Skoda Octavia 1 98-10

Chassis - Specified values
Nominal values front axle
Spring strut type axle (front- and four-wheel drive)

Standard Sport chassis 1)2) Rough road
chassis 1) suspension 3)
Chassis G06 G20 1GA G35 G04 1GB
G12 G30 1GG G85 G07 1GW
G13 G31 1GE G34
G14 G32 1GH G39
G15 G33 G40
0 10' 0 10' 0 10'
Overall track -adjustable-
Camber4) - 30' 30' - 33' 30' - 16' 30'

- 0 25' 30' 5)7) - -
- 0 28' 30' 1) - -
30' 30' 30'
Max. difference of the caster angles between left and
right side
Toe difference angle on turns of 20 of inside wheel - 1 30' 20' 1 31' 20' 1 27' 20'
not adjustable-
Toe difference angle on turns at full lock of inside 6 35' 6 40' 6 35'
wheel -not adjustable-
40 39 45' 40 45'
Max. wheel lock angle -not adjustable-
Caster angle -not adjustable- 7 40' 30' 8) 7 50' 30' 8) 7 15' 30' 8)
7 40' +30', 7 50' +30', 7 15' +30', -60' 9)
-60' 9) -60' 9)
8 23' 30' 5) - -
8 30' 6)7) - -
Max. difference between left and right side 30' 30' 30'
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water
reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
Not valid for Octavia 4x4
2)
Values are also valid for Octavia RS vehicles
3)
Values are also valid for Octavia 4x4 vehicles
4)
It is possible to adjust the camber by shifting the assembly carrier. Note: The screws and washers of the
assembly carrier must always be replaced! After carrying out corrections of steering geometry, inspect position
of steering wheel and alter to correct position, if necessary.
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
6)
Only Service Mobil (Octavia Combi 1.9 ltr./81 kW SLX)
7)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX)
8)
up to MY 2000
9)
as of MY 2001
Specified values rear axle - front-wheel drive
Twist-beam rear axle

Standard suspension Sport chassis 1) Rough road suspension
Chassis
PR Nos. are not displayed on the vehicle data sticker. The allocation of the adjusting
values to the relevant running gear occurs via the PR No. of the front axle damping.
Overall track -not 20' 10' 30' 10' 15' 10'
adjustable-2) 30' 15' 4)
- -
5)
25' 15' - -
6)
Camber -not adjustable- - 1 36' 20' - - 1 36' 20' 6)
- 1 27' 20' 7) - 1 27' 20' 7)
- 1 27' 20'
- 1 43' 20' 4) - -
- 1 35' 20' 5) - -
Max. difference between 30' 30' 30'
left and right side
Max. misalignment of 20' 20' 20'
the rear axle3)
1)
Values are also valid for Octavia RS vehicles
2)
The mean of the individual track values can be taken by moving the mounting brackets
3)
The mean value of the misalignment can be taken by moving the rear axle body
4)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX, Octavia Combi 1.9 ltr./81 kW SLX)
6)
up to 11.96
7)
as of 12.96
Specified values rear axle - four-wheel drive
Twist-beam rear axle

Rough road suspension
Chassis
PR Nos. are not displayed on the vehicle data sticker. The allocation of the adjusting
values to the relevant running gear occurs via the PR No. of the front axle damping.
Overall track -not - - 15' 10'
adjustable-1)
Camber -not adjustable- - - -30' 20'
Max. difference between - - 30'
left and right side
Max. misalignment of the - - 20'
rear axle2)
1)
The mean of the individual track values of the rear axle can be taken by moving the mounting brackets
2)
The running direction of the rear axle can be corrected by moving the mounting brackets
Nominal values rear axle
Chassis denominations with PR numbers
Different chassis are offered as additional equipment. These chassis are identified by PR numbers.
The type of chassis is identified by a chassis PR number on the vehicle data sticker.
The vehicle data sticker is located at the rear left on the luggage compartment floor and in the Service
Schedule.
Example of a vehicle data sticker

In this example the vehicle is fitted with a standard damping
running gear 1GA -arrow-.
Steering
Model All
Type of steering 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
Overall ratio of the steering 15,60
Lubricant for gear racks Fluid grease for steering gear
TL 733
N 052 733 00
Part No.: AOF 063 000 04
(e.g. DEA ORNA F6 EPO)
Filling weight (g) 23 to 27
Maximum clearance between pressure plate and cover (mm): 0,05 to 0,1
Perm. axial force for the displacement of the gear rack (N) 250
Rotating force of the track rods from the rest position (N) 1 to 3,5
Denomination of the hydraulic oil 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 (I) 0,7 ... 0.9 Itr.
Brake variants and their assignment
Engine litre/kW 1,4/44; 1,4/55 1,6/55 1,6/74; 1,6/75 1.9/50

SDI
S = Manual gearbox
S - S - S A S -
A = Automatic gearbox
Master brake cylinder - mm 23,81
Brake servo unit - Inch Left-hand drive with and without ABS 10'' 8,5
right-hand drive with and without ABS: 7''/8''- 8,5
tandem
t Front disc brake:
Front brake caliper 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 supporting mm 2,0
plate
t Rear disc brake:
Rear brake caliper, piston - mm 41,0
Rear brake disc - mm 239,0
plate
t Drum brake
Brake drum - mm 230,0
Brake drum - maximum diameter mm 231,0
Wheel-brake cylinder 1) - mm 20,64 20,64 20,64 19,05 19,05 4)
Wheel-brake cylinder 2) - mm 20,64 20,64 20,64 20,64 20,64
Brake pad, width mm 32,0
Pad thickness without supporting shoe mm 5,5
shoe
1)
Vehicles without ABS
2)
Vehicles with ABS
3)
Not valid for Taxi vehicles (identification F4E)
4)
For Octavia Combi: 20.64
Engine litre/kW 1,8/132 1,9/74 1,9/96

S = Manual gearbox
S - S - S -
Brake servo unit - Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''- tandem
t Front disc brake:
Front brake caliper FS-III 3)
Front brake caliper, piston - mm 54,0
Front brake disc - mm 256,0
Minimum thickness without supporting plate mm 2,0
t Rear disc brake:
Rear brake caliper, piston - mm 41,0
Rear brake disc - mm 239,0
Minimum thickness without supporting plate mm 2,0
t Drum brake
Brake drum - mm
Brake drum - maximum diameter mm
Wheel-brake cylinder 1) - mm
Wheel-brake cylinder 2) - mm
Lining thickness mm
Pad thickness without supporting shoe mm
Minimum thickness without supporting shoe mm
1)
2)
Vehicles with ABS
Engine litre/kW 1.9/66 TDI 1.9/81 TDI 1,8/92; 2,0/85 (82) 1,8/110
S = Manual gearbox
S A S - S A S A
Brake servo unit - Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''-
tandem
t Front disc brake:
Front brake caliper FS-III 3)5) FN 3 4)
Front brake caliper, piston - mm 54,0 54,0
Front brake disc - mm 280,0 288,0
Brake disc, thickness mm 22,0 25,0
Brake disc, minimum thickness mm 19,0 23,0
Pad thickness with supporting plate mm 19,5 19,5
Minimum thickness without supporting mm 2,0 2,0
plate
t Rear disc brake:
Rear brake caliper, piston - mm 38,0 8)
41,0 9)
Rear brake disc - mm 232,0 6) 232,0
239,0 7) 239,0 7)
plate
t Drum brake
Brake drum - mm 230,0
Brake drum - maximum diameter mm 231,0
Wheel-brake cylinder 1) - mm 20,64
Wheel-brake cylinder 2) - mm 20,64 20,64
Brake pad, width mm 32,0
Pad thickness without supporting shoe mm 5,5
shoe
1)
2)
Vehicles with ABS
3)
Not valid for Taxi vehicles (identification F4E)
4)
For Taxi vehicles (F4E) also 1.9/66; 2.0/85; 1.9/81
5)
For Taxi vehicles (F4E) also 1.4/44; 1.4/55; 1.6/55; 1.6/74; 1.6/75; 1.9/50
6)
Vehicles with ESP
7)
vehicles with four-wheel drive
8)
up to 07.98
9)
as of 08.98
Brake fluid
Classification N 052 766 ZO (USA standard FMVSS 571.116 DOT 4)

VW 501 14
Capacity 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
Change brake fluid - every 2 years
Wheels, Tyres
Wheel rims:
t Bolt hole circle diameter: 100 mm
t Centre hole diameter: 57 mm
t 5-hole fixing
t Tyre inflation pressures BookletOctavia I as well as sticker on the fuel-tank cap
Note
Only tyres of the same size and type may be fitted to the vehicle, however the same brand and tread pattern
t must always be fitted to wheels on the same axle. It is exceptionally allowed to use a different tyre
temporarily in the event of breakdown. Take into account a change in driving and braking behaviour.
t Use wheel bolts with spherical collar and a thread of M14 x 1.5 - tightening torque: 120 Nm.
t Only use authorised rims on the relevant vehicle.
When replacing rims always use wheel bolts that belong to these rims (different length and spherical cap
t
shape).
t Also observe the national legislation.
If winter tyres are used with a lower speed rating than the maximum permissible driving speed, it has to be
t pointed out with a sticker providing an additional note which must be fixed in the field of vision of the
driver.
The information given on the sticker determines the maximum permissible driving speed for the winter tyres
t
fitted, which must not be exceeded during the operation of the vehicle.
The note on the sticker can be replaced with the system installed in the vehicle for life (for example the
t
onboard computer) Operating instructions.
On vehicles with the tyre pressure inspection system, it must be adapted again after changing one or several
t
wheels Operating instructions.
Caution
Tyres that are more than 6 years old must only be used in case of emergency and while driving very carefully.
Engine Wheel size 1) Light-alloy rim Steel rim Offset (mm) Snow chains permitted
yes no
175/80 R14 88 T, H - 6J x 14 H2 38 X -
195/65 R15 91 T, H, V 6J x 15 H2 6J x 15 H2 38 X -
1.4 ltr./44kW 43 - X
1.4 ltr./55kW 205/60 R15 91 H 6.5J x 15 H2 -
1.6 ltr./55 kW
1.9 ltr./50 kW 205/55 R16 91 H 6.5J x 16 H2 - 42 - X
205/55 R16 91 W 5,5J x 16 H2 - 36 X -
1.6ltr./74 kW 175/80 R14 88 H - 6J x 14 H2 38 X -

1.6 ltr./75 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 6.5J x 15 H2 - 43 - X
205/55 R16 91 H 6.5J x 16 H2 - 42 - X
205/55 R16 91 W 5,5J x 16 H2 - 36 X -
2.0 ltr./85 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 6.5J x 15 H2 - 43 - X
205/55 R16 91 H 6.5J x 16 H2 - 42 - X
205/55 R16 91 W 5,5J x 16 H2 - 36 X -
1,8 Itr./92 kW 195/65 R15 91 H, V 6J x15 H2 6Jx15 H2 38 X -
205/60 R15 91 H, V 6.5J x 15H2 - 43 - X
205/55 R16 91 H, V, W 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.8 ltr./110 kW 195/65 R15 91 V 6J x 15 H2 6Jx15 H2 38 X -
205/55 R16 91 V, W 6.5J x 16H2 - 42 - X
205/60 R15 91 V 6.5J x 15H2 - 43 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.8 ltr./132 kW 205/55 R16 91 W 6.5J x 16H2 6.5Jx16H2 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
205/50R17 89W2) 7J x 17 H2 - 38 X -
1.9 ltr./66 kW TDI 195/65 R15 91 T, H, V 6J x15 H2 6Jx15 H2 38 X -
205/60 R15 91 H 6.5J x 15H2 - 43 - X
205/55 R16 91 H 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.9 Itr./74 kW PDi 195/65 R15 91 V 6J x 15 H2 6Jx15 H2 38 X -
205/60 R15 91 V 6.5J x 15H2 - 43 - X
205/55 R16 91 V 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.9 ltr./81 kW TDI 195/65 R15 91 H, V 6J x 15 H2 6Jx15 H2 38 X -
205/60 R15 91 H 6.5J x 15H2 - 43 - X
205/55 R16 91 H, V, W 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.9 Itr./96 kW PDi 195/65 R15 91 V 6J x 15 H2 6Jx15 H2 38 X -
205/60 R15 91 V 6.5J x 15H2 - 43 - X
205/55 R16 91 V, W 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1)
Tyre inflation pressures BookletOctavia
2)
Not valid for Octavia Combi RS
Load rating-indexes (Load index): 88 = 560 kg 91 = 615 kg

