Skoda Octavia Mechanical Components

7/31/2019 Skoda Octavia Mechanical Components

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Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 List of SupplementsS00.5134.52.20

List of Supplements to Workshop Manual

Octavia 19971.6 l/75 kW Engine - Mechanical ComponentsEdition 01.01SupplementEdition Subject Article Number 01.01 Basic Edition S00.5134.50.201 08.02 Changes for engine BFQ S00.5134.51.20

2 11.04 Modifications in Rep. Gr. 10, 13 and 15 S00.5134.52.20Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsList of Supplements Edition 11.04S00.5134.52.20

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Table of ContentsS00.5134.52.20

ITable of Contents00 – Technical DataTechnical Data ..........................................................................................

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

13 – Crankgear Disassembling and assembling engine ...........................................................



- Removing and installing V-ribbed belt ..............................................................Removing and installing, tightening the timing belt ...........................................- Summary of components .............................................................................- Removing toothed belt ................................................................................- Installing toothed belt, tensioning (setting timing) ................................................- Inspecting the semi-automatic timing belt tensioning pulley ....................................Removing and installing sealing flange and pressure plate .................................- Replacing gasket ring for crankshaft -on the belt pulley side- ..................................- Removing and installing the front sealing flange . ................................................- Removing and installing drive plate . . ..............................................................Removing and installing crankshaft ...............................................................Disassembling and assembling piston and conrod ............................................

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

17 – LubricationRemoving and installing parts of the lubrication system .....................................

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Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsTable of Contents Edition 11.04S00.5134.52.20

II- Disassembling and assembling the oil filter holder ..............................................Removing and installing oil pan ....................................................................Testing oil pressure and oil pressure switch ....................................................

19 – CoolingParts of cooling system - Summary of components ...........................................- Parts of the cooling system fitted to body .........................................................- Parts of cooling system engine side ................................................................- Connection diagram for coolant hoses .............................................................- Draining and filling up coolant . . .....................................................................

- Removing and installing radiator ....................................................................- Removing and installing coolant pump ............................................................Electronically controlled cooling system .........................................................- Operation ...............................................................................................- Testing electronically controlled cooling system ..................................................- Disassembling and assembling coolant distributor housing ....................................- Testing thermostat for map-controlled engine cooling ...........................................

20 – Fuel SupplyRemoving and installing parts of the fuel supply system ....................................- Removing and installing the fuel tank with component parts and fuel filter ..................- Safety precautions when working on the fuel supply system ...................................- Rules of cleanliness ...................................................................................- Removing and installing the fuel delivery unit ....................................................

- Removing and installing the fuel gauge sender ..................................................- Removing and installing the fuel tank ..............................................................- Connecting remote control ...........................................................................- Disconnecting the fuel delivery unit with crash signal .... .......................................- Testing fuel pump .....................................................................................- Inspecting fuel flow rate ..............................................................................Inspecting the electronic power control (electronic throttle) ................................Activated charcoal filter system ....................................................................- Operation ...............................................................................................- Repairing parts of the activated charcoal filter system ... .......................................



26 – Exhaust SystemRemoving and installing parts of the exhaust system ........................................- Exhaust manifold, exhaust pipe with catalytic converter and attached parts ................- Silencer with hanger ..................................................................................- Removing and installing front exhaust pipe .......................................................- Removing and installing exhaust manifold ........................................................

- Replacing front or rear silencer .....................................................................- Aligning exhaust system free of stress .............................................................- Checking the exhaust system for leaks ............................................................Secondary air system .................................................................................- Removing and installing parts of the secondary air injection system .........................Exhaust gas recirculation system ..................................................................- Exhaust gas recirculation system - summary of components . . ................................

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Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing engine - Part 2S00.5134.52.20

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10-2 Removing and installingengine - Part 2Special tools, test and measuring equipment andauxiliary items required

_ Chapter 10-1

Installing the engine _ Always replace the seals and gaskets during assembly work.

_ Replace the self-locking nuts and screws. _ Clean all threaded holes into which self-locking boltsare inserted, with a thread tap to remove residues of the locking fluid.

_ Coat stud bolts of exhaust manifold with hot bolt paste-G 052 112 A3- before installing.

_ Tightening torques 10-2 page 3.

_ Assembly bracket 10-2 page 4.

_ If the battery is disconnected and reconnected, carry out certain additional operations Electrical System;Rep. Gr. 27.

ProcedureInstallation is performed in the reverse order. Pay attentionto the following points:

– Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; insertif necessary.

– Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.

Vehicles fitted with a manual gearbox

– Grease the drive shaft serration with grease

-G 000 100-.

– If necessary check the centering of the clutch disc.

– Install slave cylinder of hydraulic clutch 5-Speed

Manual Gearbox 02K; Rep. Gr. 30.

– Install shift mechanism 5-Speed Manual Gearbox

02K; Rep. Gr. 34.

– Set shift mechanism 5-Speed Manual Gearbox

02K; Rep. Gr. 34.

Vehicles with automatic gearbox

– Use only nuts -arrow- which are approved in the Parts

List, for attaching torque converter to the driven plate.

– Replace lock washer at support bracket of selector lever

cable.NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing engine - Part 2 Edition 11.04S00.5134.52.20



10-2 page 2

10

– Install selector lever cable at gearbox or adjustAutomatic Gearbox 01M; Rep. Gr. 37.

Continued for all vehicles

– When installing the engine/gearbox units, ensure

clearance to the subframe as well as to the radiator.

– Run pressure line of power-assisted steering past the

gearbox.

– Align unit mounting for engine - gearbox 10-2

page 3.

For vehicles with air conditioning

– Install AC compressor Heating, Air Conditioning;

Rep. Gr. 87.

– To facilitate the positioning of the AC compressor

drive the threaded bushings -B- for fixing screws -Aslightlybackwards in the direction of the arrow.

Continued for all vehicles – Install power-assisted steering hydraulic pump

Chassis; Rep. Gr. 48.

– Install the V-ribbed belt Chapter 13-1.

– Install the right drive shaft and screw the left drive

shaft onto the gearbox Chassis; Rep. Gr. 40.

– Install the exhaust pipe Chap. 26-1.

– Install the coolant hoses Chapter 19-1.

