motor arv,aqv,aze,azf,ame,atz,aqw

5/25/2018 Motor Arv,Aqv,Aze,Azf,Ame,Atz,Aqw

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Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5305.00.20

Workshop ManualFABIA 2000

1.0/37; 1.4/44; 1.4/50 Engine, MechanicalComponents

Edition 08.99Engine code ARV AQV AZE AZF AME ATZ AQW


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Service5

The Workshop Manual is intended only for use within the Organisation koda.It is not permitted to pass it on to other persons.

KODA AUTO a. s.

Printed in Czech RepublicS00.5305.00.20


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FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components

List of SupplementsEdition 09.03S00.5305.04.20

List of Supplements to Workshop Manual

FABIA 2000

1.0/37; 1.4/44; 1.4/50 Engine, Mechanical ComponentsEdition 08.99

Supple-ment

Edition Subject Article Number

08.99 Basic Edition S00.5305.00.20

1 06.00 Supplement to Basic Edition S00.5305.01.20

2 03.01 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.02.20

3 02.02 Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26 S00.5305.03.20

4 09.03 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.04.20


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List of Supplements Edition 09.03S00.5305.04.20


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Table of ContentsEdition 09.03S00.5305.04.20

I

Table of Contents

00 Technical Data

Technical Data ..........................................................................................

10 Removing and Installing Engine

Removing and Installing Engine ....................................................................- Removing engine ................. ................. ................. ................ ............... ....

- Installing the engine ................. ................. ............... ................ ................. .

- Tightening torques ............... ................. ................. ................ ............... ....

- Assembly bracket ................. ................. ................. ................ ............... ....

13 Crankgear

Removing and installing V-ribbed belt ............................................................

- Summary of components - Vehicles without air conditioning ... ... ... ... ... .. ... ... ... ... .. ... .

- Summary of components - Vehicles with air conditioning ... ... ... ... ... ... .. ... ... ... ... .. ... ..

- Removing the V-ribbed belt ................ ................. ................. ................. .......- Installing the V-ribbed belt ................. ................. ................. ................. .......

Disassembling and Assembling Cylinder Block and Crankshaft ...........................

- Summary of components ............... ................. ................. ................. ...........

- Inspecting synchronous running of sprockets ... ... ... ... ... ... .. ... ... ... ... .. ... ... ... ... .. ... ..

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

- Replacing ring gear .............. ................. ................. ................ ............... ....

Disassembling and Assembling Pistons, Connecting Rod and Liner .....................

15 Cylinder Head, Valve Gear

Removing and installing cylinder head ...........................................................- Summary of components ............... ................. ................. ................. ...........

- Removing and installing cylinder head ..... ..... .... ..... ..... .... ..... ..... .... ..... .... ..... .....

Repairing cylinder head ..............................................................................

- Inspect valve guides ................ ................. ............... ................ ................. .

- Removing and installing valves ............... ................. ................. ............... .....

- Reworking valve seats ............... ................ ............... ................. .................

- Replacing valve stem seal ................. ................. ................. ................. .......

- Basic setting of hydraulic valve clearance compensation ... ... ... ... ... ... .. ... ... ... ... .. ... ..

- Testing the compression ............... ................. ................. ................. ...........

Repairing valve gear ...................................................................................

- Removing and installing camshaft .... .... ..... .... ..... ..... ..... ..... ..... ..... ..... .... ..... .....

- Removing and installing rocker arms ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....

- Inspecting hydraulic tappets ............... ................. ................. ................. .......

17 Lubrication

Removing and installing parts of the lubrication system .....................................

- Summary of components ............... ................. ................. ................. ...........

Removing and installing oil pan ....................................................................

- Removing and installing oil pan - for a 1.0 litre engine ... ... ... ... ... ... ... .. ... ... ... ... .. ... ..

- Removing and installing oil pan - for a 1.4 litre engine ... ... ... ... ... ... ... .. ... ... ... ... .. ... ..

Testing Oil Pressure and Oil Pressure Switch ..................................................

00-1 page 1

10-1 page 110-1 page 1

10-1 page 7

10-1 page 9

10-1 page 9

13-1 page 1

13-1 page 1

13-1 page 3

13-1

page 413-1 page 5

13-2 page 1

13-2 page 1

13-2 page 3

13-2 page 4

13-2 page 7

13-3 page 1

15-1 page 115-1 page 1

15-1 page 2

15-2 page 1

15-2 page 1

15-2 page 2

15-2 page 3

15-2 page 6

15-2 page 6

15-2 page 7

15-3 page 1

15-3 page 1

15-3 page 2

15-3 page 3

17-1 page 1

17-1 page 2

17-2 page 1

17-2 page 1

17-2 page 1

17-3 page 1


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Table of Contents Edition 09.03S00.5305.04.20

II

19 Cooling

Parts of cooling system - Summary of components ...........................................

- Parts of the cooling system fitted to body .... ..... .... .... ..... ..... .... ..... ..... ..... ..... ..... .

- Parts of cooling system engine side ..... .... ..... ..... .... .... ..... ..... .... ..... ..... .... ..... ....

- Connection diagram for coolant hoses ..... .... ..... ..... .... ..... ..... .... .... ..... .... ..... ..... .

- Draining and filling up coolant .... ..... ..... .... ..... ..... .... ..... .... .... ..... ..... ..... ..... ..... .

- Checking the coolant system for tightness .... ..... ..... .... ..... ..... .... ..... ..... .... .... ..... .

Removing and Installing Radiator, Coolant Pump .............................................

- Removing and installing radiator .... ..... .... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .

- Removing and installing coolant pump ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... .... ..

20 Fuel Supply

Removing and Installing Parts of the Fuel Supply System ...................................

- Safety precautions when working on the fuel supply system ... ... ... ... ... ... ... ... ... ... ... ..

- Cleanliness rules .............. ................. .............. ................. ................. .......

Activated Charcoal Filter System ..................................................................

- Repairing parts of the activated charcoal filter system ... ... ... ... ... .. ... ... ... ... .. ... ... ... ..

26 Exhaust System

Removing and installing parts of the exhaust system ........................................

- Aligning exhaust system free of stress ..... .... ..... ..... .... ..... ..... .... .... ..... .... ..... ..... .

- Replacing front or rear silencer ..... ..... .... .... ..... ..... .... ..... ..... .... ..... ..... .... ..... ....

- Checking the exhaust system for leaks ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .

19-1 page 1

19-1 page 1

19-1 page 3

19-1 page 5

19-1 page 5

19-1 page 7

19-2 page 1

19-2 page 1

19-2 page 2

20-1 page 1

20-1 page 3

20-1 page 3

20-2 page 1

20-2 page 1

26-1 page 1

26-1 page 2

26-1 page 3

26-1 page 3


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Technical DataEdition 09.03S00.5305.04.20

00-1page 1

00

00-1 Technical Data

Engine number

The engine number (engine identification charactersand serial number) is located on the end face of the cyl-inder block on the belt pulley side, at the connection tothe cylinder head -arrow-.

In addition, a sticker with engine identification and seri-al number is affixed to the cylinder head cover.

The engine identification characters are also indicated onthe vehicle data sticker.

Engine characteristics

00 Technical Data

Engine identification charac-ters

ARV AQV AZE AZF

Manufactured 01.0107.02 01.0107.02 04.00 03.03 04.00 03.03

Exhaust limits conforming to EU-2 EU-3 EU-2 EU-4

Displacement l 0,997 0,997 1,397 1,397

Power output kW atrpm

37/5000 37/5000 44/5000 44/5000

Torque Nm atrpm

84/2750 84/2750 118/2600 118/2600

Bore mm 72 72 75,5 75,5

Stroke mm 61,2 61,2 78,0 78,0

Compression 10 : 1 10 : 1 10 : 1 10 : 1

Fuel - RON 95 unleaded1)

1) At least 91 RON in exceptional cases; the engine output is reduced however

95 unleaded1) 95 unleaded1) 95 unleaded1)

Fuel injection and ignition sys-tem

Simos 3PB Simos 3PA Simos 3PB Simos 3PA

Knock control yes yes yes yes

Self-diagnosis yes yes yes yes

Lambda control 1 lambda probe 2 lambda probes 1 lambda probe 2 lambda probesCatalytic converter 1 Catalyst 2 Catalysts 1 Catalyst 2 Catalysts

Turbocharging no no no no

Exhaust gas recirculation no no no no

Secondary air system no no no no

Camshaft adjustment no no no no


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Technical Data Edition 09.03S00.5305.04.20

