Skoda Octavia Workshop Manual

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Service

Workshop Manual

OCTAVIA

2.0-ltr./85 kW Engine,

Mechanical Components

Service Department. Technical Information

S00.5127.50.20 Edition 08.99

Table of Contents

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Summary of Contents for Skoda Octavia

Page 1 Service Workshop Manual OCTAVIA 2.0-ltr./85 kW Engine, Mechanical Components Service Department. Technical Information S00.5127.50.20 Edition 08.99...
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: 04.03 OCTAVIA 2.0 l/85 kW Engine, Mechanical Components Replaces List of Supplements - Edition: 01.02 Subject Edition Article Number Supple- ment 08.99 Basic Edition of Workshop Manual S00.5127.50.20 12.99 Modifications for Engine Code Letters APK S00.5127.51.20...
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 ....................10-11 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 ................... 19-2 Inspecting cooling system for leaks ..................19-5 Removing and installing radiator ....................
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 of the engine and gearbox. A sticker with „engine code“ and „serial number“ is affixed to the toothed belt guard.
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 as- signed; mark if necessary. Procedure On models fitted with coded radio set, pay attention to coding;...
Page 11 OCTAVIA Removing and Installing Engine K The two jacking points at the rear are located at the rear of the two side members, at the level of the marking on the sill. Remove middle noise insulation panel -ar- rows-. First of all remove air ducts on out- side.
Page 12 2 ) ' 4 ¨ ' 0 ' ) ¨ § ' 0 5 0 ¨ § ' 0 2 0 ¨ § ¨ 4 4 ¦ OCTAVIA Removing and Installing Engine ¦...
Page 15 ¤ ¢ § ¢ ¢ © § ¢ $ ¢ ( © 6 ¤ ¢ ( © OCTAVIA Removing and Installing Engine 7 8 9 @ A B C D E F G H I P Q I B R A I S T 9 U ¨...
Page 16 OCTAVIA Removing and Installing Engine Unplug connectors: at vehicle speed sender -G68- at reversing light switch -F4- Remove slave cylinder -arrow- and place down to the side, secure with wire. Do not open line system. Note: Do not depress clutch pedal.
Page 17: Removing And Installing Engine
$ % & ' § ¤ ¦ ¨ ¦ £ ¢ ¢ OCTAVIA Removing and Installing Engine 0 § ¦ £ ¥ ¢ ¥ " ¤ ¥ 1 ¦...
Page 20: Installing Engine
` A X B " & & A # ( 0 & Y T 9 0 ) D 9 ( A ( ' % ) # ( ( ) ' U OCTAVIA Removing and Installing Engine ! " & ' E ( ' & B ( " & ' E ( ' & ' 0 E & 9 @ ) G " ) A 0 & 9 2 3 8 5 6 7 6 ' 0 # % ! & 9 # A & & 1 & #...
Page 21 ¥ § ! ¥ § ¨ ¦ F ¦ © E ! © # ¦ F ¦ © ¦ © © ! ¥ ¨ ¦ ¥ % H I I I P I I OCTAVIA Removing and Installing Engine D ¥...
Page 22 OCTAVIA Removing and Installing Engine Models with air conditioning Install the AC compressor. ⇒ Heating, Air Conditioning; Repair Group 87; Servicing heating and air conditioning - en- gine compartment Knock back threaded bushes -B- for retain- ing bolts -A- slightly in direction of arrow to more easily fit on the AC compressor.
Page 23 OCTAVIA Removing and Installing Engine After re-connecting the battery: Encode radio. Set clock. Initialise power windows. ⇒ Inspection and Maintenance Inspect oil level before starting the engine. Interrogate and erase fault memory. ⇒ 2.0-ltr./85 kW Engine, Motronic Fuel Injec- tion and Ignition System; Repair Group 01;...
Page 24: Tightening Torques
OCTAVIA Removing and Installing Engine K Gearbox mounting The edges -a- and -b- must be parallel to each other. Tightening torques Notes: ♦ Tightening torques apply only to nuts and bolts which have been lightly greased, oiled, phosphatized or blackened.
Page 25 OCTAVIA Removing and Installing Engine Component mounting Tightening torques K Engine mounts 40 Nm + 90° (¼ turn) 25 Nm 100 Nm Replace bolts K Gearbox mounts 40 Nm + 90° (¼ 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 1 - 25 Nm 2 - Bracket 3 - Alternator ♦ Knock back threaded bushes for re- taining bolts slightly to facilitate fitting alternator to bracket 4 - Compact holder ♦...
