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Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
List of Supplements to Workshop Manual

Octavia 1997
1.6 l/75 kW Engine - Mechanical Components
Edition 01.01
Supple-
Edition Subject Article Number
ment
01.01 Basic Edition S00.5134.50.20
1 08.02 Changes for engine BFQ S00.5134.51.20
2 11.04 Modifications in Rep. Gr. 10, 13 and 15 S00.5134.52.20
Edition 11.04 List of Supplements

S00.5134.52.20
List of Supplements Edition 11.04

S00.5134.52.20
Table of Contents
00 – Technical Data
Technical Data .......................................................................................... 00-1 page 1
10 – Removing and Installing Engine

...........................................................Removing and installing engine - Part 1 10-1 page 1
- Removing engine ...................................................................................... 10-1 page 1
- Attaching engine to assembly stand ................................................................ 10-1 page 8
...........................................................Removing and installing engine - Part 2 10-2 page 1
- Installing the engine ................................................................................... 10-2 page 1
- Align unit mounting for engine - gearbox .......................................................... 10-2 page 3
- Tightening torques .................................................................................... 10-2 page 3
- Assembly bracket ...................................................................................... 10-2 page 4
13 – Crankgear
Disassembling and assembling engine ........................................................... 13-1 page 1
- Removing and installing V-ribbed belt .............................................................. 13-1 page 1
Removing and installing, tightening the timing belt ........................................... 13-2 page 1
- Summary of components ............................................................................. 13-2 page 1
- Removing toothed belt ................................................................................ 13-2 page 2
- Installing toothed belt, tensioning (setting timing) ................................................ 13-2 page 5
- Inspecting the semi-automatic timing belt tensioning pulley .................................... 13-2 page 6
Removing and installing sealing flange and pressure plate ................................. 13-3 page 1
- Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-3 page 2
- Removing and installing the front sealing flange ................................................. 13-3 page 4
- Removing and installing drive plate ................................................................ 13-3 page 6
Removing and installing crankshaft ............................................................... 13-4 page 1
Disassembling and assembling piston and conrod ............................................ 13-5 page 1
15 – Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 page 1
- Cylinder head - summary of components .......................................................... 15-1 page 2
- Removing and installing cylinder head ............................................................. 15-1 page 3
- Inspecting the cylinder head for distortion ......................................................... 15-1 page 6
- Reworking a cylinder head ........................................................................... 15-1 page 6
- Testing the compression ............................................................................. 15-1 page 6
Repairing Valve Gear .................................................................................. 15-2 page 1
Camshaft ................................................................................................. 15-3 page 1
- Replacing camshaft gasket ring ..................................................................... 15-3 page 1
- Removing and installing camshaft .................................................................. 15-3 page 2
Valve stem seals, valves guides, valve seats .................................................... 15-4 page 1
- Replacing valve stem seals .......................................................................... 15-4 page 1
- Inspect valve guides .................................................................................. 15-4 page 2
- Reworking valve seats ................................................................................ 15-4 page 2
17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1
Edition 11.04 Table of Contents I

S00.5134.52.20
- Disassembling and assembling the oil filter holder .............................................. 17-1 page 3
Removing and installing oil pan .................................................................... 17-2 page 1
Testing oil pressure and oil pressure switch .................................................... 17-3 page 1
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 2
- Connection diagram for coolant hoses ............................................................. 19-1 page 3
- Draining and filling up coolant ....................................................................... 19-1 page 3
- Removing and installing radiator .................................................................... 19-1 page 5
- Removing and installing coolant pump ............................................................ 19-1 page 8
Electronically controlled cooling system ......................................................... 19-2 page 1
- Operation ............................................................................................... 19-2 page 1
- Testing electronically controlled cooling system .................................................. 19-2 page 1
- Disassembling and assembling coolant distributor housing .................................... 19-2 page 3
- Testing thermostat for map-controlled engine cooling ........................................... 19-2 page 3
20 – Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 page 1
- Removing and installing the fuel tank with component parts and fuel filter .................. 20-1 page 2
- Safety precautions when working on the fuel supply system ................................... 20-1 page 3
- Rules of cleanliness ................................................................................... 20-1 page 3
- Removing and installing the fuel delivery unit .................................................... 20-1 page 4
- Removing and installing the fuel gauge sender .................................................. 20-1 page 5
- Removing and installing the fuel tank .............................................................. 20-1 page 5
- Connecting remote control ........................................................................... 20-1 page 6
- Disconnecting the fuel delivery unit with crash signal ........................................... 20-1 page 7
- Testing fuel pump ..................................................................................... 20-1 page 7
- Inspecting fuel flow rate .............................................................................. 20-1 page 8
Inspecting the electronic power control (electronic throttle) ................................ 20-2 page 1
Activated charcoal filter system .................................................................... 20-3 page 1
- Operation ............................................................................................... 20-3 page 1
- Repairing parts of the activated charcoal filter system .......................................... 20-3 page 2
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Exhaust manifold, exhaust pipe with catalytic converter and attached parts ................ 26-1 page 1
- Silencer with hanger .................................................................................. 26-1 page 3
- Removing and installing front exhaust pipe ....................................................... 26-1 page 3
- Removing and installing exhaust manifold ........................................................ 26-1 page 4
- Replacing front or rear silencer ..................................................................... 26-1 page 5
- Aligning exhaust system free of stress ............................................................. 26-1 page 5
- Checking the exhaust system for leaks ............................................................ 26-1 page 7
Secondary air system ................................................................................. 26-2 page 1
- Removing and installing parts of the secondary air injection system ......................... 26-2 page 1
Exhaust gas recirculation system .................................................................. 26-3 page 1
- Exhaust gas recirculation system - summary of components .................................. 26-3 page 1
Table of Contents Edition 11.04

II S00.5134.52.20
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6
Octavia 1997 1.6 l/75 kW Engine - Mechanical Components 10
10-2 Removing and installing

engine - Part 2
Special tools, test and measuring equipment and
auxiliary items required
♦ µ Chapter 10-1
Installing the engine
Note
♦ Always replace the seals and gaskets during assem-
bly work.
♦ Replace the self-locking nuts and screws.
♦ Clean all threaded holes into which self-locking bolts
are inserted, with a thread tap to remove residues of
the locking fluid.
♦ Coat stud bolts of exhaust manifold with hot bolt paste
-G 052 112 A3- before installing.
♦ Tightening torques µ 10-2 page 3.
♦ Assembly bracket µ 10-2 page 4.
♦ If the battery is disconnected and reconnected, carry
out certain additional operations µ Electrical System;
Rep. Gr. 27.
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.
– Insert intermediate plate on sealing flange and push
onto the dowel sleeves -arrows-.
Vehicles fitted with a manual gearbox

