Motor ARV, AQV, AZE, AZF, AME, ATZ, AQW

Service 5
Workshop Manual
FABIA 2000 ³
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical
Components
Edition 08.99
Engine code ARV AQV AZE AZF AME ATZ AQW
Service Department. Technical Information Printed in Czech Republic

S00.5305.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5305.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
List of Supplements to Workshop Manual

FABIA 2000 ³
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Edition 08.99
Supple-
Edition Subject Article Number
ment
08.99 Basic Edition S00.5305.00.20
1 06.00 Supplement to Basic Edition S00.5305.01.20
2 03.01 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.02.20
3 02.02 Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26 S00.5305.03.20
4 09.03 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.04.20
Edition 09.03 List of Supplements

S00.5305.04.20
List of Supplements Edition 09.03

S00.5305.04.20
Table of Contents
00 – Technical Data
Technical Data .......................................................................................... 00-1 page 1
10 – Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 page 1
- Removing engine ...................................................................................... 10-1 page 1
- Installing the engine ................................................................................... 10-1 page 7
- Tightening torques .................................................................................... 10-1 page 9
- Assembly bracket ...................................................................................... 10-1 page 9
13 – Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 page 1
- Summary of components - Vehicles without air conditioning ................................... 13-1 page 1
- Summary of components - Vehicles with air conditioning ....................................... 13-1 page 3
- Removing the V-ribbed belt .......................................................................... 13-1 page 4
- Installing the V-ribbed belt ........................................................................... 13-1 page 5
Disassembling and Assembling Cylinder Block and Crankshaft ........................... 13-2 page 1
- Summary of components ............................................................................. 13-2 page 1
- Inspecting synchronous running of sprockets ..................................................... 13-2 page 3
- Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-2 page 4
- Replacing ring gear ................................................................................... 13-2 page 7
Disassembling and Assembling Pistons, Connecting Rod and Liner ..................... 13-3 page 1
15 – Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 page 1
- Removing and installing cylinder head ............................................................. 15-1 page 2
Repairing cylinder head .............................................................................. 15-2 page 1
- Inspect valve guides .................................................................................. 15-2 page 1
- Removing and installing valves ..................................................................... 15-2 page 2
- Reworking valve seats ................................................................................ 15-2 page 3
- Replacing valve stem seal ........................................................................... 15-2 page 6
- Basic setting of hydraulic valve clearance compensation ....................................... 15-2 page 6
- Testing the compression ............................................................................. 15-2 page 7
Repairing valve gear ................................................................................... 15-3 page 1
- Removing and installing camshaft .................................................................. 15-3 page 1
- Removing and installing rocker arms ............................................................... 15-3 page 2
- Inspecting hydraulic tappets ......................................................................... 15-3 page 3
17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1
Removing and installing oil pan .................................................................... 17-2 page 1
- Removing and installing oil pan - for a 1.0 litre engine .......................................... 17-2 page 1
- Removing and installing oil pan - for a 1.4 litre engine .......................................... 17-2 page 1
Testing Oil Pressure and Oil Pressure Switch .................................................. 17-3 page 1
Edition 09.03 Table of Contents I

S00.5305.04.20
19 – Cooling
Parts of cooling system - Summary of components ........................................... 19-1 page 1
- Parts of the cooling system fitted to body ......................................................... 19-1 page 1
- Parts of cooling system engine side ................................................................ 19-1 page 3
- Connection diagram for coolant hoses ............................................................. 19-1 page 5
- Draining and filling up coolant ....................................................................... 19-1 page 5
- Checking the coolant system for tightness ........................................................ 19-1 page 7
Removing and Installing Radiator, Coolant Pump ............................................. 19-2 page 1
- Removing and installing radiator .................................................................... 19-2 page 1
- Removing and installing coolant pump ............................................................ 19-2 page 2
20 – Fuel Supply
Removing and Installing Parts of the Fuel Supply System ................................... 20-1 page 1
- Safety precautions when working on the fuel supply system ................................... 20-1 page 3
- Cleanliness rules ...................................................................................... 20-1 page 3
Activated Charcoal Filter System .................................................................. 20-2 page 1
- Repairing parts of the activated charcoal filter system .......................................... 20-2 page 1
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Aligning exhaust system free of stress ............................................................. 26-1 page 2
- Replacing front or rear silencer ..................................................................... 26-1 page 3
- Checking the exhaust system for leaks ............................................................ 26-1 page 3
Table of Contents Edition 09.03

II S00.5305.04.20
FABIA 2000 ³ 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 00
00 – Technical Data
00-1 Technical Data

Engine 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
Engine identification charac- ARV AQV AZE AZF

ters
Manufactured 01.01 ³ 07.02 01.01 ³ 07.02 04.00 ³ 03.03 04.00 ³ 03.03
Exhaust limits conforming to EU-2 EU-3 EU-2 EU-4
Displacement l 0,997 0,997 1,397 1,397
Power output kW at 37/5000 37/5000 44/5000 44/5000
rpm
Torque Nm at 84/2750 84/2750 118/2600 118/2600
rpm
Bore ∅ mm 72 72 75,5 75,5
Stroke mm 61,2 61,2 78,0 78,0
Compression 10 : 1 10 : 1 10 : 1 10 : 1
Fuel - RON 95 unleaded1) 95 unleaded1) 95 unleaded1) 95 unleaded1)
Fuel injection and ignition sys- Simos 3PB Simos 3PA Simos 3PB Simos 3PA
tem
Knock control yes yes yes yes
Self-diagnosis yes yes yes yes
Lambda control 1 lambda probe 2 lambda probes 1 lambda probe 2 lambda probes
Catalytic converter 1 Catalyst 2 Catalysts 1 Catalyst 2 Catalysts
Turbocharging no no no no
Exhaust gas recirculation no no no no
Secondary air system no no no no
Camshaft adjustment no no no no
1) At least 91 RON in exceptional cases; the engine output is reduced however
Edition 09.03 Technical Data 00-1 page 1

S00.5305.04.20
00 FABIA 2000 ³ 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Engine identification characters AME ATZ AQW

Manufactured 08.99 ³ 04.03 11.99 ³ 07.00 08.00 ³ 03.03
Exhaust limits conforming to EU-2 D4 EU-4, EU3-DDK
Displacement l 1,397 1,397 1,397
Power output kW at rpm 50/5000 50/5000 50/5000
Torque Nm at rpm 120/2500 120/2500 120/2500
Bore ∅ mm 75,5 75,5 75,5
Stroke mm 78,0 78,0 78,0
Compression 10 : 1 10 : 1 10 : 1
Fuel - RON 95 unleaded1) 95 unleaded1) 95 unleaded1)
Fuel injection and ignition system Simos 3PB Simos 3PA Simos 3PA
Knock control yes yes yes
Self-diagnosis yes yes yes
Lambda control 1 lambda probe 2 lambda probes 2 lambda probes
Catalytic converter 1 Catalyst 2 Catalysts 2 Catalysts
Turbocharging no no no
Exhaust gas recirculation no no no
Secondary air system no no no
Camshaft adjustment no no no
1) At least 91 RON in exceptional cases; the engine output is reduced however
Technical Data Edition 09.03

00-1 page 2 S00.5305.04.20
10 – Removing and Installing Engine
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-)
♦ 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
Note
♦ 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. S10-0135
Edition 02.02 Removing and Installing Engine 10-1 page 1

S00.5305.03.20
– 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.
A10-0118
– Remove engine cover -1- as follows:

1 2 3
♦ Release logo -2- and carefully lever off the cap -3-. 4
♦ Release nuts -4- (5 Nm).
♦ Pull out oil dipstick -6-.
♦ Remove engine cover -1- towards the top (do not un- 6 4
screw cap -5-).
– Close the oil filler inlet on the cylinder head cover with 5
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
S10-0138
⇒ 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-. 1
2
S10-0142
Removing and Installing Engine Edition 02.02

10-1 page 2 S00.5305.03.20
– Remove coolant hoses -1- and -2- from the coolant
regulator housing.
– Remove the vacuum connection from the brake servo 1
unit.
Caution!
M
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
M
the connection point.
2 S10-0141
– Remove the fuel presupply pipe -4- by pressing the re-

lease buttons at the separation point. 2
– Remove coolant hoses -1- and -2- from the expansion
reservoir.
– Release vacuum hose -3- from the solenoid valve
-N80-.
1
3 4
S10-0137
– Release nut -arrow A- and tie up holder -1-.
B S34-0397

S00.5305.03.20
– Disconnect the Bowden cable support from gearbox

-arrows-.
S34-0389
– Detach selector cable -A-, for this step remove circlip

-arrow 1- from the relay lever. A
– Remove bearing bolt -arrow 2- from the reversing le- 1
ver of the selector cable -A-.
– Remove the shift cable -B- with the gearbox shift le- 3
ver, for this step unscrew nut -arrow 3-.
2
B
S34-0398
– Remove the hose line holder -1- from the gearbox -ar-
row A-.
– Remove -arrow B- the slave cylinder -2- and lay aside, 2
secure with wire, do not open the line system.
Note A
Do not depress the clutch pedal.
B
1
B
S34-0400