Page 28 OCTAVIA Crank Assembly 13 - Ribbed V-belt ♦ Mark direction of running before re- moving ♦ Inspect condition ⇒ Inspection and Maintenance; Descriptions of operations ♦ Do not kink ♦ Routing of ribbed V-belt on models without air conditioning ⇒ Fig. 1 ♦...
Page 29 ¡ ¢ £ ¥ ¦ § ¨ © ¦ © ¤ OCTAVIA Crank Assembly nstalling AC Knock back threaded bushes -B- for retain- ¡ ¢ £ ¡ ¢ ¡ ¢ ¦ © ¥ ¦ §...
Page 30 OCTAVIA Crank Assembly Note: K The tensioning device can be locked with a ∅ 4.5 mm drift, about 55 mm long. On models without headlamp cleaning system, it is also possible to use the conrod support MP 1-225, for this purpose.
Page 31: Removing And Installing, Tensioning Toothed Belt
OCTAVIA Crank Assembly Removing and installing, tensioning toothed belt 7 - Toothed belt ♦ Mark direction of running before re- moving ♦ Inspect for wear ♦ Do not kink ♦ Removing ⇒ page 13-7 ♦ Installing ⇒ page 13-10 8 - 25 Nm...
Page 33 Crank Assembly OCTAVIA Removing toothed belt l Engine installed Note: If it is only necessary to remove the toothed belt from a toothed belt sprocket or from the toothed belt tensioning pulley, the engine support as well as the engine mount must not be removed.
Page 34 OCTAVIA Crank Assembly Remove noise insulation panel in the middle and on the right -arrows-. Remove air guide at right on outside first of all. Rotate crankshaft at central bolt of the toothed belt sprocket of the crankshaft in di- rection of rotation of engine and position it to TDC marking of cyl.
Page 35 2 ) § § ¦ ¥ 0 1 ¡ ¡ OCTAVIA Crank Assembly ¢ 0 ! § ¥ ¢ ¢ ¥ £ ) ¤ ¤ § ¥ ¢ ¢ ¥ ) ¢ § ¢ $ ¥ ¢ ¢ ¥ ) ¢ § § © ¥ 0 $ " & ¨ £ & ' §...
Page 36 OCTAVIA Crank Assembly Installing toothed belt Note: When the camshaft is rotated, the crankshaft must not be positioned at TDC otherwise there is a risk of damage to the valves and piston crowns. Requirement l The piston must not be positioned at top dead centre.
Page 38: Inspect The Semi-Automatic Toothed Belt Tensioning Pulley
OCTAVIA Crank Assembly Inspecting semi-automatic toothed belt tensioning pulley Fitting location: K l Lock bracket -arrow- in the recesses at the cylinder head. Inspection procedure Set engine to TDC of piston of cylinder 1. Apply pressure to the toothed belt with your thumb.
Page 39: Removing And Installing Sealing Flange And Flywheel
Crank Assembly OCTAVIA Removing and installing sealing flange and flywheel For engine with identification characters AEG, APK, AQY and AZH 3 - 15 Nm 4 - Sealing ring ♦ replace ⇒ page 13-15 ♦ pay attention to different versions ⇒ Fig. 1 5 - Front sealing flange ♦...
Page 40 Crank Assembly OCTAVIA For engine with engine identification characters AZJ 3 - 15 Nm 4 - Sealing ring ♦ replace ⇒ page 13-15 ♦ pay attention to different versions ⇒ Fig. 1 5 - Front sealing flange ♦ must be located on dowel sleeves ♦...
Page 41 OCTAVIA Crank Assembly Edition 01.02 ------------ 13-13.2 ------------- S00.5127.53.20...
Page 42 Crank Assembly OCTAVIA K Fig. 1 Seal versions Elastomer seal 1 sealing lip -1-; with worm spring II PTFE seal Several sealing lips -2-; without worm spring Notes: Do not moisten PTFE seal with oil before in- stalling. The shaft must also be free of oil and grease.
Page 43: 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 ♦ Thrust sleeve MP 1-231/1 ♦ Guide sleeve MP 1-314 ♦ Thrust sleeve T10053 ♦ Guide sleeve T10053/1 ♦...