00-1page 2

00

Engine identification characters AME ATZ AQW

Manufactured 08.99 04.03 11.99 07.00 08.0003.03

Exhaust limits conforming to EU-2 D4 EU-4, EU3-DDK

Displacement l 1,397 1,397 1,397

Power output kW at rpm 50/5000 50/5000 50/5000

Torque Nm at rpm 120/2500 120/2500 120/2500

Bore mm 75,5 75,5 75,5

Stroke mm 78,0 78,0 78,0

Compression 10 : 1 10 : 1 10 : 1

Fuel - RON 95 unleaded1)

1) At least 91 RON in exceptional cases; the engine output is reduced however

95 unleaded1) 95 unleaded1)

Fuel injection and ignition system Simos 3PB Simos 3PA Simos 3PA

Knock control yes yes yes

Self-diagnosis yes yes yes

Lambda control 1 lambda probe 2 lambda probes 2 lambda probes

Catalytic converter 1 Catalyst 2 Catalysts 2 Catalysts

Turbocharging no no no

Exhaust gas recirculation no no no

Secondary air system no no no

Camshaft adjustment no no no


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Removing and Installing EngineEdition 02.02S00.5305.03.20

10-1page 1

10

10-1 Removing and InstallingEngine

Special tools, test and measuring equipment andauxiliary items required

Workshop crane (e.g. -V.A.G 1202 A-)

Catch pan (e.g. -V.A.G 1306-)

Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-)

Torque wrench 40 to 200 Nm (e.g. -V.A.G 1332-)

Pliers for spring strap clips

Engine mount -MP 1-180-

Assembly stand -MP 9-101-

Lifting device -MP 9-201-

Grease -G 000 100-

Hot screw paste -G 052 112 A3-

Wire

Adhesive tape

Removing engine

The engine is removed towards the front together with

the gearbox. Supporting points for lift platform Inspection and

Maintenance.

The hose connections are secured with screw-typeclips, spring-type clips or clamp-type clips. Always re-place warm-type clamps with spring strap clips orwarm-type clamps.

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

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

Pay attention to the correct assignment of the connec-tors, if necessary mark.

Procedure

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

Disconnect the earth strap from the battery with the ig-nition off.

Remove noise insulation -arrows-.

Unscrew the drive shaft to the right and left of thegearbox.

Raise drive shafts and secure.

10 Removing and Installing Engine

Note

S10-0135


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Removing and Installing Engine Edition 02.02S00.5305.03.20

10-1page 2

10

Remove front exhaust pipe with catalyst Chap. 26-1.

Place drip tray below the engine (e. g. -V.A.G 1306-).

Loosen the drain screw on the coolant expansion bot-tle.

Turn the drain plug -arrow- on the radiator to the left

and draw backwards, if necessary fit auxiliary hoseonto connection.

Remove engine cover -1- as follows:

Release logo -2- and carefully lever off the cap -3-.

Release nuts -4- (5 Nm). Pull out oil dipstick -6-.

Remove engine cover -1- towards the top (do not un-screw cap -5-).

Close the oil filler inlet on the cylinder head cover withthe cap fitted to the bottom of the engine cover (if notavailable use other means).

Remove the air filter with hoses 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24.

Remove the cable from the starter solenoid switch

Electrical System; Rep. Gr. 27. Remove battery and battery tray Electrical System;

Rep. Gr. 27.

Release the generator cables from the battery coverand remove the wiring loom from the holder.

Unplug connector -1- from the engine control unit.

Separate plug connection -2-.

Unclip cable clip -3- -arrows-.

A10-0118

S10-0138

1

6 4

5

3

4

2

1

2

S10-0142

3


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10-1page 3

10

Remove coolant hoses -1- and -2- from the coolantregulator housing.

Remove the vacuum connection from the brake servounit.

Remove the fuel presupply pipe -4- by pressing the re-lease buttons at the separation point.

Remove coolant hoses -1- and -2- from the expansionreservoir.

Release vacuum hose -3- from the solenoid valve-N80-.

Release nut -arrow A- and tie up holder -1-.

M

M

1

2 S10-0141

Caution!

The fuel system is under pressure! Before openingthe system lay cleaning cloths around the connec-tion point. Reduce pressure by carefully releasingthe connection point.

2

1

3 4

S10-0137

B

1

S34-0397

A


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10-1page 4

10

Disconnect the Bowden cable support from gearbox-arrows-.

Detach selector cable -A-, for this step remove circlip-arrow 1- from the relay lever.

Remove bearing bolt -arrow 2- from the reversing le-ver of the selector cable -A-.

Remove the shift cable -B- with the gearbox shift le-ver, for this step unscrew nut -arrow 3-.

Remove the hose line holder -1- from the gearbox -ar-row A-.

Remove -arrow B- the slave cylinder -2- and lay aside,secure with wire, do not open the line system.

Do not depress the clutch pedal.

S34-0389

A

1

3

B

2

S34-0398

2

A

B1

B

S34-0400

Note


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10-1page 5

10

Remove the earth strap -1- from the front of the gear-box.

Disconnect plug -2- from the reversing light switch-F4-.

Separate plug connection -3-.

Remove coolant hose from the rear coolant pipe -ar-row-.

Remove connector -1- from thermo-switch -F18- andseparate plug connections -2- on the holder of the airduct scoop.

To do so press the latch clips.

There are 2 plug connections on vehicles fitted with airconditioning.

Separate the coolant hose from the radiator at the topand bottom of the connection fittings.

To do so pull the retaining clip -3- up to the stop andremove the quick coupling towards the rear.

1

3

2

S10-0143

S10-0139

1

2

3

S19-0078


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10-1page 6

10

Unbolt the pendulum support -arrows-.

Vehicles without air conditioning

Removing the lock carrier with radiator Body Work;Rep. Gr. 50.

Vehicles with air conditioning

Remove the V-ribbed belt Chapter 13-1.

Remove connector from the AC compressor.

Remove AC compressor with the refrigerant lines con-nected.

Secure the AC compressor -1- to the lock carrier -ar-row-.

Remove the lock carrier with the radiator and con-denser Body work; Rep. Gr. 50, swivel to the sideand position on support -2- in such a way that there isno risk of tilting.

Do not buckle the refrigerant lines.

Use cloths to protect the right headlight glass fromdamage, removing the headlight if necessary.

Continued for all vehicles

Hook on lifting device -MP 9-201- as follows and raiseslightly with the workshop crane.

On the belt pulley side:2nd hole of the vertical perforated bar in position 1

On the flywheel side:2nd hole of the vertical perforated bar in position 5

The rig positions on the supporting bracket marked 1to 4 point towards the belt pulley.

The holes in the vertical perforated bars are countedfrom the hook.

S34-0403

Caution!

Do not open the refrigerant circuit of the air condi-tioning system.

2

1

S10-0136

Note

MP 9-201

S10-0134

2 3 4 7 81 5 6

Warning!

Use securing pins on the hooks and rig pins.

Note


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10-1page 7

10

Release screws -2-.

Unscrew the fixing screws -arrows- from the gearboxmount.

Slightly lower the engine/gearbox unit and pull outcarefully towards the front.

Secure the engine with engine mount -MP 1-180- on theassembly support -MP 9-101- before performing assem-bly work.

Grip the engine on the supports of the engine mount -ar-rows-.

Instead of engine mount -MP 1-180- it is also possible touse engine mount -MP 1-202-.

Installing the engine

Always replace the seals and gaskets during assem-bly work.

Always replace self-locking nuts.

Apply hot screw paste -G 052 112 A3- to the pinscrews on the exhaust manifold.

Tightening torques 10-1page 9

Assembly bracket 10-1page 9

3

2

1

S10-0140

S10-0120

MP 1-180

MP 9-101

S10-0082

Note

Note


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10-1page 8

10

Procedure

Installation is performed in the reverse order. Pay atten-tion to the following points:

Check whether the dowel sleeves for centering theengine/gearbox are present in the cylinder block; in-sert if necessary.

If necessary check the centering of the clutch driverdisc.

Inspect clutch release bearing for wear, replace if nec-essary.

Lubricate the drive shaft serration lightly with grease-G 000 100 -.

Install the slave cylinder of the hydraulic clutch Gearbox 002; Rep. Gr. 30.

Adjust the gearshift mechanism and cable control Gearbox 002; Rep. Gr. 34.

When installing the engine/gearbox unit make sure alladjoining components are clear.

Align the engine/gearbox unit.

Tightening torques 10-1page 9.

Vehicles with air conditioning

Install the AC compressor Chapter 13-1.

Install alternator Electrical System; Rep. Gr. 27.

