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Repair Manual Instrument Cluster Skoda Octavia I made on a 20V turbo built in 2000
(Instrument Clusters from 1999-2003 are identical – Diesel as well as Petrol driven cars) I wrote this Repair Manual as a private person. The Manual is to be seen as support for you to repair an Instrument Cluster for a Skoda Octavia based on the defects described on page 1. I cannot give any guarantee for a successful repair and I also cannot be held reliable for the repair. The experiences made with this Manual have been outstand outstandingly ingly positiv positive. e. All of my experiences have been included in this Manual which is also updated regularly. (Stand April 2008)
Indicated defects Malfunction of analogue needles -
Tachometer Speedometer Coolant Temperature Refuelling Indicator
In additional, there can be malfunctions of some signal lamps: - Immobiliser System - Handbreak - Signal lamp for oil - Signal buzzer for light - …
It is a well-known problem of Instrument Clusters from Skoda, VW, Seat, should these malfunctions be indicated at your car temporarily or permanent. The reason for the malfunction is a so-called ´cold solder joint´ on the circuit board of your Instrument Cluster.
You need: -
1 Torx Screwdriver T10 1 Torx Screwdriver T20 2 small Slot Screwdriver 1 Soldering iron with a fine tip some Solder some Superglue some Tape
Time needed for repairing incl. demounting and mounting: approx. 2 hours
I would advise you to get all the stated tools and to take enough time for the procedure. Do it step-by-step and above all: be self-confident ! Many people have already succeeded in this repair.
Demounting of the Instrument Cluster A
1.
Pull the steering wheel downwards and to your body at the adjustment (if existant). Now you can work easily in the area of your Instrument Cluster.
2.
Remove the round covers (A) (left and right) with a small Slot Screwdriver.
3.
Loosen both Torx screws under the covers with a suitable screwdriver T20. If possible, please use a short screwdriver, otherwise you may be hindered by the steering wheel.
A
A Important notice: Draw off ignition key
Before demounting your Instrument Cluster be sure to draw off your ignition key. Also on mouting. Otherwise your immobilser system may show a defect.
A
Demounting of the Instrument Cluster
B 4.
Remove the black cover (B).Pull it to you and jiggle if neccesary to loosen the clips.
5.
After loosening the cover it is still connected to the steering column by a soft cover (C). Remove some clips underneath the cover to loosen it completely.
6.
Now loosen both Torx screws T20 (D) (left and right) Afterwards the Instrument Cluster can be withdrawn from both holders (E) left and right This step can effort some energy so you perhaps have to use the screwdriver as a lever.
C
Soft cover – connected by some clips to hard cover.
D
E Use screwdriver as a lever for loosening
Demounting of the Instrument Cluster
7.
The Instrument Cluster is now only held by the two cable looms (F). Cautiously turn the Instrument Cluster to the side for loosening the cables.
8.
To release the cables, open the safety clips of the plugs (G). This could need a higher effort. You can use a small screwdriver as support.
9.
F
G
G
After loosening both plugs, you can take the Instrument Cluster out of the cockpit.
You have now done the first step of the repair. Next steps are describing the deconstruction of your Instrument Cluster.
F
Deconstruction of the Instrument Cluster
10. Next step is to deconstruct the Instrument Cluster. At first remove the plexiglass cover by loosening the clips. 11. Afterwards turn the Instrument Cluster around and unscrew both Torx-screws T10 (H) left and right on the back next to the plug socket. (small picture) Then loosen the 6 clips (I) around the cover which you can take away from the circuit board afterwards.
I
I
H
Marking the needle positions
12. The positions of the needles are to be marked now. Turn the needles to the right side as far as possible. You will notice a remarkable block. (At „0“-positions there are no mechanical blocks) 12. Put some tape slightly underneath every needle onto the foil and mark the end position with a pen. Next step is to draw off the needles. The tape with the markings has to remain on the foil to put the needles back on the right position when mounting after the repair. Proceed very carefully during this step. Important notice for mounting: Don´t press the needles to strong while mounting to prevent that they touch the foil. Should the needles slip a little bit away when putting them back on, do the following when the Instrument Cluster is mounted back into the car and the ignition is turned on: Turn the needles again to the far right side to correct them appropriately.
K
K
Remove needles
L 14. Take away the black covers (L) from the needles. That is really hard to do and you might destroy some small bolts underneath the covers. No problem! You can use some superglue to fix the covers back on the needles after the repair. 15. For loosening the needles you can use two small slot screwdrivers like on the picture on the right side. You can also use two small coffee spoons instead of the screwdriver – that might sound crazy, but it works!
You now have the circuit board without the needles but with the final needle positions marked with some tape.
Exposing the circuit board
16. Now take away both tacho foils. Turn the left one (Tachometer) a bit and take it away. The right one (Speedometer, Cooling Temperature, Refulling Indicator) is fixed with some glue. Draw off carefully. 17. First of all you have to loosen both metal fasteners of the displays (M) from the circuit board. Take a small slot screwdriver and turn the fasteners a bit, jiggle and you can take them with the display away. 18. Remove the white panel (N). You have to jiggle a lot to loosen all clips which connect the panel with the circuit board. In front of you, you have now the circuit board as well as the white panel with the displays on it.
M
M
M
Bend up Metal-Fastener for loosening displays from circuit board.
Turn a bit for loosening the Reset-Button
N
Repair cold solder joints
19. The failure is to be found on the top left side of the circuit board. 7 joints (P) are not correctly soldered. (connections of 3 resistors and 1 connection inbetween) Solder them carefully. Take some solder on a hot solder iron – put it onto the joints so that the existing solder gets fluid. To be sure, you can build a brigde (Z) with solder between the two resistors. (The existing bridge is only very thin.
P P
The solder joints should be shiny.
Z
Building here a bridge between the 2 resistors. The existing bridge is very thin. Use some solder for this step.
Testing
20. Now you you can test if your soldering was successful. Put the needle of the refuelling indicator softly onto the circuit board and take it to your car. Plug the both connectors in – turn your ignition key on. Normally the needle of the refuelling indicator will rise up according to the fuelling level you have. Congratulations - you made it and saved a lot of money. Nothing happens? – Don´t panic! Solder the 7 joints once again. Up to now only these soldering joints have been the reason for the malfunction. You can solder further joints if it doesn´t work. I adwise you not to solder lots of joints carelessly. The risk to produce a cold solder joint yourself is very high.
Mounting Instrument Cluster
21. Mounting your Instrument Cluster is to be made according to steps 1-18 vice versa.
What is a cold solder joint?
A cold solder joint occurs when there is no proper connection between solder and joint partner. The Instrument Cluster is industrially manufactured. It can happen that the solder roboter has a wrong time- or temperature-presetting, i. e. soldering is made with too high or too low temperature. Less solder has been used for the solder bridge. The result: the solder joint is not strong enough! It can take years till you finally recognize the cold solder joint. Such a solder joint is of less quality and cannot resist high mechanical stress. Caused by vibration in the car or temperature differences, the solder joint might then cause contact failures between component part and circuit board or between component parts. This also causes the failure of the Instrument Cluster.