– Grease the drive shaft serration with grease
-G 000 100-.
– If necessary check the centering of the clutch disc.
– Install slave cylinder of hydraulic clutch µ 5-Speed
Manual Gearbox 02K; Rep. Gr. 30.
– Install shift mechanism µ 5-Speed Manual Gearbox
02K; Rep. Gr. 34.
– Set shift mechanism µ 5-Speed Manual Gearbox
02K; Rep. Gr. 34.
Vehicles with automatic gearbox

– Use only nuts -arrow- which are approved in the Parts
List, for attaching torque converter to the driven plate.
– Replace lock washer at support bracket of selector le-
ver cable.
Edition 11.04 Removing and installing engine - Part 2 10-2 page 1

S00.5134.52.20
10 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
– Install selector lever cable at gearbox or adjust

µ Automatic Gearbox 01M; Rep. Gr. 37.
Continued for all vehicles

– When installing the engine/gearbox units, ensure
clearance to the subframe as well as to the radiator.
– Run pressure line of power-assisted steering past the
gearbox.
– Align unit mounting for engine - gearbox µ 10-2
page 3.
For vehicles with air conditioning

– Install AC compressor µ Heating, Air Conditioning;
Rep. Gr. 87.
– To facilitate the positioning of the AC compressor
drive the threaded bushings -B- for fixing screws -A-
slightly backwards in the direction of the arrow.
Continued for all vehicles

– Install power-assisted steering hydraulic pump
µ Chassis; Rep. Gr. 48.
– Install the V-ribbed belt µ Chapter 13-1.
– Install the right drive shaft and screw the left drive
shaft onto the gearbox µ Chassis; Rep. Gr. 40.
– Install the exhaust pipe µ Chap. 26-1.
– Install the coolant hoses µ Chapter 19-1.
Note
The drained off coolant must only be then re-used if the
cylinder head, cylinder block, radiator or heat exchanger
were not replaced.
– Top up coolant µ Chapter 19-1.

– Electrical connections and proper routing µ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.
– Install top part of intake manifold µ 1.6-litre/75 kW
Engine, Fuel Injection and Ignition System;
Rep. Gr. 24.
– Install secondary air pump.
– Install noise insulation panel in middle as well as on
left and right -arrows-. Install air guide parts on out-
side.
– Before starting the engine, inspect oil level
µ Inspection and Maintenance.
– Adapt engine control unit to throttle valve control unit
-J338- and to EGR valve µ 1.6-litre/75 kW Engine,
Fuel Injection and Ignition System; Rep. Gr. 24.
– Read out and generate readiness code µ 1.6-litre/75
kW Engine, Fuel Injection and Ignition System;
Rep. Gr. 01.
Removing and installing engine - Part 2 Edition 11.04

10-2 page 2 S00.5134.52.20
– The basic setting must always be additionally initiated
on vehicles with an automatic gearbox µ Automatic
Gearbox 01M; Rep. Gr. 01.
– Undertake a test drive and interrogate and erase the
fault memory µ 1.6 litre/75 kW Engine, Fuel Injection
and Ignition System; Rep. Gr. 01.
Align unit mounting for engine - gearbox
Caution!
Before slackening the bolts, the unit must be se-
cured with the supporting device -MP 9-200-.
Engine mounting
a = 14.0 mm
b = at least 10.0 mm
Both bolt heads -1- must end flush with the edge -c-.
Gearbox mounting
The edges -a- and -b- must be positioned parallel to each
other.
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. Under no circumstances use Molykote.
♦ Do not use degreased parts.
♦ Unless otherwise indicated the following tightening
torques apply:
Component Nm
Screws and nuts M6 9
M7 13
M8 20
M10 40
M12 70
In variation of this:
Engine mounting, gearbox µ Assembly
mount, pendulum support bracket
Driver plate on the torque converter 60
Connecting bolts for the engine/the gearbox
µ 5-speed manual gearbox 02K; Rep. Gr. 34
µ Automatic gearbox; Rep. Gr. 37.
Edition 11.04 Removing and installing engine - Part 2 10-2 page 3

S00.5134.52.20
Assembly bracket
Tightening torques
Engine assembly bracket
1 - 40 Nm + 90° (1/4 turn) 1)

2 - 25 Nm1)
3 - 100 Nm1)
Gearbox assembly bracket
1 - 40 Nm + 90° (1/4 turn) 2)

2 - 25 Nm2)
3 - 100 Nm2)
Hinged bracket
1 - 40 Nm +45° 3)
2 - 40 Nm +45°3)
3 - 20 Nm + 90° (1/4 turn)3)
1) Replace bolts
2) Replace bolts
3) Replace bolts
Removing and installing engine - Part 2 Edition 11.04

10-2 page 4 S00.5134.52.20
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6
13-2 Removing and installing, tightening the timing belt
Summary of components
Special tools, test and measuring equipment and aids required
♦ Torque wrench
♦ Pressure pad -T30004-
♦ Two-hole nut turner -T10020-
♦ Supporting device -MP 9-200-
Note
Before removing the timing belt, mark direction of running. Reversing the rotation direction of an already used belt may
destroy it.
1 - Bottom toothed belt guard

s unbolt vibration damper in or-
der to remove µ Chap. 13-1
2 - Middle toothed belt guard
3 - 10 Nm
4 - Engine support bracket
s removing µ 13-2 page 2
5 - 45 Nm
s 3 pieces
6 - Top toothed belt guard
s removing µ Fig. 1 in 13-2
page 2
7 - Timing belt
s before removing mark run-
ning direction
s check for wear
s do not kink
s removing µ 13-2 page 2
s installing µ 13-2 page 5
8 - 25 Nm
9 - Corrugated washer
10 - 100 Nm
s to release and tighten use
counterholder -T30004-
11 - Camshaft sprocket
s for engines with engine iden-
tification characters AVU
with rotor for camshaft posi-
tion sensor -G163-
s for removing and installing,
remove toothed belt µ 13-2
page 2
s installation position fixed by parallel key µ item 13
12 - Rear timing belt guard
13 - Parallel key
s check tightness
14 - Camshaft
s for engines with engine identification characters AVU without rotor for camshaft position sensor -G163-
15 - Camshaft position sensor -G163-
s for engines with engine code AVU
Edition 11.04 Removing and installing, tightening the timing belt 13-2 page 1
S00.5134.52.20
s camshaft position sensor -G163- is identical with Hall sender -G40-

s when bolting on, ensure base plate is centered
16 - 15 Nm
17 - Semi-automatic tensioning pulley
s inspecting semi-automatic timing belt tensioning pulley µ 13-2 page 6
s Fitting position µ Fig. 2 in 13-2 page 2
18 - O-ring
s replace
19 - Coolant pump
s removing and installing µ Chapter 19-1
20 - Crankshaft toothed belt sprocket
s there must not be any oil present on contact surface between timing belt sprocket and the crankshaft
s can be installed only in one position
21 - 90 Nm + torque a further 90° (1/4 turn)
s replace
s to release and tighten use counterholder -T30004-
s bolt on counterholder -T30004- µ Removing and installing front sealing flange µ Chap. 13-3
Fig. 1: Remove top toothed belt guard
– -A- Position securing bolt -arrow- vertically.

