Skoda Octavia Mk1 - 01 - Running Gear

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    SKODA OCTAVIA

    MK1

    RUNNING GEARCHASSIS

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    Summary of components of rear a0le.....................................................................................................12)

     eplacing the rubber-metal bearing......................................................................................................1$4

    R$%&'()*+ $ /$-$'& $')*+ - $)* 1..................................................................................134R$%&'()*+ $ /$-$'& $')*+ - $)* 2..................................................................................143

     emoving and installing shock absorberspring....................................................................................1!4

     *isassembling and assembling shock absorber.....................................................................................1!!

    R EPAIRING THE WHEEL BEARING................................................................................................................156 epairing the &heel bearing, vehicles &ith front-&heel drive - drum brake.........................................1!7 

     epairing the &heel bearing - disc brake...............................................................................................1$

    R EPAIRING REAR  A!LE 7VEHICLES WITH FOUR -WHEEL DRIVE..................................................................1# ear a0le &ith four-&heel drive - vervie&...........................................................................................1)

    +oil spring and shock absorber on vehicles &ith four-&heel drive - Summary of components.............171

     emoving and installing coil spring.......................................................................................................17$

     emoving and installing shock absorber...............................................................................................17#

    TRAILING AR" AND SUSPENSION AR" - SU""ARY OF CO"PONENTS........................................................180 "ressing out and pressing in...................................................................................................................1#4

     emoving and installing rubber-metal bearing for trailing arm...........................................................1)' emoving and installing guide (oint.......................................................................................................1)2

     emoving and installing trailing arm.....................................................................................................1)7 

     emoving and installing suspension arm...............................................................................................2'2

    SU""ARY OF CO"PONENTS - ASSE"BLY CARRIER  WITH FINAL DRIVE......................................................205 emoving and installing assembly carrier &ith final drive....................................................................2'7 

     emoving and installing rubber-metal bearing for assembly carrier....................................................212

     emoving and installing rubber-metal bearing for final drive..............................................................214

    R EPAIRING DRIVE SHAFT.............................................................................................................................218

     emoving and installing a drive shaft....................................................................................................21# epairing drive shaft &ith + (oint........................................................................................................221

    WHEELS, TYRES. AXLE ALIGN............................................................................................................227

    VEHICLE ALIGN"ENT..................................................................................................................................2263eneral points........................................................................................................................................227 

    est conditions........................................................................................................................................22#

     5easurement preliminaries....................................................................................................................22)

    +hassis terms..........................................................................................................................................2$'

     6ominal values for vehicle alignment....................................................................................................2$'

    +hecking the transversal inclination of the vehicle...............................................................................2$1+hecking the camber on the front a0le, if necessary take the mean.......................................................2$2

    +hecking the camber on the rear a0le....................................................................................................2$$

    +hecking the track on the rear a0le, if necessary taking the meanad(usting........................................2$4

    +hecking the track on the front a0le, ad(usting if necessary..................................................................2$!

    +hecking the left and right steering angle.............................................................................................2$ 

    +alculation of the misalignment on the rear a0le..................................................................................2$7 

    WHEELS AND TYRES...................................................................................................................................2383eneral points........................................................................................................................................2$#

     *isc &heel..............................................................................................................................................2$) ight-alloy &heel....................................................................................................................................24'

    VEHICLES WITH TYRE REPAIR  SET...............................................................................................................242yre sealant.............................................................................................................................................24$

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    yre disassembly.....................................................................................................................................244

     /ssembly of ne& tyres.............................................................................................................................24!

     *isposing of tyre sealant........................................................................................................................24 

    ABS, ADR, TCS, EDL, ESP........................................................................................................................247

    A NTILOCK  BRAKING SYSTE" 7ABS ITT "ARK  20 IE..............................................................................246Safety precautions, basic information on fault finding and on repairing /BS and /BS* % 5ark 2'

     %............................................................................................................................................................247  6otes on repair &ork on /BS and /BS* % 5ark 2' %................................................................24#

     e8uired technical information..............................................................................................................24)

    DISTINGUISHING FEATURES OF THE ABS ITT "ARK  20 IE AND THE ABS9EDL ITT "ARK  20 IE...........2503eneral %nstructions...............................................................................................................................2!'

     /BS % 5ark 2' %...............................................................................................................................2!1

     /BS* % 5ark 2' %......................................................................................................................2!2

     9itting position /BS or /BS* % 5ark 2' %................................................................................2!$

    SELF-DIAGNOSIS..........................................................................................................................................254

    Self-diagnosis functions..........................................................................................................................2!4 %ndication of faults by means of &arning lights -:47- and -:14$$-.....................................................2!!

    ehicle fitted &ith /BS* - * does not operate.............................................................................2! 