Fit V-ribbed belt Chapter 13-1.

Continued for all vehicles

Install the drive shaft on the right and left of the gear-box Chassis; Rep. Gr. 40.

Install the front exhaust pipe with catalyst and fit theexhaust pipe free of stress Chapter 26-1.

Electrical connections and cables Current Flow Di-agrams, Electrical Fault Finding and Fitting Locations.

Install coolant hoses Chapter 19-1.

The drained off coolant must only be re-used if the cylin-der block, cylinder head, radiator or heat exchanger werenot replaced.

Top up coolant Chapter 19-1

After connecting the battery:

Code radio.

Set clock.

Initialise power window lifter.

Inspection and Maintenance

Check oil level before starting the engine.

Note


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10-1page 9

10

Adapt the engine control unit to the throttle valve con-trol unit -J338- 1.4/1.0; 1.4/44 engine - fuel injec-tion; Rep. Gr. 24.

Perform a test drive and interrogate and erase faultmemory 1.0/37; 1.4/44; 1.4/50 engine - fuel injec-tion; Rep. Gr. 01 .

Tightening torques

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

Other lubricants such as engine and gearbox oil areallowed. Do not use Molykote.

Do not use degreased parts.

Unless otherwise indicated the following tighteningtorques apply:

Assembly bracket

Tightening torques

Engine mounting

1 - 20 Nm + 90(1/4turn) - replace

2 - 30 Nm + 90(1/4turn) - replace

Gearbox mounting

1 - 50 Nm + 90(1/4turn) - replace

2 - 40 Nm + 90(1/4turn) - replace

Note

Component Torque

Screws/nuts M6 9 Nm

M7 13 Nm

M8 20 Nm

M10 40 Nm

M12 70 Nm

deviations:

Engine to gearbox connectingscrews

Manual gearbox002; rep. size 34

Drive shaft to gearbox mount-ing flange Chassis; rep. size40

21

1 1

S10-0132

2

11

1

1 S10-0125


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10-1page 10

10

Hinged bracket

Tighten screws -1- in the elongated holes of the supportin such a way that the maximum permissible distance isobtained between the gearbox and the assembly carrier.

1 - 30 Nm + 90

(1

/4turn) - replace2 - 40 Nm + 90(1/4turn) - replace

2

1

S10-0133

Note


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Removing and installing V-ribbed beltEdition 02.02S00.5305.03.20

13-1page 1

13

13-1 Removing and installing V-ribbed belt

Summary of components - Vehicles without air conditioning

Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already usedbelt may destroy it.

Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.

1 - Coolant pump

removing and installing Chapter 19-2

2 - Bracket

for clamp removing and installing

Chapter 15-1

3 - Screw

4 - Clamp

5 - 25 Nm

replace

6 - Generator

to facilitate positioning of thegenerator on the holder,drive the bushing of the re-taining screw slightly back-

wards7 - Screw

8 - 30 Nm

replace

9 - 45 Nm

10 - 25 Nm

coat with -AMV 105 500-(Loctite 242) before inserting

11 - Bracket

for generator

12 - Guide pulley

13 - Washer

Camber towards the outside

14 - 20 Nm

Left-hand thread coat with -AMV 154 100- (Loctite 648) before inserting

15 - Belt pulley

for crankshaft

16 - 100 Nm

to release and tighten lock flywheel Engine removed: with -MP 1-504- Engine installed: with locking screw Chapter 13-2

17 - V-ribbed belt

Routing of the ribbed V-belt Fig. 1 in 13-1page 2 removing 13-1page 4

13 Crankgear

Note

1

S13-0241

17

7

9

10

121314

1516 11

3

2

5

6

4

8


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Removing and installing V-ribbed belt Edition 02.02S00.5305.03.20

13-1page 2

13

installing 13-1page 5

Fig. 1: Routing of the ribbed V-belt

1 - Belt pulley - generator

2 - Belt pulley - crankshaft

3 - Guide pulley4 - Belt pulley - coolant pump

1

2

3

4

S13-0242


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13-1page 3

13

Summary of components - Vehicles with air conditioning

Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already usedbelt may destroy it.

Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.

1 - Coolant pump


2 - Lever with tensioner

grease bearing points inholder before fitting

3 - Bracket

for generator and AC com-pressor

4 - Gasket

replace

5 - 20 Nm

6 - 10 Nm

7 - Screw

tightening order and tighten-ing torque Fig. 2 in 13-1page 4

8 - Washer

9 - Screw

tightening order and tighten-ing torque Fig. 2 in 13-1page 4


10 - Bushing

11 - Guide pulley

12 - Washer

Camber towards the outside

13 - 35 Nm


14 - Screw

tightening order and tightening torque Fig. 2 in 13-1page 4

15 - Dowel sleeves for AC compressor must be present in holder item 3 in 13-1page 3

16 - 45 Nm

17 - 25 Nm

18 - Generator

to facilitate the positioning of the generator on the holder drive the bushing of the retaining screw slightly back-wards

19 - 25 Nm

20 - Belt pulley

for crankshaft

21 - 100 Nm

to release and tighten lock flywheel Engine removed: with -MP 1-504- Engine installed: with locking screw Chapter 13-2

Note

S13-0344

1

22

2021

3

4

24

6

5

7

9

1011

1213

1415

16

17

18

19

9

7

5

8

8


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13-1page 4

13

22 - V-ribbed belt

Routing of the ribbed V-belt Fig. 3 in 13-1page 4 removing 13-1page 4 installing 13-1page 6

Fig. 2: Tightening torques and tightening order for

alternator bracket and AC compressor

1 - 23 Nm

2 - Bracket for alternator and AC compressor

3 - 45 Nm

4 - Washer

5 - 23 Nm

6 - 45 Nm

7 - 23 Nm

Screws are tightened up in two stages in the following or-der:

1. Stage: tighten to 2 Nm one after the other in the or-der of items: 1, 2, 3, 4, 5

2. Stage: the desired final tightening torque - tighten inthe same order as for the 1st stage

Fig. 3: Routing of the V-ribbed belt

1 - Belt pulley - AC compressor

2 - Guide pulley

3 - Belt pulley - generator

4 - Belt pulley - crankshaft

5 - Tensioning pulley6 - Belt pulley - coolant pump

Removing the V-ribbed belt

Removing - vehicles without air conditioning

Mark the routing of the V-ribbed belt.

Release securing screws -arrows- and pivot the gen-erator towards the engine.

Remove the V-ribbed belt.

Removing- vehicles with air conditioning


Wrench for V-ribbed belt -T30022-

The assistance of a second mechanic is required to tight-en the V-ribbed belt.

S13-0244

2

3

4

65

1

S13-0245

Note


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13-1page 5

13


Mark the routing of the V-ribbed belt.

Release screw -1- from the tensioner -3-.

Remove camshaft position sensor -2-.

Insert wrench for ribbed V-belt -T30022 - in the ten-sioner -3- up to the stop.

Loosen tensioning pulley (tighten tensioner -3-). Tothis end rotate wrench in the direction of the arrow.

Remove the V-ribbed belt from the tensioning pulleyand pivot tensioning pulley back.

Installing the V-ribbed belt

Check V-ribbed belt for wear Inspection and Main-tenance.

Before fitting the V-ribbed belt make sure that all as-semblies (generator, coolant pump, AC compressor)are securely mounted.

Check smooth operation of belt pulley, tensioning andguide pulley.

Pay attention to the rotation direction of already usedV-ribbed belts.

Installing- Vehicles without air conditioning


Torque wrench

V-ribbed belt tensioning tool (e.g. NP 002 manufac-tured by Nolt)

Belt tension measuring tool (e.g. of the firm Optibelt orClavis)

Replace self-locking nuts -arrows- and tighten whilemaking sure the generator can still be rotated.

Fit the ribbed V-belt.

S10-0135

1

23

T30022

S13-0246

Note

S13-0245


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13-1page 6

13

Insert V-ribbed belt tensioning tool NP 002 in theclamp and tension the V-ribbed belt by screwing outthe handle -in direction of the arrow-.

Position the belt tension measuring tool (in the figureof the firm Optibelt) on the V-ribbed belt and read offthe belt tension value -arrow- on the scale Operat-

ing Instructions for the relevant measuring tool.

Tighten the new ribbed V-belt with 500 +100N, run enginefor approximately 1 minute in idle and re-adjust the belttension.

Nominal values for the tension of the V-ribbed belt:

New ribbed V-belt (run in for 1 minute): 400 +80 N

Used V-ribbed belt: 400 +50 N

Once the nominal value has been reached, tighten thenuts of the generator mounting:

1 - 25 Nm

2 - 25 Nm

3 - 30 Nm

Check belt tension again, correct if necessary.

