Service

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 ŠKODA
Organisation; it is not permitted to pass it on to third parties.
© 1996 ŠKODA, automobilová 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

Supple- Edition Subject Article Number

ment
08.96 Basic Edition of Workshop Manual S00.5103.50.20
1 09.96 Supplement to Basic Edition S00.5103.51.20
2 03.97 Supplement to Repair Group 40 and 42; Repair Group S00.5103.52.20
44, 45 and 48
3 11.97 Engine 1.9 l/81 kW TDI S00.5103.53.20
4 10.98 Engine 1.8 l/110 kW; Octavia Estate S00.5103.54.20
5 12.98 Drive shafts, vehicle measurement, Brake FN-3 S00.5103.55.20
6 06.99 Modifications to steering system, brakes, rear axle, S00.5103.56.20
ABS; Engine 1.4 l/44 kW
7 11.99 4 wheel drive (4 x 4) S00.5103.57.20
8 04.00 Vehicles with ABS/EDS/ESP S00.5103.58.20
9 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 S00.5103.64.20
46
15 11.02 Engine 1.9 l/96 kW PD, Supplement to Repair Group S00.5103.65.20
00, 40, 42 and 45
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
19
20

Contents ⇒ next page.

The Service Manual is intended only for use within the

Škoda Organisation; it is not permitted to pass it on
to third persons. Printed in CR
© 2005 ŠKODA AUTO a. s. S00.5103.68.20
OCTAVIA Service
Table of Contents

00 Technical Data Page

Technical Data ............................................................................................................................. 00-1
- The chassis .............................................................................................................................. 00-1
- The steering system ................................................................................................................. 00-5
- The brake system .................................................................................................................... 00-6
- Wheels, tyres ........................................................................................................................... 00-8

40 Front wheel suspension Page

Repairing the front wheel suspension ...................................................................................... 40-1
- I - Summary of the components of the assembly carrier, anti-roll bar, track control arm ......... 40-2
- Removing and installing the track control bar .......................................................................... 40-4
- Pressing out and pressing in the bearing for track control arm ................................................ 40-8
- Removing and installing the assembly carrier ......................................................................... 40-10
- Pressing out and pressing in the rubber-metal bearing ........................................................... 40-12
- II - Summary of the components of the wheel bearing, suspension strut, drive shaft, brakes .... 40-13
- Repairing a wheel bearing housing .......................................................................................... 40-16
- Checking the steering joint ....................................................................................................... 40-19
- Removing and installing the steering joint ............................................................................... 40-20
- Removing and installing a suspension strut and a wheel bearing housing .............................. 40-21
- Repairing the suspension strut at the front .............................................................................. 40-25
- Checking dampers ................................................................................................................... 40-28
- Disposing of dampers .............................................................................................................. 40-31
- Removing and installing drive shafts ....................................................................................... 40-34
Repairing a drive shaft ............................................................................................................... 40-38
- Repairing a drive shaft with an outer and inner constant velocity joint .................................... 40-38
- Repairing a drive shaft with an outer and inner constant velocity joint VL 3700 ...................... 40-39.1
- Checking an outer constant velocity joint ................................................................................. 40-45
- Checking an inner constant velocity joint ................................................................................. 40-46
- Repairing a drive shaft with an inner tripod joint AAR 2900 and outer constant joint velocity ..... 40-49
- Dismantling a tripod joint AAR 2900 and assembling it again .................................................. 40-51
- Repairing a drive shaft with an inner tripod joint AAR 2000 and outer constant velocity joint ..... 40-56
- Dismantling a tripod joint AAR 2000 and assembling it again .................................................. 40-58

42 Rear wheel suspension Page

Repairing the rear axle - drum brakes....................................................................................... 42-1
- Removing and installing the rear axle ...................................................................................... 42-1
- Summary of components of the rear axle ................................................................................ 42-4
- Removing and installing a rubber-metal bearing ..................................................................... 42-7
- Removing and installing dampers/springs ............................................................................... 42-10
- Dismantling a damper and assembling it again ....................................................................... 42-11
Repairing the rear axle - disc brakes ........................................................................................ 42-12
- Removing and installing the rear axle ...................................................................................... 42-12
- Summary of components of the rear axle ................................................................................ 42-15
- Removing and installing a rubber-metal bearing ..................................................................... 42-18
- Removing and installing dampers/springs ............................................................................... 42-21
- Dismantling a damper and assembling it again ....................................................................... 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 ------------ I ------------

S00.5103.68.20
Service OCTAVIA
Repairing the rear axle (vehicles with a four-wheel drive) ...................................................... 42-32
- An overview of the rear axle with four-wheel drive .................................................................. 42-32
- Summary of components for springs and dampers on vehicles with a four-wheel drive ......... 42-33
- Removing and installing helical springs ................................................................................... 42-35
- Removing and installing dampers ............................................................................................ 42-39
Summary of components of the trailing arm and suspension arm........................................ 42-41
- Pressing out and pressing in the wheel bearing ...................................................................... 42-44
- Removing and installing the rubber-metal bearing for the trailing arm .................................... 42-50
- Removing and installing guide joints ........................................................................................ 42-52
- Removing and installing a trailing arm ..................................................................................... 42-54
- Removing and installing a suspension arm ............................................................................. 42-58
A summary of components for an assembly carrier with axial drive..................................... 42-60
- Removing and installing an assembly carrier with axial drive .................................................. 42-61
- Removing and installing the rubber-metal bearing for an assembly carrier ............................. 42-66
- Removing and installing the rubber-metal bearing for an axial drive ....................................... 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 ................................................................................................................. 44-1
- Conditions for performing checking and tests .......................................................................... 44-2
- Making preparations to take measurements ............................................................................ 44-2.1
- Designations of the various chassis available ......................................................................... 44-2.2
- Nominal value for vehicle measurement .................................................................................. 44-2.2
- Checking the lateral inclination ................................................................................................ 44-2.3
- Checking the wheel camber of the front axis, averaging if necessary ..................................... 44-2.4
- Checking the wheel camber of the rear axis ............................................................................ 44-2.5
- Checking the wheel camber of the rear axis, averaging/adjusting if necessary ...................... 44-2.5
- Checking the wheel camber of the front axis, adjusting if necessary ...................................... 44-2.6
- Checking the steering angle on the left and right ..................................................................... 44-2.6
- Mathematical determination of the deviation of the rear axle from the direction of travel ........ 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 .............................................................................. 45-1
- Safety measures, basics concerning searching for faults and repair
of the ABS and ABS/EDL ITT Mark 20 IE ................................................................................ 45-1
- Information concerning repair work on an ABS and ABS/EDL ITT Mark 20 IE ........................ 45-1
- Required technical information ................................................................................................ 45-3
Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE ..... 45-4
- General comments ................................................................................................................... 45-4
- The ABS ITT Mark 20 IE .......................................................................................................... 45-4
- The ABS/EDL ITT Mark 20 IE .................................................................................................. 45-5
- Installed position of the ABS or ABS/EDL ITT Mark 20 IE ....................................................... 45-5
Self-diagnosis.............................................................................................................................. 45-6
- Function of the self-diagnostic system ..................................................................................... 45-6
- Indication of faults concerning the warning lamps K47 and K14/33 ........................................ 45-7
- A vehicle with ABS/EDL has no EDL function .......................................................................... 45-8

------------ II ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Service
Undertaking the self-diagnosis.................................................................................................. 45-9
- Conditions for performing checking and tests .......................................................................... 45-9
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-9
- Querying the control unit version ............................................................................................. 45-10
- An overview of the functions which can be selected ................................................................ 45-12
- Interrogating the fault memory ................................................................................................. 45-12
- The automatic testing sequence .............................................................................................. 45-13
- The fault table .......................................................................................................................... 45-14
- Deleting the fault memory ........................................................................................................ 45-21
- Ending output ........................................................................................................................... 45-22
- Coding the control unit ............................................................................................................. 45-22
- Reading the measuring value block ......................................................................................... 45-24
- Actuator diagnosis ................................................................................................................... 45-29
- Initiating the basic setting ......................................................................................................... 45-36
Electrical testing of the ABS and ABS/EDL ITT Mark 20 IE ..................................................... 45-41
- Conditions for performing checking and tests .......................................................................... 45-41
- Multiple plug connectors with contact allocation ...................................................................... 45-42
- An overview of the test steps ................................................................................................... 45-43
- Testing table ............................................................................................................................. 45-44
Electrical/electronic components and installed locations of the ABS,
ABS/EDL ITT Mark 20 IE ............................................................................................................. 45-51
- Removing and installing the hydraulic control unit and holder ................................................. 45-52
- Repairing the hydraulic control unit .......................................................................................... 45-57
- Testing parts of the ABS system on the front axle/removing and installing .............................. 45-60
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes - front-wheel drive ................................................................................ 45-65
- Removing and installing as well as adjusting a brake light switch up to MY 1999 ................... 45-69
- Removing and installing as well as adjusting a brake light switch as of MY 2000 ................... 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 ............ 45-71
- Querying the control unit version ............................................................................................. 45-71
- Fault table for ABS/EDL for a four-wheel drive vehicles with a Haldex clutch ......................... 45-72
- Coding the control unit ............................................................................................................. 45-73
- Testing the sender for longitudinal acceleration -G251- ........................................................... 45-74
- Testing the data-bus lines ........................................................................................................ 45-75
- Initiating the basic setting ......................................................................................................... 45-76
- Switching off the sender for longitudinal acceleration -G251- .................................................. 45-76
- Zero balancing of the sender for longitudinal acceleration -G251- .......................................... 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................................................... 45-88
- Safety measures, basics concerning searching for faults and repair ....................................... 45-88
- Information concerning repair work on the ABS/EDL/ESP ITT Mark 20 IE .............................. 45-88
- Required technical information ................................................................................................ 45-88
Differences in the features of the ABS ITT Mark 20 IE and the ABS/EDL/ESP ITT
Mark 20 IE .................................................................................................................................... 45-89
- General comments ................................................................................................................... 45-89
- The ABS/EDL/ESP ITT Mark 20 IE .......................................................................................... 45-90
- Fitting position of the ABS/EDL/ESP ITT Mark 20 IE ............................................................... 45-90
Self-diagnosis of the diagnosis ABS/EDL/TCS/ESP ITT Mark 20 IE ....................................... 45-91
- Function of the self-diagnostic system ..................................................................................... 45-91
- Indication of faults concerning the warning lamps K47, K118 and K155 ................................. 45-92
- A vehicle with ABS/EDL/ESP has no EDL function .................................................................. 45-96

