Skoda Fabia 2000 Workshop Manual Engine Mechanical Components

Service 5
Workshop Manual
FABIA 2000 ➤
1.2/40; 1.2/47 Engine, Mechanical Components
Edition 08.02
Engine code AWY AZQ BMD BME
Service Department. Technical Information Printed in Czech Republic

S00.5322.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5322.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ➤ 1.2/40; 1.2/47 Engine, Mechanical Components
List of Supplements to Workshop Manual

FABIA 2000 ➤
1.2/40; 1.2/47 Engine, Mechanical Components
Edition 08.02
Supple-
Edition Subject Article Number
ment
08.02 Basic Edition S00.5322.00.20
1 04.03 Changes for engine with engine identification characters AZQ S00.5322.01.20
2 06.04 Changes for engine with engine identification characters BMD S00.5322.02.20
3 12.04 Changes for engine with engine identification characters BME S00.5322.03.20
Edition 12.04 List of Supplements

S00.5322.03.20
List of Supplements Edition 12.04

S00.5322.03.20
Table of Contents
00 – Technical Data
Technical Data .......................................................................................... 00-1 page 1
10 – Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 page 1
- Removing engine ...................................................................................... 10-1 page 1
- Installing the engine ................................................................................... 10-1 page 4
- Tightening torques .................................................................................... 10-1 page 5
- Assembly bracket ...................................................................................... 10-1 page 5
13 – Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 page 1
- Summary of components ............................................................................. 13-1 page 1
Disassembling and assembling engine ........................................................... 13-2 page 1
- Valve control drive - summary of components ... ................................................. 13-2 page 1
- Removing and installing the timing gear cover ................................................... 13-2 page 5
Removing and installing the camshaft sprocket, setting the timing ....................... 13-3 page 1
- Inspect setting of the timing .......................................................................... 13-3 page 1
- Removing and installing the camshaft sprocket, setting the timing ............................ 13-3 page 3
Removing and installing the gasket ring and flywheel ........................................ 13-4 page 1
- Replacing gasket ring for crankshaft - on the belt pulley side .................................. 13-4 page 2
- Replacing the gasket ring for the crankshaft - flywheel side .................................... 13-4 page 2
- Replacing ring gear ................................................................................... 13-4 page 3
15 – Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 page 1
- Removing and installing cylinder head ............................................................. 15-1 page 4
- Testing the compression ............................................................................. 15-1 page 5
Repairing the valve gear - Part 1 .................................................................... 15-2 page 1
- Removing and installing camshaft .................................................................. 15-2 page 3
Repairing the valve gear - Part 2 .................................................................... 15-3 page 1
- Replacing valve stem seal ........................................................................... 15-3 page 1
- Inspect valve guides .................................................................................. 15-3 page 3
- Reworking valve seats ................................................................................ 15-3 page 4
17 – Lubrication
Removing and installing parts of the lubrication system - Part 1 .......................... 17-1 page 1
- Dismantling and assembling the oil filter ........................................................... 17-1 page 4
Removing and installing parts of the lubrication system - Part 2 .......................... 17-2 page 1
- Removing and installing oil pan ..................................................................... 17-2 page 1
- Removing and installing oil pump ................................................................... 17-2 page 2
Testing oil pressure and oil pressure switch .................................................... 17-3 page 1
19 – Cooling
Edition 12.04 Table of Contents I

S00.5322.03.20
Removing and installing parts of the cooling system - Summary of components .... 19-1 page 1
- Parts of the cooling system fitted to body ......................................................... 19-1 page 2
- Parts of cooling system engine side ................................................................ 19-1 page 3
- Connection diagram for coolant hoses ............................................................. 19-1 page 5
Removing and installing parts of the cooling system - Part 1 ............................... 19-2 page 1
- Draining and filling up coolant ....................................................................... 19-2 page 1
- Checking the coolant system for tightness ........................................................ 19-2 page 2
Removing and installing parts of the cooling system - Part 2 ............................... 19-3 page 1
- Removing and installing radiator .................................................................... 19-3 page 1
- Removing and installing coolant pump ............................................................ 19-3 page 2
20 – Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 page 1
- Removing and installing fuel tank with attached parts and fuel filter .......................... 20-1 page 1
- Safety precautions when working on the fuel supply system ................................... 20-1 page 1
- Rules of cleanliness ................................................................................... 20-1 page 1
- Removing and installing the fuel delivery unit .................................................... 20-1 page 1
- Removing and installing the fuel gauge sender .................................................. 20-1 page 1
- Removing and installing the fuel tank .............................................................. 20-1 page 1
- Inspecting the fuel delivery unit and fuel system ................................................. 20-1 page 2
- Inspecting the operating and holding pressure of the fuel, inspecting the non-return valve
of the fuel delivery unit .............................................................................. 20-1 page 2
- Disconnecting the fuel delivery unit with crash signal ........................................... 20-1 page 2
Inspecting the electronic power control (electronic throttle) ................................ 20-2 page 1
- Summary of components ............................................................................ 20-2 page 1
Activated charcoal filter system .................................................................... 20-3 page 1
- Summary of components of activated charcoal filter system ................................... 20-3 page 1
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Silencer with hangers ................................................................................. 26-1 page 4
- Aligning exhaust system free of stress ............................................................. 26-1 page 4
- Replacing front or rear silencer ..................................................................... 26-1 page 5
- Checking the exhaust system for leaks ............................................................ 26-1 page 5
Exhaust gas recirculation system .................................................................. 26-2 page 1
- Exhaust gas recirculation system - Summary of components .................................. 26-2 page 1
Table of Contents Edition 12.04

II S00.5322.03.20
FABIA 2000 ➤ 1.2/40; 1.2/47 Engine, Mechanical Components 00
00 – Technical Data
00-1 Technical Data

Engine number
The engine number („engine identification characters“
and „serial number“) is located in the front left on the cyl-
ACHTUNG! Bei
Motorkennbuchstaben:
inder block at the engine/gearbox joint -arrow B-.
Pruef- und Einstellarbeiten

XXX 000 000
In addition, a sticker with „engine identification charac-
ters“ and „serial number“ is affixed to the timing gear cov-
er -arrow A-.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
Engine identification AWY BMD AZQ BME

characters
Manufactured 02.02 ➤ 05.04 05.04 ➤ 01.03 ➤ 12.04 12.04 ➤
Exhaust limits conforming EU-4, EU-3 DDK, EU-4, EU-2 DDK EU-4, EU-3 DDK, EU-4, EU-2 DDK
to EU-2 DDK EU-2 DDK
Displacement l 1,198 1,198 1,198 1,198
Power output kW at rpm 40/4750 40/4750 47/5400 47/5400
Torque Nm at rpm 106/3000 108/3000 112/3000 112/3000
Bore ∅ mm 76,5 76,5 76,5 76,5
Stroke mm 86,9 86,9 86,9 86,9
Compression 10,3 : 1 10,3 : 1 10,5 : 1 10,5 : 1
Firing order 1-2-3 1-2-3 1-2-3 1-2-3
Fuel - RON 95 unleaded1) 95 unleaded1) 95 unleaded1) 95 unleaded1)
Fuel injection and ignition Simos 3PD Simos 3PG Simos 3PE Simos 3PG
system
Lambda control 2 Lambda probes2) 2 Lambda probes2) 2 Lambda probes 2 Lambda probes
Catalytic converter 1 Catalyst 1 Catalyst 1 Catalyst 1 Catalyst
Turbocharging no no no no
Exhaust gas recirculation no no yes yes
Secondary air system no no no no
Camshaft adjustment no no no no
1) At least 91 RON in exceptional cases; the engine output is reduced however
2) Engine version complying with exhaust emission standard EU-2 DDK only with one lambda probe before catalyst
Edition 12.04 Technical Data 00-1 page 1

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00 FABIA 2000 ➤ 1.2/40; 1.2/47 Engine, Mechanical Components
Technical Data Edition 12.04

00-1 page 2 S00.5322.03.20
10 – Removing and Installing Engine
10-1 Removing and Installing

Engine
Special tools, test and measuring equipment and
auxiliary items required
♦ Workshop crane, e.g. -V.A.G 1202 A-
♦ Catch pan e.g. - V.A.G 1306-
♦ Pliers for spring strap clips
♦ Engine mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Lifting device -MP 9-201-
♦ Grease -G 000 100-
♦ Hot bolt paste -G 052 112 A3-
♦ Wire
♦ Adhesive tape
Removing engine
Note
♦ The engine is removed towards the front together with
the gearbox.
♦ Jacking up points for raising the vehicle ⇒ Inspection
and Maintenance.
♦ Pay attention to the correct assignment of the connec-
tors, if necessary mark.
♦ If the battery is disconnected and reconnected, carry
out certain additional operations ⇒ Electrical System;
Rep. Gr. 27.
Procedure
– Disconnect the battery-earth strap with the ignition off.
S10-0135
– Remove noise insulation -arrows-.
– Unscrew the drive shaft to the right and left of the
gearbox flange ⇒ Chassis; Rep. Gr. 40.
– Raise drive shafts and secure.
– Removing exhaust pipe ⇒ Chapter 26-1. 1
– Drain coolant ⇒ Chapter 19-2. 2
– Remove engine cover with air filter ⇒ 1.2/40; 1.2/47
Engine, Fuel Injection; Rep. Gr. 24.
– Remove battery and battery tray ⇒ Electrical System;
Rep. Gr. 27. 3
– Unplug connector -1- from the engine control unit.
– Separate plug connection -2-.
– Unclip cable clip -3- -arrows-.
S10-0142
Edition 04.03 Removing and Installing Engine 10-1 page 1

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The engine is removed together with the cable harness.
– Disconnect all cables for the engine, gearbox, starter

motor and radiator which are will get in the way during
removal.
– Remove the coolant hose which connects the coolant
regulator to the heat exchanger.
– Remove the vacuum hose from the brake servo unit.
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.
– Detach the fuel feed line -5-, or fuel return line -4- and
ventilation line -3- by pressing on their release but-
tons.
– Unplug the plug connection -2- and remove solenoid
valve for the activated charcoal filter system -N80- -1-.
– Remove the cooling system ventilation hose -7- from
the coolant pipe at the front.
– Remove the coolant hose -6- on the pipe behind the
expansion reservoir.
– Remove Bowden cable support ⇒ Manual gearbox
002; Rep. Gr. 34.
– Remove the slave cylinder of the hydraulic clutch
⇒ Manual gearbox 002; Rep. Gr. 30.
– Separate the coolant hose from the radiator at the top
and bottom of the connection fittings.
– Unbolt the pendulum support -arrows-.
Vehicles without air conditioning

– Removing the lock carrier ⇒ Body work; Rep. Gr. 50.
For vehicles with air conditioning

S34-0403
WARNING!
Do not open the refrigerant circuit of the air condi-
tioning system.
– Remove the V-ribbed belt ⇒ Chapter 13-1.

– Remove connector from the AC compressor.
1
– Remove AC compressor with the refrigerant lines con-
nected.
– Secure the AC compressor -1- to the lock carrier -ar-
row-.
– Remove the lock carrier with the radiator and con-
denser ⇒ Body work; Rep. Gr. 50, swivel to the side
and position on a suitable base -2- on which there is
no risk of tilting. 2 S10-0136
Removing and Installing Engine Edition 04.03

10-1 page 2 S00.5322.01.20
Note
♦ Do not buckle the refrigerant lines.
♦ Use cloths to protect the right headlight glass from
damage, removing the headlight if necessary.
Continued for all vehicles

– Hook lifting device -MP 9-201- into the engine lifting
eyes and raise slightly using the workshop crane.
Caution!
Use securing pins on the hooks and rig pins to pre-
vent release.
– Release screws -1-.
– Unscrew the screws -arrows- from the gearbox

mount.
– Slightly lower the engine with gearbox and pull out
carefully towards the front.
– Remove the engine from the gearbox.
S10-0120

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Secure the engine with engine mount -MP 1-202- (using

3 screws -arrows-) on the assembly stand -MP 9-101- for
performing assembly work.
Installing the engine
Note
♦ Always replace the seals and gaskets during assem-
bly work.
♦ Always replace self-locking nuts.
♦ Tightening torques ⇒ 10-1 page 5.
♦ Assembly bracket ⇒ 10-1 page 5.
Procedure
Installation is performed in the reverse order. Pay atten-
tion to the following points:
– Check whether the dowel sleeves for centering the

gearbox are present in the cylinder block 2; insert if
necessary.
– If necessary check the centering of the clutch driver
disc.
– Inspect clutch release bearing for wear, replace if nec-
essary.
– Grease the drive shaft serration with grease
-G 000 100-.
– When installing engine/gearbox unit, ensure ade-
quate clearance to neighbouring components.
– Align the engine and gearbox so that they are tension-
free.
– Install the slave cylinder of the hydraulic clutch
⇒ Gearbox 002; Rep. Gr. 30.
– Adjust the gearshift mechanism and shift cables
⇒ Manual gearbox 002; Rep. Gr. 34.