Start engine and check belt run.

Installing - Vehicles with air conditioning


Wrench for ribbed V-belt -T30022-

The assistance of a second mechanic is required to loos-en the V-ribbed belt.

Position the V-ribbed belt on the belt pulleys andguide pulley.

S27-0014

NP 002

S13-0240

Note

S13-0249

1 2

3

Note


25/88



13-1page 7

13

Insert wrench for V-ribbed belt -T30022 - in the ten-sioner -3- up to the stop.

Loosen tensioning pulley (tighten tensioner -3-). Tothis end rotate wrench in the direction of the arrow.

Position the V-ribbed belt on the tensioning pulley andpivot tensioning pulley back.

Tighten screw -1- on the tensioner -3-.

Tightening torque: 10 Nm

Fit camshaft position sensor -2-.


Start engine and check belt run.

Fit noise insulation -arrows-.

1

23

T30022

S13-0246

S10-0135


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13-1page 8

13


27/88


Disassembling and Assembling Cylinder Block and CrankshaftEdition 09.03S00.5305.04.20

13-2page 1

13

13-2 Disassembling and As-sembling Cylinder Blockand Crankshaft

Summary of components

1.4 ltr. engine

1.0 litre engine 13-2page 3

The design of the 1.0 litre engine is essentially identical to that of the 1.4 ltr. engine. Differences exist only in theversion of the crankshaft and its mounting 13-2page 3.

Repairing the clutch Manual Gearbox 002; Rep. Gr. 30; Repairing the clutch.

The engine should be attached to the engine repair stand -MP 1-180- or -MP 1-202 - on the engine holder-MP 9-101- to carry out removal and installation work.

1 - 75 Nm

2 - Crankshaft bearing unit

3 - Thrust washer

for middle bearing lubricating grooves point out-

wards

4 - 8 Nm


5 - Flywheel

with rotor for engine speed

sender -G28- lock with -MP 1-504- for re-

moving and installing replace ring gear 13-2

page 7 installation position to crank-

shaft: on the 1.0 ltr. engine the 2

missing teeth of the rotormust face forward whencrankshaft position at TDC ofcyl. 1 (marking of belt pulley -

crankshaft is positioned op-posite marking 0 at timinggear cover)

only one installed position ispossible for the 1.4 litre en-gine (since the bore holesare varying distances apart)

6 - 30 Nm + torque a further 1/4

turn (90)

replace coat with -AMV 200 000- (Loctite 270) before inserting

7 - Gasket ring

replace remove when removing the sealing flange lightly oil sealing lip and outer edge before installing

Note

S13-0170

1

16

15

1718

26

27

28

19

29

5

6

7

8

13

24 23 22 21 20

25

4

2

3

10

9

11

12

14


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Disassembling and Assembling Cylinder Block and Crankshaft Edition 09.03S00.5305.04.20

13-2page 2

13

press into the sealing flange

8 - Sealing flange

not available as replacement part (only together with cylinder block) coat with -AMV 188 520- (Loctite 574) before inserting

9 - Shield

for knock sensor -G61-

10 - 5 Nm

11 - 20 Nm

The tightening torque influences the knock sensor function

12 - Knock sensor -G61-

13 - Cylinder block

disassembling and assembling pistons, conrod and liner Chapter 13-3

14 - 8 Nm

15 - Timing gear cover

16 - Gasket ring

replace 13-2page 4

17 - Belt pulley

for crankshaft18 - 100 Nm

to release and tighten lock flywheel Engine removed: with -MP 1-504- Engine installed: with locking screw 13-2page 4

19 - 7 Nm

coat with -AMV 105 500- (Loctite 242) before inserting

20 - Gasket

replace

21 - Camshaft sprocket

after replacing, inspect synchronous running of chain sprockets Fig. 1 in 13-2page 3

22 - Helical gear for oil pump drive

23 - 25 Nm

coat with -AMV 154 100- (Loctite 648) before inserting

24 - Timing chain

mark running direction (installed position) before removing always replace complete with crankshaft sprocket and camshaft sprocket

25 - Bearing shell

for cylinder block with lubricating groove do not mix up used bearing shells (mark)

26 - Crankshaft sprocket

after replacing, inspect synchronous running of chain sprockets 13-2page 3 Camshaft setting Fig. 1 in 13-2page 3

27 - Woodruff key

check tightness

28 - Crankshaft

Axial play when new: 0.03 to 0.13 mm Wear limit: 0.26 mm

29 - Bearing shell

for crankshaft bearing unit without lubricating groove do not mix up used bearing shells (mark)


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13-2page 3

13

Modifications of the 1.0 litre engine compared to the 1.4 litre engine

1 - Bearing caps

Bearing cap 1: on the beltpulley side

Bearing cap 2: with recessesfor thrust washers

2 - Bearing shell for bearing cap without lubri-

cating groove do not mix up used bearing

shells (mark)

3 - Thrust washer

for bearing cap 2 check for firm seating

4 - Crankshaft

Axial play when new: 0.03 to0.13 mm

Wear limit: 0.26 mm

5 - Bearing shell

for cylinder block with lubri-cating groove

do not mix up used bearingshells (mark)

Fig. 1: Camshaft setting

Insert chain sprockets -2- and -3- into the timing chain-1- so that the distance -a- (from marking to marking-arrows-) is 12 chain pins.

Inspecting synchronous running ofsprockets

This inspection should be carried out if the sprocketshave been replaced.


Straightedge

Feeler gauge

The crankshaft sprocket is available in 3 different widths;

graduations: marked 0.2 mm with letters E, F or G.The wheel with an average thickness, marked with theletter F, is supplied together with the camshaft sprocket

S13-0209

1

2

3

4

5

a=1

2

S15-0028

1

2

3


30/88



13-2page 4

13

in a set, the wheels marked with the letters E and Gare only supplied individually Spare Part Catalogue.

Marking of the crankshaft sprocket radially in the area ofthe slot for the Woodruff key -arrow- is carried out with theletters E, F or G.

If chain sprockets are replaced, order crankshaft sprock-et with same code letter and check synchronous run-ning of chain sprockets.

Test sequence

Press the chain sprockets until they make contact,with the markings -arrows- for the timing pointing out-wards.

Place straightedge flat onto the camshaft sprocketand measure size of gap at crankshaft sprocket.

Position of chain sprockets

1 - Camshaft sprocket

2 - Crankshaft sprocket

Pfeil-points towards flywheel side

I - Nominal dimension -a- = 0.09 0.2 mm

II - max. tolerance -b- = 0.29 mm

III - min. tolerance -c- = -0.11 mm (crankshaft sprocketis positioned further out)

If the size of the gap is not within the tolerance range,install crankshaft sprocket of a different width and re-peat the inspection.

Replacing gasket ring for crankshaft -onthe belt pulley side-


Pressure plate -MP 6-401/1-

Supporting device -MP 9-200-

Two-arm extractor -Kukko 20-10-

Removal hooks -T10040/1-

Pressure plate -T10041-

*

S13-0172

Note

S15-0027

I II III

1

2

b

1

2

c

1

2

a

S13-0171


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13-2page 5

13

Flywheel lock -MP 1-504-

Torque wrench

Screw M 6x40 (grade: 8.8)

make a 60point at the extremity of the bolt (lockingscrew)

Nut M6

Removing

Removing engine cover Chapter 10-1.

Mount supporting device -MP 9-200- and take up theweight of the engine/gearbox assembly at the spin-dles.

Unscrew bolts -2-.

Remove right wheel-well inner panel.


Lower engine approximately 50 mm.

Remove the V-ribbed belt Chapter 13-1.

3

2

1

S10-0140

S10-0135


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13-2page 6

13

To lock the crankshaft remove the engine speedsender and screw in the locking screw -1- instead.

Slightly rotate the crankshaft on the central screw untilthe locking screw can be fully tightened (screw tip islocated between 2 teeth of the ring gear).

Tighten up the screw and secure in place with thecounternut -2-.

If the engine has been removed use a flywheel lock-MP 1-504- to lock the crankshaft.

Remove the central screw and belt pulley crankshaft.

Pull out gasket ring with two-arm extractor -A- (Kukko-20-10-), extractor hook -T10040/1 - and pressureplate -MP 6-401/1-.

Installing

Crankshaft is locked with flywheel lock -MP 1-504 -, orlocking bolt.

Lightly oil the sealing lip of the gasket ring.