– -B- Push retaining lugs -arrow- up.
Fig. 2: Fitting position of the semi-automatic ten-

sioning pulley
The angle bracket -arrow- must engage in the recess at
the cylinder head.
Removing toothed belt

• Engine installed.
Removing and installing, tightening the timing belt Edition 11.04

13-2 page 2 S00.5134.52.20
– Remove right noise insulation.
– Remove the V-ribbed belt µ Chapter 13-1.
– Remove ribbed V-belt tensioning device.
– Rotate crankshaft to TDC cylinder 1 -arrow- (vehicles
with manual gearbox).
TDC marking on flywheel and reference mark must be
aligned.
– Rotate crankshaft to TDC cylinder 1 -arrow- (vehicles

with automatic gearbox).
TDC marking on drive plate and reference mark must be
aligned.
Note
When engine removed, position vibration damper to TDC
cylinder 1 -arrows-.
S00.5134.52.20
– Remove engine cover.

– Insert supporting device -MP 9-200- and take up
weight of engine with the spindle of the supporting de-
vice (only on right). MP 9-200
– Remove vibration damper.
– Remove top toothed belt guard.
– Unbolt coolant expansion reservoir and power-steer-
ing reservoir; hoses remain connected.
S13-0104
– Unbolt engine support from engine mount and engine

mount from body -arrows-.
– Unbolt engine support from engine -arrows-.
Note
♦ To slacken the front bolt of the engine support, raise
engine slightly with spindle of supporting device
-MP 9-200-.
♦ To take off engine support, raise or lower engine, re-
spectively with the supporting device -MP 9-200-.
– Remove the vibration damper without altering the

TDC position.
– Remove middle and bottom timing belt guard.
– Mark the rotation direction of the timing belt.
– Slacken semi-automatic tensioning pulley and take off
toothed belt.
– Turn crankshaft slightly back.

13-2 page 4 S00.5134.52.20
Installing toothed belt, tensioning (set-
ting timing)
Note
♦ Also when carrying out repairs which necessitate tak-
ing the toothed belt only off the camshaft sprocket, it
is then necessary to carry out the installation of the
toothed belt as follows.
♦ When rotating the camshaft, the crankshaft must not
be positioned at TDC. Risk of damaging valves and
piston crowns.
Condition
• The pistons must not be positioned at top dead centre.

– Bring the marking on the camshaft sprocket in line
with the marking on the rear timing belt guard -ar-
rows-.
– Position crankshaft to TDC cylinder 1 µ 13-2 page 2
(except when engine removed).
– Fit toothed belt onto toothed belt sprocket of crank-
shaft and coolant pump (pay attention to direction of
running) µ 13-2 page 1
Note
When engine removed, after this, install bottom toothed
belt guard and vibration damper. Position crankshaft to
TDC of cylinder 1 -arrows-.
– Fit timing belt onto tensioning pulley and onto cam-

shaft sprocket.
Pay attention to installation position of semi-automatic
tensioning pulley µ Fig. 2 in 13-2 page 2
– Before tensioning the toothed belt, rotate the tension-

ing pulley at the eccentric with the two-hole nut turner
-T10020- about 5 times in both directions as far as the
stop.
– Turn the semi-automatic tensioning pulley fully to the
left with two-hole nut turner -T10020- -in direction of
arrow-.
– Loosen tensioning pulley until the notch -1- and the
pointer -2- are positioned opposite.
– Tighten nut securing semi-automatic tensioning pulley
to 25 Nm.
– Turn crankshaft two turns further in the direction of
running of the engine and again position on TDC for
cylinder 1.
When doing this, it is important that the last 45° (1/8

turn) are rotated without any interruption.
– Once again inspect tension of toothed belt.

Specified value: Pointer and notch are positioned op-
posite.
– Install bottom and middle toothed belt guard.
S00.5134.52.20
– Install belt pulley with vibration damper. Tightening

torque: 25 Nm
Note
Before installing engine support, insert bolts into engine
support.
– Install engine support and engine mounts. Tightening

torques:
♦ Engine support to cylinder block: 45 Nm
♦ Engine mount to engine support µ Chap. 10-2
1
♦ Engine mount to body µ Chap. 10-2
– Align component mounting engine µ Chap. 10-2. S13-0279

– Remove supporting device -MP 9-200-.
– Install top toothed belt guard.
– Install tensioning device for V-ribbed belt. Tightening
torque: 25 Nm.
– Install coolant expansion reservoir.
– Install the reservoir for the power-assisted steering.
– Install noise insulation and engine cover
Inspecting the semi-automatic timing

belt tensioning pulley
Fitting position
• The angle bracket -arrow- must engage in the recess
at the cylinder head.
Test condition
• Toothed belt fitted on and tensioned.
• Engine temperature not above 30 °C.
Test sequence
– Position engine on TDC cylinder 1.
– Load timing belt by firmly pressing down with thumb.
The pointer -2- must move.
– Relieve the pressure again on the timing belt and ro-
tate crankshaft a further two revolutions in direction of
rotation of engine and position again at TDC of cylin-
der 1.
When doing this, it is important that the last 45° (1/8

turn) are rotated without any interruption.
– The tensioning pulley must move back into its initial

position (notch -1- and pointer -2- are again positioned
opposite).

13-2 page 6 S00.5134.52.20
Note
For the inspection use a mirror.
S00.5134.52.20

13-2 page 8 S00.5134.52.20
13-3 Removing and installing sealing flange and pressure plate
Note
♦ Repairs to clutch µ 5-Speed Manual Gearbox 02K; Rep. Gr. 30.
♦ Secure the engine with engine mount -MP 1-202- and distance sleeves -T30010- on the assembly stand before
performing assembly work.
1 - 15 Nm
2 - Gasket ring
s do not oil sealing lip of gasket 1 2 3 4 5 6 7
ring
s replace µ 13-3 page 2
3 - Front sealing flange
s must be positioned on dowel
sleeves
s removing and installing
µ 13-3 page 4
s remove oil pan for removing
and installing
4 - Threaded pin, 10 Nm
s replace
s unscrew for attaching engine
holder -T10012-
5 - Cylinder block
crankshaft µ Chapter 13-4
s disassembling and assem-
bling pistons and conrod
µ Chapter 13-5
6 - Gasket ring
s replace
7 - 100 Nm
8 - 60 Nm + torque a further 90°
(1/4 turn)
s replace
12 1 11 10 9 8
9 - Washer
s Check fitting position
S13-0281
10 - Pressure plate/driver disc
s remove and install flywheel
and pressure plate µ 5-Speed Manual Gearbox 02K; Rep. Gr. 30
s removing and installing drive plate µ 13-3 page 6
11 - Intermediate plate
s hang on the sealing flange µ Fig. 1 in 13-3 page 2
s must be positioned on dowel sleeves
s do not damage/bend during assembly work
12 - Rear sealing flange with gasket ring
s must be replaced completely
s use supporting sleeve supplied for installing
s remove oil pan for removing and installing
s Neither grease nor oil sealing lip of sealing ring
s before installing remove grease residue from crankshaft journal with a clean cloth
s supporting sleeve must not be removed until after pushing sealing flange onto the crankshaft journal
Edition 11.04 Removing and installing sealing flange and pressure plate 13-3 page 1
S00.5134.52.20
Fig. 1: Install intermediate plate
– Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.
Replacing gasket ring for crankshaft -on

