Skoda Octavia Workshop Manual

1.8 ltr. / 92 kw engine, mechanical components

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Workshop Manual

OCTAVIA

1.8 ltr. / 92 kW Engine, Mechanical

Components

Service Department. Technical Information

S00.5104.50.20

Edition 08.96

Table of Contents

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Page 1 Service Workshop Manual OCTAVIA 1.8 ltr. / 92 kW Engine, Mechanical Components Service Department. Technical Information S00.5104.50.20 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: 04.03 OCTAVIA 1.8 l/92 kW Engine, Mechanical Components Replaces List of Supplements - Edition: 02.02 Subject Edition Article Number Supple- ment 08.96 Basic Edition Workshop Manual S00.5104.50.20 11.96 Supplement to Basic Edition S00.5104.51.20...
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 ........................10-1 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 ...................... 19-1 Draining and filling system with coolant ................... 19-3 Removing and installing coolant pump ..................19-5 Removing and installing, testing coolant thermostat ..............
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 joint between engine and gearbox joint. In addition, a sticker with „engine code“ and „serial number“ is affixed to the toothed belt guard.
Page 8 OCTAVIA Technical Data ------------ 00-2 ------------ Edition 10.99 S00.5104.53.20...
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 ♦ It is recommended to use the pliers for spring strap clamps for removing and installing such clamps. ♦ Ensure the connectors are correctly plugged in, mark if necessary. Procedure On vehicles fitted with coded radio set, pay attention to coding;...
Page 11: Removing And Installing Engine
OCTAVIA Removing and Installing Engine K The two rear jacking points are located at the rear of both side members at the level of the marking on the sill. Remove noise insulation panel -arrow-. Open cap of coolant expansion tank.
Page 13 OCTAVIA Removing and Installing Engine Unplug connector from the Hall sender (G40) -arrow-. Unplug connector from the intake manifold temperature sender (G72) -1-. Detach connection hose -2- to the intake hose -5-. Detach vacuum hose -3- to the brake servo unit at the throttle valve control unit (J338).
Page 14 OCTAVIA Removing and Installing Engine Detach the earth cable -1- from the top en- gine/gearbox connecting bolt. Unplug connector -2- and pull out of the fix- ture. Take off cable -3- and -4- at the starter. Detach cables from the fixture at the starter and place to the side.
Page 16 OCTAVIA Removing and Installing Engine Remove slave cylinder -arrows- and place to the side, secure with wire; do not open line system. Note: Do not depress clutch pedal. Models with automatic gearbox Use a screwdriver to press selector lever cable -1- off at the gearbox selector lever -4-, pull off locking clasp -3- at the support bracket.
Page 17 @ " OCTAVIA Removing and Installing Engine " ' " " & # % 0 " & % 5 & # ' 0 ' " # # ' % " 8 4 "...
Page 18 OCTAVIA Removing and Installing Engine Models with air conditioning Warning! The refrigerant circuit of the air conditioning sys- tem must not be opened. Unbolt compressor of air conditioning sys- tem, lower together with the connected re- frigerant hoses and tie up with a wire at the towing eye on the inside of the bumper -ar- row-.
Page 19 ¡ § ¨ ¥ ¤ ¨ § ¤ ¤ ¦ ¢ OCTAVIA Removing and Installing Engine ¡ ¢ £ ¤ ¥ ¦ § ¨ ¥ © § ¢ § § £ ¨ ¡ § ¨ ¥ ¢ © ¤ ¥ ¡ § ¨ ¥ ¥ § ¤ ¤ ¦ ¢ Note: ¤...
Page 20: Installing Engine
