Skoda Octavia 1996 User manual

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

The Workshop Manual is intended only for use within the ŠKODA
Organisation; it is not permitted to pass it on to third parties.
© 1996 ŠKODA, automobilová a.s. Printed in Czech Republic

Service
List of Supplements to
OCTAVIA Workshop Manual Edition: 10.02
1.6 l/ 4 kW Engine, Mechanical Components
Replaces List of Supplements - Edition: 05.01
Supple- Edition Subject Article Number
ment
08.96 Basic Edition of Workshop Manual S00.5105.50.20
1 05.9 Supplement to Basic Edition S00.5105.51.20
2 12.99 Modifications to Repair Groups 00, 10, 13, 15, S00.5105.52.20
1 , 19, 20, 26
3 05.01 Modifications to Repair Groups 10, 13, 15, 1 , 20 S00.5105.53.20
4 10.02 Modifications to Repair Groups 13, 15, 1 , 19, 26 S00.5105.54.20
5
6
8
9
10
11
12
13
14
15
16
1
18
19
20
Contents ⇒ next page.
The Service Manual is intended only for use within
the koda Organisation; it is not permitted to pass it
on to third persons.
© 2002 KODA AUTO a. s.
Printed in CR
S00.5105.54.20

Edition 10.02
S00.5105.54.20
------------ 1 ------------
OCTAVIA Service
Contents
00 Technical Data Page
Technical data .............................................................................................................................. 00-1
- Engine number ......................................................................................................................... 00-1
- Engine features ........................................................................................................................ 00-1
10 Re oving and Installing Engine Page
Re oving and installing engine ................................................................................................ 10-1
- Removing engine ..................................................................................................................... 10-1
- Attaching engine to repair stand ............................................................................................... 10-10
- Installing engine........................................................................................................................ 10-11
- Tightening torques .................................................................................................................... 10-14
- Aligning engine gearbox mounting ........................................................................................... 10-15
- Engine gearbox mounting ........................................................................................................ 10-16
13 Crank Asse bly Page
Disasse bling and asse bling engine .................................................................................... 13-1
- Removing and installing ribbed V-belt ...................................................................................... 13-1
- Removing and installing, tensioning toothed belt ..................................................................... 13-5
- Inspecting semi-automatic toothed belt tensioning pulley ........................................................ 13-10
Re oving and installing crankshaft.......................................................................................... 13-11
- Replacing crankshaft seal-belt pulley side ............................................................................... 13-14
- Removing and installing pressure plate ................................................................................... 13-15
- Removing and installing driven plate ........................................................................................ 13-15
- Removing and installing front sealing flange ............................................................................ 13-17
Disasse bling and asse bling pistons and connecting rod ................................................ 13-19
15 Cylinder Head, Valve Gear Page
Re oving and installing cylinder head..................................................................................... 15-1
- Removing and installing top part of intake manifold ................................................................. 15-4
- Removing and installing cylinder head cover ........................................................................... 15-6
- Removing cylinder head ........................................................................................................... 15-7
- Inspecting cylinder head for distortion ...................................................................................... 15-10
- Reworking cylinder head .......................................................................................................... 15-11
- Installing cylinder head ............................................................................................................. 15-11
- Testing compression ................................................................................................................ 15-13
Service valve gear ....................................................................................................................... 15-14
- Replacing camshaft seal .......................................................................................................... 15-16
- Removing and installing camshaft ........................................................................................... 15-17.2
- Inspecting hydraulic bucket tappets ......................................................................................... 15-19
- Replacing valve stem seals ...................................................................................................... 15-20
- Inspecting valve guides ............................................................................................................ 15-22
- Replacing valve guides ............................................................................................................. 15-22
- Reworking valve seats ............................................................................................................. 15-23
17 Lubrication Syste Page
Re oving and installing parts of the lubrication syste ....................................................... 17-1
- Disassembling and assembling oil filter holder ........................................................................ 17-2
- Removing and installing oil pan ................................................................................................ 17-3
- Testing oil pressure and oil pressure switch ............................................................................. 17-5

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OCTAVIA Technical Data 00
Edition 12.99
S00.5105.52.20
------------ 00-1 ------------
Technical data
Engine number
KThe engine number (engine code letters and
serial number) is located at the front at the joint
between engine and gearbox.
In addition, a sticker with engine code letters
and serial number is affixed to the toothed belt
guard.
The engine code letters are also listed on the
vehicle data sticker.
Engine features
Code letters AEH AKL
anufactured 04.97 ä08.97 ä
Displacement ltr. 1.595 1.595
Power output kW at rpm 74/5600 74/5600
Torque Nm at rpm 145/3800 145/3800
Bore Ø mm 81.0 81.0
Stroke mm 77.4 77.4
Compression ratio 10.3:1 10.3:1
Firing order 1-3-4-2 1-3-4-2
RON 95 unleaded1) 95 unleaded1)
Injection/ignition system Simos 2 Simos 2
Knock control system x x
Self-diagnosis x x
Lambda control x x
Catalytic converter x x
Exhaust gas recirculation - -
Air charging - -
Emission limits conforming to EU-2/ECE EU-3D
1) In exceptional cases at least 91 RON, but engine output reduced

