Skoda Octavia Mk1 - 05 - Drive Unit

SKODA OCTAVIA MK1

Drive Unit1.6 ltr./74 kW Engine, Simos 2 injection and ignition system

1.6 ltr./74 kW Engine - Mechanical Components5Technical Data5Engine number5Engine characteristics6Engine assy,cylinder block,crankcase7Removing and Installing Engine7Removing7Securing the engine to the assembly stand17Install19Tightening torques20Align unit mounting for engine - gearbox21Assembly bracket22Enginecrankshaft group, pistons24Disassembling and assembling engine24Removing and installing V-ribbed belt24Removing and installing, tightening the timing belt28Inspecting semi-automatic tensioning pulley35Removing and installing crankshaft36Replacing gasket ring for crankshaft -on the belt pulley side-41Removing and installing pressure plate44Removing and installing drive plate44Removing and installing the front sealing flange47Disassembling and assembling piston and conrod50Engine cylinder head, valve gear55Removing and installing cylinder head55Removing and installing upper part of collecting intake manifold58removing and installing cylinder head cover61Removing cylinder head61Inspecting the cylinder head for distortion65Reworking a cylinder head65Installing cylinder head66Testing the compression67Repairing Valve Gear69Replacing camshaft gasket ring73Removing and installing camshaft75Testing hydraulic bucket tappets77Replacing valve stem seals78Inspect valve guides80Replacing the valve guides80Reworking valve seats81Engine lubrication85Removing and installing parts of the lubrication system85Disassembling and assembling oil filter holder87Removing and installing oil pan88Testing oil pressure and oil pressure switch90Engine cooling94Removing and installing parts of the cooling system94Parts of the Cooling System94Draining and filling up coolant95Removing and installing radiator98Removing and installing coolant pump101Removing and installing, testing coolant thermostat103Installing coolant pipe105Checking the coolant system for tightness105Fuel supply, gas operation107Removing and installing parts of the fuel supply system107Removing and installing fuel tank with attached parts and fuel filter107Safety precautions when working on the fuel supply system111Rules of cleanliness111Removing and installing the fuel delivery unit111Removing and installing the fuel gauge sender113Removing and installing the fuel tank113Connecting remote control115Check the fuel delivery unit116Check fuel flow rate118Removing and installing activated charcoal filter system119Repairing the accelerator control120Adjust accelerator control120Exhaust system122Removing and installing parts of the exhaust system122Removing and installing front exhaust pipe124Removing and installing exhaust manifold125Replacing front or rear silencer126Aligning exhaust system free of stress127Checking the exhaust system for leaks1281.6 ltr./74 kW Engine, Simos 2 injection and ignition system130Self diagnosis, V.A.G Inspection Service130Operation130Technical data of self-diagnosis130Connecting up the vehicle system tester -V.A.G1552- and selecting the control unit for engine electronics131Interrogating and erasing fault memory133Actuator diagnosis134Coding control unit136Self-diagnosis I138Fault table138Self-diagnosis II159Reading measured value block159Read measured value block; display groups 000 to 010159Read measured value block: display groups 011 to 099171Repair Simos 2 injection system186Safety measures186Rules of cleanliness186Technical data186Overview of fitting locations187For vehicles 07.97187For vehicles 08.97 189Removing and installing parts of the injection system191Disassembling and assembling top part of intake manifold196Disassembling and assembling fuel distributor197Disassembling and assembling the air filter197Removing and installing engine covers198Testing lines and components with the test box -V.A.G1598/22-198Replacing engine control unit199Adapt the engine control unit to the electronic immobiliser200Testing components and functions202Idle testing202Test fuel pressure regulator and holding pressure203Testing injection valves205Inspecting the injection rate, tightness and jet formation of the injectors208Test fuel pump relay and control210Test air mass meter -G70-213Testing the intake system for tightness (unmetered air)216Test voltage supply of engine control unit217Test intake air temperature sender218Test coolant temperature sender -G62-222Checking lambda control225Irregularities of the engine after cold start225Check the function of the lambda control227Check lambda probe heater230Test lambda probe signal line and lambda probe control unit231Checking the fuel tank venting233Testing activated charcoal filter system solenoid valve 1233Inspecting throttle valve control unit236Check throttle valve control unit for vehicles 07.97237Check throttle valve control unit for vehicles 08.97 240Adapt the engine control unit to the throttle valve control unit246Test intake manifold changeover249Inspect the vacuum system249Test variable intake manifold changeover valve -N156-250Testing auxiliary signals253Inspecting AC compressor disconnection253

1.6 ltr./74 kW Engine - Mechanical ComponentsTechnical DataEngine number

The engine number (engine identification characters and serial number) is located at the joint separating the engine and the gearbox.

In addition, a sticker with the engine identification characters and serial number is affixed to the toothed belt guard.

The engine code letters are also listed on the vehicle data sticker.

Engine characteristics

Engine identification charactersAEHAKL

Manufactured04.97 ? 08.97 ?

Displacementl 1,5951,595

Power outputkW at rpm74/560074/5600

TorqueNm at rpm145/3800145/3800

Bore mm81,081,0

Strokemm77,477,4

Compression10,3:110,3:1

Firing order1-3-4-21-3-4-2

Fuel - RON95 unleaded Note95 unleaded Note

Ignition system/fuel injectionSimos 2Simos 2

Knock controlxx

Autodiagnosticxx

Lambda controlxx

Catalytic converterxx

Exhaust gas recirculation--

Turbocharging--

Exhaust limits conforming toEU-2/ECEEU-3D

1) At least 91 RON in exceptional cases, although engine output is reduced

Engine assy,cylinder block,crankcaseRemoving and Installing Engine

Special tools and workshop equipment required

t Workshop crane (e.g. - V.A.G1202A-)

t Catch pan (e.g. -V.A.G1306 -)

t Torque wrench 5 to 50 Nm (e.g. -V.A.G1331 -)


t Engine/gearbox jack (e.g. -V.A.G1383A -)

t Pliers for spring strap clips

t Engine mount -T10012-

t Engine mount -MP1-202-

t Repair stand -MP9-101-

t Suspension fixture -MP9-201 -

t Grease -G000100- (for vehicles with gearbox)

t Cable strap

Removing

Notet The engine is removed downwards together with the gearbox.

t All cable straps that have been loosened or cut open when the engine was removed must be fitted again in the same location when the engine is installed again.

t The hose connections are secured with screw-type clips, spring-type clips or clamp-type clips.

t Always replace clamp-type clips with spring-type clips or screw -type clips.

t Fuel hoses at the engine must only be secured with spring-type clips. The use of clamp-type or screw-type clips is not allowed.

t Use pliers for spring strap clips to fit the spring strap clips.

t Pay attention to the correct assignment of the connectors, if necessary mark.

Procedure

On models fitted with a coded radio set, pay attention to the coding; determine if necessary.

Remove the battery: Electrical System, Rep. Gr. 27; Removing and installing the battery

Remove battery tray -arrows-.

Open the cap of the coolant expansion reservoir.

Raise vehicle with a lift platform, pay attention to the following points:

The arms of the lift platform must be positioned under the frame side rail.

WARNINGUnder no circumstances may the arms of the lift platform be positioned under the sills, the front or rear axles.

Both jacking up points at front are located on both front frame side rails at the height of the marking on the sill.

WARNINGNever start the engine or engage a gear when the vehicle is raised, while even one driving wheel is still in contact with the ground.

Both rear jacking up points are located on both front frame side rails at the height of the marking on the sill.

Remove noise insulation panel -arrows-.

Position drip tray (e.g. -V.A.G1306-) under the engine.

Turn drain valve -arrow- at radiator to the left and pull to the rear, fit auxiliary hose if necessary.

Remove bottom coolant hose on the oil cooler -arrow- and drain residual coolant.

Remove caps for nuts and remove engine cover -arrows-.

Detach air guide hose at throttle valve connection and at vent housing of the crankcase ventilation -arrows-.

Detach vent hose -1- and unplug connector from air mass meter -2-.

Unscrew screws -3- and -4-, remove air filter box completely.

Remove wiper arms Electrical System Rep.- Gr. 92; windscreen wiper and washer system

Remove the cooling water tank cover. Body Work; Rep.-Gr. 66; Trim panels

Unplug the 28-pin connector at engine control unit -J361-.

Open the cable duct below the air filter unplug the 10-pin connector.

Detach wiring harness from the engine and attach to the engine.

Unbolt earth strap -1-.

Detach cables -3- and -4- at starter.

Separate plug connection -2- and pull out of fixture.

Detach cables from fixture at starter and lay to the side, unscrew the fixture.

Unbolt cable -1- of terminal 30/B+ at alternator.

Unplug connector -2- of terminal D+.

Unscrew cable lug -3-.

Detach cable from the fixture.

Unplug connector from monitoring switch for coolant temperature sensor -F14- (only for vehicles with air conditioning system).

Unhook throttle control cable -arrows-.

Vehicles fitted with a manual gearbox

Press off shift rods -1- and -2- with a screwdriver.

Unbolt shift mechanism at gearbox -arrows-.

