Skoda OCTAVIA 1999 Workshop Manual
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Skoda OCTAVIA 1999 Workshop Manual

Skoda OCTAVIA 1999 Workshop Manual

1.4-ltr./44 kw engine, mechanical components
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Service
Workshop Manual
OCTAVIA
1.4-ltr./44 kW Engine,
Mechanical Components
Service Department. Technical Information
S00.5125.50.20 Edition 01.99

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Summary of Contents for Skoda OCTAVIA 1999

  • Page 1 Service Workshop Manual OCTAVIA 1.4-ltr./44 kW Engine, Mechanical Components Service Department. Technical Information S00.5125.50.20 Edition 01.99...
  • 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 © 1999 ŠKODA AUTO a. s.
  • Page 3 Service List of Supplements to Workshop Manual Edition: 09.03 OCTAVIA 1.4 l/44 kW Engine, Mechanical Components Replaces List of Supplements - Edition: 06.01 Subject Edition Article Number Supple- ment 01.99 Basic Edition of Workshop Manual S00.5125.50.20 06.01 Supplement to Basic Edition S00.5125.51.20 09.03 Modifications in Repair Group 10, 13, 15, 17 and 19 S00.5125.52.20...

  • 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 ........................10-2 Installing engine ........................10-11 Aligning engine/gearbox assembly ................... 10-13 Tightening torques ........................
  • Page 6 ¡ ¢ £ ¤ ¥ ¦ § ¨ ¦ © ¥ ¦   ¨   ¥ ¦ §   ¡   ¨ ¦   ¥   ¨   ¨   ¡ ©  ¨   ¨...

  • Page 7: Technical Data Page

    OCTAVIA Technical Data Technical data Engine number K The engine number („engine code“ and „serial number“) is located on the end face of the cylin- der block at the belt pulley side, at the connec- tion to the cylinder head. In addition, a sticker with „engine code“...

  • Page 9: Removing And Installing Engine

    Removing and Installing Engine OCTAVIA 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 1-180- ♦...
  • Page 10 Removing and Installing Engine OCTAVIA Removing Notes: ♦ The engine is removed upwards together with the gearbox. ♦ The hose connections are secured with screw-type clips, spring-type clips or clamp- type clips. Always replace clamp-type clips with spring-type clips or screw -type clips. ♦...
  • Page 11 OCTAVIA Removing and Installing Engine The two jacking points at the front are lo- cated at the front of the two longitudinal mem- bers at the level of the marking on the door sill. Warning! When the vehicle is raised, do not start the engine and engage a gear so long as even only one driven wheel is touching the ground.
  • Page 12 OCTAVIA Removing and Installing Engine Place drip tray (e.g. V.A.G 1306) below the engine. Open cap of coolant expansion reservoir. Turn drain plug -arrow- at the radiator to the left and pull back; allow coolant to flow out; fit auxiliary hose onto connection, if neces- sary.
  • Page 13 ¤ ¥ ¦ § ¨ © ¨  ¦   ¨   ¦ ¨ ¨ ¥    ¦    §  ¦ § ¦  !  ! " § #  $ ¨   # ¥...
  • Page 14 OCTAVIA Removing and Installing Engine Position pressure line at left of gearbox to the outside and attach. Unplug connectors: 1 - from camshaft position sensor -G163- 3 - from oil pressure switch -F1- Disconnect earth cable at the bolt connect- ing engine/gearbox -2-.
  • Page 15 ¤ ¥ ¦ § ¨ ©   ¦ ¨     # $ ¥ % ¨ $ &    ©   ©      ! "  © ©  ¥  §...
  • Page 16 ¤ ¥ ¦ § ¨ ©   ¥   ¨       §  ©       § !  " # $  © % & ' (   &...
  • Page 17 ¤ ¥ ¦ § ¨ ©   ¥   ¥  ¨  ©    ¨  ¨  ©            ¦ ¦ ¨ ! ! ¦ ¨ ©  "  ¨ ©  # $ ¨...
  • Page 18 ¡ ¢ £ ¤ ¥ ¦ § ¨ © ¢ £   £  ¡ ¥    © £  ¥  § ¦ § ¨ © ¢ £      £ © ¥  ¨ © © £    ! £...

