Skoda OCTAVIA Workshop Manual
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Skoda OCTAVIA Workshop Manual

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See also: Workshop Manual , Owner's Manual
Service
Workshop Manual
OCTAVIA
1.9-ltr./66 kW (TDI) Engine,
Mechanical Components
Service Department. Technical Information
S00.5110.52.20 Edition 03.98

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Summary of Contents for Skoda OCTAVIA

  • Page 1 Service Workshop Manual OCTAVIA 1.9-ltr./66 kW (TDI) Engine, Mechanical Components Service Department. Technical Information S00.5110.52.20 Edition 03.98...
  • Page 2 The Service Manual is intended only for use within the Škoda Organisation; it is not permitted to pass it onto third persons. Printed in CR © 1998 ŠKODA AUTO a. s.
  • Page 3 Service List of Supplements to Workshop Manual Edition: 04.04 OCTAVIA 1.9 l/66 kW (TDI) Engine, Mechanical Components Replaces List of Supplements - Edition: 11.02 Subject Edition Article Number Supple- ment 08.96 Basic Edition S00.5110.50.20 11.96 Supplement to Basic Edition S00.5110.51.20 03.98...

  • Page 5: Table Of Contents

    OCTAVIA Service Contents Technical Data Page Technical data ..........................00-1 Engine number ......................... 00-1 Engine features ........................00-1 Removing and installing Engine Page Removing and installing engine ....................10-1 Removing engine ........................10-1 Attaching engine to repair stand ....................10-12 Installing engine ........................
  • Page 6 Service OCTAVIA Cooling System Page Removing and installing parts of the cooling system ............. 19-1 Parts of the cooling system fitted to body ................. 19-2 Parts of the cooling system attached to engine ................ 19-2.2 Connection diagram for coolant hoses ..................

  • Page 7: Technical Data Page

    OCTAVIA Technical Data Technical data Engine number K The engine number („engine code“ and „serial number“) is located at the front at the connec- tion of the engine/gearbox. In addition, a sticker with „engine code“ and „se- rial number“ is affixed to the toothed belt guard.

  • Page 9: Removing And Installing Engine

    OCTAV1A Removing and Installing Engine Removing and installing engine Special tools, testers and aids required ♦ Workshop crane (e.g. V.A.G 1202 A) ♦ Catch pan (e.g. V.A.G 1306) ♦ Torque wrench ♦ Pliers for spring strap clips ♦ Engine mount MP 1-202 ♦...
  • Page 10 OCTAVIA Removing and Installing Engine ♦ Pay attention to the correct assignment of the connectors; mark if necessary. Procedure Pay attention to code of vehicles fitted with a coded radio set; determine if necessary. Switch off ignition (if not already off) and dis- connect earth strap at the battery.
  • Page 11 OCTAVIA Removing and Installing K The two rear jacking points are located at the rear longitudinal members at the level of the marking at the sill. Remove noise insulation panel in the middle and also on the left and right -arrows-.
  • Page 12 OCTAVIA Removing and Installing In addition, detach coolant hose at bottom of oil cooler -arrow- and allow remaining cool- ant to flow out. Detach air guide hose -1-. Detach vent hose -3- and connector for air mass meter -2-. Slacken bolts -4- and -5- and remove air fil- ter housing.
  • Page 13 ©    § ¨ !    © ©    ©   ©    ¥ ! $ ¨    © § ©    ) !   ¤ ¥ ¦ § ¨ ©  § ¨ !    OCTAVIA Removing and Installing Engine ¤ ¥ ¦ § ¨ © ©   ( ) ¥  ¨...
  • Page 14 OCTAVIA Removing and Installing Engine Models fitted with manual gearbox Mark installation position of the shift cable -B- relative to the gearbox shift lever. Take off balancing weight -A- and shift cable -B- at shift lever. Pull selector cable off relay lever driver -C-;...
  • Page 15 §  ©          % 1 2 ( OCTAVIA Removing and Installing Engine      #   0     ¦          §      §  0    3 ¤...
  • Page 16 ! 2 0 8 % 2 9  5 2 5  ) H ) @ I  6 ' P  OCTAVIA Removing and Installing Engine A (  5 & 2  0 ( $ ' 0 ( 5 0 2 3 8 ( 0 ! 5 " & 2 5 ( ' 9  ! " # #  $ ' & & ' 1 2 3 8 " ' ' & ! 3 # ' (  ( V W ' ' 6 "...
  • Page 17 ¤ ¥ ¦ § ¨ ©   ¥ ¥       ( ! ¥   6  )  ¥ ! (  § 0 ( §  ¦   §  ¥  ! 0 "  § "  # $ 3 OCTAVIA Removing and Installing Engine @ A &...
  • Page 18 OCTAVIA Removing and Installing Engine Models fitted with air conditioning Warning! Refrigerant circuit of air conditioning system must not be opened. Remove AC compressor and tie up with wire at the towing eye -arrow- together with the connected hoses. Note: Protect bumper with adhesive tape from scratches.