    PERFOR" SELF-DIAGNOSIS..........................................................................................................................256est re8uirements....................................................................................................................................2!7 

    +onnecting vehicle system tester -./.3 1!!2- and selecting function..................................................2!#

     %nterrogating control unit version..........................................................................................................2!)

    vervie& of selectable functions............................................................................................................21

     %nterrogating fault memory....................................................................................................................22

     /utomatic test se8uence.........................................................................................................................2$

     9ault table..............................................................................................................................................24

     rasing fault memory.............................................................................................................................271

     nding output.........................................................................................................................................272

    +oding control unit.................................................................................................................................27$

     eading measured value block...............................................................................................................27!

     /ctuator diagnosis..................................................................................................................................27#

     Basic setting............................................................................................................................................2#$

    ELECTRICAL TEST OF THE ABS AND ABS9EDL ITT "ARK  20 IE.............................................................286est conditions........................................................................................................................................2##

     5ulti-pin plug connection &ith contact assignment...............................................................................2#)vervie& of test steps.............................................................................................................................2)1

    est table.................................................................................................................................................2)2

    ELECTRIC9ELECTRONIC CO"PONENTS AND FITTING LOCATIONS ABS, ABS9EDL "ARK  20.....................2## emoving and installing the hydraulic control unit and the bracket.....................................................$'2

     epairing the hydraulic control unit......................................................................................................$')

    +heckingremoving and installing parts of the /BS system on the front a0le........................................$1$

    +heckingremoving and installing parts of the /BS system on the rear a0le ;disc brake and drum brake<

    - front-&heel drive..................................................................................................................................$2'

     emoving and installing as &ell as ad(usting brake light s&itch up to model year 1)))......................$27  emoving and installing as &ell as ad(usting brake light s&itch as of model year 2'''......................$2)

    SU""ARY OF CO"PONENTS OF HYDRAULIC CONTROL U NIT, BRAKE SERVO U NIT9"ASTER  BRAKE CYLINDER  FOR  VEHICLES WITH ABS, ABS9EDL "ARK  20.......................................................................330

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    SELF-DIAGNOSIS OF THE ABS9EDL FOR  FOUR -WHEEL DRIVE VEHICLES WITH HALDE! COUPLING..........333 %nterrogating control unit version..........................................................................................................$$4

     9ault table for the /BS* of four-&heel drive vehicles &ith =alde0 coupling..................................$$!

    +ode /BS* control unit....................................................................................................................$$ 

    +heck longitudinal acceleration sender -32!1-....................................................................................$$ 

    +hecking the data B>S cable.................................................................................................................$$#

     %nitiating basic setting............................................................................................................................$4'

    S&itch off longitudinal acceleration sender -32!1-..............................................................................$4'

     6ull balance of the longitudinal acceleration sender -32!1-................................................................$41

    ELECTRICAL TEST OF THE ABS9EDL FOR  FOUR -WHEEL DRIVE VEHICLES WITH HALDE! COUPLING........342est table.................................................................................................................................................$4$

    ELECTRIC9ELECTRONIC CO"PONENTS AND FITTING LOCATIONS 7FOUR -WHEEL DRIVE.............................345 emoving and installing longitudinal acceleration sender -32!1-.......................................................$4#

    +heckingremoving and installing parts of the /BS system on the rear a0le ;disc brake< - four-&heel

    drive........................................................................................................................................................$4)

    A NTILOCK  BRAKING SYSTE" ABS9 EDL9ESP "ARK  20...........................................................................354

    Safety precautions, basic information on fault finding and on repairing...............................................$!4 6otes on repair &ork on /BS*S" 5ark 2'..................................................................................$!4

     e8uired technical information..............................................................................................................$!4

    DISTINGUISHING FEATURES OF THE ABS9EDL ITT "ARK  20 IE AND THE ABS9EDL9ESP ITT "ARK  20 IE....................................................................................................................................................................355

    3eneral %nstructions...............................................................................................................................$!!

     /BS*S" % 5ark 2' %..............................................................................................................$! 

     9itting position /BS*S" % 5ark 2' %.....................................................................................$!7 

    SELF-DIAGNOSIS OF THE ABS9EDL9TCS9ESP "ARK  20...........................................................................358

     *escription of the function.....................................................................................................................$!# %ndication of faults by means of &arning lights -:47-, -:14$$- and -:1!!-.......................................$!)

    ehicle fitted &ith /BS*S" - * does not operate.....................................................................$$

    ELECTRICAL TEST OF THE ABS9EDL9ESP ITT "ARK  20 IE......................................................................34est conditions........................................................................................................................................$!