Page 44 OCTAVIA Crank Assembly Oil threaded head of seal extractor MP 1-226 and screw as far as possible into the seal using considerable pressure. Slacken knurled screw and turn inner part against the crankshaft until the seal is pulled out. Installing Notes: ♦...
Page 45 Crank Assembly OCTAVIA Installing PTFE seal Note: The sealing lips of the seal must not be oiled or greased. Use a clean cloth to remove oil residues on the crankshaft journal. Fit guide sleeve T10053/1 onto the crank- shaft journal.
Page 46: Removing And Installing Front Sealing Flange
Crank Assembly OCTAVIA Removing and installing front seal- ing flange Special tools, testers and aids required ♦ Torque wrench ♦ Thrust sleeve MP 1-231/1 ♦ Guide sleeve T10053/1 (for PTFE seals) ♦ Guide sleeve MP 1-314 ♦ Thrust sleeve T10053 ♦...
Page 48 Crank Assembly OCTAVIA Notes: ♦ If a PTFE seal is fitted (⇒ page 13-14, Fig. 1, the crankshaft journal must be free of oil and grease and the seal must be oiled. K ♦ Use the following devices for fitting on the...
Page 49: 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 drive plate.
Page 50 Crank Assembly OCTAVIA Check installation dimension in three points of the drive plate and determine mean value. ♦ Specified value dimension -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 51: Removing And Installing Crankshaft
Crank Assembly OCTAVIA Removing and installing crankshaft 3 - Chain sprocket ♦ for oil pump drive 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) ♦...
Page 52 Crank Assembly OCTAVIA K Fig. 1 Marking top crankshaft bearing The top bearing shells are allocated to the cyl- inder block with the right thickness at the fac- tory. Coloured points are used to mark the bear- ing shell thickness.
Page 53: Disassembling And Assembling Pistons And Connecting Rod
Crank Assembly OCTAVIA Disassembling and assembling pistons and connecting rod For engine with identification characters AEG, APK, AQY and AZH 3 - Connecting rod ♦ pay attention to different versions ♦ always replace as a set ♦ mark matching cylinder see -arrow B- ♦...
Page 54 ¥ ¦ § ¨ © ¦ ¥ ¥ OCTAVIA Crank Assembly Conrod bolt ♦ replace together with nut, item 5 Piston pin ♦ if stiff, heat piston to 60 °C ♦ use drift VW 222 A for removing and...
Page 55 Crank Assembly OCTAVIA 4 - Circlip 7 - Cylinder block ♦ inspecting cylinder bore ⇒ Fig. 5 5 - Conrod ♦ cylinder ∅ = 82.51 mm ♦ always replace as a set ♦ mark matching cylinder 8 - Conrod bearing cap see -arrow B- ♦...
Page 56 OCTAVIA Crank Assembly ¡ ¢ £ ¤ ¥ £ ------------ ------------- Edition 01.02 S00.5127.53.20...
Page 57 Crank Assembly OCTAVIA K Fig. 2 Inspecting piston ring end clear- ance Special tools, testers and aids required ♦ Feeler gauge Inspection procedure Clean ring groove before inspecting. Piston ring End clearance wear limit Compression ring 0.06…0.09 0.20 Oil scraper ring 0.03…0.06...
Page 58 Crank Assembly OCTAVIA K Fig. 5 Inspecting cylinder bore Special tools, testers and aids required ♦ Internal precision measuring instrument 50 to 100 mm Inspection procedure Measure at 3 points diagonally across in transverse direction -A- and in longitudinal direction -B- ♦...
Page 59: Cylinder Head, Valve Gear Page
OCTAVIA Cylinder Head/Valve Gear Removing and installing cylinder head 5 - Gasket ♦ for engine codes AEG, APK, AQY and ♦ replace if damaged 6 - Supporting plate ♦ for engine codes AEG, APK, AQY and 7 - Gasket ♦ replace 8 - Screw plug, 15 Nm ♦...
Page 60: Removing Cylinder Head
OCTAVIA Cylinder Head/Valve Gear Removing and installing cylinder head Special tools, testers and aids required ♦ Guide pin T30011/2A ♦ Extractor MP 1-208 ♦ Assembly tool T10029 ♦ Wrench 3452 (for polydrive cylinder head bolts) ♦ Drip tray (e.g. V.A.G 1306) ♦...