89 = 580 kg
Speed symbols: T =190km/h H = 210km/h
V = 240 km/h W = 270 km/h
Tyre legend
Marking e.g. 175/80 R14 88 T Meaning
175/80 Tyre width (mm) section ratio between height - width (%)
R Tyre type (radial)
14 Rim diameter (inch)
88 Load rating-index
T Speed symbol
Production date
DOT...394 Manufactured during week 39 of 1994
( = denomination of the decade 1990...1999)
DOT...0300 Manufactured during week 3 of 2000
+ 03 = 3rd calendar week, 00 = year 2000)
Repairing front wheel suspension
I - Removing and installing assembly carrier, anti-roll bar,

track control arm Chapter
II - Removing and installing wheel bearing, suspension strut,
drive shaft, brake Chapter
l - Summary of components assembly carrier, anti-roll
bar, track control arm
Note
When moving vehicles with drive shaft removed, it is

advisable to install an external joint instead of the drive
t
shaft and tighten with a torque of 50 Nm otherwise the
wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing
t
and wheel control components of the wheel suspension.
t Self-locking nuts must always be replaced.
t Always replace corroded self-locking nuts and screws.
1- track control arm

t removing and installing Chapter
t Oblong holes are not intended for camber adjustment!
2- 15 Nm + 90
3- Coupling rod
t coupling rods of the same version must be present on one axle
t Assignment Electronic Catalogue of Original Parts
4- 15 Nm + 90
t replace after each removal
5- Coupling rod
t only for anti-roll bars with a diameter of 23 mm
t replace with steel version
t coupling rods of the same version must be present on one axle
6- Front bearing for track control arm
t pressing in and pressing out Chapter
7- 70 Nm + 90
8- Pendulum support
9- 40 Nm + 90
10 - 40 Nm + 90
11 - 20 Nm + 90
12 - Assembly carrier
t The repair of the thread for the screwed connection of the front track control arm is not permissible!
13 - Self-locking nut
t M10 - 15 Nm + 90
t M12 - 90 Nm
14 - Anti-roll bar
t to remove and install lower assembly carrier
15 - Rubber bearing
16 - 25 Nm
17 - Clamp
18 - Coupling rod
t mount the spherical head with the long joint stub -A- (top) to the spring cap
t mount the spherical head with the short joint stub -B- (bottom) to the anti-roll bar
19 - Nut, 90 Nm
20 - Rubber-metal bearing
22 - 100 Nm + 90
23 - Rear bearing for track control arm
t Fitting position Anchor
t pressing in and pressing out Anchor
24 - 100 Nm + 90
25 - 70 Nm + 90
26 - Lock washer
27 - 20 Nm + 90
28 - Steering joint
t check Chapter
t Inspect rubber bellows for damage, if necessary replace
t removing and installing only in combination with the wheel bearing housing Chapter
mark fitting position before removal, set in the middle of the oblong hole when replacing the track control
t
arm and check track
29 - 20 Nm + 90
Removing and installing the track control arm

Special tools and workshop equipment required
t Extractor -MP 6-425-
t Supporting device -MP 9-200-
t Torque wrench, e.g. -V.A.G 1756-
Removing
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).
Raise the vehicle until the front axle is free of stress.
Slacken twelve-point nut.
Raise vehicle and remove wheel.
Release twelve-point nut.
Removing noise insulation Engine - Mechanics; Rep. gr.10
Only for vehicles with automatic gearbox:
Insert supporting device -MP 9-200- and support engine/gearbox
in this position.
For all vehicles:
Note
Mark installation position of bolts -1-, otherwise the steering

geometry must be checked.
Release screws -1-.

Push out the drive shaft. To do so position the tool as shown in the
fig.
Note
While pushing out the drive shaft make sure there is sufficient
clearance.
Unscrew screws -3-, if present, at the track control arm.

Screw out screws -1- and -2-.
Remove the track control arm.
Only for vehicles with autom. gearbox
Release screws -4- for pendulum support.
Unscrew screws -5- and -6- for assembly carrier.
Note
Release the screw -1- downwards by slightly pressing the assembly

carrier and take out the wheel-bearing housing.
Install
(Valid for vehicles with manual and automatic gearbox).
Remove possible corrosion in the thread/serration of the outer joint.
Insert track control arm and secure.
Secure assembly carrier.
Moisten the serration of the wheel hub with oil.
Insert outer joint as far as possible into the serration of the wheel
hub.
Screw the steering joint and track control arm with the new screws
in the former positions.

Screw the pendulum support to the gearbox.
If necessary, screw the coupling rod with the track control arm or
with the suspension strut.

Moisten the contact surface of the twelve-point nut as well as the
serration and the thread of the outer joint with oil and screw on new
twelve-point nut as far as possible.
Insert the outer joint into the wheel hub until the outer joint rests in
the wheel bearing.

Install noise insulation Engine, Mechanics; Rep. gr.10.
Attach the wheel.
Lower vehicle, when doing so, ensure that the wheels do not yet
touch the ground.

Use new screws!
If the wheel bearings are loaded through the vehicle's own weight, the
wheel bearing will be initially damaged. This shortens the life of the
wheel bearing.
Depress brake pedal (assistance of second mechanic required).
Tighten new twelve-point nut to 225 Nm and release by 1/2 a turn.
Torque wheel hub a further min. 90.
Tighten twelve-point nut:
Tightening torque:
50 Nm + 60.
Note
The torque wrench is recommended e.g. for tightening the twelve-

point nut -V.A.G 1756-.
Tightening torques:
Assembly carrier to body 100 Nm + 90
t Use new screws!
Steering joint to track control arm 20 Nm + 90
t Use new screws and new lock washer!
Pendulum support to gearbox 40 Nm + 90
t Use new screws!
Coupling rod to track control arm 15 Nm + 90
t Use new screws!
Pressing out and in the bearing for the track control arm
t Pressure plate -MP 3-406-
t Pipe section -MP 3-414-
t Pressure washer -MP 3-456-
t Assembly device -MP 5-402-
t Pressure spindle -MP 6-405-
t Base -MP 6-407-
t Pressure pipe -MP 6-408-
t Workshop press, e.g. -V.A.G 1290 A-
t acid-free lubricant, e.g. -G 294 421-
Press off front bearing for track control arm
Press in front bearing for track control arm

Insert bearing into pipe section -MP 3-414-.
Note
Use acid-free lubricant, e.g. -G 294 421-, when pressing in the

bearing. Under no circumstances use grease or detergent.
Fitting position of rear bearing for track control arm

One of the embossed arrows points to the impression in the track
control arm, the kidney-shaped recess (-arrow A-) in the bearing
points to the centre of the vehicle.
Pressing out and in the rear bearing for the track control arm
Pay attention to the fitting position when pressing in Anchor.
Removing and installing assembly carrier

t Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2-
Removing
Remove wheel trim caps of the front wheels, for light-alloy wheels remove the caps (pull-off hook in tool
kit).
Slacken left and right twelve-point nut.
Raise vehicle and remove wheel.
Unscrew left and right twelve-point nut.
Remove noise insulation Engine - Mechanics; Rep. gr.10.
Note
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.
Release screws -1-.

Press out left and right drive shaft. To do so position the tool as
shown in the fig.

Note
clearance.
Separate left and right track control arm from steering joint.
Swivel out the wheel-bearing housing with the steering joint and
support.
Release screws -1- and -2- and remove pendulum support.

Release screws for power-steering gear -5-.
Unscrew nut -7- for coupling rod from anti-roll bar.
Unscrew screws -6- for exhaust system.
Position the gearbox jack with adapter, e.g. -V.A.G 1383/A- with
-V.A.G. 1359/2-, under the assembly carrier.

Unscrew screws -3- and -4- for assembly carrier.
Lower assembly carrier with gearbox jack.
Note
Ensure that the steering gear loosens from the assembly carrier.
Support steering gear, if necessary clamp with tensioning strap to
the top.
Install
Before inserting the screws for the assembly carrier, position the
steering gear on the assembly carrier and insert the screws for the
steering gear.
The threaded bush -1- must fit in the hole of the assembly carrier.
Further installation occurs in reverse order.
Tightening torques Chapter.
Once the steering gear has been installed it is then important to check
the position of the steering wheel during a test drive.
If the vehicle drifts, a chassis alignment must be performed.
Pressing out and in rubber-metal bearing

t Counterholder -MP 6-410-
t Workshop press, e.g. -V.A.G. 1290A-
t Gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G 1359/2-
t acid-free lubricant, e.g. -G 294 421 A1-.
Pressing out and in the rubber-metal bearings is only possible after removing the assembly carrier.
Removing and installing assembly carrier Chapter.
Pressing out the rubber-metal bearing
Pressing in rubber-metal bearing

Note
Coat rubber-metal bearing and assembly carrier with acid-free

lubricant before pressing them in, e.g. -G 294 421 A1-. Under no
circumstances use grease or detergent.
II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake
Note
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
t
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing and wheel control components of the front
t
wheel suspension.
t Always replace self-locking nuts.
t Always replace corroded self-locking nuts and screws.
1- Self-locking nut, 60 Nm
2- Stop
3- Suspension strut
t repairing Chapter
4- Drive shaft with inner CV joint
t repairing Chapter
5- Shim
6- Fillister head screw with internal serrations
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 180
M10 = 50 Nm + 45
7- Drive shaft with inner tripod joint
t repairing Chapter
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 90
M10 = 50 Nm + 45
9- Brake disc (FS-III)
t without marking for axial run-out
t with a fixing hole for the wheel hub
10 - Wheel screw, 120 Nm
11 - Self-locking twelve-point nut
t slacken and tighten Chapter
12 - 4 Nm
13 - Brake discs (FS-III)
14 - Brake caliper (FS-III)
Including for vehicles with engine up to 92 kW.
t do not release brake hose when working on the front wheel suspension
t tie up with wire or anything similar
t repairing Chapter
15 - Guide bolt (FS-III), 30 Nm
16 - Cap (FS-III)
17 - Brake disc (FN 3)
t with marking for maximum axial run-out
t with 5 fixing holes for the wheel hub
18 - Wheel hub with pulse rotor for wheel speed sensor
t with marking for minimum axial run-out
t only on vehicles with ABS
t pressing out Chapter
t installing Chapter
t Pull off the inner ring of the bearing Chapter
t Check axial run-out of pulse rotor Chapter
19 - Brake discs (FN-3)
20 - Retaining spring (FN-3)
21 - Brake carrier (FN-3)
22 - Brake caliper (FN-3)
Including for vehicles with engine as of 96 kW.
t do not release brake hose when working on the front wheel suspension
t tie up with wire or anything similar
t Removing and installing brake pads Chapter
t repairing Chapter
23 - Guide bolt (FN-3), 30 Nm
24 - Cap (FN-3)
25 - Screw with securing collar (FN-3), 124 Nm
t Clean ribbing on the underside
26 - Wheel-bearing housing
Including for vehicles with engine as of 96 kW.
t repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing evenly
t
with -G 052 723 A2-
27 - Cover plate
28 - Self-locking nut, 50 Nm
29 - Steering joint
t check Chapter
t Inspect rubber bellows for damage, if necessary replace
30 - Wheel-bearing housing
Including for vehicles with engine up to 92 kW.
t repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing evenly
t
with -G 052 723 A2-
31 - Self-locking nut, 20 Nm + 90
32 - Screw
33 - 8 Nm
34 - ABS wheel speed sensor
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
t up to 05.98: 50 Nm + 90
t as of 06.98: 60 Nm + 90
36 - Track rod with track rod end
37 - 10 Nm
38 - Wheel bearing
t press out Chapter
t replace, is damaged when pressing out
t The spare part is only delivered as a set wheel bearing with mounting parts (Pos. 11, 39, 38, 28, 31 and 35)
39 - Circlip
t pay attention to correct position Chapter
40 - Wheel hub without pulse rotor
t only on vehicles without ABS
41 - Wheel hub with pulse rotor for wheel speed sensor
t without marking for minimum axial run-out
t press out Chapter
t Pull off the inner ring of the bearing Chapter
t Check axial run-out of pulse rotor Chapter
Repairing wheel bearing housing

t Thrust plate -MP 3-467-
t Ring spanner SW 46 -MP 6-413-
t Assembly device -MP 6-414/1-
t Washer -MP 6-415-
t Washer -MP 6-416-
t Thrust piece -MP 6-418-
t Pipe -MP 6-419-
t Pressure pipe -MP 6-420-
t Socket wrench insert SW 21 -MP 6-427-
t Spreader -VAS 3424-
t Puller Kukko -V 176-
t Cross member Kukko 18-0
t Grease -G 052 723 A2- (molykote grease)
It is only possible to repair the wheel-bearing housing, by pressing out and in the wheel hub and the wheel
bearing, after removing the suspension strut and the wheel-bearing housing.
Remove and install suspension strut and wheel bearing housing Chapter.
Press the wheel hub out of the wheel bearing
Removing and installing circlip

Remove or replace circlip with commercially available circlip
pliers.
Note
t Replace.
t When inserting, pay attention to the correct position of the circlip.
Press the wheel bearing out of the wheel bearing housing

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-.
Position thrust plate -MP 3-467- onto wheel hub and pull off the
inner ring of the bearing by turning the threaded spindle.
Press the wheel bearing into the wheel bearing housing

-A- Wheel bearing
Before pressing in the wheel bearing, coat the entire wheel bearing
seat in the wheel bearing housing evenly with -G 052 723 A2-.
Note
After pressing in the wheel bearing, the circlip must be

inserted Anchor.
Press the wheel hub into the wheel bearing

Note
When pressing in the wheel hub, ensure that the washer -MP 6-
t
415- rests against the inner ring of the bearing.
For wheel bearing housing and wheel hub on vehicles including
t with engine as of 110 kW (brake FN-3) observe the assignment of
the wheel hub electronic catalogue of original parts.
Wheel hubs with a 3 mm wide ink-jet marking for marking the
minimum axial run-out can also be combined with brake discs
t
without marking of the maximum axial run-out. Then the reduction
of the overall axial run-out of the brake FN 3 is not effective.
Inspecting the steering joint

Inspecting axial play
Pull the track control arm down with force and push up again.
Inspecting radial play
Forcefully push the wheel at the bottom towards the inside and the
outside.
Note
t For these two tests no play may be felt or be visible.

t Observe the steering joint during the tests.
Take into account possible wheel bearing play or play in top
t
suspension strut bearing.
t Inspect rubber bellows for damage, if necessary replace.
Removing and installing the steering joint

t Extractor Matra -V176-
Removing
It is only possible to remove the steering joint after removing the suspension strut and the wheel bearing
housing.
Remove and install suspension strut and wheel bearing housing Chapter.
Position the special tools as shown in the fig. and slacken the
hexagon nut.
-A- Torx screw -T 30-
Place the extractor as shown in the fig. and push out the steering
joint.
Install
Installation is carried out in the reverse order.
Note
Replace hexagon collar nut.
Tightening torques:
Steering joint to wheel-bearing housing 20 Nm + 90
Remove and install suspension strut and wheel bearing housing

t Extractor Matra -V176-
Removing
Remove wheel and raise vehicle.
Note
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.
Release screws -1-.

