Skoda OCTAVIA Instruction manual
Service
Workshop Manual
OCTAVIA
Service Department. Technical Information
S00.5127.50.20 E ition 08.99
2.0-ltr./85 kW 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.
© 1999 KODA AUTO a. s.
Printed in CR
Service
List of Supplements to
Workshop Manual OCTAVIA Edition: 04.03
2.0 l/85 kW En ine, Mechanical Components
Replaces List of Supplements - Edition: 01.02
Supple- Edition Subject Article Number
ment
08.99 Basic Edition of Workshop Manual S00.5127.50.20
1 12.99 Modifications for En ine Code Letters APK S00.5127.51.20
2 02.01 Supplement for 4x4 Models S00.5127.52.20
3 01.02 Modifications to en ine identification characters S00.5127.53.20
AEG, AZJ
4 04.03 Modifications to en ine identification characters S00.5127.54.20
AZJ
5
6
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 onto
third persons.
© 2003 KODA AUTO a. s.
Printed in CR
S00.5127.54.20
Edition 04.03
S00.5127.54.20
------------
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
# % #
# #
# , #
# - . #
# "/ #0
# +- . #
13 Crank Assembly Pa e
Disassemblin and assemblin en ine .................................................................................... 13-1
# % 1# 2#
# %3 2#
# ,# ! 2#
Removin and installin sealin flan e and flywheel ............................................................. 13-13
# &# !# 2#
# % 2#4
# %% 2#
Removin and installin crankshaft.......................................................................................... 13-23
Disassemblin and assemblin pistons and connectin rod ................................................ 13-25
15 Cylinder Head, Valve Gear Pa e
Removin and installin cylinder head..................................................................................... 15-1
# %! #
# ,! #4
# &!5 #4
# " #6
Service valve ear ....................................................................................................................... 15-11
# #
# % #0
# ,! & #4
# %% #6
# ,%% #
# %% #
# &%% #
17 Lubrication System Pa e
Removin and installin parts of the lubrication system ....................................................... 17-1
# * #
# % #2
# " #
# % . #4
# * . #
Service OCTAVIA
Edition 04.03
S00.5127.54.20
------------
II ------------
19 Coolin System Pa e
Removin and installin parts of the coolin system ............................................................. 19-1
# ! 6#
# *! 6#
# ,!& 6#
# % 6#0
# % 6#
# %3 6#
# , 6#2
20 Fuel Supply System Pa e
Removin and installin parts of the fuel supply system ....................................................... 20-1
# %& #
# !&!! #
# #
# %%! #
# % #0
# %& #0
# #4
# " #6
# "%! #
# %%! #
# % #2
# 7 #2
Removin and installin parts of the fuel supply system for 4 x 4 Models .......................... 20-15
# %&.8 #
# %.8 #
# %&.8 #6
26 Exhaust System Pa e
Removin and installin parts of the exhaust system ............................................................ 26-1
# +.3.!% 0#
# 0#
# %. 0#2
# 0#
# .! 0#0
# ,.!& 0#
Removin and installin parts of the exhaust system for 4 x 4 Models ................................ 26-7.1
# +.3.!% 0#
# 0#
# .8 0#2
# ,!%9!:;3<=3<>) 0#4
Secondary air injection system (only for en ines AQY, AZH, AZJ) ........................................ 26-10
# ? 0#
# %!7! 0#
# " %% 0#
# "! 0#2
# "!7%%#@# 0#
# % %% 0#
OCTAVIA Technical Data 00
Edition 01.02
S00.5127.53.20
------------
00-1 -------------
Engine features
Engine code AEG APK AQY AZH AZ
Manufactured 09.01 ä03.00 ä04.99 ä 02.02 05.00 ä 02.02 02.02 ä
Displacement ltr. 1.984 1.984 1.984 1.984 1.984
Power output kW at rpm 85 5400 85 5200 85 5200 85 5400 85 5400
Torque Nm at rpm 165 2800 170 2400 170 2400 170 2400 172 3200
Bore ∅ mm 82.5 82.5 82.5 82.5 82.5
Stroke mm 92.8 92.8 92.8 92.8 92.8
Compression ratio 10 : 1 10.5 : 1 10.5 : 1 10.5 : 1 10.5 : 1
Fuel - RON min. min. 87 leaded 95 unleaded1) 95 unleaded1) 95 unleaded1) 95 unleaded1)
unleaded
Fuel injection ignition M3.8.3 M5.9.2 M5.9.2 ME 7.5 ME 7.5
system
Knock control yes yes yes yes yes
Lambda control 1 lambda 1 lambda 2 lambda 2 lambda 2 lambda
probe probe probes probes probes
Catalytic converter yes yes yes yes yes
Exhaust gas no no no no no
recirculation
Turbocharger no no no no no
Secondary air injection no no yes yes yes
system
Intake manifold no no no no yes
changeover
Camshaft adjustment no no no no no
Complies with emission TIER-1 EU-2 EU-4 EU-3 EU-4 EU-4
limits conforming to and D-42)
Technical data
Engine number
KThe 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.
