut and also splines and thread of outer
joint with oil and screw on twelve-point
nut as far as possible.
$
%
&
------------ 40-23 ------------
40
Front Wheel Suspension
Tightening torque:
OCTAVIA
Suspension strut to suspension
strut dome
60 Nm
Coupling rod to suspension strut
90 Nm
Steering joint to track control arm
20 Nm + 90
Use new nuts!
Use new nuts!
Use new screws and new lock
washer!
Brake caliper to wheel bearing housing
-
28 Nm
Make sure when lowering the vehicle that
the wheels do not touch the ground.
The wheel bearing will be damaged if the wheel
bearings are burdened through the weight of the
vehicle. The working life of the wheel bearing
decreases through this.
-
Operate brake (second mechanic required)
Tighten new twelve-point nut with 225 Nm
and slacken half a turn.
Turn wheel hub at least 90.
Tighten twelve-point nut:
Tightening torque
50 Nm and torque a further 60
Note:
K It is recommended to use the torque wrench
V.A.G 1756 for tightening the twelve-point nut.
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
40
Front Suspension
Servicing front suspension strut
1 - Shock absorber
Always replace complete
Assigning Parts List
Can be replaced individually
Inspecting shock absorber
page 40-28
Disposal page 40-31
2 - Bump stop
3 - Protective sleeve
4 - Coil spring
Removing and installing from page
40-26, Fig. 1, 2, 3, 4
Assigning Parts List
Pay attention to colour coding
Surface of spring coil must not be
damaged
Always replace on both sides
Use only coil springs of same manufacturer on an axle
5 - Spring disc
Special tools, testers and aids required
Wrench insert waf 21 MP 6-427
Spring tensioning device, e.g. S 505 501 V
or V.A.G 1752/1
Suspension strut mount, e.g. V.A.G 1752/2
Spring holder with protective insert, e.g.
V.A.G 1752/4
6 - Bush
Only on models with heavy-duty suspension (PR No. 1GB). This PR No.
is indicated on the vehicle data sticker
in the boot or in the Service Schedule
page 00-4
7 - Axial grooved ball bearing
8 - Suspension strut bearing
9 - Collar nut, 60 Nm
Replace each time removed
Slackening and tightening
page 40-26
10 - Stop
11 - Hexagon collar nut, self-locking, 60
Nm
Replace each time removed
Edition 06.99
S00.5103.56.20
------------ 40-25 ------------
40
K Fig. 1
Removing coil spring
Clamp suspension strut mount, e.g. V.A.G
1752/2, in a vice.
Clamp suspension strut at shock absorber
tube in suspension strut mount.
Prestress screwdriver sufficiently with
tensioning device, e.g. V.A.G 1752/1, until
the spring disc at the top is free.
K Fig. 2
-
------------
Removing coil spring
Ensure that the coil spring is correctly located
in the adapter, e.g. V.A.G 1752/4, -arrow-.
K Fig. 3
------------
OCTAVIA
Front Suspension
Removing coil spring
Use special tool -MP 6-427- to unscrew collar
nut from the piston rod; restrain with hexagon
socket wrench during this step.
Take off individual parts of suspension strut
and prestressed screwdriver with tensioning
device, e.g. V.A.G 1752/1.
Edition 09.96
S00.5103.51.20
OCTAVIA
K Fig. 4
-
Edition 09.96
S00.5103.51.20
40
Front Suspension
Installing coil spring
Mount pretensioned screwdriver with tensioning device, e.g. V.A.G 1752/1, onto spring
base at bottom; the end of the spring coil
should be touching the stop -arrow- when this
is done.
------------
------------
40
Front Suspension
OCTAVIA
Inspecting shock absorbers
K Leaks at shock absorbers
A slight oil leakage (sweating) at the gasket of
the piston rod is not a reason for replacing the
shock absorber.
If an oil stain is visible (but mat, possibly dry
because of dust) and does not spread any further than from the top shock absorber closure
(piston rod seal) to the bottom spring retainer
(arrow), the shock absorber is regarded as being in proper order.
Note:
A slight outflow of oil is advantageous as this
lubricates the seal and thus increases the service life. This applies both to the front and rear
shock absorbers.
Noises at shock absorbers
We have reason to point out that, if a complaint
is received regarding noise, the shock absorbers are too often regarded as a source of the
noise.
Note:
When dealing with complaints which can be interpreted as a rumbling or snapping noise, it is
essential to first of all carry out a road test together with the customer in order to find out
where, when and how the noises exist (this is
best done on a dry road surface with bumps).
------------
------------
Edition 10.98
S00.5103.54.20
OCTAVIA
40
Front Suspension
Inspecting shock absorber without gas pressure
Faulty shock absorbers can be detected when
driving as a result of rumbling noises - as a consequence of the wheel jumping - particularly on
a poor road surface, and should be replaced.
The cause of the problem is in most cases a
loss of oil. The shock absorber can then be compressed and/or pulled apart suddenly. There is
an idle travel before the shock absorber begins to operate.
Note:
Shock absorbers require no maintenance. It is
not possible to top up the shock absorber fluid.
Edition 10.98
S00.5103.54.20
------------
------------
40
Front Suspension
OCTAVIA
Testing shock absorber with gas pressure
Faulty shock absorbers with gas pressure are
also recognizable from loud rumbling noises
because of the wheel jumping and, in most
cases, as a result of an oil loss visible on the
outside.
It is possible to carry out an inspection by hand
to determine whether the shock absorber is
faulty or not:
-
Compress shock absorber by hand.
When this is done, it must be possible to
move the piston rod with even pressure and
free of jerks over the entire stroke.
Release piston rod; if the shock absorber has
an adequate gas pressure, the piston rod automatically returns to its initial position.
If this is not the case, it is not immediately
necessary to replace the shock absorber as
it continues to operate like a conventional
shock absorber (see Notes below).
Notes:
The damping function is fully retained even
without gas pressure provided no major oil
loss has occurred. There may, however, be
a deterioration in the noise characteristics.
On older vehicles, a shock absorber which
has become pressureless but is otherwise
operating properly, can continue to be reused.
Shock absorbers with gas pressure are fitted only to the rear axle.
The gas pressure in the shock absorber improves the noise characteristics and operation when driving on poor road surfaces.
------------
------------
Edition 10.98
S00.5103.54.20
OCTAVIA
40
Front Suspension
Disposing of shock absorbers
Special tools, testers and aids required
Pipe cutter, e.g. Stahlwille Express 150/3
Protective goggles
Oil drip tray
Warning!
Cover over opening and wear eye protection when
releasing the gas pressure (gas pressure of new
shock absorber as much as 25 bar).
Notes:
All the shock absorbers contain hydraulic
fluid. The hydraulic fluid can be drained after drilling into, sawing or cutting open the
part. In addition, gas pressure shock absorbers are filled with gas. The gas should be
released from the gas pressure shock absorbers before disposing of them.
The hydraulic fluids used in shock absorbers do not contain any harmful substances.
These fluids can be disposed of together with
old oil from engines and gearboxes.
Old oils (this term refers to used engine and
gearbox oils incl. ATF as well as mineral hydraulic fluids), which are suitable for reprocessing, must on no account be mixed with
brake fluid, antifreeze agent, synthetic resin
or nitro thinners, chemicals etc.
After draining, allow any remaining fluid to
adequately drip out.
Edition 10.98
S00.5103.54.20
------------
------------
40
Front Suspension
OCTAVIA
Draining front shock absorber
K-
Clamp shock absorber in a vice.
Use an assembly lever or a similar tool to
lever off the protective cap, and take off protective tube.
Protective cap and protective tube are fitted only
to caulked shock absorbers.
------------
Fit on pipe cutter, e.g. Stahlwille Express
150/3, and cut through outer tube.
Pull up piston rod; hold the inner tube tight
with water pipe pliers for this step, and push
down so that the inner tube remains in the
outer tube when the piston rod is pulled
slowly up.
------------
Pull piston rod off the inner tube.
Drain shock absorber.
Edition 10.98
S00.5103.54.20
OCTAVIA
40
Front Suspension
Draining rear shock absorber (gas pressure
shock absorber)
-
Clamp shock absorber vertically in a vice,
with the piston rod facing down.
K-
Drill a 3 mm hole (arrow A) in the outer
tube.
Warning!
Wear eye protection.
Note:
Gas escapes when drilling through the first pipe
wall (only in the case of gas pressure shock absorbers).
-
Continue drilling until you have drilled through
the inner tube (about 25 mm deep).
Drill a second 6 mm hole (arrow B) deep
enough to pierce the inner tube.
Hold shock absorber over oil drip tray, move
piston rod up and down several times over
the entire stroke until no further fluid flows
out.
Note:
K Shock absorber can also be opened with a pipe
cutter page 40-32. First of all, render the
shock absorber pressureless by drilling into the
outer tube (arrow A) previous Fig. (S40-0073).
Edition 10.98
S00.5103.54.20
------------
------------
40
OCTAVIA
Front Suspension
Removing and installing drive
shafts
Special tools, testers and aids required
Removal tool MP 6-425
Torque wrench 75 ... 400 Nm,
e.g. V.A.G 1576
Tightening angle wrench, e.g. V.A.G 1756
Removing
Notes:
If the twelve-point nut is slackened, do not
apply a load on the wheel bearing. If the
weight of the vehicle is allowed to press on
the wheel bearing, it will suffer initial damage and the life of the wheel bearing will be
reduced as a result.
If it is necessary to remove a vehicle at which
the drive shaft has been removed, first of all
install an outer joint in place of the drive shaft
and tighten to 50 Nm to avoid the wheel bearing being damaged.
Assignment and marking of drive shafts
Parts List.
-
Take off wheel trim; pull off cap on light-alloy
wheels (hook included in tool kit).
Jack up vehicle so that no load is pressing
on the front suspension.
Slacken twelve-point nut.
Take off wheel and raise vehicle.
- Remove noise insulation panel.
Engine, Mechanical Components; Repair
Group 10; Removing and installing engine
-
Unbolt drive shaft from flange shaft/gearbox.
Note:
Mark installation position of the bolts -1- otherwise the axle geometry must be checked.
K-
------------
------------
Unscrew bolts -1-.
Edition 10.98
S00.5103.54.20
OCTAVIA
40
Front Suspension
K-
Press out drive shaft. Position tool as shown
in the illustration for this step.
Notes:
Ensure adequate clearance when pressing
out the drive shaft.
The drive shaft must not hang down when it
is pressed out. Otherwise, the inner joint will
be damaged as a result of excessive flexing.
-
Take out drive shaft.
Note:
The step described below only requires to be
carried out on models with automatic gearbox.
K-
Slacken gearbox supporting bolts -arrow- at
the subframe.
K-
Use assembly iron to lever engine/gearbox
unit in direction of travel; the tripod drive shaft
can be taken out at the same time.
Edition 06.99
S00.5103.56.20
Arrow points in direction of travel.
------------
------------
40
!
#
(
+
)
,
$*
&'
%
!
"
'
&
*
.
0
1
/
2
)
3
$
4
5
6
)
*
*
.
7
8
0
1
/
OCTAVIA
Front Suspension
Installing
(models fitted with manual and automatic
gearbox)
Remove any corrosion present in the thread/
spline of the outer joint.
-
Moisten contact surface of twelve-point
nut and also splines and thread of outer
joint with oil and screw on new twelvepoint nut as far as possible.
Tightening torques:
Use new bolts and new
locking plate!
Use new bolts!
Use new bolts!
Use new bolts!
------------
------------
Edition 02.01
S00.5103.60.20
OCTAVIA
40
Front Wheel Suspension
-
Make sure when lowering the vehicle that
the wheels do not touch the ground.
The wheel bearing will be damaged if the wheel
bearings are burdened through the weight of the
vehicle. The working life of the wheel bearing
decreases through this.
-
Operate brake (second mechanic required)
Tighten new twelve-point nut with 225 Nm
and slacken half a turn
Turn wheel hub at least 90
Tighten twelve-point nut:
Tightening torque:
50 Nm and torque a further 60
Note:
K It is recommended to use the torque wrench
V.A.G 1756 for tightening the twelve-point nut.
Edition 11.02
S00.5103.65.20
------------
------------
40
OCTAVIA
Front Wheel Suspension
Servicing drive shaft
Servicing drive shaft with outer and
inner CV joint
Special tools, testers and aids required
Circlip pliers, e.g. VW 161 A
Thrust plate MP 3-406
Thrust plate MP 3-407
Thrust plunger MP 3-448
Supporting sleeve MP 6-428
Clamping device MP 6-429
Workshop press, e.g. V.A.G 1290 A
Torque wrench
Tensioning pliers, e.g. V.A.G 1682
Sealant D 454 300 A2
Notes:
Assignment of the drive shafts
Electronic catalogue of original parts
Grease joint if necessary, when replacing
the joint boot.
Spread the grease filling evenly in the joint
boot - only on the joint side.
1 - Right drive shaft (tubular shaft)
assignment electronic catalogue of
original parts
2 - Fillister head screw with internal serration
replace after each disassembly
initially tighten to 10 Nm, subsequently
tighten crosswise to final torques
M 8 = 40 Nm
M 10 = 70 Nm
assignment electronic catalogue of
original parts
3 - Shim
assignment electronic catalogue of
original parts
4 - Warm-type clamp
replace
tighten Fig. 10
------------ 40-38 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Suspension
Grease quantities and grade of grease
Grease packing of CV joints with high-temperature grease G 000 603 or G 000 633.
Notes:
G 000 603 - Can containing 90 g grease
G 000 633 - Can containing 120 g grease
Re-grease joint, if necessary, when replacing joint boot.
Engine/
gearbox
Left/right
drive shaft
Part No.
1.6 l/55 kW
(AEE)
02K
1 J0 407 271 F
1 J0 407 272 F
1.6 l/74 kW
(AEH, AKL)
02K
1 J0 407 271 Q
1 J0 407 272 AB
1.8 l/92 kW
(AGN)
02J
357 407 271 R
1 J0 407 272 AC
1.9 l/50 kW
(AGP)
02K
Outer
joint
mm
Grease
of which in:
Total
Joint 1)
quantity
(g)
(g)
Joint
boot 2)
(g)
Inner
joint
mm
Grease
of which in:
Total
Joint 1)
quantity
(g)
(g)
Joint
boot 2)
(g)
81
80
40
40
94
80
60
20
81
80
40
40
94
80
60
20
90
100
50
50
100
110
80
30
1 J0 407 271 F
1 J0 407 272 F
81
80
40
40
94
80
60
20
1.9 l/66 kW
(AGR)
02J
1 J0 407 271 H
1 J0 407 272
90
100
50
50
100
110
80
30
1.9 l/81 kW
(AHF)
02J
1 J0 407 271 H
1 J0 407 272
90
100
50
50
100
110
80
30
1)
The quantity of grease stated for the inner joint should be inserted into the joint from both sides.
2)
Distribute the grease packing evenly in the joint boot.
Edition 11.97
S00.5103.53.20
------------ 40-38.1 ------------
40
------------ 40-38.2 ------------
Front Suspension
OCTAVIA
Edition 03.97
S00.5103.52.20
OCTAVIA
40
Front Wheel Suspension
5 - Joint boot for inner CV joint, 94 mm
material: Hytrel (Polyelastomere)
inspect for tears and chafing points
remove CV joint with drift
fitting location of joint boot for inner
CV joint for left shaft is identical to the
fitting location of the joint boot for the
outer CV joint 84 mm Fig. 12
fitting location of joint boot for inner CV
joint for right shaft is identical to the
fitting location of the joint boot for the
outer CV joint 84 mm Fig. 12
before assembling coat inner cap with
sealant D 454 300 A2
assignment electronic catalogue of
original parts
6 - Joint boot for inner CV joint,
100 mm
material: rubber
inspect for tears and chafing points
remove from CV joint with drift
fitting location for left shaft Fig. 6
fitting location for right shaft
Fig. 7
before assembling coat inner cap with
sealant D 454 300 A2
assignment electronic catalogue of
original parts
7 - Disc spring
Fitting location Fig. 3
8 - Inner CV joint
must be replaced completely
pressing out Fig. 2
pressing on Fig. 5
grease page 40-62
inspecting page 40-46
assignment electronic catalogue of
original parts
9 - Gasket
adhesive surface on the inner CV joint
must be free of grease and oil!
replace
pull off protective foil and stick gasket
in the housing
assignment electronic catalogue of
original parts
10 - Circlip
replace
remove with circlip pliers,
e.g. VW 161 A
assignment electronic catalogue of
original parts
11 - Left drive shaft (solid shaft)
assignment electronic catalogue of
original parts
12 - Warm-type clamp
replace
tighten Fig. 9
13 - Joint boot
material: Hytrel (Polyelastomere)
inspecting for tears and chafing
points
assignment electronic catalogue of
original parts
pay attention to different version:
84 mm
90 mm
fitting location of joint boot for outer
CV joint for left shaft 90 mm
Fig. 11
fitting location of joint boot for outer
CV joint 90 mm for right shaft determined by the fitting location on the
shaft is identical as Fig. 11
fitting location of joint boot for outer
CV joint 84 mm for left shaft
Fig. 12
fitting location of joint boot for outer
CV joint 84 mm for right shaft
Fig. 12
14 - Warm-type clamp
replace
tighten with tensioning pliers, e.g.
V.A.G 1682 Fig. 8
15 - Disc spring
fitting location Fig. 4
16 - Thrust ring
fitting location Fig. 4
17 - Circlip
replace
insert in the groove on the shaft
18 - Outer CV joint
must be replaced completely
removing Fig. 1
installing: drive onto the shaft with a
plastic hammer until the compressed
circlip expands
grease page 40-62
inspecting page 40-45
19 - M8 = 25 Nm, M10 = 35 Nm
20 - Protective cap
Edition 06.05
S00.5103.68.20
------------ 40-39 ------------
40
OCTAVIA
Front Wheel Suspension
Servicing drive shaft with outer and
inner CV joint VL 3700
Special tools, testers and aids required
page 40-38
Notes:
Assignment of the drive shafts
Electronic catalogue of original parts
Grease joint if necessary, when replacing
the joint boot.
1 - Outer CV joint
must be replaced completely
removing inspect for tears and chafing
points
remove Fig. 1
installing: drive onto the shaft with a
plastic hammer until the compressed
circlip expands
grease page 40-62
inspect page 40-45
2 - Circlip
replace
insert in the groove on the shaft
3 - Thrust ring
Fitting location Fig. 4
4 - Disc spring
Fitting location Fig. 4
5 - Clamp
replace
tighten with tensioning pliers, e.g.
V.A.G 1682 Fig. 8
6 - Joint boot for outer CV joint
material: Hytrel (Polyelastomere)
inspect for tears and chafing points
fitting location for left shaft Fig. 14
fitting location for right shaft
Fig. 15
assignment electronic catalogue of
original parts
7 - Clamp
replace
tighten Fig. 9
8 - Left drive shaft (solid shaft)
assignment electronic catalogue of
original parts
------------ 40-39.1 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
9 - Joint boot for inner CV joint
material: Arnitel (Polyelastomere)
inspect for tears and chafing points
fitting location for left shaft Fig. 13
fitting location for right shaft
Fig. 13
assignment electronic catalogue of
original parts
10 - Clamp
replace
11 - Cap
remove from CV joint with drift
before assembling coat sealing surface
of cap with sealant D 454 300 A2
sealing surface must be clean and
free of grease
12 - Inner CV joint
must be replaced completely
pressing out Fig. 2
pressing on Fig. 5
grease page 40-62
inspecting page 40-46
assignment electronic catalogue of
original parts
13 - Circlip
replace
remove with circlip pliers,
e.g. VW 161 A
Edition 06.05
S00.5103.68.20
40
Front Wheel Suspension
14 - Fillister head screw with internal serration
replace after each disassembly
initially tighten to 10 Nm, subsequently
tighten crosswise to final torques
M 8 = 40 Nm
M 10 = 70 Nm
assignment electronic catalogue of
original parts
15 - Shim
assignment electronic catalogue of
original parts
16 - Gasket
adhesive surface on the inner CV joint
must be free of grease and oil!
replace
pull off protective foil and stick gasket
in the joint
assignment electronic catalogue of
original parts
17 - Cap
remove from CV joint with drift
before assembling coat sealing surface
of cap with sealant D 454 300 A2
sealing surface must be clean and
free of grease
------------ 40-39.2 ------------
40
Front Wheel Suspension
OCTAVIA
Grease quality and grease quantity
Notes:
The outer joints of the drive shaft are filled
with:
-
grease for normal temperatures
Part-No. G 052 738 A2
grease from the relevant repair kit
High temperature grease
Part No. G 052 133 A2, or
Part No. G 052 133 A3
The inner joints of the drive shaft must be
filled with high temperature grease from the
relevant repair kit or with grease
Part No. G 052 133 A2 or
Part No. G 052 133 A3
Electronic catalogue of original parts
Grease quantity
page 40-62
Fig. 1
Removing outer CV joint
Remove the CV joint with a drift.
Drive off the drive shaft with a strong blow
of a plastic hammer.
Fig. 2
Pressing off inner CV joint
Note:
Support ball hub.
Fig. 3
Fitting position of the disc spring
at outer joint (gearbox side)
1 - Disc spring
------------ 40-40 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Wheel Suspension
Fig. 4
Fitting position of the disc spring
and thrust ring at outer joint (gearbox side)
1 - Disc spring
2 - Thrust ring
Fig. 5
Pressing in the inner CV joint
Press the joint up to the stop.
Compressing the circlip.
Note:
Chamfer on inner diameter of the ball hub (serration) must point towards the bearing collar of
the drive shaft.
Fig. 6
Fitting position of the joint boot for
the outer joint 100 mm on the left
shaft
Dimension a = 17 mm
Note:
Mark dimension -a- before assembling the joint
boot on the drive shaft, e.g. using colour or
adhesive tape. The paintwork must never be
damaged with a sharp object.
Edition 06.05
S00.5103.68.20
------------ 40-41 ------------
40
Front Wheel Suspension
Fig. 7
OCTAVIA
Fitting position of the joint boot for
the outer joint 100 mm on the
right shaft
The ventilation chamber -A- must be located on
the largest pipe diameter.
B - Ventilation hole
Fig. 8
Tighten warm-type clamp at outer
joint (large diameter)
Notes:
In view of the hard material (as opposed to
rubber) of the joint boot, which requires the
use of a stainless steel warm-type clamp, it
can only be correctly tightened with tensioning pliers e.g. V.A.G 1682.
Tightening torque: 25 Nm
Use a torque wrench.
Make sure the thread of the spindle -A- of
the tensioning pliers is smooth. If necessary
grease with Molykote MoS2.
If it is not smooth, e.g. if the thread is dirty, the
necessary tensioning force of the warm-type
clamp is not reached at the given torque.
-
Position the tensioning pliers, e.g. V.A.G
1682, as shown in the Fig. Make sure the
cutting edges of the pliers are positioned in
the corners (arrows -B-) of the warm-type
clamp.
Tighten the warm-type clamp by turning the
spindle with a torque wrench (do not tilt the
pliers during this process)
A - Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
Fig. 9
------------ 40-42 ------------
Tighten warm-type clamp at outer
joint (small diameter)
Position the tensioning pliers, e.g. V.A.G
1682, as shown in the Fig. Make sure the
cutting edges of the pliers are positioned in
the corners (arrows -B-) of the warm-type
clamp.
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Wheel Suspension
Tighten the warm-type clamp by turning the
spindle with a torque wrench (do not tilt the
pliers during this process)
A - Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
C - Torque wrench
Fig. 10
Tighten warm-type clamp at inner
joint
Position the tensioning pliers, e.g. V.A.G
1682, as shown in the Fig. Make sure the
cutting edges of the pliers are positioned in
the corners (arrows -B-) of the warm-type
clamp.
Tighten the warm-type clamp by turning the
spindle with a torque wrench (do not tilt the
pliers during this process).
A - Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
C - Torque wrench
Fig. 11
Fitting position of the joint boot for
the outer joint 90 mm on the left
shaft
The sealing surface of the joint boot must be
positioned up to the stop on the shoulder of
the shaft.
Fig. 12
Fitting position of the joint boot for
the outer joint 84 mm on the left
and right shaft
1 to 1 1/2 groove must be visible on the drive
shaft
Note:
The above-mentioned condition regarding the
fitting position is valid also for the joint boot for
inner CV joint 94 mm.
Edition 06.05
S00.5103.68.20
------------ 40-43 ------------
40
------------ 40-44 ------------
Front Wheel Suspension
OCTAVIA
Fig. 13
Fitting position of the joint boot for
the inner joint on the left and right
shaft
Fig. 14
Fitting position of the joint boot for
the outer joint on the left shaft
Fig. 15
Fitting position of the joint boot for
the outer joint on the right shaft
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Suspension
Inspecting outer CV joint
The joint should be disassembled to replace the
grease if the grease is extremely dirty or if the
running surfaces of the balls need to be inspected for signs of wear and damage.
Removing
K-
Use an electric pen or dressing stone to mark
the position of the ball hub relative to the ball
cage and the housing before disassembling
(see arrow).
Swivel ball hub and ball cage
Take out the balls one after the other
K-
K-
Rotate cage until two cage windows (arrow)
are positioned at the joint body.
Lift out cage with hub.
Swivel segment of the hub into the cage window.
Tilt hub out of cage.
Note:
The 6 balls for each joint are assigned to a
tolerance group. Inspect stub axle, hub, cage
and balls for pitting and signs of rubbing. Excessive torsional play in the joint is noticeable from load change jolts. The joint should
be replaced in such cases. Smooth areas
and traces of running produced by the balls
are not a reason for replacing the joint.
Inspect cage for cracks.
Edition 12.98
S00.5103.55.20
------------
------------
40
OCTAVIA
Front Wheel Suspension
Installing
-
Press the required grease quantity into the
joint part page 40-62; grease quality and
grease quantity
Insert the cage and hub in the joint body.
Note:
The cage must be inserted in the correct position.
-
Press in opposite balls one after the other,
during this process observe the prior position
of the ball hub relatively to the ball cage and
to the joint body.
Insert new circlip in the groove of the shaft.
Spread any residual grease in the joint boot
page 40-62
Assembling the joint boot page 40-41 and
further.
Inspecting inner CV joint
Disassemble the joint to replace badly soiled
grease and if the contact surfaces and the balls
must be inspected for wear and damage.
Removing
Note:
The ball hub and joint piece are paired and
must be marked before disassembly. Do not
interchange the bearing track assignment.
-
------------ 40-46 ------------
Rotate the ball hub and ball cage.
Press the ball hub and ball cage out of the
joint part -arrow-.
Press out the balls from the cage.
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Suspension
K-
Tilt the ball hub out of the ball cage over the
ball track (arrow).
Inspect the joint body, ball hub, ball cage and
balls for pitting and signs of rubbing.
Note:
Excessive torsional play in the joint is noticeable from load change jolts. The joint should be
replaced in such cases. Smooth areas and
traces of running produced by the balls are not
a reason for replacing the joint.
Installing
K-
Insert the ball hub over the two chamfers in
the ball cage. The fitting location is at random. Press the balls in the cage.
Insert the hub with cage and balls edgeways
into the joint body.
Note:
K During insertion make sure wide distance
-a- on the joint body coincides with narrow
distance -b- on the hub after swivelling (arrow).
Chamfer on the inside diameter of the ball
hub (serration) must point towards the large
diameter of the joint body.
Edition 12.98
S00.5103.55.20
------------
------------
40
Front Wheel Suspension
OCTAVIA
Swivel in the ball hub. To do so swivel the hub
out of the cage until the balls are at bearing
track distance -arrow-.
Lock the hub with the balls into position by
exerting considerable pressure on the cage
-arrow-.
Inspecting the operation of the inner CV
joint:
The CV joint is correctly assembled if the
ball hub can be rolled by hand up and down
the entire linear compensation.
-
Push the clamp and the joint boot onto the
drive shaft.
Install the drive shaft.
Push the grease quantity indicated for the
inner joint from both sides into the joint.
Distribute the specified grease quantity
evenly into the joint boot.
Grease quality and grease quantity page
40-62.
------------ 40-48 ------------
Install joint boot page 40-42 and further.
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Wheel Suspension
Servicing drive shaft with tripod
joint AAR 2900 and CV joint
Special tools, testers and aids required
Thrust plate MP 3-406
Thrust plunger MP 3-448
Tube section MP 3-4012
Tensioning pliers, e.g. V.A.G 1275,
V.A.G 1682
Workshop press, e.g. V.A.G 1290 A
Torque wrench
Circlip pliers (commercially available)
Grease quality and grease quantity
Notes:
Only use high temperature grease from the
relevant repair kit for filling the inner CV joints
and tripod joints
Spare Part catalogue
Quantity of grease for outer CV joint page
40-62
Quantity of grease for inner tripod joint
page 40-62.
Edition 11.02
S00.5103.65.20
------------ 40-49 ------------
40
Front Wheel Suspension
OCTAVIA
6 - Fillister head screw with internal serration
replace after each diassembly
initially tighten to 10 Nm, subsequently
tighten crosswise to final torques
M 8 = 40 Nm
M10 = 70 Nm
assignment electronic catalogue of
original parts
7 - Rollers
8 - Tripod spider
Chamfer -arrow- points toward the
drive shaft serration
9 - Circlip
replace
insert in the groove on the shaft
10 - O-ring seal
not required for assembling the drive
shaft
Notes:
Assignment of drive shafts
electronic catalogue of original parts
Grease joint if necessary, when replacing
joint boot.
On tripod joints only apply grease in the joint
never in the joint boot
1 - Joint boot for inner CV joint
inspecting for tears and chafing points
assignment electronic catalogue of
original parts
2 - Warm-type clamp
replace
tighten page 40-42, Fig. 8
3 - Warm-type clamp
replace
tighten page 40-42, Fig. 9
4 - Drive shaft
assignment electronic catalogue of
original parts
11 - Rectangular seal
seal is contained in the repair kit
seal is not fitted in the series, it is only
necessary for the spare part sector
assignment electronic catalogue of
original parts
12 - Cover
is destroyed after every removal
It is not required any more for assembling the drive shaft and is therefore
not available as a spare part
13 - Warm-type clamp
for tripod joint
always replace
14 - Joint boot for tripod joint
Inspecting for tears and chafing
points
15 - Warm-type clamp
for tripod joint
always replace
tighten page 40-55, Fig. S40-0107
16 - Disc spring
fitting location page 40-41, Fig. 4
5 - Joint part
grease page 40-62
assignment electronic catalogue of
original parts
------------ 40-50 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Wheel Suspension
17 - Thrust ring
fitting location page 40-41, Fig. 4
19 - Outer CV joint
must be replaced completely
removing page 40-40, Fig. 1
installing: drive onto the shaft with a
plastic hammer until the compressed
circlip expands
grease page 40-62
inspecting page 40-45
18 - Circlip
replace
insert in the groove on the shaft
Disassembling and assembling Tripod joint AAR 2900
Special tools, testers and aids required
page 40-49
Grease quality and grease quantity
page 40-62
Disassembling
-
Open warm-type clamp on joint part.
Open warm-type clamp to the drive shaft and
push back joint boot.
Clamp drive shaft on joint part in a vice with
protective jaws.
Lever the cover -1- off with a screwdriver.
Notes:
If the cover cannot be levered out, we recommend the re-insertion of the screwdriver
on the opposite side and then lever out the
cover.
The cover will be damaged when levered off
and it is no longer required for assembling
the drive shaft.
Edition 06.05
S00.5103.68.20
------------ 40-51 ------------
40
Front Suspension
K-
Take O-ring -arrow- out of groove.
Mark fitting location of parts 1 ... 3.
OCTAVIA
1 - Joint
2 - Tripod star
3 - Drive shaft
Notes:
If parts 1 ... 3 are not marked and are not reinstalled in their previous position when assembled, this may result in noise problems
subsequently when driving.
A waterproof felt pen is suitable for marking
the position of the parts.
-
Hold joint tight and take drive shaft out of
the vice.
Ensure that the rollers do not slip off the
tripod star and fall onto the ground!
Hold drive shaft with joint vertically and slowly
push back the joint with your other hand.
K-
Clamp the drive shaft in a vice with protective jaws.
Mark fitting location of the rollers -1- relative
to the tripod star -2- with a felt pen.
Take off rollers -1- and place down on a clean
surface.
K-
Remove circlip.
1 - Commercially available circlip pliers
------------
------------
Edition 12.98
S00.5103.55.20
OCTAVIA
40
Front Suspension
Insert drive shaft into press.
K-
Hold drive shaft tight and press out the tripod star.
Pull joint together with joint boot off the drive
shaft.
Clean drive shaft and joint.
Assembling
-
Fit small hose strap for joint boot onto the
drive shaft.
Push joint boot onto the drive shaft.
Push joint onto the drive shaft.
Installing tripod star
K-
Clamp the drive shaft in a vice with protective jaws.
Note:
Chamfer -arrow- on the tripod star should face
toward the drive shaft. The chamfer is used as
an assembly aid.
Edition 12.98
S00.5103.55.20
Fit tripod star onto the drive shaft according
to the marking made and knock on as far as
the stop.
Insert new circlip; ensure circlip is correctly
located.
Fit rollers onto the tripod star according to
the markings.
Take drive shaft out of the vice.
Push joint over the rollers and hold tight.
Clamp joint in the vice.
------------
------------
40
Front Wheel Suspension
OCTAVIA
Insert rectangular seal -A- from repair kit into
the groove -arrow-.
Notes:
A direct sealing between tripod joint (joint
part) and joint flange (gearbox side) occurs
through the shape of the rectangular section
of the seal.
Cover is no longer required.
Press high temperature grease from the
repair kit evenly in the tripod joint (tripod
spider side) -arrow A- and in the rear of the
tripod joint -arrow B-.
Grease quality and grease quantity
page 40-62
------------ 40-54 ------------
Fit on joint boot.
Tighten warm-type clamp with pliers.
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Wheel Suspension
K-
Tighten warm-type clamp (drive shaft side)
with tensioning pliers e.g. V.A.G 1275.
K-
Cover tripod joint with cardboard disk -A- and
adhesive tape -B-.
Notes:
After repairing, the tripod joint is covered with
a clean cut cardboard disk -A- and adhesive
tape -B-. A contamination of the tripod spider, the joint part and the grease filling is prevented through this. Furthermore an accidental push back of the tripod joint is avoided
when installing the drive shaft.
The adhesive tape and cardboard disk must
only be removed when screwing the drive
shaft to the drive flange.
Edition 11.02
S00.5103.65.20
------------
------------
40
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OCTAVIA
Front Wheel Suspension
Servicing drive shaft with inner tripod joint AAR 2000 and outer CV
joint
Special tools, testers and aids required
Thrust plate MP 3-406
Thrust plate MP
Thrust
MP
MP
Thrust
MP
MP
MP
T
T
pliers
Grease quality and grease quantity
Notes:
Only use high temperature grease from the
relevant repair kit for filling the inner
Part
------------
------------
40-62
of grease for outer
page
of grease for inner
page 40-62
Edition 11.02
S00.5103.65.20
OCTAVIA
40
Front Wheel Suspension
5 - Joint part
grease page 40-62
assignment electronic catalogue of
original parts
6 - Tripod spider with rollers
chamfer -arrow- points toward the
drive shaft serration.
7 - Circlip
replace
insert in the groove on the shaft
8 - O-ring seal
replace
9 - Cover
replace
10 - Warm-type clamp
for tripod joint
always replace
11 - Joint boot for tripod joint
inspecting for tears and chafing points
assignment electronic catalogue of
original parts
Notes:
Assignment of drive shafts
electronic catalogue of original parts
Grease joint if necessary, when replacing
the joint boot
On tripod joints only apply grease in the joint,
never in the joint boot.
1 - Joint boot with inner CV joint
inspecting for tears and chafing points
assignment electronic catalogue of
original parts
2 - Warm-type clamp
replace
tighten page 40-42, Fig. 8
3 - Fillister head screw with internal serration
replace after each disassembly
initially tighten to 10 Nm, subsequently
tighten crosswise to tightening torques
M 8 = 40 Nm
M 10 = 70 Nm
assignment electronic catalogue of
original parts
12 - Drive shaft
assignment electronic catalogue of
original parts
13 - Warm-type clamp
replace
tighten page 40-42, Fig. 9
14 - Disc spring
fitting location page 40-41, Fig. 4
15 - Thrust ring
fitting location page 40-41, Fig. 4
16 - Circlip
replace
insert in the groove on the shaft
17 - Outer CV joints
must be replaced completely
removing page 40-40, Fig. 1
installing: drive onto the shaft with a
plastic hammer until the compressed
circlip expands
grease page 40-62
inspecting page 40-45
assignment electronic catalogue of
original parts
4 - Shim
assignment electronic catalogue of
original parts
Edition 06.05
S00.5103.68.20
------------ 40-57 ------------
40
OCTAVIA
Front Wheel Suspension
Disassembling and assembling tripod joint AAR 2000
Special tools, testers and aids required
page 40-56
Grease quality and grease quantity
page 40-62
Disassembling
-
Open warm-type clamp on joint part.
Push back joint boot.
------------ 40-58 ------------
Straighten the metal tabs -arrows- with a
screwdriver and lever off.
Edition 06.05
S00.5103.68.20
OCTAVIA
40
Front Suspension
K-
Take O-ring seal -arrow- out of groove.
Mark fitting location of parts 1 ... 3.
1 - Joint
2 - Tripod star
3 - Drive shaft
Notes:
If parts 1 ... 3 are not marked and are not reinstalled in their previous position when assembled, this may result in noise problems
subsequently when driving.
A waterproof felt pen is suitable for marking
the position of the parts.
-
Hold joint tight and take drive shaft out of
the vice.
K-
Clamp drive shaft in a vice with protective
jaws.
Remove circlip
1 - commercially available circlip pliers
Edition 12.98
S00.5103.55.20
------------
------------
40
OCTAVIA
Front Suspension
Insert drive shaft into press.
K-
Hold drive shaft tight and press out the tripod star.
Remove tripod star with rollers and place on
a clean surface.
Pull joint off the drive shaft.
Pull joint boot off the drive shaft.
Clean drive shaft and joint.
Assembling
-
Push joint boot onto the drive shaft.
Push joint onto the drive shaft.
Installing tripod star
Note:
Chamfer -arrow- on the tripod star should face
toward the drive shaft. The chamfer is used as
an assembly aid.
------------
------------
K-
Fit tripod star onto the drive shaft according
to the marking made and knock on as far as
the stop.
Insert new circlip; ensure circlip is correctly
located.
Push joint over the rollers and hold tight.
Remove drive shaft from special tool and
clamp in vice.
Edition 12.98
S00.5103.55.20
OCTAVIA
40
Front Wheel Suspension
Press high temperature grease from the
repair kit evenly in the tripod joint (tripod
spider side) -arrow A- and in the rear of the
tripod joint -arrow B-.
Grease quality and grease quantity
page 40-62
-
Assembling the joint boot.
Note:
The bead in the joint boot must fit into the groove
of the joint part.
Remove drive shaft from the vice and clamp
the joint part.
Insert new gasket ring -arrow- from the repair
kit in the groove.
Fit the new cover on the joint part.
Note:
The bores of the cover and the joint part must
be flush.
-
Edition 06.05
S00.5103.68.20
Tighten warm-type clamp with pliers.
------------ 40-61 ------------
40
OCTAVIA
Front Wheel Suspension
Grease quantity
Outer CV joint
mm
Total grease
(g)
Inner CV joint
mm
Total grease
(g)
Joint
(g)
Joint
boot
(g)
90
45
45
Distribute evenly into the
joint
81
90
94 (joint)1)
90
110
100 (joint)1)
90
of which
120
60
60
110
108 (tripod)
1)
110
110
90
110
124 (tripod)1)
140
140
98
130
100 (joint)2)
190
190
1)
Valid for all vehicle, except engines 1.9 l/74 kW PD and 1.9 l/96 kW PD.
2)
Valid for vehicles with engines 1.9 l/74 kW PD and 1.9 l/96 kW PD.
Grease quantity - outer CV joint
Outer CV joints can be filled with the following grease qualities:
Grease for normal temperatures, Part-No.: G 052 738 A2
Grease from the relevant repair kit
High temperature grease,
Part-No.: G 052 133 A2 or
Part-No.: G 052 133 A3
Grease quantity - inner CV joint
Outer CV joints can be filled with the following grease qualities:
Grease from the relevant repair kit
High temperature grease,
Part-No.: G 052 133 A2 or
Part-No.: G 052 133 A3
Notes:
G 052 133 A2 - can with 90g grease content
G 052 133 A3 - can with 120g grease content
Put grease into the joint if necessary or grease joint if necessary, when replacing the joint boot.
Distribute grease quantity for joint evenly into the joint on the left and right.
Distribute grease quantity for joint boot evenly into the joint boot - only on the joint side.
------------ 40-62 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Suspension
Servicing rear suspension drum brakes
Removing and installing rear suspension
Special tools, testers and aids required
Tester for brake pressure regulator,
e.g. V.A.G 1310
Gearbox jack with attachment,
e.g. V.A.G 1383 A with V.A.G 1359/2
Brake filling and bleeding appliance,
e.g. ROMESS S 15
Sealing plug for brake line
Brake fluid page 00-8
Assembly paste G 052 150 A2
Removing
Note:
To remove the rear suspension, do not slacken
bearing bracket at the body otherwise it is necessary to check the wheel toe of the rear suspension and to align if necessary.
K-
Remove bolts -1- with vehicle standing on
its wheels. Jack up vehicle sufficiently, if necessary, until the bolts are accessible.
Jack up vehicle to fitting height so that no
load is pressing on the coil spring.
Take off wheels.
Release handbrake.
Tilt forward rear centre console, remove if
necessary.
Body Fitting Work; Repair Group 68; Interior Equipment
K-
Edition 10.98
S00.5103.54.20
Slacken adjusting nut -arrow-.
------------ 42-1 ------------
OCTAVIA
K
K
Note:
Seal lines with plugs.
! "#$%
K
------------ 42-2 ------------
S00.5103.56.20
OCTAVIA
42
Rear Suspension
Continued for all models:
-
Support rear axle with gearbox lifter and adapter, e.g. V.A.G 1383 A with V.A.G 1359/2.
K-
Unscrew hexagon bolts -1- of the bonded
rubber bush and lower rear axle.
Installing
-
Before inserting the rear axle, grease the kidney-shaped cavities of the bonded rubber
bushes with assembly paste G 052 150 A2.
Installation is carried out in the reverse order.
Notes:
When tightening the hexagon bolt of the
bonded rubber bush, the axle beam must be
in the horizontal position (unladen weight
condition).
When installing the handbrake cables, pay
attention to Fitting location page 46-18.
-
Bleed brake system from page 47-18.
Inspect load-sensitive brake pressure regulator, if fitted, and adjust if necessary page
47-16.
After completing installation, it is necessary to
check the position of the steering wheel during
a road test.
If the steering wheel is not straight, carry out a
check of the wheel alignment!
Note:
After slackening or replacing the bearing
bracket, check total wheel toe of rear axle, and
align if necessary.
Tightening torques:
Shock absorber to body
Use new bolts!
30 Nm + 90
Rear axle to bearing bracket
Use new nuts and bolts!
45 Nm + 90
Bolts attaching brake lines
Edition 04.00
S00.5103.58.20
14 Nm
------------
------------
42
Rear Wheel Suspension
OCTAVIA
Summary of components of rear axle
Notes:
Welding and straightening on axle body and
axle studs not allowed.
Always replace the self-locking nuts and
screws.
Tighten pipe screws of the brake lines to
14 Nm.
3 - Brake drum
reset brake before removing the brake
drum page 42-24, Fig. 1
4 - Cap
replace after each removal
pressing off page 24-25,
Fig. 2 and 3
inserting page 42-27, Fig. 8
1 - Wheel bolt, 120 Nm
2 - Screw, 4 Nm
------------ 42-4 ------------
Edition 06.05
S00.5103.68.20
"
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$
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OCTAVIA
Replace each time removed
hub
and
Only on models with ABS
Wheel bearing and wheel hub are installed together in a housing
This wheel bearing/wheel hub unit requires no maintenance and is free of
play. It is not possible to carry out any
setting or servicing work!
Removing and installing from page
42-23
hub
Only on models without ABS
Wheel bearing and wheel hub are installed together in a housing
This wheel bearing/wheel hub unit requires no maintenance and is free of
play. It is not possible to carry out any
setting or servicing work!
Removing and installing from page
42-23
+
and torque a
ther 60
Replace each time removed
shoe
10
Replace
11
12
13
14
42
Rear Suspension
rear
After installing, inspect total wheel toe
of rear axle, and align if necessary
Do not slacken if possible for removing rear axle
16
1
Bonded rubber bush
Removing and installing page 42-7
18
pressure
19 B
Only on models without ABS
Inspecting and setting page 47-16
20 H
21
22
20
20
20
and torque a
ther
Replace each time removed
23
24
26
Contact surface and threaded holes
for axle journal must be free of paint
and dirt
ABS
speed sensor
Only on models with ABS
8
Replace each time removed
30
and
torque a
90
Replace each time removed
If thread of welded nut is damaged,
thread can be repaired with Heli-Coil
threaded insert. Pay attention to
manufacturers instructions.
Reworking of thread of welded nut is
permissible at not more than 2 bolted
connection points on each side of vehicle.
and torque a
ther 90
Replace each time removed
Insert from outside of vehicle
When tightening hexagon bolt, axle
beam should be horizontal (unladen
weight condition)
Edition 04.00
S00.5103.58.20
28
Removing and installing
page 42-10
Inspect for paint damage, touch up
any paint damage
Assigning Parts List
Always replace on both sides of axle
Fit only coil springs of same manufacturer to rear axle
29
op base
Installing Notes, page 42-10
30
60
Replace each time removed
Insert from inside of vehicle
When tightening, pay attention to installation angle of rear axle to shock
absorber Fig. 1
Tighten hexagon bolt when vehicle
standing on its wheels and load of
about 100 kg in boot
------------
------------
OCTAVIA
Replace each time removed
If thread of welded nut is damaged,
thread can be repaired with Heli-Coil
threaded insert. Pay attention to
manufacturers instructions.
Reworking of thread of welded nut is
permissible at not more than 1 bolted
connection points on each side of vehicle.
Can be replaced individually
Removing and installing
page 42-10
Assigning Parts List
Disposal page 40-31
Inspecting shock absorber page
40-28
Fit only shock absorbers of same
make to rear axle
Note:
No provision made for servicing shock absorbers.
Replace each time removed
------------ 42-6 ------------
S00.5103.56.20
OCTAVIA
42
Rear Suspension
34 - Brake line
36 - Stone chip guard
35 - Axle stub
No straightening work permitted!
It is not permitted to re-tap thread.
37 - Element for attaching stone chip guard
Included in parts supplied with stone
chip guard
K Fig. 1
Installation angle of rear axle/shock
absorber
1 - Shock absorber
2 - Track control arm
- approx. 104
Removing and installing bonded
rubber bush
Special tools, testers and aids required
Universal tool MP 3-419
Thrust piece MP 5-400/1
Thrust piece MP 5-400/2
Supporting tube MP 5-400/3
Installation device MP 5-401
Removing
K-
Edition 06.99
S00.5103.56.20
Unclip brake cables -arrows-.
Detach clips -2- of brake hose fixture.
Unscrew hexagon bolt -1- of bonded rubber
bush at both track control arms.
------------
------------
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OCTAVIA
Note:
Place a soft block of wood of about 10 cm between axle beam and body in order to be able
to fit on the special tool.
K
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Note:
It is essential to install the bonded rubber
bush in the specified position in the rear axle
beam otherwise this will result in a deterioration in the handling of the car when cornering.
K
------------
------------
$
S00.5103.56.20
OCTAVIA
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42
Rear Suspension
K-
K-
Note:
When tightening the hexagon bolt of the bonded
rubber bush, the axle beam must be in horizontal position (unladen weight condition).
-
Note:
When installing the handbrake cables, pay attention to Fitting location page 46-18.
-
Edition 04.00
S00.5103.58.20
------------
------------
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OCTAVIA
Gearbox lifter with adapter, e.g. V.A.G 1383
A with V.A.G 1359/2
Notes:
It is not necessary to take out the coil spring
in order to remove the shock absorber.
It is not necessary to take out the shock absorber in order to remove the coil spring.
Take off wheel trim or pull off cap on lightalloy wheels (hook for removing cap included
in car tool kit).
Take off wheel and raise vehicle.
K-
Unscrew bolts -1- and -2- and take out shock
absorber.
Take off wheel trim or pull off cap on lightalloy wheels (hook for removing cap included
in car tool kit).
Take off wheel and raise vehicle.
Separate plug connection of wheel speed
sensor cable.
Unscrew bolt -2-.
Lower gearbox lifter and take out spring.
Installation is carried out in the reverse order.
Notes:
Ensure that the top base (rubber) for the
spring is correctly inserted when placing into
the mount of the body.
Pay attention to the correct colour coding.
The start of the coil at the bottom must always point toward the middle of the vehicle.
K-
------------
------------
Start of spring -arrow- must be positioned at
the stop of the bottom base.
S00.5103.56.20
OCTAVIA
42
Rear Suspension
Disassembling and assembling shock absorber
1 - Shock absorber
Can be replaced individually
Removing and installing
page 42-10
Assigning Parts List
Disposing page 40-31
Inspecting shock absorber
page 40-28
Note:
Shock absorbers must not be disassembled or
repaired.
2 - Protective cap
3 - Protective tube
4 - Bump stop
5 - Top shock absorber bearing
6 - Self-locking hexagon nut, 25 Nm
Replace each time removed
Counterhold at the piston rod of the
shock absorber for slackening and
tightening the hexagon nut
7 - Cover
Edition 10.98
S00.5103.54.20
------------ 42-11 ------------
42
OCTAVIA
Rear Suspension
Servicing rear suspension disc brakes
Removing and installing rear suspension
Special tools, testers and aids required
Gearbox jack with attachment,
e.g. V.A.G 1383 A with V.A.G 1359/2
Brake filling and bleeding appliance,
e.g. ROMESS S 15
Sealing plug for brake line
Brake fluid page 00-8
Assembly paste G 052 150 A2
Removing
Note:
To remove the rear suspension, do not slacken
bearing bracket at the body otherwise it is necessary to check the total wheel toe of the rear
suspension and to align if necessary.
------------ 42-12 ------------
K-
Remove bolts -1- with vehicle standing on
its wheels. Jack up vehicle sufficiently, if necessary, until the bolts are accessible.
Jack up vehicle to fitting height in order to
take the load off the coil spring.
Take off wheels.
Release handbrake.
Edition 10.98
S00.5103.54.20
OCTAVIA
!
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Rear Suspension
K
Note:
Seal lines with plugs.
K
K
Edition 06.99
S00.5103.56.20
------------
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OCTAVIA
-
Notes:
When tightening the hexagon bolt of the
bonded rubber bush, the axle beam must be
in the horizontal position (unladen weight
condition).
When installing the handbrake cables, pay
attention to Fitting location page 46-18.
Note:
After slackening or replacing the bearing
bracket, check total wheel toe of rear axle, and
align if necessary.
------------
------------
S00.5103.58.20
OCTAVIA
42
Rear Wheel Suspension
Summary of components of rear axle
Notes:
3 - Brake disc
Welding and straightening on axle body and
axle studs not allowed.
4 - Cap
replace after each removal
pressing off page 42-29,
Fig. 1 and 2
inserting page 42-31, Fig. 8
Always replace the self-locking nuts and
screws.
Tighten pipe screws of the brake lines to
14 Nm.
1 - Wheel bolt, 120 Nm
5 - Self-locking twelve-point nut, 70 Nm
and tighten a further 40
replace after each removal
2 - Screw, 4 Nm
Edition 06.05
S00.5103.68.20
------------ 42-15 ------------
OCTAVIA
Only on models with ABS
Wheel bearing and wheel hub are installed together in a housing
This wheel bearing/wheel hub unit requires no maintenance and is free of
play. It is not possible to carry out any
setting or servicing work!
Removing and installing from page
42-28
Always replace complete
------------
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2
and
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Replace each time removed
thread
thread can
repaired
threaded
a ttention to
thread
at not more than
connection
on each
40
and
Replace each time removed
Replace each time removed
attention to i
rear
to
vehicle
on
and load
in
and
a
Replace each time removed
thread
thread can
repaired
threaded
a ttention to
rear
rear
not
rear
and
total
toe
and
Replace each time removed
Replace each time removed
and threaded
Note:
28
speed sensor
20
and dirt
paint
22
or paint
paint
replace on
coil
chip
in
stone
and
not permitted to
0 Stone
to rear
No provision made for servicing shock absorbers.
20
on
replaced
and
thread
at not more than
connection
on each
and
42
Rear Suspension
and
a
Replace each time removed
24
Edition 04.00
S00.5103.58.20
------------
------------
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OCTAVIA
K
1 - Shock absorber
2 - Track control arm
- approx. 104
Universal tool MP 3-419
Thrust piece MP 5-400/1
Thrust piece MP 5-400/2
Supporting tube MP 5-400/3
Installation device MP 5-401
K-
------------
------------
Unclip brake cables -arrows-.
Detach clips -2- of brake hose fixture.
Unscrew hexagon bolt -1- of bonded rubber
bush at both track control arms.
S00.5103.56.20
OCTAVIA
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42
Rear Suspension
Note:
Place a soft block of wood of about 10 cm between axle beam and body in order to be able
to fit on the special tool.
K
K
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Note:
It is essential to install the bonded rubber
bush in the specified position in the rear axle
beam otherwise this will result in a deterioration in the handling of the car when cornering.
K
Edition 06.99
S00.5103.56.20
$
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OCTAVIA
K-
K-
Note:
When tightening the hexagon bolt of the bonded
rubber bush, the axle beam must be in horizontal position (unladen weight condition).
-
Note:
When installing the handbrake cables, pay attention to Fitting location page 46-18.
-
------------
------------
S00.5103.58.20
OCTAVIA
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42
Rear Suspension
and
testers and aids
Gearbox lifter with adapter, e.g. V.A.G 1383
A with V.A.G 1359/2
Notes:
It is not necessary to take out the coil spring
in order to remove the shock absorber.
It is not necessary to take out the shock absorber in order to remove the coil spring.
Take off wheel trim or pull off cap on lightalloy wheels (hook for removing cap included
in car tool kit).
Take off wheel and raise vehicle.
K-
Unscrew bolts -1- and -2- and take out shock
absorber.
Take off wheel trim or pull off cap on lightalloy wheels (hook for removing cap included
in car tool kit).
Take off wheel and raise vehicle.
Separate plug connection of wheel speed
sensor cable.
Unscrew bolt -2-.
Lower gearbox lifter and take out spring.
Installation is carried out in the reverse order.
Notes:
Ensure that the top base (rubber) for the
spring is correctly inserted when placing into
the mount of the body.
Pay attention to the correct colour coding.
The start of the coil at the bottom must always point toward the middle of the vehicle.
K-
Edition 06.99
S00.5103.56.20
Start of spring -arrow- must be positioned at
the stop of the bottom base.
------------
------------
42
Rear Suspension
OCTAVIA
Disassembling and assembling shock absorber
1 - Shock absorber
Can be replaced individually
Removing and installing
page 42-21
Assigning Parts List
Disposing page 40-31
Inspecting shock absorber
page 40-28
Note:
Shock absorbers must not be disassembled or
repaired.
2 - Protective cap
3 - Protective tube
4 - Bump stop
5 - Top shock absorber bearing
6 - Self-locking hexagon nut, 25 Nm
Replace each time removed
Counterhold at the piston rod of the
shock absorber for slackening and
tightening the hexagon nut
7 - Cover
------------ 42-22 ------------
Edition 10.98
S00.5103.54.20
OCTAVIA
42
Rear Wheel Suspension
Repairing the wheel bearing
Repairing the wheel bearing, vehicles with front-wheel-drive vehicles - drum
brakes
1 - Screw, 4 Nm
2 - Brake drum
reset brake before removing the brake
drum Fig. 1
3 - Cap
replace after each removal
pressing off Fig. 2 and 3
inserting Fig. 8
4 - Self-locking twelve-point nut, 175 Nm
replace after each removal
Special tools, testers and aids required
Drive bushing MP 3-427
Assembly device MP 5-403
Hub cover puller MP 5-404
Puller Kukko 20/2
Puller Kukko 204/1
Edition 06.05
S00.5103.68.20
5 - Wheel hub with wheel bearing and
pulse rotor
only on vehicles with ABS
wheel hub and wheel bearing are fitted together in one housing
the wheel hub and the wheel bearing
are a single unit; it does not need
servicing and is free of play; it is not
possible to undertake any kind of
adjustment or repair work on it
replace completely after each removal
Remove wheel hub with wheel bearing from axle stud Fig. 4
Pull the wheel hub with wheel bearing
onto the axle stud Fig. 6 and 7
Notes:
After pulling off the wheel hub with the
wheel bearing, the inner ring of the bearing
remains on the axle stud, then pull off the
old inner ring of the bearing before pressing
on the new wheel hub with wheel bearing
Fig. 5.
The inner ring of the bearing is a component
part of the new wheel hub with wheel bearing
and is therefore not pressed on separately.
------------ 42-23 ------------
42
OCTAVIA
Rear Suspension
6 - Wheel hub with wheel bearing without
pulse rotor
Only on models without ABS
Wheel bearing and wheel hub are installed together in a housing
This wheel bearing/wheel hub unit requires no maintenance and is free of
play. It is not possible to carry out setting or repair work!
Replace complete each time removed
Pulling wheel hub and bearing off axle
end Fig. 4
Notes:
Item 5
Fitting wheel hub and bearing onto
axle end Figs. 6 and 7
7 - Axle end
It is not permitted to carry out straightening work
It is not permitted to re-tap the thread
8 - Axle beam
K Fig. 1
------------ 42-24 ------------
Moving back brake
To do this, insert the screwdriver through a
hole in the brake drum and push the wedge
up.
Removing brake drum page 46-6, Removing and installing rear brakes.
Edition 10.98
S00.5103.54.20
OCTAVIA
K Fig. 2
-
Pressing off cap
Detach cap from its seat by striking with light
blows on the claw.
K Fig. 3
Edition 10.98
S00.5103.54.20
42
Rear Suspension
Pressing off cap
------------
------------
42
OCTAVIA
Rear Suspension
K Fig. 4
Pulling wheel hub and wheel bearing off axle end
Use a commercially available puller, e.g. Kukko
20/2.
K Fig. 5
Pulling bearing inner race off axle
end
Use a commercially available puller, e.g. Kukko
204/1.
Note:
Do not damage the ABS sensor when pulling
out the bearing inner race.
K Fig. 6
Fitting wheel hub and wheel bearing onto axle end
Use special tool MP 5-403.
------------
------------
Fit wheel hub and wheel bearing as far as
possible onto axle end.
Screw on special tool MP 5-403 and pull on
wheel hub and wheel bearing as far as the
stop.
Edition 10.98
S00.5103.54.20
OCTAVIA
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Rear Suspension
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Notes:
Edition 04.00
S00.5103.58.20
------------
------------
42
Rear Wheel Suspension
OCTAVIA
Repairing the wheel bearing - Disc brake
4 - Brake disc
assignment electronic catalogue of
original parts
5 - Cap
replace after each removal
pressing off Fig. 1 and 2
inserting Fig. 8
6 - Self-locking twelve-point nut, 70 Nm
and tighten a further 40
replace after each removal
Special tools, testers and aids required
Drive bushing MP 3-427
Assembly device MP 5-403
Hub cover puller MP 5-404
Puller Kukko 20/2
Puller Kukko 204/1
1 - Brake disc, internally ventilated
assignment electronic catalogue of
original parts
2 - Wheel bolt, 120 Nm
3 - Screw, 4 Nm
7 - Wheel hub with wheel bearing and
pulse rotor
only on vehicles with ABS
wheel hub and wheel bearing are fitted together in one housing
the wheel hub and the wheel bearing
are a single unit; it does not need
servicing and is free of play; it is not
possible to undertake any kind of
adjustment or repair work on it
replace completely after each removal
Remove wheel hub with wheel bearing from axle stud Fig. 4
Pull the wheel hub with wheel bearing
onto the axle stud Fig. 6 and 7
Notes:
After pulling off the wheel hub with the
wheel bearing, the inner ring of the bearing
remains on the axle stud, then pull off the
old inner ring of the bearing before pressing
on the new wheel hub with wheel bearing
Fig. 5.
The inner ring of the bearing is a component
part of the new wheel hub with wheel bearing
and is therefore not pressed on separately.
8 - Axle body
removing and installing
page 42-12
9 - Brake caliper
removing Fig. 3.
10 - Axle stud
Straightening work is not allowed!
Re-cutting the thread is not allowed.
------------ 42-28 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
K Fig. 1
-
Pressing off cap
Detach cap from the seat by applying light
blows to the claw.
K Fig. 2
Edition 09.96
S00.5103.51.20
42
Rear Suspension
Pressing off cap
------------ 42-29 ------------
42
Rear Wheel Suspension
Fig. 6
OCTAVIA
Removing the brake caliper
Unscrew screws -A-, remove brake caliper
and tie up with wire to the body.