  • Page 19: Removing Engine

    OCTAVIA Removing and Installing Engine Installing engine Notes: ♦ Always replace seals and gaskets when car- rying out removal and installation work. ♦ Always replace self-locking nuts. ♦ Coat stud bolts at exhaust manifold with hot bolt paste G 052 112 A3. ♦...
  • Page 20 OCTAVIA Removing and Installing Engine Install front exhaust pipe and align exhaust system free of stress ⇒ page 26-4. Note: Avoid an excessive deflection of the decoupling element at the front exhaust pipe (max. 10°). Install the power steering hydraulic pump. ⇒...
  • Page 21 OCTAVIA Removing and Installing Engine Aligning engine/gearbox unit Warning! The unit must be supported by supporting device MP 9-200 before slackening the bolts. 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 22: Tightening Torques

    OCTAVIA Removing and Installing Engine Tightening torques Notes: ♦ Tightening torques apply only to nuts and bolts which are slightly greased, oiled, phosphatized or blackened. ♦ Additional lubricants such as engine or gear oils are permissible, but not Moly- kote. ♦...
  • Page 23 OCTAVIA Removing and Installing Engine K Gearbox mounting 1 - 40 Nm + 90° (1/4 turn) 2 - 25 Nm 3 - 100 Nm Replace bolts K Pendulum support 1 - 40 Nm + 45° 2 - 40 Nm + 45° 3 - 20 Nm + 90°...

  • Page 25: Crank Assembly Page

    OCTAVIA Crank Assembly Disassembling and assembling engine Removing and installing ribbed V-belt 9 - 45 Nm 10 - 25 Nm 11 - Guide pulley 12 - 20 Nm ♦ Left-hand thread 13 - Belt pulley ♦ For crankshaft 14 - 100 Nm ♦...
  • Page 26 Crank Assembly OCTAVIA K Fig. 1 Routing of ribbed V-belt 1 - Alternator 2 - Vane pump for the power-assisted steer- 3 - Crankshaft 4 - Guide pulley 5 - Coolant pump 6 - Tensioning pulley Removing Mark the direction of running of the ribbed V-belt.

  • Page 27: Disassembling And Assembling Cylinder Block, Crankshaft And Flywheel

    OCTAVIA Crank Assembly Disassembling and assembling cylinder block, crankshaft and flywheel Notes: 1 - 75 Nm ♦ Servicing clutch 2 - Crankshaft bearing unit ⇒ 5-Speed Manual Gearbox 002; Repair Group 30; Servicing clutch 3 - Thrust washer ♦ for middle bearing ♦...
  • Page 28 OCTAVIA Crank Assembly 5 - Flywheel 7 - Seal ♦ with sensor rotor for engine speed ♦ replace sender -G28- ♦ take off sealing flange for removing ♦ lock with MP 1-504 for removing and and installing installing ♦ before installing, lightly oil sealing lip ♦...
  • Page 29 ¤ ¥ ¦ § ¨ ©   4 0  5 § 0 6 7 8 1  ! © 7 ¥    ¥       ¥ ©  ¨ 0  ) © 0 1 ¥...

  • Page 30: Inspecting Synchronous Running Of Chain Sprockets

    Crank Assembly OCTAVIA Inspecting synchronous running of chain sprockets This inspection should be carried out if the sprockets have been replaced. Special tools, testers and aids required ♦ Straightedge ♦ Feeler gauge The crankshaft sprocket is available in 3 differ- ent widths;...
  • Page 31 ¡ ¢ £ ¤ ¥ ¦ § ¨ © ¤ §    ¤   ¥  £ £ ¡  ¢    ! " # $ $ # % & '  ( ) ! '  0 OCTAVIA Crank Assembly seal at belt...

  • Page 32: Replacing Ring Gear

    OCTAVIA Crank Assembly Use two-legged puller -A- (Kukko 20-10), extraction hook T10040/1 and thrust piece MP 6-401/1 to pull out sealing ring. Installing l Crankshaft is locked with MP 1-504 or with ”locking bolt”. Lightly oil sealing lip of sealing ring. Use thrust piece T10041 to press in the seal- ing ring until it makes contact with the sleeve.
  • Page 33 ¤ ¥ ¦ § ¦ ¦ ¨ ©   ¥   § ¦ ¦ ¨ ©   ¥    ¥ ¦    ¦       !  ¥  ¨  6 7 &...
  • Page 34 ¤ ¥ ¦ § ¨ ©     ¦    ¦ §  ©   ¨ ©   ¤ ¤ OCTAVIA Crank Assembly ¤ ♦ Do not mix up used bearing shells ♦ Ensure they are tightly located in the ¤...
  • Page 35 ¡ ¢ £ ¤ ¥ ¦ § ¨ ©   ¡ ¦ ¢ ¨ ¡ §   ¦  ¡ ¦ ¢  ©     ¦  ©  ¨ ©  ¡      §...
  • Page 36 ¤ ¥ ¦ § ¨ ©       ¥  ¦     ¥     ! "  # $ ¥ "  % OCTAVIA Crank Assembly reload o liners testers and aids ♦...