10-1 page 4 S00.5305.03.20
– Remove the earth strap -1- from the front of the gear-
box.
– Disconnect plug -2- from the reversing light switch
-F4-.
1
– Separate plug connection -3-.
3
2
S10-0143
– Remove coolant hose from the rear coolant pipe -ar-

row-.
S10-0139
– Remove connector -1- from thermo-switch -F18- and

separate plug connections -2- on the holder of the air 1
duct scoop.
To do so press the latch clips.
There are 2 plug connections on vehicles fitted with air 2
conditioning.
– Separate the coolant hose from the radiator at the top

and bottom of the connection fittings. 3
To do so pull the retaining clip -3- up to the stop and
remove the quick coupling towards the rear.
S19-0078

S00.5305.03.20
– Unbolt the pendulum support -arrows-.
Vehicles without air conditioning

– Removing the lock carrier with radiator ⇒ Body Work;
Rep. Gr. 50.
Vehicles with air conditioning
Caution!
Do not open the refrigerant circuit of the air condi-
tioning system.
S34-0403
– 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 1
and position on support -2- in such a way that there is
no risk of tilting.
Note
♦ Do not buckle the refrigerant lines.
♦ Use cloths to protect the right headlight glass from
damage, removing the headlight if necessary. 2 S10-0136
Continued for all vehicles

– Hook on lifting device -MP 9-201- as follows and raise MP 9-201
slightly with the workshop crane.
On the belt pulley side:
2nd hole of the vertical perforated bar in position 1
On the flywheel side: 6 7 8
1 2 3 4 5
2nd hole of the vertical perforated bar in position 5
Warning!
Use securing pins on the hooks and rig pins.
Note
S10-0134
♦ 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.

10-1 page 6 S00.5305.03.20
– Release screws -2-.
2
3
S10-0140
– Unscrew the fixing screws -arrows- from the gearbox

mount.
– Slightly lower the engine/gearbox unit and pull out
carefully towards the front.
S10-0120
Secure the engine with engine mount -MP 1-180- on the

assembly support -MP 9-101- before performing assem-
bly work.
Note
Grip the engine on the supports of the engine mount -ar- MP 1-180
rows-.
Instead of engine mount -MP 1-180- it is also possible to MP 9-101
use engine mount -MP 1-202-.
Installing the engine
Note S10-0082
♦ 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

S00.5305.03.20
Procedure
Installation 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.

– 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.
Note
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.

10-1 page 8 S00.5305.03.20
– 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
Note
♦ 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:
Component Torque
Screws/nuts M6 9 Nm
M7 13 Nm
M8 20 Nm
M10 40 Nm
M12 70 Nm
deviations:
⇒ Manual gearbox
2
Engine to gearbox connecting 1
screws 002; rep. size 34
Drive shaft to gearbox mount- ⇒ Chassis; rep. size
ing flange 40
Assembly bracket
1
1
Tightening torques
Engine mounting
S10-0132
1 - 20 Nm + 90° (1/4 turn) - replace
2 - 30 Nm + 90° (1/4 turn) - replace
Gearbox mounting 2
1 - 50 Nm + 90° (1/4 turn) - replace
1
2 - 40 Nm + 90° (1/4 turn) - replace
1
1 S10-0125

S00.5305.03.20
Hinged bracket
Note
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.
1 - 30 Nm + 90° (1/4 turn) - replace

2 - 40 Nm + 90° (1/4 turn) - replace
1
2 S10-0133

10-1 page 10 S00.5305.03.20
13 – Crankgear
13-1 Removing and installing V-ribbed belt
Summary of components - Vehicles without air conditioning
Note
♦ 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 pump
T removing and installing
⇒ Chapter 19-2
2 - Bracket
T for clamp 1
T removing and installing 2
⇒ Chapter 15-1
3 - Screw
3
4 - Clamp
5 - 25 Nm
T replace 4
6 - Generator
5
T to facilitate positioning of the 6
generator on the holder,
drive the bushing of the re-
taining screw slightly back-
wards
7
7 - Screw 8
8 - 30 Nm 9
T replace
9 - 45 Nm
10 - 25 Nm
T coat with -AMV 105 500-
(Loctite 242) before inserting 17
14 13 12
11 - Bracket
T for generator
12 - Guide pulley 16 15 11 10
13 - Washer
T Camber towards the outside
14 - 20 Nm S13-0241
T Left-hand thread
T coat with -AMV 154 100- (Loctite 648) before inserting
15 - Belt pulley
T for crankshaft
16 - 100 Nm
T to release and tighten lock flywheel
♦ Engine removed: with -MP 1-504-
♦ Engine installed: with locking screw ⇒ Chapter 13-2
17 - V-ribbed belt
T Routing of the ribbed V-belt ⇒ Fig. 1 in 13-1 page 2
T removing ⇒ 13-1 page 4
Edition 02.02 Removing and installing V-ribbed belt 13-1 page 1

S00.5305.03.20
T installing ⇒ 13-1 page 5
Fig. 1: Routing of the ribbed V-belt

1- Belt pulley - generator
2- Belt pulley - crankshaft
3- Guide pulley
4- Belt pulley - coolant pump
4 1
3
2 S13-0242
Removing and installing V-ribbed belt Edition 02.02

13-1 page 2 S00.5305.03.20
Summary of components - Vehicles with air conditioning
Note
♦ 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 pump
5
⇒ Chapter 19-2 1 2 3
2 - Lever with tensioner
T grease bearing points in 4 6
holder before fitting
3 - Bracket 8 5
T for generator and AC com- 10 7
pressor 11
4 - Gasket 13 12 7 9
8
T replace
9
5 - 20 Nm
6 - 10 Nm
15
7 - Screw 14
T tightening order and tighten-
ing torque ⇒ Fig. 2 in 13-1
page 4
16
8 - Washer
9 - Screw
ing torque ⇒ Fig. 2 in 13-1
page 4 17
(Loctite 242) before inserting
10 - Bushing 22
11 - Guide pulley
12 - Washer 18
T Camber towards the outside
13 - 35 Nm 19
(Loctite 270) before inserting 21 20 S13-0344
14 - Screw
T tightening order and tightening torque ⇒ Fig. 2 in 13-1 page 4
15 - Dowel sleeves for AC compressor
T must be present in holder ⇒ item 3 in 13-1 page 3
16 - 45 Nm
17 - 25 Nm
18 - Generator
T to facilitate the positioning of the generator on the holder drive the bushing of the retaining screw slightly back-
wards
19 - 25 Nm
20 - Belt pulley
T for crankshaft
21 - 100 Nm
♦ Engine installed: with locking screw ⇒ Chapter 13-2

S00.5305.03.20
22 - V-ribbed belt
T Routing of the ribbed V-belt ⇒ Fig. 3 in 13-1 page 4
T removing ⇒ 13-1 page 4
T installing ⇒ 13-1 page 6
Fig. 2: Tightening torques and tightening order for

alternator bracket and AC compressor
1- 23 Nm
2- Bracket for alternator and AC compressor
3- 45 Nm
4- Washer
5- 23 Nm
6- 45 Nm
7- 23 Nm
Screws are tightened up in two stages in the following or-
der:
♦ 1. Stage: tighten to 2 Nm one after the other in the or-
der of items: 1, 2, 3, 4, 5
♦ 2. Stage: the desired final tightening torque - tighten in
the same order as for the 1st stage 1
Fig. 3: Routing of the V-ribbed belt
1- Belt pulley - AC compressor
2- Guide pulley
3- Belt pulley - generator 6 5
4- Belt pulley - crankshaft
5- Tensioning pulley 2
6- Belt pulley - coolant pump
Removing the V-ribbed belt

3
Removing - vehicles without air conditioning 4 S13-0244
– 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-
Note
The assistance of a second mechanic is required to tight- S13-0245
en the V-ribbed belt.

13-1 page 4 S00.5305.03.20
– Mark the routing of the V-ribbed belt.
S10-0135
– Release screw -1- from the tensioner -3-.

T30022
– Remove camshaft position sensor -2-.
1
– Insert wrench for ribbed V-belt -T30022 - in the ten-
sioner -3- up to the stop.
– Loosen tensioning pulley (tighten tensioner -3-). To 3 2
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
Note
S13-0246
♦ 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.
S13-0245

S00.5305.03.20
– 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-.
NP 002
S27-0014
– 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.
Note
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

S13-0240
– Once the nominal value has been reached, tighten the

nuts of the generator mounting: 2
1
1 - 25 Nm
2 - 25 Nm
3 - 30 Nm
– Check belt tension again, correct if necessary.

– Start engine and check belt run.
3
Installing - Vehicles with air conditioning

auxiliary items required S13-0249
♦ Wrench for ribbed V-belt -T30022-
Note
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.

13-1 page 6 S00.5305.03.20
– Insert wrench for V-ribbed belt -T30022 - in the ten-
sioner -3- up to the stop. T30022
– Loosen tensioning pulley (tighten tensioner -3-). To 1
this end rotate wrench in the direction of the arrow.
– Position the V-ribbed belt on the tensioning pulley and 3 2
pivot tensioning pulley back.
– Tighten screw -1- on the tensioner -3-.
Tightening torque: 10 Nm
– Fit camshaft position sensor -2-.