Push out the drive shaft. To do so position the tool as shown in the
fig.
Note
clearance.
Press the track rod off the steering arm using the extractor Matra
-V176- (commercially available).

Disconnect the plug -1- of the ABS wheel speed sensor.
Remove the ABS wheel speed sensor cable from the ties -arrows-.
Remove caps -2- and unscrew brake caliper. Secure brake carrier
with wire to body.

Remove the brake disc (the brake disc is secured with a screw to
the wheel hub).

If necessary, unscrew the coupling rod from the suspension strut.
Unscrew the suspension strut on the body with socket wrench
insert -MP 6-427-.

Take out the suspension strut with the wheel bearing housing.
Separate the suspension strut from the wheel bearing housing
Insert the spreader -VAS 3424- as shown and spread open the
wheel bearing housing.

Remove the suspension strut.
Install
- Remove possible corrosion in the thread/serration of the outer joint.
Insert the suspension strut with the wheel bearing housing and
secure it to the suspension strut dome.

If necessary, secure the coupling rod to the suspension strut.
hub.
Screw the steering joint and track control arm with the new screws
in the former positions.

Secure the brake caliper housing to the wheel bearing housing.
Note
Tighten the FN-3 brakes at the wheel bearing housing to 124 Nm.
Insert the cable of the ABS wheel speed sensor into the brackets.
Mount the plug of the ABS wheel speed sensor.
- Moisten the contact surface of the twelve-point nut as well as the
Insert the outer joint into the wheel hub until the outer joint rests in
the wheel bearing.

Attach the wheel.
touch the ground.

If the wheel bearings are loaded through the vehicle's own weight, the
wheel bearing will be initially damaged. This shortens the life of the
wheel bearing.
Tighten new twelve-point nut to 225 Nm and release by 1/2 a turn.
Tightening torque:
50 Nm + 60
Note
A torque wrench is recommended for tightening the twelve-point nut
-V.A.G 1756-.
Tightening torques:
Suspension strut to suspension strut dome 60 Nm
Coupling rod to suspension strut 90 Nm
t Use new nuts!
t Use new nuts!
Brake caliper housing to wheel bearing housing 30 Nm
Repairing the suspension strut

t Spring tensioning device, e.g. -S 505 501 V- or V.A.G 1752/1-
t Suspension strut support, e.g. -V.A.G 1752/2-
t Spring holder with protective lining, e.g. -V.A.G 1752/4-
1- Shock absorber with spring cap

t must be replaced completely
t can be replaced individually
t Inspecting the shock absorber Chapter
t disposing of Chapter
2- Stop buffer
3- Boot
4- Coil spring
t removing Fig.
t installing Fig.
t check colour coding
t The surface of the spring coil must not be damaged
t replace on both sides of the axle
t per axle only use coil springs of the same make
5- Spring cap
6- Bush
Only present on vehicles with rough road suspension (PR No. 1GB). This PR No. can be found on the vehicle
t
data sticker in the luggage compartment or in the Service Schedule Chapter
7- Axial grooved ball bearing
8- Suspension strut bearing
9- Collar nut, 60 Nm
t loosen and tighten
10 - Spring cap
11 - Collar nut, self-locking, 60 Nm
t replace after each removal Fig.
Removing the coil spring

Clamp the suspension strut support, e.g. -V.A.G 1752/2-, in the
vice.
Clamp the suspension strut to the shock absorber pipe in the
suspension strut support.

Preload the coil spring with spring tensioning device, e.g. -V.A.G
1752/1-, until the top spring cap is released.

Pay attention to the correct seating of the coil spring in the adapter,
e.g. -V.A.G 1752/4--arrow-.

Unscrew the collar nut from the piston rod using the socket wrench
insert -MP 6-427-, to do so counterhold with Allen key.

Remove individual parts of the suspension strut and the preloaded
coil spring using the spring tensioning device, e.g. -V.A.G 1752/1-.
Installing the coil spring
Position the preloaded coil spring with spring tensioning device,
e.g. -V.A.G 1752/1-, on the bottom spring washer, to do so the
spring coil end must lie against the stop -arrow-.
Inspecting the shock absorber

Leaks on the shock absorbers
Minor oil leakage (sweating) on the piston rod seal does not entail the replacement of the shock absorber.
If an oil leak is visible (but blunt, dull, possibly dried by dust) and does not propagate any further than from the
top shock-absorber plug (piston rod seal) to the bottom spring cap -arrow-, the shock absorber is deemed to be
O.K.
Note
A slight oil leak is beneficial as the gasket is lubricated and this increases the
life time. This applies for shock absorbers on the front as well as the rear
axle.
Noises on the shock absorbers
Attention must be drawn to the fact that in the event of complaints about
noise, the shock absorbers are very often regarded as being the source of
noise.
Note
In the event of complaints about noises interpreted as knocking or cracking

noises, always first perform a test drive with the customer to determine
where, when and how these noises occur (preferably on a bumpy dry road).
Inspect shock absorber without gas pressure
Defective shock absorbers become noticeable while driving because of the knocking noises - caused by wheel
hopping - more specifically on poor road and they must be replaced. The failure is mainly caused by the loss of
oil. The shock absorber then compresses and/or expands in jolts. It has an "idle travel" before taking effect.
Note
Shock absorbers are maintenance-free. It is not possible to top up the shock absorber oil.
Inspect shock absorber with gas pressure
Defective shock absorbers with gas pressure are also noticeable because of loud knocking noises caused by
wheel hopping and externally usually exhibit considerable oil leakage.
Manual testing, as described below, can determine if the shock absorber is damaged or not:
Compress the shock absorber by hand.
While doing so, the piston rod can be moved during the entire stroke time with a uniform resistance and
without jerking.
Release the piston rod. On sufficiently pressurized shock absorbers it will automatically return to its original
position.
If this is not the case, the shock absorber need not necessarily be replaced, as it will still operate as a
conventional shock absorber (see instructions below).

Note
The absorbing function is still fully present without gas pressure as long as the oil leakage is not too
t important. However, the noise intensity can deteriorate. On older vehicles it is possible to continue using an
operational yet pressureless shock absorber without problem.
t The spring shock absorbers with gas pressure are only installed on the rear axle.
The gas pressure in the shock absorber improves the noise behaviour and the function when driving over
t
poor road surfaces.
Disposing of the shock absorber

t Pipe cutter, e.g. Stahlwille Express -150/3-
t Protective goggles
t Oil catching pan
WARNING
Cover the opening during degassing (gas pressure in as-new condition up to 2.5 MPa) and wear protective
googles.
Note
Defective shock absorbers with gas pressure are also noticeable because of loud knocking noises caused by
t
wheel hopping and externally usually exhibit considerable oil leakage.
The oils used in the shock absorbers do not contain any harmful substances. These oils can be disposed of
t
together with drained engine and gearbox oil.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral hydraulic oils),
t suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or thinners,
chemicals etc.
t After "draining" the used parts must be allowed to drip adequately.
Drain front shock absorber
Clamp shock absorber in a vice.
Lever off protective cap with assembly lever or anything similar
and remove protective tube.

The protective cap and the protective tube are only present on
caulked shock absorbers.
Position a pipe cutter, e.g. Stahlwille Express -150/3-, and cut
through the outer pipe.

Pull the piston rod upwards and while doing so grip the inner pipe
with pipe pliers and press it down in such a way that it remains in
the outer pipe when the piston rod is slowly pulled out.
Pull the piston rod out of the inner pipe.
Drain shock absorber.
Drain rear shock absorber (shock absorber with gas pressure)
Clamp shock absorber vertically with the piston rod pointing downwards in a vice.
Drill a hole in the outer pipe 3 mm -arrow A-.
WARNING
Wear safety goggles.

Note
Gas will escape during drilling of the first pipe wall (only for pressurized shock
absorbers).
Drill further until the inner pipe has also been drilled through (approx. 25 mm
deep).
Drill a second hole (-arrow B-) 6 mm through the inner pipe.

Hold the shock absorber over an oil catching pan, move the piston rod several
times up and down over its entire stroke until no more oil escapes.
Note
The shock absorber can also be opened with a pipe
cutter Anchor. First the shock absorber must be depressurized by
center drilling the outer pipe (-arrow A-) previous fig. Anchor.
Removing and installing a drive shaft

Removing
Note
The wheel bearing must not be loaded when the twelve-point nut is loose. At full load the wheel bearing is
t
initially damaged through the vehicle's own weight, thus shortening the life of the wheel bearing.
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
t
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Assignment of the drive shaft and marking electronic catalogue of original parts.
Remove noise insulation Engine - Mechanics; Rep. gr.10.
Unscrew the drive shaft from the flange shaft/gearbox.
Note
Mark installation position of bolts -1-, otherwise the steering

geometry must be checked.
Release screws -1-.
Push out the drive shaft. To do so position the tool as shown in
the fig.
Note
t
clearance.
The drive shaft must not hang down while being pressed out.
t
Otherwise overstretching will cause damage to the inner joint.
Remove the drive shaft.
Note
The following working step must only be performed on vehicles

with automatic gearbox.
Slacken screws of gearbox-pendulum support -arrow- at
assembly carrier.
Lever out the engine/gearbox assembly with a tyre iron in
direction of travel, at the same time the drive shaft with tripod
can be removed.
The -arrow- shows the direction of travel.
Install (vehicles with manual and automatic gearbox)
- Remove possible corrosion in the thread/serration of the outer
joint.
Insert drive shaft.
hub.
Screw the steering joint and track control arm with the new
screws in the former positions.

Screw drive shaft onto flange shaft.
Screw the pendulum support to the assembly carrier.
- Moisten the contact surface of the twelve-point nut as well as the
Insert the outer joint into the wheel hub until the outer joint rests
in the wheel bearing.

Install noise insulation Engine, Mechanics; Rep. gr.10.
Attach the wheel.
touch the ground.