Remove the slave cylinder -arrows- and lay aside, secure with wire, do not open the line system.

NoteDo not depress the clutch pedal.

Unplug connector from reversing light switch -F4 -.

Detach wiring loom for the fixtures and run out to the side.

Vehicles with automatic gearbox

Use screwdriver to press off selector lever cable -1- at gearbox selector lever -4-, pull off securing clasp -3- at support bearing.

Take off selector lever cable and place to the side.

Unbolt bracket for pressure line of power-assisted steering at gearbox support.

Disconnect the following plug connections:

1-for solenoid valves

2-for vehicle speed sender - G68-

3-for multi-function switch -F125 -

4-for gearbox speed sender -G38 -

Unplug the connector from the speedometer sender -G22-.

Detach cable harness for the fixtures and run out to the side.

All vehicles

WARNINGThe fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.

Remove fuel feed line -1- and fuel feed line -2-, to do so press latch clips at the separation point. Lines and release buttons are colour-coded.

Detach hose -3- at the ACF tank.

Detach coolant hoses:

t to expansion reservoir (at front coolant pipe)

t to thermostat housing (at bottom of radiator and at thermostat housing)

t to top radiator (at left flange on cylinder head)

t to heating system heat exchanger (each 1 hose at coolant pipe and left at cylinder head)

t lateral at coolant pipe

t at throttle valve supports (2 hoses)

t at ATF radiator (vehicles with an automatic gearbox)

Disconnect the vacuum line from the brake servo unit.

NoteMark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it. Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.

Swing the the tensioning device in -the direction of the arrow- detension the V-ribbed belt.

Remove the V-ribbed belt.

Remove 2 brackets for the pressure line of power-assisted steering (on left at gearbox and below starter).

Remove the belt pulley of the vane pump.

Unbolt the vane pump of power-assisted steering and tie up to the front of the vehicle. The lines on the vane pump remain connected up.

Vehicles with air conditioning

WARNINGDo not open the refrigerant circuit of the air conditioning system.

Unscrew the holder for refrigerant hoses.

Remove AC compressor and tie up together with the connected refrigerant hoses to the towing lug on the inside of the bumper -arrow-.

NoteProtect the bumper with soft base from damage.

All vehicles

Remove pendulum support -arrows-.

Remove the drive shafts from the gearbox flanges.

Lay both drive shafts to the rear and secure with wire to the body.

Remove front exhaust pipe Chapter.

Insert engine mount -T10012- into engine/gearbox jack (e.g. -V.A.G1383A -).

Screw engine mount - T10012- to the cylinder block with fixing nuts and bolts M10 to 40Nm.

Slightly raise the engine and gearbox with the engine/gearbox jack (e.g. -V.A.G1383A -).

Unbolt engine support from engine mount -arrows-.

NoteUse the double ladder (e.g. -VAS5085-) for removing the fixing bolts.

Slacken the screws from gearbox mount from the top -arrows-.

Carefully lower the engine with gearbox.

NoteEngine with gearbox must be guided carefully, in order to avoid damage and body damage.

Securing the engine to the assembly stand

Secure the engine with the engine and gearbox mount -MP1-202- and on the assembly stand before performing assembly work.

NoteWhen measuring the cylinder bore Fig. the engine must not be fixed to the assembly stand.

Procedure

Position the engine and gearbox with the engine/gearbox jack e.g. -V.A.G1383A - onto the storage table.

Lower the engine with gearbox in such a way that the gearbox is positioned on the support.

Release screws -1 through 8- at engine/gearbox flange.

Separate gearbox from engine.


Pull off plug in hole of torque converter cover plate.

Unscrew 3 nuts -arrow- from torque converter, rotate crankshaft each time 1/3 revolution for this step.

After separating engine and gearbox, secure torque converter in gearbox to prevent it dropping out.

All vehicles

Hook on the suspension fixture -MP9-201- as follows and raise slightly with the workshop crane (e.g. -1202A-).

t On the belt pulley side: 1st hole of the perforated bar in position 1

t On the flywheel side: 4th hole of the perforated bar in position 5

WARNINGUse securing pins on the hooks and rig pins.

Secure engine with engine mount -MP1-202- to the assembly stand.

Install

Notet Always replace the seals and gaskets during assembly work.

t Always replace self-locking nuts.

Procedure

Installation is performed in the reverse order. Pay attention to the following points:

Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; insert if necessary.

Insert intermediate plate on sealing flange and push onto the dowel sleeves -arrows-.

Vehicles fitted with a manual gearbox

Lubricate the drive shaft serration lightly with grease -G000100 -.

If necessary check the centering of the clutch disc.

Install slave cylinder: 5 speed Manual gearbox 02K; Rep. Gr. 30; Repairing the clutch control.

Installing shift mechanism: 5 speed Manual gearbox 02K; Rep. Gr. 34; Repairing the gearshift mechanism.

Setting the shift mechanism: 5 speed Manual gearbox 02K; Rep. Gr. 34; Setting the gearshift mechanism.


Only use nuts which are approved in the parts list, for attaching torque converter to the driver disc.


Install AC compressor: Heating, Air conditioning, Rep. Gr. 87; Air conditioning; Removing and installing compressor from holder.

All vehicles

Install the vane pump for the power-assisted steering: Running gear, Rep. Gr. 48; Removing and installing the vane pump for power-assisted steering.

Install drive shafts: Running gear, Rep. Gr. 40; Repairing front wheel suspension; Removing and installing the drive shaft.

Install the front exhaust pipe and the exhaust system so that they are not under tension Chapter.

Align unit mounting Chapter.

Install the V-ribbed belt Chapter.

Install coolant hose Chapter.

Filling system with coolant Chapter.

The drained off coolant must only be then re-used if the cylinder head, cylinder block, radiator or heat exchanger were not replaced.

Place connecting harness for engine into cable duct and connect the 10-pin plug connection.

Connect the 28-pin connector at engine control unit -J361-.

Fit cooling water tank cover. Body Work; Rep.-Gr. 66; Trim panels

Install windscreen wiper arms Electrical System Rep.- Gr. 92; windscreen wiper and washer system.

Electrical connections and laying of cables: Current flow diagrams and Fitting locations

Adjusting throttle control cable Chapter.

Install the engine cover.

Check oil level before starting the engine Octavia.

NoteIf the battery earth strap is disconnected and connected, carry out additional operations Electrical System, Rep. Gr. 27.

Tightening torques

Notet Tightening torques apply only for lightly greased, oiled, phosphatized or blackened nuts and screws.

t Other lubricants such as engine and gearbox oil are allowed. Do not use Molykote.

t Do not use degreased parts.

t Unless otherwise indicated the following tightening torques apply:

Component Nm

Screws/nutsM69

M713

M820

M1040

M1270

In variation of this:

Driver plate on the torque converter60

Engine mounting, gearbox mount, pendulum supportChapter

Connecting bolts for the engine/the gearbox5-speed manual gearbox 02K; Rep. Gr. 34Automatic gearbox; Rep. Gr. 37

Align unit mounting for engine - gearbox

WARNINGBefore slackening the bolts, the unit must be secured with the supporting device -MP9-200-.

Engine mounting

a = 14.0 mm

b = at least 10.0 mm

Both bolt heads -1- must end flush with the edge -c-.

Gearbox mounting

The edges -a- and -b- must be positioned parallel to each other.

Assembly bracket

Tightening torques

Engine assembly bracket

1 -40 Nm + 90 (1/4 turn) Note

2 -25 Nm

3 -100 Nm Note

Gearbox assembly bracket

1 -40 Nm + 90 (1/4 turn) Note

2 -25 Nm

3 -100 Nm Note

Hinged bracket

1 -40 Nm +45 Note

2 -40 Nm +45 Note

3 -20 Nm + 90 (1/4 turn) Note

1) Replace bolts

Enginecrankshaft group, pistonsDisassembling and assembling engineRemoving and installing V-ribbed belt


t Torque wrench

t Locating bolts -T10060-

Notet The following figure shows the belt drive of vehicles without air conditioning.

t Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it. Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.

t Removing and installing the air conditioning compressor Heating, Air conditioning; Rep. Gr. 87.

1-V-ribbed belt

before removing mark running direction

check for wear

do not kink

routing of ribbed V-belt on vehicles without air conditioning Fig.

routing of ribbed V-belt on vehicles with air conditioning Fig.

Removing and installing ribbed V-belt Anchor

Engines fitted with an AC compressor are equipped with a double ribbed V-belt.

2-25 Nm

3-Tensioning device for ribbed V-belt

swivel tensioning device for V-ribbed belt with open-end wrench to slacken the V-ribbed belt Anchor

4-Belt pulley

can be installed only in one position

5-45 Nm

6-AC generator

to facilitate the positioning of the AC generator on the holder drive the threaded bushings of the retaining screws slightly backwards

7-AC compressor

Do not open refrigerant circuit

to facilitate the positioning of the AC compressor on the holder drive the threaded bushings of the retaining screws slightly backwards

8-Distance sleeve

9-Support

10-45 Nm

order of tightening Fig.

