Motor Arv,Aqv,Aze,Azf,Ame,Atz,Aqw

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, Mechanical ComponentsEdition 08.99Engine code ARV AQV AZE AZF AME ATZ AQW

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

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 ManualFABIA 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 S00.5305.00.201 06.00 Supplement to Basic Edition S00.5305.01.202 03.01 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.02.203 02.02 Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26 S00.5305.03.204 09.03 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.04.20


List of Supplements Edition 09.03S00.5305.04.20


Table of ContentsEdition 09.03S00.5305.04.20

I

Table of Contents

00 Technical DataTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Removing and Installing EngineRemoving and Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Removing engine ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Installing the engine ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Tightening torques ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- Assembly bracket ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CrankgearRemoving 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 GearRemoving 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 LubricationRemoving 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 110-1 page 710-1 page 910-1 page 9



13-3 page 1

15-1 page 115-1 page 115-1 page 2

15-2 page 115-2 page 115-2 page 215-2 page 315-2 page 615-2 page 615-2 page 7

15-3 page 115-3 page 115-3 page 215-3 page 3

17-1 page 117-1 page 2

17-2 page 117-2 page 117-2 page 1

17-3 page 1


Table of Contents Edition 09.03S00.5305.04.20II

19 CoolingParts 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 SupplyRemoving 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 SystemRemoving 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 119-1 page 119-1 page 319-1 page 519-1 page 519-1 page 7

19-2 page 119-2 page 119-2 page 2

20-1 page 120-1 page 320-1 page 3

20-2 page 120-2 page 1

26-1 page 126-1 page 226-1 page 326-1 page 3


Technical DataEdition 09.03S00.5305.04.20

00-1 page 1

00

00-1 Technical DataEngine number

The engine number (engine identification characters and serial number) is located on the end face of the cyl-inder block on the belt pulley side, at the connection to the 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 on the vehicle data sticker.

Engine characteristics

00 Technical Data

Engine identification charac-ters

ARV AQV AZE AZF

Manufactured 01.01 07.02 01.01 07.02 04.00 03.03 04.00 03.03Exhaust limits conforming to EU-2 EU-3 EU-2 EU-4Displacement l 0,997 0,997 1,397 1,397Power output kW at

rpm37/5000 37/5000 44/5000 44/5000

Torque Nm atrpm

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

Bore mm 72 72 75,5 75,5Stroke mm 61,2 61,2 78,0 78,0Compression 10 : 1 10 : 1 10 : 1 10 : 1Fuel - 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 yesSelf-diagnosis yes yes yes yesLambda control 1 lambda probe 2 lambda probes 1 lambda probe 2 lambda probesCatalytic converter 1 Catalyst 2 Catalysts 1 Catalyst 2 CatalystsTurbocharging no no no noExhaust gas recirculation no no no noSecondary air system no no no noCamshaft adjustment no no no no


Technical Data Edition 09.03S00.5305.04.2000-1 page 2

00

Engine identification characters AME ATZ AQWManufactured 08.99 04.03 11.99 07.00 08.00 03.03Exhaust limits conforming to EU-2 D4 EU-4, EU3-DDKDisplacement l 1,397 1,397 1,397Power output kW at rpm 50/5000 50/5000 50/5000Torque Nm at rpm 120/2500 120/2500 120/2500Bore mm 75,5 75,5 75,5Stroke mm 78,0 78,0 78,0Compression 10 : 1 10 : 1 10 : 1Fuel - 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 3PAKnock control yes yes yesSelf-diagnosis yes yes yesLambda control 1 lambda probe 2 lambda probes 2 lambda probesCatalytic converter 1 Catalyst 2 Catalysts 2 CatalystsTurbocharging no no noExhaust gas recirculation no no noSecondary air system no no noCamshaft adjustment no no no


Removing and Installing EngineEdition 02.02S00.5305.03.20

10-1 page 1

10

10-1 Removing and Installing Engine

Special tools, test and measuring equipment and auxiliary 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-type clips, spring-type clips or clamp-type clips. Always re-place warm-type clamps with spring strap clips or warm-type clamps.

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

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

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

Procedure

On models fitted with a coded radio set, pay attention to 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 the

gearbox. Raise drive shafts and secure.

10 Removing and Installing Engine

Note

S10-0135


Removing and Installing Engine Edition 02.02S00.5305.03.2010-1 page 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 hose onto 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 with the cap fitted to the bottom of the engine cover (if not available 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 cover and 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

34

2

12

S10-0142

3



10-1 page 3

10

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

Remove the vacuum connection from the brake servo unit.

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

Remove coolant hoses -1- and -2- from the expansion reservoir.

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 opening the system lay cleaning cloths around the connec-tion point. Reduce pressure by carefully releasing the connection point.