  • Page 19: Removing And Installing Engine

    ¤ ¨ ¥ ¡ ¤ ¨ ¦ ¢  OCTAVIA Removing and Installing Engine § ¤  £  ¥    ¤  ¤ ¨ ¦   ¡ ¢ £ ¤ ¥ ¦ § ¨ ©  ¢  ¤ ¨   ¥  ¤ § ¨...
  • Page 20 ¡ ¡ ¢ £ ¤ ¥ ¦ § ¨ ©  ¢ ¥ ¨ OCTAVIA Removing and Installing Engine engine to stand The engine should be attached with the engine holder MP 1-202 to the repair stand for carrying out removal and installation operations.
  • Page 21 " # $ %    & ¨ ¥ ¨ © '  ¨  (  ) 0 1 2 3 4  % ¨   '   % 5 D 3 $    § &    ¨ ¥  ¦ 8 7 E  ¦  ¥ A 9 OCTAVIA Removing and Installing Engine 4  % ©...

  • Page 22: Tightening Torques

    OCTAVIA Removing and Installing Engine Hoses and valves to mechanical exhaust gas recirculation valve, charge pressure control and intake manifold flap valve (N239) ⇒ page 21-4, Connection diagram for charge pressure control ⇒ page 26-5; Connection diagram for exhaust gas recirculation system.

  • Page 23: Aligning Engine/Gearbox Mounting

    OCTAVIA Removing and Installing Engine Aligning engine/gearbox mounting Warning! Before slackening the bolts, the engine/gearbox assembly must be secured with the supporting device MP 9-200. K Engine mounting a = 14.0 mm b = at least 10.0 mm Both bolt heads -1- must finish flush with the edge -c-.
  • Page 24 OCTAV1A Removing and Installing Engine Assembly bracket Tightening torques K Engine assembly bracket 40 Nm + 90° ( turn) - replace 25 Nm 60 Nm + 45° ( turn) - replace K Gearbox assembly bracket 40 Nm + 90° ( turn) - replace 25 Nm 60 Nm + 45°...

  • Page 25: Crank Assembly Page

    OCTAVIA Crank Assembly Disassembling and assembling engine Removing and installing ribbed V-belt 3 - Belt pulley of hydraulic pump 4 - Hydraulic pump ♦ removing and installing ⇒ Running Gear; Repair Group 48 5 - 10 Nm + torque a further turn (90°)
  • Page 26 OCTAVIA Crank Assembly K Fig. 1 Routing of ribbed V-belt on vehi- cles without air conditioning K Fig. 2 Routing of ribbed V-belt on vehi- cles with air conditioning K Fig. 3 Attaching guide pulley of ribbed V- belt Only on vehicles fitted with AC...
  • Page 27 ¡ ¢ £ ¤ ¥ ¦ § ¨ ©         § §   OCTAVIA Crank Assembly        ¡    ! "    ¨...

  • Page 28: Removing And Installing Toothed Belt

    Crank Assembly OCTAV1A Removing and installing toothed belt ♦ Locking pin 3359 Note: Mark the direction of running of the toothed belt ♦ Adjusting straightedge MP 1-312 before removing it. If an already used belt is fit- ted on again to run in the opposite direction, it ♦...
  • Page 29 OCTAVIA Crank Assembly 1 - 120 Nm + torque a further ¼ turn (90°) 18 - Camshaft sprocket ♦ Use counterholder MP 1-310 or lever ♦ Use special tool T40001 for pulling off T30004 for slackening and tightening taper of camshaft ♦...
  • Page 30 Crank Assembly OCTAV1A K Fig. 1 Installation position of the semi- automatic tensioning pulley The holding claw -arrow- must engage in the recess on the rear toothed belt guard. Removing toothed belt Engine installed in the vehicle Remove right headlights ⇒ Electrical Sys- tem;...
  • Page 31 OCTAVIA Crank Assembly Engine installed Rotate crankshaft to TDC of cylinder 1 -ar- row-. Check whether TDC marking on flywheel and driven plate with reference mark are aligned -arrow-. I - Manual gearbox II - Automatic gearbox Note: Rotating crankshaft to TDC of cylinder 1 with the engine removed ⇒...
  • Page 32 4 ©   5  ©     © ¦  %  © ¦ $ #  OCTAVIA Crank Assembly  #  ¥  ©     © !        # $ ¦ § ¨ ©  6 $  ! ©     ©      $  ¦  % ©     ©      $  6 $  ! #  %  1 ¦ $ 1 $  4  1   #  ¥...
  • Page 33 OCTAVIA Crank Assembly Fix in position the bolt for attaching the cam- shaft sprocket (camshaft sprocket can still be rotated). Align injection pump gear to centre position in the slots. Fit toothed belt onto crankshaft toothed belt sprocket, guide pulley, coolant pump, injec- tion pump gear and tensioning pulley (pay attention to direction of running).
  • Page 34 7 ¦  ¤  © ©  ¥ ¦ ¤  ¥    ¤  ¦ ! ¤ ¨     ¤ ¨ # ¤ ¨ ¨ ¤ £ ¥ ! § ¥ © ¤ ¢    ! 1 OCTAVIA 7 ¦...