Page 61 OCTAVIA Cylinder Head/Valve Gear Remove the top part of the intake manifold as follows: Detach intake hose -1- (arrows). Vent hose -2- remains connected. Remove throttle cable. Unplug connec- tor of throttle valve control unit -J338-. Separate coolant hoses to throttle valve control unit (straight connection at quick- coupling at heat exchanger).
Page 62 8 § ¦ $ ¦ © © § $ © ¤ § ¦ ¨ $ ! OCTAVIA Cylinder Head/Valve Gear 8 § ¦ $ § $ ¦ © ¦ § ¨ © ¨ § § ¨ # ¦ © © § $ © ¤ ¤ © § $ ¦ ¨ $ ! " 6 © § ¦ 6 ¨...
Page 63 Cylinder Head/Valve Gear OCTAVIA Remove cylinder head cover Slacken the cylinder head bolts in the speci- fied order and unscrew. Note: Use spanner 3452 to remove the Polydrive cyl- inder head bolts. Carefully remove the cylinder head. Installing cylinder head Notes.
Page 66 3 4 $ 1 " 2 ' " ) ' " 1 " 5 6 ) ! " # ' $ ( 6 ! 1 ( # " 2 4 1 " OCTAVIA Cylinder Head/Valve Gear head tion ♦ Feeler gauge ♦...
Page 67: Testing Compression
OCTAVIA Cylinder Head/Valve Gear Testing compression Special tools, testers and aids required ♦ Spark plug wrench (e.g. 3122 B) ♦ Assembly tool T10029 ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) ♦ Compression tester (e.g. V.A.G 1763) Test condition l Engine oil temperature must be at least 30 °C.
Page 68 OCTAVIA Cylinder Head/Valve Gear Compression pressures: (in MPa) Wear limit Difference between engine cylinders 1.0 to 1.3 0.75 max. 0.3 Interrogate fault memory and erase. ⇒ 2.0 l/85 kW Engine, Fuel Injection and Igni- tion System; Repair Group 01; Interrogating and...
Page 69: Removing And Installing Camshaft
Cylinder Head/Valve Gear OCTAVIA Repairing Valve Gear 3 - Seal ♦ replace ⇒ page 15-14 4 - Parallel key ♦ ensure tightly fitted 5 - 20 Nm 6 - Bearing cap ♦ installation position ⇒ Fig. 2 ♦ installation sequence ⇒ page 15-16, Removing and installing camshaft ♦...
Page 70 ¤ ¥ ¦ § ¨ © ¥ OCTAVIA Cylinder Head/Valve Gear Cylinder ♦ reworking valve seats ⇒ page 15-22 Valve ♦ do not rework, only grinding in is per- missible ♦ valve dimensions ⇒ Fig. 3 §...
Page 71 Cylinder Head/Valve Gear OCTAVIA K Fig. 3 Valve dimensions Note: Valves must not be reworked. Only grinding in is permissible. Dimension Inlet valve Outlet valve ∅ a 39.5 ± 0.15 32.9 ± 0.15 ∅ b 6.92 ± 0.02 6.92 ± 0.02 91.85...
Page 72 ! " # $ % & & $ ' ( # " 1 2 " ) 0 % ' % OCTAVIA Cylinder Head/Valve Gear 3 4 & 5 " 6 7 ♦ Ring inserter MP 1-214 ♦ Ring extractor MP 1-215 ♦...
Page 73 ¦ § ¢ ¦ £ ¥ § £ © ¥ ¡ § & ¡ ¦ ' ( ) 0 1 2 2 3 ( 4 5 6 7 8 3 9 6 @ 6 ( 0 OCTAVIA Cylinder Head/Valve Gear A ¤ ¦...
Page 74 ¤ ¥ ¦ § ¨ ¥ © ! " # $ " % OCTAVIA Cylinder Head/Valve Gear Removing and installing testers and aids ♦ Torque wrench 5...50 Nm (e.g.
Page 75 ¤ ¥ ¦ § ¨ © © ¥ ¥ § OCTAVIA Cylinder Head/Valve Gear l Pistons must not be positioned at top dead centre. Notes: ♦ The cams for cylinder 1 must be pointing up when installing the camshaft.
Page 76 6 7 ' 4 % 5 0 % 2 0 % 8 9 9 @ A B 9 C D E F G H I P Q A @ R A OCTAVIA Cylinder Head/Valve Gear S T 2 $ % & 0 ' 1 T $ 4 1 &...