2

1

3 4

S10-0137

B

1

S34-0397

A



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

A1

3

B2

S34-0398

2

A

B1B

S34-0400

Note



10-1 page 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- and separate plug connections -2- on the holder of the air duct scoop.

To do so press the latch clips.

There are 2 plug connections on vehicles fitted with air conditioning.

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

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

1

3

2

S10-0143

S10-0139

1

2

3

S19-0078



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 side and position on support -2- in such a way that there is no risk of tilting.

Do not buckle the refrigerant lines. Use cloths to protect the right headlight glass from

damage, removing the headlight if necessary.

Continued for all vehicles

Hook on lifting device -MP 9-201- as follows and raise slightly 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 1 to 4 point towards the belt pulley.

The holes in the vertical perforated bars are counted from 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 4 781 5 6

Warning!

Use securing pins on the hooks and rig pins.

Note



10-1 page 7

10

Release screws -2-.

Unscrew the fixing screws -arrows- from the gearbox mount.

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

Secure the engine with engine mount -MP 1-180- on the assembly 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 to use 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 pin

screws on the exhaust manifold. Tightening torques 10-1 page 9 Assembly bracket 10-1 page 9

3

2

1

S10-0140

S10-0120

MP 1-180

MP 9-101

S10-0082

Note

Note



10

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

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

If necessary check the centering of the clutch driver disc.

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 all adjoining components are clear.

Align the engine/gearbox unit.Tightening torques 10-1 page 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 the exhaust 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 were not 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



10-1 page 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 fault memory 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 are allowed. Do not use Molykote.

Do not use degreased parts. Unless otherwise indicated the following tightening

torques apply:

Assembly bracket

Tightening torquesEngine mounting

1 - 20 Nm + 90 (1/4 turn) - replace2 - 30 Nm + 90 (1/4 turn) - replace

Gearbox mounting


Note

Component TorqueScrews/nuts M6 9 Nm

M7 13 NmM8 20 NmM10 40 NmM12 70 Nm

deviations:Engine to gearbox connecting screws

Manual gearbox 002; rep. size 34

Drive shaft to gearbox mount-ing flange

Chassis; rep. size 40

21

1 1

S10-0132

2

11

1

1 S10-0125



10

Hinged bracket

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


2

1

S10-0133

Note


Removing and installing V-ribbed beltEdition 02.02S00.5305.03.20

13-1 page 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 used belt may destroy it.

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

1 - Coolant pumpT removing and installing

Chapter 19-22 - BracketT for clampT removing and installing

Chapter 15-13 - Screw4 - Clamp5 - 25 NmT replace

6 - GeneratorT to facilitate positioning of the

generator on the holder, drive the bushing of the re-taining screw slightly back-wards

7 - Screw8 - 30 NmT replace

9 - 45 Nm10 - 25 Nm

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

11 - BracketT for generator

12 - Guide pulley13 - Washer

T Camber towards the outside14 - 20 Nm

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

15 - Belt pulleyT for crankshaft

16 - 100 NmT to release and tighten lock flywheel Engine removed: with -MP 1-504- Engine installed: with locking screw Chapter 13-2

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

13 Crankgear

Note

1

S13-0241

17

79

10

121314

1516 11

3

2

5

6

4

8


Removing and installing V-ribbed belt Edition 02.02S00.5305.03.2013-1 page 2

13

T installing 13-1 page 5

Fig. 1: Routing of the ribbed V-belt

1 - Belt pulley - generator2 - Belt pulley - crankshaft3 - Guide pulley4 - Belt pulley - coolant pump

1

2

34

S13-0242



13-1 page 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 used belt may destroy it.

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

1 - Coolant pumpT removing and installing

Chapter 19-22 - Lever with tensionerT grease bearing points in

holder before fitting3 - BracketT for generator and AC com-

pressor4 - GasketT replace

5 - 20 Nm6 - 10 Nm7 - ScrewT tightening order and tighten-

ing torque Fig. 2 in 13-1 page 4

8 - Washer9 - ScrewT tightening order and tighten-

ing torque Fig. 2 in 13-1 page 4


10 - Bushing11 - Guide pulley12 - Washer

T Camber towards the outside13 - 35 Nm


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

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

16 - 45 Nm17 - 25 Nm18 - Generator

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

19 - 25 Nm20 - Belt pulley

T for crankshaft21 - 100 Nm

T 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

6579

10111213

1415

16

17

18

19

9

7

5

8

8



13

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

Fig. 2: Tightening torques and tightening order for alternator bracket and AC compressor

1 - 23 Nm2 - Bracket for alternator and AC compressor3 - 45 Nm4 - Washer5 - 23 Nm6 - 45 Nm7 - 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 in the same order as for the 1st stage

Fig. 3: Routing of the V-ribbed belt

1 - Belt pulley - AC compressor2 - Guide pulley3 - Belt pulley - generator4 - Belt pulley - crankshaft5 - 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

34

6 5

1

S13-0245

Note



13-1 page 5

13

Remove noise insulation -arrows-. 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-). To

this end rotate wrench in the direction of the arrow. Remove the V-ribbed belt from the tensioning pulley

and 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 and guide pulley.

