Škoda Octavia III 2013–2014 1.8 & 2.0 TSI Engine Workshop Manual (132kW / 162kW)

Technical Highlights

• Engine coverage: 1.8 TSI (132 kW) and 2.0 TSI (162 kW)

• Model years: 2013–2014

• Engine codes covered: CJS, CJSB, CHH

• Fuel system: FSI / MPI direct injection

• Turbocharging and charge-air systems

• Complete engine removal and installation procedures

• Factory torque values, tightening sequences, and safety instructions

• OEM Škoda service documentation (Edition 11.2013)

Delivery

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Full Contents

Technical data

• Technical data

• Engine number

• Engine characteristics

Self-diagnosis

• Self-diagnosis, safety measures, cleanliness regulations and directions

• Safety precautions when working on fuel supply system

• Safety measures for vehicles with start/stop system

• Releasing pressure in the high-pressure fuel system

• Cleanliness rules for fuel supply system

• Test conditions for fuel supply system

• Safety measures for fuel injection and ignition systems

• General notes on injection system

• General notes on ignition system

• General instructions for charge air system

• Additional instructions for air-conditioning system assembly work

Removing and installing engine

• Engine trim panel

  • Removing and installing engine trim panel

• Engine removal and installation

  • Removing engine

  • Separating engine from gearbox

  • Securing engine to assembly stand

  • Installing engine

• Assembly bracket and mountings

  • Assembly bracket for manual gearbox

  • Assembly bracket for DSG gearbox

  • Removing and installing engine mount

  • Removing and installing engine support

  • Removing and installing gearbox mount

  • Removing and installing pendulum support

  • Checking assembly bracket setting

  • Adjusting unit mounting

Crankshaft group

• Cylinder block – belt pulley side

  • V-ribbed belt drive – summary of components

  • Removing and installing poly V-belt

  • Removing and installing tensioner pulley

  • Removing and installing auxiliary unit bracket

  • Removing and installing ribbed belt pulley

• Cylinder block – gearbox end

• Sealing flange and flywheel

  • Summary of components

  • Removing and installing dual-mass flywheel

  • Removing and installing sealing flange on gearbox side

• Crankshaft

  • Summary of components

  • Assigning bearing shells

  • Replacing needle bearing

• Balancing shafts

  • Summary of components

  • Removing and installing inlet camshaft balancing shaft

  • Replacing sealing ring

  • Removing and installing exhaust camshaft balancing shaft

• Pistons and conrods

  • Summary of components

  • Removing and installing piston

  • Inspecting piston, piston rings and cylinder bore

  • Separating new conrod

Cylinder head and valve gear

• Timing chain covers

  • Summary of components

  • Removing and installing camshaft adjustment valves N205 / N318

  • Removing and installing top timing chain cover

  • Removing and installing bottom timing chain cover

  • Replacing crankshaft V-ribbed belt pulley seal

• Chain drive

  • Camshaft timing chain – summary of components

  • Removing and installing camshaft timing chain

  • Balancing shaft timing chain – summary of components

  • Removing and installing balancing shaft timing chain

  • Checking timing chain length

  • Checking valve timing

• Cylinder head

  • Summary of components

  • Removing and installing cylinder head

  • Checking compression

  • Testing combustion chamber tightness

• Valve gear

  • Summary of components

  • Oil trap and vacuum pump – summary of components

  • Removing and installing camshafts

  • Installing ball for camshaft slide

  • Replacing valve stem seals

  • Checking valve guides

  • Valve dimensions

Lubrication

• Oil sump and oil pump

  • Summary of components

  • Removing and installing oil level and oil temperature sender G266

  • Removing and installing oil sump bottom part

  • Removing and installing oil sump top part

  • Removing and installing oil pump

• Auxiliary unit bracket with oil filter and engine oil cooler

  • Summary of components

  • Removing and installing engine oil cooler

  • Removing and installing mechanical switch valve

• Crankcase ventilation

  • Summary of components