– Install the AC compressor ⇒ Chapter 13-1.
– Install the V-ribbed belt ⇒ Chapter 13-1.
Continued for all vehicles

– Install the drive shaft on the right and left of the gear-
box ⇒ Chassis; Rep. Gr. 40.
– Align the front exhaust pipe with catalyst and fit the ex-
haust system free of stress ⇒ Chapter 26-1.
– Electrical connections and proper routing ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.
– Install coolant hoses ⇒ Chapter 19-1.

10-1 page 4 S00.5322.01.20
Note
The drained off coolant must only be then re-used if the
cylinder block, cylinder head, radiator or heat exchanger
were not replaced.
– Top up coolant ⇒ Chapter 19-2.

– Check oil level before starting the engine.
– Adapt engine control unit to the throttle valve control
unit -J338- ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection;
Rep. Gr. 24.
– Read the readiness code and generate it ⇒ 1.2/40;
1.2/47 Engine, Fuel Injection; Rep. Gr. 01.
– Perform a test drive, interrogate fault memory and de-
lete it ⇒ 1.2/40; 1.2/47, Fuel Injection; Rep. Gr. 01.
Tightening torques
Note
♦ Tightening torques apply only for lightly greased,
oiled, phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are
allowed. Under no circumstances use Molykote.
♦ Do not use degreased parts.
♦ Unless otherwise indicated the following tightening
torques apply:
Component Nm
Screws/nuts M6 9
M7 15
M8 23
M10 40
M12 60
deviations:
Engine mounting, gearbox ⇒ Assembly
mount, pendulum support bracket
Engine to gearbox connect- M10 45
ing screws
Assembly bracket
Tightening torques
Engine mounting
1 - 20 Nm + 90° (1/4 turn) - replace

2 - 30 Nm + 90° (1/4 turn) - replace

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Gearbox mounting
2
1 - 50 Nm + 90° (1/4 turn) - replace
2 - 40 Nm + 90° (1/4 turn) - replace 1
1
1 S10-0125
Hinged bracket
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
1 - 30 Nm + 90° (1/4 turn) - replace

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

10-1 page 6 S00.5322.01.20
13 – Crankgear
13-1 Removing and installing V-ribbed belt
Summary of components
Note
♦ Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used
belt may destroy it.
♦ Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.
♦ Vehicles without an air-conditioning system do not have an air-conditioning compressor or guide pulley.
1 - 22 Nm
2 - Belt pulley
❑ on the coolant pump
3 - Trim
4 - Tensioner with tensioning
pulley
❑ do not remove the tensioning
pulley.
5 - 40 Nm
6 - Generator
❑ to facilitate positioning of the
generator on the cylinder
block, drive the threaded
bushings of the screws
slightly backwards
7 - Guide pulley
8 - Washer
❑ Camber towards the outside
9 - Belt pulley
❑ for crankshaft
10 - 90 Nm + torque a further 90
(1/4 turn)
❑ replace
❑ interlock the crankshaft with
a drift -T10121- for loosening
and tightening it up
⇒ Chapter 13-3
11 - Distance sleeve
❑ for generator
12 - 23 Nm
13 - Distance sleeve
❑ for the AC compressor
14 - Dowel sleeves for AC compressor
❑ must be inserted in the cylinder block
15 - V-ribbed belt
❑ Routing of the V-ribbed belt
vehicles without air conditioning ⇒ Fig. 1 in 13-1 page 2
Vehicles with air conditioning ⇒ Fig. 2 in 13-1 page 3
❑ removing and installing ⇒ 13-1 page 2
Edition 08.02 Removing and installing V-ribbed belt 13-1 page 1

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Removing
– Mark the rotation direction of the V-ribbed belt.
– Lever off the cover for the tensioning roller -A-.
– Swing out the tensioning roller -A- with Torx key 50 -B-
in the direction of travel up to the stop and remove the
V-ribbed belt.
Note
The tensioning roller can be interlocked by inserting a rig
pin.
Installing
Note
♦ Inspect V-ribbed belt ⇒ Inspection and Maintenance.
♦ Before fitting the V-ribbed belt make sure that all as-
semblies (generator, coolant pump and AC compres-
sor) are securely mounted.
♦ Check smooth operation of belt pulley, tensioning and
guide pulley.
♦ Pay attention to the rotation direction of already used
V-ribbed belts.
– Position the V-ribbed belt on the belt pulleys and

guide pulley.
– Swing out the tensioning roller -A- with Torx key 50 -B-
in the direction of travel up to the stop and lay the V-
ribbed belt in place.
– Press on the cover of the tensioning roller -A-.
– Start engine and check belt run.
Fig. 1: V-ribbed belt run - without an air condition-
ing system
1- Belt pulley - crankshaft
2- Belt pulley - coolant pump
3- Tensioning pulley
4- Belt pulley - generator
Removing and installing V-ribbed belt Edition 08.02

13-1 page 2 S00.5322.00.20
Fig. 2: V-ribbed belt run - with an air conditioning
system
1- Belt pulley - crankshaft
2- Belt pulley - coolant pump
3- Tensioning pulley
4- Belt pulley - generator
5- Belt pulley - AC compressor
6- Guide pulley
Edition 08.02 Removing and installing V-ribbed belt 13-1 page 3

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Removing and installing V-ribbed belt Edition 08.02

13-1 page 4 S00.5322.00.20
13-2 Disassembling and assembling engine

Valve control drive - summary of components
WARNING!
Top and bottom part of cylinder block must not be disassembled.
For engine with engine identification characters AWY, BMD
1 - Cylinder head with cover

❑ removing and installing
⇒ Chapter 15-1
2 - Cylinder block
❑ 2 part
❑ do not separate
3 - Crankshaft gear
❑ for balancing shaft draft
❑ Wheel position for balancing
shaft gear ⇒ Fig. 2 in 13-2
page 5
4 - Balancing shaft gear
❑ do not remove
❑ Wheel position for crankshaft
gear ⇒ Fig. 2 in 13-2
page 5
5 - Chain tensioner for the oil
pump
6 - Oil pump
⇒ Chapter 17-2
7 - Guide rail
8 - Chain sprocket on the crank-
shaft for the camshaft drive
❑ interlocked with spring on the
crankshaft
shaft for the oil pump drive
❑ not interlocked on the crank-
shaft
10 - Oil pump chain
11 - Oil pump sprocket
12 - Oil pan
❑ removing and installing ⇒ Chapter 17-2
13 - 9 Nm
14 - Cover
❑ Oil pump sprocket
15 - 20 Nm + torque a further 90 (1/4 turn)
❑ replace
16 - O-ring
❑ replace if damaged
❑ replace the sealing of the housing with silicone sealant
17 - Housing
❑ Replace together with O-ring ⇒ item 16
❑ Replace silicone sealant sealing with O-ring ⇒ item 16
Edition 12.04 Disassembling and assembling engine 13-2 page 1

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❑ fit onto cleaned crankshaft

❑ install only after putting the timing gear cover in place otherwise the gasket ring can be damaged
18 - Gasket ring
❑ Replace in case of damage ⇒ Chap. 13-4
❑ replace together with housing ⇒ item 17
❑ for crankshaft on the belt pulley side
❑ Neither grease nor oil sealing lip of sealing ring
❑ before installing remove grease residue on the housing with a clean cloth
19 - Belt pulley - crankshaft
❑ replace
❑ Interlock crankshaft with an assembly device -T10121- for removing and installing it ⇒ Chapter 13-3
21 - 25 Nm
22 - 45 Nm
23 - 10 Nm
❑ if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have sealant
on them
24 - To intake manifold
❑ ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24
25 - The vacuum regulating valve (PCV valve)
❑ pay attention to the spare part number
26 - O-ring
27 - Timing gear cover
28 - Oil separator
❑ clipped in the steering wheel housing
❑ replace
❑ Interlock camshaft with an assembly device -T10120- for removing and installing it ⇒ Chapter 13-3
30 - Timing chain
❑ tensioning ⇒ Fig. 1 in 13-2 page 5
31 - Camshaft sprocket
❑ not interlocked on the camshaft but simply fitted onto it
❑ removing and installing, setting the timing ⇒ Chapter 13-3
32 - Bolts, 18 Nm
❑ for tensioning rail or possibly also guide rail
33 - Tensioning rail
❑ interlock tensioner ⇒ Fig. 1 in 13-2 page 5
34 - Hydraulic control chain tensioner
❑ tension (loosen control chain) ⇒ Fig. 1 in 13-2 page 5
Disassembling and assembling engine Edition 12.04

13-2 page 2 S00.5322.03.20
For engine with engine identification characters AZQ, BME

⇒ Chapter 15-1
2 - Cylinder block
❑ 2 part
❑ do not separate
3 - Balancing shaft
4 - Balancing shaft gear
❑ do not remove
❑ Wheel position for crankshaft
gear ⇒ Fig. 2 in 13-2
page 5
5 - Oil pump
⇒ Chapter 17-2
6 - Bolts, 18 Nm
❑ for tensioning rail or possibly
also guide rail
7 - Guide rail
shaft for the camshaft drive
❑ interlocked with spring on the
crankshaft
shaft for the oil pump drive
❑ not interlocked on the crank-
shaft
10 - Oil pump chain
12 - Oil pan
⇒ Chapter 17-2
13 - 9 Nm
14 - Cover
❑ Oil pump sprocket
❑ replace
16 - O-ring
17 - Housing
❑ Replace silicone sealant sealing with O-ring ⇒ item 16
18 - Gasket ring
❑ Replace in case of damage ⇒ Chap. 13-4
❑ replace together with housing ⇒ item 17

S00.5322.03.20

❑ replace
❑ Interlock crankshaft with an assembly device -T10121- for removing and installing it ⇒ Chapter 13-3
21 - 25 Nm
22 - 50 Nm
❑ if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have sealant
on them
24 - To intake manifold
❑ ⇒ 1.2/47 Engine, Fuel Injection; Rep. Gr. 24
25 - 10 Nm
26 - The vacuum regulating valve (PCV valve)
❑ pay attention to the spare part number
27 - O-ring
29 - Cover
30 - O-ring
❑ replace
❑ Interlock camshafts with a pipe section -T10123- for removing and installing it ⇒ Chapter 13-3
32 - Tensioning rail
❑ interlock tensioner ⇒ Fig. 1 in 13-2 page 5
33 - Hydraulic control chain tensioner
34 - 15 Nm
35 - Timing chain
❑ removing and installing, setting the timing ⇒ Chapter 13-3
37 - 15 Nm
❑ for engine with engine identification characters AZQ
38 - Sliding block
39 - Washer
❑ replace

13-2 page 4 S00.5322.03.20
Fig. 1: Interlock tensioner
– Press on the piston of the hydraulic tensioner -2- in the

-direction of travel- over the tensioning rail -1- until the
piston can be interlocked with the safety drift -B- (e.g.
with a 3 mm box spanner).
Fig. 2: Set the point of installation of the gearwheel

on the crankshaft
– Place the marking at the gearwheel on the crankshaft

opposite to the marking at the gearwheel on the bal-
ancing shaft -arrows-.
Removing and installing the timing gear

cover
• Engine installed in the vehicle
♦ Supporting device -MP 9-200-
♦ Hand-held power drill with plastic brush insert
♦ Flat scraper
♦ Silicone sealant -AMV 174 003-
Removing
– If necessary remove engine cover with air filter ⇒ 1.2/
40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
– Mount supporting device -MP 9-200- and take up the
weight of the engine/gearbox assembly at the spin-
dles.
– Remove the right engine mounting ⇒ Chap. 10-1.
– Remove pulley wheel of the coolant pump ⇒ Chapter
19-1.
– Remove the guide pulley (only on vehicles with air
conditioning) ⇒ Chapter 13-1.
– Remove the tensioner with tensioning roller
⇒ Chapter 13-1.
– Remove alternator ⇒ Electrical System; Rep. Gr. 27.
– Remove the ventilation pipe of the cooling system
⇒ Chapter 19-1.