Pay attention to the rotation direction of already used V-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 or

Clavis)

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

Fit the ribbed V-belt.

S10-0135

1

23

T30022

S13-0246Note

S13-0245



13

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

Position the belt tension measuring tool (in the figure of the firm Optibelt) on the V-ribbed belt and read off the belt tension value -arrow- on the scale Operat-ing Instructions for the relevant measuring tool.

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

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 the nuts 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 and guide pulley.

S27-0014

NP 002

S13-0240

Note

S13-0249

12

3

Note



13-1 page 7

13

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

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

Position the V-ribbed belt on the tensioning pulley and pivot tensioning pulley back.

Tighten screw -1- on the tensioner -3-.Tightening torque: 10 Nm

Fit camshaft position sensor -2-.Tightening torque: 8 Nm

Start engine and check belt run. Fit noise insulation -arrows-.

1

23

T30022

S13-0246

S10-0135



13


Disassembling and Assembling Cylinder Block and CrankshaftEdition 09.03S00.5305.04.20

13-2 page 1

13

13-2 Disassembling and As-sembling Cylinder Block and Crankshaft

Summary of components

1.4 ltr. engine1.0 litre engine 13-2 page 3

The design of the 1.0 litre engine is essentially identical to that of the 1.4 ltr. engine. Differences exist only in the version of the crankshaft and its mounting 13-2 page 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 Nm2 - Crankshaft bearing unit3 - Thrust washerT for middle bearingT lubricating grooves point out-

wards4 - 8 NmT coat with -AMV 188 520-

(Loctite 574) before inserting5 - FlywheelT with rotor for engine speed

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

moving and installingT replace ring gear 13-2

page 7T installation position to crank-

shaft: on the 1.0 ltr. engine the 2

missing teeth of the rotor must face forward when crankshaft position at TDC of cyl. 1 (marking of belt pulley - crankshaft is positioned op-posite marking 0 at timing gear cover)

only one installed position is possible for the 1.4 litre en-gine (since the bore holes are varying distances apart)

6 - 30 Nm + torque a further 1/4 turn (90)T replaceT coat with -AMV 200 000- (Loctite 270) before inserting

7 - Gasket ringT replaceT remove when removing the sealing flangeT lightly oil sealing lip and outer edge before installing

Note

S13-0170

1

16

15

1718

262728

19

295

6

78

13

24 23 22 21 20

25

4

2

3

109

111214


Disassembling and Assembling Cylinder Block and Crankshaft Edition 09.03S00.5305.04.2013-2 page 2

13

T press into the sealing flange8 - Sealing flangeT not available as replacement part (only together with cylinder block)T coat with -AMV 188 520- (Loctite 574) before inserting

9 - ShieldT for knock sensor -G61-

10 - 5 Nm11 - 20 Nm

T The tightening torque influences the knock sensor function12 - Knock sensor -G61-13 - Cylinder block

T disassembling and assembling pistons, conrod and liner Chapter 13-314 - 8 Nm15 - Timing gear cover16 - Gasket ring

T replace 13-2 page 417 - Belt pulley

T for crankshaft18 - 100 Nm

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

19 - 7 NmT coat with -AMV 105 500- (Loctite 242) before inserting

20 - GasketT replace

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

22 - Helical gearT for oil pump drive

23 - 25 NmT coat with -AMV 154 100- (Loctite 648) before inserting

24 - Timing chainT mark running direction (installed position) before removingT always replace complete with crankshaft sprocket and camshaft sprocket

25 - Bearing shellT for cylinder block with lubricating grooveT do not mix up used bearing shells (mark)

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

27 - Woodruff keyT check tightness

28 - CrankshaftT Axial play when new: 0.03 to 0.13 mmT Wear limit: 0.26 mm

29 - Bearing shellT for crankshaft bearing unit without lubricating grooveT do not mix up used bearing shells (mark)



13-2 page 3

13

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

1 - Bearing capsT Bearing cap 1: on the belt

pulley sideT Bearing cap 2: with recesses

for thrust washers2 - Bearing shellT for bearing cap without lubri-

cating grooveT do not mix up used bearing

shells (mark)3 - Thrust washerT for bearing cap 2T check for firm seating

4 - CrankshaftT Axial play when new: 0.03 to

0.13 mmT Wear limit: 0.26 mm

5 - Bearing shellT for cylinder block with lubri-

cating grooveT do not mix up used bearing

shells (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 of sprocketsThis inspection should be carried out if the sprockets have been replaced.