Edition 06.05 ------------ III ------------

S00.5103.68.20
Service OCTAVIA
Undertaking the self-diagnosis.................................................................................................. 45-97
- Conditions for performing checking and tests .......................................................................... 45-97
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-97
- Querying the control unit version ............................................................................................. 45-98
- The automatic testing sequence .............................................................................................. 45-100
- An overview of the functions which can be selected ................................................................ 45-100
- Interrogating the fault memory ................................................................................................. 45-101
- The fault table .......................................................................................................................... 45-102
- Deleting the fault memory ........................................................................................................ 45-113
- Ending output ........................................................................................................................... 45-114
- Coding the control unit ............................................................................................................. 45-114
- Reading the measuring value block ......................................................................................... 45-116
- Initiating the basic setting ......................................................................................................... 45-124
- The logging-in procedure ......................................................................................................... 45-131
Electrical testing of the ABS/EDL/ESP ITT Mark 20 IE............................................................. 45-133
- Conditions for performing checking and tests .......................................................................... 45-133
- Multiple plug connectors with contact allocation ...................................................................... 45-134
- Testing table ............................................................................................................................. 45-138
- Test steps 1 - 20 ....................................................................................................................... 45-138
- Test steps 21 - 28 ..................................................................................................................... 45-148
Electrical/electronic components and installed locations of the ABS/EDL/ESP ITT
Mark 20 IE .................................................................................................................................... 45-155
- Removing and installing the hydraulic control unit ABS/EDL/ESP and holder ......................... 45-158
- Repairing the hydraulic control unit ABS/EDL/ESP.................................................................. 45-163
- Testing parts of the ABS system on the front axle/removing and installing .............................. 45-166
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes - front-wheel drive ................................................................................ 45-170
- Removing and installing parts of the ESP system ................................................................... 45-170
- Removing and installing as well as adjusting a brake light switch ........................................... 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 ..................................................................................... 45-179
- Safety measures, basics concerning searching for faults and repair of the ABS
and ABS/TCS/EDL ITT MK 60 ................................................................................................. 45-179
- Information concerning repair work on an ABS and ABS/TCS/EDL ITT MK 60 ....................... 45-179
- Required technical information ................................................................................................ 45-179
- General guidelines ................................................................................................................... 45-179
- ABS and ABS/TCS/EDL ........................................................................................................... 45-179
- Installed position of the ABS or ABS/TCS/EDL ITT MK 60 ...................................................... 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.................................................................................................. 45-182
- Conditions for performing checking and tests .......................................................................... 45-182
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-182
- An overview of the functions which can be selected ................................................................ 45-182
- The fault table .......................................................................................................................... 45-183
- Coding the control unit ............................................................................................................. 45-190
- Table of codes for vehicles with Anti-Lock Brake System Mark 60 .......................................... 45-191
- Reading the measuring value block ......................................................................................... 45-192
- Actuator diagnosis ................................................................................................................... 45-194
- Initiating the basic setting ......................................................................................................... 45-194
Electrical/electronic components and installed location of the Mark 60 ............................... 45-195
- Removing and installing the hydraulic control unit and holder ................................................. 45-196
- Repairing the hydraulic control unit .......................................................................................... 45-200
- Testing parts of the ABS system on the front axle/removing and installing .............................. 45-201
- Testing parts of the ABS system on the rear axle/removing and installing
(drum and disc brakes) - front-wheel drive .............................................................................. 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 ....................................................................... 45-205
- Conditions for performing checking and tests .......................................................................... 45-205
- Multiple plug connectors with contact allocation ...................................................................... 45-206
- Testing table ............................................................................................................................. 45-208
The anti-lock braking system ABS/EDL/ESP MK 60 ................................................................ 45-214
- Safety measures, basics concerning searching for faults and repairs ..................................... 45-214
- Information concerning repair work on an ABS/EDL/ESP Mark 60.......................................... 45-214
- Required technical information ................................................................................................ 45-214
Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP
Mark 60 ä MY02 .......................................................................................................................... 45-215
Electrical/electronic components and installed locations of the ABS/EDL/TCS/ESP
Mark 60 MY02 ä .......................................................................................................................... 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
Undertaking the self-diagnosis.................................................................................................. 45-223
- Conditions for performing checking and tests .......................................................................... 45-223
- Connecting up to the V.A.G vehicle tester 1552 and selecting a function................................ 45-223
- Querying the control unit version ............................................................................................. 45-223
- An overview of the functions which can be selected ................................................................ 45-224
- The fault table .......................................................................................................................... 45-224
- Coding the control unit ............................................................................................................. 45-237
- Reading the measuring value block ......................................................................................... 45-238
- Initiating the basic setting ......................................................................................................... 45-241
- The logging-in procedure ......................................................................................................... 45-249
Electrical testing of the ABS/EDL/ESP Mark 60 ....................................................................... 45-250
- Conditions for performing checking and tests .......................................................................... 45-250
- Multiple plug connectors with contact allocation ...................................................................... 45-251
- Testing table ............................................................................................................................. 45-254

46 Brakes/brake mechanics Page

Repairing a front wheel brake .................................................................................................... 46-1
- Repairing a front wheel brake, brake calliper FS-III ................................................................. 46-1
- Removing and installing brake linings or brake calliper (FS-III) ............................................... 46-3
- Repairing a front wheel brake, brake calliper FN-3 .................................................................. 46-5
- Removing and installing brake linings/brake calliper (FN-3) .................................................... 46-5.2
- Removing and installing brake discs (FN-3) ............................................................................ 46-5.7
Repairing a rear wheel brake - front wheel drive/drum brake................................................. 46-6
- Removing and installing a rear brake ...................................................................................... 46-6
- Resetting a brake ..................................................................................................................... 46-7
- Repairing a rear wheel brake ................................................................................................... 46-8
- Removing and installing brake linings ...................................................................................... 46-10
- Adjusting the handbrake (drum brake) ..................................................................................... 46-12
Repairing a rear wheel brake - front wheel drive/disc brake .................................................. 46-13
- Removing and installing a rear brake ...................................................................................... 46-13
- Removing and installing brake lining ....................................................................................... 46-15
- Adjusting the handbrake (disc brake) ...................................................................................... 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 ------------ V ------------

S00.5103.68.20
Service OCTAVIA
Repairing a rear wheel brake - four-wheel drive/disc brake ................................................... 46-24
- Removing and installing a rear brake ...................................................................................... 46-24
- Removing and installing brake linings ...................................................................................... 46-26
- Adjusting the handbrake .......................................................................................................... 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 ............................................................................................. 47-1
- Removing and installing the master brake cylinder ................................................................. 47-2
- Checking the brake booster ..................................................................................................... 47-4
- Removing and installing the brake booster .............................................................................. 47-4.1
- Removing and installing the vacuum pump for the brake booster ........................................... 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 ................................................................................................................................. 47-18
- Ventilating the brake system using a brake draining and ventilation device such
as ROMESS S15 for vehicles with Mark 20 ............................................................................. 47-20
- Ventilating the brake system without the use of a brake draining and ventilation device ........ 47-21
- Changing the brake fluid .......................................................................................................... 47-22
- Ventilating the brake system using a brake draining and ventilation device such a
s ROMESS S15 for vehicles with Mark 60 ............................................................................... 47-23
Tightness test of the master brake cylinder ............................................................................. 47-24
A summary of components: brake booster/master brake cylinder for vehicles
with ABS/EDL/ESP Mark 20 ........................................................................................................ 47-26
- Removing and installing sender -1- for brake pressure -G201- and sender -2- for
brake pressure -G214- ............................................................................................................. 47-28
- Removing and installing the master brake cylinder ................................................................. 47-30
- Checking the brake booster ..................................................................................................... 47-32
- Removing and installing the brake booster .............................................................................. 47-32
- Removing and installing the vacuum pump for the brake booster ........................................... 47-35
A summary of components: brake booster/master brake cylinder for vehicles
with ABS/EDL/TCS/ESP Mark 60................................................................................................ 47-36
- Removing and installing sender -1- for brake pressure -G201- ............................................... 47-37
- Removing and installing the master brake cylinder ................................................................. 47-37
- Checking the brake booster ..................................................................................................... 47-37
- Removing and installing the brake booster .............................................................................. 47-37
- Removing and installing vacuum pump for the brake -V192- .................................................. 47-38
- Checking vacuum pump for the brake -V192- ......................................................................... 47-39

48 The steering system Page

Steering column and steering wheel with airbag..................................................................... 48-1
- Checking the steering column for damage .............................................................................. 48-1
- Removing and installing the steering column .......................................................................... 48-2
- Removing and installing the ignition lock housing with the steering column mounted in place... 48-8.3

------------ VI ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Service
A summary of components: the power-assisted steering gearing system ........................... 48-9
- Removing and installing the expansion bottle for hydraulic oil ................................................ 48-11
- Removing and installing the power-assisted steering gearing system .................................... 48-12
- Repairing the power-assisted steering gearing system (ZF) ................................................... 48-19
- Altered track rod ends .............................................................................................................. 48-23.1
- Altered track rods ..................................................................................................................... 48-23.2
- Disposing of a power-assisted steering gearing system .......................................................... 48-24
- Adjusting a power-assisted steering gearing system (ZF) ....................................................... 48-25
- Checking the hydraulic fluid level on a power-assisted steering system and topping it
up where necessary ................................................................................................................. 48-26
- Emptying a power-assisted steering system, filling and ventilating ......................................... 48-28
- Checking a power-assisted steering system for leaks ............................................................. 48-30
- Noises on a power-assisted steering system ........................................................................... 48-31
A summary of components: the vane pump ............................................................................ 48-33
- A summary of components for vane pumps which are mounted above and below ................. 48-33
- Pressure switch for the power-assisted steering system ......................................................... 48-34
- Checking the delivery pressure of the vane pump ................................................................... 48-35
Removing and installing the vane pump .................................................................................. 48-37
- Vehicles with the vane pump mounted above .......................................................................... 48-37.1
- Vehicles with the vane pump mounted below .......................................................................... 48-41
- Disposing of a vane pump ....................................................................................................... 48-45

Edition 06.05 ------------ VII ------------

S00.5103.68.20
OCTAVIA Technical Data 00

Technical Data
Chassis
Nominal values front axle

Spring strut axle (Front and 4 Wheel Drive)

Standard Sport suspension Rough road
suspension7) suspension
Chassis G06 G20 1GA G35 G04 1GB
G12 G30 1GG G85 G07 1GW
G13 G31 1GE G34
G14 G32 1GH G39
G15 G33 G40
Explanation concerning this PR No. see page 00-4
Overall track2) 0° ± 10' 0° ± 10' 0° ± 10'
Track for 14"7) (mm)2)
wheels 0±1 - 0±1
Measuring point: 184 mm from wheel centre
Track for 15" (mm)2) wheels 0° ± 1.1 - 0° ± 1.1
Measuring point: 196 mm from wheel centre
Track for 16"7) (mm)2) wheels 0 ± 1.2 0 ± 1.2 0 ± 1.2
Measuring point: 209 mm from wheel centre
Track for 17"8) (mm)2) wheels - 0 ± 1.3 -
Measuring point: 225 mm from wheel centre
Toe difference angle on turns - 1° 30' ± 20' - 1° 31' ± 20' - 1° 27' ± 20'
of 20° of inside wheels1)
Toe difference angle on turns - 6° 35' - 6° 40' - 6° 35'
at full lock of inside wheel1)
Max. wheel lock angle1) 40° 39° 45' 40° 45'
Continued table ⇒ page 00-2

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
2) Adjustable
7) Not valid for Octavia 4 x 4
8) Only Octavia RS (1.8 l/32 kW)

Edition 11.02 ------------ 00-1 ------------

S00.5103.65.20
00 Technical Data OCTAVIA

Continuation of table „Nominal values of front axle“ of page 00-1

Spring strut axle (Front and 4-Wheel Drive)
Standard suspension7) Sport suspension Rough road suspension
Camber3) -30’ ± 30’ -33’ ± 30’ -16’ ± 30’
4)6)
-0° 25’ ± 30’ - -
-0° 28’ ± 30’5) - -
Max. difference between 30’ 30’
left and right side
Caster angle1) 7° 40’ ± 30’8) 7° 50’ ± 30’8) 7° 15’ ± 30’8)
7° 40’ +30’, -60’9) 7° 50’ +30’, -60’9) 7° 15’ +30’, -60’9)
8° 23’ ± 30’4) - -
8° ± 30’5)6) - -
Max. difference of caster 30’ 30’
angle between left and
right side

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
V3
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OCTAVIA Technical Data 00

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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).