Page 77 ¥ ¨ § ¥ ! " # # " $ % & ' $ OCTAVIA Cylinder Head/Valve Gear valve l Cylinder head installed ) 0 # 1 2 3 required ♦...
Page 78 ¡ $ % & $ ¡ ¡ ¢ OCTAVIA ( ) 0 1 2 3 3 4 ) 5 Cylinder Head/Valve Gear 6 $ ¡ $ 7 ¡ ¢ ¢ ¢ ¦ 8 ¦ # ¢ ¢ ¡ ¢ $ ! ! % $ # % ¢...
Page 79 ¨ ¨ © ¤ ¢ ! OCTAVIA Cylinder Head/Valve Gear valve " ! tools, testers and aids ♦ Universal dial gauge holder MP 3-447 ♦ Dial gauge Insert new valve into guide.
Page 81: Reworking Valve Seats
Cylinder Head/Valve Gear OCTAVIA Calculating maximum permissible reworking dimension Insert valve and press firmly against the valve seat. Note: If the valve is replaced when carrying out repair work, use a new valve for the measurement. Measure distance -a- between the valve stem end and the upper face of the cylinder head.
Page 82 OCTAVIA Cylinder Head/Valve Gear Procedure Reworking can be carried out with a machine or by hand. It is essential that the following condi- tions are met: l Wear limit of valve guides must not be greater than the permissible dimension ⇒...
Page 83 OCTAVIA Cylinder Head/Valve Gear Grind in valve/valve seat -arrows- with fine grinding paste so as to obtain a proper con- tact pattern. Inspect valve for leaks. The inspection can be carried out with water colour (proper contact pattern around entire cir-...
Page 85: Lubrication System Page
OCTAVIA Lubrication System Removing and installing parts of the lubrication system Engine codes AEG, APK, AQY and AZH 1 - Oil pump ♦ with pressure relief valve 1.2 MPa (12 bar) ♦ before installing, check whether the two dowel sleeves for centering oil pump/cylinder block are present ♦...
Page 86 OCTAVIA Lubrication System 16 - Partition wall 17 - Oil pan ♦ install with silicone sealant „D 176 404 A2“ ⇒ page 17-4 18 - Seal ♦ replace 19 - Oil drain plug, 30 Nm Engine code AZJ Notes: ♦ If considerable quantities of metal swarf, or...
Page 87 ¡ ¥ ¦ ) 0 £ 1 1 § 2 " ¡ ¨ ' OCTAVIA Lubrication System ( ¡ F 5 & ' Seal ♦ detach for extracting oil ♦ replace ¡...
Page 88 ! " # $ % & ' ! % ( ) 0 1 3 ) 4 5 6 0 OCTAVIA 8 4 9 & 5 Lubrication System A ) ' B ' B &...
Page 89: Removing And Installing Oil Pan
OCTAVIA Lubrication System 8 - Cap 15 - 15 Nm + torque a further ¼ turn (90°) ♦ Replace 9 - Retaining clamp 16 - Gasket 10 - Screw plug, 15 Nm ♦ Replace ♦ Fit into lugs at oil cooler 11 - Seal ♦...
Page 91 2 % £ % ¦ ¢ £ ¦ OCTAVIA Lubrication System " ¢ £ ¥ £ £ % ¤ ¦ £ ¤ £ ¤ ¢ ¦ § ¨ ¥ # ¨ % 1 ¤ ) £ ¤ ¨ ¢ ¥ ¨ ¦ £ ¤ % 5 2 ¤...
Page 93 H % 4 4 5 ' % 5 ) " & ( 6 2 7 2 8 2 9 2 @ A I D P E OCTAVIA Lubrication System % % ' " ( $ ) ) 0 $ ) 1 ' ...
Page 94 ¢ ! " # $ % & ' ( ) ) ' 0 1 ¡ 2 # 3 4 % 2 # 5 6 # 7 ) 8 % 9 @ OCTAVIA Lubrication System If the specification is exceeded: Inspect oil galleries.
Page 95 OCTAVIA Lubrication System Expose chain tensioner with a screwdriver -arrow- and lock with Allen key -1-. Remove chain sprocket for oil pump and re- lease chain from the gearbox with balance shafts. Unscrew bolts on gearbox with balance shafts by working from the outside into the middle.