The drained off coolant must only be then re-used if thecylinder head, cylinder block, radiator or heat exchanger were not replaced.

– Top up coolant Chapter 19-1.

– Electrical connections and proper routing Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.

– Install top part of intake manifold 1.6-litre/75 kW

Engine, Fuel Injection and Ignition System;Rep. Gr. 24.

– Install secondary air pump.

– Install noise insulation panel in middle as well as on

left and right -arrows-. Install air guide parts on outside.

– Before starting the engine, inspect oil levelInspection and Maintenance.

– Adapt engine control unit to throttle valve control unit

-J338- and to EGR valve 1.6-litre/75 kW Engine,

Fuel Injection and Ignition System; Rep. Gr. 24. – Read out and generate readiness code 1.6-litre/75

kW Engine, Fuel Injection and Ignition System;Rep. Gr. 01.NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing engine - Part 2S00.5134.52.20

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10

– The basic setting must always be additionally initiated

on vehicles with an automatic gearbox AutomaticGearbox 01M; Rep. Gr. 01.

– Undertake a test drive and interrogate and erase the

fault memory 1.6 litre/75 kW Engine, Fuel Injection

and Ignition System; Rep. Gr. 01.

Align unit mounting for engine - gearboxEngine mountinga = 14.0 mmb = at least 10.0 mmBoth bolt heads -1- must end flush with the edge -c-.

Gearbox mountingThe edges -a- and -b- must be positioned parallel to eachother.

Tightening torques _ Tightening torques apply only for lightly greased,oiled, phosphatized or blackened nuts and screws.

_ Other lubricants such as engine and gearbox oil areallowed. Under no circumstances use Molykote.

_ Do not use degreased parts. _ Unless otherwise indicated the following tightening torques apply:Caution!Before slackening the bolts, the unit must be secured with the supporting device -MP 9-200-.NoteComponent NmScrews and nuts M6 9M7 13M8 20

M10 40M12 70In variation of this:Engine mounting, gearboxmount, pendulum support

Assembly

bracketDriver plate on the torque converter 60Connecting bolts for the engine/the gearbox

5-speed manual gearbox 02K; Rep. Gr. 34

Automatic gearbox; Rep. Gr. 37.

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing engine - Part 2 Edition 11.04S00.5134.52.20

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Assembly bracketTightening torquesEngine assembly bracket

1 - 40 Nm + 90° (1/4 turn)1)

2 - 25 Nm1)



3 - 100 Nm1)

Gearbox assembly bracket

1 - 40 Nm + 90° (1/4 turn)2)

2 - 25 Nm2)

3 - 100 Nm2)

Hinged bracket

1 - 40 Nm +45°3)2 - 40 Nm +45°3)

3 - 20 Nm + 90° (1/4 turn)3)

1) Replace bolts2) Replace bolts3) Replace bolts

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_ __ _____ ________ _(__ __ __ _______ _ _ 0___$___$ _ ___&_________________ _ __&__ __

_ ________ __ __ _____)_ ___%___ ___ __________ _ __ _&__ _______ _ ___________"# _____ _ _ __________!_$ _ &_____ ___ _ _____(__&_ _______'#____)______ ____)_ (# _____________&________#__# _____________ __ __*+_



__________ _ __ __ _ ________&_______ _ ,__ ___ _________ _

_ -__+_ 1 _ (_________&___)_$_______/_$_

_______!_____$___

_ ___&___________ _________ _ __&_ _ __ (______________ __ __ _________%___ ___ __________ _ ___&__ _______ _ ___________ __(____"_____

_ ____%_ __ ___ _____ __ + _____-_.___ /__ ___ _ _ ,____&_. _ &___ (____________

__ 2 _$______$+___

_______ ___ _ ____ __________________________________ ___________ __ __________ __ _ _ _____ ______ ______________

____ _____ _

__ _3 _ #_$_ _!_ __ _ __&________%_ ____"___ _ _________ _ _ __"_&_______ _ ___ ___"_ " _ _ _ ___&_________ __ _*+____________________________ _________________'#____

"_______ ____________ ___ ___ ____________ ________ _____ ___________ __________ ___ ___ ___________________ ________________ ____________ __________________ _ _____ ______ __________ ____________________ ____ __ __

0 ___%_____ ___ _ ___%_____ _#________ __&______#____

____"_ __ __'#_____________ _____"____ ____"_ ___ _ #____$_#_

________ _____ _______________________ ____$____ __%_________

0 .___%___ __'#____________

4_______ &_____ ____ ______ ___________'____________________

____(_______'_ !_________'_______ ______)____ ______________

0 ,____ _________'#_____ "_&______)_$_ _!_#_ ______________/____&____$_____ !________ "_&______)_$_ _!_#_ ______________/______$____!__

_______ *_ ____ ______ _____ !______________+_ ______ ___

_________ ____________ +___

____$_ 6_______ +___ +___

A13-0097 A13-0098



+___ _______ ___ _ ____ __________________________________ _____________ ______ ___ __ __________ __ _ _ ______________

____ _____ _ __ 0 ____"_ ___ ___ _ ___%____&__________'#______ ______

_______"_ ___ _#____$_#_#______#_

0 _______ _ ___ ___ __"_________ 5__6 _7 4_____8______$____$

0 ___&___________ _________ _ __&__ __*+____________ ___%___ ___ __________ _ __#1#_&___&_2_ ________#*#_ ___ __(____"_______ __ __________ __&__ ________

0 __ ______________ 3__ 5__6 *7 (___________$!_$__)_ ____)_$_________ $____

__

____$_ 6_______

*1$_______

_ _ _ _ _ 6_______

_______ ___ _ ____ __________________________________ ___________ __ __________ __ _ _ _____ ______

______________

____ _____ _ __ Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing, tightening the timing beltS00.5134.52.20

13-2 page 1

13

13-2 Removing and installing, tightening the timing beltSummary of components

Special tools, test and measuring equipment and aids required _ Torque wrench _ Pressure pad -T30004- _ Two-hole nut turner -T10020- _ Supporting device -MP 9-200-Before removing the timing belt, mark direction of running. Reversing the rotation direction of analready used belt may destroy it.1 - Bottom toothed belt guard

unbolt vibration damper in order



to remove Chap. 13-1

2 - Middle toothed belt guard3 - 10 Nm4 - Engine support bracket

removing 13-2 page 2

5 - 45 Nm

3 pieces6 - Top toothed belt guard

removing Fig. 1 in 13-2

page 27 - Timing belt

before removing mark running

directioncheck for wear

do not kink

removing 13-2 page 2

installing 13-2 page 5

8 - 25 Nm9 - Corrugated washer

10 - 100 Nmto release and tighten use

counterholder -T30004-11 - Camshaft sprocket

for engines with engine identification

characters AVUwith rotor for camshaft positionsensor -G163-

for removing and installing,

remove toothed belt 13-2

page 2installation position fixed by parallel key item 13

12 - Rear timing belt guard

13 - Parallel keycheck tightness

14 - Camshaftfor engines with engine identification characters AVU without rotor for camshaft position sensor

