Skoda OCTAVIA 1998 Workshop Manual

1.8-ltr./110 kw engine, mechanical components

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Table Of Contents

1 Table of Contents
2 Technical Data Page
- 2.1 Technical Data
  - 2.1.1 Engine Number
- 2.2 Removing and Installing the Engine
3 The Crankshaft Drive Page
- 3.1 Removing and Installing the Cylinder Head
  - 3.1.1 Removing the Cylinder Head
  - 3.1.2 Installing the Cylinder Head
- 3.2 Removing and Installing Parts of the Lubrication System
  - 3.2.1 Dismantling and Assembling the Oil Filter Holder
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Service

Workshop Manual

OCTAVIA

1.8-ltr./110 kW Engine,

Mechanical Components

Service Department. Technical Information

S00.5123.50.20 Edition 08.98

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Page 1 Service Workshop Manual OCTAVIA 1.8-ltr./110 kW Engine, Mechanical Components Service Department. Technical Information S00.5123.50.20 Edition 08.98...
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 Supplement Overview for the Repair Manual Edition: 06.02 OCTAVIA 1.8 litre/110 kW engine, mechanics Replaces the Supplement Overview - Edition: 04.01 Subject Edition Article Number Supple- ment 08.98 Basic Edition Workshop Manual S00.5123.50.20 04.01 Supplement to Basic Edition S00.5123.51.20 06.02 Changes to Rep.
Page 5: Table Of Contents
OCTAVIA Service Table of contents Technical data Page Technical data ..........................00-1 Engine number ......................... 00-1 Engine characteristics ......................00-1 Removing and installing the engine Page Removing and installing the engine ..................10-1 Removing ..........................10-1 Fixing the engine on the assembly stand ................. 10-8 Installing ...........................
Page 6 ¡ ¢ £ ¤ ¥ £ ! " # $ % # & ' ( ) 0 1 2 3 4 5 3 6 2 3 7 8 5 9 9 2 3 4 @ 5 A 8 7 0 B 8 C ( D 0 0 9 2 3 4 7 E 7 8 ( ) F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F G H I G P Q R S T U V W X Y U U ` a b c d T S X e f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f...
Page 7: Technical Data Page
OCTAVIA Technical Data Technical data Engine number K The engine number („engine code“ and „con- secutive number“) is located on the front of the engine/gearbox joint. In addition, a sticker with „engine code“ and „con- secutive number“ is affixed to the toothed belt guard.
Page 8 OCTAVIA Technical Data Code letters Valve timing at 1 mm valve stroke and 0 mm valve clearance Inlet opens after TDC 18° Inlet closes after BDC 28° Exhaust opens before BDC 28° Exhaust closes before TDC 8° ------------ 00-2 ------------- Edition 08.98 S00.5123.50.20...
Page 9: Removing And Installing The 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 ♦ Engine/gearbox jack, (e.g. V.A.G 1383 A) ♦ Pliers for spring strap clips ♦...
Page 10 OCTAVIA Removing and Installing Engine ♦ Fuel hoses at the engine must be secured only with spring strap clips. It is not permit- ted to use collar clamps or screw-type clips. ♦ Ensure the connectors are plugged in at the correct point, pay attention to marking.
Page 16: Installing
¤ ¥ ¥ ¦ § ¨ © ¦ © ! " # $ % & ' ' ( & ' ) 0 ! ' 1 0 ' & 2 0 3 4 OCTAVIA Removing and Installing Engine engine to...
Page 17 OCTAVIA Removing and Installing Engine Adjust shift cables: ⇒ 5-Speed Manual Gearbox 02J; Repair Group 34. Models fitted with automatic gearbox Replace lock washer at support of selector lever cable. Install selector lever cable at gearbox, ad- just if necessary: ⇒...
Page 18: Tightening Torques
OCTAVIA Removing and installing the engine Note: Additional work has to be undertaken when dis- connecting and reconnecting the battery ⇒ Electrical System, Rep. Gr. 27. Tightening torques Notes: ♦ Tightening torques are valid for lightly greased, oiled, phosphated or blackened nuts and screws.