# ¤ ¥ ¥ ¡ ¡ ¥ ¡ ¥ ¤ § ¨ ¥ OCTAVIA " Removing and Installing Engine % £ ¨ ¥ ¥ ¤ ¦ ¨ © $ ¥ ¤ ( ) 1 1 &...
Page 21 OCTAVIA Removing and Installing Engine Procedure Installation is carried out in the reverse order; pay attention to the following points: Check whether dowel sleeves for centering engine/gearbox are present in the cylinder block, insert if necessary. Attach intermediate plate to sealing flange and push onto the dowel sleeves -arrows-.
Page 22: Tightening Torques
OCTAVIA Removing and Installing Engine Note: Only re-use drained coolant if cylinder block, cyl- inder head, cylinder head gasket, radiator, or heat exchanger have not been replaced. Pour in coolant ⇒ page 19-3. Inspect engine oil level before starting en- gine ⇒...
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 27: Crank Assembly Page
OCTAVIA Crank Assembly Disassembling and assembling engine Removing and installing ribbed V-belt 3 - Vibration damper ♦ can be installed only in one position 4 - 25 Nm 5 - Alternator ♦ push back threaded bushes for secur- ing bolts slightly to more easily fit al-...
Page 28 Crank Assembly OCTAVIA 18 - Ribbed V-belt ♦ mark the direction of running before removing it. ♦ inspect for wear ♦ do not kink ♦ routing of ribbed V-belt on models not fitted with AC ⇒ Fig. 1 ♦ routing of ribbed V-belt on models fit- ted with AC ⇒...
Page 29 ¡ ¢ £ ¤ ¥ ¦ § ¨ ¥ © © ¡ © ¡ OCTAVIA Crank Assembly ¦ ¥ ¦ § © ¡ Note: Mark direction of running of the ribbed V-belt before removing it.
Page 30 OCTAVIA Crank Assembly ------------ 13-4 ------------ Edition 04.01 S00.5104.54.20...
Page 31 ¥ ! " # $ % & ' $ ( ) ' 0 1 2 3 4 5 6 7 1 OCTAVIA Crank Assembly @ ( A 4 @ A @ B 2 C D D 7 E belt ' ( ) 7 3 ♦...
Page 32 OCTAVIA Crank Assembly Special tools, testers and aids required ♦ Torque wrench ♦ Counterholder MP 1-216 ♦ Holder MP 1-224 ♦ Counterholder MP 1-310 ♦ Supporting device for engine MP 9-200 ♦ Locking pin, e.g. T40011 ♦ Tensioning bolt T 10092...
Page 33 OCTAVIA Crank Assembly Unbolt engine support from engine mount and engine mount from the body -arrows-. Remove engine support -arrows-. Note: Raise engine slightly with the spindle of the sup- porting device MP 9-200, if necessary. Remove middle part of toothed belt guard.
Page 34 OCTAVIA Crank Assembly Check whether TDC marking on flywheel and reference mark on driven plate are aligned -arrow-. I - Manual gearbox II - Automatic gearbox Remove vibration damper. Remove bottom part of toothed belt guard. Mark direction of running of toothed belt.
Page 35 Crank Assembly OCTAVIA Align marking on ribbed V-belt pulley with marking on bottom part of toothed belt guard Check whether TDC marking on flywheel and drive plate with reference mark are aligned -arrow-. I - Manual gearbox II - Automatic gearbox Fit toothed belt onto camshaft sprocket.
Page 36: Removing And Installing Sealing Flange And Flywheel
Crank Assembly OCTAVIA Removing and installing sealing flange and flywheel 4 - Sealing ring ♦ replace ⇒ page 13-12 ♦ pay attention to different versions ⇒ Fig. 2 5 - Front sealing flange ♦ must be located on dowel sleeves ♦...
Page 37 Crank Assembly OCTAVIA K Fig. 1 Installing intermediate plate Attach intermediate plate to the sealing flange and fit onto dowel sleeves -arrows-. K Fig. 2 Seal versions Elastomer seal 1 sealing lip -1-; with worm spring II PTFE seal Several sealing lips -2-; without worm spring Notes: ♦...
Page 38: Replacing Crankshaft Seal-Belt Pulley Side
Crank Assembly OCTAVIA Replacing crankshaft seal -belt pul- ley side- Special tools, testers and aids required ♦ Torque wrench ♦ Seal extractor MP 1-226 ♦ Guide sleeve MP 1-314 ♦ Thrust sleeve MP 1-315 ♦ Guide sleeve T10053/1 ♦ Thrust sleeve T10053 ♦...
