Skoda Workshop Service and Repair Manuals

Install gearbox (Octavia II) Installation is performed in the reverse order, pay attention to the following points:   Note t  Install the gearbox DSG - 02E for vehicles with four-wheel drive together with the angle gearbox. t  When performing installation work replace the self-locking nuts and screws. t  Use new screws which must be tightened to a torquing angle as well as gasket rings and seals. t  Secure all hose connections with hose clamps which comply with the series design → Electronic Catalogue of Original Parts. t  All cable straps which are detached or cut open when removing, should be fitted on again in the same place when installing.

t  Check the needle bearing -arrow- in the crankshaft. If it is damaged or tarnished blue (caused by overheating), it must be replaced → Engine; Rep. gr.13. t  Lightly grease the needle bearing -arrow- and the drive shaft pin (not the serration) with high-temperature grease -G 052 133 A2-. t  Lightly grease the stud of the drive shaft with the high-temperature grease -G 052 133 A2-.

t  Check whether the dowel sleeves -A- for centering the gearbox are present in the cylinder block, insert if necessary. t  If the gearbox is inserted, ensure the intermediate plate between the engine and gearbox is correctly installed.

–  Carefully raise gearbox with the engine/gearbox jack -V.A.G 1383 A- and put in its installation position with the gearbox mount -3282-. l  The gearbox is pulled off from the engine by approx. 30 mm. Vehicles with four-wheel drive

–  Screw on the screws -arrows- of the gearbox mount -A- before positioning the gearbox on the engine by hand. Continued for all vehicles –  Do not get the cables trapped when inserting the gearbox. –  Screw on gearbox to engine → Chapter. –  Attach the selector lever control cable to the gearbox → Chapter.   Note Do not bend or buckle selector lever control cable. Install the unit mounting as follows:

–  Insert the gearbox console -A- between the gearbox and the supporting arm of the gearbox mount. –  Tighten the gearbox console -A- with new screws -1- at the gearbox. –  Also lift the gearbox with the spindles of the supporting device to the supporting arm of the gearbox mount at the same time. –  Insert new screws -2- and tighten by hand.   Caution Before screwing in the screws -2- the gearbox console and the supporting arm of the gearbox mount must be absolutely parallel to one another, otherwise the thread is damaged. –  Remove the gearbox mount -3282- from the gearbox. Vehicles with four-wheel drive

–  Screw the gearbox mount -A- to the angle gearbox by hand -arrow 1-. –  Then tighten the screws -arrows 1 … 3- to the recommended tightening torque, while doing so observe the tightening order → Chapter. Vehicles with intermediate shaft (front-wheel drive)

–  Replace O-ring -1- for rigid shaft, if no new gearbox is installed. –  Mount the intermediate shaft of the right drive shaft correctly on the serration of the rigid shaft at the gearbox → Chassis; Rep. gr.40. Continued for all vehicles –  Screw the drive shaft on left and right on the flange shafts of the gearbox or the right drive shaft on the flange of the intermediate shaft → Chassis; Rep. gr.40.

–  Install protective cap for right drive shaft on the engine, to do so tighten the screws -arrows- to 35 Nm. Vehicles with four-wheel drive

–  Install the protective cap for the right drive shaft on the angle gearbox -arrows-. Vehicles with diesel particle filter –  Install particle filter with bracket for particle filter → Engine; Rep. gr.26. Continued for all vehicles –  Install the assembly carrier → Chassis; Rep. gr.40. –  If present, install the front left vehicle level sensor -G78- → Chassis; Rep. gr.40 and check the headlight beam setting → Electrical System; Rep. gr.94. Vehicles with four-wheel drive –  Press the engine/gearbox unit towards the bulkhead plenum chamber; at the same time the stud of the output flange of the angle gearbox must be carefully inserted into the flange of the propshaft.   Note

t  The gasket rings -arrow- in the flanges of the propshaft must not be damaged when removing and installing. In case of damaged gasket rings the propshaft must be replaced. t  Slide the propshaft horizontally onto the stud of the angle gearbox. Continued for all vehicles

–  Screw the pendulum support with new screws -arrows- onto the gearbox → Engine; Rep. gr.10. Vehicles with four-wheel drive –  Screw propshaft onto the flange of the angle gearbox → Chapter.   Note If the previous gearbox must be installed again, the markings made on the propshaft and on the output flange of the angle gearbox during the removal must be opposite each other. Continued for all vehicles –  Installing starter and cable → Electrical System; Rep. gr.27.

–  Mount the plug -A- of the mechatronics as follows: l  The arrows -D- on the mechatronics -B- and on the plug -A- as well as the peg -C- must be on the same line and point upwards. l  Then mount the plug -A- carefully up to the stop and lock the cap by turning it to the right in -direction of arrow-. –  Assemble exhaust system free of stress and install bracket for the exhaust system at the assembly carrier → Engine; Rep. gr.26.

–  Install fan shroud -arrow- with fans → Engine; Rep. gr.19. –  Install left and right charge air hose → Engine; Rep. gr.21. –  Check the setting of the assembly bearings → Engine; Rep. gr.10. –  Tighten the new screws of the gearbox console at the supporting arm of the gearbox mount to the recommended tightening torque, while doing so observe the tightening sequence → Chapter.   Note If the battery earth strap is disconnected and connected, carry out certain additional operations → Electrical System; Rep. gr.27. –  Install the battery tray and battery → Electrical System; Rep. gr.27. –  Inspect setting of selector lever control cable and adjust if necessary → Chapter. –  Install air filter → Engine; Rep. gr.23. –  Inspect coolant level in the cooling system, top up if necessary → Engine; Rep. gr.19. –  Inspect gear oil level and top up if necessary → Chapter. –  Install the front left wheelhouse liner → Body Work; Rep. gr.66. –  Install sound dampening → Body Work; Rep. gr.50 and install front left and right wheelhouse liner → Body Work; Rep. gr.66. –  Install front wheel → Chassis; Rep. gr.44.