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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
Supplement 1 2

Edition 01.01 08.02 11.04

Subject Basic Edition Changes for engine BFQ Modifications in Rep. Gr. 10, 13 and 15

Article Number S00.5134.50.20 S00.5134.51.20 S00.5134.52.20

Edition 11.04 S00.5134.52.20

List of Supplements

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

List of Supplements

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

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 - Removing engine ...................................................................................... 10-1 - Attaching engine to assembly stand ................................................................ 10-1 ...........................................................Removing and installing engine - Part 2 10-2 - Installing the engine ................................................................................... 10-2 - Align unit mounting for engine - gearbox .......................................................... 10-2 - Tightening torques .................................................................................... 10-2 - Assembly bracket ...................................................................................... 10-2 page page page page page page page page 1 1 8 1 1 3 3 4

13 – Crankgear
Disassembling and assembling engine ........................................................... 13-1 - Removing and installing V-ribbed belt .............................................................. 13-1 Removing and installing, tightening the timing belt ........................................... 13-2 - Summary of components ............................................................................. 13-2 - Removing toothed belt ................................................................................ 13-2 - Installing toothed belt, tensioning (setting timing) ................................................ 13-2 - Inspecting the semi-automatic timing belt tensioning pulley .................................... 13-2 Removing and installing sealing flange and pressure plate ................................. 13-3 - Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-3 - Removing and installing the front sealing flange ................................................. 13-3 - Removing and installing drive plate ................................................................ 13-3 Removing and installing crankshaft ............................................................... 13-4 Disassembling and assembling piston and conrod ............................................ 13-5 page page page page page page page page page page page page page 1 1 1 1 2 5 6 1 2 4 6 1 1

15 – Cylinder Head, Valve Gear
Removing and installing cylinder head ........................................................... 15-1 - Cylinder head - summary of components .......................................................... 15-1 - Removing and installing cylinder head ............................................................. 15-1 - Inspecting the cylinder head for distortion ......................................................... 15-1 - Reworking a cylinder head ........................................................................... 15-1 - Testing the compression ............................................................................. 15-1 Repairing Valve Gear .................................................................................. 15-2 Camshaft ................................................................................................. 15-3 - Replacing camshaft gasket ring ..................................................................... 15-3 - Removing and installing camshaft .................................................................. 15-3 Valve stem seals, valves guides, valve seats .................................................... 15-4 - Replacing valve stem seals .......................................................................... 15-4 - Inspect valve guides .................................................................................. 15-4 - Reworking valve seats ................................................................................ 15-4 page page page page page page page page page page page page page page 1 2 3 6 6 6 1 1 1 2 1 1 2 2

17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1

Edition 11.04 S00.5134.52.20

Table of Contents

I

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components page page page 3 1 1

- Disassembling and assembling the oil filter holder .............................................. 17-1 Removing and installing oil pan .................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3

19 – Cooling
Parts of cooling system - Summary of components ........................................... 19-1 - Parts of the cooling system fitted to body ......................................................... 19-1 - Parts of cooling system engine side ................................................................ 19-1 - Connection diagram for coolant hoses ............................................................. 19-1 - Draining and filling up coolant ....................................................................... 19-1 - Removing and installing radiator .................................................................... 19-1 - Removing and installing coolant pump ............................................................ 19-1 Electronically controlled cooling system ......................................................... 19-2 - Operation ............................................................................................... 19-2 - Testing electronically controlled cooling system .................................................. 19-2 - Disassembling and assembling coolant distributor housing .................................... 19-2 - Testing thermostat for map-controlled engine cooling ........................................... 19-2 page page page page page page page page page page page page 1 1 2 3 3 5 8 1 1 1 3 3