Page 19 ¡ ¢ £ ¡ ¤ ¥ ¢ ¤ ¦ § ¨ © ! " OCTAVIA Removing and Installing Engine mounting # $ % & ' ! K Engine mounting 40 Nm + 90°...
Page 20 OCTAVIA Removing and Installing Engine Slacken engine mounts from the engine sup- port from above -arrows-. Note: Use ladder, e.g. VAS 5085, for removing the securing bolts. Slacken gearbox mounts from the gearbox support from above -arrows-. Carefully lower engine and gearbox. When doing this, guide pressure line of power steering past the gearbox.
Page 21 OCTAVIA Removing and Installing Engine Attaching engine to repair stand The engine should be attached with the engine and gearbox holder MP 1-202 to the repair stand MP 9-101 for carrying out removal and installa- tion work. Procedure Use lifter, e.g. V.A.G 1383 A, to move en- gine/gearbox unit onto a workbench.
Page 22 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 the turbocharger with hot bolt paste G 052 112 A3. Procedure Installation is carried out in the reverse order;...
Page 27 OCTAVIA Crank Assembly Disassembling and assembling engine Removing and installing, tensioning toothed belt 8 - Camshaft sprocket ♦ for exhaust camshaft ♦ take off toothed belt for removing and installing ⇒ page 13-2 ♦ pay attention to fitting location: the narrow web of the camshaft sproc- ket points out and the TDC marking of cyl.
Page 28 OCTAVIA The crankshaft drive Required special tools, testing and measur- ing equipment as well auxiliary devices and material ♦ Torque wrench ♦ Supporting device for the engine MP 9-200 ♦ Locking pin ♦ Tensioning screw Removing the V-belt l Engine removed Remove the V-ribbed belt and tensioning device ⇒...
Page 29 OCTAVIA The crankshaft drive Place the crankshaft in the engine turning direction at the TDC marking for Cylinder 1 -arrow- Check whether the TDC marking on the fly- wheel and the reference mark are aligned -arrow- manual gearbox II - automatic gearbox Remove the engine mount and the engine support bracket.
Page 31 OCTAVIA Crank Assembly Install engine mounts ⇒ page 10-11. Remove supporting device MP 9-200. Install top part of toothed belt guard. Install ribbed V-belt and tensioning device ⇒ 1.8 l/92 kW Engine - Mechanical Compo- nents; Repair Group 13. Attach coolant reservoir and power steering reservoir.
Page 32 OCTAVIA Crank Assembly Fit on the toothed belt in the following se- quence: coolant pump, tensioning pulley, camshaft sprocket. Pull out locking drift -arrow- and relieve ten- sion of pressure plunger of tensioning de- vice for toothed belt. Unscrew headless set screw -1-.
Page 33: Removing And Installing The Cylinder Head
OCTAVIA Cylinder Head, Valve Gear Removing and installing cylinder head Testing compression ⇒ 1.8 l/92 kW Engine - Mechanical Compo- nents; Repair Group 15. 1 - Cylinder head ♦ after replacing, fill system with fresh coolant ♦ removing cylinder head ⇒ page 15-2 ♦...
Page 34: Removing The Cylinder Head
OCTAVIA Cylinder Head, Valve Gear 11 - Intake manifold ♦ removing and installing ⇒ 1.8 l/110 kW Engine - Motronic Fuel Injection and Ignition System; Repair Group 24 12 - 20 Nm 13 - Gasket ♦ replace 14 - Bracket ♦...
Page 35 OCTAVIA Cylinder Head, Valve Gear Note: All the cable straps which have been slackened or cut open when removing, must be fitted on again at the same point when installing. On models fitted with coded radio set, pay ¤ ¥ ¦ § ¨ © § ¨ ¥ ¨ § ¥ ¥ ¨ attention to coding, determine if necessary.
Page 37 OCTAVIA The cylinder head/valve gear Remove the sound dampening and engine cover on the right. Turn the crankshaft in the direction of rota- tion of the engine to the TDC marking for Cylinder 1 -arrow- Screw in the clamping screw T10092 into the tensioning device for the timing belt.