Press down gasket ring with pressure plate -T10041 -up to the stop into the bushing.

Use to press in the central screw.

Install the crankshaft belt pulley.

Tighten central screw with 100 Nm.

Release locking screw and install engine speed send-er.


Do not start engine as long as the locking screw is locat-ed in the gearbox housing!

Install the V-ribbed belt Chapter 13-1.

Installing pendulum support and attaching enginemounting Chapter 10-1.

Attaching the double clamp of the exhaust system Chapter 26-1.

S13-0173

1

2

1 aNote

MP 6-401/1

A

T10040/1

T10040/1

S13-0175

T10041

N13-0425

Note

Note


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13-2page 7

13

Replacing ring gear

Flywheel removed

Removing

Fit on flywheel flat and position ring gear in stages bystriking over the entire circumference. Heat ring gearif stiff.

Installing

Heat ring gear to approx. 150 C and fit onto the fly-wheel; knock on as far as the stop evenly with a driftover the entire circumference, if necessary.


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13-2page 8

13


35/88


Disassembling and Assembling Pistons, Connecting Rod andLiner

Edition 06.00S00.5305.01.20

13-3page 1

13

13-3 Disassembling and Assembling Pistons, Connecting Rod andLiner

Secure the engine with engine holder -MP 1-180- or -MP 1-202- on the assembly stand -MP 9-101- before performingassembly work.

Special tools, test and measuring equipment and aids required

Liner extractor 75.5 mm -MP 1-105-

Piston pin drift -T10046-

1 - Piston ring (chrome-plated)

use piston ring pliers for re-moving and installing

marking TOP faces pistoncrown

inspecting piston ring gapclearance Fig. 1 in 13-3page 2

inspecting piston ring endclearance Fig. 2 in 13-3page 3

2 - Piston ring (grey)

use piston ring pliers for re-moving and installing

marking TOP faces pistoncrown

inspecting piston ring gapclearance Fig. 1 in 13-3page 2

inspecting piston ring endclearance Fig. 2 in 13-3page 3

offset gap 120relative to toppiston ring

3 - Oil scraper ring (3 part)

remove and install by hand installing Fig. 3 in 13-3

page 3

4 - Piston

mark installation position and

matching liner arrow on piston crown faces

towards the camshaft side use piston ring tensioning strap for installing install pistons of the same weight class only (+ pr - on piston crown) available as replacement part only as a set with liners (4 in total)

5 - Conrod

Check fitting position: engraved number (1 to 4 for appropriate cylinder) -arrow A- points towards camshaftside, mark if necessary

Oil drilling -arrow B- for piston pin lubrication available as replacement part only in set (4 conrods with 4 conrod caps)

6 - Conrod bolt only 1.4 ltr. engine check fitting position press out to replace

Note

1

A

2

3

4

5

6

7

9

11

12

13

15

11

S13-0210

14

B

8

10


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Edition 06.00S00.5305.01.20

13-3page 2

13

7 - Cylinder block

seat surfaces for liners must be clean and flat remove contamination on seat surfaces of the liners by cleaning only; do not use emery paper, flat scraper or

similar

8 - Conrod bolt, 20 Nm + torque a further 1/4 turn (90)

only 1.0 ltr. engine replace

oil thread and head contact surface9 - 40 Nm

only 1.4 ltr. engine oil thread and head contact surface

10 - Conrod cap

check fitting position item 5 in 13-3page 1

11 - Bearing shell

do not mix up used bearing shells 1.0 ltr. engine insert in middle 1.4 ltr. engine ensure tightly located in retaining lugs

12 - Gasket ring

replace different thicknesses are available to correct the liner pretension

13 - Liner

remove with -MP 1-105- available as replacement part only as a set with pistons (4 in total) check pretension Fig. 4 in 13-3page 3

14 - Circlip

15 - Piston pin

remove and install with -T10046-, if stiff, heat piston to 60 C

Fig. 1: Inspecting piston ring gap clearance


Feeler gauge

Push in ring, at right angles about 15 mm away fromtop edge of liner.

S13-0006

new

Piston ring

dimensionsin mm

1.0 ltr. en-

gine

1.4 ltr. en-

gine

Wear limit

1. Piston ring(chrome-plat-ed)

0,20...0,50 0,40...0,72 1,0

2. Piston ring(grey)

0,20...0,50 0,30...0,62 1,0

Oil scraperring

0,40...1,40 0,40...1,40 ---1)

1) no specification possible for wear limit


37/88



Edition 06.00S00.5305.01.20

13-3page 3

13

Fig. 2: Inspecting piston ring end clearance


Feeler gauge

Clean ring groove before inspecting.

Fig. 3: Installing oil scraper ring

The oil scraper ring consists of a shaped spring ring and

a top and bottom metal ring.

Installation steps:

Insert spring ring into the groove. Position joint so thatthere is no hole behind it.

Compress joint of spring ring and insert top metal ring.The joint of the top metal ring should be positioned45...90to the left of the joint of the spring ring.

Compress joint of spring ring and insert bottom metalring. The joint of the bottom metal ring should be posi-tioned 45...90to the right of the joint of the spring

ring.

Fig. 4: Inspecting pretension of liners


Measuring tool for liner pretension -MP 1-107-

Dial gauge

The seat surfaces of the liners and of the cylinder blockmust be clean and flat.

Remove contamination on seat surfaces of the liners bycleaning only; do not use emery paper, flat scraper orsimilar

Insert liners with seal firmly into the cylinder block upto the stop.

Measure projection (preload) of liners to top edge ofcylinder block.

The projection must be 0.07...0.12 mm; if necessary ad-just to correct projection by fitting seals of different thick-nesses.

V13 - 0687

Piston ring dimen-sionsin mm

new Wear limit

1. Piston ring(chrome-plated)

0,04...0,08 0,15

2. Piston ring (grey) 0,04...0,08 0,15

Oil scraper ring cannot be measured

S13-0008

MP 1-107

S13-0128


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Edition 06.00S00.5305.01.20

13-3page 4

13

Seals are available in thicknesses of 0.10; 0.12 and0.14 mm.

The difference in the projections of the liners to eachother must not exceed 0.04 mm.

The liners must not touch at the flattened points -ar-

rows-.

Note


39/88


Removing and installing cylinder headEdition 09.03S00.5305.04.20

15-1page 1

15

15-1 Removing and installing cylinder head


Testing compression pressure Chap. 15-2

Removing and installing intake manifold: 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24

Removing and installing exhaust manifold Chapter 26-1

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

1 - 3 Nm

2 - Seal

replace

3 - Cylinder head bolt

moisten with oil beforescrewing in

tightening order and tighten-ing torque 15-1page 4

4 - Washer

5 - Lifting eye - on the left

6 - Rocker arm shaft

removing and installing rock-er arms Chapter 15-3

performing basic setting of

hydraulic valve clearancecompensation Chap. 15-2

7 - Bracket

for ignition terminal

8 - Shim

9 - 23 Nm

do not tighten fully until cylin-der head bolts have beentightened

10 - 20 Nm

self-locking, replace

do not tighten fully until cylin-der head bolts have beentightened

11 - 20 Nm

wet with -AMV 105 500-(Loctite 242) before screwingin

do not tighten fully until cylinder head bolts have been tightened

12 - Bracket

for generator support

13 - Cylinder head gasket

Observe installation position; with part no. marking faces up replace

14 - Cylinder head

check for distortion Fig. 1 in 15-1page 2

15 Cylinder Head, Valve Gear

Note


40/88


Removing and installing cylinder head Edition 09.03S00.5305.04.20

15-1page 2

15

removing and installing 15-1page 2 after replacing fill entire system with fresh coolant

15 - Oil deflector

16 - 25 Nm

17 - Lifting eye - on the right

18 - Gasket for cylinder head cover

replace if damaged

19 - Cylinder head cover

20 - Cap

fit on during installation work

Fig. 1: Inspecting the cylinder head for distortion


Straightedge

Feeler gaugeMax. permissible distortion: 0.05 mm (minimum clear-ance of straightedge base: 100 mm)

If the distortion is greater than 0.05 mm, replace cylinderhead, do not rework.

Removing and installing cylinder head

Engine installed

Special tools, test and measuring equipment and

auxiliary items required

Catch pan (e.g. -V.A.G 1306-)

Torque wrench

Pliers for spring strap clips

Flat scraper

Braking agent -AMV 105 500- (Loctite 242)

Removing

On models fitted with a coded radio set, first deter-

mine the coding. Disconnect the battery-earth strap with the ignition off.