the belt pulley side-
♦ Torque wrench
♦ Gasket ring extractor -MP 1-226-
♦ Assembly device -T10053-
♦ Counterholder -T30004- or -MP 1-310-
Removing
– Remove tensioning element for V-ribbed belt.
T 30004
– Remove the timing belt µ Chapter 13-2.
– Remove crankshaft toothed belt sprocket. To this end
lock the toothed belt gear with counterholder -T30004-
or -MP 1-310-.
Note
When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and counter-
holder.
MP 1-310
S13-0156
– To guide the gasket ring extractor, screw central bolt

by hand fully into the crankshaft.
– Unscrew inner part of the gasket ring extractor
-MP 1-226- nine turns (approx. 20 mm) out of the out-
er part and lock with knurled screw.
Removing and installing sealing flange and pressure plate Edition 11.04
13-3 page 2 S00.5134.52.20
– Oil the thread head of the gasket ring extractor
-MP 1-226-, position and forcefully screw it into the
gasket ring as far as possible.
– Release knurled screw and turn the inner side against
the crankshaft until the gasket ring is pulled out.
Installing
Note
Do not oil sealing lip of the gasket ring.
MP 1-226
– Remove oil residue on the crankshaft stub with a S13-0093

clean cloth.
– Insert guide bushing -T10053/1- on the crankshaft
stub.
– Slide gasket ring over the guide bushing onto the
crankshaft stub.
– Press in gasket ring fully with pressure sleeve

-T10053- and bolt -T10053/2- (M16 x 1.5 x 60).
Note
If the bolt -T10053/2- (M16x1.5x60) is not available, the
old central bolt for the crankshaft toothed belt sprocket
can be used.
S00.5134.52.20
– Install timing belt gear crankshaft and lock with coun-

terholder -T30004- or -MP 1-310-. Tightening torque:
90 Nm + torque a further 90° (1/4 turn)
T 30004
Note
♦ Thread and collar must be free of oil and grease.
♦ When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and coun-
terholder.
♦ Replace central screw for crankshaft toothed belt
gear.
– Installing the toothed belt and setting the timing

µ Chapter 13-2.
– Installing tensioning element for the V-ribbed belt. MP 1-310
Removing and installing the front seal-

ing flange
auxiliary items required S13-0156
♦ Torque wrench
♦ Assembly device -T10053-
♦ Counterholder -T30004 - or -MP 1-310-
♦ Hand-held power drill with plastic brush insert
♦ Flat scraper
♦ Silicone sealant -D 176 404 A2-
Removing
– Remove tensioning element for V-ribbed belt.
T 30004
– Remove the timing belt µ Chapter 13-2.
– Remove crankshaft toothed belt sprocket. To this end
lock the toothed belt gear with counterholder -T30004-
or -MP 1-310-.
Note
When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and counter-
holder.
– Drain engine oil.

– Removing oil pan µ Chapter 17-2. MP 1-310
– Unscrew front sealing flange.
– Remove sealing flange, if necessary release by apply-
ing slight blows with a rubber-headed hammer.
– Use a flat scraper to remove sealant residues on the
cylinder block.
– Cover the gasket ring with a clean cloth. S13-0156
13-3 page 4 S00.5134.52.20
– Use a rotating plastic brush to remove sealant resi-
dues on the sealing flange (wear protective goggles).
– Clean the sealing surfaces. They must be free of oil
and grease.
Installing
– Cut off nozzle tube at the front marking (∅ of nozzle
approx. 3 mm).
– Apply silicone sealant to the clean sealing surface of
the sealing flange, as shown in the illustration.
♦ Thickness of sealant bead -arrows-: 2…3 mm
Note
♦ Before applying the sealant bead cover over the gas-
ket ring with a clean cloth.
♦ The sealant bead must not be thicker otherwise ex-
cess sealant can clog the strainer in the oil suction
pipe.
♦ Pay attention to the 'use by date' on sealant.
♦ The sealing flange must be installed within 5 minutes
after applying the silicone sealant.
♦ When installing the sealing flange with the gasket ring
fitted use guide sleeve -T10053/1-.
♦ After installing, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
S00.5134.52.20
– Fit sealing flange immediately and lightly tighten all

bolts.
– Tighten the fixing screws of the sealing flange cross-
wise. Tightening torque: 15 Nm
T 30004
– Remove excess sealant.
– Installing oil pan µ Chapter 17-2.
– Install timing belt gear crankshaft and lock with coun-
terholder -T30004- or -MP 1-310-. Tightening torque:
90 Nm + torque a further + 90° (1/4 turn)
Note
♦ Thread and collar must be free of oil and grease.
♦ When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and coun-
terholder. MP 1-310
♦ Replace central screw for crankshaft toothed belt
gear.
– Installing the toothed belt and setting the timing

µ Chapter 13-2.
– Installing tensioning element for the V-ribbed belt.
– Install the V-ribbed belt µ Chapter 13-1. S13-0156
Removing and installing drive plate

♦ Torque wrench
♦ Pressure pad -MP 1-221-
♦ Depth gauge
B
Releasing and tightening the drive plate
MP 1-221
– Attach counterholder -MP 1-221- with M8x45 bolt to
the drive plate. Place two M10 nuts -arrow- between
the counterholder and the driver disc.
Fitting position of the counterholder: S13-0280
A - for slackening A
B - for tightening
Installing the drive plate 1 2

