1,6 75 kW Engine

Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5706.00.20

Workshop ManualOCTAVIA II 2004 1,6/75 kW Engine Edition 02.04Engine code BGU BSE BSF

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 RepublicS00.5706.00.20

OCTAVIA II 2004 1,6/75 kW Engine

List of SupplementsEdition 12.05S00.5706.02.20

List of Supplements to Workshop ManualOCTAVIA II 20041,6/75 kW Engine Edition 02.04

Supplement Edition Subject Article Number

02.04 Basic Edition S00.5706.00.201 09.04 Modifications in Rep. Gr. 10, 13, 15, 19, 20 and 24 S00.5706.01.202 12.05 Modifications in Rep. Gr. 13, 15, 17, 19, 20, 24, 26 and 28 S00.5706.02.20


List of Supplements Edition 12.05S00.5706.02.20


Table of ContentsEdition 12.05S00.5706.02.20

I

Table of Contents

00 Technical DataTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Engine number ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Engine characteristics .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01 Self-diagnosisSelf diagnosis, safety measures, cleanliness regulations, directions . . . . . . . . . . . . . . . . . . . . .- Self-diagnosis ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Safety precautions when working on the fuel supply system ......... . . . . . . . . . . . . . . . . . . . . . . . . . .- ... .. . . . . . . . . . . . . . . . .Rules of cleanliness to observe when working on the fuel supply system- Safety measures to apply when working on the fuel injection and ignition system ...... ...- General notes on the injection system ....... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- General notes on the ignition system ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Additional instructions when undertaking assembly work on the air-conditioning system .

10 Removing and Installing EngineRemoving and Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Installing ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Adjust assembly bracket ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Assembly bracket .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CrankgearDisassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- V-ribbed belt - Summary of components .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing V-ribbed belt ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Toothed belt drive - Overview of components ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing, tightening the timing belt ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspecting the semi-automatic timing belt tensioning pulley .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing sealing flanges and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Sealing flanges and flywheel - Overview of components ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing gasket ring for crankshaft -on the belt pulley side- .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the front sealing flange ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the rear sealing flange ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Crankshaft - Overview of components ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling and assembling piston and conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Piston and conrod - Overview of components ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Cylinder Head, Valve GearRemoving and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Cylinder head - Overview of components ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing cylinder head ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Installing cylinder head ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing the compression ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

00-1 page 100-1 page 100-1 page 1

01-1 page 101-1 page 101-1 page 101-1 page 201-1 page 201-1 page 201-1 page 301-1 page 3

10-1 page 110-1 page 110-1 page 710-1 page 910-1 page 10

13-1 page 113-1 page 113-1 page 213-1 page 413-1 page 513-1 page 10


13-3 page 113-3 page 1

13-4 page 113-4 page 1


15-2 page 115-2 page 1


Table of Contents Edition 12.05S00.5706.02.20II

- Replacing camshaft gasket ring ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing camshaft ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspect supporting elements with hydraulic compensation ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Inspect valve guides ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing valve stem seals ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Reworking valve seats .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 LubricationRemoving and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Lubrication system - Overview of components ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling oil filter holder ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing oil pan ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing oil pump ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing oil pressure and oil pressure switch ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 CoolingRemoving and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Parts of the cooling system fitted to body ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Parts of cooling system engine side ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Connection diagram for coolant hoses ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Draining and filling up coolant ... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing coolant pump ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing coolant regulator .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing radiator ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the coolant system for tightness ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing radiator fan -V7- and -V177- .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Fuel SupplyRemoving and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing fuel tank with attached parts and fuel filter .. ..... . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel delivery unit ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel gauge sender .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing the fuel tank ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Fuel filter with component parts 09.05 .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing fuel filter ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check the fuel delivery unit ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Vent the fuel system ...... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing Electronic Engine Power Control (Electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing accelerator pedal module ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Repairing parts of the activated charcoal filter system ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the fuel tank venting ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 Fuel Formation, InjectionRepairing the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Overview of fitting locations ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing intake manifold .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling fuel distributor with injectors ........ . . . . . . . . . . . . . . . . . . . . . . . . . .- Disassembling and assembling air filter with component parts ....... . . . . . . . . . . . . . . . . . . . . . . . . .



19-1 page 119-1 page 219-1 page 319-1 page 419-1 page 519-1 page 719-1 page 819-1 page 1019-1 page 1119-1 page 12

20-1 page 120-1 page 220-1 page 320-1 page 420-1 page 520-1 page 720-1 page 820-1 page 820-1 page 13

20-2 page 120-2 page 1

20-3 page 120-3 page 120-3 page 2



Table of ContentsEdition 12.05S00.5706.02.20

III

Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the tightness and injection rate of the injection valve ....... . . . . . . . . . . . . . . . . . . . . . . . . .- Test fuel pressure regulator and holding pressure ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Testing the intake manifold changeover ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Replacing engine control unit ... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 Exhaust SystemRemoving and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Exhaust system - Overview of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Separate middle and rear silencer .... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing front exhaust pipe with catalytic converter ....... . . . . . . . . . . . . . . . . . . .- Removing and installing exhaust manifold .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Aligning exhaust system free of stress ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Checking the exhaust system for leaks ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Exhaust gas recirculation system - Overview of components - Engines with identification

characters BGU .... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing parts of the secondary air system - Engines with identification

characters BGU, BSE ..... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Check secondary air injection combination valve for proper operation and leaks - Engines

with identification characters BGU, BSE ..... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 Ignition SystemRepairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing and installing parts of the ignition system .... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24-2 page 124-2 page 124-2 page 424-2 page 5

24-3 page 124-3 page 1

26-1 page 126-1 page 126-1 page 226-1 page 326-1 page 526-1 page 626-1 page 7

26-2 page 1

26-2 page 1

26-3 page 1

26-3 page 1

26-3 page 1

28-1 page 128-1 page 1


Table of Contents Edition 12.05S00.5706.02.20IV


Technical DataEdition 12.05S00.5706.02.20

00-1 page 1

00

00-1 Technical Data

Engine numberThe engine number (engine code and serial number) is located at the front at the joint separating engine/gear-box.

In addition, a sticker with the engine identification char-acters and serial number is affixed to the timing belt guard.

The engine identification characters are also indicated on the vehicle data sticker.

Engine characteristics

00 Technical Data

Engine identification characters BGU BSE BSFManufactured 02.04 05.05 06.05 06.05 Exhaust limits conforming to EU-4, EU-2 DDK EU-4 EU-2Displacement l 1,595 1,595 1,595Power output kW at

rpm 75/5600 75/5600 75/5600

Torque Nm atrpm 148/3800 148/3800 148/3800

Bore mm 81,0 81,0 81,0Stroke mm 77,4 77,4 77,4Compression 10,5 10,5 10,5Fuel - RON 951)

1) Unleaded petrol RON 91 is also permitted, although engine output is reduced

951) 951)

Ignition system/fuel injection Simos 7.1 Simos 7.1 Simos 7.1Knock control yes yes yesSelf-diagnosis yes yes yesLambda control 2 lambda probes 2 lambda probes 2 lambda probesCatalytic converter yes yes yesTurbocharging no no noExhaust gas recirculation system yes no noIntake manifold change-over yes yes yesCamshaft adjustment no no noSecondary air system yes yes no


Technical Data Edition 12.05S00.5706.02.2000-1 page 2

00


Self diagnosis, safety measures, cleanliness regulations, directions

Edition 02.04S00.5706.00.20

01-1 page 1

01

01-1 Self diagnosis, safety measures, cleanliness regulations, directions

Self-diagnosisThis Rep.-Gr. is deleted.