Page 39 OCTAVIA Crank Assembly Screw central bolt by hand into the crank- shaft as far as the stop in order to guide the seal extractor. Turn inner part of seal extractor MP 1-226 two turns out of the outer part, and lock with knurled screw.
Page 40 $ ¨ ¢ ¦ ¡ ¥ " ¡ ¦ ¥ % £ ¦ $ © $ ¡ ) £ ¢ ¦ § ' ¡ ¢ £ £ ¤ ¥ £ ¢ ¦ § ¦ £ $ ¦ ¡ ¦ £ © ¢ £ © & OCTAVIA Crank Assembly £...
Page 41 & 0 & ! ( % % $ ! " # $ % % # & ' ( & ) ! % " & % A # & OCTAVIA Crank Assembly...
Page 42: Removing And Installing Drive Plate
Crank Assembly OCTAVIA Removing and installing drive plate Special tools, testers and aids required ♦ Torque wrench ♦ Counterholder MP 1-221 ♦ Depth gauge Slackening and tightening drive plate Attach counterholder MP 1-221 with hexa- gon screw M8x45 to the drive plate. Insert two M10 hexagon nuts between the counter- holder and the driven plate.
Page 43: Removing And Installing Front Sealing Flange
Crank Assembly OCTAVIA Check installation dimension in three points of the drive plate and determine mean value. Specified value -a- 19.5….21.1 mm Note: The measurement is made through the hole of the drive plate to the milled surface of the cylin- der block.
Page 45 Crank Assembly OCTAVIA Apply silicone sealant bead to the clean seal- ing surface of the sealing flange as shown in the illustration. Fit on sealing flange immediately and tighten all the bolts slightly. Notes: ♦ If a PTFE seal is fitted ⇒ page 13-11, Fig. 2, the crankshaft journal must be free of oil and grease and the seal must not be oiled.
Page 46: Removing And Installing Crankshaft
Crank Assembly OCTAVIA Removing and installing crankshaft 4 - Bearing shells 1, 2, 4 and 5 ♦ for bearing cap without lubricating groove ♦ for cylinder block with lubricating groove ♦ do not mix up used bearing shells (mark) ♦ in case of replacement pay attention to different versions.
Page 47 Crank Assembly OCTAVIA K Fig. 1 Marking top crankshaft bearing Different coloured bearing shells For engines with identification characters AGN approx. 03. 1997 ä For engines with identification characters AGU, ARX, AUM, AUQ approx. 09. 2000 ä The top bearing shells are allocated to the cyl- inder block with the right thickness at the fac- tory.
Page 48: Disassembling And Assembling Pistons And Connecting Rod
Crank Assembly OCTAVIA Disassembling and assembling pistons and connecting rod 3 - Connecting rod ♦ always replace as a set ♦ mark matching cylinder see installa- tion position -B- markings -A- must be positioned one above the other ♦ with oil drilling for lubricating piston pin 4 - Conrod bearing cap ♦...
Page 49 OCTAVIA Crank Assembly K Fig. 1 Inspecting piston ring gap clearan- Special tools, testers and aids required ♦ Feeler gauge Inspection procedure Insert ring at right angles to cylinder wall from above into the lower cylinder opening, about 15 mm away from edge of cylinder. Use piston without rings for inserting.
Page 50 Crank Assembly OCTAVIA K Fig. 2 Inspecting pistons Special tools, testers and aids required ♦ External micrometer 75 to 100 mm Inspection procedure Measure about 10 mm from bottom edge, at right angles to piston pin axis. ♦ Variations compared to nominal size max.
Page 51: Cylinder Head, Valve Gear Page
Cylinder Head, Valve Gear OCTAVIA Removing and installing cylinder head 2 - Sealing cover ♦ replace gasket if damaged 3 - Cylinder head cover ♦ removing and installing ⇒ page 15-2 4 - Gaskets for cylinder head cover ♦ replace if damaged ♦...
Page 52: Removing And Installing Cylinder Head Cover