  • Page 37: Cylinder Head/Valve Gear Page

    OCTAVIA Cylinder Head/Valve Gear Removing and installing cylinder head 6 - Rocker arm shaft ♦ removing and installing rocker arms ⇒ page 15-18 ♦ conducting basic setting of hydraulic valve clearance compensation ⇒ pa- ge 15-14 7 - Bracket ♦ for ignition strip 8 - Washer ♦...

  • Page 38: Removing And Installing Cylinder Head

    OCTAVIA Cylinder Head/Valve Gear K Fig. 1 Inspecting cylinder head for distor- tion Special tools, testers and aids required ♦ Straightedge ♦ Feeler gauge Max. permissible distortion: 0.05 mm (minimum clearance of base of straightedge: 100 mm) If the distortion is greater 0.05 mm, replace cyl- inder head, do not rework.
  • Page 39 OCTAVIA Cylinder Head/Valve Gear Unplug the following connectors: 1 - from throttle valve control unit -J338- 3 - from intake manifold pressure sender -G71- together with intake manifold tem- perature sender -G72- 5 - from coolant temperature sender -G62- 6 - from injectors -N30...N33- Unclip connector strip -4- -arrows- and take wiring harness out of fixtures.
  • Page 40 Cylinder Head, Valve Gear OCTAVIA First remove the rocker arm shaft. Then unscrew the remaining cylinder head bolts/nuts. Remove alternator support bracket ⇒ page 15-1, item 12. Remove the push rods and place down in accordance with installation position. Carefully remove cylinder head. Installing Notes: ♦...
  • Page 41 Cylinder Head, Valve Gear OCTAVIA Note: Before inserting the cylinder head make sure all liners are correctly fitted in the cylinder block. Insert the cylinder head. Insert the push rods with the ball socket from the top in accordance with their original lo- cation.
  • Page 42 Cylinder Head, Valve Gear OCTAVIA Install alternator support bracket ⇒ page 15-1, item 12. Subsequently tighten the rocker arm shaft screws crosswise with 25 Nm. Perform basic setting of hydraulic valve clear- ance compensation ⇒ page 15-14. Note: The basic setting of the hydraulic valve clear- ance compensation must not be carried out again, if only the cylinder head gasket is re- placed.

  • Page 43: Servicing Cylinder Head

    OCTAVIA Cylinder Head/Valve Gear Servicing cylinder head 1 - Valve collets 2 - Valve spring retainer 3 - Valve spring ♦ removing and installing ⇒ page 15-8 4 - Valve stem seal ♦ replacing ⇒ page 15-13 5 - Cylinder head ♦...

  • Page 44: 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 must be flush with guide. Determine valve rock. Wear limit Inlet valve guide Exhaust valve guide...
  • Page 45 Cylinder Head, Valve Gear OCTAVIA Attach valve spring assembly lever -MP 1-114- and insert -MP 1-114/1- together with threaded connector -1- onto the cylinder head. Press down assembly lever -2-. Take out collets. Note: Release collets that are tight by striking light blows with a hammer on the assembly lever.
  • Page 46 ¤ ¥ ¦ § ¨ ©     ¥        ! " # $ $ " % & #  % #  ) 0 '  ( OCTAVIA Cylinder Head/Valve Gear valve ♦...

  • Page 47: Reworking Valve Seats

    OCTAVIA Cylinder Head/Valve Gear Example: Maximum dimension 42.7 mm - Distance measured 41.9 mm = Max. permissible reworking dimension 0.8 mm Note: If the max. permissible reworking dimension is 0 mm, repeat measurement with a new valve. If the max. permissible reworking dimension is still 0 mm, replace cylinder head.
  • Page 48 Cylinder Head, Valve Gear OCTAVIA K Reworking valve seats with NAC milling cut- Place cylinder head on a felt base and se- cure to prevent it from turning. Match diameter of guide drift to diameter of valve guide. Valve guide Guide drift ∅...
  • Page 49 OCTAVIA Cylinder Head/Valve Gear Use fine grinding paste to grind in valve/valve seat -arrows- so as to achieve a proper con- tact pattern. ¤ ¥ ¦ § ¨ ©     ¥ ¨ §   ¥  Inspect valve for leaks.