Note:
Do not unscrew the brake hose to remove the
brake caliper.
-
Unscrew the fixing screws of the brake disc
and remove brake disc.
Unscrew twelve-point nut
Fig. 7
Removing wheel-bearing housing
from axle stud
Use puller (commercially available) Kukko
20/2.
Fig. 8
Removing inner ring of the bearing
from axle stud
Use puller (commercially available) Kukko
204/1.
Note:
Do not damage the ABS-speed sensor when
removing the inner ring of the bearing.
------------ 42-30 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
(1)"
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42
Rear Suspension
and
Use special tool MP 5-403.
Fit wheel hub and wheel bearing as far as
possible onto axle stud.
Screw on special tool MP 5-403 and pull on
wheel hub and wheel bearing as far as the
stop.
Remove special tool MP 5-403 and screw
on wheel hub with twelve-point collar nut and
tighten fully.
Tightening torque: 70 Nm + torque a further
40
Install brake disc, insert cross-head screw
and tighten to 4 Nm.
in
Notes:
Edition 04.00
S00.5103.58.20
Install brake caliper and tighten hexagon
socket bolts fully to 65 Nm.
------------
------------
42
Rear Suspension
OCTAVIA
Servicing rear suspension (4x4 models)
Overview of rear suspension for 4x4 models
Notes:
Always replace self-locking nuts and bolts.
Always replace nuts and bolts which have signs of
surface rust.
1 - Subframe
Assembly overview page 42-60
------------ 42-32 ------------
2 - Final drive
Removing and installing
5-Speed Manual Gearbox 02C 4x4; Repair
Group 39; Removing and installing rear final drive
Servicing
For technical reasons it has not yet been
possible to prepare the repair description.
It will be published in a subsequent supplement.
At present, if any faults exist at the rear
final drive, it should be replaced complete.
Edition 11.99
S00.5103.57.20
OCTAVIA
3 - Cross member
4 - Clamp
5 - Anti-roll bar
if necessary eliminate paint damage
and carry out protection against corrosion
6 - Pressurized shock absorber
summary of components
page 42-33
removing and installing
page 42-39
7 - Wheel bearing
pressing in and out page 42-44
8 - Trailing arm
summary of components
page 42-41
9 - Suspension arm
summary of components
page 42-41
42
Rear Wheel Suspension
10 - Spacer
only on vehicles with rough road suspension
on vehicles without spacer this must
not be installed subsequently
summary of components
page 42-33
11 - Stop buffer
summary of components
page 42-33
12 - Helical spring
summary of components
page 42-33
13 - Propshaft
removing and installing
5-speed Manual Gearbox 02C Four-wheel
drive; epair Group 39; Removing and installing propshaft
repairing
5-speed Manual Gearbox 02C Four-wheel
drive; Repair Group 39; Repairing propshaft
14 - Screw, 60 Nm
15 - Support for final drive
summary of components
page 42-60
Summary of components - helical spring and shock absorber on vehicles with
four-wheel drive
1 - Screw, 60 Nm
replace after each removal
2 - Shock absorber bushing
3 - Pressurized shock absorber
removing and installing
page 42-39
inspecting page 40-30
assignment electronic catalogue of
original parts
disposing age 40-31
can be replaced individually
per rear axle only use shock absorbers of the same make
4 - Anti-roll bar
5 - Nut, self-locking 25 Nm
replace after each removal
6 - Screw 110 Nm
M 14 x 1.5 x 90
7 - Coupling rod
Edition 06.05
S00.5103.68.20
------------ 42-33 ------------
42
Rear Wheel Suspension
OCTAVIA
11 - Stop buffer with positioning pin
as of 08.99
the correct fitting position is determined by the positioning pin
the positioning pin must be removed
on the bottom side when used for
vehicles manufactured before 08.99
the start of the spring coil must lie
against the leg -arrow Fitting position of helical spring
page 42-38
12 - Helical spring
removing and installing
page 42-35
check for paint damage, if necessary
eliminate paint damage
check colour coding
assignment electronic catalogue of
original parts
replace axle-wise
per rear axle only use shock absorbers of the same make
13 - Base
8 - Trailing arm
Thread -arrow A- for support of the
stop buffer -Pos. 10- is no longer applicable as of 08.99
in case the stop buffer -Pos. 11- is
installed in the trailing arm before the
manufacturing date 08.99 the thread
-arrow A- is bored out to 10.5 mm
9 - Spacer
only on vehicles with rough road suspension
on vehicles without spacer, it must not
be installed subsequently
10 - Stop buffer with threaded pin, 10 Nm
no longer inserted as of 08.99
stop buffer -Pos. 11- is supplied as
spare part
------------ 42-34 ------------
14 - Thread in the frame side rail
in the event of damage of the thread
of the welded nuts in the trailing arm,
the thread can be repaired with the
Heli-Coil-Thread kit
reworking the thread of the welded
nuts is allowed on two permissible
screw points per vehicle side
pay attention to installation instructions of the manufacturer
15 - Thread in the cross arm
in the event of damage of the thread
of the welded nuts in the trailing arm,
the thread can be repaired with the
Heli-Coil-Thread kit
pay attention to installation instructions of the manufacturer
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Suspension
Removing and installing coil
springs
Special tools, testers and aids required
Spring tensioning device, e.g. V.A.G 1752/1
Spring retainer set, e.g. V.A.G 1752/15
The spring retainer set consists of:
Spring retainer, e.g. V.A.G 1752/15 L. U.
(left bottom)
Spring retainer, e.g. V.A.G 1752/15 L. O.
(left top)
Spring retainer, e.g. V.A.G 1752/15 R. U.
(right bottom)
Spring retainer, e.g. V.A.G 1752/15 R. O.
(right top)
Notes:
The spring retainer set V.A.G 1752/15 has
been specially developed for 4x4 vehicles in
order to provide reliable removal and installation of the coil springs.
Very high forces are produced when
tensioning the coil springs. For this reason,
it is important to closely observe the following safety precautions.
Warning!
Ensure that the spring retainers are positioned
as close as possible to the spring coils.
During the tensioning operation, ensure that the
spring retainers are correctly located at the
spring coils.
On no account use an impact screwdriver!
Removing left coil spring
K-
Edition 11.99
S00.5103.57.20
Install the spring retainer, e.g. V.A.G 1752/
15 L. U. at the spring tensioning device, e.g.
V.A.G 1752/1.
------------ 42-35 ------------
K
K
OCTAVIA
!
Note:
Do not use an impact screwdriver or similar for
tensioning the coil spring.
K
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It is essential to end the tensioning device once
the spring coils touch.
------------
------------
S00.5103.57.20
OCTAVIA
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42
Rear Suspension
K
nspect
spring retainers are
positioned at
spring
just position, necessary.
Notes:
Do not use an impact screwdriver or similar
coil
for tensioning or
It is essential to end t
once
spring coils
tensioning device
K
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Edition 11.99
S00.5103.57.20
------------
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OCTAVIA
K Models without stop on bump stop:
The start of the spring coil -3- must be in the 9
oclock (9:00) position.
1 - Coil spring
2 - Bump stop without stop for coil spring
F - Direction of travel
Notes:
The
The
K Models with stop at bump stop:
The start of the spring coil -3- must be positioned against the stop -arrow-.
1 - Coil spring
2 - Bump stop without stop for coil spring
F - Direction of travel
Notes:
Release the tension of the coil spring by turning the shaft of the spring tensioning device
in an anti-clockwise direction.
------------
------------
K-
Unscrew hexagon nut -1- and take off bolt
together with spring retainer.
Take spring tensioning device out of the coil
spring.
S00.5103.57.20
OCTAVIA
42
Rear Suspension
Removal and installation of the right coil spring
is similar to the procedure for the left coil spring
page 42-35.
In place of the special tools
Spring retainer, e.g. V.A.G 1752/15 L. U. (left
bottom)
Spring retainer, e.g. V.A.G 1752/15 L. O. (left
top)
use the
Spring retainer, e.g. V.A.G 1752/15 R. U.
(right bottom)
Spring retainer, e.g. V.A.G 1752/15 R. O.
(right top).
The installation position of the right coil spring
is identical to that of the left coil spring page
42-38.
Removing and installing
sorbers
tools, testers and aids required
Gearbox lift, e.g. V.A.G 1383 A
Attachment, e.g. V.A.G 1359/2
Removing
Edition 11.99
S00.5103.57.20
Raise vehicle.
Take off wheel.
Remove coil spring page 42-35.
Unclip cable for wheel speed sensor from
fixture.
K-
Partially detach wheelhouse liner, if necessary.
------------
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------------
------------
S00.5103.57.20
OCTAVIA
42
Rear Wheel Suspension
Summary of components - trailing arm and suspension arm
Notes:
Never load the wheel-bearing, if the drive
shaft was removed!
In case the vehicle is placed onto its wheels
and moved, temporarily the outer joint of a
drive shaft must be inserted.
1 - Fillister head screw with internal serration, 40 Nm
replace after each removal
initially tighten to 10 Nm, subsequently
tighten crosswise to final torques
2 - Shim
Welding and straightening work is not allowed on the bearing and wheel control components of the front wheel suspension.
Always replace self-locking nuts.
Always replace corroded screws/nuts.
Edition 06.05
S00.5103.68.20
------------ 42-41 ------------
42
Rear Wheel Suspension
OCTAVIA
3 - Assembly carrier
removing and installing
page 42-61
6 - Tighten screw 70 Nm and 90
M 12 x 1.5 x 75
replace after each removal
4 - Drive shaft with inner CV joint
removing and installing
page 42-72
repairing page 42-75
7 - Top suspension arm
removing and installing
page 42-58
different versions, assignment
electronic catalogue of original
parts
5 - Tighten screw 70 Nm and 90
M 12 x 1.5 x 80
replace after each removal
8 - Guide joint
removing and installing
page 42-52
9 - Collar screw, 65 Nm
------------ 42-42 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Wheel Suspension
10 - Brake carrier with brake caliper
repairing page 46-24
removing and installing brake pads
page 46-26
24 - Rubber metal bearing
for trailing arm
removing and installing
page 42-50
11 - Screw, 10 Nm
25 - Trailing arm
removing and installing
page 42-54
Thread -arrow A- for support of the
stop buffer -Pos. 29- is no longer applicable as of 08.99
in case the stop buffer -Pos. 30- is
installed in the trailing arm before the
manufacturing date 08.99 the thread
-arrow A- is bored out to 10.5 mm
12 - Self-locking twelve-point nut
tightening page 42-74
replace after each removal
13 - Screw, 4 Nm
14 - Brake disc
assignment electronic catalogue of
original parts
15 - Brake disc, internally ventilated
assignment electronic catalogue of
original parts
16 - Wheel hub with pulse rotor for speed
sensor
pulse rotor is welded to the wheel
hub
inspect axial run-out of pulse rotor
page 45-61
pressing in and out page 42-44
17 - Circlip
replace after each removal
check for firm seating
18 - Wheel bearing
pressing in and out page 42-44
replace, is destroyed when pressing
out
spare part supplied only as kit wheel
bearing with assembly parts (with
Pos. 12, 17)
19 - Cover plate
20 - Nut, self-locking
replace after each removal
21 - Bottom suspension arm
removing and installing
page 42-58
different versions, assignment
electronic catalogue of original
parts
22 - Guide joint
removing and installing
page 42-52
23 - Screw, 90 Nm
replace after each removal
insert from the vehicle outside
Edition 06.05
S00.5103.68.20
26 - Screw 75 Nm
replace after each removal
27 - Mount for rear axle
check the overall tracking of the rear
axle after installation and take the
mean as necessary
the track can be correct by moving the
mount
28 - Spacer
only on vehicles with rough road suspension
on vehicles without spacer this must
not be installed subsequently
29 - Stop buffer with threaded pin, 10 Nm
no longer inserted as of 08.99
stop buffer -Pos. 30- is supplied as
spare part
30 - Stop buffer with positioning pin
as of 08.99
the correct fitting position is determined by the positioning pin
the positioning pin must be removed
on the bottom side when used for
vehicles manufactured before 08.99
the start of the spring coil must lie
against the leg -arrow fitting position of helical spring page
42-38 and page 42-39
31 - Speed sensor
removing and installing
page 45-82
insert with solid lubricant paste G 000
650 (e.g. Wolfrakote Top Paste)
32 - Allen screw, 8 Nm
33 - Flange shaft of rear axle gearbox
------------ 42-43 ------------
OCTAVIA
Gearbox lift with attachment, e.g. V.A.G 1383
A with V.A.G 1359/2
Foot pump with high-pressure hose, e.g.
V.A.G 1389 A/1 (Paschke)
Hydraulic removal and insertion device for
wheel bearings, e.g. V.A.G 1459 B (Paschke)
with the following individual tools:
Hollow piston cylinder, e.g. HKZ-15, with
thrust piece, e.g. E-0-204T
Tensile pin, e.g. E-0-217 + 218
Special nut, e.g. E-8-214
Thrust piece, e.g. E-5
Centring device with clip, e.g. E-76-2
Complementary set, e.g. V.A.G 1459 B/2
with the following individual tools:
Thrust sleeve, e.g. E-44
Bell, e.g. E-40
Thrust piece, e.g. E-6-1
Thrust piece, e.g. E-13-1
Thrust plate, e.g. E-39 (VAS 5146)
Thrust plate MP 3-467
Grip of wheel bearing inner race MP 6-416
Cross member Kukko 18-0
------------ 42-44 ------------
Raise vehicle.
Take off wheel.
Remove drive shaft page 42-72.
S00.5103.57.20
OCTAVIA
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Rear Suspension
K
Note:
Top bolt attaching brake carrier is concealed.
out
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S00.5103.57.20
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Note:
Place gearbox lift with attachment below, e.g.
V.A.G 1383/A with V.A.G 1359/2 (risk of accident from parts dropping off when wheel hub
pressed out).
K
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------------
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S00.5103.57.20
OCTAVIA
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Rear Suspension
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Edition 11.99
S00.5103.57.20
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OCTAVIA
Notes:
Replace circlip each time removed.
When inserting circlip, ensure it is correctly
installed.
K
K
K
Note:
The collar -arrow- of the thrust piece -4- must
be pointing toward the special nut -3-.
------------
------------
S00.5103.57.20
OCTAVIA
42
Rear Wheel Suspension
Build up pressure by pumping with the foot
pump.
Check if all tools are correctly centered, if
necessary correct position.
Then press in wheel hub by pumping with
the foot pump.
Further installation occurs in reverse order.
-
Install ABS speed sensor page 45-82.
Install brake disc.
Install brake carrier with brake calliper.
Install drive shaft page 42-72.
Tightening torques:
Screw for ABS speed sensor
8 Nm
Screw for brake disc
4 Nm
Brake carrier with brake calliper to
trailing arm
65 Nm
Tighten drive shaft to flange shaft M8
crosswise in 2 steps
(I and II)
Use new screws!
Wheel screw
I - 10 Nm
II - 40 Nm
120 Nm
Nut to wheel hub
Always use new nut!
Tightening torque page 42-74
Edition 06.05
S00.5103.68.20
------------ 42-49 ------------
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OCTAVIA
Assembly device MP 5-401
Assembly device MP 5-402
Assembly device T10030
Assembly device T30016
Raise vehicle.
Take off wheel.
K-
Unbolt bracket for brake line -2- from trailing
arm.
Unclip brake line from bracket.
K-
------------
------------
Remove coil spring -1- page 42-35.
Mark the installation position of the bearing
bracket at the body -arrows-.
Unbolt the bearing bracket from the body.
S00.5103.57.20
OCTAVIA
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Rear Suspension
K
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K
K
Edition 11.99
S00.5103.57.20
------------
------------
42
OCTAVIA
Rear Wheel Suspension
Removing and installing the guide
joint
Special tools, testers and aids required
Assembly device MP 5-401
Assembly device MP 5-402
Assembly device T10030
Assembly device T30017
Caution!
If the top and bottom guide joint must be replaced,
first of all the helical spring must be removed.
-
Remove helical spring page 42-35.
Removing guide joint
-
Raise vehicle.
Remove wheel
Unscrew bottom suspension arm from the
trailing arm -arrow-.
Screw the wheel bolt up to the stop into the
brake disc.
Fit socket nut with two extensions onto the
wheel bolt.
Press extension slightly upwards -arrow- and
pull out screw -2-.
1 - Screw for top suspension arm - do not
slacken!
3 - Trailing arm
4 - Bottom suspension arm - do not remove!
5 - Top suspension arm
------------ 42-52 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Wheel Suspension
Press down the bottom suspension arm
only so far, that the assembly device can be
mounted.
Position the special tools as shown.
Pull out the guide joint by turning the spindle.
Installing bottom guide joint
-
Before positioning, the pressure plate
T10030/1A must be marked along the entire
circumference.
Distance: 3 mm
The marking must be towards the open
side.
Note:
The marking is required for positioning the guide
joint in the trailing arm.
Edition 06.05
S00.5103.68.20
Position the special tools as shown.
Press in the guide joint -1- by turning the
spindle until the marking on the pressure
plate T10030/1A reaches the support on the
trailing arm.
Slacken special tools, do not remove.
Check if the guide joint is located in the middle in the support of the trailing arm.
If this is not the case, correct the fitting position of the guide joint accordingly.
Install bottom suspension arm
page 42-58.
Install the wheel.
Lower the vehicle.
------------ 42-53 ------------
42
OCTAVIA
Rear Wheel Suspension
Removing top guide joint
Caution!
If the top and bottom guide joint must be replaced,
first of all the helical spring must be removed.
-
Raise the vehicle.
Remove the wheel.
Unscrew screws -A-, remove brake caliper
and tie up with wire or anything similar.
Note:
Do not unscrew the brake hose to remove the
brake caliper.
-
Unscrew the screw for the brake disc and
remove brake disc.
Unscrew screw -1- from the assembly carrier.
------------ 42-53.1 ------------
Unscrew nut -2- for top suspension arm.
Unscrew nut of screw -1-.
Screw the wheel bolt up to the stop into the
wheel hub.
Fit socket nut with two extensions onto the
wheel bolt.
Press extension slightly upwards -arrow- and
pull out screw -1-.
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Wheel Suspension
Press down the extension only so far
-arrow 1-, that the top suspension arm can
be removed upwards -arrow 2-.
Note:
If the extension is pushed so far downwards,
the drive shaft can be damaged.
-
Pull screw and top suspension arm out of
the assembly carrier.
Position the special tools as shown.
Pull out the guide joint by turning the spindle.
Installing top guide joint
-
Before positioning, the pressure plate
T10030/1A must be marked along the entire
circumference.
Distance: 3 mm
The marking must be towards the open
side.
Note:
The marking is required for positioning the guide
joint in the trailing arm.
Edition 06.05
S00.5103.68.20
------------ 42-53.2 ------------
42
OCTAVIA
Rear Wheel Suspension
Position the special tools as shown.
Press in the guide joint -1- by turning the
spindle until the marking on the pressure
plate T10030/1A reaches the support on the
trailing arm.
Slacken special tools, do not remove.
Check if the guide joint is located in the middle in the support of the trailing arm.
If this is not the case, correct the fitting position of the guide joint accordingly.
Install bottom suspension arm
page 42-58.
Install the wheel.
Lower the vehicle.
Removing and installing the trailing
arm
Special tools, testers and aids required
Gearbox jack e.g. V.A.G 1383 A
Adapter e.g. V.A.G 1359/2
Removing
-
Raise the vehicle.
Remove the wheel.
------------ 42-54 ------------
Remove helical spring -1- page 42-35.
Edition 06.05
S00.5103.68.20
OCTAVIA
K
K
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Edition 11.99
S00.5103.57.20
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Rear Suspension
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Note:
Top bolt attaching brake carrier is concealed.
K
------------
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S00.5103.57.20
OCTAVIA
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Rear Suspension
K
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Notes:
If the trailing arm is replaced, use the existing track control arm.
The installation position of the bearing
bracket must then be set as described on
page 42-57.
installation position
to trailing
installing,
and
toe on axle
stand, and set
essary page 44-1.
Edition 11.99
S00.5103.57.20
------------
------------
42
OCTAVIA
Rear Wheel Suspension
Tightening torques:
Brake carrier with brake calliper to
trailing arm
65 Nm
Bracket to trailing arm
90 Nm
Bracket to body
75 Nm
Suspension arm to trailing arm
Use new screws and nuts!
70 Nm + 90
Shock absorber to trailing arm
Vehicle must be standing on its
wheels and loaded with one person
on the rear seat.
110 Nm
Tighten drive shaft to flange shaft M8
crosswise in 2 steps (I and II)
Use new screws!
I - 10 Nm
II - 40 Nm
Pipe bolted connection - brake line
14 Nm
Wheel screw
120 Nm
Nut to wheel hub
Always use new nut!
Tightening torque page 42-74
Removing and installing suspension arm
Caution!
If the top and bottom guide joint must be replaced,
first of all the helical spring must be removed.
-
Remove helical spring page 42-35.
Removing bottom suspension arm
------------ 42-58 ------------
Raise the vehicle.
Remove the wheel.
Unscrew bottom suspension arm from the
trailing arm -arrow-.
Screw the wheel bolt up to the stop into the
brake disc.
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Wheel Suspension
Fit socket nut with two extensions onto the
wheel bolt.
Press extension slightly upwards -arrow- and
pull out screw -2-.
1 - Screw for top suspension arm - do not
slacken!
3 - Trailing arm
4 - Bottom suspension arm - do not remove!
5 - Top suspension arm
Unscrew screw -2- from the assembly carrier.
Unscrew bottom suspension arm -4- from
the assembly carrier.
Installing bottom suspension arm
Further installation occurs in reverse order.
The screw for bottom suspension arm must
only be tightened for a vehicle standing on
its wheels!
After installation inspect the wheel toe and
camber, if necessary adjust page 44-1.
Tightening torques:
Edition 06.05
S00.5103.68.20
Suspension arm to trailing arm
Use new screws and nuts!
70 Nm + 90
Suspension arm to assembly carrier
Use new screws and nuts!
70 Nm + 90
------------ 42-59 ------------
42
OCTAVIA
Rear Wheel Suspension
Removing top suspension arm
Caution!
If the top and bottom suspension arm must be
replaced, first of all the helical spring must be
removed.
-
Raise the vehicle.
Remove the wheel.
------------ 42-59.1 ------------
Unscrew screw -1- from the assembly carrier.
Unscrew nut -2- for top suspension arm.
Unscrew nut of screw -1-
Screw the wheel bolt up to the stop into the
brake disc.
Fit socket nut with two extensions onto the
wheel bolt.
Press extension slightly upwards -arrow- and
pull out screw -1-.
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Wheel Suspension
Press down the extension only so far
-arrow 1-, that the top suspension arm can
be removed upwards -arrow 2-.
Note:
If the extension is pushed too far downwards,
the drive shaft can be damaged.
-
Pull screw and top suspension arm out of
the assembly carrier.
Installing top suspension arm
Further installation occurs in reverse order.
The screw for top suspension arm must
only be tightened for a vehicle standing on
its wheels!
After installation inspect the wheel toe and
camber, if necessary adjust page 44-1.
Tightening torques:
Edition 06.05
S00.5103.68.20
Suspension arm to trailing arm
Use new screws and nuts!
70 Nm + 90
Suspension arm to assembly carrier
Use new screws and nuts!
70 Nm + 90
Assembly carrier to body
Use new screw!
110 Nm + 90
------------ 42-59.2 ------------
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Rear Suspension
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Edition 11.99
S00.5103.57.20
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Note:
After unbolting the propshaft, it is essential to
mark the installation position. If the propshaft is
installed incorrectly, the imbalance will be too
large.
K
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------------
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S00.5103.57.20
OCTAVIA
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Rear Suspension
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Edition 11.99
S00.5103.57.20
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Edition 11.99
S00.5103.57.20
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------------
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OCTAVIA
Pipe section MP 3-409
Assembly device MP 5-402
Assembly device T10030
Raise vehicle.
Take off wheels.
Remove coil spring page 42-35.
Remove subframe together with final drive
page 42-61.
K-
Install the special tools.
Pull out the bonded rubber bush by turning
the spindle.
Notes:
The bonded rubber bushes are supplied as
replacement parts in a sealed plastic bag.
Do not use bonded rubber bushes which
have been stored unwrapped!
K-
Fit together special tools and the bonded
rubber bush.
The ribbed side must point in direction -arrow B- to ensure the bonded rubber bush is
correctly installed in the subframe.
Shoulder of special tool T10030/4 -arrow Apoints toward bonded rubber bush -1-.
------------
------------
S00.5103.57.20
OCTAVIA
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Rear Suspension
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Note:
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Edition 11.99
S00.5103.57.20
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OCTAVIA
Assembly device MP 5-401
Assembly device MP 5-402
Assembly device T10030
Assembly device T30016
-
Raise vehicle.
Take off wheels.
Remove coil spring page 42-35.
K-
Remove
page 42-61.
together with final drive
Use gearbox lift with attachment, e.g. V.A.G
1383 A with T10031, for this step.
the final drive -1-.
Note:
The
K-
he
Remove anti-roll bar -3-, if necessary.
Unscrew bolts -1-.
Take off clamp -2- and anti-roll bar together
and
rod.
with
4-
------------
------------
S00.5103.57.20
OCTAVIA
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Rear Suspension
Note:
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K
K
K
Edition 11.99
S00.5103.57.20
------------
------------
OCTAVIA
K The kidney-shaped openings -A- and the arrow
on the bonded rubber bush -1- must be pointing
up or down.
Variation from vertical of 2 permissible.
-
K-
Coat the bonded rubber bush with water, if
necessary, for drawing in.
Install the special tools.
1 - Bonded rubber bush
Draw in the bonded rubber bush by turning
the spindle.
Install subframe together with final drive
page 42-61.
K-
If removed, install anti-roll bar -3- together
with coupling rod. 2nd person required for
this step.
Place clamp -2- onto the bearing, insert both
bolts -1- and tighten initially to 5 Nm.
Tighten both bolts finally to the specified tightening torque.
4 - Subframe
Further installation is carried out in the reverse
order.
------------
------------
Bleed brake system page 47-18.
Adjust handbrake page 46-29.
S00.5103.57.20
OCTAVIA
#
$!
"
42
Rear Suspension
toe on
and
and set
Bearing bracket to body
75 Nm
Subframe to body
110 Nm +
90
Anti-roll bar to subframe
20 Nm
Propshaft to final drive
Shock absorber to trailing arm
Vehicle must be standing on its wheels
and one person sitting on the rear seat
for this step.
110 Nm
Support for final drive to subframe
60 Nm
Cross member for final drive to subframe
60 Nm
Pipe union of brake line
14 Nm
Wheel bolt
Edition 11.99
S00.5103.57.20
60 Nm
120 Nm
------------
------------
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OCTAVIA
Release tool MP 6-425
Torque wrench 75...400 Nm, e.g. 1576
Torque angle wrench, e.g. V.A.G 1756
Notes:
No load should be acting on the wheel bearing when the twelve-point nut is slackened.
If a load from the deadweight of the vehicle
is acting on the wheel bearing, it will suffer
initial damage and the wheel bearing life will
thus be reduced.
If it is necessary to move the vehicle on which
the drive shaft has been taken out, first of all
install an outer joint in place of the drive shaft
and tighten to 50 Nm otherwise the wheel
bearing will be damaged.
Drive shaft assignment and marking
Parts List
Take off wheel trim; pull off cap of light alloy
wheels (pulling hook in tool kit).
Raise vehicle sufficiently to take the load off
the rear axle.
The wheel must still be touching the ground.
Slacken twelve-point nut.
Raise vehicle to working height.
K-
------------
------------
Unbolt drive shaft -1- from the flange shaft
of the final drive -2-.
S00.5103.57.20
OCTAVIA
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Rear Suspension
K
Note:
Ensure adequate clearance when pressing
out the drive shaft.
K
R
rosion present in
residues
Edition 11.99
S00.5103.57.20
------------
------------
42
Rear Wheel Suspension
OCTAVIA
Make sure when lowering the vehicle that
the wheels do not touch the ground.
The wheel bearing will be damaged if the wheel
bearings are burdened though the weight of the
vehicle. The working life of the wheel bearing
decreases through this.
-
Operate brake (second mechanic required)
or tighten handbrake
Tighten the new twelve-point nut with 250
Nm and slacken half a turn.
Turn wheel hub at least 90
Tighten twelve-point nut:
Tightening torque:
50 Nm and torque a further 60
Note:
It is recommended to use the torque wrench
V.A.G 1756 for tightening the twelve-point nut.
------------ 42-74 ------------
Edition 06.05
S00.5103.68.20
OCTAVIA
42
Rear Wheel Suspension
Servicing drive shaft with CV joint
1 - Outer CV joint
must be replaced completely
removing Fig. 1
installing: drive onto the shaft with a
plastic hammer until the compressed
circlip expands
grease page 40-40
inspecting page 40-45
2 - Circlip
replace
insert in the groove on the shaft
3 - Thrust ring
fitting location Fig. 4
4 - Disc spring
fitting location Fig. 4
5 - Warm-type clamp
replace
tighten with tensioning pliers,
e.g. V.A.G 1682 Fig. 6
Special tools, testers and aids required
Circlip pliers, e.g. VW 161 A
Thrust plate MP 3-406
Thrust plate MP 3-407
Thrust plunger MP 3-448
Supporting sleeve MP 6-428
6 - Joint boot
material: Hytrel (Polyelastomere)
inspecting for tears and chafing points
7 - Warm-type clamp
replace
tighten Fig. 7
8 - Drive shaft (solid shaft)
assignment Spare Part catalogue
9 - Fillister head screw with internal serration, 40 Nm
M8 x 48
Clamping device MP 6-429
10 - Shim
Tensioning pliers, e.g. V.A.G 1682
11 - Warm-type clamp
replace
tighten Fig. 8
Torque wrench
Workshop press, e.g. V.A.G 1290 A
Notes:
Assignment of drive shafts
Spare Part catalogue
Grease joint if necessary, when replacing the
joint boot
12 - Joint boot for inner CV joint
material: Hytrel (Polyelastomere
inspecting for tears and chafing points
drive off with drift
13 - Disc spring
fitting location Fig. 3
Spread the grease filling evenly in the joint
boot
Edition 11.02
S00.5103.65.20
------------ 42-75 ------------
42
OCTAVIA
Rear Suspension
14 - Inner CV joint
always replace complete
pressing off Fig. 2
pressing on Fig. 5
greasing page 42-76
inspecting page 40-46
15 - Gasket
bonded surface at CV joint must be
free of oil and grease
replace
pull off protective sheet and stick gasket into inner joint
16 - Circlip
replace
use circlip pliers, e.g. VW 161 A, for
removing and installing
Grade and quantities of grease
Note:
CV joints are packed with normal-temperature grease, e.g. N 052 738.00.
Outer joint
Grease
Total qty.
Joint
Joint boot
90
90
40
50
120
50
70
mm
Inner joint
100
K Fig. 1
-
------------ 42-76 ------------
of which in:
[g]
[g]
[g]
Removing outer CV joint
Knock joint off drive shaft by striking firmly
with a plastic-headed hammer.
Edition 08.01
S00.5103.62.20
OCTAVIA
42
Rear Suspension
Notes:
Knock joint boot off first of all with a drift.
Support ball hub.
p osition
at inner
1 - Dished washer
and
1 - Dished washer
p osition
at outer oint
2 - Thrust ring
Edition 11.99
S00.5103.57.20
------------
------------
42
Rear Wheel Suspension
K Fig. 5
OCTAVIA
Pressing in inner CV joint
Note:
Chamfer on inner diameter of the ball hub (serration) must point toward the bearing collar of
the drive shaft.
-
Press in the joint up to the stop
Compressing the circlip.
Notes:
In view of the hard material (as opposed to
rubber) of the joint boot, which requires the
use of a stainless steel warm-type clamp, it
can only be tightened with tensioning pliers,
e.g. V.A.G 1682.
Tightening torque: 20 Nm
Use a torque wrench.
Make sure the thread of the spindle -A- of
the tensioning pliers is smooth . If necessary
grease with Molykote MOS2.
If it is not smooth, e.g. if the thread is dirty,
the necessary tensioning force of the warmtype clamp is not reached at the given torque.
K Fig. 6
Tighten warm-type clamp at outer
joint (large diameter)
Position the tensioning pliers, e.g. V.A.G
1682, as shown in the Fig. Make sure the
cutting edges of the pliers are positioned in
the corners -arrows B-. of the warm-type
clamp.
Tighten the warm-type clamp by turning the
spindle with a torque wrench (do not tilt the
pliers during this process).
A - Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
77 /
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Rear Wheel Suspension
at outer
K
-
at inner
K
-
Edition 11.02
S00.5103.65.20
------------
------------
OCTAVIA
44
Wheels/tyres/vehicle measurement
Vehicle measurement
General points
The vehicle must only be measured up using
an axle measuring device which is authorised
for use by the vehicle manufacturer!
We recommend that one measures the front and
the rear axle during every vehicle measurement
operation.
Correct driving behaviour cannot be guaranteed
otherwise!
Comments:
It is only meaningful to measure up the vehicle once it has driven its first 1000 to 2000
km. since it is only then that the helical
springs have settled into place.
One should always seek to precisely obtain
the nominal values in each case when making adjustments.
The basic setting should be undertaken after measuring up the axles on vehicles with
ESP, Function 04, Group 060 Page 45-124.
If the installed position of the rear axle and thus
the running direction of the vehicle is not taken
into account then a tilted steering wheel can be
the result.
Removing and installing the steering wheel
Body work; Re. Gr. 69
The necessity for undertaking a vehicle
measurement exists when:
There is some deficiency in the driving characteristics of the vehicle;
There is damage to the vehicle due to an
accident and parts had to be replaced;
Parts of the axle have been removed;
There is one-sided wear on the tyres.
Component on the front
axle replaced
Axle guide
Wheel bearing housing
Measurement
necessary
Yes
X
No
Component on the rear
axle replaced
Shock absorber
Helical spring
Measurement
necessary
Yes
Track rod/track rod end
Rear axle complete
Assembly carrier
Suspension strut
Transverse control arm below 1)
Transverse control arm above 1)
Steering gear
1)
Assembly carrier 1)
Trailing arm 1)
No
X
Only for vehicles with four-wheel drive
Edition 06.02
S00.5103.64.20
------------ 44-1 ------------
44
-
!"#$%&' (! )*+,
OCTAVIA
l Establishment of the chassis design according to the vehicle data carrier
Page 00-4
l The wheel suspension, wheel bearings,
steering and steering linkage have been
checked for inadmissibility high levels of play
and damage and have been repaired if necessary.
l The tyre pressure has been checked and
corrected as necessary.
Inspection and Maintenance; or a sticker on
the vehicle
l The tyre profiles have been checked.
The difference between the left and right
hand tyres on a given axle should not exceed 2 mm.
l The empty weight of the vehicle has been
checked according to the vehicles papers.
Empty weight:
The weight of a ready-to-operate vehicle with
a fully filled fuel tank as well as the water
reservoir for the windscreen/headlight washing system, spare wheel, tools and lifting jack
must be at the position specified by the vehicle manufacturer.
l The vehicle is aligned, rocked a number of
times to settle the springs and settled.
l Make sure that no sliding base and turning
plate has reached its end position during the
measurement process.
l The steering wheel must be in the position
required to drive straight ahead.
------------
------------
S00.5103.64.20
OCTAVIA
44
Wheels/Tyres/Chassis Alignment
Attention!
l For correct fitting and adjustment of the
wheel-alignment analyser, strictly adhere to
the operating instructions of the equipment
manufacturer!
If necessary, ask the manufacturer of your
wheel-alignment analyser to instruct you on
its use.
The wheel-alignment platform and wheelalignment analyser/analysing computer may
in the course of time vary from their original
levelling/setting.
The wheel-alignment platform and wheelalignment analyser/analysing computer
should at least once per year, as part of
the routine maintenance, be checked and
if necessary adjusted in accordance with
the data specified in the operating instructions of the equipment manufacturer!
These highly sensitive apparatus should
be treated carefully and scrupulously!
Measuring preparations
The lateral rim runout present must be compensated, otherwise an incorrect measurement result is obtained.
A correct toe-in setting is not possible without rim runout compensation!
Make sure to observe the relevant instructions
of the wheel-alignment analyser manufacturer.
-
Perform rim runout compensation.
Lower vehicle and bounce.
K-
Edition 12.98
S00.5103.55.20
Use brake-pedal arrester, e.g. V.A.G 1238
/B.
------------
------------
44
Wheels/Tyres/Vehicle Alignment
OCTAVIA
Overview of procedure for checking vehicle
alignment
It is essential to observe the following sequence of steps!
1 - Find out which suspension is fitted to the
vehicle.
You can find this information on the vehicle data sticker page 00-4.
2 - Inspect camber at front suspension, centre if necessary page 44-2.4.
3 - Inspect camber at rear suspension
page 44-2.5.
4 - Inspect toe at rear suspension, centre/
set if necessary page 44-2.5.
FWD models:
The toe of the rear suspension cannot be
set, but only centred.
4x4 models:
The toe of the rear suspension can be
set.
5 - Inspect toe at front suspension, set if necessary page 44-2.6.
The following general rule applies!
If one of the measurements obtained is not within
the tolerance, it is necessary to check the lateral inclination of the vehicle before carrying out
the setting page 44-2.3.
Suspension designations
page 00-4
Specifications for vehicle alignment
Specifications for front suspension
page 00-1
Specifications for rear suspension
page 00-3 and page 00-3.2
------------ 44-2.2 ------------
Edition 11.99
S00.5103.57.20
OCTAVIA
44
Wheels/Tyres/Chassis Alignment
Inspecting the vehicles transversal
inclination
Zero position transversal inclination of vehicle
If the measured values fall outside the tolerances of the front and rear axle nominal values ( page 00-1), this may be caused by
the inclined position of the vehicle.
Right-hand drive vehicles or vehicles with automatic transmission may exhibit a slight inclination.
This is normal and is due to the fitting position
of the assemblies and the associated weight
transfer.
-
Bounce vehicle several times and allow to
settle.
Note:
Dimension a to be determined only on the rear
axle.
K-
Determining dimension a for the left and
right vehicle side.
aleft - left vehicle side
aright - right vehicle side
= 90
Compare dimensions aleft and aright.
The deviation between aleft and aright should
not exceed 5.0 mm in either direction.
Correct deviations that fall outside the
5.0 mm tolerance.
If the positive tolerance is exceeded, e.g.
+ 8.0 mm, the deviation shall be corrected
on the rear axle by placing weights in the
bootspace on the relevant side.
Edition 12.98
S00.5103.55.20
------------
------------
44
OCTAVIA
Wheels/Tyres/Chassis Alignment
If the negative tolerance is exceeded, e.g.
-8.0mm, the deviation shall be corrected on
the front axle by placing weights on the relevant suspension strut dome in the bootspace
Sandbags of approx. 10 kg can be used as
weight.
Inspecting front suspension camber, center if necessary
The camber cannot be aligned but only
centered!
If the values are out of tolerance, first the transversal inclination must be inspected and compensated if necessary page 44-2.3
Uniform centering of the camber to bring it within
the tolerance range is only possible by shifting
the assembly support.
K-
Loosen screws -1- and -2-.
Shift the assembly support until a uniform
camber is obtained on both sides.
Subsequently check the castor offset.
The caster offset may have changed due
to the shifting of the assembly support.
Screw down the assembly support using new
screws.
Tightening torques:
------------ 44-2.4 ------------
Assembly support on body
screw postion -1Use new screws!
100 Nm + 90
Assembly support on body
screw postion -2Use new screws!
100 Nm + 90
Edition 12.98
S00.5103.55.20
OCTAVIA
44
Wheels/Tyres/Vehicle Alignment
Inspecting camber at rear suspension
The camber cannot be set.
If the measurements are not to tolerance, it is
first of all necessary to check the lateral inclination and to equalise this page 44-2.3.
If the measurements are still not within the permissible tolerance, inspect the axle beam for
damage and replace, if necessary.
Inspecting toe at rear suspension,
centring/setting if necessary
If the measurements are not to tolerance, it is
first of all necessary to check the lateral inclination and to equalise this page 44-2.3.
FWD models
It is not possible to set the total toe of the rear
suspension.
It is possible to uniformly centre the individual
toe settings only by altering the position of the
bearing brackets.
K-
Slacken all the bolts of the bearing bracket
-1-.
Move bearing bracket -1- in transverse direction.
2 - Rear axle beam
Tighten the bolts fully to 30 Nm + 90.
Always use new bolts!
If the measurements obtained are still not within
the permissible tolerance, inspect the axle beam
for damage and replace, if necessary.
4x4 models
The toe of the rear suspension can be set.
K-
Slacken all the bolts of the bearing bracket
-1-.
Move bearing bracket -1- in transverse direction.
2 - Trailing arm
Edition 11.99
S00.5103.57.20
Tighten the bolts fully to 75 Nm.
Always use new bolts!
After setting the individual wheel toe, inspect
total wheel toe.
Total wheel toe must equal the specification
page 00-3.2.
------------ 44-2.5 ------------
44
OCTAVIA
Wheels/Tyres/Chassis Alignment
Inspecting front suspension track,
align if necessary
If the values are out of tolerance, first the transversal inclination must be inspected and compensated if necessary page 44-2.3.
K-
Loosen locknut -1-.
Align front end by moving the left and/or right
tie rods.
For this, an open-end spanner can be used
on the hexagon of the tie rod (see arrow).
Make sure that the bellows are not twisted
after moving the tie rods!
Twisted bellows wear rapidly.
-
Tighten locknut -1- with 50 Nm and again
check the track width.
After tightening locknut -1- the set value may
have changed slightly.
Make sure that this value always lies within the
nominal value tolerance. If this is not the case,
the front-end alignment must be repeated.
Inspecting steering angle left and
right
This inspection only needs to be carried out:
if the steering angles, starting from the steering centre, vary more than 2,
if on one side there is contact between the
tyres and the front-axle or body components
with maximum steering angle,
if there is a difference between the turning
clearane circle left/right.
------------
------------
Edition 12.98
S00.5103.55.20
OCTAVIA
44
Wheels/Tyres/Chassis Alignment
K The distance between front-axle components
and tyres (arrow) must be the same on both
sides with maximum steering angle.
If this is not the case, the distance can be corrected by moving the left and right tie rods.
Example:
Distance between front-axle components and
tyres is smaller on the right side than on the left.
-
Loosen locknuts of tie rods.
Move left tie rod (screw out of tie-rod end)
Move right tie rod over same distance in opposite direction (screw into tie-rod end).
Check total track.
After this alignment the total track must
correspond with the nominal value specified!
Tighten locknuts with 50 Nm.
After tightening the locknuts the set value may
have changed slightly.
Make sure that this value always lies within the
nominal value tolerance. If this is not the case,
the total track alignment must be repeated.
Make sure that the bellows are not twisted
after moving the tie rods!
Edition 12.98
S00.5103.55.20
------------
------------
44
Wheels/Tyres/Chassis Alignment
OCTAVIA
Arithmetical determination of rolling direction deviation of rear suspension
Note:
The values below are only given by way of example.
-
For track values with the same sign (+/+ or -/-), substract the smaller value and divide by 2.
Track value for rear left wheel
Track value for rear right wheel
+15
+5
15 - 5 = 10
10 : 2 = 5
Rolling direction deviation = 5
-
Values with different signs (+/-) are added together and the sum is divided by 2.
Track value for rear left wheel
Track value for rear right wheel
+15
-5
15 + 5 = 20
20 : 2 = 10
Rolling direction deviation = 10
The result thus obtained is the actual rolling direction deviation of the longitudinal vehicle axis.
------------
------------
Edition 12.98
S00.5103.55.20
OCTAVIA
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Because of design variations the disc wheel
and wheel trim cap may differ from the figure.
When using anti-theft wheel bolts, the antitheft bolt must be as close as possible to the
valve.
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------------ 44-3 ------------
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OCTAVIA
Note:
Light alloy wheel and wheel trim may differ in
appearance from the illustration as a result of
design modifications.
6J x 15 H2, offset 38
6J x 15 H2, offset 43
6J x 16 H2, offset 42
Contained in car tool kit
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flange
,
Fit only valve as specified in Parts List
------------
------------
S00.5103.56.20
OCTAVIA
Anti-Lock Brake System
Anti-lock brake system (ABS)
ITT Mark 20 IE
45
Safety precautions, basic information on fault finding and on servicing ABS and ABS/EDL ITT Mark
20 IE
The ABS, ABS/EDL are vehicle safety
systems; system knowledge is required for
working on such systems.
K Faults are indicated by the ABS warning light
(K47) -1- and the red warning light for handbrake/brake fluid level (K14/33) -2- coming
on. Certain faults are not detected until after
a minimum speed of 20 km/h has been
exceeded (conduct a road test).
If the ABS warning light -K47- and handbrake/brake fluid warning light -K14/33- do
not come on and the brake system is
nevertheless not fully operational, look for
the fault in the conventional brake system
from page 46-1 and from page 47-1.
Notes on rectifying current faults
Technical Service Handbook and
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
Notes on repair work on ABS and
ABS/EDL IT Mark 20 IE
Before commencing work on the ABS system,
it is necessary to interrogate the fault memory
in order to be able to check complaints and
conduct specific fault finding.
Do not separate plug connections unless the
ignition is switched off.
Before commencing work on the ABS, ABS/
EDL, switch off ignition and disconnect the
earth strap at the battery. On models fitted
with coded radio set, pay attention to coding;
determine if necessary.
Welding work using electric welding equipment may affect the ABS, ABS/EDL system.
Edition 06.99
S00.5103.56.20
------------ 45-1 ------------
45
Anti-Lock Brake System
OCTAVIA
Before carrying out welding work with electric welding equipment:
-
Disconnect the negative terminal of the
battery and cover over the negative pole
of the battery; remove battery if necessary.
Connect the earth connection of the electric welding equipment directly to the part
to be welded. There must not be any electrically insulated parts between the earth
connection and the welding point.
Do not allow electronic control units and
electric wiring to come into contact with
the earth connection or the welding electrode.
Do not drive the vehicle with the connector
unplugged from the control unit.
The only work which may be carried out on
the hydraulic control unit are the repair measures stated in this manual.
Scrupulous cleanliness is essential when
working on the anti-lock brake system. On
no account, use products containing mineral
oils, such as oils, grease etc.
Thoroughly clean connection points and the
surrounding area before disconnecting, but
do not use any aggressive cleaning products, such as brake cleaner, petroleum, thinner or similar products.
Place removed parts down on a clean surface and cover over.
Fit on the transport protection for the valve
domes after separating the control unit/hydraulic unit.
Carefully cover over or seal open components if repairs are not carried out immediately (use the plugs from repair kit 1H0 698
311 A).
Do not use any fluffing cloth.
Do not remove replacement parts from their
wrapping until just before installing.
Use only genuine, wrapped parts.
If the system is opened, avoid working with
compressed air and avoid moving the vehicle.
Ensure that no brake fluid flows into the connectors.
------------ 45-2 ------------
Edition 03.97
S00.5103.52.20
OCTAVIA
45
Anti-Lock Brake System
Pay attention to the applicable instructions
when handling brake fluid
from page 47-18.
After completing work which involved opening the brake system, bleed brake system
with the brake filling and bleeding appliance,
e.g. ROMESS S15 page 47-18.
When carrying out the final road test, ensure
that a controlled brake application is carried
out at least once (pulsing at the brake pedal
must be felt).
Technical information required
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
Self Study Programme No. 26: Vehicle
safety - new technical information
Technical Service Handbook
Edition 04.00
S00.5103.58.20
------------
------------
OCTAVIA
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K Distinguishing features:
Dimension A: 100 mm
8 valve domes: The protective sleeves for
the valves are visible if the control unit is
separated from the hydraulic unit page
45-57.
Control unit identification
The control unit version appears in the
display of V.A.G 1552. Select function 01
Interrogating control unit version for this
purpose page 45-9.
ABS without CAN-BUS
ABS with CAN-BUS
0
List of available functions page 45-12.
------------ 45-4 ------------
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
ABS/EDL ITT Mark 20 IE
K Recognition features:
Dimension A: 130 mm
10 valve domes: The protective sleeves for
the valves are visible when the control unit
is separated from the hydraulic unit page
45-57.
Control unit identification
The control unit identification appears in the
display of V.A.G 1552. Select function 01 Interrogate control unit version for this purpose page 45-9.
ABS/EDL without CAN-BUS
ABS/EDL with CAN-BUS
Parts List
List of available functions page 45-12.
Installation position of ABS or ABS/
EDL ITT Mark 20 IE
K LHD models
1 - Brake servo unit 10
2 - Hydraulic unit
3 - Control unit, 25-pin
bolted to hydraulic unit
K RHD models
1 - Brake servo unit 7/8
2 - Hydraulic unit
3 - Control unit, 25-pin
bolted to hydraulic unit
Edition 11.99
S00.5103.57.20
------------ 45-5 ------------
45
Anti-Lock Brake System
OCTAVIA
Self-diagnosis
Function of self-diagnosis
Models fitted with data BUS (CAN-BUS)
In view of the various control units which are interlinked over a databus
line, the first step when commencing fault finding is always to interrogate
the contents of the fault memories of the control units fitted to the vehicle.
This is done with the Automatic test sequence which is activated with
the key function 00.
The point to verify here is whether a fault which may be stored, could
have an effect on the ABS system.
All models
The 25-pin ABS control unit (J104), together with the hydraulic unit, forms
a compact unit. The unit is located in the left of the engine compartment.
The control unit is equipped with a fault memory. The connection for selfdiagnosis is located in the storage compartment on the drivers side.
Self-diagnosis relates to the electrical/electronic part of the ABS, in other
words faults are detected only over the electrical connection to the control unit (e.g. open circuit of a wheel speed sensor).
The control unit detects faults during operation of the vehicle and stores
them in a permanent memory. This information is retained even if the
battery voltage is disconnected.
Faults which occur sporadically are likewise detected and stored. If this
fault no longer occurs during 50 vehicle starts and starting-off operations,
it is erased in the fault memory (fault delete counter), with the exception
of the fault Control unit defective.
After the ignition is switched on, the ABS warning light (K47) and the red
warning light for handbrake/brake fluid level (K14/33) come on for about
2 seconds.
During this period a self-check is performed in the control unit with the
following functions:
Test of supply voltage, min. 10.0 V.
Test of control unit including valve coils.
Check of coding of control unit.
Static test of wheel speed sensors (without wheel speed signal).
If, after starting off and reaching a vehicle speed of about 20 km/h, it is
found that the wheel speed signal is not o.k., the ABS warning light
-K47- comes on again.
When commencing fault finding, always initiate self-diagnosis and interrogate the information stored with the
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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Anti-Lock Brake System
system tester .
or
reader .
Notes:
The description which follows relates only to the vehicle system
tester V.A.G 1552 using the current programme card.
Use of the fault reader V.A.G 1551 with integrated printer is similar.
Slight differences in the readouts which appear in the display are
possible.
To end self-diagnosis or to switch to another address word, select
function 06 End output.
The faults presented can be identified by referring to the fault table,
and then conducting fault rectification.
means
and
Edition 06.99
S00.5103.56.20
------------
------------
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K If the ABS warning light goes out, but the
handbrake/brake fluid level warning light
(K14/33) -2- remains on, the causes of the
fault may be:
a - the handbrake is still applied
b - the brake fluid level is too low
c - there is a fault in the wiring
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
If the ABS warning light -1- and the handbrake/brake fluid level warning light -2- do
go out, the ABS and EBD (electronic brake
pressure distribution) systems have then
failed.
d - switch -F9- for the warning light -K14/33is faulty or incorrectly set.
() )
Vehicle system tester V.A.G 1552
Diagnosis cable V.A.G 1551/3
-)
When dealing with such a complaint, a possible
cause of the fault may be that the brake light
switch is incorrectly set or not operating page
45-24, Reading measured value block, display
group number 003 and page 45-69, Setting
brake light switch.
------------
------------
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
Performing self-diagnosis
Test requirements
l Approved tyre size fitted to all wheels; tyres
inflated to the specified pressure.
l Mechanical/hydraulic part of brake system
together with brake light switch and brake
lights operating properly.
l No leaks in hydraulic connections and lines
(visual inspection of hydraulic unit, brake
calipers, wheel brake cylinders, tandem
brake master cylinder).
l Wheel bearings and wheel bearing play o.k.
l Control unit correctly bolted to hydraulic unit.
l Plug connection at control unit (J104) correctly plugged in (lock is engaged).
l Inspect plug contacts of ABS components
for damage and correct fitting.
l All fuses according to current flow diagram
o.k. (as a check, remove fuses from fuse
box).
l Supply voltage o.k. (at least 10.0 V).
Connecting vehicle system tester
V.A.G 1552 and selecting function
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3
Edition 04.00
S00.5103.58.20
------------ 45-9 ------------
45
OCTAVIA
Anti-Lock Brake System
Notes:
The ABS function in the control unit is
switched off during self-diagnosis.
The fault memory can be erased after completing repairs and interrogating memory.
K-
Switch off ignition (if not already off) and connect vehicle system tester V.A.G 1552 to the
diagnosis connection using diagnostic cable
V.A.G 1551/3.
Interrogating control unit version
Test of vehicle systems
Enter address word XX
HELP
K Readout in display:
If no readout appears in the display, inspect plug
connection for self-diagnosis, Electrical Test
from page 45-41, test steps 14 and 15.
Notes:
Depending on the programme, additional
user information can be displayed by pressing the HELP key of V.A.G 1552.
The key is used for moving forward within
the test programme.
Test of vehicle systems
Enter address word XX
------------
------------
HELP
Switch on ignition.
K Readout in display:
-
Press keys 0 and 3 for the address word
Brake electronics and confirm the entry with
the key Q.
Edition 04.00
S00.5103.58.20
OCTAVIA
1J0907379 ABS ITT AE 20 Gl
Coding 03604
V00
WSC XXXXX
K The following readout then appears (example):
What is displayed is:
the control unit identification number, e.g.
1J0907379
the system designation, e.g.
ABS ITT AE 20 GI
the number of the version, e.g. V00
the code No. of the control unit, e.g. 03604
the workshop code (WSC)
Operating instructions of vehicle system
tester V.A.G 1552
1J0907379 H ABS/EDL 20 IE CAN 0001
Coding 13504
WSC XXXXX
K The following readout then appears (example):
1J0907379 C ABS FRONT MK60
Coding 0001025
K The following readout then appears (example):
0102
WSC XXXXX
! "
Assignment of control unit
Parts List
Coding control unit page 45-22.
If the control unit identification number does not
appear page 45-12, List of available functions.
S00.5103.59.20
------------ 45-11 ------------
45
Anti-Lock Brake System
-
OCTAVIA
Press key.
Note:
A list of the possible functions is displayed after
pressing the HELP key:
The programme returns to the initial position
after pressing the key.
Test of vehicle systems
Select function XX
HELP
K Readout in display:
page 45-12, List of available functions.
List of available functions
00 -
Automatic test sequence
02 -
Interrogating fault memory
04 -
Initiating basic setting 1)
01 03 05 -
45-10
Final control diagnosis
45-29
45-12
45-36
Erasing fault memory
45-21
Coding control unit
45-22
Ending output
08 -
Reading measured value block
1)
45-13
Interrogating control unit version
06 -
07 -
Page
45-22
45-24
is required only for models fitted with EDL
Interrogating fault memory
Test of vehicle systems
Select function XX
HELP
X faults recognized!
No fault recognized!
K Readout in display:
Press keys 0 and 2 for the function Interrogate fault memory and confirm the entry with
the key Q.
K The number of stored faults or No fault recognized appears in the display.
Press key.
The faults stored are displayed one after the
other.
------------ 45-12 ------------
Edition 06.99
S00.5103.56.20
OCTAVIA
-
Look in the fault table to find the fault message displayed page 45-14. In the case
of MK 60 page 45-183.
In the same way as when No fault recognized! is displayed, the programme returns
key is
to the initial position when the
pressed:
Test of vehicle systems
Select function XX
HELP
K Readout in display:
-
End output (function 06) page 45-22.
Switch ignition off and separate diagnostic
plug connection.
Notes:
If a fault has been recognized:
1. Rectify fault (repair)
2. Interrogate fault memory (function 02)
3. Erase fault memory (function 05)
4. End output (function 06)
5. Conduct road test
6. Once again interrogate fault memory.
Note:
With the automatic test sequence the contents
of all the fault memories of the control units are
interrogated.
-
Test of vehicle systems
Select function XX
HELP
1J0907379 H ABS/EDL 20 IE CAN 0001
Coding 13504
WSC XXXXX
Switch ignition on.
K Readout in display:
-
Press key 0 twice for the function Automatic
test sequence and confirm the entry with
the key Q.
K The control unit identification appears in the display.
After this, all the control unit identifications appear in the display together with any entries from
the fault memories.
-
S00.5103.59.20
End output (function 06) page 45-22.
------------ 45-13 ------------
45
OCTAVIA
Anti-Lock Brake System
Fault table
Notes:
In view of the control units which are interlinked over a databus line, always commence fault finding by
initiating the Automatic test sequence with the key function 0 and 0 at all the control units fitted to the
vehicle. This interrogates the control unit fitted to the vehicle and any faults which may be stored in them.
All the possible faults which can be detected by the ABS control unit (J104) and displayed on V.A.G 1552,
are listed below according to the 5-digit fault code.
In addition, the fault type may also be indicated in the fault table.
Reference is made in the column Rectifying fault to individual test steps of the electrical test.
Before replacing components indicated as faulty, test the appropriate plug connections, cables and earth
connections according to the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
After completing repairs, always once again interrogate and then erase the fault memory with the vehicle
system tester V.A.G 1552, and conduct a road test (at a speed of more than 20 km/h).
After conducting the road test, once again interrogate the fault memory.
Readout in display of
V.A.G 1552
Possible cause of fault
No fault recognized
If no fault recognized appears after completing repairs, self-diagnosis is ended.
Rectifying fault
If the ABS does not operate properly although no fault recognized is displayed, then
proceed as described below:
1. Conduct a road test at a speed of more than 20 km/h.
2. Once again interrogate the fault memory; if no fault is again stored.
3. Continue fault finding without self-diagnosis and work through the electrical test in full
page 45-41.
00283
Front left wheel speed sensor
-G47
------------ 45-14 ------------
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G47and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Damage to pulse rotor or speed
sensor -G47
Coil of speed sensor -G47- faulty
- Inspect speed sensor -G47- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G47 page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-57
Edition 06.99
S00.5103.56.20
OCTAVIA
Readout in display of
V.A.G 1552
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G47and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Electrical interference because of
external sources (high-frequency
interference, e.g. ignition cable not
insulated)
- Read measured value block page 45-24,
display group number 001
Damage to pulse rotor or speed
sensor -G47
- Inspect speed sensor -G47- and pulse rotor
for damage
Air gap between speed sensor -G47and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G47 page 45-60 and 45-65
Air gap between speed sensor -G47and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G47and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-24,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-57
00283
Front left wheel speed sensor
-G47
Signal not to tolerance1)
00283
Front left wheel speed sensor
-G47
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
Edition 06.99
S00.5103.56.20
------------ 45-15 ------------
45
OCTAVIA
Anti-Lock Brake System
Readout in display of
V.A.G 1552
Possible cause of fault
Rectifying fault
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G45and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Damage to pulse rotor or speed
sensor -G45
Coil of speed sensor -G45- faulty
- Inspect speed sensor -G45- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G45 page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-57
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G45and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Electrical interference because of
external sources (high-frequency
interference, e.g. ignition cable not
insulated)
- Read measured value block page 45-24,
display group number 001
Damage to pulse rotor or speed
sensor -G45
- Inspect speed sensor -G45- and pulse rotor
for damage
Air gap between speed sensor -G45and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G45 page 45-60 and 45-65
Air gap between speed sensor -G45and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G45and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-24,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-57
00285
Front right wheel speed sensor
-G45
00285
Front right wheel speed sensor
-G45
Signal not to tolerance1)
00285
Front right wheel speed sensor
-G45
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
------------ 45-16 ------------
Edition 06.99
S00.5103.56.20
OCTAVIA
Readout in display of
V.A.G 1552
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G44and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Damage to pulse rotor or speed
sensor -G44
Coil of speed sensor -G44- faulty
- Inspect speed sensor -G44- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G44 page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-57
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G44and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Electrical interference because of
external sources (high-frequency
interference, e.g. ignition cable not
insulated)
- Read measured value block page 45-24,
display group number 001
Damage to pulse rotor or speed
sensor -G44
- Inspect speed sensor -G44- and pulse rotor
for damage
Air gap between speed sensor -G44and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G45 page 45-60 and 45-65
Air gap between speed sensor -G44and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G44and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-24,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-57
00287
Rear right wheel speed sensor
-G44
00287
Rear right wheel speed sensor
-G44
Signal not to tolerance1)
00287
Rear right wheel speed sensor
-G44
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
Edition 06.99
S00.5103.56.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Readout in display of
V.A.G 1552
Possible cause of fault
Rectifying fault
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G46and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Damage to pulse rotor or speed
sensor -G46
Coil of speed sensor -G46- faulty
- Inspect speed sensor -G46- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G46 page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-57
00290
Rear left wheel speed sensor
-G46
00290
Rear left wheel speed sensor
-G46
Signal not to tolerance1)
00290
Rear left wheel speed sensor
-G46
Mechanical fault1)
1)
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G46and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Electrical interference because of
external sources (high-frequency
interference, e.g. ignition cable not
insulated)
- Read measured value block page 45-24,
display group number 001
Damage to pulse rotor or speed
sensor -G46
- Inspect speed sensor -G46- and pulse rotor
for damage
Air gap between speed sensor -G46and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G46 page 45-60 and 45-65
Air gap between speed sensor -G46and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G46and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-24,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-57
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
------------
------------
Edition 06.99
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OCTAVIA
45
Anti-Lock Brake System
Coding table
Engine
identification
letters
Engine
Model year code number
ABS variant
1997
1998
1999
AMD
1.4 l/44 kW
ABS
03604
AMD
1.4 l/44 kW
ABS/EDS
03604
AEE
1.6 l/55 kW
ABS
03604
03604
03604
AEE
1.6 l/55 kW
ABS/EDS
03604
03604
03604
AEH
1.6 l/74 kW
ABS
03604
03504
03504
AEH
1.6 l/74 kW
ABS/EDS
03604
13504
13504
AGN
1.8 l/92 kW
ABS
03604
03504
03504
AGN
1.8 l/92 kW
ABS/EDS
03604
13504
13504
AGU
1.8 l/110 kW
ABS
03504
03504
AGU
1.8 l/110 kW
ABS/EDS
13504
13504
AGP
1.9 l/50 kW
ABS
03604
03604
03304
AGP
1.9 l/50 kW
ABS/EDS
03604
03604
03304
AGR
1.9 l/66 kW
ABS
03604
03504
03304
AGR
1.9 l/66 kW
ABS/EDS
03604
13504
13304
AHF
1.9 l/81 kW
ABS
03604
03504
03304
AHF
1.9 l/81 kW
ABS/EDS
03604
13504
13304
1J0 907 379A ABS/EDS ITTAE 20 GI V00
Coding 03604
WSC XXXXX
Test of vehicle systems
Select function XX
Edition 12.98
S00.5103.55.20
HELP
K The control unit coding is shown in the display,
e.g. 03604:
Press key.
