Skoda OCTAVIA 1998 Instruction manual

Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5123.50.20 E ition 08.98
1.8-ltr./110 kW Engine,
Mechanical Components
ProCarManuals.com

The Service Manual is intended only for use within the koda Organisation;
it is not permitted to pass it onto third persons.
© 1998 KODA AUTO a. s.
Printed in CR
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Service
Supplement Overview for
the Repair Manual OCTAVIA Edition: 06.02
1.8 litre/110 W engine, mechanics
Replaces the Supplement Overview - Edition: 04.01
Supple- Edition Subject Article Number
ment
08.98 Basic Edition Wor shop Manual S00.5123.50.20
1 04.01 Supplement to Basic Edition S00.5123.51.20
2 06.02 Changes to Rep. Gr. 10, 13, 15, 17 and 21 S02.5123.52.20
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Contents ⇒ next page.
This document is copyright protected.
Any use of this document without the agreement of
the copyright owner is forbidden.
© 2002 KODA AUTO a. s.
Printed in Czech Republic
S00.5123.52.20
ProCarManuals.com

ProCarManuals.com

Edition 06.02
S00.5123.52.20
------------ 1 ------------
OCTAVIA Service
Table of contents
00 Technical data Page
Technical data .............................................................................................................................. 00-
- Engine number ......................................................................................................................... 00-1
- Engine characteristics .............................................................................................................. 00-1
0 Removing and installing the engine Page
Removing and installing the engine .......................................................................................... 0-
- Removing ................................................................................................................................. 10-1
- Fixing the engine on the assembly stand ................................................................................. 10-8
- Installing ................................................................................................................................... 10-8
- Tightening torques .................................................................................................................... 10-10
- ounting the assemblies .......................................................................................................... 10-11
3 The crankshaft drive Page
Dismantling the engine and putting it together ....................................................................... 3-
- Removing and installing the V-ribbed belt ................................................................................ 5
- Removing and installing the timing belt, tensioning ................................................................. 13-1
Removing and installing the sealing flange and flywheel ....................................................... 5
- Replacing the sealing ring for the crankshaft - on the vibration damper side .......................... 5
- Removing and installing the flywheel ....................................................................................... 5
- Removing and installing the driver plate .................................................................................. 5
- Removing and installing the sealing flange .............................................................................. 5
Removing and installing the crankshaft ................................................................................... 5
- Dimensions of the crankshaft ...................................................................................................5
Dismantling and putting together a piston and piston rod ..................................................... 5
- Dimensions of the piston and piston rod .................................................................................. 5
5 The cylinder head/valve gear Page
Removing and installing the cylinder head .............................................................................. 5-
- Removing the cylinder head ..................................................................................................... 15-2
- Installing the cylinder head ....................................................................................................... 15-6
- Checking the compression (pressure) ..................................................................................... 5
Repairing the valve gear ............................................................................................................. 5-8
- Checking the axial play on the camshaft .................................................................................. 5
- Removing and installing camshafts and the hydraulic chain tensioner .................................... 5
- Replacing the gasket rings for the camshaft ............................................................................ 5
- Valve dimensions ..................................................................................................................... 5
- Checking the hydraulic bucket tappet ...................................................................................... 5
- Replacing the valve shaft seals ................................................................................................5
- Checking valve guides ............................................................................................................. 5
- Reworking valve seats ............................................................................................................. 5
7 Lubrication Page
Removing and installing parts of the lubrication system ....................................................... 7-
- Dismantling and assembling the oil filter holder ....................................................................... 17-2
- Dismantling and assembling the oil pump ................................................................................ 5
- Removing and installing the oil pan .......................................................................................... 17-3
- Checking the oil pressure and oil pressure switch ................................................................... 17-3
- Checking the oil level ............................................................................................................... 5
5see the Service anual for the 1.8 litre/92 kW engine, mechanics
ProCarManuals.com