  • Page 35: Inspecting Semi-Automatic Toothed Belt Tensioning Pulley

    Crank Assembly OCTAV1A Install the noise insulation. Install right headlights ⇒ Electrical System; Repair Group 94, Removing and installing headlights. Dynamically test and set commencement of injection: ⇒ 1.9l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System, Repair Group 23; Dy- namically test and set commencement of injection.
  • Page 36 OCTAVIA Crank Assembly Set adjusting device to 96 mm -arrow- (the left-hand notch of the vernier -arrow A- is the reference point). Rotate crankshaft until TDC marking -arrow B- on the flywheel is aligned with the edge of the adjusting device.
  • Page 37 C " © ¡  ¨ ©    !  £ 9  D # £ ¡ ¢ % OCTAVIA Crank Assembly Rotate crankshaft of the   #  ¡ £ ¡ £ ¤ ¤  ¢  © ¢ £ # ¡ % £...
  • Page 38 ¥ ¦ § ¨ ¢ ¤ £  ¤      ¥     #     ¡  !  § ¦ ¤ ¨ " # ¦ ©  $ ¢  # %  § & OCTAVIA Crank Assembly With crankshaft ribbed V-belt pulley installed ' ( )
  • Page 39 OCTAVIA Crank Assembly ¡ ¢ Edition 05.01 ------------ 13-1 ------------ S00.5110.55.20...
  • Page 40 5 " # & 1 ( 2 0 6 " $ $ A 6 & B 0 ) C # 0 6 " & 0 OCTAVIA Crank Assembly D   E ) ' & F B " # 3 B & ) 6 " &...
  • Page 41 ¢ £ ¤ ¥ ¦ § ¨ © ¥ ¤ § ¨ £  ¦   ¡ ¡ % ¡  §  £  ( £ ! ¦ ¤  £ 6 $ ' ( ¡ OCTAVIA Crank Assembly Rear seal ♦ replace ♦ always replace complete ♦...
  • Page 42 ¡ ¢ £ ¤ ¡ ¥ ¦ § ¨ © ¦      OCTAVIA Crank Assembly K Fig. 3 Elastomer seal Sealing lip -1-; with worm spring seal Several sealing lips -2-; without worm spring Notes: ♦ Do not moisten PTFE seal with oil before installing.
  • Page 43 ©  ¨ § § ¥ ! ¦ " # $ % & ' ( ) ) ( 0 1 2 $ 3 4 & 2 $ 5 OCTAVIA Crank Assembly seal side testers and aids ♦ Torque wrench 6 $ 7 ) 8 & 9 @ ♦...
  • Page 44 4 & 0  §       '  &  ¨ 0  & ¦ & &   (   ¨  1  ¦ &  ¨ ¨ ©     & 4  ©   ¨ 0 & ¨ ¦ § ¨ ©     § ¦  ( 0 § §    0 ¨ 2 §   4  & OCTAVIA Crank Assembly 5 &  (   ¨...
  • Page 45 Crank Assembly OCTAV1A Installing PTFE seal Note: The sealing lips of the seal must not be oiled or greased. Use a clean cloth to remove oil residues on the crankshaft journal. Fit guide sleeve T10053/1 onto the crank- shaft journal. Push seal over guide sleeve onto the crank- shaft journal.

  • Page 46: Removing And Installing Flywheel

    Crank Assembly OCTAV1A Removing and installing flywheel Special tools, testers and aids required ♦ Torque wrench ♦ Counterholder MP 1-223 Insert counterholder MP 1-223 into the hole in the cylinder block and lock the flywheel. Note: Fitting position of counterholder: A - for tightening B - for slackening Release bolts for flywheel.
  • Page 47 OCTAVIA Crank Assembly Installing Position driven plate using the washer with recesses -1-. Insert new bolts -3- and tighten to 30 Nm. Check installed dimension at three points of driven plate and calculate average value. ♦ Specification -a-: 19.5...21.1 mm...

  • Page 48: Removing And Installing Front Sealing Flange

    Crank Assembly OCTAV1A Removing and installing front seal- ing flange Special tools, testers and aids required ♦ Counterholder MP 1-310 or T 30004 ♦ Guide sleeve from MP 1-314 ♦ Silicone sealant D176 404 A2 Removing Remove ribbed V-belt ⇒ page 13-1. Remove toothed belt ⇒...
  • Page 49 ¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § OCTAVIA Crank Assembly ©      ©              !  " #  $ ¨    ©    &...
  • Page 50 OCTAVIA Crank Assembly ¡ ¢ £ ¤ ------------ ------------ Edition 03.00 S00.5110.54.20...

  • Page 51: Inspecting Piston Projection At Tdc

    ¡ ¢ £ ¤ ¥ ¢ ¦ ¤ ¥ ¥ § ¦ £ ¡ ¥ ¨ ©       OCTAVIA Crank Assembly Disassembling and assembling ©          ♦ with combustion chamber ♦...
  • Page 52 ! "  # $ "  % £ ¤ © & ' § ¨ ( ' © £ ) § © £ ' © ¥ 2  $ 3 4 OCTAVIA Crank Assembly Conrod ♦ mark matching cylinder -A- ♦...
  • Page 53 OCTAVIA Crank Assembly K Fig. 2 Inspecting piston ring end clearan- Special tools, testers and aids required ♦ Feeler gauge Clean annular groove before inspecting Piston ring Wear limit Dimensions in mm 1st compression ring 0.06 .. 0.09 0.25 2nd compression ring 0.05 ..
  • Page 54 OCTAVIA Crank Assembly K Fig. 4 Installation position of pistons and matching piston/cylinder Special tools, testers and aids required ♦ Electric pen Procedure Mark installation position and matching piston on the inside of piston (not on piston crown) with electric pen or felt pen.
  • Page 55 ¡ ¢ £ ¤ ¥ ¦ § £ ¨ © ¦ ¡ OCTAVIA Crank Assembly of cylinder head ♦ Part No. = arrow 1 ♦ Control code = arrow 2 (ignore!) ♦ Openings = arrow 3 Note: If different measurements are obtained when measuring the piston projection, the highest measurement applies for assigning the gasket.