OCTAVIA
00 Technical Data
------------



------------ Edition 12.99
S00.5105.52.20

OCTAVIA  

S00.5105.52.20
------------




------------



♦Workshop crane (e.g. V.A.G 1202 A)
♦Drip tray (e.g. V.A.G 1306)
♦Torque rench 5...50 Nm
(e.g. V.A.G 1331)
♦Torque rench 40...200 Nm
(e.g. V.A.G 1332)
♦Engine/gearbox lift (e.g. V.A.G 1383 A)
♦Pliers for spring strap clamps
♦Engine holder T10012
♦Engine holder MP 1-202
♦Repair stand MP 9-101
♦Suspension device MP 9-201
♦Grease G 000 100
(models ith manual gearbox)
♦Cable straps

Notes:
♦The engine is removed downward together
with the gearbox.
♦All the cable straps which are detached or
cut open when removing the engine, should
be fitted on again at the same point when
installing the engine.
♦Hose connections are secured with screw-
type, spring strap or collar clamps.
♦Always replace collar clamps with spring
strap or screw-type clamps.
♦Fuel hoses at the engine must be secured
only with spring strap clamps. It is not
permitted to use collar or screw-type clamps.
♦It is recommended to use the special pliers
for removing and installing the spring strap
clamps.
♦nsure the connectors are plugged in at the
correct point; mark if necessary.

OCTAVIA
10 Removing and Installing Engine
------------




------------ Edition 12.99
S00.5105.52.20
Procedure
 

 
⇒ 

K 
 
 

K

Warning!
The arms of the lift platform must on no account
be positioned below the sill, the front or rear
suspension.
K


Warning!
When the vehicle is raised, never start the engine
and engage a gear so long as only one driven wheel
is touching the ground.

OCTAVIA  

S00.5105.52.20
------------




------------
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OCTAVIA
10 Removing and Installing Engine
------------




------------ Edition 12.99
S00.5105.52.20
♦to top of radiator (at flange on left of cylin-
der head)
♦to heating system heat exchanger (1 hose
each at coolant pipe and on left of cylinder
head)
♦on side at coolant pipe
♦at throttle valve connector (2 hoses)
♦at ATF cooler (models with automatic
gearbox)
- etach vacuum hose to the brake servo unit.
Note:
Before removing the ribbed V-belt, mark the
direction of running. If a used belt is fitted on
again to run in the opposite direction, it may be
destroyed. When installing the belt, ensure it is
correctly located in the belt pulleys.
K- Swivel tensioning device in direction of arrow
in order to slacken the ribbed V-belt.
- Take off ribbed V-belt.
- Unbolt 2 brackets for pressure line of power-
assisted steering (on left at gearbox and
below starter).
- Unbolt belt pulley of hydraulic pump for
power-assisted steering.
- Unbolt hydraulic pump of power-assisted
steering and tie up to the front at the front of
the vehicle. The lines remain connected.

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Warning!
The refrigerant circuit of the air conditioning
system must not be opened.
- Unbolt bracket for refrigerant hoses.
K- Unbolt compressor of air conditioning system
and suspend on the inside of the bumper
-arrow- together with the connected refrige-
rant hoses.
Note:
Protect the bumper from damage by using a wire
with a soft cover.

OCTAVIA  

S00.5105.52.20
------------
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Note:
Use the assembly ladder (e.g. V.A.S 5085) for
removing the securing bolts.

OCTAVIA
10 Removing and Installing Engine
------------





------------ Edition 12.99
S00.5105.52.20
K
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Note:
When lowering engine/gearbox unit, guide
carefully in order to avoid any damage as a result
of the slight clearance to the body.
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OCTAVIA  

S00.5105.52.20
------------
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♦Always replace seals and gaskets when
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OCTAVIA
10 Removing and Installing Engine
------------ 10-12 ------------ Edition 05.01
S00.5105.53.20
K- Attach intermediate plate to sealing flange
and push onto the dowel sleeves -arrows-.
Models fitted with manual gearbox
- Apply a thin film of grease G 000 100 to the
splines of the gearbox input shaft.
- Inspect centering of clutch plate, if neces-
sary.
- Install slave cylinder of hydraulic clutch
⇒5-Speed Manual Gearbox 02K; Repair
Group 30; Servicing clutch mechanism.
- Install shift mechanism
⇒5-Speed Manual Gearbox 02K; Repair
Group 34; Servicing shift mechanism.
- Adjust shift mechanism
⇒5-Speed Manual Gearbox 02K; Repair
Group 34; Adjusting shift mechanism.
Models fitted with automatic gearbox
- Use only nuts approved in the Parts List for
attaching the torque converter to the driven
plate.
Models fitted with air conditioning
- Install AC compressor
⇒Heating, Air Conditioning; Repair Group 87;
Air Conditioning; Removing and installing
compressor at bracket.
Continued for all models
- Install power steering hydraulic pump
⇒Running Gear; Repair Group 48; Remov-
ing and installing power steering hydraulic
pump.
- Install drive shafts
⇒Running Gear; Repair Group 40; Servicing
front suspension; Removing and installing
drive shaft.
- Install front exhaust pipe and align exhaust
system free of stress ⇒ page 26-2.
- Align engine/gearbox mounting ⇒ page 10-
15.