When the battery is disconnected and reconnected, carryout rework Electrical System; Rep. Gr. 27.

Remove front exhaust pipe with catalyst Chapter26-1.

Drain coolant Chapter 19-1.

Removing engine cover Chapter 10-1.

V15 - 0673

Note

S10-0138

1

6 4

5

3

4

2


41/88



15-1page 3

15

Disconnect plug:

2 - from the throttle valve control unit -J338-

3 - from the intake manifold pressure sender -G71- withintake manifold temperature sender - G72-

6 - from the coolant temperature sender -G62-

7 - from the injector cylinders - N30 bis N33-

Unclip edge connector -4- -arrows- and remove wiringloom from holders.

Remove ventilation hoses -1- and -8-.

Remove intake hose -5-.

Disconnect air hose from hot air collector.

Remove coolant hoses -1- and -2- from the thermoregulator housing.

Remove vacuum line from the brake servo unit. Remove pipe supports for intake manifold.

Unscrew the guide tube for the oil dipstick from the ex-haust manifold.

Remove ignition terminal.

Remove the fuel presupply pipe -4- by pressing the re-lease buttons at the separation point.

Remove the coolant hose -2- from the expansion res-ervoir.

Release ventilation hose -3- from the solenoid valve.

Remove the cylinder head cover.

Release the cylinder head bolts/nuts (do not yet fullyunscrew).

First remove the rocker arm shaft. Then unscrew the remaining cylinder head bolts/nuts.

Remove the generator support bracket item 12 in15-1page 1

Prior to this remove the V-ribbed belt on vehicles withair conditioning Chapter 13-1.

Remove the push rods and lay aside according totheir fitting position.

Carefully remove the cylinder head.

8

6

4

2

3

7

5

1

S15-0157

M

M

1

2

S10-0141

Caution!

The fuel system is under pressure! Before openingthe system lay cleaning cloths around the connec-tion point. Reduce pressure by carefully releasing

the connection point.

2

1

3 4

S10-0137


42/88



15-1page 4

15

Installing

Remove the new cylinder head seal from its wrappingimmediately before fitting.

Treat the seal with the utmost care. Any damage willresult in leaks.

There must not be any oil or coolant present in theblind holes for the cylinder head bolts.

Insert a clean cleaning cloth in the liners and in theopenings for the push rods to ensure no dirt contami-nates the liners or tappets.

Carefully clean the sealing surfaces of the cylinderhead, cylinder block and liners using a flat scraper orusing a suitable chemical device for this purpose.Make sure this does not cause any extended scoringor scratching.

Carefully remove old residual seal and the cleaningcloths.

Turn the crankshaft in such a way that all pistons areat the same height. While doing so the liners must nobe pushed out; if necessary press down.

Position the new cylinder head gasket in such a waythat the part no. marking is at the top.

Before inserting the cylinder head make sure all liners arecorrectly fitted in the cylinder block.

Insert the cylinder head.

Insert the push rods with the ball socket from the topin accordance with their original location.

When inserting the push rods carefully introduce them inthe ball socket of the tappet and in the ball knobs of theadjusting screws. Wrongly inserted push rods (with ballhead on the edge of the tappet or with the edge on theball head of the adjusting screw) result in faults in the ba-sic setting of the valve gear or damage when the engine

is started.

Moisten the thread of the cylinder head bolts with oil.

Fit the rocker arm shaft and tighten the fixing screwsby hand.

Insert the other cylinder head bolts/nuts and tighten byhand. Observe the following bolt length and installa-tion with/without washers:

Note

Note

Note

10

N15-0221

6 2 3 7

8459 1

13 11 12 14Position Bolt length Washer

1, 2, 3, 6, 7 168 mm yes

4, 5, 8, 9 185 mm no10 132 mm yes


43/88



15-1page 5

15

Tighten the cylinder head bolts/nuts in the followingsequence:

Install the generator support bracket item 12 in15-1page 1

Insert bolt item 11 in 15-1page 1 with lockingagent -AMV 105 500-.

Tighten the rocker arm shaft screws crosswise evenly

to 25 Nm. Perform basic setting of hydraulic valve clearance

compensation Chapter 15-2.

The basic setting of the hydraulic valve clearance com-pensation must not be carried out again, if only the cylin-der head gasket is replaced.

Install the V-ribbed belt on vehicles with air condition-ing Chapter 13-1.

Further installation occurs in a similar way in reverse or-der to removal. Pay attention to the following:

Install front exhaust pipe with catalyst Chapter 26-1.

Top up coolant Chapter 19-1.

Adapt the engine control unit to the throttle valve con-trol unit -J338- 1.0/37; 1.4/44; 1.4/50 engine - fuelinjection; Rep. Gr. 24.

Perform a test drive, interrogate and erase fault mem-ory 1.0/37; 1.4/44; 1.4/50 engine - fuel injection;Rep. Gr. 01

Position Tightening method

1 to 10 Stage I: 20 Nm

Stage ll: 1/4turn (90) with a rigidwrench

Stage lll: 1/4turn (90) with a rigidwrench

11 to 14 20 Nm

Note


44/88



15-1page 6

15


45/88


Repairing cylinder headEdition 09.03S00.5305.04.20

15-2page 1

15

15-2 Repairing cylinder head

1 - Valve collets

2 - Valve spring retainer

3 - Valve spring

removing and installing 15-2page 2

4 - Valve stem seal

replace 15-2page 6

5 - Cylinder head

reworking valve seats 15-2page 3

inspecting valve guides 15-2page 1

6 - Valves

do not rework, only grindingin is permissible

removing and installing

15-2page 2 Valve dimensions 15-2

page 3

7 - Cylinder head marking

8 - Plug

installing Fig. 1 in 15-2page 1

Fig. 1: Knocking plug into cylinder head


Injection drift pin -MP 1-173-

Sealant -AMV 200 000- (Loctite 270)

Coat outer circumference of plug with -AMV 200 000-.

Use -MP 1-173- to knock in plug.

Inspect valve guides


Universal dial gauge holder -MP 3-447-

Dial gauge

1

2

3

4

5

66

7

8

S15-0148

MP 1-173S15-0011


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Repairing cylinder head Edition 09.03S00.5305.04.20

15-2page 2

15

Procedure

Insert valve into guide. End of valve stem must beflush with guide.

Determine valve rock.

Wear limit

If the wear limit is exceeded, repeat measurementwith new valve. If the wear limit is again exceeded - re-place cylinder head.

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

Removing and installing valves

Removing


Valve supporting plate -MP 1-113-

Valve spring assembly lever -MP 1-114-

Insert for conical spring -MP 1-114/1-

Threaded connector M8x40

Fit cylinder head onto the valve supporting plate- MP 1-113-.

Attach valve spring assembly lever -MP 1-114- and in-sert -MP 1-114/1- together with threaded connector-1- onto the cylinder head.

Press down assembly lever -2-.

Take out collets.

Release collets that are tight by striking light blows with ahammer on the assembly lever.

Pull out valves.

Inlet valve Exhaust valve

0.5 mm 0.6 mm

Note

MP 1-113

S15-0008

S15-0124

2

1

MP 1-113

MP 1-114/1

MP 1-114

Note


47/88



15-2page 3

15

Valve dimensions

Valves must not be reworked. Only grinding in is permis-sible.

Reworking valve seats



Depth gauge/caliper gauge

NAC milling cutter for reworking valve seats

Grinding paste

When carrying out repairs on engines with leakingvalves, it is not sufficient to machine or replace thevalve seats and valves. It is also necessary to inspectthe valve guides for wear, particularly on engines witha high mileage.

Rework valve seats only sufficiently in order to obtaina proper contact pattern. Calculate the maximum per-missible reworking dimension before commencing. Ifthe reworking dimension is exceeded, proper opera-tion of the valve gear is no longer assured and the cyl-inder head must be replaced.

Calculating maximum permissible reworking di-mension

Insert valve and press firmly against the valve seat.

If the valve is replaced when carrying out repair work, usea new valve for the measurement.

Measure distance -a- between the valve stem and theseat surface for valve spring.

Calculate max. permissible reworking dimension fromthe distance measured and the maximum dimension.

Note

Inlet valve Exhaust valve

Dimension 1.0 ltr 1.4 ltr 1.0 ltr 1.4 ltr

a mm 34,0 34,0 27,0 30,0

b mm 7,0 7,0 7,0 7,0

c mm 104,0 101,0 104,0 101,0

45 45 45 45

Note

Note

S15-0093

a

Maximum dimen-sions

in mm

1.0 ltr. en-gine

1.4 ltr. en-gine

Inlet valve 43,1 42,7

Exhaust valve 43,0 42,8


48/88



15-2page 4

15

Maximum dimension less distance measured = max. per-missible reworking dimension.