OCTAVIA Cylinder Head, Valve Gear Removing and installing cylinder head cover l Engine installed. Notes: ♦ Hose connections are secured with screw- type, spring strap or collar clamps. ♦ Always replace collar clamps by spring strap clamps or screw-type clamps.
Page 53 OCTAVIA Cylinder Head, Valve Gear Models 08.97 ä Remove ignition cable guide -arrows-. Detach throttle cable at the throttle valve control unit and support bearing at intake manifold (do not remove catch). Unclip throttle cable and ignition cables from the ignition cable guide.
Page 56 OCTAVIA Cylinder Head, Valve Gear Continued for all models Note: Seal intake galleries in cylinder head with clean cloth. Remove top part of toothed belt guard. Remove cylinder head cover. Installing Installation is carried out in the reverse order; pay attention to the following points: Notes: ♦...
Page 57 OCTAVIA Cylinder Head, Valve Gear Tightening torques Notes: ♦ Tightening torques apply only to lightly greased, oiled, phosphatized or blackened nuts and bolts. ♦ Additional lubricants such as engine oil or gearbox oil are permissible, but not Molykote. ♦ Do not use degreased parts.
Page 58: Removing Cylinder Head
OCTAVIA Cylinder Head, Valve Gear Removing cylinder head l Engine installed Requirements l Engine cold Special tools, testers and aids required ♦ Connecting rod support MP 1-225 ♦ Locking pin from supporting device MP 9-201 ♦ Tensioning bolt T 10092 ♦...
Page 59 OCTAVIA Cylinder Head, Valve Gear Rotate crankshaft at the central bolt of the toothed belt sprocket of the crankshaft in di- rection of rotation of engine and position it at the TDC marking of cylinder 1 -arrows-. Check whether TDC marking on the flywheel and reference mark are aligned ⇒...
Page 60 OCTAVIA Cylinder Head, Valve Gear Slacken the cylinder head bolts in the correct ¤ ¥ ¦ § ¨ © ¥ ¥ ¨ © order. ¦ ¥...
Page 61: Installing Cylinder Head
OCTAVIA Cylinder Head, Valve Gear Installing cylinder head Requirements l Pistons are not positioned at TDC Notes: ♦ Always replace cylinder head bolts with new bolts. ♦ There must not be any oil or coolant in the blind holes of the cylinder head bolts in the cylinder block.
Page 62 ¡ ¢ £ ¤ ¥ ¦ § ¨ ¢ ¤ £ © ¤ # ¦ ¥ 1 ¦ 1 § © # ¨ ¢ ¥ ¦ § ¨ ¢ ¤ £ © ¤ # & ¡ ¢ ¤ § ¦ # © § ! OCTAVIA Cylinder Head, Valve Gear 180°...
Page 63: Testing Compression
OCTAVIA Cylinder Head, Valve Gear Testing compression Test condition l Coolant temperature at least 30 °C Special tools, testers and aids required ♦ Compression tester, (e.g. V.A.G 1381 or V.A.G 1763) ♦ Spark plug wrench Test procedure Unplug connector from ignition transformer and connectors from injectors.
Page 64: Service Valve Gear
OCTAVIA Cylinder Head, Valve Gear Servicing valve gear Notes: (otherwise, valves may strike the pistons); ♦ Cylinder heads with cracks between the after this, rotate crankshaft twice. valve seats or between a valve seat ring and the spark plug thread may continue to be ♦...
Page 65 Cylinder Head, Valve Gear OCTAVIA 2 - Inlet camshaft 10 - Cover for hall sender ♦ runout: max. 0.03…0.05 mm ♦ assembly is only possible in one posi- ♦ inspecting axial play ⇒ page 15-15 tion ♦ removing and installing camshaft ♦...
Page 66 Cylinder Head, Valve Gear OCTAVIA 24 - Double bearing cap 26 - Camshaft ♦ must be located on dowel sleeves ♦ runout: max. 0.03…0.05 mm ♦ seal the joints between the double ♦ timing ⇒ page 00-1, Engine charac- bearing cap/cylinder head ⇒ Fig. 1 teristics ♦...
Page 67: Inspecting Axial Play Of Camshafts
OCTAVIA Cylinder Head, Valve Gear K Fig. 1 Sealing connections of double bearing cap/cylinder head Use a small screwdriver to carefully apply a thin film of sealants ”D 454 300 A2” to the two edges at the sealing surfaces of double bearing cap/cylinder head -arrows-.