The engine code is also additionally stated on
the data sticker.
1) In exceptional cases at least 91 RON, but engine power output reduced
2) Applies to models fitted with automatic gearbox
OCTAVIA Removing and Installing Engine 10
Edition 08.99
S00.5127.50.20
------------
10-1 -------------
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)
♦Engine/gearbox jack (e.g. V.A.G 1383 A)
♦Pliers for spring strap clamps
♦Engine holder T10012
♦Spacer sleeves T30010
♦Engine holder MP 1-202
♦Repair stand MP 9-101
♦Suspension device MP 9-201
♦Grease G 000 100
(models ith manual gearbox)
♦Hot bolt paste G 052 112 A3
♦Bolt M 10x25/8.8
♦Wire
♦Adhesive tape
Removing engine
Notes:
♦The engine is removed downward together
with the gearbox.
♦Hose connections are secured by screw-
type, 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 by spring strap clamps. It is not permit-
ted to use collar screw-type clamps.
OCTAVIA
10 Removing and Installing Engine
Edition 08.99
S00.5127.50.20
------------
10-2 -------------
♦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
K
!"
#!
!$
% $ !
⇒&"'
(
)
K *!
!
Warning!
The arms must on no account be positioned be-
low the sill, or the front and rear axles.
K *$
Warning!
Never start the engine and engage a gear when
the vehicle is raised so long as only one driven
wheel is still touching the ground.
OCTAVIA Removing and Installing Engine 10
Edition 02.01
S00.5127.52.20
------------
10-3 -------------
KThe 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.
K- Remove middle noise insulation panel -ar-
rows-. First of all remove air ducts on out-
side.
- Unbolt heat shield for right drive shaft.
- Remove drive shafts
⇒Running Gear Repair Group 40 Remov-
ing and installing drive shaft.
- Remove front exhaust pipe ⇒ page 26-1.
Note:
Avoid an excess of deflection of the decoupling
element at the front exhaust pipe (max. 10°).
4x4 models
- Detach prop shaft from gearbox
⇒5-Speed Manual Gearbox 02C Repair
Group 39 Removing and installing prop-
shaft.
Continued for all models
K- Unscrew the protective cover -arrows- and
separate the plug connection (black) -1- to
the catalytic converter lambda probe -G39-.
- Unclip the cable to the lambda probe from
the guides.
OCTAVIA
10 Removing and Installing Engine
Edition 08.99
S00.5127.50.20
------------
-------------
!"
"
#
$
K
%
&
&
#
#
&
'
(
"
#
)
""
K
*
)
"
#
#
+
#
&
,
+$
,
+$
'
⇒
-
.
"
+(
,
&
/
0
(
,
+$
#
"
,
+$
'
+
"
"1
K
2
'
"
#
#
"
"
#
/
#
+
"
,
+$
&
&
#
+
$
$
&
#
34
#
.
""
$
$
&
"
5&
'
#
&
!
2
$&&+
"
&
""&
&
6
"
"
+
'
+
#
5&1
7
+
OCTAVIA Removing and Installing Engine 10
Edition 08.99
S00.5127.50.20
------------
10-
-------------
K
Note:
Seal off the intake passages in the bottom part
of the intake manifold with a clean cloth.
!
"
K
#
#
$
K
#
%
#
$
&
'
(
OCTAVIA
10 Removing and Installing Engine
Edition 08.99
S00.5127.50.20
------------
-------------
K
Warning!
Fuel feed line is pressurized! Place cleaning cloths
around the connection point before detaching the
hose connections. Then, release pressure by care-
fully detaching the hose.
K
!
"
#$%
!
$
&
'"%
'""
!
(
)
K
!
(
(
*
"%+,
-
.
!
-
/
0
(
"
OCTAVIA Removing and Installing Engine 10
Edition 08.99
S00.5127.50.20
------------
10-
-------------
K
!
"
#
$
%
&
'
(
)
*
+,
-
.
/
01231
*
4)15
6
'7
K
8
9
K
:
$
#
%
#
%
9
:
9
OCTAVIA
10 Removing and Installing Engine
Edition 08.99
S00.5127.50.20
------------
10-8 -------------
K
Note:
Do not depress clutch pedal.