S13-0246
– Start engine and check belt run.
– Fit noise insulation -arrows-.
S10-0135

S00.5305.03.20

13-1 page 8 S00.5305.03.20
13-2 Disassembling and As-

sembling Cylinder Block
and Crankshaft
Summary of components
1.4 ltr. engine

1.0 litre engine ⇒ 13-2 page 3
Note
♦ 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 Nm 1 2
2 - Crankshaft bearing unit
3 - Thrust washer
T for middle bearing
T lubricating grooves point out- 29 4
wards 5
4 - 8 Nm 28
T coat with -AMV 188 520- 27 6
(Loctite 574) before inserting
5 - Flywheel 26
T with rotor for engine speed 25 3
sender -G28-
T lock with -MP 1-504- for re-
moving and installing
T replace ring gear ⇒ 13-2
page 7
T installation position to crank-
7
shaft: 8
♦ on the 1.0 ltr. engine the 2 9
»missing« teeth of the rotor
10
must face forward when 13
crankshaft position at TDC of 11
cyl. 1 (marking of belt pulley -
crankshaft is positioned op-
12
posite marking „0“ at timing 24 23 22 21 20 14
gear cover)
♦ only one installed position is
possible for the 1.4 litre en- 15
gine (since the bore holes
are varying distances apart)
6 - 30 Nm + torque a further 1/4
turn (90°) 19 18 17 16 S13-0170
T replace
7 - Gasket ring
T replace
T remove when removing the sealing flange
T lightly oil sealing lip and outer edge before installing
Edition 09.03 Disassembling and Assembling Cylinder Block and Crankshaft 13-2 page 1
S00.5305.04.20
T press into the sealing flange

8- Sealing flange
T not available as replacement part (only together with cylinder block)
9- Shield
T for knock sensor -G61-
10 - 5 Nm
11 - 20 Nm
T The tightening torque influences the knock sensor function
12 - Knock sensor -G61-
13 - Cylinder block
T disassembling and assembling pistons, conrod and liner ⇒ Chapter 13-3
14 - 8 Nm
15 - Timing gear cover
16 - Gasket ring
T replace ⇒ 13-2 page 4
17 - Belt pulley
T for crankshaft
18 - 100 Nm
♦ Engine installed: with locking screw ⇒ 13-2 page 4
19 - 7 Nm
20 - Gasket
T replace
21 - Camshaft sprocket
T after replacing, inspect synchronous running of chain sprockets ⇒ Fig. 1 in 13-2 page 3
22 - Helical gear
T for oil pump drive
23 - 25 Nm
24 - Timing chain
T mark running direction (installed position) before removing
T always replace complete with crankshaft sprocket and camshaft sprocket
25 - Bearing shell
T for cylinder block with lubricating groove
T do not mix up used bearing shells (mark)
26 - Crankshaft sprocket
T after replacing, inspect synchronous running of chain sprockets ⇒ 13-2 page 3
T Camshaft setting ⇒ Fig. 1 in 13-2 page 3
27 - Woodruff key
T check tightness
28 - Crankshaft
T Axial play when new: 0.03 to 0.13 mm
T Wear limit: 0.26 mm
29 - Bearing shell
T for crankshaft bearing unit without lubricating groove
T do not mix up used bearing shells (mark)
Disassembling and Assembling Cylinder Block and Crankshaft Edition 09.03

13-2 page 2 S00.5305.04.20
Modifications of the 1.0 litre engine compared to the 1.4 litre engine
1 - Bearing caps
T Bearing cap 1: on the belt 1
pulley side
T Bearing cap 2: with recesses
for thrust washers
2 - Bearing shell
T for bearing cap without lubri-
cating groove
T do not mix up used bearing
shells (mark)
3 - Thrust washer
2
T for bearing cap 2
T check for firm seating
4 - Crankshaft
T Axial play when new: 0.03 to
0.13 mm
T Wear limit: 0.26 mm 3
5 - Bearing shell
T for cylinder block with lubri-
cating groove
T do not mix up used bearing
shells (mark)
5
S13-0209
Fig. 1: Camshaft setting 1

– 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.
12
Inspecting synchronous running of

a=
sprockets
This inspection should be carried out if the sprockets
have been replaced.
2

S15-0028
♦ Straightedge 3
♦ Feeler gauge
The crankshaft sprocket is available in 3 different widths;

graduations: marked 0.2 mm with letters „E“, „F“ or „G“.
The wheel with an average thickness, marked with the
letter „F“, is supplied together with the camshaft sprocket
S00.5305.04.20
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“.
Note
If chain sprockets are replaced, order crankshaft sprock-
et with same „code letter“ and check synchronous run-
*
ning of chain sprockets.
S13-0172
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.
S15-0027
Position of chain sprockets

1 - Camshaft sprocket I II III
2 - Crankshaft sprocket
Pfeil-points towards flywheel side
I - Nominal dimension -a- = 0.09 ± 0.2 mm 1 1 1
II - max. tolerance -b- = 0.29 mm
III - min. tolerance -c- = -0.11 mm (crankshaft sprocket
is positioned further out) a b c
– If the size of the gap is not within the tolerance range, 2 2 2
install crankshaft sprocket of a different width and re-
peat the inspection.
Replacing gasket ring for crankshaft -on S13-0171
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-

13-2 page 4 S00.5305.04.20
♦ 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. 2
3
S10-0140

– Lower engine approximately 50 mm.
– Remove the V-ribbed belt ⇒ Chapter 13-1.
S10-0135
S00.5305.04.20
– 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 1
located between 2 teeth of the ring gear).
– Tighten up the screw and secure in place with the 2
counternut -2-.
Note
If the engine has been removed use a flywheel lock 1 a
-MP 1-504- to lock the crankshaft.
S13-0173
– 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-.
A
Installing
• Crankshaft is locked with flywheel lock -MP 1-504 -, or
locking bolt. T10040/1
T10040/1
MP 6-401/1
S13-0175
– Lightly oil the sealing lip of the gasket ring.
– Press down gasket ring with pressure plate -T10041 -
up to the stop into the bushing.
Note
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-
T10041
er.
Note N13-0425
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.

13-2 page 6 S00.5305.04.20
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.
S00.5305.04.20

13-2 page 8 S00.5305.04.20
13-3 Disassembling and Assembling Pistons, Connecting Rod and

Liner
Note
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- 1
moving and installing
T marking „TOP“ faces piston 2
crown
T inspecting piston ring gap
clearance ⇒ Fig. 1 in 13-3 3
page 2
T inspecting piston ring end
page 3 15
2 - Piston ring (grey) 5
T use piston ring pliers for re- 14
moving and installing 6
T marking „TOP“ faces piston
crown 13 B
T inspecting piston ring gap
page 2
T inspecting piston ring end
12
page 3 A
T offset gap 120° relative to top 10
piston ring
3 - Oil scraper ring (3 part) 9
T remove and install by hand
T installing ⇒ Fig. 3 in 13-3
page 3 8
4 - Piston 7
T mark installation position and
matching liner
T arrow on piston crown faces S13-0210
towards the camshaft side
T use piston ring tensioning strap for installing
T 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 - Conrod
T Check fitting position: engraved number („1“ to „4“ for appropriate cylinder) -arrow A- points towards camshaft
side, mark if necessary
T Oil drilling -arrow B- for piston pin lubrication
T available as replacement part only in set (4 conrods with 4 conrod caps)
6 - Conrod bolt
T only 1.4 ltr. engine
T check fitting position
T press out to replace
Edition 06.00 Disassembling and Assembling Pistons, Connecting Rod and 13-3 page 1
S00.5305.01.20 Liner
7 - Cylinder block
T seat surfaces for liners must be clean and flat
T remove contamination on seat surfaces of the liners by cleaning only; do not use emery paper, flat scraper or
similar
8 - Conrod bolt, 20 Nm + torque a further 1/4 turn (90°)
T replace
T oil thread and head contact surface
9 - 40 Nm
T oil thread and head contact surface
10 - Conrod cap
T check fitting position ⇒ item 5 in 13-3 page 1
11 - Bearing shell
T do not mix up used bearing shells
T 1.0 ltr. engine insert in middle
T 1.4 ltr. engine ensure tightly located in retaining lugs
12 - Gasket ring
T replace
T different thicknesses are available to correct the liner pretension
13 - Liner
T 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 - Circlip
15 - 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.
new
Piston ring 1.0 ltr. en- 1.4 ltr. en- Wear limit
dimensions gine gine
in mm
1. Piston ring 0,20...0,50 0,40...0,72 1,0 S13-0006
(chrome-plat-
ed)
2. Piston ring 0,20...0,50 0,30...0,62 1,0
(grey)
Oil scraper 0,40...1,40 0,40...1,40 ---1)
ring
1) no specification possible for wear limit
Disassembling and Assembling Pistons, Connecting Rod and Edition 06.00