Page 68: Removing And Installing Camshafts And Camshaft Adjuster
Cylinder Head, Valve Gear OCTAVIA K Inlet camshaft Wear limit for inlet and intake camshaft ♦ Wear limit: max. 0.20 mm Removing and installing camshafts and camshaft adjuster (with cylinder head installed) Special tools, testers and aids required ♦ Torque wrench ♦...
Page 70 ¥ ¦ ¤ © ¡ ¨ © ¤ § £ § ¦ ¤ § © ! § " £ ¤ § £ § ¦ ¤ § ¨ ¤ © ¢ § ¤ © ¨ © § ¢ ¡ § £ § OCTAVIA Cylinder Head, Valve Gear ¡ § ¥ § ¨ ¨ 2 § ¢ ¥ £ £...
Page 72 OCTAVIA Cylinder Head, Valve Gear Install camshaft sprocket. ♦ Pay attention to installation position: The narrow web of the camshaft sprocket points out -arrows- and the TDC marking of cyl. 1 is visible. Install the bolt for attaching camshaft sprocket and tighten to 65 Nm (use counterholder MP 1-216).
Page 74 & ' ( ¢ ¥ % ¦ £ " ) ¦ ¨ ¡ ¥ ¥ ¥ £ 0 ! OCTAVIA Cylinder Head, Valve Gear Replacing seal for exhaust camshaft Removing ⇒...
Page 75 OCTAVIA Cylinder Head, Valve Gear Screw bolt for attaching camshaft sprocket -arrow- by hand into the camshaft as far as the stop in order to guide the seal extractor. Turn inner part of seal extractor MP 1-215 two turns (about 3 mm) out of the outer part, and lock with knurled screw.
Page 77 & 6 ( % " & 8 ( % P C E Q ) OCTAVIA Cylinder Head, Valve Gear 2 B ! % ' 2 B & ! " # $ % & ' ( 8 ! % ' 2 B & 1 2 8 ( % " ( 8 & D ( % ) R 2 B ! % ' 2 B &...
Page 80 ¨ ¡ ¢ £ ¥ § ¢ ¢ ¡ ¥ ¢ ¢ ¢ § ¦ ¨ § ¨ © ¢ ¤ £ ¡ © £ ¨ § ¦ £ ¥ £ ¦ ¨ £ ' ¢ § ¡ ¥ ¢ ¢ ¢ OCTAVIA Cylinder Head, Valve Gear ¡ ¢ ¨ © ¡ ¨ ¡ ¥ ¢ ¢ ¢ ! " # # $ " % £...
Page 81: Valve Dimensions
OCTAVIA Cylinder Head, Valve Gear Valve dimensions K Dimensions for inlet and exhaust valves Note: Inlet and exhaust valves must not be reworked. It is only permissible to grind them in. Dimension Inlet valve Exhaust valve ∅ a 26.80 ... 27.00 29.80 ...
Page 82: Replacing Valve Stem Seals
OCTAVIA Cylinder Head, Valve Gear Special tools, testers and aids required ♦ Feeler gauge ♦ Wooden or plastic wedge Inspection procedure Start engine and run until the radiator fan has cut in once. Increase engine speed to about 2500 rpm for 2 minutes.
Page 83 OCTAVIA Cylinder Head, Valve Gear ♦ Valve depressor MP 1-229 ♦ Thrust piece MP 1-229/1 ♦ Puller MP 1-230 ♦ Fitting tool MP 1-233 ♦ Spark plug wrench Removing Remove camshafts ⇒ page 15-16. Remove bucket tappets (do not mix up) and place down with the running surface facing down.
Page 84 OCTAVIA Cylinder Head, Valve Gear Inlet side K The inlet valves have a different installation angle in the cylinder head. The valve depressor MP 1-229 has two different positions: ♦ 1 - Top position for centre inlet valve ♦ 2 - Bottom position, for the two outer inlet valves ♦...
Page 85 D E F ) G H H $ 2 6 & $ 5 ' A I # # @ OCTAVIA Cylinder Head, Valve Gear P Q R S T U V W X Y ` Q V W S Q Y T W...
Page 86 © ¡ © ! " % & # $ ! OCTAVIA Cylinder Head, Valve Gear Notes: ♦ If the wear limit is exceeded, repeat meas- urement with new valves.
Page 87: Reworking Valve Seats
OCTAVIA Cylinder Head, Valve Gear Calculate maximum permissible reworking dimension from the distance -a- measured and from the minimum dimension. Minimum dimension: Inlet valves on outside 31.0 mm Inlet valve in middle 32.3 mm Exhaust valve 31.9 mm Distance -a- measured less minimum dimen- sion = max.
Page 88 OCTAVIA Cylinder Head, Valve Gear Procedure Reworking can be carried out manually or with a machine. It is important that the following con- ditions are met: l Wear limit of valve guides must not be greater than permissible dimension ⇒ page 15-31.