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Edition 11.02 ------------ ------------

S00.5103.65.20
00 Technical Data OCTAVIA

------------ 00-3.1
00-4 ------------
------------ 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 reser-
voir for the windscreen wiper washer system, spare wheels, tool kit, jack and without driver).
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------------ 00-3.2 ------------

S00.5103.67.20
00 Technical data OCTAVIA

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

Front axis
PR No. Engine installed / gearbox design PR No. Engine installed / gearbox design
1GA ♦ All petrol engines up to 74 kW with a 1GE ♦ All petrol engines up to 74 kW with a
manual gearbox manual or an automatic gearbox
♦ All diesel engines over 66 kW with a
manual gearbox
1GG ♦ All petrol engines up to 74 kW with an au- 1GB ♦ All petrol and diesel engines with a manual
tomatic gearbox or an automatic gearbox
♦ All diesel engines over 66 kW with a ♦ Octavia 4 x 4
manual gearbox

Rear axis
PR No. Engine installed / gearbox design PR No. Engine installed / gearbox design
1JD ♦ Only a sedan 1JB ♦ All petrol and diesel engines with a manual
♦ All petrol and diesel engines with a manual or an automatic gearbox
or an automatic gearbox other than the
1.8-ltr./110 kW engine
1JH ♦ Only estate cars 1JW ♦ Octavia 4 x 4
♦ All petrol and diesel engines with a manual
or an automatic gearbox other than the
1.6-ltr./55 kW engine

------------ 00-4 ------------ Edition 06.02

S00.5103.64.20
OCTAVIA Technical Data 00

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 15.60
Lubricant for gear racks 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 0.05...0.1
(mm)
Authorised axial force for the displacement of the gear 250
rack (N)
Rotating force of the track rods from rest position (N) 1...3.5
Hydraulic oil designation 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) 0.7...0.9 l

Edition 06.05 ------------ 00-5 ------------

S00.5103.68.20
00 Technical Data OCTAVIA
Brakes
Engine l/kW 1.4/44; 1.4/55 1.6/55 1.6/74;1.6/75 1.9/50 SDI
S = (Manual) shift gearbox S - S - S A S -
A = Automatic gearbox

Brake master cylinder ∅ mm 23.81

Brake servo unit ∅ Inch LHD models with and without ABS: 10“
RHD models with and without ABS: 7“/8“ tandem
Front disc brakes
Front brake calliper FS-III 3)
Front brake caliper, piston ∅ mm 54.0
Front brake disc ∅ mm 256.0
Brake disc, thickness mm 22.0
Brake disc, minimum thickness mm 19.0
Pad thickness with supporting plate mm 19.5
Minimum thickness without mm 2.0
supporting plate
Rear disc brakes

Rear brake caliper, piston ∅ mm - 41.0 -

Rear brake disc ∅ mm - 239.0 -
Brake disc, thickness mm - 9.0 -
Brake disc, minimum thickness mm - 7.0 -
Pad thickness with supporting plate mm - 17.0 -
Minimum thickness without mm - 2.0 -
supporting plate
Rear drum brakes

Brake drum ∅ mm 230.0

Brake drum - maximum diameter mm 231.0
Wheel brake cylinder1) ∅ mm 20.64 - 20.64 - 20.64 19.05 19.054) -

Wheel brake cylinder2) ∅ mm 20.64 - 20.64 - 20.64 20.64 20.64 -

Brake lining, width mm 32.0

Lining thickness without supporting mm 5.5
shoe
Minimum thickness without mm 2.5
supporting shoe

1) Models without ABS 3) Not for taxi models (designation F4E)

2) Models with ABS 4) For Octavia Combi: 20.64

------------ 00-6 ------------ Edition 05.01

S00.5103.61.20






!"
OCTAVIA Technical Data 00

M = Manual gearbox M - M - M -
A = Automatic gearbox
Master brake cylinder - ∅ mm 23.81
Brake booster - ∅ Inch Left-hand drive with and without ABS: 10"
Right-hand drive with and without ABS: 7"/8" - Tandem

Front brake caliper

#$%&'
Front brake caliper, piston - ∅ mm 54.0 54.0 54.0
Front brake disc - ∅ mm 312,0 280,0 288,0
Brake disc, thickness mm 25,0 22,0 25,0
Brake disc, minimum thickness mm 23,0 19,0 23,0
Pad thickness with supporting mm 19,5 19,5 19,5
plate
Minimum thickness without mm 2,0 2,0 2,0
supporting plate
d
Rear brake caliper, piston - ∅ mm 38,0 41,0 41,0
Rear brake disc - ∅ mm 256,0 239,0 232,0
Brake disc, thickness mm 22,0 9,0 9,0
Brake disc, minimum thickness mm 20,0 7,0 7,0
Pad thickness with supporting mm 17,37 17,37 17,0
plate
Minimum thickness without mm 2,0 2,0 2,0
supporting plate

Brake drum - ∅ mm -
Brake drum - maximum diameter mm -
Wheel brake cylinder1) - ∅ mm -
Wheel brake cylinder2) - ∅ -
Pad thickness mm -
Pad thickness without supporting mm -
plate
Minimum thickness without mm -
supporting plate
1) Vehicles without ABS 2) Vehicles with ABS

Edition 11.02 ------------ ------------

S00.5103.65.20
00 Technical Data OCTAVIA

------------ 00-6.2 ------------ Edition 05.01

S00.5103.61.20
OCTAVIA Technical Data 00

Engine l/kW 1.9/66 TDI 1.9/81 TDI 1.8/92; 2.0/85 (82) 1.8/110
M = Manual gearbox M A M - M A M A
A = Automatic gearbox
Master brake cylinder - ∅ mm 23.81
Brake booster - ∅ Inch 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 sup- mm 2.0 2.0
porting plate
Rear disc brake
Rear brake caliper, piston - ∅ mm 38.08)
41.09)
Rear brake disc - ∅ mm 232.06) 232.0
239.07) 239.07)
Brake disc, thickness mm 9.0
Brake disc, minimum thickness mm 7.0
Pad thickness with supporting plate mm 17.0
Minimum thickness without sup- mm 2.0
porting plate
Drum brake
Brake drum - ∅ mm 230.0 —
Brake drum - maximum diameter mm 231.0 —
1)
Wheel brake cylinder - ∅ mm 20.64 — — — — — — —
Wheel brake cylinder2) - ∅ mm 20.64 20.64 — — — — — —
Pad thickness, width mm 32.0 —
Pad thickness without supporting mm 5.5 —
plate
Minimum thickness without sup- mm 2.5 —
porting plate

1) 5)
Vehicles without ABS For Taxi vehicles (F4E) also 1.4/44; 1.4/55;
2) 1.6/55; 1.6/74; 1.6/75; 1.9/50
Vehicles with ABS
6)
3) Vehicles with ESP
Not valid for Taxi vehicles (identification
7)
F4E) Four-wheel drive vehicles
4) 8)
For Taxi vehicles (F4E) also 1.9/66; 2.0/85; up to 07.98
1.9/81 9)
as of 08.98

Edition 06.05 ------------ 00-7 ------------

S00.5103.68.20
00 Technical Data OCTAVIA

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 l 0.49 Vehicles with rear drum brakes, without ABS
0.53 Vehicles with rear drum brakes, with ABS
0.57 Vehicles with rear disc brakes, with ABS
Brake fluid change - 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 Steel rim Offset Snow chains
(mm) Permitted
yes no
1.4 l/44 kW 175/80 R14 88 T, H - 6J x 14 H2 38 X -
1.4 l/55 kW 195/65 R15 91 T, H, V 6J x 15 H2 6J x 15 H2 X -
1.6 l/55 kW 205/60 R15 91 H 61/2J x 15 H2 - 43 - X
1
1.9 l/50 kW 205/55 R16 91 H 6 /2J x 16 H2 - 42 - X
205/55 R16 91 W 51/2J x 16 H2 - 36 X -
1.6 l/74 kW 175/80 R14 88 H - 6J x 14 H2 38 X -
1.6 l/75 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 X -
205/60 R15 91 H 61/2J x 15 H2 - 43 - X
205/55 R16 91 H 61/2J x 16 H2 - 42 - X
1
205/55 R16 91 W 5 /2J x 16 H2 - 36 X -
2.0 l/85 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 61/2J x 15 H2 43 - X
205/55 R16 91 H 61/2J x 16 H2 42 - X
205/55 R16 91 W 51/2J x 16 H2 36 X -
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

1,8 l/92 kW

1,8 l/110 kW

1,8 l/132 kW

T






195/65 R15 91 H, V
205/60 R15 91 H, V
205/55 R16 91 H, V, W
205/55 R16 91 W
195/65 R15 91 V
205/55 R16 91 V, W
205/60 R15 91 V
205/55 R16 91 W
205/55 R16 91 W
205/55 R16 91 W
205/50 R17 89 W2)
Technical Data

6J x 15 H2
6
6
1/

1/
2

6J x 15 H2
6
6
1/

1/
2

2
J x 15 H2
J x 16 H2
5 1/2 J x 16 H2

J x 16 H2
J x 15 H2
5 1/2 J x 16 H2
6 1/2 J x 16 H2
5 1/
2
7J x 17 H2
J x 16 H2
6J x 15 H2
-
-
-
6J x 15 H2
-
-
-
6 1/2 J x 16 H2
-
-
38
43
42
36
38
42
43
36
42
36
38
X
-
-
X
X
-
-
X
-
X
X
no
-
X
X
-
-
X
X
-
X
-
-
00

1,9 l/66 kW TDI 195/65 R15 91 T, H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 6 1/2 J x 15 H2 - 43 - X
205/55 R16 91 H 6 1/
2 J x 16 H2 - 42 - X
205/55 R16 91 W 5 1/
2 J x 16 H2 - 36 X -
1,9 l/74 kW PDi 195/65 R15 91 V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 V 6 1/2 J x 15 H2 - 43 - X
205/55 R16 91 V 6 1/
2 J x 16 H2 - 42 - X
205/55 R16 91 W 5 1/
2 J x 16 H2 - 36 X -
1,9 l/81 kW TDI 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 6 1/2 J x 15 H2 - 43 - X
205/55 R16 91 H, V, W 6 1/
2 J x 16 H2 - 42 - X
205/55 R16 91 W 5 1/
2 J x 16 H2 - 36 X -
1,9 l/96 kW PDi 195/65 R15 91 V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 V 6 1/2 J x 15 H2 - 43 - X
205/55 R16 91 V, W 6 1/
2 J x 16 H2 - 42 - X
205/55 R16 91 W 5 1/
2 J x 16 H2 - 36 X -

1) Tyre inflation pressure 2) Not valid for Octavia Estate RS

⇒ Inspection and Maintenance as well as
sticker on vehicle

Edition 11.02 ------------ ------------

S00.5103.65.20
00 Technical Data OCTAVIA

Load rating-index (Last Index): 88 = 560 kg 91 = 615 kg

89 = 580 kg
Speed symbol: T = 190 km/h H = 210 km/h
V = 240 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 Technical Data 00

Tyre inscription

Inscription e.g. 175/80 R14 88 T Meaning

175/80 Tyre width (mm)/cross section ratio of height - width (%)

R Tyre construction (radial)
14 Wheel diameter (inch)
88 Load index
T Speed symbol
Date of manufacture

DOT ... 394 K Manufactured in 39th week 1994

(K = designates decade 1990 ... 1999)
DOT ... 0300 Manufactured in 3rd week 2000
(03 = 3rd calendar week, 00 = year 2000)