K Readout in display:
------------
------------
45
Anti-Lock Brake System
OCTAVIA
Press the keys 0 and 6 for the function End
output and confirm entry with the key Q.
Notes:
If the control unit is incorrectly coded, the
ABS warning lamp (K47) and the handbrake/
brake fluid level warning lamp -K14/33- come
on and remain on.
At the same time a fault is entered into the
fault memory page 45-12, Interrogating
fault memory (02).
If the coding is accepted, no fault is entered
into the fault memory and the ABS warning
lamp does not flash.
If the control unit is not coded (code 00000),
the ABS warning lamp (K47) and the handbrake/brake fluid level warning lamp -K14/
33- flash (once a second).
------------
------------
Edition 12.98
S00.5103.55.20
OCTAVIA
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
Open circuit, short circuit to positive
or to earth in wiring
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Control unit -J104- incorrectly coded
Bridge in multipin connector to
control unit -J104- from contact 3 to
contact 14 open circuit or short
circuit
- Check coding of control unit -J104- page
45-22.
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Electrical interference caused by
external sources (high-frequency
interference, e.g. ignition cables not
insulated)
- Erase fault memory
- Conduct road test at more than 20 km/h
- Once again interrogate fault memory
Open circuit, short circuit to positive
or to earth in wiring
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-57
ABS hydraulic pump -V64
Plug connection of el. motor to
control unit
- Perform final control diagnosis page 45-29
Signal out of tolerance1)
Open circuit, short circuit to positive
or to earth in wiring
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Hydraulic pump -V64- faulty
- If hydraulic pump -V64- starts properly when
conducting test step 18 in electrical test
page 45-41, replace control unit -J104-
ABS control unit -J104- faulty
- Replace control unit -J104- page 45-57
Readout in display of
V.A.G 1552
00668
System voltage terminal 30
Signal out of tolerance
01044
Control unit incorrectly coded
01130
ABS operation
Implausible signal1)
01276
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
Edition 06.99
S00.5103.56.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Readout in display of
V.A.G 1552
Possible cause of fault
Rectifying fault
ABS control unit -J104- incorrectly
coded
Engine control unit incorrectly coded
- Check coding of control unit -J104- page
45-22
- Check coding of engine control unit
Repair Group 01 of relevant engine
Open circuit, short circuit to positive
or to earth in wiring
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Ignition/starter switch rotates too
slowly
- Erase fault memory page 45-21
- No further measures necessary
- Inform customer
01312
Data BUS drive defective1)
or:
Data BUS drive defective1)
sporadically
01314
Engine control unit
no communication
01315
Gearbox control unit2)
no communication
01316
Brake control unit
no communication
1)
2)
Open circuit, short circuit to positive
or to earth in data BUS wiring
- Test wiring and plug connections of data
BUS cables according to current flow
diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Open circuit, short circuit to positive
or to earth in data BUS wiring
- Test wiring and plug connections of data
BUS cables according to current flow
diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
Open circuit, short circuit to positive
or to earth in data BUS wiring
- Test wiring and plug connections of data
BUS cables according to current flow
diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-41
The fault Data BUS drive defective does not cause the ABS warning light -K47- or the handbrake/brake fluid level
warning light -K14/33- to come on. The full ABS function is retained in this case.
Only on models fitted with automatic gearbox.
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
Readout in display of
V.A.G 1552
Rectifying fault
Fault entered in engine control unit
- Read fault memory of the engine control unit
Repair Group 01 of relevant engine
ABS control unit -J104- faulty
- Replace control unit -J104- page 45-57
65535
Control unit defective
Possible cause of fault
18256
Please read fault memory of
engine ECU
45
Anti-Lock Brake System
Erasing fault memory
Requirement:
l Fault memory has been interrogated.
-
Test of vehicle systems
Select function XX
Test of vehicle systems
Fault memory is erased!
Test of vehicle systems
Select function XX
Attention!
Fault memory was not interrogated
Edition 06.99
S00.5103.56.20
HELP
Press
key.
K Readout in display:
-
Press keys 0 and 5 for the function Erase
fault memory and confirm the entry with the
key Q.
K Readout in display:
-
HELP
Press
key.
K Readout in display:
Notes:
K If this readout appears in the display, then
the test sequence was incorrect.
Follow the test sequence exactly:
First of all, interrogate fault memory and then
erase it.
------------
------------
45
"
!
OCTAVIA
Anti-Lock Brake System
output
Test of vehicle systems
Enter address word XX
HELP
Press keys 0 and 6 for the function End
output and confirm the entry with the key Q.
K Readout in display:
-
Switch off ignition.
Separate plug connection to the vehicle
system tester.
Switch on ignition.
ABS warning light (K47) and handbrake/brake
fluid level warning light (K14/33) must go out
after about 2 seconds.
unit
testers and aids
Vehicle system tester V.A.G 1552
Diagnosis cable V.A.G 1551/3
The control unit fitted to the vehicle is coded.
New control units supplied through the Parts
Sector are not coded and must be re-coded after
being installed.
Coding is only possible if the workshop code
(WSC) is entered in V.A.G 1552.
Procedure
Test of vehicle systems
Select function XX
------------
------------
HELP
Determine the engine code letter and the type
of ABS hydraulic control unit fitted to the
vehicle.
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit
(address word 03) page 45-9; ignition
switched on for this step.
K Readout in display:
-
Press the keys 0 and 7 for the function Code
control unit and confirm the entry with the
key Q.
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
Code the control unit
Enter code number XXXXX
Q
(0-32767)
K Read out on display
-
Enter the relevant code number of the vehicle and confirm entry with Q button.
Table of codes page 45-23.
Table of codes
Code number - Model year
Engine code
letters
Engine
Variant ABS
AMD
1.4 l/44 kW
ABS
AMD
1.4 l/44 kW
ABS/EDS
AEE
1.6 l/55 kW
ABS
AEE
1.6 l/55 kW
ABS/EDS
AEH
1.6 l/74 kW
ABS
AEH
1.6 l/74 kW
ABS/EDS
AGN
1.8 l/92 kW
ABS
AGN
1.8 l/92 kW
ABS/EDS
AGU
1.8 l/110 kW
ABS
AGU
1.8 l/110 kW
ABS/EDS
AGP
1.9 l/50 kW
ABS
AGP
1.9 l/50 kW
ABS/EDS
AGR
1.9 l/66 kW
ABS
AGR
1.9 l/66 kW
ABS/EDS
AHF
1.9 l/81 kW
ABS
AHF
1.9 l/81 kW
ABS/EDS
AQY
2.0 l/85 kW
ABS
AQY
2.0 l/85 kW
ABS/EDS
ARX
1.8 l/110 kW
4x4
AGR
1.9 l/66 kW
4x4
ATD
1.9 l/74 kW
4x4
AZJ
2.0 l/85 kW
4x4
1997
1998
1999
2000
2001
03604
03604
03604
03604
03604
03604
03604
03604
03604
03604
03604
03604
03604
03504
03504
03504
03604
13504
13504
13504
03604
03504
03504
03604
13504
13504
03504
03504
03504
13504
13504
13504
03604
03604
03304
03304
03604
03604
03304
03304
03604
03504
03304
03304
03604
13504
13304
13304
03604
03504
03304
03304
03604
13504
13304
13304
03404
13504
13504
13504
13504
13504
13504
Vehicles without CAN-BUS
1J0907379 A ABS/EDS
Coding 03604
ITT AE 20GI V00
WSC XXXXX
K The control unit coding is shown on the display,
for example 03604:
Vehicles with CAN-BUS
1J0907379 H ABS/EDS
Coding 13504
Edition 04.03
S00.5103.66.20
20 IE
CAN 0001
WSC XXXXX
K The control unit coding is shown on the display,
for example 13504:
------------
------------
45
Anti-Lock Brake System
OCTAVIA
Continued for all models
Test of vehicle systems
Select function XX
HELP
Press key.
K Readout in display:
-
Press keys 0 and 6 for the function End
output and confirm the entry with the key Q.
Notes:
If the control unit is incorrectly coded, the
ABS warning light (K47) and the handbrake/
brake fluid level warning light (K14/33) come
on and remain on.
At the same time, an entry is made in the
fault memory page 45-12, Interrogating
fault memory (02).
If the control unit is coded with an approved
code, no fault entry is made in the fault memory and the ABS warning light does not
flash.
If the control unit is not coded (code 00000),
the ABS warning light (K47) and the handbrake/brake fluid level warning light (K14/33)
flash (once a second). No entry is made in
the fault memory in this case.
Reading measured value block
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnosis cable V.A.G 1551/3
The control unit is able to transmit a large
number of measured values. These measured
values supply information regarding the
operating state of the system or of the sensors
connected. In many cases, the measured values
transmitted can be used for assisting fault finding
and rectification of faults. As it is not possible to
assess all of these measured values at the same
time, they are combined into individual display
groups which can be selected by means of
display group numbers.
------------ 45-24 ------------
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
Safety precautions
If it is necessary to use test and measuring
equipment during a road test, pay attention to
the following procedure:
The test and measuring equipment should
always be attached to the rear seat and
operated from that point by a second person.
If the test and measuring equipment were
operated from the front passenger seat, this
could result in injury to the person occupying
that seat in the event of an accident if the
front passenger airbag is deployed.
Test procedure and test tables with measured values
-
Test of vehicle systems
Select function XX
HELP
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit
(address word 03) page 45-9; ignition
switched on for this step.
K Readout in display:
-
Press keys 0 and 8 for the function Read
measured value block and confirm the entry
with the key Q.
Testing wheel speed sensor assignment
Display group number 001:
K Readout in display:
Read measured value block
Enter display group number XXX
Read measured value block
1
2
3
Read measured value block
0 km/h
0 km/h
0 km/h
0 km/h
Edition 06.99
S00.5103.56.20
Press keys 0 and 1 for Display group number 01 and confirm the entry with the key Q.
K-
The measured value block is always composed of 4 display blocks -arrows- 1 to 4.
K Readout in display (vehicle stationary):
The momentary wheel speeds are displayed.
They are used for checking the assignment of
the wheel speed sensors to the wheels. (The
vehicle must be raised for this purpose and the
wheel rotated by hand).
------------ 45-25 ------------
45
OCTAVIA
Anti-Lock Brake System
Example:
Read measured value block
0 km/h
4 km/h
0 km/h
0 km/h
K Readout in display (wheel rotated):
The momentary speed of the front right wheel
is displayed.
The vehicle must be raised for this purpose and
the wheel rotated by hand by a second person.
Display
block
1
2
3
4
-
Designation
Front left wheel speed
(km/h)
Readout on
V.A.G 1552
0...255
Front right wheel speed
(km/h)
0...255
Rear right wheel speed
(km/h)
0...255
Rear left wheel speed
(km/h)
0...255
Press key C.
If the key is pressed, it is then necessary after
this to once again press keys 0 and 8 to return
to the procedure Read measured value block.
Test of wheel speed sensors
Display group number 002:
K Readout in display:
Read measured value block
Enter display group number XXX
Press keys 0 and 2 for the Display group
number 02 and confirm the entry with the
key Q.
The ABS control unit stores the first analysable
voltage signals from the wheel speed sensor
when starting off and displays these as fixed
values in the measured value block.
Read measured value block
1
2
3
K-
The measured value block is always composed of 4 display blocks -arrows- 1 to 4.
The readouts which appear in display blocks 1
and 2 must on no account be more than 6 km/h.
The readouts which appear in display blocks 3
and 4 must not be more than 2 km/h.
------------ 45-26 ------------
Edition 06.99
S00.5103.56.20
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OCTAVIA
45
Anti-Lock Brake System
If
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Edition 06.99
S00.5103.56.20
------------
------------
45
Anti-Lock Brake System
OCTAVIA
Testing the brake light switch for the ABS
and ABS/EDL function
Display group number 003
Read measured value block
Enter display group number XXX
Read measured value block
1
2
3
Read measured value block
0
K Readout in display:
Press keys 0 and 3 for Display group
number 03 and confirm the entry with the
key Q.
K-
There are always 4 display blocks -arrows1 to 4 in the measured value block.
K Readout in display:
Display
block
1
Test conditions
Brake pedal not
operated
Brake pedal operated
not assigned
not assigned
Readout
on V.A.G 1552
not op.
operated
not assigned
If the readout in V.A.G 1552 is -0- although the
footbrake is operated, or -1- although the
footbrake is not operated:
-
Perform electrical test from page 45-41.
It is also possible that the brake light switch is
not correctly set page 45-69.
-
------------ 45-28 ------------
Press the keys 0 and 6 for the function End
output and confirm the entry with the key Q.
Edition 11.99
S00.5103.57.20
OCTAVIA
45
Anti-Lock Brake System
Final control diagnosis
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnosis cable V.A.G 1551/3
Final control diagnosis is part of the electrical
test. Final control diagnosis is used for testing
the pump motor and also to check correct
operation of the hydraulic circuits (assignment
of brake pressure lines to the wheel brakes, and
also operation of the valves) to ensure they are
correctly connected and are not leaking.
Notes:
The vehicle must be raised so that the wheels
are clear of the ground (2nd person required
for rotating the wheels).
It is possible to quit the test procedure at any
time by pressing the key C.
After depressing the brake pedal several
times, the vacuum in the brake servo unit is
reduced. Greater effort is then required to
operate the brake pedal in order to achieve
the same fluid pressure in the brake system,
as with vacuum assistance.
Once the vacuum in the brake servo unit has
been reduced, it is possible that the wheels
do not lock start engine in order to build
up vacuum in the brake servo unit.
Operate vehicle system tester by referring
to the Readout in the display.
Example:
Readout in display of V.A.G 1552 during final
control diagnosis
(e.g. front left wheel, fl)
Final control diagnosis
IFL: VBAT OFL: 0V
Wheel FL locked
IFL = Inlet valve front left
VBAT = Battery voltage; voltage present at valve
Edition 06.99
S00.5103.56.20
------------ 45-29 ------------
45
OCTAVIA
Anti-Lock Brake System
OFL = Exhaust valve front left
0V = 0 volts; no voltage exists at valve
locked/free = Wheel status; has to be checked
by a 2nd person
Final control diagnosis
EDL valves / Hydr p : V BAT Wheel FL/FR lock
Hydr p = Hydraulic pump
Performing final control diagnosis
-
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit
(address word 03) page 45-9; ignition
switched on for this step.
Release handbrake.
Test of vehicle systems
Select function XX
Test of vehicle systems
03 - Final control diagnosis
HELP
K Readout in display:
-
Press keys 0 and 3 for the function Final
control diagnosis.
K Readout in display:
-
Confirm the entry with the key Q.
ABS hydraulic pump -V64- must run.
Note:
During the next steps the ABS warning light
flashes twice a second and the handbrake/brake
fluid warning light 4 times a second.
Final control diagnosis
ABS hydraulic pump -V64
Final control diagnosis
Operate brake
------------
------------
K Readout in display:
-
Press key within the next 60 seconds.
K Readout in display:
-
Operate the brake pedal.
Press key.
Edition 06.99
S00.5103.56.20
OCTAVIA
(
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Anti-Lock Brake System
, ()
45
K
If the wheel does not block, it is possible that
there is a fault in the mechanical/hydraulic part
of the brake system.
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If the wheel does not block, it is possible that
there is a fault in the mechanical/hydraulic part
of the brake system.
Edition 06.99
S00.5103.56.20
------------
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OCTAVIA
Anti-Lock Brake System
K
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If the wheel does not block, it is possible that
there is a fault in the mechanical/hydraulic part
of the brake system.
K
K
If the wheel
, it is possible that the brake
pressure lines to the wheel brakes are wrongly
connected.
K
------------
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not
Edition 06.99
S00.5103.56.20
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OCTAVIA
45
Anti-Lock Brake System
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If the wheel does not block, it is possible that
there is a fault in the mechanical/hydraulic part
of the brake system.
K
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If the wheel does not block, it is possible that
there is a fault in the mechanical/hydraulic part
of the brake system.
,
K
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If the wheel locks, it is possible that the brake
pressure lines to the wheel brakes are wrongly
connected.
Edition 06.99
S00.5103.56.20
------------
------------
45
Anti-Lock Brake System
OCTAVIA
K !
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Edition 06.99
S00.5103.56.20
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OCTAVIA
45
Anti-Lock Brake System
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Edition 06.99
S00.5103.56.20
-K47-
------------
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45
OCTAVIA
Anti-Lock Brake System
K
Final control diagnosis is ended.
K
Notes:
If the ABS warning light does not go out, there
is a fault in the system.
Carry out the test sequence exactly:
First of all, interrogate fault memory, then
erase it.
tools, testers and aids required
On models fitted with EDL, the
the hydraulic unit.
.
Note:
Operate vehicle system tester referring to the
Readout in the display.
Warning!
When replenishing brake fluid with a brake filling
and bleeding appliance, e.g. ROMESS S15, it is
important to ensure that the filling pressure of 0.1
MPa (1 bar) is not exceeded.
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
If the filling pressure of 0.1 MPa (1 bar) is
exceeded, proper bleeding of the hydraulic unit
is no longer assured.
Test of vehicle systems
Select function XX
Test of vehicle systems
04 - Basic setting
Basic setting
Enter display group number XXX
System in basic setting
Depress pedal and hold...
HELP
Connect brake filling and bleeding appliance,
e.g. ROMESS S15.
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit
(address word 03) page 45-9; ignition
switched on for this step.
K Readout in display:
-
K Readout in display:
-
HELP
Press keys 0 and 4 for the function Initiate
basic setting.
Confirm the entry with the key Q.
K Readout in display:
-
Press keys 0, 0 and 1.
Confirm the entry with the key Q.
K Readout in display:
Pedal yields
Hydraulic pump starts running
Pedal moves back
System in basic setting
Rel. pedal; FR+FL bleeder screws OPEN < >
K Readout in display:
-
Press
key.
Note:
If you are using V.A.G 1551, a <3> appears in
place of < >.
System in basic setting
please wait . . . (10 sec.)
System in basic setting
Dep. pedal x10; bleeder screws CLOSED < >
Edition 06.99
S00.5103.56.20
K Readout in display:
Hydraulic pump starts running
K Readout in display:
-
Press
key.
------------
------------
5
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OCTAVIA
Anti-Lock Brake System
K
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K
K
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------------
------------
Edition 06.99
S00.5103.56.20
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OCTAVIA
45
Anti-Lock Brake System
K
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Edition 06.99
S00.5103.56.20
------------
------------
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OCTAVIA
Anti-Lock Brake System
78
K
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K
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K
K
K
K
K
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
Electrical test of ABS and
ABS/EDL ITT Mark 20 IE
Special tools, testers and aids required
Test box V.A.G 1598/21
Adapter cable set 1594/A
Hand-held multimeter, e.g. V.A.G 1526 A
Test steps from page 45-44 apply to:
Models on which the self-diagnosis does not
provide any indication of the source of the
fault. In this case, work through the complete
electrical test.
Models on which the self-diagnosis provides
a direct indication of the source of the fault.
In this case, work through only the test step
recommended in the fault table (specific fault
finding).
Test requirements
l Fuses according to current flow diagram
must be in proper order.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
As a check, remove fuse from the fuse holder
on the battery and on the left fuse holder on
the dash panel.
l Before commencing the test, switch off
ignition and electrical components (headlights, lighting, fan etc.).
K l Separate multi-pin connector from control unit
(J104) and connect test box V.A.G 1598/21
-1- to the connector of the wiring loom -2-.
The specifications are matched to V.A.G 1526
A and do not necessarily apply to other test
equipment.
Edition 06.99
S00.5103.56.20
------------ 45-41 ------------
45
OCTAVIA
Anti-Lock Brake System
Multi-pin connectors with contact
assignment
Note:
Not all of the contacts listed are presently
assigned and must on no account be connected
to other components!
K Contact assignment of plug connection T25a
wiring loom/control unit -J104
Contact
1
Front left wheel speed sensor -G47
Coding bridge to contact 14
2
4
Front left wheel speed sensor -G47
Voltage supply terminal 15
5
6
7
8
9
10
11
14
16
18
19
20
22
23
24
25
------------
Cable connection to component ...
------------
Rear left wheel speed sensor -G46
Rear left wheel speed sensor -G46
Plug connection T16a/7 K wire
Earth terminal 31
Voltage supply of battery +
Data BUS line (CAN-L)
Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
binder
Data BUS line (CAN-H)
Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
binder
Coding bridge for contact 3
ABS warning light
Brake light switch -F-
Front right wheel speed sensor -G45
Front right wheel speed sensor -G45
Rear right wheel speed sensor -G44
Rear right wheel speed sensor -G44
Earth point on left below battery
Voltage supply of battery +
Edition 06.99
S00.5103.56.20
!
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OCTAVIA
45
Anti-Lock Brake System
connections
s
a nd
system tester
Contact 4
= Earth (terminal 31)
Contact 16
= Positive (terminal 30)
Contact 5
Contact 7
= Earth (terminal 31)
= K wire through cable connection diagnosis - to control unit (J104)
contact 7
test s
Te
45-44
Voltage supply for hydraulic pump -V64- to control unit -J104
- Perform test step 1
Voltage supply (terminal 15) to control unit -J104
- Perform test step 3
Resistance of front right wheel speed sensor -G45
- Perform test step 5
Resistance of rear right wheel speed sensor -G44
- Perform test step 7
Voltage signal of front right wheel speed sensor -G45
- Perform test step 9
Voltage supply of valves in hydraulic unit -N55- to control unit -J104
Operation of brake light switch -F
Resistance of front left wheel speed sensor -G47
Resistance of rear left wheel speed sensor -G46
Voltage signal of front left wheel speed sensor -G47
- Perform test step 2
- Perform test step 4
- Perform test step 6
- Perform test step 8
- Perform test step 10
Voltage signal of rear right wheel speed sensor -G44
- Perform test step 11
Coding bridge
- Perform test step 13
Resistance of K wire for V.A.G 1552, plug connection T16
- Perform test step 15
Voltage signal of rear left wheel speed sensor -G46
Voltage supply for V.A.G 1552, plug connection T16
- Perform test step 12
- Perform test step 14
Operation of ABS warning light -K47
- Perform test step 16
Operation of hydraulic pump -V64
- Perform test step 18
Operation of handbrake/brake fluid level warning light -K14/33
Test of data BUS lines
Edition 06.99
S00.5103.56.20
- Perform test step 17
- Perform test step 19
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Test table
The socket assignments of the test box V.A.G 1598/21 are identical with contact designations of the
control unit (J104) in the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the measurements obtained differ from the specifications, carry out measurements for rectifying faults
in the right-hand part of the table.
If the specifications are achieved, additionally test the cables for short circuit to positive and to earth.
Use the adapter cable set V.A.G 1594 A for conducting continuity test (bridges).
If the measurements obtained differ only slightly from the specifications, clean sockets and connectors of
the test equipment and test cables (e.g. with contact spray) and repeat test. Before replacing the relevant
components, test cables and connections and, particularly for specifications of less than 10 ohms, repeat
the resistance measurement at the component.
Switch on measuring range: Voltage measurement (20 V =)
Test
step
V.A.G
1598/21
Sockets
Test of
8 + 25
Voltage supply for
hydraulic pump -V64to control unit -J104-
Ignition switched off
10.0 - 14.5 V
- Test cable from contact 8 to
earth.
- Test cable from contact 25
through fuse to battery +.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
9 + 24
Voltage supply for
valves in hydraulic
-N55- to control unit
-J104-
Ignition switched off
10.0 - 14.5 V
- Test cable from contact 24 to
earth.
- Test cable from contact 9
through fuse to battery +.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
4+8
Voltage supply
Ignition switched on
(terminal 15) to control
unit -J104-
10.0 - 14.5 V
- Test cable from contact 8 to
earth.
- Test cable from contact 4 to
connection of terminal 15
(relay plate).
8 + 18
Operation of brake
light switch -F-
Ignition switched off
Brake pedal not
depressed
0.0 - 0.5 V
- Test fuse.
- Test brake light switch -Fand read measured value
block page 45-24, display
group number 003.
- Test cable from contact 8 to
earth.
- Test cable from contact 18 to
brake light switch.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Depress brake pedal
approx.
battery
voltage
------------ 45-44 ------------
Test conditions
- Additional operations
Specification
Measures if readout differs
from specification
- Test brake light switch -F page 45-69.
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
Switch on measuring range: Resistance measurement (2 k)
Test
step
V.A.G
1598/21
Sockets
19 + 20
Test of
Resistance of front
right wheel speed
sensor -G45-
Test conditions
- Additional operations
Ignition switched off
Specification
Measures if readout differs
from specification
1.0...1.3 k
- Separate plug connection at
wheel speed sensor -G45-.
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Move cables during test
(loose contact)
If no fault is found in the wiring:
- Replace wheel speed sensor
-G45- page 45-60.
1+2
Resistance of front left Ignition switched off
wheel speed sensor
-G47-
1.0...1.3 k
- Separate plug connection at
wheel speed sensor -G47-.
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Move cables during test
(loose contact)
If no fault is found in the wiring:
- Replace wheel speed sensor
-G47- page 45-60.
22 + 23
Resistance of rear
right wheel speed
sensor -G44-)
Ignition switched off
1.0...1.3 k
- Separate plug connection at
wheel speed sensor -G44-.
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Move cables during test
(loose contact)
If no fault is found in the wiring:
- Replace wheel speed sensor
-G44- page 45-65.
Edition 06.99
S00.5103.56.20
------------ 45-45 ------------
$ !! ""#
!
#
45
OCTAVIA
Anti-Lock Brake System
on
est
est
Sockets
5+6
Resistance of rear left
wheel speed sensor
-G46-
est conditions
Ignition switched off
cation
1.0...1.3 k
- Separate plug connection at
wheel speed sensor -G46-.
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Move cables during test
(loose contact)
If no fault is found in the wiring:
- Replace wheel speed sensor
-G46- page 45-65.
on
est
est
Sockets
10
19 + 20
1+2
------------ 45-46 ------------
Voltage signal of front
right wheel speed
sensor -G45-
Voltage signal of front
left wheel speed
sensor -G47-
est conditions
cation
Vehicle raised
Ignition switched off
- Check installation of wheel
speed sensor -G45- and of
pulse rotor.
- Rotate front right wheel
at approx. 1 rev/s
min. 65 mV
alternating
voltage
- Check correct connection of
wheel speed sensor -G45 page 45-24, Reading
measured value block,
display group number 001.
Vehicle raised
Ignition switched off
min. 65 mV
alternating
voltage
- Check installation of wheel
speed sensor -G47- and of
pulse rotor.
- Rotate front left wheel
at approx. 1 rev/s
- Check correct connection of
wheel speed sensor -G47 page 45-24, Reading
measured value block,
display group number 001.
Edition 06.99
S00.5103.56.20
OCTAVIA
!
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11
22 + 23
%
+
Voltage signal of rear
right wheel speed
sensor -G44-
%
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Vehicle raised
Ignition switched off
- Rotate rear right wheel
at approx. 1 rev/s
12
5+6
Voltage signal of rear
left wheel speed
sensor -G46-
&+
- Check installation of wheel
speed sensor -G44- and of
pulse rotor.
min. 190 mV
alternating
voltage
Vehicle raised
Ignition switched off
- Rotate rear left wheel
at approx. 1 rev/s
,
+
++
+
&+
- Check correct connection of
wheel speed sensor -G44 page 45-24, Reading
measured value block,
display group number 001.
- Check installation of wheel
speed sensor -G46- and of
pulse rotor.
min. 190 mV
alternating
voltage
- Check correct connection of
wheel speed sensor -G46 page 45-24, Reading
measured value block,
display group number 001.
-
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3 + 14
Coding bridge
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Ignition switched off
&+
0.0 -1.0
,
+
++
+
&+
- Test cable and contacts in
connector.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
If readout differs from
specification:
- Replace coding bridge.
!
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+
Voltage supply for
V.A.G 1552, plug
connection T16a 1)
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Ignition switched off
- Connect hand-held
multimeter V.A.G 1526
A with adapter cable
set V.A.G 1594 A to
T16a 1):
10.0 -14.5 V
Contact 4 - earth
Contact 16 - positive
1)
,
+
++
+
&+
- Test cable from T16a/4 to
earth.
- Test cable from T16a/16
through fuse to terminal 30.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
page 45-43, Contact assignment of plug connection for voltage supply and self-diagnosis using vehicle system
tester V.A.G 1552.
S00.5103.56.20
------------ 45-47 ------------
45
OCTAVIA
Anti-Lock Brake System
Switch on measuring range: Resistance measurement (200 )
Test
step
V.A.G
1598/21
Sockets
15
Test of
Resistance of K wire
for V.A.G 1552, plug
connection T16a 1)
Operational test: ABS warning light (K47)
Test
step
16
1)
Test conditions
- Additional operations
Specification
Measures if readout differs
from specification
Ignition switched off
- Separate multi-pin
connector from control
unit -J104- Connect test box
V.A.G 1598/21
- Connect hand-held
multimeter V.A.G 1526
with adapter cable set
V.A.G 1594 to contacts
T16/71) and T25/7 of
multi-pin connector of
control unit -J104-
max. 1.5
- Test cable from T16/7
through cable connection diagnosis - to contact 7.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
V.A.G
1598
Sockets
-
Test of
Operation of ABS
warning light -K47-
Test conditions
- Additional operations
Ignition switched on
Specification
Measures if readout differs
from specification
Warning light
-K47- comes
on for about
2 seconds
and goes out
again
- Test cable from contacts 7
and 9 of blue connector at
dash panel insert to earth.
- Test cable from contact 19 of
blue connector at dash panel
insert to contact 16 of ABS
connector.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Test dash panel insert, fault
in dash panel insert:
Electrical System; Repair
Group 90; Dash panel insert
page 45-43, Contact assignment of plug connection for voltage supply and self-diagnosis using vehicle system
tester V.A.G 1552.
------------
------------
Edition 06.99
S00.5103.56.20
"
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OCTAVIA
/
17
Operation of
handbrake/brake fluid
level warning light
-K14/33-
/
18
Operation of hydraulic
pump -V64-
Brake fluid at correct
level
Ignition switched on
Warning light - Test cable from contacts 7
-K14/33and 9 of blue connector at
comes on for
dash panel insert to earth.
about 2
- Test cable from contact 29 of
seconds and
blue connector at dash panel
goes out
insert to brake fluid level
again
warning contact -F34-.
- Test cable from contact 13 of
green connector at dash
panel insert to handbrake
indicator switch -F9-.
- Test brake fluid level warning
contact -F34- in cap.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
- Test dash panel insert, fault
in dash panel insert:
Electrical System; Repair
Group 90; Dash panel insert
- Replace handbrake indicator
switch -F9page 46-18.
Ignition switched off
- Separate plug
connection T2 of
hydraulic pump -V64at control unit -J104-
- Apply earth to plug
connection of hydraulic
pump T2/1 and battery
voltage to T2/2
S00.5103.56.20
Hydraulic
pump runs
properly
(max. 10
sec.)
page 45-29, Perform final
control diagnosis.
- Replace control unit -J104page 45-57.
Hydraulic
pump does
not run
- Replace hydraulic unit -N55page 45-57.
------------
------------
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)
45
OCTAVIA
Anti-Lock Brake System
on
est
est
Sockets
19
11 + 10
Databus lines
est conditions
cation
Ignition switched off
200 range set
- Separate multi-pin
connectors of control
units connected to a
databus line
- Connect test box V.A.G
1598/21
- Test databus lines for
open circuit
20 M
max. 1.5
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
range set
- Remove fuse
- Test cables for short
circuit to positive or to
earth
------------
------------
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
Edition 06.99
S00.5103.56.20
OCTAVIA
Antilock Brake System
Electrical/electronic components and fitting locations ABS, ABS/EDL Mark
20
45
5 - Handbrake/brake fluid level warning
light (K14/33)
fitting location: in dash panel insert
Function:
The handbrake/brake fluid warning
light comes on:
- when handbrake applied
- if brake fluid level is low
- for about 2 seconds after ignition is
switched on
- if the electronic brake force distribution fails, i.e. if the ABS warning light
comes on
page 45-7
All the components marked with
by the self-diagnosis.
1)
are tested
1 - Brake servo unit with brake master
cylinder and brake fluid reservoir
assembly overview page 47-1
2 - Hydraulic control unit 1)
fitting location: in left of engine compartment
removing and installing page 4552
servicing page 45-57
3 - Diagnostic connection
fitting location: in stowage compartment driver side
4 - ABS warning light (K47)
fitting location: in dash panel insert
Function:
ABS warning light comes on:
- for about 2 seconds after ignition is
switched on and/or engine start
- if fault is detected (e.g. open circuit to
wheel speed sensor)
page 45-7
Edition 05.01
S00.5103.61.20
6 - Parts of ABS system at rear axle
(illustration shows only disc brakes)
rear right and left wheel speed sensor -G44/G46 1)
- removing and installing page 4565
- installing wheel speed sensor cables
page 45-67
rear right and left pulse rotor for wheel
speed sensor
- testing page 45-66
- removing and installing: the pulse rotor should be replaced together with
the wheel hub page 42-23 and 4228
7 - Brake light switch -F is open in off position
- adjusting page 45-69
- remove by turning 90 to left page
45-69
- install by turning 90 to right page
45-69
must be tested in measured value
block page 45-24
8 - Parts of ABS system at front axle
front right and left wheel speed sensor -G45/G47 1)
- removing and installing page 4560
- installing wheel speed sensor cables
page 45-62
front right and left pulse rotor for wheel
speed sensor
- testing page 45-61
- removing and installing: the pulse rotor should be replaced together with
the wheel hub page 40-13
------------ 45-51 ------------
45
OCTAVIA
Anti-Lock Brake System
Removing and installing hydraulic
control unit and bracket
Note:
As a general rule, always ensure that no brake
fluid gets into the connector housing of the
control unit.
This can result in corrosion to the contacts and
thus in a failure of the system.
If the plug housing is soiled, it should be carefully
cleaned with compressed air.
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3
Brake pedal depressor, e.g. V.A.G 1238/B
Caps from repair kit Part No. 1HO 698 311
A
Brake filling and bleeding appliance, e.g.
ROMESS S15
Bleeder bottle (commercially available)
Brake fluid page 00-8
1 - Hydraulic control unit
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit
-J104- together form the hydraulic
control unit.
The hydraulic control unit should be
removed and installed as a complete
unit page 45-53.
Servicing page 45-57
2 - Brake line, 14 Nm
Between brake master cylinder/
floating piston circuit and hydraulic unit
3 - Brake line, 14 Nm
Hydraulic unit to front left brake caliper
------------ 45-52 ------------
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
4 - Brake line, 14 Nm
Hydraulic unit to rear right wheel
cylinder/brake caliper
8 - Multipin connector of control unit
25-pin
Do not separate plug connection
before self-diagnosis is completed.
Switch off ignition before separating
the plug connection.
5 - Brake line, 14 Nm
Hydraulic unit to rear left wheel cylinder/brake caliper
9 - Hexagon nut, self-locking, 20 Nm
6 - Brake line, 14 Nm
Hydraulic unit to front right brake
caliper
10 - Bracket
11 - Fit bolt, 8 Nm
7 - Brake line, 14 Nm
Between brake master cylinder/
pushrod piston circuit and hydraulic
unit
12 - Cap nut, 25 Nm
Removing hydraulic control unit
Notes:
Before disconnecting the battery, determine
the code of radio set fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
-
Disconnect battery.
Note:
The following 2 steps do not apply to the 1.6ltr./55 kW engine:
Edition 06.99
S00.5103.56.20
K-
Unplug the connector -1- of the air mass
meter at the air guide pipe of the air filter.
Take out the bolts -2- at the air filter -3- and
place filter to the side.
On diesel engines, remove relay carrier
above brake servo unit.
Extract as much brake fluid as possible from
the brake fluid reservoir with a bleeder bottle.
------------
------------
45
Anti-Lock Brake System
OCTAVIA
K-
Depress brake pedal and lock in position with
brake pedal depressor, e.g. V.A.G 1238/B.
Fit the bleeder hose of the bleeder bottle onto
the bleeder screw of the front left brake
caliper and open bleeder screw.
After brake fluid has flowed out, close bleeder
screw.
Detach bleeder hose from the bleeder screw.
K-
Release multi-pin connector and unplug from
control unit.
Note:
Ensure that no brake fluid gets onto the contacts.
K-
Place an absorbent mat below the hydraulic
control unit to absorb the brake fluid.
Note:
Brake lines in the area of the hydraulic unit must
not be bent.
------------ 45-54 ------------
Detach the brake lines from the brake master
cylinder to hydraulic unit, see arrows, and fit
on caps from repair kit Part No. 1H0 698 311
A to protect them from dirt.
On models with left-hand steering, tie up the
detached brake lines with a welding wire as
high up as possible so that the ends of the
lines project above the fluid level in the brake
fluid reservoir -arrows-.
Detach the remaining brake lines from the
hydraulic unit.
Edition 06.99
S00.5103.56.20
OCTAVIA
$
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45
Anti-Lock Brake System
K-
K-
Notes:
Do not remove plugs at the hydraulic unit
until the appropriate brake line is fitted on.
If the plugs are removed sooner from the
hydraulic unit, brake fluid may flow out with
the result that the system is no longer
properly filled and bled.
Note:
Do not fully tighten bolts. This makes it easier
to connect the individual brake lines to the
hydraulic control unit.
Edition 06.99
S00.5103.56.20
------------ 45-55 ------------
45
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Anti-Lock Brake System
K-
and
K-
torques:
fit new nuts!
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
"
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45
Anti-Lock Brake System
testers and aids
Caps from repair kit Part No. 1H0 698 311 A
Disassembly and assembly of the hydraulic
control unit is described at an ABS unit.
The procedure for the other versions of the ABS
ITT Mark 20 IE is identical page 45-4.
The hydraulic control unit is serviced by separating the control unit -J104- from the hydraulic
unit -N55-, which is connected to the hydraulic
pump -V64-. The faulty component is replaced.
Unplug connector for hydraulic pump motor
from control unit.
K-
Remove screws from control unit -arrowsand pull off control unit.
Note:
K When pulling off the control unit -b-, ensure that
the valve domes of the hydraulic unit -a- are not
twisted with the magnetic coils of the control unit.
-
Edition 06.99
S00.5103.56.20
Cover over coils of control unit with nonfluffing cloths.
------------
------------
45
$
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OCTAVIA
Anti-Lock Brake System
K-
This is a condition for any warranty claims.
K Hydraulic unit (N55) and hydraulic pump
(V64) -a-:
Hydraulic unit: The valve block contains the
control valves.
Hydraulic pump -V64- and hydraulic unit
-N55- must not be separated from each
other.
If the hydraulic unit is replaced, fit the
transport protection for valve domes Fig.
N45-0039, (item 1) onto the old part and seal
the old part with the plugs ( page Fig. N450039, (items 2 and 3). This is a condition for
any warranty claims.
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Anti-Lock Brake System
K ABS control unit (J104) -b-:
page 45-42, Contact assignment
page 45-41, Test requirements
Notes:
It is essential that the area of the control unitvalve block is clean.
When assembling control unit and hydraulic
unit, ensure that the valve domes of the
hydraulic unit are not tilted with the coils of
the control unit.
Edition 06.99
S00.5103.56.20
Attach control unit to hydraulic unit. Max.
tightening torque 4 Nm (always use the
screws supplied).
Plug in connector of the hydraulic pump
motor.
------------
------------
45
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OCTAVIA
Anti-Lock Brake System
ABS system at
and
testers and aids
Wiring loom repair kit, e.g. koda Service
Case, order No. S 504 500 V
Solid lubricating paste G 000 650
sors
-
K-
------------
------------
and
sen-
Raise vehicle.
Separate plug connection of wheel speed
sensor - wheel speed sensor cable -arrow-.
Remove hexagon socket screw -2-.
Pull wheel speed sensor -G45/G47- out of
wheel bearing housing.
Before inserting the wheel speed sensor,
clean the inner surface of the hole and coat
with solid lubricating paste G 000 650.
Insert wheel speed sensor into the hole of
the wheel bearing housing and tighten
hexagon socket screw to a final torque of 8
Nm.
Fit together plug connection of speed sensor
cable - wheel speed sensor.
Turn steering to full left and then to full right
and check clearance of wheel speed sensor
cable.
Lower vehicle.
Edition 06.99
S00.5103.56.20
OCTAVIA
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Anti-Lock Brake System
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Edition 06.99
S00.5103.56.20
------------
------------
45
Anti-Lock Brake System
Removing and installing
sensor
OCTAVIA
speed
Removing
Notes:
It is prohibited to carry out repairs to screened
cables of the ABS system.
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Note:
The following 2 steps do not apply to the 1.6ltr./55 kW engine:
------------
------------
K
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Edition 06.99
S00.5103.56.20
OCTAVIA
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K-
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Edition 06.99
S00.5103.56.20
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Anti-Lock Brake System
K-
K-
Note:
When
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------------
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Edition 06.99
S00.5103.56.20
OCTAVIA
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Anti-Lock Brake System
and
and
testers and aids
Wiring loom repair
e.g.
o
No. 504 500 V
l
G 000 650
a nd
rakes -
sensors
-
K-
plug
K-
out
bearing
the
the inner
l
the
into the hole
t ighten
to a
torque
b earing
8 Nm.
Fit together plug
-
and
sors
sen-
in the
page 45-65.
the hole
G 000 650.
the
the
Edition 06.99
S00.5103.56.20
------------
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Anti-Lock Brake System
and
Notes:
The illustrations show only the rear wheel
with disc brake.
Parts of ABS system at rear wheel with drum
brake is similar to version with disc brake.
K-
K-
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
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Anti-Lock Brake System
sensor
and
rear
Notes:
It is prohibited to carry out repairs to screened
cables of the ABS system.
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
The illustrations show only the rear wheel
with disc brake.
of the ABS system at rear wheel with
drum brake are similar to version with disc
brake.
K
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Edition 06.99
S00.5103.56.20
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Anti-Lock Brake System
K-
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K-
Notes:
When
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
45
Antilock Brake System
-
Connect battery page 45-67.
Interrogate fault memory page 45-12.
Erase fault memory page 45-21.
Removing and installing, and also
setting brake light switch, up to MY
1999
Special tools, testers and aids required
Poly resin grease -G 052 142 A2Note:
The brake light switch must be removed for setting.
- Remove trim in driver footwell.
Body Fitting Work; Repair Group 68; Storage compartments, covers and trim panels
-
Unplug connector from brake light switch.
K-
Remove brake light switch -1- by turning 90
to the left.
Pull out plunger -2- of brake light switch for
setting.
Note:
Before installing the brake light switch, grease
contact surface of plunger and brake pedal with
poly resin grease -G 052 142 A2-.
-
Depress brake pedal as far as possible with
your hand.
Guide brake light switch through the assembly opening and install by turning 90 to the
right.
Release brake pedal.
Plug connector into brake light switch.
- Install footwell trim on driver side.
Body Fitting Work; Repair Group 68; Storage compartments, covers and trim panels
-
Check operation of brake lights.
Depress brake pedal all the brake lights
come on.
Release brake pedal all the brake lights
go off.
Edition 02.01
S00.5103.60.20
-----------------------45-175
45-69 ------------
45
OCTAVIA
Antilock Brake System
Removing and installing, as well as
setting brake light switch, from MY
2000
Special tools, testers and aids required
Poly resin grease -G 052 142 A2Note:
The brake light switch must be removed for setting.
-
Unplug connector from brake light switch.
K-
Remove brake light switch by turning 45 to
the left.
Pull out plunger fully for setting. When the
brake light switch is installed, the plunger
adjusts automatically.
Note:
Before installing the brake light switch, coat contact surface of plunger and brake pedal with poly
resin grease -G 052 142 A2-.
-
Guide switch through assembly opening,
press against the pedal and attach by turning 45 to the right.
Brake pedal always remains in off position during this step (do not depress!).
-
Plug in connector of brake light switch.
Check operation of brake lights.
After installing the brake light switch, check
whether the brake pedal is in the end position (release position).
------------ 45-176
45-69.1-----------------------
Edition 02.01
S00.5103.60.20
OCTAVIA
Edition 02.01
S00.5103.60.20
Antilock Brake System
45
-----------------------45-69.2
45-177 ------------
45
Antilock Brake System
OCTAVIA
Assembly overview of hydraulic control unit, brake servo unit/brake master
cylinder for models with ABS, ABS/EDL Mark 20
7 - Brake master cylinder
8 - Self-locking hexagon nut, 20 Nm
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11 - Fit bolt, 8 Nm
12 - Rubber shock absorber
13 - Bracket
14 - Self-locking hexagon nut, 20 Nm
15 - ABS or ABS/EDL control unit
16 - ABS or ABS/EDL hydraulic unit
Notes:
The hydraulic control unit should be removed
and installed complete from page 45-52.
Servicing from page 45-57.
Connections of brake lines should be tightened as a general rule to a torque of 14 Nm.
1 - Brake servo unit
2 - Cap
3 - Brake fluid reservoir
4 - Seal
5 - Self-locking hexagon nut, 20 Nm
17 - Brake line connection
!
18 - Brake line connection
!
!
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19 - Brake line connection
!
!
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20 - Brake line connection
!
21 - Brake line
! &
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22 - Brake line
! &
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6 - Retaining pin
------------
------------
Edition 05.01
S00.5103.61.20
OCTAVIA
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Anti-Lock Brake System
Self-diagnosis for 4x4 models fitted with the
Haldex coupling is practically identical to models fitted with ABS/EDL.
Note:
Only the differences in the self-diagnosis to the
standard ABS/EDL system are described.
ted
in t
case
A longitudinal acceleration sender -G251- is installed in the ABS system.
Fitting location page 45-81
Fault table page 45-72
The longitudinal acceleration sender -G251must be switched off for testing the brake system on a roller dynamometer, page 45-76,
Initiating basic setting, display group number
040.
The longitudinal acceleration sender -G251- is
re-activated by switching ignition off and on
once.
All 4x4 models with Haldex coupling are
equipped with the EDL electronic differential
lock.
version
Connect vehicle system tester V.A.G 1552
page 45-9.
Interrogating control unit version page 45-10.
1J0 907 379 L ABS/EDL 20 IE CAN V006
Coding 13504
WSC XXXXX
K Readout in display (example):
What is displayed is:
the control unit identification number,
e.g. 1J0 907 379 L
the system designation,
e.g. ABS/EDL 20 IE
Data BUS: CAN
Edition 11.99
S00.5103.57.20
------------
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OCTAVIA
Anti-Lock Brake System
the number of the version, e.g. V006
the code No. of the control unit, e.g. 13504
the workshop code (WSC)
Operating instructions of vehicle system
tester V.A.G 1552
Assignment of control unit
Parts List
Coding control unit page 45-22.
Interrogating fault memory page 45-12.
in
01279
Longitudinal acceleration
sender -G251electrical fault in circuit
Open circuit, short circuit to positive
or to ground in the wiring
- Read measured value block page 45-74,
display group number 006
- Test wiring and plug connections according
to current flow diagram
- Perform electrical test page 45-79
Installation position of longitudinal
acceleration sender -G251- is not
correct
- Check installation position of longitudinal acceleration sender -G251-
Longitudinal acceleration sender
-G251- faulty
- Replace longitudinal acceleration sender
-G251- page 45-82
- Carry out zero adjustment:
- Initiate basic setting page 45-76, display
group number 069
------------
------------
Edition 11.99
S00.5103.57.20
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45
Anti-Lock Brake System
in
01279
Longitudinal acceleration sender
-G251implausible signal
- Read measured value block page 45-74,
display group number 006
Installation position of longitudinal
acceleration sender -G251- is not
correct
- Check installation position of longitudinal acceleration sender -G251-
Longitudinal acceleration sender
-G251- faulty
- Replace longitudinal acceleration sender
-G251- page 45-82
- Carry out zero adjustment:
- Initiate basic setting page 45-76, display
group number 069
01324
4x4 control unit -J492no communication
Open circuit, short circuit to positive
or to ground in data BUS cables
- Read measured value block page 45-75,
display group number 125
- Test cables and plug connections of data
BUS cables according to current flow diagram
- Perform electrical test page 45-41
Code number for ABS/EDL 4x4 models fitted
with Haldex coupling page 45-23.
Coding control unit page 45-22.
page 45-24
Edition 11.99
S00.5103.57.20
------------
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OCTAVIA
Anti-Lock Brake System
Testing
sender
Read measured value block page
Read measured value block
Enter display group number XXX
K Readout in
keys
and
group
key
Read measured value block
K Readout in
Test conditions
in
ration sender
rises constantly
not assigned
rises
constantly
negative sign
not assigned
not assigned
readout
electrical test page
------------
------------
Edition 11.99
S00.5103.57.20
OCTAVIA
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Anti-Lock Brake System
data
Read measured value block page
Read measured value block
Enter display group number XXX
K Readout in
the keys
and
group
key
Read measured value block
Engine
K Readout in
conditions
to engine
control unit
in
connection
no connection
to
control unit
connection
no connection
to automatic
control unit
connection
no connection
assigned
the readout
the
Read the
memories
connected to the data
the control units
Engine control unit
automatic
control unit
Test the
according to the current
Current F
Electrical Fault
Finding and Fitting Locations binder
Edition 11.99
S00.5103.57.20
------------
------------
45
Antilock Brake System
OCTAVIA
Initiating basic setting
Function 04 Initiating basic setting is enlarged
on 4x4 models with Haldex clutch by two display group numbers:
Display group number 040 is required for
switching off the longitudinal acceleration
sender -G251-, e.g. for checking the brake
system on a chassis dynamometer page
45-76.
Display group number 069 is required for the
zero adjustment of the longitudinal acceleration sender -G251- page 45-77.
Note:
The longitudinal acceleration sender -G251- is
reactivated by switching the ignition off and on
once.
-
Initiating basic setting page 45-36.
Switching off longitudinal acceleration sender -G251Note:
No Login procedure is carried out for switching off the longitudinal acceleration sender.
Display group number: 040
Basic setting
Enter display group number XXX
System in basic setting
------------ 45-180
45-76 -----------------------
HELP
40
K Readout in display:
-
Press keys 0, 4 and 0 for display group
number 040 and confirm the entry with the
key Q.
The ABS warning light flashes.
K Readout in display:
-
The longitudinal acceleration sender -G251is now switched off.
After completing the check, the longitudinal
acceleration sender -G251- must be reactivated by switching the ignition off and on
once.
Edition 02.01
S00.5103.60.20
OCTAVIA
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Anti-Lock Brake System
ac-
sender
Note:
The login procedure must first of all be carried
out before the zero adjustment. To do this, first
of all enter the workshop code in the vehicle
system tester V.A.G 1552.
Test of vehicle systems
Select function XX
HELP
Login procedure
Enter code number XXXXX
Press the key 1 twice for the function login
procedure and confirm the entry with the key
Q.
K Readout in display:
-
Test of vehicle systems
Select function XX
HELP
Basic setting
Enter display group number XXX
HELP
System in basic setting
Adjustment o.k.
K Readout in display:
and
en-
K Readout in display:
-
69
0.3 m/s2
Enter code
try with the key Q.
Press the keys 0 and 4 for function Initiate
basic setting and confirm the entry with the
key Q.
K Readout in display:
-
Press the keys 0, 6 and 9 for display group
number 069 and confirm the entry with the
key Q.
The ABS warning light flashes.
K Readout in display:
Adjustment is thus completed.
The readout does not move back exactly to
0.00 m/s2.
Function is unknown or cannot be
performed at the moment
K If this readout appears in the display, the login
procedure was not successfully performed.
-
System in basic setting
Adjustment n. possible
Edition 11.99
S00.5103.57.20
69
5.0 m/s2
Repeat login procedure.
K If this readout appears in the display, the measured values are not within a tolerance range
permitted for the zero adjustment.
------------
------------
45
Anti-Lock Brake System
OCTAVIA
1. Interrogate fault memory (function 02)
2. Erase fault memory (function 05)
3. End output (function 06)
4. Switch ignition off.
5. Switch ignition on.
6. Carry out the zero adjustment once again.
Test of vehicle systems
Select function XX
------------
HELP
Press the key.
K Readout in display:
-
Press the keys 0 and 6 in order to end the
output.
ABS warning light comes on for about 2 seconds.
------------
Edition 11.99
S00.5103.57.20
6
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45
Anti-Lock Brake System
test
Electrical test of ABS/EDL page 45-41.
Multipin connectors with contact assignment page 45-42.
nection
-J104-
contact
con-
13
Longitudinal acceleration sender -G251-
17
Longitudinal acceleration sender -G251-
15
Longitudinal acceleration sender -G251-
Actuation of longitudinal acceleration sender -G251-
45-79
- Perform test step 20
1 to 19
45-44
The socket designations of test box V.A.G 1598/21 are identical with contact designations of the control unit (J104)
in the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the measurements obtained differ from the specifications, carry out measures for rectifying faults stated in the
right-hand column of the table.
If the specifications are achieved, additionally test the cables for short circuit to positive and to earth.
Perform continuity tests with adapter cable set V.A.G 1594 A (bridges).
If the measurements obtained differ only slightly from the specifications, clean sockets and connectors of the test
equipment and test cables (e.g. with contact spray) and repeat test. Before replacing the relevant components,
inspect cables and connections, and repeat the resistance measurement at the component, particularly in the case
for specifications of less than 10 ohms.
Edition 11.99
S00.5103.57.20
------------
------------
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OCTAVIA
Anti-Lock Brake System
on
Sockets
20
est conditions
- Additional
tion
Cables for longitudinal Ignition switched off
acceleration sender
Set measuring range
-G251
200
- Separate plug connection from longitudinal
acceleration sender
-G251- Separate multipin connector T25a from control unit -J104- Connect test box
V.A.G 1598/21
- Test cables between
multipin connector of
longitudinal acceleration sender -G251- and
multipin connector of
control unit -J104- for
open circuit
max.
1.5
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
Set measuring range
20 M
- Remove fuse S9
- Test wiring for short
circuit to positive or
earth
------------
------------
- Test wiring according to CFD
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations binder
Edition 11.99
S00.5103.57.20
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OCTAVIA
45
Anti-Lock Brake System
and
5-
Fitting location: in dash panel insert
Function:
The handbrake/brake fluid level warning light comes on:
- if handbrake is applied
- if brake fluid level is low
- for about 2 seconds after ignition
switched on
- if electronic brake pressure distribution fails, i.e. if ABS warning light
comes on
page 45-7
6-
All the components marked with 1) are covered
by the self-diagnosis.
1 - Brake master
-
and
Fitting location: in left of engine compartment
Removing and installing
page 45-52
Servicing page 45-57
switch -F7 - Brake
Is open in off position
- Setting page 45-69
- Remove by turning 90 to the left
page 45-69
- Install by turning 90 to the right
page 45-69
Must be tested in measured value
block page 45-24
8-
connection
Fitting location: in shelf on driver side
4 - ABS
Fitting location: in dash panel insert
Function:
The ABS warning light comes on:
- For about 2 seconds after ignition is
switched on and/or engine start
- If fault detected (e.g. open circuit to
wheel speed sensor)
page 45-7
ABS system at rear
sion
(illustration shows only disc brakes)
Rear right and left wheel speed sensor -G44/G46 1)
- Removing and installing
page 45-82
- Installing wheel sensor cables
page 45-85
Pulse rotor for rear right and left wheel
speed sensors
- Testing page 45-84
- Removing and installing: the pulse
rotor is replaced together with the
wheel hub page 42-44.
9-
sion
Front right and left wheel speed sensor -G45/G47 1)
- Removing and installing
page 45-60
- Installing wheel sensor cables
page 45-62
Pulse rotor for front right and left wheel
speed sensors
- Testing page 45-61
- Removing and installing: the pulse
rotor is replaced together with the
wheel hub page 42-13.
s ender
Fitting location: at central tube on right,
close to right A pillar
Removing and installing
page 45-82
Edition 11.99
S00.5103.57.20
------------
------------
45
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Anti-Lock Brake System
and
sender -
and
parts
ABS system at rear
pension
testers and aids
and
sors at rear
speed senmod-
K-
------------
------------
Edition 11.99
S00.5103.57.20
OCTAVIA
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Anti-Lock Brake System
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Edition 11.99
S00.5103.57.20
------------
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OCTAVIA
Anti-Lock Brake System
and installing
rotor
K-
Note:
Top bolt attaching brake carrier is concealed.
-
------------
------------
Edition 11.99
S00.5103.57.20
OCTAVIA
45
Anti-Lock Brake System
sensor
and
rear
Notes:
It is prohibited to carry out any repairs on
shielded cables of the ABS system.
Before disconnecting the battery, determine
the coding of radio sets fitted with anti-theft
code.
When the battery is re-connected, check the
vehicle equipment:
- encode radio,
- re-set clock,
- initialise power windows.
Inspection and Maintenance
-
Disconnect battery.
Raise vehicle.
Take off wheel.
K-
Open cover -2- of plug connection -1-.
Separate plug connection -1- of wheel speed
sensor cable - wheel speed sensor.
Remove side trim panel of luggage compartment.
Body Fitting Work; Repair Group 70; Trim
panels of cargo area and luggage compartment
Edition 11.99
S00.5103.57.20
K-
Locate weld connection at wheel speed sensor cable.
Pull insulating grommet off the welded connection.
------------
------------
45
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$
Anti-Lock Brake System
OCTAVIA
K-
K-
K-
Note:
When installing the wheel speed sensors, ensure that the wheel speed sensor cable in the
wheelhouse is installed free of twists.
------------
------------
Edition 11.99
S00.5103.57.20
OCTAVIA
Edition 11.99
S00.5103.57.20
"
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Anti-Lock Brake System
------------
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OCTAVIA
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The ABS/EDL/ESP is a vehicle safety system; work on this system requires system
knowledge.
K Indication of faults by the warning lights for:
- ABS (K47) -1- Handbrake/brake fluid level (K14/33) -2- Electronic stability programme (K155) -3 page 45-92.
Certain faults are not detected until the vehicle speed is more than 20 km/h (conduct a
road test).
If the ABS warning light -K47- and the handbrake/brake fluid level warning light -K14/33do not come on and the brake system is
nevertheless not fully operational, look for the
fault in the conventional brake system
from page 46-1 and from page 47-26.
Information on rectifying current faults
Service Technical Handbook and
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
% $ # $
The same information applies to repair operations on the ABS/EDL/ESP Mark 20 as to the
ABS Mark 20 and to the ABS/EDL Mark 20
page 45-1.
& ' (!
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
Service Technical Handbook
Self Study Programme 26: Vehicle Safety New Technical Information
Self Study Programme 28: Electronic Stability Programme, Fundamentals, Design,
Operation
------------ 45-182
45-88 -----------------------
S00.5103.60.20
OCTAVIA
!
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45
Anti-Lock Brake System
and
The ABS prevents the wheels locking during a
brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for
the differential by electronically controlling the
braking of the driven wheel which is slipping.
The engine power is thus available for the gripping wheel with the better adhesion. This also
applies when reversing.
You can find a description of the design and
operation of the ABS and EDL in Self Study Programme No. 26.
