Skoda Octavia 1996 Service Manual
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Skoda Octavia 1996 Service Manual

Skoda Octavia 1996 Service Manual

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Service
Workshop Manual
OCTAVIA
1.6 ltr. / 74 kW Engine,
Mechanical Components
Service Department. Technical Information
S00.5105.50.20
Edition 08.96

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Summary of Contents for Skoda Octavia 1996

  • Page 1 Service Workshop Manual OCTAVIA 1.6 ltr. / 74 kW Engine, Mechanical Components Service Department. Technical Information S00.5105.50.20 Edition 08.96...
  • Page 2 The Workshop Manual is intended only for use within the ŠKODA Organisation; it is not permitted to pass it on to third parties. Printed in Czech Republic © 1996 ŠKODA, automobilová a.s.
  • Page 3 Service List of Supplements to Workshop Manual Edition: 10.02 OCTAVIA 1.6 l/74 kW Engine, Mechanical Components Replaces List of Supplements - Edition: 05.01 Subject Edition Article Number Supple- ment 08.96 Basic Edition of Workshop Manual S00.5105.50.20 05.97 Supplement to Basic Edition S00.5105.51.20 12.99 Modifications to Repair Groups 00, 10, 13, 15,...

  • 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 ....................10-10 Installing engine ........................
  • Page 6 ¡ ¢ £ ¤ ¥ £      ! " # $ % & ' ( ) 0 1 # ( 2 3 4 5 6 7 8 9 @ 8 A 7 8 B C @ D D 7 8 9 E @ F C B 5 G C H 3 I 5 5 D 7 8 9 B P B C 3 4 Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q R S T R U V W X Y ` a b c d ` ` e f g h i Y X c p q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q...

  • Page 7: Technical Data

    OCTAVIA Technical Data Technical data Engine number K The engine number (“engine code letters” and “serial number”) is located at the front at the joint between engine and gearbox. In addition, a sticker with “engine code letters” and “serial number” is affixed to the toothed belt guard.
  • Page 8 OCTAVIA Technical Data ¡ ¢ ------------ ------------ Edition 12.99 S00.5105.52.20...

  • Page 9: Removing And Installing Engine

    OCTAVIA Removing and Installing Engine Removing and installing engine Special tools, testers and aids required ♦ Workshop crane (e.g. V.A.G 1202 A) ♦ Drip tray (e.g. V.A.G 1306) ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦ Torque wrench 40...200 Nm (e.g.
  • Page 10 OCTAVIA Removing and Installing Engine Procedure Pay attention to coding on models fitted with coded radio set, determine if necessary. Remove battery: ⇒ Electrical system; Repair Group 27; Remov- ing and installing battery Remove battery carrier -arrows-. Open cap of coolant expansion reservoir. Raise vehicle with lift platform;...
  • Page 11 ¤ ¥ ¦ § ¨ © §  ©       ¦   ¤   ¦  © ¤ ¨  © § ¨ © ¤ ¤ ! ¨ ¤ ¥ ¦  ¦    ¤ "...
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  • Page 15 ¤ ¥ ¦ § ¨ ©        ¥       §   ¥ ! 6 $ 1 $ ' & % & ' $ ( ) ' 0 1 $ ' 2 3 4 ' $ # # 5 # $ 6 $ &...
  • Page 16 OCTAVIA Removing and Installing Engine ♦ to top of radiator (at flange on left of cylin- der head) ♦ to heating system heat exchanger (1 hose each at coolant pipe and on left of cylinder head) ♦ on side at coolant pipe ♦...
  • Page 17 ¤ ¥ ¥ ¦ § ¨ ©     §          ©      © !   " ¦ § ¨ ©     ©...

  • Page 18: Removing And Installing Engine

    £ ¤ ¥ ¦ § ¨ ©  ¤       ¦ ¤    ¦ © ¨  © ¦  ¨ ¨ ©  ¤       ¦ ¤  ¦  ¤ ¨   © © ¦      ©...