20 – Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 - Removing and installing the fuel tank with component parts and fuel filter .................. 20-1 - Safety precautions when working on the fuel supply system ................................... 20-1 - Rules of cleanliness ................................................................................... 20-1 - Removing and installing the fuel delivery unit .................................................... 20-1 - Removing and installing the fuel gauge sender .................................................. 20-1 - Removing and installing the fuel tank .............................................................. 20-1 - Connecting remote control ........................................................................... 20-1 - Disconnecting the fuel delivery unit with crash signal ........................................... 20-1 - Testing fuel pump ..................................................................................... 20-1 - Inspecting fuel flow rate .............................................................................. 20-1 Inspecting the electronic power control (electronic throttle) ................................ 20-2 Activated charcoal filter system .................................................................... 20-3 - Operation ............................................................................................... 20-3 - Repairing parts of the activated charcoal filter system .......................................... 20-3 page page page page page page page page page page page page page page page 1 2 3 3 4 5 5 6 7 7 8 1 1 1 2

26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Exhaust manifold, exhaust pipe with catalytic converter and attached parts ................ 26-1 - Silencer with hanger .................................................................................. 26-1 - Removing and installing front exhaust pipe ....................................................... 26-1 - Removing and installing exhaust manifold ........................................................ 26-1 - Replacing front or rear silencer ..................................................................... 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Secondary air system ................................................................................. 26-2 - Removing and installing parts of the secondary air injection system ......................... 26-2 Exhaust gas recirculation system .................................................................. 26-3 - Exhaust gas recirculation system - summary of components .................................. 26-3 page page page page page page page page page page page page 1 1 3 3 4 5 5 7 1 1 1 1

II

Table of Contents

Edition 11.04 S00.5134.52.20

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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 attention to the following points:

– Check whether the dowel sleeves for centering the
engine/gearbox are present in the cylinder block; insert 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 lever cable.

Edition 11.04 S00.5134.52.20

Removing and installing engine - Part 2

10-2 page 1

10
– Install selector lever cable at gearbox or adjust
µ Automatic Gearbox 01M; Rep. Gr. 37.

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

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 -Aslightly 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 Locations.

– 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 outside.

– 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.

10-2 page 2

Removing and installing engine - Part 2

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

10

– 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 secured 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 Screws and nuts M6 M7 M8 M10 M12 In variation of this: Engine mounting, gearbox mount, pendulum support Driver plate on the torque converter Connecting bolts for the engine/the gearbox µ 5-speed manual gearbox 02K; Rep. Gr. 34 µ Automatic gearbox; Rep. Gr. 37. µ Assembly bracket 60 Nm 9 13 20 40 70

Edition 11.04 S00.5134.52.20

Removing and installing engine - Part 2

10-2 page 3

10

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

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) 2) 3)

Replace bolts Replace bolts Replace bolts

10-2 page 4

Removing and installing engine - Part 2

Edition 11.04 S00.5134.52.20

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Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13

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 order 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 running 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 -T3000411 - Camshaft sprocket s for engines with engine identification characters AVU with rotor for camshaft position sensor -G163s 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 -G16315 - Camshaft position sensor -G163s for engines with engine code AVU
Edition 11.04 S00.5134.52.20 Removing and installing, tightening the timing belt

13-2 page 1

13

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

16 17 -

18 19 20 -

s camshaft position sensor -G163- is identical with Hall sender -G40s when bolting on, ensure base plate is centered 15 Nm 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 O-ring s replace Coolant pump s removing and installing µ Chapter 19-1 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 -T30004s 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 tensioning pulley

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

Removing toothed belt
• Engine installed.

13-2 page 2

Removing and installing, tightening the timing belt

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13

– – – –

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-.

Edition 11.04 S00.5134.52.20

Removing and installing, tightening the timing belt

13-2 page 3

13

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

– Remove engine cover. – Insert supporting device -MP 9-200- and take up
weight of engine with the spindle of the supporting device (only on right).

MP 9-200

– Remove vibration damper. – Remove top toothed belt guard. – Unbolt coolant expansion reservoir and power-steering 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

Removing and installing, tightening the timing belt

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13

Installing toothed belt, tensioning (setting 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 -arrows-.

– Position crankshaft to TDC cylinder 1 µ 13-2 page 2
(except when engine removed).