11-Hollow screw, 30 Nm

12-Gasket ring

replace

13-Pressure line

14-The vane pump for the power-assisted steering

to facilitate the positioning of the hydraulic pump on the holder drive the threaded bushings of the retaining screws slightly backwards

removing and installing: Running gear; rep. size 48

15-Belt pulley

for vane pump

16-Fixing screw

Screw with firmness 8.8; 25 Nm - replace, as replacement, use a screw with firmness 10.9 Electronic Catalogue of Original Parts

Screw with firmness 10.9: 40 Nm

Combining different firmness is not permissible

Routing of ribbed V-belt on vehicles without air conditioning

Routing of ribbed V-belt on vehicles with air conditioning

NoteEngines fitted with an AC compressor are equipped with a double ribbed V-belt.

Tightening sequence of the compact holder screws

Removing the V-ribbed belt

NoteMark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it. Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.

Swivel tensioning device in -direction of arrow- to slacken the V-ribbed belt and secure with locating bolts -T10060-.

NoteThe tensioning device can also be locked using a 3 mm hexagon wrench.

Remove the V-ribbed belt.

Installing the V-ribbed belt

NoteBefore installing the ribbed V-belt, ensure that all components (alternator, AC compressor, hydraulic pump) are properly installed.

Fit the ribbed V-belt.

Slacken ribbed V-belt tensioning device. Pull out locating bolts -T10060--arrows-.

Start engine and check belt run.

NoteEngines fitted with an AC compressor are equipped with a double ribbed V-belt.

Removing and installing, tightening the timing belt

NoteBefore removing the timing belt, mark direction of running. Reversing the rotation direction of an already used belt may destroy it.

1-Bottom toothed belt guard

unscrew to remove the vibration dampener Chapter

2-Middle toothed belt guard

3-10 Nm

replace

4-Engine support bracket

removing Anchor

5-45 Nm

6-Top toothed belt guard

7-Timing belt

before removing mark running direction

check for wear

do not kink

removing Anchor

installing Anchor

8-25 Nm

9-Washer

10-100 Nm

to release and tighten use the counterholder -MP1-216-

11-Camshaft sprocket

with sensor rotor for the Hall sensor -G40-

Removing and installing timing belt Anchor

Installation position fixed by woodruff key -pos. 14-

12-Toothed belt guard

13-10 Nm

14-Woodruff key

check tightness

15-Hall sender -G40-

when bolting on, ensure base plate is centered

16-10 Nm

17-Rear timing belt guard

18-20 Nm

19-Semi-automatic tensioning pulley

check semi-automatic tensioning pulley Chapter

Fitting position Fig.

20-Coolant pump

removing and installing Chapter

21-15 Nm

22-Timing belt gear - crankshaft

there must not be any oil present on contact surface between timing belt sprocket and the crankshaft

can be installed only in one position

23-90 Nm + torque a further 1/4 turn (90)

replace

counter-hold Chapter with counter-holder -T30004- or counterholder -MP1-310- for slackening and tightening

Fitting position of the semi-automatic tensioning pulley

The angle bracket -arrow- must engage in the recess at the cylinder head.


t Torque wrench

t Counterholder -MP1-216-

t Two-hole nut turner -T10020-


t Supporting device - MP9-200-

Removing toothed belt

Engine installed

Remove V-ribbed belt Chapter.

Remove ribbed V-belt tensioning device.

Rotate crankshaft to TDC of cylinder 1 -arrow- (vehicles with manual gearbox).

TDC marking on flywheel and reference mark must be aligned.

Rotate crankshaft to TDC cylinder 1 -arrow- (vehicles with automatic gearbox).

TDC marking on drive plate and reference mark must be aligned.

Note

When engine removed, position vibration damper to TDC cylinder 1 -arrows-.

Remove engine cover.

Insert supporting device -MP9-200- and take up weight of engine with the spindle of the supporting device (only on right).

Remove vibration damper.

Remove top, bottom and middle timing belt guard.

Unscrew the reservoir for the power-assisted steering.

Unbolt engine support from engine console and engine console from body -arrows-.

Mark the rotation direction of the timing belt.

Slacken semi-automatic tensioning pulley and take off toothed belt.

Turn crankshaft slightly back.

Unbolt engine support from engine -arrows-.

Notet To slacken the front bolt of the engine support, raise engine slightly with spindle of supporting device -MP9-200-.

t To take off engine support, raise or lower engine, respectively with the supporting device -MP9-200-.

Installing toothed belt, tensioning (setting timing)

Notet Also when carrying out repairs which necessitate taking the toothed belt only off the camshaft sprocket, it is then necessary to carry out the installation of the toothed belt as follows.

t When rotating the camshaft, the crankshaft must not be positioned at TDC. Risk of damaging valves and piston crowns.

Precondition

l The pistons must not be positioned at top dead centre.

Bring the marking on the camshaft sprocket in line with the marking on the rear timing belt guard -arrows-.

Position crankshaft to TDC cylinder 1 (except when engine removed) Anchor.

Fit timing belt onto the crankshaft timing belt sprocket (pay attention to direction of running) Chapter.

Note

When engine removed, install bottom toothed belt guard and vibration damper. Position crankshaft to TDC of cylinder 1 arrows.

Fit timing belt onto tensioning pulley and onto camshaft sprocket.

Pay attention to installation position of semi-automatic tensioning pulley:

t The angle bracket -arrow- must engage in the recess at the cylinder head.

Tighten the timing belt. Turn with -T10020- at centering piece to the left (in direction of arrow) up to the stop.

Slacken the timing belt until the notch -1- and the pointer -2- are positioned opposite.

Tighten clamping sleeve securing semi-automatic tensioning pulley to 25Nm.

Turn the crankshaft fully twice and check the setting.

Install bottom timing belt guard.

Install vibration damper (pay attention to fitting position: hole of the vibration damper is above the lobe on the timing belt sprocket).

NoteBefore installing engine support, insert bolts into engine support.

Install engine support Anchor.

Install engine mount Chapter.

Remove supporting device.

Install middle and top timing belt guard.

Install tensioning device for V-ribbed belt. Tightening torque:

Install the V-ribbed belt Anchor.

Inspecting semi-automatic tensioning pulley

Test condition

l Toothed belt fitted on and tensioned.

Load timing belt by firmly pressing down with thumb -arrows-. The pointer -2- must move to the side.

Relieve the toothed belt again. The tensioning roller must go back again to its initial position. (The notch -1- and the pointer -2- are again standing opposite to each other.)

NoteUse mirror.

Removing and installing crankshaft

Notet Repairs to the clutch: 5 speed Manual gearbox 02K; Rep. Gr. 30; Repairing the clutch.

t The engine should be attached to the engine repair stand with engine holder -MP1-202- for carrying out removal and installation work.

1-15 Nm

2-Gasket ring

replace Chapter

pay attention to different version Fig.

3-Front sealing flange


4-Thrust washers

pay attention to different version

in bearing 3, for cylinder block or bearing cap

lubricating grooves point outwards

5-Bearing shell

Identification for ordering replacement parts Fig.

for cylinder block with lubricating groove

do not mix up used bearing shells (mark)

6-Sprocket

for oil pump drive

7-Crankshaft

Axial play when new: 0.07...0.21 mm

Wear limit: 0.30 mm

Crankshaft bearing journal: 54.00 mm

Conrod bearing journal 47.80 mm

8-Bearing shell

Identification for ordering replacement parts Fig.

for bearing cap without lubricating groove



replace

10-Bearing caps

Bearing cover 1; on the belt pulley side

Fitting position: retaining lugs of the bearing shells of the cylinder block/bearing cap must be on top of one another

11-Rotor

replace if damaged

for engine speed sender -G28 -

assembly only possible in one position -holes offset-

Removing and installing sensor rotor Fig.


replace

13-Pressure plate/driver disc

Removing and installing pressure plate Chapter

removing and installing drive plate Chapter

14-Washer

Check fitting position


replace

16-Gasket ring

replace

17-Screw plug - 100 Nm

18-Intermediate plate

inserted on sealing flange Fig.

must be positioned on dowel sleeves

do not damage/bend during assembly work

19-15 Nm

20-Rear sealing flange with gasket ring

must be replaced completely

must be positioned on dowel sleeves

remove oil pan Chapter for removing

clean sealing surface before installing

the sealing flange with PTFE gasket ring is supplied as a spare part

install gasket ring dry, the crankshaft stub must be free of grease

fit new sealing flange with guide bushing (do not pull guide bushing out of gasket ring before fitting)

Installing intermediate plate

Insert intermediate plate on sealing flange and push onto the dowel sleeves -arrows-.

Gasket ring versions

IElastomer gasket ring1 sealing lip -1-; with garter spring

IIPTFE gasket ringmultiple sealing lips -2-; without garter spring

Notet Do no moisten the PTFE gasket ring with oil before inserting. The shaft must also be free from oil and grease.

t Never install an elastomer gasket ring (old version), if a PTFE gasket ring (new version) was fitted.

t An elastomer gasket ring can be replaced by a PTFE gasket ring.

