Skoda OCTAVIA Instruction manual
Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5110.52.20 Edition 0 .98
1.9-ltr./66 kW (TDI) Engine,
Mechanical Components
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
Service
List of Supplements to
OCTAVIA Workshop Manual dition: 04.04
1.9 l/66 kW (TDI) ngine, Mechanical Components
Replaces List of Supplements - dition: 11.02
Supple- dition Subject Article Number
ment
08.96 Basic dition S00.5110.50.20
1 11.96 Supplement to Basic dition S00.5110.51.20
2 03.98 Modifications to ngines from 08.97 S00.5110.52.20
3 06.99 Supplement for 4 x 4 Models S00.5110.53.20
4 03.00 Modifications to Repair Groups 10, 13, 15, 19, 21, 26 S00.5110.54.20
5 05.01 Modifications to Vehicles MJ01 S00.5110.55.20
6 11.02 Modifications to Repair Groups 00, 10, 13, 15, 17, S00.5110.56.20
19, 20
7 04.04 Modifications to Repair Groups 10, 13, 15, 17, 19, S00.5110.57.20
21, 26
8
9
10
11
12
13
14
15
16
17
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.
© 2004 KODA AUTO a. s.
Printed in CR
S00.5110.57.20
dition 04.04
S00.5110.57.20
------------
I ------------
OCTAVIA Service
Contents
00 Technical Data Page
Technical data .............................................................................................................................. 00-1
! ) !
! ) !
10 Removing and installing ngine Page
Removing and installing engine ................................................................................................ 10-1
! # !
! * !
! + !
! , !-
! *./ !
! )./ !0
13 Crank Assembly Page
Disassembling and assembling engine .................................................................................... 13-1
! #1! 2!
! # 2!-
! +! 2!
! $ (# 2!
Removing and installing crankshaft.......................................................................................... 13-12
! $!! 2!
! # 2!0
! ## 2!0
! # 2!3
Disassembling and assembling pistons and connecting rod ................................................ 13-21
! +4 ( 2!-
15 Cylinder Head, Valve Gear Page
Removing and installing cylinder head..................................................................................... 15-1
! # !-
! + !0
! !3
Servicing valve gear .................................................................................................................... 15-10
! 5## !
! +## !-
! ## !-
! # !0
! +$ !3
! ## !6
17 Lubrication System Page
Removing and installing parts of the lubrication system ....................................................... 17-1
! ( !
! # !2
! !
Service OCTAVIA
dition 04.04
S00.5110.57.20
------------
II ------------
19 Cooling System Page
Removing and installing parts of the cooling system ............................................................. 19-1
! 6!
! 6!
! 6!-
! ( 6!2
! # 6!
! # 6!
! +$ 6!3
! # 6!6
! # 6!
20 Fuel Supply System Page
Removing and installing parts of the fuel supply system ....................................................... 20-1
! #$ !
! # !
! $ !2
! !2
! # !-
! #$ !-
Removing and installing parts of the fuel supply system - 4 x 4 models .............................. 20-6
! #$!-/- !0
! #!-/- !3
! #$!-/- !6
21 Turbocharging Page
Charge air system with turbocharger ........................................................................................ 21-1
! !
! #*5 !
! #*78 !2
! !-
! ## !
! # !0
! # !6
! # !
26 xhaust system Page
Removing and installing parts of the exhaust system ............................................................ 26-1
! 0!
! */ 0!2
Removing and installing parts of the exhaust system - 4 x 4 models ................................... 26-4.1
! !-/- 0!-
xhaust gas recirculation system ............................................................................................. 26-5
! / 0!
! /## 0!
! #/ 0!3
OCTAVIA Technical Data 00
Edition 11.02
S00.5110.56.20
------------
00-1 -------------
Technical data
Engine number
KThe engine number (engine code and serial
number) is located at the front at the connec-
tion of the engine gearbox.
In addition, a sticker with engine code and se-
rial number is affixed to the toothed belt guard.
The engine code is also indicated on the vehi-
cle data stickers.
Engine features
Engine code AGR ALH
Manufactured 10.96 ä08.00 ä
Displacement l 1.896 1.896
Power output kW at rpm 66 4000 66 3750
Torque Nm at rpm 210 1900 210 1900
Bore ∅ mm 79.5 79.5
Stroke mm 95.5 95.5
Compression ratio 19.5 : 1 19.5 : 1
min. CN 49 49
Injection order 1-3-4-2 1-3-4-2
Catalytic converter yes yes
Exhaust gas recirculation yes yes
Turbocharging yes yes
Charge air cooling yes yes
Complies with emission limits EU2 EU3
OCTAV1ARemoving and Installing Engine 10
Edition 04.04
S00.5110.57.20
Removing and installing engine
Special tools, testers and aids required
♦"$91*5*'
♦91*520'
♦,
♦
♦):!
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♦;:/.33
♦)./4$91*5232*'
♦(91*3'
♦7#:6!