-G163-15 - Camshaft position sensor -G163-

for engines with engine code AVU

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing, tightening the timing belt Edition 11.04S00.5134.52.20

13-2 page 2

13camshaft position sensor -G163- is identical with Hall sender -G40-

when bolting on, ensure base plate is centered

16 - 15 Nm17 - Semi-automatic tensioning pulley

inspecting semi-automatic timing belt tensioning pulley 13-2 page 6

Fitting position Fig. 2 in 13-2 page 2

18 - O-ringreplace



19 - Coolant pumpremoving and installing Chapter 19-1

20 - Crankshaft toothed belt sprocketthere must not be any oil present on contact surface between timing belt sprocket and the

crankshaftcan be installed only in one position

21 - 90 Nm + torque a further 90 (1

/4

turn)replace

to release and tighten use counterholder -T30004-

bolt on counterholder -T30004- Removing and installing front sealing flange Chap. 13-3

Fig. 1: Remove top toothed belt guard

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

– -B- Push retaining lugs -arrow- up.

Fig. 2: Fitting position of the semi-automatic tensioningpulleyThe angle bracket -arrow- must engage in the recess atthe cylinder head.

Removing toothed belt Engine installed.

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing, tightening the timing beltS00.5134.52.20

13-2 page 3

13

– Remove right noise insulation.

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

– Remove ribbed V-belt tensioning device.

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

with manual gearbox).TDC marking on flywheel and reference mark must be

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

with automatic gearbox).TDC marking on drive plate and reference mark must bealigned.When engine removed, position vibration damper to TDC cylinder 1 -arrows-.NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing, tightening the timing belt Edition 11.04S00.5134.52.20

13-2 page 4

13 – Remove engine cover.

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

– Remove vibration damper.

– Remove top toothed belt guard.

– Unbolt coolant expansion reservoir and power-steering



reservoir; hoses remain connected.

– Unbolt engine support from engine mount and engine

mount from body -arrows-.

– Unbolt engine support from engine -arrows-.

_ To slacken the front bolt of the engine support, raiseengine slightly with spindle of supporting device

-MP 9-200-. _ To take off engine support, raise or lower engine, respectively with the supporting device -MP 9-200-.

– Remove the vibration damper without altering the

TDC position.

– Remove middle and bottom timing belt guard.

– Mark the rotation direction of the timing belt.

– Slacken semi-automatic tensioning pulley and take off

toothed belt.

– Turn crankshaft slightly back.

MP 9-200

S13-0104

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing, tightening the timing beltS00.5134.52.20

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13

Installing toothed belt, tensioning (settingtiming)

_ Also when carrying out repairs which necessitate taking the toothed belt only off the camshaft sprocket, it is then necessary to carry out the installation of the

toothed belt as follows. _ When rotating the camshaft, the crankshaft must not be positioned at TDC. Risk of damaging valves and

piston crowns.Condition

The pistons must not be positioned at top dead centre.

– Bring the marking on the camshaft sprocket in line

with the marking on the rear timing belt guard -arrows-.

– Position crankshaft to TDC cylinder 1 13-2 page 2

(except when engine removed).

– Fit toothed belt onto toothed belt sprocket of crankshaft

and coolant pump (pay attention to direction of

running) 13-2 page 1When engine removed, after this, install bottom toothed belt guard and vibration damper. Position crankshaft toTDC of cylinder 1 -arrows-.

– Fit timing belt onto tensioning pulley and onto camshaft

sprocket.Pay attention to installation position of semi-automatic

tensioning pulley Fig. 2 in 13-2 page 2

– Before tensioning the toothed belt, rotate the tensioning



pulley at the eccentric with the two-hole nut turner -T10020- about 5 times in both directions as far as thestop.

– Turn the semi-automatic tensioning pulley fully to the

left with two-hole nut turner -T10020- -in direction of arrow-.

– Loosen tensioning pulley until the notch -1- and thepointer -2- are positioned opposite.

– Tighten nut securing semi-automatic tensioning pulleyto 25 Nm.

– Turn crankshaft two turns further in the direction of

running of the engine and again position on TDC for cylinder 1.

When doing this, it is important that the last 45° (1/8turn) are rotated without any interruption.

– Once again inspect tension of toothed belt.

Specified value: Pointer and notch are positioned opposite.

– Install bottom and middle toothed belt guard.NoteNoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing, tightening the timing belt Edition 11.04S00.5134.52.20

13-2 page 6

13

– Install belt pulley with vibration damper. Tightening

torque: 25 NmBefore installing engine support, insert bolts into enginesupport.

– Install engine support and engine mounts. Tightening

torques: _ Engine support to cylinder block: 45 Nm _ Engine mount to engine support Chap. 10-2

_ Engine mount to body Chap. 10-2

– Align component mounting engine Chap. 10-2.

– Remove supporting device -MP 9-200-.

– Install top toothed belt guard.

– Install tensioning device for V-ribbed belt. Tightening

torque: 25 Nm.


– Install coolant expansion reservoir.

– Install the reservoir for the power-assisted steering.

– Install noise insulation and engine cover

Inspecting the semi-automatic timingbelt tensioning pulleyFitting position

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

Test condition

Toothed belt fitted on and tensioned.



Engine temperature not above 30 °C.

Test sequence

– Position engine on TDC cylinder 1.

– Load timing belt by firmly pressing down with thumb.

The pointer -2- must move.