  • Page 50: Basic Setting Of Hydraulic Valve Clearance Compensation

    Cylinder Head, Valve Gear OCTAVIA Basic setting of hydraulic valve clearance compensation The hydraulic valve clearance compensation is maintenance-free, the setting must not be chan- ged. After completing repair work on the cylinder head/valve gear, however, it is necessary to carry out the basic setting of the hydraulic valve clearance compensation as follows: Note:...
  • Page 51 ¡ ¢ £ ¤ ¥ ¦ § ¨ ©   ¡ ¢ ¢ ¤ ¨ ¥   ¡ ¢ ¢   ¡         ! " & '  $  % #  $ ! OCTAVIA Cylinder Head/Valve Gear...
  • Page 52 OCTAVIA Cylinder Head/Valve Gear Compression pressures Wear limit Difference between cylinders min. 1.2 Mpa 0.75 Mpa max. 0.3 MPa Install spark plugs, ignition strip, fuse 32 and engine trim panel. Interrogate fault memory and erase. ⇒ 1.4-ltr./44 kW Engine, Simos 3PB Fuel In- jection and Ignition System;...

  • Page 53: Servicing Valve Gear

    ¡ ¢ £ ¤ ¥ ¦ § ¥ ¦ ¨ ©    ¥ ¦ §   ¢ ¨    ©       " # $ %  & ' ( )     OCTAVIA Cylinder Head/Valve Gear...
  • Page 54 ¡ ¢ £ ¤ ¥ ¦ § ¨ © ¦   ¨    ¡  ¢       ! " #  #   %  !   # $  % &    ' ( ' "...
  • Page 55 ¤ ¥ ¦ §    © ¨ © ©   ¦   ©   ©  ©     ©  ©   ©      OCTAVIA Cylinder Head/Valve Gear 1 - Straight rocker arm ! "...
  • Page 56 ¡ ¡ ¢ £ ¤ ¢ ¥ ¤ ¦ § ¥ § ¨ © ¨ £ ¦  ¤  ¢   § ¤ ¡ ¡ © §  ©  ©  ¤ ¢ §   ¢   ¨ § ¢ £  § ¨ ¤ ¥ ¥ ¦ ©  ¥  ¡ ¢ ¤  §   © ¦  © ¥  § ¥ § ¨ © ¤ ¦  ©...

  • Page 57: Lubrication System Page

    OCTAVIA Lubrication System Removing and installing parts of the lubrication system 1 - End cover ♦ fit on for removal and installation work 2 - Gasket ♦ replace if damaged ♦ at engine cover 3 - Oil pressure switch -F1-, 45 Nm ♦...
  • Page 58 OCTAVIA Lubrication System 18 - 8 Nm 19 - Oil pump cover with pressure relief valve ♦ opening pressure: approx. 0.46 MPa ♦ clean strainer if soiled 20 - Gasket ♦ replace ♦ install only if axial play of oil pump gears is not adequate ⇒...

  • Page 59: Removing And Installing Oil Pan

    Lubrication System OCTAVIA K Fig. 2 Removing and installing guide tube for oil dipstick Unscrew nut -1- on the exhaust manifold and lift guide tube -2- up and out. When installing replace seal -3-. Tighten new self-locking nut -1- to 20 Nm. Removing and installing oil pan Special tools, testers and aids required ♦...
  • Page 60 Lubrication System OCTAVIA Use a rotating plastic brush to remove seal- ant residues on the oil pan (wear protective goggles). Clean sealing surfaces, they must be free of oil and grease. Installing Notes: ♦ Pay attention to the ‚use by date‘ on sealant. ♦...
  • Page 61 OCTAVIA Lubrication System Engine installed Fit intermediate plate onto oil pan support. Immediately position oil pan and oil pan sup- port against the cylinder block and tighten the bolts as follows: 1 - Tighten all the oil pan/cylinder block bolts only very slightly in the order stated.