If the wheel bearings are loaded through the vehicle's own weight,
the wheel bearing will be initially damaged. This shortens the life of
the wheel bearing.
Tighten new twelve-point nut to 225 Nm and release by 1/2 a
turn.
Tightening torque:
50 Nm + 60.
Note
The torque wrench is recommended e.g. for tightening the twelve-point nut -V.A.G 1756-.
Tightening torques:
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
I. 2nd
Screw M8 x 18 10 Nm 20 Nm + 90
Screw M8 x 48 10 Nm 20Nm + 180
t Use new screws!
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
I. 2nd
Screw M10 10 Nm 50 Nm + 45
t Use new screws!
Pendulum support to assembly carrier 20 Nm + 90
t Use new screws!
Repairing drive shaft

Repairing drive shaft with outer and inner CV joint
t Circlip pliers, e.g. -VW 161 A-
t Strutting bushing -MP 6-428-
t Tensioner -MP 6-429-
t Tensioning pliers, e.g. -V.A.G 1682-
t Sealant -D 454 300 A2-
Note
t Assignment of the drive shafts Electronic Catalogue of Original Parts.

t Grease joint if necessary, when replacing the joint boot.
t Spread the grease mass evenly in the joint boot - only on the side of the joint.
1- Right joint boot (tubular shaft)

initially tighten to 10 Nm, subsequently tighten crosswise to
t
final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
3- Shim
4- Open warm-type clamp
t replace
t tensioning Fig.
5- Joint boot for inner CV joint, 94 mm
t inspect for tears and chafing points
t remove from CV joint with drift
The fitting position of the joint boot for the inner CV joint for the right shaft is the same as the fitting position
t
of the joint boot for the outer CV joint 84mm Fig.
t before installation coat the inside of the cap with sealant -D 454 300 A2-
6- Joint boot for inner CV joint, 100 mm
t Fitting position for the left shaft Fig.
t Fitting position for the right shaft Fig.
t before installation coat the inside of the cap with sealant -D 454 300 A2-
7- Disc spring
t Fitting position Fig.
8- Inner CV joint
t pressing out Fig.
t pressing on Fig.
t grease Anchor
t check Chapter
9- Gasket
t The adherend on the inner CV joint must be free of grease and oil!
t replace
t Remove the protective foil from the gasket and stick it into the inner joint
10 - Circlip
t replace
t remove with circlip pliers, e.g. -VW 161 A-,
11 - Left drive shaft (solid shaft)
12 - Open warm-type clamp
t replace
t tensioning Fig.
13 - Joint boot for outer CV joint
t pay attention to different version: 84 mm, 90 mm
t The fitting position of the joint boot for the outer CV joint 90 mm for the left shaft Fig.
The fitting position of the joint boot for the outer CV joint 90 mm for the right shaft is determined by the
t
fitting position on the shaft, identical as Fig.
t The fitting position of the joint boot for the outer CV joint 84 mm for the left shaft Fig.
t The fitting position of the joint boot for the outer CV joint 84 mm for the right shaft Fig.
t replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
15 - Disc spring
16 - Thrust ring
17 - Circlip
t replace
t insert into the groove at the shaft
18 - Outer CV joint
t removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t grease Anchor
t check Chapter
19 - 22 Nm
20 - M8 = 20 Nm, M10 = 33 Nm
21 - Protective housing
Repairing drive shaft with outer and inner CV joint VL 3700

t Chapter
Note

1- Outer CV joint
t removing Fig.
install: drive onto the shaft with a plastic hammer until the
t
compressed circlip expands
t grease Anchor
t check Chapter
2- Circlip
t replace
t insert into the groove at the shaft
3- Thrust ring
4- Disc spring
t replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
6- Joint boot for outer CV joint
t Material: Hytrel (Polyelastomere)
t replace
t tensioning Fig.
8- Drive shaft
9- Joint boot for inner CV joint
t Material: Arnitel (Polyelastomere)
t replace
11 - Cover
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2-
t The sealing surface must be free of oil and grease!
12 - Inner CV joint
t pressing out Fig.
t pressing on Fig.
t grease Anchor
t check Chapter
13 - Circlip
t replace
t remove with circlip pliers, e.g. -VW 161A-,
14 - Fillister head screw with internal serrations
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
15 - Shim
16 - Gasket
t The adherend on the inner CV joint must be free of grease and oil!
t replace
t Remove the protective foil from the gasket and stick it into the inner joint
17 - Cover
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2-
t The sealing surface must be free of oil and grease!
Grease quality and grease quantity

Note
The outer joints of the drive shaft are filled with:

Grease for operating at 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-
t The inner joints of the drive shaft must only 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 Anchor
Removing outer CV joint

Drive off joint boot with a drift.
Drive off the drive shaft with a strong blow of a plastic hammer.
Pressing out the inner CV joint

Note
Support ball hub
Fitting position of the disc spring on the outer joint (gearbox side)
-1- Disc spring
Fitting position of the disc spring and thrust ring on the outer joint
-1- Disc spring
-2- Thrust ring
Pressing in the inner CV joint

Press the joint up to the stop.
Insert the circlip.
Note
Chamfer on inner diameter of the ball hub (serration) must point

towards the bearing collar of the drive shaft.
Fitting position of the joint boot for the inner CV joint 100 mm on
the left shaft
Dimension -a- = 17 mm
Note
Mark the dimension -a- before installing the joint boot on the drive
shaft, e.g. using colour or adhesive tape. Under no circumstances the
paintwork must be damaged with a sharp object.
Fitting position of the joint boot for the inner CV joint 100 mm
on the right shaft
The ventilation chamber -A- must be located on the large pipe
diameter.
-B- Ventilation hole.
Tighten the open warm-type clamp on the outer joint (at the large
diameter)
Note
In view of the hard material (as opposed to rubber) of the joint

boot, which requires the use of a stainless steel open warm-type
t
clamp, the latter can only be correctly tightened with tensioning
pliers, e.g. -V.A.G 1682-.
t Tightening torque: 25 Nm.
t Use a torque wrench.
Make sure the thread of spindle -A- of the tensioning pliers is
t
smooth. If necessary grease with grease, e.g. molykote MoS2.
If it is not smooth, e.g. if the thread is dirty, the necessary
t clamping force of the open 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 open warm-type clamp.
Tighten the open 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
Tighten the open warm-type clamp on the outer joint (small

diameter)
fig. Make sure the cutting edges of the pliers are positioned in the
corners (-arrows B-) of the open warm-type clamp.
-C- Torque wrench
Tighten the open warm-type clamp on the inner joint

fig. Make sure the cutting edges of the pliers are positioned in the
corners (-arrows B-) of the open warm-type clamp.
-C- Torque wrench
Fitting position of the joint boot for the outer CV joint 90 mm on
the left shaft
The sealing surface of the joint boot must rest up to the stop on the
shoulder of the shaft
Fitting position of the joint boot for the outer CV joint 84 mm on

the left and right shaft
On the drive shaft, 1 to 1 1/2 groove must be visible
Note
The condition mentioned above regarding the fitting position is also

valid for the joint boot for the inner CV joint 94 mm.
Fitting position of the joint boot for the inner CV joint at the left and
right shaft
Fitting position of the joint boot for the outer CV joint at the left
shaft
Fitting position of the joint boot for the outer CV joint at the right
shaft
Inspecting outer CV joint

Disassemble the joint to replace badly soiled grease or if the contact
surfaces of the balls must be inspected for wear and damage.
Removing
With an electric stylus or rubstone mark the position of the ball hub
relatively to the ball cage and housing before disassembling -arrow-.

Rotate the ball hub and ball cage.
Remove the balls one after the other.
Turn the cage until the two rectangular cage windows (-arrow-) rest
on the joint part.

Remove cage with hub.
Turn the hub segment in the rectangular window of the cage.

Swivel the hub out of the cage.
Note
The 6 balls of each joint belong to a tolerance group. Inspect the axle studs, hub, cage and balls for small
depressions (pitting = point erosion) and seizing marks. Load alteration shocks indicate too much torsional
t
clearance in the joint, if this is the case replace the joint. Smoothing and bearing marks do not justify a joint
replacement.
t Inspect the cage for tears.
Install
Press the required quantity of grease into the joint part.
Grease quality and grease quantity Anchor.
Insert the cage with the hub in the joint part.
Note
The cage must be inserted in the correct position.

Press in opposite balls one after the other, during this process
observe the prior position of the ball hub relatively to the ball cage and to the joint part.
Insert new circlip in the groove of the shaft.
Spread any residual grease in the joint boot Anchor.
Installing the joint boot Fig..
Inspecting inner CV joint

Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected for
wear and damage.
Removing
Note
The ball hub and joint part are paired and must be marked before removal. Do not interchange the bearing
track assignment.
Swivel the ball hub with the ball cage.

Press the ball hub and the ball cage out of the joint part -arrow-.
Press out the balls from the cage.
Swivel the ball hub out of the ball cage over the ball bearing
track -arrows-.
Inspect the joint part, ball hub, ball cage and balls for small
broken out depressions (pitting = point corrosion) and seizing
marks.
Note
Load alteration shocks indicate too much torsional clearance in

the joint. If this is the case, replace the joint. Smoothing and
bearing marks do not justify a joint replacement.
Install
Insert the ball hub in the ball cage over the two chamfers. The
fitting location is random. Press the balls into the cage.

Insert the hub with cage upright into the joint part.
Note
When inserting make sure the greatest distance -a- on the joint
t part is close to the short distance -b- on the hub after it has been
swivelled in -arrow-.
Chamfer on inner diameter of the ball hub (serration) must point
t
towards the largest diameter of the joint part.
Swivel in the hub. To do so swivel the hub out of the cage -
arrows-until the balls are at bearing track distance.

Lock the hub with the balls into position by exerting
considerable pressure on the cage -arrow-.

Inspect the operation of the inner CV joint
The CV joint is correctly assembled if the ball hub in the joint
l part can be rolled by hand up and down the entire linear
compensation.
Push the clamp and the joint boot onto the drive shaft.
Install drive shaft.
Press the specified grease quantity for the inner joint into the
joint from both sides.

Spread the prescribed grease quantity evenly into the joint boot.
Grease quality and grease quantity Anchor.
Installing the joint boot Fig..
Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint
t Tensioning pliers, e.g. -V.A.G 1275-, -V.A.G 1682-
t Circlip pliers (commercially available)
Note
The inner joints and the inner tripod joints must only be filled with high temperature grease from the
t
relevant repair kit electronic catalogue of original parts.
t Grease quantity for outer CV joint Anchor.
t Grease quantity for inner tripod joint Anchor.
Note
t Assignment of the drive shafts electronic catalogue of original parts

t On tripod joints only apply grease in the joint, never in the grease boot.
q inspect for tears and chafing points
q Assignment Electronic Catalogue of Original Parts
q replace
q tensioning Fig.
q replace
q tensioning Fig.
4- Drive shaft
5- Joint part
q grease Anchor
q replace after each removal
q initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 18 = 20 Nm + 90
M10 x 23 = 50 Nm + 45
7- Rollers
8- Tripod spider
q Chamfer -arrow- points towards the drive shaft serration
9- Circlip
q replace
q insert into the groove at the shaft
10 - O-ring seal
q no longer necessary for the assembly of the repaired drive shaft
11 - Oblong gasket ring
q The gasket ring belongs to the repair set
q The gasket ring is not fitted in the series, it is only necessary for the spare parts sector
12 - Cover
q is damaged when removing.
is no longer necessary for the assembly of the repaired drive shaft and is therefore only available as a spare
q
part
q for tripod joint
q always replace
14 - Joint boot for tripod joint
q for tripod joint
q always replace
q tensioning Anchor
16 - Disc spring
q Fitting position Fig.
17 - Thrust ring
18 - Circlip
q replace
19 - Outer CV joint
q must be replaced completely
q removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q grease Anchor
q check Chapter
Disassembling and assembling the tripod joint AAR 2900

t Chapter
Anchor
Dismantling
Open warm-type clamp on joint part.
Open the open warm-type clamp at the drive shaft and push back the joint boot.
Clamp the drive shaft on the joint part in a vice with protective jaws.
Lever off the cover with a screwdriver -1-.
Note
If the cover cannot be levered off, do likewise on the opposite side of

t
the cover.
The cover is damaged when levering off, it is no longer necessary for
t
the assembly of the repaired drive shaft.
Remove O-ring seal -arrow- from slot.

Mark fitting position of parts -1- ... -3- with the help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they are not fitted in their
t original position again when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from the vice.
Ensure that the rollers do not topple off the tripod spider and fall onto
the floor!
Hold the drive shaft with the joint part vertically and with the other
hand gradually push back the joint part.

Clamp the drive shaft in a vice with protective jaws.
Mark the fitting position of the rollers -1- to the tripod spider -2- with
a felt-tip pen.
Remove rollers -1- and place them down on a clean surface.
Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.
Hold the drive shaft and press out of the tripod spider.
Remove the joint part along with the joint boot from the drive shaft.
Clean the drive shaft and the joint part.
Assembling together
Push a small open warm-type clamp for the joint boot onto the drive
shaft.
Insert the joint boot on the drive shaft.
Insert the joint part on the drive shaft.
Mounting the tripod spider
Note
Chamfer -arrow- on the tripod spider must point towards the drive shaft.
Chamfer serves as an assembly aid.
Position the tripod spider on the drive shaft according to the marking
and drive in up to the stop.