  • Page 57: Removing And Installing Cylinder Head

    OCTAVIA Cylinder Head/Valve Gear Removing and installing cylinder head ♦ If the cylinder head is replaced, the entire Removing and installing toothed belt coolant system must be replaced. ⇒ page 13-4 ♦ It is not allowed to rework the cylinder heads Testing compression pressure ⇒...
  • Page 58 OCTAVIA Cylinder Head/Valve Gear 3 - Cylinder head 6 - Oil deflector ♦ inspecting for distortion ⇒ Fig. 1 ♦ from 07.97 ♦ removing cylinder hear ⇒ page 15-4 ♦ installing cylinder head ⇒ page 15-6 7 - Cylinder head cover ♦...
  • Page 59 ' ¢ ¨ £ ¥  ¦ © ¥ ¦ ¢  ¨ ¦  ¢ £ ¤  OCTAVIA Cylinder Head/Valve Gear  © © ¤  ¦  £  ! " ¤ ¨   #   # 17 Sealing...

  • Page 60: Removing Cylinder Head

    Cylinder Head, Valve Gear OCTAV1A Remove cylinder head Note: All cable straps that have been loosened or cut open when removed must be fitted again in the same location when installed. Special tools, testers and aids required ♦ Workshop crane (e.g. V.A.G 1202 A) ♦...
  • Page 61 Cylinder Head, Valve Gear OCTAV1A Remove air guide hose -1-. Detach vent hose -3- and unplug connector for air mass meter -2-. Release screws -4- and -5-. Remove air fil- ter housing. Unscrew and remove air guide hose for air filter/turbocharger at induction pipe.

  • Page 62: Installing Cylinder Head

    Cylinder Head, Valve Gear OCTAV1A Hang the lifting device MP 9-201 at the cyl- inder head. Note: Attach the induction pipe with a wire to the car- rier lug of the lifting device in order to achieve a stable centre of gravity for the cylinder head. Slightly raise the cylinder head with the work- shop crane.
  • Page 63 Cylinder Head, Valve Gear OCTAV1A Work procedure Before fitting the cylinder head position the crankshaft on TDC marking of cylinder 1 ⇒ page 13-7. The adjusting straightedge MP 1-312 must allow itself to be used in the cam- shaft. Fit on the cylinder head gasket. To centre it, screw in the guide bolts MP 1- 208 into the outer holes on the suction side.

  • Page 64: Testing Compression

    Cylinder Head, Valve Gear OCTAV1A 2nd torque further with a rigid wrench: Stage III = 90° ( turn) Stage IV = 90° ( turn) Note: Tightening up the cylinder head bolts after do- ing repair work is not necessary. Install toothed belt ⇒ page 13-4. Testing compression pressure Test conditions l Engine oil temperature at least 30 °C...
  • Page 65 Cylinder Head, Valve Gear OCTAV1A Note: Use of tester ⇒ operating instructions Operate starter until the tester no longer in- dicates a pressure rise. Compression readings: New engine Wear limit Pressure difference between indivi- dual cylinders 2.5...3.1 MPa 1.9 MPa max.
  • Page 66 0  1  (     ( 2 3 3  ( % 4 © %      © OCTAVIA Cylinder Head/Valve Gear %      © valve ♦ do not mix up ♦...
  • Page 67 OCTAVIA Cylinder Head, Valve Gear K Fig. 1 Inspecting axial play of camshaft Special tools, testers and aids required ♦ Universal dial gauge holder MP 3-447 ♦ Dial gauge Wear limit: max. 0.15 mm Carry out measurements with bucket tappets removed and first and last bearing caps installed.
  • Page 68    ¦   ¦ § ¨     ¦ § ¨ OCTAVIA Cylinder Head/Valve Gear ¡ ¢ £ §   ! § "   §  # ¡  ¢ Sealing lip -1-; with worm spring ∅...
  • Page 69 OCTAVIA Cylinder Head, Valve Gear Calculating maximum permissible reworking dimension Insert valve and press firmly against the valve seat. Note: If the valve is replaced as part of repair work, use a new valve for the measurement. Measure the distance -a- between end of valve stem and top edge of cylinder head.
  • Page 70 OCTAVIA Cylinder Head, Valve Gear K Reworking exhaust valve seat Dimension Valve seats ∅ a 31.4 mm Valve seat diameter max. perm. reworking dimension 2.7 mm Valve seat width Cylinder head bottom edge 45° Valve seat angle Procedure Reworking can be carried out with a machine or by hand.
  • Page 71 Cylinder Head, Valve Gear OCTAV1A Calculating maximum permissible reworking dimension Insert valve and press firmly against the valve seat. Note: If the valve is replaced when carrying out repair work, use a new valve for the measurement. Measure distance -a- between the valve stem end and the upper face of the cylinder head.

  • Page 72: Inspecting Valve Guides

    Cylinder Head, Valve Gear OCTAV1A Grind in valve/valve seat with fine grinding paste so as to achieve a perfect contact pat- tern -arrows-. Inspect valve for leaks. The inspection can be carried out with water colour (perfect contact pattern over entire cir- cumference) or by filling fuel into the combus- tion chamber (no fuel must flow out at the valve seat).
  • Page 73 OCTAVIA Cylinder Head, Valve Gear Removing Remove camshaft ⇒ page 15-16. Remove bucket tappets (do not mix up) and place down with running surface facing down. Move piston of the relevant cylinder into top dead centre (TDC). Insert assembly device MP 1-213 and set mounting at height of stud bolt.