Edition 11.00
S00.5103.59.20
------------
------------
OCTAVIA Front Suspension 40

Servicing front suspension

I - Removing and installing subframe, anti-roll II - Removing and installing wheel mounting,
bar, track control arm ⇒ page 40-2 suspension strut, drive shaft, brake
⇒ page 40-13

Edition 10.98 ------------ 40-1 ------------

S00.5103.54.20
40 Front wheel suspension OCTAVIA

I - Summary of the components of the assembly carrier, anti-roll bar, track control arm

Comments: 1 - Axle guide

♦ Removing and installing ⇒ Page 40-4
♦ If vehicles on which the universal drive shaft
♦ Elongated holes only serve to adjust
has been removed have to be moved then
the wheel camber!
an outer joint must be fitted instead of the
universal drive shaft which should be tight-
2 - 15 Nm and turn through a further 90°
ened to 50 Nm otherwise the wheel bearing
will be damaged.
3 - Shift rail
♦ It is not allowed to do welding and straight- ♦ Shift rails on a given axle must be of
ening work on weight carrying and wheel the same design
guiding components of the wheel suspen- ♦ Allocation ⇒ spare parts catalogue
sion system.
♦ Self-locking nuts must always be replaced.
♦ Corroded bolts/nuts must always be replaced.
------------ 40-2 ------------ Edition 06.02
S00.5103.64.20
OCTAVIA Front wheel suspension 40
4 - 15 Nm and turn through a further 90° 18 - Shift rail
♦ Replace after every disassembly op- ♦ Mount the spherical head with the long
eration threaded pin -A- (above) on the spring
plate
5 - Shift rail ♦ Mount the spherical head with the
♦ Only for anti-roll bars with a diameter short threaded pin -B- (below) on the
of 23 mm anti-roll bar
♦ Replace with a steel unit ♦ Allocation ⇒ spare parts catalogue
♦ Shift rails on a given axle must be of
the same design 19 - 90 Nm
♦ Allocation ⇒ spare parts catalogue ♦ Replace after every disassembly op-
eration
6 - Bearing at the front for the axle guide
♦ Pressing out and pressing in ⇒ Page 20 - Metal - rubber bearing
40-8 ♦ Pressing out and pressing in ⇒ Page
40-12
7 - 70 Nm and turn through a further 90°
♦ Replace after every disassembly op- 21 - Nut, self-locking
eration ♦ Replace after every disassembly op-
eration
8 - Rocking pier
22 - 100 Nm and turn through a further 90°

9 - 40 Nm and turn through a further 90° ♦ Replace after every disassembly op-
♦ Replace after every disassembly op- eration
eration
23 - Bearing behind for the axle guide
10 - 40 Nm and turn through a further 90° ♦ Installed location ⇒ Page 40-9
♦ Replace after every disassembly op- ♦ Pressing out and pressing in ⇒ Page
eration 40-9

11 - 20 Nm and turn through a further 90° 24 - 100 Nm and turn through a further 90°
♦ Replace after every disassembly op- ♦ Replace after every disassembly op-
eration eration

12 - Assembly carrier 25 - 70 Nm and turn through a further 90°

♦ Removing and installing ⇒ Page ♦ Replace after every disassembly op-
40-10 eration
♦ The undertaking of repairs on the
thread of the front axle guide screw 26 - Securing plate
connection is not allowed! ♦ Replace after every disassembly op-
eration
13 - 15 Nm and turn through a further 90°
♦ Replace after every disassembly op- 27 - 20 Nm and turn through a further 90°
eration ♦ Replace after every disassembly op-
eration
14 - Anti-roll bar
♦ The assembly carrier must be lowered 28 - Axle joint
in order to remove and install this ♦ Checking ⇒ Page 40-19
♦ Check the rubber bellows for damage
15 - Rubber bearing and replace the axle joint as neces-
sary
16 - 25 Nm ♦ Removing and installing only in con-
nection with the wheel bearing hous-
17 - Clamp ing ⇒ Page 40-20
♦ Mark the installed location before re-
moving 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 op-
eration

Edition 06.02 ------------ ------------

S00.5103.64.20
40 Front Suspension OCTAVIA

Removing and installing track con-

trol 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 light-

alloy 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- other-
wise the axle geometry must be checked.

K- Unscrew bolts -1-.

------------ 40-4 ------------ Edition 10.98

S00.5103.54.20
OCTAVIA Front Suspension 40

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 wish-

bone.

- 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 ------------ 40-5 ------------

S00.5103.60.20
40 Front Suspension OCTAVIA

Installing

(applies to models fitted with manual and auto-

matic 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 wish-

bone.

- 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 100 Nm + 90°

Use new bolts!

Steering joint to wishbone 20 Nm + 90°

Use new bolts and new
locking plate!

Pendulum support to gearbox 40 Nm + 90°

Use new bolts!

Coupling rod to wishbone 15 Nm + 90°

Use new bolt!

------------ ------------ Edition 02.01

S00.5103.60.20
OCTAVIA Front Wheel Suspension 40

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 ------------ 40-7 ------------

S00.5103.65.20
40 Front Suspension OCTAVIA

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 in-
serting the bush. On no account use grease or
soapsuds.

------------ 40-8 ------------ Edition 12.98

S00.5103.55.20
OCTAVIA Front Suspension 40

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 insert-

ing ⇒ Fig. V40-1010.

Edition 10.98 ------------ ------------

S00.5103.54.20
40 Front Suspension OCTAVIA

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 in-
cluded 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. Posi-

tion tool as shown in illustration for this step.

Note:
Ensure adequate clearance when pressing out
the drive shafts.

- Separate track control arm on left and right

from steering joint.

- Swivel wheel bearing housing and steering

joint out and support.

------------ 40-10 ------------ Edition 10.98

S00.5103.54.20
OCTAVIA Front Suspension 40

K- Unscrew bolts -1- and -2- and take off pen-

dulum 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, po-

sition steering gear on subframe and then in-
sert 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 ------------ 40-11 ------------

S00.5103.54.20
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 acid-
free lubricant, e.g. G 294 421 A1, before press-
ing in. On no account use grease or soap suds.

------------ 40-12 ------------ Edition 11.99

S00.5103.57.20
OCTAVIA Front Suspension 40

II - Assembly overview of wheel mounting, suspension strut, drive shaft, brake

Notes: ♦ Always replace corroded nuts and bolts.

♦ If it is necessary to move a vehicle on which
1 - Self-locking hexagon collar nut, 60 Nm
the drive shaft has been removed, first of all
♦ replace each time removed
install an outer joint in place of the drive shaft
and tighten to 50 Nm otherwise the wheel
2 - Stop
bearing will be damaged.
♦ It is not permitted to carry out any welding 3 - Suspension strut
and straightening work on load-bearing and ♦ removing and installing ⇒ page
wheel-locating components of the front sus- 40-21
pension. ♦ servicing ⇒ page 40-25
♦ assignment ⇒ Parts List
♦ Always replace self-locking nuts.

Edition 05.01 ------------ 40-13 ------------

S00.5103.61.20
40 Front Suspension OCTAVIA

4 - Drive shaft with inner CV joint 7 - Drive shaft with inner tripod joint
♦ removing and installing ⇒ page 40- ♦ removing and installing ⇒ page 40-
34 34
♦ servicing ⇒ page 40-38 ♦ servicing ⇒ page 40-49

5 - Base plate 8 - Machine bolt with internally serrated

head
6 - Machine bolt with internally serrated ♦ replace each time removed
head ♦ tighten initially to 10 Nm, then diago-
♦ replace each time removed nally across to final torque
♦ tighten initially to 10 Nm, then diago- M8 = 40 Nm
nally across to final torque M10 = 70 Nm
M8 = 40 Nm ♦ assignment ⇒ Parts List
M10 = 70 Nm
♦ assignment ⇒ Parts List

------------ 40-14 ------------ Edition 05.01

S00.5103.61.20
OCTAVIA Front Wheel Suspension 40
9 - Brake disc (FS-III) 21 - Brake carrier (FN-3)
♦ without marking for axial run-out
♦ with a fixing hole for the wheel hub 22 - Brake caliper (FN-3)
♦ assignment ⇒ electronic catalogue of For vehicles with engine as of 96 kW
original parts ♦ do not release brake hose when work-
ing on the front wheel suspension
10 - Wheel bolt, 120 Nm ♦ tie up with wire or anything similar
♦ removing and installing brake pads
11 - Twelve-point nut, self-locking ⇒ Repair Group 46
♦ loosen and tighten ⇒ page 40-6 ♦ repairing ⇒ Repair Group 47
♦ replace after each disassembly
23 - Guide bolts (FN-3), 28 Nm
12 - Screw, 4 Nm ♦ removing and installing
⇒ page 46-5.2
13 - Brake pads (FS-III)
♦ removing and installing 24 - Cap (FN-3)
⇒ page 46-3
25 - Bolt with safety collar (FN-3), 125 Nm
14 - Brake caliper (FS-III) ♦ clean ribbing on underside
For vehicles with engine up to 92 kW.
♦ do not release brake hose when work- 26 - Wheel bearing housing
ing on the front wheel suspension For vehicles with engine as of 96 kW
♦ tie up with wire or anything similar ♦ removing and installing
♦ repairing ⇒ page 47-8 ⇒ page 40-21
♦ repairing ⇒ from page 40-16
15 - Guide bolts (FS-III), 28 Nm ♦ before pressing in wheel bearing coat
♦ removing and installing ⇒ from page evenly the entire wheel bearing seat
46-3 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 28 - Self-locking nut, 45 Nm
♦ with 5 fixing holes for the wheel hub ♦ replace after each disassembly
♦ removing and installing ⇒ from page
46-5.7 29 - Steering joint
♦ assignment ⇒ electronic catalogue of ♦ inspecting ⇒ page 40-19
original parts ♦ inspecting rubber bellows for damage,
if necessary replace steering joint
18 - Wheel hub with pulse rotor for speed ♦ removing and installing
sensor ⇒ page 40-20
♦ with marking for minimum axial run-
out 30 - Wheel bearing housing
♦ only on vehicles with ABS For vehicles with engine up to 92 kW
♦ pressing out ⇒ page 40-16 and futher ♦ removing and installing
♦ pressing in ⇒ page 40-16 and further ⇒ page 40-21
♦ removing inner ring of bearing ⇒ page ♦ repairing ⇒ from page 40-16
40-16 and further ♦ before pressing in wheel bearing coat
♦ inspecting lateral run-out of pulse ro- evenly the entire wheel bearing seat
tor ⇒ page 45-61 in the wheel bearing housing with G
♦ assignment ⇒ electronic catalogue of 052 723 A2
original parts

19 - Brake pads (FN-3)

♦ removing and installing
⇒ page 46-5.2

20 - Retaining spring (FN-3)

Edition 06.05 ------------ 40-15 ------------

S00.5103.68.20
40 Front Suspension OCTAVIA

31 - Self-locking hexagon collar nut, 20 Nm 35 - Self-locking hexagon collar nut

+ torque a further 90° (1/4 turn) ♦ up to 05.98: 50 Nm + torque a further
♦ replace each time removed 90° (1/4 turn)
from 06.98: 60 Nm + torque a further
32 - Hexagon bolt 90° (1/4 turn)
♦ replace each time removed ♦ torque not less than 90°
♦ torquing angle tolerance 90° to 120°
33 - Hexagon socket bolt, 10 Nm ♦ replace each time removed

34 - ABS wheel speed sensor 36 - Track rod with track rod end
♦ only on models with ABS ♦ removing and installing ⇒ page 40-
♦ insert with lubricating paste G 000 650 22
(e.g. Wolfrakote Top Paste)
37 - Hexagon bolt, 10 Nm

------------ 40-15.1 ------------ Edition 05.01

S00.5103.61.20
OCTAVIA Front Suspension 40
38 - Wheel bearing 40 - Wheel hub without pulse rotor
♦ pressing out ⇒ from page 40-16 ♦ only on models without ABS
♦ replace, is destroyed when pressed ♦ assignment ⇒ Parts List
out
♦ pressing in ⇒ from page 40-16 41 - Wheel hub with pulse rotor for wheel
♦ replacement part only available as kit speed sensor
“wheel bearing with assembly parts” ♦ without marking for minimum axial
(items 11, 39, 38, 28, 31 and 35) runout
♦ only on models with ABS
39 - Circlip ♦ pressing out ⇒ from page 40-16
♦ ensure properly installed ⇒ from page ♦ pressing in ⇒ from page 40-16
40-16 ♦ pulling off bearing inner race ⇒ from
♦ replace each time removed page 40-16
♦ inspecting lateral runout of pulse ro-
tor ⇒ page 45-61
♦ assignment ⇒ Parts List

Edition 05.01 ------------ 40-15.2 ------------

S00.5103.61.20
40 Front Wheel Suspension OCTAVIA

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 sus-
pension strut and wheel bearing housing.