– Relieve the pressure again on the timing belt and rotatecrankshaft a further two revolutions in direction of rotation of engine and position again at TDC of cylinder 1.

When doing this, it is important that the last 45° (1/8turn) are rotated without any interruption.

– The tensioning pulley must move back into its initialposition (notch -1- and pointer -2- are again positionedopposite).

1

S13-0279

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing, tightening the timing beltS00.5134.52.20

13-2 page 7

13

For the inspection use a mirror.NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing, tightening the timing belt Edition 11.04S00.5134.52.20

13-2 page 8

13

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing sealing flange and pressure plateS00.5134.52.20

13-3 page 1

13

13-3 Removing and installing sealing flange and pressureplate

_ Repairs to clutch 5-Speed Manual Gearbox 02K; Rep. Gr. 30. _ Secure the engine with engine mount -MP 1-202- and distance sleeves -T30010- on theassembly stand before

performing assembly work.1 - 15 Nm2 - Gasket ring

do not oil sealing lip of gasket

ring

replace 13-3 page 2

3 - Front sealing flangemust be positioned on dowel

sleevesremoving and installing



13-3 page 4

remove oil pan for removing

and installing4 - Threaded pin, 10 Nm

replace

unscrew for attaching engine

holder -T10012-5 - Cylinder blockremoving and installing

crankshaft Chapter 13-4

disassembling and assembling

pistons and conrodChapter 13-5

6 - Gasket ringreplace

7 - 100 Nm

8 - 60 Nm + torque a further 90

(1 /4 turn)replace

9 - Washer Check fitting position

10 - Pressure plate/driver discremove and install flywheel

and pressure plate 5-Speed Manual Gearbox 02K; Rep. Gr. 30

removing and installing drive plate 13-3 page 6

11 - Intermediate plate

hang on the sealing flange Fig. 1 in 13-3 page 2

must be positioned on dowel sleeves

do not damage/bend during assembly work

12 - Rear sealing flange with gasket ringmust be replaced completely

use supporting sleeve supplied for installing

remove oil pan for removing and installing Neither grease nor oil sealing lip of sealing ring

before installing remove grease residue from crankshaft journal with a clean cloth

supporting sleeve must not be removed until after pushing sealing flange onto the crankshaft journalNote

1 2 3 4 5 6 7

12 1 11 10 9 8

S13-0281

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing sealing flange and pressure plate Edition 11.04S00.5134.52.20

13-3 page 2

13

Fig. 1: Install intermediate plate

– Insert intermediate plate on sealing flange and push

onto the dowel sleeves -arrows-.

Replacing gasket ring for crankshaft -onthe belt pulley side-



Special tools, test and measuring equipment andauxiliary items required

_ Torque wrench _ Gasket ring extractor -MP 1-226- _ Assembly device -T10053- _ Counterholder -T30004- or -MP 1-310-

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

– Remove tensioning element for V-ribbed belt.

– Remove the timing belt Chapter 13-2.

– Remove crankshaft toothed belt sprocket. To this end

lock the toothed belt gear with counterholder -T30004-or -MP 1-310-.When attaching the counterholder -MP 1-310- place2 washers between toothed belt sprocket and counterholder.

– To guide the gasket ring extractor, screw central bolt

by hand fully into the crankshaft.

– Unscrew inner part of the gasket ring extractor

-MP 1-226- nine turns (approx. 20 mm) out of the outer part and lock with knurled screw.

T 30004

MP 1-310

S13-0156

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing sealing flange and pressure plateS00.5134.52.20

13-3 page 3

13

– Oil the thread head of the gasket ring extractor -MP 1-226-, position and forcefully screw it into thegasket ring as far as possible.

– Release knurled screw and turn the inner side against

the crankshaft until the gasket ring is pulled out.

InstallingDo not oil sealing lip of the gasket ring.

– Remove oil residue on the crankshaft stub with a

clean cloth.

– Insert guide bushing -T10053/1- on the crankshaft

stub.

– Slide gasket ring over the guide bushing onto the

crankshaft stub. – Press in gasket ring fully with pressure sleeve

-T10053- and bolt -T10053/2- (M16 x 1.5 x 60).If the bolt -T10053/2- (M16x1.5x60) is not available, theold central bolt for the crankshaft toothed belt sprocket can be used.S13-0093

MP 1-226Note



NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing sealing flange and pressure plate Edition 11.04S00.5134.52.20

13-3 page 4

13

– Install timing belt gear crankshaft and lock with counterholder -T30004- or -MP 1-310-. Tightening torque:

90 Nm + torque a further 90° (1/4 turn) _ Thread and collar must be free of oil and grease. _ When attaching the counterholder -MP 1-310- place2 washers between toothed belt sprocket and counterholder.

_ Replace central screw for crankshaft toothed belt gear.

– Installing the toothed belt and setting the timing

Chapter 13-2.

– Installing tensioning element for the V-ribbed belt.


Removing and installing the front sealingflangeSpecial tools, test and measuring equipment andauxiliary items required

_ Torque wrench _ Assembly device -T10053- _ Counterholder -T30004 - or -MP 1-310- _ Hand-held power drill with plastic brush insert _ Flat scraper _ Silicone sealant -D 176 404 A2-

Removing

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

– Remove tensioning element for V-ribbed belt. – Remove the timing belt Chapter 13-2.

– Remove crankshaft toothed belt sprocket. To this end

lock the toothed belt gear with counterholder -T30004-or -MP 1-310-.When attaching the counterholder -MP 1-310- place2 washers between toothed belt sprocket and counterholder.

– Drain engine oil.

– Removing oil pan Chapter 17-2.

– Unscrew front sealing flange.

– Remove sealing flange, if necessary release by applying

slight blows with a rubber-headed hammer.

– Use a flat scraper to remove sealant residues on thecylinder block.

– Cover the gasket ring with a clean cloth.

T 30004

MP 1-310

S13-0156

Note



T 30004

MP 1-310

S13-0156

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical Components

Edition 11.04 Removing and installing sealing flange and pressure plateS00.5134.52.20

13-3 page 5

13

– Use a rotating plastic brush to remove sealant residues

on the sealing flange (wear protective goggles).

– Clean the sealing surfaces. They must be free of oil

and grease.

Installing

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

approx. 3 mm).