For this use the Vehicle self-diagnosis, Measuring method and Fault finding Vehicle Diagnosis, Meas-uring and Information System VAS 5051; .

Safety precautions when working on the fuel supply system

Pay attention to the following points when removing and installing the fuel gauge sender or the fuel delivery unit on a fuel tank that is filled or partially filled:

The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the assembly opening of the fuel tank in order to extract the released fuel gases, even before the work is com-menced. If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume above 15 m3/h must be used.

Avoid skin contact with fuel! Wear fuel-resistant gloves!

01 Self-diagnosis

WARNING!

When undertaking all assembly work, particularly in the engine compartment due to its cramped con-struction, please observe the following:

Lay lines of all kinds (e.g. for fuel, hydraulic flu-id, the active charcoal container-unit, cooling fluid and refrigerent, brake fluid, vacuum) and electrical lines in such a way that the original line guide is re-established.

Ensure that there is adequate free access to all moving or hot components.

WARNING!

The fuel system is under pressure! Place a clean cleaning cloth around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.



Edition 02.04S00.5706.00.2001-1 page 2

01

Rules of cleanliness to observe when working on the fuel supply systemCarefully observe the following five rules for cleanliness when working on the fuel supply/injection system:

Thoroughly clean the connection points and their sur-roundings before releasing.

Place removed parts on a clean surface and cover. Do not use fuzzy cloths!

Carefully cover or close opened components if the re-pair is not completed immediately.

Only install clean parts: Remove spare parts from their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes).

When the system is open: Avoid using compressed air. Avoid moving the vehicle.

Safety measures to apply when working on the fuel injection and ignition system

Observe the following points to prevent injury to persons and/or damage to the injection and ignition system:

Do not touch or remove ignition leads with the engine running or at start speed.

Ignition must be switched off before disconnecting and re-connecting cables of the fuel injection and igni-tion system as well as of test equipment.

If the engine must be operated at start speed without the engine starting, as for example, when checking the compression pressure, open lid of fuse carrier in the engine compartment and unplug fuses F6 und F32 for ignition transformer and injection valves.

If test and measuring devices are required during test drives observe the following:

Always secure the test and measuring devices on the rear seat and have a second person operate them there.

If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.

General notes on the injection systemRepairing ignition system 28-1 page 1

WARNING!

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



Edition 02.04S00.5706.00.20

01-1 page 3

01

The engine control unit is equipped with a self-diagno-sis system. Before repairs and also for fault finding, first of all interrogate the fault memory. Also check the vacuum hoses and connections (unmetered air).

Fuel hoses in the engine compartment must be se-cured with spring band clamps. The use of clamp-type or screw-type clips is not allowed.

A minimum voltage of 11.5 V is required for perfect functioning of the electrical components.

Do not use sealants containing silicone. Traces of sil-icone elements drawn in by the engine are not burnt in the engine and damage the lambda probe.

Certain inspections may cause the control unit to de-tect and store a fault. It is therefore necessary to inter-rogate the fault memory after having completed all inspections and repairs, and if necessary delete Vehicle Diagnosis, Measuring and Information System VAS 5051; .

Safety measures 01-1 page 2

General notes on the ignition system Switch off the ignition before disconnecting and con-

necting the battery, as this may damage the 4AV con-trol unit.

The engine control unit and other components are fit-ted with the self diagnosis function; check it Vehicle Diagnosis, Measuring and Information System VAS 5051; .

A minimum voltage of 11.5 V is required for perfect functioning of the electrical components.

Certain inspections may cause the control unit to de-tect and store a fault. It is therefore necessary to inter-rogate the fault memory after having completed all inspections and repairs, and if necessary delete Vehicle Diagnosis, Measuring and Information System VAS 5051; .

Safety measures 01-1 page 2Setting data, spark plugs Maintenance Manual; Binder Octavia II

Additional instructions when undertak-ing assembly work on the air-condition-ing system

WARNING!

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



Edition 02.04S00.5706.00.2001-1 page 4

01

In 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.

Steps which should be taken in order to remove and in-stall the engine without opening the refrigerant circuit.

Remove the holding clamp(s) on the refrigerent lines. Remove AC compressor Heating, Air Conditioning;

Rep. Gr. 87. Mount the AC compressor in such a way that the re-

frigerant lines/hoses are not under tension.

Note


Removing and Installing EngineEdition 09.04S00.5706.01.20

10-1 page 1

10

10-1 Removing and Installing Engine

Special tools, test and measuring equipment and auxiliary items required

Catch pan, e.g. -V.A.G 1306- Engine/gearbox jack, e.g. -V.A.G 1383 A- Pliers for spring strap clips Double ladder, e.g. -VAS 5085- Engine mount -T10012- Assembly stand -MP 9-101- Engine and gearbox mount -MP 1-202- Supporting device -T30099- Workshop crane, e.g. -V.A.G 1202 A-

Removing

The engine is removed downwards together with the gearbox.

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.

Collect drained coolant in a clean container for reuse or proper disposal.

Observe supplementary instructions and assembly work 01-1 page 1.

Remove engine cover -arrows-. Disconnect the battery-earth strap with the ignition off.

Open the cap of the coolant expansion reservoir. Remove both front wheels. Remove the sound dampening system Body Work;

Rep. Gr. 50. Remove the left and right sound dampening system Body Work; Rep. Gr. 66.

10 Removing and Installing Engine

Note

WARNING!

Observe measures when disconnecting the battery Electrical System; Rep. Gr. 27.

WARNING!

Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully.


Removing and Installing Engine Edition 09.04S00.5706.01.2010-1 page 2

10

Disconnect plug connection at coolant temperature sender-radiator outlet -G83-.

Drain coolant Chapter Draining and filling up cool-ant in 19-1.

Pull off intake air duct below at pre-cubic contents. Disconnect hoses -1-, -3- and -4-. Remove the air guide hose, to do so release spring

strap clips -2- and -5-.

Pull off hoses -1- and -2- at air filter housing. Release screw -3-. Remove the air filter housing. Pull off intake air duct to pre-cubic contents from lock

carrier and take out. Remove battery and battery tray Electrical System;

Rep. Gr. 27. Remove the cooling water tank cover Body Work;

Rep. Gr. 66. Expose rear engine wiring harness at the intermediate

wall for the cooling water tank.

Remove the intermediate wall for cooling water tank -arrows-.



10-1 page 3

10

Remove the engine control unit Chapter 24-3. Separate plug connection -2- for engine wiring har-

ness.

The plug connection -1- remains in position.

Release channel for engine wiring harness and pull out upwards.

Remove the plug connection -arrows- for lambda probe -G39- (upstream of catalytic converter) from the bracket and disconnect.

Open bracket of cable guide.

Expose plug connection -1- and disconnect. Open the bracket -2- lying below the cable guide. Take engine wiring harness for control unit out of the

cable guide. Unscrew earth cables and cables at starter.

Note



10

Separate plug connection -3- for reversing light switch.

Expose engine wiring harness at bracket -2-. Release nut -1- and remove bracket with electrical ca-

bles from threaded bore. Separate the plug connection at the secondary air

pump motor -V101-. Expose cable. Detach the coolant hoses to the heat exchanger at the

bulkhead. Disconnect the vacuum line from the brake servo unit

at the intake manifold.