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– Interlock the crankshaft with an assembly device

-T10121- ⇒ Chapter 13-3, screw out the screw of the
crankshaft and pull off the belt pulley - crankshaft.
– Remove the oil pan, guide pipe of the oil dipstick anbd
possibly also the sender for the oil level/temperature
-G266- (vehicles with WIV) ⇒ Chapter 17-1/17-2.
– Remove the connection for the vacuum regulating
valve (PCV valve).
– Screw out all screws on the timing gear cover.
– Remove the timing gear cover. Use slight knocks with
a rubber-headed hammer from outside to loosen the
cover as necessary (the timing gear cover sits on the
fitting sleeves).
– Use a flat scraper to remove plastic sealant residues
from the engine.
Note
Cover the area around the sealing surfaces so that no
sealant residues can find their way into the timing gear
drive.
– Remove sealant residues on the timing gear cover

with a rotating brush, e.g. a hand drill with plastic
brush attachment (wear protective goggles).
– Clean the sealing surfaces on the timing gear cover
and engine. They must be free of oil and grease.
Installing
Note
♦ Install housing ⇒ item 17 in 13-2 page 1, ⇒ item 17
in 13-2 page 3 only after putting the timing gear cover
in place otherwise the gasket ring can be damaged.
♦ Remove sealant residues of silicone sealant applied
inside the housing and insert a new O-ring ⇒ item 16
in 13-2 page 1, ⇒ item 16 in 13-2 page 3 into the
housing.
♦ Check whether the oil scraper has been damaged
while removing (e.g. broken off wings).
♦ Pay attention to the 'use by date' on sealant.
♦ The timing gear cover must be installed within 5 min-
utes after applying the silicone sealant.
♦ if no blue sealant mass is left in the thread of the M6
screws, replace the screws for ones which have seal-
ant on them.
– Cut off nozzle tube at the front marking (∅ of nozzle

approx. 3 mm).
– Apply silicone sealant to the clean sealing surface of
the timing gear cover, according to the illustration -ar-
rows A-.

13-2 page 6 S00.5322.03.20
Note
Apply silicone sealant to the separation point of the cylin-
der head/cylinder block according to the parting plane
-arrows C-.
For engine with engine identification characters
AWY, BMD

AZQ, BME
Continued for all engines
B - Position of the fitting sleeves
♦ Thickness of sealant bead: 2…3 mm.
Note
The sealant bead must not be thicker than 3 mm other-
wise excess sealant may get into the oil pan and clog the
strainer in the oil pump.
– Fit timing gear cover immediately and lightly tighten all

bolts.
– Tighten all bolts fully in the given sequence: Tighten-
ing torques ⇒ 13-2 page 8.

S00.5322.03.20

AWY, BMD

AZQ, BME
– Install the housing ⇒ item 17 in 13-2 page 1,

⇒ item 17 in 13-2 page 3.
Note
The sealing of the housing must be carried out with an O-
ring ⇒ item 16 in 13-2 page 1, ⇒ item 16 in 13-2
page 3.
Size of screws and the tightening torque

AWY, BMD
Position Size of bolt Torque

3 M10x162 45 Nm
1, 2 M10x142 45 Nm
22, 23 M8x55 25 Nm
others M6x401) 10 Nm
1) if no blue sealant mass is left in the thread of the screws, replace
the screws for ones which have sealant on them.

AZQ, BME

13-2 page 8 S00.5322.03.20
Position Size of bolt Torque

1, 2, 3 M10x120 50 Nm
4, 5 M8x55 25 Nm
6, 7, 8, 11, 14, M6x401) 8 Nm + torque a
15 further 90° (1/4
others M6x221) turn)
1) if no blue sealant mass is left in the thread of the screws, replace
the screws for ones which have sealant on them.

Further installation occurs in reverse order. Pay attention
to the following:
♦ Replace crankshaft screw.
Tightening torque: 90 Nm + torque a further 90° (1/4

turn)

S00.5322.03.20

13-2 page 10 S00.5322.03.20
13-3 Removing and installing

the camshaft sprocket,
setting the timing
Inspect setting of the timing

AWY, BMD

♦ Assembly device -T10120-
♦ Extractor -T10094-
Note
♦ The crankshaft is at TDC of the piston for cylinder 1 for
mixture ignition only then when the camshaft is stand-
ing atTDC of the piston for cylinder 1 (both devices
must be interlocked).
♦ The assembly device -T10121- also serve at the same
time as a fixing lever to loosen and tighten up the
crankshaft screws.
♦ The engine can be easily turned once the spark plugs
have been removed.

– Remove camshaft position sensor -G163- at cylinder
head cover.
– Remove engine speed sender -G28- on the cylinder
block.
– Insert assembly device -T10120- according to the il-
lustration into the hole.
– Rotate crankshaft in direction of rotation of engine
long enough until the assembly device -T10120- can
be inserted down to the stop.
– Interlock crankshaft, press the assembly -T10121-
into the hole in the flywheel.
Note
If the assembly device -T10121- cannot be inserted, re-
move the assembly device -T10120- out of the camshaft.
Rotate crankshaft in direction of rotation of engine (360 )
and repeat the procedure.
If both devices cannot be inserted:
– Setting the timing ⇒ 13-3 page 3.

If both devices can be inserted:
– Remove the devices from the holes and install cam-

shaft position sensor as well as engine speed sender.
Further installation occurs in reverse order.
Edition 12.04 Removing and installing the camshaft sprocket, setting the timing 13-3 page 1
S00.5322.03.20

AZQ, BME

♦ Pipe section -T10123-
Note
♦ The crankshaft is at TDC of the piston for cylinder 1 for
mixture ignition only then when the camshaft is stand-
ing atTDC of the piston for cylinder 1 (both devices
must be interlocked).
♦ The assembly device -T10121- also serve at the same
time as a fixing lever to loosen and tighten up the
crankshaft screws.
have been removed.

– Remove caps at cylinder head cover -arrows-.
– Remove engine speed sender -G28- on the cylinder
block.
– Rotate crankshaft in direction of rotation of engine
long enough until the grooves are positioned horizon-
tally in both camshafts.
– Pipe sections -T10123- must be lightly pushed into the
camshafts.
– Fasten both devices with screws (M6).
T10123
– Interlock crankshaft, press the assembly device

-T10121- into the hole in the flywheel.
Note
If the assembly device -T10121- cannot be inserted, re-
move the pipe sections -T10123- out of the camshaft. Ro-
tate crankshaft in direction of rotation of engine (360 )
and repeat the procedure.
If both devices cannot be inserted:
– Setting the timing ⇒ 13-3 page 3.

If both devices can be inserted:
– Remove the devices from the holes and install caps

as well as engine speed sender.
Removing and installing the camshaft sprocket, setting the timing Edition 12.04
13-3 page 2 S00.5322.03.20
Removing and installing the camshaft
sprocket, setting the timing
♦ Pressure pad -MP 1-216-
Removing the camshaft sprocket

AWY, BMD
– Interlock camshaft and crankshaft at TDC for cylinder

1 ⇒ 13-3 page 1.
– Remove the timing gear cover ⇒ Chapter 13-2.
– Interlock the control chain tensioner ⇒ Chapter 13-2.
– Remove the camshaft screw and take out the cam-
shaft sprocket.
– Screw in the crankshaft screw with housing and belt
pulley - crankshaft.
Tightening torque: 90 Nm + torque a further + 45° (1/8

turn)
– Remove the assembly device -T10121- and turn the

crankshaft 45° in the opposite direction of rotation of
the engine.
Work can be performed on the valve drive while it is in this
position.
Installing the camshaft sprocket, setting the tim-

ing
AWY, BMD
• The pistons must not be positioned at top dead centre.
Note
♦ To turn the camshaft when the sprocket has been re-
moved one can screw in a screw with two washers to
a maximum of 20 Nm + 45 (1/8 turns) into the cam-
shaft and turn the camshaft. The pistons must not be
at TDC.
♦ The central screw of the camshaft is to be replaced
whenever the camshaft is removed
♦ The assembly device -T10120- also serves at the
same time as a fixing lever to loosen and tighten up
the camshaft screws.
have been removed.
– Position camshaft to TDC of cylinder 1 and lock into

place ⇒ 13-3 page 1.
One should not be able to move the camshaft in any
direction after interlocking.
S00.5322.03.20
– Screw out the camshaft screws.

– Remove oil residues on the camshaft studs and cam-
shaft sprocket in the points of contact using a clean
cloth.
– Place the camshaft sprocket with the control chain laid
on it on the camshaft and screw in the new camshaft
screw so that the camshaft sprocket can still turn.
– Tension control chain ⇒ Chapter 13-2
– Turn the crankshaft through a further 45° in the direc-
tion of rotation of the engine to TDC for cylinder 1 and
interlock.
Note
♦ If the crankshaft is turned beyond TDC for cylinder 1
(observe the marking on the flywheel) then it should
turned back and the TDC for cylinder 1 set again.
♦ If the crankshaft is turned further it will collide with the
piston on the valves.
– Turn the camshaft sprocket -1- with pressure pad

-MP1-216- opposite the direction of rotation of the en-
gine -arrow- up to the stop, hold the camshaft sprock-
et in this position and tighten up the screw -2-.

turn)
Note
The assistance of a 2nd mechanic is required for this
work.
– Carefully crank engine at least 2 revolutions to ensure

that no valve touches the piston when the engine is
started, check timing again ⇒ 13-3 page 1.
– Check position of camshaft to crankshaft in the dis-

play group 012 display field 3 and 4 ⇒ 1.2/40, 1.2/47
Removing the camshaft sprockets

AZQ, BME
– Interlock camshafts and crankshaft at TDC for cylin-

der 1 ⇒ 13-3 page 1.
– Interlock the control chain tensioner ⇒ Chapter 13-2.
– Remove the camshaft screws and take out the cam-
shaft sprockets.
– Screw in the crankshaft screw with housing and belt
pulley - crankshaft.
Tightening torque: 90 Nm + torque a further + 45° (1/8

turn)
13-3 page 4 S00.5322.03.20
– Remove the assembly device -T10121- and turn the
crankshaft 45° in the opposite direction of rotation of
the engine.
Work can be performed on the valve drive while it is in this
position.
Installing the camshaft sprockets, setting the

timing
AZQ, BME
Note
♦ To turn the camshaft when the sprocket has been re-
moved one can screw in a screw with two washers to
a maximum of 50 Nm + 45 (1/8 turns) into the cam-
shaft and turn the camshaft. The pistons must not be
at TDC.
♦ The central screws of the camshafts and the washers
of the sprockets on engine with engine identification
characters AZQ are to be replaced when the cam-
shafts are removed.
♦ The pipe section -T10123- also serves at the same
time as a fixing lever to loosen and tighten up the cam-
shaft screws.
have been removed.
– Position camshafts to TDC of cylinder 1 and lock into

place ⇒ 13-3 page 1.
– Screw out the camshaft screws.
– Remove oil residues on the camshaft studs and cam-
shaft sprockets in the points of contact using a clean
cloth.
– Place the camshaft sprockets with the control chain
laid on it on the camshafts and screw in the new cam- T10123
shaft screws so that the camshaft sprockets can still
turn.
– Tension control chain ⇒ Chapter 13-2
– Turn the crankshaft through a further 45° in the direc-
tion of rotation of the engine to TDC for cylinder 1 and
interlock.
Note
♦ If the crankshaft is turned beyond TDC for cylinder 1
(observe the marking on the flywheel) then it should
turned back and the TDC for cylinder 1 set again.
♦ If the crankshaft is turned further it will collide with the
piston on the valves.
S00.5322.03.20
– Tighten screws -2- of camshaft sprockets -1- to 50 Nm