Page 96 ¤ ¨ ¦ £ ¦ ¡ ¡ ¢ OCTAVIA Lubrication System l Chain tensioner pretensioned ⇒ page 17-12. Insert gearbox with balance shafts. Insert bolts working from the middle toward the outside and tighten to 15 Nm and then torque a further 90°...
Page 97 ) £ $ 0 " £ £ ) $ £ 0 ¢ ! 1 2 3 4 3 3 5 6 7 8 2 9 @ OCTAVIA Lubrication System...
Page 98 OCTAVIA Lubrication System 13 - O-ring ♦ replace 14 - Bolt with O-ring ♦ 15 Nm + torque a further 90° (¼ turn) 15 - Dowel sleeve 16 - Outer rotor ♦ inspect contact surface for wear ♦ marking must be visible 17 - Inner rotor ♦...
Page 99: Cooling System Page
OCTAVIA Cooling System Removing and installing parts of the cooling system Parts of cooling system 1 - Radiator ♦ After replacing, fill complete system with fresh coolant 2 - Oil cooler ♦ Removing and installing ⇒ page 17-3, item 17 3 - Coolant thermostat ♦...
Page 100: Draining And Filling System With Coolant
OCTAVIA Cooling System Draining and filling system with coolant Quantity of coolant approx. 5.0 litres Special tools, testers and aids required ♦ Drip tray (e.g. V.A.G 1306) ♦ Antifreeze concentration tester Draining system Warning! Hot steam may escape when the expansion reser- voir is opened.
Page 101 Cooling system OCTAVIA In addition remove coolant hose at bottom on the oil cooler -arrow- and drain residual coolant. Notes: ♦ Drained coolant must be caught for disposal. ♦ Observe the disposal instructions for cool- ant. Filling up Select the appropriate coolant additive from the original spare parts catalogue ŠKODA or from...
Page 102 Cooling system OCTAVIA Recommended mixture ratios: Antifreeze Antifreeze Drinking protection concentration water 1)2) down to -25 °C 40 % (2.8 l) 60 % (4.1l) -35 °C 50 % (3.45 l) 50 % (3.45 l) Because of inadequate corrosion protection, the antifreeze concentration must not be...
Page 103 OCTAVIA Cooling System Warning! Hot steam may escape when the expansion reser- voir is opened. Cover over cap with a cloth and open carefully. Inspect coolant level and top up, if neces- sary. When the engine is at normal operat- ing temperature, the coolant level must be at the „max“...
Page 104: Removing And Installing Radiator
1 § © © ¦ § ¦ § 2 5 ! $ % ! ! ! 5 ! $ 6 7 8 © ! @ § 2 A © @ A § ¦ § ¦ § ¦ § OCTAVIA Cooling System Testing pressure relief valve in cap B §...
Page 105 ¦ ! " # $ % & ' ( ( # " ) ' ( 0 1 ' 2 3 ! 4 " ' ( ' ! 4 ' 4 5 OCTAVIA Cooling System ¦ ¤ ¢...
Page 108 % $ 3 ) 1 " 4 5 $ 1 " 3 ' " ) ' " 6 " 7 ( 8 $ 2 9 OCTAVIA Cooling System ♦ Torque wrench 5...50 Nm (e.g. V.A.G 1331) Remove engine trim panel -2-.
Page 110 & 7 8 9 @ A B C D A B E A 9 F G B H A I E P 8 I Q E B OCTAVIA Cooling System R # S ) T % 3 U V W...
Page 111 & ' $ 2 3 4 5 6 7 8 9 6 7 @ 6 4 A B 7 C 6 D @ E 3 D F @ 7 OCTAVIA Cooling System G H 9 4 7 C 5 A I G 6 4 A B...
Page 113: 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 spring strap or collar clamps. ♦ Collar clamps must always be replaced by spring strap clamps or screw-type clamps. ♦ Fuel hoses at the engine must be secured only with spring strap clamps.
Page 114: 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 line ♦ to activated charcoal filter 2 - O-ring ♦ replace 5 - Cap ♦ replace seal if damaged 3 - Gravity valve ♦...
Page 115 ¡ " # £ ¨ £ ¨ ¦ £ $ # ¤ ¥ ¡ ¡ § £ OCTAVIA Fuel Supply System Retaining ♦ Inspecting ⇒ Fig. 1 ♦ For fuel filter £...