Unclip lock washers -1- and -2- on both control cables. Remove cable locks from gearbox shift lever and relay

lever.

Disconnect cable support from gearbox and lay aside -arrows-.

Remove the slave cylinder and lay aside, do not open the line system.

WARNING!

After removing the slave cylinder, do not operate the clutch pedal.



10-1 page 5

10

Remove coolant hose at top of radiator -arrow-.

Detach coolant hoses -1- and -2-. Detach coolant hose at expansion reservoir. Disconnect the vacuum hose to the activated charcoal

filter.

Disconnect the fuel feed line -2-, to do so pull the un-locking button.

Disconnect the vacuum hose -1- to the activated char-coal filter, to do so press the unlocking button.

Pull activated charcoal filter with its attached lines to the top out of the bracket.

Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.

Note



10

Remove V-ribbed belt Chapter Removing and in-stalling V-ribbed belt in 13-1.

Remove alternator Electrical System; Rep. Gr. 27. Unscrew screws -arrows- of assembly bracket at en-

gine by about 2 turns.

Unscrew screws -arrows- of assembly bracket at gearbox by about 2 turns.

Remove the air conditioning compressor Chapter V-ribbed belt - Summary of components in 13-1.

Tie up AC compressor with connected refrigerant hos-es towards the top to the front bumper.

Separate plug connection at oil level/temperature sender -G266-.

Remove exhaust pipe Chapter Removing and in-stalling front exhaust pipe with catalytic converter in 26-1.

The decoupling elements in the front part of the exhaust pipe should not be bent by more than 10 - danger of damaging it.

Unscrew the left drive shaft from the flange of the gearbox and tie up.

Remove drive shaft to the right Chassis; Rep. Gr. 40.

Release screws -1 ... 3- and remove pendulum sup-port.

Note



10-1 page 7

10

Unscrew front sealing screw -arrow- at cylinder block.

Screw engine mount -T10012- to the cylinder block with fixing nut and bolt to approx. 20 Nm.

Insert engine/gearbox jack at engine mount -T10012- and slightly raise.

Use double ladder to release the screws for the assembly bracket.

Release screws for assembly bracket at engine and at gearbox.

Check whether all hose and line connections between engine, gearbox and body are released.

When lowering carefully guide the engine/gearbox jack unit, in order to avoid damage.

Pull engine/gearbox unit as far forward as possible and lower slowly downwards.

Securing the engine to the assembly stand

Secure the engine with engine mount -MP 1-202- on the assembly stand -MP 9-101- before performing assembly work.

Unscrew engine from gearbox. Screw engine to engine mount -MP 1-202-, which is

fixed to the assembly stand -MP 9-101-.

InstallingProcedure

Engine mounted on engine mount -T10012-.Installation is performed in the reverse order. Pay atten-tion to the following points:

Note

Note



10

When performing installation work replace the self-locking nuts and screws.

Replace screws which have been tightened to a turn-ing angle as well as gasket rings and seals.

All cable straps should be fitted on again in the same place when installing.

Secure all hose connections with hose clips. Clean the drive shaft serration and hub serration on

used clutch discs, remove corrosion. Apply a very thin layer of grease -G 000 100- onto the serration. Subse-quently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Remove all excess grease.

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

Ensure that the intermediate plate has been inserted on the sealing flange and is pushed onto the dowel sleeves -arrows-.

Check the centering of the clutch disc Gearbox 0AF; Rep. Gr. 30.

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

Screw on gearbox to engine. Insert engine/gearbox assembly in the body. First of all tighten screws for assembly bracket at en-

gine and at gearbox by hand. Use new screws for attaching.

The screws are tightened to a final torque only when ad-justing the engine mounting.

Unscrew engine mount -T10012- from engine. Insert sealing screw -arrow- with locking agent

-D 000 600 A2-. Tighten pendulum support to the gearbox and to the

assembly carrier. Install drive shafts Chassis; Rep. Gr. 40. Install exhaust system and align free of stress Chapter Aligning exhaust system free of stress in 26-1.

Install AC compressor Chapter V-ribbed belt - Summary of components in 13-1.

Install the slave cylinder of the hydraulic clutch control Gearbox 0AF; Rep. Gr. 30.

Attach shift mechanism to gearbox and adjust Gearbox 0AF; Rep. Gr. 34.

To facilitate the positioning of the generator, drive the bushings of the retaining screws slightly backwards

Note

Note



10-1 page 9

10

Install alternator Electrical System; Rep. Gr. 27. Install the V-ribbed belt Chapter Removing and in-

stalling V-ribbed belt in 13-1. Adjust engine mounting 10-1 page 9. Electrical connections and proper routing Current

Flow Diagrams, Electrical Fault Finding and Fitting Lo-cations.

Install wiper arms Electrical System; Rep. Gr. 92. Install battery Electrical System; Rep. Gr. 27 Vent the fuel system Chapter Vent the fuel sys-

tem in 20-1. Checking the oil level Maintenance Manual;

Binder Octavia II. Filling system with coolant Chapter Draining and

filling up coolant in 19-1.

Do not use drained coolant again, if the cylinder head or cylinder block were replaced.

Dirty coolant must not be used again.Tightening torques

Adjust assembly bracketThe following distances must be achieved:

Between engine support and frame side rail on right there must be a distance -a- = 16 mm.

The cast iron edge on the engine support -2- must be parallel to the supporting arm -1- (dimension -x- = di-mension -x-).

The distance -a- = 16 mm can be checked e.g. with suit-able round bars.

Note

Component NmScrews and nuts M6 9

M7 13M8 20

M10 40M12 70

deviations:Sealing screw in cylinder block 10 1)

Assembly bracket screws 10-1 page 10Engine/gearbox connecting screws Gearbox 0AF; Rep. Gr. 34

1) Insert using locking agent -D 000 600 A2-

Note



10

Assembly bracketTightening torques

Engine assembly bracket

A - 20 Nm + 90 (1/4 turn)1)B - 40 Nm + 90 (1/4 turn)1)C - 60 Nm + 90 (1/4 turn)1)

Gearbox assembly bracket

A - 40 Nm + 90 (1/4 turn)1)B - 60 Nm + 90 (1/4 turn)1)

Hinged bracket

A - 40 Nm + 90 (1/4 turn)1)B - 100 Nm + 90 (1/4 turn)1)

1) Replace bolts


Disassembling and assembling engineEdition 12.05S00.5706.02.20

13-1 page 1

13

13-1 Disassembling and assembling engine

V-ribbed belt - Summary of components

1 - Belt pulleyT for the V-ribbed belt

2 - 10 Nm + torque a further 90 (1/4 turn)T replace

3 - 23 Nm4 - Tensioning device for ribbed

V-beltT swivel tensioning device for

V-ribbed belt with open-end wrench to slacken the V-ribbed belt

T Secure tensioning device with a hexagon wrench

5 - Bracket for auxiliary units6 - Deflector7 - GeneratorT removing and installing Electrical System; Rep. Gr. 27

T to facilitate positioning of the generator, drive the threaded bushings of the retaining screws at the generator slightly backwards

8 - 45 NmT replaceT observe the order of tighten-

ing up Fig. 2 in 13-1 page 2

9 - BushT 2 pieces

10 - 25 Nm11 - AC compressor

T removing and installing Heating, Air Conditioning; Rep. Gr. 8712 - V-ribbed belt

T mark the direction of rotation with chalk or a felt-tip pen before removingT check for wearT do not kinkT removing and installing 13-1 page 2T Routing of the ribbed V-belt Fig. 1 in 13-1 page 2

13 Crankgear


Disassembling and assembling engine Edition 12.05S00.5706.02.2013-1 page 2

13

Fig. 1: Routing of the V-ribbed belt

Fig. 2: Bolts at bracket for auxiliary units - tighten-ing sequence

Removing and installing V-ribbed beltRemoving

Remove engine guard -arrows-.