Marking on crankshaft bearing for ordering replacement parts

The crankshaft bearing shells are factory-classified. Align the top crankshaft bearing shells according to the marking on the cylinder block (stamped letters).

Notet -Arrow- points to the belt pulley.

t Identification of the bearing is visible without removal of the oil pan.

Colour coding of bearing shells matches the letters on the cylinder block

R=red

G=yellow

B=blue

W=white

The bottom crankshaft bearing shells are always supplied as replacement parts with the colour coding yellow.

Removing and installing sensor rotor

Replace sensor rotor -2- and bolt -1- each time they are slackened.

Notet After being attached a second time, the attachment point in the sensor rotor -2- is sufficiently misshapen that the bolt head -1- rests against crankshaft -3--arrows- and the sensor rotor is positioned loosely below the screw.

t Assembly only possible in one position -holes offset-.

Replacing gasket ring for crankshaft -on the belt pulley side-


t Torque wrench

t Counterholder -T30004- or Counterholer -MP1-310 -

t Gasket ring extractor -MP1-226-

t Insertion sleeve -MP1-314-

t Insertion sleeve -MP1-315-

t Guide bushing -T10053/1-

t Pressure bushing -T10053-

Removing


Removing timing belt Chapter.

Remove crankshaft timing belt sprocket. Lock toothed belt gear - crankshaft with counterholder -T30004- or counterholder -MP1-310 -.

When screwing on the counterholder place 2 washers between the timing belt gear and the counterholder.

Screw central screw of timing belt again into the crankshaft.

Unscrew inner part of the gasket ring extractor -MP1-226- two turns (approx. 3 mm) out of the outer part and lock with knurled screw.

Oil the thread head of the gasket ring extractor -MP1-226-, position and forcely screw into the gasket ring as far as possible.

Slacken knurled bolt and turn inner part against the crankshaft until the gasket ring is pulled out.

Install elastomer gasket ring.

Lightly oil the sealing lip of the gasket ring.

Fit insertion sleeve from -MP1-314- on the crankshaft stub.

Slide gasket ring over the insertion sleeve.

Press in the gasket flush using the central screw -1- and press in the insertion sleeve from -MP1-315-.

Install PTFE gasket ring.

NoteThe sealing lips of the gasket ring must be neither oiled nor greased.

Remove oil residue on the crankshaft stub with a clean cloth.

Install -T10053/1- guide bushing on the crankshaft stub.

Slide gasket ring over the guide bushing onto the crankshaft stub.

Press in gasket ring with pressure bushing -T10053- up to the stop. Use the old central screw for the crankshaft timing belt sprocket for this purpose.

Proceed as follows for both versions

Install timing belt gear onto the crankshaft and lock with counterholder - MP1-310-.

NoteReplace central screw for toothed belt gear.

Tighten central screw to 90 Nm and torque a further 1/4 turn (90).

Installing the timing belt Chapter.


Removing and installing pressure plate



t Counterholder for clutch -MP1-221-

Put the counterholder -MP1-221- into the bore hole on the cylinder block and screw onto the pressure plate.

Release screws for pressure plate.

NoteReplace screws for pressure plate.

Tighten bolts to 60 Nm and torque a further 90 1/4 turn.

Removing and installing drive plate




t Counterholder for clutch -MP1-221-

t Depth gauge

Removing

Attach counterholder -MP1-221- with M8x45 bolt to the drive plate. Place two M10 nuts between the counterholder and the driver disc -1-.

Release screws for driver disc.

Install

Remove the intermediate plate Anchor.

Only insert the drive plate using the washer with recesses -1-.

Insert bolts -3- and tighten to 30 Nm.

Inspect installed dimension of drive plate at the 3 mounting holes for the torque converter and calculate mean value.

t Nominal value -a- 19.5...21.1 mm

NoteThe measurement is made through the 3 outer holes of the drive plate to the milled surface of the cylinder block.

If the specified value is reached:

Installing the drive plate.

Installing intermediate plate.

Attach drive plate with washer and new screws, torque 60 Nm + 1/4 turn (90).

If the measurement is less than the specification:

Remove the driver plate.

Installing intermediate plate.

Place spacer washer -2- between crankshaft and drive plate.

Lock drive plate with spacer washer -1- and attach new bolts -3- to 60 Nm + torque a further 1/4 turn (90).

Removing and installing the front sealing flange


t Torque wrench 5 - 50 Nm (e.g. -V.A.G1331 -)

t Torque wrench 40 - 200 Nm (e.g. -V.A.G1332 -)

t Counterholder -T30004- or Counterholer -MP1-310 -

t Insertion sleeve from -MP1-314-

t Hand-held power drill with plastic brush insert

t Silicone sealant -D176404A2 -

t Flat scraper

Removing


Removing timing belt Chapter.

Remove crankshaft timing belt sprocket. Lock toothed belt gear - crankshaft with counterholder -MP1-310- or counterholder -T30004 -.

NoteWhen screwing on the counterholder place 2 washers between the timing belt gear and the counterholder.

Drain engine oil.

Removing the oil pan Chapter.

Unscrew front sealing flange.

Remove sealing flange, if necessary release by applying slight blows with a rubber-headed hammer.

Use a flat scraper to remove sealant residues on the cylinder block.

Use a rotating plastic brush to remove sealant residues on the sealing flange (wear protective goggles).

Clean sealing surfaces, they must be free of oil and grease.

Install

NoteThe sealing flange must be installed within 5 minutes after applying the silicone sealant.

Cut off tip of tube at the front marking ( of opening approx. 3 mm).

t Thickness of sealant bead -arrows-: 2 to 3 mm.

NoteThe sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.

Apply silicone sealant bead to the clean sealing surface of the sealing flange, as shown in the illustration.

Fit sealing flange immediately and lightly tighten all bolts.

Notet For version with PTFE gasket ring ( Fig.), the crankshaft stub must be free of oil and grease and the gasket ring must not be oiled.

t When installing the sealing flange with the gasket ring fitted use the following devices:

t Elastomer gasket ring - -MP1-314 -

t PTFE gasket ring - -T10053/1-

Tighten the screws crosswise to 15 Nm.

Install oil pan Chapter.

NoteAfter installing, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in.

Install the crankshaft timing belt sprocket.

NoteReplace central screw of toothed belt gear.

Tighten central screw to 90 Nm and torque a further 1/4 turn (90).

Installing the timing belt Chapter.

Disassembling and assembling piston and conrod

NoteThe engine should be attached to the engine repair stand with engine holder -MP1-202- for carrying out removal and installation work.

1-Piston rings

Offset joint 120

use piston ring pliers for removing and installing

marking TOP must face towards piston crown

inspect gap clearance Fig.

inspect end clearance Fig.

2-Piston

check Fig.

mark installation position relative to conrod and mark matching cylinder with waterproof felt pen

arrow on piston crown faces towards the belt pulley side

use piston ring tensioning strap for installing

Piston 80.965 mm

3-Conrod


always replace as a set only

mark assignment to cylinder -B-

Fitting position: Markings -A- must be positioned one above the other and point to the belt pulley side

with oil drilling for lubricating piston pin

4-Conrod cap

mark assignment to cylinder -B-

Fitting position: Markings -A- must be positioned one above the other and point to the belt pulley side

5-30 Nm + torque a further 90 (1/4 turn)

replace with conrod bolt -pos. 10-

oil thread and head contact surface

6-Pressure relief valve, 27 Nm

opens at: test pressure 0.13...0.16 MPa (1.3...10.6 bar) positive pressure

replace without sealant

7-Oil injection nozzle

For piston cooling

8-Bearing shell



ensure tightly located in retaining lugs

Axial play when new: 0.10...0.35 mm, wear limit: 0.40 mm

with oil drilling for lubricating piston pin

9-Cylinder block

inspect cylinder bore Fig.

Cylinder 81.01 mm

10-Conrod bolt

replace together with nut; -Pos. 5-

11-Circlip

12-Piston pin

if stiff, heat piston to approx. 60C

with drift -VW222A - removing and installing

Inspecting piston ring gap clearance

Special tools, test equipment as well as aids required

t Feeler gauge

Test sequence

Push in ring at right angles to the cylinder wall from the top through to the bottom cylinder opening, about 15 mm from the cylinder edge.

Piston ring dimensions in mmnewWear limit

1st compression ring0.20 to 0.400,8

2. Compression ring0.20 to 0.400,8

Oil scraper ring0.25 to 0.500,8

Inspect piston ring end clearance


t Feeler gauge

Clean annular groove before measurement is taken.

Piston ring dimensions in mmnewWear limit

1st Compression ring0.06 to 0.090,20

2nd Compression ring0.05 to 0.080,20

Oil scraper ring0.03 to 0.060,15

Inspecting pistons


t External micrometer 75...100 mm

Test sequence

Measure about 10 mm from the lower edge, offset at right angles to the piston pin shaft.

t Variations compared to nominal diameter max. 0.04 mm

Inspecting cylinder bore


t Internal precision measuring instrument 50...100 mm

Test sequence

Measure at three points crosswise in a transverse direction -A- and lengthwise -B-.

t Variations compared to nominal dimension max. 0.08 mm

NoteDo not measure the cylinder bore if the cylinder block is fixed to the assembly stand with the engine mount -MP1-202-, as this may result in incorrect measurements.