  • Page 19: Installing Engine

    £ ¤ ¥ ¦ § ¨ ©       ¤       ¦    ¤ ! " # # $ % & # " ' ( ) 0 1 2 1 $ # 2 $ % 0 1 2 0 $ 3 4 "...
  • Page 20 OCTAVIA Removing and Installing Engine Attach intermediate plate to sealing flange and push onto the dowel sleeves -arrows-. Models fitted with manual gearbox Apply a thin film of grease G 000 100 to the splines of the gearbox input shaft. Inspect centering of clutch plate, if neces- sary.
  • Page 21 OCTAVIA Removing and Installing Engine Install ribbed V-belt ⇒ page 13-4. Install coolant hoses ⇒ page 19-1. Fill system with coolant ⇒ page 19-2. Do not re-use drained coolant if cylinder block, cylinder head, radiator or heat ex- changer has been replaced. Place engine connecting loom in cable duct and plug together with 10-pin plug connec- tion.

  • Page 22: Tightening Torques

    OCTAVIA Removing and Installing Engine Tightening torques Notes: ♦ Tightening torques apply only to nuts and bolts which are lightly greased, oiled, phosphatized or blackened. ♦ Additional lubricants such as engine oil or gear oil, are permissible, but not Molykote. ♦...

  • Page 23: Aligning Engine/Gearbox Mounting

    OCTAVIA Removing and Installing Engine Aligning engine/gearbox mounting Warning! The engine/gearbox assembly must be secured with the supporting device MP 9-200 before slack- ening the bolts. K Engine mounting a = 14.0 mm b = at least 10.0 mm Both bolt heads -1- must end flush with the edge -c-.

  • Page 24: Engine/Gearbox Mounting

    OCTAVIA Removing and Installing Engine Engine/gearbox mounting Tightening torques K Engine mounting 40 Nm + 90° (1/4 turn) 25 Nm 100 Nm Replace bolts K Gearbox mounting 40 Nm + 90° (1/4 turn) 25 Nm 100 Nm Replace bolts K Pendulum support 40 Nm + 45°...

  • Page 25: Crank Assembly Page

    OCTAVIA Crank Assembly Disassembling and assembling engine Removing and installing ribbed V-belt 2 - 25 Nm 3 - Tensioning device for ribbed V-belt ♦ swivel with open-end wrench for slack- ening ribbed V-belt ⇒ page 13-3 4 - Vibration damper ♦...
  • Page 26 OCTAVIA Crank Assembly K Fig. 1 Routing of ribbed V-belt on mod- els not fitted with AC K Fig. 2 Routing of ribbed V-belt on mod- els fitted with AC Note: Engines equipped with AC compressor have a double ribbed V-belt. ------------ 13-2 ------------ Edition 10.02 S00.5105.54.20...
  • Page 27 OCTAVIA Crank Assembly K Fig. 1 Tightening sequence of bolts at compact holder Removing ribbed V-belt Note: Mark the direction of running of the ribbed V- belt before removing it. If an already used belt is fitted on again to run in the opposite direction, it may be destroyed.
  • Page 28 OCTAVIA Crank Assembly ------------ 13-4 ------------ Edition 05.01 S00.5105.53.20...

  • Page 29: Removing And Installing, Tensioning Toothed Belt

    OCTAVIA Crank Assembly Removing and installing, tensioning toothed belt 9 - Corrugated washer 10 - 100 Nm ♦ use counterholder MP 1-216 for slack- ening and tightening 11 - Camshaft sprocket ♦ with sensor rotor for Hall sensor -G40- ♦ removing and installing toothed belt ⇒ page 13-5 ♦...
  • Page 30 OCTAVIA Crank Assembly K Fig. 1 Installation position of the semi-au- tomatic tensioning pulley The angle bracket- -arrow- must engage in the recess at the cylinder head. Special tools, testers and aids required ♦ Torque wrench ♦ Counterholder MP 1-216 ♦...
  • Page 31 OCTAVIA Crank Assembly Rotate crankshaft to TDC of cylinder 1 -arrow- (models with automatic gearbox). TDC marking on driven plate and reference mark should be aligned. Note: K With engine removed, position vibration damper to TDC of cylinder 1 -arrows-. Remove engine cover.
  • Page 32 OCTAVIA Crank Assembly Remove vibration damper. Remove top, bottom and centre toothed belt guards. Unbolt PAS reservoir. Unbolt engine support from the engine mounting bracket and engine mounting bracket from the body -arrows-. Mark direction of running of toothed belt. Slacken semi-automatic tensioning pulley and take off toothed belt.
  • Page 33 OCTAVIA Crank Assembly Position crankshaft to TDC of cylinder 1 ⇒ page 13-6 (except if engine removed). Fit toothed belt onto toothed belt sprocket of crankshaft (pay attention to direction of running) ⇒ page 13-5. Note: K If engine removed, after this fit on bottom toothed belt guard and toothed belt sprocket and position crankshaft to TDC of cylinder 1 -arrows-.
  • Page 34 OCTAVIA Crank Assembly Note: Insert bolts into engine support before installing Install engine support ⇒ page 13-5. Install engine mount ⇒ page 10-16. Remove supporting device. Install middle and top toothed belt guard. Install tensioning device for ribbed V-belt. Tightening torque: 20 Nm. Install ribbed V-belt ⇒...