13-3 page 2 Liner S00.5305.01.20
Fig. 2: Inspecting piston ring end clearance

♦ Feeler gauge
Clean ring groove before inspecting.
Piston ring dimen- new Wear limit

sions
in mm
1. Piston ring 0,04...0,08 0,15
(chrome-plated)
2. Piston ring (grey) 0,04...0,08 0,15
Oil scraper ring cannot be measured V13 - 0687
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. S13-0008
Fig. 4: Inspecting pretension of liners

auxiliary items required MP 1-107
♦ Measuring tool for liner pretension -MP 1-107-
♦ Dial gauge
The 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. S13-0128
– 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.
Edition 06.00 Disassembling and Assembling Pistons, Connecting Rod and 13-3 page 3
S00.5305.01.20 Liner
Note
♦ 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-.
Disassembling and Assembling Pistons, Connecting Rod and Edition 06.00

13-3 page 4 Liner S00.5305.01.20
15 – Cylinder Head, Valve Gear
15-1 Removing and installing cylinder head
– Testing compression pressure ⇒ Chap. 15-2
Note
♦ Removing and installing intake manifold: ⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24
♦ Removing and installing exhaust manifold ⇒ Chapter 26-1
♦ If the cylinder head is replaced, the system must be completely filled with fresh coolant.
1 - 3 Nm
2 - Seal
T replace
3 - Cylinder head bolt
T moisten with oil before
screwing in
ing torque ⇒ 15-1 page 4
4 - Washer
5 - Lifting eye - on the left
6 - Rocker arm shaft
T removing and installing rock-
er arms ⇒ Chapter 15-3
T performing basic setting of
hydraulic valve clearance
compensation ⇒ Chap. 15-2
7 - Bracket
T for ignition terminal
8 - Shim
9 - 23 Nm
T do not tighten fully until cylin-
der head bolts have been
tightened
10 - 20 Nm
T self-locking, replace
T do not tighten fully until cylin-
der head bolts have been
tightened
11 - 20 Nm
T wet with -AMV 105 500-
(Loctite 242) before screwing
in
T do not tighten fully until cylinder head bolts have been tightened
12 - Bracket
T for generator support
13 - Cylinder head gasket
T Observe installation position; with part no. marking faces up
T replace
14 - Cylinder head
T check for distortion ⇒ Fig. 1 in 15-1 page 2
Edition 09.03 Removing and installing cylinder head 15-1 page 1

S00.5305.04.20
T removing and installing ⇒ 15-1 page 2

T after replacing fill entire system with fresh coolant
15 - Oil deflector
16 - 25 Nm
17 - Lifting eye - on the right
18 - Gasket for cylinder head cover
T replace if damaged
19 - Cylinder head cover
20 - Cap
T fit on during installation work
Fig. 1: Inspecting the cylinder head for distortion

♦ Straightedge
♦ Feeler gauge
Max. 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 V15 - 0673

• Engine installed
♦ 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. 1 2 3
4
Note
When the battery is disconnected and reconnected, carry
out rework ⇒ Electrical System; Rep. Gr. 27. 6 4
– Remove front exhaust pipe with catalyst ⇒ Chapter 5
26-1.
– Drain coolant ⇒ Chapter 19-1.
– Removing engine cover ⇒ Chapter 10-1.
S10-0138
Removing and installing cylinder head Edition 09.03

15-1 page 2 S00.5305.04.20
– Disconnect plug:
2
2 - from the throttle valve control unit -J338-
3 - from the intake manifold pressure sender -G71- with 5
intake manifold temperature sender - G72-
1 3
6 - from the coolant temperature sender -G62-
7 - from the injector cylinders - N30 bis N33- 4
– Unclip edge connector -4- -arrows- and remove wiring

loom from holders.
– Remove ventilation hoses -1- and -8-.
6
– Remove intake hose -5-. 7 S15-0157
8
– 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. 1
– Remove pipe supports for intake manifold.
– Unscrew the guide tube for the oil dipstick from the ex-
haust manifold.
M
– Remove ignition terminal.
Caution! M
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 S10-0141
– Remove the fuel presupply pipe -4- by pressing the re-

lease buttons at the separation point. 2
– 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
1
unscrew).
– First remove the rocker arm shaft. 3 4
– Then unscrew the remaining cylinder head bolts/nuts.
– Remove the generator support bracket ⇒ item 12 in
15-1 page 1
S10-0137
– 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.

S00.5305.04.20
Installing
Note
♦ 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.
Note
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.
Note
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. 6 2 3
10 7
– Insert the other cylinder head bolts/nuts and tighten by
hand. Observe the following bolt length and installa-
tion with/without washers: 9 5 1 4 8
Position Bolt length Washer
13 11 12 14
1, 2, 3, 6, 7 168 mm yes
4, 5, 8, 9 185 mm no
10 132 mm yes
N15-0221

15-1 page 4 S00.5305.04.20
– Tighten the cylinder head bolts/nuts in the following
sequence:
Position Tightening method

1 to 10 Stage I: 20 Nm
Stage ll: 1/
4 turn (90°) with a rigid
wrench
Stage lll: 1/ turn (90°) with a rigid
4
wrench
11 to 14 20 Nm
– 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.
Note
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

S00.5305.04.20

15-1 page 6 S00.5305.04.20
15-2 Repairing cylinder head

1 - Valve collets
2 - Valve spring retainer
1
3 - Valve spring
⇒ 15-2 page 2 2
4 - Valve stem seal
T replace ⇒ 15-2 page 6
3
5 - Cylinder head
T reworking valve seats
⇒ 15-2 page 3 4
T inspecting valve guides
⇒ 15-2 page 1
6 - Valves
T do not rework, only grinding
in is permissible
⇒ 15-2 page 2
T Valve dimensions ⇒ 15-2 8
page 3
7 - Cylinder head marking
8 - Plug
T installing ⇒ Fig. 1 in 15-2
page 1 7 5
6 6
S15-0148
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

MP 1-173
S15-0011
♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Edition 09.03 Repairing cylinder head 15-2 page 1

S00.5305.04.20
Procedure
– Insert valve into guide. End of valve stem must be
flush with guide.
– Determine valve rock.
Wear limit
Inlet valve Exhaust valve

0.5 mm 0.6 mm
Note
♦ 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-
MP 1-113
♦ Threaded connector M8x40
S15-0008
– Fit cylinder head onto the valve supporting plate
- MP 1-113-.
– Attach valve spring assembly lever -MP 1-114- and in- MP 1-114
sert -MP 1-114/1- together with threaded connector 2
-1- onto the cylinder head.
– Press down assembly lever -2-.
– Take out collets. 1
Note
Release collets that are tight by striking light blows with a
hammer on the assembly lever.
– Pull out valves.

MP 1-113
S15-0124
MP 1-114/1
Repairing cylinder head Edition 09.03

15-2 page 2 S00.5305.04.20
Valve dimensions
Note
Valves must not be reworked. Only grinding in is permis-
sible.
Inlet valve Exhaust valve

Dimension 1.0 ltr 1.4 ltr 1.0 ltr 1.4 ltr
∅a mm 34,0 34,0 27,0 30,0
∅b mm 7,0 7,0 7,0 7,0
c mm 104,0 101,0 104,0 101,0
α ∠° 45 45 45 45
Reworking valve seats

♦ Depth gauge/caliper gauge
♦ NAC milling cutter for reworking valve seats
♦ Grinding paste
Note
♦ 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.
Note
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.
a
Maximum dimen- 1.0 ltr. en- 1.4 ltr. en-
sions gine gine
in mm
Inlet valve 43,1 42,7
S15-0093
Exhaust valve 43,0 42,8

S00.5305.04.20
Maximum dimension less distance measured = max. per-

missible reworking dimension.
Example:
Maximum dimension 43,1 mm

- Measured distance 42,7 mm
= Max. permissible reworking di- 0,4 mm
mension
Note
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

Z
Dimension Valve seats a
1.0 ltr. en-
gine:
b 30°
∅a mm Valve seat 33,4 ± 0.1 - inlet valve
diameter: 26.4 ± 0.1 - exhaust valve
1.4 ltr. en- 45°
gine:
c
∅a mm Valve seat 32.9 -0.1 - inlet valve
60°
diameter: 29.6 -0.1 - exhaust valve
b mm Max. permissible reworking dimension
1.0 ltr. en- S15-0058
gine:
c mm Valve seat 1.3 up to 1.6 - inlet and ex-
width: haust valve
1.4 ltr. en-
gine:
c mm Valve seat 1.45 up to 1.75 - inlet
width: valve
1.65 up to 1.95 - exhaust
valve
Z Bottom edge of cylinder head
45° Valve seat angle
30° Top correction angle
60° Bottom correction angle
Procedure
Reworking can be carried out with a machine or by hand.
The following conditions must be met:
• Wear limit of valve guides must not exceed the per-

missible dimension ⇒ 15-2 page 2.
• Use NAC milling cutter with carbide metal tips (min. 90
HRC).