Page 116: Rules For Cleanliness
¦ § ¤ ¥ ¦ " ¥ ¨ # ¦ " ¥ ¨ ! ¥ ¨ ¥ " OCTAVIA Fuel Supply System & ' Safety precautions when carrying ( " ¥ ¨...
Page 117 % & $ ' ( ) 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 119 " ¦ @ ¢ # ¦ 1 § ¦ 9 ¦ £ ¤ @ ¢ # ¢ ¥ ¢ ¨ § § ¢ # ¦ 1 § ¦ OCTAVIA Fuel Supply System C ¢...
Page 121 $ " % & " $ ! " OCTAVIA # $ ! # Fuel Supply System pump ♦ Hand-held multimeter (e.g. V.A.G 1526) ♦...
Page 122 OCTAVIA Fuel Supply System If the fuel pump does not run: Unbolt cover (below rear seat). Release and unplug 4-pin connector from flange at fuel tank. Connect hand-held multimeter (e.g. V.A.G 1526) to the outer contacts of the connector using adapter cables (e.g. from V.A.G 1594 Operate remote control.
Page 123 $ % " ! ! " # " ! & ' $ ! & " OCTAVIA Fuel Supply System 0 " $ % ! ' ) % uel pump ♦ Adapter (e.g. V.A.G 1318/17) ♦...
Page 125 3 % " % ) $ ( ) 0 4 # ( 0 ! 5 $ $ # " # % ! 6 % " 7 1 % $ # OCTAVIA Fuel Supply System 3 # % ( ) 0 & 8 9 % 9 # 7 ! 1 &...
Page 126 ¦ ¦ © § § ¨ C ¨ G ¦ © ¨ ¦ § © © ¨ ¦ ¦ ¨ ¦ F F ¦ ¦ F ¦ ¨ ! " # $ % & ' ( ) 0 0 % $ 1 ) 0 2 4 6 0 # 3 4 0 ) ¦ ¦ H ¦ OCTAVIA Fuel Supply System I 7 % 4 8 9 # @ A B ©...
Page 127: Removing And Installing Fuel Tank
OCTAVIA Fuel Supply System Removing and installing parts of the fuel supply system - 4x4 models Removing and installing fuel tank with attached parts - 4x4 models ¡ ¢ £ ¤ Notes: 1 - Fuel tank ♦ removing and installing ⇒ page 20- ♦...
Page 130 ! " ¦ ¦ ¦ ¦ OCTAVIA Fuel Supply System Unscrew cover below rear seat on left. Use wrench MP 1-227 to slacken union nut and pull closing flange together with sender out of the fuel tank.
Page 132 £ ¦ ¡ 6 ¥ ¡ ¨ ¡ % ¨ ¡ £ ¤ # & £ © ' £ ¦ 6 ¦ 8 6 ¡ ¤ ¥ ¦ ¥ § ¥ ¥ ¡ 6 £ 9 ! OCTAVIA Fuel Supply System @ ¡ A B ¡ ¡ £ ¥ ¡ ¦ §...
Page 133: Removing And Installing Parts Of The Exhaust System
OCTAVIA Exhaust System Removing and installing parts of the exhaust system ists to the body exists at all points and the Notes: weight of the exhaust system is evenly dis- ♦ When carrying out removal and installation tributed over the hangers.
Page 134 OCTAVIA Exhaust System 12 - Front exhaust pipe with catalytic con- 15 - Brace verter ♦ to remove, separate plug connection 16 - Gasket for lambda probe -item 10- and take ♦ replace cable out of fixtures ♦ pay attention to installation position: ♦...
Page 135 ' ( ) ! & ! 2 3 4 5 6 # $ 7 & OCTAVIA Exhaust System 3 6 # $ 7 & 8 ( 0 0 # $ 7 0 ! &...
Page 136 5 # ( " 7 2 ) $ 4 ( ) $ ' ) 1 " 8 4 ) 2 $ 2 6 4 1 # 9 " & @ OCTAVIA Exhaust System ¡ ¢ £ ------------ ------------- Edition 01.02...
Page 138 OCTAVIA Exhaust System Unbolt right drive shaft from gearbox. ⇒ Running Gear; Repair Group 40; Remov- ing and installing drive shafts Remove the connection pipe between com- bination valve and exhaust manifold. Unbolt the intake manifold support. Unscrew the protective cover -arrows- and...