  • Page 74: Removing And Installing Camshaft

    Cylinder Head, Valve Gear OCTAV1A ♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started. Removing and installing camshaft Special tools, testers and aids required ♦...
  • Page 75 Cylinder Head, Valve Gear OCTAV1A At the same time the adjusting straightedge MP 1-312 must be inserted easily into the slot at the rear of the camshaft (without the illustrated gauges). Notes: ♦ If the adjusting straightedge cannot be in- serted, rotate the crankshaft 1 further turn (360°).

  • Page 76: Inspecting Hydraulic Bucket Tappets

    OCTAVIA Cylinder Head, Valve Gear Notes: ♦ After installing the camshaft, the engine must not be started for about 30 minutes. The hy- draulic valve clearance compensating ele- ments have to settle (otherwise valves will strike the pistons). ♦ After carrying out work on the valve gear,...

  • Page 77: Replacing Valve Guides

    OCTAVIA Cylinder Head, Valve Gear Notes: ♦ After installing the camshaft, the engine must not be started for about 30 minutes. The hy- draulic valve clearance compensating ele- ments have to settle (otherwise valves will strike the pistons). ♦ After carrying out work on the valve gear,...

  • Page 79: Lubrication System Page

    OCTAVIA Lubrication system Removing and installing parts of the lubrication system 2 - Chain sprocket for oil pump ♦ pay attention to installation position ♦ can be fitted onto oil pump shaft only in one position 3 - 25 Nm 4 - Chain for oil pump ♦...

  • Page 80: Disassembling And Assembling Oil Filter Holder

    OCTAVIA Lubrication system Disassembling and assembling oil filter holder 6 - Screw plug, 10 Nm ♦ up to 03.01 7 - Screw plug ♦ up to 03.01 ♦ must not be opened 8 - Spring ♦ up to 03.01 ♦ for pressure relief valve 0.5 MPa (5 bar)

  • Page 81: Removing And Installing Oil Pan

    OCTAVIA Lubrication System Removing and installing oil pan Special tools, testers and aids required ♦ Torque wrench ♦ Silicone sealant D176 404 A2 ♦ Hand drill with rotating plastic brush attach- ment ♦ Flat scraper Removing Remove noise insulation panel in middle as well as on left and right -arrows-.
  • Page 82 OCTAVIA Lubrication System Installing Note: The oil pan must be installed within 5 minutes after applying the silicone sealant. Cut off tube nozzle at the front marking (∅ of tube about 3 mm). ♦ Thickness of sealant bead: 2 ... 3 mm...

  • Page 83: Testing Oil Pressure And Oil Pressure Switch

    OCTAVIA Lubrication System Testing oil pressure and oil pres- sure switch Special tools, testers and aids required ♦ Oil pressure tester (e.g. V.A.G 1342) ♦ Diode test lamp (e.g. V.A.G 1527) ♦ Adapter cable set (e.g. V.A.G 1594) ♦ Current flow diagram...
  • Page 84 Lubrication System OCTAV1A Test conditions l Inspect engine oil level to ensure that it is OK ⇒ Inspection and Maintenance. l Warning light for oil pressure (K3) must light up briefly when switching on the ignition. l Engine oil temperature must be at least 80 °C (radiator fan must run once).

  • Page 85: Engine Oil

    OCTAVIA Lubrication System Engine oil The engine is factory-filled with a branded multigrade oil which can also be used as an all- seasons oil - except in extremely cold climatic zones. The specifications stated below must be indi- cated individually or together with other specifi- cations on the can.
  • Page 86 9 @ 9 8 A B C D E 6 D F D 9 E G H 9 I 6 E G Q F R OCTAVIA Lubrication System S T 7 E U W C D 7 X T R Note: ¡...

  • Page 87: Removing And Installing Parts Of The Cooling System

    OCTAV1A Cooling System Removing and installing parts of the cooling system Notes: ♦ When the engine is warm the cooling sys- tem is under pressure. If necessary reduce pressure before repairs. ♦ The hose connections are secured with spring strap clips. In the event of repairs only use spring strap clips.

  • Page 88: Parts Of The Cooling System Fitted To Body

    OCTAV1A Cooling System Parts of the cooling system fitted to body 1 - Radiator 4 - Fan shroud ♦ after replacing fill entire system with fresh coolant 5 - 10 Nm ♦ removing and installing ⇒ page 19-9 6 - Auxiliary fan ♦...
  • Page 89 OCTAV1A Cooling System 8 - Retaining clips 15 - Bottom coolant hose ♦ for fan cable ♦ attached to radiator using a retaining ♦ check tightness clip ♦ connection diagram for coolant hoses ⇒ page 19-2.4 9 - Connector 10 - Radiator fan 16 - O-ring ♦...

  • Page 90: Parts Of The Cooling System Attached To Engine

    OCTAV1A Cooling System Parts of the cooling system attached to engine 1 - 15 Nm 4 - To top radiator ♦ connection diagram for coolant hoses ⇒ page 19-2.4 2 - Coolant pipe ♦ inspect for smooth operation ♦ pay attention to fitting position 5 - To cylinder head ♦...
  • Page 91 OCTAV1A Cooling System 7 - To heat exchanger for heating 17 - From heat exchanger for heating ♦ connection diagram for coolant hoses ♦ connection diagram for coolant hoses ⇒ page 19-2.4 ⇒ page 19-2.4 8 - Radiator for exhaust gas recirculation 18 - 10 Nm ♦...