15-2 page 4 S00.5305.04.20
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.
Valve guide Guide drift ∅ mm

Inlet valve 7,0 -0,01
Exhaust valve
– Match diameter of milling cutter to diameter of valve

seat.
S15-0098
Valve seat ∅ Mill- ∅ Milling ∅ Mill-
ing cut- cutter ing cut-
ter 90° 120° ter 60°
mm mm mm
1.0 ltr. 36 38 21/34
90°
Inlet
valve
engine
1.4 ltr. 36 38 21/34
1.
engine
1.0 ltr. 30 30 max. 301)
Exhaust engine 120°
valve 1.4 ltr. 32 32 21/34
engine a
1) May not yet be contained in NAC milling cutter kit. 2.
Milling sequence
1 - Machine valve seat with 90° milling tool until until a 60°
perfect contact pattern is achieved. (Do not exceed
maximum permissible reworking dimension!) 3.
2 - Chamfer top correction angle with 120° milling cut-
ter until valve seat diameter „a“ (⇒ 15-2 page 4) is
c
achieved.
3 - Rework bottom correction angle with 60° milling cut-
ter until valve seat width „c“ (⇒ 15-2 page 4) is S15-0062
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).
Note
After installing the cylinder head, carry out basic setting
of the hydraulic valve clearance compensation.
S15-0063

S00.5305.04.20
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.
S15-0016
– Oil valve stem seal, place into insertion tool -A-, then
carefully fit onto the valve stem and press onto the
valve guide. A
Basic setting of hydraulic valve clear-

ance compensation
The hydraulic valve clearance compensation is mainte-
nance-free; the setting must not be changed.
After completing repair work on the cylinder head/valve
gear, however, it is necessary to carry out the basic set-
ting of the hydraulic valve clearance compensation as fol-
lows:
S15-0110
Note
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.

15-2 page 6 S00.5305.04.20
– Carry out the setting operations on the other cylinders
according to the table below:
Setting Valve overlap

Cylinder 1 Cylinder 4
Note
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 °C
♦ Compression tester (e. g. -V.A.G 1381- or
-V.A.G 1763-)
♦ Spark plug wrench (e.g. - 3122 B-)
♦ Torque wrench
Test sequence
– Remove engine cover.
– Unplug 4-pin connector -arrow- from the ignition termi-
nal.
– Remove the fixing screws of the ignition terminal and
detach ignition terminal from the park plugs.
– Unscrew spark plugs with spark plug wrench (e. g.
-3122 B-).
– Remove fuse 35.
Note
Removing fuse 35 interrupts the voltage supply of the in-
jectors.
– Have a second mechanic fully depress the accelerator N15-0219

pedal.
– Use compression tester (e. g. -V.A.G 1381 - or
-V.A.G 1763 -) to test compression.
Note
Use of tester ⇒ Operating Instructions.

S00.5305.04.20
– Operate starter until the tester no longer indicates a

pressure rise.
Compression readings
New engine Wear limit Difference be-

tween cylinders
min. 12 bar (1.2 7.5 bar (0.75 max. 3 bar (0.3
MPa) MPa) MPa)
– 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.
Note
Separating the plug connections causes faults to be
stored.
Tightening torques
Component Nm
Spark plugs in cylinder head 30
Ignition terminal to bracket 9

15-2 page 8 S00.5305.04.20
15-3 Repairing valve gear

Removing and installing camshaft
1 - Tappet rod
T pay attention to correct in- 1 2 3
stallation position
T do not interchange
2 - Hydraulic tappets
T with hydraulic valve clear-
4
ance compensation
T check ⇒ 15-3 page 3
T use auxiliary tool to pull out 5
of cylinder block ⇒ Fig. 1 in
15-3 page 1
T do not interchange
T lay aside with contact sur- 6
face facing down
T oil contact surface
3 - Cylinder block
T Removing and installing cyl-
inder block ⇒ Chap. 15-1
T Removing and installing tim-
ing gear cover and sprockets
⇒ Chap. 13-2
4 - O-ring
5 - Camshaft position sensor
-G163-
6 - 8 Nm 7
7 - Camshaft
T with timing segment for cam-
shaft position sensor -arrow- 8
T Camshaft setting ⇒ Fig. 2 in
15-3 page 2
10 9
8 - Woodruff key S15-0149
T check tightness
9 - Retaining plate of camshaft
10 - 5 Nm
Fig. 1: Removing hydraulic tappet
– Make auxiliary tool (wire) -2- as shown in illustration. 1

-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.
2
a
S15-0130
Edition 03.01 Repairing valve gear 15-3 page 1

S00.5305.02.20
Fig. 2: Camshaft setting

1
– 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.
12
a=
2
S15-0028
3
Removing and installing rocker arms

1 - Rocker arm shaft
⇒ Chap. 15-1
1
2 - Circlip
3 - Rocker arm bracket, on out- 9
side
T for M11 cylinder head bolt 11
4 - Spring washer
5 - Rocker arm 9
6 - Adjusting screw
T performing basic setting of 9
hydraulic valve clearance 8
compensation ⇒ Chap. 15-2 7
7 - Lock nut 6 2
5 10
T 13 Nm 4
8 - Rocker arm bracket 2 5
T for M8 bolt
8
9 - Rocker arm 9
T pay attention to different ver- 3
sion ⇒ Fig. 3 in 15-3 page 3
3
10 - Rocker arm bracket, on inside 9
T for M11 cylinder head bolt 8
11 - Tensioning ring 11
12 - Spring 9 10
12
8
S15-0150
Repairing valve gear Edition 03.01

15-3 page 2 S00.5305.02.20
Fig. 3: Arrangement of rocker arms and rocker arm
brackets
1- Straight rocker arm
1 2 2 2 1
2- Inclined rocker arm, to the left
3 3 3
3- Inclined rocker arm, to the right
A- Rocker arm bracket for M11 bolt, on outside
B- Rocker arm bracket for M8 bolt
C- Rocker arm bracket for M11 bolt, on inside
Note
The rocker arms for the inlet valves are shown in dark in
B C B B C B
the illustration. A A
S15-0132
Inspecting hydraulic tappets
♦ Feeler gauge
♦ Wooden or plastic wedge
Note
♦ 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.
S15-0189
– Inspect tappets at the other cylinders by carrying out
the same procedure.
Edition 03.01 Repairing valve gear 15-3 page 3

S00.5305.02.20
Inspection Valve overlap

Note
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).
Repairing valve gear Edition 03.01

15-3 page 4 S00.5305.02.20
17 – Lubrication
17-1 Removing and installing

parts of the lubrication
system
Note
♦ 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.
Edition 02.02 Removing and installing parts of the lubrication system 17-1 page 1
S00.5305.03.20
1 - Cap
T fit on during installation work
2 - Gasket
T replace if damaged
T on the engine cover
3 - 0.9 bar (0.09 MPa) oil pres-
sure switch - F1-, 45 Nm
T grey
T inspecting ⇒ Chapter 17-3
T cut open seal if leaking and
replace
4 - Oil filter
T slacken with tensioning strap
T moisten seal with oil
T tighten by hand
T pay attention to installation
instructions on oil filter
T pay attention to change inter-
vals
5 - Split pin
6 - Ball
T for pressure relief valve
T when installing, knock in
slightly with aluminium drift
so that the seat of the ball is
smoothened
7 - 40 Nm
8 - Pressure spring
T for pressure relief valve
9 - 8 Nm
S17-0081
10 - Intermediate plate
T clamped onto oil pan support of 1.4 ltr. engine
11 - Oil pan support
T for 1.4 litre engine only:
12 - Bracket
T for middle coolant pipe
T for 1.0 ltr. engine only: 2 bolts M6x22 (different colour and shape); do not mix up with other bolts (M6x20)
13 - 10 Nm
14 - 20 Nm
15 - 45 Nm
T for 1.4 litre engine only:
16 - Oil drain plug, 30 Nm
17 - Gasket
T replace
18 - Oil pan
T removing and installing ⇒ Chapter 17-2
19 - Gasket
T for 1.0 litre engine only
T replace
T 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 4
20 - 8 Nm
Removing and installing parts of the lubrication system Edition 02.02

17-1 page 2 S00.5305.03.20
21 - Oil pump cover with pressure relief valve
T opening pressure: approx. 4.6 bar (0.46 MPa) overpressure
T clean strainer if dirty
22 - Gasket
T replace
T install only if insufficient axial play of oil pump gears ⇒ Fig. 1 in 17-1 page 3
23 - Gears
T inspecting axial play ⇒ Fig. 1 in 17-1 page 3
24 - Guide tube
T removing and installing ⇒ Fig. 2 in 17-1 page 3
25 - Dipstick
T oil level must not exceed "max" marking!
T Inspect engine oil level ⇒ Inspection and Maintenance
Fig. 1: Oil pump - inspect axial play

♦ Feeler gauge
♦ Straightedge
Axial clearance for new part: 0.02 through 0.10 mm

wear limit: 0.13 mm
Note
♦ If the wear limit is reached, replace timing gear cover
⇒ Chapter 13-2 S17-0038
♦ 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-.
1
– Tighten new self-locking nut -1- to 20 Nm.
2
3 S17-0039
Edition 02.02 Removing and installing parts of the lubrication system 17-1 page 3
S00.5305.03.20
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 parts of the lubrication system Edition 02.02