– Insert the drive plate using the washer with recesses
-1-.
– Insert new bolts -2- and tighten to 30 Nm.
S13-0282
13-3 page 6 S00.5134.52.20
– Inspect installed dimension of drive plate at the 3
mounting holes for the torque converter and calculate
mean value.
Specification -a-: 19,5…21.1 mm
Note
The measurement is made through the hole of the drive
plate to the milled surface of the cylinder block. a
If the specified value is not reached:
S13-0197
– Once again remove drive plate and repeat measure-

ment with the shim -3-.
If the specified value is reached: 3 1 2
– Lock drive plate with counterholder -MP 1-221- and
tighten new bolts -2- to 60 Nm and torque a further 90°
(1/4 turn).
S13-0285
S00.5134.52.20
13-3 page 8 S00.5134.52.20
13-4 Removing and installing crankshaft
Note
♦ Before removing the crankshaft, ensure a suitable place is available for placing it down so that the sensor rotor
µ item 7 in 13-4 page 1 does not rest on anything or get damaged.
♦ To carry out removal and installation operations, attach the engine with the engine holder -MP 1-202- and the
sleeves -T30010- to the assembly stand -MP 9-101- µ Chapter 10-1.
♦ Pay attention to colour coding when inserting bearing shells µ Fig. 2 in 13-4 page 2
1 - Oil pump
1 2 3 4 5 6 4 7 8
µ Chapter 17-1
2 - 15 Nm
3 - Sprocket
s for oil pump drive
4 - Bearing shells 1, 2, 3, 4 and 5 5
s Identification for ordering re- 4
placement parts µ Fig. 2 in 3
13-4 page 2 2
1
s for bearing cap without lubri-
cating groove
s for cylinder block with lubri-
cating groove
s do not mix up used bearing
shells (mark)
5 - 40 Nm + torque a further 90° 9
(1/4 turn)
4
s replace
s tighten thread
6 - Bearing caps
s Bearing cap 1: on the belt
4 10
pulley side
s retaining lugs of the bearing
shells of the cylinder block/
bearing cap must be on top
of one another
7 - Rotor
s for engine speed sender
-G28-
s assembly only possible in S13-0288
one position -holes offset-
s replace sensor rotor each time the bolts are slackened
s removing and installing µ Fig. 1 in 13-4 page 2
s replace
9 - Crankshaft
s Axial play when new: 0,07…0.23 mm
Wear limit: 0.30 mm
s Crankshaft bearing journal: ∅ 48.00 mm
s Conrod bearing journal: ∅ 42.00 mm
10 - Thrust washer
s for bearing 3
s Fitting position: Oil grooves point to the crank webs
Edition 11.04 Removing and installing crankshaft 13-4 page 1

S00.5134.52.20
Fig. 1: Removing and installing sensor rotor
– Always replace the sensor rotor -2- each time the

bolts -1- are slackened.
Note
♦ After being attached a second time, the attachment
point of the recess head screws in the sensor rotor is
sufficiently misshapen that the bolt heads rest against
crankshaft -3- -arrows- and the sensor rotor is posi-
tioned loosely below the screws.
♦ It is only possible to install the sensor rotor in one po-
sition, the holes are offset.
Fig. 2: Marking on crankshaft bearing for ordering

replacement parts
The crankshaft bearing shells are factory-classified. Align 1
the top crankshaft bearing shells according to the mark-
ing on the cylinder block (stamped letters).
Note
2
Bearing 1 points toward belt pulley.
Colour coding of bearing shells matches the letters
on the cylinder block
3
S = black
R = red
G = yellow
B = blue 4
W = white
The bottom crankshaft bearing shells are always sup-

plied as replacement parts with the colour coding „yel- 5
low“.
S13-0286
Removing and installing crankshaft Edition 11.04

13-4 page 2 S00.5134.52.20
∅
13-5 Disassembling and assembling piston and conrod
Note
For carrying out removal and installation operation, attach the engine with the engine holder -MP 1-202- and the
sleeves -T30010- to the assembly stand -MP 9-101-.
1 - Circlip
2 - Piston pin 1 2 3 1 4
s if stiff, heat piston to 60°C
s use drift -VW 222A- for re-
moving and installing
3 - Piston
s check µ Fig. 3 in 13-5
page 3
s mark installation position rel-
ative to conrod and mark
matching cylinder with felt
pen
s arrow on piston crown faces
towards the belt pulley side 6 5
s use piston ring tensioning
strap for installing
s Piston 80.965 mm
4 - Piston ring (compression
ring) 11 12
s Offset joint 120°
s use piston ring pliers for re- A B
moving and installing com-
pression rings
s marking „TOP“ must face to-
wards piston crown
s inspect gap clearance
µ Fig. 1 in 13-5 page 2 7
s inspect end clearance
µ Fig. 2 in 13-5 page 2
5 - Piston ring (oil scraper ring)
s carefully remove and install 10 9 8
by hand S13-0283
s marking „TOP“ must face to-
wards piston crown
s inspect gap clearance µ Fig. 1 in 13-5 page 2
s inspect end clearance µ Fig. 2 in 13-5 page 2
6 - Conrod
s replace as a set only
s mark assignment to cylinder -B-
s Fitting position:
Markings -A- must be positioned one above the other and point to the belt pulley side
s with oil drilling for lubricating piston pin
7 - Conrod bearing cap
s as a result of the conrod separated in the cracking process, the cover fits only in one position and only to the
relevant conrod
s mark assignment to cylinder -B-
s Fitting position:
Markings -A- must be positioned one above the other and point to the belt pulley side
Edition 11.04 Disassembling and assembling piston and conrod 13-5 page 1
S00.5134.52.20

s replace
s oil thread and head contact surface
9 - Pressure relief valve, 27 Nm
s opens at:
0,13…0.16 MPa (1.3…1.6 bar) overpressure
s replace without sealant
10 - Oil injection nozzle
s For piston cooling
11 - Cylinder block
s inspect cylinder bore µ Fig. 5 in 13-5 page 3
s ∅ Cylinder 81.01 mm
12 - Bearing shell
s check fitting position µ Fig. 4 in 13-5 page 3
s do not mix up used bearing shells
s insert bearing shells in the centre
s Axial play when new: 0,05…0.31 mm
Wear limit: 0.37 mm
s with oil drilling -arrow- for lubricating piston pin
Fig. 1: Inspecting piston ring gap clearance

♦ Feeler gauge
– Insert ring at right angles from above down into lower

cylinder opening, about 15 mm away from edge of cyl-
inder. To insert use piston without rings.
Gap clearance
Piston ring new Wear limit
(mm) (mm)
Compression ring 0,20…0,40 0,80
Oil scraper ring 0,25…0,50 0,80
Fig. 2: Inspect piston ring end clearance

♦ Feeler gauge
– Clean ring groove before inspecting.
End clearance
Piston ring new Wear limit
(mm) (mm)
Compression ring 0,06…0,09 0,20
Oil scraper ring 0,03…0,06 0,15
Disassembling and assembling piston and conrod Edition 11.04

13-5 page 2 S00.5134.52.20
Fig. 3: Inspecting pistons

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

right angles to the piston pin shaft.
Deviations from specified dimension: max. 0.04 mm
Fig. 4: Bearing shell installation position

Bearing shell -1- with oil drilling -arrow- for conrod.
Bearing shell -2- without oil drilling for conrod bearing
cap.
– Insert bearing shells into conrod and into conrod bear-

ing cap centred.
Dimension -a- must be the same on right and left, max.
variation: 0.2 mm.
Fig. 5: Inspecting cylinder bore