– Fit toothed belt onto toothed belt sprocket of crankshaft 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 camshaft 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 tensioning 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 opposite.

– Install bottom and middle toothed belt guard.
Edition 11.04 S00.5134.52.20 Removing and installing, tightening the timing belt

13-2 page 5

13
torque: 25 Nm Note

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

– Install belt pulley with vibration damper. Tightening

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 ♦ Engine mount to body µ Chap. 10-2

1

– – – – – – – –

Align component mounting engine µ Chap. 10-2. Remove supporting device -MP 9-200-. Install top toothed belt guard. Install tensioning device for V-ribbed belt. Tightening torque: 25 Nm. Install the V-ribbed belt µ Chapter 13-1. Install coolant expansion reservoir. Install the reservoir for the power-assisted steering. Install noise insulation and engine cover

S13-0279

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 rotate crankshaft a further two revolutions in direction of rotation of engine and position again at TDC of cylinder 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

Removing and installing, tightening the timing belt

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13

Note For the inspection use a mirror.

Edition 11.04 S00.5134.52.20

Removing and installing, tightening the timing belt

13-2 page 7

13

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13-2 page 8

Removing and installing, tightening the timing belt

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13

13-3
Note

Removing and installing sealing flange and pressure plate

♦ 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 1 2 3 4 5 6 7 s do not oil sealing lip of gasket 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 -T100125 - Cylinder block s removing and installing crankshaft µ Chapter 13-4 s disassembling and assembling 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 11 10 1 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 S00.5134.52.20

Removing and installing sealing flange and pressure plate

13-3 page 1

13
Fig. 1: Install intermediate plate

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

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

Replacing gasket ring for crankshaft -on the belt pulley sideSpecial tools, test and measuring equipment and auxiliary items required
♦ Torque wrench ♦ Gasket ring extractor -MP 1-226♦ Assembly device -T10053♦ Counterholder -T30004- or -MP 1-310-

Removing

– – – –

Remove the V-ribbed belt µ Chapter 13-1. Remove tensioning element for V-ribbed belt. Remove the timing belt µ Chapter 13-2. Remove crankshaft toothed belt sprocket. To this end lock the toothed belt gear with counterholder -T30004or -MP 1-310-. Note

T 30004

When attaching the counterholder -MP 1-310- place 2 washers between toothed belt sprocket and counterholder.

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 outer part and lock with knurled screw.

13-3 page 2

Removing and installing sealing flange and pressure plate

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

13

– 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
clean cloth.
S13-0093

– 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.

Edition 11.04 S00.5134.52.20

Removing and installing sealing flange and pressure plate

13-3 page 3

13

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

– Install timing belt gear crankshaft and lock with counterholder -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

T 30004

2 washers between toothed belt sprocket and counterholder.
♦ 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.

MP 1-310

Removing and installing the front sealing flange
Special tools, test and measuring equipment and auxiliary items required
♦ 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 A2S13-0156

Removing

– – – –

Remove the V-ribbed belt µ Chapter 13-1. Remove tensioning element for V-ribbed belt. Remove the timing belt µ Chapter 13-2. Remove crankshaft toothed belt sprocket. To this end lock the toothed belt gear with counterholder -T30004or -MP 1-310-. Note

T 30004

When attaching the counterholder -MP 1-310- place 2 washers between toothed belt sprocket and counterholder.

– – – –

Drain engine oil. Removing oil pan µ Chapter 17-2. Unscrew front sealing flange. Remove sealing flange, if necessary release by applying slight blows with a rubber-headed hammer. cylinder block.

MP 1-310

– Use a flat scraper to remove sealant residues on the – Cover the gasket ring with a clean cloth.
S13-0156

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– Use a rotating plastic brush to remove sealant residues 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.

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13
bolts.