- Removing and installing suspension strut

and wheel bearing housing ⇒ page 40-21.

------------ 40-16 ------------ Edition 04.03

S00.5103.66.20
OCTAVIA Front Suspension 40

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 ------------ 40-17 ------------

S00.5103.52.20
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 turn-
ing the threaded spindle.

K Press wheel bearing into wheel bearing hous-
ing
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 in-
ner 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 mark-
ing 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 Front Suspension 40

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 ------------ 40-19 ------------

S00.5103.51.20
40 Front Suspension OCTAVIA

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 illustra-

tion, 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 Front Suspension 40

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 ------------ 40-21 ------------

S00.5103.52.20
40 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 cal-

liper. 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-bear-

ing housing.

------------ 40-22 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Suspension 40

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.

!"

#

$ !"

- 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.

$ %

&

Edition 02.01 ------------ 40-23 ------------

S00.5103.60.20
40 Front Wheel Suspension OCTAVIA

Tightening torque:
Suspension strut to suspension 60 Nm
strut dome
Use new nuts!
Coupling rod to suspension strut 90 Nm
Use new nuts!
Steering joint to track control arm 20 Nm + 90°
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 Front Suspension 40

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 manu-
facturer on an axle

5 - Spring disc

6 - Bush
♦ Only on models with heavy-duty sus-
pension (PR No. 1GB). This PR No.
Special tools, testers and aids required is indicated on the vehicle data sticker
in the boot or in the Service Schedule
♦ Wrench insert waf 21 MP 6-427 ⇒ page 00-4

♦ Spring tensioning device, e.g. S 505 501 V 7 - Axial grooved ball bearing
or V.A.G 1752/1
8 - Suspension strut bearing
♦ Suspension strut mount, e.g. V.A.G 1752/2
9 - Collar nut, 60 Nm
♦ Spring holder with protective insert, e.g. ♦ Replace each time removed
V.A.G 1752/4 ♦ Slackening and tightening
⇒ page 40-26

10 - Stop

11 - Hexagon collar nut, self-locking, 60

Nm
♦ Replace each time removed

Edition 06.99 ------------ 40-25 ------------

S00.5103.56.20
40 Front Suspension OCTAVIA

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 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 Front Suspension 40

K Fig. 4 Installing coil spring

- Mount pretensioned screwdriver with tension-

ing 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.

Edition 09.96
S00.5103.51.20
------------

------------
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 fur-
ther than from the top shock absorber closure
(piston rod seal) to the bottom spring retainer
(arrow), the shock absorber is regarded as be-
ing in proper order.

Note:
A slight outflow of oil is advantageous as this
lubricates the seal and thus increases the serv-

ice 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 absorb-
ers are too often regarded as a source of the
noise.

Note:
When dealing with complaints which can be in-
terpreted as a rumbling or snapping noise, it is
essential to first of all carry out a road test to-
gether 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 Front Suspension 40

Inspecting shock absorber without gas pres-

sure

Faulty shock absorbers can be detected when

driving as a result of rumbling noises - as a con-
sequence 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 com-
pressed and/or pulled apart suddenly. There is
an „idle travel“ before the shock absorber be-
gins 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 au-
tomatically 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 re-
used.
♦ Shock absorbers with gas pressure are fit-
ted only to the rear axle.
♦ The gas pressure in the shock absorber im-
proves the noise characteristics and opera-
tion when driving on poor road surfaces.

------------ ------------ Edition 10.98

S00.5103.54.20
OCTAVIA Front Suspension 40

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 af-
ter drilling into, sawing or cutting open the
part. In addition, gas pressure shock absorb-
ers are filled with gas. The gas should be
released from the gas pressure shock ab-
sorbers before disposing of them.
♦ The hydraulic fluids used in shock absorb-
ers 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 hy-
draulic fluids), which are suitable for reproc-
essing, 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 pro-
tective 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 Front Suspension 40

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 ab-
sorbers).

- 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 Front Suspension OCTAVIA

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 dam-
age 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 bear-
ing 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- other-
wise the axle geometry must be checked.

K- Unscrew bolts -1-.

------------ ------------ Edition 10.98

S00.5103.54.20
OCTAVIA Front Suspension 40

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 flex-
ing.

- 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.

- Arrow points in direction of travel.

Edition 06.99 ------------ ------------

S00.5103.56.20

!




,
!

#
+
(








-


)
$*



















5
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&8
'

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-
*
.
0
/
1
40 Front Suspension OCTAVIA

2

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)
3

4
Installing

6
(models fitted with manual and automatic
gearbox)

)
*
Remove any corrosion present in the thread/

*
.
7
spline of the outer joint.

-
0
/1

- Moisten contact surface of twelve-point
nut and also splines and thread of outer
joint with oil and screw on new twelve-
point 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 Front Wheel Suspension 40

- 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 Front Wheel Suspension OCTAVIA

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 ser-

ration
♦ 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
Grease quantities and grade of grease

gearbox

1.6 l/55 kW
(AEE)
02K
1.6 l/74 kW
(AEH, AKL)
02K
1.8 l/92 kW
(AGN)
02J
1.9 l/50 kW
(AGP)
02K
Left/right
drive shaft

Part No.

1 J0 407 271 F
1 J0 407 272 F

1 J0 407 271 Q
1 J0 407 272 AB

357 407 271 R

1 J0 407 272 AC

1 J0 407 271 F
1 J0 407 272 F
∅∅
Outer
joint

mm

81

81

90

81
Front Suspension

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/ Grease

Total
quantity
(g)

80

80

100

80
(g)
of which in:

Joint 1)

40

40

50

40
Joint
boot 2)
(g)

40

40

50

40
Inner
joint

mm

94

94

100

94
Grease

Total
quantity
(g)

80

80

110

80
of which in:

Joint 1)
(g)

60

60

80

60
Joint
boot 2)
(g)

20

20

30

20
40

1.9 l/66 kW 1 J0 407 271 H

(AGR) 1 J0 407 272 90 100 50 50 100 110 80 30
02J
1.9 l/81 kW 1 J0 407 271 H
(AHF) 1 J0 407 272 90 100 50 50 100 110 80 30
02J

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 ------------ 40-38.1 ------------

S00.5103.53.20
40 Front Suspension OCTAVIA

------------ 40-38.2 ------------ Edition 03.97

S00.5103.52.20
OCTAVIA Front Wheel Suspension 40
5 - Joint boot for inner CV joint, ∅ 94 mm 11 - Left drive shaft (solid shaft)
♦ material: Hytrel (Polyelastomere) ♦ assignment ⇒ electronic catalogue of
♦ inspect for tears and chafing points original parts
♦ remove CV joint with drift
♦ fitting location of joint boot for inner 12 - Warm-type clamp
CV joint for left shaft is identical to the ♦ replace
fitting location of the joint boot for the ♦ tighten ⇒ Fig. 9
outer CV joint ∅ 84 mm ⇒ Fig. 12
♦ fitting location of joint boot for inner CV 13 - Joint boot
joint for right shaft is identical to the ♦ material: Hytrel (Polyelastomere)
fitting location of the joint boot for the ♦ inspecting for tears and chafing
outer CV joint ∅ 84 mm ⇒ Fig. 12 points
♦ before assembling coat inner cap with ♦ assignment ⇒ electronic catalogue of
sealant D 454 300 A2 original parts
♦ assignment ⇒ electronic catalogue of ♦ pay attention to different version:
original parts ∅ 84 mm
∅ 90 mm
6 - Joint boot for inner CV joint, ♦ fitting location of joint boot for outer
∅ 100 mm CV joint for left shaft ∅ 90 mm
♦ material: rubber ⇒ Fig. 11
♦ inspect for tears and chafing points ♦ fitting location of joint boot for outer
♦ remove from CV joint with drift CV joint ∅ 90 mm for right shaft de-
♦ fitting location for left shaft ⇒ Fig. 6 termined by the fitting location on the
♦ fitting location for right shaft shaft is identical as ⇒ Fig. 11
⇒ Fig. 7 ♦ fitting location of joint boot for outer
♦ before assembling coat inner cap with CV joint ∅ 84 mm for left shaft
sealant D 454 300 A2 ⇒ Fig. 12
♦ assignment ⇒ electronic catalogue of ♦ fitting location of joint boot for outer
original parts CV joint ∅ 84 mm for right shaft
⇒ Fig. 12
7 - Disc spring
♦ Fitting location ⇒ Fig. 3 14 - Warm-type clamp
♦ replace
8 - Inner CV joint ♦ tighten with tensioning pliers, e.g.
♦ must be replaced completely V.A.G 1682 ⇒ Fig. 8
♦ pressing out ⇒ Fig. 2
♦ pressing on ⇒ Fig. 5 15 - Disc spring
♦ grease ⇒ page 40-62 ♦ fitting location ⇒ Fig. 4
♦ inspecting ⇒ page 40-46
♦ assignment ⇒ electronic catalogue of 16 - Thrust ring
original parts ♦ fitting location ⇒ Fig. 4

9 - Gasket 17 - Circlip
♦ adhesive surface on the inner CV joint ♦ replace
must be free of grease and oil! ♦ insert in the groove on the shaft
♦ replace
♦ pull off protective foil and stick gasket 18 - Outer CV joint
in the housing ♦ must be replaced completely
♦ assignment ⇒ electronic catalogue of ♦ removing ⇒ Fig. 1
original parts ♦ installing: drive onto the shaft with a
plastic hammer until the compressed
10 - Circlip circlip expands
♦ replace ♦ grease ⇒ page 40-62
♦ remove with circlip pliers, ♦ inspecting ⇒ page 40-45
e.g. VW 161 A
♦ assignment ⇒ electronic catalogue of 19 - M8 = 25 Nm, M10 = 35 Nm
original parts
20 - Protective cap

Edition 06.05 ------------ 40-39 ------------

S00.5103.68.20
40 Front Wheel Suspension OCTAVIA

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 Front Wheel Suspension 40
9 - Joint boot for inner CV joint 14 - Fillister head screw with internal ser-
♦ material: Arnitel (Polyelastomere) ration
♦ inspect for tears and chafing points ♦ replace after each disassembly
♦ fitting location for left shaft ⇒ Fig. 13 ♦ initially tighten to 10 Nm, subsequently
♦ fitting location for right shaft tighten crosswise to final torques
⇒ Fig. 13 M 8 = 40 Nm
♦ assignment ⇒ electronic catalogue of M 10 = 70 Nm
original parts ♦ assignment ⇒ electronic catalogue of
original parts
10 - Clamp
♦ replace 15 - Shim
♦ assignment ⇒ electronic catalogue of
11 - Cap original parts
♦ remove from CV joint with drift
♦ before assembling coat sealing surface 16 - Gasket
of cap with sealant D 454 300 A2 ♦ adhesive surface on the inner CV joint
♦ sealing surface must be clean and must be free of grease and oil!
free of grease ♦ replace
♦ pull off protective foil and stick gasket
12 - Inner CV joint in the joint
♦ must be replaced completely ♦ assignment ⇒ electronic catalogue of
♦ pressing out ⇒ Fig. 2 original parts
♦ pressing on ⇒ Fig. 5
♦ grease ⇒ page 40-62 17 - Cap
♦ inspecting ⇒ page 40-46 ♦ remove from CV joint with drift
♦ assignment ⇒ electronic catalogue of ♦ before assembling coat sealing surface
original parts of cap with sealant D 454 300 A2
♦ sealing surface must be clean and
13 - Circlip free of grease
♦ replace
♦ remove with circlip pliers,
e.g. VW 161 A

Edition 06.05 ------------ 40-39.2 ------------

S00.5103.68.20
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 Front Wheel Suspension 40

⊳ Fig. 4 Fitting position of the disc spring

and thrust ring at outer joint (gear-
box 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 (ser-
ration) 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 ------------ 40-41 ------------

S00.5103.68.20
40 Front Wheel Suspension OCTAVIA

⊳ Fig. 7 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 tension-
ing 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 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.