  • Page 35: Removing And Installing Crankshaft

    OCTAVIA Crank Assembly Removing and installing crankshaft 6 - Chain sprocket ♦ for oil pump drive 7 - Crankshaft ♦ axial play of new part: 0.07 to 0.21 mm wear limit: 0.30 mm ♦ crankshaft bearing journal: ∅ 54.00mm ♦ conrod bearing journal: ∅ 47.80 mm 8 - Bearing shell ♦...
  • Page 36 OCTAVIA Crank Assembly 18 - Intermediate plate ♦ is attached to sealing flange ⇒ Fig. 1 ♦ must be placed on dowel sleeves ♦ do not damage or bend when carry- ing out removal and installation work 19 - 15 Nm 20 - Rear sealing flange with seal ♦...
  • Page 37 ¡ ¢ £ ¤ ¥ ¦ § ¡ ¨ ¢ ©  ¥ ¦ ¡ ¨ ¢   ¦ ¡ ¨ ¢   ¥     ¨   ¥ ¦  ¦  OCTAVIA Crank Assembly ♦...
  • Page 38 ¡ ¢ £ ¤ ¥ ¦ § ¨ © ¤ §    ¤     ¡ £   £  ¥ ¢ £ ¡   ¦  ¡  ! " # $ % & ' ( ( & ) 0 1 "...
  • Page 39 OCTAVIA Crank Assembly When bolting on counterholder, place 2 washers between toothed belt sprocket and counterholder. Screw central bolt of toothed belt sprocket into the crankshaft again. Turn out inner part of seal extractor MP 1- 226 two turns (about 3 mm) out of the outer part and lock with knurled screw.
  • Page 40 ¦ § ¨ ©     §        ! " # ! $ " # % & ' & % (  1 2 3  % $ & ' " ( ! $ ( ) % 0 4  ' ! 5 &...

  • Page 41: Removing And Installing Pressure Plate

    OCTAVIA Crank Assembly Removing and installing pressure plate Special tools, testers and aids required ♦ Torque wrench 40...200 Nm (e.g. V.A.G 1332) ♦ Counterholder MP 1-221 Insert counterholder MP 1-221 into hole on cylinder block and bolt on at pressure plate. Slacken bolts for pressure plate.
  • Page 42 OCTAVIA Crank Assembly Installing Remove intermediate plate (⇒ page 13-12, item 18). Fit on driven plate, using only washer with recesses -1-. Insert at least 3 old securing bolts -3- and tighten to 30 Nm. Check installation dimension of driven plate at the 3 mounting holes for the torque converter and calculate average value.

  • Page 43: Removing And Installing Front Sealing Flange

    OCTAVIA Crank Assembly Removing and installing front sealing flange Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦ Torque wrench 40...200 Nm (e.g. V.A.G 1332) ♦ Locking lever T 30004 or counterholder MP 1-310 ♦...
  • Page 44 ¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § OCTAVIA Crank Assembly ©      ©                  !  " #  $ ¨...
  • Page 45 ¡ ¢ £ ¢ ¢ ¤ ¥ ¦ § ¡ ¨ © £ ¢ ¢ ¤ ¥ ¦ § ¡ ¨ ©  ¡ ¢   ¨ ¢   ¨ ¨ ¤   ¡ ¨ © #  $ %   " &...
  • Page 46 OCTAVIA Crank Assembly K Fig. 1 Inspecting piston ring gap clear- ance Special tools, testers and aids required ♦ Feeler gauge Inspection procedure Insert ring at right angles to cylinder wall from the top as far as the bottom cylinder opening about 15 mm away from edge of cylinder.
  • Page 47 ¡ ¢ £ ¤ ¥ ¦ § ¨ ©  ¡ ¥ ¢ § ¡ ¦   ¥ ¦  § ¨ © ¡      ¦  ¨   ¡  ¨  ¤ ¥ ¦ § ¨ ©  ¡  ¥ §   © ¨    ¨ OCTAVIA Crank Assembly ¡...
  • Page 48 OCTAVIA Crank Assembly ------------ 13-22 ------------ Edition 12.99 S00.5105.52.20...