13-1 page 3

13

Pull activated charcoal filter with its attached lines to the top out of the bracket and place to the side.

Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.

Swivel tensioning device for ribbed V-belt in -direction of arrow- in order to slacken the ribbed V-belt.

Lock tensioning device for ribbed V-belt with a hexa-gon wrench.

Remove the V-ribbed belt.

Installing

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

Before fitting the ribbed V-belt make sure that all assem-blies (generator and AC compressor) are securely mounted.

Position the V-ribbed belt on the belt pulleys of the crankshaft and AC compressor.

Position the ribbed V-belt on the belt pulley last, re-lease the tensioning device.

Check correct positioning of the ribbed V-belt. Start engine and inspect running of belt.

Note

A13-0083

Note



13

Toothed belt drive - Overview of components

1 - 10 NmT insert using locking agent

-D 000 600 A2-2 - Middle toothed belt guard3 - Engine support bracketT removing and installing 13-1 page 5

4 - 45 Nm5 - Top toothed belt guardT removing and installing 13-1 page 5

6 - 23 Nm7 - Washer8 - Semi-automatic tensioning

pulleyT check 13-1 page 10T Fitting position 13-1

page 59 - 100 NmT to release and tighten use

counterholder -T 30004-10 - Camshaft sprocket

T for removal and installation, remove toothed belt 13-1 page 5

T Installation position fixed by woodruff key item 13


-D 000 600 A2-12 - Rear timing belt guard13 - Woodruff key

T check tightness14 - O-ring

T replace15 - Coolant pump

T removing and installing Chapter Removing and installing coolant pump in 19-116 - 15 Nm17 - Crankshaft toothed belt sprocket

T there must not be any oil present on contact surface between timing belt sprocket and the crankshaftT can be installed only in one position

18 - 90 Nm + torque a further 90 (1/4 turn)T replaceT do not oilT to release and tighten use counterholder -T 30004 oder MP 1-310-

19 - Timing beltT mark the direction of rotation with chalk or a felt-tip pen before removingT check for wearT removing 13-1 page 5T install (set the timing) 13-1 page 9

20 - Bottom toothed belt guardT unscrew crankshaft for the removal of the belt pulley



13-1 page 5

13

Removing and installing, tightening the timing belt


Supporting device -T30099- Supporting plate -T30099/1- Two-hole nut turner - T10020-

Removing

Remove engine guard -arrows-. Disconnect the vacuum hose to the activated charcoal

filter at the solenoid valve -N80-.

Disconnect the fuel feed line -2-, to do so pull the un-locking button.

Disconnect the vacuum hose -1- to the activated char-coal filter, to do so press the unlocking button.

Pull activated charcoal filter with its attached lines to the top out of the bracket.

Unbolt bracket -3- for activated charcoal filter. Unscrew bolts on filler neck for windshield washer flu-

id reservoir -2-. Disconnect the line to the switch for the coolant short-

age warning light -F66- at the expansion bottle -1-. Unscrew the coolant expansion bottle and and lay

with connected lines to one side. Remove V-ribbed belt 13-1 page 2.

WARNING!

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



13

Remove deflector -2- and tensioning device -1- for V-ribbed belt.

Remove top toothed belt guard.

To remove, turn fixing screw -1- in vertical position. Raise catches -arrows- and remove top toothed belt

guard. Remove the middle sound dampening system Body Work; Rep. Gr. 50.



13-1 page 7

13

Rotate crankshaft at central bolt of crankshaft timing belt sprocket in direction of rotation of engine and po-sition to TDC marking of cylinder 1. Position 1 -ar-rows-.

Simultaneously the front marking on the camshaft sprocket must be aligned with the marking on the rear toothed belt guard -arrows-. If necessary rotate crank-shaft on a further 1 revolution.

Unscrew the crankshaft belt pulley.

To loosen and tighten the belt pulley, counterhold crank-shaft with ring spanner at the central bolt.

Note



13

Unscrew bottom and middle toothed belt guard -ar-rows-.

Fit on supporting device -T30099- and supporting plate -T30099/1 -.

Hang the hook of the spindle on the lifiting eye. Pre-tension the engine.

Release screws -1- and -2- and remove connecting stud.

Release screws -3 ... 6- and remove engine console.



13-1 page 9

13

Release screws -1 ... 3- and remove engine support.

To slacken the bolts of the engine support, raise engine slightly with spindle of supporting device -T30099-.

Mark the direction of rotation of the timing belt with chalk or a felt-tip pen.

Loosen nut for tensioning pulley by a few turns. Remove timing belt.

Installing (set the timing)

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

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

Fit timing belt onto the crankshaft sprocket, while do-ing so pay attention to direction of running.

Install bottom timing belt guard. Secure belt pulley with a screw, while doing so pay at-

tention to locating element.

Once again check if the crankshaft is on TDC for cyl-inder 1 -arrows-.

Fit timing belt in the order cooling pump, tensioning pulley, camshaft sprocket.

Note

Note



13

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

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

Tightening the timing belt

Rotate the tensioning pulley at the eccentric with the two-hole nut turner -T10020- in -direction of arrow- as far as the stop.

Slacken tensioning pulley until the pointer -2- is ap-prox. 10 mm below the notch -1-.

Rotate the tensioning pulley at the eccentric again in -direction of arrow- as far as the stop.

Slacken tensioning pulley again until the pointer -2- is approx. 10 mm below the notch -1-.

Now slacken tensioning pulley until the notch -1- and the pointer -2- are positioned opposite.

Tighten fixing nut to 23 Nm. Turn crankshaft twice at central bolt of crankshaft tim-

ing belt sprocket in direction of rotation of engine and check whether the camshaft and crankshaft markings coincide with their reference points on TDC.

Once again inspect tension of toothed belt, if neces-sary repeat setting.

Install timing belt guard.Further installation occurs in reverse order, while paying attention to the following:

Tighten screws for engine support bracket. Install engine console. Install the crankshaft belt pulley. Adjust engine mounting Chapter Adjust assembly

bracket in 10-1. Install the V-ribbed belt 13-1 page 2. Vent the fuel system Chapter Vent the fuel sys-

tem in 20-1.

Inspecting the semi-automatic timing belt tensioning pulleyTest condition

Engine temperature should not exceed 40 C.

A13-0078

N13-0402

1

2T 10020

N13-0402



13-1 page 11

13

Test sequence

Position engine on TDC cylinder 1. Load timing belt by firmly pressing down with thumb

-arrows-. The pointer -2- must move to the side. Relieve the pressure on the toothed belt and rotate

crankshaft a further two revolutions in direction of ro-tation of engine until the engine is again positioned at TDC of cylinder 1. When doing this, it is important that the last 45 (1/8 turn) are rotated without any interrup-tion.

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

For the inspection use a mirror.Note



13


Removing and installing sealing flanges and flywheelEdition 12.05S00.5706.02.20

13-2 page 1

13

13-2 Removing and installing sealing flanges and fly-wheel

Repairing the clutch Gearbox 0AF; Rep. Gr. 30.