(to do so use the pressure pad -MP1-216-).
– Then, torque the bolts a further 90° (1/4 turn) with a rig-
id wrench.

turn)
Note
The assistance of a 2nd mechanic is required for this
work.
– Carefully crank engine at least 2 revolutions to ensure

started, check timing again ⇒ 13-3 page 1.
– Check position of camshaft to crankshaft in the dis-

play group 012 display field 3 and 4 ⇒ 1.2/40, 1.2/47
13-3 page 6 S00.5322.03.20
13-4 Removing and installing the gasket ring and flywheel
Note
♦ Repairs on the clutch ⇒ Manual gearbox 002; Rep. Gr. 30.
♦ The engine should be attached to the engine repair stand with the engine holder -MP 1-202- for carrying out re-
moval and installation work.
(1/4 turn)
❑ replace
❑ Interlock crankshaft with a
fixing bolt -T10121- for re-
moving and installing it
⇒ Chapter 13-3
3 - Housing
❑ Replace together with O-ring
⇒ item 4
❑ Replace silicone sealant
sealing with O-Ring ⇒ item 4
4 - O-ring
❑ replace the sealing of the
housing with silicone sealant
5 - Gasket ring
❑ for crankshaft on the belt pul-
ley side
❑ Neither grease nor oil sealing
lip of sealing ring
❑ before installing remove
grease residue on the hous-
ing with a clean cloth
❑ replace if damaged ⇒ 13-4
page 2
❑ Replace together with hous-
ing ⇒ item 3
6 - Cylinder block
(1/4 turn)
❑ replace
❑ tighten up in two steps:
Step I = 60 Nm
Step II = 90° (1/4 turn)
8 - Flywheel
❑ assembly only possible in one position -holes offset-
❑ Interlock crankshaft flywheel with a fixing bolt -T10121- for removing and installing it ⇒ Chapter 13-3
❑ replace ring gear ⇒ 13-4 page 3
9 - Intermediate plate
❑ must be positioned on dowel sleeves
❑ do not damage/bend during assembly work
10 - Gasket ring
❑ for crankshaft on the flywheel side
Edition 04.03 Removing and installing the gasket ring and flywheel 13-4 page 1
S00.5322.01.20
❑ before installing remove grease residue on crankshaft journal with a clean cloth
❑ replace ⇒ 13-4 page 2
Replacing gasket ring for crankshaft - on

the belt pulley side
Removing
– Remove belt pulley - crankshaft and housing
⇒ Chapter 13-2.
– Remove the gasket ring carefully using a screwdriver
-A-.
Note
The adhesive surface must not get damaged when re-
moving the gasket ring.
Installing

♦ Pressure plate -T40008-
Note
The sealing lips of the gasket ring must be neither oiled
nor greased.
– Position the gasket ring on the steering wheel housing

and drive in using a pressure piece -T40008- down to
the stop on the device.
– Carefully place a new grease and oil free housing into
the gasket ring ⇒ Chapter 13-2.
Replacing the gasket ring for the crank-

shaft - flywheel side
♦ Assembly fixture -T10122-
• Gearbox removed
– Remove the flywheel ⇒ item 8 in 13-4 page 1.
– Remove the gasket ring carefully using a screwdriver
-A-.
Note
The adhesive surface must not get damaged when re-
moving the gasket ring.
Removing and installing the gasket ring and flywheel Edition 04.03
13-4 page 2 S00.5322.01.20
Installing
Note
The sealing lips of the gasket ring must be neither oiled
nor greased.
– Push the assembly device -T10122/1- into the assem-

bly device -T10122/2- and gasket ring -A-, then push
onto the assembly device -T10122/2-, as shown.
– Remove assembly device -T10122/1-.
– Remove oil residue on the crankshaft stub with a
clean cloth.
– Insert the gasket ring with assembly device -T10122/

2 -.
– Drive in gasket ring with assembly device -T10122/3-
up to the stop.
Replacing ring gear

• Flywheel removed
Removing
– Fit on flywheel flat and position ring gear in stages by
striking over the entire circumference. Heat ring gear
if stiff.
Installing
– Heat ring gear to approx. 150 °C and fit onto the fly-
wheel evenly; knock on as far as the stop with a drift
over the entire circumference, if necessary.
Note
Lay the flywheel in place so that the rotor for the engine
speed is not damaged.
Edition 04.03 Removing and installing the gasket ring and flywheel 13-4 page 3
S00.5322.01.20
Removing and installing the gasket ring and flywheel Edition 04.03
13-4 page 4 S00.5322.01.20
15 – Cylinder Head, Valve Gear
15-1 Removing and installing cylinder head
– Testing compression pressure ⇒ 15-1 page 5.
Note
♦ Removing and installing intake manifold ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
♦ Removing and installing exhaust manifold ⇒ Chapter 26-1
♦ Removing and installing coolant regulator housing ⇒ Chapter 19-1.
♦ If the cylinder head is replaced, the system must be completely filled with fresh coolant.

❑ check for distortion ⇒ Fig. 1
in 15-1 page 4
⇒ 15-1 page 4
❑ after replacing fill entire sys-
tem with fresh coolant
❑ repair the valve gear
⇒ Chapter 15-2/15-3
2 - Collar
❑ for engine with engine identi-
fication characters AWY
3 - Gasket
4 - Cap
5 - 20 Nm
6 - Lifting eye - on the left
7 - Cylinder head bolt
❑ replace
❑ observe the mounting in-
structions and sequence for
loosening and tightening
⇒ 15-1 page 4
8 - From connecting hose
fication characters BMD
9 - Ventilation hose with non-re-
turn valve
fication characters BMD
10 - From air filter
11 - Ventilation hose
❑ for engine with engine identification characters AWY
12 - Camshaft position sensor -G163-
13 - 8 Nm
Edition 12.04 Removing and installing cylinder head 15-1 page 1

S00.5322.03.20
14 - Gasket ring
15 - Bracket
❑ for the cable harness
16 - 0.045 MPa (0.45 bar) oil pressure switch -F1-, 25 Nm
❑ inspect ⇒ Chapter 17-3
17 - Gasket ring
❑ replace
18 - Cylinder head gasket
❑ replace
❑ check fitting position: The spare part number must be legible
19 - Bolts, 18 Nm
❑ for tensioning rail or possibly also guide rail
❑ replace
22 - Lifting eye - on the right

AZQ, BME
(1/4 turn)
❑ replace
2 - O-ring
3 - Camshaft position sensor
-G163-
4 - 8 Nm
5 - 10 Nm
6 - Bracket
❑ for the cable harness
7 - Cap
8 - Exhaust camshaft
❑ inspect axial play ⇒ Chapter
15-2
9 - Bearing cap for camshaft
❑ When installing pay attention
to the smooth operation of
the camshafts
❑ inspect axial play ⇒ Chapter
15-2
10 - Roller rocker arm
❑ do not get them confused
with each other.
❑ inspect roller bearings
❑ oil contact surface
❑ for installing, clip onto hy-
draulic supporting element
with locking clip
Removing and installing cylinder head Edition 12.04

15-1 page 2 S00.5322.03.20
11 - Supporting element
❑ do not get them confused with each other.
❑ with hydraulic valve clearance compensation
12 - Valve collets
13 - Valve spring retainer
14 - Valve spring
❑ removing and installing ⇒ Chapter 15-3; replacing the valve stem seal
15 - Valve stem seal
❑ replacing ⇒ Chapter 15-3
16 - 0.045 MPa (0.45 bar) oil pressure switch -F1-, 25 Nm
17 - Valve
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ Chapter 15-2
18 - Cylinder head bolt
❑ replace
❑ observe the mounting instructions and sequence for loosening and tightening ⇒ 15-1 page 4
19 - Cylinder head
❑ Inspect valve guides ⇒ Chapter 15-3
❑ check for distortion ⇒ Fig. 1 in 15-1 page 4
20 - Gasket ring
❑ Clean strainer if dirty
21 - 20 Nm
22 - Lifting eye
❑ replace
❑ Interlock camshafts with a pipe section -T10121- for removing and installing it ⇒ Chapter 13-3
25 - Washer
❑ replace
26 - Inlet camshaft
27 - 15 Nm
28 - Sliding block
29 - Cylinder head cover
❑ sealing surfaces must not be reworked.
❑ removing and installing ⇒ Chapter 15-2, removing and installing the camshaft

S00.5322.03.20
Fig. 1: Inspecting the cylinder head for distortion

♦ Straightedge
♦ Feeler gauge
Max. permissible distortion: 0.05 mm (minimum clear-

ance of straightedge base: 100 mm)
If the distortion is greater than 0.05 mm, replace cylinder
head.
Removing and installing cylinder head
Removing
– Remove the camshaft sprocket, if necessary the cam-
shaft sprockets ⇒ Chapter 13-3.
– Remove cylinder head cover ⇒ Chapter 15-2.
– Loosen the cylinder head screws in two stages and re-
move in the known order.
AWY, BMD

AZQ, BME
– Carefully remove the cylinder head.
Note
Do not lay the cylinder head on the surface with the head
combustion chamber - danger of damaging the spark
plugs.
Installing
Note
♦ Always replace the cylinder head bolts.
♦ 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.

15-1 page 4 S00.5322.03.20
♦ When conducting repairs sealant residues should be
removed from the contact surface of the cylinder head
using a chemical cleaner.
♦ Treat the new seal with the utmost care. Any damage
will result in leaks.
– Check whether both sleeves which are intended for

the guide of the cylinder head, are inserted into the
cylinder block above; insert if necessary.
– Fit on new cylinder head gasket. The legend (spare
part no.) must be legible.
– Insert the cylinder head.
– Insert new cylinder head screws into the screw con-
tact surface lightly oiled and tighten by hand.
– Tighten cylinder head in three stages in the following
order:
AWY, BMD
AZQ, BME
1. Pre-tighten with torque wrench:
Step I = 30 Nm
2. Tighten further with a rigid wrench:
Stage II = 1/4 turn (90°)

Stage III = 1/4 turn (90°)
Further installation occurs in reverse order. Pay attention

to the following:
♦ Carefully crank engine at least 2 revolutions to ensure
started.
Testing the compression
Test condition
• Engine oil temperature at least 30 °C

♦ Compression tester e.g. -1763-
♦ Spark plug wrench e.g. -3122 B-
Test sequence
– Disconnect the 4-pin plug plug connector from ignition
coils with a power output stage -N70-, -N127-, - N291-

S00.5322.03.20
⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24 if

necessary pull the ignition coils out slighty.
– Pull out with extractor -T10094- ignition coils with a
power output stage -N70-, -N127-, -N291- ⇒ 1.2/40;
– Disconnect all plug connections of the injection valves
⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
– Unscrew the spark plugs.
– Test compression with compression tester,
e.g.-V.A.G 1763-
Note
Use of tester ⇒ Operating Instructions.
– Operate starter until the tester no longer indicates a

pressure rise.
Compression readings
new Wear limit Difference be-

tween cylinders
min. 15 bar (1.5 11 bar (1.1 max. 3 bar (0.3
MPa) MPa) MPa)
– Screw in the spark plug and then tighten fully to 30

Nm.
– Install ignition coils with a power output stage -N70-,
-N127-, -N291- ⇒ 1.2/40; 1.2/47 Engine, Fuel Injec-
tion; Rep. Gr. 24.
– Plug in the plug connector for the ignition coils with the
power output stage and the injectors.
– Install engine cover with air filter ⇒ 1.2/40; 1.2/47 En-
gine, Fuel Injection; Rep. Gr. 24.
– Interrogate fault memory and erase ⇒ 1.2/40; 1.2/47
Note
Separating the plug connections causes faults to be
stored.