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– Fit sealing flange immediately and lightly tighten all – Tighten the fixing screws of the sealing flange crosswise. Tightening torque: 15 Nm

T 30004

– Remove excess sealant. – Installing oil pan µ Chapter 17-2. – Install timing belt gear crankshaft and lock with counterholder -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 counterholder.
♦ Replace central screw for crankshaft toothed belt

MP 1-310

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
Special tools, test and measuring equipment and auxiliary items required
♦ 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: A - for slackening B - for tightening

A

S13-0280

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

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– 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. If the specified value is not reached:

a

S13-0197

– Once again remove drive plate and repeat measurement 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

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13-3 page 8

Removing and installing sealing flange and pressure plate

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13-4
Note

Removing and installing crankshaft

♦ 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 s removing and installing µ Chapter 17-1 2 - 15 Nm 3 - Sprocket s for oil pump drive 4 - Bearing shells 1, 2, 3, 4 and 5 s Identification for ordering replacement parts µ Fig. 2 in 13-4 page 2 s for bearing cap without lubricating groove s for cylinder block with lubricating groove s do not mix up used bearing shells (mark) 5 - 40 Nm + torque a further 90° (1/4 turn) s replace s tighten thread 6 - Bearing caps 4 s Bearing cap 1: on the belt 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 -G28s assembly only possible in one position -holes offsets replace sensor rotor each time the bolts are slackened s removing and installing µ Fig. 1 in 13-4 page 2 8 - 10 Nm + torque a further 90° (1/4 turn) 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

5

6

4

7

8

5 4 3 2 1

9 4

10

S13-0288

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Fig. 1: Removing and installing sensor rotor

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– 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 positioned 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 the top crankshaft bearing shells according to the marking on the cylinder block (stamped letters). Note Bearing 1 points toward belt pulley. Colour coding of bearing shells matches the letters on the cylinder block

1

2

3
S = black R = red G = yellow B = blue

4

W = white The bottom crankshaft bearing shells are always supplied as replacement parts with the colour coding „yellow“.

5
S13-0286

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13-5
Note

Disassembling and assembling piston and conrod

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 3 1 4 1 2 s if stiff, heat piston to 60°C s use drift -VW 222A- for removing and installing 3 - Piston s check µ Fig. 3 in 13-5 page 3 s mark installation position relative 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 Piston 80.965 mm s 4 - Piston ring (compression ring) 11 12 s Offset joint 120° s use piston ring pliers for reB A moving and installing compression rings s marking „TOP“ must face towards 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) 10 9 s carefully remove and install 8 S13-0283 by hand s marking „TOP“ must face towards 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 -Bs 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 -Bs Fitting position: Markings -A- must be positioned one above the other and point to the belt pulley side

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8 - 30 Nm + torque a further 90° (1/4 turn) 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

Special tools, test and measuring equipment and auxiliary items required
♦ Feeler gauge

– Insert ring at right angles from above down into lower
cylinder opening, about 15 mm away from edge of cylinder. To insert use piston without rings. Gap clearance Piston ring Compression ring Oil scraper ring Fig. 2: new (mm) 0,20…0,40 0,25…0,50 Wear limit (mm) 0,80 0,80

Inspect piston ring end clearance

Special tools, test and measuring equipment and auxiliary items required
♦ Feeler gauge

– Clean ring groove before inspecting.
End clearance Piston ring Compression ring Oil scraper ring new (mm) 0,06…0,09 0,03…0,06 Wear limit (mm) 0,20 0,15

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13

Inspecting pistons

Special tools, test and measuring equipment and auxiliary items required
♦ 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 bearing cap centred. Dimension -a- must be the same on right and left, max. variation: 0.2 mm.

Fig. 5:

Inspecting cylinder bore

Special tools, test and measuring equipment and auxiliary items required
♦ Internal precision measuring instrument 50...100 mm

Test sequence

– Measure at three points crosswise in a transverse direction -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 measurements.

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Disassembling and assembling piston and conrod

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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.