Different versions of conrods

Cut open conrod -A- = locating face smooth

Split conrod -B- = locating face coarse

Engine cylinder head, valve gearRemoving and installing cylinder head

Removing and installing timing belt Chapter.

Testing compression pressure Chapter.

Notet Always replace cylinder head bolts.

t Always replace self-locking nuts.

t Always replace the seals and gaskets during assembly work.

t When installing an exchange cylinder head with the camshaft installed, it is necessary to oil the contact surfaces between bucket tappets and the cam track after installing the head.

t Do not remove the plastic bases supplied as a protection for the open valves until just before fitting on the cylinder head.

t If the cylinder head is replaced, the system must be completely filled with fresh coolant.

t Cylinder heads with cracks between the valve seats or between a valve seat ring and the spark plug thread may continue to be used without any reduction in life provided these are slight initial cracks which are not more than 0.3 mm wide, or cracks exist only at the first 4 turns of the spark plug thread.

1-15 Nm

2-20 Nm

3-Rear timing belt guard

4-Cylinder head

q after replacing fill entire system with fresh coolant

q removing Chapter

q check for distortion Chapter

q rework Chapter

q installing Chapter

5-Cylinder head bolt

q replace

q pay attention to order for slackening Anchor

q pay attention to order for tightening Anchor

6-Oil separator

7-Gasket for cylinder head cover

q replace if damaged

q before fitting, coat surface of cylinder head cover and cylinder head surface with -D 454 300 A2-

8-Reinforcing strip

9-Cylinder head cover

q removing and installing Chapter

10-10 Nm

11-Upper part of collecting intake manifold

q removing and installing Chapter

q with variable intake manifold changeover

q Check function of variable intake manifold changeover 1.6 ltr./74kW engine, Simos 2 Injection and ignition system ; Rep. Gr. 24

12-Cap

13-Gasket

14-Breather housing

q remove cylinder head cover Item for removing, release spring ends and turn breather housing to the left

15-Gasket


16-Support

17-Gasket


18-Lower part of collecting intake manifold

19-Gasket

q replace

20-Screw plug - 15 Nm

q replace

21-Gasket ring

q replace

22-Flange

23-Gasket

q replace

24-Lifting eye

25-Cylinder head gasket

q replace Chapter

Removing and installing upper part of collecting intake manifold


t Torque wrench 5 to 50 Nm (e.g. -V.A.G1331-)


t 2 hose clamps -MP7-602 -

t Cable strap

Removing

NoteAll cable straps which are detached or cut open when removing, should be fitted on again in the same place when installing.


Disconnect the earth strap from the battery with the ignition off.




Unscrew bolts -3- and -4- and remove air filter housing.

Disconnect the vacuum line from the brake servo unit.

Disconnect wiring/plug:

1-Plug for intake air temperature sender -G42-

2-Unplug connector for throttle valve control unit -J338-

Detach hose to the ACF tank.

Unhook throttle control cable -arrows-.

Unscrew earth strap at cylinder head cover.

Pinch off and disconnect 2 coolant hoses for throttle valve supports with hose clamps -MP7-602- (first of all drain pressure from cooling system).

Disconnect plug -1- from valve for variable intake manifold changeover -N156-.

Release vacuum hose -2-.

Release left and right retaining lugs at collecting intake manifold -arrow-.

Release on left and right each one screw -arrow- of the rear intake manifold suspension.

Press off upper part of collecting intake manifold to the rear from lower part of collecting intake manifold.

NoteSeal the intake passages in the bottom part of the collecting intake manifold with plug (clean cloth).

Install

NoteReplace seals if damaged.

Insert upper part of collecting intake manifold onto the bottom part.

Allow to clip left and right retaining eyes.

Coat screws of rear intake manifold suspension at collar with commercially available lubricant and tighten to 10 Nm.


If necessary, top up with coolant Chapter.

Interrogate fault memory, perform basic setting: 1.6 ltr./74 kW engine, Simos 2 Injection and ignition system; Rep. Gr. 01; Self-diagnosis; Interrogate and erase fault memory, Basic setting of engine

removing and installing cylinder head cover



Removing

Remove upper part of collecting intake manifold Chapter.

Remove top toothed belt guard.

Unscrew nuts for cylinder head cover.

Remove reinforcing strips, bracket, toothed belt guard and cylinder head cover.

Install

NoteReplace seals if damaged.

Remove cylinder head cover, reinforcing strips, toothed belt guard and bracket.

Tighten the nuts crosswise to 10 Nm.

Removing cylinder head

NoteAll cable straps which are detached or cut open when removing, should be fitted on again in the same place when installing.


t Catch pan (e.g. -V.A.G1306-)


t Wrench for cylinder head bolts (e.g. 3452)

Engine installed


Disconnect the earth strap from the battery with the ignition off.

Remove upper part of collecting intake manifold Chapter.


Remove noise dampening in the middle as well as on the left -arrows-.

Unbolt front exhaust pipe from exhaust manifold Chapter.

Turn drain valve -arrow- at radiator to the left and pull to the rear, fit auxiliary hose onto connection if necessary.

Remove further the bottom coolant hose on the oil cooler -arrow- and drain residual coolant.



Unscrew bolts -3- and -4- and remove air filter housing.

Rotate crankshaft to TDC cylinder 1 -arrow- (vehicles with manual gearbox). TDC marking on flywheel and reference mark must be aligned.

Marking on flywheel and reference mark must be aligned.

Rotate crankshaft to TDC cylinder 1 -arrow- (vehicles with automatic gearbox). TDC marking on drive plate and reference mark must be aligned.

TDC marking on drive plate and reference mark must be aligned.

Note

When engine removed, position vibration damper to TDC cylinder 1 -arrows-.


Slacken tensioning pulley and take timing belt off camshaft sprocket.

WARNINGThe fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.

Detach fuel feed line -1- and fuel return-flow line -2- by pressing on the release buttons. Lines and line connections are colour-coded.

Detach hose -3- at the ACF tank.

Disconnect plug at phase sensor (Hall sender -G40-) and at all four injection valves.

Detach cable harness for the fixtures and run out to the side.

Remove the spark plug connector and place to the side.

Unscrew M8 bolts for rear toothed belt guard.

Detach left coolant hose at cylinder head.

Unscrew left coolant flange at cylinder head.

Pull out coolant pipe towards the left.

Remove cylinder head cover Chapter.

Release the cylinder head bolts in the order 1 to 10.

Remove cylinder head with cylinder head gasket.

Inspecting the cylinder head for distortion


t Feeler gauge

t Knife-edge straightedge

Test sequence

Inspect cylinder head at several points for distortion using a knife-edge straightedge and feeler gauge.

t max. permissible distortion: 0.1 mm

Reworking a cylinder head

Procedure

Reworking of the cylinder head (face-grinding) is only permissible up to minimum dimension -a-.

t Minimum dimension a: 132.6 mm

NoteIf the sealing surface is reworked, the valves should be set lower by the same amount (rework valve seat rings) otherwise the valves will strike the pistons. Ensure that the maximum permissible dimensions are maintained Fig..

Installing cylinder head

Notet Always replace the cylinder head bolts.

t Remove sealant residues. When doing this, ensure that no scores or scratches are produced. When using emery paper the grain must not be less than 100.

t Carefully remove any emery and sanding residues.

t Remove the new cylinder head seal from its wrapping immediately before fitting.

t Treat the new seal with the utmost care. Damage to the silicone layer and in the area of the bead results in leakages.

t There must be no oil or coolant in the blind holes of the cylinder head bolts in the cylinder block.


t Torque wrench


t Wrench for cylinder head bolts (e.g. 3452)

Procedure

Set the crankshaft and camshaft to TDC for cylinder 1 before attaching the cylinder head Anchor.

Position the cylinder head gasket and lock the dowel sleeves. The legend (spare part no.) must be legible.

Insert new cylinder head bolts and tighten by hand.

Tighten the cylinder head screws in two stages in the indicated tightening sequence as follows:

1st Stage: 40 Nm

2nd stage: tighten further with a rigid wrench: torque a further 180 (1/2 turn) 2 x 90 is not permissible

NoteTightening up the cylinder head bolts after doing repair work is not necessary.

Installing toothed belt, tensioning (setting timing) Chapter.


Install cylinder head cover Chapter.

Install upper part of collecting intake manifold Chapter.



Interrogate fault memory, perform basic setting: 1.6 ltr./74 kW engine, Simos 2 Injection and ignition system; Rep. Gr. 01; Self-diagnosis; Interrogate and erase fault memory, Basic setting of engine.

Testing the compression

Test condition

l Engine oil temperature at least 30C


t Compression tester (e. g. -V.A.G1381- or -V.A.G1763-)

t Spark plug wrench

Test sequence

If the ignition is switched off, disconnect plug at all four injection valves.