Page 139 OCTAVIA Exhaust System Removing front and rear silencer Special tools, testers and aids required ♦ Torque wrench 5...50 Nm ♦ Body saw A separation point is provided for replacing the front silencer or the rear silencer when carrying out repairs.
Page 140 ¡ ¢ £ ¤ ¢ ¤ £ ¥ ¦ § ¨ © ¥ ¥ ¥ OCTAVIA Exhaust System stress Special tools, testers and aids required ♦ Torque wrench 5...50 Nm (e.g.
Page 141 OCTAVIA Exhaust System Align centre and rear silencer horizontally: The hanger bolt at the exhaust pipe must be positioned parallel to the tunnel bridge (dimension -X- on left and right the same). Note: On vehicles with separation point ⇒ page 26-5, additionally check horizontal position of rear si- lencer at the tail pipe.
Page 142 Y R H F S b Y d d F b H Q Y d q h r t U ‚ € U G d Q a Y R S i D g G I OCTAVIA Exhaust System ƒ F H the exhaust system „...
Page 143 ! " # $ % & ' ( OCTAVIA Exhaust System ) 0 1 2 ' 3 4 2 ' 5 $ ( ( # 6 ( &...
Page 145 OCTAVIA Exhaust System ¡ ¢ £ ¤ ¥ Edition 01.02 ------------ ------------- S00.5127.53.20...
Page 146 ' ( ) 0 1 2 3 1 4 5 ) 6 ' 9 2 ' 4 2 ' & OCTAVIA Exhaust System ' 4 2 & ( ' 9 and aids ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A, 3B or 3C...
Page 147 OCTAVIA Exhaust System Engine codes AQY and AZH Check amplitude ratio in display field 3: Specification: max. 0.55 Engine code AZJ Check efficiency of catalytic converter in dis- play field 3: Specification: at least 1.00 Continued for all engines Note: The diagnosis of the catalytic converter takes about 100 seconds.
Page 148: Secondary Air Injection System (Only For Engines Aqy, Azh, Azj)
Exhaust System OCTAVIA Secondary air injection system (only for engines AQY, AZH, AZJ) Function The secondary air injection system blows air The actuation of the combination valve and the behind the escape valve during a cold start. This secondary air injection pump (V 101) is per-...
Page 149 Exhaust System OCTAVIA 14 - 10 Nm 18 - For connection at exhaust manifold 15 - Holder 19 - 30 Nm ♦ for secondary air pump ♦ attached to intake manifold 20 - Connection pipe 16 - Connector 21 - Heat shield ♦...
Page 150 OCTAVIA Exhaust System ¡ ¢ £ ¤ ¥ ------------ ------------- Edition 01.02 S00.5127.53.20...
Page 151 Exhaust System OCTAVIA Inspecting combination valve For engines with identification characters AQY and AZH ä 07.2000 Special tools, testers and aids required ♦ Hand vacuum pump (e.g. V.A.G 1390) Test conditions l No fault in fault memory ⇒ 2.0 litre/85 kW Engine, Fuel Injection and Ignition System;...
Page 152 Exhaust System OCTAVIA Build up hand vacuum pump with vacuum. Valve must open. If the combination valve does not open Replace combination valve ⇒ page 26-14 For engines with identification characters AQY and AZH ä 08.2000 For engine AZJ Special tools, testers and aids required ♦...
Page 153: Testing Secondary Air Pump
Exhaust System OCTAVIA Testing secondary air pump Special tools, testers and aids required ♦ Vehicle system tester V.A.G 1552 with cable V.A.G 1551/3, 3A, 3B or 3C ♦ Multimeter e.g. V.A.G 1526 A Test conditions K l Fuse for secondary air pump relay -J299- -arrow- in main fuse box on battery o.k.
Page 154: Testing Secondary Air Injection Valve -N12
Exhaust System OCTAVIA Testing secondary air injection valve -N112- For engines with identification characters AQY and AZH ä 07.2000 Test conditions l Coolant temperature 5…33 °C l Secondary air pump and relay O.K. l Vacuum lines are not blocked. Test procedure Detach top part of vacuum hose -1- from sec- ondary air injection valve.
Page 155 Exhaust System OCTAVIA Removing From above: Removing engine cover ⇒ page 10-2. Removing intake hose -1- (arrows). The vent hose -2- remains connected. Detach pressure and vacuum hose from combination valve. Slacken top union nut at connection pipe leading from secondary air pump to combi- nation valve.

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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