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OCTAVIA Technical Data 00
Edition 04.01
S00.5123.51.20
------------ 00-1 -------------
1) In exceptional cases at least 91 RON, although engine power output reduced.
2) Applies to vehicles with automatic gear ox.
Engine codes AGU ARZ AUM ARX
Manufactured from 02.98 05.99 08.00 09.00
to 08.00
Displacement l 1.781 1.781 1.781 1.781
Power output kW at rpm 110/5700 110/5700 110/5700 110/5700
Torque Nm at rpm 210/1750... 210/1750... 210/1750... 210/1750...
4600 4600 4600 4600
Bore ∅ mm 81.0 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4 86.4
Compression ratio 9.5 : 1 9.5 : 1 9.5 : 1 9.5 : 1
Fuel - RON minimum 95 95 95 95
unleaded1) unleaded1) unleaded1) unleaded1)
Fuel injection /ignition system Motronic Motronic Motronic Motronic
Knock control yes yes yes yes
Self-diagnosis yes yes yes yes
Lam da control 1 lam da 2 lam da 2 lam da 2 lam da
pro e pro es pro es pro es
Catalytic converter yes yes yes yes
Tur ocharging yes yes yes yes
Secondary air injection system no yes yes yes
Camshaft adjustment no no yes yes
Complies with emission limits EU-2/D32) EU-2/D32) EU-4 EU-3
Technical data
Engine number
KThe engine num er (engine code and con-
secutive num er) is located on the front of the
engine/gear ox joint.
In addition, a sticker with engine code and con-
secutive num er is affixed to the toothed elt
guard.
The engine code is also listed on the vehicle
data sticker.
Engine eatures
ProCarManuals.com

OCTAVIA
00 Technical Data
Edition 08.98
S00.5123.50.20
------------ 00-2 -------------
Code letters AGU
Valve timing
at 1 mm valve stroke and 0 mm valve
clearance
Inlet opens after TDC 18°
Inlet closes after BDC 28°
Ex aust opens before BDC 28°
Ex aust closes before TDC 8°
ProCarManuals.com

OCTAVIA  

S00.5123.51.20
------------



-------------
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

♦Workshop crane, (e.g. V.A.G 1202 A)
♦Drip tray, (e.g. V.A.G 1306)
♦Torq e wrench
♦Engine/gearbox jack, (e.g. V.A.G 1383 A)
♦Pliers for spring strap clips
♦Engine holder T10012
♦Engine holder MP 1-202
♦Holder MP 1-224
♦Repair stand MP 9-101
♦S spension device MP 9-201
♦Grease G 000 100
(models with man al gearbox)
♦Hot bolt paste G 052 112 A3
♦Bolt M10 x 25/8.8
♦Cable straps
♦Wire
♦Adhesive tape

Notes:
♦The engine is lifted up and out 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 by spring strap clips
or screw-type clips.
ProCarManuals.com

OCTAVIA
 

S00.5123.51.20
------------




-------------
♦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.

- On models fitted with coded radio set, pay
attention to coding; determine if necessary.
- Switch ignition off and disconnect earth strap
of battery.
- Remove engine
⇒Body Fitting Wor ; Repair Group 55.
K- Remove top engine trim panel -arrows-.
K- Remove inta e manifold trim panel -arrows-
- Drain coolant
⇒1.8 l/92 W Engine - Mechanical Compo-
nents; Repair Group 19.
K- Open cover of fuse holder on battery and
disconnect cable -arrow-.
- Remove battery and battery rac
⇒Electrical System; Repair Group 27.
- Remove air filter together with inta e hose
⇒1.8 l/110 W Engine - Motronic Fuel Injec-
tion and Ignition System; Repair Group 23.
- Remove inta e hose from air filter up to tur-
bocharger (detach hoses and connectors as
necessary) ⇒ page 21-1.
ProCarManuals.com

OCTAVIA  

S00.5123.51.20
------------

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Note:
Do not depress clutch pedal!
ProCarManuals.com

OCTAVIA
 

S00.5123.51.20
------------


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ProCarManuals.com

OCTAVIA  

S00.5123.51.20
------------



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ProCarManuals.com

OCTAVIA
 
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ProCarManuals.com

OCTAVIA  

S00.5123.51.20
------------
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Engine and gearbox must be guided with care
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ProCarManuals.com