15-1 page 6 S00.5322.03.20
15-2 Repairing the valve gear - Part 1

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.
1 - Cylinder head cover

❑ sealing surfaces must not be
reworked.
❑ with integrated camshaft
bearings
⇒ 15-2 page 3, removing
and installing the camshaft
2 - 6 Nm + torque a further 90 (1/
4 turn)
❑ replace
3 - Camshaft
⇒ 15-2 page 3
❑ Pay attention to the marking
⇒ Fig. 2 in 15-2 page 2
4 - Roller rocker arm
with each other.
❑ inspect roller bearings
❑ for installing, clip onto hy-
draulic supporting element
with locking clip
5 - Supporting element
with each other.
❑ with hydraulic valve clear-
ance compensation
6 - Valve collets
7 - Valve spring retainer
8 - Valve spring
❑ replace springs as a set only
♦ Removing and installing and valves for a removed cylinder head ⇒ Chapter 15-3
♦ With cylinder head installed ⇒ Chapter 15-3, remove the valve stem seal
9 - Valve stem seal
❑ replacing ⇒ Chapter 15-3
10 - Cylinder head
❑ sealing surfaces on the camshaft side must not be reworked.
❑ Inspect valve guides ⇒ Chapter 15-3
11 - Valve
❑ do not re-mill, only grinding with the valve seat is permissible
❑ Valve dimensions ⇒ Fig. 3 in 15-2 page 2
Edition 12.04 Repairing the valve gear - Part 1 15-2 page 1

S00.5322.03.20
❑ reworking valve seats ⇒ Chapter 15-3
Fig. 1: Inspecting axial play of camshaft

MP 3-447
♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
Perform measurement with the supporting elements re-

moved and the cylinder head cover removed.
– Load camshaft at the middle camshaft bearing cap.

Wear limit: max. 0.20 mm
S15-0178
Fig. 2: Camshaft identification

Identification
Engine identifica- AWY BMD

tion characters
Camshaft „03D K“, „03D P“
„03D N“
Fig. 3: Valve dimensions
Note
The valves must not be reworked. Only grinding in with
grinding paste in the related valve seat is permissible.
AWY, BMD
Dimension Inlet valve Exhaust valve

∅a mm 34,5 28
∅b mm 5,98 5,96
c mm 99,25 99,25
α ∠° 45 45

AZQ, BME
Repairing the valve gear - Part 1 Edition 12.04

15-2 page 2 S00.5322.03.20
Dimension Inlet valve Exhaust valve

∅a mm 29,5 26
∅b mm 5,973 5,953
c mm 100,9 100,57
α ∠° 45 45
Removing and installing camshaft

AWY, BMD

♦ Sealant -D 154 103 A1-
♦ Grease -G 052 735 A2-
Removing
– Remove the camshaft sprocket ⇒ Chapter 13-3.
– Remove assembly device -T10120-.
– Unscrew screws from the cylinder head cover.
– Remove the cylinder head cover and use slight
knocks from above to loosen as necessary (the cylin-
der head cover sits on the fitting sleeves).
– Carefully lift out camshaft and place down on a clean
surface.
– Remove the roller rocker arm together with the hy-
draulic supporting elements and lay aside on a clean
surface.
Ensure that the roller rocker arm and the supporting
element is not mixed up.
– Cover the bore holes for the hydraulic supporting ele-

ments and valve springs with clean cloth.
– Cover or close the oil channel for camshaft bearings.
– Remove residual sealant on the cylinder head and on
the cylinder head cover using flat scraper.
Note
Sealant residues must not remain in the cylinder head.
– Clean the camshaft bearings on the cylinder head and

on the cylinder head cover.
Installing
• Sealing surfaces must be free of oil and grease.

S00.5322.03.20
– Oil the hydraulic supporting elements and insert at the

same location together with the corresponding roller
arms as when removing into the cylinder head.
Make sure all roller rocker arms -1- are correctly posi-
tioned on the end of valve stems -2- and on the corre-
sponding hydraulic supporting elements -3-.
– Coat the camshaft bearing -A- on the cylinder head

and the cylinder head cover with a constant layer of
grease -G 052 735 A2-.
– Cut off nozzle of tube of the sealant -D 154 103 A1- at
the front marking (∅ of nozzle approx. 2 mm).
– Apply sealant bead to the clean sealing surface of the
cylinder head, as shown in the illustration.
♦ Thickness of sealant bead -B-: 2…3 mm.
♦ Be careful how you apply sealant in the areas of -ar-
rows- so that excess sealant is not pushed into the
bearing and thus the camshaft is not glued solid by
this.
♦ The sealant must be run past on the inside in the area
of the bolt holes.
Note
♦ The sealant bead must not be thicker than 3 mm oth-
erwise excess sealant may get into the oil pan and
clog the strainer in the oil pump.
♦ The cylinder head cover must be installed within 15
minutes after applying the silicone sealant.
– Place the camshaft in such a way that the opening of

the OT -arrow- points forwards towards exhaust gas
channels.
– Place the cylinder head cover so that the sleeves -A-
in the bore holes grip in the cylinder head.

15-2 page 4 S00.5322.03.20
– Insert new fixing screws and tighten in the direction
given.

turn)
– Wipe away exuded sealant particularly in the area

steering wheel cover.
AZQ, BME

♦ Sealant -D 154 103 A1-
♦ Grease -G 052 735 A2-
Removing
Remove cylinder head cover
Note
Sealing surfaces of cylinder head must not be reworked.

– Remove the camshaft sprockets ⇒ Chapter 13-3.
– Remove pipe sections -T10123-
– Pull out with extractor -T10094- ignition coils with a
power output stage -N70-, -N127-, -N291- ⇒ 1.2/40;
– Slacken the bolts of the cylinder head cover crosswise
from outside to inside and remove.
– Carefuelly remove the cylinder head cover and apply
slight knocks with a rubber-headed hammer from
above to loosen as necessary (the cylinder head cov-
er sits on the fitting sleeves).
– Remove residual sealant on the cylinder head and on
the cylinder head cover using flat scraper.
Note
Sealant residues must not remain in the cylinder head.
Remove the camshafts
– Slacken the screws of the camshaft bearing in the giv-

en sequence and remove.
– Carefully remove camshaft bearing cap.
– Carefully lift out camshafts and place down on a clean
surface.
Installing
Install camshafts

S00.5322.03.20
Note
Lug of inlet camshaft must be positioned on the hole for
the hall sender.
– Coat the camshaft bearing on the cylinder head and

on the camshaft covers with a constant layer of
grease -G 052 735 A2-.
– Carefully insert camshafts into the cylinder head cov-
er.
– Fit on camshaft bearing cap.
– Install screws of camshaft bearing in given sequence
and tighten by hand.
Make sure that the camshaft bearing caps are not tilted.

turn)
Pay attention to smooth operation of the camshafts.
Install cylinder head cover
• Sealing surfaces must be free of oil and grease.

Note
When turning the camshaft the valves may touch the pis-
ton in TDC.
– Cut off nozzle of tube of the sealant -D 154 103 A1- at

the front marking (∅ of nozzle approx. 2 mm).
– Apply a narrow even sealant bead on the clean seal-
ing surface of the cylinder head.
♦ Thickness of sealant bead: 2…3 mm.
♦ The sealant must be run past on the inside in the area
of the bolt holes.
Note
♦ The sealant bead must not be thicker than 3 mm oth-
erwise excess sealant may get into the oil ducts and
can cause engine damage.
♦ The cylinder head cover must be installed within 15
minutes after applying the silicone sealant.
– Make sure all roller rocker arms are correctly posi-

tioned on the end of valve stems -1- and on the rele-
vant hydraulic supporting elements -2-.

15-2 page 6 S00.5322.03.20
– Carefully fit cylinder head cover onto the fitting sleves
-arrows- vertically from above into the cylinder head.
– Insert the new fixing screws and tighten diagonally

and evenly from the inside to the outside.
Make sure that the cylinder head cover is not tilted.

turn)
– Wipe away exuded sealant particularly in the area

steering wheel cover.
Note
After installing the cylinder head cover, allow the sealant
to dry for about 30 minutes.

S00.5322.03.20

15-2 page 8 S00.5322.03.20
15-3 Repairing the valve gear -

Part 2
Replacing valve stem seal
Removing
AWY, BMD

♦ Valve spring assembly lever -MP 1-211-
♦ Valve supporting plate -MP 1-218-
♦ Assembly device -MP 1-213-
♦ Gasket ring extractor -MP 1-230-
♦ Insertion tool -MP 1-233-
• Cylinder head and camshaft removed

• Components removed (intake manifold, exhaust man-
ifold, spark plugs etc.)
(with cylinder head removed)
Note
Build up pressure with installed cylinder head, see proce-
dure for engine with engine identification characters
AZQ, BME.
– Fit cylinder head onto the valve supporting plate.

– Screw on assembly device -MP 1-213-.
Always use cylinder head cover screws (M7) -1- with
4 M8 washers -2-.
– Place the valve spring assembly lever -MP 1-211- on

the valve spring and press the valve springs together.
– Remove the safety valve collets.
Note
Release collets that are tight by striking with light blows of
a hammer on the valve lever.

S00.5322.03.20
– Pull off valve stem seal with extractor for valve stem
seal -MP 1-230-.
Press sleeve -1- down slightly during this step.
Installing
– In order to avoid damage to the new valve stem seals,
fit the supplied plastic sleeve -A- onto the valve stem.
– Oil valve stem seal -B-, insert into the insertion tool
-MP 1-233- and carefully push onto the valve guide.
– Remove plastic sleeve.
Removing
AZQ, BME

♦ Supporting device -MP 9-200-
♦ Spark plug wrench, e.g. -3122B-
♦ Assembly device -MP 1-229- with pressure plate
- MP 1-229/1-
♦ Gasket ring extractor -MP 1-230-
♦ Insertion tool -MP 1-233-
♦ Pressure pad -T 30004- with replaceable stud
-T30004/1-
♦ Counterholder -MP 1-216-
♦ Pressure hose -MP 1-210-
(with cylinder head installed)
Note
Use valve supporting plate -MP 1-218- with cylinder head
removed, see procedure for engine with engine identifi-
cation characters AWY, BMD.

– Remove cylinder head cover ⇒ Chapter 15-2.
– Unscrew the spark plugs with spark plug wrench
-3122B-.

15-3 page 2 S00.5322.03.20
– Remove roller rocker arm and place on a clean sur-
face. Make sure that you do not mix up the roller rock-
er arms. MP1-229 MP1-229/1
– Position piston of the relevant cylinder in bottom dead
centre.
– Screw on assembly device -MP 1-229- with pressure
plate -MP 1-229/1-.
– Screw the pressure hose -MP 1-210- in the spark plug
thread.
– Connect pressure hose to compressed air (min. 0.6
MPa (6 bar) overpressure) and remove the valve
springs with device -MP 1-229-.
– Pull off valve stem seals with extractor -MP 1-230-.
Installing
MP1-210
– Insert the supplied plastic bushings on the relevant
valve stem. This will prevent any damage to the new S15-0158
valve stem seals.
– Insert the new valve stem seal -B- in the insertion tool
-MP 1-233-.
MP1-233
– Oil the sealing lip of the valve stem seal and carefully
slide onto the valve guide -A-.
Install cylinder head cover ⇒ Chapter 15-2.
Installing the camshaft sprockets and setting the timing B
⇒ Chapter 13-3.
Further installation occurs in reverse order. A
Inspect valve guides

• Cylinder head and valve spring removed
S15-0161
♦ Dial gauge
Procedure
Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
– Insert valve into guide. End of valve stem must be

flush with end of guide (without valve stem seal).
Because of the different stem diameters only use inlet
valve in inlet guide or outlet valve in outlet guide.