Page 89 OCTAVIA Cylinder Head, Valve Gear Use fine grinding paste to grind in valve/valve seat -arrows- until a proper honing pattern is achieved. Inspect valve for leaks. The inspection can be carried out using water colour (proper honing pattern around entire cir-...
Page 90 OCTAVIA Cylinder Head, Valve Gear ¡ ¢ £ ¤ ------------ ------------ Edition 08.98 S00.5104.52.20...
Page 91: Lubrication System Page
OCTAVIA Lubrication System Removing and installing parts of the lubrication system Inspecting engine oil level, oil capacity and Notes: oil specification: ♦ If considerable quantities of metal swarf or ⇒ Inspection and Maintenance abrasion are found in the engine oil when...
Page 92 OCTAVIA Lubrication System 1 - Plug 6 - Retaining clip ♦ replace seal if damaged ♦ check to ensure tight 2 - Dipstick 7 - O-ring ♦ oil level must not extend beyond the ♦ replace if damaged max. marking!
Page 93 OCTAVIA Lubrication System 10 - Gasket with baffle plate 21 - Dowel sleeve ♦ Replace ♦ For centering oil pump/cylinder block ♦ Pay attention to installation position 22 - Chain for oil pump 11 - Oil spray nozzle ♦ Mark direction of running before re- ♦...
Page 94: Disassembling And Assembling Oil Filter Holder
OCTAVIA Lubrication System Disassembling and assembling oil filter holder 8 - Seal ♦ Replace 9 - 25 Nm 10 - 0.14 MPa oil pressure switch (F1), 25 Nm ♦ Black insulation ♦ Cable: green/black ♦ Testing ⇒ page 17-8 ♦ Cut open seal if leaking, and replace 11 - 15 Nm + torque a further 90°...
Page 95: Disassembling And Assembling Oil Pump
Lubrication System OCTAVIA Disassembling and assembling oil pump 1 - 15 Nm 2 - Suction line ♦ clean strainer if soiled 3 - O-ring ♦ replace 4 - Oil pump ♦ if scores exist on running surfaces and gears, replace ♦...
Page 96: Removing And Installing Oil Pan
OCTAVIA Lubrication System Removing and installing oil pan Special tools, testers and aids required ♦ Hinged wrench 3185 ♦ Wrench bit 3249 ♦ Hand drill with plastic brush attachment ♦ Flat scraper ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦...
Page 98: Testing Oil Pressure And Oil Pressure Switch
OCTAVIA Lubrication System Testing oil pressure and oil pressure 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 99 ¤ ¥ ¦ § ¨ © ¨ ¥ ¦ ¦ ¥ OCTAVIA Lubrication System Unplug connector of 0.14 MPa oil pressure switch (black insulation) and remove oil pres- sure switch -arrow-. Screw oil pressure switch into the oil pres- sure tester.
Page 100 OCTAVIA Lubrication System ¡ ¢ £ ------------ ------------ Edition 02.02 S00.5104.55.20...
Page 101 OCTAVIA Lubrication System K Marking range on dipstick: a - Oil must not be topped up. b - Oil may be topped up. After topping up, it is possible that the oil level will then be within the range -a-.
Page 103: Cooling System Page
OCTAVIA Cooling System Removing and installing parts of the cooling system Parts of the cooling system ¡ ¢ Notes: ♦ Route coolant hoses free of stress when installing so as to avoid contact with other ♦ The cooling system is pressurized when the components (pay attention to marking on engine is warm.
Page 104 OCTAVIA Cooling System Coolant mixing ratios ⇒ page 19-3. 3 - Connection fitting with throttle valve control unit Inspecting cooling system for leaks ⇒ page 19-8. 4 - Heat exchanger for heating system Note: 5 - ATF cooler ♦ Only on models with automatic gear- Always replace seals and gaskets.
Page 105 ¥ # ¨ © $ % & ' ( ) ( ) 0 ¥ 2 3 4 5 5 6 ' ) 2 OCTAVIA Cooling System 7 ! © § ¨ § 8 ♦ Removing and installing ⇒...