Insert new circlip and pay attention to correct position.
Fit the rollers corresponding to the markings onto the tripod spider.
Remove the drive shaft from the vice.
Slide the joint part over the rollers and hold down.
Clamp joint part into the vice.
Insert the oblong gasket ring -A- from the repair set into the groove -
arrow-.
Note
Direct sealing occurs between the tripod joint (joint part) and the joint
t flange (on the gearbox side) due to the oblong profile shape of the
gasket ring.
t The cover is no longer necessary.
Press the high temperature grease from the repair set evenly into the
tripod joint (on the tripod spider side) -arrow A- and into the rear side
of the tripod joint -arrow B-.
Anchor
Installing the joint boot.
Tighten open warm-type clamp using pliers.
Tighten open warm-type clamp on the drive shaft side with tensioning
pliers e.g. -V.A.G 1275-.
Cover the tripod joint with a cardboard disc -A- and adhesive tape -B-.
Note
Cover the tripod joint after the repair with a self-cut, clean cardboard disc
-A- and adhesive tape -B-. This prevents the tripod spider, the joint part and
t
the grease mass from clogging up with dirt. In addition, this prevents that
the tripod joint is inadvertently pushed back when installing the drive shaft.
The adhesive tape and the cardboard disc should be removed only
immediately before screwing the drive shaft together with the joint flange.
Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint
t Spacer sleeves -MP 3-458/2-
t Strutting bushing -MP 6-428-
t Tensioner -MP 6-429-
t Tensioning pliers, e.g. -V.A.G 1275-, -V.A.G 1682-
t Circlip pliers (commercially available)
Note
The inner joints and the inner tripod joints must only be filled with high temperature grease from the relevant
t
repair kit electronic catalogue of original parts.
t Grease quantity for outer CV joint Anchor.
t Grease quantity for inner tripod joint Anchor.
Note
t Assignment of the drive shafts electronic catalogue of original parts

t On tripod joints only apply grease in the joint, never in the grease boot.
q replace
q tensioning Fig.
q replace after each removal
initially tighten to 10 Nm, subsequently tighten crosswise to
q
final torque:
M8 x 28 = 20 Nm + 90
4- Shim
5- Joint part
q grease Anchor
6- Tripod spider with rollers
q Chamfer -arrow- points towards the drive shaft serration
7- Circlip
q replace
8- O-ring seal
q replace
9- Cover
q replace
q for tripod joint
q always replace
11 - Joint boot for tripod joint
12 - Drive shaft
q replace
q tensioning Fig.
14 - Disc spring
15 - Thrust ring
16 - Circlip
q replace
17 - Outer CV joint
q must be replaced completely
q removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q grease Anchor
q check Chapter
Disassembling and assembling the tripod joint AAR 2000

t Chapter
Anchor
Dismantling
Open warm-type clamp on joint part.
Push back the joint boot.
Straighten the metal tabs -arrows- with a screwdriver and lever off
cover.
Remove O-ring seal -arrow- from slot.

Mark fitting position of parts -1- ... -3- with the help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they are not fitted in
t their original position again when assembling, at a later stage this
could cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from the vice.
Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.
Hold the drive shaft and push tripod spider off the drive shaft.
Remove the tripod spider with rollers and lay aside on a clean
surface.
Remove the joint part from the drive shaft.
Remove the joint boot from the drive shaft.
Clean the drive shaft and the joint part.
Assembling together
Insert the joint boot on the drive shaft.
Insert the joint part on the drive shaft.
Install tripod joint
Note
Chamfer on the tripod spider must point towards the drive shaft.
Chamfer serves as an assembly aid.
Position the tripod spider on the drive shaft according to the
marking and drive in up to the stop.

Insert new circlip and pay attention to correct position.
Slide the joint part over the rollers and hold down.
Remove the drive shaft from the special tool and clamp in the
vice.
Press the high temperature grease from the repair set evenly into
the tripod joint (on the tripod spider side) -arrow A- and into the
rear side of the tripod joint -arrow B-.
Anchor
Installing 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 joint part must be flush.

Tighten open warm-type clamp using pliers.
Grease quantity
Outer joint Total quantity of grease Inner joint mm Total quantity of grease of which in
mm (g) (g)
Spread evenly in the Joint Joint boot
joint (g) (g)
94 (synchronous
81 90 90 45 45
running) 1)
100 (synchronous
90 110 120 60 60
running) 1)
90 110 108 (tripod) 1) 110 110 _
90 110 124 (tripod) 1) 140 140 _
100 (synchronous
98 130 190 190 _
running) 2)
1)
Valid for all vehicles, except 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
2)
Valid for vehicles with 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
Grease quality - outer CV joint
The outer CV joints can be filled with the following grease qualities:
t Grease for operating at normal temperatures, part no.: -G 052 738 A2-
t Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3-
Grease quality - inner CV joint
The inner CV joints can be filled with the following grease qualities:
t Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3-
Note
t -G 052 133 A2- Can with a grease quantity of 90 g

t -G 052 133 A3- Can with a grease quantity of 120 g
t Spread the quantity of grease for the joint evenly in the joint on the left and right.
t Spread the quantity of grease for the joint boot evenly in the joint boot - only on the side of the joint.
Removing and installing rear suspension

t Tester for brake-power regulator, e.g. -V.A.G 1310-
t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-
t Brake filling and bleeding device, e.g. -VAS 5234-
t Remove plugs for brake line
t Brake fluid Chapter
t Assembly paste -G 052 150 A2-
Removing
Remove wheels.
Release the hand-brake.
Note
Do not slacken the mounting bracket on body for the removal of the rear axle, otherwise the overall track of
the rear axle must be checked, adjusted if necessary.
Remove the screws -1- while the vehicle is standing on its wheels.
To do so, raise the vehicle if necessary until the screws can be
reached.
Raise the vehicle to the height required for installation in order to
relieve tension from coil spring.

Tilt the rear centre console, if necessary remove Body
Work; Rep. gr.68

Release adjusting nut -arrow-.
Remove the hand-brake cables -1- from the hand-brake lever.

Pull hand-brake cables out of guide tubes.
Unclip brake cables -arrows-.

Detach retaining clips -2- from brake hose fixture.
Separate brake lines.
Note
Seal lines with plugs.

Unplug connectors from the wheel speed sensors.
Unclip the wheel speed sensor cable from the bracket.
Only on vehicles fitted with brake-power regulator (vehicles without
ABS):
Unscrew bolt -1- of the brake-power regulator.

Valid for all vehicles:
Support the rear axle with gearbox jack with adapter, e.g. -V.A.G
1383A- with -V.A.G 1359/2-.

Unscrew bolt -1- of the brake-power regulator.
Install
Before inserting the rear axle, grease the kidney-shaped cavities of
the rubber-metal bearings with assembly paste -G 052 150 A2-.

Note
When tightening the screw of the rubber-metal bearing, the axle

t
body must be in the horizontal position (unladen condition).
When installing the hand brake cables, pay attention to the correct
t
fitting position Chapter.
Bleeding Brake System Chapter.
If fitted, inspect the load-sensitive brake pressure regulator and set
if necessary Chapter.
Once the steering gear has been installed it is then important to check
the position of the steering wheel during a test drive.
If the vehicle drifts, a chassis alignment must be performed.
Note
After slackening or changing the mounting bracket, check the overall

track of the rear axle, adjust if necessary.
Tightening torques:
Shock absorber to body 30 Nm + 90
t Use new screws!
Rear suspension to bearing bracket 45 Nm + 90
Pipe screws, screws to brake lines 14 Nm
Summary of components of rear axle

Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.
1- Wheel screw, 120 Nm
2- 4 Nm
3- Brake disc
t reset brake before removing the brake drum
4- Cap
t press off Fig.
t inserting Fig.
5- Self-locking twelve-point nut 70 Nm +40
6- Wheel hub with wheel bearing and pulse rotor
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair work
t
are not possible
7- Wheel hub with wheel bearing without pulse rotor
t
are not possible
8- 50 Nm + 60
9- Brake carrier with brake shoe
10 - Holder for hand-brake cable
t replace
11 - Hand-brake cable
13 - Self-locking screw, 30 Nm + 90
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side
14 - 45 Nm + 90
t insert from the outside of the vehicle
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
15 - Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t avoid slackening in order to remove the rear axle
18 - Socket nut
19 - Brake-power regulator
t testing and adjusting Chapter
20 - 20 Nm
21 - 16 Nm
22 - 20 Nm + 45
23 - Balancing weight
24 - Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
26 - 8 Nm
27 - bottom base
28 - Coil spring
t check for paint damage, if necessary eliminate paint damage
t only use helical springs of the same make on the rear axle
29 - top base
t installing Anchor
30 - 40 Nm + 90
t insert from the inside of the vehicle
t when tightening, take the installation angle of the rear axle to the shock absorber into account Fig.
While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and tighten
t
the screw
if thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying attention
t
to the notes of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 1 screw point per vehicle side
32 - Shock absorber
t only use helical springs of the same make on the rear axle
Note
Shock absorbers are not to be repaired.

34 - Brake line
35 - Axle stud
t Straightening work is not allowed!
t Re-cutting the thread is not allowed
36 - Protection against stones
37 - Fixing element for protection against stones
t Protection against stones included in the scope of delivery
Installation angle of rear axle/shock absorber

1- Shock absorber
- approx. 104
Replacing the rubber-metal bearing - version 1

t Assembly device -MP5-400/1-
t Assembly device (screw) -MP5-401/2-
t Assembly device (nut) -MP5-401/3-
t Assembly device (bearing) -MP5-402-
t Pipe -T10263/6-
t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2-
Removing:
Raise vehicle and remove rear wheels.
Unscrew screws of front wheelhouse liners on both vehicle sides
Body Work; Rep. gr.66.

Unhook handbrake cable from the holders -arrows- (on both
vehicle sides).
Release the clamps -arrow A- for attaching the brake lines from the
brake line holders (on both vehicle sides).
Remove the screw -1- from the brake line holder on the right
vehicle side.
Unhook the brake lines from the line holders. Do not separate the
brake lines.
Vehicles with ABS
Unhook the ABS line from the clips.
Vehicles fitted with load-sensitive brake pressure regulator (vehicles

without ABS)
Release screw -1-.
Continued for all vehicles
Insert wooden insert -A- into the adapter e.g. -V.A.G 1359/2-
Support the axle with engine/gearbox jack with adapter.
Vehicles with fixing screws mounted on the outside
Unscrew the nuts of the fixing screws -1- from the axle.
Remove fixing screws -1- from the axle.
Vehicles with fixing screws mounted on the inside
Remove the screws -2- of the bearing bracket for the axle on the
right vehicle side from the body.

Note
Before removing the screws of the bearing brackets for the axle, mark
the position of the bearing bracket on the body.
Remove the fixing screw -1- for the axle on the left vehicle side
from the bearing bracket for the axle.

Slightly lower the rear axle out of the bearing brackets so that the
brake line is not damaged.

Remove the fixing screw -1- for the axle on the right vehicle side

Remove the bearing bracket from the axle.
Secure axle e.g with wire to body.
Position assembly devices, as shown, and pull the rubber-metal
bearing -1- out of the axle body -2-.

Note
The pipe -T10263/6- must be installed on the rubber-metal bearing
t in such a way that the contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g with a sharp knife so
t that the pipe cutout -arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the plastic
t shoulder/rubber-metal bearing breaks off. In case of breakage, a
loud crack can be heard.
Pull out rubber-metal bearing by turning the assembly device (nut)
-MP5-401/3-.
Counterhold the assembly devices by hand when completing the
pull-out process.
Remove assembly devices and unscrew assembly device (nut)
-MP5-401/3-.
Clamp the pipe -T10263/6- in the vice, as shown in the fig.

Remove the rubber-metal bearing from the pipe -T10263/6-, for
example using a screwdriver, drive out with a hammer if necessary.

Installing:
Fasten rubber-metal bearing -1- with assembly devices and nut -
2- and insert into the axle body -3-.

Pay attention to the correct fitting position of the rubber-metal
bearing.
Fitting position of the rubber-metal bearing
Align orientation nubs -1- or orientation bead -2- to edge of track
control arm -3--arrow-.
Insert the rubber-metal bearing -1- by turning the nut -MP 5-
401/3- up to the stop in the axle body -2-.

Check the fitting position of the rubber-metal bearing.
Grease the kidney-shaped cavities of the rubber-metal bearing
with assembly paste -G052 150 A2-.

Carefully raise the rear axle so that the rubber-metal bearing
engages in the bearing brackets for the axle.
Insert the new fixing screws -1- into the bearing brackets for the
axle.
Screw new nuts onto the fixing screws -1- for bearing brackets of
the rear axle and tighten.

Position the bearing bracket for the axle on the right vehicle side
on the rubber-metal bearing.

Insert a new fixing screw -1- from the inside into the bearing
bracket for the axle on the right vehicle side.

engages on the left vehicle side in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on the right vehicle
side rests at the same time against the body in the marked position.
Screw the new fixing screws -2- of the bearing bracket for the axle
on the right vehicle side into the body and tighten.

Note
When tightening the rubber-metal bearing screws and nuts, the axle
body must be in the unladen condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
without ABS)
Screw in the screw -1-.

Inspecting or adjusting the brake-power regulator Chapter.
Install the screw -1- for the brake line holder on the right vehicle
side.
Hook on the brake lines in the line holders.
Push clamps -arrow A- into the brake hose fixtures (on both
vehicle sides).
Note
Hook hand brake cables into the holders -arrows- (on both vehicle
sides).
Screw in screws of front wheelhouse liners on both vehicle
sides Body Work; Rep. gr.66.

Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the test drive.
Caution
If after the test drive and with the front wheels pointing straight
ahead the steering wheel is off straight, perform a chassis
alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle 45 Nm + 90
t Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure 30 Nm + 90
t Use new screws!
t Install in the marked position
Brake line holder to vehicle body 16 Nm
Screw for brake-power regulator 16 Nm

t Assembly device (nut) -T10254/4-
t Assembly device (screw) -T10254/5-
t Pipe -T10263/6-
t Hydraulic cylinder -VAS 6178-
t Foot pump -VAS 6179-
t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2-
Removing:
Raise vehicle and remove rear wheels.
Unscrew screws of front wheelhouse liners on both vehicle sides Body Work; Rep. gr.66.
Unhook handbrake cable from the holders -arrows- (on both vehicle
sides).
Release the clamps -arrow A- for attaching the brake lines from the
brake line holders (on both vehicle sides).
Remove the screw -1- from the brake line holder on the right vehicle
side.
Unhook the brake lines from the line holders. Do not separate the
brake lines.
Vehicles with ABS
Unhook the ABS line from the clips.

without ABS)
Release screw -1-.
Insert wooden insert -A- into the adapter e.g. -V.A.G 1359/2-
Support the axle with engine/gearbox jack with adapter.
Unscrew the nuts of the fixing screws -1- from the axle.
Remove fixing screws -1- from the axle.
Remove the screws -2- of the bearing bracket for the axle on the
right vehicle side from the body.

Note
Before removing the screws of the bearing brackets for the axle, mark
the position of the bearing bracket on the body.
Remove the fixing screw -1- for the axle on the left vehicle side

Slightly lower the rear axle out of the bearing brackets so that the
brake line is not damaged.

Remove the fixing screw -1- for the axle on the right vehicle side

Remove the bearing bracket from the axle.
Secure axle e.g with wire to body.
Connect hydraulic line -1- of hydraulic pump -VAS 6179- with
quick coupling to hydraulic cylinder -VAS 6178-.

Connect compressed air supply -2- with quick coupling to hydraulic
pump -VAS 6179-.

Position assembly devices, as shown, screw together and
counterhold by hand.
Note
The pipe -T10263/6- must be installed on the rubber-metal bearing

t in such a way that the contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g with a sharp knife so
t that the pipe cutout -arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the plastic
t shoulder/rubber-metal bearing breaks off. In case of breakage, a loud
crack can be heard.
Carefully depress the pedal of the hydraulic pump -VAS 6179--
arrow A-.
The hydraulic cylinder -VAS 6178- is therefore activated.
Pull the rubber-metal bearing -1- out of the axle body -2-.
Counterhold the assembly devices by hand when completing the
pull-out process.
arrow B-.
While doing so, the hydraulic cylinder -VAS 6178- returns to the
initial position.
-T10254/4-.
Clamp the pipe -T10263/6- in the vice, as shown in the fig.

Remove the rubber-metal bearing from the pipe -T10263/6-, for
example using a screwdriver, drive out with a hammer if necessary.

Installing:
Position assembly devices, as shown, screw together and
counterhold by hand.
1- Rubber-metal bearing
2- Axle body
Pay attention to the correct fitting position of the rubber-metal
bearing.
Fitting position of the rubber-metal bearing
Align orientation nubs -1- or orientation bead -2- to edge of track
control arm -3--arrow-.

arrow A-.
The hydraulic cylinder -VAS 6178- is therefore activated.
Insert the rubber-metal bearing -1- up to the stop into the axle
body -2-.
Check the fitting position of the rubber-metal bearing.
arrow B-.
While doing so, the hydraulic cylinder -VAS 6178- returns to the
initial position.
-T10254/4-.
Grease the kidney-shaped cavities of the rubber-metal bearing with
assembly paste -G052 150 A2-.

engages in the bearing brackets for the axle.

Insert the new fixing screws -1- into the bearing brackets for the
axle.
Screw new nuts onto the fixing screws -1- for bearing brackets of the
rear axle and tighten.

Position the bearing bracket for the axle on the right vehicle side on
the rubber-metal bearing.
Insert a new fixing screw -1- from the inside into the bearing
bracket for the axle on the right vehicle side.

engages on the left vehicle side in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on the right vehicle side
rests at the same time against the body in the marked position.
Screw the new fixing screws -2- of the bearing bracket for the axle
on the right vehicle side into the body and tighten.

Note
When tightening the rubber-metal bearing screws and nuts, the axle
body must be in the unladen condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
without ABS)
Screw in the screw -1-.

Inspecting or adjusting the brake-power regulator Chapter.
Install the screw -1- for the brake line holder on the right vehicle
side.
Hook on the brake lines in the line holders.
Push clamps -arrow A- into the brake hose fixtures (on both vehicle
sides).
Note
Hook hand brake cables into the holders -arrows- (on both vehicle
sides).
Screw in screws of front wheelhouse liners on both vehicle
sides Body Work; Rep. gr.66.

Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the test drive.
Caution
If after the test drive and with the front wheels pointing straight ahead
the steering wheel is off straight, perform a chassis
alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle 45 Nm + 90
t Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure 30 Nm + 90
t Use new screws!
t Install in the marked position
Brake line holder to vehicle body 16 Nm
Screw for brake-power regulator 16 Nm
Removing and installing shock absorber/spring

t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-
Note
t The coil spring does not have to be removed in order to remove the shock absorber.
t The shock absorber does not have to be removed in order to remove the coil spring.
Remove the shock absorber
Raise the relevant side of the axle body with the gearbox jack.
Screw out screws -1- and -2- and take out shock absorber.
Remove spring
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-
off hook in tool kit).

Pull the wheel speed sensor cable out of the supports.
Raise the relevant side of the axle body with the gearbox jack.
Release screw -2-.
Lower the gearbox jack and remove the helical spring.
Install
Note
Make sure that the top base (rubber) for the spring is correctly fitted
t
when inserting it into the support of the body.
t Pay attention to colour coding.
The bottom short circuit in coil must always point to the centre of the
t
vehicle.
The beginning of the spring -arrow- must be positioned at the stop at
the top of the base.

Tightening torques:
Chapter.
Disassembling and assembling shock absorber
1- Shock absorber
Note
The shock absorbers must not be disassembled and repaired.

2- Protective cap
3- Protective tube
4- Stop buffer
5- Top shock absorber bushing
6- Self-locking screw, 25 Nm
t counterhold the piston rod of the shock absorber in order to slacken and tighten the nut
7- Protective cap
Summary of components of rear axle
Removing and installing rear suspension

Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.
2- 4 Nm
3- Brake disc
4- Cap
t press off Chapter, - Pos. 5
t drive in Chapter, - Pos. 5
t
are not possible
7- 30 Nm + 90
8- Cover plate
9- Holder for hand-brake cable
t replace
10 - Hand-brake cable
11 - 45 Nm + 90
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
t
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
14 - Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t avoid slackening in order to remove the rear axle
17 - 20 Nm + 45
18 - Balancing weight
20 - 8 Nm
21 - Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
22 - bottom base
23 - Coil spring
t check for paint damage, if necessary eliminate paint damage
t per rear axle only use helical springs of the same make
24 - top base
t installing Anchor
25 - 40 Nm + 90
t insert from the outside of the vehicle
t when tightening, take the installation angle of the rear axle to the shock absorber into account Fig.
While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and tighten
t
the screw
t
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
27 - Shock absorber
t per rear axle only use shock absorbers of the same make
Note
Shock absorbers are not to be repaired.

29 - Axle stud
30 - Protection against stones
31 - Fixing element for protection against stones
t Protection against stones included in the scope of delivery
32 - Brake line
33 - 30 Nm + 30
34 - Brake caliper
t repairing Chapter
Installation angle of rear axle/shock absorber
1- Shock absorber
- approx. 104
Removing and installing shock absorber/spring
Disassembling and assembling shock absorber
Repairing the wheel bearing, vehicles with front-wheel drive - drum brake
t Drive bushing -MP 3-427-
t Hub cap extractor -MP 5-404-
t Puller Kukko -20/2-
1- 4 Nm
2- Brake drum
t reset brake before removing the brake drum Fig.
3- Cap
t press off Fig. and Fig.
t inserting Fig.
t
are not possible
t replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel bearing,
t the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with wheel
bearing Fig..
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is therefore
t
not pressed on separately.
6- Wheel hub with wheel bearing without pulse rotor
t
are not possible
t replace completely after each removal
Note
Item
7- Axle stud
8- Axle body
Resetting brake
To do so, use a screwdriver to push the wedge up through a hole in
the brake drum.

Remove the brake drum Chapter.
Press off cap

Release cap from its position by gently tapping the claw.
Press off cap

Remove the wheel bearing housing from the axle stud
Use puller (commercially available) Kukko -20/2-.
Remove inner ring of the bearing from axle stud

Note
Do not damage the ABS wheel speed sensor when pulling off the inner
ring of the bearing.
Pull wheel hub with wheel bearing onto axle stud

Use assembly device -MP 5-403-.
Screw wheel hub with wheel bearing up to the stop onto axle stud.
Screw on assembly device -MP 5-403- and pull wheel hub with
wheel bearing up to the stop.

Unscrew assembly device -MP 5-403- and screw on new twelve-
point nut and tighten.

Install brake drum Chapter.
Drive in cap
Note
t Replace cap after each removal.

Damaged caps allow moisture to penetrate. Therefore absolutely use
t
the shown tool.
Tightening torques:
Wheel hub with wheel bearing on axle stud 70 Nm + 40
Repairing the wheel bearing - disc brake

t Drive bushing -MP 3-427-
t Hub cap extractor -MP 5-404-
1- Brake disc, internally ventilated

3- 4 Nm
4- Brake disc
Assignment Electronic Catalogue of Original Parts
5- Cap
t press off Fig. and Fig.
t inserting Fig.
this wheel hub/wheel bearing unit is maintenance-free and has no play; it is not possible to undertake any
t
kind of adjustment or repair work on it!
t only replace completely after each removal
Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel bearing,
t the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with wheel
bearing Fig.
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is therefore
t
not pressed on separately.
8- Axle body
9- Brake caliper
t dismantling Fig.
10 - Axle stud
t Re-cutting the thread is not allowed.
Press off cap

Release cap from its position by gently tapping the claw.
Press off cap
Remove brake caliper

Unscrew screws -A-, remove brake caliper and attach e.g. with wire
to body.
Note
Do not unscrew the brake hose to remove the brake caliper.

Unscrew the fixing screw of the brake disc and remove brake disc.
Release twelve-point nut.
Remove the wheel bearing housing from the axle stud

Remove inner ring of the bearing from axle stud

Note
Do not damage the ABS wheel speed sensor when pulling off the inner
ring of the bearing.
Use assembly device -MP 5-403-.
Fit the wheel hub with wheel bearing as far as possible onto the axle
stud.
Screw on assembly device -MP 5-403- and pull wheel hub with
wheel bearing up to the stop.

Screw on assembly device -MP 5-403- and tighten wheel hub with
twelve-point nut.
Install brake disc, screw in phillips head screw and tighten.
Drive in cap
Note
t Replace cap after each removal.

Damaged caps allow moisture to penetrate. Therefore absolutely use
t
the shown tool.
Install brake caliper and tighten Allen screws.
Tightening torques:
Wheel hub with wheel bearing on axle stud 70 Nm + 40
Securing screw for brake disc 4 Nm
Screws for brake caliper 65 Nm
General points
The vehicle must only be aligned using an alignment gauge released by the manufacturer!
It is recommended to align the front and rear axles during each vehicle alignment procedure.
Otherwise correct vehicle driving behaviour cannot be guaranteed!
Note
t Only perform a vehicle alignment after the first 1000 to 2000 km to allow the helical springs to fully settle.
t During adjustment work try to approximate the nominal values.
For vehicles equipped with ESP, the basic setting must be carried out after the axial measurement,
t
function 04, group 060 Chapter.
If the fitting position of the rear axle and hence the running direction of the vehicle are not considered this
could result in a skewed steering wheel.
Removing and installing steering wheel Body Work; Rep. gr.69.
It is necessary to perform a vehicle alignment in the event of:
t incorrect driving behaviour;
t damage caused by accident and if parts have been replaced;
t axle parts have been removed;
t there is unilateral tyre wear.
Front axle part replaced Chassis alignment required Rear axle part replaced Chassis alignment required
yes no yes no
track control arm X Shock absorber X
Wheel-bearing housing X Coil spring X
Track rod/track-rod ends X Complete rear axle X
Steering gear X Assembly carrier 1) X
Assembly carrier Bottom suspension arm 1)

X X
Top suspension arm 1)
Suspension strut X Trailing arm 1) X

1)
Only on vehicles with four-wheel drive
Test conditions
l Determine the chassis version according to the vehicle data sticker Chapter.
Check the wheel suspensions, wheel bearing, steering and steering linkage for impermissible play and
l
damage, if necessary repair.
l Check tyre inflation pressure, if necessary correct BookletOctavia or fuel-tank cap sticker.
l Check the tyre tread depth. The difference between the left and right tyres on an axle must not exceed 2 mm.
l The unladen weight of the vehicle must correspond with the vehicle documents.
Unladen weight: Weight of the vehicle with full fuel tank and full water reservoir for windscreen wiper/washer
and headlamp cleaning system, spare wheel, tool kit, jack and without driver. The spare wheel, tool kit and jack
must be located in the position prescribed by the vehicle manufacturer.
Vehicle must be aligned, with the springs having been repeatedly deflected and having returned to their
l
original position.
l Make sure that during alignment no sliding base and no rotating plate touch the limit stop.
l The steering wheel must be in the posItion required to drive straight ahead .
Very important!
The measuring device must be positioned and adjusted in compliance with the specifications; observe the
l
manufacturer's instructions!
If necessary obtain information on your alignment gauge from the manufacturer.
In the course of time the alignment platform and alignment gauge/alignment computer may deviate from their
original adjustment/setting.
The alignment platform and alignment gauge/alignment computer must be tested and adjusted during a
maintenance operation at least once a year or following the manufacturer's instructions and if necessary be
adjusted!
Treat these precision instruments with great care.
Measurement preliminaries
The lateral runout on the rims must be balanced (compensated).
Correct toe-in adjustment is impossible if the rim run-out has not been compensated!
Comply with the instructions of the alignment gauge manufacturer.
Perform a rim runout compensation.
Lower vehicle and deflect the springs.
Insert brake pedal arrester, e.g. -V.A.G 1238/B-.