♦ Internal precision measuring instrument 50...100 mm
Test sequence
– Measure at three points crosswise in a transverse di-

rection -A- and lengthwise -B-.
Deviations from specified dimension: max. 0.10 mm
Note
Do not measure the cylinder bore if the cylinder block is
fixed to the assembly stand with the engine mount
-MP 1-202-, as this may result in incorrect measure-
ments.
Edition 11.04 Disassembling and assembling piston and conrod 13-5 page 3
S00.5134.52.20
Disassembling and assembling piston and conrod Edition 11.04

13-5 page 4 S00.5134.52.20
15 – Cylinder Head, Valve Gear
15-1 Removing and installing

cylinder head
Removing and installing toothed belt µ Chapter 13-2
Test compression pressure µ 15-1 page 6
Note
♦ Always replace cylinder head bolts.
♦ Always replace self-locking nuts.
♦ Always replace the seals and gaskets during assem-
bly work.
♦ When installing a cylinder head, all the contact surfac-
es between the hydraulic tappets, roller rocker arms
and the cam tracks must be oiled before installing the
cylinder head cover.
♦ Do not remove the plastic bases supplied as a protec-
tion for the open valves until just before fitting on the
cylinder head.
♦ If the cylinder head is replaced, the system must be
completely filled with fresh coolant.
♦ Disassembling and assembling intake manifold
µ 1.6-litre/75 kW Engine, Fuel Injection and Ignition
System; Rep. Gr. 24.
Edition 11.04 Removing and installing cylinder head 15-1 page 1

S00.5134.52.20
Cylinder head - summary of components

1 - Cap
2 - Gasket
s replace if damaged
3 - Breather housing
s to disassemble, turn to the
left
4 - Oil deflector
5 - Camshaft position sensor
-G163-
s for engines with engine code
BFQ
6 - Gasket ring
s before fitting moisten with
clean engine oil
7 - Bracket
8 - 10 Nm
9 - Coolant distributor housing
s Disassembling and assem-
bling coolant distributor
housing µ Chapter 19-2
10 - Gasket ring
s replace
11 - 20 Nm
12 - Cylinder head gasket
s replace µ 15-1 page 3
13 - Camshaft position sensor
-G163-
s for engines with engine code
AVU
14 - Rear timing belt guard
15 - 15 Nm
17 - 100 Nm
s to release and tighten use counterholder -T30004-
18 - Parallel key
19 - Cylinder head
s removing and installing µ 15-1 page 3
s check for distortion µ 15-1 page 6
s rework cylinder head µ 15-1 page 6
s after replacing fill entire system with fresh coolant
20 - Cylinder head bolt
s replace
s pay attention to order for slackening µ 15-1 page 4
s pay attention to order for tightening µ 15-1 page 5
s removing and installing with socket insert -T10070-
21 - Gasket for cylinder head cover
s press into the spacer sleeves
22 - Cylinder head cover
23 - Vent connection
s to the expansion reservoir
Removing and installing cylinder head Edition 11.04

15-1 page 2 S00.5134.52.20
Removing and installing cylinder head

♦ Guide bolt -T30011/2A-
♦ Removal tool -T30011/3-
♦ Assembly tool -T10112-
♦ Socket insert -T10070-
♦ Catch pan (e.g. -V.A.G 1306-)
♦ Torque wrench
♦ Pliers for spring strap clips
Requirements
• Engine temperature not above 30 °C.
Note
♦ If the battery is disconnected and reconnected, carry
out certain additional operations µ Electrical System;
Rep. Gr. 27.
♦ All cable straps which are detached or cut open when
removing, should be fitted on again in the same place
when installing.
Removing cylinder head

– Remove engine cover.
– Remove connecting part for exhaust gas recirculation.
– Open the cap of the coolant expansion reservoir.
– Remove noise dampening in the middle and on the
right -arrows-.
– Unbolt front exhaust pipe together with catalytic con-
verter and holder µ Chapter 26-1.
– Drain coolant µ Chapter 19-1.
– Remove intake hose and air filter µ 1.6-ltr./75 kW En-
gine, Fuel Injection and Ignition System; Rep. Gr. 24.
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
– Remove fuel feed line -1- and fuel feed line -2-, to do
so press latch clips. Lines and line connections are
colour-coded.
– Detach hose -3- at the ACF tank.
– Remove inlet line and pressure line of secondary air
pump.

S00.5134.52.20
– Remove the secondary air pump with pressure hose

and holder.
– Remove top part of intake manifold µ 1.6-ltr./75 kW
Engine, Fuel Injection and Ignition System;
Rep. Gr. 24.
Note
Seal the intake passages in the bottom part of the intake
manifold with a clean cloth.
– Disconnect plug for camshaft position sensor -G163-

on all four injection valves -N30...N33-.
– Detach the unplugged wiring loom from the holders
and lay to the side.
– Use assembly tool -T10112- to unplug spark plug con-
nector and place to the side.
– Detach coolant hose from cylinder head.
– Unscrew coolant distributor housing.
– Remove top toothed belt guard.
– Position camshaft sprocket to TDC marking of cylin-
der 1. Marking on camshaft sprocket must be aligned
with arrow on the toothed belt guard.
– T30004
– Then turn crankshaft slightly backwards.
– Remove camshaft sprocket. Hold the camshaft
sprocket tight with counterholder -T30004- to slacken
the bolts.
– Remove parallel key from the camshaft.
– Remove rear timing belt guard.
– Slacken the bolts of the cylinder head cover from the
outside to the inside.
– Remove cylinder head cover.
S15-0179
– Slacken the cylinder head bolts using the socket insert

-T10070- in the specified order and unscrew.
– Carefully remove the cylinder head.
Installing cylinder head
Note
♦ There must not be any oil or coolant present in the
holes for the cylinder head bolts.
♦ Remove the new cylinder head seal from its wrapping
immediately before fitting.
♦ Treat the new seal with the utmost care. Any damage
will result in leaks.
– Make sure that when cleaning the cylinder head and

cylinder block no foreign bodies can get into the cylin-
der or into the oil and coolant galleries.

15-1 page 4 S00.5134.52.20
– When conducting repairs sealant residues should be
removed from the contact surface of the cylinder
head/cylinder block using a chemical cleaner.
– If the crankshaft was rotated in the meantime: Position
piston for cyl. 1 on TDC and turn back crankshaft
slightly.
– For centering screw guide pins -T30011/2A- into the
front outer holes for cylinder head bolts.
T30011/3
Note
The tolerance of the centering holes has been constricted T30011/2A
in the top area. For this reason, check first of all, before
fitting on the cylinder head, whether the guide pins can be
removed upward. If necessary, slightly grind off the knurl-
ing of the guide pins.
– Fit on new cylinder head gasket. Text (part number)

must be visible.
– Insert the cylinder head. Screw in the remaining 8 cyl-
inder head bolts and tighten by hand. S15-0185
– Use the removal tool to unscrew guide bolts -T30011/

3-. Turn the removal tool to the left for this step until
the bolts are free.
– Screw in the remaining cylinder head bolts and tighten
by hand.
– Tighten cylinder head bolts in the tightening order
shown as follows:
♦ Tighten all bolts initially to 40 Nm.
♦ Then, torque all bolts a further 90° (1/4 turn) using a
rigid wrench.
♦ Then once again turn all bolts through a further 90° (1/
4 turn).
Further installation occurs in a similar way in reverse or-

der to removal.
– Install toothed belt and tension µ Chapter 13-2.