------------ 40-42 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Wheel Suspension 40

- 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 ------------ 40-43 ------------

S00.5103.68.20
40 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

------------ 40-44 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Suspension 40

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 in-
spected 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- Rotate cage until two cage windows (arrow)
are positioned at the joint body.

- Lift out cage with hub.

K- Swivel segment of the hub into the cage win-

dow.

- 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. Ex-
cessive torsional play in the joint is notice-
able 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 Front Wheel Suspension OCTAVIA

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 posi-
tion.

- 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.

⊳- 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.

------------ 40-46 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Suspension 40

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 notice-
able 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 ran-
dom. 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 (ar-
row).
♦ 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.

- Install joint boot ⇒ page 40-42 and further.

------------ 40-48 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Wheel Suspension 40

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 ------------ 40-49 ------------

S00.5103.65.20
40 Front Wheel Suspension OCTAVIA

6 - Fillister head screw with internal ser-

ration
♦ 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

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
Notes: ♦ assignment ⇒ electronic catalogue of
original parts
♦ Assignment of drive shafts
⇒ electronic catalogue of original parts 12 - Cover
♦ Grease joint if necessary, when replacing ♦ is destroyed after every removal
joint boot. ♦ It is not required any more for assem-
bling the drive shaft and is therefore
♦ On tripod joints only apply grease in the joint not available as a spare part
never in the joint boot
13 - Warm-type clamp
1 - Joint boot for inner CV joint ♦ for tripod joint
♦ inspecting for tears and chafing points ♦ always replace
♦ assignment ⇒ electronic catalogue of
original parts 14 - Joint boot for tripod joint
♦ Inspecting for tears and chafing
2 - Warm-type clamp points
♦ replace
♦ tighten ⇒ page 40-42, Fig. 8 15 - Warm-type clamp
♦ for tripod joint
3 - Warm-type clamp ♦ always replace
♦ replace ♦ tighten ⇒ page 40-55, Fig. S40-0107
♦ tighten ⇒ page 40-42, Fig. 9
16 - Disc spring
4 - Drive shaft ♦ fitting location ⇒ page 40-41, Fig. 4
♦ assignment ⇒ electronic catalogue of
original parts

5 - Joint part
♦ grease ⇒ page 40-62
♦ assignment ⇒ electronic catalogue of
original parts

------------ 40-50 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Wheel Suspension 40
17 - Thrust ring 19 - Outer CV joint
♦ fitting location ⇒ page 40-41, Fig. 4 ♦ must be replaced completely
♦ removing ⇒ page 40-40, Fig. 1
18 - Circlip ♦ installing: drive onto the shaft with a
♦ replace plastic hammer until the compressed
♦ insert in the groove on the shaft circlip expands
♦ grease ⇒ page 40-62
♦ inspecting ⇒ page 40-45

Disassembling and assembling Tri-

pod 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 rec-
ommend 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 ------------ 40-51 ------------

S00.5103.68.20
40 Front Suspension OCTAVIA

K- Take O-ring -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 re-
installed in their previous position when as-
sembled, 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 protec-

tive 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 Front Suspension 40

- Insert drive shaft into press.

K- Hold drive shaft tight and press out the tri-

pod 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 protec-

tive jaws.

Note:
Chamfer -arrow- on the tripod star should face
toward the drive shaft. The chamfer is used as
an assembly aid.

- 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.

Edition 12.98 ------------ ------------

S00.5103.55.20
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

- Fit on joint boot.

- Tighten warm-type clamp with pliers.

------------ 40-54 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Wheel Suspension 40

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 spi-
der, the joint part and the grease filling is pre-
vented through this. Furthermore an acciden-
tal 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

7
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Front Wheel Suspension

Servicing drive shaft with inner tri-

pod joint AAR 2000 and outer CV
joint
Special tools, testers and aids required

♦ Thrust plate MP 3-406

♦ Thrust plate MP

♦ Thrust

♦ Thrust

♦
MP

MP

MP

MP
MP
OCTAVIA

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♦

♦ e

♦ T

♦ T

♦ pliers

Grease quality and grease quantity

Notes:
♦ Only use high temperature grease from the
relevant repair kit for filling the inner

⇒ Part
♦ of grease for outer ⇒ page
40-62
♦ of grease for inner
⇒ page 40-62

------------ ------------ Edition 11.02

S00.5103.65.20
OCTAVIA Front Wheel Suspension 40

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: 12 - Drive shaft

♦ assignment ⇒ electronic catalogue of
♦ Assignment of drive shafts original parts
⇒ electronic catalogue of original parts
♦ Grease joint if necessary, when replacing 13 - Warm-type clamp
the joint boot ♦ replace
♦ tighten ⇒ page 40-42, Fig. 9
♦ On tripod joints only apply grease in the joint,
never in the joint boot. 14 - Disc spring
♦ fitting location ⇒ page 40-41, Fig. 4
1 - Joint boot with inner CV joint
♦ inspecting for tears and chafing points 15 - Thrust ring
♦ assignment ⇒ electronic catalogue of ♦ fitting location ⇒ page 40-41, Fig. 4
original parts
16 - Circlip
2 - Warm-type clamp ♦ replace
♦ replace ♦ insert in the groove on the shaft
♦ tighten ⇒ page 40-42, Fig. 8
17 - Outer CV joints
3 - Fillister head screw with internal ser- ♦ must be replaced completely
ration ♦ removing ⇒ page 40-40, Fig. 1
♦ replace after each disassembly ♦ installing: drive onto the shaft with a
♦ initially tighten to 10 Nm, subsequently plastic hammer until the compressed
tighten crosswise to tightening tor- circlip expands
ques ♦ grease ⇒ page 40-62
M 8 = 40 Nm ♦ inspecting ⇒ page 40-45
M 10 = 70 Nm ♦ assignment ⇒ electronic catalogue of
♦ assignment ⇒ electronic catalogue of original parts
original parts

4 - Shim
♦ assignment ⇒ electronic catalogue of
original parts

Edition 06.05 ------------ 40-57 ------------

S00.5103.68.20
40 Front Wheel Suspension OCTAVIA

Disassembling and assembling tri-

pod 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.

⊳- Straighten the metal tabs -arrows- with a

screwdriver and lever off.

------------ 40-58 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Front Suspension 40

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 re-
installed in their previous position when as-
sembled, 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 Front Suspension OCTAVIA

- Insert drive shaft into press.

K- Hold drive shaft tight and press out the tri-

pod 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 Front Wheel Suspension 40

⊳- 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.

- Tighten warm-type clamp with pliers.

Edition 06.05 ------------ 40-61 ------------

S00.5103.68.20
40 Front Wheel Suspension OCTAVIA
Grease quantity

Outer CV joint Total grease Inner CV joint Total grease of which

∅ mm (g) ∅ mm (g)
Distribute evenly into the Joint Joint
joint (g) boot
(g)
81 90 94 (joint)1) 90 45 45
90 110 100 (joint)1) 120 60 60
90 110 108 (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 Rear Suspension 42

Servicing rear suspension -

drum brakes
Removing and installing rear sus-
pension
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 nec-
essary to check the wheel toe of the rear sus-
pension and to align if necessary.

K- Remove bolts -1- with vehicle standing on

its wheels. Jack up vehicle sufficiently, if nec-
essary, 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; Inte-
rior Equipment

K- Slacken adjusting nut -arrow-.

Edition 10.98 ------------ 42-1 ------------

S00.5103.54.20
OCTAVIA

K

K

Note:
Seal lines with plugs.

! "#$%

K

------------ 42-2 ------------

S00.5103.56.20
OCTAVIA Rear Suspension 42

Continued for all models:

- Support rear axle with gearbox lifter and adap-

ter, 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 kid-

ney-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 regu-

lator, 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 30 Nm + 90°

Use new bolts!

Rear axle to bearing bracket 45 Nm + 90°

Use new nuts and bolts!

Bolts attaching brake lines 14 Nm

Edition 04.00 ------------ ------------

S00.5103.58.20
42 Rear Wheel Suspension OCTAVIA

Summary of components of rear axle

Notes: 3 - Brake drum

♦ reset brake before removing the brake
♦ Welding and straightening on axle body and
drum ⇒ page 42-24, Fig. 1
axle studs not allowed.
♦ Always replace the self-locking nuts and 4 - Cap
screws. ♦ replace after each removal
♦ pressing off ⇒ page 24-25,
♦ Tighten pipe screws of the brake lines to
Fig. 2 and 3
14 Nm.
♦ 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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OCTAVIA 42

Rear Suspension

1 rear
♦ After installing, inspect total wheel toe
♦ Replace each time removed of rear axle, and align if necessary
♦ Do not slacken if possible for remov-
6 hub and ing rear axle

♦ Only on models with ABS 16
♦ Wheel bearing and wheel hub are in-

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stalled together in a housing 1 Bonded rubber bush

♦ This wheel bearing/wheel hub unit re- ♦ Removing and installing ⇒ page 42-7

quires no maintenance and is free of
play. It is not possible to carry out any 18 t
setting or servicing work!
♦ Removing and installing ⇒ from page 19 B pressure
42-23 ♦ Only on models without ABS
♦ Inspecting and setting ⇒ page 47-16
hub
20 H 20
♦ Only on models without ABS
♦ Wheel bearing and wheel hub are in- 21 20
stalled together in a housing
♦ This wheel bearing/wheel hub unit re- 22 20 and torque a
quires no maintenance and is free of ther
play. It is not possible to carry out any ♦ Replace each time removed
setting or servicing work!
♦ Removing and installing ⇒ from page 23
42-23
24
8 + and torque a ♦ Contact surface and threaded holes
ther 60° for axle journal must be free of paint
♦ Replace each time removed and dirt

9 shoe 2 ABS speed sensor

♦ Only on models with ABS
10
♦ Replace 26 8

11 2

12 28
♦ Replace each time removed ♦ Removing and installing
⇒ page 42-10
13 30 and ♦ Inspect for paint damage, touch up
torque a 90° any paint damage
♦ Replace each time removed ♦ Assigning ⇒ Parts List
♦ If thread of welded nut is damaged, ♦ Always replace on both sides of axle
thread can be repaired with Heli-Coil ♦ Fit only coil springs of same manu-
threaded insert. Pay attention to facturer to rear axle
manufacturer’s instructions.
♦ Reworking of thread of welded nut is 29 op base
permissible at not more than 2 bolted ♦ Installing ⇒ Notes, page 42-10
connection points on each side of ve-
hicle. 30 60
♦ Replace each time removed
14 and torque a ♦ Insert from inside of vehicle
ther 90° ♦ When tightening, pay attention to in-
♦ Replace each time removed stallation angle of rear axle to shock
♦ Insert from outside of vehicle absorber ⇒ Fig. 1
♦ When tightening hexagon bolt, axle ♦ Tighten hexagon bolt when vehicle
beam should be horizontal (unladen standing on its wheels and load of
weight condition) about 100 kg in boot

Edition 04.00 ------------ ------------

S00.5103.58.20
OCTAVIA

♦ Replace each time removed

♦ If thread of welded nut is damaged,

thread can be repaired with Heli-Coil
threaded insert. Pay attention to
manufacturer’s instructions.
♦ Reworking of thread of welded nut is
permissible at not more than 1 bolted
connection points on each side of ve-
hicle.

