SKODA OCTAVIA 1997 & ON 1.6 ENGINE REPAIR WORKSHOP MANUAL

Automated PDF to Text preview page 4 to 6:

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

List of Supplements

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

Table of Contents
00 ­ Technical Data
Technical Data .......................................................................................... 00-1 page 1

10 ­ Removing and Installing Engine
...........................................................Removing and installing engine - Part 1 10-1 - Removing engine ...................................................................................... 10-1 - Attaching engine to assembly stand ................................................................ 10-1 ...........................................................Removing and installing engine - Part 2 10-2 - Installing the engine ................................................................................... 10-2 - Align unit mounting for engine - gearbox .......................................................... 10-2 - Tightening torques .................................................................................... 10-2 - Assembly bracket ...................................................................................... 10-2 page page page page page page page page 1 1 8 1 1 3 3 4

13 ­ Crankgear
Disassembling and assembling engine ........................................................... 13-1 - Removing and installing V-ribbed belt .............................................................. 13-1 Removing and installing, tightening the timing belt ........................................... 13-2 - Summary of components ............................................................................. 13-2 - Removing toothed belt ................................................................................ 13-2 - Installing toothed belt, tensioning (setting timing) ................................................ 13-2 - Inspecting the semi-automatic timing belt tensioning pulley .................................... 13-2 Removing and installing sealing flange and pressure plate ................................. 13-3 - Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-3 - Removing and installing the front sealing flange ..............................
................... 13-3 - Removing and installing drive plate ................................................................ 13-3 Removing and installing crankshaft ............................................................... 13-4 Disassembling and assembling piston and conrod ............................................ 13-5 page page page page page page page page page page page page page 1 1 1 1 2 5 6 1 2 4 6 1 1

15 ­ Cylinder Head, Valve Gear
Removing and installing cylinder head ........................................................... 15-1 - Cylinder head - summary of components .......................................................... 15-1 - Removing and installing cylinder head ............................................................. 15-1 - Inspecting the cylinder head for distortion ......................................................... 15-1 - Reworking a cylinder head ........................................................................... 15-1 - Testing the compression ............................................................................. 15-1 Repairing Valve Gear .................................................................................. 15-2 Camshaft ................................................................................................. 15-3 - Replacing camshaft gasket ring ..................................................................... 15-3 - Removing and installing camshaft ..................
................................................ 15-3 Valve stem seals, valves guides, valve seats .................................................... 15-4 - Replacing valve stem seals .......................................................................... 15-4 - Inspect valve guides .................................................................................. 15-4 - Reworking valve seats ................................................................................ 15-4 page page page page page page page page page page page page page page 1 2 3 6 6 6 1 1 1 2 1 1 2 2

17 ­ Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1

Edition 11.04 S00.5134.52.20

Table of Contents

I

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components page page page 3 1 1

- Disassembling and assembling the oil filter holder .............................................. 17-1 Removing and installing oil pan .................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3

19 ­ Cooling
Parts of cooling system - Summary of components ........................................... 19-1 - Parts of the cooling system fitted to body ......................................................... 19-1 - Parts of cooling system engine side ................................................................ 19-1 - Connection diagram for coolant hoses ............................................................. 19-1 - Draining and filling up coolant ....................................................................... 19-1 - Removing and installing radiator .................................................................... 19-1 - Removing and installing coolant pump ............................................................ 19-1 Electronically controlled cooling system ......................................................... 19-2 - Operation ............................................................................................... 19-2 - Testing electronically controlled cooling system ...........
....................................... 19-2 - Disassembling and assembling coolant distributor housing .................................... 19-2 - Testing thermostat for map-controlled engine cooling ........................................... 19-2 page page page page page page page page page page page page 1 1 2 3 3 5 8 1 1 1 3 3

20 ­ Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 - Removing and installing the fuel tank with component parts and fuel filter .................. 20-1 - Safety precautions when working on the fuel supply system ................................... 20-1 - Rules of cleanliness ................................................................................... 20-1 - Removing and installing the fuel delivery unit .................................................... 20-1 - Removing and installing the fuel gauge sender .................................................. 20-1 - Removing and installing the fuel tank .............................................................. 20-1 - Connecting remote control ........................................................................... 20-1 - Disconnecting the fuel delivery unit with crash signal ........................................... 20-1 - Testing fuel pump .........................................................
............................ 20-1 - Inspecting fuel flow rate .............................................................................. 20-1 Inspecting the electronic power control (electronic throttle) ................................ 20-2 Activated charcoal filter system .................................................................... 20-3 - Operation ............................................................................................... 20-3 - Repairing parts of the activated charcoal filter system .......................................... 20-3 page page page page page page page page page page page page page page page 1 2 3 3 4 5 5 6 7 7 8 1 1 1 2

26 ­ Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Exhaust manifold, exhaust pipe with catalytic converter and attached parts ................ 26-1 - Silencer with hanger .................................................................................. 26-1 - Removing and installing front exhaust pipe ....................................................... 26-1 - Removing and installing exhaust manifold ........................................................ 26-1 - Replacing front or rear silencer ..................................................................... 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Secondary air system ................................................................................. 26-2 - Removing and installing parts of the secondary air injection system ..
....................... 26-2 Exhaust gas recirculation system .................................................................. 26-3 - Exhaust gas recirculation system - summary of components .................................. 26-3 page page page page page page page page page page page page 1 1 3 3 4 5 5 7 1 1 1 1

II

Table of Contents

Edition 11.04 S00.5134.52.20