♦55
♦
♦"
♦*#
Removing
Notes:
♦The engine is removed downwards together
with the gearbox.
♦All cable straps that have to be loosened
when the engine was removed must be fitted
again in the same location.
♦The hose connections are secured with
screw-type clips, spring-type clips or clamp-
type clips.
♦Always replace clamp-type clips with spring-
type clips or screw -type clips.
♦Fuel lines at the engine must only be secured
with spring-type clips. The use of clamp-type
or screw-type clips is not allowed.
♦Use pliers for spring strap clips for installing
the spring strap clips.
------------
10-1 ------------
OCTAVIA
10 Removing and Installing Engine
------------
10-2 ------------ Edition 03.98
S00.5110.52.20
♦Pay attention to the correct assignment of
the connectors; mark if necessary.
Procedure
K
! "
#$
K%
Warning!
On no account may the arms of the lift platform be
positioned below the sills, the front or rear sus-
pension.
K%&"
"
Warning!
Never start the engine when the vehicle is raised
and engage a gear so long as only one driven gear
is making contact with the ground.
OCTAVIA Removing and Installing 10
Edition 03.00
S00.5110.54.20
------------
10-3 ------------
KThe two rear jacking points are located at the
rear longitudinal members at the level of the
marking at the sill.
K- Remove noise insulation panel in the middle
and also on the left and right -arrows-.
- Open cap of coolant expansion reservoir.
K- Turn drain plug -arrow- at the radiator to the
left or fit hose onto connection, as appropri-
ate.
OCTAVIA
10 Removing and Installing
Edition 03.00
S00.5110.54.20
------------
------------
K
K
K ! " "
OCTAVIA Removing and Installing Engine 10
Edition 03.98
S00.5110.52.20
------------
------------
K
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Models with air conditioning
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OCTAVIA
10 Removing and Installing Engine
Edition 05.01
S00.5110.55.20
------------
10-6 ------------
Models fitted with manual gearbox
K
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K
K "#
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Note:
Do not depress clutch pedal.
OCTAVIA Removing and Installing Engine 10
Edition 05.01
S00.5110.55.20
------------
------------
K
Models fitted with automatic gearbox
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OCTAVIA
10 Removing and Installing Engine
Edition 05.01
S00.5110.55.20
------------
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OCTAVIA Removing and Installing Engine 10
Edition 05.01
S00.5110.55.20
------------
------------
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Note:
Before removing the ribbed V-belt, mark direc-
tion of running. If an already used belt is fitted
on to run in the opposite direction, it may be
destroyed. When installing the belt, ensure that
it is correctly located in the belt pulleys.
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OCTAVIA
10 Removing and Installing Engine
Edition 05.01
S00.5110.55.20
------------
10-10 ------------
Models fitted with air conditioning
K
Note:
Protect bumper with adhesive tape from
scratches.
Warning!
Refrigerant circuit of air conditioning system must
not be opened.
Continued for all models
K
4 x 4 models
⇒
!"#$
Models with heavy duty cooling system
%
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Continued for all models
⇒
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OCTAVIA Removing and Installing Engine 10
Edition 05.01
S00.5110.55.20
------------
10-11 ------------
Note:
Use a ladder, e.g. V.A.S 5085, to remove the
bolts attaching the engine and gearbox brack-
ets.
K
K
Note:
It is essential to have a second person g ide
the engine/gearbox assembly when lowering it
in order to avoid any damage to the body be-
ca se of the tight clearance. At the same time,
ens re that the boots of the joint shafts are not
damaged.
Models fitted with automatic gearbox
K
!
"#
$
%
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Continued for all models
#
&
OCTAVIA
10 Removing and Installing Engine
Edition 05.01
S00.5110.55.20
------------
10-12 ------------
engine to
stand
The engine should be attached with the engine
holder MP 1-202 to the repair stand for carrying
out removal and installation operations.
Note:
The engine must not be attached to the repair
stand for measuring the cylinder bore ⇒ page
13-23.
K- Attach suspension device MP -201 to the
plates at the engine and take up weight of
engine with a workshop crane, e.g. V.A.G
1202 A:
♦Belt pulley side:
2nd hole in rail - item 1
♦Flywheel side:
2nd hole in rail - item 7
Warning!
Use locking pins at the hooks and at the rig pins
to prevent them slipping out.
- Attach engine to repair stand with engine
holder MP 1-202.
Installing
Notes:
♦Always install new seals and gaskets when
carrying out removal and installation work.
♦Always install new self-locking nuts.
Installation is carried out in the reverse order;
pay attention to the following points:
- Check whether dowel sleeves for centering
engine/gearbox are inserted in the cylinder
block.
K- Attach intermediate plate to sealing flange
and push onto the dowel sleeves -arrows-.
- Check centering of the clutch driven plate.
- Check clutch release bearing for wear, re-
place if necessary.
- Apply a thin film of grease G 000 100 to the
splines of the input shaft.
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