------------ 42-6 ------------

Note:
♦ 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

No provision made for servicing shock absorb-

ers.

♦ Replace each time removed

S00.5103.56.20
OCTAVIA
34 - Brake line

35 - Axle stub
♦ No straightening work permitted!
♦ It is not permitted to re-tap thread.

α
Rear Suspension

36 - Stone chip guard

37 - Element for attaching stone chip guard

K Fig. 1
♦ Included in parts supplied with stone
chip guard

Installation angle of rear axle/shock

absorber

1 - Shock absorber
2 - Track control arm
- approx. 104°
42

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- Unclip brake cables -arrows-.

- Detach clips -2- of brake hose fixture.

- Unscrew hexagon bolt -1- of bonded rubber

bush at both track control arms.

Edition 06.99 ------------ ------------

S00.5103.56.20


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Note:
Place a soft block of wood of about 10 cm be-
tween 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 deterio-
ration in the handling of the car when cor-
nering.

K $

------------ ------------

S00.5103.56.20

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t

Note:
When tightening the hexagon bolt of the bonded
rubber bush, the axle beam must be in horizon-
tal position (unladen weight condition).

Note:
When installing the handbrake cables, pay at-
tention to Fitting location ⇒ page 46-18.

Edition 04.00 ------------ ------------

S00.5103.58.20

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♦ 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 ab-
sorber in order to remove the coil spring.

- Take off wheel trim or pull off cap on light-

alloy 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 light-

alloy 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 al-
ways 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 Rear Suspension 42

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 ------------ 42-11 ------------

S00.5103.54.20
42 Rear Suspension OCTAVIA

Servicing rear suspension -

disc brakes
Removing and installing rear sus-
pension
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 nec-
essary to check the total 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 nec-
essary, 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.

------------ 42-12 ------------ Edition 10.98

S00.5103.54.20




















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Note:
Seal lines with plugs.

K

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Edition 06.99 ------------ ------------

S00.5103.56.20
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OCTAVIA

Notes:

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♦ 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 Rear Wheel Suspension 42

Summary of components of rear axle

Notes: 3 - Brake disc

♦ Welding and straightening on axle body and
4 - Cap
axle studs not allowed.
♦ replace after each removal
♦ Always replace the self-locking nuts and ♦ pressing off ⇒ page 42-29,
screws. Fig. 1 and 2
♦ inserting ⇒ page 42-31, Fig. 8
♦ Tighten pipe screws of the brake lines to
14 Nm.
5 - Self-locking twelve-point nut, 70 Nm
and tighten a further 40°
1 - Wheel bolt, 120 Nm
♦ replace after each removal
2 - Screw, 4 Nm

Edition 06.05 ------------ 42-15 ------------

S00.5103.68.20
OCTAVIA

------------
















♦ Only on models with ABS
♦ Wheel bearing and wheel hub are in-
stalled together in a housing

setting or servicing work!

♦ Removing and installing ⇒ from page
42-28
♦ Always replace complete

------------

♦ This wheel bearing/wheel hub unit re-

quires no maintenance and is free of
play. It is not possible to carry out any
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♦ Replace each time removed

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♦ thread
♦ Replace each time removed thread can repaired
♦ threaded a ttention to
♦
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at not more than
connection on each
4 rear
♦ total toe
rear and 2
♦ not ♦ replaced
rear ♦ and
⇒
♦ ⇒
♦ ⇒
♦
♦ and ⇒
⇒ ♦
to rear
20 and a
Note:
♦ Replace each time removed
No provision made for servicing shock absorb-
ers.
8
28
speed sensor
♦ Replace each time removed
♦ on
2
20 8
♦
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♦ Replace each time removed
♦ ⇒
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4
♦
♦ coil
♦ ⇒

24
♦ ⇒

Edition 04.00 ------------ ------------

S00.5103.58.20






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1 - Shock absorber
2 - Track control arm
α - 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
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Note:
Place a soft block of wood of about 10 cm be-
tween 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 deterio-
ration in the handling of the car when cor-
nering.

K $

Edition 06.99 ------------ ------------

S00.5103.56.20

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Note:
When tightening the hexagon bolt of the bonded
rubber bush, the axle beam must be in horizon-
tal position (unladen weight condition).

Note:
When installing the handbrake cables, pay at-
tention to Fitting location ⇒ page 46-18.

------------ ------------

S00.5103.58.20





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and a

t 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 ab-
sorber in order to remove the coil spring.

- Take off wheel trim or pull off cap on light-

alloy 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 light-

alloy 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 al-
ways point toward the middle of the vehicle.

K- Start of spring -arrow- must be positioned at

the stop of the bottom base.

Edition 06.99 ------------ ------------

S00.5103.56.20
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 Rear Wheel Suspension 42
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

5 - Wheel hub with wheel bearing and

pulse rotor
♦ only on vehicles with ABS
♦ wheel hub and wheel bearing are fit-
ted 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 re-
moval
♦ Remove wheel hub with wheel bear-
ing from axle stud ⇒ Fig. 4
Special tools, testers and aids required ♦ Pull the wheel hub with wheel bearing
onto the axle stud ⇒ Fig. 6 and 7
♦ Drive bushing MP 3-427
Notes:
♦ Assembly device MP 5-403 ♦ After pulling off the wheel hub with the
wheel bearing, the inner ring of the bearing
♦ Hub cover puller MP 5-404 remains on the axle stud, then pull off the
old inner ring of the bearing before pressing
♦ Puller Kukko 20/2 on the new wheel hub with wheel bearing
⇒ Fig. 5.
♦ Puller Kukko 204/1
♦ 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.

Edition 06.05 ------------ 42-23 ------------

S00.5103.68.20
42 Rear Suspension OCTAVIA

6 - Wheel hub with wheel bearing without

pulse rotor
♦ Only on models without ABS
♦ Wheel bearing and wheel hub are in-
stalled together in a housing
♦ This wheel bearing/wheel hub unit re-
quires no maintenance and is free of
play. It is not possible to carry out set-
ting 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 straight-
ening work
♦ It is not permitted to re-tap the thread

8 - Axle beam

K Fig. 1 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, Remov-

ing and installing rear brakes.

------------ 42-24 ------------ Edition 10.98

S00.5103.54.20
OCTAVIA Rear Suspension 42

K Fig. 2 Pressing off cap

- Detach cap from its seat by striking with light

blows on the claw.

K Fig. 3 Pressing off cap

Edition 10.98 ------------ ------------

S00.5103.54.20
42 Rear Suspension OCTAVIA

K Fig. 4 Pulling wheel hub and wheel bear-

ing 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 bear-

ing 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


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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

7 - Wheel hub with wheel bearing and

pulse rotor
♦ only on vehicles with ABS
♦ wheel hub and wheel bearing are fit-
ted 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 re-
moval
♦ Remove wheel hub with wheel bear-
ing from axle stud ⇒ Fig. 4
♦ Pull the wheel hub with wheel bearing
Special tools, testers and aids required onto the axle stud ⇒ Fig. 6 and 7

♦ Drive bushing MP 3-427 Notes:

♦ After pulling off the wheel hub with the
♦ Assembly device MP 5-403 wheel bearing, the inner ring of the bearing
remains on the axle stud, then pull off the
♦ Hub cover puller MP 5-404 old inner ring of the bearing before pressing
on the new wheel hub with wheel bearing
♦ Puller Kukko 20/2 ⇒ Fig. 5.
♦ Puller Kukko 204/1 ♦ The inner ring of the bearing is a component
part of the new wheel hub with wheel bearing
1 - Brake disc, internally ventilated and is therefore not pressed on separately.
♦ assignment ⇒ electronic catalogue of
original parts 8 - Axle body
♦ removing and installing
2 - Wheel bolt, 120 Nm ⇒ page 42-12

3 - Screw, 4 Nm 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 Rear Suspension 42

K Fig. 1 Pressing off cap

- Detach cap from the seat by applying light

blows to the claw.

K Fig. 2 Pressing off cap

Edition 09.96 ------------ 42-29 ------------

S00.5103.51.20
42 Rear Wheel Suspension OCTAVIA

⊳ Fig. 6 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

Rear Suspension

42

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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.

K in

Notes:
♦
♦

- Install brake caliper and tighten hexagon

socket bolts fully to 65 Nm.

Edition 04.00 ------------ ------------

S00.5103.58.20
42 Rear Suspension OCTAVIA

Servicing rear suspension (4x4 models)

Overview of rear suspension for 4x4 models

Notes: 2 - Final drive

♦ Removing and installing
♦ Always replace self-locking nuts and bolts.
⇒ 5-Speed Manual Gearbox 02C 4x4; Repair
♦ Always replace nuts and bolts which have signs of Group 39; Removing and installing rear fi-
surface rust. nal drive
♦ Servicing
1 - Subframe For technical reasons it has not yet been
♦ Assembly overview ⇒ page 42-60 possible to prepare the repair description.
It will be published in a subsequent sup-
plement.
At present, if any faults exist at the rear
final drive, it should be replaced complete.