17-1 page 4 S00.5305.03.20
17-2 Removing and installing

oil pan
Removing and installing oil pan - for a

1.0 litre engine
Removing
The 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. 12 8 4 1 5 9
Tightening torque: 10 Nm 13
16 17
Note 19 18
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 20 14

1.4 litre engine
15 11 7 3 2 6 10
N17-0079
♦ 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.
Edition 09.03 Removing and installing oil pan 17-2 page 1

S00.5305.04.20
– 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
Note
♦ 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 N17-0012
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
Note
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.
N17-0019
– Apply silicone sealant to the clean sealing surface of

the oil pan, as shown in the illustration.
Note
♦ It is particularly important to maintain the specified ap-
plication pattern for the bead in the area of the sealing A
flange to the flywheel -arrows A-.
A
♦ There is an opening in the cylinder block -arrow B- ∅
13 mm, which must be reliably sealed off by an accu- B A
mulation of sealant -a- = 15 mm; -b- = 4 mm.
b
a
S17-0040
Removing and installing oil pan Edition 09.03

17-2 page 2 S00.5305.04.20
Engine installed
– Fit intermediate plate onto oil pan support. 12 8 4 1 5 9
13
– Position oil pan together with oil pan support immedi-
ately against the cylinder block and tighten the bolts 16 17
as follows: 19 18
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. 20 14
4 - Tighten two bolts of oil pan support/gearbox to 45
Nm. 15 11 7 3 2 6 10
5 - Tighten all the bolts of the oil pan/cylinder block to N17-0079
the prescribed torque in the given sequence:
M6 = 10 Nm; M8 = 20 Nm.
Engine removed
T30008
(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.
S17-0041
– Position oil pan together with oil pan support immedi-

ately against the cylinder block and tighten the bolts 12 8 4 1 5 9
as follows: 13
1 - Tighten all the bolts of the oil pan/cylinder block only 16 17
very slightly in the given sequence. For this step
press oil pan support against the counterholders 19 18
-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 20 14
pan bolts again and correct position of the oil pan.
15 11 7 3 2 6 10
Note N17-0079
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 descriptions

Further installation occurs in a similar way in reverse or-
der to removal.
Edition 09.03 Removing and installing oil pan 17-2 page 3

S00.5305.04.20
Note
After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled in.
Removing and installing oil pan Edition 09.03

17-2 page 4 S00.5305.04.20
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 diagram
Function 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 immediately activated and
is not cancelled below 1500 rpm. The oil pressure
warning is cancelled if the oil pressure switch is closed
for more than 5 s at a speed of more than 1500 rpm,
or at „Ignition off“.
Test conditions
• Engine oil at correct level, inspecting ⇒ Chap. 17-1

• Oil pressure warning lamp (-K3-) must light up for
about 3 s when ignition is switched on.
• Engine oil temperature at least 80 °C (radiator fan
must have cut in once).
Test sequence
Edition 06.00 Testing Oil Pressure and Oil Pressure Switch 17-3 page 1
S00.5305.01.20
– Unplug connector from oil pressure switch.

– Unscrew oil pressure switch and screw in oil pressure V.A.G 1342
tester (e.g. -V.A.G 1342-).
– Screw oil pressure switch -2- into -V.A.G 1342-.
– Connect brown cable -1- of tester to earth (-).
– Connect diode test lamp (e. g. -V.A.G 1527 B-) to oil
pressure switch -2- and battery positive (+).
The LED must not light up.
+ -
– If the LED lights up, replace the oil pressure switch.
1
– Start engine and slowly increase engine speed. 2
– The LED must light up at 0.075 ... 0.105 MPa over-
pressure, if not, replace oil pressure switch. A17-0025
– Increase engine speed further. At 2000 rpm and an oil
temperature of 80 °C the oil pressure should be at
least 0.2 MPa.
If the nominal value is not reached:
– Inspect axial play of oil pump ⇒ Chap. 17-1.

At higher engine speeds the oil pressure must not be low-
er than 0.7 MPa. If necessary, replace oil pump cover to-
gether with pressure relief valve.
Testing Oil Pressure and Oil Pressure Switch Edition 06.00

17-3 page 2 S00.5305.01.20
19 – Cooling
19-1 Parts of cooling system -

Note
♦ When the engine is warm the cooling system is under
pressure. If necessary reduce pressure before re-
pairs.
♦ The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress,
without them touching any other components (pay at-
tention to the marking on the coolant connection and
hose).
Coolant mixing ratios ⇒ 19-1 page 6
Parts of the cooling system fitted to body

1 - Radiator
⇒ Chapter 19-2
1 2 3
T after replacing, fill entire sys-
tem with fresh coolant 4 5 6
2 - O-ring
T replace
7 8 9
3 - Top coolant hose
T attached to radiator with re- 20
taining clips
G12
T Connection diagram for cool-
ant hoses ⇒ 19-1 page 5
4 - Cover plate 19 18
T check pressure ⇒ 19-1 10
page 7
11
5 - Connector
6 - Double screw, 2 Nm
7 - Air duct scoop 17 5
8 - 5 Nm 5
9 - 5 Nm 12
10 - Expansion bottle
T check the coolant system for 16
tightness ⇒ 19-1 page 7
13
T connection diagram for cool-
ant hoses ⇒ 19-1 page 5 9
11 - Retaining clip 14
T for fan cable 2 15
T check tightness
12 - Auxiliary fan
T for vehicles with air condi- 5 8 S19-0074
tioning system or additional
equipment
Edition 02.02 Parts of cooling system - Summary of components 19-1 page 1

S00.5305.03.20
13 - The fan ring

14 - Fan for radiator
15 - Bottom coolant hose
T attached to radiator by retaining clips
T connection diagram for coolant hoses ⇒ 19-1 page 5
16 - Bracket
T for fan connector
17 - Thermoswitch for radiator fan -F18-, 35 Nm
T or for both fans
T switching temperatures:
1. Stage
♦ on: 91 through 97 °C
♦ off: 84 through 91 °C
2. Stage
♦ on: 99 through 105 °C
♦ off: 91 through 98 °C
18 - Bottom radiator bearing
T black
19 - 5 Nm
20 - Top radiator bearing
T white
Parts of cooling system - Summary of components Edition 02.02

19-1 page 2 S00.5305.03.20
Parts of cooling system engine side
coolant regulator housing
Note
Draining coolant and filling up ⇒ Chap. 19-1
1 - Towards the top expansion

reservoir
2 - Towards top radiator 2 3 4 5
3 - coolant regulator housing 4
T Opening start: approx. 88 °C
T Opening end: approx. 103 °C
4 - O-ring 6
T replace
5 - Sender for the coolant tem-
perature -G62-
6 - Retaining clip 7
7 - 20 Nm
8 - To heat exchanger 8
7
1
S19-0115

S00.5305.03.20
Coolant pump, front coolant pipe
1 - Gasket
T replace
2 - Coolant pump 1 2 3 4 5 6
T check smooth operation
T if damage and leak present -
replace completely
⇒ Chapter 19-2
3 - 20 Nm
T self-locking, replace
4 - Belt pulley
T for the V-ribbed belt
5 - 10 Nm
6 - V-ribbed belt
T before removing mark run- 7
ning direction
T do not kink 13 8
T check for wear
⇒ Chapter 13-1
7 - 20 Nm
8 - Coolant hose
12 9
T insert up to stop on coolant
pump/front coolant pipe
9 - Front coolant pipe
11
10 - 20 Nm
11 - to connection fitting for heat 10
exchanger
12 - to bottom radiator
13 - to bottom expansion reser- S19-0085
voir

19-1 page 4 S00.5305.03.20
Connection diagram for coolant hoses
1 - Radiator
T after replacing, fill entire sys-
tem with fresh coolant 5 6 7
⇒ Chapter 19-2
8
2 - Front coolant pipe
3 - Cylinder block
4 - Coolant pump
⇒ Chapter 19-2
T check smooth operation 9
5 - Expansion bottle
6 - Coolant pipe
T for ventilation line
7 - Heat exchanger 4
8 - Connection fittings
T for heat exchanger
3 10
9 - Coolant hose with heat pro-
tection
10 - coolant regulator housing
T with coolant regulator
2
⇒ 19-1 page 3
11 - Quick coupling
T for radiator connections 11
T Replace gasket rings, mois- 1
ten with coolant additives
S19-0087
Draining and filling up coolant

Coolant capacity approx. 5.6 ltr.

♦ antifreeze tester
Draining
Caution!
Hot steam may escape when the expansion reser-
voir is opened. Cover the cap with a cloth and
open carefully.
– Open the coolant cap.

– Remove noise insulation -arrows-. S10-0135

S00.5305.03.20
– Place a catch pan under the engine.