The electronic stability programme -ESP- detects critical driving situations and stabilises the
vehicle by braking individual wheels and intervening in the engine management system. This
happens independently of the operation of the
brake or of the accelerator pedal.
The ESP operates throughout the entire speed
range of the vehicle. If the ESP is in the control
mode, the ESP warning light flashes three times
a second.
You can find a description of the design and
operation of the ESP in the Self Study Programme No. 28.
The brake system is split diagonally. Brake servo
assistance is provided pneumatically by the
vacuum brake servo unit.
Models fitted with ABS/EDL/ESP ITT Mark 20
IE do not have a mechanical brake pressure
regulator. Specifically matched software in the
control unit, the electronic brake pressure distribution, EBD, regulates the brake pressure at
the rear wheels.
The hydraulic pump -V64-, the hydraulic unit
-N55- and the control unit -J104- form the hydraulic control unit. Repairs can only be carried
out when the parts are removed.
New control units supplied through the Parts
Sector are not coded. They require to be coded
after being installed.
Edition 04.00
S00.5103.58.20
------------
------------
45
!
!
"
Anti-Lock Brake System
OCTAVIA
K Distinguishing features:
Dimension A: 135 mm
Internal electrical plug connection between
hydraulic unit and control unit.
12 valve domes: The protective sleeves for
the valves are visible if the control unit is
separated from the hydraulic unit page
45-163.
1 - Control unit, 47-pin
Control unit identification
The control unit version appears in the display of V.A.G 1552. Select function 01 Interrogating control unit version for this purpose page 45-10.
List of available functions page 45-100.
1 - Brake servo unit 10
2 - Hydraulic unit
3 - Control unit, 47-pin, bolted to hydraulic
unit
1 - Brake servo unit 7/8
2 - Hydraulic unit
3 - Control unit, 47-pin, bolted to hydraulic
unit
------------ 45-90 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
Antilock Brake System
45
Self-diagnosis of ABS/EDL/TCS/ESP Mark 20
Function
In view of the control units which are all interlinked by a databus line, always
interrogate the contents of the fault memories of the control units fitted in
the vehicle at the start of fault finding.
This is done with the Automatic test sequence which is activated with the
key function 00.
What is checked here is whether any faults which might affect the ABS
system, are stored.
Self-diagnosis relates to the electrical/electronic part of the ABS, in other
words only faults relating to the electrical connection to the control unit (e.g.
open circuit in wiring of a wheel speed sensor) are detected.
The 47-pin ABS control unit -J104-, together with the hydraulic unit, forms a
compact unit. This unit is located in the left of the engine compartment. The
control unit is equipped with a fault memory. The connection for self-diagnosis is located in the storage compartment on the driver side.
The control unit detects faults during operation of the vehicle and stores
them in a permanent memory. This information is retained even if the battery voltage is disconnected.
Faults which occur sporadically (occasionally), are likewise detected and
stored. If, however, faults relating to the databus system are no longer detected during 15 vehicle starts and moving-off operations, or other faults are
no longer detected during 50 vehicle starts and moving-off operations, the
fault is then erased in the fault memory with the exception of the fault Control unit defective (fault delete counter).
After the ignition is switched on and/or the engine is started, the ABS warning light -K47-, the red handbrake/brake fluid level warning light -K14/33and the electronic stability programme warning light -K155- come on for
about 2 seconds.
During this time a test procedure (self-check) with the following functions is
performed in the control unit:
Test of supply voltage at least 10.0 V.
Test of control unit including valve coils.
Test of coding of control unit.
Static test of wheel speed sensors (without wheel speed signal).
If it is found, after starting off and once a speed of about 20 km/h has
been reached, that the wheel speed signal is not o.k., the ABS warning
light -K47- comes on again.
Edition 02.01
S00.5103.60.20
----------------------- 45-91 ------------
,
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OCTAVIA
Notes:
The description which follows relates only to the vehicle system tester
V.A.G 1552 using the up-to-date programme card.
Use of the fault reader V.A.G 1551 with integrated printer is similar. Slight
variations are possible in the readouts in the display.
To end self-diagnosis or to switch to another address word, select function 06 End output.
The faults displayed can be identified by referring to the fault table, and
the fault can then be rectified.
1
2
ABS warning light -K47-
Handbrake/brake fluid level warning light
-K14/33-
Electronic stability programme warning light
-K155-
Warning!
After the ABS warning light -K47- and the handbrake/brake fluid level warning light -K14/33- come
on, the rear wheels may lock even during a slight
brake application.
------------ 45-184-----------------------
S00.5103.60.20
# $
!
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OCTAVIA
45
Antilock Brake System
ABS
Ignition on
(if systems o.k., lights go out
after about 3 s)
Electronic
on
on
on
ESP failure or ESP deactivated by
pushbutton;
ABS, EDL and EBD active
off
off
on
ESP control cycle
off
off
off
off
ABS/EDL/ESP/EBD failure;
(e.g. a wheel speed sensor faulty)
Systems o.k.
ABS/EDL/ESP failure;
EBD remains active
(e.g. a wheel speed sensor faulty)
Brake fluid level too low;
all systems o.k.
on
off
off
flashes
on
on
on
off
on
off
on
K ABS
If the ABS warning light (K47) -1- does not
go out after the ignition is switched on and
after completion of the self-check, the causes
of the fault may be the following:
-a- voltage supply is less than 10 V
-b- there is a fault in the ABS
If there is a fault in the ABS -b-, the antilock
brake system is switched off. The EBD (electronic brake force distribution) function remains active, and in this case the conventional brake system remains fully operational.
Interrogate fault memory page 45-101.
-c- there was a sporadic wheel speed sensor fault after vehicle last started.
If there was a wheel speed sensor fault -c-,
the ABS warning light -K47- goes out automatically after vehicle is again started and a
speed of more than 20 km/h is reached.
Edition 02.01
S00.5103.60.20
-----------------------45-185 ------------
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OCTAVIA
-d- cable from ABS control unit -J104- for operating the ABS warning light -K47- in the
dash panel insert -J218- has an open circuit.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
-e- the dash panel insert is faulty.
If the ABS warning light (K47) -1- goes out,
but the handbrake/brake fluid level warning
light (K14/33) -2- remains on, and 3 warning
signals are heard, the causes of the fault may
be:
-a- the brake fluid level is too low.
-b- the handbrake is applied.
-c- switch -F9- for the warning light -K14/33is faulty or incorrectly set.
-d- there is a fault in the operation of the
handbrake/brake fluid level warning light
-K14/33-.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
If the ABS warning light (K47) -1- and the
handbrake/brake fluid level warning light
(K14/33) -2- come on, this indicates that the
ABS system and the EBD (electronic brake
force distribution) are not operating.
If the ABS warning light (K47) -1- and the
handbrake/brake fluid level warning light
(K14/33) -2- come on and 3 warning signals
are heard, this indicates that the ABS system and the EBD (electronic brake force distribution) are not operating.
Note:
The
Warning!
After the ABS warning light -K47- and the handbrake/brake fluid level warning light -K14/33- come
on, the rear wheels may already lock during a slight
application of the brakes.
------------ 45-94 -----------------------
S00.5103.60.20
OCTAVIA
$
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45
Antilock Brake System
K Electronic
rogramme
If the electronic stability programme warning light (K155) -3- does not go out after the
ignition is switched on and after completion
of the self-check, the causes of the fault may
be the following:
There is a fault which affects only the ESP
safety system. The ABS/EDL and EBD safety
systems of the vehicle remain fully operational.
Interrogate fault memory page 45-101.
-a- short to positive in ESP pushbutton
-E256-.
-b- short to earth in operation of electronic
stability programme warning light -K155-.
-c- open circuit in cable for operating electronic stability programme warning light
-K155-.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
-d- the ESP system was switched off by the
ESP pushbutton -E256-.
ing
onds
ing
electronic
comes on
ignition is
control
100
a
entered.
Code control unit page 45-114.
ing
electronic
system is in
control mode.
If the ABS warning light (K47) -1-, the handbrake/brake fluid level warning light (K14/33)
-2- and the electronic stability programme
warning light (K155) -3- flash continuously,
the control unit is not yet coded.
Code control unit page 45-114.
Edition 02.01
S00.5103.60.20
----------------------- 45-95 ------------
45
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OCTAVIA
Anti-Lock Brake System
does not
testers and aids
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 or
V.A.G 1551/3 A
system
does not
When dealing with such a complaint, a possible
cause of the fault may be that the brake light
switch is incorrectly set or not operating page
45-116, Reading measured value block, display
group number 003 and page 45-69, Setting
brake light switch.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
Antilock Brake System
Performing self-diagnosis
45
Test requirements
l Approved size of tyres fitted to all wheels;
tyres inflated to the specified inflation pressure.
l Mechanical/hydraulic part of brake system
together with brake light switch and brake
lights o.k.
l No leaks in hydraulic connections and lines
(visual inspection at hydraulic unit, brake
calipers, wheel brake cylinders, tandem
brake master cylinder).
l Wheel bearings and wheel bearing play o.k.
l Control unit -J104- correctly bolted to hydraulic unit -N55-.
l Plug connection at control unit (J104) correctly inserted (lock is engaged).
l Plug contacts of ABS components free of
damage and correctly installed.
l All fuses according to CFD o.k. (as a check,
remove fuses from fuse holder).
l Supply voltage o.k. (at least 10.0 V).
Connecting vehicle system tester
V.A.G 1552 and selecting function
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 or V.A.G
1551/3 A, respectively
Notes:
The ABS function in the control unit is
switched off during self-diagnosis.
The ABS warning light -K47-, the electronic
stability programme warning light -K155- and
the handbrake/brake fluid level warning light
-K14/33- come on and remain on.
Edition 02.01
S00.5103.60.20
-----------------------45-189
45-97 ------------
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OCTAVIA
Anti-Lock Brake System
The fault memory can be erased after completing repairs and interrogating memory.
K-
Switch off ignition (if not already off) and connect vehicle system tester V.A.G 1552 with
diagnostic
V.A.G
or with V.A.G
A to the diagnosis connection.
Interrogating control unit version
Test of vehicle systems
Enter address word XX
HELP
in display:
If no readout appears in the display, inspect plug
connection for self-diagnosis, Electrical Test
from page 45-133, test steps 27 and 28.
Notes:
Depending on the programme, additional
user information can be displayed by pressing the HELP key of V.A.G 1552.
The key is used for moving forward within
the test programme.
Test of vehicle systems
Enter address word XX
Coding 18945
HELP
in display:
XXXXX
Switch on ignition.
Press keys 0 and for the address word
Brake electronics and confirm the entry with
the key Q.
then appears
K The following
is displayed is:
the control
identification
the system
e.g. ESP 20
present (CAN)
Flow
Electrical
Finding and Fitting Locations
the
of the
e.g. V002
the code No. of the control
the workshop code
Operating
tester V.A.G 1552
------------
------------
e.g.
e.g. 18945
of vehicle system
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Assignment of control unit
Parts List
Coding control unit page 45-114
If the control unit identification number does not
appear page 45-100, List of available functions.
-
Test of vehicle systems
Select function XX
HELP
Press
key.
K Readout in display:
Note:
A list of the possible functions is displayed after
pressing the HELP key:
Test of vehicle systems
Select function XX
HELP
K Readout in display; (function selection, e.g. 02 Interrogating fault memory)
Note:
If one of the fault messages shown opposite
appears in the display, the possible causes
of the fault can be displayed by pressing the
HELP key.
Test of vehicle systems
Control unit does not answer!
HELP
K A possible cause of the fault are the fuses of
the inlet/outlet valves S13, S162, S163.
Test of vehicle systems
K wire not switching to positive!
HELP
K Check whether ignition is switched on.
K Faults occurred when interrogating the control
unit identification (also external sources of interference).
Test of vehicle systems
No signal from control unit!
Test of vehicle systems
Tester sends address word 03
1J0 907 379 ESP 20
Coding 18945
Test of vehicle systems
Select function XX
Edition 04.00
S00.5103.58.20
CAN
Test diagnostic cable and also voltage supply and earth connection for ABS (J104)
page 45-133, Electrical test.
After rectifying the possible causes of the
faults, once again enter address word 03 for
Brake Electronics and confirm the entry
with the key Q.
K Readout in display after entering address word
03
V005
WSC XXXXX
HELP
K and the following readout then appears:
-
Press
key.
K Readout in display:
------------ 45-99 ------------
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OCTAVIA
Anti-Lock Brake System
Note:
All the contents of the fault memories of the control units are interrogated with the automatic test
sequence.
-
Switch
with
with
List
with
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
memory
Test of vehicle systems
Select function XX
HELP
Press keys 0 and 2 for the function Interrogate fault memory and confirm the entry with
the key Q.
K The number of stored faults or No fault recognised appears in the display.
X faults recognised!
No fault recognised!
K Readout in display:
Press key.
The faults stored are displayed one after the
other.
Use the fault message displayed to refer to
the fault table page 45-102.
If No fault recognised appears, the programme returns to the initial position after
pressing the key:
Test of vehicle systems
Select function XX
HELP
K Readout in display:
-
End output (function 06) page 45-114.
Switch off ignition and separate diagnosis
plug connection.
Notes:
If a fault was detected:
1. Rectify fault (repair)
2. Interrogate fault memory (function 02)
3. Erase fault memory (function 05)
4. End output (function 06)
5. Road test
6. Once again interrogate fault memory.
Edition 04.00
S00.5103.58.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Fault table
Notes:
In view of the control units which are interlinked over a databus line, always commence fault finding by initiating the
Automatic test sequence with the key function 0 and 0 at all the control units fitted to the vehicle. This interrogates
the control unit fitted to the vehicle and any faults which may be stored in them.
All the possible faults which can be detected by the ABS control unit (J104) and displayed on V.A.G 1552, are listed
below according to the 5-digit fault code.
If faults occur only occasionally or if the fault memory was not erased after rectifying faults, these faults are displayed for a defined period as sporadically occurring faults -SP- page 45-91, Fault recognition of ABS control
unit.
In addition, the fault type may also be indicated in the fault table.
Reference is made in the column Rectifying fault to individual test steps of the electrical test.
Before replacing components indicated as faulty, test the appropriate plug connections, cables and earth connections according to the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
After completing repairs, always once again interrogate and then erase the fault memory with the vehicle system
tester V.A.G 1552, and conduct a road test (at a speed of more than 20 km/h).
After conducting the road test, once again interrogate the fault memory.
Readout in display of V.A.G 1552 Possible cause of fault
No fault recognised
Rectifying fault
If no fault recognised appears after completing repairs, self-diagnosis is ended.
If the ABS/EDL/ESP does not operate properly although no fault recognised is displayed,
then proceed as described below:
1. Conduct a road test at a speed of more than 20 km/h.
2. Once again interrogate the fault memory; if no fault is again stored.
3. Continue fault finding without self-diagnosis and work through the electrical test in full
page 45-133.
00283
Front left wheel speed sensor
-G47
------------ 45-102 ------------
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G47and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Read measured value block page 45-116,
display group number 001
- Perform electrical test page 45-133, test
steps 8 and 12
Damage to pulse rotor or speed sensor -G47
Coil of speed sensor -G47- faulty
- Inspect wheel speed sensor -G47- and pulse
rotor for damage
- Replace pulse rotor/speed sensor -G47page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-163
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
Rectifying fault
00283
Front left wheel speed sensor
-G47
Signal not to tolerance1)
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G47and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Perform electrical test page 45-133, test
steps 8 and 12
Electrical interference because of external sources (high-frequency interference, e.g. ignition cable not insulated)
- Read measured value block page 45-116,
display group number 001
Damage to pulse rotor or speed sensor -G47
- Inspect speed sensor -G47- and pulse rotor
for damage
Air gap between speed sensor -G47and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G47page 45-60 and 45-65
Air gap between speed sensor -G47and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G47and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-116,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-163
00283
Front left wheel speed sensor
-G47
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
Edition 04.00
S00.5103.58.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
in
cause
00285
Front right wheel speed sensor
-G45
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G45and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Read measured value block page 45-116,
display group number 001
- Perform electrical test page 45-133, test
steps 7 and 11
Damage to pulse rotor or speed sensor -G45
Coil of speed sensor -G45- faulty
- Inspect speed sensor -G45- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G45page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-163
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G45and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Perform electrical test page 45-133, test
steps 7 and 11
Electrical interference because of external sources (high-frequency interference, e.g. ignition cable not insulated)
- Read measured value block page 45-116,
display group number 001
Damage to pulse rotor or speed sensor -G45
- Inspect speed sensor -G45- and pulse rotor
for damage
Air gap between speed sensor -G45and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G45page 45-60 and 45-65
Air gap between speed sensor -G45and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G45and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-116,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-163
00285
Front right wheel speed sensor
-G45
Signal not to tolerance1)
00285
Front right wheel speed sensor
-G45
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
------------ 45-104 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
Rectifying fault
00287
Rear right wheel speed sensor
-G44
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G44and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Read measured value block page 45-116,
display group number 001
- Perform electrical test page 45-133, test
steps 9 and 13
Damage to pulse rotor or speed sensor -G44
Coil of speed sensor -G44- faulty
- Inspect speed sensor -G44- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G44page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-163
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G44and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Perform electrical test page 45-133, test
steps 9 and 13
Electrical interference because of external sources (high-frequency interference, e.g. ignition cable not insulated)
- Read measured value block page 45-116,
display group number 001
Damage to pulse rotor or speed sensor -G44
- Inspect speed sensor -G44- and pulse rotor
for damage
Air gap between speed sensor -G44and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G44page 45-60 and 45-65
Air gap between speed sensor -G44and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G44and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-116,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-163
00287
Rear right wheel speed sensor
-G44
Signal not to tolerance1)
00287
Rear right wheel speed sensor
-G44
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
Edition 04.00
S00.5103.58.20
------------ 45-105 ------------
45
OCTAVIA
Anti-Lock Brake System
in
cause
00290
Rear left wheel speed sensor
-G46
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G46and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Read measured value block page 45-116,
display group number 001
- Perform electrical test page 45-133, test
steps 10 and 14
Damage to pulse rotor or speed sensor -G46
Coil of speed sensor -G46- faulty
- Inspect speed sensor -G46- and pulse rotor
for damage
- Replace pulse rotor/speed sensor -G46page 45-60 and 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-163
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between wheel speed sensor -G46and control unit -J104
- Test wiring, plug connections and wheel
speed sensors
- Perform electrical test page 45-133, test
steps 10 and 14
Electrical interference because of external sources (high-frequency interference, e.g. ignition cable not insulated)
- Read measured value block page 45-116,
display group number 001
Damage to pulse rotor or speed sensor -G46
- Inspect speed sensor -G46- and pulse rotor
for damage
Air gap between speed sensor -G46and pulse rotor too large (signal not
o.k.)
- Replace pulse rotor/speed sensor -G46page 45-60 and 45-65
Air gap between speed sensor -G46and pulse rotor too large (signal not
o.k.)
- Inspect installation of speed sensor -G46and pulse rotor page 45-60 and 45-65
- Read measured value block page 45-116,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-163
00290
Rear left wheel speed sensor
-G46
Signal not to tolerance1)
00290
Rear left wheel speed sensor
-G46
Mechanical fault1)
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
Rectifying fault
00538
Reference voltage
Open circuit, short circuit to positive
or earth in wiring of
- Yaw rate sensor -G202- Lateral acceleration sensor -G200- Brake pressure sensor 1 -G201
- Brake pressure sensor 2 -G214
- Test fuses, cables, plug connections and
also voltage supply to control unit:
page 45-133, Electrical Test, test steps
20, 21, 22 and 23
Open circuit, short circuit to positive
or to earth in wiring
Fuses S162 and S163 faulty
- Test fuses, cables, plug connections and
also voltage supply to control unit:
page 45-133, Electrical Test, test steps 1
and 2
00668
System voltage terminal 30
Signal out of tolerance
00778
Steering angle sensor -G85
No communication1)
Open circuit or loose contact in
- Test fuses, cables, plug connections and
databus lines between steering angle
also voltage supply to control unit:
sensor -G85 and control unit -J104
page 45-133, Electrical Test, test step 19
- Read measured value block page 45-116,
display group number 004
Steering angle sensor -G85 faulty
- Replace steering angle sensor -G85page 45-174
- Perform zeroing:
page 45-124, Basic setting, display group
number 060
00778
Steering angle sensor -G851)
No or incorrect setting
Steering angle sensor -G85 transmits - Perform zeroing:
incorrect settings or no settings at all
page 45-124, Basic setting, display group
number 060
00778
Steering angle sensor -G851)
Mechanical fault
1)
Incorrect specification from steering
angle sensor -G85
Installation position of steering angle
sensor -G85 is incorrect
- Check installation position of steering angle
sensor -G85- page 45-174
Chassis geometry is not correct
- Check chassis alignment
Repair Group 44
Steering wheel was removed and no
zeroing carried out when re-fitted
- Perform zeroing:
page 45-124, Basic setting, display group
number 060
Data between the control unit -J104 and steering angle sensor -G85 is transferred over the CAN databus.
Edition 04.00
S00.5103.58.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
in
cause
00778
Steering angle sensor -G85
Implausible signal1)
Installation position of steering angle
sensor -G85 is incorrect
- Check installation position of steering angle
sensor -G85- page 45-174
Chassis geometry is not correct
- Check chassis alignment
Repair Group 44
Impermissible vibrations in steering
because of wear
- Perform zeroing:
page 45-124, Basic setting, display group
number 060
Steering angle sensor -G85 faulty
- Replace steering angle sensor -G85page 45-174
- Perform zeroing:
page 45-124, Basic setting, display group
number 060
Earth connection to sensor for brake
pressure 1 or 2 interrupted
Short circuit in signal cable to sensor
for brake pressure 1 or 2
- Test fuses, cables, plug connections and
also voltage supply to control unit:
page 45-133, Electrical Test, test steps 22
and 23
- Read measured value block page 45-116,
display group number 005
Sensor 1 -G201- or sensor 2 -G214for brake pressure faulty
- Replace sensor 1 -G201- or sensor 2 -G214for brake pressure page 47-28
- Perform zeroing:
page 45-124, Basic setting, display group
number 060
A hydraulic brake circuit has failed
- Check brake system
Repair Group 47
00778
Steering angle sensor -G85
Defective1)
00810
Sensor 1/2 for brake pressure
Implausible signal
Sensor 1 -G201
Sensor 2 -G214
1)
Data between the control unit -J104 and steering angle sensor -G85 is transferred over the CAN databus.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
Rectifying fault
00812
Release switch f. solenoid f.
brake pressure -F841)
Open circuit, short circuit to positive
or to earth in wiring to brake recognition switch -F83
Test brake recognition switch -F83
- Test cables, plug connections and also earth
cables according to current flow diagram:
page 45-133, Electrical Test, test step 25
- Perform operational check
page 45-124, Basic setting, display group
number 031
Brake servo unit faulty
If the fault occurs once again:
- Replace brake servo unit page 47-32
Open circuit or loose contact in wiring between brake pressure sensor 2
-G214 and control unit -J104
- Test fuses, cables, plug connections and
also voltage supply to control unit
page 45-133, Electrical Test, test step 23
- Read measured value block page 45-116,
display group number 005
Brake pressure sensor 2 -G214
faulty
- Replace brake pressure sensor 2 -G214page 47-28
- Perform zeroing:
page 45-124, Basic setting, display group
number 066
Open circuit or loose contact in wiring between brake pressure solenoid
-N247 and control unit -J104
- Test fuses, cables, plug connections and
also voltage supply to control unit
page 45-133, Electrical Test, test step 24
Brake pressure solenoid -N247 faulty
- Conduct operational check page 45-124,
Basic setting, display group number 031
Brake servo unit faulty
If the fault occurs once again:
- Replace brake servo unit page 47-32
Output stage in control unit faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-163
- Check coding of control unit page 45-114
- Perform zeroing:
page 45-124, Basic setting, display group
number 060, 063 and 066
00813
Sensor 2 for brake pressure
-G214
Electr. fault in circuit
00814
Brake pressure solenoid -N247
1)
The release switch for brake pressure solenoid -F84- is identical with the ESP brake recognition switch -F83-.
Edition 04.00
S00.5103.58.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
in
cause
01044
Control unit incorrectly coded
An incorrect code number was entered with V.A.G 1552
- Check coding of control unit page 45-114.
Electrical interference caused by external sources (high-frequency interference, e.g. ignition cables not insulated)
Open circuit, short circuit to positive
or to earth or loose contact in wiring
ABS control unit -J104- faulty
- Test all cables, plug connections for short circuit to positive or to earth
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Erase fault memory
- Conduct road test at more than 20 km/h
- Once again interrogate fault memory
If the fault occurs once again:
- Replace control unit -J104- page 45-163
Internal connection of el. motor to
control unit
Short circuit to positive or to earth or
open circuit
Control unit faulty
Pump motor faulty
- Test cables, plug connections and also earth
cables according to current flow diagram
page 45-133, Electrical Test, test step 1
- Perform an operational check page 45-29,
Final control diagnosis
- If hydraulic pump does not start during final
control diagnosis, replace control unit -J104-,
as a check
01130
ABS operation
Implausible signal1)
01276
ABS hydraulic pump -V64
Signal out of tolerance1)
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-163
01312
Drive databus defective2)
1)
2)
Open circuit, short circuit to positive
or to earth or loose contact in
databus line
- Test databus line for open circuit or short circuit according to current flow diagram
page 45-133, Electrical Test, test step 26
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
Occurs in the case of ESP only together with the fault: steering angle sensor -G85- no communication.
------------ 45-110 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
Rectifying fault
01314
Engine control unit
Fault in engine control unit
- Read out fault memory of engine control unit:
Open circuit, short circuit to positive
or to earth in the databus lines
- Test databus lines for open circuit or short
circuit according to current flow diagram
page 45-133, Electrical Test, test step 26
Open circuit, short circuit to positive
or to earth in the databus lines
- Test databus lines for open circuit or short
circuit according to current flow diagram
page 45-133, Electrical Test, test step 26
Open circuit, short circuit to positive
or to earth or loose contact in wiring
between lateral acceleration sensor
-G200- and control unit -J104
- Test lateral acceleration sensor -G200- Read measured value block page 45-116,
display group number 004
- Test wiring, plug connections and also earth
cables according to current flow diagram
page 45-133, Electrical Test, test step 20
Lateral acceleration sensor -G200not correctly installed
- Inspect installation position of lateral acceleration sensor -G200- page 45-171
Lateral acceleration sensor -G200faulty
- Replace lateral acceleration sensor -G200page 45-172
- Perform zeroing:
page 45-124, Basic setting, display group
number 063
Lateral acceleration sensor -G200not correctly installed
- Test lateral acceleration sensor -G200- Read measured value block page 45-116,
display group number 004
- Inspect installation position of lateral acceleration sensor -G200- page 45-171
Lateral acceleration sensor -G200faulty
- Replace lateral acceleration sensor -G200page 45-172
- Perform zeroing:
page 45-124, Basic setting, display group
number 063
01314
Engine control unit
No communication
01315
Gearbox control unit1)
No communication
01423
Lateral acceleration sensor
-G200
Electr. fault in circuit
01423
Lateral acceleration sensor
-G200
Implausible signal
1)
Only on vehicles fitted with automatic gearbox.
Edition 04.00
S00.5103.58.20
------------ 45-111 ------------
45
OCTAVIA
Anti-Lock Brake System
in
cause
01435
Sensor 1 for brake pressure
-G201
Electr. fault in circuit
Open circuit or loose contact in wiring between sensor 1 for brake pressure -G201 and control unit -J104
- Test sensor 1 for brake pressure -G201- Read measured value block page 45-116,
display group number 005
- Test fuses, wiring, plug connections and also
voltage supply to control unit:
page 45-133, Electrical Test, test step 22
Sensor 1 for brake pressure -G201faulty
- Replace sensor 1 for brake pressure -G201 page 47-28
- Perform zeroing:
page 45-124, Basic setting, display group
number 066
Open circuit in earth connection to
yaw rate sensor -G202
- Test yaw rate sensor -G202- Read measured value block page 45-116,
display group number 004
- Test wiring, plug connections to control unit
page 45-133, Electrical Test, test step 21
Yaw rate sensor -G202- not correctly
installed
- Inspect installation position of yaw rate sensor page 45-171
Yaw rate sensor -G202- faulty
- Replace yaw rate sensor -G202 page 45-172
Open circuit or loose contact in wiring between yaw rate sensor -G202
and control unit -J104
- Test yaw rate sensor -G202- Read measured value block page 45-116,
display group number 004
- Test fuses, wiring, plug connections and also
voltage supply to control unit
page 45-133, Electrical Test, test step 21
Yaw rate sensor -G202- faulty
- Replace yaw rate sensor -G202 page 47-172
01542
Yaw rate sensor -G202
Implausible signal
01542
Yaw rate sensor -G202
Electr. fault in circuit
------------ 45-1
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
Readout in display of V.A.G 1552 Possible cause of fault
65535
Control unit defective
45
Anti-Lock Brake System
Rectifying fault
Control unit faulty
- Replace control unit -J104- page 45-163
- Perform zeroing:
page 45-124, Basic setting, display group
number 060, 063 and 066
Erasing fault memory
Requirement:
l Fault memory has been interrogated.
-
Test of vehicle systems
Select function XX
Test of vehicle systems
Fault memory is erased!
Test of vehicle systems
Select function XX
Attention!
Fault memory was not interrogated
Edition 04.00
S00.5103.58.20
HELP
Press
key.
K Readout in display:
-
Press keys 0 and 5 for the function Erase
fault memory and confirm the entry with the
key Q.
K Readout in display:
-
HELP
Press
key.
K Readout in display:
Notes:
K If this readout appears in the display, then
the test sequence was incorrect.
Follow the test sequence exactly:
First of all, interrogate fault memory and then
erase it.
------------ 45-1
------------
45
Antilock Brake System
OCTAVIA
Ending output
Test of vehicle systems
Select function XX
HELP
Test of vehicle systems
Enter address word XX
HELP
K Readout in display:
-
Press keys 0 and 6 for the function End
output and confirm the entry with the key Q.
K Readout in display:
-
Switch ignition off.
Separate plug connection to the vehicle system tester.
Switch ignition on.
ABS warning light (K47), handbrake/brake fluid
level warning light (K14/33) and electronic stability programme warning light (K155) must go
out after about 2 seconds.
Coding control unit
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 or V.A.G
1551/3 A, respectively
The control unit installed in the vehicle is coded.
New control units supplied from the Parts Store
are not coded and must be coded after being
installed.
Requirement for coding
Coding is only possible if the workshop code
(WSC) has been entered in V.A.G 1552.
Test procedure
------------ 45-114 ------------
Determine the engine code letters and the
type of ESP hydraulic control unit fitted to
the vehicle.
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit (address word 03) page 45-97; ignition is
switched on for this step.
Edition 02.01
S00.5103.60.20
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OCTAVIA
est of vehicle systems
K Readout in display:
-
control unit
code
code
ABS
Press keys 0 and for the function
control unit and confirm the entry with the
key Q.
K Readout in display:
-
letters
45
Antilock Brake System
the correct code
of the vehicle and confirm the entry with the key Q.
control unit identification appears in the display of the vehicle system tester
ear code
2000
Note:
If a code is entered which does not match the
engine code letters, the code is accepted by the
control unit, but must always be corrected.
-
est of vehicle systems
Press key.
K Readout in display:
-
output
Note:
If a code is entered in the control unit which does
not match the vehicle model:
not accepted
K Readout in display:
If the control unit is coded with code 00000, the
ABS warning light (K47) and the handbrake/
brake fluid level warning light (K14/33) flash,
while the electronic stability programme warning light (K155) comes on and remains on.
If the electronic stability programme warning light
(K155) comes on for only 100 milliseconds after the ignition is switched on, a code without
TCS/ESP control has been entered.
Edition 02.01
S00.5103.60.20
------------ 45-115 ------------
45
$
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,OCTAVIA
Anti-Lock Brake System
testers and aids
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3
The control unit is able to transmit a large
number of measured values. These measured
values supply information regarding the operating state of the system or of the sensors connected. In many cases, the measured values
transmitted can be used for assisting fault finding and rectification of faults. As it is not possible to assess all of these measured values at
the same time, they are combined into individual
display groups which can be selected by means
of display group numbers.
ABS or
takes
a road test
system
tester V.A.G 1552 connected and in t
dior
mode.
ABS or
do not
come on in
case.
Safety
If it is necessary to use test and measuring
equipment during a road test, pay attention to
the following procedure:
The test and measuring equipment should
always be attached to the rear seat and operated from that point by a second person.
If the test and measuring equipment were
operated from the front passenger seat, this
could result in injury to the person occupying that seat in the event of an accident if the
front passenger airbag is deployed.
Test
-
------------ 45-1
------------
and test
meas-
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit (address word 03) page 45-97; ignition
switched on for this step.
Edition 04.00
S00.5103.58.20
OCTAVIA
Test of vehicle systems
Select function XX
1)
2)
45
Anti-Lock Brake System
HELP
K Readout in display:
-
Press keys 0 and 8 for the function Read
measured value block and confirm the entry with the key Q.
Enter display group number page 45-117,
List of available display group numbers.
001
1
2
3
4
Wheel speed at front left speed sensor -G47- (km/h)
Wheel speed at front right speed sensor -G45- (km/h)
Wheel speed at rear left speed sensor -G46- (km/h)
Wheel speed at rear right speed sensor -G44- (km/h)
002
1
2
3
4
Starting speed at front left speed sensor -G47- (km/h)
Starting speed at front right speed sensor -G45- (km/h)
Starting speed at rear left speed sensor -G46- (km/h)
Starting speed at rear right speed sensor -G44- (km/h)
003
1
2
3
4
Brake light switch -FESP brake recognition switch -F83Not assigned
Not assigned
004
1
2
3
4
Steering angle sensor -G85Lateral acceleration sensor -G200Yaw rate sensor -G202Not assigned
005
1
2
3
4
Brake pressure sensor -G201- or -G214Brake pressure sensor -G201- or -G214Not assigned
Not assigned
125
1
2
3
4
Engine databus
Steering angle databus1)
Not assigned
Gearbox databus2)
Only on vehicles fitted with ABS/EDL/ESP.
Only on vehicles fitted with automatic gearbox.
Edition 04.00
S00.5103.58.20
------------ 45-1
------------
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45
OCTAVIA
Anti-Lock Brake System
speed sensor
-
K-
Pay attention to the following aspects regarding
display group number 001:
What is displayed are the wheel speeds at that
moment. They are used for checking the wheel
speed sensor assignment to the wheel. (The
vehicle must be raised for this purpose and the
wheel rotated by hand by a 2nd person).
speed at rear
speed at rear
speed at ront
speed at
speed sensor
speed sensor
speed sensor
speed sensor
------------ 45-1
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-Lock Brake System
Test of wheel speed sensors -G44-, -G45-,
-G46-, -G47Display group number 002
Read measured value block
1
2
3
2
4
Read measured value block
255 km/h
255 km/h
255 km/h
255 km/h
Press keys 0, 0 and 2 and confirm the entry
with the key Q.
K-
The measured value block is always composed of 4 display blocks -arrows-. Refer to
the test table below for the explanation of the
readouts 1 to 4 in the individual display blocks.
K Readout in display (vehicle stationary):
Pay attention to the following aspects regarding
display group number 001:
The variations in the readouts in display blocks
1 and 2 must on no account be more than 6 km/
h, and in the case of display blocks 3 and 4, on
no account more than 2 km/h.
Read measured value block
3 km/h1)
6 km/h1)
2 km/h2)
1 km/h2)
Display group number: 002
K Readout in display: (starting off slowly)
Wheel speed at rear right wheel speed sensor
(0...255 km/h)
Wheel speed at rear left wheel speed sensor
(0...255 km/h)
Wheel speed at front right wheel speed sensor
(0...255 km/h)
Wheel speed at front left wheel speed sensor
(0...255 km/h)
1)
2)
If the variations in display blocks 1 and 2 are greater than 6 km/h, the causes of the fault may be the following:
If the variations in display blocks 3 and 4 are greater than 2 km/h, the causes of the fault may be the following:
Gap between wheel speed sensor and pulse rotor too large.
- Check whether the wheel speed sensor is correctly attached to the wheel bearing housing.
External damage to wheel speed sensor or pulse rotor.
- Replace the damaged component.
The next lower display group number can be
selected consecutively in turn with the key,
and the next higher number 002 with the key.
Press key C for entering the next display group
number.
If the key is pressed, it is necessary in this
case to once again press the keys 0 and 8 in
order to re-enter the procedure Reading measured value block.
Edition 04.00
S00.5103.58.20
------------ 45-119 ------------
45
OCTAVIA
Anti-Lock Brake System
Test of brake light switch -F- and of ESP
brake recognition switch -F83Display group number 003
-
Press keys 0, 0 and 3 and confirm the entry
with the key Q.
The measured value block is always composed of 4 display blocks -arrows-. Refer to
the test table below for the explanation of
the readouts 1 to 4 in the individual display
blocks.
Read measured value block
1
2
3
3
4
K-
Read measured value block
Not oper.
Not oper.
K Readout in display (vehicle stationary):
Read measured value block
Not oper.
Not oper.
Display group number: 003
K Readout in display
Not assigned
Not assigned
ESP brake recognition switch:1)
Not oper. brake pedal not operated
Operated brake pedal operated
If variations exist page 45-133, Electrical Test, test step 25
Brake light switch:
Not oper. brake pedal not operated
Operated brake pedal operated
If the readout in the display of V.A.G 1552 is -Not oper.- although the footbrake is operated, or is -Operated- although the footbrake is not operated, carry out test step 4 of the Electrical Test
page 45-133.
It is also possible that the brake light switch is not correctly set page 45-69, Setting brake light
switch.
1)
ESP brake recognition switch -F83- is identical with brake pressure solenoid release switch -F84-.
The next lower display group number can be
selected consecutively in turn with the key,
and the next higher number 002 with the key.
Press key C for entering the next display group
number.
If the key is pressed, it is necessary in this
case to once again press the keys 0 and 8 in
order to re-enter the procedure Reading measured value block.
------------ 45-120 ------------
Edition 04.00
S00.5103.58.20
#
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OCTAVIA
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measured value block
K-
measured value block
0,0
measured value block
Press keys 0, 0 and and confirm entry
key Q.
measured value block is
comto
posed of display blocks
test table
for
of
readouts to in
individual display
blocks.
in display
Pay attention to the following aspects regarding
display group number 004:
When driving forward through a left-hand curve,
all three readouts must be positive (without sign).
When reversing through a right-hand curve, all
three readouts must be negative (-).
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in display
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at full lock and at a speed of
readout rises constantly
a positive
at full lock and at a speed of
readout rises constantly
a
lectrical Test, test step
&
sensor
conduct a
-
is tested
display
lectrical Test, test step
display
key.
Press key
number.
for
S00.5103.58.20
number
display
can
in a
it is also necessary to
number
or
control is performed
a road test
or r
measured value block mode.
or
of control unit
is ended if
speed
be selected
in a
system tester V
connected and in
do not come on in t
case.
key is pressed, it is necessary in
case to once
press
keys 0 and in
order to re-enter
procedure
measured value block.
------------ 45-121 ------------
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45
OCTAVIA
Anti-Lock Brake System
Test of brake
sensor -
and
005
Read measured value block
1
2
Read measured value block
bar
bar
-
Read measured value block
bar
and confirm the entry
K-
The measured value block is always composed of 4 display blocks -arrows-. Refer to
the test table below for the explanation of the
readouts 1 to 4 in the individual display blocks.
K Readout in display (vehicle stationary):
005
bar
K Readout in display (example)
Brake
Brake
Press keys 0, 0 and
with the key Q.
sensors
and
when brake not depressed:
Test, test steps 22 and
sensors
and
when brake not depressed:
Test, test steps 22 and
bar
bar
The next lower display
number can be
selected consecutively in turn with the key.
Press key
number.
for
the next display
the key is pressed, it is necessary in this
case to once
press the keys 0 and in
measorder to re-enter the procedure
ured value
------------ 45-122 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
45
Anti-blocking system
Checking the data-bus line
Display group number 125
-
Read the measuring value block
1
2
3
125
Read the measuring value block
125
Engine 1 Steering sh.1 4-wheel drive 1 Gearbox 1
Read the measuring value block
Engine 1
Steering
sh.1
125
4-wheel
drive 1
Gearbox 1
K-
Enter 125 and confirm the entry with Q
There are always four display fields which
appear in the measuring value block -arrowsItemisation of the values 1 to 4 in the individual display fields can be found in the following test table.
K Readout shown on the display (with the vehicle
stationary)
Display group number 125
K Readout shown on the display (an example)
CAN-BUS for the transmission1)
1 the data-bus connection is available
0 the data-bus connection is not available2)
Data-BUS for the control unit for the four-wheel drive3)
1 the data-bus connection is available
0 the data-bus connection is not available2)
Data-BUS for the steering angle
1 the data-bus connection is available
0 the data-bus connection is not available2)
Data-BUS for the engine
1 the data-bus connection is available
0 the data-bus connection is not available2)
1)
Only for vehicles with an automatic gearbox
A wrong transmission control unit or wrong coding in the transmission control unit.
The transmission control unit is defect
Rep. Gr. 01 of the corresponding transmission identification code
2) The data-bus connection was interrupted or the data-bus line has been changed around
File Current flow plans, Fault Detection on Electrics and Installed Locations
3)
Only for vehicles with four-wheel drive
Comment:
If a control unit is not connected to data-bus lines or not installed then the corresponding display field will remain blank.
Press the C-button to enter the next display
group number.
Once the button has been pressed one should
then enter the function 08 Read measuring value
block.
Edition 06.02
S00.5103.64.20
------------
------------
45
#
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OCTAVIA
Anti-Lock Brake System
basic
testers and aids
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 to V.A.G
1551/3 A
asks
04
basic
Function 04 Initiating basic setting in the case
of ESP performs several tasks:
-1- Display group number 001 is required for
bleeding the hydraulic unit.
-2- Display group number 031 is used to
perform the operational check of the brake
pressure solenoid and of the ESP brake recognition switch.
-3- Display group numbers 060, 063 and 066
are required for the zeroing of the steering
angle sensor, lateral acceleration sensor and
of the brake pressure sensors.
45-36.
is
system to
nitiate basic
on
Basic setting 04, display group number 001, is
only required if at least one chamber of the brake
fluid reservoir has been completely emptied.
Initiating the basic setting should also be carried out after completing repairs involving leaks
in the brake system.
Function 11 Login procedure is not required in
this case.
------------ 45-124 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
!
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$
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This is necessary if:
the brake servo unit has been replaced.
this is requested in the fault memory.
Function 11 Login procedure is not required in
this case.
*+
**
Display group number 060 is selected to
perform the zeroing of the steering angle
sensor -G85- page 45-127.
Display group number 063 is selected to
perform the zeroing of the lateral acceleration sensor -G200- page 45-129.
Display group number 066 is selected to
perform the zeroing of the brake pressure
sensors -G201- and -G214- page 45-130.
Conducting the zeroing of display group numbers 060, 063 and 066 requires that function 11
Login procedure has first of all been successfully completed with the aid of the vehicle system tester page 45-131.
Zeroing is necessary if:
the control unit -J104-, or the steering column has been replaced,
the steering angle sensor -G85- has been
replaced,
settings at the running gear has been changed as part of a check of chassis alignment,
the lateral acceleration sensor -G200- has
been replaced,
the brake pressure sensors -G201- and/or
-G214- have been replaced,
S00.5103.58.20
------------ 45-125 ------------
45
%
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OCTAVIA
Anti-Lock Brake System
if, when dealing with a fault entry in the fault
memory of control unit -J104-, an instruction
is contained in the fault table to carry out zeroing,
the steering wheel has been taken off.
test
and
t
Test of vehicle systems
Select function XX
HELP
Basic setting
Enter display group number XXX
HELP
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit (address word 03); ignition is switched on for
this step page 45-97.
K Readout in display:
-
Start the engine.
Press keys 0 and 4 for the function Basic
setting and confirm the entry with the key Q.
K Readout in display:
-
Press keys 0, 3 and 1 and confirm the entry
with the key Q.
ABS warning light -K47- flashes.
System in basic setting
Solenoid
activated
System in basic setting
5.95 bar
6.16 bar
31
K Readout in display:
-
not oper.
31
33
key.
K Readout in display:
Do not depress brake pedal.
-
System in basic setting
Operate pedal and hold...
Press
Press
key.
K Readout in display:
-
Depress brake pedal with firm foot pressure
and hold.
Brake lights come on.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
If the brake lights do not come on:
Brake light suppression relay -J508- faulty.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
ESP brake recognition switch -F83- or brake
pressure solenoid -N247- faulty.
System in basic setting
18.06 bar
19.12 bar
operated
System in basic setting
Release pedal
System in basic setting
0.85 bar
1.27 bar
34
Perform electrical test page 45-133, test
step 25.
Press
36
37
Test of vehicle systems
Select function XX
HELP
Press
key.
K Readout in display:
-
Take foot off brake pedal.
Press
key.
K Readout in display:
-
System in basic setting
Solenoid test ended
key.
K Readout in display:
-
35
not oper.
Press
key.
K Readout in display:
-
Press key.
K Readout in display:
-
End output (function 06) page 45-114.
S00.5103.58.20
Start the engine.
Conduct a short road test on a flat surface.
Drive straightahead and not faster than 20
km/h; pay attention to the following two
points.
-
If the steering wheel is not in the middle
position when driving straightahead, correct the position of the steering wheel as
part of a check of chassis alignment.
Carry out the zeroing.
------------
------------
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45
OCTAVIA
Anti-Lock Brake System
is no
steering
ignition
XXX
The readout in the display changes to 0.0 after
successful zeroing.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
Test of vehicle systems
Select function XX
Antilock Brake System
HELP
45
K Readout in display:
-
End output (function 06) page 45-114.
ABS warning light -K47- and ESP warning light
-K155- come on for about 2 seconds.
Display group number 063: zero adjustment
of lateral acceleration sender -G200l Vehicle is standing on level ground.
Test of vehicle systems
Select function XX
HELP
Select function 08 Read measured value
block and check the measured values
page 45-116, display group number 004.
First of all, successfully complete function
11 Login procedure with vehicle system
tester V.A.G 1552 page 45-131.
K Readout in display:
-
Press keys 0 and 4 for the function Basic
setting and confirm the entry with the key
Q.
K Readout in display:
Basic setting
Enter display group number XXX
Press keys 0, 6 and 3 and confirm the entry
with the key Q.
ABS warning light -K47- flashes.
Function is not known or cannot be
carried out at the moment
System in basic setting
Adjustment o.k.
63
0.6m/s2
K If this readout appears in the display, the login
procedure has not been successfully completed.
K Readout in display:
After successful zero adjustment, the readout
in the display does not return to 0.0 m/s2.
or:
System in basic setting
Adjustment n. possible
63
5.0m/s2
K If this readout appears in the display, the measured values are not within the tolerance range
of 2.5m/s2.
1. Interrogate fault memory (function 02)
2. Erase fault memory (function 05)
3. End output (function 06)
4. Switch ignition off.
Edition 02.01
S00.5103.60.20
------------ 45-129
45-193 ------------
45
OCTAVIA
Antilock Brake System
5. Switch ignition on.
6. Repeat the zero adjustment.
-
Test of vehicle systems
Select function XX
HELP
Press key.
K Readout in display:
-
End output (function 06) page 45-114.
ABS warning light -K47- and ESP warning light
-K155- come on for about 2 seconds.
Display group number 066: zero adjustment
of brake pressure senders -G201- and -G214l Brake pedal not operated.
-
Select function 08 Read measured value
block to check the measured values page
45-116, display group number 005.
l First of all, successfully perform the function
11 Login procedure with the vehicle system tester V.A.G 1552 page 45-131.
Test of vehicle systems
Select function XX
HELP
K Readout in display:
-
Basic setting
Enter display group number XXX
Press keys 0 and 4 for the function Basic
setting and confirm the entry with the key
Q.
K Readout in display:
-
Press keys 0, 6 and 6 and confirm the entry
with the key Q.
ABS warning light -K47- flashes.
Function is not known or cannot be
carried out at the moment
System in basic setting
Adjustment o.k.
-0.85bar
-2.12bar
66
K If this readout appears in the display, the login
procedure has not been successfully performed.
K Readout in display:
After successful zero adjustment, the readout
.
in the display does not return to 0.00
or:
------------ 45-194 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
System in basic setting
Zeroing
-10.85bar
n. possible
-12.12bar
66
K If this readout appears in the display, the measured values are not within the range of -2 bar to
8 bar which is permitted for the zeroing.
1. Interrogate fault memory (function 02)
2. Erase fault memory (function 05)
3. End output (function 06)
4. Switch the ignition off.
5. Switch the ignition on.
6. Once again carry out zeroing.
-
Test of vehicle systems
Select function XX
HELP
Press key.
K Readout in display:
-
End output (function 06) page 45-114.
ABS warning light -K47- and ESP warning light
-K155- come on for about 2 seconds.
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 or V.A.G
1551/3 A
Coding is only possible if the workshop code
(WSC) is entered in the vehicle system tester
V.A.G 1552.
-
Test of vehicle systems
Select function XX
S00.5103.58.20
HELP
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit (address word 03) page 45-97; ignition is
switched on for this step.
K Readout in display:
-
Press key 1 twice for the function Login procedure and confirm the entry with the key Q.
------------ 45-131 ------------
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45
OCTAVIA
Antilock Brake System
K Readout in display:
-
code
t
and
K Readout in display:
------------
------------
Edition 02.01
S00.5103.60.20
OCTAVIA
'
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Hand-held multimeter, e.g. V.A.G 1526 A
Adapter cable set 1594/A
Test box V.A.G 1598/A
Adapter V.A.G 1598/33
"
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,+
on which self-diagnosis does not provide any
indication of the source of the fault. In this
case, work through the complete electrical
test.
on which self-diagnosis provides a direct indication of the source of the fault. In this case,
work through only the test step recommended in the fault table (specific fault finding).
$%
l Before commencing the test, switch off ignition and electrical components (headlights,
lighting, fan...).
l Fuses S13, S15, S162, S163 must be in
proper order.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
As a check, remove fuse from the fuse holder
on the battery and on the left fuse holder on
the dash panel.
Note:
The following 2 steps do not apply to the 1.6ltr./55 kW engine.
S00.5103.58.20
K-
Unplug the connector of air mass meter -1from the air guide pipe of the air filter.
Remove screw -2- at air filter -3- and place
filter down to the side.
------------ 45-133 ------------
45
OCTAVIA
Anti-Lock Brake System
Connecting test box V.A.G 1598 A with
adapter V.A.G 1598/33
K
K
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Note:
The specifications are matched to hand-held
multimeter V.A.G 1526 A and do not necessarily apply to other test equipment.
Multipin connectors with contact
assignment
Note:
Not all the contacts listed are presently assigned
and must on no account be connected to other
components!
K Contact assignment of plug connection T16a
(diagnosis socket) with vehicle system tester
V.A.G 1552
------------ 45-134 ------------
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Edition 04.00
S00.5103.58.20
OCTAVIA
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S00.5103.58.20
------------ 45-135 ------------
45
Contact
23
Stop light switch -F-
25
Lateral acceleration sensor -G200- (voltage cable)
24
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
1)
Anti-Lock Brake System
OCTAVIA
ESP pushbutton -E256-/voltage supply relay for warning light -K155 Brake pressure sensor 2 -G214-
Yaw rate sensor -G202- (voltage cable)
Brake pressure sensor 1 -G201-
ESP brake recognition switch -F83-1)
Not assigned
Brake light suppression relay -J508-
ESP brake recognition switch - F83-1)
Left front wheel speed sensor -G47 Left front wheel speed sensor -G47-
Control unit with display unit for radio and navigation (only with navigation system)
Rear left wheel speed sensor -G46 Rear left wheel speed sensor -G46 Not assigned
Plug connection T16a/7, K wire
Lateral acceleration sensor -G200- (signal cable)
Brake pressure sensor 2 -G214-
Yaw rate sensor -G202- (signal cable)
Brake pressure sensor 1 -G201-
Voltage supply terminal 15 through S 13
Not assigned
Earth point below battery on left
Voltage supply of battery + (through S163)
ESP brake recognition switch -F83- is identical with release switch for brake pressure solenoid -F84-.
------------ 45-136 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
Antilock Brake System
Voltage supply of ABS hydraulic pump -V64-
Perform test step 1
Voltage supply of control unit -J104
Perform test step 3
Voltage supply of valves in hydraulic unit
Operation of brake light switch -F
Perform test step 2
Perform test step 4
Brake light suppression relay -J508-
Perform test step 5
Resistance of front right wheel speed sensor -G45
Perform test step 7
Resistance of rear right wheel speed sensor -G44
Perform test step 9
Voltage signal of front right wheel speed sensor -G45
Perform test step 11
Voltage signal of rear right wheel speed sensor -G44
Perform test step 13
Operation of ABS warning light -K47
Perform test step 15
Operation of ESP stability programme warning light -K155
Perform test step 17
Actuation of steering angle sender -G85
Perform test step 19
Coding bridge
Resistance of front left wheel speed sensor -G47
Resistance of rear left wheel speed sensor -G46
Voltage signal of front left wheel speed sensor -G47
Voltage signal of rear left wheel speed sensor -G46
Operation of handbrake/brake fluid level warning light -K14/33
Operation of ESP pushbutton -E256
Perform test step 6
Perform test step 8
Perform test step 10
Perform test step 12
Perform test step 14
Perform test step 16
Perform test step 18
Actuation of lateral acceleration sender -G200
Perform test step 20
Actuation of brake pressure sender -1- -G201
Perform test step 22
Actuation of yaw rate sender -G202
Actuation of brake pressure sender -2- -G214
Perform test step 21
Perform test step 23
Actuation of brake pressure solenoid -N247
Perform test step 24
Test of databus cable
Perform test step 26
Actuation of brake recognition switch -F83 1)
Voltage supply of V.A.G 1551, plug connection T16a
Resistance of K wire for self-diagnosis, plug connection T16a
1)
Perform test step 25
Perform test step 27
Perform test step 28
Brake recognition switch -F83- is identical with brake pressure solenoid release switch -F84-.
Edition 02.01
S00.5103.60.20
45
------------
------------
45
OCTAVIA
Antilock Brake System
Test table
Notes on test table
The socket designations of test box V.A.G 1598 A with adapter V.A.G 1598/33 are identical to the contact designations of the control unit -J104- in the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the measurements obtained differ from the specifications, carry out the measures indicated in the right-hand part
of the table for rectifying the fault.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Conduct continuity tests with adapter cable set V.A.G 1594 A (bridges).
If the measurements obtained differ only slightly from the specifications, then clean the sockets and connectors of
the testers and test cables (with contact spray G 000 700 04) and repeat the test. Before replacing the particular
components, inspect the cables and connections and also repeat the resistance measurement at the component,
particularly if the specifications are less than 10 .
Test steps 1 - 20
Test steps 21 - 28 page 45-148
Switch on measuring range: Voltage measurement (20 V =)
Test
step
V.A.G
1598 A
Sockets
Test of
15 + 47
Voltage supply for hydraulic pump -V64(terminal 30) at control unit -J104-
Ignition switched off
10.0 - 14.5 V
- Test cable from contact
T47a/47 through fuse S163
to battery +.
- Test cable from contact
T47a/15 to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
46 + 16
Voltage supply for
valves in hydraulic
unit -N55- (terminal
30) at control unit
-J104-
Ignition switched off
10.0 - 14.5 V
- Test cable from contact
T47a/16 through fuse S162
to battery +.
- Test cable from contact
T47a/46 to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
44 + 46
Voltage supply (terminal 15) of control unit
-J104-
Ignition switched on
10.0 - 14.5 V
- Test cable from contact
T47a/44 through fuse S13,
and ignition/starter switch.
- Test cable from contact
T47a/46 to earth.
Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations
------------ 45-138
45-198 ------------
Test conditions
- Additional operations
Specification
Measures if readout differs
from specification
Edition 02.01
S00.5103.60.20
'#($
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OCTAVIA
23 + 46
4a
Brake light switch -F-
Brake light switch -F-
0.0 - 0.5 V
- Brake pedal operated
10.0 - 14.5 V
Set measuring range
200
- Unplug multipin connector T47a from control unit -J104.
- Unplug multipin connector of brake light/
brake pedal switch.
- Test cables for open
circuit.
- Test cable from contact
23 (control unit) to contact 1 (brake light
switch).
Ignition switched off
Brake pedal not operated
Set measuring range
20 M
- Remove fuse S13.
- Test cables for short
circuit to positive or to
earth.
S00.5103.58.20
#
max. 1.5
- Set brake light switch, if
necessary
page 45-69.
- Replace brake light switch
page 45-69.
- Test contact 1 from brake
light switch -F- to fuse S13.
- Test cables for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
------------
------------
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45
OCTAVIA
Anti-Lock Brake System
on
est
A
Sockets
23 + 46
est of
Brake light suppression relay -J508-
31 + 15
est conditions
from
Ignition switched on
Brake pedal operated
10.0 - 14.5 V
- Bridge sockets 31 and
15
0.0 - 0.5 V
if
differs
- Replace brake light suppression relay -J508-.
- Test cables for open circuit
and short circuit according
to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
on
est
A
Sockets
8 + 18
------------
------------
est of
Coding bridge
est conditions
Ignition switched off
- Unplug multipin connector T47a
- Connect test box V.A.G
1598/A with adapter
V.A.G 1598/33
- Test cable for open circuit
from
max. 1.5
if
differs
- Test cable from contact 8
to contact 18 for open circuit.
Edition 04.00
S00.5103.58.20
!
OCTAVIA
3+4
Resistance of front
right wheel speed
sensor -G45-
Ignition switched off
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
If no fault is found in the wiring:
- Replace wheel speed sensor -G45- page 45-60.
33 + 34
Resistance of front left
wheel speed sensor
-G47-
Ignition switched off
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
If no fault is found in the wiring:
- Replace wheel speed sensor -G47- page 45-60.
9
7+6
Resistance of rear
right wheel speed
sensor -G44-
Ignition switched off
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
If no fault is found in the wiring:
- Replace wheel speed sensor -G44- page 45-65.
S00.5103.58.20
------------ 45-141 ------------
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45
OCTAVIA
Anti-Lock Brake System
on
est
A
Sockets
est
est conditions
on
est
A
Sockets
est
est conditions
------------
------------
Edition 04.00
S00.5103.58.20
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OCTAVIA
S00.5103.58.20
------------ 45-143 ------------
45
OCTAVIA
Antilock Brake System
Operational test: Handbrake/brake fluid level warning light -K14/33Test
step
V.A.G
1598 A
Sockets
Test of
Test conditions
- Additional operations
Specification
Measures if readout differs
from specification
16
Operation of handbrake/brake fluid level
warning light -K14/33-
Brake fluid at correct
level
Ignition switched off
Multipin connector
plugged in at control
unit -J104 and locked.
- Switch ignition on.
Warning light
-K14/33comes on for 2
s and goes out
again.
- Test brake fluid level warning contact -F34- in cap of
brake fluid reservoir.
- Test cable from contact
T32a/29 (dash panel insert) to brake fluid warning
contact for short to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test dash panel insert,
fault in dash panel insert.
Electrical System; Repair
Group 90; Dash Panel Insert
Specification
Measures if readout differs
from specification
Operational test: Electronic stability programme warning light -K155Test
step
V.A.G
1598 A
Sockets
17
Test of
Operation of ESP
warning light -K155-
Test conditions
- Additional operations
Ignition switched off
Multipin connector
plugged into control
unit -J104 and locked.
- Switch ignition on.
Warning light
- Test cable from contact
-K155- comes
T47a/22 (control unit)
on for 2 s and
through voltage supply regoes out again.
lay -J535- to contact T32b/
14 (dash panel insert) for
open circuit and short to
positive.
If warning light -K155- comes
on and remains on:
- Test cable from contact
T47a/22 (control unit)
through voltage supply relay -J535- to contact T32b/
14 (dash panel insert) for
short to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test dash panel insert,
fault in dash panel insert.
- Test ESP button -E256-.
Electrical System; Repair
Group 90; Dash Panel Insert
- Test voltage supply relay
for warning light -K155-.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
------------ 45-144
45-200 ------------
Edition 02.01
S00.5103.60.20
!"
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OCTAVIA
.
/
18
18a
15 + 24
S00.5103.58.20
.
Operation of ESP
pushbutton -E256-
Operation of ESP
pushbutton -E256-
.
Ignition switched off
Operation of ESP stability programme warning light -K155- was
tested in test step 17.
Multipin connector is
plugged in at control
unit -J104- and locked.
- Switch ignition on.
Warning light
-K155- comes
on for 2 s and
goes out again
- Operate ESP
pushbutton.
Warning light
-K155- comes
on
- Operate ESP
pushbutton once
again.
Warning light
-K155- goes
out
- Switch ignition off.
- Unplug multipin connector from control unit
-J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/33.
- Switch ignition on.
- Perform test step 18a
- Test cable from contact
T47a/15 (control unit) to
earth.
- Test cable from contact
T47a/24 (control unit) to
contact T4f/2 (ESP
pushbutton) for open circuit
and short circuit to positive
or to earth.
