Skoda OCTAVIA Instruction manual
Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5104.50.20 Edition 08.96
1.8 ltr. / 92 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: 04.03
1.8 l/92 kW En ine, Mechanical Components
Replaces List of Supplements - Edition: 02.02
Supple- Edition Subject Article Number
ment
08.96 Basic Edition Workshop Manual S00.5104.50.20
1 11.96 Supplement to Basic Edition S00.5104.51.20
2 08.98 Modifications with effect from 08.97 S00.5104.52.20
3 10.99 New Coolants; New Sealin Materials S00.5104.53.20
4 04.01 Modifications to Repair Groups 10, 13, 15, 17 and 20 S00.5104.54.20
5 02.02 Modifications to Repair Groups 00, 10, 13, 15, 17, S00.5104.55.20
19 and 26
6 04.03 Modifications to Repair Groups 13, 15 and 17 S00.5104.56.20
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Contents ⇒next pa e.
The Service Manual is intended only for use within the
koda Or anisation; it is not permitted to pass it on to
third persons.
© 2003 KODA AUTO a. s.
Printed in CR
S00.5104.56.20
Edition 04.03
""""""""""""
I """"""""""""
OCTAVIA Service
Contents
00 Technical Data Pa e
Technical data .............................................................................................................................. 00-1
" * "
" * "
10 Removin and Installin En ine Pa e
Removin and installin en ine ................................................................................................ 10-1
" $ "
" + "
" , "
" !- "
" +./ "
" *./ "
13 Crank Assembly Pa e
Disassemblin and assemblin en ine .................................................................................... 13-1
" $0" 1"
" $2 1"
Removin and installin sealin flan e and flywheel ............................................................. 13-10
" %" 1"
" $ 1"1
" $$ 1"
" $ 1"
Removin and installin crankshaft.......................................................................................... 13-18
Disassemblin and assemblin pistons and connectin rod ................................................ 13-20
15 Cylinder Head, Valve Gear Pa e
Removin and installin cylinder head ..................................................................................... 15-1
" $ $ "
" $ "
" , "3
" % "3
" , "4
" ! "
Service valve ear ....................................................................................................................... 15-12
" ,/ "
" $5 "
" "
" 0$ "6
" , % "6
" $$ "3
" ,$$ "1
" %$$ "1
17 Lubrication System Pa e
Removin and installin parts of the lubrication system ....................................................... 17-1
" ) 6"
" ) 6"
" $ 6"
" ! 6"3
Service OCTAVIA
Edition 04.03
""""""""""""
II """"""""""""
19 Coolin System Pa e
Removin and installin parts of the coolin system ............................................................. 19-1
" 4"
" ) 4"1
" $ 4"
" $2 4"
" , 4"6
" , % 4"3
" $ 4"4
20 Fuel Supply System Pa e
Removin and installin parts of the fuel supply system ....................................................... 20-1
" $% "
" % "
" "
" $$ "
" $ "
" $% "
" "3
" ! "4
" !$ "
" $$ "
" $ "
" +5 "1
26 Exhaust System Pa e
Removin and installin parts of the exhaust system ............................................................ 26-1
" + $$/ "
" $/ "
" $/ "1
" "
" +/ "
" ,/ % "
OCTAVIA Technical Data 00
Edition 02.02
S00.5104.55.20
------------
00-1 ------------
Technical data
Engine number
KThe 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.
The engine code is also listed on the vehicle
data sticker.
Engine features
Engine code AGN
anufactured 08.96 ä 07.97 08.97 ä 05.99
Displacement I 1.781
Power output kW at rpm 92/6000
Torque Nm at rpm 173/4100 170/4200
Bore Ø mm 81
Stroke mm 86.4
Compression ratio 10.3:1
min. RON 95 unleaded1)
Fuel injection / ignition system Bosch otronic
Knock control yes
Self-diagnosis yes
Lambda control yes
Catalytic converter yes
Turbocharger no
Exhaust gas recirculation no
Camshaft adjustment yes
Intake manifold changeover no yes
1) In exceptional cases at least 91 RON, although engine power output is reduced.