– Apply silicone sealant to the clean sealing surface of the sealing flange, as shown in the illustration.

_ Thickness of sealant bead -arrows-: 2…3 mm _ Before applying the sealant bead cover over the gasket ring with a clean cloth.

_ The sealant bead must not be thicker otherwise excesssealant can clog the strainer in the oil suction

pipe. _ Pay attention to the 'use by date' on sealant. _ The sealing flange must be installed within 5 minutesafter applying the silicone sealant.

_ When installing the sealing flange with the gasket ring fitted use guide sleeve -T10053/1-.

_ After installing, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in.NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing sealing flange and pressure plate Edition 11.04S00.5134.52.20

13-3 page 6

13

– Fit sealing flange immediately and lightly tighten allbolts.

– Tighten the fixing screws of the sealing flange crosswise.

Tightening torque: 15 Nm

– Remove excess sealant.

– Installing oil pan Chapter 17-2.

– Install timing belt gear crankshaft and lock with counterholder

-T30004- or -MP 1-310-. Tightening torque:

90 Nm + torque a further + 90° (1/4 turn) _ Thread and collar must be free of oil and grease. _ When attaching the counterholder -MP 1-310- place2 washers between toothed belt sprocket and counterholder.

_ Replace central screw for crankshaft toothed belt



gear.

– Installing the toothed belt and setting the timing

Chapter 13-2.

– Installing tensioning element for the V-ribbed belt.


Removing and installing drive plateSpecial tools, test and measuring equipment andauxiliary items required

_ Torque wrench _ Pressure pad -MP 1-221- _ Depth gauge

Releasing and tightening the drive plate

– Attach counterholder -MP 1-221- with M8x45 bolt to

the drive plate. Place two M10 nuts -arrow- betweenthe counterholder and the driver disc.Fitting position of the counterholder:

A - for slackeningB - for tightening

Installing the drive plate

– Insert the drive plate using the washer with recesses

-1-.

– Insert new bolts -2- and tighten to 30 Nm.

T 30004

MP 1-310

S13-0156

NoteS13-0280

B

AMP 1-221

S13-0282

1 2Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing sealing flange and pressure plateS00.5134.52.20

13-3 page 7

13

– Inspect installed dimension of drive plate at the 3

mounting holes for the torque converter and calculatemean value.Specification -a-: 19,5…21.1 mmThe measurement is made through the hole of the drive

plate to the milled surface of the cylinder block.If the specified value is not reached:

– Once again remove drive plate and repeat measurement

with the shim -3-.If the specified value is reached:



– Lock drive plate with counterholder -MP 1-221- and

tighten new bolts -2- to 60 Nm and torque a further 90°(1/4 turn).S13-0197

a

Note3 1 2

S13-0285

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing sealing flange and pressure plate Edition 11.04S00.5134.52.20

13-3 page 8

13

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing crankshaftS00.5134.52.20

13-4 page 113

13-4 Removing and installing crankshaft _ Before removing the crankshaft, ensure a suitable place is available for placing it down so that the sensor rotor

item 7 in 13-4 page 1 does not rest on anything or get damaged.

_ To carry out removal and installation operations, attach the engine with the engine holder -MP 1-202- and thesleeves -T30010- to the assembly stand -MP 9-101- Chapter 10-1.

_ Pay attention to colour coding when inserting bearing shells Fig. 2 in 13-4 page 2

1 - Oil pumpremoving and installing

Chapter 17-1

2 - 15 Nm3 - Sprocket

for oil pump drive

4 - Bearing shells 1, 2, 3, 4 and 5Identification for ordering replacement

parts Fig. 2 in

13-4 page 2

for bearing cap without lubricating

groovefor cylinder block with lubricating

groovedo not mix up used bearing

shells (mark)

5 - 40 Nm + torque a further 90

(1 /4 turn)replace

tighten thread

6 - Bearing capsBearing cap 1: on the belt

pulley sideretaining lugs of the bearing



shells of the cylinder block/bearing cap must be on topof one another 7 - Rotor

for engine speed sender

-G28-assembly only possible in

one position -holes offset-replace sensor rotor each time the bolts are slackened

removing and installing Fig. 1 in 13-4 page 2

8 - 10 Nm + torque a further 90 (1 /4 turn)

replace

9 - CrankshaftAxial play when new: 0,07…0.23 mm

Wear limit: 0.30 mm

Crankshaft bearing journal: _ 48.00 mm

Conrod bearing journal: _ 42.00 mm10 - Thrust washer

for bearing 3

Fitting position: Oil grooves point to the crank websNote

9

4

5

4

3

2

1

6

4

10

1 2 3 4 5 7

4

8

S13-0288

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing crankshaft Edition 11.04S00.5134.52.20

13-4 page 213

Fig. 1: Removing and installing sensor rotor

– Always replace the sensor rotor -2- each time the

bolts -1- are slackened. _ After being attached a second time, the attachment point of the recess head screws in the sensor rotor issufficiently misshapen that the bolt heads rest against crankshaft -3- -arrows- and the sensor rotor is positioned



loosely below the screws. _ It is only possible to install the sensor rotor in one position,the holes are offset.Fig. 2: Marking on crankshaft bearing for orderingreplacement partsThe crankshaft bearing shells are factory-classified. Alignthe top crankshaft bearing shells according to the markingon the cylinder block (stamped letters).Bearing 1 points toward belt pulley.Colour coding of bearing shells matches the letterson the cylinder blockThe bottom crankshaft bearing shells are always suppliedas replacement parts with the colour coding „yellow“.NoteS13-0286

1

3

4

5

Note 2S = blackR = redG = yellowB = blueW = whiteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Disassembling and assembling piston and conrodS00.5134.52.20

13-5 page 1

13

13-5 Disassembling and assembling piston and conrodFor carrying out removal and installation operation, attach the engine with the engine holder -MP 1-202- and thesleeves -T30010- to the assembly stand -MP 9-101-.1 - Circlip2 - Piston pin

if stiff, heat piston to 60 °Cuse drift -VW 222A- for removing

and installing3 - Piston

check Fig. 3 in 13-5page 3

mark installation position relative

to conrod and markmatching cylinder with feltpen

arrow on piston crown faces

towards the belt pulley sideuse piston ring tensioning

strap for installing



∅Piston 80.965 mm4 - Piston ring (compressionring)