Overview of the work sequence for vehicle alignment
The following sequence of work steps must always be respected!
Determine what chassis has been mounted in the vehicle. This
1-
information can be found on the vehicle data sticker Chapter.
Check camber on front axle, if necessary take the
2-
mean Chapter.
3- Check camber on rear axle Chapter.
Checking the track on the rear axle, if necessary taking the
4-
mean/adjusting Chapter.
Vehicles with front-wheel drive: The track of the rear axle is not
adjustable, only take the mean of the track.
Vehicles with four-wheel drive: The track on the rear axle is
adjustable.
5 - Check the track on the front axle, if necessary adjust Chapter.
The following always applies!
Always check the transversal inclination of the vehicle before
adjustment if one of the measuring values is outside the
tolerance Chapter.
Checking the transversal inclination of the vehicle
Transversal inclination of the vehicle straight-ahead position
It is possible the vehicle is skew if the measured values lie outside the
tolerance of the nominal values for the front and rear axle
( Chapter).
RHD vehicles or e. g. vehicles with an automatic gearbox may be
slightly skew.
This is normal and is due to the fitting locations of the assemblies and
the related weight transfer.
Deflect the vehicle repeatedly and allow the springs to return to
their original position.

Note
Only determine dimension a on the rear axle.

Determining dimension a for the left and right vehicle side.
-a-left - left vehicle side
-a-right- right vehicle side
= 90
Compare dimensions -a-left and -a-right.
The deviation between -a-left and -a-right must neither exceed nor fall
short of 5.0 mm.
Correct any deviations outside the tolerance of 5.0 mm.
If the deviation is exceeded, e.g. 8,0 mm, correct the difference on the
rear axle on the relevant side by placing weights in the boot.
Suitable weights are e.g. sand bags approx. 10 kg
Checking the camber on the front axle, if necessary take the mean
The camber cannot be adjusted, it can only be centred!
If the values lie outside the tolerance the transversal inclination must be checked and if necessary
adjusted Chapter.
It is only possible to evenly center the camber within the tolerance range by shifting the complete engine-
gearbox assembly carrier.
Release screws -1- and - 2-.

Move the assembly carrier until the camber is equal on both sides.
Subsequently check the castor.
When moving the assembly carrier the castor may change.
Tighten the assembly carrier with new screws.
Tightening torques:
Assembly carrier to body 100Nm + 90

t Screw position -1-
t Use new screws!
Assembly carrier to body 100Nm + 90

t Screw position -2-
t Use new screws!
Checking the camber on the rear axle

The camber cannot be adjusted.
adjusted Chapter.
If the measured values still lie outside the tolerance, check the axle body for damage and if necessary replace.
Checking the track on the rear axle, if necessary taking the mean/adjusting
adjusted Chapter.
Vehicles with front-wheel-drive
The overall track of the rear axle is not adjustable.
It is only possible to take the mean of the individual track values equally by moving the mounting brackets.
Loosen all screws of the mounting bracket -1-.
Move the bracket of the rear axle -1- in transverse direction.
-2- Rear axle body
Tighten screws: 30 Nm + 90.
Always use new screws!
If the measured values still lie outside the tolerance, check the axle
body for damage and if necessary replace.
Vehicles with four-wheel drive
The overall track value of the rear axle is adjustable.
Loosen all screws of the mounting bracket -1-.

Move the mounting bracket -1- in transverse direction.
2- Trailing arm
Tighten screws: 75 Nm.
Always use new screws!
Check the overall track after adjusting the single track. The overall
track must correspond with the specified nominal value Chapter.
Checking the track on the front axle, adjusting if necessary

adjusted Chapter.
Release counternut -1 -.
Adjust track by turning the left and/or right track rod.
Position open-end wrench on hexagon -arrow-.
Check that the bellows have not become twisted after turning the
track rods!
Twisted bellows wear fast. Bellows replace if damaged.
Tighten counternut -1- with 50 Nm and again check track value.
After tightening counternut -1- the set value may change slightly.
Make sure this value remains within the tolerance for the nominal
value. If this is not the case repeat the track adjustment operation.
Checking the left and right steering angle

This check is only required if:
t the steering angles differ by more than 2 from the steering centre.
t at full steering angle the tyres come into contact with components on the front axle or body on one side,
t the left/right turning clearance circle differs.
The distance between the components on the front axle and the tyres -arrow- must be the same on both sides at
maximum steering angle.
If the distance is unequal it is possible to correct the distance by turning the left and right track rod.
Example:
The distance between the front axle components and the tyres is
smaller on the right than on the left.
Release the counternuts on the track rods.
Turn the track rod on the left (slightly unscrew from track-rod end).
Turn the track rod on the right to the same extent (screw into
track-rod end).
Check overall track.
After this adjustment procedure the overall track must correspond
with the specified nominal value!
Tighten counternuts to 50 Nm.
After tightening the counternuts the set value may change slightly.
Make sure this value remains within the tolerance for the nominal value. If this is not the case repeat the
overall track adjustment operation.
Check that the bellows have not become twisted after turning the track rods!
Twisted bellows wear fast. Bellows replace if damaged.
Calculation of the misalignment on the rear axle

Note
The indicated values are only given as an example.
For track values with the same preceding sign (+/+ or -/-) subtract the smaller value from the greater value
and divide by 2.
Track value Track value
on the left rear wheel on the right rear wheel
+ 15' + 5'
15' - 5' = 10'
10' : 2 = 5'
Misalignment of the rear axle = 5'

Value with a different preceding sign (+/-) are added up and the sum is divided by 2.
Track value Track value
on the left rear wheel on the right rear wheel
+ 15' + 5'
15' + 5' = 20'
20' : 2 =10'
Misalignment of the rear axle = 10'
The relevant result is the actual deviation of the running direction from the longitudinal vehicle axis.
Wheels and tyres

Wheel/tyre combinations Chapter
General points
For safety reasons never change tyres individually but at least in axle pairs.
Tyres with the greatest tread depth must always be fitted at the rear.
It is recommended to fit tyres of the same make, same type and tread pattern on all wheels.
When replacing the disc wheel or the tyre always replace the rubber valve.
Mount the tyre with the DOT marking pointing towards the outside of the wheel. This applies only to the left
side of the vehicle for directional tyres.
For directional tyres mount a wheel/tyre combination for the right side of the vehicle as spare wheel.
Disc wheel
Note
t Because of design variations the disc wheel and wheel trim cap may differ from the figure.
t When using anti-theft wheel bolts, the anti-theft bolt must be as close as possible to the valve.
1- Tyres
2- Wheel rims
t 6J x 14 H2, ET38
t 6J x 15 H2, ET38
4- Remove wheel trim cap
5- Pull-off hook
6- Wheel bolt key
t included in tool kit
7- Balancing weights
t max. 60 g allowed per rim flange
8- Retaining spring for balancing weights
9- Valve
t only use valve in accordance with spare part catalogue
Light-alloy wheel
Note
Because of design variations the light alloy rim and wheel trim cap may differ from the figure.
1- Tyres
2- Light-alloy rim
t 6J x 15H2, ET38
t 6.5J x 15 H2, ET43
t 6.5J x 16 H2, ET42
4- Wheel bolt key
5- Pull-off shackle
t included in tool kit
6- Cap
7- Wheel trim cap
8- Adapter for anti-theft wheel bolt
9- Cap for anti-theft wheel bolt
10 - Anti-theft wheel bolt, 120 Nm
11 - Balancing weights
t max. 60 g allowed per rim flange
12 - Retaining spring for balancing weights
13 - Valve
t only use valve in accordance with spare part catalogue
Brake, brake mechanics

Changing the brake pads of the front brake - Mounting instructions
When changing the pad, observe the following:
Check the protective collar of the piston for brake caliper.
Replace the protective collar if damaged.
When replacing the collar:
Check the contact surfaces of the brake piston and the brake caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and replace the sealing sleeve.
Check the brake piston and the brake caliper (corrosion, grooves on the outside of the cylinder surface),
replace the brake caliper completely if damaged.

For the piston of the brake caliper, press into the initial position:
Check if the piston can be slightly pressed into the brake caliper.
If the piston cannot be slightly pressed into the brake caliper:
Check and clean the brake piston as well as the brake caliper, replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.
Repairing front brake, the floating caliper disc brake FS-III

t Piston jig -MP 9-403-
t Brake pedal load, e.g. -V.A.G 1238/B-
t Brake filling and bleeding device, e.g. -VAS 5234-
t Bleeding bottle (commercially available)
t Brake fluid Chapter
t Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note
t Observe the instructions for changing the pad Chapter.
After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
t
ensure the brake pads are properly seated in their normal operating position.
Before removing a brake caliper or separating a brake hose from the brake caliper, the brake pedal must be
t
locked; e.g. with brake pedal load -V.A.G 1238/B-.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid from the brake
t
fluid reservoir. Brake fluid is toxic and must never be sucked into your mouth via a hose!
t Already used brake fluid must never be used again.
t Tightening torque of the wheel screws: 120 Nm
1- 4 Nm
2- Brake disc
t Thickness: 22 mm
t Wear limit: 19 mm
t if worn always replace axle-wise
t unscrew the brake caliper before removing
Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent, as you could
t
otherwise damage the brake discs.
t Technical data Chapter
3- Brake pads
with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the dash panel insert
t
lights up
t Thickness 19.5 mm including support plate
t Wear limit: 7 mm including support plate
t Inspect thickness BookletOctavia
t always replace axle-wise
t Observe the instructions for changing the pad Chapter
t 05.98 : do not interchange the inside and outside brake pads Chapter
4- Brake caliper
t removing:
Remove brake pads -Pos. 3
Insert brake pedal load.
Unscrew brake hose -Pos. 7- from brake caliper
t Installing:
Install brake pads -Pos. 3-
Screw brake hose -Pos. 7- to brake caliper
Take out brake pedal load.
Bleeding Brake System Chapter
t repairing Chapter
t Observe the instructions for changing the pad Chapter
5- Guide bolt, 30 Nm
6- Cap
7- Brake hose with banjo union and hollow screw
t cannot be disassembled, must be fully replaced
t Tightening torque: 35 Nm
8- Wheel-bearing housing
9- 8 Nm
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a solid lubricant
t
paste -G 000 650- (e.g. Wolfrakote Top Paste)
11 - Cover plate
12 - 10 Nm
13 - Wheel bearing
14 - Circlip
15 - Wheel hub with pulse rotor
16 - Wheel hub without pulse rotor
Fitting location of shift mechanism

The coupling rod -C- serves as countersupport for the selector movements
Double arrow -A- shift movement
Double arrow -B- selector movement
A- Gear shift rods for shift movement

B- Coupling rods for selector movement
Note
t On models fitted with a coded radio set, determine the coding.

Disconnect earth strap at battery before carrying out work on
t
the shift mechanism in the engine compartment Electrical System Rep. Gr.27.
When the battery is reconnected, pay attention to the work after connecting the battery Electrical
t
System Rep. Gr.27.
t Grease all bearing and contact surfaces with grease -G 000 450 02-.
I- Summary of components - shift housing / shift lever Chapter

II - Summary of components - reverse-shift mechanism at the gearbox Chapter
Removing and installing shift housing Chapter.
Setting the shift mechanism Chapter.
Summary of components - shift housing / shift lever
Note
Grease all bearing and contact surfaces with grease -G 000 450 02-.
1- Gearshift knob
q removing and installing together with the collar Pos. 2
q removing Fig. and Fig.
2- Collar
q removing and installing together with the gearshift knob Pos. 1
q removing Fig. and Fig.
q Separate collar from gearshift knob Fig.
q before installing, assemble with gearshift knob Fig.
3- Sound absorption
q only for vehicles fitted with a 1.9 litre/50 kW engine
4- Clamping sleeve
q connects collar with gearshift knob
q removing and installing Fig.
q for securing the gearshift knob to the gearshift lever
q open Fig.
q always replace Electronic Catalogue of Original Parts
q attach with hose binding claw -V.A.G 1275- onto the gearshift knob
6- Shift lever
q removing and installing from shift housing Chapter
7- Spacer bush
8- Collar screw, 25 Nm
9- Shift housing
q removing and installing Chapter
10 - Gear shift rod
q removing and installing Chapter
q after installing set shift mechanism Chapter
11 - 20 Nm
12 - 25 Nm
13 - Pressure spring
14 - Stop
q after installing set shift mechanism Chapter
15 - 25 Nm
q Coat thread with locking agent -D 000 600 A2-
16 - Ball socket
q removing Chapter
17 - Bushing
18 - Shock absorber
19 - 15 Nm
Remove gearshift knob and collar
Pull out the collar for the shift lever towards
the top -arrows-.
Open warm-type clamp
Open the open warm-type clamp -

arrow- and pull off gearshift knob together
with the collar.
Separate gearshift knob from collar and
assemble with collar
Turn collar inside out.
Lever off clamping sleeve -arrow- with
screwdriver.
Detach clamping sleeve from shift lever.
Turn gearshift knob inside out and detach
from collar.
Install
Turn collar inside out.
Insert gearshift knob into collar.
Push clamping sleeve over gearshift knob
and collar.
Press together clamping sleeve until it clicks
into place.
Setting the shift mechanism
t Shift lever gauge -3421-
Note
t The following are required for correct setting of the shift mechanism:
t Operating and transmission elements of the shift mechanism are in perfect condition.
t Shift mechanism operates freely.
t Gearbox, clutch and clutch control must be in perfect condition.
l Gearbox in Neutral.
Remove gearshift knob with collar Chapter.