Models with automatic gearbox
K
K
OCTAVIA Removing and Installing Engine 10
Edition 08.99
S00.5127.50.20
------------
10-
-------------
Models with air conditioning
Warning!
The refrigerant circuit of the air conditioning sys-
tem must not be opened.
K
!
Note:
Use adhesive tape to protect bumper from
scratches.
Continued for all models
K
"
#
$
%
$
"
&
"
$
'
(
)
⇒
&
K
%
*
$
(
+
OCTAVIA
10 Removing and Installing Engine
Edition 08.99
S00.5127.50.20
------------
10-10 -------------
K
!"!#
K
$
%
&
'
()
*
%
!"!#
K
'
+
'
Note:
Use ladder, e.g. VAS 5085, to remove the bolts
attaching the engine mount.
OCTAVIA Removing and Installing Engine 10
Edition 08.99
S00.5127.50.20
------------
10-11 -------------
K
Note:
It is important to carefully guide the engine and
gearbox when lowering in order to avoid dam-
aging the body.
!
"#
engine to
$%&
!
$
stand
'
()*
+,+
-
./01
2
3.1
K
4
5
6
7
8
9
+:;:9<
=
5
4
5
)
>
/
2
1
?
@A
B
C
D
E3
C
/FE
C
B
0G1E.
H
/I
J
K
L
9'M
K
OCTAVIA
10 Removing and Installing Engine
Edition 08.99
S00.5127.50.20
------------
-------------
K
!"
#
$%&
#
'
(
(
)
*
+
),
,
-
.
-'
(
/
0
12
3
-
3
4
3
3
5&676
8
*
*'
1
'
2
3
-
3
4
3
3
5&$%$
8
3
9
)
))
:
;
6
'
)
,
'
)
$
<)
:*
)
;
6
'
,
'
)
7
Warning!
Insert locking studs at the hooks and pins.
Notes:
♦The positions for inserting the pins in the sup-
porting arm, marked with 1...4, point toward
the belt pulley.
♦The holes in the rails are counted from the
hook.
K
-
*
-
-'
(
/
)
'
!&
#
$%$
'
)
=6%%&%
'
'
!"
#
&%&
3
Installing engine
Notes:
♦Always replace seals and gaskets when car-
rying out removal and installation operations.
♦Always replace self-locking nuts.
♦Coat stud bolts at e haust manifold with hot
bolt paste G 052 112 A3.
♦Aligning unit mounting for engine and gear-
bo ⇒ page 10-15.
♦Tightening torques ⇒ page 10-16.
♦Unit mounting ⇒ page 10-17.
>
?
@
))
''
'''
'
3
!
:
,
))
*
-
;
A
1
*
'
*
)
)
,
'
'
-
-
.
-'
(
/''
:
)
'
()
1
B
'
,
':
3
Other manuals for OCTAVIA
29
Table of contents
Other Skoda Automobile manuals
Skoda
Skoda OCTAVIA Instruction manual
Skoda
Skoda OCTAVIA Instruction manual
Skoda
Skoda OCTAVIA User manual
Skoda
Skoda SUPERB B82017 User manual
Skoda
Skoda 105 s 1980 Instruction manual
Skoda
Skoda SUPERB User manual
Skoda
Skoda Scala 2019 User manual
Skoda
Skoda SUPERB User manual
Skoda
Skoda 2009 Yeti User manual
Skoda
Skoda OCTAVIA Instruction manual
Skoda
Skoda 2009 Yeti User manual
Skoda
Skoda 2000 Fabia User manual
Skoda
Skoda OCTAVIA RS User manual
Skoda
Skoda ROOMSTER - 05-2009 User manual
Skoda
Skoda Rapid Spaceback User manual
Skoda
Skoda FABIA - 05-2007 User manual
Skoda
Skoda 2000 Fabia Instruction manual
Skoda
Skoda YETI - ANNEXE 791 User manual
Skoda
Skoda Citigo User manual
Skoda
Skoda OCTAVIA Instruction manual
Popular Automobile manuals by other brands
Chrysler
Chrysler RAM TRUCK 2500 1994 Service manual
Hyundai
Hyundai ELANTRA Quick reference guide
Toyota
Toyota 4RUNNER 2010 Quick reference guide
Jeep
Jeep Compass 2015 Operating information
Mercedes-Benz
Mercedes-Benz A-Class AMG 2020 Operator's manual
Toyota
Toyota 2010 AURIS HYBRID installation instructions