Page 106 OCTAVIA Cooling System In addition, detach bottom coolant hose at oil cooler -arrow- and drain the remaining coolant. Filling system Select coolant additives from the ŠKODA Genuine Parts Catalogue or also from the list of approved coolants ⇒ Inspection and Main- tenance;...
Page 107 OCTAVIA Cooling System Coolant additives from the Škoda Genuine Parts List conforming to Specification TL VW 774 D: Coolant additives Manufacturer Glysantin G30-72 BASF AG XT 4030 ELF OIL AG Coolant ETX 6280 TEXACO FROSTOX SF-D 12 HENKEL HAERTOL GmbH Note: The coolant additives stated can be intermixed.
Page 108 OCTAVIA Cooling System ------------ 19-4.2 ------------ Edition 08.98 S00.5104.52.20...
Page 109: Removing And Installing Coolant Pump
OCTAVIA Cooling System Removing and installing coolant pump Notes: ♦ Always replace seals and gaskets. ♦ The vibration damper and the bottom part of the toothed belt guard can remain installed. ♦ The toothed belt remains fitted on to the crankshaft toothed belt sprocket.
Page 110: Removing And Installing, Testing Coolant Thermostat
! § ¨ ¨ ¥ ¥ ¨ © & ) © ¨ ¨ © § ¦ ¥ " © 1 7 4 OCTAVIA Cooling System ! § ¨ ¦ ) ) © & 8 ) © ¨...
Page 112 OCTAVIA Cooling System Testing cooling system for leaks Special tools, testers and aids required ♦ Cooling system tester V.A.G 1274 ♦ Adapter V.A.G 1274/8 ♦ Adapter V.A.G 1274/9 Test condition l Engine at operating temperature Test procedure Open cap of coolant expansion reservoir.
Page 113: Removing And Installing Radiator
OCTAVIA Cooling System Removing and installing radiator Notes: ♦ Always replace seals and gaskets. ♦ Lifting vehicle with lift platform ⇒ page 10-1, Removing and installing engine. Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦...
Page 114 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 Remove the 4 bolts -arrows- for attaching the top radiator mount. Remove the 4 bolts -arrows- for attaching the bottom radiator mount.
Page 115 OCTAVIA Cooling System Models with air conditioning Pull out radiator slightly together with conden- ser. 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 117: Removing And Installing Parts Of The Fuel Supply System
OCTAVIA Fuel Supply System Removing and installing parts of the fuel supply system Notes: ♦ Hose connections are secured with screw- type, spring strap or clamp-type clips. ♦ Always replace clamp-type clips by spring strap clips or screw-type clips. ♦ Fuel hoses at the engine must be secured only with spring strap clips.
Page 118: Removing And Installing Fuel Tank With Attached Parts And Fuel Filter
OCTAVIA Fuel Supply System Removing and installing fuel tank with attached parts and fuel filter ¡ ¢ 1 - Overflow hose 4 - Vent pipe ♦ To activated charcoal filter 2 - O-ring ⇒ page 20-12, item 5 ♦ Replace...
Page 119 OCTAVIA Fuel Supply System 8 - Vent valve 20 - Fuel filter ♦ inspecting ⇒ Fig. 1 ♦ installation position: arrow points in direction of flow 9 - Earth connection 21 - Retaining clip 10 - 10 Nm ♦ for fuel filter...
Page 120: Rules For Cleanliness
OCTAVIA Fuel Supply System Safety precautions when carrying out work on fuel supply system Important! Fuel system is pressurised! Place cleaning rags around the connection point before opening the system. Then, release pressure by carefully loosening the connection point. Pay attention to the following points when re-...
Page 121: Removing And Installing Fuel Delivery Unit
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...
Page 122: Removing And Installing Fuel Gauge Sender
OCTAVIA Fuel Supply System Pay attention to installation position: ♦ Marking on the flange should be aligned with the marking on the fuel tank -arrows-. ♦ Blue return flow pipe -1- to connection with marking -R-. ♦ Black feed pipe -2- to connection with marking -V-.