– Turn the drain plug -arrow- on the radiator to the left
and draw backwards, if necessary fit auxiliary hose
onto connection.
Note
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original
spare parts catalogue ŠKODA or from the list of allowed
coolant additives ⇒ Inspection and Maintenance;
Rep. Gr. 02
A10-0118
Recommended mixture ratios:
Antifreeze pro- Antifreeze con- Drinking 1

tection down to centration1)2) water2)
2
-25 °C 40 % (2.25 litres) 60 % (3.35 litres)
-35 °C 50 % (2.8 ltr.) 50 % (2.8 ltr.)
1) The antifreeze concentration must not exceed 60 %; the antifreeze
protection and cooling efficiency are reduced as the concentration
increases.
2) The coolant amount may differ according to the version of the vehi-
cle.
– Insert and tighten the coolant drain plug.

– Pull out retaining clip -2- and remove sender for cool-
ant temperature -1- from the coolant regulator hous- S19-0086
ing.
– Fill with coolant gradually up to „max“ marking on the

expansion bottle.
– Install sender for coolant temperature.
– Close expansion bottle.
– Run engine until the fan on the radiator starts.
Caution!
2
G1

open carefully.
– Check the level of coolant and top up if necessary. If

the engine is warm the coolant level must be on the S19-0077
„max.“ mark. If the engine is cold the coolant level
must between the „min“ and the „max.“ mark.

19-1 page 6 S00.5305.03.20
Checking the coolant system for tight-
ness
♦ Coolant system tester (e. g. -V.A.G 1274-)
♦ Adapter (e.g. -V.A.G 1274/8-)
♦ Adapter (e.g. -V.A.G 1274/9-)
Test condition
• Engine must be warm
Test sequence
Caution!
open carefully.
– Open the cap of the coolant expansion reservoir.

– Position coolant system tester (e. g. -V.A.G 1274-)
with adapter (e. g. - V.A.G 1274/8-) on the coolant ex-
pansion bottle.
V.A.G 1274
– With the hand pump of the tester generate an over-
pressure of approx. 0.1 MPa.
– If the pressure drops determine location of the leaks
and repair them.
Testing the pressure relief valve in the cap V.A.G 1274/8

– Screw cap onto tester with adapter (e.g. -V.A.G 1274/
9-).
G12
– With the hand pump of the tester generate an over- S19-0082

pressure of approx. 0.15 MPa.
– The pressure relief valve must open for an overpres-
sure of 0.12 to 0.15 MPa.

S00.5305.03.20

19-1 page 8 S00.5305.03.20
19-2 Removing and Installing

Radiator, Coolant Pump
Removing and installing radiator

♦ Torque wrench 5...50 Nm (e.g. -V.A.G 1331-)
1
Removing
– Drain coolant ⇒ Chap. 19-1.
– Remove connector -1- from thermo-switch -F18- and 2
separate plug connection -2- on the holder of the air
duct scoop.
To do so press the latch clips. 3
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. S19-0078
To do so pull the retaining clip -3- up to the stop and
remove the quick coupling towards the rear.
Vehicles without air conditioning

– Removing front bumper ⇒ Body Work; Rep. Gr. 63.
– Unscrew bolts for radiator bearing -arrows-.
Torque: 5 Nm
– Pull radiator with fan backwards and remove down-

wards.
S19-0080
Caution!
Do not open the refrigerant circuit of the air condi-
tioning system.
– Unscrew bolts for radiator bearing -arrows-.

Torque: 5 Nm
– Removing the lock carrier with component parts

⇒ Body Work; Rep. Gr. 50.
Attach the condenser with the radiator to the engine or
support.
Note
♦ Do not suspend the condenser to the wires.
♦ Do not fold the condenser wires. S19-0083
Edition 06.00 Removing and Installing Radiator, Coolant Pump 19-2 page 1
S00.5305.01.20
– Release the bolts securing the condenser -arrows-

and remove radiator with fan.
Torque: 5 Nm
Installing
The installation occurs in reverse order. Pay attention to
the following:
– Top up coolant ⇒ Chap. 19-1.

– Re-adjust headlights on vehicles fitted with air condi-
tioning.
Removing and installing coolant pump S19-0081

auxiliary items required 1 2 3
♦ Lifting device -MP 9-200- 4
♦ Torque wrench 5...50 Nm (e.g. -V.A.G 1331-)
♦ Torque wrench 40...200 Nm (e.g. -V.A.G 1332-) 6 4
Removing 5
– Drain coolant ⇒ Chap. 19-1.
– Removing engine cover ⇒ Chap. 10-1
S10-0138
– Mount lifting device -MP 9-200- and take up the

weight of the engine/gearbox unit at the spindles.
Removing and Installing Radiator, Coolant Pump Edition 06.00

19-2 page 2 S00.5305.01.20
– Remove engine mounting -1-.
To this end release bolts -2- and -3-. 2
– Only slacken the bolts of the coolant pump belt pulley.
Bolts must be on top, turn crankshaft.
– Removing the ribbed V-belt ⇒ Chap. 13-1. 1

– Unscrew front coolant pipe from front and rear cylin-
der block.
– Release clamp from coolant pump and disconnect
coolant hose.
– Remove belt pulley from the coolant pump. 3
– Unscrew coolant pump. S10-0140
Installing
Installation occurs in reverse order to removal. Pay atten-
tion to the following:
– Replace seal for coolant pump.

– First install ribbed V-belt ⇒ Chap. 13-1, then tighten
the belt pulley bolts of the coolant pump.
Torque: 10 Nm
– Tightening torques of the engine mounting ⇒ Chap.

10-1.
– Top up coolant ⇒ Chap. 19-1.
Edition 06.00 Removing and Installing Radiator, Coolant Pump 19-2 page 3
S00.5305.01.20
Removing and Installing Radiator, Coolant Pump Edition 06.00

19-2 page 4 S00.5305.01.20
20 – Fuel Supply
20-1 Removing and Installing Parts of the Fuel Supply System
Note
♦ Fuel lines are secured by plug connectors.
♦ Fuel hoses in the engine must only be secured with spring strap clamps. The use of collar clamps or screw clamps
is not allowed.
Observe safety measures ⇒ 20-1 page 3.
Observe rules for cleanliness ⇒ 20-1 page 3.
Repairing parts of the activated charcoal filter system ⇒ Chap. 20-2.
1 - Fuel tank
T support with engine/gearbox 15 16
jack -V.A.G 1383 A- when
removing 17
14 18
2 - 25 Nm
3 - 25 Nm
13 19
4 - Tensioning strap
5 - Vent line
T to solenoid valve 1 for acti- 20
vated charcoal filter in engine
compartment 12
6 - Feed line 21
T black 11
T to fuel rail (at intake mani- 10 22
fold)
9
7 - Fuel filter
T with integrated fuel pressure 8 23
regulator
T line connections: 7
♦ feed (black): in middle 2
♦ return flow (blue): on outside
8 - 3 Nm
T screw for collar clamp for fuel 1
filter
9 - Fuel level sender
10 - Fuel delivery unit
2
T clean strainer if dirty
6 5
T pay attention to installation
position of flange of fuel de-
livery unit ⇒ Fig. 1 in 20-1
page 2 4 3 S20-0084
11 - Return-flow line
T between fuel delivery unit and fuel filter
T blue
12 - Feed line
T between fuel delivery unit and fuel filter
T black
13 - Gasket ring
T moisten with fuel before installing
Edition 06.00 Removing and Installing Parts of the Fuel Supply System 20-1 page 1
S00.5305.01.20
14 - Union nut
T use wrench -MP 1-227- for removing and installing
15 - Vent valve
T to remove, unclip valve at side and take out of filler neck.
T before installing, unscrew cap
T check ⇒ Fig. 2 in 20-1 page 2
16 - End cover
17 - 1.5 Nm
18 - Fuel filler flap unit
T with rubber bowl
19 - Gravity valve
T to remove, unclip valve at top and lift out of filler neck.
T inspect valve for blockage:
♦ valve vertical: open
♦ valve tilted 45°: closed
20 - Vent line
T between activated charcoal filter ⇒ item 21 in 20-1 page 2 and vent line ⇒ item 5 in 20-1 page 1
21 - Activated charcoal filter
22 - 10 Nm
23 - Vent line
T clipped in place on fuel tank
Fig. 1: Installation position of flange of fuel deliv-

ery unit
Marking on the flange must be aligned with marking on
the fuel tank -arrows-. 2
Blue return-flow line -1- to connection marked -R-.
Black feed line -2- to connection marked -V-.
V
Note
After installing the flange of the fuel delivery unit, check R
whether the feed, return-flow and vent lines are still

clipped in place on the fuel tank. 1
A20-0096
Fig. 2: Inspecting vent valve

Lever in off position: closed
Lever pushed in direction of arrow: open
Note
Unscrew cap of fuel tank before installing the vent valve.
V20-1040
Removing and Installing Parts of the Fuel Supply System Edition 06.00
20-1 page 2 S00.5305.01.20
Safety precautions when working on the
fuel supply system
Caution!
The fuel feed line is pressurized! Place cleaning
cloths around the connection point before detach-
ing hose connections. Reduce pressure by careful-
ly removing the hose.
Pay attention to the following points when removing and

installing the fuel gauge sender or the fuel pump (fuel de-
livery 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 of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant
gloves!
Cleanliness rules
Carefully observe the following „5 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
parts which have been stored unwrapped (e.g. in tool
boxes and the like).
♦ When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
Edition 06.00 Removing and Installing Parts of the Fuel Supply System 20-1 page 3
S00.5305.01.20
Removing and Installing Parts of the Fuel Supply System Edition 06.00
20-1 page 4 S00.5305.01.20
20-2 Activated Charcoal Filter System

Repairing parts of the activated charcoal filter system
Note
♦ The hose connections are secured with spring strap or collar clamps.
♦ Collar clamps must always be replaced with spring strap clamps.
Observe the safety precautions ⇒ Chap. 20-1.