OCTAVIA
00 Technical Data
------------
00-2 ------------ Edition 10.99
S00.5104.53.20
OCTAVIA Removing and Installing Engine 10
Edition 10.99
S00.5104.53.20
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 rench 5...50 Nm
(e.g. V.A.G 1331)
♦Torque rench 40...200 Nm
(e.g. V.A.G 1332)
♦Pliers for spring strap clamps
♦Engine holder MP 1-202
♦Engine holder T10012
♦Bolt M10 x 25/8.8
♦Engine/gearbox jack, e.g. V.A.G 1383 A
♦Ladder (e.g. V.A.S 5085)
♦Holder MP 1-224
♦Suspension device MP 9-201
♦Grease G 000 100
(models ith manual gearbox)
♦Hot bolt paste G 052 112 A3
♦Cable straps
♦Wire
♦Adhesive tape
Removing engine
Notes:
♦The engine is removed downward together
with the gearbox.
♦All the cable straps which have been
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
clamps 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.
------------
10-1 ------------
OCTAVIA
10 Removing and Installing Engine
Edition 10.99
S00.5104.53.20
♦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
Models ä 07.97
!
K "
Models 08.97 ä
K "
!
Continued for all models
"
#
K$
Warning!
The arms of the lift platform must on no account
be positioned below the sills, the front axle or rear
axle.
$%
Warning!
Never start the engine and engage a gear when
the vehicle is raised so long as even only one
driven wheel is touching the ground.
------------
10-2 ------------
OCTAVIA Removing and Installing Engine 10
Edition 11.96
S00.5104.51.20
------------
10-3 ------------
KThe two rear jacking points are located at the
rear of both side members at the level of the
marking on the sill.
K- Remove noise insulation panel -arrow-.
- Open cap of coolant expansion tank.
- Place drip tray (e.g. V.A.G 1306) below the
engine.
K- Turn drain plug -arrow- at the radiator to the
left; fit auxiliary hose onto connection if ne-
cessary.
OCTAVIA
10 Removing and Installing Engine
Edition 10.99
S00.5104.53.20
------------
------------
K
K
!
"
#
$
%
&
'
(
)
*
+,
--
(
'
.
,
-
/
0
,
12&3
',
-
,
&3
,
34
!
56
!
#
!
7
89:;
<
&3
-
,
3=(
'+
&10
))
>&
'
(
)
*
K
!
#
#
?
!
7
7
8@"
A
;
#
!
8B"BC";
"
OCTAVIA Removing and Installing Engine 10
Edition 11.96
S00.5104.51.20
------------
------------
K- Unplug connector from the Hall sender (G40)
-arrow-.
K- 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).
- Detach vent hose -4- to the activated char-
coal filter.
- Detach connection hose -6-.
- Remove intake hose -5- between top part of
air filter and throttle valve control unit (J338).
K- Unplug connector -1- from the air mass me-
ter (G70).
- Slacken the securing bolts -2- and remove
air filter housing -3-.
OCTAVIA
10 Removing and Installing Engine
------------
------------ Edition 11.96
S00.5104.51.20
K- 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. Unbolt fixture.
K- Detach fuel feed pipe -1- and fuel return flow
pipe -2- (press release catches).
Important!
Fuel feed pipe is pressurised! Place cleaning rags
around the connection point before detaching the
hose connections. After this, release the pressure
by carefully detaching the hose.
K- Unplug the following electrical connections:
1 - Knock sensor I (G61) (black)
2 - Knock sensor II (G66) (brown)
3 - Engine speed sender (G28) (grey)
OCTAVIA
S00.5104.53.20
------------
------------
♦
♦
!
♦
"
♦
#
#
$%
♦
#
&
&
'(%
♦
)
)
&
*
%
+
"
,
%%
*
*
-
&
&
K -
.
/
#
-
#
0
.
/
0
/
&
/
1
/
*
-
#
0
.
*
&
#
2
#
/
3
&
4
#2
&
K
*
-
/
/
&
&
OCTAVIA
10 Removing and Installing Engine
------------
10-8 ------------ Edition 08.98
S00.5104.52.20
K- 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
K- Use a screwdriver to press selector lever
cable -1- off at the gearbox selector lever
-4-, pull off loc ing clasp -3- at the support
brac et.
- Ta e off selector lever cable and place to
the side.
K- Unplug the following connectors:
1 - to the solenoid valves (10-pin connectors)
2 - to the vehicle speed sender (G68)
3 - at the multifunction switch (F125)
4 - at the gearbox speed sender (G38)
- Unbolt brac et for pressure line -5- of the
power steering at the gearbox support.
