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Octavia Mk1

Components
Components
Gearbox
t  When installing the manual gearbox, ensure the dowel sleeves are correctly located between the engine and gearbox.
t  When assembling mounts as well as waxed components, the contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
t  When replacing the manual gearbox or the angle gearbox, the oil level must be checked, if necessary top up gear oil to lower edge of the filler hole → Chapter.
t  When replacing the rear final drive, the oil level must be checked, if necessary top up gear oil and oil for the Haldex coupling to lower edge of the filler hole.
t  Filling contents → Chapter.
t  Gearbox oil specification → Electronic Catalogue of Original Parts.
Sealant
t  Clean contact surfaces thoroughly and apply sealant -AMV 188 200 03-.
t  Apply sealant -AMV 188 200 03- evenly, and not too thickly.
Gasket rings, O-rings, gaskets
t  Always replace gasket rings, O-rings and gaskets → Electronic Catalogue of Original Parts.
t  After removing the gasket rings, check the contact surface on the housing or on the shaft for burrs or damage which occured during the assembly.
   
t  Radial shaft seals - before mounting lightly oil at outside diameter and fill half the space between the sealing lips -arrow- with sealing grease -G 052 128 A1-.
t  The open side of the sealing rings is turned towards the fluid to be sealed.
t  Press in new gasket ring in such a way that the sealing lip is not located on the same point as the sealing lip of the old gasket ring (use tolerance for insertion depth).
t  Before inserting lightly oil the O-rings, in order to prevent the rings being squashed during installation.
t  Check the oil level after replacing the gaskets and gasket rings.
t  Check the gear oil level in the manual gearbox and angle gearbox → Chapter.
t  Check the gear oil level in the rear final drive → Chapter.
Shaft seal for flange/propshaft on the Haldex coupling
t  Lightly oil before installing on the outside diameter and the space between the sealing lips with high efficiency oil for Haldex coupling -G 052 175 A1-.
t  After the installation, check the oil level in the Haldex coupling → Chapter.
Locking elements
t  Do not over-tension the circlips.
t  Always replace damaged or over-tensioned circlips → Electronic Catalogue of Original Parts.
t  Circlips must be positioned in the base of the groove.
  S00-0264
t  Replace roll pins. Fitting location: slot longitudinally to power flow.
Screws/nuts
t  Slacken and tighten fixing screws or fixing nuts of covers and housings crosswise.
t  Tightening torques apply for non-oiled nuts and bolts.
t  Always replace the self-locking nuts and screws.
t  It is important to ensure at all bolted connections that the contact surfaces as well as the nuts and bolts are waxed only after being installed, should this be necessary.
t  Clean all threaded holes into which self-locking screws are screwed in, using a screw-tap to remove locking agent residues. Otherwise there is a risk that the bolts will shear at the next disassembling.
Bearings
t  Insert moist all bearings into the gearbox with gear oil.
t  Before installing, heat the inner rings of the bearing on a heating plate or with the induction heater unit -VAS 6414- to approx. 100°C, when installing press in axial and play-free up to the stop.
t  The temperature can be checked with a temperature measuring instrument.
t  Do not mix up the outer and inner races of bearings of the same size.
t  Always jointly replace tapered-roller bearings on the same shaft and use products of the same manufacturer.
t  Always position needle bearing with the lettered side (thicker end) towards the drift pin.
Shims
  V34-1515
t  Gauge shims at several points with a micrometer. Different tolerances allow to measure the required thickness for each washer very precisely.
t  Inspect for burrs and damage.
t  Install only adjusting washers which are in perfect condition.
Synchronizer rings
t  These are not interchangeable. If re-using, allocate synchronizer rings to the same sliding gear.
t  Inspect for wear, replace if necessary → Electronic Catalogue of Original Parts.
  N30-10156
t  Check grooves -arrow 1- on synchronizer ring -A-, or check the inside of the ring for flattened parts (grooves worn).
t  When installing the intermediate ring -B-, check whether it has no scores, blue coloring (caused by overheating) and other damages on the outer -arrow 2- and inner -arrow 3- friction surface.
t  Insert with some gearbox fluid.
Pinions
t  Clean and heat on a heating plate or with the induction heater unit -VAS 6414- to approx. 100°C before pressing on.
t  The temperature can be checked with a temperature measuring instrument.
t  Check fitting position.
Sliding gears
t  Check 1st to 6th gear sliding gears after assembly for low axial play or for smooth operation.
Clutch control
t  Do not tilt the clutch pressure plate, release or tighten in small stages crosswise
t  If the clutch pedal does not return to its initial position after the coupling procedure - clutch pedal in home position - the clutch system must be bled (further measures → Chapter).
t  In order to reduce unpleasant odours if the clutch is burnt, thoroughly clean the clutch housing as well as the flywheel and the engine on the side of the gearbox.
  N35-10107

Targeted fault finding, Vehicle self-diagnosis and Measuring method > < General repair information