– Top up coolant µ Chapter 19-1.
– Generate readiness code µ 1.6-ltr./75 kW Engine,
– Adapt engine control unit to throttle valve control unit
-J338- and to EGR valve µ 1.6-litre/75 kW Engine,
– The basic setting must always be additionally initiated
on vehicles with an automatic gearbox µ Automatic
Gearbox 01M; Rep. Gr. 01.

S00.5134.52.20
Inspecting the cylinder head for distor-

tion
♦ Feeler gauge
♦ Knife-edge straightedge
Test sequence
– Inspect cylinder head at several points for distortion
using a knife-edge straightedge and feeler gauge.
♦ Max. permissible distortion: 0.1 mm (minimum clear-
ance of straightedge base: 100 mm)
– If the distortion is greater than 0.1 mm, replace cylin-

der head or rework.
Reworking a cylinder head
Procedure
– Reworking of the sealing surface of the cylinder head
(face-grinding) is only permissible up to minimum di-
mension -a-.
♦ Minimum dimension -a-: 132.6 mm
Note
If the sealing surface is reworked, the valves should be
set lower by the same amount (rework valve seat rings)
otherwise the valves will strike the pistons. When doing
this, ensure that the permissible maximum dimension -
µ Chap. 15-4 - is not exceeded.
Testing the compression

♦ Spark plug wrench (e.g. -3122 B-)
♦ Torque wrench
♦ Compression tester (e.g. -V.A.G 1381- or
-V.A.G 1763-)
Test condition
• Engine oil temperature must be at least 30°C.
Test sequence
– Unplug 4-pin plug (-1-) from ignition transformer
-N152- (-2-).
– Disconnect the connector of the injection valves.

15-1 page 6 S00.5134.52.20
nector and unscrew spark plugs with spark plug
wrench.
– Check compression pressure using the compression
tester.
Note
Use of tester µ Operating instructions
– Have a second mechanic operate starter with the

throttle valve fully opened until no further pressure rise
is indicated by the tester.
Compression readings
Engine new Wear limit Difference be-

tween cylinders
1,0…1.3 MPa 0.75 MPa max. 0.3 MPa
(10…13 bar) (7.5 bar) (3 bar)
– Conclude by deleting the fault memory of the engine

control unit µ 1.6-litre/75 kW Engine, Fuel Injection
and Ignition System; Rep. Gr. 01.

S00.5134.52.20

15-1 page 8 S00.5134.52.20
15-2 Repairing Valve Gear
Note
♦ Cylinder head and ladder frame must always be replaced together.
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touch-
es the piston when the engine is started.
1 - 100 Nm
s to release and tighten use
counterholder -T30004-
s to remove and install, re-
move toothed belt
µ Chapter 13-2
s installation position fixed by
parallel key µ item 4
s for engines with engine iden-
tification characters AVU
with rotor for hall sender
-G40-
3 - Gasket ring
s do not oil sealing lip of gasket
ring
s replacing µ Chapter 15-3
4 - Parallel key
5 - 20 Nm
6 - Ladder frame
s Reworking of sealing surfac-
es not permissible
s with integrated camshaft
bearing
s Bearing 1 for camshaft
sprocket
s pay attention to tightening or-
der of camshaft bearings
µ Chapter 15-3
s Apply sealant
-D 188 800 A1- carefully in
the sealant groove and to the
bottom sealing surface
7 - Camshaft
s The rework of the camshaft is not permissible
s inspecting axial play µ Fig. 1 in 15-2 page 2
s removing and installing µ Chapter 15-3
s Slack: max. 0.01 mm
s for engines with engine identification characters AVU without rotor for hall sender -G40-
8 - Roller rocker arm
s do not interchange
s inspect roller bearings
s oil contact surface
s for installing, clip onto hydraulic supporting element with locking clip
9 - Supporting element
s do not interchange
s with hydraulic valve clearance compensation
s oil contact surface
Edition 11.04 Repairing Valve Gear 15-2 page 1

S00.5134.52.20
10 - Valve collets
11 - Valve spring retainer
12 - Valve spring
– with cylinder head removed:
with -MP 1-211- and -MP 1-213- with valve supporting plate -MP 1-218-
– with cylinder head installed µ Chapter 15-4
13 - Valve stem seal
s replacing µ Chapter 15-4
14 - Cap
s insert flush
s for removal, only push the rubber through the middle using a screwdriver and release
15 - Valve guide
s inspect µ Chapter 15-4
16 - Cylinder head
s reworking valve seats µ Chapter 15-4
17 - Valve
s do not rework, only grinding in is permissible
s Valve dimensions µ Fig. 2 in 15-2 page 2
Fig. 1: Checking the axial play of the camshaft

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

Wear limit: max. 0.17 mm
Fig. 2: Valve dimensions
Note
The valves must not be reworked. Only grinding in is per-
missible.
Dimension Inlet valve Exhaust valve

∅a mm 39,5 ± 0,15 32,9 ± 0,15
∅b mm 5,98 ± 0,007 5,965 ± 0,007
c mm 93,85 93,85
α ∠° 45 45
Repairing Valve Gear Edition 11.04

15-2 page 2 S00.5134.52.20
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6
15-4 Valve stem seals, valves

guides, valve seats
Replacing valve stem seals

Cylinder head fitted

♦ Extractor for valve stem seal -MP 1-230-
♦ Pressure hose -MP 1-210-
♦ Valve lever -MP 1-211-
♦ Valve stem seal insertion tool -MP 1-233-
♦ Assembly device -MP 1-213-
♦ Spark plug wrench (e.g. -3122B-)
♦ Valve supporting plate -MP 1-218-
Note
With cylinder head removed, place cylinder head onto the
valve supporting plate -MP 1-218-.
Removing
– Removing camshaft µ Chap. 15-3.
– Remove the roller rocker arm together with the sup-
porting element. Lay aside on a clean surface.
– Ensure that the roller rocker arm and the supporting
element is not mixed up.
nector and unscrew spark plugs with spark plug
wrench.
– Put the piston of the relevant cylinder at „bottom dead
centre“.
– Insert assembly device -MP 1-213- and adjust bearing
to stay bolt height.
– Screw the pressure hose -MP 1-210- into the spark
plug thread and apply constant pressure of at least 0.6
MPa (6 bar) in the cylinder.
– Remove valve springs with valve lever -MP 1-211-.
MP 1-230
Note
If valve collets are tight, slacken with slight blows of a
hammer on the valve lever.
– Pull off valve stem seal with extractor for valve stem
seal -MP 1-230-.
S15-0183
Edition 11.04 Valve stem seals, valves guides, valve seats 15-4 page 1
S00.5134.52.20
Installing
– In order to avoid damage to the new valve stem seals,
fit the supplied plastic sleeve -A- onto the valve stem. MP 1-233
– Oil valve stem seal -B-, insert into the valve stem seal
insertion tool -MP 1-233- and carefully push onto the A B
valve guide.
– Remove plastic sleeve.
Further installation occurs in a similar way in reverse or-
der to removal.
Note
After carrying out work on the valve gear, carefully crank
engine at least 2 revolutions to ensure that no valve
S15-0184
touches the piston when the engine is started.
Inspect valve guides

♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
Procedure
– Insert valve into guide. End of valve stem must end
flush with the guide (because of the different stem di-
ameter, use only inlet valve in inlet guide and exhaust
valve in exhaust guide).
– Determine valve rock.
Wear limit: 0.6 mm
Note
If the wear limit is exceeded, repeat measurement with
new valves. If the wear limit is again exceeded, replace
cylinder head.
Reworking valve seats
Note
If no perfect contact pattern is achieved by grinding in the
valve seats, rework the valve seats.

♦ Depth gauge/caliper gauge
♦ NAC milling cutter for reworking valve seats
♦ Grinding paste
Valve stem seals, valves guides, valve seats Edition 11.04

15-4 page 2 S00.5134.52.20
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 µ 15-4 page 2.
♦ Rework valve seats only sufficiently in order to obtain
a proper contact pattern.
♦ Calculate the maximum permissible reworking dimen-
sion before commencing.
♦ If the reworking dimension is exceeded, proper oper-
ation of the hydraulic valve clearance compensation is
no longer assured and the cylinder head must be re-
placed.
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 end of the valve

stem and the upper face of the cylinder head.
– Calculate max. permissible reworking dimension from
the distance -a- measured and from the minimum di-
mension.
• Minimum dimension for inlet and exhaust valve: 31.7

mm.
Distance measured -a- minus minimum dimension =
max. permissible reworking dimension.
Example:
Measured distance 32.0 mm

- Minimum dimension 31.7 mm
= max. permissible reworking di- 0.3 mm
mension1)
1) The max. permissible reworking dimension is shown in the figures
for reworking the valve seats as dimension „b“.
Note
If the max. permissible reworking dimension is 0 mm or
less than 0 mm, repeat measurement with a new valve. If
the measuring result is still 0 mm or less than 0 mm, re-
place cylinder head.
S00.5134.52.20
∅
∅
Reworking inlet valve seat
Di- Inlet valve seat

men
sion
a mm 39,2
b mm Max. permissible reworking dimension
c mm 1,8 … 2,2
Z Bottom edge of cylinder head
45° Valve seat angle
30° Top correction angle
S Combustion chamber floor area
Reworking exhaust valve seat
Di- Exhaust valve seat

men
sion
a mm 32.4 mm
b mm Max. permissible reworking dimension
c mm 2,2 … 2.6 mm
Z Bottom edge of cylinder head
45° Valve seat angle
30° Top correction angle
S Combustion chamber floor area
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 µ 15-4 page 2.
• Use NAC milling cutter with carbide metal tips (min. 90
HRC).
• Mill with the milling cutter using slight pressure in such
a way that an even removal of swarfs is ensured over
the whole working surface.
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 in mm

Inlet valve
6,0 -0,01
Exhaust valve
S15-0098

15-4 page 4 S00.5134.52.20
– Match diameter of milling cutter to diameter of valve
seat. 90 °
Valve seat Milling cutter
90°¸ mm
Milling cutter
120°¸ mm
1.
Inlet valve 41 41
Exhaust valve 34 34 120 °
a
Milling sequence 2.
1. Machine valve seat with 90° milling tool until until a
perfect contact pattern is achieved. (Do not exceed
maximum permissible reworking dimension!)
c
2. Initially mill top correction angle with 120° milling cut- S15-0060
ter until the valve seat diameter -a- or valve seat width
-c- is achieved µ 15-4 page 4.
– Grind in valve/valve seat -arrows- with fine grinding
paste so as to achieve a perfect contact pattern.
– Check contact pattern e.g. with water colour (perfect
contact pattern over entire circumference).
– Install valve springs.
– Inspect valve for leaks.
The tightness of the valve can be checked by filling petrol
into the inlet and outlet canal (no petrol must flow out at
the valve seat)
After completing the repair measure the dimension -a-
again and calculate the maximum permissible reworking
dimension µ 15-4 page 3. S15-0061
Note
If the reworking dimension is exceeded, proper operation
of the valve gear is no longer assured and the cylinder
head must be replaced.
S00.5134.52.20

15-4 page 6 S00.5134.52.20
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Manual Service Skoda Octavia 1997

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6HUYLFH 5

List of Supplements to Workshop Manual

Edition 11.04 List of Supplements

List of Supplements Edition 11.04

10 – Removing and Installing Engine

15 – Cylinder Head, Valve Gear

Edition 11.04 Table of Contents I

Table of Contents Edition 11.04

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10-2 Removing and installing

Installing the engine

– Check whether the dowel sleeves for centering the

Vehicles fitted with a manual gearbox

Vehicles with automatic gearbox

Edition 11.04 Removing and installing engine - Part 2 10-2 page 1

– Install selector lever cable at gearbox or adjust

Continued for all vehicles

For vehicles with air conditioning

Continued for all vehicles

– Top up coolant µ Chapter 19-1.

Removing and installing engine - Part 2 Edition 11.04

Align unit mounting for engine - gearbox

Edition 11.04 Removing and installing engine - Part 2 10-2 page 3

1 - 40 Nm + 90° (1/4 turn) 1)

Gearbox assembly bracket

1 - 40 Nm + 90° (1/4 turn) 2)

Removing and installing engine - Part 2 Edition 11.04

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13-2 Removing and installing, tightening the timing belt

1 - Bottom toothed belt guard

s camshaft position sensor -G163- is identical with Hall sender -G40-

Fig. 1: Remove top toothed belt guard

– -A- Position securing bolt -arrow- vertically.

Fig. 2: Fitting position of the semi-automatic ten-

Removing toothed belt

Removing and installing, tightening the timing belt Edition 11.04

– Rotate crankshaft to TDC cylinder 1 -arrow- (vehicles

– Remove engine cover.

– Unbolt engine support from engine mount and engine

– Unbolt engine support from engine -arrows-.

– Remove the vibration damper without altering the

Removing and installing, tightening the timing belt Edition 11.04

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

– Fit timing belt onto tensioning pulley and onto cam-

– Before tensioning the toothed belt, rotate the tension-

When doing this, it is important that the last 45° (1/8

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