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Octavia II 2004
Skoda Octavia II 2004 User Manual
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ng for private or commercial
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e, is not permitted
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KODA AUTO A.
S.
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KODA AUTO A. S.
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nformation in this document. Copyrig
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KODA AUTO A. S.
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Workshop Manual
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2.0/100; 103 kW TDI PD Engine
Engine ID
BKD
AZV
BMM
Edition 01.2018
Service
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Table of Contents
Table of Contents
3
Technical Data
7
Engine Number
7
Engine Characteristics
7
Self-Diagnosis
8
Self Diagnosis, Safety Measures, Cleanliness Regulations and Directions
8
Additional Instructions When Undertaking Assembly Work on the Air-Conditioning System
8
Safety Precautions When Working on Fuel Supply System
9
Safety Precautions When Working on the Diesel Direct Injection System
9
Regulations Concerning Cleanliness When Working on the Fuel Supply/Fuel Injection System
10
Regulations Concerning Cleanliness When Working on the Exhaust Gas Turbocharger
10
General Instructions for Charge Air System
11
Removing and Installing Engine
13
Removing Engine
13
Securing the Engine to the Assembly Stand
20
Installing Engine
21
Unit Mounting - Tightening Torques
25
Checking and Adjusting the Assembly Bracket
26
Crankshaft Group
29
Disassembling and Assembling Engine
29
Removing and Installing V-Ribbed Belt
29
Removing and Installing Toothed Belt for Engines with Code BKD, AZV
32
Removing and Installing Toothed Belt for Engines with Code BMM
44
Removing and Installing Sealing Flange and Flywheel
54
Replace Crankshaft Seal on Belt Pulley Side
55
Removing and Installing the Sealing Flange on the Belt Pulley Side
57
Replace Sealing Flange on the Gearbox Side
59
Removing and Installing the Two-Mass Flywheel
65
Crankshaft, Piston and Conrod
67
Removing and Installing Crankshaft
67
Removing and Installing Drive Chain Sprocket
68
Replace Needle Bearing for Crankshaft
68
Disassembling and Assembling Pistons and Conrods
69
Inspect Piston Projection at TDC
73
Separating New Connecting Rod
74
Cylinder Head, Valve Gear
75
Removing and Installing Cylinder Head
75
Summary of Components for Engines with Code BKD, AZV
75
Removing and Installing Cylinder Head Cover for Engines with Code BKD, AZV
78
Removing and Installing Cylinder Head for Engines with Code BKD, AZV
79
Checking the Compression Pressure for Engines with Code BKD, AZV
87
Summary of Components for Engines with Code BMM
87
Removing and Installing Cylinder Head Cover for Engines with Code BMM
89
Removing and Installing Cylinder Head for Engines with Code BMM
91
Checking the Compression Pressure for Engines with Code BMM
99
Repairing Valve Gear
101
Summary of Components for Engines with Code BKD, AZV
101
Checking the Axial Play of the Camshafts for Engines with Code BKD, AZV
103
Replacing the Sealing Rings for Camshafts for Engines with Code BKD, AZV
103
Removing and Installing Camshafts for Engines with Code BKD, AZV
104
Removing and Installing Valve Levers for Engines with Code BKD, AZV
111
Checking the Hydraulic Supporting Elements for Engines with Code BKD, AZV
113
Replacing Valve Stem Seals for Engines with Code BKD, AZV
114
Valve Dimensions for Engines with Code BKD, AZV
116
Summary of Components for Engines with Code BMM
117
Checking the Axial Play of the Camshaft for Engines with Code BMM
118
Replacing the Sealing Ring for Camshaft for Engines with Code BMM
119
Removing and Installing the Camshaft for Engines with Code BMM
121
Checking the Hydraulic Bucket Tappets for Engines with Code BMM
124
Replacing Valve Stem Seals for Engines with Code BMM
125
Valve Dimensions for Engines with Code BMM
127
Inspecting Valve Guides
127
Lubrication
128
Removing and Installing Parts of the Lubrication System
128
Disassembling and Assembling the Oil Filter Holder
130
Removing and Installing Oil Pan
131
Removing and Installing Oil Pump
133
Testing Oil Pressure and Oil Pressure Switch
133
Cooling
135
Removing and Installing Parts of the Cooling System
135
Parts of the Cooling System Fitted to Body for Engines with Code BKD, AZV
135
Parts of the Cooling System Engine Side for Engines with Code BKD, AZV
137
Connection Diagram for Coolant Hoses for Engines with Code BKD, AZV
139
Draining and Topping up Coolant for Engines with Code BKD, AZV
141
Removing and Installing
143
Removing and Installing Radiators for Engines with Code BKD, AZV
144
Parts of the Cooling System Fitted to Body for Engines with Code BMM
145
Parts of the Cooling System Engine Side for Engines with Code BMM
147
Connection Diagram for Coolant Hoses for Engines with Code BUD
149
Draining and Topping up Coolant for Engines with Code BMM
149
Fan Shroud for Radiator Fans V7 and V35 for Engines with Code BMM Removing and Installing
151
Removing and Installing the Radiator for Engines with Code BMM
152
Removing and Installing Coolant Pump
153
Removing and Installing Coolant Regulator
153
Check Cooling System for Leaks
154
Fuel Supply System
156
Removing and Installing Parts of the Fuel Supply System