S00.5322.03.20
– Determine valve rock.
Wear limit
Inlet valve guide Exhaust valve guide

0,5 mm 0,55 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

♦ Dial gauge
♦ Micrometer or caliper gauge
♦ NAC milling cutter for reworking valve seats
♦ Grinding paste
Note
♦ When carrying out repairs on engines with leaking
valves, it is not sufficient to machine or replace the
valve seats and valves. It is also necessary to inspect
the valve guides for wear, particularly on engines with
a high mileage ⇒ 15-3 page 3. If the wear limit is ex-
ceed, replace cylinder head.
♦ Do not re-mill valve seats. Only opposite grinding in of
the valve with the corresponding valve seat with grind-
ing paste is permissible, in order to obtain a proper
contact pattern. Calculate the maximum permissible
reworking dimension before commencing ⇒ 15-3
page 4. If the reworking dimension is exceeded, prop-
er operation of the valve gear is no longer assured and
the cylinder head must be replaced.
Calculating maximum permissible reworking di-

mension
– Insert valve and press firmly against the valve seat.
Note
♦ If the valve is replaced when carrying out repair work,
use a new valve for the measurement.
♦ If no new valve is used, then the valve disc must be
thoroughly cleaned.
AWY, BMD
– Attach universal dial gauge holder with bolt to cylinder

head.

15-3 page 4 S00.5322.03.20
– Measure distance -h- from the bottom edge of the cyl-
inder head to the bottom edge of the valve disc. Meas-
ure in the immediate vicinity of the recess from the
valve disc center -arrows-.
– Measure valve length -c-.
Note
Measure dimension -c- in the immediate vicinity of the re-
cess from the valve disc center.
– Calculate max. permissible reworking dimension from

the distances -c, h- measured and from the maximum
dimension.
Maximum dimension for both valves: 103.7 mm
The maximum permissible reworking dimension =
103.7 - (c + h).
Example:
Maximum dimension for both 103,7 mm

valves
- (Valve length -c- + measured (99,2 + 4,35) mm
distance -h-)
= max. permissible reworking di- 0,15 mm
mension1)
1) The max. permissible reworking dimension is shown in the figures
for reworking the valve seats as dimension „b“.

AZQ, BME
– Measure distance between the valve stem end and

the upper face of the cylinder head.
– Calculate max. permissible reworking dimension from
the distance measured and the minimum dimension.
Minimum dimension: for inlet and exhaust 7.6 mm

valve
„Measured distance“ - „minimum dimension“ = „max. per-

missible reworking dimension“.
Example:

S00.5322.03.20
Measured distance 8.0 mm

- Minimum dimension 7.6 mm
= max. permissible reworking dimension 1) 0.4 mm
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, if
necessary repeat measurement with a new valve. If the
max. permissible reworking dimension is again 0 mm, re-
place cylinder head.
Reworking inlet valve seat

AWY, BMD
Di- Inlet valve seat

men
sion
∅a mm 33,4
b mm Max. permissible reworking dimension
c mm 1,5...1,7
Z Bottom edge of cylinder head
α 45° valve seat angle
β 30° top correction angle
γ 60° bottom correction angle
S Combustion chamber floor area

AZQ, BME
Di- Inlet valve seat

men
sion
∅a mm 28,7
c mm 1,5...1,8
Reworking exhaust valve seat

AWY, BMD

15-3 page 6 S00.5322.03.20
Di- Exhaust valve seat

men
sion
∅a mm 27,1
c mm 1,6...1,8

AZQ, BME
Di- Exhaust valve seat

men
sion
∅a mm 25,0
c mm approx. 1.8
Procedure
Reworking can be carried out by hand while complying
with the following conditions:
• Wear limit of valve guides must not exceed the per-

missible dimension ⇒ 15-3 page 3.
• 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

S00.5322.03.20
– Match diameter of milling cutter to diameter of valve

seat.
Valve seat Mill- Milling Mill-

ing cut- cutter ing cut-
ter 90 120 ter 60
mm mm mm
AWY, 36 38 21/34
BMD 90°
Inlet engine
valve AZQ,
BME en-
32 32 21/34 1.
gine
AWY, 30 30 21/34
BMD 120°
Exhaust engine
valve AZQ, 30 30 21/34 a
BME en- 2.
gine
Milling sequence
60°
1 - Machine valve seat with 90° milling tool until until a
perfect contact pattern is achieved. (Do not exceed
maximum permissible reworking dimension!)
3.
2 - Chamfer top correction angle with 120° milling cut- c
ter until the valve seat diameter -a- (⇒ 15-3
page 6) is achieved.
3 - Chamfer bottom correction angle with 60° milling S15-0062
cutter until valve seat width -c- (⇒ 15-3 page 6) is
achieved.
– 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 -h-
again and calculate the maximum permissible reworking
dimension ⇒ 15-3 page 4. S15-0063
Note
If the reworking dimension is exceeded, proper operation
of the valve gear is no longer assured and the cylinder
head must be replaced.

15-3 page 8 S00.5322.03.20
17 – Lubrication
17-1 Removing and installing parts of the lubrication system - Part

1
Note
♦ If considerable quantities of metal swarf or abrasion (caused by rubbing damage such as damage to the crankshaft
and conrod bearings) is found in the engine oil when carrying out engine repairs, it is necessary to determine the
cause of the rubbing damage and replace the damaged parts, then carefully clean the oil galleries in order to avoid
consequential damage.
♦ The oil level must lie between the markings and not be above the "max" marking - risk of damage to catalytic con-
verter!
Check the engine oil, amount of oil, oil specification
⇒ Inspection and Maintenance
1 - 0.045 MPa (0.45 bar) oil pres-

sure switch - F1-, 25 Nm
❑ green insulation
❑ cut open gasket ring if leak-
ing and replace
2 - Dowel sleeves
3 - Oil pump
❑ with the overpressure valve
⇒ Chapter 17-2
4 - 24 Nm
5 - Oil pan
❑ clean sealing surface before
installing
❑ before installing, coat with
silicone sealant
-D 176 404 A2- ⇒ Chapter
17-2
6 - 9 Nm
7 - Gasket ring
❑ replace
8 - Oil drain plug, 30 Nm
9 - 8 Nm
10 - Cover
❑ for oil pump chain
(1/4 turn)
❑ replace
❑ check fitting position
13 - Oil pump chain
14 - Chain tensioner for the oil pump drive
Edition 04.03 Removing and installing parts of the lubrication system - Part 1 17-1 page 1
S00.5322.01.20
15 - Guide bolts, 15 Nm
❑ for chain tensioner for the oil pump drive
16 - Chain sprocket on the crankshaft for the oil pump drive
❑ not interlocked on the crankshaft
17 - O-ring
18 - Housing
❑ Replace silicone sealant sealing with O-Ring ⇒ item 17
19 - Gasket ring
❑ Replace in case of damage ⇒ Chap. 13-4.
❑ Replace together with housing ⇒ item 18
❑ replace
❑ Interlock crankshaft with a fixing bolt -T10121- for removing and installing it ⇒ Chapter 13-3
22 - O-ring
23 - Oil level and oil temperature sender -G266-
❑ only for vehicles with WIV
❑ check ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
24 - Gasket ring
25 - Guide tube
26 - Dipstick
❑ the oil level must not be above the „max“ marking!
❑ Inspect engine oil level ⇒ Inspection and Maintenance
28 - Support
❑ for engine with engine identification characters AWY
❑ for the oil filter
29 - Oil filter
❑ removing and installing oil filter insert ⇒ 17-1 page 3
❑ disassembling and assembling ⇒ 17-1 page 4
30 - 24 Nm
Removing and installing parts of the lubrication system - Part 1 Edition 04.03
17-1 page 2 S00.5322.01.20
Removing and installing oil filter insert
a
– Screw out the screw plug from the nose elevation -a-
-arrow- and leave in this position for at least one
minute to allow the oil to run out of the oil filter insert.
Note a
If the screw plug is removed completely without waiting a
while the oil will flow into the DC generator.
– Remove the screw plug with the oil filter insert holder.
– Lightly knock the screw plug with the oil filter insert
holder -1- on a fixed base -3- (e.g. wooden plate) -ar-
row-.
This loosens the oil filter insert -2-.
– Place the screwdriver carefully in the groove -arrow-

of the screw plug and plug off the O-ring.
– Insert the new O-ring.
– Insert the new oil filter insert and tighten screw plug to
25 Nm.
S00.5322.01.20
Dismantling and assembling the oil filter

1 - Screw plug with the oil filter
insert holder, 25 Nm
❑ do not separate
2 - Gasket ring
❑ replace
❑ delivered with the oil filter in-
sert
3 - Oil filter element
⇒ 17-1 page 3
4 - 8 Nm
5 - Support
6 - Gasket
7 - 24 Nm
8 - Oil filter holder
9 - O-rings
17-1 page 4 S00.5322.01.20

parts of the lubrication
system - Part 2
Removing and installing oil pan

♦ Silicone sealant -D 176 404 A2-
♦ Hand-held power drill with plastic brush insert
♦ Flat scraper
♦ Protective goggles
Removing
– Remove lower engine guard -arrows-.

– Drain engine oil. S10-0135
– Release the oil pan's fixing screws.

– Remove oil pan, if necessary release by applying
slight blows with a rubber-headed hammer.
– Use a flat scraper to remove sealant residues on the
crankcase.
– Use a rotating plastic brush to remove sealant resi-
dues on the oil pan (wear protective goggles).
– Clean sealing surfaces, they must be free of oil and
grease.
Installing
Note
♦ Pay attention to the 'use by date' on sealant.
N17-0012
♦ The oil pan must be installed within 5 minutes after ap-
plying the silicone sealant.
– Cut off nozzle tube at the front marking (∅ of nozzle

approx. 3 mm).
A17-0081
S00.5322.00.20
– Apply silicone sealant -A- to the clean sealing surface

of the oil pan, as shown in the illustration.
♦ Thickness of sealant bead: 2…4 mm
Note
The sealant bead must not be thicker than 4 mm other-
wise excess sealant may get into the oil pan and clog the
strainer in the oil pump.
– Fit oil pan immediately and lightly tighten all bolts.

– Tighten all bolts fully in the given sequence:
Tightening torque: 9 Nm
Note
After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled in.
Removing and installing oil pump
Removing
– Removing the oil pan ⇒ 17-2 page 1.
– Screw out screw -1- and unclip the chain guard for the
oil pump -2- in the area of -arrow-.
– Release screw -2-.