  • Page 49: Removing And Installing Cylinder Head

    OCTAVIA Cylinder Head/Valve Gear Removing and installing cylin- der head Removing and installing toothed belt ⇒ page 13-6. Testing compression ⇒ page 15-13. Notes: ♦ Always replace cylinder head bolts. ♦ Always replace self-locking nuts. ♦ Always replace seals and gaskets when car- rying out removal and installation operations.
  • Page 50 OCTAVIA Cylinder Head, Valve Gear 1 - 15 Nm 5 - Cylinder head bolt ♦ replace 2 - 20 Nm ♦ pay attention to slackening sequence ⇒ page 15-10 3 - Rear toothed belt guard ♦ pay attention to tightening sequence ⇒...
  • Page 51 OCTAVIA Cylinder Head, Valve Gear 8 - Reinforcing strip 17 - Gasket ♦ replace if damaged 9 - Cylinder head cover ♦ removing and installing ⇒ page 15-6 18 - Bottom part of intake manifold 10 - 10 Nm 19 - Gasket ♦...

  • Page 52: Removing And Installing Top Part Of Intake Manifold

    OCTAVIA Cylinder Head, Valve Gear Removing and installing top part of intake manifold Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦ Pliers for spring strap clamps ♦ 2 hose clamps MP 7-602 ♦ Cable straps Removing Note: All cable straps which have been detached or...
  • Page 53 OCTAVIA Cylinder Head/Valve Gear Detach vacuum hose to brake servo unit. Unplug cables/connectors: 1 - Connector for intake air temperature sender -G42- 2 - Connector for throttle valve control unit -J338- Detach hose to the ACF. Detach throttle cable -arrows-. Unbolt earth strap at the cylinder head cover.

  • Page 54: Removing And Installing Cylinder Head Cover

    OCTAVIA Cylinder Head/Valve Gear Installing Note: Replace gaskets if damaged. Fit top part of intake manifold onto the bottom part. Press in retaining lugs on left and right until they engage. Coat collar of bolts of rear intake manifold suspension with commercially available lubricant and tighten to 10 Nm.

  • Page 55: Removing Cylinder Head

    OCTAVIA Cylinder Head/Valve Gear Removing cylinder head Note: All cable straps which are detached or cut open when removing the cylinder head, should be fit- ted on again at the same point when installing. Special tools, testers and aids required ♦...
  • Page 56 OCTAVIA Cylinder Head/Valve Gear In addition, detach coolant hose at bottom of oil cooler -arrow- and allow remaining coolant to flow out. Detach air guide hose at throttle valve body and at ventilation housing of crankcase ventilation -arrows-. Detach ventilation hose -1- and unplug connector for air mass meter -2-.
  • Page 57 OCTAVIA Cylinder Head/Valve Gear Rotate crankshaft to TDC of cylinder 1 -arrow- (models with automatic gearbox). TDC marking on driven plate and reference mark should be aligned. Note: K If engine removed, position flywheel damper to TDC of cylinder 1 -arrows-. Remove top toothed belt guard.

  • Page 58: Inspecting Cylinder Head For Distortion

    OCTAVIA Cylinder Head/Valve Gear Unplug connector at the plug connection for phase sensor (Hall sender -G40-) and connectors at all four injectors. Release wiring loom from the fixtures and run out to the side. Unplug spark plug connectors and place to the side.
  • Page 59 ¡ ¢ £ ¤ ¥ ¦ § ¨ ©   ¦ §  ¡ ¤  ¡        !   OCTAVIA Cylinder Head/Valve Gear " § # $    ¦ § ¨ ©...
  • Page 60 OCTAVIA Cylinder Head/Valve Gear Procedure Position crankshaft and camshaft to TDC of cylinder 1 before fitting on the cylinder head ⇒ page 15-8. Fit on cylinder head gasket and lock dowel sleeves. Inscription (part number) should be legible. Insert new cylinder head bolts and tighten by hand.