Loosen warm-type clamp -arrow-. The shift
rod/selector lever should move freely.
Remove the bushing -3- from the shift
lever Anchor.
Slacken screw -1- and -2- and on the right

side press downwards to the stop -arrow-.
Tighten screw again -1-.
Position shift lever gauge -3421-, for this
step move shift lever completely to the
right (into the gate).
Press shift lever to the left into the support
of the shift lever gauge -3421-.
After this align shift lever and selector lever
free of stress.
Note
Make sure that no gear is engaged at the

gearbox (neutral position).
Tighten nut -arrow- for warm-type clamp to

20 Nm and take out shift lever gauge
-3421-.
Install bushing for shift lever Chapter.
Depress clutch.
Engage reverse gear.
Release screw -1-.
Note
Then press down the left side of the stop -

direction of arrow-.
Tighten screws-1- and -2- to 25 Nm.
Take out reverse gear.
Depress clutch.
Shift through all gears several times. Pay

particular attention to proper operation of
the reverse gear lock.
If a gear catches when repeatedly engaging,

proceed as follows:
Engage 1st gear.
Eliminate the play in the shift mechanism

by carefully pressing the shift lever to the
left.
l The distance -a- must then be 2.0 mm
If this is not the case, carry out fine
adjustment.
Fine adjustment
Shift lever must be positioned in Neutral in

l
the gate of 3rd/4th gear.
Slacken screws -1- and -2- only so far so

that the stop remains in a new position
when adjusting.
Engage 1st gear.
Eliminate the play in the shift mechanism

by carefully pressing the shift lever to the
left.
Set dimension -a- (2.0 mm) by carefully
adjusting the stop.
Tighten again the screws -1- and -2- in this

position to 25 Nm. Thus, hold stop and shift
lever in the correct position.
Install gearshift knob with collar Chapter.

Overview of fitting locations
Note
t Components marked with an * are tested by self-diagnosis Chap. 01-1.

Components marked with ** are tested by final control diagnosis Chapter
t
01-1.
1- Activated charcoal filter system solenoid valve 1 -N80-*/**

q resistance: 2230
2- Return-flow line
q secure with spring strap clamps
q to fuel delivery unit in fuel tank
3- Feed line
q secure with spring strap clamps
q from fuel filter
4- Camshaft position sensor -G163-*
q for engines with engine code AVU
q under top toothed belt guard
q inspect Chapter 28-1
5- Variable intake manifold changeover valve - N156- */**
6- Top part of intake manifold
q disassembling and assembling Chapter
7- Bottom part of intake manifold
8- Connector, 81 pin
q only insert or remove plug when the ignition is switched off
q unlock before removing
9- Engine control unit*
q Fitting location: in plenum chamber
q replacing Chapter 24-6
10 - Connector, 40 pin
q only insert or remove plug when the ignition is switched off
q unlock before removing
11 - Throttle valve control unit -J338-*
q 6-pin connector
q contacts gold-plated
12 - Camshaft position sensor -G163-*
q for engines with engine code BFQ
q at rear of cylinder head
13 - EGR valve - N18- */**
q with EGR potentiometer -G212-
q 6-pin connector
q Adaptation Chap. 24-6
14 - Combination valve
Secondary air pump 1.6 l/75 kW Engine, Mechanical Components; Rep.
q
Gr.26
15 - Protective housing for relays and fuses
q installation position:
t Secondary air injection pump relay -J299- */**
t Power supply of Simos engine control unit -J363-
q only on vehicles fitted with automatic gearbox
t Fuse for brake vacuum pump - V192-
t Fuse for secondary air injection pump motor -V101-
16 - coolant temperature sender -G62 -*
q green
q for engine control unit
q with coolant temperature sender - G2-
q resistances Chapter
17 Brake vacuum pump -V192- with brake servo unit control unit -J542- (only
- on vehicles fitted with automatic gearbox) */**
18 - Air mass meter -G70- with intake air temperature sender -G42- *
q contacts of sender and of connector gold-plated
q resistances for intake air temperature sender -G42- Chapter
19 - Air filter
20 - Power output stage -N122- with ignition coil -N, N128-
q with identification for ignition leads, do not switch
q resistances Chapter 28-1
21 - Engine speed sender -G28-*
q resistance: 7301000
22 - Injection valves -N30N33-*
q resistance: 1217 (at approx. 20 C)
test injected quantity, leak tightness and spray pattern of
q
injectors Chapter 24-2.
23 - Secondary air injection pump motor -V101- */**
Secondary air system: 1.6 ltr./75 kW Engine - Mechanical
q
Components; Rep. Gr.26
24 - Knock sensor I -G61-*
25 - Fuel pressure regulator
26 - 4-pin connector
q Brown
for lambda probe heater -Z29- and lambda probe downstream of catalytic
q
converter -G130-
q on underside of vehicle on right
27 - Lambda probe downstream of catalytic converter -G130-, 50 Nm*
only coat thread with hot screw paste G 052 112 A3; the paste must not
q
get into the slot of the probe body.
Test lambda probe -G130- and lambda control downstream of catalytic
q
converter Chapter 24-4
28 - 6-pin connector
q black
for lambda probe heater -Z19- and lambda probe upstream of catalytic
q
converter -G39-
q on underside of vehicle on right
29 - Lambda probe upstream of catalytic converter -G39-, 50 Nm*
q Fitting location: in the exhaust manifold
only coat thread with hot screw paste G 052 112 A3; the paste must not
q
get into the slot of the probe body.
Test lambda probe -G39- and lambda control upstream of catalytic
q
converter Chapter 24-4
30 - PAS pressure switch -F88- *
Pedal assembly - installed position
1- Clutch pedal switch -F36-
Brake light switch -F- and Brake pedal

2-
switch -F47-
Accelerator pedal position sender -G79-

3 - and accelerator pedal position sender 2
-G185-
Fuel Injection System
Removing and installing parts of the injection system
Note
Components marked with an * are tested by self-diagnosis Chap. 01-1.
1- Air filter
2- 6 Nm
3- 10 Nm
4- 3 Nm
5- Bottom part of intake manifold
6- Feed line
q white
q secured with spring strap clip
q from fuel filter 1.6 ltr./75 Engine, Mechanical Components; Rep. Gr.20
7- Return-flow line
q blue
q secured with spring strap clip
to fuel delivery unit in fuel tank 1.6 ltr./75 kW Engine, Mechanical
q
8- Fuel rail with injection valves
9- 3-pin plug connection
q for engines with engine code AVU
q black
q for camshaft position sensor -G163-
10 - 15 Nm
11 - Connector
q for coolant temperature sender -G62-
q 4-pin
q black
12 - coolant temperature sender -G62 -*
q green
q with coolant temperature sender - G2-
q resistances Chapter
q before removing, reduce pressure in cooling system if necessary
13 - O-ring
q replace if damaged
14 - Retaining clip
q check tightness
15 - Gasket ring
q replace
16 - Connector
q black, 2 pin
q for injection valve -N30...N33-
17 - Gasket ring
18 - Connector
q black, 2 pin
q for variable intake manifold changeover valve -N156-
19 - Cable rail
20 - Body-bound rivet
21 - Top part of intake manifold
q with variable intake manifold changeover
22 - 3-pin plug connection
q grey
q for engine speed sender
q Fitting location: close to dipstick
23 - Engine speed sender -G28-*
q Resistance 730...1000
24 - Support
q between intake manifold and cylinder head
25 - 8 Nm
q for attaching vent connection
26 - Rubber bush
27 - 8 Nm
28 - To activated charcoal filter solenoid valve 1 -N80-
Activated charcoal filter 1.6 ltr./75 kW Engine, Mechanical
q
29 - From heater feed
30 - Connector
q 6-pin
q for throttle valve control unit -J338-
31 - To T-connection and on to coolant expansion bottle
32 - 10 Nm
33 - Camshaft position sensor -G163-
34 - Connector
q 3-pin
q for camshaft position sensor -G163-
35 - To the brake servo unit
36 - Gasket ring
q replace if damaged
q before fitting moisten with clean engine oil
37 - Gasket
q replace
38 - From exhaust gas recirculation valve
39 - Air intake hose
q with crankcase ventilation valve
q with crankcase ventilation with heating resistor (only for models with
optional equipment)
40 - For housing ventilation
41 - To EGR valve - N18-
q clean air connection to fresh air supply
42 - To secondary air pump
43 - Air mass meter -G70- with intake air temperature sender -G42- *
q resistances for intake air temperature sender -G42- Chapter
Disassembling and assembling top part of intake manifold

Note
t Components marked with an * are tested by self-diagnosis Chap. 01-1.

Components marked with ** are tested by final control diagnosis Chapter
t
01-1.
1- 8 Nm
2- Throttle valve control unit -J338-*
q 6-pin connector
q if replaced adapt engine control unit Chapter 24-6
if replaced, adapt automatic gearbox control unit Automatic
q
Gearbox; Rep. Gr.01
3- Gasket ring
q replace
4- Pressure relief valve
q protects intake manifold from damage if excess pressure exists
5- Top part of intake manifold
6- Body-bound rivet
7- Variable intake manifold changeover valve - N156- */**

Skoda Octavia 1 98-10

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Chassis - Specified values

Nominal values front axle

Spring strut type axle (front- and four-wheel drive)

Camber4) - 30' 30' - 33' 30' - 16' 30'

Twist-beam rear axle

Specified values rear axle - four-wheel drive

Twist-beam rear axle

Example of a vehicle data sticker

Engine litre/kW 1,4/44; 1,4/55 1,6/55 1,6/74; 1,6/75 1.9/50

Engine litre/kW 1,8/132 1,9/74 1,9/96

Classification N 052 766 ZO (USA standard FMVSS 571.116 DOT 4)

1.6ltr./74 kW 175/80 R14 88 H - 6J x 14 H2 38 X -

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

Repairing front wheel suspension

I - Removing and installing assembly carrier, anti-roll bar,

When moving vehicles with drive shaft removed, it is

1- track control arm

Removing and installing the track control arm

Insert supporting device -MP 9-200- and support engine/gearbox

Mark installation position of bolts -1-, otherwise the steering

Release screws -1-.

Unscrew screws -3-, if present, at the track control arm.

Release the screw -1- downwards by slightly pressing the assembly

in the former positions.

with the suspension strut.

the wheel bearing.

touch the ground.

The torque wrench is recommended e.g. for tightening the twelve-

Press in front bearing for track control arm

Use acid-free lubricant, e.g. -G 294 421-, when pressing in the

Fitting position of rear bearing for track control arm

Removing and installing assembly carrier

Release screws -1-.

shown in the fig.

Release screws -1- and -2- and remove pendulum support.

-V.A.G. 1359/2-, under the assembly carrier.

Pressing out and in rubber-metal bearing

Pressing out the rubber-metal bearing

Pressing in rubber-metal bearing

Coat rubber-metal bearing and assembly carrier with acid-free

Repairing wheel bearing housing

Press the wheel hub out of the wheel bearing

Removing and installing circlip

Press the wheel bearing out of the wheel bearing housing

inner ring of the bearing by turning the threaded spindle.

Press the wheel bearing into the wheel bearing housing

After pressing in the wheel bearing, the circlip must be

Press the wheel hub into the wheel bearing

Inspecting the steering joint

t For these two tests no play may be felt or be visible.

Removing and installing the steering joint

Replace hexagon collar nut.

Remove and install suspension strut and wheel bearing housing

Release screws -1-.

-V176- (commercially available).

with wire to body.

the wheel hub).

Unscrew the suspension strut on the body with socket wrench

insert -MP 6-427-.

wheel bearing housing.

secure it to the suspension strut dome.

in the former positions.

the wheel bearing.