– Swing the chain tensioner for the oil pump drive -4- in
the -direction of the arrow- and remove the sprocket
for the oil pump from the oil pump.
The sprocket for the oil pump stays in the chain for the
oil pump.
– Screw out screws -1- and remove the oil pump from
the cylinder block.
Installing
Installation is carried out in the reverse order. Pay atten-
tion to the following:
♦ The oil pump must sit in the sleeves then tighten to 24
Nm.
♦ Replace the sprocket screw for the oil pump, tighten-
ing torque: 20 Nm + torque a further 90° (1/4 turn)
17-2 page 2 S00.5322.00.20
17-3 Testing oil pressure and

oil pressure switch
♦ Oil pressure tester (e.g. - V.A.G 1342-)
♦ Diode test lamp (e.g. -V.A.G 1527 B-)
♦ Adapter cable set (e.g. -V.A.G 1594 A- or
-V.A.G 1594 C -)
♦ Current flow diagram
Function of dynamic oil pressure warning system if

oil pressure low
The oil pressure switch is opened when pressureless and
closed when the switching pressure is reached.
The oil pressure warning is activated for about 10 sec-
onds after the ignition is switched on („terminal 15 on“).
Activation delay of oil pressure warning: approx. 3 s.
Off delay of oil pressure warning: approx. 5 s.
Test pressure warning light
After the ignition is switched on and engine not running,
the oil pressure warning light in the dash panel insert
must come on for about 3 seconds and then go out. The
check is ended when the engine is started.
Warning criteria
The visual oil pressure warning is switched on (oil pres-
sure warning light flashes) and the buzzer sounds 3 times
as an audible warning if one of the following conditions
exists:
♦ „Ignition on“, engine not running, oil pressure switch
closed
♦ Engine speed greater than 1500 rpm, oil pressure
switch opened
– At an engine speed greater than 5000 rpm, the oil

pressure warning is not cancelled, also not if the oil
pressure switch is closed. The oil pressure warning is
cancelled once engine speed is below 5000 rpm.
– If the oil pressure switch is opened for only 0.5 … 3
seconds at an engine speed of more than 1500 rpm,
this is stored in the dash panel insert. If this situation
occurs 3 times when the engine is running, the oil
pressure warning is immediately activated and is also
not cancelled below an engine speed of 1500 rpm.
The oil pressure warning is cancelled once the oil
pressure switch is closed for more than 5 seconds at
an engine speed of more than 1500 rpm, or if the „ig-
nition is switched off“.
Test conditions
Edition 08.02 Testing oil pressure and oil pressure switch 17-3 page 1
S00.5322.00.20
• Inspect engine oil level to ensure that it is OK

⇒ Inspection and Maintenance
• Oil pressure warning light -K3- must come on for
about 3 seconds when the ignition is switched on.
• Engine oil temperature at least 80 °C (radiator fan
must have run at least once).
Testing oil pressure switch
Detach cable from oil pressure switch.
– Unscrew oil pressure switch and screw in oil pressure V.A.G 1342
tester e.g. -V.A.G 1342-).
– Screw oil pressure switch -2- into -V.A.G 1342 -.
– Connect brown cable -1- of tester to earth (-).
– Connect diode test lamp (e.g. -V.A.G 1527 B-) to oil
pressure switch -2- and battery positive (+).
The LED must not light up.
+ -
– If the LED lights up, replace the oil pressure switch.
1
– Start engine and slowly increase engine speed. 2
– At 0.03…0.06 MPa (0.3…0.6 bar) the LED must light
up, if not replace oil pressure switch. A17-0025
Testing oil pressure
– Unscrew oil pressure switch and -V.A.G 1342- scew

in.
– Screw oil pressure switch into -V.A.G 1342-.
– Start engine (engine oil temperature at least 80 °C).
• Oil pressure at 2000 rpm: at least 0.2 MPa (2 bar)
• At a higher engine speed the oil pressure must not be
greater than 0.6 MPa (6 bar).
If the specified value is not reached:
– Eliminate any mechanical damage, e.g. bearing dam-

age.
– Replace oil pump with pressure relief valve
⇒ Chapter 17-2.
If the specified pressure is exceeded:
– Inspect oil galleries.

– Replace oil pump with pressure relief valve if neces-
sary ⇒ Chapter 17-2.
Testing oil pressure and oil pressure switch Edition 08.02

17-3 page 2 S00.5322.00.20
19 – Cooling

parts of the cooling sys-
tem - Summary of compo-
nents
Note
♦ When the engine is warm the cooling system is under
pressure. Reduce pressure before repairs.
♦ The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.
♦ Use pliers for spring strap clips for installing the spring
strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress,
without them touching any other components (pay at-
tention to the marking on the coolant connection and
hose).
Parts of the cooling system fitted to body ⇒ 19-1 page 2.
Parts of cooling system engine side ⇒ 19-1 page 3
connection diagram for coolant hoses ⇒ 19-1 page 5
Draining coolant and filling up ⇒ Chap. 19-2
Coolant mixing ratios ⇒ Chapter 19-2.
Edition 12.04 Removing and installing parts of the cooling system - Summary of 19-1 page 1
S00.5322.03.20 components
Parts of the cooling system fitted to body

1 - Radiator
⇒ Chapter 19-3
2 - O-ring
❑ replace
3 - Top coolant hose
❑ attached to radiator by a
spring strap clamp
❑ connection diagram for cool-
ant hoses ⇒ 19-1 page 5
4 - Cap
❑ Check pressure ⇒ Chapter
19-2
5 - Connector
6 - Double screw, 2 Nm
7 - Fan shroud
8 - 5 Nm
9 - 5 Nm
10 - Expansion reservoir
❑ Inspect cooling system for
leaks ⇒ Chapter 19-2
11 - Retaining clip
❑ for ventilator cable
❑ check tightness
12 - Auxiliary fan
❑ on vehicles with air condi-
tioning, or additional equip-
ment
13 - Fan holder
14 - Fan for radiator
15 - Bottom coolant hose
❑ attached to radiator by a spring strap clamp
❑ connection diagram for coolant hoses ⇒ 19-1 page 5
16 - Bracket
❑ for fan connector
17 - Thermoswitch for radiator fan -F18-, 35 Nm
❑ for electric fan
❑ switching temperatures:
1. Stage
♦ on: 91…97 °C
♦ off: 84…91 °C
2. Stage
♦ on: 99…105 °C
♦ off: 91…98 °C
18 - Bottom radiator bearing
❑ black
19 - 5 Nm
Removing and installing parts of the cooling system - Summary of Edition 12.04
19-1 page 2 components S00.5322.03.20
20 - Top radiator bearing
❑ white
Parts of cooling system engine side
Coolant regulator housing
1 - Sender for the coolant tem-

perature -G62-
2 - O-ring
3 - Retaining clip
4 - 8 Nm
5 - Coolant regulator housing
❑ with coolant regulator
❑ must be replaced completely
❑ The function of the coolant
regulator cannot be checked
6 - Coolant pipe
7 - Gasket ring
8 - To connection fitting on the
heat exchanger
❑ connection on the duct on
the right (in the direction of
travel)
9 - From connection fitting on
the heat exchanger
❑ connection on the duct on
the left (in the direction of
travel)
10 - From bottom radiator connec-
tion
11 - To top radiator connection
❑ connection diagram for coolant hoses ⇒ 19-1 page 5
Coolant pump
1 - 22 Nm
❑ Hold the belt pulley with V-
ribbed belt attached for loos-
ening and fixing it
2 - Belt pulley
❑ for the V-ribbed belt
3 - 24 Nm
4 - Coolant pump
❑ check smooth operation
❑ Inspect the plastic screw for
tears
❑ the pump should be replaced
completely if the seal on it is
damaged
⇒ Chapter 19-3
5 - 24 Nm
❑ do not mix up with other
screws
❑ cement should be spread on
the thread
Connection diagram for coolant hoses
For engine with engine identification characters AWY, BME
1 - Radiator
⇒ Chapter 19-3
2 - Ventilation tube
3 - Crankcase
4 - Coolant pump
⇒ Chapter 19-3
6 - Coolant pipe
7 - Heat exchanger
⇒ 19-1 page 3
9 - Quick coupling
❑ for radiator connections
❑ replace the gaskets if dam-
aged then wet with coolant
additive before inserting
For engine with engine identification characters BMD
1 - Ventilation hose
2 - PCV ventilation pipe
❑ with heating through coolant
3 - Coolant pipe
4 - Heat exchanger
⇒ 19-1 page 3
6 - Quick coupling
❑ for radiator connections
❑ replace the gaskets if dam-
aged then wet with coolant
additive before inserting
7 - Radiator
⇒ Chapter 19-3
8 - Crankcase
9 - Coolant pump
⇒ Chapter 19-3

tem - Part 1
Information concerning the mixture ratios ⇒ 19-2 page 1
Draining and filling up coolant

Coolant capacity approx. 5.0 ltr.

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

S10-0135
– Remove noise insulation -arrows-.
– Place a catch pan under the engine.
– Turn the drain plug -arrow- on the radiator to the left
and draw backwards; fit auxiliary hose onto connec-
tion if necessary.
Note
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original
spare parts catalogue ŠKODA or from the list of allowed
coolant additives ⇒ Inspection and Maintenance.
Recommended mixture ratios: A10-0118
Antifreeze pro- Antifreeze con- Drinking

tection down to centration1)2) water2)
-25 °C 40 % (2,0 ltr.) 60 % (3.0 litres)
-35 °C 50 % (2.5 litres) 50 % (2.5 litres)
1) In order to obtain adeqaute corrosion protection the antifreeze con-
centration must not be less than 30% and not more than 60 %; the
antifreeze protection and cooling efficiency are reduced as the con-
centration increases.
2) The coolant amount may differ according to the version of the vehi-
cle.
– Insert and tighten the coolant drain plug.

– Remove the coolant temperature sender.
Edition 08.02 Removing and installing parts of the cooling system - Part 1 19-2 page 1
S00.5322.00.20
– Fill up with with coolant slowly until the sender for the
coolant temperature is visible in the filler neck.
– Install the coolant temperature sender
– Fill up coolant gradually up to „max“ marking on the
expansion reservoir.
– Close expansion bottle.
– Run engine until fan starts.
WARNING!
2
G1
open carefully.
– Check the level of coolant and top up if necessary.

When engine is at operating temperature the coolant
S19-0077
level must be at the „max“ marking, when engine is
cold between the „min“ and „max“ markings.
Checking the coolant system for tight-

ness
♦ Coolant system tester, e.g. -V.A.G 1274-
♦ Adapter, e.g. -V.A.G 1274/8 -
♦ Adapter, e.g. -V.A.G 1274/9 -
Test condition
• Engine must be warm
Test sequence
WARNING!
open carefully.
– Open the cap of the coolant expansion reservoir.

– Position coolant system tester, e.g. -V.A.G 1274- with
adapter, e.g. - V.A.G 1274/8- on the coolant expan- V.A.G 1274
sion bottle.
– Using the hand pump of the tester generate an over-
pressure of approx. 0.14 Mpa (1.4 bar).
– If the pressure drops determine location of the leaks
and repair them.
V.A.G 1274/8
Testing the pressure relief valve in the cap
– Screw cap onto the tester using an adapter, e.g.
2
G1
-V.A.G 1274/9 -.
S19-0082
Removing and installing parts of the cooling system - Part 1 Edition 08.02
19-2 page 2 S00.5322.00.20
– Using the hand pump of the tester generate an over-
pressure of approx. 0.16 Mpa (1.6 bar).
– The pressure relief valve should open at a pressure of
0.14…0.16 MPa (1.4… 1.6 bars).
S00.5322.00.20
19-2 page 4 S00.5322.00.20

tem - Part 2
Removing and installing radiator

Removing
– Drain coolant ⇒ Chapter 19-2.
– Remove connector -1- from thermo-switch for the 1
coolant fan -F18- and disconnect plug connection -2-
on the holder of the air duct scoop.
To do so press the latch clips. 2
There are 2 plug connections on vehicles fitted with air
conditioning.
– Separate the coolant hose from the radiator at the top 3

and bottom of the connection fittings.
To do so pull the retaining clip -3- up to the stop and
remove the quick coupling towards the rear.
– Remove the lock carrier with component parts

S19-0078
⇒ Body work; Rep. Gr. 50.
WARNING!
Do not open the refrigerant circuit of the air condi-
tioning system.
– Attach the condenser with the radiator to the engine or

support.
Note
♦ Do not suspend the condenser to the wires.
♦ Do not fold the condenser wires.
S19-0081
– Release the bolts securing the condenser -arrows-
and remove radiator with fan.
Installing
♦ Top up coolant ⇒ Chapter 19-2.
S00.5322.00.20
Removing and installing coolant pump