Example:

If the max. permissible reworking dimension is 0 mm, re-peat measurement with a new valve. If the max. permis-sible reworking dimension is again 0 mm, replacecylinder head.

Reworking valve seats

Procedure

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

Wear limit of valve guides must not exceed the per-

missible dimension 15-2

page 2. Use NAC milling cutter with carbide metal tips (min. 90

HRC).

Maximum dimension 43,1 mm

- Measured distance 42,7 mm

= Max. permissible reworking di-mension

0,4 mm

Note

S15-0058

30

45

60

a

b

c

Z

Dimension Valve seats

1.0 ltr. en-gine:

a mm Valve seatdiameter:

33,4 0.1 - inlet valve26.4 0.1 - exhaust valve

1.4 ltr. en-gine:

a mm Valve seatdiameter:

32.9 -0.1 - inlet valve29.6 -0.1 - exhaust valve

b mm Max. permissible reworking dimension

1.0 ltr. en-gine:

c mm Valve seatwidth:

1.3 up to 1.6 - inlet and ex-haust valve

1.4 ltr. en-gine:

c mm Valve seatwidth:

1.45 up to 1.75 - inletvalve1.65 up to 1.95 - exhaustvalve

Z Bottom edge of cylinder head

45 Valve seat angle

30 Top correction angle

60 Bottom correction angle


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15-2page 5

15

Reworking valve seats with NAC milling cutter

Place cylinder head on a felt base and secure to pre-vent it from turning.

Match diameter of guide drift to diameter of valveguide.

Match diameter of milling cutter to diameter of valveseat.

Milling sequence

1 - Machine valve seat with 90milling tool until until aperfect contact pattern is achieved. (Do not exceedmaximum permissible reworking dimension!)

2 - Chamfer top correction angle with 120milling cut-ter until valve seat diameter a ( 15-2page 4) isachieved.

3 - Rework bottom correction angle with 60milling cut-ter until valve seat width c ( 15-2page 4) isachieved.

Grind in valve/valve seat -arrows- with fine grinding

paste so as to achieve a perfect contact pattern. Check valve for tightness.

The inspection can be carried out with water colour (per-fect contact pattern over entire circumference) or by fillingfuel into the combustion chamber (no fuel must flow outat the valve seat).

After installing the cylinder head, carry out basic settingof the hydraulic valve clearance compensation.

S15-0098

Valve guide Guide drift mm

Inlet valve 7,0 -0,01

Exhaust valve

Valve seat Mill-ing cut-ter 90

mm

Millingcutter120mm

Mill-ing cut-ter 60

mm

Inletvalve

1.0 ltr.engine 36 38 21/34

1.4 ltr.engine

36 38 21/34

Exhaustvalve

1.0 ltr.engine

30 30 max. 301)

1.4 ltr.engine

32 32 21/34

1) May not yet be contained in NAC milling cutter kit.

c

120

90

1.

2.

S15-0062

60

3.

a

S15-0063

Note


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15-2page 6

15

Replacing valve stem seal


Valve stem seal insertion tool -MP 1-212-

Valve supporting plate -MP 1-113-

Carefully lever off valve stem seal -arrow-. Insert valve into guide.

Oil valve stem seal, place into insertion tool -A-, thencarefully fit onto the valve stem and press onto thevalve guide.

Basic setting of hydraulic valve clear-ance compensation

The hydraulic valve clearance compensation is mainte-nance-free; the setting must not be changed.

After completing repair work on the cylinder head/valvegear, however, it is necessary to carry out the basic set-ting of the hydraulic valve clearance compensation as fol-lows:

The basic setting of the hydraulic valve clearance com-pensation must not be carried out again, if only the cylin-der head gasket is replaced.


Torque wrench

Procedure

Rotate crankshaft until the valves of cylinder 4 overlap(inlet valve opens and exhaust valve closes).

At cylinder 1, slacken the lock nuts for the adjustingbolts of the rocker arms.

Then, turn back the adjusting bolts in the rocker armsuntil play can be felt between rocker arm and valve.

Turn adjusting bolts of both rocker arms slightlyagainst the valves until valve gear has no play. Checkthe gradual reduction of the play through swingingmovements of the adjusting rocker arm. The point withno play which has appeared determines the exactcontact location.

From this point, turn adjusting bolts in a further twoturns. Screw in lock nut and then tighten fully to 13Nm.

S15-0016

S15-0110

A

Note


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15-2page 7

15

Carry out the setting operations on the other cylindersaccording to the table below:

After installing new hydraulic tappets, the engine mustnot be started for about 30 minutes. Hydraulic compensa-tion elements must settle (otherwise valves may remainconstantly open and strike the piston).

Testing the compression

Test conditions

Engine oil temperature at least 30 C


Compression tester (e. g. -V.A.G 1381- or-V.A.G 1763-)

Spark plug wrench (e.g. - 3122 B-)

Torque wrench

Test sequence

Remove engine cover.

Unplug 4-pin connector -arrow- from the ignition termi-nal.

Remove the fixing screws of the ignition terminal anddetach ignition terminal from the park plugs.

Unscrew spark plugs with spark plug wrench (e. g.-3122 B-).

Remove fuse 35.

Removing fuse 35 interrupts the voltage supply of the in-jectors.

Have a second mechanic fully depress the acceleratorpedal.

Use compression tester (e. g. -V.A.G 1381 - or-V.A.G 1763 -) to test compression.

Use of tester Operating Instructions.

Setting Valve overlap

Cylinder 1 Cylinder 4




Note

N15-0219

Note

Note


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15-2page 8

15

Operate starter until the tester no longer indicates apressure rise.

Compression readings

Plug connectors into the ignition strip.

Install spark plugs, ignition terminal, fuse 35 and en-gine cover.

Interrogate fault memory and erase 1.0/37; 1.4/44;1.4/50 Engine, Fuel Injection System; Rep. Gr. 01.

Separating the plug connections causes faults to bestored.

Tightening torques

New engine Wear limit Difference be-tween cylinders

min. 12 bar (1.2MPa)

7.5 bar (0.75MPa)

max. 3 bar (0.3MPa)

Note

Component Nm

Spark plugs in cylinder head 30

Ignition terminal to bracket 9


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Repairing valve gearEdition 03.01S00.5305.02.20

15-3page 1

15

15-3 Repairing valve gear

Removing and installing camshaft

1 - Tappet rod

pay attention to correct in-stallation position

do not interchange

2 - Hydraulic tappets

with hydraulic valve clear-ance compensation

check 15-3page 3 use auxiliary tool to pull out

of cylinder block Fig. 1 in15-3page 1

do not interchange lay aside with contact sur-

face facing down

oil contact surface3 - Cylinder block

Removing and installing cyl-inder block Chap. 15-1

Removing and installing tim-ing gear cover and sprockets Chap. 13-2

4 - O-ring

5 - Camshaft position sensor-G163-

6 - 8 Nm

7 - Camshaft

with timing segment for cam-shaft position sensor -arrow-

Camshaft setting Fig. 2 in15-3page 2

8 - Woodruff key

check tightness

9 - Retaining plate of camshaft

10 - 5 Nm

Fig. 1: Removing hydraulic tappet

Make auxiliary tool (wire) -2- as shown in illustration.

-a- 1.8 to 1.9 mm

Inset shop-made tool -2- in the tappet bore -1-, tiltslightly and pull tappet out of the guide in the cylinderblock.

31 2

4

6

5

8

910

7

S15-0149

2

a

1

S15-0130


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Repairing valve gear Edition 03.01S00.5305.02.20

15-3page 2

15

Fig. 2: Camshaft setting

Insert chain sprockets -2- and -3- into the timing chain-1- so that the distance -a- (from marking to marking-arrows-) is 12 chain pins.

Removing and installing rocker arms

1 - Rocker arm shaft

removing and installing Chap. 15-1

2 - Circlip

3 - Rocker arm bracket, on out-side

for M11 cylinder head bolt

4 - Spring washer

5 - Rocker arm

6 - Adjusting screw

performing basic setting ofhydraulic valve clearancecompensation Chap. 15-2

7 - Lock nut

13 Nm

8 - Rocker arm bracket

for M8 bolt

9 - Rocker arm

pay attention to different ver-sion Fig. 3 in 15-3page 3

10 - Rocker arm bracket, on inside

for M11 cylinder head bolt

11 - Tensioning ring

12 - Spring

a=12

S15-0028

1

2

3

1

24

3

8

10

8

56

79

9

11

12

9

11

8

9

10

9

8

3

5

2

9

S15-0150


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Repairing valve gearEdition 03.01S00.5305.02.20

15-3page 3

15

Fig. 3: Arrangement of rocker arms and rocker armbrackets

1 - Straight rocker arm

2 - Inclined rocker arm, to the left

3 - Inclined rocker arm, to the right

A - Rocker arm bracket for M11 bolt, on outside

B - Rocker arm bracket for M8 boltC - Rocker arm bracket for M11 bolt, on inside

The rocker arms for the inlet valves are shown in dark inthe illustration.