------------ 42-32 ------------ Edition 11.99

S00.5103.57.20
OCTAVIA Rear Wheel Suspension 42
3 - Cross member 10 - Spacer
♦ only on vehicles with rough road sus-
4 - Clamp pension
♦ on vehicles without spacer this must
5 - Anti-roll bar not be installed subsequently
♦ if necessary eliminate paint damage ♦ summary of components
and carry out protection against cor- ⇒ page 42-33
rosion
11 - Stop buffer
6 - Pressurized shock absorber ♦ summary of components
♦ summary of components ⇒ page 42-33
⇒ page 42-33
♦ removing and installing 12 - Helical spring
⇒ page 42-39 ♦ summary of components
⇒ page 42-33
7 - Wheel bearing
♦ pressing in and out ⇒ page 42-44 13 - Propshaft
♦ removing and installing
8 - Trailing arm ⇒ 5-speed Manual Gearbox 02C Four-wheel
♦ summary of components drive; epair Group 39; Removing and install-
⇒ page 42-41 ing propshaft
♦ repairing
9 - Suspension arm ⇒ 5-speed Manual Gearbox 02C Four-wheel
♦ summary of components drive; Repair Group 39; Repairing prop-
⇒ page 42-41 shaft

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 absorb-
ers 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 ------------ 42-33 ------------

S00.5103.68.20
42 Rear Wheel Suspension OCTAVIA

11 - Stop buffer with positioning pin

♦ as of 08.99
♦ the correct fitting position is deter-
mined 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 absorb-
ers of the same make

13 - Base

14 - Thread in the frame side rail

♦ in the event of damage of the thread
8 - Trailing arm of the welded nuts in the trailing arm,
♦ Thread -arrow A- for support of the the thread can be repaired with the
stop buffer -Pos. 10- is no longer ap- Heli-Coil-Thread kit
plicable as of 08.99 ♦ reworking the thread of the welded
♦ in case the stop buffer -Pos. 11- is nuts is allowed on two permissible
installed in the trailing arm before the screw points per vehicle side
manufacturing date 08.99 the thread ♦ pay attention to installation instruc-
-arrow A- is bored out to ∅ 10.5 mm tions of the manufacturer

9 - Spacer 15 - Thread in the cross arm

♦ only on vehicles with rough road sus- ♦ in the event of damage of the thread
pension of the welded nuts in the trailing arm,
♦ on vehicles without spacer, it must not the thread can be repaired with the
be installed subsequently Heli-Coil-Thread kit
♦ pay attention to installation instruc-
10 - Stop buffer with threaded pin, 10 Nm tions of the manufacturer
♦ no longer inserted as of 08.99
♦ stop buffer -Pos. 11- is supplied as
spare part

------------ 42-34 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Rear Suspension 42

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 instal-
lation of the coil springs.
♦ Very high forces are produced when
tensioning the coil springs. For this reason,
it is important to closely observe the follow-
ing 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- 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.

Edition 11.99 ------------ 42-35 ------------

S00.5103.57.20
OCTAVIA

K

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Note:
Do not use an impact screwdriver or similar for
tensioning the coil spring.

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It is essential to end the tensioning device once
the spring coils touch.

------------ ------------

S00.5103.57.20
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positioned at spring
just position, necessary.

Notes:
♦ Do not use an impact screwdriver or similar
for tensioning or coil
♦ It is essential to end t tensioning device
once spring coils

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Edition 11.99 ------------ ------------

S00.5103.57.20
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: 9
K Models without stop on bump stop:

; 5
The start of the spring coil -3- must be in the 9
o’clock (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 posi-

tioned against the stop -arrow-.
1 - Coil spring
2 - Bump stop without stop for coil spring
F - Direction of travel

Notes:
♦
i
♦

- Release the tension of the coil spring by turn-

ing 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 Rear Suspension 42

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

- 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 neces-

sary.

Edition 11.99 ------------ ------------

S00.5103.57.20
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S00.5103.57.20
OCTAVIA Rear Wheel Suspension 42
Summary of components - trailing arm and suspension arm

Notes: 1 - Fillister head screw with internal ser-

ration, 40 Nm
♦ Never load the wheel-bearing, if the drive
♦ replace after each removal
shaft was removed!
♦ initially tighten to 10 Nm, subsequently
♦ In case the vehicle is placed onto its wheels tighten crosswise to final torques
and moved, temporarily the outer joint of a
drive shaft must be inserted. 2 - Shim
♦ Welding and straightening work is not al-
lowed on the bearing and wheel control com-
ponents of the front wheel suspension.
♦ Always replace self-locking nuts.
♦ Always replace corroded screws/nuts.

Edition 06.05 ------------ 42-41 ------------

S00.5103.68.20
42 Rear Wheel Suspension OCTAVIA

3 - Assembly carrier 6 - Tighten screw 70 Nm and 90°

♦ removing and installing ♦ M 12 x 1.5 x 75
⇒ page 42-61 ♦ replace after each removal

4 - Drive shaft with inner CV joint 7 - Top suspension arm

♦ removing and installing ♦ removing and installing
⇒ page 42-72 ⇒ page 42-58
♦ repairing ⇒ page 42-75 ♦ different versions, assignment
⇒ electronic catalogue of original
5 - Tighten screw 70 Nm and 90° parts
♦ 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 Rear Wheel Suspension 42
10 - Brake carrier with brake caliper 24 - Rubber metal bearing
♦ repairing ⇒ page 46-24 ♦ for trailing arm
♦ removing and installing brake pads ♦ removing and installing
⇒ page 46-26 ⇒ page 42-50

11 - Screw, 10 Nm 25 - Trailing arm

♦ removing and installing
12 - Self-locking twelve-point nut ⇒ page 42-54
♦ tightening ⇒ page 42-74 ♦ Thread -arrow A- for support of the
♦ replace after each removal stop buffer -Pos. 29- is no longer ap-
plicable as of 08.99
13 - Screw, 4 Nm ♦ in case the stop buffer -Pos. 30- is
installed in the trailing arm before the
14 - Brake disc manufacturing date 08.99 the thread
♦ assignment ⇒ electronic catalogue of -arrow A- is bored out to ∅ 10.5 mm
original parts
26 - Screw 75 Nm
15 - Brake disc, internally ventilated ♦ replace after each removal
♦ assignment ⇒ electronic catalogue of
original parts 27 - Mount for rear axle
♦ check the overall tracking of the rear
16 - Wheel hub with pulse rotor for speed axle after installation and take the
sensor mean as necessary
♦ pulse rotor is welded to the wheel ♦ the track can be correct by moving the
hub mount
♦ inspect axial run-out of pulse rotor
⇒ page 45-61 28 - Spacer
♦ pressing in and out ⇒ page 42-44 ♦ only on vehicles with rough road sus-
pension
17 - Circlip ♦ on vehicles without spacer this must
♦ replace after each removal not be installed subsequently
♦ check for firm seating
29 - Stop buffer with threaded pin, 10 Nm
18 - Wheel bearing ♦ no longer inserted as of 08.99
♦ pressing in and out ⇒ page 42-44 ♦ stop buffer -Pos. 30- is supplied as
♦ replace, is destroyed when pressing spare part
out
♦ spare part supplied only as kit „wheel 30 - Stop buffer with positioning pin
bearing with assembly parts“ (with ♦ as of 08.99
Pos. 12, 17) ♦ the correct fitting position is deter-
mined by the positioning pin
19 - Cover plate ♦ the positioning pin must be removed
on the bottom side when used for
20 - Nut, self-locking vehicles manufactured before 08.99
♦ replace after each removal ♦ the start of the spring coil must lie
against the leg -arrow-
21 - Bottom suspension arm ♦ fitting position of helical spring ⇒ page
♦ removing and installing 42-38 and page 42-39
⇒ page 42-58
♦ different versions, assignment 31 - Speed sensor
⇒ electronic catalogue of original ♦ removing and installing
parts ⇒ page 45-82
♦ insert with solid lubricant paste G 000
22 - Guide joint 650 (e.g. Wolfrakote Top Paste)
♦ removing and installing
⇒ page 42-52 32 - Allen screw, 8 Nm

23 - Screw, 90 Nm 33 - Flange shaft of rear axle gearbox

♦ replace after each removal
♦ insert from the vehicle outside

Edition 06.05 ------------ 42-43 ------------

S00.5103.68.20

♦ 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:

OCTAVIA

♦ 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

- Raise vehicle.

- Take off wheel.

- Remove drive shaft ⇒ page 42-72.

------------ 42-44 ------------

S00.5103.57.20
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Place gearbox lift with attachment below, e.g.
V.A.G 1383/A with V.A.G 1359/2 (risk of acci-
dent from parts dropping off when wheel hub
pressed out).

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♦ Replace circlip each time removed.
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The collar -arrow- of the thrust piece -4- must
be pointing toward the special nut -3-.

------------ ------------

S00.5103.57.20
OCTAVIA Rear Wheel Suspension 42

- 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 I - 10 Nm

crosswise in 2 steps II - 40 Nm
(I and II)
Use new screws!

Wheel screw 120 Nm

Nut to wheel hub

Always use new nut!

Tightening torque ⇒ page 42-74

Edition 06.05 ------------ 42-49 ------------

S00.5103.68.20

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♦ Assembly device MP 5-401

♦ Assembly device MP 5-402

♦ Assembly device T10030

♦ Assembly device T30016

-
Raise vehicle.

Take off wheel.

OCTAVIA

K- Remove coil spring -1- ⇒ page 42-35.

- Unbolt bracket for brake line -2- from trailing

arm.

- Unclip brake line from bracket.

K- Mark the installation position of the bearing

bracket at the body -arrows-.

- Unbolt the bearing bracket from the body.

------------ ------------

S00.5103.57.20
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Edition 11.99 ------------ ------------

S00.5103.57.20
42 Rear Wheel Suspension OCTAVIA

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 Rear Wheel Suspension 42

- 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 spin-

dle.

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.

⊳- 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 mid-

dle in the support of the trailing arm.

- If this is not the case, correct the fitting posi-

tion of the guide joint accordingly.

- Install bottom suspension arm

⇒ page 42-58.

- Install the wheel.

- Lower the vehicle.

Edition 06.05 ------------ 42-53 ------------

S00.5103.68.20
42 Rear Wheel Suspension OCTAVIA

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 car-

rier.

- 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-.

------------ 42-53.1 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Rear Wheel Suspension 42

⊳- 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 spin-

dle.

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 ------------ 42-53.2 ------------

S00.5103.68.20
42 Rear Wheel Suspension OCTAVIA

⊳- 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 mid-

dle in the support of the trailing arm.

- If this is not the case, correct the fitting posi-

tion 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.

⊳- Remove helical spring -1- ⇒ page 42-35.

------------ 42-54 ------------ Edition 06.05

S00.5103.68.20


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Notes:
♦ If the trailing arm is replaced, use the exist-
ing track control arm.
♦ The installation position of the bearing
bracket must then be set as described on
page 42-57.

installation position
to trailing

K

⇒

⇒

installing, and
toe on axle stand, and set
essary ⇒ page 44-1.

Edition 11.99 ------------ ------------

S00.5103.57.20
42 Rear Wheel Suspension OCTAVIA
Tightening torques:

Brake carrier with brake calliper to 65 Nm

trailing arm

Bracket to trailing arm 90 Nm

Bracket to body 75 Nm

Suspension arm to trailing arm 70 Nm + 90°

Use new screws and nuts!

Shock absorber to trailing arm 110 Nm

Vehicle must be standing on its
wheels and loaded with one person
on the rear seat.

Tighten drive shaft to flange shaft M8 I - 10 Nm

crosswise in 2 steps (I and II) II - 40 Nm
Use new screws!

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 suspen-

sion 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

- 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.

------------ 42-58 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Rear Wheel Suspension 42

⊳- 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 car-

rier.

- 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:

Suspension arm to trailing arm 70 Nm + 90°

Use new screws and nuts!

Suspension arm to assembly carrier 70 Nm + 90°

Use new screws and nuts!

Edition 06.05 ------------ 42-59 ------------

S00.5103.68.20
42 Rear Wheel Suspension OCTAVIA

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.

⊳- Unscrew screw -1- from the assembly car-

rier.

- 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-.

------------ 42-59.1 ------------ Edition 06.05

S00.5103.68.20
OCTAVIA Rear Wheel Suspension 42

⊳- 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:

Suspension arm to trailing arm 70 Nm + 90°

Use new screws and nuts!

Suspension arm to assembly carrier 70 Nm + 90°

Use new screws and nuts!

Assembly carrier to body 110 Nm + 90°

Use new screw!

Edition 06.05 ------------ 42-59.2 ------------

S00.5103.68.20