Straightedge Feeler gaugeThe 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 the letter F, is supplied together with the camshaft sprocket

S13-0209

1

2

3

4

5

a=12

S15-0028

1

2

3



13

in a set, the wheels marked with the letters E and G are only supplied individually Spare Part Catalogue.Marking of the crankshaft sprocket radially in the area of the slot for the Woodruff key -arrow- is carried out with the letters 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 sprocket and measure size of gap at crankshaft sprocket.

Position of chain sprockets1 - Camshaft sprocket2 - Crankshaft sprocket

Pfeil-points towards flywheel sideI - Nominal dimension -a- = 0.09 0.2 mmII - max. tolerance -b- = 0.29 mmIII - min. tolerance -c- = -0.11 mm (crankshaft sprocket

is 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 -on the 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

2b

1

2c

1

2a

S13-0171



13-2 page 5

13

Flywheel lock -MP 1-504- Torque wrench Screw M 6x40 (grade: 8.8) make a 60 point at the extremity of the bolt (locking

screw)

Nut M6

Removing

Removing engine cover Chapter 10-1. Mount supporting device -MP 9-200- and take up the

weight of the engine/gearbox assembly at the spin-dles.

Unscrew bolts -2-. Remove right wheel-well inner panel.

Remove noise insulation -arrows-. Lower engine approximately 50 mm. Remove the V-ribbed belt Chapter 13-1.

3

2

1

S10-0140

S10-0135



13

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

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

Tighten up the screw and secure in place with the counternut -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 pressure plate -MP 6-401/1-.

Installing

Crankshaft is locked with flywheel lock -MP 1-504 -, or locking 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.

Tightening torque: 10 Nm

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 engine

mounting 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

T10040/1T10040/1

S13-0175

T10041

N13-0425

Note

Note



13-2 page 7

13

Replacing ring gear Flywheel removed

Removing

Fit on flywheel flat and position ring gear in stages by striking over the entire circumference. Heat ring gear if 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 drift over the entire circumference, if necessary.



13


Disassembling and Assembling Pistons, Connecting Rod and Liner

Edition 06.00S00.5305.01.20

13-3 page 1

13

13-3 Disassembling and Assembling Pistons, Connecting Rod and Liner

Secure the engine with engine holder -MP 1-180- or -MP 1-202- on the assembly stand -MP 9-101- before performing assembly 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)T use piston ring pliers for re-

moving and installingT marking TOP faces piston

crownT inspecting piston ring gap

clearance Fig. 1 in 13-3 page 2

T inspecting piston ring end clearance Fig. 2 in 13-3 page 3

2 - Piston ring (grey)T use piston ring pliers for re-

moving and installingT marking TOP faces piston

crownT inspecting piston ring gap

clearance Fig. 1 in 13-3 page 2

T inspecting piston ring end clearance Fig. 2 in 13-3 page 3

T offset gap 120 relative to top piston ring

3 - Oil scraper ring (3 part)T remove and install by handT installing Fig. 3 in 13-3

page 34 - PistonT mark installation position and

matching linerT arrow on piston crown faces

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

5 - ConrodT Check fitting position: engraved number (1 to 4 for appropriate cylinder) -arrow A- points towards camshaft

side, mark if necessaryT Oil drilling -arrow B- for piston pin lubricationT available as replacement part only in set (4 conrods with 4 conrod caps)

6 - Conrod boltT only 1.4 ltr. engineT check fitting positionT press out to replace

Note

1

A

2

3

4

5

6

7

9

1112

13

15

11

S13-0210

14

B

8

10



Edition 06.00S00.5305.01.2013-3 page 2

13

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

similar8 - Conrod bolt, 20 Nm + torque a further 1/4 turn (90) T only 1.0 ltr. engineT replaceT oil thread and head contact surface

9 - 40 NmT only 1.4 ltr. engineT oil thread and head contact surface

10 - Conrod capT check fitting position item 5 in 13-3 page 1

11 - Bearing shellT do not mix up used bearing shellsT 1.0 ltr. engine insert in middleT 1.4 ltr. engine ensure tightly located in retaining lugs

12 - Gasket ringT replaceT different thicknesses are available to correct the liner pretension

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

14 - Circlip15 - Piston pin

T 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 from

top edge of liner.

S13-0006

newPiston ring dimensions in 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 scraper ring

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

1) no specification possible for wear limit



Edition 06.00S00.5305.01.20

13-3 page 3

13

Fig. 2: Inspecting piston ring end clearance


Feeler gaugeClean 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 that there is no hole behind it.

Compress joint of spring ring and insert top metal ring. The joint of the top metal ring should be positioned 45...90 to the left of the joint of the spring ring.

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

Fig. 4: Inspecting pretension of liners


Measuring tool for liner pretension -MP 1-107- Dial gaugeThe seat surfaces of the liners and of the cylinder block 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

Insert liners with seal firmly into the cylinder block up to the stop.