- Pushbutton of -E256not pressed and warning light -K155- comes
on.
3.5 - 5.0 V
- Hold pushbutton of
-E256- pressed and
warning light -K155comes on.
8.0 - 14.5 V
- Test cable from contact
T47a/24 (control unit) to
contact T32b/14 (dash
panel) for open circuit and
for short circuit to positive
or to earth.
- Test voltage supply of contact T4f/1 (ESP
pushbutton) through fuse
S13 for open circuit.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Replace ESP pushbutton.
Body Fitting Work; Repair
Group 70; Dash Panel
------------ 45-145 ------------
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OCTAVIA
Anti-Lock Brake System
on
est
step
19
in test step
A
Sockets
-
est
Earth and voltage
supply of steering angle sensor -G85
resistance
est conditions
operations
Ignition switched off
- Unplug multipin connector T47a from control unit -J104-.
- Separate plug connection of steering angle
sensor.
- Test voltage supply of
steering angle sensor
at plug connection
T6w.
- Test cable between
contact T6w/4 and
contact T6w/1.
Ignition switched on
- Test cable between
contact T6w/5 and
contact T6w/1.
19a
Cables of steering angle sensor -G85
Measuring range
20M set
- Remove fuse S13.
- Test cables for short
circuit to positive or to
earth.
------------
- Test cable from contact
T6w/4 (steering angle sensor) to fuse S15 for open
circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
10.0 - 14.5 V
10.0 - 14.5 V
- Test cable from contact
T6w/5 (steering angle sensor) to fuse S13 for open
circuit.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Measuring range
200 set
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/33.
- Test the following cables for open circuit:
- Cable from contact
T6w/3 (steering angle
sensor) to contact
T47a/19 (control unit).
- Cable from contact
T6w/2 (steering angle
sensor) to contact
T47a/20 (control unit).
- Cable from contact
T6w/1 to earth.
------------
in test step
max. 1.5
- Test cables for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Edition 04.00
S00.5103.58.20
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OCTAVIA
Anti-Lock Brake System
est
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21
A
Sockets
-
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Cables of yaw rate
sensor -G202-
est conditions
Ignition switched off
Measuring range
200 set
- Unplug multipin connector T47a from control unit -J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/33.
- Separate plug connection T3m from yaw rate
sensor -G202-.
- Test cables for open
circuit:
- Cable from contact
max. 1.5
T3m/1 (yaw rate sensor) to contact T47a/42
(control unit).
- Test cables for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Cable from contact
T3m/2 (yaw rate sensor) to contact T47a/11
(control unit).
- Cable from contact
T3m/3 (yaw rate sensor) to contact T47a/27
(control unit).
Measuring range
20M set
- Remove fuse S13.
- Test cables for short
circuit to positive or to
earth.
------------
------------
Edition 04.00
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Sockets
23
est
est conditions
------------
------------
Edition 04.00
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Anti-Lock Brake System
on
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A
Sockets
est
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------------
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Edition 04.00
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OCTAVIA
Anti-Lock Brake System
on
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A
Sockets
est of
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from
if
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A
Sockets
est of
est conditions
from
------------ 45-154 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
Antilock Brake System
Electrical/electronic components and fitting locations
1 - Brake servo unit with brake master
cylinder and brake fluid reservoir
The brake servo unit includes the following components:
release switch for brake pressure solenoid -F84-. This switch is identical
with the ESP brake recognition switch
-F83-.
Edition 05.01
S00.5103.61.20
45
Mark 20
ESP brake recognition switch -F83- is
tested by self-diagnosis
brake pressure solenoid in brake
servo unit -N247 brake pressure solenoid in brake
servo unit -N247- is tested by self-diagnosis
------------ 45-155 ------------
45
Anti-Lock Brake System
OCTAVIA
- Brake
sensor
Is tested by self-diagnosis
Brake pressure sensor -1- and brake
pressure sensor -2- are identical components
Brake pressure sensor -1- can also
be fitted at the same location as brake
pressure sensor -2-, item 3
Removing and installing
page 47-28
- Brake
sensor
Is tested by self-diagnosis
Brake pressure sensor -2- and brake
pressure sensor -1- are identical components
Brake pressure sensor -2- can also
be fitted at the same location as brake
pressure sensor -1-, item 2
Removing and installing
page 47-28
4-
------------
------------
ESP brake recognition switch -F83 Brake pressure solenoid -N247-
Edition 04.00
S00.5103.58.20
OCTAVIA
5 - Plug connection T14c
Brake recognition switch -F83 Brake pressure solenoid in brake
servo unit -N247 Sender -1- for brake pressure -G201 Sender -2- for brake pressure -G2146 - Lateral acceleration sender -G200 Fitting location: next to steering column below dash panel
Is tested by self-diagnosis
7 - Yaw rate sender -G202 Fitting location: next to steering column below dash panel
Is tested by self-diagnosis
8 - Steering angle sender -G85 Fitting location: on steering column
between steering wheel and steering
column switch
Is tested by self-diagnosis
9 - Electronic stability programme warning light -K155 Fitting location: in dash panel insert
Operation page 45-92
10 - Handbrake/brake fluid level warning
light -K14/33 Fitting location: in dash panel insert
Operation page 45-92
11 - ABS warning light
Fitting location: in dash panel insert
Operation page 45-92
12 - Parts of ABS system at rear suspension
(Fig. shows only disc brakes)
Rear right and left wheel speed sensors -G44/G46 Is tested by self-diagnosis
- Removing and installing
page 45-65
- Installing wheel speed sensor cables
page 45-67
Pulse rotor for rear right and left wheel
speed sensors
- Testing page 45-66
- Removing and installing: pulse rotor
is replaced together with wheel hub
page 42-23 and 42-28.
Edition 02.01
S00.5103.60.20
45
Antilock Brake System
13 - Parts of ABS system at front suspension
Front right and left wheel speed sensors -G45/G47 1)
- Removing and installing
page 45-60
- Installing wheel speed sensor cables
page 45-62
Pulse rotor for front right and left wheel
speed sensors
- Testing page 45-61
- Removing and installing: pulse rotor
is replaced together with wheel hub
page 40-13.
14 - Voltage relay for warning light K155
-J535 Fitting location: additional relay holder,
position 7
15 - Diagnostic connection
Fitting location: in storage compartment driver side
16 - Brake light switch -F Open in off position
- Setting page 45-69
- Remove by turning 90 to the left
page 45-69
- Install by turning 90 to the right
page 45-69
Must be tested in measured value
block page 45-116
17 - ABS/EDL/ESP control unit -J104 Fitting location: at hydraulic unit in left
of engine compartment
Is tested by self-diagnosis
Test of multipin connection to control
unit page 45-134
Do not unplug multipin plug connection before completing self-diagnosis.
Switch ignition off before separating
plug connection.
18 - Hydraulic control unit for ABS/EDL/
ESP -N55 Fitting location: in left of engine compartment
Hydraulic unit -N55- consists of hydraulic pump -V64- and valve block
with inlet and outlet valves
Is tested by self-diagnosis
If hydraulic unit is replaced, it is essential to seal old part with plugs from
installation parts kit; Part No. Parts
List
Removing and installing hydraulic control unit (hydraulic unit -N55- with control unit -J104-) page 45-158
Hydraulic pump -V64- and valve block
must not be separated
Servicing hydraulic control unit
page 45-163
------------ 45-157
45-201 ------------
45
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Anti-Lock Brake System
and
and
Note:
As a general rule, always ensure that no brake
fluid gets into the connector housing of the control unit.
This can result in corrosion to the contacts and
thus in a failure of the system.
If the plug housing is soiled, it should be carefully cleaned with compressed air.
testers and aids
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 or
V.A.G 1551/3A
Brake pedal depresser, e.g. V.A.G 1238/B
or V.A.G 1869/2
Installation parts kit, Part No. Parts List
Installation parts kit consists of plugs and protective cap
Brake filling and bleeding appliance, e.g.
ROMESS S15
Bleeder bottle (commercially available)
Brake fluid page 00-8
connector
47-pin
Do not separate plug connection before self-diagnosis is completed.
Switch off ignition before separating
the plug connection.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104together form the hydraulic control unit.
The hydraulic control unit should be
removed and installed as a complete
unit page 45-159.
Servicing page 45-163
- Brake
Between brake master cylinder/floating piston circuit and hydraulic unit
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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Hydraulic unit to front left brake caliper
Hydraulic unit to rear right wheel cylinder/brake caliper
Hydraulic unit to rear left wheel cylinder/brake caliper
Hydraulic unit to front right brake caliper
Between brake master cylinder/pushrod piston circuit and hydraulic unit
Notes:
Before disconnecting the battery, determine
the code of radio set fitted with anti-theft coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
-
S00.5103.58.20
Disconnect battery.
------------
------------
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Anti-Lock Brake System
Note:
The following 2 steps do not apply to the 1.6ltr./55 kW engine:
K
K
K
Note:
Ensure that no brake fluid gets onto the contacts.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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Note:
Brake lines in the area of the hydraulic unit must
not be bent.
K
K
Note:
Third bolt attaching hydraulic control unit is concealed by hydraulic pump -V64-.
S00.5103.58.20
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OCTAVIA
Anti-Lock Brake System
Notes:
Do not remove plugs at the hydraulic unit
until the appropriate brake line is fitted on.
If the plugs are removed sooner from the hydraulic unit, brake fluid may flow out with the
result that the system is no longer properly
filled and bled.
Note:
Do not fully tighten bolts. This makes it easier
to connect the individual brake lines to the hydraulic control unit.
K
Note:
Third bolt attaching hydraulic control unit is concealed by hydraulic pump -V64-.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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S00.5103.58.20
------------
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45
Anti-Lock Brake System
OCTAVIA
Note:
K When pulling off the control unit -b-, ensure that
the valve domes of the hydraulic unit -a- are not
twisted with the solenoids of the control unit.
K
Notes:
Protective cap -1- and plugs -2 and 3- are
included in the Installation parts kit.
It is also possible to use the same parts from
the new hydraulic units fitted in place of the
plugs and protective cap supplied with the
Installation parts kit.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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K Hydraulic unit (N55) and hydraulic pump
(V64) -a-:
Hydraulic unit: The valve block contains the
control valves.
Hydraulic pump -V64- and hydraulic unit -N55must not be separated from each other.
If the hydraulic unit is replaced, fit the protective cap for valve domes ( page 45-164,
Fig. S45-0047, item 1) onto the old part and
seal the old part with the plugs ( Fig. S450047, items 2 and 3). This is a condition for
any warranty claims.
1
ABS control unit (J104) -b-:
Notes:
It is essential that the area of the control unitvalve block is clean.
When assembling control unit and hydraulic
unit, ensure that the valve domes of the hydraulic unit are not tilted with the solenoids
of the control unit.
S00.5103.58.20
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Anti-Lock Brake System
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testers and aids
Wiring loom repair kit, e.g. koda Service
Case, order No. S 504 500 V
Solid lubricating paste G 000 650
sors
and
sen-
page 45-60
page 45-61
page 45-61
sensor
and
Notes:
It is prohibited to carry out repairs to screened
cables of the ABS system.
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
-
Disconnect battery.
Note:
The following 2 steps do not apply to the 1.6ltr./55 kW engine:
------------
------------
K-
Unplug connector of the air mass meter -1from the air guide pipe of the air filter.
Remove screws -2- at the air filter -3- and
place filter to the side.
On diesel engines, remove relay carrier
above brake servo unit.
Edition 04.00
S00.5103.58.20
OCTAVIA
K
K
K
S00.5103.58.20
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------------
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OCTAVIA
Anti-Lock Brake System
K Contact assignment
Contact
3+4
------------
connection
Front right wheel speed sensor
-G45
33 + 34
Front left wheel speed sensor -G47
36 + 37
Rear left wheel speed sensor -G46
6+7
------------
connection
Rear right wheel speed sensor
-G44
K-
Use a suitable ejection tool from the wiring
loom repair kit to knock out the appropriate
contacts.
Release connector at wheel speed sensor
and separate plug connection.
Remove faulty wheel speed sensor cable.
Pull in new wheel speed sensor cable.
Connect wheel speed sensor cable to wheel
speed sensor.
Edition 04.00
S00.5103.58.20
OCTAVIA
K
Note:
When installing the wheel speed sensor cable,
ensure that it is fitted free of twisting in the wheelhouse.
K
S00.5103.58.20
------------
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K
and
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testers and aids
------------
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Edition 04.00
S00.5103.58.20
OCTAVIA
The procedure for removal and installation of
the yaw rate sensor -G202- and of the lateral
acceleration sensor -G200- is identical with the
exception of the particular sensor to be replaced.
Notes:
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
Disconnect battery.
K - Remove bottom part of dash panel -1-.
Body Fitting Work; Repair Group 70; Dash
Panel
-
Remove bottom part of steering column trim
-2-.
Body Fitting Work; Repair Group 70; Dash
Panel
K The yaw rate sensor (G202) -1- and the lateral
acceleration sensor (G200) -2- are attached by
means of a common bracket -3- to the bearing
bracket -4- of the steering column -a-.
Note:
Because of the common bracket, it is not possible to remove the sensors individually. After removing the bracket, the yaw rate sensor -G202and the acceleration sensor -G200- can be replaced separately.
S00.5103.58.20
Unplug the connectors -arrows- of the yaw
rate sensor -G202- and of the lateral acceleration sensor -G200-.
Remove hexagon bolt -5- and take out bracket
-3- together with yaw rate sensor -G202- and
lateral acceleration sensor -G200-.
------------
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Anti-Lock Brake System
rate sensor
K
sensor -
K
K
Note:
The
------------
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Edition 04.00
S00.5103.58.20
OCTAVIA
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testers and aids
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3 or V.A.G
1551/3A
Notes:
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Disconnect battery.
into
tion.
steering
Airbag
as
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bottom
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into
------------
------------
necessary
steering angle sensor
gether
the airbag
in
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contact
Edition 04.00
S00.5103.58.20
OCTAVIA
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Anti-Lock Brake System
K
Note:
After removing the transport protection or the
adhesive tape, respectively, do not turn clock
spring contact; it is only permissible to position
the steering angle sensor -G85- in the middle
position.
K
and
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------------
------------
Edition 04.00
S00.5103.58.20
45
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cylinder
models
Notes:
The hydraulic unit should be removed and
installed complete page 45-158.
Servicing from page 45-163.
Connections of brake lines should be tightened as a general rule to a torque of 14 Nm.
Complete brake master cylinders and brake
servo units can be replaced separately from
each other.
Edition 05.01
S00.5103.61.20
45
Antilock Brake System
control
master
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Anti-Lock Brake System
4 - Boot
Ensure correctly installed; risk of suction noises
5-
Is attached to the edge of the brake
servo unit
Is used for mounting connector -item
15-
a
With integrated brake fluid level warning contact -F34-
- Brake
-
0-
0-
- Bracket
-
4 - ABS/EDL/ESP
5 - ABS/EDL/ESP
-
For fixing position of wiring loom -item
16-
Moisten with brake fluid and press in
expansion reservoir
Insert through brake master cylinder
- Brake
sensor
In floating piston circuit
Removing and installing
page 47-28
4 - Brake
sensor
In pushrod piston circuit
Removing and installing
page 47-28
Only on vehicles with 110 kW engines
Replace
- Brake master
Must not be repaired; replace complete if fault exists
Removing and installing
page 47-30
5-
OCTAVIA
Hydraulic unit to front left brake caliper
Hydraulic unit to rear right wheel cylinder/brake caliper
Hydraulic unit to rear left wheel cylinder/brake caliper
Hydraulic unit to front right brake caliper
0 - Brake
Brake master cylinder/floating piston
circuit to hydraulic unit
- Brake
Brake master cylinder/pushrod piston
circuit to hydraulic unit
-V
With non-return valve
Insert into brake servo unit
Connects wiring loom of dash panel/
engine compartment
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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page 45-1, Antilock brake system (ABS) ITT
Mark 20 IE.
page 45-1, Antilock brake system (ABS) ITT
Mark 20 IE.
& ,
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
ABS Self-Study Programme
Technical Service Handbook
.
page 45-4.
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There is no exterior distinction between the ABS
and ABS/TCS/EDL systems.
Control unit identification
The control unit version appears in the display of V.A.G 1552. Select function 01 for
this Interrogate control unit version page
45-182.
Parts List
List of available functions page 45-182.
()
page 45-195, Electrical/electronic components and fitting locations.
S00.5103.59.20
------------
------------
45
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page 45-6
Note:
The MK60 is equipped with a 47-pin control unit.
K If the ABS warning light (K47) -1- does not
go out after the ignition is switched on and
after completion of the test sequence, the
causes of the fault may be:
a - voltage supply is less than 11 V
b - an ABS fault is present
If an ABS fault is present, the anti-lock
brake system remains switched off while
the conventional brake system remains
fully operational.
c - a fault existed at a wheel speed sensor
after last vehicle start (sporadic fault).
If a fault exists at a wheel speed sensor,
the ABS warning light goes out automatically after restarting the vehicle and speed
increased to more than 20 km/h.
d - there is an interruption in the link from
the dash panel insert to control unit
-J104-.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
e - the dash panel insert is faulty.
f - the ABS control unit is incorrectly coded.
The ABS warning light (K47) -1- flashes
at a rate of about 1 Hz if the ABS control
unit is not coded.
The ABS warning light (K47) -1- and the
handbrake/brake fluid level warning light
(K14/33) -2- flash while self-diagnosis is
being performed.
------------
------------
S00.5103.59.20
OCTAVIA
K If the ABS warning light goes out, but the
handbrake/brake fluid level warning light
(K14/33) -2- remains on, the causes of the
fault may be:
a - the handbrake is still applied
b - the brake fluid level is too low
c - there is a fault in the wiring
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
If the ABS warning light -1- and the handbrake/brake fluid level warning light -2- do
go out, the ABS and EBD (electronic
brake pressure distribution) systems have
then failed.
d - switch -F9- for the warning light -K14/33is faulty or incorrectly set.
S00.5103.59.20
------------
------------
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45
OCTAVIA
page
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------------
------------
S00.5103.59.20
OCTAVIA
45
Antilock Brake System
Fault table
Notes:
In view of the fact that the control units are interconnected by a databus line, it is always necessary to initiate the
Automatic test sequence with function 00 at all the control units fitted to the vehicle. When this is done, the control
units fitted to the vehicle together with the possible faults they contain are interrogated.
After this, all the possible faults which can be detected by the ABS control unit (J104) and displayed by V.A.G 1552,
are listed according to the 5-digit fault code.
In addition, a fault type may also appear in the fault table.
Reference is made to individual test steps of the electrical test in the column Rectifying fault.
Before replacing components which have been displayed as faulty, inspect all the corresponding plug connections,
cables and earth connections according to the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
After completing the repairs, always once again interrogate the fault memory with the vehicle system tester V.A.G
1552 and erase it, and also conduct a test at more than 20 km/h.
After the road test, once again interrogate the fault memory.
Readout in display of V.A.G 1552 Possible cause of fault
No fault recognized
Rectifying fault
If after completing the repairs no fault recognized appears, the self-diagnosis is ended.
If the ABS does not operate properly despite the readout no fault recognized, then proceed as follows:
1. Conduct a road test at more than 20 km/h.
2. Once again interrogate the fault memory; if there is still no fault stored.
00003
Edition 01.02
S00.5103.63.20
3. Continue fault finding without self-diagnosis and carry out the electrical test in full
page 45-205.
Open circuit or loose contact in
the wiring to control unit -J104-
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Conduct a road test at a speed of more than
20km/h
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-196
------------ 45-183
45-239 ------------
!
OCTAVIA
"
00283
Front left wheel speed sensor
-G47Implausible signal
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G47- and control unit -J104-
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Conduct electrical test from page 45-205
Pulse rotor or wheel speed sensor
-G47- damaged
Wheel speed sensor -G47- faulty
- Inspect wheel speed sensor -G47- and pulse
rotor for damage
- Replace pulse rotor and, if necessary, wheel
speed sensor -G47- page 45-60
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-196
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G47- and control unit -J104-
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Conduct electrical test from page 45-205
Electrical interference as a result
of external sources (high-frequency radiation, e.g. ignition cables not insulated)
- Read data block page 45-192, display group
number 001
- Replace wheel speed sensor -G47page 45-60
Excessive gap between wheel
speed sensor -G47- and pulse rotor (signal not o.k.)
- Inspect installation of wheel speed sensor -G47and pulse rotor page 45-60
- Read data block page 45-192, display group
number 002
- Conduct final control diagnosis page 45-60
Outlet valves in hydraulic unit
-N55- faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-196
00283
Front left wheel speed sensor
-G47Electrical fault in circuit
00283
Front left wheel speed sensor
-G47Mechanical fault1)
1)
Fault can only be detected from a speed of 20 km/h (conduct road test).
------------ 45-184
45-240 ------------
S00.5103.63.20
OCTAVIA
!
"
00285
Front right wheel speed sensor
-G45
Implausible signal
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G45- and control unit -J104
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Damage to pulse rotor or speed
sensor -G45
Coil of speed sensor -G45- faulty
- Inspect speed sensor -G45- and pulse rotor for
damage
- Replace pulse rotor/speed sensor -G45page 45-60
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-196
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G45- and control unit -J104
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
00285
Front right wheel speed sensor
-G45
Electrical fault in circuit
Electrical interference because of - Read measured value block page 45-192,
display group number 001
external sources (high-frequency
interference, e.g. ignition cable not - Replace speed sensor -G45- page 45-60
insulated)
00285
Front right wheel speed sensor
-G45
Mechanical fault1)
1)
Air gap between speed sensor
-G45- and pulse rotor too large
(signal not o.k.)
- Inspect installation of speed sensor -G45- and
pulse rotor page 45-60
- Read measured value block page 45-192,
display group number 002
- Perform final control diagnosis page 45-194
Outlet valves in hydraulic unit
-N55- faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-196
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
S00.5103.59.20
------------ 45-185 ------------
45
Antilock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
OCTAVIA
Rectifying fault
00287
Rear right wheel speed sensor
-G44
Implausible signal
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G44- and control unit -J104
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Damage to pulse rotor or speed
sensor -G44
Coil of speed sensor -G44- faulty
- Inspect speed sensor -G44- and pulse rotor for
damage
- Replace pulse rotor/speed sensor -G44page 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-196
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G44- and control unit -J104
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
00287
Rear right wheel speed sensor
-G44
Electrical fault in circuit
- Read measured value block page 45-192,
Electrical interference because of
display group number 001
external sources (high-frequency
interference, e.g. ignition cable not - Replace speed sensor -G44- page 45-65
insulated)
00287
Rear right wheel speed sensor
-G44
Mechanical fault1)
1)
Air gap between speed sensor
-G44- and pulse rotor too large
(signal not o.k.)
- Inspect installation of speed sensor -G44- and
pulse rotor page 45-65
- Read measured value block page 45-192,
display group number 002
- Perform final control diagnosis page 45-194
Outlet valves in hydraulic unit
-N55- faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-196
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
------------ 45-186 ------------
Edition 11.00
S00.5103.59.20
OCTAVIA
!
"
00290
Rear left wheel speed sensor
-G46
Implausible signal
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G46- and control unit -J104
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Damage to pulse rotor or speed
sensor -G46
Coil of speed sensor -G46- faulty
- Inspect speed sensor -G46- and pulse rotor for
damage
- Replace pulse rotor/speed sensor -G46page 45-65
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-196
Open circuit, short circuit to positive or to earth or loose contact in
wiring between wheel speed sensor -G46- and control unit -J104
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
00290
Rear left wheel speed sensor
-G46
Electrical fault in circuit
Electrical interference because of - Read measured value block page 45-192,
display group number 001
external sources (high-frequency
interference, e.g. ignition cable not - Replace speed sensor -G46- page 45-65
insulated)
00290
Rear left wheel speed sensor
-G46
Mechanical fault1)
Air gap between speed sensor
-G46- and pulse rotor too large
(signal not o.k.)
- Inspect installation of speed sensor -G46- and
pulse rotor page 45-65
- Read measured value block page 45-192,
display group number 002
- Perform final control diagnosis page 45-194
Outlet valves in hydraulic unit
-N55- faulty
If the fault occurs once again:
- Replace hydraulic unit -N55- page 45-196
Open circuit, short circuit to positive or to earth in wiring
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
00668
System voltage terminal 30
Implausible signal
1)
Fault type cannot be detected until speed more than 20 km/h (conduct road test).
S00.5103.59.20
------------
------------
45
Antilock Brake System
Readout in display of V.A.G 1552 Possible cause of fault
OCTAVIA
Rectifying fault
01044
Control unit incorrectly coded
Control unit -J104- incorrectly
coded
Bridge in multipin connector to
control unit -J104- from contact 3
to contact 14 open circuit or short
circuit
- Check coding of control unit -J104 page 45-190
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Electrical interference caused by
external sources (high-frequency
interference, e.g. ignition cables
not insulated)
- Erase fault memory
- Conduct road test at more than 20 km/h
- Once again interrogate fault memory
Open circuit, short circuit to positive or to earth in wiring
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace control unit -J104- page 45-196
Open circuit, short circuit to positive or to earth in wiring
- Perform final control diagnosis page 45-194
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Hydraulic pump -V64- faulty
ABS control unit -J104- faulty
- Replace hydraulic unit -N55- page 45-196
01130
ABS operation
Implausible signal
01276
ABS hydraulic pump -V64
Implausible signal
------------ 45-188 ------------
Edition 11.00
S00.5103.59.20
OCTAVIA
!
"
01312
Databus drive
defective1)
or:
Databus drive
defective1)
sporadically
ABS control unit -J104- incorrectly
coded
Engine control unit incorrectly
coded
- Check coding of control unit -J104 page 45-190
- Check coding of engine control unit
Repair Group 01 of relevant engine
Open circuit, short circuit to positive or to earth in wiring
- Test wiring and plug connections according to
current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Ignition/starter switch rotates too
slowly
- Erase fault memory page 45-21
- No further measures necessary
- Inform customer
Open circuit, short circuit to positive or to earth in databus wiring
- Test wiring and plug connections of databus cables according to current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Open circuit, short circuit to positive or to earth in databus wiring
- Test wiring and plug connections of databus cables according to current flow diagram
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
- Perform electrical test from page 45-205
01314
Engine control unit
No communication
Please read fault memory
01315
Gearbox control unit2)
No communication
1)
2)
The fault Databus drive defective does not cause the ABS warning light -K47- or the handbrake/brake fluid level
warning light -K14/33- to come on. The full ABS function is retained in this case.
Only on models fitted with automatic gearbox.
S00.5103.59.20
------------
------------
45
Anti-Lock Brake System
OCTAVIA
Coding the control unit
Required special tools, testing and measuring equipment as well as auxiliary devices
and material
Vehicle system tester V.A.G 1552
Diagnostics line V.A.G 1551/3, 3A, 3B or 3C
The control unit which is installed in the vehicle
is coded. New control units from the spare parts
store are uncoded and must be newly coded
before being installed.
Pre-requisites for coding
Coding is only possible when the workshop
code (WSC) is entered into the V.A.G 1552.
Checking procedure
Vehicle system test
Select function XX
HELP
Determine the engine identification code and
the type of ABS hydraulic control unit which
has been installed on the vehicle.
Connect up the vehicle system tester
V.A.G 1552 and select the address word
03 Brake electronics with the ignition on
page 45-182.
Read out on display:
Code control unit
Enter code number XXXXX
Q
(0-32767)
Enter 07 for the function Code the control
unit and confirm the entry with Q.
Read out on display:
Enter the appropriate code number for the
vehicle and confirm entry with Q.
Code table page 45-191.
1C0907379 C ABS FRONT MK60 0102
Coding 0001025
WSC XXXXX
The display shows the control unit coding, e.g.
0001025.
-
Vehicle system test
Select function XX
HELP
Read out on display:
------------ 45-190 ------------
Press the button.
Enter function 06 Stop output and confirm
the entry with Q.
Edition 06.05
S00.5103.68.20
OCTAVIA
45
Anti-Lock Brake System
Notes:
If the control unit is incorrectly coded, the
ABS warning light -K47- and the brake system warning light light up and remain lit.
There is a simultaneous entry in the fault
memory of the engine control unit page
45-12, Interrogate fault memory 02.
If the control unit is coded with an approved
code, no fault entry is made in the fault
memory and the ABS warning light does not
flash.
If the control unit is not coded (Code 00000),
the ABS warning light -K47- flashes (once
per second)
Table of codes for vehicles with Anti-Lock Brake System Mark 60
Note:
Use E-gas on vehicles with MSR.
Engine
1.4 l/44 kW
1.4 l/55 kW
16V
Edition 06.05
S00.5103.68.20
Chassis
Code
Brakes Accelerator
control with Standard Rough road number
MSR
suspension
Engine
code letters
ABS control
unit number
Variant
ABS
AMD
1C0907379K
TCS
FS-III
yes
yes
yes
13313
1C0907379L
ABS
FS-III
no
yes
yes
04097
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
11266
1C0907379M
ESP
FS-III
yes
no
yes
11394
1C0907379C
ABS
FS-III
no
yes
yes
04097
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379E
ESP
FS-III
yes
yes
no
11266
1C0907379E
ESP
FS-III
yes
yes
yes
11394
AXP
BCA
1C0907379J
ABS
FS-III
no
yes
yes
04097
1C0907379G
ESP
FS-III
yes
yes
no
11266
1C0907379G
ESP
FS-III
yes
no
yes
11394
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
no
yes
11394
1C0907379M
ESP
FS-III
yes
yes
no
11266
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379C
ABS
FS-III
no
yes
yes
04097
1C0907379D
TCS
FS-III
yes
yes
yes
13313
1C0907379E
ESP
FS-III
yes
no
yes
11394
1C0907379E
ESP
FS-III
yes
yes
no
11266
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379K
TCS
FS-III
yes
yes
yes
13313
1C0907379G
ESP
FS-III
yes
yes
no
11266
1C0907379G
ESP
FS-III
yes
no
yes
11394
------------ 45-191 ------------
45
OCTAVIA
Anti-Lock Brake System
Engine
1.6 l/55 kW
1.6 l/74 kW
1.6 l/75 kW
Chassis
Code
Brakes Accelerator
control with Standard Rough road number
MSR
suspension
Engine
code letters
ABS control
unit number
Variant
ABS
AEE
1C0907379L
ABS
FS-III
no
yes
yes
04097
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
11266
1C0907379M
ESP
FS-III
yes
no
yes
11394
1C0907379C
ABS
FS-III
no
yes
yes
04097
1C0907379E
ESP
FS-III
yes
yes
no
11266
1C0907379E
ESP
FS-III
yes
no
yes
11394
1C0907379J
ABS
FS-III
no
yes
yes
04097
1C0907379G
ESP
FS-III
yes
yes
no
11266
AEH
AKL
AVU
BFQ
------------ 45-191.1 ------------
1C0907379G
ESP
FS-III
yes
no
yes
11394
1C0907379L
ABS
FS-III
no
yes
yes
04097
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379C
ABS
FS-III
no
yes
yes
04097
1C0907379E
ESP
FS-III
yes
yes
no
11266
1C0907379J
ABS
FS-III
no
yes
yes
04097
1C0907379G
ESP
FS-III
yes
yes
no
11266
1C0907379L
ABS
FS-III
no
yes
yes
04097
1C0907379M
ESP
FS-III
yes
yes
no
11266
1C0907379K
TCS
FS-III
yes
yes
yes
13313
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
yes
11266
1C0907379M
ESP
FS-III
yes
no
yes
11394
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
13313
1C0907379E
ESP
FS-III
yes
yes
no
11266
1C0907379E
ESP
FS-III
yes
no
yes
11394
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379G
ESP
FS-III
yes
yes
no
11266
1C0907379G
ESP
FS-III
yes
no
yes
11394
Edition 06.05
S00.5103.68.20
OCTAVIA
Engine
1.8 l/92 kW
45
Anti-Lock Brake System
Chassis
Code
Brakes Accelerator
control with Standard Rough road number
MSR
suspension
Engine
code letters
ABS control
unit number
Variant
ABS
AGN
1C0907379K
TCS
FS-III
yes
yes
yes
13313
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
11266
1C0907379M
ESP
FS-III
yes
no
yes
11394
1C0907379N
ESP 4x4
FS-III
no
yes
no
14342
1C0907379N
ESP 4x4
FS-III
no
no
yes
14470
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
13313
1C0907379E
ESP
FS-III
yes
yes
no
11266
1C0907379E
ESP
FS-III
yes
no
yes
11394
1C0907379F
ESP 4x4
FS-III
no
yes
no
14342
1C0907379F
ESP 4x4
FS-III
no
no
yes
14470
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379G
ESP
FS-III
yes
yes
no
11266
1C0907379G
ESP
FS-III
yes
no
yes
11394
1C0907379H
ESP 4x4
FS-III
no
yes
no
14342
1C0907379H
ESP 4x4
FS-III
no
no
yes
14470
1.8 l/110 kW
AGU
ARZ
AUM
ARX
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1.8 l/132 kW
AUQ
1C0907379M
ESP
FN-3
yes
yes
no
19970
1C0907379L
ABS
FN-3
yes
yes
yes
01025
1C0907379L
ABS
FN-3
no
yes
yes
04097
1C0907379M
ESP
FN-3
yes
no
yes
20098
1C0907379N
ESP 4x4
FN-3
no
yes
no
23046
1C0907379N
ESP 4x4
FN-3
no
no
yes
23174
1C0907379C
ABS
FN-3
yes
yes
yes
01025
1C0907379D
TCS
FN-3
yes
yes
yes
21505
1C0907379E
ESP
FN-3
yes
yes
no
19970
1C0907379E
ESP
FN-3
yes
no
yes
20098
1C0907379F
ESP 4x4
FN-3
no
yes
no
23046
1C0907379F
ESP 4x4
FN-3
no
no
yes
23174
1C0907379C
ABS
FN-3
no
yes
yes
04097
1C0907379J
ABS
FN-3
yes
yes
yes
01025
1C0907379J
ABS
FN-3
no
yes
yes
04097
1C0907379G
ESP
FN-3
yes
yes
no
19970
1C0907379G
ESP
FN-3
yes
no
yes
20098
1C0907379H
ESP 4x4
FN-3
no
yes
no
23046
1C0907379H
ESP 4x4
FN-3
no
no
yes
23174
Edition 06.05
S00.5103.68.20
------------ 45-191.2 ------------
45
OCTAVIA
Anti-Lock Brake System
Engine
2.0 l/85 kW
2.0 l/82 kW
1.9 l/50 kW
(SDI)
Chassis
Code
Brakes Accelerator
control with Standard Rough road number
MSR
suspension
Engine
code letters
ABS control
unit number
Variant
ABS
AQY
APK
AZH
AZJ
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
19458
1C0907379M
ESP
FS-III
yes
no
yes
19586
1C0907379N
ESP
FS-III
no
yes
no
22534
1C0907379N
ESP
FS-III
no
no
yes
22662
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
ABS
FS-III
yes
yes
yes
21505
1C0907379E
ESP
FS-III
yes
yes
no
19458
1C0907379E
ESP
FS-III
yes
no
yes
19586
1C0907379F
ESP 4x4
FS-III
no
yes
no
22534
1C0907379F
ESP 4x4
FS-III
no
no
yes
22662
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379G
ESP
FS-III
yes
yes
no
19458
1C0907379G
ESP
FS-III
yes
no
yes
19586
1C0907379H
ESP 4x4
FS-III
no
yes
no
22534
1C0907379H
ESP 4x4
FS-III
no
no
yes
22662
1C0907379L
ABS
FS-III
no
yes
yes
04097
1C0907379M
ESP
FS-III
no
yes
no
22530
1C0907379M
ESP
FS-III
no
no
yes
22658
1C0907379C
ABS
FS-III
no
yes
yes
04097
1C0907379E
ESP
FS-III
no
yes
no
22530
1C0907379E
ESP
FS-III
no
no
yes
22658
1C0907379J
ABS
FS-III
no
yes
yes
04097
1C0907379G
ESP
FS-III
no
yes
no
22530
1C0907379G
ESP
FS-III
no
no
yes
22658
1C0907379K
TCS
FS-III
yes
yes
yes
21505
AEG
AGM
AQM
------------ 45-191.3 ------------
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
19458
1C0907379M
ESP
FS-III
yes
no
yes
19586
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
21505
1C0907379E
ESP
FS-III
yes
yes
no
19458
1C0907379E
ESP
FS-III
yes
no
yes
19586
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379G
ESP
FS-III
yes
yes
no
19458
1C0907379G
ESP
FS-III
yes
no
yes
19586
Edition 06.05
S00.5103.68.20
OCTAVIA
Engine
1.9 l/66 kW
1.9 l/74 kW
Edition 06.05
S00.5103.68.20
45
Anti-Lock Brake System
Chassis
Code
Brakes Accelerator
control with Standard Rough road number
MSR
suspension
Engine
code letters
ABS control
unit number
Variant
ABS
AGR
ALH
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
19458
1C0907379M
ESP
FS-III
yes
no
yes
19586
1C0907379N
ESP 4x4
FS-III
no
yes
no
22534
1C0907379N
ESP 4x4
FS-III
no
no
yes
22662
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
21505
1C0907379E
ESP
FS-III
yes
yes
no
19458
1C0907379E
ESP
FS-III
yes
no
yes
19586
1C0907379F
ESP 4x4
FS-III
no
yes
no
22534
1C0907379F
ESP 4x4
FS-III
no
no
yes
22662
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1C0907379G
ESP
FS-III
yes
yes
no
19458
1C0907379G
ESP
FS-III
yes
no
yes
19586
1C0907379H
ESP 4x4
FS-III
no
yes
no
22534
1C0907379H
ESP 4x4
FS-III
no
no
yes
22662
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
19458
1C0907379M
ESP
FS-III
yes
no
yes
19586
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
21505
1C0907379E
ESP
FS-III
yes
yes
no
19458
1C0907379E
ESP
FS-III
yes
no
yes
19586
1C0907379F
ESP 4x4
FS-III
no
yes
no
22534
1C0907379F
ESP 4x4
FS-III
no
no
yes
22662
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379G
ESP
FS-III
yes
yes
no
19458
1C0907379G
ESP
FS-III
yes
no
yes
19586
1C0907379N
ESP 4x4
FS-III
no
yes
no
22534
1C0907379N
ESP 4x4
FS-III
no
no
yes
22662
ATD
------------ 45-191.4 ------------
45
OCTAVIA
Anti-Lock Brake System
Engine
1.9 l/81 kW
1.9 l/96 kW
Chassis
Code
Brakes Accelerator
control with Standard Rough road number
MSR
suspension
Engine
code letters
ABS control
unit number
Variant
ABS
AHF
ASV
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FS-III
yes
yes
no
19458
1C0907379M
ESP
FS-III
yes
no
yes
19586
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
21505
1C0907379E
ESP
FS-III
yes
yes
no
19458
1C0907379E
ESP
FS-III
yes
no
yes
19586
ASZ
------------ 45-191.5 ------------
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379G
ESP
FS-III
yes
yes
no
19458
1C0907379G
ESP
FS-III
yes
no
yes
19586
1C0907379K
TCS
FS-III
yes
yes
yes
21505
1C0907379L
ABS
FS-III
yes
yes
yes
01025
1C0907379M
ESP
FN-3
yes
yes
no
19970
1C0907379M
ESP
FN-3
yes
no
yes
20098
1C0907379N
ESP 4x4
FN-3
no
yes
no
23046
1C0907379N
ESP 4x4
FN-3
no
no
yes
23174
1C0907379C
ABS
FS-III
yes
yes
yes
01025
1C0907379D
TCS
FS-III
yes
yes
yes
21505
1C0907379E
ESP
FN-3
yes
yes
no
19970
1C0907379E
ESP
FN-3
yes
no
yes
20098
1C0907379F
ESP 4x4
FN-3
no
yes
no
23046
1C0907379F
ESP 4x4
FN-3
no
no
yes
23174
1C0907379J
ABS
FS-III
yes
yes
yes
01025
1C0907379J
TCS
FS-III
yes
yes
yes
21505
1C0907379G
ESP
FN-3
yes
yes
no
19970
1C0907379G
ESP
FN-3
yes
no
yes
20098
1C0907379H
ESP 4x4
FN-3
no
yes
no
23046
1C0907379H
ESP 4x4
FN-3
no
no
yes
23174
Edition 06.05
S00.5103.68.20
OCTAVIA
Edition 06.05
S00.5103.68.20
Anti-Lock Brake System
45
------------ 45-191.6 ------------
45
OCTAVIA
Anti-Lock Brake System
Reading measured value block
Special tools, testers and aids required
page 45-24
Safety measures
page 45-25
Test sequence and test table with measured
values
page 45-25
------------ 45-192 ------------
Edition 06.05
S00.5103.68.20
&
"
#
$
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'
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OCTAVIA
page 45-25
page 45-26
#
#
'()*
#
,
Read measured value block
Enter display group number XXX
Read measured value block
1
2
Read measured value block
not op.
off
off
K Readout in display:
-
Press keys 0, 0 and 3 for the Display group
number 003 and confirm the entry with the
key Q.
3
4
K-
The measured value block is always composed of 4 display blocks -arrows- 1 to 4.
K Readout in display:
Brake pedal not
operated
Brake pedal operated
K47
Not assigned
./
not op.
operated
off/on
K14/33
off/on
The readout in display blocks 2 and 3 changes
constantly from off to on.
S00.5103.59.20
------------
------------
45
'$
!
( ")
*!"#
$
%
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(
+
OCTAVIA
Antilock Brake System
If the readout does not appear as described:
-
Perform electrical test from page 45-41.
Another possible cause of the fault may be that
the brake light switch is not correctly set page
45-96.
-
Read measured value block
Enter display group number XXX
Read measured value block
1
2
Read measured value block
eng 1
Press the keys 0 and 6 for the function End
output and confirm the entry with the key Q.
K Readout in display:
3
4
3
gearb 1
Press keys 1, 2 and 5 for Display group
number 125 and confirm the entry with the
key Q.
K-
There are always 4 display blocks -arrows1 to 4 in the measured value block.
K Readout in display:
Engine control module
at databus
Engine control module
not at databus
Not assigned
Gearbox control unit
at databus1)
Not assigned
Gearbox control unit
not at databus1)
1)
V.A.G
eng 1
eng 0
gearb 1
gearb 0
Only on models fitted with automatic gearbox
Final control
Antilock Brake System (ABS) ITT Mark 20
IE, Self-Diagnosis page 45-29.
Antilock Brake System (ABS) ITT Mark 20
IE, Self-Diagnosis page 45-36.
------------
------------
Edition 11.00
S00.5103.59.20
() !!*"#$%&'
+
*. 0 !!
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./+56789
OCTAVIA
45
Antilock Brake System
Electrical/electronic components and fitting locations
5
fitting location: in dash panel insert
Function:
The handbrake/brake fluid warning
light comes on:
- when handbrake applied
- if brake fluid level is low
- for about 2 seconds after ignition is
switched on
- if the electronic brake force distribution fails, i.e. if the ABS warning light
comes on
page 45-180
All the components marked with
by the self-diagnosis.
1)
of ABS system at rear
(illustration shows only disc brakes)
rear right and left wheel speed sensor -G44/G46 1)
- removing and installing page 4565
- installing wheel speed sensor cables
page 45-67
rear right and left pulse rotor for wheel
speed sensor
- testing page 45-66
- removing and installing: the pulse rotor should be replaced together with
the wheel hub page 42-23 and 4228
are tested
1 Brake
master
cylinder and
assembly overview page 47-36
is open in off position
- adjusting page 45-69
- remove by turning 90 to left page
45-69
- install by turning 90 to right page
45-69
must be tested in measured value
block page 45-192
fitting location: in left of engine compartment
removing and installing page 45196
servicing page 45-200
connection
fitting location: in stowage compartment driver side
4 ABS
fitting location: in dash panel insert
Function:
ABS warning light comes on:
- for about 2 seconds after ignition is
switched on and/or engine start
- if fault is detected (e.g. open circuit to
wheel speed sensor)
page 45-180
Edition 05.01
S00.5103.61.20
of ABS system at front
front right and left wheel speed sensor -G45/G47 1)
- removing and installing page 4560
- installing wheel speed sensor cables
page 45-201
front right and left pulse rotor for wheel
speed sensor
- testing page 45-61
- removing and installing: the pulse rotor should be replaced together with
the wheel hub page 40-13
------------
------------
45
!"
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7
OCTAVIA
Antilock Brake System
control
and
and
Note:
As a general rule, always ensure that no brake
fluid gets into the connector housing of the control unit.
This can result in corrosion to the contacts and
thus in a failure of the system.
If the plug housing is soiled, it should be carefully cleaned with compressed air.
testers and aids
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3
Brake pedal depresser, e.g. V.A.G 1238/B
Caps from repair kit Part No. 1HO 698 311A
Brake filling and bleeding appliance, e.g.
ROMESS S15
Bleeder bottle (commercially available)
Brake fluid page 00-8
1
control
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit
-J104- together form the hydraulic
control unit.
The hydraulic control unit should be
removed and installed as a complete
unit page 45-197.
The connections of the brake lines are
stamped on the hydraulic unit.
Servicing page 45-200
Bracket
5 Brake
14 Nm
Hydraulic unit to rear left wheel cylinder/brake caliper
------------
------------
Edition 11.00
S00.5103.59.20
OCTAVIA
Hydraulic unit to rear right wheel cylinder/brake caliper
Hydraulic unit to front left brake caliper
Between brake master cylinder/floating piston circuit and hydraulic unit
47-pin
Do not separate plug connection before self-diagnosis is completed.
Switch off ignition before separating
the plug connection.
Hydraulic unit to front right brake caliper
Between brake master cylinder/pushrod piston circuit and hydraulic unit
Notes:
Before disconnecting the battery, determine
the code of radio set fitted with anti-theft coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
-
Disconnect battery.
Note:
The following 2 steps do not apply to the
1.4-ltr./55 kW engine:
S00.5103.59.20
K-
Unplug the connector -1- of the air mass
meter at the air guide pipe of the air filter.
Take out the bolts -2- at the air filter -3- and
place filter to the side.
On diesel engines, remove relay carrier
above brake servo unit.
Extract as much brake fluid as possible from
the brake fluid reservoir with a bleeder bottle.
------------
------------
45
Antilock Brake System
OCTAVIA
K
!
!! !
!
! " ! "
!#
K
$
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"
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"
Note:
Ensure that no brake fluid gets onto the contacts.
% # & "
"
! "
Note:
Brake lines in the area of the hydraulic unit must
not be bent.
------------
------------
K
!#
#
&
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! " )
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!#
& " "
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& " " "!#
Edition 11.00
S00.5103.59.20
OCTAVIA
1
+
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+
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K
Note:
Do not remove plugs at the hydraulic unit until
the appropriate brake line is fitted on.
Note:
Do not fully tighten bolts. This makes it easier
to connect the individual brake lines to the hydraulic control unit.
K
S00.5103.59.20
------------
------------
45
Antilock Brake System
OCTAVIA
Servicing hydraulic control unit
Notes:
The components of the hydraulic control unit
are plugged together and connected by
means of 2screws.
Before removing the Torx screws, use adhesive tape to prevent hydraulic pump unintentionally separating from the hydraulic unit.
Hydraulic pump and hydraulic unit are supplied as a single replacement part.
Warning!
The hydraulic pump must not be separated from
the hydraulic unit.
1 - Torx screw, 8 Nm
2 - Hydraulic unit
The hydraulic unit consists of:
a - Hydraulic pump -V64b - Hydraulic unit -N55 the valve block contains the control
valves
after separating from control unit, fit
on transport protection for valve
domes
3 - ABS or ABS/TCS/EDL control unit
-J104 when detaching from hydraulic unit,
the valve domes of the hydraulic unit
must not be tilted with the solenoids
of the control unit
cover over solenoids with a non-fluffing cloth
contact assignment page 45-202
test requirements page 45-9
Assembling hydraulic unit
Notes:
There must not be any impurities in the area
of the control unit-valve block.
When assembling control unit and hydraulic
unit, ensure that the valve domes of the hydraulic unit are not tilted with the solenoids
of the control unit.
------------
------------
Edition 05.01
S00.5103.61.20
OCTAVIA
$%
! "#
&'()*+
Antilock Brake System (ABS) ITT Mark 20
IE, Self-Diagnosis page 45-60.
Notes:
It is prohibited to carry out repairs to screened
cables of the ABS system.
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
-
Disconnect battery.
Note:
The following 2 steps do not apply to the
1.4-ltr./55 kW engine:
S00.5103.59.20
K-
Unplug connector of the air mass meter -1from the air guide pipe of the air filter.
Remove screws -2- at the air filter -3- and
place filter to the side.
On diesel engines, remove relay carrier
above brake servo unit.
K-
Release multipin connector and unplug from
control unit -arrows-.
------------
------------
45
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OCTAVIA
Antilock Brake System
K
K
connection
------------
------------
Edition 11.00
S00.5103.59.20
OCTAVIA
$
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K
Note:
When installing the wheel speed sensor cable,
ensure that it is fitted free of twisting in the wheelhouse.
&
S00.5103.59.20
------------
------------
7
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45
OCTAVIA
Antilock Brake System
control
cylinder
master
4 Brake
5
moisten with brake fluid and press in
expansion reservoir
7 Brake master cylinder
cannot be serviced; replace complete
if fault exists
removing and installing page 47-2
replace
Nm
9 Brake line
brake master cylinder/pushrod piston
circuit to hydraulic unit
10 Brake line
brake master cylinder/floating piston
circuit to hydraulic unit
11
Notes:
The hydraulic control unit should be removed
and installed complete from page 45-196.
Servicing from page 45-200.
Connections of brake lines should be tightened as a general rule to a torque of 14 Nm.
1
operational check page 47-4
removing and installing page 4732
Seal
replace
a
with integrated brake fluid level warning contact -F34-
------------
------------
fitted only to certain models
replace
Nm
Heat
fitted only to certain models
control
removing and installing page 45196
servicing page 45-200
brake line connections page 45-205
14 Bracket
with rubber shock absorber
15 I
1
Edition 05.01
S00.5103.61.20
OCTAVIA
! ",
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/456789
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1
45
Antilock Brake System
Electrical test
t
testers and aids
Hand-held multimeter, e.g. V.A.G 1526 A
Adapter cable set V.A.G 1594 A
Test box V.A.G 1598 A
Adapter V.A.G 1598/36
test
to models
only
Vehicles on which self-diagnosis does not
provide any indication of the source of the
fault. In this case, carry out the complete
electrical test.
Vehicles on which self-diagnosis provides a
direct indication of the source of the fault. In
this case, carry out only the test steps recommended in the fault table (specific testing).
Overview of all the test steps of the electrical
test page 45-207.
Test
Before commencing the test, switch off ignition and electrical components (headlights,
lighting, fan ...).
Fuses must be o.k. (as a check, remove
fuses from fuse holder).
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
Edition 02.01
S00.5103.60.20
Remove protective housing for relays from
cable duct.
K-
Unlock connector -1- at control unit -J104-arrow a- and unplug -arrow b-.
------------ 45-205 ------------
45
6
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9
OCTAVIA
Antilock Brake System
K-
Connect test box V.A.G 1598 A with adapter
V.A.G 1598/36 -1- to the multipin plug connection of the control unit -J104- -2-.
Note:
The specifications are matched to V.A.G 1526
A and do not necessarily apply to other testers.
connections
of
socket
of
connection
of
connection
page 45-134
Note:
Plug contacts not listed are not assigned.
1 - Voltage supply battery + (through S162)
2 - Plug connection T16a/7, K wire
4 - Terminal 15 through S9
8 - Only on models with Navigation system
10 - Only on models with Navigation system
and gas discharge headlights
11 - Databus line
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
13 - TCS/ASR pushbutton -E13214 - Coding bridge to contact 38
15 - Databus line
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
16 - Earth
32 - Voltage supply of battery + (through S163)
33 - Front right wheel speed sensor -G4534 - Front right wheel speed sensor -G45-
------------
------------
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
36 - Rear left wheel speed sensor -G4637 - Rear left wheel speed sensor -G4638 - Coding bridge to contact 14
41 - Brake light switch -F-
42 - Rear right wheel speed sensor -G4443 - Rear right wheel speed sensor -G44-
44 - Dash panel insert, only models fitted with
ABS
45 - Front left wheel speed sensor -G4746 - Front left wheel speed sensor -G4747 - Earth
Voltage supply of hydraulic pump -V64- to control unit -J104
Voltage supply of valves in hydraulic unit -N55- to control unit -J104
Perform test step 1
Perform test step 2
Voltage supply (ignition/starter switch) to control unit -J104
Perform test step 3
Resistance of front right wheel speed sensor -G45
Perform test step 5
Resistance of rear right wheel speed sensor -G44
Perform test step 7
Voltage signal of front right wheel speed sensor -G45
Perform test step 9
Operation of brake light switch -F
Resistance of front left wheel speed sensor -G47
Resistance of rear left wheel speed sensor -G46
Voltage signal of front left wheel speed sensor -G47
Perform test step 4
Perform test step 6
Perform test step 8
Perform test step 10
Voltage signal of rear right wheel speed sensor -G44
Perform test step 11
Operation of ABS warning light -K47-
Perform test step 13
Operation of TCS/ASR pushbutton -E132
Perform test step 15
Voltage supply of V.A.G 1551, plug connection T16a
Perform test step 17
Voltage signal of rear left wheel speed sensor -G46
Operation of handbrake/brake fluid level warning light -K14/33Test of databus line
Resistance of K wire for self-diagnosis, plug connection T16a
Coding bridge
Edition 02.01
S00.5103.60.20
Perform test step 12
Perform test step 14
Perform test step 16
Perform test step 18
Perform test step 19
------------
------------
45
OCTAVIA
Antilock Brake System
Test table
Notes on test table
The socket designations of test box with adapter V.A.G 1598/36 are identical to the contact designations
of the control unit -J104- in the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the measurements obtained differ from the specifications, carry out the measures indicated in the righthand part of the table for rectifying the fault.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Conduct continuity tests with adapter cable set V.A.G 1594 A (bridges).
If the measurements obtained differ only slightly from the specifications, then clean the sockets and
connectors of the testers and test cables (with contact spray G 000 700 04) and repeat the test. Before
replacing the particular components, inspect the cables and connections and also repeat the resistance
measurement at the component, particularly if the specifications are less than 10 .
Switch on measuring range: Voltage measurement (20 V =)
Test
step
V.A.G
1598 A
Sockets
1 + 47
Specification
Measures if readout differs
from specification
Voltage supply for hy- Ignition switched off
draulic pump -V64(terminal 30) at control
unit -J104
10.0 - 14.5 V
- Test wiring according to
current flow diagram
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
32 + 16
Voltage supply for
valves in hydraulic
unit -N55- (terminal
30) at control unit
-J104
Ignition switched off
10.0 - 14.5 V
- Test wiring according to
current flow diagram
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
4 + 47
Voltage supply (terminal 15) of control unit
-J104
Ignition switched on
10.0 - 14.5 V
- Test wiring according to
current flow diagram
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
47 + 41
Operation of brake
light switch -F
Ignition switched off
Brake pedal not operated
Test of
Test conditions
- Additional operations
0.0 - 0.5 V
- Test brake light switch -Fand read measured value
page 45-192, disblock
play group number 003.
- Test wiring according to
current flow diagram
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Operate brake pedal
------------ 45-208 ------------
approx. battery
voltage
- Test brake light switch -Fpage 45-69.1.
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
Switch on measuring range: Resistance measurement (2 k
)
Test
step
V.A.G
1598 A
Sockets
33 + 34
Test of
Resistance of front
right wheel speed
sensor -G45
Test conditions
- Additional operations
Ignition switched off
Specification
1.0...1.3 k
Measures if readout differs
from specification
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G45- page 45-60.
45 + 46
Resistance of front left
wheel speed sensor
-G47
Ignition switched off
1.0...1.3 k
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G47- page 45-60.
7
42 + 43
Resistance of rear
right wheel speed
sensor -G44
Ignition switched off
1.0...1.3 k
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G44- page 45-65.
8
37 + 36
Resistance of rear left
wheel speed sensor
-G46
Ignition switched off
1.0...1.3 k
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G46- page 45-65.
Edition 02.01
S00.5103.60.20
------------
------------
45
OCTAVIA
Anti-blocking system
Test
step
9
V.A.G
1598 A
bushes
33 + 34
Test of
Test conditions
Additional work required
Voltage signal of the Vehicle raised up
rotational speed sen- Ignition off
sor at the front on
the right -G45
- Turn the wheel at the front
on the right at ca. 1 r.p.m.
10
11
12
------------
45 + 46
42 + 43
37 + 36
------------
Nominal
value
Voltage signal of the Vehicle raised up
rotational speed sen- Ignition off
sor at the front on
the left -G47
- Turn the wheel at the front
on the left at ca. 1 r.p.m.
Voltage signal of the Vehicle raised up
rotational speed sen- Ignition off
sor at the rear on the
right -G44
- Turn the wheel at the rear
on the right at ca. 1 r.p.m.
Voltage signal of the Vehicle raised up
rotational speed sen- Ignition off
sor at the rear on the
left -G46
- Turn the wheel at the rear
on the left at ca. 1 r.p.m.
Measures to be taken when
there is deviation from the
nominal value
- Check installation of the rotational speed sensor -G45- and
of the rotor
AC voltage
of at least
65 mV
- Check whether the rotational
speed sensor -G45- has been
swapped around and read the
measuring value block
Page 45-192, indicator
group number 001.
- Check installation of the rotational speed sensor -G47- and
of the rotor
AC voltage
of at least
190 mV
- Check whether the rotational
speed sensor -G47- has been
swapped around and read the
measuring value block
Page 45-192, indicator
group number 001.
- Check installation of the rotational speed sensor -G44- and
of the rotor
AC voltage
of at least
190 mV
- Check whether the rotational
speed sensor -G44- has been
swapped around and read the
measuring value block
Page 45-192, indicator
group number 001.
- Check installation of the rotational speed sensor -G46- and
of the rotor
AC voltage
of at least
190 mV
- Check whether the rotational
speed sensor -G46- has been
swapped around and read the
measuring value block
Page 45-192, indicator
group number 001.
Edition 06.02
S00.5103.64.20
!
"#
OCTAVIA
45
Antilock Brake System
ABS
est
V.A.G
1598 A
Sockets
13
est of
Operation of ABS
warning light -K47-
Handbrake/brake
est
V.A.G
1598 A
Sockets
14
Edition 02.01
S00.5103.60.20
est conditions
Ignition switched off
- Switch ignition on
from
Warning light
-K47- comes
on for about 2
s and goes out
again.
if
differs
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Fault in dash panel insert.
Electrical System; Repair
Group 90; Dash Panel Insert; Self-Diagnosis of
Dash Panel Insert
level
est of
Operation of handbrake/brake fluid level
warning light -K14/33-
est conditions
from
if
differs
Handbrake not applied
Brake fluid at correct
level
Ignition switched on
Warning light
-K14/33- does
not come on.
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Apply handbrake
Warning light
-K14/33comes on.
- Fault in dash panel insert.
Electrical System; Repair
Group 90; Dash Panel Insert; Self-Diagnosis of
Dash Panel Insert
------------
------------
45
OCTAVIA
Antilock Brake System
Operational test: Operation of TCS/ASR pushbutton -E132Test
step
V.A.G
1598 A
Sockets
15
Test of
Operation of TCS
pushbutton -E132-
Test conditions
- Additional operations
V.A.G
1598 A
Sockets
Test of
16
11 or 15
Databus lines
TCS warning
light -K86comes on for 2
seconds and
goes out again.
- Operate TCS button
-E132-.
TCS warning
light -K86comes on.
- Test wiring according to
CFD
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Operate TCS button
-E132- once again.
TCS warning
light -K86goes out.
- Replace TCS button
-E132 Body Fitting Work; Repair
Group 70; Dash Panel;
Removing and installing
dash panel
/20 M )
Test conditions
- Additional operations
Ignition switched off
Measuring range
200 set
- Separate multipin connections from the control units connected by
means of a databus
line:
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
- Test databus lines for
open circuit.
- Set measuring range
20 M .
- Remove fuse S9.
- Test wiring for short circuit to positive or to
earth.
------------ 45-212 ------------
Measures if readout differs
from specification
Ignition switched on
Switch on measuring range: Resistance measurement (200
Test
step
Specification
Specification
max. 1.5
Measures if readout differs
from specification
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
Switch on measuring range: Voltage measurement (20 V =)
Test
step
V.A.G
1598 A
Sockets
Test of
Test conditions
- Additional operations
17
Voltage supply for
V.A.G 1552, plug connection T16a1)
Ignition switched off
- Connect hand-held
multimeter V.A.G 1526
A with adapter cable
set V.A.G 1594 to plug
connection T16a1):
1)
Contact assignment of diagnostic connector
V.A.G
1598 A
Sockets
18
Test of
Resistance of K wire
for V.A.G 1552 plug
connection T16a1)
2)
Test conditions
- Additional operations
Contact assignment of control unit connector
19
14 + 38
Edition 02.01
S00.5103.60.20
Test of
Coding bridge for
ABS/EDL/TCS
Measures if readout differs
from specification
max. 1.5
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
page 45-206.
page 45-206.