  • Removing and installing oil separator

• Oil pressure system

  • Oil pressure switch – summary of components

  • Removing and installing piston cooling nozzle control valve N522

  • Removing and installing oil pressure switches F22, F378, F447

  • Removing and installing oil pressure control valve N428

  • Testing oil pressure

  • Checking oil pressure for piston cooling nozzles

Cooling

• Cooling system

  • Coolant hose connection diagrams for manual and DSG gearboxes

  • Draining and filling coolant

  • Checking cooling system for leaks

• Coolant pump and temperature control

  • Summary of components

  • Coolant recirculation pump

  • Coolant valves for gearbox and cylinder head

  • Removing and installing coolant pump

  • Removing and installing coolant recirculation pump V51

  • Removing and installing coolant shut-off valve N82

  • Removing and installing positioning element N493

  • Removing and installing coolant temperature senders G62 and G83

• Coolant pipes

  • Summary of components

  • Removing and installing front coolant pipe

  • Removing and installing top coolant pipe

• Radiator and radiator fan

  • Summary of components

  • Removing and installing radiator fan

  • Removing and installing fan shroud

Fuel supply system

• Fuel tank

  • Front-wheel drive – summary of components

  • All-wheel drive – summary of components

  • Extracting fuel

  • Removing and installing fuel tank

• Fuel delivery unit and fuel gauge senders

  • Summary of components

  • Removing and installing fuel delivery unit

  • Removing and installing fuel gauge senders G and G169

  • Checking fuel delivery unit

• Fuel pump control unit

  • Removing and installing J538

• Suction spray pump

• Separating push-on couplings

• Accelerator pedal

  • Summary of components

  • Removing and installing accelerator module

• Activated charcoal filter system

  • Summary of components

  • Removing and installing activated charcoal filter

Turbocharging / supercharging

• Exhaust gas turbocharger

  • Summary of components

  • Removing and installing turbocharger

  • Removing, adjusting and setting charge pressure regulator V465

• Charge air system

  • Charge air cooling – summary of components

  • Removing and installing charge air cooler

  • Removing and installing charge pressure sender G31

  • Checking charge air system for leaks

Mixture preparation – injection

• Injection system layout and installation locations

• Air filter

  • Summary of components

  • Removing and installing air filter housing

• Intake manifold and fuel distributor

  • Intake manifold – summary of components

  • Fuel distributor FSI – summary of components

  • Fuel distributor MPI – summary of components

  • Removing and installing intake manifold

  • Removing and cleaning throttle valve control unit J338

• Injectors

  • Removing and installing FSI injection valves

  • Removing and installing MPI injection valves

  • Cleaning FSI injection valves

• Sensors and senders

  • Removing and installing fuel pressure sender G247

  • Checking fuel pressure sender

  • Removing and installing low-pressure fuel pump control unit G410

• High-pressure pump

  • Summary of components

  • Removing and installing high-pressure pump

• Lambda probes

  • Summary of components

  • Removing and installing Lambda probe G39

  • Removing and installing Lambda probe after catalytic converter G130

• Engine control unit

  • Removing and installing engine control unit J623 without protective housing

  • Removing and installing engine control unit J623 with protective housing

  • Removing and installing engine noise speaker

Exhaust system

• Front exhaust system

  • Summary of components

  • Removing and installing exhaust pipe

• Middle and rear exhaust system

  • Summary of components

  • Replacing exhaust sections

  • Removing and installing exhaust system

  • Aligning exhaust system free of stress

  • Aligning exhaust tailpipes

  • Inspecting exhaust system for leaks

Ignition system

• Ignition system

  • Summary of components

  • Removing and installing ignition coils with output stage

  • Removing knock sensor G61

  • Removing and installing Hall sender G40

  • Removing and installing Hall sender G300

  • Removing and installing engine speed sender G28