Measure projection (preload) of liners to top edge of cylinder 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-sions in mm

new Wear limit

1. Piston ring (chrome-plated)

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

2. Piston ring (grey) 0,04...0,08 0,15Oil scraper ring cannot be measured

S13-0008

MP 1-107

S13-0128



Edition 06.00S00.5305.01.2013-3 page 4

13

Seals are available in thicknesses of 0.10; 0.12 and 0.14 mm.

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

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

Note


Removing and installing cylinder headEdition 09.03S00.5305.04.20

15-1 page 1

15

15-1 Removing and installing cylinder head

Summary of components 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 Nm2 - SealT replace

3 - Cylinder head boltT moisten with oil before

screwing inT tightening order and tighten-

ing torque 15-1 page 44 - Washer5 - Lifting eye - on the left6 - Rocker arm shaftT removing and installing rock-

er arms Chapter 15-3T performing basic setting of

hydraulic valve clearance compensation Chap. 15-2

7 - BracketT for ignition terminal

8 - Shim9 - 23 NmT do not tighten fully until cylin-

der head bolts have been tightened

10 - 20 NmT self-locking, replaceT do not tighten fully until cylin-

der head bolts have been tightened

11 - 20 NmT wet with -AMV 105 500-

(Loctite 242) before screwing in

T do not tighten fully until cylinder head bolts have been tightened12 - Bracket

T for generator support13 - Cylinder head gasket

T Observe installation position; with part no. marking faces upT replace

14 - Cylinder headT check for distortion Fig. 1 in 15-1 page 2

15 Cylinder Head, Valve Gear

Note


Removing and installing cylinder head Edition 09.03S00.5305.04.2015-1 page 2

15

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

15 - Oil deflector16 - 25 Nm17 - Lifting eye - on the right18 - Gasket for cylinder head cover

T replace if damaged19 - Cylinder head cover20 - Cap

T 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 cylinder head, do not rework.

Removing and installing cylinder head Engine installedSpecial 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, carry out rework Electrical System; Rep. Gr. 27. Remove front exhaust pipe with catalyst Chapter

26-1. Drain coolant Chapter 19-1. Removing engine cover Chapter 10-1.

V15 - 0673

Note

S10-0138

1

6 4

5

34

2



15-1 page 3

15

Disconnect plug:2 - from the throttle valve control unit -J338-3 - from the intake manifold pressure sender -G71- with

intake 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 wiring loom 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 thermo

regulator 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 fully

unscrew). First remove the rocker arm shaft. Then unscrew the remaining cylinder head bolts/nuts. Remove the generator support bracket item 12 in 15-1 page 1

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

Remove the push rods and lay aside according to their fitting position.

Carefully remove the cylinder head.

86

4

2

3

7

51

S15-0157

M

M

1

2 S10-0141

Caution!

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.

2

1

3 4

S10-0137



15

Installing

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

Treat the seal with the utmost care. Any damage will result in leaks.

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

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

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

Carefully remove old residual seal and the cleaning cloths.

Turn the crankshaft in such a way that all pistons are at the same height. While doing so the liners must no be pushed out; if necessary press down.

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

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

Insert the cylinder head. Insert the push rods with the ball socket from the top

in accordance with their original location.

When inserting the push rods carefully introduce them in the ball socket of the tappet and in the ball knobs of the adjusting screws. Wrongly inserted push rods (with ball head on the edge of the tappet or with the edge on the ball 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 screws

by hand. Insert the other cylinder head bolts/nuts and tighten by

hand. 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 Washer1, 2, 3, 6, 7 168 mm yes4, 5, 8, 9 185 mm no10 132 mm yes



15-1 page 5

15

Tighten the cylinder head bolts/nuts in the following sequence:

Install the generator support bracket item 12 in 15-1 page 1

Insert bolt item 11 in 15-1 page 1 with locking agent -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 - fuel injection; 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 method1 to 10 Stage I: 20 Nm

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

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

11 to 14 20 Nm

Note



15


Repairing cylinder headEdition 09.03S00.5305.04.20

15-2 page 1

15

15-2 Repairing cylinder head

1 - Valve collets2 - Valve spring retainer3 - Valve springT removing and installing

15-2 page 24 - Valve stem sealT replace 15-2 page 6

5 - Cylinder headT reworking valve seats

15-2 page 3T inspecting valve guides

15-2 page 16 - ValvesT do not rework, only grinding

in is permissibleT removing and installing

15-2 page 2T Valve dimensions 15-2

page 37 - Cylinder head marking8 - PlugT installing Fig. 1 in 15-2

page 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


Repairing cylinder head Edition 09.03S00.5305.04.2015-2 page 2

15

Procedure

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

Determine valve rock.

Wear limit

If the wear limit is exceeded, repeat measurement with 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 a hammer on the assembly lever.