156
Fuel Tank with Attached Parts for Vehicles with Front-Wheel Drive
156
Fuel Tank with Attached Parts for Vehicles with Four-Wheel Drive
158
Removing and Installing Fuel Filter
160
Extract Fuel from the Fuel Tank
161
Removing and Installing Fuel Cooler
163
Remove and Install the Fuel Tank for Vehicles with Front-Wheel Drive
163
Removing and Installing Fuel Tank for Vehicles with Four-Wheel Drive
165
Removing and Installing the Fuel Delivery Unit on Vehicles with Front-Wheel Drive
167
Removing and Installing the Fuel Delivery Unit on Vehicles with Four-Wheel Drive
168
Removing and Installing the Fuel Gauge Sender G
173
Removing and Installing Fuel Gauge Sender G169 on Vehicles with Four-Wheel Drive
175
Removing and Installing the Suction Jet Pump for Vehicles with Four-Wheel Drive
176
Removing and Installing Tandem Pump, Vehicles with Engine Code BKD, AZV
177
Removing and Installing Tandem Pump, Vehicles with Engine Code BMM
178
Inspecting a Tandem Pump
180
Inspecting Fuel Pump
185
Accelerator Control
188
Assembly Overview - Accelerator Module
188
Removing and Installing Accelerator Pedal Module
188
Turbocharging/Supercharging
190
Charge-Air System with Exhaust Gas Turbocharger - Part 1
190
Connection Diagram for Vacuum Hoses for Engines with Code BKD, AZV
190
Connection Diagram for Valve Block and Vacuum Sockets for Engines with Code BKD, AZV
191
Checking the Vacuum Actuator and Tension Rods for Charge Pressure Regulation for Engines with Code BKD, AZV
191
Connection Diagram for Vacuum Hoses for Engines with Code BUD
192
Charge-Air System with Exhaust Gas Turbocharger - Part 2
194
Removing and Installing Exhaust Gas Turbochargers for Engines with Code BKD, AZV
194
Removing and Installing Charge Air Cooling Parts for Engines with Code BKD, AZV
197
Removing and Installing the Exhaust Gas Turbocharger for Engines with Code BMM
199
Removing and Installing Charge Air Cooling Parts for Engines with Code BMM
202
Removing and Installing Charge Air Cooler
203
Hose Connections with Quick Couplings
204
Checking the Charge-Air System for Leak-Tightness
205
Mixture Preparation - Injection
208
Repairing Diesel Direct Injection System
208
Installation Locations for Engines with Code BKD, AZV - Overview
208
Intake Manifold - Summary of Components for Engines with Code BKD, AZV
211
Wiring Harness for Unit Injectors and Glow Plugs - Summary of Components for Engines with
212
Code BKD, AZV
212
Removing and Installing the Wiring Harness for Unit Injectors and Glow Plugs for Engines with
212
Removing and Installing the Air Filter for Engines with Code BKD, AZV
214
Repairing Unit Injectors for Engines with Code BKD, AZV
216
Removing and Installing Unit Injectors for Engines with Code BKD, AZV
216
Replacing the O-Rings of the Unit Injector for Engines with Code BKD, AZV
221
Installation Locations for Engines with Code BMM - Overview
222
Intake Manifold - Summary of Components for Engines with Code BMM
225
Removing and Installing the Air Filter for Engines with Code BMM
226
Repairing Unit Injectors for Engines with Code BMM
227
Removing and Installing Unit Injectors for Engines with Code BMM
227
Replacing the O-Rings of the Unit Injector for Engines with Code BMM
231
Removing and Installing the Engine Speed Sender G28
232
Engine Control Unit
233
Removing and Installing Engine Control Unit
233
Exhaust System
235
Removing and Installing Parts of the Exhaust System
235
Summary of Components for Engines with Code BKD, AZV
235
Summary of Components for Engines with Code BMM
237
Exhaust System for Vehicles with Four-Wheel Drive - Summary of Components
239
Removing and Installing Pre-Exhaust Pipe with Diesel Particle Filter
240
Replacing Middle or Rear Part of the Exhaust System
244
Align Exhaust System Free of Stress
245
Inspecting the Exhaust System for Leaks
246
Exhaust Gas Recirculation System
247
Removing and Installing Exhaust Gas Recirculation System Parts for Engines with Code BKD
247
Azv
247
Summary of Components - Radiator for Exhaust Gas Recirculation System for Engines with Code BKD, AZV
248
Checking the Mechanical Exhaust Gas Recirculation Valve for Engines with Code BKD, AZV
249
Function of the Exhaust Gas Recirculation Radiator
250
Checking the Change-Over for Exhaust Gas Recirculation Radiator for Engines with Code BKD
250
Azv
250
Removing and Installing the Radiator for Exhaust Gas Recirculation for Engines with Code BKD, AZV
251
Removing and Installing the Exhaust Gas Recirculation System for Engines with Code BMM
252
Summary of Components - Radiator for Exhaust Gas Recirculation System for Engines with Code BMM
253
Checking the Change-Over for Exhaust Gas Recirculation Radiator for Engines with Code
254
Bmm
254
Removing and Installing the Exhaust Gas Recirculation Radiator for Engines with Code BMM
254
Connection Diagram for Exhaust Recirculation Vacuum Hoses for Engines with Code BMM
255
Glow Plug System
256
Removing and Installing the Glow Plugs for Engines with Code BKD, AZV
256
Checking the Glow Plugs for Engines with Code BKD, AZV
256
Removing and Installing the Glow Plugs for Engines with Code BMM
256
Checking the Glow Plugs for Engines with Code BMM
257
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Skoda Octavia II 2004 Specifications
General
Brand
Skoda
Model
Octavia II 2004
Category
Automobile
Language
English
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