  • Page 92: Connection Diagram For Coolant Hoses

    OCTAV1A Cooling System Connection diagram for coolant hoses 1 - Radiator 3 - Coolant pump, coolant regulator ♦ after replacing fill entire system with ♦ removing and installing coolant pipe fresh coolant ⇒ page 19-5 ♦ removing and installing ⇒ page 19-9 ♦...
  • Page 93 OCTAV1A Cooling System 4 - Cylinder block 8 - Heat exchanger for heating 5 - Expansion reservoir 9 - ATF radiator ♦ only on vehicles with automatic gear- 6 - Intake manifold 7 - Radiator for exhaust gas recirculation 10 - Heater for coolant ♦...
  • Page 94 OCTAV1A Cooling System Turn drain plug -arrow- on the radiator to the left, if necessary fit auxiliary hose onto con- nection. In addition remove coolant hose at bottom on the oil cooler -arrow- and drain residual coolant. Filling up Select the appropriate coolant additive from the original spare parts catalogue Škoda or from the list of allowed coolant additives ⇒...
  • Page 95 OCTAVIA Cooling System ♦ If the two coolants are mixed, the coolant turns brown in colour. Brown coolant should be drained immediately, the cooling system flushed out with drinking water and filled with fresh coolant. If this is not done, there is a risk of damage to the engine and the cooling system.
  • Page 96 OCTAVIA Cooling System ------------ 19-4.2 ------------ Edition 03.98 S00.5110.52.20...

  • Page 97: Removing And Installing Coolant Pump

    OCTAV1A Cooling System Fill with coolant gradually up to „max“ mark- ing on the expansion reservoir. Start engine and run for max. 2 minutes at approx. 1500 rpm; fill up coolant to overflow opening of expansion reservoir. Close expansion reservoir. Run engine until the fan starts.
  • Page 98 OCTAV1A Cooling System Unbolt fixing nut -3- for air guide pipe -2-. Remove air guide pipe -2-. Remove the V-ribbed belt ⇒ page 13-1. Remove tensioning pulley ⇒ page 13-1. Remove top and middle toothed belt guard ⇒ page 13-4. Remove toothed belt from camshaft sprocket and from injection pump gear ⇒...
  • Page 99 OCTAV1A Cooling System Install toothed belt ⇒ page 13-4. Install the V-ribbed belt ⇒ page 13-1. Fill coolant ⇒ page 19-3. Removing and installing coolant regulator Special tools, testers and aids required ♦ Torque wrench ♦ Pliers for spring strap clips Removing Drain coolant ⇒...
  • Page 100 OCTAVIA Cooling System Installing coolant pipe Before installing, clean or smooth sealing surface for O-ring. Moisten O-ring -1- with coolant and fit onto coolant pipe -2-. Insert coolant pipe into the hole on the cylinder block. Bolt bracket for coolant pipe tight to 10 Nm-...

  • Page 101: Removing And Installing Radiator

    OCTAV1A Cooling System Removing and installing the radia- Notes: ♦ Always replace gasket rings and seals. ♦ Raise vehicle with lift platform ⇒ page 10-1. Special tools, testers and aids required ♦ Torque wrench ♦ Wire Removing Drain coolant ⇒ page 19-3. Disconnect connector -1- from thermoswitch (-F18-) and separate plug connections -2- and -3- at fan shroud (press catches).
  • Page 102 OCTAVIA Cooling System Detach bracket -arrow- for refrigerant pipe. Continued for all models Remove both headlights: ⇒ Electrical System; Repair Group 94; Remov- ing and installing headlights Remove the 4 bolts -arrows- for attaching the top radiator mount. Remove the 4 bolts -arrows- for attaching the bottom radiator mount.
  • Page 103 OCTAVIA Cooling System Models with air conditioning Pull out radiator slightly together with con- denser. Detach clip -arrow- for attaching refrigerant pipe. Continued for all models Remove fan shroud (4 bolts). Note: When removing and installing the fan shroud, ensure that the radiator ribs are not damaged.

  • Page 104: Removing And Installing Fan

    OCTAVIA Cooling System Removing and installing fan Note: ♦ Raise vehicle with lift platform ⇒ page 10-1, Removing and installing engine. Special tools, testers and aids required Separate plug connections -2- and -3- at the fan ring (press catches) and detach plug connections from the holder.

  • Page 105: Fuel Supply System Page

    OCTAVIA Fuel Supply System Removing and installing parts of the fuel supply system Removing and installing fuel tank with attached parts 3 - Fuel gauge sender ♦ with closing flange ♦ removing and installing ⇒ page 20-4 ♦ position of sender with strainer can be...

  • Page 106: Removing And Installing Fuel Cooler

    OCTAVIA Fuel Supply System 17 - Clamping washer ♦ removing: turn to left ♦ installing: tighten to 2 Nm 18 - Heat shield ♦ for fuel tank 19 - Cover ♦ for fuel tank ♦ not fitted to all models 20 - 20 Nm + torque a further turn (90°)

  • Page 107: Rules For Cleanliness

    OCTAVIA Fuel Supply System Safety precautions when carrying out work on fuel supply system Pay attention to the following points when removing and installing the fuel gauge sender or the fuel pump (fuel delivery unit) from the fuel tank: ♦ The extraction hose of an exhaust extraction...