Pull out valves.

Inlet valve Exhaust valve0.5 mm 0.6 mm

Note

MP 1-113S15-0008

S15-0124

2

1

MP 1-113

MP 1-114/1

MP 1-114

Note



15-2 page 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 leaking valves, it is not sufficient to machine or replace the valve seats and valves. It is also necessary to inspect the valve guides for wear, particularly on engines with a high mileage.

Rework valve seats only sufficiently in order to obtain a proper contact pattern. Calculate the maximum per-missible reworking dimension before commencing. If the 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, use a new valve for the measurement.

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

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

Note

Inlet valve Exhaust valveDimension 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 7,0c mm 104,0 101,0 104,0 101,0 45 45 45 45

Note

Note

S15-0093

aMaximum dimen-sions in mm

1.0 ltr. en-gine

1.4 ltr. en-gine

Inlet valve 43,1 42,7Exhaust valve 43,0 42,8



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, replace cylinder head.

Reworking valve seats

ProcedureReworking 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-

mension0,4 mm

Note

S15-0058

30

4560

a

b

c

ZDimension Valve seats1.0 ltr. en-gine: a mm Valve seat

diameter:33,4 0.1 - inlet valve 26.4 0.1 - exhaust valve

1.4 ltr. en-gine: a mm Valve seat

diameter:32.9 -0.1 - inlet valve 29.6 -0.1 - exhaust valve

b mm Max. permissible reworking dimension1.0 ltr. en-gine:c mm Valve seat

width:1.3 up to 1.6 - inlet and ex-haust valve

1.4 ltr. en-gine:c mm Valve seat

width:1.45 up to 1.75 - inlet valve 1.65 up to 1.95 - exhaust valve

Z Bottom edge of cylinder head45 Valve seat angle30 Top correction angle60 Bottom correction angle



15-2 page 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 valve guide.

Match diameter of milling cutter to diameter of valve seat.

Milling sequence1 - Machine valve seat with 90 milling tool until until a

perfect contact pattern is achieved. (Do not exceed maximum permissible reworking dimension!)

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

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

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 filling fuel into the combustion chamber (no fuel must flow out at the valve seat).

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

S15-0098

Valve guide Guide drift mmInlet valve 7,0 -0,01

Exhaust valve

Valve seat Mill-ing cut-ter 90

mm

Milling cutter 120 mm

Mill-ing cut-ter 60

mm

Inlet valve

1.0 ltr. engine

36 38 21/34

1.4 ltr. engine

36 38 21/34

Exhaust valve

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



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-, then carefully fit onto the valve stem and press onto the valve guide.

Basic setting of hydraulic valve clear-ance compensationThe hydraulic valve clearance compensation is mainte-nance-free; the setting must not be changed.

After completing repair work on the cylinder head/valve gear, 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 adjusting bolts of the rocker arms.

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

Turn adjusting bolts of both rocker arms slightly against the valves until valve gear has no play. Check the gradual reduction of the play through swinging movements of the adjusting rocker arm. The point with no play which has appeared determines the exact contact location.

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

S15-0016

S15-0110

A

Note



15-2 page 7

15

Carry out the setting operations on the other cylinders according to the table below:

After installing new hydraulic tappets, the engine must not be started for about 30 minutes. Hydraulic compensa-tion elements must settle (otherwise valves may remain constantly open and strike the piston).

Testing the compression

Test conditions

Engine oil temperature at least 30 CSpecial tools, test and measuring equipment and auxiliary items required

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 and

detach 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 accelerator pedal.

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

Use of tester Operating Instructions.

Setting Valve overlapCylinder 1 Cylinder 4Cylinder 3 Cylinder 2Cylinder 4 Cylinder 1Cylinder 2 Cylinder 3

Note

N15-0219

Note

Note



15

Operate starter until the tester no longer indicates a pressure 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 be stored.

Tightening torques

New engine Wear limit Difference be-tween cylinders

min. 12 bar (1.2 MPa)

7.5 bar (0.75 MPa)

max. 3 bar (0.3 MPa)

Note

Component NmSpark plugs in cylinder head 30Ignition terminal to bracket 9


Repairing valve gearEdition 03.01S00.5305.02.20

15-3 page 1

15

15-3 Repairing valve gear

Removing and installing camshaft

1 - Tappet rodT pay attention to correct in-

stallation positionT do not interchange

2 - Hydraulic tappetsT with hydraulic valve clear-

ance compensationT check 15-3 page 3T use auxiliary tool to pull out

of cylinder block Fig. 1 in 15-3 page 1

T do not interchangeT lay aside with contact sur-

face facing downT oil contact surface

3 - Cylinder blockT Removing and installing cyl-

inder block Chap. 15-1 T Removing and installing tim-

ing gear cover and sprockets Chap. 13-2

4 - O-ring5 - Camshaft position sensor

-G163-6 - 8 Nm7 - CamshaftT with timing segment for cam-

shaft position sensor -arrow- T Camshaft setting Fig. 2 in 15-3 page 2

8 - Woodruff keyT check tightness

9 - Retaining plate of camshaft10 - 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-, tilt slightly and pull tappet out of the guide in the cylinder block.