- Detach wiring loom from the fixtures and run
out to the side.
OCTAVIA
S00.5104.53.20
K
!
"
#
$
%
&
"
'
(
)
(
##
*
$
#
⇒
!
+
$
!
,
K
#
#
-
%
$
$
./
,
%
#
'
0
,
#
#
%
1
1
%
%
.
%
(
0
,
#
1
%
%
#
1
2
,
------------
3
4
5
6
------------
K
!
7
#
&
"
'
+
"
'
8
"
'
(
9
"
(
(
%
OCTAVIA
10 Removing and Installing Engine
------------
10-10 ------------ Edition 08.98
S00.5104.52.20
Models with air conditioning
Warning!
The refrigerant circuit of the air conditioning sys-
tem must not be opened.
K- 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-.
Note:
Protect bumper from scratches with adhesive
tape.
All models
- Remove drive shaft cover.
- Remove catalytic converter ⇒ page 26-1.
K- Unbolt pendulum support -arrows-.
- Unbolt drive shafts from flange shaft of gear-
box.
- lace left drive shaft to the rear and secure
with wire.
- Remove right drive shaft:
⇒Running Gear; Repair Group 40; Servicing
drive shaft
- Insert engine holder T10012 into engine/
gearbox lift (e.g. V.A.G 1383 A).
K- Attach engine holder T10012 to the cylinder
block using the securing nut and M10 bolt,
tightened to a torque of about 40 Nm.
- Raise engine and gearbox slightly with en-
gine/gearbox lift (e.g. V.A.G 1383 A).
OCTAVIA Removing and Installing Engine 10
Edition 08.98
S00.5104.52.20
------------
10-11 ------------
K-
-
Note:
Use ladder (e.g. V.A.S 5085) for removing the
bolts.
K-
-
Note:
When lowering engine and gearbox, it is essen
tial to have the aid of a second mechanic to guide
the block in order to avoid damage to the body
work because of the narrow clearance. Pay at
tention to the drive shaft boots.
Models with automatic gearbox
-
-
K-
!
"
#$
-
%
All models
-
$
OCTAVIA
10 Removing and Installing Engine
------------
10-12 ------------ Edition 08.98
S00.5104.52.20
K-
-
K-
!
"
#
$
%
&
'
(
)
"
(
*
+
"
(
,
Warning
-
./
0
1
/
2
34
56
784
26
9.:7
;
0
1
/
1
33
5
.:7
;
9
6
7.
<
=
3
0
/.>
♦The insertion positions of the supporting arm
marked with 1...4 point toward the belt pul-
ley.
♦The holes in the rails are counted from the
hook.
?
@@
AB
CD
EF
engine to r
G
HA
D
I
stand
J
"
K
#
=
3
0
/>
The engine must not be attached to the repair
stand for measuring the cylinder bore (⇒ page
13-22).
Installing engine
=
3
0
/.>
♦lways replace seals and gaskets when car-
rying out removal and installation work.
♦lways replace self-locking nuts.
♦Coat stud bolts at exhaust manifold with hot
bolt paste G 052 112 3.
Other manuals for OCTAVIA
29
Table of contents
Other Skoda Automobile manuals
Skoda
Skoda 2009 Yeti User manual
Skoda
Skoda 2014 Rapid Spaceback User manual
Skoda
Skoda OCTAVIA User manual
Skoda
Skoda 2000 Fabia Instruction manual
Skoda
Skoda 2012 Citigo User manual
Skoda
Skoda 2009 Yeti User manual
Skoda
Skoda Fabia III 2015 Instruction manual
Skoda
Skoda SUPERB User manual
Skoda
Skoda ROOMSTER User manual
Skoda
Skoda 2011 Yeti User manual
Skoda
Skoda 2014 Rapid Spaceback User manual
Skoda
Skoda OCTAVIA Instruction manual
Skoda
Skoda Citigo User manual
Skoda
Skoda FABIA - ANNEXE 45 User manual
Skoda
Skoda FABIA RS - ANNEXE 118 User manual
Skoda
Skoda 2009 Yeti User manual
Skoda
Skoda OCTAVIA iV 2020 User manual
Skoda
Skoda ROOMSTER - 03-2010 User manual
Skoda
Skoda Enyaq iV User manual
Skoda
Skoda OCTAVIA - 05-2005 User manual