  • Page 108: Removing And Installing Fuel Gauge Sender

    OCTAVIA Fuel Supply System Removing and installing fuel gauge sender Special tools, testers and aids required ♦ Wrench for union nut MP 1-227 Removing Unscrew cover (below rear seat). Slacken fuel feed line and fuel return-flow line and detach. Separate multipin connector for fuel gauge.
  • Page 109 OCTAVIA Fuel Supply System Unbolt cover (below rear seat). Unplug multi-pin connector for fuel gauge. Open fuel filler cap and lever out tensioning ring in rubber bowl (around filler neck). Push rubber bowl through to the inside. Remove rear right wheelhouse liner.

  • Page 110: Removing And Installing Fuel Tank With Attached Parts - 4 X 4 Models

    OCTAVIA Fuel Supply System Removing and installing parts of fuel supply system for 4 x 4 models Removing and installing fuel tank with attached parts for 4 x 4 models Notes: ♦ Servicing fuel filter: ⇒ 1.9-ltr./66 kW (TDI) Engine, Fuel Injection ♦...
  • Page 111 OCTAVIA Fuel Supply System 2 - Seal 14 - Vent valve ♦ moisten with fuel for installing ♦ carefully insert seal into the fuel tank 15 - 10 Nm before installing fuel gauge sender 16 - Vent hoses 3 - Right fuel gauge sender ♦...
  • Page 112 $ " (  ) ! 0  1 2 3 &   2  & 2  "  1 '  $ 4 ! 1 $  2 5 6 OCTAVIA Fuel Supply System Removing and installing...

  • Page 113: Removing And Installing Fuel Tank - 4 X 4 Models

    OCTAVIA Fuel Supply System Removing and installing fuel tank for 4 x 4 models Special tools, testers and aids required ♦ Engine/gearbox lifter (e.g. V.A.G 1383 A) ♦ Fuel extractor (e.g. V.A.G 1433 A) Removing Use fuel extractor (e.g. V.A.G 1433 A) to empty fuel tank.
  • Page 114 OCTAVIA Fuel Supply System Separate connector at ABS and Haldex cou- pling. Detach vent hoses of Haldex coupling. Support the rear final drive with the engine/ gearbox lifter (e.g. V.A.G 1383 A). Unscrew bolts at rear axle -arrows-. Swivel out rear axle by lowering the lifter.

  • Page 115: Charge Air System With Turbocharger

    OCTAV1A Turbocharging Charge air system with turbo- charger Notes: ♦ Observe the cleanliness regulations ⇒ page 21-1. ♦ Connection diagram for charge pressure control ⇒ page 21-4. ♦ The hose connections are secured with clamps. ♦ The charge air system must be tight. ♦...

  • Page 116: Removing And Installing Turbocharger For The Engine Agr With Attached Parts

    OCTAV1A Turbocharging Removing and installing turbocharger for the engine AGR with attached parts 1 - Intake manifold 4 - Vacuum setting element ♦ on engines ä 07.97 ♦ on engines 08.97 ä ♦ with mechanical exhaust gas recircu- ♦ for intake manifold flap lation valve 5 - Induction pipe ♦...
  • Page 117 OCTAV1A Turbocharging 6 - 10 Nm 24 - O-ring ♦ replace 7 - From charge air cooler 25 - Oil return-flow line ♦ for vehicles ä 04.99 8 - Gasket ♦ fitting position: Bead points towards ♦ to cylinder block intake manifold 26 - Banjo bolt, 40 Nm 9 - Gasket...

  • Page 118: Removing And Installing Turbocharger For The Engine Alh With Attached Parts

    OCTAV1A Turbocharging Removing and installing turbocharger for the engine ALH with attached parts 1 - Exhaust manifold 5 - 25 Nm ♦ with turbocharger ♦ must be replaced completely 6 - Gasket ♦ pay attention to fitting position 2 - Intake manifold 7 - Washer 3 - From charge air cooler 8 - 25 Nm...
  • Page 119 OCTAV1A Turbocharging 9 - From air filter 20 - O-ring ♦ replace ♦ for oil return-flow line ♦ replace 10 - To charge air cooler 21 - Turbocharger ♦ can only be replaced complete with 11 - Vacuum setting element ♦...

  • Page 120: Connection Diagram Of Charge Pressure Control

    OCTAV1A Turbocharging Connection diagram for charge pressure control Engines AGR: 1 - Charge pressure control solenoid valve (-N75-) 2 - Air guide pipe ♦ from air filter 3 - Turbocharger ♦ with pressure connection for charge pressure control 4 - Vacuum setting element ♦...
  • Page 121 OCTAV1A Turbocharging Inspecting vacuum setting element of charge pressure control Test conditions: l Engine oil temperature at least 80 °C Engines AGR: Test procedure Remove plug from charge pressure control solenoid valve -N75 (pos. 2). Start the engine and bring the engine up to high revolutions by pressing rapidly on the accelerator pedal.