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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 -G163s for engines with engine code BFQ 6 - Gasket ring s replace if damaged s before fitting moisten with clean engine oil 7 - Bracket 8 - 10 Nm 9 - Coolant distributor housing s Disassembling and assembling 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 -G163s for engines with engine code AVU 14 - Rear timing belt guard 15 - 15 Nm 16 - Camshaft sprocket 17 - 100 Nm s to release and tighten use counterholder -T3000418 - 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 -T1007021 - Gasket for cylinder head cover s replace if damaged s press into the spacer sleeves 22 - Cylinder head cover 23 - Vent connection s to the expansion reservoir

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Removing and installing cylinder head

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Removing and installing cylinder head
Special tools, test and measuring equipment and auxiliary items required
♦ 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-. verter and holder µ Chapter 26-1.

– Unbolt front exhaust pipe together with catalytic con– Drain coolant µ Chapter 19-1. – Remove intake hose and air filter µ 1.6-ltr./75 kW Engine, Fuel Injection and Ignition System; Rep. Gr. 24.

WARNING! The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection 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.

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and holder.

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– Remove the secondary air pump with pressure hose – 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 -G163on 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 connector 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 cylinder 1. Marking on camshaft sprocket must be aligned with arrow on the toothed belt guard.

– – Then turn crankshaft slightly backwards. – Remove camshaft sprocket. Hold the camshaft
sprocket tight with counterholder -T30004- to slacken the bolts.

T30004

– 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 cylinder or into the oil and coolant galleries.

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– 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 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 knurling of the guide pins.

T30011/2A

– Fit on new cylinder head gasket. Text (part number)
must be visible.

– Insert the cylinder head. Screw in the remaining 8 cylinder 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 order to removal.

– – – –

Install toothed belt and tension µ Chapter 13-2. Install the V-ribbed belt µ Chapter 13-1. Top up coolant µ Chapter 19-1. Generate readiness code µ 1.6-ltr./75 kW Engine, Fuel Injection and Ignition System; Rep. Gr. 01. -J338- and to EGR valve µ 1.6-litre/75 kW Engine, Fuel Injection and Ignition System; Rep. Gr. 24.

– Adapt engine control unit to throttle valve control unit – The basic setting must always be additionally initiated
on vehicles with an automatic gearbox µ Automatic Gearbox 01M; Rep. Gr. 01.

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Inspecting the cylinder head for distortion
Special tools, test and measuring equipment and auxiliary items required
♦ 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 cylinder 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 dimension -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
Special tools, test and measuring equipment and auxiliary items required
♦ Spark plug wrench (e.g. -3122 B-) ♦ Assembly tool -T10112♦ 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.

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Removing and installing cylinder head

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– Use assembly tool -T10112- to unplug spark plug connector 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 1,0…1.3 MPa (10…13 bar) Wear limit 0.75 MPa (7.5 bar) Difference between cylinders max. 0.3 MPa (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.

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15-1 page 8

Removing and installing cylinder head

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15

15-2
Note

Repairing Valve Gear

♦ 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 -T300042 - Camshaft sprocket s to remove and install, remove toothed belt µ Chapter 13-2 s installation position fixed by parallel key µ item 4 s for engines with engine identification characters AVU with rotor for hall sender -G403 - 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 surfaces not permissible s with integrated camshaft bearing s Bearing 1 for camshaft sprocket s pay attention to tightening order 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 -G408 - 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

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10 - Valve collets 11 - Valve spring retainer 12 - Valve spring s removing and installing – 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

Special tools, test and measuring equipment and auxiliary items required
♦ 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 permissible. Dimension ∅a ∅b c α mm mm mm ∠° Inlet valve 39,5 ± 0,15 5,98 ± 0,007 93,85 45 Exhaust valve 32,9 ± 0,15 5,965 ± 0,007 93,85 45

15-2 page 2

Repairing Valve Gear

Edition 11.04 S00.5134.52.20

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Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

15

15-4

Valve stem seals, valves guides, valve seats

Replacing valve stem seals
Cylinder head fitted Special tools, test and measuring equipment and auxiliary items required
♦ 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-) ♦ Assembly tool -T10112♦ 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 supporting element. Lay aside on a clean surface.