  • Page 62: Testing Oil Pressure And Oil Pressure Switch

    OCTAVIA Lubrication System There must not be any gap between the oil pan support and counterholder T30008. Slacken the oil pan bolts once again, if necessary, and ad- just the position of the oil pan. Note: A gearbox housing or a gearbox may also be attached in place of the counterholder T30008.
  • Page 63 £ ¤ ¥ ¦ § ¨ ©    ¨ § ¨ ©  § ©  ¦   ¨ § ¨ © OCTAVIA Lubrication System After the ignition is switched on and engine not running, the oil pressure warning light in the dash panel insert must come on for about 3 s and then go out.
  • Page 64 ¤ ¤ ¥ ¦ § ¨ ©   ¥   © ¥ OCTAVIA Lubrication System est conditions l Engine oil level o.k., inspecting ⇒ Inspec- tion and Maintenance. l Oil pressure warning light (K3) must come on for about 3 s when the ignition is switched l Engine oil temperature at least 80 °C (radia- tor fan must have run once).
  • Page 65 ¤ ¥ ¦ § ¨ ©   ¥  ¨ ¥   ¥ ¨        !  OCTAVIA Lubrication System        !   " !   # $ "  oil level conditions l Carry out a measurement of the oil level only...

  • Page 67: Cooling System Page

    Cooling System OCTAVIA Removing and installing parts of the cooling system Parts of the cooling system 1 - Radiator ♦ after replacing fill entire system with fresh coolant ♦ removing and installing page 19-6 2 - Front coolant pipe 3 - Cylinder block 4 - Coolant pump ♦...

  • Page 68: Draining And Filling System With Coolant

    OCTAVIA Cooling System Draining and filling system with coolant Special tools, testers and aids required ♦ Drip tray (e.g. V.A.G 1306) ♦ Antifreeze tester Draining system Warning! Hot steam may escape when the expansion reser- voir is opened. Cover over cap with cloth and open carefully.
  • Page 69 Cooling System OCTAVIA Filling up Select the appropriate coolant additive from the original spare parts catalogue Škoda or from the list of allowed coolant additives ⇒ Inspection and Maintenance; Repair group Recommended mixture ratios: Antifreeze Antifreeze Drinking protection concentration water down to -25 °C 40 % (2.25 l)
  • Page 70 Cooling System OCTAVIA Fill coolant slowly into the expansion reser- voir, until the sender for the coolant tempera- ture is visible in the filler neck. Install sender for coolant temperature and close expansion reservoir. Run engine until the fan on the radiator starts. Caution! Hot steam may escape when the expansion reser- voir is opened.
  • Page 71 OCTAVIA Cooling System Testing coolant 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 normal operating temperature Test procedure Warning! Hot steam may escape when the expansion reser- voir is opened.

  • Page 72: Removing And Installing Radiator

    ¤ ¥ ¦ § ¨ ©  ¦ ©             ¦ ! "  # !  $ % &  '   ¥ ¥ OCTAVIA Cooling System ( ©...

  • Page 73: Removing And Installing Coolant Thermostat Housing, Rear Coolant Pipe

    OCTAVIA Cooling System Removing and installing coolant thermostat housing, rear coolant pipe Notes: ♦ Draining and filling system with coolant ⇒ page 19-2. ♦ Do not separate coolant thermostat housing otherwise the leaktightness of the housing is no longer assured. If operational problems occur at the thermostat, replace coolant ther- mostat housing complete ⇒...