If the ignition is switched off, disconnect plug at the ignition coils with power amplifier.

Unscrew the spark plugs with spark plug wrench.

Open throttle valve fully.

Test compression with compression tester (e.g. -V.A.G1381- and/or -V.A.G1763-).

NoteUse of tester: Operating Instructions

Operate starter until the tester no longer indicates a pressure rise.

Compression readings:

New engineWear limitPressure difference between individual cylinders

1.0 to 1.3 MPa0.75 MPamax. 0.3 MPa

Interrogating fault memory: 1.6 ltr./74 kW engine, Simos 2 Injection and ignition system; Rep. Gr. 01; Self-diagnosis; Interrogate and erase fault memory.

NoteSeparating the plug connections causes faults to be stored. After the test, interrogate the fault memory and delete it as required.

Repairing Valve Gear

Notet Cylinder heads with cracks between the valve seats or between a valve seat ring and the spark plug thread may continue to be used without any reduction in life provided these are slight initial cracks which are not more than 0.3mm wide, or cracks exist only at the first 4turns of the spark plug thread.

t After installing new bucket tappets, the engine must not be started for about 30 minutes (otherwise place the valves on the pistons).

t After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started.

1-100 Nm

to release and tighten use the counterholder -MP1-216-

2-Camshaft sprocket

with sensor rotor for the phase sensor (Hall sender -G40-)

for removing and installing, remove toothed belt Chapter

Installation position fixed by woodruff key -pos. 4-

3-Gasket ring

replace Chapter


4-Woodruff key

check tightness

5-20 Nm

6-Bearing caps

Fitting position Fig.

order of installation Chapter

Lightly coat head contact surface 1 with sealant -AMV 174 004 01-

7-Camshaft

inspecting axial play Fig.


Slack: max. 0.05 mm

8-Bucket tappets

do not interchange

with hydraulic valve clearance compensation

check Chapter

lay aside with contact surface facing down

before installing check axial play of the camshaft Fig.

oil contact surface

9-Valve collets

10-Valve spring retainer

11-Valve spring

removing and installing

with cylinder head removed: with -MP1-211- and -MP1-213- with valve supporting plate -MP1-218-

with cylinder head installed: Chapter

12-Valve stem seal

replace Chapter

13-Valve guide

check Chapter

replace Chapter

Repair of the guide with a collar

14-Cylinder head

pay attention to the notes Anchor

reworking valve seats Chapter

15-Valve

do not rework, only grinding in is permissible

Valve dimensions Fig.

inspect camshaft, axial play


t Universal dial gauge holder -MP3-447-

t Dial gauge

Wear limit: max. 0.15 mm

Perform measurement with the bucket tappets removed and the first and last bearing cap fitted.

Fitting position of the camshaft bearing cap

Pay attention to centre displacement. Before installing the camshaft fit bearing cap and determine the fitting position.

Valve dimensions

NoteValves must not be reworked. Only grinding in is permissible.

DimensionInlet valveExhaust valve

amm39,5 0,1532,9 0,15

bmm6,92 0,026,92 0,02

cmm91,8591,15

4545

Replacing camshaft gasket ring



t Gasket ring extractor -MP1-215-

t Insertion tool -MP1-214-

t Torque wrench

t Pressure bushing -T10071-

t Guide bushing -T10071/1-

Removing


Loosen the camshaft sprocket (use counterholder -MP1-216-).

Position camshaft sprocket to TDC marking of cylinder 1 by rotating at crankshaft. Marking on camshaft sprocket must be aligned with arrow on the toothed belt guard.

Slacken tensioning pulley and take off timing belt.

Remove camshaft sprocket.

Remove Woodruff key from the camshaft.

Screw in bolt for attaching camshaft sprocket fully into the camshaft.

Set the inner part of the sealing ring extractor -MP1-215- flush with the outer part and interlock with the knurled screw.

Oil the thread head of the gasket ring extractor, position and forcely screw into the gasket ring as far as possible.

Slacken knurled screw and turn inner part against the camshaft until the gasket ring is pulled out.

Install elastomer gasket ring

Lightly oil the sealing lip of the gasket ring.

Apply the gasket ring with guide bushing made out of -MP1-214- and press in flush using a pressure bushing made out of -MP1-214-.

Install PTFE gasket ring

NoteDo not oil sealing lips of the gasket ring.

Remove oil residue on the camshaft stud with a clean cloth.

Insert guide bushing -T10071/1- on the camshaft stub.

Position gasket ring over the guide bushing onto the camshaft stub and remove sleeve.

Press in the gasket ring with pressure bushing -T10071- and screw -T10071/2- up to the stop.

Proceed as follows for both versions

Insert Woodruff key.

Install camshaft sprocket and tighten to 100 Nm (use counterholder -MP1-216-).

Installing and tensioning toothed belt (setting timing) Chapter.

Removing and installing camshaft


t Torque wrench


Removing


Loosen the camshaft sprocket (use counterholder -MP1-216-).

Position camshaft sprocket to TDC marking of cylinder 1 by rotating at crankshaft. Marking on camshaft sprocket must be aligned with arrow on the toothed belt guard.

Slacken tensioning pulley and take off timing belt.

Remove upper part of collecting intake manifold and cylinder head cover Chapter or Chapter.

Remove camshaft sprocket.

Remove Woodruff key from the camshaft.

First remove bearing caps 1, 3 and 5. Release bearing caps 2 and 4 alternately and crosswise.

Install

Notet Replacing camshaft gasket ring.

t When fitting the camshaft the cams of cylinder 1 must point upwards.

t When installing the bearing caps pay attention to the centre displacement of the bores, before installing insert bearing cap and determine fitting position.

t When installing the bearing cap 1, lightly coat the contact surface with sealant -AMV 174 004 01-.

Oil contact surfaces of camshafts.

Screw in bearing caps 2 and 4 alternately crosswise and tighten to 20 Nm.

Install bearing caps 5, 1 and 3 and also tighten to 20 Nm.

Set the Woodruff key in the camshaft.

Install camshaft sprocket and tighten to 100 Nm (use counterholder -MP1-216-).

Installing and tensioning toothed belt (setting timing) Chapter.

Notet After installing the camsaft, the engine must not be started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).


Testing hydraulic bucket tappets


t Feeler gauge

t Wooden or plastic wedge

Notet Always replace bucket tappet complete (cannot be adjusted or repaired).

t Irregular valve noises when starting engine are normal.

t Lay aside removed bucket tappets with the contact surface (camshaft side) facing down onto a clean surface.

t After installing new bucket tappets, the engine must not be started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).


Test sequence

Start engine and allow to run until the radiator fan has cut in once.

Increase engine speed to about 2500 1 rpm for 2 minutes and undertake a test drive if necessary.

NoteIf the irregular valve noises disappear but occur regularly during short trips then the oil retaining valve must be replaced. The installed location of the oil retaining valve: In the oil filter holder Chapter.

If the bucket tappets are still loud, check the faulty tappet as follows:

Remove upper part of collecting intake manifold and cylinder head cover Chapter or Chapter.

Turn the crankshaft clockwise until the cam of the bucket tappet to be tested is positioned on top.

Press down the bucket tappet using a wooden or plastic wedge. If a 0.20 mm feeler gauge can be inserted between the camshaft and the bucket tappet, the tappet must be replaced.

Replacing valve stem seals

l Cylinder head fitted


t Extractor -MP1-206-

t Pressure hose -MP1-210-

t Valve lever -MP1-211-

t Insertion tool -MP1-212-

t Assembly device for valves -MP1-213-

Removing

Remove the camshaft Chapter.

Remove bucket tappets (do not interchange) and lay aside with the contact surface facing down.

Unscrew the spark plugs.

Position piston of the relevant cylinder in bottom dead centre.

Insert the assembly device -MP1-213- and adjust bearing to the stay bolt height.

Screw the pressure hose -MP1-210- into the spark plug thread and apply constant pressure of at least 0.6 MPa (6 bar) in the cylinder.

Remove valve springs with valve lever -MP1-211 -.

NoteIf valve collets are tight, slacken with slight blows of a hammer on the valve lever.

Use pulling device -MP1-206- to pull off valve stem seals.

Install

To avoid damaging the new valve stem seals insert plastic bushing -A- on the valve stem.

Insert valve stem seal -B- in the insertion tool -MP1-212-, oil sealing lip and carefully push onto the valve guide.

Remove plastic sleeve.

Notet After installing the camsaft, the engine must not be started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).


Inspect valve guides


t Universal dial gauge holder -MP3-447-

t Dial gauge

Procedure

Insert valve into guide. End of valve stem must be flush with guide.

Determine valve rock.

Wear limit

Inlet valveExhaust valve

1.0 mm1.3 mm

Notet If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded, replace valve guide.

t If the valve is replaced when carrying out repair work, use a new valve for the measurement.

Replacing the valve guides


t Driver - MP1-205-

t Reamer - MP1-204- and diluted soluble oil

Removing

Clean the cylinder head and check it. Heads whose valve seat rings can no longer be reworked or cylinder heads which have already been machined down to their minimum dimension are unsuitable for replacing the valve guides.