  • Page 61: Testing Compression

    OCTAVIA Cylinder Head/Valve Gear Testing compression pressure Test condition l Engine oil temperature at least 30 °C Special tools, testers and aids required ♦ Compression pressure tester (e.g. V.A.G 1381 or V.A.G 1763) ♦ Spark plug wrench Test procedure Switch off ignition (if not already off) and unplug connectors at all four injectors.
  • Page 62 ¡ ¢ £ ¤ ¥ ¤ ¦ § § ¡ ¨ ¢ (    & & # & " # © 0 1   2 © 3 #   4 5 6 !   © OCTAVIA ©...
  • Page 63 ¡ ¢ £   ¦      ¡   §   ¤ ¥ ¦ § ¨ ©    § ¨ © ¡   ©    ¦  ¡ " ¦ # $ ¡...

  • Page 64: Replacing Camshaft Seal

    OCTAVIA Cylinder Head/Valve Gear Replacing camshaft seal Special tools, testers and aids required ♦ Counterholder MP 1-216 ♦ Seal extractor MP 1-215 ♦ Seal insertion tool MP 1-214 ♦ Torque wrench ♦ Thrust sleeve T10071 ♦ Guide sleeve T10071/1 Removing Remove top part of toothed belt guard.
  • Page 65 ¢ £ ¤ ¥ ¥ ¦ ¡ ¨ ¥ ¤ ¢ £ © ¢ ¨ ¤ ¥ ¡ § ¨          ! "   #  ! "  & OCTAVIA Cylinder Head/Valve Gear (  ) !  ! !
  • Page 66 OCTAVIA Cylinder Head/Valve Gear ------------ 15-17.1 ------------ Edition 05.01 S00.5105.53.20...
  • Page 67 ¢ £ ¤ ¥ ¥ ¡ ¢ © ¤  £ ¡ ¦ § ¤ ¨      !  "   "  # "  OCTAVIA Cylinder Head/Valve Gear Removing and ♦ Torque wrench ♦...
  • Page 68 ¢ £ ¤ ¥ ¥ ¦ ¡ ¡ § OCTAVIA Cylinder Head/Valve Gear Notes: ♦ Replace camshaft seal. ♦ When installing camshaft, the cams of cylin- der 1 must be facing up. K ♦ When installing bearing caps, pay attention ©...

  • Page 69: Inspecting Hydraulic Bucket Tappets

    OCTAVIA Cylinder Head/Valve Gear Inspecting hydraulic bucket tappets Special tools, testers and aids required ♦ Feeler gauge ♦ Wooden or plastic wedge Notes: ♦ Always replace a faulty bucket tappet complete (cannot be set or repaired). ♦ Irregular valve noises when starting engine are normal.

  • Page 70: Replacing Valve Stem Seals

    OCTAVIA Cylinder Head/Valve Gear Use a wooden or plastic wedge to press bucket tappet down. If it is possible to insert a 0.20 mm feeler gauge between camshaft and bucket tappet, replace tappet. Replacing valve stem seals l Cylinder head installed Special tools, testers and aids required ♦...
  • Page 71 OCTAVIA Cylinder Head/Valve Gear Use assembly lever and thrust piece MP 1-211 to remove valve springs. Note: If valve collets are tight, detach with slight blows from a hammer on the assembly lever. Use MP 1-206 to pull of valve stem seals. Installing Fit plastic sleeve -A- onto the valve stem in order to avoid damage to the new valve stem...

  • Page 72: Inspecting Valve Guides

    OCTAVIA Cylinder Head/Valve Gear Inspecting valve guides Special tools, testers and aids required ♦ Universal dial gauge holder MP 3-447 ♦ Dial gauge Procedure Insert valve into guide. End of valve stem should be flush with guide. Determine valve rock. Wear limit Inlet valve guide Exhaust valve guide...

  • Page 73: Reworking Valve Seats

    OCTAVIA Cylinder Head/Valve Gear Installing Moisten new guides with oil and press into the cold cylinder head from the camshaft side as far as the collar with MP 1-205. Note: After the guide makes contact with the collar, do not increase the insertion force to more than 10 kN otherwise the collar may shear off.
  • Page 74 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 when carrying out repairs, use a new valve for the measurement. Measure distance -a- between end of valve stem and top edge of cylinder head.
  • Page 75 OCTAVIA Cylinder Head/Valve Gear Procedure Reworking can be carried out on a machine or by hand. It is essential to comply with the following conditions: l Wear limit of valve guides must not exceed maximum permissible dimension ⇒ page ∅ ∅ ∅ ∅ ∅...
  • Page 76 OCTAVIA Cylinder Head/Valve Gear Use fine grinding paste to grind in valve/valve seat -arrows- so that a proper contact pattern is achieved. Inspect valve for leaks. The inspection can be carried out with water colour (proper contact pattern around the entire circumference) or by filling fuel into the combustion chamber (no fuel should flow out at the valve seat).