Observe the rules for cleanliness ⇒ Chap. 20-1.
1 - Vent line
T from solenoid valve 1 -N80- 1
(in engine compartment)
2 - 10 Nm
3 - Throttle valve control unit
4 - Solenoid valve 1 -N80-
7
T in right of engine compart-
ment
T valve is actuated (pulsed) by
engine control unit when en-
gine is warm
T testing ⇒ 1.0/37; 1.4/44 En-
gine, Fuel Injection;
Rep. Gr. 01; Final Control 6
5 - Connector
T black, 2 pin
T for solenoid valve 1 -N80-
6 - Activated charcoal filter
T Fitting location: in rear right 2
wheelhouse
T attached to body
7 - Vent line 3
T from gravity valve to fuel tank
4
S20-0088
Edition 06.00 Activated Charcoal Filter System 20-2 page 1

S00.5305.01.20
Activated Charcoal Filter System Edition 06.00

20-2 page 2 S00.5305.01.20
26 – Exhaust System
26-1 Removing and installing parts of the exhaust system
Note
♦ Always replace gaskets and self-locking nuts.
♦ Use a screwdriver to slacken and tighten the clamps of the heat shields. Tightening torque: 2 Nm
1 - Gasket
T replace
2 - Gasket
T replace
T fitting position: notch faces
down
3 - 25 Nm
T coat with hot screw paste G
052 112 A3 before inserting
4 - Exhaust manifold
T to remove take off intake
manifold ⇒ 1.0/37; 1.4/44;
1.4/50 engine - fuel injection;
Rep. Gr. 24.
5 - 20 Nm
T replace
6 - Hot air collector/shield
7 - Guide tube
T for the oil dipstick
8 - Retaining strap
T made of silicone
T press off from cross member
⇒ item 9 to remove front ex-
haust pipe with catalytic con-
verter
9 - Cross member
10 - 25 Nm
11 - Double clamp
T align exhaust system free of
stress before tightening
⇒ 26-1 page 2
T fitting position: bolts at bot-
tom and horizontal
T tighten bolted connections evenly
12 - Lambda probe downstream of catalytic converter -G130-, 50 Nm.
T only on engines complying with D4-/EU4 exhaust-emission standard
T only coat thread with hot screw paste G 052 112 A3; hot screw paste must not get into the slot of the probe
body
T use lambda probe wrench for removing and installing
T testing ⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01
T test lambda control and lambda probe heater ⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24
13 - 25 Nm
T replace
14 - Hanger
T retaining strap made of EPDM
Edition 02.02 Removing and installing parts of the exhaust system 26-1 page 1
S00.5305.03.20
15 - Hanger
T retaining strap made of EPDM
T pay attention to the spare part number
16 - Separation point
T for repairs ⇒ 26-1 page 3
17 - Hanger
T retaining strap made of silicone
T pay attention to the spare part number
18 - Front and rear silencer
T replace individually when carrying out repairs ⇒ 26-1 page 3
T align exhaust system free of stress ⇒ 26-1 page 2
19 - Front exhaust pipe with catalytic converter
T only on engines complying with D4-/EU4 exhaust-emission standard
T with 2 catalytic converters
20 - Lambda probe 1 downstream of catalytic converter -G39-, 50 Nm
T only coat thread with hot screw paste G 052 112 A3; hot screw paste must not get into the slot of the probe
body
T use lambda probe wrench for removing and installing
T testing ⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01
T test lambda control and lambda probe heater ⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24
21 - Front exhaust pipe with catalytic converter
T only on engines complying with EU2 exhaust-emission standard
22 - 40 Nm
T replace
T coat stud bolts with hot bolt paste G 052 112 A3
Aligning exhaust system free of stress

Procedure
• The exhaust system is aligned when cold.
– Slacken bolted connections of double clamp between
catalytic converter and front silencer and replace nuts.
– Position double clamp at the distance -a- = 5 mm from
the marking on the pipe of the catalytic converter
(bolts at bottom and horizontal) and tighten front bolt-
ed connection slightly.
a
S26-0064
Removing and installing parts of the exhaust system Edition 02.02

26-1 page 2 S00.5305.03.20
– Push front silencer -1- sufficiently far forward into the
double clamp until the dimension -b- of 3 to 7 mm is
achieved between hanger and the body and the hang- 1
er and the front silencer.
-Arrow- points in direction of travel.
– Tighten bolted connections on the double clamp in

this position.
Note
After tightening the double clamp, inspect dimension -b- b
and adjust if necessary.
S26-0065
Replacing front or rear silencer

♦ Body saw (e.g. -V.A.G 1523 -)
A separation point is provided for repair purposes for re-

placing the front silencer or rear silencer.
– Separate exhaust pipe at right angles at the separa-

tion point -arrow 1- with body saw. 4
– When installing double clamp -4- position on the side
markings -arrows 2 and 3-.
– Align exhaust system free of stress ⇒ 26-1 page 2.
– Align rear silencer horizontally.
– Tighten bolted connections of the double clamp even- 3
ly to 25 Nm. 2
Installation position of double clamp: bolts positioned ver-
tically at front of exhaust pipe.
1
Checking the exhaust system for leaks S26-0063
– Start engine and run in idle.

– Seal off tail pipe for the duration of the leak check (e.g.
with cloth or plug).
– Check the connection points for leaks by listening:
Cylinderhead/exhaust manifold, exhaust manifold/ex-
haust pipe with catalytic converter, etc.
– Eliminate any leak found.
Edition 02.02 Removing and installing parts of the exhaust system 26-1 page 3
S00.5305.03.20
Removing and installing parts of the exhaust system Edition 02.02

26-1 page 4 S00.5305.03.20

Motor ARV, AQV, AZE, AZF, AME, ATZ, AQW

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Motor ARV, AQV, AZE, AZF, AME, ATZ, AQW

Încărcat de

Drepturi de autor:

Formate disponibile

Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 09.03 List of Supplements

List of Supplements Edition 09.03

10 – Removing and Installing Engine

15 – Cylinder Head, Valve Gear

Edition 09.03 Table of Contents I

Table of Contents Edition 09.03

00-1 Technical Data

Engine identification charac- ARV AQV AZE AZF

Edition 09.03 Technical Data 00-1 page 1

Engine identification characters AME ATZ AQW

Technical Data Edition 09.03

10 – Removing and Installing Engine

10-1 Removing and Installing

Edition 02.02 Removing and Installing Engine 10-1 page 1

– Remove front exhaust pipe with catalyst ⇒ Chap. 26-

– Remove engine cover -1- as follows:

Removing and Installing Engine Edition 02.02

– Remove the fuel presupply pipe -4- by pressing the re-

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

Edition 02.02 Removing and Installing Engine 10-1 page 3

– Disconnect the Bowden cable support from gearbox

– Detach selector cable -A-, for this step remove circlip

Removing and Installing Engine Edition 02.02

– Remove coolant hose from the rear coolant pipe -ar-

– Remove connector -1- from thermo-switch -F18- and

– Separate the coolant hose from the radiator at the top

Edition 02.02 Removing and Installing Engine 10-1 page 5

– Unbolt the pendulum support -arrows-.

Vehicles without air conditioning

Vehicles with air conditioning

Continued for all vehicles

Removing and Installing Engine Edition 02.02

– Unscrew the fixing screws -arrows- from the gearbox

Secure the engine with engine mount -MP 1-180- on the

Installing the engine

Edition 02.02 Removing and Installing Engine 10-1 page 7

– Check whether the dowel sleeves for centering the

Vehicles with air conditioning

Continued for all vehicles

– Top up coolant ⇒ Chapter 19-1

– Check oil level before starting the engine.

Removing and Installing Engine Edition 02.02

Edition 02.02 Removing and Installing Engine 10-1 page 9

1 - 30 Nm + 90° (1/4 turn) - replace

Removing and Installing Engine Edition 02.02

13-1 Removing and installing V-ribbed belt

Summary of components - Vehicles without air conditioning

Edition 02.02 Removing and installing V-ribbed belt 13-1 page 1

T installing ⇒ 13-1 page 5

Fig. 1: Routing of the ribbed V-belt

Removing and installing V-ribbed belt Edition 02.02

Edition 02.02 Removing and installing V-ribbed belt 13-1 page 3

Fig. 2: Tightening torques and tightening order for

Removing the V-ribbed belt

– Mark the routing of the V-ribbed belt.

Removing- vehicles with air conditioning

Special tools, test and measuring equipment and

Removing and installing V-ribbed belt Edition 02.02

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