Sealing flanges and flywheel - Overview of components

1 - 15 Nm2 - Gasket ringT replace 13-2 page 2T do not oil

3 - Front sealing flangeT must be positioned on dowel

sleevesT removing and installing 13-2 page 4

4 - Threaded pin, 10 NmT insert using locking agent

-D 000 600 A2-5 - Cylinder block6 - Gasket ringT replace

7 - Screw plug - 100 Nm8 - 60 Nm + torque a further 90

(1/4 turn)T replace

9 - FlywheelT for removing and installing

secure the flywheel using -MP 1-223-

T Assembly is only possible in one position through offset holes.

10 - Intermediate plateT must be positioned on dowel

sleevesT do not damage/bend during

assembly workT inserted on sealing flange Fig. 1 in 13-2 page 2

11 - Rear sealing flangeT with gasketT removing and installing 13-2 page 6T do not oil

Note


Removing and installing sealing flanges and flywheel Edition 12.05S00.5706.02.2013-2 page 2

13

Fig. 1: Install intermediate plate

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

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


Gasket ring extractor -MP 1-226- Counterholder -T30004 oder MP 1-310- Assembly fixture -T10053-Removing

Engine installed. Removing timing belt Chapter Removing and in-

stalling, tightening the timing belt in 13-1. Remove crankshaft timing belt sprocket, to this end

lock the timing belt sprocket with counterholder -T30004 oder MP 1-310- (the illustration shows an-other engine).

Before inserting the gasket ring extractor, screw the central bolt of the timing belt sprocket into the crank-shaft up to the stop.

T 30004

MP 1-310

S13-0156



13-2 page 3

13

Unscrew inner part of the gasket ring extractor -MP 1-226- nine turns out of the outer part and lock with knurled screw.

Oil the thread head of the gasket ring extractor, posi-tion and forcefully screw into the gasket ring as far as possible.

Release knurled screw and turn the inner side against the crankshaft until the gasket ring is pulled out.

Clamp gasket ring extractor into the vice at the flats. Remove gasket ring with pliers. Clean the contact and sealing surface.

Installing

Do not oil the sealing lip and the outer edge of the gasket before pressing it in.

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

Slide gasket ring over the guide bushing. Press in the gasket ring with pressure bushing

-T10053- and screw -T10053/2- up to the stop. Replace central screw for toothed belt gear.

S13-0093

MP 1-226

Note



13

Tighten crankshaft timing belt sprocket, to this end counterhold the timing belt sprocket with counterhold-er -T30004 oder MP 1-310- (the illustration shows an-other engine). Tightening torque: 90 Nm + torque a further 1/4 turn (90)

There must not be any oil present on contact surface between timing belt sprocket and crankshaft.

Do not oil the screw for the timing belt sprocket crank-shaft.

install (set the timing) Chapter Removing and in-stalling, tightening the timing belt in 13-1.

Install the V-ribbed belt Chapter Removing and in-stalling V-ribbed belt in 13-1.

Removing and installing the front seal-ing flange


Counterholder -T30004 oder MP 1-310- Sealant remover gasket stripper (bearing code GST,

Part no. R 34402), manufacturer Retech GmbH Cleaning agent and grease remover e.g.

-D 000 401 04- Protective goggles and gloves Silicone sealant -D 176 404 A2- Torque wrenchRemoving

Engine installed. Removing timing belt Chapter Removing and in-

stalling, tightening the timing belt in 13-1. Remove crankshaft timing belt sprocket, to this end

lock the timing belt sprocket with counterholder -T30004 oder MP 1-310- (the illustration shows an-other engine).

Drain engine oil. Removing the oil pan Chapter Removing and in-

stalling oil pan in 17-1. Unscrew front sealing flange. Remove and lever off front sealing flange, if neces-

sary release by applying slight blows with a rubber-headed hammer.

T 30004

MP 1-310

S13-0156

Note

T 30004

MP 1-310

S13-0156

WARNING!

Wear protective googles and gloves when working with sealant and grease remover!



13-2 page 5

13

Clean sealant residues with chemical sealant remover from the sealing surface on the flange and cylinder block.

Degrease the sealing surfaces. Cover the gasket ring with a clean cloth. If necessary drive out the gasket ring on the disman-

tled flange.

Installing

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

Apply silicone sealant bead -arrow- to the clean seal-ing surface of the upper part of the sealing flange, as shown.

Thickness of sealant bead: 2 3 mm.

Before applying the sealant bead cover over the gas-ket ring with a clean cloth.

The sealant bead must not be thicker than recom-mended otherwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.

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

When installing the sealing flange with the gasket ring fitted use guide sleeve -T10053/1-.

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

Fit sealing flange immediately and lightly tighten all bolts.

Tighten the fixing screws of the sealing flange cross-wise. Tightening torque: 15 Nm

Remove excess sealant. Installing the oil pan Chapter Removing and in-

stalling oil pan in 17-1. If necessary install the gasket ring for the crankshaft -

on the belt pulley side 13-2 page 3. Installing the timing belt Chapter Removing and in-

stalling, tightening the timing belt in 13-1.

Note



13

Removing and installing the rear sealing flange


Sealant remover gasket stripper (bearing code GST, Part no. R 34402), manufacturer Retech GmbH

Cleaning agent and grease remover e.g. -D 000 401 04-

Protective goggles Silicone sealant -D 176 404 A2- Torque wrenchRemoving

Gearbox removed. Remove the flywheel item 9 in 13-2 page 1. Unhook intermediate plate at sealing flange and at

dowel sleeves -arrows-. Drain engine oil. Removing the oil pan Chapter Removing and in-

stalling oil pan in 17-1. Unscrew rear sealing flange. Remove and lever off rear sealing flange, if necessary

release by applying slight blows with a rubber-headed hammer.

Clean sealant residues with chemical sealant remover from the sealing surface on the flange and cylinder block.

Degrease the sealing surfaces.Installing

To install, push the sealing flange -2- together with guide bushing -1- (inserted in the spare part) onto the crankshaft.

Then carefully push sealing flange onto the dowel pins at engine block.

Tighten the fixing screws of the sealing flange cross-wise. Tightening torque: 15 Nm

Installing the oil pan Chapter Removing and in-stalling oil pan in 17-1.

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

Install the flywheel item 9 in 13-2 page 1.

WARNING!



Removing and installing crankshaftEdition 02.04S00.5706.00.20

13-3 page 1

13

13-3 Removing and installing crankshaft

Before removing the crankshaft, ensure a suitable place is available for placing it down so that the sensor rotor item 9 in 13-3 page 2 does not rest on any-thing or get damaged.

Pay attention to colour coding when inserting bearing shells Fig. 2 in 13-3 page 2

Secure the engine with engine and gearbox mount -MP 1-202- on the assembly stand -MP 9-101- before performing assembly work.

Crankshaft - Overview of components

1 - Thrust washersT for bearing 3T Fitting position: Oil grooves

point to the crank webs2 - Bearing shellT for cylinder block with lubri-

cating grooveT do not mix up used bearing

shells (mark)T insert new bearing shells for

cylinder block with correct identification Fig. 2 in 13-3 page 2

T pay attention to locating ele-ment

3 - SprocketT for oil pump drive

4 - CrankshaftT Axial play when new: 0.07...