  • Page 77: Lubrication System Page

    OCTAVIA Lubrication System Removing and installing parts of the lubrication system 3 - 20 Nm 4 - Chain for oil pump 5 - Sealing flange ♦ insert with silicone sealant D 176 404 A2 ⇒ page 13-17 ♦ replacing crankshaft seal ⇒...

  • Page 78: Disassembling And Assembling Oil Filter Holder

    OCTAVIA Lubrication System Disassembling and assembling oil filter holder 8 - Cap 9 - Locking clasp 10 - Screw plug, 15 Nm 11 - Seal ♦ cut open and replace if leaking 12 - 0.14 MPa oil pressure switch -F1-, 25 Nm ♦...

  • Page 79: Removing And Installing Oil Pan

    OCTAVIA Lubrication System Removing and installing oil pan Special tools, testers and aids required ♦ Hinged wrench 3185 ♦ Wrench socket insert 3249 ♦ Hand drill with plastic brush attachment ♦ Flat scraper ♦ Torque wrench ♦ Silicone sealant D 176 404 A2 Removing Remove noise insulation panel in the middle and also on left and right -arrows-.
  • Page 80 OCTAVIA Lubrication System Take off oil pan; detach with light blows with rubber-headed hammer, if necessary. Use a flat scraper to remove sealant residues in cylinder block. Use a rotating plastic brush to remove seal- ant residues on oil pan (wear eye protection). Clean sealing surfaces;...