Switch on measuring range: Resistance measurement (200
V.A.G
1598 A
Sockets
Specification
Ignition switched off
- Separate multipin connection from control
unit -J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
Contact assignment of diagnostic connector
Test
step
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Connect hand-held
multimeter V.A.G 1526
with adapter cable set
V.A.G 1594 to contacts
T16a/71) and T47a/22)
of multipin connection
of control unit -J104-.
1)
10.0-14.5 V
Measures if readout differs
from specification
page 45-206.
Switch on measuring range: Resistance measurement (200
Test
step
Specification
Test conditions
- Additional operations
Ignition switched off
Specification
0.0 - 1.0
Measures if readout differs
from specification
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
------------ 45-213 ------------
45
*
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6+"
./$0
1
& 2
374 5' %"
&#
,
%
89:;<
OCTAVIA
Antilock Brake System
system
Antilock
tion on
and
Antilock Brake System ABS/EDL/ESP Mark
20IE page 45-88
on
to
Antilock Brake System ABS/EDL/ESP Mark
20IE page 45-88
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
Service Technical Handbook
------------
------------
Edition 05.01
S00.5103.61.20
OCTAVIA
45
Anti-blocking system
Electrical/electronic components and installed location of the ABS/EDL/ASR/
ESP Mark 60 MJ 02
All components marked with 1) are detected by
the self-diagnosis system.
1 - Brake booster
With the master brake cylinder and
brake fluid reservoir
Removing and installing the brake
booster Page 47-32
2 - Sender -1- for the brake pressure
-G201- 1)
Removing and installing
Page 47-28
3 - Sender for transverse acceleration
-G200- 1)
Installed location: next to the steering
column under the dash panel
4 - Sender for the rotational speed
-G202- 1)
Installed location: next to the steering
column under the dash panel
Edition 06.02
S00.5103.64.20
------------
------------
45
Antilock Brake System
OCTAVIA
5 - Steering angle sender -G85- 1)
Fitting location: on steering column between steering wheel and steering
column switch
7 - Handbrake/brake fluid level warning
light -K14/33 Fitting location: in dash panel insert
Operation page 45-219
6 - ABS warning light -K47 Fitting location: in dash panel insert
Operation page 45-219
8 - Electronic stability programme warning light -K155 Fitting location: in dash panel insert
Operation page 45-219
------------ 45-216 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
9 - Parts of ABS system at rear suspension
Rear right and left wheel speed sensors -G44/G46- 1)
- Removing and installing page
45-65
- Installing wheel speed sensor cables
page 45-67
Pulse rotor for rear right and left wheel
speed sensors
- Testing page 45-66
- Removing and installing: pulse rotor
is replaced together with wheel hub
page 42-23 and 42-28.
10 - Brake vacuum pump -V192 Only fitted to vehicles with automatic
gearbox and in combination with EU4 engines
Fitting location: at left of subframe
Is tested by self-diagnosis in engine
control unit
Engine, Fuel Injection and Ignition System;
Repair Group 01
Removing and installing
page 47-38
11 - Diagnostic connection
Fitting location: in storage compartment driver side
12 - Brake light switch -F- 1)
Open in off position
- Setting page 45-69.1
- Remove by turning 90 to the left
page 45-69.1
- Install by turning 90 to the right
page 45-69.1
Must be tested in measured value
block 003 page 45-238
14 - Hydraulic control unit for ABS/EDL/
ESP -N55- 1)
Fitting location: in left of engine compartment
Hydraulic unit -N55- consists of hydraulic pump -V64- and valve block
with inlet and outlet valves
If hydraulic unit is replaced, it is essential to seal old part with plugs from
installation parts kit; Part No. Parts
List
Removing and installing hydraulic control unit (hydraulic unit -N55- with control unit -J104-) page 45-196
Hydraulic pump -V64- and valve block
must not be separated
Servicing hydraulic control unit
page 45-200
15 - Parts of ABS system at front suspension
Front right and left wheel speed sensors -G45/G47- 1)
- Removing and installing
page 45-60
- Installing wheel speed sensor cables
page 45-201
Pulse rotor for front right and left wheel
speed sensors
- Testing page 45-61
- Removing and installing: pulse rotor
is replaced together with wheel hub
page 40-13.
16 - Longitudinal acceleration sender
-G251- 1)
Fitting location: at right of central tube,
close to right A pillar
Removing and installing
page 45-82
13 - ABS/EDL/ESP control unit -J104 Fitting location: at hydraulic unit in left
of engine compartment
Is tested by self-diagnosis
Test of multipin connection to control
unit page 45-251
Do not unplug multipin plug connection before completing self-diagnosis.
Switch ignition off before separating
plug connection.
Edition 02.01
S00.5103.60.20
------------ 45-217 ------------
45
Anti-Lock Brake System
OCTAVIA
Electric/Electronic components and installation locations ABS/EDS/ASR/ESP
Mark 60 MY 02
All the components marked1) with are detected
by the self-diagnosis
1 - Brake booster
with master brake cylinder and brake
fluid reservoir
removing and installing brake booster
page 47-32
2 - Brake pressure sender -1- -G201-1)
removing and installing page 47-28
------------ 45-217.1 ------------
3 - ESP -G419- sender unit
4 x 4 vehicles RHD without -G251 Installation location: next to the steering column below the dash panel
4 - Steering angle sender -G85-1)
Installation location: on steering column between steering wheel and
steering column switch
Edition 11.02
S00.5103.65.20
OCTAVIA
5 - Warning lamp for ABS -K47 Installed location: in the dash panel
insert
Function Page 45-219
6 - Warning lamp for the handbrake and
brake fluid level -K14/33 Installed location: in the dash panel
insert
Function Page 45-219
7 - Warning lamp for the ESP -K155 Installed location: in the dash panel
insert
Function Page 45-219
8 - Parts of the ABS system on the rear
axle
The rotational speed at the rear on the
right and the left -G44/G46- 1)
- Removing and installing Page 45-65
- Mounting of the rotational speed sensor lines Page 45-67
Impulse wheel for the rotational speed
sensor at the rear on the right and the
left
- checking Page 45-66
- removing and installing: the impulse
wheel should be changed along with the
wheel hub Page 42-23 and 42-28
9 - Vacuum pump for the brake -V192- 1)
Only for vehicles with an automatic
gearbox in connection with exhaust
gas limit values according to EU-4
Installed location: on the assembly
carrier on the left
Is checked by the self-diagnosis in the
engine control unit
Engine, Injection and Ignition System; Rep.
Gr. 01
Removing and installing Page 47-38
45
Anti-blocking system
13 - Hydraulic unit for ABS/EDL/ESP
-N55- 1)
Installed location: in the engine compartment on the left
The hydraulic unit -N55- consists of
the hydraulic pump -V64- and the
valve block with the inlet and outlet
valves
When replacing an old part one must
absolutely close it off with stops from
the assembly set; spare part no.
spare parts catalogue
The hydraulic control unit (hydraulic
unit -N55- with control unit -J104 Page 45-196
The hydraulic pump -V64- and the
valve block must be not be separated
Repairing the hydraulic control unit
Page 45-200
14 - Parts of the ABS system on the front
axle
The rotational speed at the rear on the
right and the left -G45/G47-1)
- removing and installing Page 45-60
- mounting of the rotational speed sensor lines Page 45-201
Impulse wheel for the rotational speed
sensor at the front on the right and the
left
- checking Page 45-61
- removing and installing: the impulse
wheel should be changed along with
the wheel hub Page 40-13
15 - Sender for the longitudinal acceleration -G251- 1)
Installed location:
- only for vehicles 4 x 4 RHD on the
central pipe on the right near the A
column on the right
10 - Connection for diagnosis
Installed location: in the storage compartment on the drivers side
11 - Brake light switch -F- 1)
Is open in the idle state
- adjusting Page 45-69.1
- remove by turning through 90 to the
left Page 45-69.1
- remove by turning through 90 to the
right Page 45-69.1
Testing: measuring value block 003
Page 45-238
12 - Control unit for ABS/EDL/ESP -J104 Installed location: on the hydraulic unit
in the engine compartment on the left
Is checked by the self-diagnosis
Check the multiple plug connection to
the control unit Page 45-251
The ignition should be switched off before disconnecting the plug connection
Edition 06.02
S00.5103.64.20
------------ 45-217.2 ------------
45
$
%+5>
66)$77 08
8
1
' (
)*+ ,-. /
& 99 :: ;;2<<==!3"4#
?@ABCD
OCTAVIA
Antilock Brake System
and
page 45-89
location
1 - Brake servo unit 10
2 - Hydraulic unit
3 - Control unit, 47-pin, bolted to hydraulic
unit
1 - Brake servo unit 9/8
2 - Hydraulic unit
3 - Control unit, 47-pin, bolted to hydraulic
unit
------------
------------
Edition 05.01
S00.5103.61.20
OCTAVIA
45
Antilock Brake System
Self-diagnosis of the ABS/EDL/TCS/ESP Mark 60
Function
page 45-91
Indication of faults by warning
lights K47, K14/33 and K155
K Positioning of warning lights
Item
1
2
3
Designation
ABS warning light -K47-
Handbrake/brake fluid level warning light
-K14/33
Electronic stability programme warning light
-K155-
Warning!
After the ABS warning light -K47- and the handbrake/brake fluid level warning light -K14/33- come
on, the rear wheels may lock already during a slight
brake application.
Edition 02.01
S00.5103.60.20
------------ 45-219 ------------
45
OCTAVIA
Antilock Brake System
Overview
Explanation
Ignition on
(if systems o.k., lights go out
after about 3 s)
ABS warning light
-K47
Handbrake/brake fluid Electronic stability
level warning light
programme warning
-K14/33light -K155-
on
on
on
ESP failure or ESP deactivated
by pushbutton;
ABS, EDL and EBD active
off
off
on
ESP control cycle
off
off
off
off
Systems o.k.
ABS/EDL/ESP failure;
EBD remains active
(e.g. a wheel speed sensor faulty)
ABS/EDL/ESP/EBD failure;
(e.g. a wheel speed sensor faulty)
Brake fluid level too low;
all systems o.k.
on
off
off
flashes
on
on
on
off
on
off
on
K ABS warning light -K47 If the ABS warning light (K47) -1- does not
go out after the ignition is switched on and
after completion of the self-check, the causes
of the fault may be the following:
-a- voltage supply is less than 10 V
-b- there is a fault in the ABS
If there is a fault in the ABS -b-, the antilock
brake system is switched off. The EBD (electronic brake force distribution) function remains active, and in this case the conventional brake system remains fully operational.
Interrogate fault memory page 45-101.
-c- there was a sporadic wheel speed sensor fault after vehicle last started.
If there was a wheel speed sensor fault -c-,
the ABS warning light -K47- goes out automatically after vehicle is again started and a
speed of more than 20 km/h is reached.
------------ 45-220 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
-d- open circuit in the link from the ABS control unit -J104- to the dash panel insert
-J218-.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
-e- the dash panel insert is faulty.
K Warning light -K47- and -K14/33 If the ABS warning light (K47) -1- goes out,
but the handbrake/brake fluid level warning
light (K14/33) -2- remains on, and 3 warning
signals sound, the causes of the fault may
be:
-a- the brake fluid level is too low.
-b- the handbrake is applied.
-c- the switch -F9- for the warning light -K14/
33- is faulty or incorrectly set.
-d- there is a fault in the actuation of the handbrake/brake fluid level warning light -K14
/33-.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
If the ABS warning light (K47) -1- and the
handbrake/brake fluid level warning light
(K14/33) -2- come on, the ABS system and
the EBD (electronic brake force distribution)
have failed.
If the ABS warning light (K47) -1- and the
handbrake/brake fluid level warning light
(K14/33) -2- come on and 3 warning signals
sound, the ABS and the EBD (electronic
brake force distribution) have failed.
Note:
The handbrake/brake fluid level warning light
(K14/33) -2- does not come on until the vehicle
has exceeded a speed of 10 km/h, or engine
speed has exceeded 2000 rpm.
Warning!
After the ABS warning light -K47- and the handbrake/brake fluid level warning light -K14/33- come
on, the rear wheels may lock already during a slight
brake application.
Edition 02.01
S00.5103.60.20
------------
------------
45
!"
OCTAVIA
Antilock Brake System
K Electronic
If the electronic stability programme warning light (K155) -3- does not go out after the
ignition is switched on and after completion
of the self-check, the causes of the fault may
be the following:
There is a fault which affects only the ESP
safety system. The ABS/EDL and EBD safety
systems of the vehicle remain fully operational.
Interrogate fault memory page 45-12.
-a- short to positive in ESP pushbutton
-E256-.
-b- short to earth in operation of electronic
stability programme warning light -K155-.
-c- open circuit in the link from the ABS control unit -J104- to the dash panel insert
-J218-.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
-d- the ESP system was switched off by the
ESP pushbutton -E256-.
electronic
onds
comes on
is
control
100
a
entered.
Code control unit page 45-237.
electronic
system is in
control mode.
If the ABS warning light (K47) -1-, the handbrake/brake fluid level warning light (K14/33)
-2- and the electronic stability programme
warning light (K155) -3- flash continuously,
the control unit is not yet coded.
Code control unit page 45-237.
------------ 45-222 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
)
*
!
"
'
(
#
$
%
&
45
Antilock Brake System
est
page 45-9
vehicle system tester
V.A.G 1552 and
Special tools, testers and aids
page 45-9
control
Test of vehicle systems
Enter address word XX
1C0907379E ESP
Coding 19970
FRONT
HELP
K Readout in display:
-
MK60 0103
WSC XXXXX
version
Press the keys 0 and 3 for the address word
Brake electronics and confirm the entry with
the key Q.
K The following readout then appears (example):
What is displayed is:
the control unit identification number, e.g.
1C0907379E
the system designation, e.g. ESP FRONT
MK60
the version number, e.g. 0103
the code No. of the control unit, e.g. 19970
the workshop code (WSC)
Operating instructions of vehicle system
tester V.A.G 1552
Assignment of control unit
Parts List
Coding control unit page 45-237.
If the control unit identification number is not
shown page 45-224, List of available functions.
-
Edition 02.01
S00.5103.60.20
Press
key.
------------
------------
45
OCTAVIA
Antilock Brake System
00 -
Automatic test sequence
02 -
Interrogating fault memory
04 -
Basic setting 1)
01 03 04 -
05 -
06 -
07 -
08 11 1)
2)
Page
45-13
Interrogating control unit version
45-223
Final control diagnosis
45-29
Basic setting
45-12
45-36
45-241
2)
Erasing fault memory
45-21
Ending output
45-22
Coding control unit
45-237
Login procedure
45-249
Reading measured value block
45-238
Is required only for bleeding the hydraulic
unit of vehicles fitted with EDL system.
Is required for the zero adjustment of the
steering angle sender, lateral acceleration
sender, brake pressure sender and of the
longitudinal acceleration sender.
Notes:
In view of the fact that the control units are interlinked over a databus line, always begin fault finding by initiating the
Automatic test sequence with the key function 0 and 0 at all the control units installed in the vehicle. This ensures
that the control units fitted to the vehicle are interrogated for any possible faults.
All the possible faults which can be detected by the ABS control unit (J104) and displayed on V.A.G 1552, are listed
below according to the 5-digit fault code.
The fault type may also additionally appear in the fault table.
Reference is made to individual test steps of the electrical test in the column Rectifying fault.
Before replacing any component which is shown as faulty, test all the corresponding plug connections, cables and
earth connections according to the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
After completing repairs, always once again interrogate the fault memory with the vehicle system tester V.A.G 1552
and erase it, and then conduct a road test at a speed of more than 20 km/h.
After completing the road test, once again interrogate the fault memory.
------------ 45-224 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Anti-Lock Brake System
Read out on display of V.A.G 1552
Possible cause of fault
Rectifying fault
no fault detected
If after repair No fault detected is displayed, the self-diagnosis is completed.
If despite the display read-out No fault detected, the ABS does not operate without
fault, proceed as follows:
1. Perform a test drive at a speed above 20 km/h.
2. Interrogate the fault memory again, if still no fault is stored.
00003
3. Continue fault finding without self-diagnosis and completely run through the electrical test page 45-205
(Info in the literature)
no signal/no communication
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring to the ESP control
unit
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations
defective
ESP control unit defective
- Replacing ESP control unit page 45-196.
Speed sensor vl
-G47
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between speed sensor -G47- and control unit -J104-
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations
- Perform electrical test page 45-205.
Damage to impulse wheel or
speed sensor -G47 Speed sensor -G47- defective
- Inspect speed sensor -G47- and impulse
wheel for damage.
- Replacing impulse wheel if necessary speed
sensor -G47- page 45-60.
Control unit for ABS -J104- defective
If the fault occurs again:
- Replacing ESP control unit page 45-196.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between speed sensor -G47- and control unit -J104-
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
- Perform electrical test page 45-205.
Electrical malfunctions due to external interference (high frequency irradiation e.g. non insulated ignition cable)
- Reading measured value block page
45-116, Display group number 001
- Replacing speed sensor -G47- page
45-60.
00283
implausible signal
00283
Speed sensor vl
-G47
electrical fault in the circuit
Edition 11.02
S00.5103.65.20
------------ 45-225 ------------
45
OCTAVIA
Anti-Lock Brake System
Read out on display of V.A.G 1552
Possible cause of fault
Rectifying fault
Air gap is too large between
speed sensor -G47- and impulse
wheel (signal not OK)
- Inspect installation of speed sensor -G47and impulse wheel page 45-60.
- Reading measured value block page
45-116, Display group number 002.
- Perform actuator diagnosis page 45-29.
Outlet valves in hydraulic unit
-N55- defective
If the fault occurs again:
- Replacing ESP control unit page 45-196.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between speed sensor -G45- and control unit -J104-
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
- Perform electrical test page 45-205.
Damage to impulse wheel or
speed sensor -G45 Speed sensor coil -G45- defective
- Inspect speed sensor -G45- and impulse
wheel for damage.
- Replacing impulse wheel if necessary speed
sensor -G45- page 45-60.
Control unit for ABS -J104- defective
If the fault occurs again:
- Replacing ESP control unit page 45-196.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between speed sensor -G45- and control unit -J104-
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
- Perform electrical test page 45-205.
00283
Speed sensor vl
-G47
mechanical fault1)
00285
Speed sensor vr
-G45
implausible signal
00285
Speed sensor vr
-G45
electrical fault in the circuit
00285
Electrical malfunctions due to ex- - Reading measured value block page
ternal interference (high fre45-116, Display group number 001.
quency irradiation e.g. non-insu- - Replacing speed sensor -G45- page
lated ignition cable)
45-60.
Speed sensor vr
-G45
mechanical fault1)
1)
Air gap too large between speed
sensor -G45- and impulse wheel
(signal not OK)
- Inspect installation of speed sensor -G45and impulse wheel page 45-60.
- Reading measured value block page
45-116, Display group number 002.
- Perform actuator diagnosis page 45-29.
Outlet valves in hydraulic unit
-N55- defective
If the fault occurs again:
- Replacing ESP control unit page 45-196.
Type of fault can only be detected as of 20 km/h (perform test drive).
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
45
Antilock Brake System
in
1552
00287
Rear right wheel speed sensor
-G44
implausible signal
Open circuit, short to positive or to
earth or loose contact in wiring between wheel speed sensor -G44and control unit -J104-
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Pulse rotor or sensor -G44- damaged
Wheel speed sensor -G44- faulty
- Inspect sensor -G44- and rotor for damage
ABS control unit -J104- faulty
If the fault occurs once again:
- Replace ESP unit page 45-196
Open circuit, short to positive or to
earth or loose contact in wiring between wheel speed sensor -G44and control unit -J104
- Test wiring and plug connections according
to current flow diagram
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
- Perform electrical test from page 45-205
Electrical interference caused by external sources (high-frequency radiation, e.g. ignition cables not insulated)
- Read measured value block page 45-116,
display group number 001
- Replace wheel speed sensor -G44- page
45-65
Excessive gap between wheel speed
sensor -G44- and rotor (signal not
o.k.)
- Inspect installation of sensor -G44- and of rotor page 45-65
- Read measured value block page 45-116,
display group number 002
- Perform final control diagnosis page 45-29
Outlet valves in hydraulic unit -N55faulty
If the fault occurs once again:
- Replace ESP unit page 45-196
- Replace rotor/sensor -G44- page 45-65
00287
Rear right wheel speed sensor
-G44
electrical fault in circuit
00287
Rear right wheel speed sensor
-G44
Mechanical fault1)
1)
Fault type can only be detected from a speed of more than 20 km/h (conduct road test).
Edition 02.01
S00.5103.60.20
------------
------------
45
Read out on
00290
1552
Speed sensor hl
-G46
Implausible signal
00290
Speed sensor hl
-G46
electrical fault in the circuit
00290
Speed sensor hl
-G46
mechanical fault1)
00474
(Info in the literature)
no signal/no communication
1)
OCTAVIA
Anti-Lock Brake System
cause
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between speed sensor - G46- and control unit
-J104-
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
- Perform electrical test page 45-205.
Damage to impulse wheel or
speed sensor -G46 Speed sensor coil -G46- defective
- Inspecting speed sensor -G46- and impulse
wheel for damage.
- Replacing impulse wheel if necessary speed
sensor -G46- page 45-65.
Control unit for ABS -J104- defective
If fault occurs again:
- Replacing ESP control unit page 45-196.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between speed sensor -G46- and control unit -J104-
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams. Electrical
Fault Finding and Fitting Locations
- Perform electrical test as of page 45-205.
Electrical malfunctions due to external interference (high frequency irradiation e.g. non-insulated ignition cable)
- Reading measured value block page
45-116, Display group number 001.
- Replacing speed sensor -G46- page
45-65.
Air gap too large between speed
sensor -G46- and impulse wheel
(signal not OK)
- Inspect installation of speed sensor -G46and impulse wheel page 45-65.
- Reading measured value block page
45-116, Display group number 002.
- Perform actuator diagnosis page 45-29.
Outlet valves in hydraulic unit
-N55- defective
If fault occurs again:
- Replacing ESP control unit page 45-196.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between reading
coil for immobilizer and dash
panel insert
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
Type of fault can only be detected as of 20 km/h (perform test drive).
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
Read out on display of V.A.G 1552
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between ESP sender -G419- and control unit
-J104-
- Inspect installation of sender -G419-.
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
ESP sender -G419- defective
- Replacing ESP sender -G419-.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between ESP
sender -G419- and control unit
-J104-
- Inspect installation of sender -G419-.
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
ESP sender -G419- defective
- Replacing ESP sender -G419-.
Line interruption, short-circuit to
positive or earth or loose contact
in the wiring between ESP
sender -G419- and control unit
-J104-
- Inspect installation of sender -G419-.
- Check wiring and plug connections according to the Current Flow Diagram.
Binder: Current Flow Diagram, Electrical
Fault Finding and Fitting Locations
ESP sender -G419- defective
- Replacing ESP sender -G419-.
Line interruption, short-circuit to
positive or earth
Incorrect setting of the brake
light switch
Brake light switch defective
- Reading measured value block page
45-116, Display group number 002.
- Perform electrical test page 45-250, Test
step 4.
- Adjust brake light switch page 45-69.1.
Short-circuit to positive
Voltage supply is less than 5 V
on:
- Yaw rate sender -G202- Lateral acceleration sensor
-G200- Brake pressure sender -1-G201- Longitudinal acceleration sender
- G251-1)
- Check fuses, cables, plug connections as
well as voltage supply to the control unit:
- Perform electrical test page 45-250, Test
step 4.
00493
(Info in the literature)
no signal/no communication
00494
(Info in the literature)
00495
(Info in the literature)
electrical fault in the circuit
00526
Brake light switch -F
Implausible signal
00538
electrical fault in the circuit
1)
Not for 4 Wheel Drive vehicles.
Edition 11.02
S00.5103.65.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Read out on display of V.A.G 1552
Possible cause of fault
Rectifying fault
Line interruption, short-circuit to
positive or earth in the wiring
Fuses S162 and S163 defective
- Check fuses, cables, plug connections as
well as voltage supply to the control unit:
Electrical test, page 45-250, Test steps 1
and 2
Interruption or loose contact in
the Data BUS cables between
steering angle sender -G85- and
control unit -J104-
- Check fuses, cables, plug connections as
well as voltage supply to the control unit:
Electrical test, page 45-250, Test step 19
Incorrect specifications of sender
for steering angle -G85-
- Reading measured value block page
45-116, Display group number 004.
Steering angle sender -G85- defective
- Replacing steering angle sender -G85page 45-174
- Perform null balance:
Basic setting, page 45-241, Display group
number 060
Steering angle sender
-G851)
no setting or incorrect setting
Steering angle sender -G85sends no or incorrect setting values
- Perform null balance:
Basic setting, page 45-241, Display group
number 060
Steering angle sender
-G851)
mechanical fault
Fitting location of the steering
angle sender -G85- is not OK
- Inspect fitting location of steering angle
sender -G85- page 45-174.
Chassis geometry is not OK
- Perform vehicle measurement
Repair Group 44
Steering wheel is removed and
no null balance is performed
- Perform null balance:
Basic setting, page 45-241, Display
Group 060
Fitting location of the steering
angle sender -G85- is not OK
- Inspect fitting location of steering angle
sender -G86- page 45-174.
Chassis geometry is not OK
- Perform vehicle measurement
Repair Group 44
Non-permissible vibrations in the
steering due to wear
- Perform null balance:
Basic setting, page 45-241, Display group
number 060
00668
El. syst. voltage tml. 30
implausible signal
00778
Steering angle sender
-G85
no communication1)
00778
00778
00778
Steering angle sender
-G85
implausible signal1)
1)
The data transfer between the control unit -J104- and the steering angle sender -G85- occurs with a data BUS.
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
Read out on display of V.A.G 1552
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
Steering angle sender -G85- defective
- Replacing steering angle sender -G85page 45-174.
00778
Steering angle sender
-G85
defective1)
- Perform null balance:
Basic setting, page 45-241, Display group
number 060
01044
Control unit wrongly coded
01130
ABS operation
implausible signal2)
Incorrect or no coding of the con- - Check coding of the control unit page
trol unit
45-237.
Electrical malfunctions due to external interference (high frequency irradiation, e.g. non insulated ignition cable
Line interruption, short-circuit to
positive or earth or loose contact
Control unit for ABS -J104- defective
- Check all lines and plug connections for
short-circuit to positive or earth.
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
- Erasing fault memory.
- Perform test drive with more than 20 km/h.
- Interrogate fault memory again.
If the fault occurs again:
- Replacing ESP control unit page 45-196.
Line interruption between sender
-G419- and ESP control unit
- Check lines and plug connections to Current
Flow Diagram.
Binder: Current Flow Diagram, Electrical
Fault Finding and Fitting Locations
Internal connection E-engine to
control unit
Short-circuit to positive or earth
or interruption
ABS control unit defective
Pump motor defective
- Check lines and plug connections as well as
ground lines to Current Flow Diagram
Electrical test, page 45-250, Test step
no.1
- Perform functional test:
Actuator diagnosis, page 45-29
- If the hydraulic pump does not run during the
actuator diagnosis, replace control unit for
ABS -J104-.
If the fault occurs again:
- Replacing ESP control unit page 45-196.
01164
(Info in the literature)
implausible signal
01276
ABS Hydraulic pump
-V64
Signal outside the tolerance2)
defective2)
electrical fault in the circuit
1)
2)
The data transfer between the control unit -J104- and the steering angle sender -G85- occurs with the data BUS.
Type of fault can only be detected as of 20 km/h (perform test drive).
Edition 11.02
S00.5103.65.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Read out on display of V.A.G 1552
Possible cause of fault
Rectifying fault
Inspecting plug connections
Voltage supply is less than 5 V
Line interruption, short-circuit to
positive or earth
- Reading measured value block page
45-238, Display group number 006.
- Check lines and plug connections according
to Current Flow Diagram.
- Perform electrical test page 45-250.
Longitudinal acceleration sender
-G251- defective
- Replacing longitudinal acceleration sender
-G251- page 45-82.
- Perform null balance:
Basic setting, page 45-241, Display group
number 069
01279
Longitudinal acceleration sender
-G251-1)
electrical fault in the circuit
01279
Longitudinal acceleration sender
-G251-2)
Implausible signal
- Reading measured block value page
45-238, Display group number 006.
The fitting location for the longitudinal acceleration sender
-G251- is not OK
- Inspect fitting location of longitudinal acceleration sender -G251-.
Line interruption, short-circuit to
positive or earth
- Check lines and plug connections according
to Current Flow Diagram.
- Perform electrical test page 45-250.
Longitudinal acceleration sender
-G251- defective
- Replacing longitudinal acceleration sender
-G251- page 45-82.
- Perform null balance:
Basic setting, page 45-241, Display group
number 069
Longitudinal acceleration sender
-G251-2)
no or incorrect basic setting/adaptation
Longitudinal acceleration sender
-G251- sends no setting values
or incorrect setting values
- Perform null balance:
Basic setting, page 45-241, Display group
number 069
(Info in the literature)
no signal/no communication
Gateway data line defective
- Inspect Gateway data line Electrical system; Repair Group 90.
01279
01299
1)
2)
Type of fault can only be detected as of 20km/h (perform test drive).
Only for 4 Wheel Drive vehicles.
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
Read out on display of V.A.G 1552
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
Line interruption, short-circuit to
positive or earth or loose contact
in the Data BUS cable
- Inspecting Data BUS cable according to Current Flow Diagram for interruption or shortcircuit.
Electrical system, page 45-253, Test step
no. 23
Line interruption, short-circuit to
positive or earth in the Data BUS
cable
Error entry in the engine control
unit
- Inspecting Data BUS cable according to Current Flow Diagram for interruption or shortcircuit
Electrical test, page 45-253, Test step
no. 23
- Read out fault memory
Engine, Injection and Ignition system, if necessary Glow plug system; Repair Group 01
Line interruption, short-circuit to
positive or earth in the Data BUS
cable
- Inspecting Data BUS cable according to Current Flow Diagram for interruption or shortcircuit
Electrical test, page 45-253, Test step
no. 23
Control unit -J285- wrongly
coded
- Check coding of control unit -J285 Electrical system; Repair Group 90; dash
panel insert
Line interruption, short-circuit to
positive or earth or loose contact
in the Data BUS cables
- Reading measured value block page
45-238 Display group number 125.
- Inspecting Data BUS cable according to Current Flow Diagram for interruption or shortcircuit Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
01312
Data BUS drive
defective1)
01314
Engine control unit
no communication
please read out fault memory
01315
Gearbox control unit2)
no communication
01317
Control unit in dash panel insert
-J28501324
Control unit for 4 Wheel Drive
-J492-3)
no communication
1)
Occurs only on ESP together with a fault of the steering angle sender -G85- without communication.
2)
Only on vehicles with automatic gearbox.
3)
Only for 4 Wheel Drive.
Edition 04.03
S00.5103.66.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Read out on display of V.A.G 1552
Possible cause of fault
Rectifying fault
Line interruption, short-circuit to
positive or earth or loose contact
in the lines between lateral acceleration sensor -G200- and
control unit for ABS -J104-
- Inspecting lateral acceleration sensor
-G200-.
- Reading measured value block page
45-116, Display group number 004.
- Inspecting lines, plug connections as well as
ground lines according to Current Flow Diagram.
Electrical test, page 45-250, Test step
no.20
The fitting location of the lateral
acceleration sensor -G200- is
not OK
- Inspecting fitting location of lateral acceleration sensor -G200- page 45-171.
Lateral acceleration sensor
-G200- defective
- Replacing lateral acceleration sensor -G200 page 45-172.
- Perform null balance:
Basic setting, page 45-241, Display group
number 063
01423
Lateral acceleration sensor
-G2001)
electrical fault in the circuit
01423
Lateral acceleration sensor
-G2001)
implausible signal
01423
Lateral acceleration sensor
-G2001)
no or incorrect basic setting/adaptation
1)
The fitting location of the lateral
acceleration sensor -G200- is
not OK
- Inspecting lateral acceleration sensor
-G200-.
- Reading measured value block page
45-116, Display group number 004.
- Inspecting fitting location of lateral acceleration sensor -G200- page 45-171.
Lateral acceleration sensor
-G200- defective
- Replacing lateral acceleration sensor -G200 page 45-172.
- Perform null balance:
Basic setting, page 45-241, Display group
number 063
The null balance is not at all or
incorrectly performed
- Perform null balance:
Basic setting, page 45-241, Display group
number 063
Only for 4 Wheel Drive vehicles.
------------
------------
Edition 11.02
S00.5103.65.20
OCTAVIA
Read out on display of V.A.G 1552
45
Anti-Lock Brake System
Possible cause of fault
Rectifying fault
01435
Brake pressure sender 1
-G201
electrical fault in the circuit
Interruption or loose contact in
- Inspecting brake pressure sender -1the lines between brake pres-G201-.
sure sender 1 -G201- control unit - Reading measure value block page
for ABS -J10445-238, Display group number 005.
- Inspecting fuses, lines, plug connections as
well as voltage supply to the control unit:
Electrical test, page 45-250, Test step
no.22
Brake pressure sender 1 - G201defective
- Replacing brake pressure sender -1- -G201 page 47-28.
- Perform null balance:
Basic setting, page 45-241, Display group
number 066
Brake pressure sender 1
-G201
no or incorrect basic setting/adaptation
The null balance was not performed or incorrectly performed
- Perform null balance:
Basic setting, page 45-241, Display group
number 066
Brake pressure sender 1
-G201
implausible signal
Line interruption, short-circuit to
positive or earth
- Reading measured value page 45-238,
Display group number 005.
- Check lines and plug connections according
to the Current Flow Diagram.
- Perform electrical test, page 45-250, Test
step no. 22.
Incorrect setting of the brake
light switch
Brake light defective
- Setting brake light switch page 45-69.1.
Brake pressure sender -1-G201- defective
- Replacing brake pressure sender 1 -G201page 47-28.
- Perform null balance:
Basic setting, page 45-241, Display group
number 066
01435
01435
Edition 11.02
S00.5103.65.20
------------
------------
45
OCTAVIA
Anti-Lock Brake System
Read out on display of V.A.G 1552
Possible cause of fault
Rectifying fault
01486
(Info in the literature)
The ESP drive test has been activated
01487
(Info in the literature)
Overrun time of the ESP drive
test
- Perform ESP drive test correctly and completely; the fault will then erase itself.
- Initiate basic setting page 45-241, Display
group number 093.
yaw rate sender
-G202
implausible signal
Ground connection to yaw rate
sender -G202- interrupted
- Inspect yaw rate sender -G202-.
- Reading measured value block page
45-116, Display group number 004.
- Inspect lines, plug connections to control
unit.
Electrical test, page 45-250, Test step
no.21
The fitting location of the yaw
rate sender -G202- is not OK
- Inspect fitting location of the yaw rate sender
page 45-171.
Yaw rate sender -G202- defective
- Replacing yaw rate sender -G202- page
45-172.
One or several control units
wrongly coded
One or several incorrect control
units used
- Check the coding of all control units.
Fault stored in the fault memory
of the engine control unit
- Read out fault memory from engine control
unit and after eliminating possible faults
erase corresponding engine; Injection and
Ignition system; Repair Group 01.
Engine control unit defective
- Replacing engine control unit Petrol engine; Injection and Ignition system; Repair
Group 24; Diesel engine; Injection and Glow
plug system; Repair Group 23.
01542
18055
Inspect coding/variants of the control
units in the drive
18056
Read out fault memory of the engine
control unit
------------
- Perform ESP drive test correctly and completely in the given time.
------------
- Check correctness of all used control units.
Edition 11.02
S00.5103.65.20
OCTAVIA
Read out on
18258
1552
Databus drive missing message from
engine control unit
18262
Databus drive
Hardware defective
65535
Control unit defective
Edition 11.02
S00.5103.65.20
45
Anti-Lock Brake System
cause
Interruption of voltage supply,
short-circuit to positive or earth
or loose contact in the voltage
supply to engine control unit
Line interruption, short-circuit to
positive or earth or loose contact
in the Data BUS cables
Engine control unit defective
- Inspect voltage supply to engine control unit
for interruption or short-circuit.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
- Reading measured value block page
45-116, Display group number 125.
- Inspect Data BUS cables for interruption or
short-circuit.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
- Replacing engine control unit Petrol engine; Injection and Ignition system; Repair
Group 24, Diesel engine; Injection and Glow
Plug system; Repair Group 23.
One or several incorrect control
units used
- Check the correctness of all used control
units, if necessary replace incorrect control
units.
Control unit defective
- Replacing ESP control unit page 45-196.
------------ 4
------------
45
------------
Anti-Lock Brake System
------------
OCTAVIA
Edition 11.02
S00.5103.65.20
OCTAVIA
45
Anti-Lock Brake System
Coding the control unit
page 45-190
1C0907379E ESP
Coding 19970
FRONT
MK60 0103
WSC XXXXX
The control unit identification is shown on the
display of the vehicle system tester V.A.G 1552,
for example:
Table of codes
page 45-191
Edition 06.05
S00.5103.68.20
------------ 45-237 ------------
45
OCTAVIA
Anti-blocking system
Reading a measuring value block
Page 45-116
An overview of the selectable display group numbers
Display group
number
Display
field
001
1
2
3
4
Wheel speed at the rotational speed sensor at the front on the left -G47- (km/h.)
Wheel speed at the rotational speed sensor at the front on the right -G45- (km/h.)
Wheel speed at the rotational speed sensor at the rear on the left -G46- (km/h.)
Wheel speed at the rotational speed sensor at the rear on the right -G44- (km/h.)
1
2
3
4
Brake light switch -FWarning lamp for the handbrake/brake fluid level -K14/33Warning lamp for the ABS -K47Warning lamp for the ESP -K155-
002
003
004
005
006 1)
125
1)
2)
3)
1
2
3
4
Designation
Starting speed at the rotational speed sensor at the front on the left -G47- (km/h.)
Starting speed at the rotational speed sensor at the front on the right -G45- (km/h.)
Starting speed at the rotational speed sensor at the rear on the left -G46- (km/h.)
Starting speed at the rotational speed sensor at the rear on the right -G44- (km/h.)
1
2
3
4
Sender for the steering angle -G85Sender for transverse acceleration -G200Sender for the rotational speed -G202Not used
1
2
3
4
Sender for longitudinal acceleration 2)
Not used
Not used
Not used
1
2
3
4
1
2
3
4
Sender for the brake pressure -G201Not used
Not used
Not used
Data-bus for the engine
Data-bus for the steering angle
Data-bus for the four-wheel drive2)
Can-bus for the transmission3)
Not to be taken account of
Only for vehicles with four-wheel drive
Only for vehicles with an automatic transmission
Checking the allocation of the rotational
speed -sensors -G44-, -G45-, -G46-, -G47in the display group number 1
Page 45-118
Checking the rotational speed -sensors
-G44-, -G45-, -G46-, -G47- in the display
group number 002
Page 45-119
------------ 45-238 ------------
Edition 06.02
S00.5103.64.20
OCTAVIA
45
Anti-blocking system
Checking the brake light switch -F- and the
warning lamps -K47-, -K14/33-, -K155Display group number 003
-
Enter 003 and confirm the entry with Q
Read the measuring value block
1
2
3
3
4
K-
Read the measuring value block
Unactuated Unactuated
K Readout shown on the display (with the vehicle
stationary)
Read the measuring value block
Unactuated
Off
Off
3
Off
There are always four display fields which
appear in the measuring value block -arrowsItemisation of the values 1 to 4 in the individual display fields can be found in the following test table.
Display group number 003
Readout shown on the display
Warning lamp for the ASR/ESP
Off
On
Warning lamp for the ABS
Off
On
Warning lamp for the handbrake/brake fluid level
Off
On
Brake light switch
Unactuated brake pedal not actuated
Actuated brake pedal actuated
If one can read unactuated on the display screen of the V.A.G 1552 despite the fact that the brake
pedal is actuated or actuated despite the fact that the brake pedal is unactuated then undertake
test step no. 4 of the electrical testing sequence, page 45-139.
It is also possible that the brake light switch is not set up properly Adjusting the brake light switch,
page 45-69.1
A lower display group number can be selected
by pressing the - - key while a higher display
group number can be selected by pressing the
-- key.
Press the C-button to enter the next display
group number.
If the -- button is pressed one should then
enter 08 afterwards in order to again enter into
the Read measuring value block sequence.
Edition 06.02
S00.5103.64.20
------------
------------
45
Antilock Brake System
OCTAVIA
Testing steering angle sender -G85-, lateral
acceleration sender -G200- and yaw rate
sender -G202- in display group number 004
page 45-121
Testing brake pressure sender -G201Display group number 005
Read measured value block
1
2
Read measured value block
-1.27 bar
Press keys 0, 0 and 5 and confirm the entry
with the key Q.
K-
There are always 4 display blocks -arrowsin the measured value block. Explanation of
the readouts 1 to 4 in the individual display
blocks are given in the test table below.
K Readout in display (vehicle stationary):
Read measured value block
-1.27 bar
Display group number: 005
K Readout in display (example)
not assigned
not assigned
not assigned
Brake pressure sender -G201- and -G214 Specification if brake not depressed: 7 bar
page 45-250, Electrical Test, test steps 22 and 23
It is possible to consecutively select in turn the
next lower display group number with the -key.
Press the key C in order to enter the next display group number.
If the key is pressed, it is then necessary after this to re-enter function Read measured
value block by pressing keys 0 and 8.
Testing longitudinal acceleration sender
-G251 page 45-76
Testing databus line
page 45-123
------------ 45-240 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
Initiating basic setting
Special tools, testers and aids required
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3, V.A.G
1551/3A, V.A.G 1551/3B or V.A.G 1551/3C
Tasks of function 04 Initiating basic setting
Function 04 Initiating basic setting performs
several tasks in the case of the ESP:
-1- Display group number 001 is required for
bleeding the hydraulic unit.
-2- Display group number 040 is required for
switching off the longitudinal acceleration
sender -G251-, for example for checking the
brake system on a chassis dynamometer
page 45-76.
-3- Display group numbers 060, 063, 066 and
069 are required for the zero adjustment of
the steering angle sender, lateral acceleration sender, brake pressure sender and longitudinal acceleration sender.
-4- Display group number 093 is required for
the driving test page 45-247. It is designed
to check the plausibility of the signals from
the steering angle sender -G85-, lateral acceleration sender -G200-, yaw rate sender
-G200- and the brake pressure sender
-G201-.
-1- The hydraulic unit on vehicles fitted with
the ESP system is bled by selecting the display group number 001. Initiate basic setting
page 45-36.
Basic setting 04, display group number 001, is
only required if at least one chamber of the brake
fluid replenishing reservoir has run completely
empty.
Also initiate the basic setting after repairing any
leaks in the brake system.
Function 11 Login procedure is not required in
this case.
Edition 01.02
S00.5103.63.20
------------
------------
OCTAVIA
# %
## $
Function 11 Login procedure is not required in
this case.
*
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The zero adjustment of the steering angle
sender -G85- is performed using display
group number 060 page 45-243.
The zero adjustment of the lateral acceleration sender -G200- is performed using display group number 063 page 45-245.
The zero adjustment of the brake pressure
sender -G201- is performed using display
group number 066 page 45-246.
The zero adjustment of the longitudinal acceleration sender -G251- is performed using display group number 069 page 45-77.
Performing the zero adjustment of display group
numbers 060, 063 and 066 necessitates that
function 11 Login procedure has been successfully carried out first of all with the vehicle
system tester page 45-249.
Note:
The Login procedure should be carried out
separately for each display group number before then initiating the basic setting.
Zero adjustment requires to be performed if:
the control unit -J104- or the steering column is replaced,
the steering angle sender -G85- is replaced,
settings at the running gear are modified as
part of a chassis alignment,
the lateral acceleration sender -G200- is replaced,
the brake pressure sender -G201- is replaced,
------------ 45-242 ------------
S00.5103.63.20
OCTAVIA
45
Antilock Brake System
the longitudinal acceleration sender -G251is replaced,
if the text in the fault table relating to a fault
entry in the fault memory of control unit
-J104-, instructs you to perform the zero adjustment,
the steering wheel has been taken off.
-4- Display group number 093 is used for
checking the plausibility of the signals supplied by the steering angle sender -G85-, lateral acceleration sender -G200-, yaw rate
sender -G200- and the brake pressure sender
-G201-.
Activation of the ESP driving test.
After replacing control unit -J104-, it is necessary to carry out a zero adjustment for the following components:
Lateral acceleration sender -G200 Steering angle sender -G85 Brake pressure sender 1 -G201-
If individual senders are replaced, it is only necessary to carry out a zero adjustment for the
component replaced.
Display group number 060: zero adjustment
of steering angle sender -G85.
-
Start the engine.
Conduct a short road test on a flat road. Drive
straightahead and not faster than 20 km/h;
pay attention to the following point:
If the steering wheel is not in the centre
position when driving straightahead, correct the position of the steering wheel as
part of a chassis alignment and carry out
the zero adjustment of the steering angle
sender.
-
If the steering wheel is properly centred during the road test, bring the vehicle to a stop
from straightahead running.
Ensure that the position of the steering
wheel is no longer altered. Do not switch off
the ignition!
Edition 02.01
S00.5103.60.20
------------
------------
45
OCTAVIA
Antilock Brake System
Test of vehicle systems
Select function XX
HELP
Basic setting
Enter display group number XXX
HELP
Check zero adjustment with function 08
Read data block page 45-116, display
group number 004.
First of all, perform function 11 Login procedure with vehicle system tester V.A.G
1552 page 45-249.
K Readout in display:
-
Press keys 0 and 4 for the function Basic
setting and confirm entry with the key Q.
K Readout in display:
-
Press keys 0, 6 and 0 and confirm entry with
the key Q.
ABS indicator lamp -K47- flashes.
Function is not known or cannot be
carried out at the moment
Basic setting
60
Adjustment o.k.
OFF
<4-ON>
0.0
K If this readout appears in the display, the login
procedure has not been successfully performed.
K Readout in display:
If zero adjustment is successfully set, the value
0.0 once again appears in the display.
or:
Basic setting
60
Adjustment n. possible
OFF
<4-ON>
12.0
K If this readout appears in the display, the measured values are not within the permitted range
of 10 for the zero adjustment.
1. Interrogate fault memory (function 02)
2. Erase fault memory (function 05)
3. End output (function 06)
4. Switch ignition off.
5. Switch ignition on.
6. Once again perform zero adjustment.
-
Test of vehicle systems
Select function XX
HELP
Press
key.
K Readout in display:
-
End output (function 06) page 45-22.
ABS indicator lamp -K47- and ESP indicator
lamp -K155- light up for about 2 seconds.
-
------------ 45-244 ------------
Switch engine off.
Edition 01.02
S00.5103.63.20
OCTAVIA
45
Antilock Brake System
Display group number 063: zero adjustment
of lateral acceleration sender -G200l Vehicle is parked on level ground.
Test of vehicle systems
Select function XX
HELP
Switch ignition on.
Check measured values with function 08
Read data block page 45-116, display
group number 004.
First of all, perform function 11 Login procedure with vehicle system tester V.A.G
1552 page 45-249.
K Readout in display:
-
Basic setting
Enter display group number XXX
HELP
Press keys 0 and 4 for the function Basic
setting and confirm entry with the key Q.
K Readout in display:
-
Press keys 0, 6 and 3 and confirm the entry
with the key Q.
The ABS indicator lamp -K47- flashes.
Function is not known or cannot be
carried out at the moment
Basic setting
63
Adjustment o.k.
OFF
<4-ON>
K If this readout appears in the display, the login
procedure has not been successfully performed.
K Readout in display:
0.6m/s2
If zero adjustment is successfully set, the value
0.0m/s2 no longer appears in the display.
or:
Basic setting
63
Adjustment n. possible
OFF
<4-ON>
5.0m/s2
K If this readout appears in the display, the measured values are not within the tolerance range
of 2.5 m/s2.
1. Interrogate fault memory (function 02)
2. Erase fault memory (function 05)
3. End output (function 06)
4. Switch ignition off.
5. Switch ignition on.
6. Once again perform zero adjustment.
-
Edition 01.02
S00.5103.63.20
Press
key.
------------ 45-245 ------------
45
OCTAVIA
Antilock Brake System
Test of vehicle systems
Select function XX
HELP
K Readout in display:
-
End output (function 06) page 45-22.
ABS indicator lamp -K47- and ESP indicator
lamp -K155- light up for about 2 seconds.
Display group number 066: zero adjustment
of brake fluid pressure sender -G201l Brake pedal not depressed.
Test of vehicle systems
Select function XX
HELP
Basic setting
Enter display group number XXX
HELP
Switch ignition on.
Check measured values with function 08
Read data block page 45-240, display
group number 005.
First of all, perform function 11 Login procedure with vehicle system tester V.A.G
1552 page 45-249.
K Readout in display:
-
Press keys 0 and 4 for the function Basic
setting and confirm entry with the key Q.
K Readout in display:
-
Press keys 0, 6 and 6 and confirm entry with
the key Q.
ABS indicator lamp -K47- flashes.
Function is not known or cannot be
carried out at the moment
Basic setting
66
OFF
Adjustment o.k.
-0.85bar
<4-ON>
K If this readout appears in the display, the login
procedure has not been successfully performed.
K Readout in display:
If zero adjustment is successfully set, the value
0.00 bar no longer appears in the display.
or:
Basic setting
66
Adjustment n. possible
OFF
<4-ON>
-10.85bar
K If this readout appears in the display, the measured values are not within the permitted range
of -2bar up to 8 bar for the zero adjustment.
1. Interrogate fault memory (function 02)
2. Erase fault memory (function 05)
------------ 45-246 ------------
Edition 01.02
S00.5103.63.20
OCTAVIA
3. End output (function 06)
4. Switch ignition off.
5. Switch ignition on.
6. Repeat the zero adjustment.
-
Test of vehicle systems
Select function XX
HELP
Press key.
K Readout in display:
-
End output (function 06) page 45-22.
ABS warning light -K47- and ESP warning light
-K155- come on for about 2 seconds.
! " #
$ "
The ESP driving test is used for checking the
plausibility of the signals supplied by the lateral
acceleration sender -G200-, the yaw rate sender
-G202- and the brake pressure sender 1
-G201-.
The ESP driving test should be carried out each
time parts of the ESP system are removed or
replaced.
Test of vehicle systems
Select function XX
HELP
Basic setting
Enter display group number XXX
HELP
Basic setting
93
Syst. test activated
K Readout in display:
-
ON
Press keys 0, 9 and 3 and confirm the entry
with the key Q.
K Readout in display:
ABS warning light -K47- comes on.
-
Test of vehicle systems
Select function XX
Press keys 0 and 4 for the function Basic
setting and confirm the entry with the key
Q.
K Readout in display:
-
<8>
Switch the ignition on.
HELP
Press key.
K Readout in display:
-
End output (function 06) page 45-22.
Note:
Warning light -K47- remains on.
S00.5103.60.20
------------ 45-247 ------------
45
OCTAVIA
Antilock Brake System
-
Separate diagnostic plug connection.
Start engine.
Depress brake firmly (brake pressure of
more than 35 bar) until the ESP warning light
-K155- flashes.
The stationary adjustment is thus completed.
-
Now, conduct a road test lasting not more
than 50 seconds at a speed of 15 km/h...30
km/h:
Warning:
Priority must always be given to observing
the rules of the road and paying proper attention to traffic conditions.
-
The vehicle must be driven in such a way
that no ABS, EDL, TCS or ESP control is
necessary.
Drive a curve with a steering turn of at
least 90.
The ABS warning light -K47- and the ESP warning light -K155- go out, which indicates that the
ESP driving test has been successfully completed.
If the ABS warning light -K47- does not go out,
the ESP driving test has not been correctly performed.
-
------------
------------
If the ABS warning light -K47- does not go
out and the ESP warning light -K155- comes
on again, interrogate fault memory page
45-13.
Edition 02.01
S00.5103.60.20
OCTAVIA
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3, V.A.G 1551/
3A, V.A.G 1551/3B or V.A.G 1551/3C
Coding is only possible if the workshop code
(WSC) has been entered in the vehicle system
tester V.A.G 1552.
Test of vehicle systems
Select function XX
HELP
Coding 2
Enter code number xxxxx
HELP
Test of vehicle systems
Select function XX
HELP
S00.5103.60.20
Connect vehicle system tester V.A.G 1552
and select brake electronics control unit (address word 03) page 45-97; ignition is
switched on for this step.
K Readout in display:
-
Press key 1 twice for the function Login procedure and confirm the entry with the key
Q.
K Readout in display:
-
Enter the code number 40168 and confirm
the entry with the key Q.
K Readout in display:
------------
------------
45
OCTAVIA
Antilock Brake System
Electrical test of ABS/EDL/
TCS/ESP Mark 60
Special tools, testers and aids required
Handheld multimeter, e.g. V.A.G 1526 A
Adapter cable set V.A.G 1594/A
Test box V.A.G 1598/A
Adapter V.A.G 1598/36
The test steps from page 45-253 apply
only to models with ABS/EDL/TCS/ESP
on which the self-diagnosis does not provide
an indication of the source of the fault. In
this case, perform the complete electrical
test.
on which the self-diagnosis provides a direct
indication of the source of the fault. In this
case, perform only the test step recommended in the fault table (specific testing).
Test requirements
page 45-133
Note:
The following 2 steps do not apply to the 1.6 l/
55 kW engine.
Removing air filter
K-
Unplug connector of the air mass meter -1from the air guide pipe of the air filter.
Remove screws -2- at the air filter -3- and
place this down to the side.
Connecting test box V.A.G 1598 A with adapter V.A.G 1598/36
page 45-134
------------ 45-250 ------------
Edition 05.01
S00.5103.61.20
OCTAVIA
)
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page 45-134
Note:
Plug contacts not listed are not assigned.
1 - Voltage supply of battery + (through S162)
2 - Plug connection T16a/7, K wire
3 - Signal wire of longitudinal acceleration
sender -G251- 4x4 models
4 - Voltage supply terminal 15 (through S9)
5 - Earth cable of longitudinal acceleration
sender -G251- 4x4 models
6 - Lateral acceleration sender -G200- (signal)
7 - Voltage supply of longitudinal acceleration sender -G251- 4x4 models
8 - Only models fitted with Navigation system
9 - Coding bridge to contact 12 4x4 models
10 - Only on models fitted with Navigation system and gas discharge headlights
11 - Databus line
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
12 - Coding bridge to contact 38 FWD
Coding bridge to contact 9 4x4
13 - TCS/ESP pushbutton -E256-
14 - Coding bridge to contact 38 only TCS
15 - Databus line
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
16 - Earth
17 - Not assigned
18 - Voltage supply of brake pressure sender
1 -G201-
S00.5103.60.20
------------
------------
45
OCTAVIA
Antilock Brake System
19 - Earth cable of brake pressure sender 1
-G20120 - Signal cable of brake pressure sender 1
-G201
20 - to 23 - not assigned
24 - Earth cable of lateral acceleration sender
-G200- and of yaw rate sender -G20225 - not assigned
26 - Voltage supply of lateral acceleration
sender -G200- and of yaw rate sender
-G20227 to 30 - not assigned
32 - Voltage supply of battery + (through S163)
33 - Front right wheel speed sensor -G4534 - Front right wheel speed sensor -G4536 - Rear left wheel speed sensor -G4637 - Rear left wheel speed sensor -G46-
38 - Coding bridge to contact 12 FWD models and ESP
Coding bridge to contact 14 FWD models and TCS
39 and 40 - not assigned
41 - Brake light switch -F-
42 - Rear right wheel speed sensor -G4443 - Rear right wheel speed sensor -G4445 - Front left wheel speed sensor -G4746 - Front left wheel speed sensor -G4747 - Earth
------------ 45-252 ------------
Edition 02.01
S00.5103.60.20
9
2
7
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8
OCTAVIA
V
V
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S00.5103.60.20
------------
------------
45
OCTAVIA
Antilock Brake System
Test table
Notes on the test table
The socket designations of test box V.A.G 1598 A with adapter V.A.G 1598/36 are identical to the contact designations of control unit -J104- in the current flow diagram.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
If the measurements obtained differ from the specifications, carry out the measures stated in the right-hand column
of the table in order to rectify the faults.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder
Use adapter cable set V.A.G 1594 A to conduct continuity tests (bridges).
If the measurements obtained differ only slightly from the specifications, then clean the sockets and connectors of
the testers and the test cables (with contact spray G 000 700 04) and repeat the test. Before replacing the particular
components, test the wiring and connections and repeat the resistance measurement at the component, particularly
in the case of specifications of less than 10 .
Switch on measuring range: Voltage measurement (20 V =)
Test
step
V.A.G
1598 A
Sockets
1 + 47
Specification
Measures if readout differs
from specification
Voltage supply for hy- Ignition switched off
draulic pump -V64(terminal 30) at control
unit -J104
10.0 - 14.5 V
- Test cable from contact
T47a/1 through fuse S163
to battery +.
- Test cable from contact
T47a/47 to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
32 + 16
Voltage supply for
valves in hydraulic
unit -N55- (terminal
30) at control unit
-J104
Ignition switched off
10.0 - 14.5 V
- Test cable from contact
T47a/32 through fuse S162
to battery +.
- Test cable from contact
T47a/16 to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
4 + 47
Voltage supply (terminal 15) of control unit
-J104
Ignition switched on
10.0 - 14.5 V
- Test cable from contact
T47a/4 through fuse S13,
and ignition/starter switch.
- Test cable from contact
T47a/47 to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
------------ 45-254 ------------
Test of
Test conditions
- Additional operations
Edition 02.01
S00.5103.60.20
! "
#
$
$'
&
OCTAVIA
41 + 47
4a
+
Brake light switch -F-
Brake light switch -F-
,
+
Ignition switched off
Brake pedal not operated
0.0 - 0.5 V
- Brake pedal operated
10.0 - 14.5 V
Set measuring range
200
- Unplug multipin connector T47a from control unit -J104.
- Unplug multipin connector from brake light/
brake pedal switch.
- Test wiring for open circuit.
max. 1.5
+
++
- Set brake light switch, if
necessary
page 4569.1.
- Replace brake light switch
page 45-69.1.
- Read measured value
page 45-238, disblock
play group number 003.
- Test contact 1 of brake
light switch -F- to fuse S13.
- Test wiring for open circuit.
- Repair cable connections
according to current flow
diagram.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test cable from contact
41 (control unit) to contact 1 (brake light
switch).
Set measuring range
20 M
- Remove fuse S13.
- Test wiring for short to
positive or to earth.
S00.5103.60.20
------------ 45-255 ------------
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45
OCTAVIA
Antilock Brake System
on
Test
A
Sockets
12 + 38
14 + 38
9 + 12
Test
Coding bridge
on
Test
Test conditions
Additional
Ignition switched off
- Unplug multipin connector T47a
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36
- Test wiring for open circuit
max. 1.5
- Test cable from contact 9/
12/14 to contact 12/38 for
open circuit.
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
A
Sockets
33 + 34
Test
Resistance of front
right wheel speed
sensor -G45-
Test conditions
Additional
Ignition switched off
If no fault is found in the wiring:
- Replace wheel speed sensor -G45- page 45-60.
45 + 46
Resistance of front left
wheel speed sensor
-G47-
Ignition switched off
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G47- page 45-60.
------------
------------
Edition 02.01
S00.5103.60.20
!
OCTAVIA
8
*
42 + 43
Resistance of rear
right wheel speed
sensor -G44-
Ignition switched off
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G44- page 45-65.
37 + 36
Resistance of rear left
wheel speed sensor
-G46-
Ignition switched off
1.0...1.3 k
- Separate plug connection
at wheel speed sensor.
- Test wiring according to
CFD.
- Move cables during test.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
If no fault is found in the wiring:
- Replace wheel speed sensor -G46- page 45-65.
S00.5103.60.20
------------ 45-257 ------------
#!
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45
OCTAVIA
Antilock Brake System
on
Test
A
Sockets
Test
Test conditions
Additional
10
33 + 34
Voltage signal of front
right wheel speed
sensor -G45
Vehicle raised
Ignition switched off
- Rotate front right wheel
at approx. 1 rev/sec.
min. 65 mV alternating voltage
- Inspect installation of
wheel speed sensor and of
rotor.
- Inspect wheel speed sensor -G45- for incorrect connection and read measpage
ured value block
45-116, display group
number 001.
11
45 + 46
Voltage signal of front
left wheel speed sensor -G47-
Vehicle raised
Ignition switched off
- Rotate front left wheel
at approx. 1 rev/sec.
min. 65 mV alternating voltage
- Inspect installation of
wheel speed sensor and of
rotor.
- Inspect wheel speed sensor -G47- for incorrect connection and read measpage
ured value block
45-116, display group
number 001.
12
42 + 43
Voltage signal of rear
right wheel speed
sensor -G44-
Vehicle raised
Ignition switched off
- Rotate rear right wheel
at approx. 1 rev/sec.
min. 190 mV
- Inspect installation of
alternating voltwheel speed sensor and of
age
rotor.