  • Page 74: Removing And Installing Coolant Pump, Front Coolant Pipe

    OCTAVIA Cooling System Removing and installing coolant pump, front coolant pipe 1 - Gasket ♦ replace 2 - Coolant pump ♦ ensure unobstructed running ♦ if damaged and leaking, replace com- plete ♦ removing and installing ⇒ page 19-9 ♦ push on coolant hose (item 8) up to marking -arrow- 3 - 20 Nm ♦...
  • Page 75 ¡ ¢ £ ¤ ¥ ¦ § ¨ ¦ © ¥ ¦   ¨   ¥ ¦ §  £ £  ¨ ¦    ¢    ¡  ¥ ¨  £ £   ¡...
  • Page 76 ¤ ¥ ¦ § ¨ © ©  ¥  OCTAVIA Cooling System Unbolt engine mounts -arrows-. Unbolt coolant pump. Installation is carried out in the reverse order of removal. Pay attention to the following points: Replace gasket for coolant pump. First of all, install ribbed V-belt then fully tighten bolts of belt pulley of coolant pump.
  • Page 77 OCTAVIA Fuel Supply System Removing and installing parts of the fuel supply system Notes: ♦ Hose connections are secured with spring strap clips or clamp-type clips. ♦ Always replace clamp-type clips by spring strap clips or screw-type clips. ♦ Fuel hoses at the engine must only be se- cured with spring strap clips.
  • Page 78 OCTAVIA Fuel Supply System Removing and installing fuel tank with attached parts and fuel filter ¡ ¢ 1 - Overflow hose 4 - Vent line ♦ To activated charcoal filter 2 - O-ring ♦ Replace 5 - Fuel filler cap ♦...
  • Page 79 OCTAVIA Fuel Supply System 8 - Vent valve 21 - Retaining clamp ♦ inspecting ⇒ Fig. 1 ♦ for fuel filter 9 - Earth connection 22 - Seal ♦ moisten with fuel for installing 10 - 10 Nm ♦ replace if damaged 11 - Vent line 23 - Fuel delivery unit ♦...
  • Page 80 ¤ ¥ ¦ § ¨ ©   §  ¥  ¨       §    !      ¦  § "     " ©  ©  ¨ § # $ % &...
  • Page 81 ¤ ¥ ¦ § ¨ ¦ § ©  ¦   ¥  ©       ! % &  $  ' " #  $ " ( ) 0 1 2 3 4 5 ) 6 1 7 5 1 1 6 8 9 @ A B C C D OCTAVIA Fuel Supply System E 1 F 5 G 0 H I...
  • Page 82 OCTAVIA Fuel Supply System Pay attention to installation position: ¤ ¥ ¦ § ¥ ¨ ♦ Marking on closing flange must be aligned with marking on the fuel tank -arrows-. ♦ Blue return-flow line -1- to connection marked with -R-. ♦...
  • Page 83 ¤ ¥ ¦ § ¨ ©       © ¨      § ¨ © ¨   ¨  §  ©  !  "    © ¥   § ¥  §  § ¨  ¥ ¨...
  • Page 84 ¤ ¥ ¦ § ¨ ©    ¥  ©       ¦       §    © §  ¦   © !     ¥...
  • Page 85 ¤ ¥ ¦ § ¨ ©    ¥        $  % " & '   ' " %  ( )  %  ' ! ! " #  " OCTAVIA  ! &...
  • Page 86 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 A) to the outer contacts of the connec- tor.
  • Page 87 ¤ ¥ ¦ § ¨ ©   ¥   © ¥       ! " #    # $ % # # &   '  &  #  ( ) 0 1 $ 2 3 4 5 6 7 4 1     &...
  • Page 88 ¤ ¥ ¦ § ¨ §  §   ¥ §     ¥ ¦   ¥  ©   §  ¦ ¥ ©   ! " # $ % & ' ! & " (  ) 0 1  2 # # "...
  • Page 89 ¥ ¦ § ¨ ©  ©     §     ¦  ¦     ©   ! " # $ % & ' ( $ # ) 0 " 1 2 3 &...
  • Page 91 OCTAVIA Exhaust System Removing and installing parts of the exhaust system Exhaust manifold, front exhaust pipe with catalytic converter, lambda probe 3 - 25 Nm ♦ insert with heat-resistant bolt paste G 052 112 A3 4 - Exhaust manifold ♦ take off intake manifold for removing: ⇒...
  • Page 92 OCTAVIA Exhaust System Silencer with hangers 4 - To catalytic converter 5 - Double clip ♦ Align exhaust system free of stress before tightening ⇒ page 26-4 ♦ Installation position: horizontal in ve- hicle, bolted connection pointing to the left ♦...
  • Page 93 OCTAVIA Exhaust System Replacing front or rear silencer Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦ Body saw (e.g. V.A.G 1523) A separation point is provided for repair pur- poses for replacing the front or the rear silencer. Separate exhaust pipe at right angles at the separation point -arrow 2- with a body saw (e.g.
  • Page 94 ¤ ¥ ¦ § ¨ ¦ ¨ § ©           ©    © ©     ©   ! " # $ % & ' ( ) ) ' 0 1 3 4 % 2 # 5 ( # 0 ( # 6 2 ) $ # 5 4 2 #...
  • Page 95 OCTAVIA Exhaust System Align front and rear silencer horizontally: The hanger bolt at the exhaust pipe must be positioned parallel to the tunnel bridge (dimension -X- identical on left and right). Note: On models provided with separation point ⇒ page 26-3, additionally inspect horizontal po- sition of rear silencer at the tail pipe.

This manual is also suitable for:

Octavia 2000Octavia 2001

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