  • Page 122: Removing And Installing Turbocharger

    OCTAV1A Turbocharging Removing and installing turbo- charger Special tools, testers and aids required ♦ Torque wrench ♦ Pliers for spring strap clips ♦ Hot bolt paste G 052 112 A3 Engines AGR: Removing Unbolt fixing nut -3- and air guide pipe -2- together with hose to turbocharger.
  • Page 123 OCTAV1A Turbocharging For 4x4 vehicles Lift turbocharger up and out. For other vehicles Take turbocharger down and out. Installing Fit hose onto vacuum setting element for charge pressure control valve and secure with collar clamp. Coat thread and head contact surface of fix- ing bolts -1- with hot bolt paste G 052 112 Fit turbocharger onto exhaust manifold and tighten securing bolt -1- by hand.
  • Page 124 OCTAV1A Turbocharging Install air guide pipe from charge air cooler with hose to turbocharger. Install air guide pipe from air filter to turbo- charger. Note: After installing the turbocharger, run engine at idling speed for about 1 minute but do no yet rev up to ensure proper supply of oil to turbo- charger.

  • Page 125: Removing And Installing Parts Of The Charge Air Cooling System

    OCTAVIA Turbocharging system Removing and installing parts of the charge air cooling system Notes: ♦ Hose connections are secured with spring strap clips. Only spring strap clips may be used when carrying out repairs. ♦ It is recommended to use the pliers for re- moving and installing the spring strap clips.

  • Page 126: Removing And Installing Charge Air Cooler

    OCTAVIA Turbocharging Removing and installing charge air cooler Special tools, testers and aids required ♦ Torque wrench ♦ Pliers for spring strap clips Remove noise insulation in middle and on right -arrows-. Detach fuel lines -arrows- to injection pump, seal with plugs and place to the side.
  • Page 127 OCTAVIA Turbocharging Unscrew nut -3- securing air guide pipe -2-. Take off air guide pipe. Detach right wheelhouse liner at the front edge. Turn down nut -1- at bracket for intercooler. Remove intercooler downward. ------------ 21-11 ------------ Edition 08.96 S00.5110.50.20...

  • Page 129: Exhaust System Page

    OCTAV1A Exhaust System Removing and installing parts of the exhaust system 7 - Gasket ♦ replace 8 - Front exhaust pipe ♦ with oxidation catalytic converter ♦ protect catalytic converter against shocks and blows ♦ avoid a large deflection, max. deflec- tion 10°...
  • Page 130 OCTAV1A Exhaust System K Fig. 1 Separation point ♦ When replacing middle silencer or rear si- lencer ♦ Marked by three recesses around circum- ference of exhaust pipe K Fig. 2 Fitting position of the hangers The angled side -arrow- at the base of the hanger points in direction of travel.

  • Page 131: Aligning Exhaust System Free Of Stress

    OCTAV1A Exhaust System Align exhaust system free of stress Special tools, testers and aids required ♦ Torque wrench l The exhaust system is aligned when cold Work procedure Shop-made tool from an M10 bolt to the di- mensions stated for aligning the exhaust system.
  • Page 132 OCTAV1A Exhaust System Position double clamp with a distance of about 5 mm to the line of the marking -A ar- row 1- and tighten evenly to 40 Nm in the horizontal position. Notes: ♦ The marking -A- applies to vehicles with manual gearbox and automatic gearbox.
  • Page 133 OCTAV1A Exhaust System Removing and installing parts of the exhaust system for 4x4 vehicles 3 - Front exhaust pipe 4 - Gasket ♦ replace 5 - Oxidation catalytic converter ♦ protect against shocks and blows 6 - 25 Nm ♦ replace 7 - Bolt 8 - Retaining strap 9 - 25 Nm...
  • Page 134 OCTAV1A Exhaust System K Fig. 1 Separation point ♦ When replacing middle silencer or rear si- lencer ♦ Marked by three recesses around circum- ference of exhaust pipe Replacing middle silencer or rear silencer for 4x4 vehicles Special tools, testers and aids required ♦...

  • Page 135: Exhaust Gas Recirculation System

    OCTAV1A Exhaust System Exhaust gas recirculation system Notes: ♦ The exhaust gas recirculation system is ac- ♦ The mechanical exhaust gas recirculation tuated by the diesel direct injection system valve with conically shaped valve tappets control unit -J248 through the EGR valve permits different opening cross-sections at -N18 to the mechanical exhaust gas recircu- different valve lift.
  • Page 136 OCTAV1A Exhaust System For vehicles 08.00 ä 1 - Vacuum setting element for intake manifold flap 2 - Intake manifold flap change-over valve (-N239-) 3 - Distributor 4 - Non-return valve ♦ white connection points to charge pres- sure control solenoid valve -N75-). 5 - Vacuum unit 6 - To air filter 7 - Charge pressure control solenoid val-...

  • Page 137: Testing Mechanical Exhaust Gas Recirculation Valve

    OCTAV1A Exhaust System Testing mechanical exhaust gas recirculation valve Special tools, testers and aids required ♦ Hand vacuum pump (e.g. V.A.G 1390) Test procedure Remove engine trim panel. Separate air guide pipe between inlet con- nection and charge air cooler at inlet con- nection.
  • Page 138 OCTAV1A Exhaust System Removing and installing parts of the exhaust gas recirculation 1 - Intake manifold 4 - Mechanical exhaust gas recirculation valve ♦ component of the induction pipe can- 2 - O-ring ♦ replace not be replace separately ♦ testing ⇒ page 26-7 3 - Induction pipe ♦...
  • Page 139 OCTAV1A Exhaust System 7 - Gasket 13 - Connecting tube ♦ replace ♦ from exhaust manifold to radiator ♦ only on engines ALH with automatic gearbox 8 - 25 Nm 9 - Connecting tube 14 - To heat exchanger for heating ♦...

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