– Ensure that the roller rocker arm and the supporting
element is not mixed up.

– Use assembly tool -T10112- to unplug spark plug connector 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-.
Note If valve collets are tight, slacken with slight blows of a hammer on the valve lever.

MP 1-230

– Pull off valve stem seal with extractor for valve stem
seal -MP 1-230-.

S15-0183

Edition 11.04 S00.5134.52.20

Valve stem seals, valves guides, valve seats

15-4 page 1

15
Installing

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

– In order to avoid damage to the new valve stem seals,
fit the supplied plastic sleeve -A- onto the valve stem.

MP 1-233 A B

– Oil valve stem seal -B-, insert into the valve stem seal
insertion tool -MP 1-233- and carefully push onto the valve guide.

– Remove plastic sleeve.
Further installation occurs in a similar way in reverse order to removal. Note After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started.

S15-0184

Inspect valve guides
Special tools, test and measuring equipment and auxiliary items required
♦ 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 diameter, 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. Special tools, test and measuring equipment and auxiliary items required
♦ Depth gauge/caliper gauge ♦ NAC milling cutter for reworking valve seats ♦ Grinding paste

15-4 page 2

Valve stem seals, valves guides, valve seats

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

15

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 replaced.

Calculating maximum permissible reworking dimension

– 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 dimension.

• Minimum dimension for inlet and exhaust valve: 31.7
mm. Distance measured -a- minus minimum dimension = max. permissible reworking dimension. Example: Measured distance =
1)

32.0 mm 31.7 mm 0.3 mm

Minimum dimension max. permissible reworking dimension1)

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, replace cylinder head.

Edition 11.04 S00.5134.52.20

Valve stem seals, valves guides, valve seats

15-4 page 3

15

Reworking inlet valve seat
Dimen sion a b c

Reworking exhaust valve seat
Dimen sion a b c

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 permissible dimension µ 15-4 page 2. HRC).

• Use NAC milling cutter with carbide metal tips (min. 90 • 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 prevent it from turning. guide.

– Match diameter of guide drift to diameter of valve
Valve guide Inlet valve Exhaust valve ¸ Guide drift in mm 6,0 -0,01
S15-0098

15-4 page 4

∅ ∅
Inlet valve seat mm 39,2 mm mm 1,8 … 2,2 Z 45° 30° Valve seat angle Top correction angle S Exhaust valve seat mm 32.4 mm mm mm 2,2 … 2.6 mm Z 45° S Valve seat angle 30° Top correction angle

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

Max. permissible reworking dimension Bottom edge of cylinder head

Combustion chamber floor area

Max. permissible reworking dimension Bottom edge of cylinder head

Combustion chamber floor area

Valve stem seals, valves guides, valve seats

Edition 11.04 S00.5134.52.20

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

15
90 °

– Match diameter of milling cutter to diameter of valve
seat. Valve seat Inlet valve Exhaust valve Milling cutter 90°¸ mm 41 34 Milling cutter 120°¸ mm 41 34

1.
120 °

Milling sequence
1. Machine valve seat with 90° milling tool until until a perfect contact pattern is achieved. (Do not exceed maximum permissible reworking dimension!) 2. Initially mill top correction angle with 120° milling cutter until the valve seat diameter -a- or valve seat width -c- is achieved µ 15-4 page 4.

2.

a

c
S15-0060

– 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 -aagain and calculate the maximum permissible reworking dimension µ 15-4 page 3. Note If the reworking dimension is exceeded, proper operation of the valve gear is no longer assured and the cylinder head must be replaced.

S15-0061

Edition 11.04 S00.5134.52.20

Valve stem seals, valves guides, valve seats

15-4 page 5

15

Octavia 1997

1.6 l/75 kW Engine - Mechanical Components

15-4 page 6

Valve stem seals, valves guides, valve seats

Edition 11.04 S00.5134.52.20

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