31 2

4

6

5

8910

7

S15-0149

2

a

1

S15-0130


Repairing valve gear Edition 03.01S00.5305.02.2015-3 page 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 shaftT removing and installing

Chap. 15-12 - Circlip3 - Rocker arm bracket, on out-

sideT for M11 cylinder head bolt

4 - Spring washer5 - Rocker arm6 - Adjusting screwT performing basic setting of

hydraulic valve clearance compensation Chap. 15-2

7 - Lock nutT 13 Nm

8 - Rocker arm bracketT for M8 bolt

9 - Rocker armT pay attention to different ver-

sion Fig. 3 in 15-3 page 310 - Rocker arm bracket, on inside

T for M11 cylinder head bolt11 - Tensioning ring12 - Spring

a=12

S15-0028

1

2

3

1

24

3

8

10

8

56

79

9

11

129

11

8

9

10

9

8

3

5

2

9

S15-0150


Repairing valve gearEdition 03.01S00.5305.02.20

15-3 page 3

15

Fig. 3: Arrangement of rocker arms and rocker arm brackets

1 - Straight rocker arm2 - Inclined rocker arm, to the left3 - Inclined rocker arm, to the rightA - Rocker arm bracket for M11 bolt, on outsideB - 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 in the illustration.

Inspecting hydraulic tappets


Feeler gauge Wooden or plastic wedge

Always replace hydraulic tappet complete (cannot be adjusted or 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 min-utes.

If the hydraulic tappets are still loud, determine the faulty tappet 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 wooden or 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 rocker arm and valve and the tappet at the same time moves down, replace the tappet.

If play was measured only between rocker arm and valve (tappet does not move down), carry out basic setting of the 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

AC C B

3 2 3 2 3

BB

S15-0132

Note

Note

S15-0189


Repairing valve gear Edition 03.01S00.5305.02.2015-3 page 4

15

After installing new hydraulic tappets, the engine must not be started for about 30 minutes. Hydraulic compensa-tion elements must settle (otherwise valves may remain constantly open and strike the piston).

Inspection Valve overlapCylinder 1 Cylinder 4Cylinder 3 Cylinder 2Cylinder 4 Cylinder 1Cylinder 2 Cylinder 3

Note


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

17-1 page 1

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17-1 Removing and installing parts of the lubrication system

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

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

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

Oil capacity and oil specification:

Inspection and Maintenance.

17 Lubrication

Note


Removing and installing parts of the lubrication system Edition 02.02S00.5305.03.2017-1 page 2

17

Summary of components

1 - CapT fit on during installation work

2 - GasketT replace if damagedT on the engine cover

3 - 0.9 bar (0.09 MPa) oil pres-sure switch - F1-, 45 NmT greyT inspecting Chapter 17-3T cut open seal if leaking and

replace4 - Oil filterT slacken with tensioning strapT moisten seal with oilT tighten by handT pay attention to installation

instructions on oil filterT pay attention to change inter-

vals5 - Split pin6 - BallT for pressure relief valveT when installing, knock in

slightly with aluminium drift so that the seat of the ball is smoothened

7 - 40 Nm8 - Pressure springT for pressure relief valve

9 - 8 Nm10 - Intermediate plate

T clamped onto oil pan support of 1.4 ltr. engine11 - Oil pan support

T for 1.4 litre engine only:12 - Bracket

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

13 - 10 Nm14 - 20 Nm15 - 45 Nm

T for 1.4 litre engine only:16 - Oil drain plug, 30 Nm17 - Gasket

T replace18 - Oil pan

T removing and installing Chapter 17-219 - Gasket

T for 1.0 litre engine onlyT replaceT coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing the

oil pan with gasket Fig. 3 in 17-1 page 420 - 8 Nm

S17-0081


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

17-1 page 3

17

21 - Oil pump cover with pressure relief valveT opening pressure: approx. 4.6 bar (0.46 MPa) overpressureT clean strainer if dirty

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

23 - GearsT inspecting axial play Fig. 1 in 17-1 page 3

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

25 - DipstickT oil level must not exceed "max" marking!T Inspect engine oil level Inspection and Maintenance

Fig. 1: Oil pump - inspect axial play


Feeler gauge StraightedgeAxial 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 in 17-1 page 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 guide tube -2- up and out.

When installing replace seal -3-. Tighten new self-locking nut -1- to 20 Nm.