OCTAVIA
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
S00.5123.51.20
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The engine must be attached to the repair stand
MP 9-101 with engine holder MP 1-202 for car-
rying out removal and installation operations.
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- etach gearbox from engine.
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- Unscrew nuts of torque converter and se-
cure to prevent it dropping out.
- etach hoses from ATF cooler.
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- Attach engine to repair stand MP 9-101 with
engine holder MP 1-202.
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Notes:
♦Always replace sealing rings and gaskets
when carrying out removal and installation
operations.
♦Always replace self-locking nuts.
♦Coat stud bolts at turbocharger with hot bolt
paste G 052 2 A3.
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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.
K- Attach intermediate plate to sealing flange
and push onto the dowel sleeves -arrows-.
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- Inspect centering of clutch driven plate, if
necessary.
- Inspect clutch release bearing for wear, re-
place if necessary.
- Apply a thin film of grease G 000 100 to the
spline of the input shaft.
ProCarManuals.com

OCTAVIA Removing and Installing Engine 10
Edition 04.01
S00.5123.51.20
------------ 10-9 -------------
- Adjust shift cables:
⇒5-Speed Manual Gearbox 02J; Repair
Group 4.
Models fitted with automatic gearbox
- Replace lock washer at support of selector
lever cable.
- Install selector lever cable at gearbox, ad-
just if necessary:
⇒Automatic Gearbox; Repair Group 7.
Continued for all models
- Run past pressure line of power steering at
gearbox.
K- Align engine in transverse direction so that
a clearance -a- of about 10 mm exists be-
tween engine mount -1- and engine support
bracket.
- When bolting together engine mount and
engine support bracket, these components
must not be twisted relative to each other
(align parallel).
Tightening torques ⇒ page 10-11.
Models fitted with AC
- Install AC compressor
⇒Heating, Air Conditioning; Repair Group 87.
Continued for all models
- Install power steering hydraulic pump
⇒Running Gear; Repair Group 48.
- Install hoses for charge air system ⇒ page
21-1.
- Install coolant hoses ⇒ page 19-1.
- Inspect oil level before starting engine.
- Electrical connections and routing of wiring
⇒Current Flow Diagrams, Electrical Fault
Finding, Fitting Locations.
-Engine code AGU - Adjust throttle cable
⇒1.8 l/92 kW Engine - Mechanical Compo-
nents; Repair Group 20.
ProCarManuals.com

OCTAVIA
10 Removing and installing the engine
Edition 06.02
S00.5123.52.20
------------ 10-10 -------------
Note:
Additional work has to be undertaken when dis-
connecting and reconnecting the battery
⇒ Electrical System, Rep. Gr. 27.
Tightening torques
Notes:
♦ightening torques are valid for lightly
greased, oiled, phosphated or blackened
nuts and screws.
♦Additional lubricants such as engine oil and
gearbox oil are allowed but Molykote should
never be used.
♦Do not use any degreased parts
♦he tolerance for the tightening torques is
± 15%
Component Nm
Screws / nuts M6 9
M7 13
M8 20
M10 40
M12 70
of which are deviating:
Engine ount, trans ission ount, ⇒ Asse bly
rocking support ount
Propeller shaft on the jointed flange/ ⇒ Chassis
trans ission Rep. Gr. 40
Bolts connecting the engine to the trans ission
⇒ 5-speed anual gearbox 02J, Rep. Gr. 34
⇒ 5-speed anual gearbox 02C, Rep. Gr. 34
⇒ auto atic gearbox, Rep. Gr. 37
ProCarManuals.com

OCTAVIA Removing and Installing Engine 10
Edition 04.01
S00.5123.51.20
------------ 10-11 -------------
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mounting
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KEngine mounting
1 - 40 Nm + 90° (1/4 turn)1)
2 - 25 Nm
3 - 100 Nm1)
1) Replace bolts
K
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1 - 40 Nm + 90° (1/4 turn)1)
2 - 25 Nm
3 - 100 Nm1)
1) Replace bolts
K
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1 - 40 Nm + 45° (1/8 turn)1)
2 - 40 Nm + 45° (1/8 turn)1)
3 - 20 Nm + 90° (1/4 turn)1)
1) Replace bolts
ProCarManuals.com

OCTAVIA
10 Removing and Installing Engine
Edition 08.98
S00.5123.50.20
------------ 10-12 -------------
K 
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Note:
Use ladder, e.g. VAS 5085, for removing the
securing bolts.
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Note:
Engine and gearbox must be guided carefully
hen lo ering in order to avoid damage to the
body ork.
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