Offset joint 120 °use piston ring pliers for removing

and installing compression

ringsmarking „TOP“ must face towards

piston crowninspect gap clearance

Fig. 1 in 13-5 page 2

inspect end clearance

Fig. 2 in 13-5 page 2

5 - Piston ring (oil scraper ring)carefully remove and install

by handmarking „TOP“ must face towards

piston crown

inspect gap clearance Fig. 1 in 13-5 page 2

inspect end clearance Fig. 2 in 13-5 page 26 - Conrod

replace as a set only

mark assignment to cylinder -B-

Fitting position:

Markings -A- must be positioned one above the other and point to the belt pulley sidewith oil drilling for lubricating piston pin

7 - Conrod bearing capas a result of the conrod separated in the cracking process, the cover fits only in one position

and only to therelevant conrod

mark assignment to cylinder -B-

Fitting position:

Markings -A- must be positioned one above the other and point to the belt pulley sideNote

1 2 3 1 4

6 5

11 12

7

10 9 8

A B

S13-0283

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsDisassembling and assembling piston and conrod Edition 11.04S00.5134.52.20

13-5 page 2

13

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

replace

oil thread and head contact surface



9 - Pressure relief valve, 27 Nmopens at:

0,13…0.16 MPa (1.3…1.6 bar) overpressurereplace without sealant

10 - Oil injection nozzleFor piston cooling

11 - Cylinder block

inspect cylinder bore Fig. 5 in 13-5 page 3

_ Cylinder 81.01 mm12 - Bearing shell

check fitting position Fig. 4 in 13-5 page 3

do not mix up used bearing shells

insert bearing shells in the centre

Axial play when new: 0,05…0.31 mm

Wear limit: 0.37 mmwith oil drilling -arrow- for lubricating piston pin

Fig. 1: Inspecting piston ring gap clearanceSpecial tools, test and measuring equipment andauxiliary items required

_ Feeler gauge – Insert ring at right angles from above down into lower cylinder opening, about 15 mm away from edge of cylinder.To insert use piston without rings.Fig. 2: Inspect piston ring end clearanceSpecial tools, test and measuring equipment andauxiliary items required

_ Feeler gauge

– Clean ring groove before inspecting.Piston ringGap clearancenew(mm)

Wear limit(mm)Compression ring 0,20…0,40 0,80Oil scraper ring 0,25…0,50 0,80Piston ringEnd clearancenew(mm)Wear limit(mm)Compression ring 0,06…0,09 0,20Oil scraper ring 0,03…0,06 0,15Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Disassembling and assembling piston and conrodS00.5134.52.20

13-5 page 3

13

Fig. 3: Inspecting pistonsSpecial tools, test and measuring equipment andauxiliary items required

_ External micrometer 75...100 mm



– Measure about 10 mm from the lower edge, offset atright angles to the piston pin shaft.Deviations from specified dimension: max. 0.04 mmFig. 4: Bearing shell installation positionBearing shell -1- with oil drilling -arrow- for conrod.Bearing shell -2- without oil drilling for conrod bearing

cap. – Insert bearing shells into conrod and into conrod bearing

cap centred.Dimension -a- must be the same on right and left, max.variation: 0.2 mm.Fig. 5: Inspecting cylinder boreSpecial tools, test and measuring equipment andauxiliary items required

_ Internal precision measuring instrument 50...100 mmTest sequence

– Measure at three points crosswise in a transverse direction

-A- and lengthwise -B-.Deviations from specified dimension: max. 0.10 mm

Do not measure the cylinder bore if the cylinder block isfixed to the assembly stand with the engine mount -MP 1-202-, as this may result in incorrect measurements.NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsDisassembling and assembling piston and conrod Edition 11.04S00.5134.52.20

13-5 page 4

13

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing cylinder headS00.5134.52.20

15-1 page 115

15-1 Removing and installingcylinder headRemoving and installing toothed belt Chapter 13-2

Test compression pressure 15-1 page 6

_ Always replace cylinder head bolts. _ Always replace self-locking nuts. _ Always replace the seals and gaskets during assembly work.

_ When installing a cylinder head, all the contact surfaces

between the hydraulic tappets, roller rocker armsand the cam tracks must be oiled before installing thecylinder head cover.

_ Do not remove the plastic bases supplied as a protectionfor the open valves until just before fitting on thecylinder head.

_ If the cylinder head is replaced, the system must becompletely filled with fresh coolant.

_ Disassembling and assembling intake manifold



1.6-litre/75 kW Engine, Fuel Injection and IgnitionSystem; Rep. Gr. 24.

15 – Cylinder Head, Valve Gear NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing cylinder head Edition 11.04

S00.5134.52.20

15-1 page 2

15

Cylinder head - summary of components1 - Cap2 - Gasket

replace if damaged

3 - Breather housingto disassemble, turn to the

left4 - Oil deflector 5 - Camshaft position sensor -G163-

for engines with engine code

BFQ6 - Gasket ring

replace if damaged

before fitting moisten with

clean engine oil7 - Bracket8 - 10 Nm9 - Coolant distributor housing

Disassembling and assembling

coolant distributor housing Chapter 19-2

10 - Gasket ringreplace

11 - 20 Nm12 - Cylinder head gasket

replace 15-1 page 3

13 - Camshaft position sensor -G163-

for engines with engine code

AVU14 - Rear timing belt guard15 - 15 Nm16 - Camshaft sprocket17 - 100 Nm

to release and tighten use counterholder -T30004-18 - Parallel key19 - Cylinder head

removing and installing 15-1 page 3

check for distortion 15-1 page 6

rework cylinder head 15-1 page 6

after replacing fill entire system with fresh coolant

20 - Cylinder head boltreplace



pay attention to order for slackening 15-1 page 4

pay attention to order for tightening 15-1 page 5

removing and installing with socket insert -T10070-21 - Gasket for cylinder head cover

replace if damagedpress into the spacer sleeves

22 - Cylinder head cover 23 - Vent connection

to the expansion reservoir Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing cylinder headS00.5134.52.20

15-1 page 3

15

Removing and installing cylinder headSpecial tools, test and measuring equipment andauxiliary items required

_ Guide bolt -T30011/2A-

_ Removal tool -T30011/3- _ Assembly tool -T10112- _ Socket insert -T10070- _ Catch pan (e.g. -V.A.G 1306-) _ Torque wrench _ Pliers for spring strap clips

Requirements

Engine temperature not above 30 °C. _ If the battery is disconnected and reconnected, carry out certain additional operations Electrical System;Rep. Gr. 27.