- Inspect wheel speed sensor -G44- for incorrect connection and read measpage
ured value block
45-116, display group
number 001.
13
36 + 37
Voltage signal of rear
left wheel speed sensor -G46-
Vehicle raised
Ignition switched off
- Rotate rear left wheel
at approx. 1 rev/sec.
min. 190 mV
- Inspect installation of
alternating voltwheel speed sensor and of
age
rotor.
- Inspect wheel speed sensor -G46- for incorrect connection and read measpage
ured value block
45-116, display group
number 001.
------------
------------
Edition 02.01
S00.5103.60.20
!
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OCTAVIA
14
Operation of ABS
warning light -K47
Fault memory interrogated and no fault
present in fault
memory of control unit
-J104.
Ignition switched off
Multipin connector
plugged into control
unit -J104 and locked.
- Switch ignition on.
Warning light
If the ABS warning light does
-K47- comes
not come on:
on for 2 s and
- Test wiring according to
goes out again.
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test dash panel insert,
fault in dash panel insert.
Electrical System; Repair
Group 90; Dash Panel Insert
.
15
S00.5103.60.20
Operation of handbrake/brake fluid level
warning light -K14/33-
Brake fluid at correct
level
Ignition switched off
Multipin connector
plugged into control
unit -J104 and locked.
- Switch ignition on.
Warning light
-K14/33comes on for 2
s and goes out
again.
- Test brake fluid level warning contact -F34- in cap of
brake fluid reservoir.
- Test wiring according to
CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test dash panel insert,
fault in dash panel insert.
Electrical System; Repair
Group 90; Dash Panel Insert
------------
------------
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45
Antilock Brake System
OCTAVIA
Electronic
Test
16
------------
A
Sockets
-
------------
Test
Operation of ESP
warning light -K155-
Test conditions
Additional
Ignition switched off
Multipin connector
plugged into control
unit -J104 and locked.
- Switch ignition on.
Warning light
- Test wiring for open circuit
-K155- comes
and short circuit to positive.
on for 2 s and
goes out again. If the warning light -K155comes on and remains on:
- Test cable at dash panel
insert for short to earth.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test dash panel insert,
fault in dash panel insert.
- Test ESP button -E256-.
- Test voltage supply relay
for warning light -K155-.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
Operational test: Warning light K155 for operation of ESP pushbutton -E256- in test step 17;
voltage supply (20 V=) in test step 17a
Test
step
V.A.G
1598 A
Sockets
17
17a
16 + 13
Test of
Test conditions
- Additional operations
Specification
Operation of TCS/ESP Ignition switched off
button -E256 Operation of ESP
warning light -K155was checked with test
step 17.
Multipin connector
plugged into control
unit -J104- and locked.
- Switch ignition on.
Warning light
-K155- comes
on for 2 s and
goes out again
Operation of ESP button -E256-
- Operate ESP
pushbutton.
Warning light
-K155- comes
on
- Once again operate
ESP pushbutton.
Warning light
-K155- goes
out
- Switch ignition off.
- Unplug multipin connector from control unit
-J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
- Switch ignition on.
- Button -E256- not
pressed and warning
light -K155- on.
- Hold button -E256pressed and warning
light -K155- on.
Edition 02.01
S00.5103.60.20
Measures if readout differs
from specification
- Perform test step 18a
- Test cable from contact
T47a/16 (control unit) to
earth.
- Test cable from contact
T47a/13 (control unit) to
contact T4f/2 (ESP button)
for open circuit and short to
positive or to earth.
3.5 - 5.0 V
8.0 - 14.5 V
- Test cable connection for
open circuit and short to
positive or to earth.
- Test voltage supply from
contact T4f/1 (ESP button)
through fuse S13 for open
circuit.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Replace ESP button.
Electrical System; Repair
Group 96; Servicing dash
panel
------------
------------
45
Switch on measuring range:
Voltage measurement (20 V =) in test step 18; resistance measurement (200
Test
step
V.A.G
1598 A
Sockets
Test of
Test conditions
- Additional operations
18
Earth and voltage
supply of steering angle sender -G85
Ignition switched off
- Unplug multipin connector T47a from control unit -J104-.
- Separate plug connection from steering angle sender.
- Test voltage supply of
steering angle sender
at plug connection
T6w.
- Test cable between
contact T6w/4 and
contact T6w/1.
Ignition switched on
- Test cable between
contact T6w/5 and
contact T6w/1.
18a
11 + 15
Wiring of steering angle sender -G85
Measuring range
200 set
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
- Test the following cables for open circuit:
- Cable from contact
T6w/3 (steering angle
sender) to contact
T47a/11 (control unit).
- Cable from contact
T6w/2 (steering angle
sender) to contact
T47a/15 (control unit).
- Cable from contact
T6w/1 to earth.
Measuring range 20
M set
- Remove fuse S15.
- Test wiring for short to
positive or to earth.
------------ 45-262 ------------
OCTAVIA
Antilock Brake System
/20 M ) in test step 18a
Specification
Measures if readout differs
from specification
- Test cable from contact
T6w/4 (steering angle
sender) to fuse S15 for
open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
10.0 - 14.5 V
10.0 - 14.5 V
max. 1.5
- Test cable from contact
T6w/5 (steering angle
sender) to fuse S13 for
open circuit.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Test wiring for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Edition 02.01
S00.5103.60.20
OCTAVIA
Antilock Brake System
Switch on measuring range: Resistance measurement (200
Test
step
V.A.G
1598 A
Sockets
19
Test of
/20 M )
Test conditions
- Additional operations
Wiring of lateral accel- Ignition switched off
eration sender -G200
Measuring range
200 set
- Unplug multipin connector T47a from control unit -J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
- Separate plug connection T3n from lateral
acceleration sender.
45
Specification
max. 1.5
- Test cables for open
circuit:
- Cable from contact
T3n/1 (lateral acceleration sender) to contact
T47a/6 (control unit).
- Cable from contact
T3n/2 (lateral acceleration sender) to contact
T47a/24 (control unit).
Measures if readout differs
from specification
- Test wiring for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
max. 1.5
- Cable from contact
T3n/3 (lateral acceleration sender) to contact
T47a/26 (control unit).
Measuring range 20
M set
- Test wiring for short to
positive or to earth.
Edition 02.01
S00.5103.60.20
------------ 45-263 ------------
45
OCTAVIA
Antilock Brake System
Switch on measuring range: resistance measurement (200
est
20
A
Sockets
-
est
Wiring of yaw rate
sender -G202-
M)
est conditions
Additional
Measures
Ignition switched off
Measuring range 200
set
- Unplug multipin connector T47a from control unit -J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
- Separate plug connection T3m from yaw rate
sender -G202-.
- Test wiring for open circuit:
max. 1.5
- Cable from contact
T3m/1 (yaw rate
sender) to contact
T47a/40 (control unit).
- Cable from contact
T3m/2 (yaw rate
sender) to contact
T47a/24 (control unit).
- Cable from contact
T3m/3 (yaw rate
sender) to contact
T47a/26 (control unit).
Measuring range 20
M set
- Test wiring for short to
positive or to earth.
------------ 45-264 ------------
readout
- Test wiring for open circuit.
- Repair cable connections
according to current flow
diagram.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Edition 02.01
S00.5103.60.20
OCTAVIA
Antilock Brake System
Switch on measuring range: Resistance measurement (200
Test
step
V.A.G
1598 A
Sockets
21
Test of
Wiring of brake pressure sender 1 -G201
/20 M )
Test conditions
- Additional operations
Ignition switched off
Measuring range
200 set
- Unplug multipin connector T47a from control unit -J104-.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/36.
- Separate plug connection T30 from brake
pressure sender -1-G201.
- Test cables for open
circuit:
- Cable from contact
T30/1 (brake pressure
sender) to contact
T47a/19 (control unit).
- Cable from contact
T30/2 (brake pressure
sender) to contact
T47a/20 (control unit).
- Cable from contact
T30/3 (brake pressure
sender) to contact
T47a/18 (control unit).
Measuring range 20
M set
- Test wiring for short to
positive or to earth.
Edition 02.01
S00.5103.60.20
45
Specification
max. 1.5
Measures if readout differs
from specification
- Test wiring for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
------------ 45-265 ------------
45
6
<
=
>
?
7
4
5
8
9
:
4
3
;
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1
2
)
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/
0
2
OCTAVIA
Antilock Brake System
Switch on measuring range:
Test
step
V.A.G
1598 A
Sockets
22
measurement
Test of
Test conditions
- Additional operations
Specification
Measures if readout differs
from specification
------------ 45-266 ------------
Edition 02.01
S00.5103.60.20
OCTAVIA
45
Antilock Brake System
Switch on measuring range: Resistance measurement (200
Test
step
V.A.G
1598 A
Sockets
23
11 + 15
Test of
Databus lines
/20 M )
Test conditions
- Additional operations
Specification
Measures if readout differs
from specification
Ignition switched off
Measuring range
200 set
- Unplug multipin plug
connections from the
control units connected
over the databus.
- Connect test box V.A.G
1598 A with adapter
V.A.G 1598/33.
- Test wiring for open circuit:
- to steering angle
sender
- to engine control unit
- to automatic gearbox
control unit1).
- Cable from contact
T47a/11 (control unit)
to contact T6w/3
(steering angle sender
-G85-).
- On to the connected
control units.
max. 1.5
- Test wiring for open circuit.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Cable from contact
T47a/15 (control unit)
to contact T6w/2
(steering angle sender
-G85-).
- On to the connected
control units.
Measuring range 20
M set
- Test wiring for short to
positive or to earth.
1)
Only models fitted with automatic gearbox.
Edition 02.01
S00.5103.60.20
------------
------------
45
OCTAVIA
Antilock Brake System
Switch on measuring range: Voltage measurement (20 V =)
Test
step
24
1)
V.A.G
1598 A
Sockets
Test of
Test conditions
- Additional operations
Voltage supply of vehicle system tester
V.A.G 1552, plug connection T16a
Ignition switched on
- Connect hand-held
multimeter, e.g. V.A.G
1526 A, with adapter
cable set V.A.G 1594
A to T16a1):
- Test cable between
contact T16a/4 and
contact T16a/1
Specification
10.0-14.5 V
Measures if readout differs
from specification
- Test cable from T16a/4 to
earth.
- Test cable from T16a/1
through S5.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Contact assignment of plug connection for voltage supply and self-diagnosis with vehicle system tester V.A.G
1552 page 45-251.
Switch on measuring range:
Test
step
25
measurement (200
V.A.G
1598 A
Sockets
Test of
Test conditions
- Additional operations
Resistance of K wire
for self-diagnosis,
plug connection T16a
Ignition switched off
Measuring range
200 set
- Remove fuse S13.
- Unplug multipin connector T47a from control unit -J104-.
- Connect test box
V.A.G 1598 A with
adapter V.A.G 1598/
33.
- Test cable between
contact T16a/7 and
contact T47a/39.
Measuring range 20
M set
- Test wiring for short to
positive or to earth.
------------
------------
Specification
max. 1.5
Measures if readout differs
from specification
- Test cable from T16a/7 to
contact T47a/39.
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
- Repair cable connections
according to CFD.
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
Edition 02.01
S00.5103.60.20
OCTAVIA
46
Brakes/Mechanical Components
Servicing front brakes
Servicing front brakes, brake
caliper FS-III
Special tools, testers and aids required
Piston resetting device MP 9-403
Brake pedal depressor, e.g. V.A.G 1238/B
Brake filling and bleeding appliance,
e.g. ROMESS S15
Bleeder bottle (commercially available)
Brake fluid page 00-8
Solid lubricating paste G 000 650
(e.g. Wolfrakote Top Paste)
Notes:
After replacing brake pads, depress brake
pedal firmly several times when vehicle stationary so that the brake pads adopt their
seating corresponding to the position when
driving.
Insert the brake pedal depressor, e.g. V.A.G
1238/B, before removing a brake caliper or
separating a brake hose from the brake
caliper.
Use a bleeder bottle which comes into contact only with brake fluid, for extracting brake
fluid from the brake fluid reservoir. Brake fluid
is toxic and must on no account be sucked
out with your mouth through a hose!
Do not re-use brake fluid which has been
extracted.
Tightening torque of wheel bolts: 120 Nm
Edition 10.98
S00.5103.54.20
------------ 46-1 ------------
46
OCTAVIA
Brakes/brake mechanics
4 - Brake caliper
removing:
- removing brake pads -item 3- page
46-3
- fitting brake pedal arrester.
- unscrew brake hose -item 7- from brake caliper
installing:
- installing brake pads -item 3- page
46-3
- screw brake hose -item 7- onto brake
caliper
- removing brake pedal arrester.
- bleeding brake system page 47-18
repairing page 47-8
5 - Guide bolts, 28 Nm
removing and installing page 46-3
6 - Cap
7 - Brake hose with ring fitting and hollow screw
cannot be disassembled, must be replaced completely
Tightening torque: 35 Nm
8 - Wheel bearing housing
1 - Philips head screw, 4 Nm
2 - Brake discs
thickness: 22 mm
wear limit: 19 mm
if worn always replace axle-wise
before removing unscrew brake caliper
do not use force to separate the brake
discs from the wheel hub, if necessary use rust solvent as you could otherwise damage the brake dics
Technical data Brakes; page 00-6
3 - Brake pads
with wear indicator
- with a corresponding wear (limit: 2 to
3 mm) a warning lamp on the dash
panel insert lights up
thickness 19.5 mm including supporting plate
wear limit: 7 mm including supporting
plate
inspecting thickness
Inspection and Maintenance
always replace axle-wise
removing and installing page 46-3
05.98 : do not interchange inside
and outside brake pads
page 46-4
------------
------------
9 - Allan screw, 8 Nm
10 - ABS speed sensor
before inserting speed sensor, clean
inside surface of hole and coat with
solid lubricant paste G 000 650 (e.g.
Wolfrakote-Top-Paste)
11 - Cover plate
12 - Screw, 10 Nm
13 - Wheel bearing
replacing after each removal
pressing out and in page 40-16 and
further
14 - Circlip
15 - Wheel bearing with pulse rotor
only on vehicles with ABS
pressing out and in page 40-16 and
further
16 - Wheel bearing without pulse rotor
only on vehicles without ABS
Edition 04.03
S00.5103.66.20
OCTAVIA
46
Brakes/brake mechanics
Removing and installing brake linings
or the brake calliper (FS-III)
Required special tools, testing and measuring equipment as well auxiliary devices and
material
A piston resetting device MP 9-403
A brake filling and ventilation device, e.g.
ROMESS S 15
A ventilating bottle (commercially available)
Brake fluid Page 00-8
Removal
-
Removing wheels
Comments:
Mark brake linings which are to be used again
when removing. Install at the same location
again otherwise uneven braking will result!
Do not unscrew the brake hose to change
brake linings.
-
K-
Edition 06.02
S00.5103.64.20
Disconnect the plug connection for the brake
lining wear indicator (when the vehicle is fitted with this).
Remove the caps -2-
Screw out both guide bolts from the brake
calliper and remove.
Remove the brake calliper housing and fix it
with a wire in such a way that the weight of
the brake calliper does not load down the
brake hose or damage it.
K-
Remove the brake linings from the brake calliper housing.
------------
------------
46
Brakes/brake mechanics
OCTAVIA
Installing
Comments:
Before inserting new brake linings press the piston into the cylinder using the piston resetting
device. Remove some brake fluid from the brake
fluid reservoir using a ventilatiion bottle before
pressing in again.
Otherwise - if brake fluid has been topped up in
the meantime - it may flow out and cause damage.
Take note!
Brake fluid is poisonous and must not under any
circumstances be sucked up over a hose by mouth.
-
Clean the brake calliper housing.
Comment:
One should exclusively use white spirits to clean
the brake calliper housing.
K-
Press back the piston using the piston resetting device MP 9-403.
Insert the brake linings
05.98 : do not mix up the inner and outer
brake linings
Outer brake lining: a black coloured three
finger clip
Inner brake lining: white coloured on the
piston side
K-
First place the brake calliper housing below
-arrow-.
Mount the brake calliper housing with brake
linings on the wheel bearing housing.
The lugs of the brake calliper housing -arrowmust be behind the guide for the wheel bearing housing.
------------
------------
Screw the guide bolts into the brake calliper
housing and tighten to 28 Nm.
Disconnect the plug connection for the brake
lining wear indicator (when the vehicle is fitted with this).
Edition 06.02
S00.5103.64.20
OCTAVIA
46
Brakes/Mechanical Components
K-
Fit the two protective caps -2-.
Mount wheels.
Notes:
After each change of brake pads apply strong
pressure repeatedly in standing position, to ensure the brake pads fit into their operating position.
Check the brake fluid level after changing the
brake pads, if necessary top up brake fluid.
Servicing front brakes with FN-3
brake calliper
Special tools, testers and aids required
Piston resetting device MP 9-403
Brake pedal arrester, e.g. V.A.G 1238/B
Brake filling and bleeding appliance, e.g.
ROMESS S15
Bleeder vessel (commercially available)
Brake fluid page 00-8
Solid lubricating paste G 000 650 (e.g.
Wolfrakote-Top-Paste)
Notes:
After each change of brake pads apply strong
pressure repeatedly in standing position, to
ensure the brake pads fit into their operating
position.
Before removing a brake calliper of before
disconnecting a brake pipe from the brake
calliper use brake pedal arrester (e.g. V.A.G
1238/B.)
To bleed the brake fluid from the brake fluid
reservoir use a bleeder vessel that only
comes into contact with the brake fluid. Brake
fluid is toxic and must under no circumstances be sucked out by mouth via a hose!
Never re-use used brake fluid.
Tightening torque of wheel bolts: 120 Nm.
Edition 12.98
S00.5103.55.20
------------ 46-5 ------------
46
Brakes/brake mechanics
OCTAVIA
3 - Brake discs
with approx. 5 mm wide ink jet mark
for marking maximum axial run-out
combination of brake disc with marking and wheel hub without marking is
permissible
with 5 fixing holes for wheel hub
always replace axle-wise
before removing unscrew brake caliper
do not use force to separate the brake
discs from the wheel hub, if necessary use rust solvent as you could otherwise damage the brake dics
Technical data Brakes; page 00-6
assignment Spare Part catalogue
removing and installing page 46-5.7
4 - Brake pads
with wear indicator
- with a corresponding wear (limit: 2 to
3 mm) a warning lamp on the dash
panel insert lights up
Technical data page 00-6
inspecting thickness
Inspection and Maintenance
always replace axle-wise
removing and installing page 46-5.2
1 - Philips head screw, 4 Nm
2 - Brake discs
without marking for maximum axial
run-out
combination of brake disc without
marking and wheel hub with marking
is permissible
with a fixing hole for the wheel hub
always replace axle-wise
before removing unscrew brake caliper
do not use force to separate the brake
discs from the wheel hub, if necessary use rust solvent as you could otherwise damage the brake dics
Technical data Brakes; page 00-6
assignment Spare Part catalogue
------------
------------
5 - Retaining spring
insert in both holes of the brake caliper
replace after each pad replacement
6 - Brake carrier
is installed together with adequate
quantity of grease on the guide bolts
supplied as a spare part
if protective caps or guide bolts are
damaged, use the complete repair kit,
use the enclosed grease packaging
to grease the guide bolts
7 - Brake caliper
removing:
- removing brake pads -item 4- page
46-5.2
- fitting brake pedal arrester.
- unscrew brake hose -item 10- from
brake caliper.
installing:
- installing brake pads -item 4- page
46-5.4
- screw brake hose -item 10- onto brake
caliper.
- removing brake pedal arrester.
- bleeding brake system page 47-18
repairing page 47-10.1
Edition 04.03
S00.5103.66.20
OCTAVIA
46
Brakes/Mechanical Components
8 - Guide pin, 28 Nm
removing and installing page 465.2
15 - Splash guard
9 - Cap
17 - Wheel bearing
replace each time removed
removing and inserting page 4016
16 - Hexagon bolt, 10 Nm
10 - Brake hose with union and banjo bolt
must not be disassembled; always
replace complete
tightening torque 35 Nm
18 - Circlip
11 - Hexagon bolt with locking collar,
125 Nm
clean ribbing on underside
19 - Wheel hub with pulse rotor
with and without marking for minimum
runout
combination of wheel hub without
marking and brake disc with marking,
or vice versa, is permitted. Reduction
of total runout of brake FN-3 is then
not effective
only on models with ABS
removing and inserting page 4016
assignment Parts List
12 - Wheel bearing housing
13 - Hexagon socket bolt, 8 Nm
14 - ABS wheel speed sensor
clean inner surface of hole and coat
with solid lubricating paste G 000 650
(e.g. Wolfrakote Top Paste) before
inserting the sensor
Removing and installing brake
pads/brake caliper (FN-3)
Special tools, testers and aids required
Piston setback device MP 9-403
Brake filling and bleeding appliance, e.g.
ROMESS S15
Bleeder bottle (commercially available)
Brake fluid page 00-8
Removing
-
Take off wheels.
Notes:
Mark brake pads which can be re-used when
removing. Re-install at the same point otherwise braking action will be uneven!
Do not disconnect brake hose for replacing
pads.
K-
Edition 05.01
S00.5103.61.20
Take off caps -arrows-.
------------
------------
46
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Brakes/brake mechanics
OCTAVIA
K-
K-
Comment:
One should exclusively use white spirits to clean
the brake calliper housing.
------------
------------
Edition 06.02
S00.5103.64.20
OCTAVIA
46
Brakes/Mechanical Components
Installing
K Directional brake pads
1 - right piston-side brake pad
2 - left piston-side brake pad
When installed, the arrow on the backplate of
the brake pad should point downward. Please
check!
Note:
Before inserting new brake pads, push piston
into cylinder with piston resetting device. Before pushing back, suck out brake fluid from
brake fluid reservoir using a bleeder vessel. Otherwise - if brake fluid has been topped up in the
meantime - brake fluid may escape and thus
cause damage.
Caution!
Brake fluid is toxic and must under no circumstances be sucked out by mouth via a hose.
K-
Edition 12.98
S00.5103.55.20
Push back piston.
Insert inner brake pad.
------------ 46-5.4 ------------
46
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Brakes/brake mechanics
OCTAVIA
K-
K-
------------
------------
Edition 06.02
S00.5103.64.20
OCTAVIA
46
Brakes/Mechanical Components
K-
Fit on both caps -arrows-.
K-
Insert the ends of retaining spring into the
holes of brake caliper housing -arrow A- and
then press spring behind the brake carrier
-arrow B-.
Fit on wheels.
Notes:
Each time after replacing brake pads, depress brake pedal firmly several times when
car stationary so that the brake pads are
properly seated in their normal operating
position.
Each time after replacing brake pads, check
brake fluid level, and top up brake fluid if necessary.
Edition 12.98
S00.5103.55.20
------------ 46-5.6 ------------
46
Brakes/Mechanical Components
OCTAVIA
Removing and installing brake
discs (FN-3)
Notes:
In the case of brake FN-3 brake judder, pulsing or steering wheel vibrations may occur.
The cause of this is an excessive axial runout
in the brake disc - wheel hub system.
To reduce the axial total runout the maximum
and minimum runout of the brake disc and
the wheel hub are marked by ink jet marking.
When dealing with complaints regarding excessive axial total runout, replace nonmarked wheel hubs and brake discs with
marked parts. Assignment
Parts List
If used brake discs with marking and 5-hole
attachment for wheel hub are to be re-installed, mark the position of the brake disc
to the wheel hub before removing the parts.
It is permitted to use the combination of
marked brake disc/unmarked wheel hub, or
unmarked brake disc and marked wheel hub.
Also permissible is the combination on the
left side of the vehicle of components without a marking, and on the right side of the
vehicle components with a marking, or vice
versa.
Note that in the case of the combinations
listed, the reduction of the total runout at the
FN-3 brake is not effective.
Always replace brake discs only on both
sides.
Do not use force to separate brake discs from
the wheel hub; use rust release agents, if
necessary; otherwise risk of damage to the
brake discs.
Removing
-
Take off wheel.
Note:
Do not disconnect brake hose from the brake
caliper.
-
------------
------------
Remove brake carrier together with brake
caliper and attach with wire so that the weight
of the brake caliper is not pulling on the brake
hose, or can damage it.
Edition 05.01
S00.5103.61.20
OCTAVIA
46
Brakes/Mechanical Components
-
Remove cross-head screw.
Take off brake disc.
total
-
a complaint
Remove wheel hub page 40-16.
total
a complaint
K-
Install new wheel hub -1- with ink jet marking about 3 mm wide aligned to marking of
minimum runout -arrow A- in the wheel bearing housing page 40-16.
Install new brake disc -2- with 5 holes for
attaching wheel hub and an ink jet marking
about 5 mm wide aligned with the marking
of the maximum runout -arrow B-.
Installation position:
Install brake disc on wheel hub so that the markings of the minimum runout (wheel hub) and of
the maximum runout (brake disc) are positioned
opposite.
ehicles
complaint
On vehicles which have already been driven,
it is not possible to achieve a minimising of
the axial runout after replacing the brake
discs (old wheel hub/new brake disc).
Brake discs can be installed without any special installation position.
-
Install brake discs.
The remaining installation is carried out in
the reverse order.
Brake disc to wheel hub
Brake carrier with brake
caliper to wheel bearing housing
Wheel bolt
Edition 05.01
S00.5103.61.20
4 Nm
125 Nm
120 Nm
------------
------------
46
OCTAVIA
Brakes/Mechanical Components
Servicing rear brakes - FWD models/drum brakes
Removing and installing rear brake
Notes:
After replacing wheel brake cylinder, brake
carrier and brake shoes, depress brake pedal
firmly once when vehicle stationary so that
the brake shoes are properly seated to match
their operating position.
Use a bleeder bottle which comes into contact only with brake fluid, to extract brake fluid
from the brake fluid reservoir. Brake fluid is
poisonous and must on no account be extracted by sucking it out through a hose with
your mouth!
Before removing a wheel brake cylinder,
brake carrier or separating a brake pipe from
the brake cylinder, insert the brake pedal
depresser, e.g. V.A.G 1238/B.
Brake fluid drained from the system must not
be re-used.
Tightening torque of wheel bolts: 120 Nm
1 - Cross-head screw, 4 Nm
Special tools, testers and aids required
Measuring instrument for brake drum MP 5407
Dial gauge (range 0 - 10 mm)
Bleeder bottle (commercially available)
Brake filling and bleeding appliance, e.g.
ROMESS S15
Brake pedal depresser, e.g. V.A.G 1238/B
Brake fluid page 00-8
Solid lubricating paste G 000 650 (e.g.
Wolfrakote Top Paste)
------------
------------
2 - Brake drum
Brake drum diameter 230 mm
Wear limit 231.0 mm
Clean carefully, inspect for wear, damage, dimensional tolerance and proper
braking surface
Check out-of-roundness with special
tool MP 5-407 and dial gauge (range
0 - 10 mm)
- Permissible out-of-roundness 0.03
mm; if measurement obtained is greater than 0.03 mm, replace brake drum.
Inspection and Maintenance
3 - Cap
Pressing off page 42-25
Inserting page 42-27
4 - Twelve-pointed nut, self-locking,
70Nm + torque a further 40
Replace each time removed
Edition 04.00
S00.5103.58.20
OCTAVIA
46
Brakes/Mechanical Components
5 - Wheel hub with wheel bearing and
pulse rotor
Only on models with ABS
Replace each time removed
Always replace complete
Removing and inserting from page
42-23
9 - Axle beam
10 - Axle stub
11 - Hexagon socket bolt, 8 Nm
12 - ABS wheel speed sensor
Only on vehicles with ABS
Before inserting the sensor, clean inner surface of hole and coat with solid
lubricating paste G000650 (e.g.
Wolfrakote Top Paste)
6 - Wheel hub with wheel bearing without
pulse rotor
Only on models without ABS
Replace each time removed
Always replace complete
Removing and inserting from page
42-23
7 - Bolt + washer, 50 Nm + torque a further 60
Replace each time removed
8 - Brake carrier with brake shoes
Removing:
- Setting back brake page 46-7
- Remove brake drum
- Insert brake pedal depresser
- Unbolt brake tube
- Remove brake carrier
Installing:
- Install brake carrier
- Bolt on brake tube
- Remove brake pedal depresser
- Install brake drum
- Bleed brake system page 47-18
Servicing page 46-8
Moving back brake
K-
Edition 04.00
S00.5103.58.20
Insert a screwdriver through a hole of the
wheel bolts in the brake drum and push the
wedge up.
------------
------------
46
Brakes/brake mechanics
OCTAVIA
Repairing rear wheel brake
1 - Spring cap
to remove push against pressure
spring and turn 90
2 - Pressure spring
3 - Locating spring
4 - Pressure rod
grease points of contact with solid lubricant paste G 000 650 (e.g. Wolfrakote-Top-Paste)
5 - Wedge
when removing and installing the brake drum push up through a hole for
the wheel bolt page 46-7
Special tools, testers and aids required
6 - Wheel brake cylinder
inspecting for leaks Fig. 1
repairing is not permissible
removing:
- fitting brake pedal arrester
- unscrew brake pipe
- removing wheel brake cylinder
installing:
- installing wheel brake cylinder
- screw on brake pipe.
- removing brake pedal arrester.
- bleeding brake system page 47-18
Hook (commercially available)
7 - Allan screw, 8 Nm
Brake filling and ventilation device,
e.g. ROMESS S 15
Brake pedal arrester, e.g. V.A.G 1238/B or
V.A.G 1869/2
Plastic wedge 3409
8 - Tensioning pin
9 - Brake carrier
10 - Cap
for checking the removed brake pad
thickness Fig. 2
Brake fluid page 00-8
Solid lubricant paste G 000 650
(e.g. Wolfrakote top paste)
Note:
After working on the rear wheel brake
Release hand brake.
Activate brake pedal forcefully once.
------------
------------
11 - Brake shoes
removing and installing page 46-10
minimum pad thickness without supporting plate 2.5 mm
inspecting thickness Fig. 2, visual
inspection through the inspection hole
in the brake carrier as well as repair
manual of Inspection and Maintenance
Inspection and Maintenance
always replace brake pads axle-wise
Edition 04.03
S00.5103.66.20
OCTAVIA
46
Brakes/Mechanical Components
12 - Tension spring
14 - Top restoring spring
13 - Bottom restoring spring
Grease contact points with solid lubricating paste G 000 650 (e.g. Wolfrakote Top Paste)
15 - Brake shoe with lever for handbrake
Removing and installing
page 46-10
Adjusting handbrake page 46-12
K Fig. 1
-
Inspecting wheel brake cylinder for
leaks
Lift off dust seal.
Use plastic wedge 3409 for this step.
If brake fluid is present in dust seal, replace
wheel brake cylinder.
When lifting off dust seal, ensure that the seal
is not damaged.
K Fig. 2
Inspecting thickness of brake linings through hole in brake carrier
Unclip cap from brake carrier -arrow-.
Inspect thickness of brake linings through
inspection hole in brake carrier.
Minimum thickness without supporting shoe
(wear limit) 2.5 mm.
Note:
Check to determine whether linings are smeared
by brake fluid or grease.
Edition 10.98
S00.5103.54.20
------------
------------
46
OCTAVIA
Brakes/Mechanical Components
Removing and installing brake
shoes
Special tools, testers and aids required
Hook (commercially available)
Solid lubricating paste G 000 650
(e.g. Wolfrakote Top Paste)
Removing
-
Take off wheels.
Remove brake drum page 46-6, Removing and installing rear brakes.
Remove spring retainer together with compression springs.
K-
Use a screwdriver to lever the brake shoes
down in direction of arrow behind the supporting plate.
Place brake shoes down on the supporting
plate.
Detach restoring spring at bottom.
Detach handbrake cable.
Guide the brake shoes out between the
wheel hub and the brake carrier.
Clamp brake shoe in a vice.
K-
K-
------------ 46-10 ------------
Remove tension spring -1- for wedge -2-.
Use hook -A- to release top restoring spring
-3-.
Use hook -A- to release contact spring -1-.
Take the pull rod -2- and the wedge -3- off
the brake shoe.
Edition 10.98
S00.5103.54.20
OCTAVIA
46
Brakes/Mechanical Components
Installing
K-
Attach contact spring at the brake shoe and
place brake shoe onto the pull rod.
Grease contact point of pull rod with solid
lubricating paste G 000 650 (e.g. Wolfrakote
Top Paste).
K-
Use hook -A- to attach contact spring -1- in
the pull rod -2-.
Insert the wedge -3- at the same time.
Installation position:
Raised face -arrow- should remain visible when
installed.
Edition 10.98
S00.5103.54.20
Insert brake shoe with brake lever into pull
rod.
Grease contact point of pull rod with solid
lubricating paste G 000 650 (e.g. Wolfrakote
Top Paste).
K-
Use hook -A- to attach top restoring spring
-3-.
Attach tension spring -1- for wedge -2-.
Guide the brake shoes in between the wheel
hub and the brake carrier.
Place brake shoes onto the piston of the
wheel brake cylinder.
Attach handbrake cable at the brake lever.
Insert bottom restoring spring and lever brake
shoe behind the bottom support.
Grease contact points of bottom restoring
spring at the brake shoes with solid lubricating paste G 000 650 (e.g. Wolfrakote Top
Paste).
------------ 46-11 ------------
46
Brakes/Mechanical Components
OCTAVIA
Insert compression spring with spring retainer.
Install brake drum.
Depress brake pedal firmly once.
Adjust handbrake.
Fit on wheels.
Adjusting handbrake (drum brakes)
The automatic slack adjuster of the rear wheel
brakes makes it unnecessary to re-set the handbrake. Re-setting should only be performed after replacing the handbrake cables, the brake
carrier or after fitting new brake linings/brake
shoes.
Note:
Always replace the self-locking slack adjuster
nut.
-
Release handbrake.
Remove ashtray in centre console.
Take out cross-head screws.
K-
Raise centre console at rear, or remove if
necessary
Body Fitting Work; Repair Group 68; Interior Equipment
1 - Handbrake cables
------------ 46-12 ------------
Depress brake pedal firmly once.
Apply handbrake lever to 4th detent.
K-
Tighten slack adjuster nut -arrow- sufficiently
until it is difficult to turn both wheels by hand.
Release handbrake and check whether both
wheels rotate freely; turn back slack adjuster
nut slightly, if necessary.
Edition 06.99
S00.5103.56.20
OCTAVIA
46
Brakes/Mechanical Components
Servicing rear brake - front-wheel drive/disc brake
Removing and installing rear brake
Use a bleeder bottle which comes into contact only with brake fluid for extracting brake
fluid from the brake fluid reservoir. Brake fluid
is toxic and must on no account be extracted
by sucking out through a hose with your
mouth!
Insert the brake pedal depresser, e.g. V.A.G
1869/2, before removing a brake cylinder or
separating a brake hose from the brake cylinder.
Do not re-use brake fluid which was in the
system.
Tightening torque of wheel bolts: 120 Nm
1 - Cross-head screw, 4 Nm
2 - Brake disc, internally ventilated
Diameter 256 mm
Thickness 22 mm
Wear limit 20 mm
If worn, replace on both sides of axle
Special tools, testers and aids required
Brake filling and bleeding appliance,
e.g. ROMESS S15
Brake pedal depresser, e.g. V.A.G 1238/B
Bleeder bottle (commercially available)
Brake fluid page 00-8
Solid lubricating paste G 000 650
(e.g. Wolfrakote Top Paste)
Notes:
After replacing the brake pads, depress
brake pedal firmly several times when vehicle stationary so that the brake pads are
properly seated according to their position
in operation.
3 - Brake disc
Diameter 232 mm
Thickness 9 mm
Wear limit 7 mm
If worn, replace on both sides of axle
4 - Cap
Pressing off page 42-29
Knocking in page 42-31
5 - Twelve-point nut, self-locking
Replace each time removed
Tightening page 42-74
6 - Wheel hub with wheel bearing and
pulse rotor
Fitted only to models with ABS
Replace each time removed
Always replace complete
Pressing out and in page 42-28
7 - Hexagon, 60 Nm
With dished washer
8 - Splash guard
9 - Axle stub
Edition 02.01
S00.5103.60.20
------------ 46-13 ------------
46
OCTAVIA
Brakes/Mechanical Components
16 - Brake hose with banjo union and
banjo bolt
Must not be disassembled; always replace complete
Tightening torque of banjo bolt: 35 Nm
Do not detach brake hose for replacing brake pad
17 - Hexagon bolt, self-locking, 35 Nm
Always replace
10 - Handbrake cable
Adjusting handbrake
page 46-17
Removing and installing
page 46-17.3
11 - Axle beam
12 - ABS wheel speed sensor
Clean inner surface of hole and
coat with solid lubricating paste
G000 650 (e.g. Wolfrakote Top
Paste) before inserting the sensor
13 - Hexagon socket bolt, 8 Nm
14 - Hexagon socket bolt, 65 Nm
15 - Brake carrier with guide pins and
protective caps
Is supplied as replacement part,
assembled, with adequate quantity of grease on guide pins
If damage exists at the protective
caps or the guide pins, install repair kit. Use enclosed grease packing for greasing the guide pins.
------------ 46-14 ------------
18 - Brake caliper
Do not detach brake hose for replacing brake pad
Removing:
- Remove brake pads -item 19- page
46-15
- Insert brake pedal depresser
- Detach brake hose -item 16- from
brake caliper
Installing:
- Install brake pads -item 19- page
46-15
- Attach brake hose -item 16- to brake
caliper
- Remove brake pedal depresser
- Bleed brake system page 47-18
Servicing page 47-11
After servicing or replacement, it is first
of all necessary to adjust the handbrake cable
Do not operate the footbrake before
this!
Adjusting handbrake page 46-17
19 - Brake pads
Thickness 17 mm including supporting plate
Wear limit: 7.5 mm including supporting plate
Inspecting thickness:
Inspection and Maintenance
Always replace on both sides of axle
Removing and installing
page 46-15
20 - Brake pad retaining spring
Install new spring if pad replaced
Edition 02.01
S00.5103.60.20
OCTAVIA
#
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Brakes/Mechanical Components
and
pads
testers and aids
Bleeder bottle (commercially available)
Resetting and removal tool MP 9-401
Brake filling and bleeding appliance, e.g.
ROMESS S15
Brake fluid page 00-8
Notes:
Mark brake pads which are to be re-used,
when removing. Install again at the same
point otherwise braking action will be uneven.
Do not disconnect brake hose for changing
pads.
Take off wheels.
Detach handbrake cable at brake caliper
page 46-17.3.
K-
Unscrew bolts attaching brake caliper housing; counterhold at guide pin for this step.
Take off brake caliper housing and attach
with wire so that the weight of the brake
caliper is not pulling on the brake hose, and
cannot damage it.
Remove brake pads and pad retaining
springs.
Note:
Use only methylated spirits for cleaning the
brake caliper housing.
-
Edition 04.00
S00.5103.58.20
Clean brake caliper housing, in particular the
area for bonding the brake pad. It must be
free of adhesive residues and grease.
------------
------------
46
Brakes/Mechanical Components
OCTAVIA
Installing
Notes:
Before inserting new brake pads, use resetting
and removal tool MP 9-401 to press piston into
the cylinder. Before pressing back, extract brake
fluid from the brake fluid reservoir with a bleeder
bottle otherwise - if brake fluid has been topped
up in the meantime - it may flow out and cause
damage.
Warning!
Brake fluid is toxic and must on no account be
sucked out with your mouth through a hose.
K Insert special tool MP 9-401 so that the collar (arrow B) of the tool is resting against the
brake caliper.
If piston is stiff, an open-end wrench waf 13
can be positioned at the wrench faces (arrow A) provided for this purpose.
If the position of the piston is altered with a
piston resetting device, the automatic adjuster in the brake caliper is destroyed.
------------ 46-16 ------------
Screw in piston by turning knurled wheel of
special tool MP 9-401 to the right.
K-
Insert new pad retaining springs -arrows- and
brake pads into the brake carrier.
Remove protective sheet from the supporting plate of brake pad.
Edition 10.98
S00.5103.54.20
OCTAVIA
'
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46
Brakes/Mechanical Components
Note:
The repair kit contains four self-locking hexagon bolts which must always be installed.
K-
Notes:
Each time after replacing the brake pads, depress brake pedal firmly several times when
vehicle is stationary so that the brake pads are
properly seated to match their operating position.
After replacing brake pads, check brake fluid
level and top up brake fluid if necessary.
Adjusting handbrake (disc brakes)
The automatic slack adjuster of the rear wheel
brakes makes it unnecessary to re-set the handbrake. Re-setting should only be performed if
the handbrake cables, brake calipers and brake
discs are replaced.
Notes:
The footbrake must be bled and be in proper
operating condition.
Always replace self-locking slack adjuster
nut.
-
Edition 06.99
S00.5103.56.20
------------
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46
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Brakes/Mechanical Components
OCTAVIA
K-
K-
K-
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
46
Brakes/Mechanical Components
Removing and installing handbrake
cable (FWD models/drum brakes)
Removing
- Remove rear centre console.
Body Fitting Work; Repair Group 68; Interior Equipment
K-
Release handbrake.
Slacken adjusting nut -1- sufficiently until it
is possible to take the handbrake cable out
of the compensating bar -2-.
Raise vehicle.
Take off wheel.
Remove brake drum.
Release handbrake cable from the brake lever at the brake shoe.
K-
Take handbrake cable out of the clip at the
rear axle beam -arrow A- and release it from
the fixtures -arrows-.
K-
Pull handbrake cable -2- out of the guide tube
-1- in direction of arrow.
Installing
Installation is carried out in the reverse order.
Notes:
Pay attention to installation position when
installing handbrake cables page 46-18.
Before adjusting the handbrake, pretension
handbrake cable with the adjusting nut at the
compensating arm.
Adjusting handbrake page 46-12.
Edition 11.99
S00.5103.57.20
-----------------------
------------
46
Brakes/Mechanical Components
OCTAVIA
Removing and installing handbrake cable (FWD models/disc
brakes)
Removing
- Remove rear centre console.
Body Fitting Work; Repair Group 68; Interior Equipment
-
K-
------------
-----------------------
Release handbrake.
Slacken adjusting nut -1- sufficiently until it
is possible to take the handbrake cable out
of the compensating bar -2-.
Raise vehicle.
K-
a screwdriver to lever out clip -1- and
pull down and off.
ress brake lever -2- in direction of arrow
and detach handbrake cable
K-
handbrake cable out of the clip at the
rear axle beam -arrow A- and release it from
the fixtures -arrows-.
Edition 11.99
S00.5103.57.20
OCTAVIA
46
Brakes/Mechanical Components
K-
Pull handbrake cable -2- out of the guide tube
-1- in direction of arrow.
Installing
Installation is carried out in the reverse order.
Notes:
Pay attention to installation position when
installing the handbrake cables page
46-18.
Before adjusting the handbrake, pretension
handbrake cable with the adjusting nut at the
compensating bar.
Adjusting handbrake cable page 46-17.
Edition 10.98
S00.5103.54.20
------------
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OCTAVIA
Brakes/Mechanical Components
components
handbrake
3-T
Removing:
Body Fitting Work; Repair Group 68; Interior Equipment
4 - Centre console
Removing:
Body Fitting Work; Repair Group 68; Interior Equipment
5 - Cross-head screw,
Nm
6-
7 - Compensating bar
8-
- Handbrake l
Take out centre console before removing
Body Fitting Work; Repair Group 68; Interior Equipment
2 - Handle
Pull off to the front; to do this, use
screwdriver to first of all press down
catch below handle
Replace each time removed
Adjusting handbrake:
- Models with drum brakes
page 46-12
- Models with disc brakes
page 46-17
9 - Handbrake cable
Installation position of handbrake cables Fig. 1
Removing and installing (drum brakes)
page 46-17.2
Removing and installing (disc brakes)
page 46-17.3
Different versions for rear drum and
disc brakes
Parts List
0 - Handbrake indicator switch
Clipped in place
Replace if faulty
K Fig.
Installation position
cables
handbrake
Note:
The installation position of handbrake cables is
identical on models fitted with drum or disc
brakes (illustration shows version with drum
brakes).
------------
------------
The handbrake cables are attached to the
axle beam with clips.
The clamping ring -arrow A- at the handbrake
cable must be positioned in the middle of the
clip -arrow B-.
Edition 06.99
S00.5103.56.20
OCTAVIA
46
Brakes/brake mechanics
Summary of components: foot lever system, the brake pedal
1 - Bearing support
Removing and installing
Page 46-22
2 - Hexagonal nut, self-locking, 28 Nm
Replace
4 pieces for fixing the bearing support
to the brake booster
2 pieces for fixing the bearing support
to the assembly plate
3 - Brake light switch
The brake pedal should be clipped
onto the push rod of the brake booster
before mounting the brake light switch
Page 46-21
Removing and installing
Page 45-69
Allocation spare parts catalogue
4 - The accelerator pedal
Removing and installing
Engine-mechanics, Rep. Gr. 20
5 - Hexagonal nut, self-locking, 25 Nm
Take note!
The travel distance of the brake pedal must not be
shortened by use of additional floor coverings.
Comments:
Grease the bearing and the contact surfaces
with MoS2 grease (Molykote grease)
Replace self-locking nuts
6 - The brake pedal
Disconnect from the brake booster
Page 46-20
Removing and installing
Page 46-22
7 - Cap
8 - Hexagonal nut
9 - Bearing bush
10 - Bearing bolts
When using mechanical gas actuation detach the gas actuation system from the accelerator pedal before removing the bearing
support.
Engine-mechanics, Rep. Gr. 20; repairing
the gas actuation system
Edition 06.02
S00.5103.64.20
------------ 46-19 ------------
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Brakes/Mechanical Components
pedal
Special
testers and aids
pedal
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Brakes/Mechanical Components
Note:
Illustration shows how to separate brake pedal
from brake servo unit with pedal assembly removed, to simplify illustration.
K
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Edition 04.00
S00.5103.58.20
------------
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Brakes/Mechanical Components
and installing brake
pedal
testers and aids
(
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S00.5103.58.20
OCTAVIA
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Brakes/Mechanical Components
K
Note:
Grease all bearing and contact surfaces with
MoS2 grease.
and
Edition 04.00
S00.5103.58.20
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OCTAVIA
Brakes/Mechanical Components
rear
and
rear
Notes:
After replacing the brake pads, depress
brake pedal firmly several times when vehicle stationary so that the brake pads are
properly seated according to their position
in operation.
Use a bleeder bottle which comes into contact only with brake fluid for extracting brake
fluid from the brake fluid reservoir. Brake fluid
is toxic and must on no account be extracted
by sucking out through a hose with your
mouth!
Insert the brake pedal depresser, e.g. V.A.G
before removing a brake cylinder or
separating a brake hose from the brake cylinder.
not re-use brake fluid which was in the
system.
ightening
1
2
testers and aids
Brake filling and bleeding appliance, e.g.
ROMESS S15
Brake pedal depresser, e.g. V.A.G 1238/B
Bleeder bottle (commercially available)
Brake fluid page 00-8
Solid lubricating paste G 000 650
(e.g. Wolfrakote Top Paste)
------------
------------
socket
carrier
pins and
caps
supplied as replacement part, as
sembled,
of
grease on guide pins
damage exists at t protective caps
or t guide pins, install repair kit.
enclosed grease packing for greasing
guide pins.
of wheel
replace
h ose
Must not be
place complete
Ti
ing brake pad
a nd
re-
of
35
Edition 02.01
S00.5103.60.20
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OCTAVIA
Brake caliper
Do not detach brake hose for replacing brake pad
Removing:
- Remove brake pads -item 6- page
46-25
- Insert brake pedal depresser
- Detach brake hose -item 4- from
brake caliper
Installing:
- Install brake pads -item 6 page 46-26
- Attach brake hose -item 4- to brake
caliper
- Remove brake pedal depresser
- Bleed brake system page 47-18
Servicing page 47-11
After servicing or replacement, it is first
of all necessary to adjust the handbrake cable
not operate the
Adjusting handbrake page 46-29
6 Brake pads
Thickness 17 mm including supporting plate
Wear limit: 7.5 mm including supporting plate
Inspecting thickness:
Inspection and Maintenance
Always replace on both sides of axle
Removing and installing
page 46-26
10
Replace each time removed
Tightening page 42-74
Edition 02.01
S00.5103.60.20
11
12 Brake
Diameter 256 mm
Thickness 22 mm
Wear limit 20 mm
If worn, replace on both sides of axle
14
Brake disc
Diameter 232 mm
Thickness 9 mm
Wear limit 7 mm
If worn, replace on both sides of axle
Removing and inserting
page 42-44
Circlip
Replace each time removed
16
heel
Replace each time removed
Removing and inserting
page 42-44
Brake pad
Install new spring if pad replaced
10
46
Brakes/Mechanical Components
20
21
Adjusting handbrake page 46-29
Removing and installing
page 46-31
speed sensor
Clean inner surface of hole and coat
with solid lubricating paste G000 650
(e.g. Wolfrakote Top Paste) before inserting the sensor
socket
Removing and installing
page 42-72
------------
------------
46
Brakes/Mechanical Components
OCTAVIA
Removing and installing
pads
testers and aids
Resetting and skimming tool MP 9-401
Brake filling and bleeding appliance,
e.g. ROMESS S15
Bleeder bottle (commercially available)
Brake fluid page 00-8
Notes:
Mark brake pads which are to be re-used,
when removing. Re-install at the same point
otherwise braking action will be uneven!
Do not disconnect brake line for replacing
brake pads.
Removing
- Remove rear centre console.
Body Fitting Work; Repair Group 68; Interior Equipment
-
K-
------------
------------
Release handbrake.
Slacken adjusting nut -1- sufficiently until it
is possible to take the handbrake cable out
of the compensating bar -2-.
Raise vehicle.
Take off wheels.
K-
Use a screwdriver to lever out clip -1- and
pull down and off.
Press brake lever -2- in direction of arrow
and detach handbrake cable -3-.
Edition 11.99
S00.5103.57.20
OCTAVIA
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Brakes/Mechanical Components
K-
Note:
The
K-
Note:
Notes:
Warning!
Brake fluid is poisonous and must on no account
be sucked out through a hose with your mouth.
Edition 11.99
S00.5103.57.20
------------
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Brakes/Mechanical Components
-
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Note:
The
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Notes:
------------
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Edition 11.99
S00.5103.57.20
OCTAVIA
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46
Brakes/Mechanical Components
It is not normally necessary to adjust the handbrake because of the automatic slack adjuster
of the rear brakes. A re-setting is only necessary if the handbrake cables, the brake calipers
and the brake discs are replaced.
Notes:
The footbrake must be bled and be operating properly.
Always replace self-locking adjusting nut.
K-
K-
Edition 11.99
S00.5103.57.20
------------
------------
46
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Brakes/Mechanical Components
OCTAVIA
K-
------------
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Edition 11.99
S00.5103.57.20
OCTAVIA
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Brakes/Mechanical Components
Removing and installing
models/disc
46
Removing
- Remove rear centre console.
Body Fitting Work; Repair Group 68; Interior Equipment
-
K-
Slacken adjusting nut -1- sufficiently until it
is possible to take the handbrake cable out
of the compensating bar -2-.
Raise vehicle.
K-
a screwdriver to lever out clip -1- and
pull down and off.
ress brake lever -2- in direction of arrow
and detach handbrake cable
K-
Edition 11.99
S00.5103.57.20
Release handbrake.
Remove rubber grommet -arrow
trailing arm.
from the
handbrake cable out of
-arrowand pull it out of trailing arm in direction of
arrow.
------------
------------
46
#
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OCTAVIA
Brakes/Mechanical Components
K-
Notes:
Before adjusting the handbrake, pretension
handbrake cable with the adjusting nut at the
compensating arm.
Adjusting handbrake page 46-29.
------------
------------
Edition 11.99
S00.5103.57.20
OCTAVIA
47
Brakes/Hydraulic Components
Assembly overview: brake servo unit/brake master cylinder for models without ABS and for models with ABS, ABS/EDL Mark 20
- Continued for all brake servo units
operational check page 47-4
removing and installing page 474.1
if fault exists, replace complete
separating from brake pedal page
46-20
on petrol engines, vacuum required is
drawn from intake manifold
on diesel engines, vacuum pump fitted to produce vacuum
non-return valve (in vacuum hose of
vacuum pump) page 47-7
Operational check
- It must be possible to blow through
valve in direction of arrow.
- The valve must be leaktight in opposite direction of arrow.
2 - Cap
with integrated brake fluid level warning contact -F343 - Brake fluid reservoir
locked into retaining pin with side
catches
Note:
Complete brake master cylinders and brake
servo units can be replaced separately from
each other.
1 - Brake servo unit without mechanical
brake assist
all models without ABS
RHD models with ABS, ABS/EDL
LHD models with ABS, ABS/EDL up
to and including Model Year 2001
- Brake servo unit with mechanical
brake assist
LHD models with ABS, ABS/EDL from
Model Year 2002
mechanical brake assist integrated in
brake servo unit
brake assist is recognisable only from
the part number of the brake servo unit
assignment Parts List
brake assist cannot be serviced; if
complaints exist, replace complete
brake servo unit page 47-4.1
Edition 05.01
S00.5103.61.20
4 - Sealing plug
moisten with brake fluid and press in
reservoir
5 - Retaining pin
insert through brake master cylinder
6 - Brake master cylinder
on models with ABS/EDL/ESP two
brake pressure senders (G201 and
G214) are installed additionally
page 47-28
must not be serviced; if fault exists,
replace complete
leak test page 47-24
7 - Self-locking hexagon nut, 20 Nm
only on models with 74 kW, 92 kW
and 110 kW engine
8 - Heat shield
only on models with 74 kW, 92 kW
and 110 kW engine
9 - Self-locking hexagon nut, 20 Nm
replace
------------ 47-1 ------------
47
OCTAVIA
Brakes/Hydraulic Components
10 - Seal
replace
11 - Sealing plug
12 - Vacuum hose
with non-return valve
13 - Gasket
for brake servo unit
install between brake servo unit and
bulkhead
14 - Self-locking hexagon nut, 25 Nm
replace
Removing and installing brake
master cylinder
Special tools, testers and aids required
Hose clamp MP 7-602
Extraction bottle (commercially available)
Brake fluid page 00-8
Repair kit Part No. 1H0 698 311 A
Notes:
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When re-connecting the battery, check the
vehicle equipment:
- encode radio,
- re-set clock,
- initialise power windows.
Inspection and Maintenance
Removing
-
Disconnect battery.
Note:
The following 2 steps do not apply to the 1.6 l/
55 kW engine:
------------ 47-2 ------------
K-
Unplug connector -1- of air mass meter from
air guide pipe of air filter.
Take out the screws -2- at the air filter -3and place this down to the side.
On diesel engines, remove relay carrier
above brake servo unit.
Edition 05.01
S00.5103.61.20
OCTAVIA
47
Brakes/Hydraulic Components
K-
Unplug connector -1- from brake fluid level
warning contact -F34-.
Extract as much brake fluid as possible from
the brake fluid reservoir with extraction equipment or extraction bottle.
Use special tool MP 7-602 to pinch off feed
line of clutch master cylinder -2-.
Detach feed line of clutch master cylinder
-2- from brake fluid reservoir -3- and place
up.
Detach brake lines from tandem brake master cylinder, seal brake lines with plugs from
repair kit Part No. 1H0 698 311 A.
On 74 kW, 92 kW and 110 kW engines, unbolt heat shield.
Unbolt tandem brake master cylinder from
brake servo unit.
Installing
Installation is carried out in the reverse order.
Edition 06.99
S00.5103.56.20
Replace the seal between brake master cylinder and brake servo unit.
When fitting together brake master cylinder
and brake servo unit, ensure the pushrod is
correctly located in the brake master cylinder.
After installing, pour in only fresh brake fluid.
Connect battery page 47-2.
Bleed brake system page 47-18.
------------ 47-3 ------------
47
!
OCTAVIA
Brakes/Hydraulic Components
- Bleed clutch (manual gearbox).
Manual Gearbox; Repair Group 30; Servicing clutch mechanism
Inspection and Maintenance
-
On models with EDL, initiate basic setting
page 45-36.
Interrogate fault memory page 45-12.
Erase fault memory page 45-21.
unit
Brake
unit
assist
check
With engine switched off, depress brake
pedal firmly several times (this reduces the
pressure in the brake servo unit).
Now, hold the brake pedal in the braking
position with moderate foot force and start
engine.
If the brake servo unit is operating properly,
the brake pedal will now be felt to yield under your foot (servo assistance is active).
If a problem exists, replace brake servo unit.
sist
check of
unit
Brake servo unit without brake assist, page
47-4.
check of rake assist
With engine running (full vacuum assistance
must be assured), depress brake pedal
firmly. When this is done, a clicking must
be audible (brake assist is activated).
If no clicking can be heard, there is a fault in
the brake assist and the brake servo unit must
be replaced complete.
When the brake pedal is then released, a considerably reduced force from the brake pedal
acts on the foot than is the case when braking.
------------ 47-4 ------------
Edition 05.01
S00.5103.61.20
OCTAVIA
47
Brakes/Hydraulic Components
Removing and installing brake
servo unit
Special tools, testers and aids required
Hose clamp MP 7-602
Brake pedal depresser, e.g. V.A.G 1238/B
Vehicle system tester V.A.G 1552
Diagnostic cable V.A.G 1551/3, 3A, 3B or 3C
Release tool T30021
Extraction bottle (commercially available)
Repair kit Part No. 1H0 698 311 A
Brake fluid page 00-8
Notes:
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When re-connecting the battery, check the
vehicle equipment:
- encode radio,
- re-set clock,
- initialise power windows.
Inspection and Maintenance
Edition 05.01
S00.5103.61.20
------------
------------
47
------------
Brakes/Hydraulic Components
------------
OCTAVIA
Edition 05.01
S00.5103.61.20
OCTAVIA
1
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Brakes/Hydraulic Components
K-
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Edition 06.99
S00.5103.56.20
------------
------------
47
Brakes/Hydraulic Components
OCTAVIA
Installing
K
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------------ 47-6 ------------
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Edition 04.00
S00.5103.58.20
OCTAVIA
47
Brakes/Hydraulic Components
The remaining installation is carried out in the
reverse order.
-
Pour in fresh brake fluid page 00-8.
Connect battery page 47-2.
Bleed brake system page 47-18.
- Bleed clutch (manual gearbox).
Manual Gearbox; Repair Group 30; Servicing clutch mechanism
Inspection and Maintenance
-
On models fitted with EDL, initiate basic setting page 45-36.
Interrogate fault memory page 45-12.
Erase fault memory page 45-21.
and installing
pump for brake
unit
Models with diesel engine
Engine, Mechanical Components; Repair
Group 15; Removing and installing cylinder
head
Edition 06.99
S00.5103.56.20
------------ 47-7 ------------
47
Brakes/Hydraulic Components
OCTAVIA
Servicing front brake caliper, brake caliper FS-III
Summary of components of brake caliper FS-III
Notes:
Always install complete repair kit when carrying out repairs.
New brake calipers are filled with brake fluid
and pre-bled.
Apply a thin coat of brake fluid or assembly
paste to brake cylinder, piston and seal.
1 - Dust cap
2 - Bleeder valve, 10 Nm
Before inserting, apply a thin coat of
brake fluid or assembly paste to
thread
3 - Bearing bush
Insert into brake caliper housing
4 - Guide pin, 28 Nm
5 - Cap
Insert into bearing bush
6 - Brake caliper housing
Special tools, testers and aids required
Piston resetting device MP 9-403
Plastic wedge 3409
Brake fluid page 00-8
Assembly paste G 052 150 A2
------------
------------
7 - Seal
Removing and installing from page
47-9
8 - Piston
Removing and installing from page
47-9
First of all, apply a thin coat of assembly paste or brake fluid to piston
9 - Protective cap
Do not damage when inserting piston
Edition 06.99
S00.5103.56.20
OCTAVIA
47
Brakes/Hydraulic Components
Removing and installing piston for
front brake caliper
Special tools, testers and aids required
Piston resetting device MP 9-403
Plastic wedge 3409
Brake fluid page 00-8
Assembly paste G 052 150 A2
Removing
K-
Use compressed air to press piston out of
the brake caliper housing -arrow-.
Note:
Place a wooden block in the recess so that the
piston is not damaged.
K-
Remove seal.
Use plastic wedge 3409 for this step.
Note:
When removing, ensure that the surface of the
cylinder is not damaged.
Edition 10.98
S00.5103.54.20
------------ 47-9 ------------
47
Brakes/Hydraulic Components
OCTAVIA
Installing
-
Clean surfaces of piston and seal with methylated spirits and then dry.
Apply a thin coat of brake fluid or assembly
paste G 052 150 A2 to the piston and seal
before inserting into brake caliper housing.
Insert new seal into the groove of the brake
caliper.
K-
Fit new protective cap with the outer sealing
lip onto the piston.
K-
Use a plastic wedge to insert inner sealing
lip of the protective cap into the groove of
the cylinder.
Use plastic wedge 3409 for this step.
Note:
Hold piston in front of brake caliper housing for
this step.
K-
Use piston resetting device MP 9-403 to
press piston into brake caliper housing.