Press out worn valve guides with -MP1-205- from the camshaft side (valve guides with guides with a collar requiring repair from the combustion chamber side).

Install

Press the new guides which have been wetted with oil into the cold cylinder head using the driver -MP1-205-, from the camshaft side up to the collar.

NoteOnce the guide has been pressed against the collar then the pressing in pressure should not be increased above 10 kN since otherwise the collar can break off.

Ream the valve guides using the hand broach -MP1-204-. It is essential to use dilute soluble oil while doing this.

Install new valves.

Rework the valve seats Chapter.

Reworking valve seats


t Depth gauge/caliper gauge

t NAC milling cutter for reworking valve seats

t Grinding paste

Notet When carrying out repairs on engines with leaking valves, it is not sufficient to machine or replace the valve seats and valves. It is also necessary to inspect the valve guides for wear, particularly on engines with a high mileage.

t Rework valve seats only sufficiently in order to obtain a proper contact pattern. Calculate the maximum permissible reworking dimension before commencing. If the reworking dimension is exceeded, the proper operation of the hydraulic valve clearance compensation is no longer ensured. If this is the case replace the cylinder head.

Calculating maximum permissible reworking dimension

Insert valve and press firmly against the valve seat.

NoteIf the valve is replaced when carrying out repair work, use a new valve for the measurement.

Measure distance -a- between the end of the valve stem and the upper face of the cylinder head.

Calculate max. permissible reworking dimension from the distance -a- measured and the minimum dimension.

Minimum dimension: Inlet valve .... 33.8 mm

Outlet valve .... 34.1 mm

Distance measured -a- minus minimum dimension = max. permissible reworking dimension.

Example:

-distance measured -a-Minimum dimension34.5 mm33.8 mm

=Max. permissible reworking dimension0.7 mm

NoteIf the max. permissible reworking dimension is 0 mm, repeat measurement with a new valve. If the max. permissible reworking dimension is again 0 mm, replace cylinder head.

Reworking valve seats

DimensionValve seats

ammValve seat diameter39.2 -0.1 - inlet valve 32.4 -0.1 - exhaust valve

bmmMax. permissible reworking dimension

cmmValve seat width1.9 up to 2.1 - inlet valve 2.3 up to 2.5 - exhaust valve

ZBottom edge of cylinder head

45Valve seat angle

30Top correction angle

Procedure

Reworking can be carried out with a machine or by hand. The following conditions must be met:

l Wear limit of valve guides must not exceed the permissible dimension Chapter.

l Use NAC milling cutter with carbide metal tips (min. 90 HRC).

Reworking valve seats with NAC milling cutter

Place cylinder head on a felt base and secure to prevent it from turning.

Match diameter of guide drift to diameter of valve guide.

Valve guide Guide drift in mm

Inlet valve7,0 -0,01

Exhaust valve

Match diameter of milling cutter to diameter of valve seat.

Valve seat Milling cutter 90 mm Milling cutter 120 mm

Inlet valve4141

Exhaust valve3434

Milling sequence

-1. Mill valve seat with 90 milling tool until until a perfect contact pattern is achieved. (Do not exceed maximum permissible reworking dimension!)

-2. Initially mill top correction angle with 120 milling cutter until the valve seat diameter a or valve seat width c is achieved Anchor.

Grind in valve/valve seat -arrows- with fine grinding paste until a perfect contact pattern is achieved.

Check tightness of valves.

The inspection can be carried out with water colour (perfect contact pattern over entire circumference) or by filling fuel into the combustion chamber (no fuel must flow out at the valve seat).

NoteAfter installing the cylinder head, check the hydraulic bucket tappets Chapter.

Engine lubricationRemoving and installing parts of the lubrication system

Notet If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs, carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.

t The engine oil level must never exceed the max. marking - risk of damage to catalytic converter!

Check the engine oil, amount of oil, oil specification: Octavia

1-Oil pump

Duocentric pump with pressure relief valve 1.2 MPa (12 bar)

Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present

if there is any scoring on contact surfaces and gears, replace

Torque of oil pump cover at oil pump housing: 10 Nm

2-Oil pump sprocket


Fits onto oil pump shaft in one position only

3-20 Nm

4-Oil pump chain

5-Sealing flange

coat with silicone sealant -D176404A2- Chapter

replace the gasket ring for the crankshaft Chapter

6-15 Nm

7-Collar screw, 15 Nm

8-Bush

9-Chain tensioner

together with pos. 7, 8, 10 and 11

10-Spring

11-Washer

12-Sprocket

13-O ring

replace

14-15 Nm

15-Suction line

Clean strainer if dirty

16-Baffle

17-15 Nm

18-15 Nm

loosen and tighten with hinged wrench and socket insert

19-Oil pan

install with silicone sealant -D176404A2- Chapter

20-Gasket ring

replace

21-Oil drain plug, 30 Nm

Disassembling and assembling oil filter holder

1-Screw plug

2-Gasket ring

3-Spring

for overpressure valve approx. 0.4 MPa

4-Piston

for pressure relief valve

5-Gasket

replace

6-Oil retaining valve

Tightening torque 8 Nm

integrated into the oil filter holder

7-Gasket ring

push on as far as collar of connecting tube -pos. 8-

8-Cap

9-Retaining clip

10-Screw plug, 15 Nm

11-Gasket ring

cut open if leaking and replace

12-0.14 MPa oil pressure switch -F1-, 25 Nm

black

check Chapter

13-Gasket ring

cut open if leaking and replace

14-Oil filter holder


replace

16-Gasket

replace

Insert into lugs on oil cooler

17-Oil cooler

ensure clearance to surrounding components

pay attention to the notes Chapter

18-25 Nm

19-Oil filter

slacken with tensioning strap

tighten by hand

pay attention to installation instructions on oil filter

Removing and installing oil pan


t Flexible-head wrench 3185

t Socket insert 3249

t Hand-held power drill with plastic brush insert

t Flat scraper


t Silicone sealant - D176404A2-

Removing

Remove noise insulation panel in middle as well as on left and right -arrows-.

Drain engine oil.

Unbolt oil pan.

NoteSlacken oil pan bolts at flywheel side with hinged wrench -3185- and unscrew with wrench socket -3249-.

Remove oil pan, if necessary release by applying slight blows with a rubber-headed hammer.

Use a flat scraper to remove sealant residues on the cylinder block.

Use a rotating plastic brush to remove sealant residues on the oil pan (wear protective goggles).

Clean sealing surfaces, they must be free of oil and grease.

Install

Notet The oil pan must be installed within 5 minutes after applying the silicone sealant.

t Use socket insert - 3249- to insert the oil pan bolts at flywheel side and tighten with hinged wrench -3185 -.

t The assistance of a second mechanic is required to install the oil pan.

Cut off nozzle tube of the silicone sealant -D176404A2 - at the front marking ( of nozzle approx. 3 mm).

t Thickness of sealant bead: 2 to 3 mm

t The sealant must be run past on the inside in the area of the bolt holes -arrows-.

NoteThe sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.

Apply silicone sealant to the clean sealing surface of the oil pan, as shown in the illustration.

NoteTake particular care when applying sealant bead in the area of the sealing flange at the rear -arrows-.

Fit on oil pan immediately and tighten the bolts as follows:

1. Tighten all the bolts of oil pan/cylinder block slightly diagonally across.

2. Tighten the three bolts of oil pan/cylinder block slightly.

3. Tighten all the bolts of oil pan/cylinder block slightly diagonally across.

4. Tighten the three bolts of oil pan/gearbox to 45 Nm.

5. Tighten all the bolts of oil pan/cylinder block diagonally across to 15 Nm.

Notet When installing the oil pan with the engine removed, ensure that the oil pan is flush with the cylinder block at the flywheel side.

t After installing the oil pan, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in.

Testing oil pressure and oil pressure switch


t Oil pressure testing device (e. g. - V.A.G1342-)

t Voltage tester (e.g. - V.A.G1527-)

t Measuring tool set (e.g. -V.A.G1594-)

t Current flow diagram

Function of dynamic oil pressure warning system if oil pressure low

The oil pressure switch is opened when pressureless and closed when the switching pressure is reached.

The oil pressure warning is activated for about 10 seconds after the ignition is switched on (terminal 15 on).

Activation delay of oil pressure warning system: approx. 3s.

De-activation delay of the oil pressure warning system: approx. 5s.

Test warning light

After the ignition is switched on and engine not running, the oil pressure warning light in the dash panel insert must light up for about 3 s and then go out. The check is ended when the engine is started.

Warning criteria

The visual oil pressure warning (oil pressure warning lamp flashes) is activated and the audible warning buzzer sounds 3 times if one of the following conditions exists:

l Ignition on, engine not running, oil pressure switch closed

l Engine speed above 1500 rpm, oil pressure switch open

At an engine speed above 5000 1 rpm, the oil pressure warning is also not cancelled if the oil pressure switch is closed. The oil pressure warning is cancelled once engine speed is below 5000 1 rpm.