_ All cable straps which are detached or cut open whenremoving, should be fitted on again in the same place

when installing.

Removing cylinder head

– Remove engine cover.

– Remove connecting part for exhaust gas recirculation.

– Open the cap of the coolant expansion reservoir.

– Remove noise dampening in the middle and on the

right -arrows-.

– Unbolt front exhaust pipe together with catalytic converter

and holder Chapter 26-1.

– Drain coolant Chapter 19-1.

– Remove intake hose and air filter 1.6-ltr./75 kW Engine,

Fuel Injection and Ignition System; Rep. Gr. 24.

– Remove fuel feed line -1- and fuel feed line -2-, to do

so press latch clips. Lines and line connections arecolour-coded.

– Detach hose -3- at the ACF tank.

– Remove inlet line and pressure line of secondary air

pump.NoteWARNING!



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

point. Reduce pressure by carefully releasing the connection point.Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing cylinder head Edition 11.04S00.5134.52.20

15-1 page 4

15

– Remove the secondary air pump with pressure hose

and holder.

– Remove top part of intake manifold 1.6-ltr./75 kW

Engine, Fuel Injection and Ignition System;Rep. Gr. 24.Seal the intake passages in the bottom part of the intakemanifold with a clean cloth.

– Disconnect plug for camshaft position sensor -G163-

on all four injection valves -N30...N33-.

– Detach the unplugged wiring loom from the holdersand lay to the side.

– Use assembly tool -T10112- to unplug spark plug connector

and place to the side.

– Detach coolant hose from cylinder head.

– Unscrew coolant distributor housing.

– Remove top toothed belt guard.

– Position camshaft sprocket to TDC marking of cylinder 1. Marking on camshaft sprocket must be alignedwith arrow on the toothed belt guard.

– – Then turn crankshaft slightly backwards.

– Remove camshaft sprocket. Hold the camshaft

sprocket tight with counterholder -T30004- to slackenthe bolts.

– Remove parallel key from the camshaft.

– Remove rear timing belt guard.

– Slacken the bolts of the cylinder head cover from theoutside to the inside.

– Remove cylinder head cover.

– Slacken the cylinder head bolts using the socket insert-T10070- in the specified order and unscrew.

– Carefully remove the cylinder head.

Installing cylinder head _ There must not be any oil or coolant present in theholes for the cylinder head bolts.

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

_ Treat the new seal with the utmost care. Any damagewill result in leaks.

– Make sure that when cleaning the cylinder head and

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



T30011/3

T30011/2A

S15-0185

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical Components

Removing and installing cylinder head Edition 11.04S00.5134.52.20

15-1 page 6

15

Inspecting the cylinder head for distortionSpecial tools, test and measuring equipment andauxiliary items required

_ Feeler gauge _ Knife-edge straightedge

Test sequence

– Inspect cylinder head at several points for distortion

using a knife-edge straightedge and feeler gauge. _ Max. permissible distortion: 0.1 mm (minimum clearanceof straightedge base: 100 mm)

– If the distortion is greater than 0.1 mm, replace cylinder head or rework.

Reworking a cylinder headProcedure

– Reworking of the sealing surface of the cylinder head

(face-grinding) is only permissible up to minimum dimension-a-.

_ Minimum dimension -a-: 132.6 mmIf the sealing surface is reworked, the valves should beset lower by the same amount (rework valve seat rings)

otherwise the valves will strike the pistons. When doing this, ensure that the permissible maximum dimension -

Chap. 15-4 - is not exceeded.

Testing the compressionSpecial tools, test and measuring equipment andauxiliary items required

_ Spark plug wrench (e.g. -3122 B-) _ Assembly tool -T10112- _ Torque wrench _ Compression tester (e.g. -V.A.G 1381- or -V.A.G 1763-)

Test condition

Engine oil temperature must be at least 30°C.Test sequence

– Unplug 4-pin plug (-1-) from ignition transformer

-N152- (-2-).

– Disconnect the connector of the injection valves.

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Removing and installing cylinder headS00.5134.52.20



15-1 page 7

15

– Use assembly tool -T10112- to unplug spark plug connector and unscrew spark plugs with spark plugwrench.

– Check compression pressure using the compressiontester.Use of tester Operating instructions

– Have a second mechanic operate starter with the

throttle valve fully opened until no further pressure riseis indicated by the tester.

Compression readings

– Conclude by deleting the fault memory of the engine

control unit 1.6-litre/75 kW Engine, Fuel Injection

and Ignition System; Rep. Gr. 01.NoteEngine new Wear limit Difference between

cylinders1,0…1.3 MPa(10…13 bar)0.75 MPa(7.5 bar)max. 0.3 MPa(3 bar)Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRemoving and installing cylinder head Edition 11.04S00.5134.52.20

15-1 page 8

15

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Repairing Valve Gear S00.5134.52.20

15-2 page 1

15

15-2 Repairing Valve Gear _ Cylinder head and ladder frame must always be replaced together. _ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensurethat no valve touchesthe piston when the engine is started.1 - 100 Nm

to release and tighten use

counterholder -T30004-2 - Camshaft sprocket

to remove and install, removetoothed belt

Chapter 13-2

installation position fixed byparallel key item 4

for engines with engine identificationcharacters AVU



with rotor for hall sender -G40-3 - Gasket ring

do not oil sealing lip of gasketring

replacing Chapter 15-3

4 - Parallel key5 - 20 Nm6 - Ladder frame

Reworking of sealing surfacesnot permissible

with integrated camshaftbearing

Bearing 1 for camshaftsprocket

pay attention to tightening order of camshaft bearings

Chapter 15-3

Apply sealant-D 188 800 A1- carefully in

the sealant groove and to thebottom sealing surface7 - Camshaft

The rework of the camshaft is not permissible

inspecting axial play Fig. 1 in 15-2 page 2

removing and installing Chapter 15-3

Slack: max. 0.01 mmfor engines with engine identification characters AVU without rotor for hall sender -G40-