Page 38: Installing The Cylinder Head
OCTAVIA The cylinder head/valve gear Installing the cylinder head Requirements l The engine is installed l The pistons are not standing at TDC Required special tools, testing and measur- ing equipment as well auxiliary devices and material ♦ Guide bolts T30011/2A ♦...
Page 40 OCTAVIA Cylinder Head, Valve Gear Servicing valve gear Notes: 4 - Hydraulic chain tensioner/camshaft adjuster ♦ Valve gear is identical to that of 1.8 l/92 kW ♦ models with engine codes AGU and engine. ARZ have a hydraulic chain tensioner ♦...
Page 41 OCTAVIA Cylinder Head/Valve Gear Check that no piston is positioned at TDC. Insert the guide bolts from MP 1-208 into the holes for the cylinder head bolts 8 and 10 for centering. Place on the new cylinder head gasket. The inscription (part number) should always be legible from the inlet side.
Page 42 OCTAVIA Cylinder Head/Valve Gear After connecting the battery, enter the anti- theft code of the radio. ⇒ Operating Instructions of radio Set time of clock. Interrogate fault memory. ⇒ 1.8-ltr./110 kW Engine, Motronic Fuel Injec- tion and Ignition System; Repair Group 01; Self-Diagnosis Note: Faults are stored as a result of separating the...
Page 47: Removing And Installing Parts Of The Lubrication System
OCTAVIA Lubrication System Removing and installing parts of the lubrication system Note: 8 - Oil filter holder ♦ disassembling and assembling The lubrication system is essentially identical ⇒ page 17-2 to that of the 1.8 l/92 kW engine. Differences: 29 - 10 Nm Testing oil pressure and oil pressure 30 - Oil level/oil temperature sender -G266 switch;...
Page 48: Dismantling And Assembling The Oil Filter Holder
OCTAVIA Lubrication Dismantling and assembling the oil filter holder 12 - 20 Nm 13 - Oil feed line ♦ to the exhaust turbocharger 14 - Hollow screw - 30 Nm 15 - Gasket ring ♦ replace 16 - 0.14 Mpa (1.4 bar) oil pressure switch -F1- 25 Nm ♦...
Page 50 OCTAVIA Lubrication System Warning criteria The visual oil pressure warning (oil pressure warning lamp flashes) is switched on and the buzzer sounds 3 times as an audible warning if one of the following conditions exists: l „Ignition on“, engine not running, oil pressure switch closed l Engine speed greater than 1500 rpm, oil pressure switch open...
Page 51 OCTAVIA Lubrication System Testing oil pressure switch Detach cable from oil pressure switch. Unscrew oil pressure switch and screw in oil pressure tester (e.g. V.A.G 1342). Screw oil pressure switch -2- into V.A.G 1342. Connect brown cable -1- of the tester to earth (-).
Page 53 OCTAVIA Cooling System Removing and installing parts of the cooling system Parts of cooling system 1 - Radiator ♦ after replacing , fill entire system with fresh coolant 2 - Oil cooler ♦ removing and installing ⇒ page 17-2, item 22 3 - Coolant thermostat ♦...
Page 54 OCTAVIA Cooling System Removing and installing coolant thermostat Removing Drain coolant ⇒ 1.8 l/92 kW Engine - Mechanical Compo- nents; Repair Group 19. Detach hoses from secondary air injection pump. Remove secondary air injection pipe from bracket at engine -arrows-. Unscrew bolts -2- and -3- and remove bracket of dipstick guide tube -4-.
Page 55 OCTAVIA Fuel Supply System Removing and installing parts of the fuel supply system Assembly overview of activated charcoal filter system for models with engine codes AGU and ARZ 1 - Solenoid valve 1 -N80- ♦ testing operation and actuation ⇒ 1.8 l/110 kW Engine - Motronic Fuel Injec- tion and Ignition System;...