0.23 mm, wear limit: 0.30 mm

T Crankshaft bearing journal: 48.00 mm

T Conrod bearing journal: 42.00 mm

5 - Bearing shellT for bearing cap without lubri-

cating grooveT do not mix up used bearing

shells (mark)T The crankshaft bearing

shells in the bearing caps are only supplied as replace-ment parts with the colour coding yellow

T pay attention to locating element6 - 40 Nm + torque a further 90 (1/4 turn)T replace

7 - Bearing capsT Bearing cap 1: on the belt pulley side

Note

A13-0546

8

9

6 7

54

32

1

1

2

3

4

5


Removing and installing crankshaft Edition 02.04S00.5706.00.2013-3 page 2

13

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

8 - 10 Nm + torque a further 90 (1/4 turn)T replaceT replace sensor rotor each time the bolts are slackened Fig. 1 in 13-3 page 2

9 - RotorT for engine speed sender -G28-T Assembly is only possible in one position through offset holes.T replace sensor rotor each time the bolts are slackenedT removing and installing Fig. 1 in 13-3 page 2

Fig. 1: Removing and installing sensor rotor

Always replace the sensor rotor -2- each time the bolts -1- are slackened.

After being attached a second time, the attachment point of the recess head screws in the sensor rotor is sufficiently misshapen that the bolt heads rest against crankshaft -3- -arrows- and the sensor rotor is posi-tioned loosely below the screws.

It is only possible to install the sensor rotor in one po-sition, the holes are offset.

Fig. 2: Assign the crankshaft bearing shells to the cylinder block

The cylinder block bearing shells are allocated with the right thickness at the works. Coloured points on the bear-ing shell are used to mark the bearing shell thickness.

The arrow faces towards the belt pulley side. The markings are visible without removal of the oil

pan.

The bearing shell is to be used at the location which is marked with letters, on the lower sealing surface of the cylinder block.

The crankshaft bearing shells in the bearing caps are only supplied as replacement parts with the colour coding yellow.

1 2

A13-0150

3

Note

Note

Letter on the cylinder block Colour of the support

B = blueG = yellowW = white

Note


Disassembling and assembling piston and conrodEdition 12.05S00.5706.02.20

13-4 page 1

13

13-4 Disassembling and as-sembling piston and con-rod

Oil spray jet for cooling pistons and pressure relief valve Chapter Testing oil pressure and oil pressure switch in 17-1.

Piston and conrod - Overview of components

1 - 30 Nm + torque a further 90 (1/4 turn)T replaceT oil thread and head contact

surface2 - Conrod bearing capT mark assignment to cylinder

-B-T Fitting position: markings -A-

point toward belt pulley side3 - Bearing shellsT top bearing shell with oil drill-

ing for lubricating piston pinT Fitting position Fig. 5 in 13-4 page 3

T do not mix up used bearing shells (mark)

T Axial play when new: 0.09... 0.35 mm, wear limit: 0.4 mm

4 - ConrodT replace as a set onlyT mark assignment to cylinder

-B-T Fitting position: markings -A-

point toward belt pulley sideT with oil drilling for lubricating

piston pin5 - Circlip6 - Piston pinT if stiff, heat piston to approx.

60CT use drift -VW 222 A- for re-

moving and installing7 - PistonT check Fig. 3 in 13-4 page 3T mark installation position and matching cylinderT arrow on piston crown faces towards the belt pulley sideT use piston ring tensioning strap for installingT inspect cylinder bore Fig. 4 in 13-4 page 3T Piston 81.465 mm - Dimension without graphite coatingT Graphite coating: 0.02 mmT Cylinder 81.51 mm

8 - Piston ringsT Compression rings

Note

A13-06701

2

3

4

5

6

7

8

BA

9


Disassembling and assembling piston and conrod Edition 12.05S00.5706.02.2013-4 page 2

13

T Offset joint 120T use piston ring pliers for removing and installingT marking TOP must face towards piston crownT inspect gap clearance Fig. 1 in 13-4 page 2T inspect end clearance Fig. 2 in 13-4 page 2

9 - Piston ringT Oil scraper ringT 3 partT Install joint of upper steel strip ring with 120 offset to the neighboring compression ring.T Install joints of the parts of the oil scraper ring offset to each other

Fig. 1: Inspecting piston ring gap clearance


Feeler gauge 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. To insert use piston with-out rings.

Fig. 2: Inspect piston ring end clearance


Feeler gauge Clean before inspecting the annular groove of the pis-

ton.

Piston ring (dimensions in mm)

new Wear limit

Compression ring - top

0,20 0,40 0,80

Compression ring - bottom

0,75 ... 1,00 1,40

Steel strip rings of oil scraper ring

0,25 0,50 0,80

V13 - 0687

Piston ring (dimensions in mm)

new Wear limit

Compression rings 0,06 0,09 0,20Oil scraper rings 0,03 0,06 0,15


Disassembling and assembling piston and conrodEdition 12.05S00.5706.02.20

13-4 page 3

13

Fig. 3: Inspecting pistons


External micrometer 75...100 mm Measure about 10 mm from the lower edge, offset at

right angles to the piston pin shaft.

Max. deviation from specified dimension: 0.04 mm.

Fig. 4: Inspecting cylinder bore


Internal precision measuring instrument 50...100 mm Measure at 3 points crosswise in a transverse direc-

tion -A- and lengthwise -B- with the internal precision measuring instrument 50 ... 100 mm.

Max. deviation from specified dimension: 0.08 mm.

Do not measure the cylinder bore if the cylinder block is fixed to the assembly stand with the engine mount -MP 1-202-, as this may result in incorrect measure-ments.

Fig. 5: Fitting position of the bearing shells in the conrods

Insert bearing shells in the centre of the conrod or in the conrod bearing cap.

Dimension -a- must be the same on both sides .

The bearing shell with the oil drilling must be inserted into the conrod.

Note

a

a

12

Note


Disassembling and assembling piston and conrod Edition 12.05S00.5706.02.2013-4 page 4

13


Removing and installing cylinder headEdition 12.05S00.5706.02.20

15-1 page 1

15

15-1 Removing and installing cylinder head

Removing and installing timing belt Chapter Remov-ing and installing, tightening the timing belt in 13-1.

Test compression pressure 15-1 page 7

Replace cylinder head bolts. When performing installation work replace the self-

locking nuts and screws. Replace screws which have been tightened to a turn-

ing angle as well as gasket rings and seals. When installing a cylinder head, all the contact surfac-

es between the hydraulic tappets, roller rocker arms and the cam tracks must be oiled before installing the cylinder head cover.

The plastic base for protecting the open valves should only be removed immediately before attaching the cyl-inder head.

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

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.

15 Cylinder Head, Valve Gear

Note


Removing and installing cylinder head Edition 12.05S00.5706.02.2015-1 page 2

15

Cylinder head - Overview of components


-D 000 600 A2-2 - Camshaft sprocket3 - 100 NmT to release and tighten use

counterholder -T30004-4 - 10 NmT insert using locking agent

-D 000 600 A2-5 - Rear timing belt guard6 - Woodruff key7 - Gasket ringT replace

8 - 10 Nm9 - Vent connectionT for coolant expansion reser-

voir10 - 9 Nm

T replace if damaged or leak-ing

11 - GasketT replace if damaged or leak-

ing12 - Cap13 - Cylinder head cover14 - Gasket for cylinder head cov-

erT replace if damaged or leak-

ingT fit into spacer sleeves of item 10

15 - Cylinder head boltT replaceT pay attention to order for slackening 15-1 page 5T pay attention to order for tightening 15-1 page 6

16 - Camshaft position sensor -G163-17 - O-ring

T replace18 - Cylinder head

T removing 15-1 page 3T check for distortion Fig. 1 in 15-1 page 3T Reworking dimension Fig. 2 in 15-1 page 3T installing 15-1 page 5T fill with fresh coolant after replacing

19 - Connection fittings20 - Cylinder head gasket

T replace 15-1 page 3T Fitting position: Part number must point to the cylinder head and must be legible from the inlet side



15-1 page 3

15

Fig. 1: Inspecting the cylinder head for distortion

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

Max. permissible distortion: 0.1 mm.