     5ulti-pin plug connection &ith contact assignment...............................................................................$7 

    est table.................................................................................................................................................$72

    est steps 1 - 2'......................................................................................................................................$7$

    est steps 21 - 2#....................................................................................................................................$#4

    ELECTRIC9ELECTRONIC CO"PONENTS AND FITTING LOCATIONS ABS9EDL9ESP "ARK  20.......................3#3

     emoving and installing the hydraulic control unit /BS*S" and the bracket.............................$)#

     epairing the hydraulic control unit /BS*S"..............................................................................4' 

    +heckingremoving and installing parts of the /BS system on the front a0le........................................41'

    +heckingremoving and installing parts of the /BS system on the rear a0le ;disc brake and drum brake<

    - front-&heel drive..................................................................................................................................41!

     emoving and installing parts of the S" system..................................................................................41!

     emoving and installing as &ell as setting the brake light s&itch.........................................................422

    SU""ARY OF CO"PONENTS OF HYDRAULIC CONTROL U NIT, BRAKE SERVO U NIT9"ASTER  BRAKE CYLINDER  FOR  VEHICLES WITH ABS9EDL9ESP "ARK  20.........................................................................423

    A NTILOCK  BRAKING SYSTE" 7ABS "K0...............................................................................................426Safety precautions, basic information on fault finding and on repairing /BS and /BS+S* 5: '

    ................................................................................................................................................................427 

     6otes on repair &ork on /BS and /BS+S* 5: '......................................................................427 

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     e8uired technical information..............................................................................................................427 

    3eneral %nstructions...............................................................................................................................427 

     /BS and /BS+S*..........................................................................................................................427 

     9itting position /BS or /BS+S* 5: '......................................................................................427 

    ELECTRIC9ELECTRONIC CO"PONENTS AND FITTING LOCATIONS ABS9EDL9TCS "ARK  0......................428 emoving and installing the hydraulic control unit and the bracket.....................................................4$1

     epairing the hydraulic control unit......................................................................................................4$7 

    +heckingremoving and installing parts of the /BS system on the front a0le........................................4$)

    +heckingremoving and installing parts of the /BS system on the rear a0le ;disc brake and drum brake<

    - front-&heel drive..................................................................................................................................442

    SU""ARY OF CO"PONENTS OF HYDRAULIC CONTROL U NIT, BRAKE SERVO U NIT9"ASTER  BRAKE CYLINDER  ABS9EDL9TCS "ARK  0.........................................................................................................443ELECTRICAL TEST ABS9EDL9 TCS "ARK  0............................................................................................445

    est re8uirements....................................................................................................................................44 

     5ulti-pin plug connections &ith contact assignment for /BS, /BS*+S......................................447 

    est table.................................................................................................................................................4!'

    A NTILOCK  BRAKING SYSTE" ABS9 EDL9TCS9ESP "ARK  0...................................................................456Safety precautions, basic information on fault finding and on repairing...............................................4!7 

     6otes on repair &ork on /BS*+SS" 5ark '..........................................................................4!7 

     e8uired technical information..............................................................................................................4!7 

    ELECTRIC9ELECTRONIC CO"PONENTS AND FITTING LOCATIONS ABS9EDL9TCS9ESP "ARK  0 : "Y 02....................................................................................................................................................................458ELECTRIC9ELECTRONIC CO"PONENTS AND FITTING LOCATIONS ABS9EDL9TCS9ESP "ARK  0 "Y 02 :....................................................................................................................................................................42DISTINGUISHING FEATURES ABS9EDL9TCS "ARK  0 AND ABS9EDL9TCS9 ESP "ARK  0....................4

    3eneral %nstructions...............................................................................................................................4  9itting position /BS*+SS" 5ark '........................................................................................4 

    SELF-DIAGNOSIS OF THE ABS9EDL9TCS9ESP "ARK  0...........................................................................46 *escription of the function.....................................................................................................................47 

     %ndication of faults by means of &arning lights -:47-, -:14$$- and -:1!!-.......................................47 

    ELECTRICAL TEST ABS9EDL9TCS9ESP "ARK  0.....................................................................................462est re8uirements....................................................................................................................................47$

     5ulti-pin plug connection &ith contact assignment...............................................................................474

    est table.................................................................................................................................................47#

    BRAKE, BRAKE ECHANICS...............................................................................................................494REPAIRING THE FRONT BRAKE..........................................................................................................494

    +hanging the brake pads of the front brake - 5ounting instructions....................................................4)4

     epairing front brake, the floating caliper disc brake 9S-%%%................................................................4)!

     emoving and installing brake padsbrake caliper ;9S %%%

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     emoving and installing brake shoes.....................................................................................................!2!