Page 56 OCTAVIA Fuel Supply System Assembly overview of activated charcoal system for other engine codes 1 - Activated charcoal filter ♦ with activated charcoal filter solenoid valve -N80- ♦ installation position: in right of engine compartment ♦ to remove, detach power steering res- ervoir and push to the side 2 - Solenoid valve 1 -N80- ♦...
Page 59 OCTAVIA Charging The charge air system with exhaust turbocharger ♦ The charge air system must be leak-free. Notes: ♦ Observe the cleanliness regulations ⇒ page ♦ Self-locking nuts should always be replaced. 21-2. ♦ Gaskets should always be replaced. ♦ All hose connections are secured by means of hose clamps.
Page 60 OCTAVIA Turbocharging System Connection diagram for charge pressure control for other engine codes Note: The design of the non-return valves may differ. They are not colour-coded; the taper connection corresponds to the dark side. 1 - Vent line 4 - Vacuum unit for charge pressure con- ♦...
Page 62 OCTAVIA Turbocharging Rules for cleanliness Pay careful attention to the following „5 rules“ for cleanliness when carrying out work on the turbocharger: ♦ Thoroughly clean connection points and the surrounding area before disconnecting. ♦ Place removed parts down on a clean sur- face and cover over.
Page 63 OCTAVIA Turbocharging Testing overrun shutoff valve Special tools, testers and aids required ♦ Hand vacuum pump (e.g. V.A.G 1390) Test condition l Poor performance or load change jolts Test procedure Note: The overrun shutoff valve is located in front of the turbocharger.
Page 64 ¤ ¥ ¦ § ¨ © ¤ ¨ ¤ OCTAVIA Turbocharging The charge pressure is measured at full throt- tle, when driving or on the roller dynamometer. Duration of test for each measurement not more than 10 seconds. Connect T adapter with test hose of turbo- charger tester V.A.G 1397 A between fuel pressure regulator and front of intake mani-...
Page 65 OCTAVIA Turbocharging System If the charge pressure is exceeded: Test charge pressure control solenoid valve -N75- (passage in hose from turbocharger through valve to vacuum unit with connector unplugged). Inspect hoses for leaks and for correct as- signment of connections: engine codes AGU, ARZ ⇒...
Page 66 OCTAVIA Turbocharging Start engine and increase to maximum revs by rapidly depressing accelerator. The operating rod -2- for the charge pres- sure control valve must move. If the operating rod does not move: Inspect ease of movement of lever for charge pressure control valve -1-.
Page 74 OCTAVIA Turbocharging System Drain coolant ⇒ 1.8 l/92 kW Engine - Mechanical Compo- nents; Repair Group 19. Unbolt coolant feed line at cylinder block. Detach oil return-flow line from turbocharger (from oil pan on 4x4 models). Note: On 4x4 models, drain engine oil before detach- ing oil return-flow line.
Page 81 OCTAVIA Exhaust System Removing and installing parts of the exhaust system ♦ Use a screwdriver to slacken and tighten Notes: clamping plates for heat shields. Tightening ♦ Always replace gaskets and self-locking torque: 2 Nm. nuts. ♦ Avoid an excessive deflection of the de- ♦...
Page 82 OCTAVIA Exhaust System Assembly overview - Exhaust system for 4x4 models 9 - Spacer sleeve 10 - Turbocharger ♦ removing and installing ⇒ page 21- 11 - Gasket ♦ replace 12 - Front exhaust pipe ♦ protect from shocks and knocks ♦...
Page 83 ¤ ¥ ¦ § ¨ © ¥ ¥ OCTAVIA Exhaust System ♦ For replacing front silencer or rear silencer separately ♦ Marked by three indentations around circum- ference of exhaust pipe. Use a body saw, (e.g.
Page 87 ¤ ¥ ¦ § ¨ © © ¥ OCTAVIA Exhaust System § ¥ ¥ § ¦ ! ¥ ¥ § " Installation is carried out in the reverse order; pay attention to the following point: Coat stud bolts at turbocharger and nuts at exhaust manifold with hot bolt paste...

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