Fig. 2: Reworking dimension of cylinder head

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

Minimum dimension: a = 132.8 mm

Removing cylinder head


Counterholder -T30004 - Guide bolt -T30011/2A- Removal tool -T30011/3- Catch pan, e.g. -V.A.G 1306 - Pliers for spring strap clips Extractor -T10112- Sealant remover gasket stripper (bearing code GST,

Part no. R 34402), manufacturer Retech GmbH Protective goggles and gloves Requirements

Engine temperature should not exceed 35C, be-cause the cylinder head could be twisted when slack-ening the screws.

If the battery is disconnected and reconnected, carry out certain additional operations Electrical System; Rep. Gr. 27.

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

Disconnect the battery-earth strap with the ignition off. Remove engine guard -arrows-. Drain coolant Chapter Draining and filling up cool-

ant in 19-1.

Note



15

Remove exhaust pipe Chapter Removing and in-stalling front exhaust pipe with catalytic converter in 26-1.

Remove air filter Chapter Disassembling and as-sembling air filter with component parts in 24-1.

Removing the intake manifold Chapter Removing and installing intake manifold in 24-1.

Use extractor -T10112- to unplug spark plug connec-tor.

Pull off coolant hose at rear vent connection at cylin-der head.

Disconnect plug connection at camshaft position sen-sor -G163-.

Disconnect plug connection at exhaust gas recircula-tion valve -N18-.

Expose wiring loom. Remove the plug connection -arrows- for lambda

probe -G39- (upstream of catalytic converter) from the bracket and disconnect.

Unscrew left connection fittings from cylinder head and and lay it to the side

The coolant hoses remain attached to the connection fit-tings.

Remove top toothed belt guard. Position camshaft sprocket to TDC marking of cylin-

der 1 by rotating at crankshaft. Marking on camshaft sprocket must be aligned with arrow on the toothed belt guard.

Slacken tensioning pulley and take timing belt off camshaft sprocket.

Then turn crankshaft slightly backwards. Loosen the camshaft sprocket, to do so use counter-

holder -T30004-. Pull off camshaft sprocket. Remove Woodruff key from the camshaft. Unscrew rear toothed belt guard from cylinder head. Detach hose of crankcase ventilation at cylinder head

cover. Unscrew the bolts of the cylinder head cover from the

outside to the inside. Remove the cylinder head cover.

Note

T30004

S15-0179



15-1 page 5

15

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

A second mechanic is needed to remove the cylinder head.

Swivel the cylinder head to the left out of the rear toothed belt guard and simultaneously remove the tensioning pulley.

Installing cylinder head

Replace cylinder head bolts. When performing installation work replace the self-

locking nuts and screws. Replace screws which have been tightened to a turn-

ing angle as well as gasket rings and seals. When installing an exchange cylinder head with the

camshaft installed, it is necessary to oil the contact surfaces between roller arms and the cam track after installing the head.

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

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

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

Make sure that when cleaning the cylinder head and cylinder block no foreign bodies can get into the cylin-der or into the oil and coolant galleries.

When conducting repairs sealant residues should be removed from the contact surface of the cylinder head/cylinder block using a chemical cleaner.

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

Note

Note

WARNING!




15

Once again check if the crankshaft is on TDC for cyl-inder 1 -arrows-.

To centre the cylinder head gasket and cylinder head, screw in the guide pins -T30011/2A- into the outer holes on the suction side.

The tolerance of the centering holes has been constricted in the top area. For this reason, check first of all, before fitting on the cylinder head, whether the guide pins can be removed upward. If necessary, slightly grind off the knurl-ing of the guide pins.

Position the new cylinder heads. The legend (spare part No.) must be legible.

A second mechanic is needed to fit on the cylinder head.

Swivel cylinder head into rear toothed belt guard and simultaneously push the tensioning pulley onto the threaded pin.

Fit cylinder head onto cylinder block. Insert 8 new cylinder head bolts and tighten by hand. Screw out the guide bolts through the bolt holes using

removal tool -T30011/3- and screw in the remaining cylinder head bolts.

Tighten the cylinder head in 3 stages in the order shown:

T30011/3

T30011/2A

S15-0185

Note

Note

10 4 2 6 8

7 5 1 3 9

S15-0290

Stage Tighten1 Tighten with the torque wrench to

40 Nm.2 Using a rigid wrench torque a fur-

ther 90 (1/4 turn).3 Using a rigid wrench torque a fur-

ther 90 (1/4 turn).



15-1 page 7

15

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


Install the V-ribbed belt Chapter Removing and in-stalling V-ribbed belt in 13-1.

Installing the intake manifold Chapter Removing and installing intake manifold in 24-1.

Checking the oil level Maintenance Manual; Binder Octavia ll..

In case of contaminated engine oil, carry out oil change Maintenance Manual; Binder Octavia ll.. Install exhaust pipe Chapter Removing and install-

ing front exhaust pipe with catalytic converter in 26-1.

Align exhaust system free of stress Chapter Align-ing exhaust system free of stress in 26-1.

Connect up the battery. Important instructions Electrical System; Rep. Gr. 27.

Filling system with coolant Chapter Draining and filling up coolant in 19-1.

Testing the compression


Spark plug wrench, e.g. -3122 B- Torque wrench Compression tester (e.g. -V.A.G 1381- or

-V.A.G 1763-) Extractor -T10112-Test conditions

Engine oil temperature at least 30 C. Battery voltage at least 12.7 V.Test sequence

Switch off ignition. Open lid of E-box in the engine compartment and un-

plug fuses F6 und F32 for ignition transformer and in-jection valves.

Note

Note



15

Remove engine guard -arrows-. Separate the electrical plug connections in the outer

injection valves. Use extractor -T10112- to unplug spark plug connec-

tor. Unscrew the spark plugs with spark plug wrench. Check compression pressure using the compression

tester.

Use of tester Operating Instructions. Have a second mechanic operate starter with the

throttle valve fully opened until no further pressure rise is indicated by the tester.

Compression readings

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

After the compression pressure test, the following work steps must be carried out.

Interrogating and erasing Vehicle Diagnosis, Measuring and Information System VAS 5051; fault memory of engine control unit.

Note

Engine new Wear limit Difference be-tween cylinders

1.0...1.3 MPa(10... 13 bar)

0.7 MPa(7 bar)

max. 0.3 MPa(3 bar)


Repairing Valve GearEdition 12.05S00.5706.02.20

15-2 page 1

15

15-2 Repairing Valve Gear

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.

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

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.

Always replace seals and gasket rings.