  • Page 81: Testing Oil Pressure And Oil Pressure Switch

    OCTAVIA Lubrication System Fit on oil sump immediately and tighten bolts as follows: 1. Tighten all oil sump/cylinder block bolts only very slightly and diagonally across. 2. Tighten the three oil sump/gearbox bolts slightly. 3. Tighten all oil sump/cylinder block bolts further slightly and diagonally across.
  • Page 82 OCTAVIA Lubrication System Testing warning light After the ignition is switched on (engine not running), the oil pressure warning light in the dash panel insert should come on for about 3 s and then go out. The check is completed once the engine is running.
  • Page 83 ¡ ¢ £ ¤ ¥ ¥ ¦ £ § £ ¨ ©  ¦   ¤  ¤ ¡    ¦ ¢ ¢   ¦ ¢  ¡ § £   ¤ ¡    ¦ ¢ ¢   ¦ ¢  ¡ § £  ¨ ¥ ¢ £  ¦  ¡ ¥ ¤ ¡    ¦ ¢ ¢   ¦ § ¦ ¢ § ¦   ¥...
  • Page 84 OCTAVIA Lubrication System If the specification is exceeded: Inspect oil galleries. Replace pressure relief valve in oil filter holder ⇒ page 17-2, if necessary. ¡ ¢ £ ------------ ------------ Edition 05.01 S00.5105.53.20...
  • Page 85 OCTAVIA Lubrication System Inspecting engine oil level Inspection conditions l Carry out measurement of oil level only when engine warm (oil temperature greater than 60 °C). l The vehicle should be standing on level ground when measuring oil level. Wait a few minutes after switching off the engine to allow the oil to flow back into the sump.
  • Page 87 OCTAVIA Cooling System Removing and installing parts of the cooling system Parts of cooling system 1 - Radiator ♦ Always fill system with fresh coolant after replacing 2 - Oil cooler ♦ Removing and installing ⇒ page 17-1, item 17 3 - Coolant pump, thermostat ♦...
  • Page 88 OCTAVIA Cooling System Draining and filling system with coolant Coolant quantity approx. 5 ltr. Special tools, testers and aids required ♦ Collecting tray (e.g. V.A.G 1306) ♦ Antifreeze tester Draining Important! Hot steam may escape when the expansion reservoir is opened. Cover over cap with a cloth and open carefully.
  • Page 89 OCTAVIA Cooling System Detach additional coolant hose at bottom of oil cooler -arrow- and allow remaining coolant coolant to drain. Notes: ♦ Collect drained coolant for proper disposal. ♦ Observe the disposal instructions for coolant. Filling up Select the appropriate coolant additive from the original spare parts catalogue Škoda or from the list of allowed coolant additives ⇒...
  • Page 90 OCTAVIA Cooling System Recommended mixture ratios Antifreeze Antifreeze Drinking protection concentration water 1)2) down to -25 °C 40 % (2.0 l) 60 % (3.0 l) -35 °C 50 % (2.5 l) 50 % (2.5 l) Because of sufficient corrosion protection, the antifreeze concentration must not fall below 30 % and not exceed 60%;...
  • Page 91  ¦   ¥      ¥   ¨  ¨     ¨ ¥   ¥ ¨ ¤ ¥ ¦ § ¨ ©  © ¨ ¥   ¨ ©     ¥   ¨  ¨  ! " ¦  !    §...
  • Page 92 OCTAVIA Cooling System Detach bracket -arrow- for refrigerant pipe. Continued for all models Remove both headlights: ⇒ Electrical System; Repair Group 94; Re- moving and installing headlights Unscrew the 4 bolts for the top radiator mount -arrows-. Unscrew the 4 bolts for the bottom radiator mount -arrows-.
  • Page 93 OCTAVIA Cooling System Models with air conditioning Pull out radiator and condenser slightly. Remove retaining clip -arrow- for refrigerant pipe. Continued for all models Remove fan shroud (4 bolts). Note: When removing and installing the fan shroud, ensure that the radiator fins are not damaged. Carefully lift radiator down and out.
  • Page 94 OCTAVIA Cooling System Removing and installing coolant pump Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) Removing Remove engine trim panel; take protective cover off the nuts -arrows- for this step. Drain coolant ⇒ page 19-2. Remove noise insulation panel on right -arrows- in bottom half of illustration.
  • Page 95  ¨   § ¦  £ ¤ ¥ ¦ § ¨ ¤ ©   §    ¦ §   ¨ ¨ © © ¨    ¥  § ¨ ¨   ¥ © ¨ ¨ ©  ¦...
  • Page 96 ¤ ¥ ¦ § ¨ © © ¤ ¥      © ¨ ¥ §      ¦ § ¨ §   ! " # $ % & & $ ' ( § 0 1 "...
  • Page 97 £ ¤ ¥ ¦ § ¨ ¨ © ¤     ¨ § ¤ ¦  ©        ! " " ! # $ %  & # ' (  ( # &  ) 0  &...
  • Page 98 OCTAVIA Cooling System Testing cooling system for leaks Special tools, testers and aids required ♦ Cooling system tester (e.g. V.A.G 1274) ♦ Adapter (e.g. V.A.G 1274/8) ♦ Adapter (e.g. V.A.G 1274/9) Test condition l Engine at operating temperature Test procedure Important! Hot steam may escape when the expansion reservoir is opened.

  • Page 99: Fuel Supply System

    OCTAVIA Fuel Supply System Removing and installing parts of fuel supply system Notes: ♦ Hose connections are secured with screw- type, spring strap or collar clamps. ♦ Always replace collar clamps by spring strap or screw-type clamps. ♦ Fuel hoses at the engine must be secured only with spring strap clamps.
  • Page 100 OCTAVIA Fuel Supply System Removing and installing fuel tank with attached parts and fuel filter 1 - Overflow hose 4 - Breather pipe ♦ To activated charcoal filter 2 - O-ring ⇒ page 20-12, item 5 ♦ Replace 5 - Cap 3 - Gravity valve ♦...
  • Page 101 OCTAVIA Fuel Supply System 8 - Vent valve 21 - Retaining clip ♦ inspecting ⇒ Fig. 1 ♦ for fuel filter 9 - Earth connection 22 - Seal ♦ moisten with fuel for installing 10 - 10 Nm ♦ replace if damaged 11 - Vent lines 23 - Fuel delivery unit ♦...