Page 123 OCTAVIA Fuel Supply System Removing If car 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 the battery. Empty fuel tank with fuel extraction unit (e.g.
Page 124: Connecting Remote Control
OCTAVIA Fuel Supply System Detach screw connections -arrow- at the front left and at the retaining straps. Lower fuel tank. Installing Installation is performed in the reverse order; pay attention to the following points: Connect fuel pipes to the flange of the fuel delivery unit: ♦...
Page 125: Testing Fuel Pump
OCTAVIA Fuel Supply System Testing fuel pump Special tools, testers and aids required ♦ Hand-held multimeter (e.g. V.A.G 1526) ♦ Wrench for union nut (e.g. MP 1-227) ♦ Adapter cable set (e.g. V.A.G 1594) ♦ Current flow diagram Test conditions l Holding pressure o.k.;...
Page 126: Testing Fuel Pump Delivery
OCTAVIA Fuel Supply System If the fuel pump does not run: Unbolt cover (below the rear seat). Release 4-pin connector form the flange at the fuel tank and unplug. Connect hand-held multimeter (e.g. V.A.G 1526) with auxiliary cables (e.g. from V.A.G 1594) to the outer contacts of the connector.
Page 127 OCTAVIA Fuel Supply System 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 the fuel filler neck. Important! Fuel system is pressurised! Place cleaning rags around the connection point before opening the system.
Page 128: Removing And Installing Parts Of The Activated Charcoal Filter System
OCTAVIA Fuel Supply System Removing and installing parts of the activated charcoal filter system 1 - Solenoid valve 1 (N80) ♦ Testing operation and actuation: ⇒ 1.8 ltr./92 kW Engine, Motronic Fuel Injection and Ignition System; Repair Group 24; Testing tank breather; Testing solenoid valve...
Page 129: Adjusting Throttle Cable
OCTAVIA Fuel Supply System Adjusting 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 subsequently result in the cable fracturing when driving. Throttle cables which have been kinked, must therefore not be installed.
Page 131: Removing And Installing Parts Of The Exhaust System
OCTAVIA Exhaust System Removing and installing parts of the exhaust system Assembly overview of the exhaust system 5 - Clamping sleeve ♦ aligning exhaust system free of stress ⇒ page 26-5 ♦ installation position: horizontal in vehicle; bolted connection pointing to the left ♦...
Page 132: Removing And Installing Front Exhaust Pipe
OCTAVIA Exhaust System Notes: ♦ Always replace gaskets, self-locking nuts and clamping sleeves. ♦ After carrying out removal and installation work on the exhaust system, ensure that the exhaust system is not tensioned and that adequate clearance exists to the body. If...
Page 133: Removing And Installing Exhaust Manifold
¨ ¥ ¨ ¥ © ¦ © ¥ $ ¥ ' ¥ $ ' ¨ © § ¥ 2 3 4 5 ¥ ' $ $ ' ¥ ¥ ' " OCTAVIA Exhaust System 6 ¥ ¦ $ $ ¥...
Page 134 ¤ ¥ ¦ § ¨ © © ¥ OCTAVIA Exhaust System Installation is carried out in the reverse order; ! " # $ % " & ' ( ) ¨ ©...
Page 136 OCTAVIA Exhaust System Align rear silencer horizontally: The suspension bolt at the exhaust pipe should be positioned parallel to the tun- nel bridge (dimension -X- identical on left and right). Note: On models with separation point ⇒ page 26-4, additionally check horizontal position of rear si- lencer at the tail pipes.

Skoda Octavia Workshop Manual

Technical Data Page

Removing and Installing Engine

Crank Assembly Page

Cylinder Head, Valve Gear Page

Lubrication System Page

Cooling System Page

20 Fuel Supply System

26 Exhaust System

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