Summary of components

1 - 100 NmT to release and tighten use

counterholder -T30004-2 - Camshaft sprocketT for removal and installation,

remove toothed belt Chapter Removing and installing, tightening the tim-ing belt in 13-1

T Installation position fixed by woodruff key item 4

3 - Gasket ringT replace 15-2 page 3

4 - Woodruff keyT check tightness

5 - 23 Nm6 - Ladder frameT with integrated camshaft

bearingsT Bearing 1 at belt pulley sideT removing and installing 15-2 page 5

T reworking sealing surface not permissible

7 - CamshaftT inspecting axial play Fig. 2 in 15-2 page 3

T removing and installing 15-2 page 5

T Slack: max. 0.04 mm8 - Roller rocker armT do not interchangeT inspect roller bearingsT oil contact surfaceT to install the clip onto the supporting element with the locking clips

Note


Repairing Valve Gear Edition 12.05S00.5706.02.2015-2 page 2

15

9 - Supporting elementT with hydraulic valve clearance compensationT check hydraulic valve clearance compensation 15-2 page 8T do not interchangeT oil contact surface

10 - Valve collets11 - Valve spring retainer12 - Valve spring

T with cylinder head removed, remove and install with -MP 1-211- and -MP 1-213- with valve supporting plate -MP 1-218-

13 - Valve stem sealT replace 15-2 page 9

14 - Valve guideT check 15-2 page 9

15 - CapT insert flushT to remove, pierce in the middle with a screwdriver and lever out

16 - Cylinder headT pay attention to note 15-2 page 1T inspecting valve guides 15-2 page 9T reworking valve seats 15-2 page 11T Reworking of sealing surface at camshaft side not permissible

17 - ValveT do not re-mill, only grinding with the valve seat is permissibleT Valve dimensions Fig. 1 in 15-2 page 2T inspecting valve guides 15-2 page 9T reworking valve seats 15-2 page 11

Fig. 1: Valve dimensions

Valves must not be reworked. Only grinding in with grind-ing paste in the related valve seat is permissible.

Note

Dimension Inlet valve Exhaust valve a mm 39,5 0,15 32,9 0,15 b mm 5,980 0,007 5,965 0,007c mm 93,85 93,85 45 45



15-2 page 3

15

Fig. 2: inspect camshaft, axial play


Universal dial gauge holder -MP 3-447- Dial gaugeMeasurement with ladder frame removed.

Wear limit: max. 0.17 mm

Replacing camshaft gasket ring


Counterholder -T30004- Gasket ring extractor -MP 1-215- Insertion sleeve -MP 1-315- Assembly device -T10071- Torque wrenchRemoving

Cylinder head fitted Remove top toothed belt guard. Position camshaft sprocket to TDC marking of cylin-

der 1 by rotating at crankshaft. Marking on camshaft sprocket must be aligned with arrow on the toothed belt guard.


Then turn crankshaft slightly backwards. Loosen the camshaft sprocket, to do so use counter-

holder -T30004-. Pull off camshaft sprocket. Remove Woodruff key from the camshaft.

T30004

S15-0179



15

Screw in the fixing screw for the camshaft sprocket by hand fully up to the stop in the crankshaft to the guide the gasket ring extractor.

Set the inner part of the sealing ring extractor -MP 1-215- flush with the outer part and interlock with the knurled screw.

Oil the thread head of the gasket ring extractor -MP 1-215-, position and forcefully screw it into the gasket ring as far as possible.

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

Clamp gasket ring extractor into the vice at the flats. Remove gasket ring with pliers.

Installing

Do not oil sealing lip of the gasket ring.

Slide gasket ring over the guide bushing -T10071/1-. Remove guide bushing.

Press in the gasket ring with pressure bushing -MP 1-315- and screw -T10071/2- up to the stop.

Place a larger commercially available M12 washer below the bolt in order to avoid wear to the pressure sleeve.

MP 1-215

S15-0181

Note

MP 1-315

S15-0182

Note



15-2 page 5

15

Set the Woodruff key in the camshaft. Tighten the camshaft sprocket, to do so use counter-

holder -T30004-.

Tightening torque: 100 Nm

When turning the camshaft the valves may touch the pis-ton in TDC. Therefore the pistons must not be at TDC. Risk of damaging valves and pistons.


Removing and installing camshaft


Counterholder -T30004 - Sealant remover gasket stripper (bearing code GST,

Part no. R 34402), manufacturer Retech GmbH Cleaning agent and grease remover e.g.

-D 000 401 04- Protective goggles and gloves Sealant -D 188 800 A1- Torque wrenchRemoving

Cylinder head fitted. Removing the intake manifold Chapter Removing

and installing intake manifold in 24-1. Remove top toothed belt guard. Position camshaft sprocket to TDC marking of cylin-

der 1 by rotating at crankshaft.Marking on camshaft sprocket must be aligned with arrow on the toothed belt guard.


Loosen the camshaft sprocket, to do so use counter-holder -T30004-.

Pull off camshaft sprocket. Remove Woodruff key from the camshaft. Unscrew the bolts of the cylinder head cover from the

outside to the inside. Remove the cylinder head cover.

T30004

S15-0179

Note

T30004

S15-0179



15

Unscrew rear toothed belt guard from cylinder head -arrows-.

Unscrew the nuts of bearings 5, 1 and 3. Then, slack-en bearings 2 and 4 alternately diagonally across.

Take off ladder frame. Take out camshaft. Remove the roller rocker arm together with the sup-

porting elements. Lay aside on a clean surface. Ensure that the roller rocker arms and the supporting

elements are not mixed up.

Installing

Remove the old sealant from the groove -arrow- of the ladder frame as well as from the sealing surfaces and the cylinder head using a chemical sealant remover.

Degrease the sealing surfaces. Cut off nozzle tube at the front marking ( of nozzle

approx. 1 mm). Insert the hydraulic supporting elements in the cylin-

der head and position the relevant roller rocker arm on the valve stem ends or supporting elements.

Ensure that all the roller arms are correctly positioned on the valve stem ends -1- and are clipped in place on the relevent supporting elements -2-.

Oil contact surfaces of camshaft.

WARNING!




15-2 page 7

15

Position camshaft in TDC position of cylinder 1:

At the camshaft, the cams of cylinder 1 must be point-ing up evenly -arrows-.

Apply an even, thin layer of sealant -D 188 800 A1- -1- and -2- into the clean groove of the ladder frame.

Apply a thin layer of sealant on the surfaces before the ends of the sealant bead -arrows- as well as onto the sealing surface.

The sealant must not be applied too thick. Wipe off any excess sealant with a non-fluffing cleaning cloth.

The ladder frame should be fitted on and bolted with-out any interruption as the sealing surfaces immedi-ately begin hardening as soon as they come into contact.

Insert the rear cap item 15 in 15-2 page 2 flush. Position ladder frame and slightly tighten the nuts -3-,

-4-, -5-, -6- in several stages crosswise. Then, slightly tighten the nuts -1-, -2-, -7-, -8-, -9-, -10-. Then tighten the nuts in the sequence -1 ... 10-.Tightening torque: 23 Nm

Replacing camshaft gasket ring 15-2 page 3. install (set the timing) Chapter Removing and in-

stalling, tightening the timing belt in 13-1.

After installing the ladder frame and the cylinder head cover, allow the sealant to dry for about 30 minutes.

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

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.

Note

Note



15

Inspect supporting elements with hy-draulic compensation


Feeler gauge

Supporting elements with hydraulic compensation cannot be repaired.

Irregular valve noises when starting engine are nor-mal.

Test sequence

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

Increase engine speed to about 2500 rpm for 2

Documents

1,6 75 kW Engine