Components and tightening torques ⇒ Chapter 19-1
Removing
– Drain coolant ⇒ Chapter 19-2.
– Only slacken the bolts of the coolant pump belt pulley,
do not remove them.
– Remove belt pulley from the coolant pump.
– Unscrew coolant pump.
Installing
♦ Inspect the plastic screw for the coolant pump for
tears.
♦ Top up coolant ⇒ Chapter 19-2.
19-3 page 2 S00.5322.00.20
20 – Fuel Supply

parts of the fuel supply
system
For engine with engine identification characters AWY
⇒ 2.0/85 TDI Engine, Mechanical Components;
Rep. Gr. 20
AZQ, BMD, BME
⇒ 1.4/55; 1.4/74 Engine - Mechanical Components;
Rep. Gr. 20
Removing and installing fuel tank with

attached parts and fuel filter
⇒ 2.0/85 kW Engine, Mechanics; Rep. Gr. 20
AZQ, BMD, BME
Rep. Gr. 20
Safety precautions when working on the

fuel supply system
⇒ 2.0/85 kW Engine, Mechanics; Rep. Gr. 20
Rules of cleanliness
⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
Removing and installing the fuel delivery

unit
Removing and installing the fuel gauge

sender
Removing and installing the fuel tank

AZQ, BMD, BME
Edition 12.04 Removing and installing parts of the fuel supply system 20-1 page 1
S00.5322.03.20

Rep. Gr. 20
Inspecting the fuel delivery unit and fuel

system
AZQ, BMD, BME
Rep. Gr. 20
Inspecting the operating and holding

pressure of the fuel, inspecting the non-
return valve of the fuel delivery unit
⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24
Disconnecting the fuel delivery unit with

crash signal
Removing and installing parts of the fuel supply system Edition 12.04
20-1 page 2 S00.5322.03.20
20-2 Inspecting the electronic

power control (electronic
throttle)
⇒ 2.0/85 kW Engine - Mechanics; Rep. Gr. 20
Edition 08.02 Inspecting the electronic power control (electronic throttle) 20-2 page 1
S00.5322.00.20
Inspecting the electronic power control (electronic throttle) Edition 08.02

20-2 page 2 S00.5322.00.20
20-3 Activated charcoal filter

system
Summary of components of activated

charcoal filter system
⇒ 2.0/85 kW Engine - Mechanics; Rep. Gr. 20
Edition 08.02 Activated charcoal filter system 20-3 page 1

S00.5322.00.20
Activated charcoal filter system Edition 08.02

20-3 page 2 S00.5322.00.20
26 – Exhaust System

parts of the exhaust sys-
tem
Note
Always replace gaskets and self-locking nuts.
For engine with engine identification characters AWY, AZQ
1 - Hot air collector/shield

2 - 8 Nm
3 - Exhaust manifold with inte-
grated catalytic converter
❑ Check catalytic converter
⇒ 1.2/40; 1.2/47 Engine,
Fuel Injection; Rep. Gr. 01
4 - Lambda probe -G39-, 50 Nm
❑ pay attention to the spare
part number
❑ in front of the catalytic con-
verter
❑ 4-pin connector for engine
with engine identification
characters AWY
❑ 6-pin connector for engine
with engine identification
characters AZQ
❑ coat only thread with hot bolt
paste -G 052 112 A3-; paste
must not get into the slot of
the probe body
❑ Check Lambda probe before
catalyst -G39- und lambda
control ⇒ 1.2/40; 1.2/47 En-
gine, Fuel Injection;
Rep. Gr. 24.
5 - Gasket
❑ replace
6 - Shield plate - short
❑ for vehicles without air condi-
tioning
7 - Shield plate - extended
❑ for vehicles with an air conditioning system
8 - 23 Nm
9 - Front exhaust pipe
❑ for engines complying with exhaust emission standard EU-4, EU-3 DDK
❑ for engines with engine identification characters AZQ complying with exhaust emission standard EU-2 DDK
10 - Clamping sleeve
❑ align exhaust system free of stress before fitting on ⇒ 26-1 page 4
❑ Fitting position: bolts at bottom and horizontal
❑ Tighten bolted connections evenly
Edition 12.04 Removing and installing parts of the exhaust system 26-1 page 1
S00.5322.03.20

❑ for engines with engine identification characters AWY complying with exhaust emission standard EU-2 DDK
12 - Retaining strap
13 - 20 Nm
14 - Support
15 - 40 Nm
❑ replace
❑ coat stud bolts of exhaust manifold with hot bolt paste -G 052 112 A3- before installing.
16 - Lambda probe downstream of catalytic converter -G130-, 50 Nm
❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
❑ Check Lambda probe after catalyst -G130- und lambda control ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection;
Rep. Gr. 24.
17 - Gasket
❑ replace
18 - 25 Nm
❑ replace
For engine with engine identification characters BMD, BME
1 - Shield
2 - 8 Nm
3 - Exhaust manifold with inte-
grated catalytic converter
part number
❑ Check catalytic converter
⇒ 1.2/40; 1.2/47 Engine,
Fuel Injection; Rep. Gr. 01
4 - Lambda probe -G39-, 50 Nm
part number
❑ in front of the catalytic con-
verter
❑ coat only thread with hot bolt
paste -G 052 112 A3-; paste
must not get into the slot of
the probe body
❑ Check Lambda probe before
catalyst -G39- und lambda
control ⇒ 1.2/40; 1.2/47 En-
gine, Fuel Injection;
Rep. Gr. 24.
5 - Gasket
❑ replace
6 - Shield plate - short
❑ for vehicles without air condi-
tioning
7 - Shield plate - extended
❑ for vehicles with an air condi-
tioning system
8 - 22 Nm
9 - 23 Nm
Removing and installing parts of the exhaust system Edition 12.04

26-1 page 2 S00.5322.03.20
❑ for engines with engine identification characters BMD complying with exhaust emission standard EU-4
❑ for engines with engine identification characters BME complying with exhaust emission standard EU-4 and
EU-2 DDK
11 - Clamping sleeve
❑ align exhaust system free of stress before fitting on ⇒ 26-1 page 4
❑ Fitting position: bolts at bottom and horizontal
❑ Tighten bolted connections evenly
❑ for engines with engine identification characters BMD complying with exhaust emission standard EU-2 DDK
13 - Retaining strap
14 - 20 Nm
15 - Support
16 - 40 Nm
❑ replace
17 - Lambda probe downstream of catalytic converter -G130-, 50 Nm
❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
❑ Check Lambda probe after catalyst -G130- und lambda control ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection;
Rep. Gr. 24.
18 - Gasket
❑ replace
19 - 25 Nm
❑ replace
20 - Shield
❑ for engines with engine code BME
❑ for nordic countries
S00.5322.03.20
Silencer with hangers

1 - 23 Nm
2 - Hanger
❑ retaining strap made of sili-
cone
part number
3 - Hanger
❑ retaining strap made of
EPDM
part number
4 - Hanger
❑ retaining strap made of
EPDM
5 - Separation point
❑ Disconnect the front and rear
silencers when conducting
repairs ⇒ 26-1 page 5
6 - Front and rear silencer
❑ Replace individually when
carrying out repairs ⇒ 26-1
page 5
❑ Align exhaust system free of
stress ⇒ 26-1 page 4
Aligning exhaust system free of stress

• The exhaust system is aligned when cold.
– Slacken bolted connections of clamping sleeve be-
tween catalytic converter and front silencer and re-
place nuts.
– Position clamping sleeve at the distance -a- = 5 mm
from the marking on the front exhaust pipe (bolts at
bottom and horizontal) and tighten front bolted con-
nection slightly.
a
S26-0064

26-1 page 4 S00.5322.03.20
– Push front silencer -1- sufficiently far forward into the
clamping sleeve until the dimension -b- of 3...7 mm is
achieved between hanger of body and hanger of front 1
silencer.
-Arrow- points in direction of travel.
– Tighten bolted connections on the clamping sleeve in

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

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

placing the front silencer or rear silencer.
– Separate exhaust pipe with body saw at right angles

at the separation point -arrow 1-. 4
– When installing clamping sleeve -4- position on the
side markings -arrow 2 and 3-.
– Align exhaust system free of stress ⇒ 26-1 page 4.
– Align rear silencer horizontally.
– Tighten bolted connections of the clamping sleeve 3
evenly to 23 Nm. 2
Installation position of clamping sleeve: Bolts positioned
vertically at front of exhaust pipe.
1
Checking the exhaust system for leaks S26-0063
– Start engine and run in idle.

– Seal off tail pipe for the duration of the leak check (e.g.
with cloth or plug).
– Check the connection points for leaks by listening:
Cylinderhead/exhaust manifold, exhaust manifold/ex-
haust pipe with catalytic converter, etc.
– Eliminate any leak found.
S00.5322.03.20

26-1 page 6 S00.5322.03.20
26-2 Exhaust gas recirculation

system
Exhaust gas recirculation system - Sum-

mary of components
AZQ, BME
1 - EGR valve -N18- with EGR po-

tentiometer -G212-
❑ Inspect exhaust gas recircu-
lation valve -N18- ⇒ 1.2/40;
1.2/47 Engine, Fuel Injec-
tion; Rep. Gr. 01
2 - Gasket
❑ replace
3 - Adapter
4 - 20 Nm
5 - 10 Nm
6 - 10 Nm
7 - Connecting tube
8 - 20 Nm
9 - Vacuum hose
❑ To air filter
Edition 12.04 Exhaust gas recirculation system 26-2 page 1

S00.5322.03.20
Exhaust gas recirculation system Edition 12.04

26-2 page 2 S00.5322.03.20

Skoda Fabia 2000 Workshop Manual Engine Mechanical Components

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 12.04 List of Supplements

List of Supplements Edition 12.04

10 – Removing and Installing Engine

15 – Cylinder Head, Valve Gear

Edition 12.04 Table of Contents I

Table of Contents Edition 12.04

00-1 Technical Data

Pruef- und Einstellarbeiten

Engine identification AWY BMD AZQ BME

Edition 12.04 Technical Data 00-1 page 1

Technical Data Edition 12.04

10 – Removing and Installing Engine

10-1 Removing and Installing

Edition 04.03 Removing and Installing Engine 10-1 page 1

The engine is removed together with the cable harness.

– Disconnect all cables for the engine, gearbox, starter

Vehicles without air conditioning

For vehicles with air conditioning

– Remove the V-ribbed belt ⇒ Chapter 13-1.

Removing and Installing Engine Edition 04.03

Continued for all vehicles

– Release screws -1-.

– Unscrew the screws -arrows- from the gearbox

Edition 04.03 Removing and Installing Engine 10-1 page 3

Secure the engine with engine mount -MP 1-202- (using

Installing the engine

– Check whether the dowel sleeves for centering the

For vehicles with air conditioning

Continued for all vehicles

Removing and Installing Engine Edition 04.03

– Top up coolant ⇒ Chapter 19-2.

1 - 20 Nm + 90° (1/4 turn) - replace

Edition 04.03 Removing and Installing Engine 10-1 page 5

1 - 30 Nm + 90° (1/4 turn) - replace

Removing and Installing Engine Edition 04.03

13-1 Removing and installing V-ribbed belt

Edition 08.02 Removing and installing V-ribbed belt 13-1 page 1

– Position the V-ribbed belt on the belt pulleys and

Removing and installing V-ribbed belt Edition 08.02

Edition 08.02 Removing and installing V-ribbed belt 13-1 page 3

Removing and installing V-ribbed belt Edition 08.02

13-2 Disassembling and assembling engine

For engine with engine identification characters AWY, BMD

1 - Cylinder head with cover

Edition 12.04 Disassembling and assembling engine 13-2 page 1

❑ fit onto cleaned crankshaft

Disassembling and assembling engine Edition 12.04

1 - Cylinder head with cover

Edition 12.04 Disassembling and assembling engine 13-2 page 3

20 - 90 Nm + torque a further 90 (1/4 turn)

Disassembling and assembling engine Edition 12.04

– Press on the piston of the hydraulic tensioner -2- in the

Fig. 2: Set the point of installation of the gearwheel

– Place the marking at the gearwheel on the crankshaft

Removing and installing the timing gear

Edition 12.04 Disassembling and assembling engine 13-2 page 5

– Interlock the crankshaft with an assembly device

– Remove sealant residues on the timing gear cover

– Cut off nozzle tube at the front marking (∅ of nozzle

Disassembling and assembling engine Edition 12.04

For engine with engine identification characters