    Setting the hand-brake ;drum brakenit5aster Brake +ylinder for vehicles &ithout /BS or &ith

     /BS, /BS* 5ark 2' - =* vehicles................................................................................................!7!

     emoving and installing the master brake cylinder - =* vehicles......................................................!7)

     emoving and installing the master brake cylinder - =* vehicles......................................................!7)

    +heck brake servo unit...........................................................................................................................!7)

     emoving and installing the brake servo unit - =* vehicles...............................................................!7)

     emoving and installing the brake servo unit - =* vehicles...............................................................!7)

     emoving and installing the vacuum pump for the brake servo unit.....................................................!7)

    R EPAIRING THE FRONT BRAKE CALIPER , BRAKE CALIPER  FS < III.............................................................56#Summary of +omponents of Brake +aliper 9S-%%%.................................................................................!7)

     emoving and installing the front brake caliper piston.........................................................................!7)

    R EPAIRING THE FRONT BRAKE CALIPER , BRAKE CALIPER  FN 3..................................................................56# /ssembly overvie& of the brake caliper 96$.........................................................................................!7)

     emoving and installing the front brake caliper piston.........................................................................!7)

    R EPAIRING THE REAR  BRAKE CALIPER ........................................................................................................56#Summary of components of the brake caliper........................................................................................!7)

     emoving and installing the rear brake caliper piston..........................................................................!7)

    T$%'= >)&&)*+ > '?$ ('&)%$......................................................................................................56#SU""ARY OF CO"PONENTS OF BRAKE-POWER  REGULATOR ......................................................................56#I NSPECTING AND AD@USTING THE BRAKE-POWER  REGULATOR ...................................................................56#

     /d(usting values for the load-dependent brake-po&er regulator...........................................................!7)

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    BLEED BRAKE SYSTE", VEHICLES WITH OR  WITHOUT ABS OR  ABS9EDL "ARK  20 AND "ARK  0........56# Bleeding brake system &ith brake filling and bleeding device for vehicles &ith 5ark 2'....................!7)

     Bleeding the brake system &ithout using the brake filling and bleeding device....................................!7)

     Bleeding brake system &ith brake filling and bleeding device for vehicles &ith /BS 5ark '.............!7)

    CHECKING THE "ASTER  BRAKE CYLINDER  FOR  TIGHTNESS.......................................................................56#SU""ARY OF CO"PONENTS; BRAKE SERVO U NIT9"ASTER  BRAKE CYLINDER  FOR  VEHICLES WITH ABS9EDL9ESP "ARK  20...........................................................................................................................581

     emoving and installing brake pressure sender -1--32'1- and brake pressure sender -2--3214-...... .!#4

     emoving and installing the master brake cylinder - =* vehicles......................................................!# 

     emoving and installing the master brake cylinder - =* vehicles......................................................!#)

    +heck brake servo unit...........................................................................................................................!)2

     emoving and installing the brake servo unit - =* vehicles...............................................................!)2

     emoving and installing the brake servo unit - =* vehicles...............................................................!) 

     emoving and installing the vacuum pump for the brake servo unit.....................................................!))

    SU""ARY OF CO"PONENTS; BRAKE SERVO U NIT9"ASTER  BRAKE CYLINDER  FOR  VEHICLES WITH ABS9EDL9TCS9ESP "ARK 0...................................................................................................................5##

     emoving and installing brake pressure sender -1--32'1-...................................................................'2 emoving and installing master brake cylinder.....................................................................................'2

    +heck brake servo unit...........................................................................................................................'2

     emoving and installing brake servo unit..............................................................................................'2

     emoving and installing brake vacuum pump -1)2-...........................................................................'2

    esting brake vacuum pump -1)2-.......................................................................................................'$

    STEERING..................................................................................................................................................."04

    STEERING COLU"N AND STEERING WHEEL WITH AIRBAG..........................................................................04+heck the steering column for damage..................................................................................................'4

     emoving and installing steering column..............................................................................................'!

     emoving and installing the ignition lock housing &ith the steering column mounted.........................1#

    SU""ARY OF CO"PONENTS OF POWER -STEERING GEAR  - LHD VEHICLES................................................21 emoving and installing hydraulic oil reservoir....................................................................................24

    R E"OVING AND INSTALLING THE POWER -STEERING GEAR  - LHD VEHICLES.............................................2 epairing po&er-steering gear ;@9

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    R E"OVING AND INSTALLING VANE PU"P...................................................................................................80ehicles &ith vane pump located at the top............................................................................................#1

    ehicles &ith vane pump located at the bottom......................................................................................# 

     *isposing of the vane pump...................................................................................................................)1

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