If the oil pressure switch is opened for only 0.5 to 3 s at an engine speed of above 500 rpm, it is stored in the combination processor of the dash panel insert. If this condition occurs 3 times when the engine is running, the oil pressure warning is immediately activated and is not cancelled below 1500 rpm. The oil pressure warning is cancelled if the oil pressure switch is closed for more than 5 s at a speed of more than 1500 rpm, or at Ignition off.

Test conditions

l Engine oil level o.k., test Octavia

l Oil pressure warning light -K3- must come on for about 3 seconds when the ignition is switched on.

l Engine oil temperature at least 80C (radiator fan must have run at least once)

Testing oil pressure switch

Detach cable from oil pressure switch.

Unscrew oil pressure switch and screw in oil pressure tester (e.g. - V.A.G1342-).

Screw oil pressure switch -2- into the test equipment -V.A.G1342-.

Connect brown cable -1- of tester to earth (-).

Connect voltage tester to oil pressure switch -2- and to battery positive (+).

The LED must not light up.

The oil pressure switch must be replaced if the LED lights up.

Start engine and slowly increase engine speed.

The LED must come on at an overpressure of 0.12 to 0.16 MPa (1.2 to 1.6 bar). The oil pressure switch must be replaced if it does not come on.

Testing oil pressure

Unscrew oil pressure switch and screw in the tester - V.A.G1342-.

Screw oil pressure switch into the tester -V.A.G1342 -.

Start engine (engine oil temperature at least 80C).

t Oil pressure when engine idling: min. 0,2 MPa (2 bar)

t Oil pressure at 2000 rpm: 0.30 to 0.45 MPa (3 to 4.5 bar)

If the specified values are not reached:

Eliminate any mechanical damage, e.g. bearing damage.

Replace pressure relief valve in the oil filter holder Chapter.

At a higher engine speed the oil pressure must not be greater than 0.7 MPa (7bar).

If the specified pressure is exceeded:

Inspect oil galleries.

Replace if necessary pressure relief valve in the oil filter holder Chapter.

Engine coolingRemoving and installing parts of the cooling systemParts of the Cooling System

Notet When the engine is warm the cooling system is under pressure. Reduce pressure before repairs.

t The hose connections are secured with spring-type clips. In the event of repairs only use spring-type clips.

t Use pliers for spring strap clips to fit the spring strap clips.

t Always replace seals and gasket rings.

t When installing fit the coolant hoses free of stress, without them touching any other components (pay attention to the marking on the coolant connection and hose).

t Draining and filling up coolant Chapter.

t Coolant mixing ratios Anchor.

t Checking the coolant system for tightness.

1-Radiator

after replacing fill entire system with fresh coolant

2-Oil cooler


3-Coolant pump, coolant regulator

Removing and installing coolant pump Chapter

check smooth operation

Removing and installing coolant regulator Chapter

test, data Chapter

4-Cylinder block

5-Expansion reservoir

6-Intake manifold

7-Heating for throttle valve supports

8-Heat exchanger

9-Gearbox oil cooler

for ATF

only for vehicles with automatic gearbox

Draining and filling up coolant

Coolant capacity approx. 5.0 litres

Special tools, test equipment as well as aids required

t Catch pan (e.g. -V.A.G1306-)

t antifreeze tester

Draining

WARNINGHot steam may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully.


Remove noise insulation in middle -arrows- in top half of Fig.

Position drip tray (e.g. -V.A.G1306-) under the engine.

Turn the drain plug -arrow- on the radiator to the left and draw backwards, if necessary fit auxiliary hose onto connection.

In addition, detach coolant hose at bottom of oil cooler -arrow- and allow remaining coolant to drain.

Notet Collect drained coolant for proper disposal.

t Observe the disposal instructions for coolant.

Filling up

Select the appropriate coolant additive from the catalogue of original parts koda or from the list of allowed coolant additives Octavia.

Recommended mixture ratios:

Antifreeze protection down toAntifreeze concentration Note NoteDrinking water Note

-25C-35C40% (2.0 ltr.)50% (2.5 ltr.)60% (3.0 ltr.)50% (2.5 ltr.)

1) The proportion of coolant additive must not go below 30% due to corrosion protection considerations but must also not exceed 60% otherwise the frost protection effect will be reduced and the cooling effect worsened.

2) The coolant amount may differ according to the version of the vehicle.

Screw in drain valve for coolant.

Attach coolant hose to bottom of oil cooler.

Fill up coolant gradually up to the max marking on the compensation bottle.

Start engine and run for not more than 2 minutes at approx. 1500 rpm; while doing so top up coolant in the expansion reservoir up to overflow opening.

Seal expansion reservoir.

Run engine until fan starts.

WARNINGHot steam may escape when the compensation bottle is opened. Cover the cap with cloths and open carefully.

Inspect coolant level. When engine is at operating temperature the coolant level must be at the maximum marking, when engine is cold between the minimum and the maximum markings.

Removing and installing radiator

Notet Always replace seals and gasket rings.

t Raise vehicle with the lift platform Chapter.



Removing

Drain coolant Chapter.

Unplug connector -1- from thermoswitch -F18- and separate plug connections -2- and -3- at fan shroud (press catches).

Separate coolant hoses at connection fittings of radiator (pull off retaining clip).


Unscrew the 4 bolts -arrows- attaching the condenser.

WARNINGDo not open the refrigerant circuit of the air conditioning system.

NoteIn order to avoid damage to the condenser as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent.

Take off retaining clip attaching refrigerant line.

For all vehicles

Remove both headlights: Electrical System, Rep. Gr. 94; Removing and installing headlight

Unscrew 4 bolts -arrows- attaching top radiator mount.

Unscrew 4 bolts -arrows- attaching bottom radiator mount.

For vehicles with air conditioning

Pull out radiator and condenser slightly.

Take off bracket -arrow- for refrigerant line.

For all vehicles

Remove fan shroud (4 bolts).

NoteWhen removing and installing the fan shroud, ensure that the radiator fins are not damaged.

Carefully remove radiator downward.

Install

Installation is performed in the reverse order. Pay attention to the following points:

Tighten thermoswitch -1- to 35 Nm.

Fit on brackets -2- and -3- at radiator as shown.

Tighten bolts attaching radiator mounts and fan shroud to 10 Nm.

On vehicles with air conditioning, tighten bolts attaching condenser and bracket for refrigerant lines to 10Nm.

Replace O rings in the connection fittings of the coolant hoses.

Insert and tighten the coolant drain plug.


Install headlight: Electrical System, Rep. Gr. 94; Removing and installing headlight.

Electrical connections and laying of cables: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations (Binder)

Removing and installing coolant pump



Removing



Install noise insulation; -arrows- in the lower part of the figure.


Remove ribbed V-belt tensioning device Chapter.

Remove top and middle toothed belt guard Chapter.

Position crankshaft on TDC cylinder 1 Chapter.

Take toothed belt off camshaft sprocket Chapter.

Notet The vibration damper and the bottom toothed belt guard can remain installed.

t The timing belt remains fitted onto the timing belt crankshaft sprocket.

t Pay attention to instructions for the removal and installation of the timing belt Chapter.

Release screws -1- and -5- and remove timing belt guard at rear -2-.

Unscrew coolant pump -4- and carefully guide out along the engine support.

Install

Clean sealing surface for O-ring or smoothen.

Moisten new O-ring -3- with coolant additive.

Attach the coolant pump. Fitting position: Plugs in housing point downwards.

Insert rear toothed belt guard, tighten screw -1- to 20 Nm.

Tighten screws -5- of coolant pump: 15 Nm.

Installing toothed belt, tensioning (setting timing) Chapter.



Removing and installing, testing coolant thermostat




NoteAlways replace seals and gasket rings.

Removing


Detach coolant hose from connection fitting -3-.

Release bolts -4-, remove connection fitting with O-ring -2- and thermostat -1-.

Testing coolant thermostat

Heat up regulator in a water bath.

Start of openingEnd of opening (cannot be tested)Opening stroke

approx. 87Capprox. 102C min. 7 mm

Install

Clean sealing surface for O-ring.

Insert coolant thermostat. Fitting position: The clamp of the coolant thermostat must be positioned vertically.

Moisten new O-ring with coolant additive.

Tighten bolts to 15Nm.

Filling system with coolant Anchor.

Installing coolant pipe




NoteAlways replace seals and gasket rings.

Moisten O-ring -1- with coolant additive and slide onto coolant pipe -2-.

Push the coolant pipe into the bore hole on the cylinder block.

Tighten bracket for coolant pipe to 10 Nm.

Checking the coolant system for tightness


t Coolant system tester (e.g.-V.A.G1274-)

t Adapter (e.g. -V.A.G1274/8-)

t Adapter (e.g. -V.A.G1274/9-)

Test conditions

l Engine must be warm

Test sequence

WARNINGHot steam may escape when the compensation bottle is opened. Cover the cap with cloths and open carefully.

Skoda Octavia Mk1 - 05 - Drive Unit

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Transcript of Skoda Octavia Mk1 - 05 - Drive Unit