Inspecting hydraulic tappets


Feeler gauge

Wooden or plastic wedge

Always replace hydraulic tappet complete (cannot beadjusted or repaired).

Irregular valve noises when starting engine are nor-mal.

Test sequence

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

Increase engine speed to about 2500 rpm for 2 min-utes.

If the hydraulic tappets are still loud, determine the faultytappet as follows:

Remove cylinder head cover.

Rotate crankshaft until the valves of cylinder 4 overlap(inlet valve opens and exhaust valve closes).

Apply a load to the hydraulic tappet by pressing slight-ly several times on the adjusting screw with a woodenor plastic wedge.

Attempt to insert a 0.2 mm feeler gauge -arrow- be-tween rocker arm and valve.

If it is possible to insert a feeler gauge between rockerarm and valve and the tappet at the same time movesdown, replace the tappet.

If play was measured only between rocker arm and valve(tappet does not move down), carry out basic setting ofthe hydraulic valve clearance compensation Chap. 15-

2, after the setting, repeat the inspection. Inspect tappets at the other cylinders by carrying out

the same procedure.

2

AB

1 1

A

C CB

3 2

3 2

3

BB

S15-0132

Note

Note

S15-0189


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Repairing valve gear Edition 03.01S00.5305.02.20

15-3page 4

15

After installing new hydraulic tappets, the engine mustnot be started for about 30 minutes. Hydraulic compensa-tion elements must settle (otherwise valves may remainconstantly open and strike the piston).

Inspection Valve overlap





Note


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Removing and installing parts of the lubrication systemEdition 02.02S00.5305.03.20

17-1page 1

17

17-1 Removing and installingparts of the lubrication

system

If considerable quantities of metal swarf or abrasion(caused by rubbing damage such as damage to thecrankshaft and conrod bearings) is found in the en-gine oil when carrying out engine repairs, carefullyclean the oil galleries in order to avoid consequentialdamage.

The oil level must not be above the max. marking - riskof damage to catalytic converter!

For 1.0 ltr. engine only: longer oil pan bolts on bracketfor coolant pipe, at front item 12 in 17-1page 2pay attention to these bolts, do not mix up!

Oil capacity and oil specification:

Inspection and Maintenance.

17 Lubrication

Note


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Removing and installing parts of the lubrication system Edition 02.02S00.5305.03.20

17-1page 2

17


1 - Cap

fit on during installation work

2 - Gasket

replace if damaged on the engine cover

3 - 0.9 bar (0.09 MPa) oil pres-sure switch - F1-, 45 Nm

grey inspecting Chapter 17-3 cut open seal if leaking and

replace

4 - Oil filter

slacken with tensioning strap moisten seal with oil tighten by hand pay attention to installation

instructions on oil filter pay attention to change inter-

vals

5 - Split pin

6 - Ball

for pressure relief valve when installing, knock in

slightly with aluminium driftso that the seat of the ball issmoothened

7 - 40 Nm

8 - Pressure spring

for pressure relief valve

9 - 8 Nm

10 - Intermediate plate

clamped onto oil pan support of 1.4 ltr. engine

11 - Oil pan support

for 1.4 litre engine only:

12 - Bracket

for middle coolant pipe for 1.0 ltr. engine only: 2 bolts M6x22 (different colour and shape); do not mix up with other bolts (M6x20)

13 - 10 Nm

14 - 20 Nm15 - 45 Nm

for 1.4 litre engine only:

16 - Oil drain plug, 30 Nm

17 - Gasket

replace

18 - Oil pan


19 - Gasket

for 1.0 litre engine only replace

coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing theoil pan with gasket Fig. 3 in 17-1page 4

20 - 8 Nm

S17-0081


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Removing and installing parts of the lubrication systemEdition 02.02S00.5305.03.20

17-1page 3

17

21 - Oil pump cover with pressure relief valve

opening pressure: approx. 4.6 bar (0.46 MPa) overpressure clean strainer if dirty

22 - Gasket

replace install only if insufficient axial play of oil pump gears Fig. 1 in 17-1page 3

23 - Gears

inspecting axial play Fig. 1 in17-1page 324 - Guide tube

removing and installing Fig. 2 in 17-1page 3

25 - Dipstick

oil level must not exceed "max" marking! Inspect engine oil level Inspection and Maintenance

Fig. 1: Oil pump - inspect axial play



Feeler gauge

Straightedge

Axial clearance for new part: 0.02 through 0.10 mm

wear limit: 0.13 mm

If the wear limit is reached, replace timing gear cover Chapter 13-2

If no axial play is present, install gasket item 22 in17-1page 3.

Inspect unrestricted running of the oil pump in assem-bled state with timing gear cover installed.

Fig. 2: Removing and installing dipstick guide tube

Unscrew nut -1- on the exhaust manifold and lift guidetube -2- up and out.

When installing replace seal -3-.

Tighten new self-locking nut -1- to 20 Nm.

S17-0038

Note

2

3S17-0039

1


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Removing and installing parts of the lubrication system Edition 02.02S00.5305.03.20

17-1page 4

17

Fig. 3: Apply sealant for a 1.0 litre engine

Coat the joints between the timing gear cover/cylin-derblock with sealant -AMV 188 520- before installingthe oil pan with gasket -arrows-.


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Removing and installing oil panEdition 09.03S00.5305.04.20

17-2page 1

17

17-2 Removing and installingoil pan

Removing and installing oil pan - for a1.0 litre engine

Removing

The procedure for removing the oil pan on a 1.0 ltr. and1.4 ltr. engine is identical 17-2page 1.

Installing


Torque wrench

Sealant -AMV 188 520-

Coat the joints between the timing gear cover/cylin-derblock with sealant -AMV 188 520- before installingthe oil pan with gasket -arrows-.

Lay on the gasket for the oil pan.

Tighten securing bolts in the specified order.


The bracket for the front coolant pipe is also attached withbolts -2- and -6- (M6x22). Do not interchange with theother bolts (M6x20).

Removing and installing oil pan - for a1.4 litre engine


Hand drill with plastic brush attachment

Flat scraper

Torque wrench

Silicone sealant -D 176 404 A2- or - 047 198 049-(THREE BOND 1215 J)

Counterholder -T30008-

Removing

Remove noise insulation below engine.

Drain engine oil.

Unbolt front coolant pipe (below oil pan) at the 2 fix-tures at the cylinder block.

Unbolt oil pan together with oil pan support. Remove oil pan, if necessary release by applyingslight blows with a rubber-headed hammer. Press thecoolant pipe slightly towards the outside for this step.

N17-0079

1

20

19

16

12 8 4 5 9

1515 11 7 3 2 6 10

13

17

18

14

Note


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Removing and installing oil pan Edition 09.03S00.5305.04.20

17-2page 2

17

Use a flat scraper to remove sealant residues on thecylinder block.

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

Clean sealing surfaces, they must be free of oil andgrease.

Installing

Pay attention to the 'use by date' on sealant.

The oil pan must be installed immediately after apply-ing the silicone sealant -047 198 049- (THREE BOND1215 J) . If -D 176 404 A2- is used installation must beperformed within 5 minutes.

The assistance of a second mechanic is required toinstall the oil pan. Press the front coolant pipe slightlytowards the outside.

Cut off nozzle tube at the front marking (of nozzleapprox. 3 mm).

Thickness of sealant bead: 2 to 3 mm

The sealant bead must not be thicker than 3 mm other-wise excess sealant may get into the oil pan and cloggthe strainer in the oil suction pipe.

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

It is particularly important to maintain the specified ap-plication pattern for the bead in the area of the sealingflange to the flywheel -arrows A-.

There is an opening in the cylinder block -arrow B- 13 mm, which must be reliably sealed off by an accu-

mulation of sealant -a- = 15 mm; -b- = 4 mm.

N17-0012

Note

N17-0019

Note

B

A

A

A

S17-0040

ab

Note

5/25/2018 Motor Arv,Aqv

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