  • Page 102: Rules For Cleanliness

    OCTAVIA Fuel Supply System Safety precautions when carrying out work on fuel supply system Important! Fuel system is pressurized! Place cleaning cloth around the connection point before opening the system. Then, release the pressure by carefully detaching the connection point. Pay attention to the following points when removing and installing the fuel gauge sender or the fuel pump (fuel delivery unit) from the fuel...
  • Page 103 OCTAVIA Fuel Supply System Removing and installing fuel delivery unit Pay attention to safety precautions ⇒ page 20-4. Pay attention to rules for cleanliness ⇒ page 20-4. Special tools, testers and aids required ♦ Wrench for union nut MP 1-227 Removing If vehicle is fitted with a coded radio set, pay attention to coding;...
  • Page 104 OCTAVIA Fuel Supply System Pay attention to installation position: ♦ Marking on flange should be aligned with the marking on the fuel tank -arrows-. ♦ Blue return-flow pipe -1- to connection marked with -R-. ♦ Black feed pipe -2- to connection marked with -V-.
  • Page 105 OCTAVIA Fuel Supply System Removing If vehicle is fitted with a coded radio set, pay attention to coding; determine if necessary. Switch off ignition (if not already off) and disconnect earth strap at battery. Empty fuel tank with fuel extraction unit (e.g. V.A.G 1433 A).
  • Page 106 OCTAVIA Fuel Supply System Slacken the bolted connections -arrows- at the front left and at the retaining straps. Lower fuel tank. Installing Installation is carried out in the reverse order; pay attention to the following points: Connect fuel pipes at the flange of the fuel delivery unit: ♦...
  • Page 107 OCTAVIA Fuel Supply System Testing fuel pump Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526) ♦ Adapter cable set (e.g. V.A.G 1594) ♦ Remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 ♦ Wrench for union nut MP 1-227 ♦...
  • Page 108 OCTAVIA Fuel Supply System If the fuel pump does not run: Unbolt cover (below rear seat). Release and unplug 4-pin connector from the flange in the fuel tank. Connect hand-held multimeter (e.g. V.A.G 1526) with adapter cables (e.g. from V.A.G 1594) to the outer contacts of the connector.
  • Page 109 OCTAVIA Fuel Supply System Test conditions l Battery voltage at least 12 V l Voltage supply o.k. l Fuel filter o.k. Test procedure Switch off ignition. Connect remote control V.A.G 1348/3A with adapter cable V.A.G 1348/3-2 ⇒ page 20-8. Remove cap from fuel filler neck. Important! Fuel system is pressurized! Place cleaning cloth around the connection point before opening the...
  • Page 110 OCTAVIA Fuel Supply System Removing and installing parts of activated charcoal filter system 1 - Solenoid valve 1 (N80) ♦ Testing operation and actuation: ⇒ 1.6-ltr./74 kW Engine, Simos 2 Fuel Injection and Ignition System; Repair Group 24; Testing tank ventilation; Testing solenoid valve 1 for activated charcoal filter 2 - Connector 3 - Breather pipe...
  • Page 111 OCTAVIA Fuel Supply System Setting throttle cable Notes: ♦ The throttle cable is very sensitive to kinking and should be treated with particular care when installing. ♦ A single slight kink can result in the cable fracturing subsequently when driving. Throttle cables which have been kinked, must therefore not be installed.
  • Page 113 OCTAVIA Exhaust System Removing and installing parts of the exhaust system 6 - Gasket ♦ replace 7 - Exhaust manifold ♦ removing and installing ⇒ page 26-3 8 - 25 Nm ♦ replace ♦ insert with hot screw paste G 052 112 9 - Washer 10 - Lambda probe, 50 Nm ♦...
  • Page 114 OCTAVIA Exhaust System K Fig. 1 Installation position of hanger The angled side -arrow- at the base of the hanger points in direction of travel. Removing and installing front exhaust pipe Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g.
  • Page 115 ¤ ¥ ¦ § ¨ © ¤ © ¥    ¨     © § ¨  ¦    §  ¤  ¨ §  ¨  ¦    §   © ¤    !   ©...
  • Page 116 0 1 $ " ! !  1 2 3 # 4  # 1  1 " $ 5 4 OCTAVIA Exhaust System Notes: ♦ Use only 4 mm thick washers. ♦ Replace gasket for exhaust manifold. ♦ Always replace self-locking nuts. ¤...

  • Page 117: Aligning Exhaust System Free Of Stress

    OCTAVIA Exhaust System Aligning exhaust system free of stress Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) Procedure l Exhaust system is aligned when cold. Shop-make auxiliary tool to the dimensions stated from an M10 bolt for aligning the exhaust system.
  • Page 118 OCTAVIA Exhaust System Align front and rear silencers horizontally: The suspension bolt at the exhaust pipe should be positioned parallel to the tunnel bridge (dimension -X- identical on left and right). Note: On models with separation point ⇒ page 26-4, check horizontal position of rear silencer additionally at tail pipe.

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