S17-0038

Note

2

3 S17-0039

1


Removing and installing parts of the lubrication system Edition 02.02S00.5305.03.2017-1 page 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 installing the oil pan with gasket -arrows-.


Removing and installing oil panEdition 09.03S00.5305.04.20

17-2 page 1

17

17-2 Removing and installing oil pan

Removing and installing oil pan - for a 1.0 litre engine

RemovingThe procedure for removing the oil pan on a 1.0 ltr. and 1.4 ltr. engine is identical 17-2 page 1.

Installing


Torque wrench Sealant -AMV 188 520- Coat the joints between the timing gear cover/cylin-

derblock with sealant -AMV 188 520- before installing the oil pan with gasket -arrows-.

Lay on the gasket for the oil pan. Tighten securing bolts in the specified order.

Tightening torque: 10 Nm

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

Removing and installing oil pan - for a 1.4 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 applying

slight blows with a rubber-headed hammer. Press the coolant pipe slightly towards the outside for this step.

N17-0079

1

20

1916

12 8 4 5 9

1515 11 7 3 2 6 10

131718

14

Note


Removing and installing oil pan Edition 09.03S00.5305.04.2017-2 page 2

17

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

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 BOND 1215 J) . If -D 176 404 A2- is used installation must be performed within 5 minutes.

The assistance of a second mechanic is required to install the oil pan. Press the front coolant pipe slightly towards the outside.

Cut off nozzle tube at the front marking ( of nozzle approx. 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 clogg the strainer in the oil suction pipe.

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

It is particularly important to maintain the specified ap-plication pattern for the bead in the area of the sealing flange 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


Removing and installing oil panEdition 09.03S00.5305.04.20

17-2 page 3

17

Engine installed

Fit intermediate plate onto oil pan support. Position oil pan together with oil pan support immedi-

ately against the cylinder block and tighten the bolts as follows:

1 - Tighten all the bolts of the oil pan/cylinder block only very slightly in the given sequence.

2 - Slightly tighten two bolts of oil pan support/gearbox.3 - Tighten all the bolts of the oil pan/cylinder block

slightly in the given sequence.4 - Tighten two bolts of oil pan support/gearbox to 45

Nm.5 - Tighten all the bolts of the oil pan/cylinder block to

the prescribed torque in the given sequence: M6 = 10 Nm; M8 = 20 Nm.

Engine removed(Gearbox disconnected)

To ensure clearance of intermediate plate when in-stalling the engine - gearbox, bolt counterholders -T30008- tight to cylinder block (M10) as shown in the illustration.

The flat side of the counterholders -T30008- must touch the cylinder block for this step.

Position oil pan together with oil pan support immedi-ately against the cylinder block and tighten the bolts as follows:

1 - Tighten all the bolts of the oil pan/cylinder block only very slightly in the given sequence. For this step press oil pan support against the counterholders -T30008-.

2 - Tighten all bolts to the prescribed torque in the given sequence: M6 = 10 Nm; M8 = 20 Nm.

There must not be any gap between the oil pan support and counterholders -T30008-; if necessary slacken oil pan bolts again and correct position of the oil pan.

A gearbox housing or a gearbox can also be fitted instead of the counterholders -T30008-. Relevant tightening se-quence of the bolts: as described in engine installed.

Continuation for both installation descriptionsFurther installation occurs in a similar way in reverse or-der to removal.

N17-0079

1

20

1916

12 8 4 5 9

1515 11 7 3 2 6 10

131718

14

S17-0041

T30008

N17-0079

1

20

1916

12 8 4 5 9

1515 11 7 3 2 6 10

131718

14

Note


Removing and installing oil pan Edition 09.03S00.5305.04.2017-2 page 4

17

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

Note


Testing Oil Pressure and Oil Pressure SwitchEdition 06.00S00.5305.01.20

17-3 page 1

17

17-3 Testing Oil Pressure and Oil Pressure Switch


Oil pressure tester (e. g. -V.A.G 1342-) Diode test lamp (e.g. -V.A.G 1527 B-) Adapter cable set (e.g. -V.A.G 1594 A-) Current flow diagramFunction of dynamic oil pressure warning system

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

The oil pressure warning is activated for about 10 s after the ignition is switched on (terminal 15 on). Activation delay of oil pressure warning: approx. 3 s Off delay of oil pressure warning: approx. 5 s

Check warning lamp

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

Warning criteria

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

Ignition on, engine not running, oil pressure switch closed

Engine speed greater than 1500 rpm, oil pressure switch open

At an engine speed above 5000 rpm, the oil pressure warning is not cancelled; not even if the oil pressure switch is closed. Oil pressure switch cancelled below 5000 rpm.

If the oil pressure switch is open for only 0.5...3 s at an engine speed above 1500 rpm, this is stored in the combination processor of the dash panel insert. If this condition occurs 3 times when the engine is running, the oil pressure warning is imme

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