Note:
The outer sealing lip of the protective cap jumps
into the groove on the piston when this is done.
------------
------------
Edition 10.98
S00.5103.54.20
OCTAVIA
47
Brake/Brake Hydraulics
Repairing the front brake calliper, brake calliper FN-3
Summary of Components of Brake Caliper FN-3
Notes:
Install the complete repair set when undertaking repairs.
New brake calipers are filled with brake fluid
and are pre-bled.
Thinly coat brake cylinder, piston and gasket
ring with brake fluid or assembly paste
1 - Cap
insert into bushing
2 - Guide bolts, 28 Nm
3 - Bushing
insert into brake caliper housing
4 - Dust cap
5 - Bleeder screw, 10 Nm
thinly coat thread with brake fluid or
assembly paste before screwing in
6 - Brake caliper
7 - Brake carrier
screwed to the brake caliper
Special tools, testers and aids required
Piston jig MP 9-403
Plastic wedge 3409
Brake fluid page 00-8
Assembly paste G 052 150 A2
8 - Pad retaining spring
insert with both ends in the bores of
the brake caliper.
9 - Gasket ring
removing and installing
page 47-10.2
10 - Piston
removing and installing
page 47-10.2
thinly coat piston with brake fluid or
assembly paste before fitting
piston diameter: 54 mm
11 - Protective cap
do not damage when inserting the
piston
pull with the outer sealing lip onto the
piston
insert with the inner sealing lip into the
groove of the brake caliper page
47-10.3
Edition 06.05
S00.5103.68.20
------------ 47-10.1 ------------
47
OCTAVIA
Brakes/Hydraulic Components
Removing and installing piston for
front brake calliper
Special tools, testers and aids required
Piston resetting device MP 9-403
Plastic wedge 3409
Brake fluid page 00-8
Brake cylinder paste, e.g. G 052 150 A2
Removing
K-
Use compressed air to press piston out of
brake calliper housing -arrow-.
Note:
Insert wooden block into the shaft so that the
piston is not damaged.
K-
Remove seal.
Use plastic wedge 3409 for this step.
Note:
When removing, ensure that the surface of the
cylinder is not damaged.
------------ 47-10.2 ------------
Edition 12.98
S00.5103.55.20
OCTAVIA
47
Brakes/Hydraulic Components
Installing
-
Clean the surface on the piston and seal with
spirit and dry.
Before inserting the piston and seal into the
brake cylinder, apply a thin coat of brake fluid
or brake cylinder paste, e.g. G 052 150 A2,
to all the parts.
Insert new seal into the groove of the brake
calliper.
K-
Fit new protective cap with outer sealing lip
onto the piston.
K-
Use a plastic wedge to insert inner sealing
lip of the protective cap into the groove of
the cylinder.
Use plastic wedge 3409 for this step.
Note:
Hold piston in front of brake calliper housing for
this step.
Edition 12.98
S00.5103.55.20
------------
------------
47
Brakes/Hydraulic Components
K-
OCTAVIA
Use piston resetting device MP 9-403 to
press piston into brake calliper housing.
Note:
The outer sealing lip of the protective cap jumps
into the groove on the piston when this is done.
------------ 47-10.4 ------------
Edition 12.98
S00.5103.55.20
OCTAVIA
47
Brakes/Hydraulic Components
Servicing rear brake calipers
Summary of components of brake caliper
1 - Self-locking hexagon bolt, 35 Nm
Replace
Counterhold at guide pin when slackening and tightening
2 - Bleeder valve, 10 Nm
Before screwing in, apply a thin coat
of brake fluid or assembly paste G 052
150 A2 to the thread
3 - Dust cap
4 - Guide pin
Grease before fitting on protective cap
5 - Protective cap
Fit onto brake carrier and guide pin
6 - Brake carrier with guide pins and protective cap
Is supplied as a replacement part assembled with adequate quantity of
grease on the guide pins
If the protective caps or guide pins are
damaged, install repair kit; use enclosed grease packing for greasing
the guide pins
Special tools, testers and aids required
Resetting and removal tool MP 9-401
Plastic wedge 3409
Bleeder bottle (commercially available)
Brake fluid page 00-8
Assembly paste G 052 150 A2
Notes:
When carrying out repairs, always install the
complete repair kit.
New brake calipers are filled with brake fluid
and pre-bled.
When carrying out repairs, it is essential to
pre-bleed the brake calipers accordingly before installing them in the vehicle (without
brake pads) page 47-14.
7 - Protective cap
Fit with outer sealing lip onto the piston
Insert with inner sealing lip into the
groove of the brake caliper housing
page 47-13
8 - Piston with automatic slack device
Removing and installing
from page 47-12
Apply a thin coat of brake fluid or assembly paste G 052 150 A2 to piston
before installing
9 - Seal
Use plastic wedge for removing
page 47-12
10 - Brake caliper housing with lever for
handbrake cable
If leaks exist at lever for handbrake
cable, replace brake caliper housing
After servicing, pre-bleed brake
caliper housing page 47-14
Apply a thin coat of brake fluid or assembly
paste to brake cylinder, piston and seal.
Edition 10.98
S00.5103.54.20
------------
------------
47
OCTAVIA
Brakes/Hydraulic Components
Removing and installing piston for
rear brake caliper
Special tools, testers and aids required
Resetting and removal tool MP 9-401
Plastic wedge 3409
Bleeder bottle (commercially available)
Brake fluid page 00-8
Assembly paste G 052 150 A2
Removing
Notes:
K Insert special tool MP 9-401 so that the collar (arrow B) is positioned in front of the piston.
If piston is stiff, an open-end wrench waf 13
can be positioned at the wrench faces provided for this purpose (arrow A).
K-
Remove piston from the brake caliper housing by turning the knurled wheel to the left.
Take out seal.
Use plastic wedge 3409 for this step.
Note:
When removing, ensure that the surface of the
cylinder is not damaged.
------------
------------
Edition 10.98
S00.5103.54.20
OCTAVIA
47
Brakes/Hydraulic Components
Installing
-
Clean surfaces of piston and seal with methylated spirits and then dry.
Apply a thin coat of brake fluid or assembly
paste G 052 150 A2 to piston and seal before inserting into the brake caliper housing.
K-
Fit protective cap with outer sealing lip onto
the piston.
K-
Insert inner sealing lip into the groove of the
cylinder with a plastic wedge.
Use plastic wedge 3409 for this step.
Note:
Hold piston in front of brake caliper housing for
this step.
Notes:
K Insert special tool MP 9-401 so that the collar (arrow B) of the tool is resting against
brake caliper.
If piston is stiff, an open-end wrench waf 13
can be positioned at the wrench faces provided for this purpose (arrow A).
If the position of the piston is altered with a
piston resetting device or by depressing the
footbrake, the automatic slack adjuster in the
brake caliper is destroyed.
Edition 10.98
S00.5103.54.20
Insert piston by turning knurled wheel to the
right.
Insert brake pads.
------------
------------
47
Brakes/Hydraulic Components
OCTAVIA
Pre-bleeding brake caliper
Note:
Position brake caliper upright for pre-bleeding.
K-
------------
Open bleeder bottle -arrow A-.
Use a commercially available bleeder vessel to pour in brake fluid long enough until
brake fluid flows out of the threaded hole
(brake hose connection) -arrow B- free of
bubbles.
Close bleeder screw.
------------
Edition 10.98
S00.5103.54.20
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OCTAVIA
47
Brakes/Hydraulic Components
components
pressure
pressure
lator
T
Brake line with screw union
T
3 Recessed machine screw,
Nm
Nm
nut,
5 T
6
Nm
7
8
Edition 06.99
S00.5103.56.20
------------
------------
47
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Brakes/Hydraulic Components
and
pressure
testers and aids
operation
Note:
The brake pressure regulator is set when the
vehicle is at its unladen weight.
r
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
47
Brakes/Hydraulic Components
brake pressure regulator
ersion
Rear drum brakes
Rear wheels
Front wheels
Rear wheels
bar
M a
70
41 ... 47
4.1 ... 4.7
Front wheels
Rear wheels
bar
M a
100
10
54 ... 60
5.4 ... 6.0
brake pressure regulator
Test pressure at rear wheels too high:
-
Slacken tensile spring at brake pressure
regulator.
Test pressure at rear wheels too low:
-
Tension tensile spring at brake pressure
regulator.
Note:
Do not carry out setting with load applied to
brake pedal; pay attention to the following sequence:
Edition 06.99
S00.5103.56.20
Read off pressures.
Take load of brake pedal.
Set tensile spring at brake pressure regulator.
Once again apply pressure to brake pedal.
Read off pressures and correct setting, if
necessary.
Detach pressure gauges.
Bleed brake system from page 47-18.
------------
------------
47
Brakes/Hydraulic Components
OCTAVIA
Bleeding brake system, models with and without ABS or
ABS/EDL Mark 20 and Mark 60
Notes:
Use only fresh brake fluid complying with the
Standard page 00-8.
When system is open, do not work with compressed air and do not move vehicle.
Special tools, testers and aids required
Brake filling and bleeding appliance, e.g.
ROMESS S15
Brake pedal depressor, e.g. V.A.G 1238/B
Vehicle system tester V.A.G 1552 (only for
models fitted with ABS/EDL)
Warning!
Brake fluid is hygroscopic, in other words it absorbs moisture from the surrounding air and
should therefore always be stored in airtight
sealed containers.
On no account allow brake fluid to come into
contact with fluids containing mineral oil (oil,
petroleum, cleaning products).
Mineral oils damage the plugs and seals of the
brake system.
Do not re-use brake fluid which has been extracted (which was in the system).
Pay attention to disposal regulations!
Brake fluid is poisonous, avoid contact with
skin.
Do not allow brake fluid to come into contact
with the paintwork because of its caustic effect.
If brake fluid spills, flush with plenty of water.
Disposal of brake fluid in accordance with the
applicable environmental regulations.
------------
------------
Edition 02.01
S00.5103.60.20
OCTAVIA
47
Brakes/Hydraulic Components
Vehicles not fitted with ABS or ABS/EDL
-
Connect the brake filling and bleeding appliance.
Bleeding sequence page 47-20
-
After fitting on hose of bleeder bottle, leave
bleeder screws opened until brake fluid flows
out free of bubbles.
Vehicles fitted with Mark 20 or Mark 60
-
Connect the brake filling and bleeding appliance.
Insert brake pedal depresser.
If a chamber of the brake fluid reservoir has been
run completely empty (e.g. because of a leak in
the brake system), it is then necessary to first
of all pre-bleed the brake system.
Bleeding sequence for vehicles fitted with Mark
20 page 47-20
Bleeding sequence for vehicles fitted with Mark
60 page 47-23
After this, it is then necessary to bleed the hydraulic unit with the function Basic setting and
the vehicle system tester V.A.G 1552.
Special note for RHD models
K If a chamber of the brake fluid reservoir has been
run completely empty (e.g. because of a leak in
the brake system), or after replacing the hydraulic unit, it is then necessary to bleed the system
at the bleeder screws -arrows- after carrying out
the basic setting of the brake master cylinders.
Continued for models fitted with Mark 60
After bleeding the brake system, it is necessary
to carry out the zero adjustment or brake pressure sender 1 -G201- page 45-194.
Edition 02.01
S00.5103.60.20
------------
------------
47
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Brakes/Hydraulic Components
When replenishing brake fluid with a brake filling
and bleeding appliance, e.g. ROMESS S15, it is
important to ensure that the filling pressure of 1
bar (0.1 MPa) is not exceeded.
For this reason, the brake fluid pressure must
be reduced accordingly to 0.1 MPa (1 bar) at
the brake filling and bleeding appliance Operating Instructions of ROMESS S15.
pressure
proper
unit is not assured.
0.1
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On vehicles fitted with Mark 20, initiate basic setting page 45-36.
On vehicles fitted with Mark 60, initiate basic setting page 45-194.
is
conduct a road
must include at least one
contest.
trol cycle!
and
20
Special
rake system
on models
rake
e
testers and aids required
Brake filling and bleeding appliance, e.g.
ROMESS S15
Vehicle system tester V.A.G 1552 (only for
models fitted with ABS/EDL)
Brake fluid page 00-8
It is not permitted to open the bleeder screws at
the hydraulic unit on vehicles fitted with ABS,
ABS/EDL!
------------
------------
Connect brake filling and bleeding appliance.
Remove dust caps at the bleeder screws of
the brake calipers/wheel brake cylinders.
Open bleeder screws in the specified order
and bleed brake calipers and wheel brake
cylinders.
Edition 02.01
S00.5103.60.20
OCTAVIA
!
47
Brakes/Hydraulic Components
1- Rear right wheel brake cylinder/brake caliper
2 - Rear left wheel brake cylinder/brake caliper
3 - Front right brake caliper
4 - Front left brake caliper
-
After bleeding, close the appropriate bleeder
screw and fit on protective cap.
or
road test
ried out a
least one
must be carbrake system. t
control cycle must be actiroad test!
Note:
When bleeding the rear wheel brake on vehicles fitted with a brake force regulator, move the
lever of the regulator.
tenance
and
brake
Inspection and Main-
brake system
appliance
brake
tools, testers and aids
Bleeder bottle (commercially available)
Brake fluid page 00-8
It is not permitted to open the bleeder screws at
the hydraulic unit on vehicles fitted with ABS,
ABS/EDL.
Note:
During the bleeding operation, always check
brake fluid level in the reservoir; top up brake
fluid to the MAX marking if necessary.
Edition 02.01
S00.5103.60.20
After fitting on hose to bleeder bottle, open
bleeder screw.
Pump brake fluid through brake system by
pumping the brake pedal.
------------
------------
47
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OCTAVIA
Brakes/Hydraulic Components
-
With brake pedal depressed, close bleeder
screws.
Perform pumping operation with brake pedal
at least 10x for each wheel brake and repeat operation as often as necessary until
no further air flows out.
Bleeding
1 - Rear right wheel brake cylinder/brake caliper
2 - Rear left wheel brake cylinder/brake caliper
3 - Front right brake caliper
4 - Front left brake caliper
Bleeding operation
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
or
road test
ried out a
least one
during
must
carsystem. t
control cycle must
actiroad test!
Note:
When bleeding the rear wheel brake on vehicles fitted with a brake force regulator, move the
lever of the regulator.
tenance
------------
------------
and
Edition 02.01
S00.5103.60.20
OCTAVIA
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Brakes/Hydraulic Components
system
and
testers and aids
Brake filling and bleeding appliance, e.g.
ROMESS S15
Brake pedal depresser, e.g.
brake filling and bleeding
ance.
nsert brake pedal depresser.
Open bleeder screws in
specified
and bleed brake calipers and
brake
brake caliper
Rear left brake caliper
Rear
brake caliper
fitting
bleeder screws
bleeder
carry out a road test.
trol cycle must
a
leave
brake
it is necessary to
least one
road
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1 Bleed
left and
B leed rear left and rear
fitting
bleeder screws
Edition 02.01
S00.5103.60.20
bleeder
brake
b rake
leave
brake
------------
------------
47
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Brakes/Hydraulic Components
master cylinder
for leaks
tools, testers and aids
est
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
Edition 06.99
S00.5103.56.20
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Brakes/Hydraulic Components
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OCTAVIA
Brakes/Hydraulic Components
master cylinder
Note:
Complete brake master cylinders and brake
servo units can be replaced separately from
each other.
'
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------------ 47-26 ------------
Edition 05.01
S00.5103.61.20
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47
Brakes/Hydraulic Components
nut,
replace
Nm
10
3 Gasket
11
pin
4 Boot
Brake master cylinder
13
6 Cap
8
9
nut,
15 Brake pressure sender
reservoir
16 W
Nm
plate
place
loom
17 Brake pressure sender
replace
replace
14 Heat
7 Brake
18 Connector
19
0 Vacuum
Edition 05.01
S00.5103.61.20
------------ 47-27 ------------
47
OCTAVIA
Brakes/Hydraulic Components
Removing and installing brake
pressure sensor -1- -G201- and
brake pressure sensor -2- -G214Special tools, testers and aids required
Bleeder bottle (commercially available)
Brake fluid page 00-8
Torque wrench 5...50 Nm, e.g. V.A.G 1331
Open ring wrench waf 27, e.g. Stahlwille 737/
10-10 waf 27, Code No. 9154 00709
Notes:
It is prohibited to carry out any repairs to the
screened cables of the ABS system.
Before disconnecting the battery, determine
the code of a radio set fitted with anti-theft
coding.
When re-connecting the battery, check the
vehicle equipment:
- Encode the radio,
- set the clock,
- initialise the power windows.
Inspection and Maintenance
Removing
-
------------ 47-28 ------------
Disconnect battery.
K-
Unplug the connector -1- of the air mass
meter from the air guide tube of the air filter.
Unscrew the bolts -2- at the air filter -3- and
place the filter to the side.
On diesel engines, remove relay carrier
above the brake servo unit.
Lay out adequate non-woven cloths in the
area of the plenum chamber, of the engine
and gearbox.
Extract as much brake fluid as possible with
a bleeder bottle or extraction equipment from
the brake fluid reservoir.
Edition 04.00
S00.5103.58.20
OCTAVIA
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Brakes/Hydraulic Components
K
Installing
Tightening torques:
Edition 04.00
S00.5103.58.20
------------
------------
47
Brakes/Hydraulic Components
OCTAVIA
Removing and installing brake
master cylinder
Special tools, testers and aids required
Hose clamp MP 7-602
Bleeder bottle (commercially available)
Brake fluid page 00-8
Repair kit Part No. 1H0 698 311 A
Notes:
Before disconnecting the battery, determine
the code of a radio set fitted with anti-theft
coding.
When re-connecting the battery, check the
vehicle equipment:
- Encode the radio,
- set the clock,
- initialise the power windows.
Inspection and Maintenance
Removing
-
------------ 47-30 ------------
Disconnect battery.
K-
Unplug the connector -1- of the air mass
meter from the air guide tube of the air filter.
Unscrew the bolts -2- at the air filter -3- and
place the filter to the side.
On diesel engines, remove relay carrier
above the brake servo unit.
Lay out adequate non-woven cloths in the
area of the plenum chamber, of the engine
and gearbox.
Edition 04.00
S00.5103.58.20
OCTAVIA
47
Brakes/Hydraulic Components
K-
Unplug connector -1- of the brake fluid level
warning contact -F34-.
Extract as much brake fluid as possible with
a bleeder bottle or extraction equipment from
the brake fluid reservoir -5-.
Pinch off feed line of clutch master cylinder
-2- with special tool MP 7-602.
Detach feed line of clutch master cylinder
-2- from brake fluid reservoir -5- and place
up.
3 - Brake master cylinder
4 - Heat shield
K-
Unplug the connectors -arrows- of the brake
pressure sensors -2- and -3-.
Unscrew nuts of brake master cylinder -1-.
Take off heat shield, if fitted.
Carefully take brake master cylinder -1- off
the brake servo unit.
Installing
Installation is carried out in the reverse order.
-
Replace the seal between brake master cylinder and brake servo unit.
When fitting together the brake master cylinder and the brake servo unit, ensure the
pushrod in the brake master cylinder is correctly located.
After installing, pour in only fresh brake fluid.
Re-connect battery page 47-30.
Bleed brake system page 47-18.
- Bleed clutch (manual gearbox).
5-Speed Manual Gearbox 02J; Repair
Group 30; Servicing clutch mechanism
Inspection and Maintenance
Edition 04.00
S00.5103.58.20
------------
------------
47
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Brakes/Hydraulic Components
-
unit
and
testers and aids
Notes:
Before disconnecting the battery, determine
the code of radio sets fitted with anti-theft
coding.
When re-connecting the battery, check the
vehicle equipment:
- encode radio,
- re-set clock,
- initialise power windows.
------------
------------
Edition 05.01
S00.5103.61.20
OCTAVIA
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Edition 04.00
S00.5103.58.20
------------ 47-33 ------------
47
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OCTAVIA
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K-
K-
------------ 47-34 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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Brakes/Hydraulic Components
K-
ightening torques:
Removing and installing vacuum
pump for brake servo unit
Models fitted with diesel engine
Edition 04.00
S00.5103.58.20
------------
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Brakes/Hydraulic Components
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Note:
Complete brake master cylinders and brake
servo units can be replaced separately from
each other.
1 Brake
unit
assist
RHD models with ABS/EDL/TCS/ESP
Mark 60
LHD models with ABS/EDL/TCS/ESP
Mark 60 up to and including Model
Year 2001
------------
------------
master cylinder
OCTAVIA
models
B rake
u nit
assist
LHD models with ABS/EDL/TCS/ESP
Mark 60 from Model Year 2002
mechanical brake assist integrated in
brake servo unit
brake assist is recognisable only from
the part number of the brake servo unit
brake assist cannot be serviced; if
complaints exist, replace complete
brake servo unit page 47-32
Edition 05.01
S00.5103.61.20
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10 Brake pressure sender
11
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models
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Brake master cylinder
/
47
Brakes/Hydraulic Components
and
pressure sender
0
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and
master cylinder
unit
and
Edition 05.01
S00.5103.61.20
------------
------------
47
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OCTAVIA
Brakes/Hydraulic Components
and
pump
No provision is made for repairing the brake
vacuum pump -V192-. If a fault exists, the brake
vacuum pump -V192- should be replaced.
The brake vacuum pump -V192- is installed at
the bottom left of the subframe.
K-
Unscrew bolts -1- at bracket of brake vacuum
pump -V192-.
Detach vacuum hose -arrow- from brake
vacuum pump -V192-.
Take out brake vacuum pump -V192-.
Unlock plug connection and separate from
the vacuum pump.
K Bracket -arrow- for brake vacuum pump
-V192-.
-
Unscrew lock nut -2- from bolt -1-.
Unscrew bolt -4-.
Take out bracket.
Unscrew bolts -3- for disassembling the
bracket -arrow- further.
Installation is carried out in the reverse order.
------------
------------
Nut -2- to bracket
20 Nm
Bolts -3- to bracket
8 Nm
Bolt -4- to bracket
20 Nm
Internal Torx bolt for brake vacuum
pump -V192- to bracket
8 Nm
Edition 02.01
S00.5103.60.20
OCTAVIA
47
Brakes/Hydraulic Components
pump
When the engine is started, the brake vacuum
pump -V192- must run for a short time.
Drive vehicle onto a lift platform and switch
off engine.
Start engine.
A second person must check the operation
of the brake vacuum pump -V192- by feeling with his hand.
If the brake vacuum pump -V192- does not run:
- Read out fault memory of engine control unit.
Engine, Fuel Injection and Ignition System;
Repair Group 01
Edition 02.01
S00.5103.60.20
------------
------------
OCTAVIA
Steering
Steering column and steering
wheel with airbag
48
Inspecting steering column for
damage
Special tools, testers and aids required
Locking drift T10060
Visual inspection
-
Inspect steering column components for
damage.
If damage is present, replace complete steering column.
Inspection requirement
l Universal joint of steering column detached
from steering gear
Operational check
-
Check whether steering column can be
turned freely and without catching.
Check whether the steering column can be
adjusted forward/back and for height.
If an accident has occurred, so-called deformation elements at the steering column may have
been shifted out of place.
They are located at the two top bolted connections of the steering column.
If such damage is suspected, remove the steering column sufficiently until dimension -a- can
be checked.
K-
Insert locking drift T10060.
Use slide gauge to check dimension -a-.
Dimension -a-: not more than 23 mm
If any defect is found during any of these inspections, the steering column is damaged.
-
Edition 06.99
S00.5103.56.20
In this case, replace complete steering column.
------------
------------
OCTAVIA
Notes:
New steering columns which are supplied as
a replacement part, are provided with a transport protection. Remove this transport protection after installing the steering column.
The steering column is supplied as a replacement part only complete with ignition lock
housing and without lock cylinder and also
ignition/starter switch.
The existing ignition lock housing can be
used.
Removing and installing ignition lock housing page 48-6, Fig. S48-0094.
For new steering columns which are supplied
as replacement parts, fit the existing lock
cylinder and ignition/starter switch from the
old steering column or procure as replacement part and install.
Electrical System; Repair Group 94; Servicing lock cylinder and ignition/starter switch
No provision is made for repairing the steering column.
Always replace self-locking nuts and bolts.
It is not permitted to carry out any welding
and straightening work on steering components.
Before disconnecting the battery, determine
the coding of radio sets fitted with anti-theft
code.
When the battery is re-connected, check the
vehicle equipment:
- encode radio,
- re-set clock,
- initialise power windows.
Inspection and Maintenance
-
Disconnect battery.
Move wheels into straightahead position.
K-
Remove screws -2-.
Pull footwell trim panel -1- out of the fixtures.
- Remove airbag on driver side.
Body Fitting Work; Repair Group 69; Airbag
System
- Remove steering wheel.
Body Fitting Work; Repair Group 69; Airbag
System
------------ 48-2 ------------
S00.5103.57.20
OCTAVIA
48
Steering
Unclip cover of fuse carrier.
K - Remove light switch -3-.
Electrical System; Repair Group 96; Removing and installing light switch
-
Take out screws -5- for fuse carrier.
Remove Torx screws -1-.
Remove cross-head screws -2-.
Take out bottom part of dash panel on left
-4-.
K-
Remove screws -1-, -2-, -3- and -4-.
Take off steering column adjustment handle
as well as top and bottom parts of steering
column trim.
K The illustration shows the coil spring contact -4on a vehicle not fitted with the electronic stability programme (ESP).
-
Tape over coil spring -4- with adhesive tape
-3- to prevent it being turned unintentionally.
Unplug connector -1-.
Carefully separate all the plug connections
of the steering column switch.
Arrows - locking hook of coil spring -4-
Edition 04.00
S00.5103.58.20
------------ 48-3 ------------
48
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OCTAVIA
Steering
Notes:
The next operation only requires to be carried out if the coil spring or the steering column switch is replaced.
The coil spring must only be removed and
installed when the steering wheel is in the
middle position (wheels in straightahead position).
The coil spring supplied as a replacement
part is secured in the middle position by a
cable strap.
K-
Note:
If the coil spring remains on the steering column switch, ensure that the coil spring is not
turned out of the middle position when the steering column switch is placed down.
Models fitted with ESP
K
Check to ensure the front wheels are in
the straightahead position.
------------ 48-4 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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Steering
Note:
The next
the
the
K-
K-
K-
Edition 04.00
S00.5103.58.20
------------
------------
48
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OCTAVIA
K-
K-
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
48
Steering
K-
Unscrew plastic nut -1- and remove cover
-A-.
K-
Unscrew hexagon bolt -1-.
02.97 a clamp ring is fitted.
-
Slacken hexagon socket screw of clamp ring
-2- sufficiently until it is possible to pull the
universal joint off the steering gear pinion.
Pull universal joint off the steering gear pinion -arrow-.
Notes:
An assembly lock is required when pulling
the steering column off the steering gear so
that the top and bottom parts are not pulled
apart.
If the top and bottom parts of the steering
column are pulled too far apart or pushed
into each other, the splines will be separated.
This can result in clattering noises in subsequent operation if the splines are no longer
in their original installed position.
Edition 06.99
S00.5103.56.20
Secure steering column before removing.
Push or pull the steering column sufficiently
far together or apart until the hole is visible.
K-
Insert, for example, a clip into the hole -arrow-.
------------ 48-5 ------------
48
OCTAVIA
Steering
K-
Unscrew
K-
Notes:
New steering columns are generally supplied
as a replacement part without the ignition lock
housing.
Ignition lock housings are supplied separately as replacement parts.
Replacing ignition lock housing
K-
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
48
Steering
Installing
Notes:
New steering columns supplied as replacement parts are protected by a transportation
lock.
Remove the transportation lock after installing the steering column.
Before installing new steering columns supplied as replacement parts, fit on a new bearing bush and shear bolt.
The shear bolts and bearing bush must be
replaced each time the bearing bush is removed.
K-
Insert new bearing bush -1- and install shear
bolt -2-.
K-
Tighten shear bolt -2- until the head shears
off.
Fit steering column onto central tube.
Screw in hexagon bolt -3- but do not tighten
fully at this stage.
Insert new hexagon bolt -2-.
Screw on new self-locking hexagon nut -1and tighten to 10 Nm.
Tighten hexagon bolt -3- fully to 22 Nm.
Pull out transportation lock -arrow-.
K-
Push universal joint onto the steering pinion
and tighten with new hexagon bolt -1-.
A clamping ring is installed as of 02.97 .
Edition 04.00
S00.5103.58.20
Tighten hexagon socket bolt of the clamping ring -2- to 17 Nm.
Install cover of universal joint.
Plug in connector for ignition/starter lock and
immobiliser.
------------ 48-7 ------------
48
Steering
OCTAVIA
Models not fitted with ESP
-
Models fitted with ESP
K-
Note:
Do not turn the coil spring after removing the
transportation lock or the adhesive tape, respectively; it is only permissible to move the steering
angle sensor -G85- into the middle position.
K-
K-
------------ 48-8 ------------
Edition 04.00
S00.5103.58.20
OCTAVIA
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48
Steering
K-
to ensure
are met.
two requirements
Notes:
K Fig. shows steering column switch with coil
spring -2- and steering wheel -1- on a vehicle not fitted with ESP.
On vehicles fitted with ESP the size a between the coil spring integrated in the housing and the steering wheel, is likewise 3 mm.
K-
Note:
Do not turn coil spring out of the middle position
after pulling off the adhesive tape -3-.
-
Edition 04.00
S00.5103.58.20
------------
------------
48
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OCTAVIA
Steering
- I
- I
Warning!
Ensure that no person is present inside the vehicle when the battery is re-connected.
Models not fitted with ESP:
-
Models fitted with ESP:
-
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
48
Steering
fitted on
ignition
steering
Notes:
Before disconnecting the battery, determine
the code of the radio set fitted with anti-theft
coding.
When the battery is re-connected, please
check the vehicle equipment:
- Enter radio code
- Re-set clock
- Initialise power windows.
Inspection and Maintenance
- Remove steering wheel.
Body Fitting Work; Repair Group 69; Airbag
System
- Remove bottom part of dash panel on left.
Body Fitting Work; Repair Group 70; Dash
Panel
- Remove trim of steering column switch.
Body Fitting Work; Repair Group 70; Dash
Panel
- Remove ignition/starter switch.
Electrical System; Repair Group 94; Servicing lock cylinder and ignition/starter switch
- Remove steering column switch.
Electrical System; Repair Group 94; Servicing steering column switch
- Remove dash panel insert.
Electrical System; Repair Group 90; Dash
Panel Insert
K-
Edition 04.00
S00.5103.58.20
Unplug connector -1- for ignition/starter lock
and connector -2- for immobiliser.
------------
------------
48
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OCTAVIA
Steering
K-
Warning!
Ensure that no person is present inside the vehicle when the battery is re-connected.
------------
------------
Edition 04.00
S00.5103.58.20
OCTAVIA
48
Steering
Summary of components of power-assisted steering gear
Notes:
Oil grade: central hydraulic fluid G 002 000
It is necessary to replace various components of the steering system following an
accident or damage to the front suspension
page 48-19.
Quantity of hydraulic fluid in system:
0.7 ... 0.9 ltr.
No provision is made for repairing the steering gear. In the event of complaints or problems, replace the steering gear.
1 - Heat shield
Centre with bearing bracket on power
steering gear
2 - Hexagon nut, 20 Nm
Replace self-locking nuts and bolts.
It is not permitted to carry out any welding and
straightening work on steering components.
Use only steering gear grease AOF 063 000
04 for greasing the steering rack (quantity
23 ... 27 g).
Edition 10.98
S00.5103.54.20
3 - Bearing bracket
Only on gearbox 02K
4 - Hexagon bolt, 25 Nm
5 - Universal joint of steering column
------------ 48-9 ------------
48
Steering
6 - Hexagon bolt, 30 Nm
10 - Banjo bolt, 45 Nm
!"#
7 - Sealing collar
11 - Banjo bolt, 45 Nm
!"#
8 - Return-flow line
9 - Seals
------------ 48-10 ------------
OCTAVIA
12 - Pressure line (flexible hose)
$
13 - Lock nut, 50 Nm
14 - Steering arm of wheel bearing housing
Edition 06.99
S00.5103.56.20
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OCTAVIA
48
Steering
15 - Hexagon nut, self-locking, 45 Nm
21 - Hexagon bolt, 40 Nm and torque a further 90
16 - Bolt + washer, 100 Nm and torque a
further 90
22 - Hexagon bolt, 20 Nm and torque a further 90
17 - Bolt + washer, 100 Nm and torque a
further 90
23 - Subframe
18 - Hexagon bolt, 20 Nm and torque a further 90
25 - Hexagon nut, 20 Nm
24 - Retaining clip
26 - Clip with rubber insert
19 - Pendulum support
20 - Hexagon bolt, 40 Nm and torque a further 90
27 - Power steering gear
Removing and installing hydraulic fluid reservoir
)*
,
--
1 - Reservoir with cap and dipstick
)
2 - Return-flow line
6
7"
3 - Spring strap clip
6
4 - Suction line
Special tools, testers and aids required
Edition 06.99
S00.5103.56.20
6
7"
5 - Bolt + washer, 10 Nm
------------ 48-11 ------------
48
OCTAVIA
Steering
Removing and installing PAS gear
Special tools, testers and aids required
Hose clamp MP 7-602
Pliers for spring strap clip, e.g. Matra V/131
Puller, Matra V 176
Gearbox jack with adapter, e.g. V.A.G 1383
A with V.A.G 1359/2
Sealing plug for hydraulic fluid reservoir
(commercially available)
Plastic screw plugs for pipe connections at
PAS gear (commercially available)
Central hydraulic fluid
TL 52 146
N 052 146 00
e.g. PENTOSIN CHF 11 S (G 002 000)
Notes:
No provision is made for repairs except replacing the boots and the track rods.
Scrupulous cleanliness is required when
carrying out work on the power-assisted
steering.
Thoroughly clean connection points and the
surrounding area before disconnecting.
Place removed parts down on a clean surface and cover over if repairs are not carried
out immediately.
Do not use any fluffing cloth.
Do not remove replacement parts from their
wrapping until just before installing.
Use only genuine, wrapped parts.
Do not re-use drained hydraulic fluid.
Replace seals.
Disposal page 48-24.
------------ 48-12 ------------
Edition 03.97
S00.5103.52.20
OCTAVIA
48
Steering
Removing
K-
Unscrew plastic nuts -1- and remove cover
-A-.
K-
Unscrew hexagon bolts -1-.
Important!
Move the steering wheel into middle position
(wheels straightahead) and do not turn during the
repair work otherwise the contact spring of the
airbag unit may be damaged.
02.97 a clamping ring is fitted.
-
Slacken hexagon socket screw of the clamping ring -2- sufficiently until the universal joint
can be pulled off the steering gear pinion.
Pull universal joint off steering gear pinion
-arrow-.
K-
Use special tool -MP 7-602- to pinch off
suction line -1- (reservoir for hydraulic fluid/
hydraulic pump) close to hydraulic pump.
Illustration shows routing of line and pinching
off line on 1.9-ltr./66 kW TDI engine. Routing of
suction line on other engine differs. Suction line
should be pinched off, however, close to
hydraulic pump.
Edition 11.97
S00.5103.53.20
------------ 48-13 ------------
48
OCTAVIA
Steering
K-
Use special tool, e.g. Matra V/131, to open
spring strap clip -arrow-.
Detach return-flow pipe from hydraulic fluid
reservoir and allow hydraulic fluid to flow into
a suitable vessel.
Use a sealing plug to seal off return-flow
opening at the hydraulic fluid reservoir.
K-
Remove noise insulation panelling in the
middle and also on left and right -arrows-.
Fig. shows the noise insulation panel on models with 1.9-ltr./66 kW TDI and 1.9-ltr./50 kW
SDI engines. The noise insulation panel on other
engine versions may differ from that shown in
the illustration.
K-
Use puller Matra V176 to press track rods
off the pitman arm.
Note:
Screw down hexagon nut -1- sufficiently so that
the track rod puller cannot damage the thread.
------------ 48-14 ------------
Edition 03.97
S00.5103.52.20
OCTAVIA
48
Steering
Place a drip tray below for collecting the hydraulic fluid which flows out.
K-
Detach pressure pipe -2- (expansion hose)
of PAS gear and seal with a plastic bag and
adhesive tape.
Seal threaded opening for pressure pipe
connection -2- at the PAS gear (e.g. with plastic screw plug).
The return-flow pipe -1- can only be disconnected from the PAS gear once the
subframe has been lowered.
K-
Detach pendulum support at the gearbox
side by unscrewing hexagon bolts -1- and
-2-.
K-
Unscrew bolts for bearing bracket -arrows-.
Note:
Only for gearbox 02K.
Edition 03.97
S00.5103.52.20
------------
------------
48
OCTAVIA
Steering
K
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When tightening the lines, ensure that the
lines cannot touch or chafe against any other
part.
Use new seals for the hose/line connections.
Before installing steering gear, coat sealing
collar on steering gear with a lubricant, e.g.
lubricating soap.
After positioning steering gear against drive
shaft, ensure that the sealing collar on the
steering gear is resting against the assembly plate without any creases and the opening to the footwell is correctly sealed. Otherwise risk of water leaking in and/or noises.
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
Steering
$
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Ensure that the sealing surfaces are clean.
Specified tightening torques from page
48-9.
Before installing power steering gear, check
middle position of steering rack page
48-23.
K
K
Note:
Maintain a clearance of 10 mm between returnflow line -1- and power steering gear -5- (arrow).
Note:
The old bolts for attaching the subframe should
be replaced with new bolts as part of the check
of the vehicle alignment.
Edition 06.99
S00.5103.56.20
------------
------------
48
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OCTAVIA
Steering
------------ 48-18 ------------
Edition 06.99
S00.5103.56.20
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3
OCTAVIA
48
Steering
teering gear
Notes:
Following an accident and damage to the
front axle, the steering components items 1
to 9 must always be replaced.
No provision is made for servicing the power
steering gear. If complaints are received,
determine the cause by conducting a pressure test and leaktightness test. If a fault
exists, replace the power steering gear.
It is not permitted to carry out any welding or
straightening work on steering components.
Always replace self-locking nuts and bolts.
Use only genuine clamp-type clips.
Use only steering gear grease AOF 063 000
04 for greasing the steering rack (quantity
23 ... 27g).
Pressing off from steering arm
page 48-14
Inspecting page 48-21
Removing and installing page 48-21
Pay attention to installation position
Modified from vehicle ident No.
TMBZZZ1U12W2074066 page
48-23.1
and
Puller, Kukko V/176
Torque wrench, e.g. V.A.G 1332
Replace
Open with cutting pliers for removing
Tensioning page 48-23
Open-end wrench insert, e.g. V.A.G 1332/5
Caliper gauge
Clamping pliers for hose straps, e.g. V.A.G
1275
Gearbox grease
TL 733
NO 52733 00
e.g. DEA ORNA F6 EPO (AOF 063 000 04)
Boot can only be replaced with power
steering gear removed
Before taking off boot, detach track
rod end page 48-21
Inspect for wear (splits, slits), inspect
whether sealing surfaces and sealing
lips clean and undamaged
Replace
Open with cutting pliers for removing
Tensioning page 48-23
Edition 06.99
S00.5103.56.20
------------
------------
48
OCTAVIA
Steering
6-
Tightening torque to steering rack: 75
Nm
Left and right track rods can be adjusted
Removing and installing
page 48-22
Modified from vehicle ident No.
TMBZZZ1U12W2074066 page
48-23.1
8-
9-
------------
------------
teering
No provision for servicing
Removing and installing
page 48-12
Setting page 48-25
Inspecting middle position page
48-23
Pressing off from steering arm
page 48-14
Inspecting page 48-20
Removing and installing
page 48-21
Pay attention to fitting location
Modified from vehicle ident No.
TMBZZZ1U12W2074066 page
48-23.1
With vehicle raised (wheels clear of ground),
inspect play by moving track rods and
wheels.
Specified play: no play
Inspect attachment.
Inspect sealing boots for damage and correct installation.
Edition 06.99
S00.5103.56.20
OCTAVIA
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Steering
K
Notes:
From vehicle ident No.
TMBZZZ1U12W2074066 modified track rod
ends and track rods page 48-23.1.
It is not permitted to install mixed (old and
modified) track rod ends or track rods
page 48-23.3.
Install track rod ends at the correct side.
K When installing, pay attention to marking on
track rod end
I - Left track rod end - L
II - Right track rod end - R
Pay attention to new marking on modified
track rod ends page 48-23.1.
Edition 06.99
S00.5103.56.20
------------
------------
48
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OCTAVIA
Steering
Note:
The track rods can only be removed and installed with the power steering gear removed.
K
Notes:
From vehicle ident No.
TMBZZZ1U12W2074066 modified track rod
ends and track rods page 48-23.1.
It is not permitted to install mixed (old and
modified) track rod ends or track rods
page 48-23.2.
If it is necessary to replace a track rod, always replace both track rods page 48-23.2.
Note:
Turn track rod so that the stud of the track rod
end is in the installed position.
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
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48
Steering
teering
Notes:
Move the steering rack into the middle position before installing the power steering gear.
The dimension -a- must be identical on the
right and left sides of the power steering gear.
If the dimension is not identical on both sides,
set distance -a- to correct dimension.
K
Note:
K The boot must on no account be installed twisted
(illustration shows negative example).
K
Edition 06.99
S00.5103.56.20
------------
------------
48
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OCTAVIA
Steering
rod
The production process for the track rod ends
has been optimised. There is no change in this
case to the exterior shape and the length of the
threaded shank.
The track rods have been matched to the modified track rod ends page 48-23.2.
Vehicle ident No. TMBZZZ1U12W2074066
rod
1 - Wrench face on shank, with marking R
or L
Width across flats 22 mm
Dimension -a- = 74 -1 mm
The shank -arrow- is round.
rod
1 - Hexagon on threaded shank,
width across flats 19 mm
Dimension -a- = 94 0.5 mm
Marking A for right-hand
1 - Hexagon on threaded shank,
width across flats 19 mm
Dimension -a- = 94 0.5 mm
Marking B for left-hand
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
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Steering
The
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Edition 06.99
S00.5103.56.20
------------
------------
48
OCTAVIA
Steering
Disposing of PAS gear
Special tools, testers and aids required
Hydraulic fluid vessel
Notes:
The oils used in the PAS gears do not contain any harmful substances. These oils can
be disposed of together with old oil from engines and gearboxes.
Dispose of old oils in conformity with the relevant environmental protection regulations.
Old oils (the term old oils refers to used engine and gearbox oils incl. ATF and also mineral hydraulic oils), which are suitable for
processing, must on no account be mixed
with brake fluid, antifreeze agent, synthetic
resin or nitro thinner, chemicals etc.
After emptying, the old parts should be allowed to drip adequately.
When disposing of old parts, pay attention
to legal provisions as slight residual quantities of hydraulic fluid remain in the PAS gear.
------------
------------
K-
Detach pipes -arrows A- from the PAS gear
by pulling off the clips. The clips must not be
re-used.
Hold PAS gear over a collecting vessel and
turn steering pinion several times from full
lock to full lock until no further hydraulic fluid
flows out of the holes.
Holes -arrows B- must not be sealed.
Dispose of PAS gear.
Edition 03.97
S00.5103.52.20
OCTAVIA
48
Steering
Setting PAS gear (ZF)
Note:
Two mechanics are required for setting the steering gear. The setting should be carried out with
the engine switched off.
-
Raise vehicle with lift platform.
l Wheels in straightahead position.
Edition 03.97
S00.5103.52.20
A rattling noise can be heard when the steering wheel is moved alternately around the
centre axis (about 30) if steering play is excessive.
K-
The second mechanic turns the adjusting
screw (arrow) carefully into the cover to the
point at which the rattling noise is no longer
heard in the interior.
Carry out a road test and check to ensure
that the steering moves back by itself into
the straightahead position, without sticking,
after a parking manoeuvre or cornering.
Correct setting if necessary.
K-
Secure adjusting nut against turning by striking with a chisel in the collar of the steering
gear housing.
------------
------------
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OCTAVIA
Central hydraulic fluid
TL 52 146
N 052 146 00
e.g. PENTOSIN CHF 11S (G 002 000)
Notes:
Delivery Inspection:
Oil level at MAX marking
Inspection and Maintenance
Inspection Service:
Oil level between MIN and MAX markings
Inspection and Maintenance
Do not run engine, and move front wheels
into straightahead position.
Unscrew cap.
Wipe off dipstick with a clean cloth.
Screw in cap by hand and remove again.
Only the oil level indicated when the cap has
first of all been fully inserted, is correct.
K-
Inspect oil level: The oil level must be within
the range of the MIN marking (up to 2 mm
above or the lower marking).
Notes:
If the oil level is above the range indicated,
oil must be extracted.
If the oil level is below the range indicated,
the hydraulic system must be inspected for
leaks page 48-30. It is not sufficient merely
to replenish the oil.
-
------------ 48-26 ------------
Screw in cap and tighten to 2 Nm.
S00.5103.57.20
OCTAVIA
48
Steering
Hydraulic fluid at operating temperature
(from about 50 C):
-
Engine idling, front wheels at straightahead
position, run for about 2 minutes.
Unscrew cap.
Wipe off dipstick with a clean rag.
Screw in cap by hand and remove again.
The hydraulic fluid level which applies is that for
a cap which has previously been fully inserted.
K-
Check fluid level: The fluid level should be
between the MIN and MAX markings.
Notes:
If the fluid level is above the stated range,
fluid should be extracted.
If the fluid level is below the stated range, it
is then necessary to inspect the hydraulic
system for leaks page 48-30. It is not sufficient simply to top up the hydraulic fluid.
-
Edition 03.97
S00.5103.52.20
Screw in cap and tighten to 2 Nm.
------------
------------
48
OCTAVIA
Steering
Draining, filling and bleeding PAS
system
Special tools, testers and aids required
Central hydraulic fluid
TL 52 146
N 052 146 00
e.g. PENTOSIN CHF 11S (G 002 000)
Draining
-
Do not run engine and raise vehicle sufficiently until the front wheels are clear.
Place basin below for collecting hydraulic
fluid.
Open hydraulic system at suction and return
sides and allow hydraulic fluid to flow out.
Force out remaining quantity of hydraulic fluid
by turning the steering several times from
full lock to full lock.
Lower vehicle and re-connect hydraulic
pipes.
Notes:
Do not re-use drained hydraulic fluid.
Dispose of hydraulic fluid in accordance with
the applicable environmental protection regulations.
Filling and bleeding
Notes:
A drained hydraulic system should only be
filled when engine is cold.
Central hydraulic fluid G 002 000.
Quantity of hydraulic fluid in system:
0.7 ... 0.9 ltr.
------------
------------
Refilling a hydraulic system page 48-26.
K-
If the hydraulic system is drained, fill up hydraulic fluid reservoir sufficiently until MAX
marking on dipstick is reached.
Edition 03.97
S00.5103.52.20
OCTAVIA
48
Steering
Raise vehicle sufficiently until the front
wheels are clear. Move front wheels into
straightahead position.
With engine switched off, turn steering wheel
10 x from full lock to full lock.
Check hydraulic fluid level and top up if necessary page 48-26.
Lower vehicle.
Start engine and run for about 5 seconds.
Hydraulic pump draws in hydraulic fluid.
Switch off engine.
Check hydraulic fluid level and top up if necessary page 48-26.
Start engine.
Turn steering wheel 10 x from full lock to full
lock.
When doing this, have a second mechanic
observe hydraulic fluid level in the reservoir
and top up if necessary so that no air can be
drawn in. If no air bubbles in the reservoir
flow out of the return-flow pipe, the hydraulic
system is bled. If air bubbles repeatedly occur, it is then necessary to repeat the bleeding operation.
Switch off engine.
Inspect hydraulic fluid level and top up if necessary page 48-26.
Any air which remains in the steering system
escapes by itself after driving about 10...20 km.
Edition 03.97
S00.5103.52.20
------------
------------
48
OCTAVIA
Steering
Inspecting PAS system for leaks
Notes:
If metal swarf is found in the hydraulic fluid
and/or in the reservoir, the reservoir, suction
and pressure pipe should be carefully flushed
out and replaced, if necessary.
The PAS system has to be inspected for
leaks after carrying out removal and installation work and if there is a loss of hydraulic
fluid in the reservoir.
-
Start engine.
Turn steering wheel alternately to full lock
and hold tight for a short time.
This builds up the maximum possible pressure.
-
Inspect all hose and pipe connections for
tight fit and leaks.
If leaks are present, retighten hose or pipe
connection to the specified maximum tightening torques or replace seal or pipe.
Inspect hoses and pipes for leaks. If leaks
are present, replace the relevant hose or
pipe.
Inspect hydraulic pump for leaks. If leaks are
present, replace hydraulic pump.
Inspect hydraulic fluid reservoir for leaks. If
leaks are present, replace reservoir.
Inspect hydraulic fluid level and top up if necessary page 48-26.
Note:
If a loss of hydraulic fluid in the reservoir occurs
repeatedly and an intensive inspection has been
carried out several times of the hoses and pipes
and also their connections, the hydraulic pump
and the reservoir, the PAS gear should be removed and inspected.
------------
------------
Edition 03.97
S00.5103.52.20
OCTAVIA
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48
Steering
K
Note:
If there is no further hydraulic fluid in the reservoir, the hydraulic pump may possibly have run
dry and have been damaged.
Edition 06.99
S00.5103.56.20
------------
------------
48
OCTAVIA
Steering
Inspect connections for leaks (air in the system).
Check tension of V-belt.
Check routing of the suction and delivery
pipes (pipes pinched or touching other vehicle parts).
Inspect the steering gear attachment at the
subframe.
Inspect the bolt connection of the hydraulic
pump to bracket/engine.
Inspect bolt connection of belt pulley.
Note:
In order to determine whether the noises originate from the PAS system, it is recommended
to take off the V-belt of the hydraulic pump and
to run the engine without the hydraulic pump.
------------
------------
Edition 03.97
S00.5103.52.20
OCTAVIA
48
Steering
Assembly overview: hydraulic pump
Assembly overview for horizontal and vertical hydraulic pump
5 - Tensioning element
6 - Alternator
7 - Bracket
Fig. shows bracket for models without air conditioning
Install free of stress item 8
8 - Hexagon bolt, 45 Nm
For attaching bracket -item 7- to engine block
Installing
Engine, Mechanical Components; Repair
Group 13; Disassembling and assembling
engine
9 - Hexagon bolt, 25 Nm
10 - Banjo bolt, 38 Nm
11 - Seal
Replace
12 - Pressure line (flexible hose)
13 - Seal
Replace
Note:
The
The
he
1 - Ribbed V-belt
Before removing, mark direction of
running
Assignment Parts List
Removing and installing
Engine, Mechanical Components; Repair
Group 13; Disassembling and assembling
engine
2 - Hexagon socket bolt, 10 Nm + torque
a further 90
3 - Vibration damper
With belt pulley for ribbed V-belt
14 - Hydraulic pump
For power-assisted steering
Testing delivery pressure page 4835
Fill with hydraulic oil before installing
page 48-37
Removing and installing page 4837, Notes
15 - Hexagon bolt, 25 Nm
16 - Belt pulley
For hydraulic pump
Models with 1.4-ltr./44 kW engine:
Before removing, mark front of belt
pulley. Belt pulley must not be installed
with the front on the hydraulic pump.
17 - Hexagon socket bolt, 25 Nm
18 - Hexagon bolt, 25 Nm
4 - Hexagon bolt, 25 Nm
Edition 02.01
S00.5103.60.20
------------ 48-33 ------------
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OCTAVIA
Steering
Note:
The
Switches at 4.0 MPa (40 bar)
Testing signal
Simos Fuel Injection and Ignition System;
Repair Group 24; Testing additional signals
Replace
Replace
White or yellow all round; must be positioned within holder (item 9)
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
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48
Steering
Notes:
If hydraulic fluid in reservoir is below minimum level, always inspect power steering
system for leaks page 48-30.
If leaks exist at power steering gear, first of
all inspect the lines and line connections for
leaks, re-tighten, if necessary, and wipe dry.
Inspecting seal at steering pinion and steering rack seal page 48-30. If leaks exist at
seal or at steering rack seal, replace power
steering gear.
Disposing of power steering gear page
48-24.
Edition 06.99
S00.5103.56.20
------------
------------
48
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Steering
K
K
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
48
Steering
Note:
The surrounding area is not shown in the figure
in order to simplify the illustration.
K
1 - Hydraulic pump
2 - Seal
3 - Adapter, e.g. V.A.G 1402/1 A
4 - Hose from adapter set,
e.g. V.A.G 1402/6
5 - Adapter, e.g. V.A.G 1402/3
6 - Tester for power-assisted steering,
e.g. V.A.G 1402
7 - Adapter, e.g. V.A.G 1402/2
8 - Seal
9 - Pressure line with ring union
10 - Banjo bolt
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Edition 11.99
S00.5103.57.20
------------
------------
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Edition 06.99
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OCTAVIA
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Edition 06.99
S00.5103.56.20
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OCTAVIA
Steering
Engine
Notes:
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------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
!"#$%&
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48
Steering
Notes:
No provision is made for repairing the hydraulic pump. If a complaint exists, carry out
the pressure and leaktightness test in order
to determine the cause. If a fault exists, replace the hydraulic pump.
Pumps supplied as replacement parts are
not filled with oil. For this reason, it is essential to fill the pump with hydraulic oil G 002
000 and to rotate it by hand before it is installed; if this is not done, noise problems
may occur when driving or the pump may be
damaged.
Grade of oil: central hydraulic oil G 002 000
Quantity of oil in system: 0.7 ... 0.9 ltr.
Do not remove replacement parts from their
wrapping until just before installing.
Use only genuine wrapped parts.
Do not re-use drained hydraulic oil.
Always replace seals.
Before removing the ribbed V-belt, mark the
direction of running. If a used belt is fitted on
again to run in the opposite direction, it may
be destroyed. When installing the belt, ensure it is correctly located in the belt pulleys.
Disposal page 48-45.
Version and attachment of hydraulic pump
as well as bracket may differ from the illustration depending on engine version and
whether vehicle is equipped with air conditioning or not.
Mark installation position of belt pulley before removing.
If the belt pulley of the hydraulic pump is installed in the opposite direction, this will result in an offset to the other belt pulleys. The
ribbed V-belt will be damaged as a result of
this offset running.
Edition 02.01
S00.5103.60.20
------------ 48-37 ------------
48
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OCTAVIA
Steering
Hose clamp MP 7-602
Pliers for spring strap clip, e.g. Matra V/131
Central hydraulic fluid
TL 52 146
N 052 146 00
e.g. PENTOSIN CHF 11 S (G 002 000)
Illustration shows engine trim panel of the 1.9ltr./66 kW (TDI) engine. Other engine versions
have a trim panel which differs from the illustration.
K-
Remove engine trim pane.
1 - Plug
2 - Clip
3 - Pin
------------
------------
Edition 06.99
S00.5103.56.20
OCTAVIA
Steering
!
"
! "
#
48
Illustration shows ribbed V-belt version on models with air conditioning. Different routing of
ribbed V-belt on models without air conditioning.
Note:
Before removing the ribbed V-belt, mark the direction of running. If a used belt is fitted on again
to run in the opposite direction, it may be destroyed. When installing the belt, ensure it is
correctly located in the belt pulleys.
K
Edition 06.99
S00.5103.56.20
------------
------------
48
OCTAVIA
Steering
The illustration shows the routing of the intake
manifold on the 1.9-ltr./66 kW TDI engine. The
steps described below should only be carried
out on this engine version.
K-
Use special tool, e.g. Matra V/131, to open
spring strap clip -2-.
Open screw-type clamp -3-.
Unplug connector -4-.
Remove intake manifold -1-.
Valid for all engine versions with and without air
conditioning.
K-
Unbolt belt pulley; counter-hold with hexagon socket wrench (size 9 mm).
Valid for all models with air conditioning and
hydraulic pump positioned at top.
------------
------------
K-
Use special tool MP 7-602 to pinch off suction pipe of hydraulic fluid reservoir/hydraulic pump.
Use special tool, e.g. Matra V/131, to open
spring strap clip -1- and detach suction pipe
from the hydraulic pump.
Detach pressure pipe (flexible hose) -2-.
Edition 03.97
S00.5103.52.20
OCTAVIA
'
"#$
%(
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48
Steering
K
Notes:
Hydraulic pumps supplied through the Parts
Sector are not filled with hydraulic fluid. For
this reason, it is essential to fill pump with
hydraulic fluid G 002 000 before installing
and to rotate it by hand otherwise noises may
occur in operation or the pump may be damaged.
Contact surfaces and threads on both sides
of hydraulic pump must be free of paint.
Do not re-use drained hydraulic fluid.
Replace seals.
K
K
Edition 06.99
S00.5103.56.20
------------
------------
!
5
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OCTAVIA
K
%
Note:
When installing ribbed V-belt, ensure it is correctly located in the belt pulleys.
'
Note:
Use new seals for connection of pressure line.
K
------------
------------
S00.5103.57.20
OCTAVIA
' ( #) * + ,
!-". &
#$ %
/ 0&$,' &
48
Steering
Hose clamp MP 7-602
Pliers for spring strap clip, e.g. Matra V/131
Central hydraulic fluid
TL 52 146
N 052 146 00
e.g. PENTOSIN CHF 11 S (G 002 000)
Note:
Before removing the ribbed V-belt, mark the direction of running. When installing the belt, ensure it is correctly located in the belt pulleys.
K-
open-end
to
.
pulley in direction of a
tensioning
off
Illustration shows noise insulation in middle and
on left on models with petrol engines.
K-
Edition 06.99
S00.5103.56.20
noise insulation in middle
and on right.
------------ 48-41 ------------
48
"
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$
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1
OCTAVIA
Steering
Applies to all petrol engines not fitted with air
conditioning.
Vehicles fitted with 1.4-ltr./44 kW engine:
-
Note:
If the belt pulley of the hydraulic pump is installed
in the opposite direction, this will result in an
offset to the other belt pulleys. The ribbed Vbelt will be damaged as a result of this offset
running.
Continued for all models
K-
K-
Vehicles without pressure switch (ill.)
-
Vehicles with pressure switch (not ill.)
-
Continued for all models
-
------------
------------
Edition 02.01
S00.5103.60.20
OCTAVIA
#
$$(+
%
$$'
"
",)
&*
-".
!
48
Steering
Notes:
Hydraulic pumps supplied through the Parts
Sector are not filled with hydraulic fluid. For
this reason, it is essential to fill pump with
hydraulic fluid G 002 000 before installing
and to rotate it by hand otherwise noises may
occur in operation or the pump may be damaged.
Contact surfaces and threads on both sides
of hydraulic pump must be free of paint.
Do not re-use drained hydraulic fluid.
Replace seals.
K
K
Edition 06.99
S00.5103.56.20
------------
------------
48
OCTAVIA
Steering
Models with 1.4 l/44 kW engine:
K-
Attach belt pulley with the hexagon socket
bolts to the hydraulic pump according to the
marking made; use Allen key (waf 9 mm) to
counter-hold.
Tightening torque: 25 Nm
Note:
If the belt pulley of the hydraulic pump is fitted
on the wrong way round, this will result in an
offset to the other belt pulleys. This offset will
result in the ribbed V-belt being damaged.
Continued for all models
-
Attach belt pulley to hydraulic pump with
hexagon socket bolts; use Allen key (waf 9
mm) for counter-holding.
Tightening torque: 25 Nm
- Install ribbed V-belt.
Engine, Mechanical Components; Repair
Group 13; Disassembling and assembling
engine
Notes:
When installing the ribbed V-belt, ensure it
is correctly located in the belt pulleys.
Use new seals for the connection of the pressure line.
-
Install pressure line (flexible hose).
Tightening torque of banjo bolt and of pressure switch: 38 Nm
------------ 48-44 ------------
K-
Install spring collar clamp and suction line
as shown.
Lengthwise marking -A- on the suction line
must be aligned with the shaped seam -Con the hydraulic pump.
Install spring collar clamp up to not more than
cross marking -B-.
Take hose clamp MP 7-602 off the suction
line.
Replenish hydraulic oil and bleed power
steering system, if necessary page 4828.
Edition 05.01
S00.5103.61.20
OCTAVIA
Steering
K-
Edition 02.01
S00.5103.60.20
*
,
+
"
-'
!
)#
&
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,
)
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48
------------
------------
OCTAVIA
Steering
-
"
!
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$
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!
48
Disposing of hydraulic pump
Special tools, testers and aids required
Notes:
The oils used in hydraulic pumps do not contain any harmful substances. Such oils can
be disposed of together with old oil from engines and gearboxes.
Dispose of old oils in accordance with applicable environmental protection regulations.
Old oils (the term old oils refer to used engine and gearbox oils incl. ATF as well as
mineral hydraulic oils) which are suitable for
reprocessing, must on no account be mixed
with brake fluid, antifreeze agent, synthetic
resin on nitro-thinners, chemicals etc.
After emptying, the old parts must be allowed to drain adequately by dripping.
When disposing of old parts, pay attention
to the legal regulations as slight quantities of
hydraulic oil still remain in the hydraulic
pump.
K-
Edition 05.01
S00.5103.61.20
------------ 48-45 ------------
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