8 - Roller rocker armdo not interchangeinspect roller bearingsoil contact surfacefor installing, clip onto hydraulic supporting element with locking clip

9 - Supporting elementdo not interchangewith hydraulic valve clearance compensationoil contact surface

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsRepairing Valve Gear Edition 11.04S00.5134.52.20

15-2 page 2

15

10 - Valve collets11 - Valve spring retainer

12 - Valve springremoving and installing

– with cylinder head removed:with -MP 1-211- and -MP 1-213- with valve supporting plate -MP 1-218-

– with cylinder head installed Chapter 15-4

13 - Valve stem sealreplacing Chapter 15-4

14 - Capinsert flush



for removal, only push the rubber through the middle using a screwdriver and release15 - Valve guide

inspect Chapter 15-416 - Cylinder head

reworking valve seats Chapter 15-4

17 - Valvedo not rework, only grinding in is permissible

Valve dimensions Fig. 2 in 15-2 page 2

Fig. 1: Checking the axial play of the camshaftSpecial tools, test and measuring equipment andauxiliary items required

_ Universal dial gauge holder -MP 3-447- _ Dial gaugeMeasurement with ladder frame removed.Wear limit: max. 0.17 mmFig. 2: Valve dimensionsThe valves must not be reworked. Only grinding in is permissible.NoteDimension Inlet valve Exhaust valve

_a mm 39,5

±0,15 32,9

±0,15

_ b mm 5,98 ± 0,007 5,965 ± 0,007c mm 93,85 93,85

_ _° 45 45 _______ ___ _ ____ _____________________ _ ________ ________ ______________

____ ____ _ __

____ ________ _________________________ ___ !_______""_________#_____$ _____%$_________#_

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___"____ . /___%_________!_%___

. /___%_______ 0_$_____ _________

. ______!___________!______1_________!2$__ ___02_________!__________"_______!_______

____!_______0__$___ (______(________ 0_$_ ____ _

. _$_!_____________$_2__ __________ 0_$____ !___________!____

. ____3_______!_________0_!__$___$2_

. /___%_!___________!____4_$ ___!_______ ____!_______(_____!________$ _____________ _$_!________0_$__

. /___%_____$_$__2_______!________



. _!__(_0_$________!___!___________!_____$2___ ___!________

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____________ _____________ ____ _______

/_______

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. #_________$_$__2___!________

. #____$!___________!_____ ___________)_*___ !________$ __________-_

__ ____________ __________ ___________________ _ ________ ____ _!__"________________ ____________ _______ _______________0$2_!____ ______%______ ____

______0$2_ . #____$________ 0_$_3________*__________- _ __________

___"_______#__________________ !_______""_________#_____$ _____%$_________#_

_$&___ '_______ _%$_ _# _ __________ ________ _ ___'__(___!_______)_*_____+_,__ _____- _ ___'__(___!_________)_*_____+_,__ _____-



_ ___$____1 _88 8__ ,__

___"____ _ _ __ _________ ______ ____________ ____ ____ _ ____________________ ___ ____________ ______ __ _ _ ________ ___________ ___ ________________ _ __________ ____ ____ __# __ __ _________ _

___ ____ _________ _ ____________ ____ ______ __ _ ___ _ $___ ____ ____ _____ ___ ___ __________ _ _____ ____ ___ ___ __ ______ ____________ __ __ ___ ___ __ _ _____ ___________ __ ____________ __ ____

. /___%_________!_%___

___ _ _ 5_______

)"___

______ 5_______

)"___

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(______(________ 0_$_____ _

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. ____3_______!_________0_!__$___$2_

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. _______$_ ________

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. ____________$______________(____________$__ _______$_!_________ _(____!$________!__



. _______________$________ _____________$__ ____________ _ ___

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. ________ ____ ___$______ ____________!2$__ _____ _

(_______ _"_#___"__

_ ______$_______!______0________$__ _______

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_ ________________0________ _____ __ !______

* "__#$ _

. #__________________$_________!2$_ _____ __ _$_!______$_____________%_$%_______ ___ __________$______3_____!_%_$2_ )"___ /_______

__ ______ 5_______ 0_______

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____ ____ _ __ . ___________$_____$_________!____!_$2_______

_____%_$%_______ ______ ___!$___ __$_!___ _____$_%_____________$__________

. 5$!____!______!____!________

. ______$2_$_!_!_____________!_______0______ _____!2$_ _____ _

. ,__$2___%__3_$___$2____ 0__ _____$___ _1 _88 8__ ,________!$_______%______$_ __ __________(__1___0_________$____%__$2_%_____ ___$_______!__ _ _ __ ______________ _____ ________________ ___ ___ &_ ____ _____________'___________________ _ _ ____ ____ _________ ____ ____________ ______' __________ _____________ __ _________ _____ __' _ ____ _______________________ _____ ______

_______ _ _____ ___________ __ ____________ __ ____

. #______________ !_%___$____

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. ,_______3_______________$2______ _____(___ __)__

. #____$!2$_ _____ !_%__3_________0_$____$2 ___



15-4 page 1

15

15-4 Valve stem seals, valvesguides, valve seatsReplacing valve stem sealsCylinder head fittedSpecial tools, test and measuring equipment andauxiliary items required

_ Extractor for valve stem seal -MP 1-230- _ Pressure hose -MP 1-210- _ Valve lever -MP 1-211- _ Valve stem seal insertion tool -MP 1-233- _ Assembly device -MP 1-213- _ Spark plug wrench (e.g. -3122B-) _ Assembly tool -T10112- _ Valve supporting plate -MP 1-218-With cylinder head removed, place cylinder head onto the

valve supporting plate -MP 1-218-.Removing

– Removing camshaft Chap. 15-3.

– Remove the roller rocker arm together with the supporting

element. Lay aside on a clean surface.

– Ensure that the roller rocker arm and the supporting

element is not mixed up.

– Use assembly tool -T10112- to unplug spark plug connector

and unscrew spark plugs with spark plugwrench.

– Put the piston of the relevant cylinder at „bottom dead

centre“.

– Insert assembly device -MP 1-213- and adjust bearingto stay bolt height.

– Screw the pressure hose -MP 1-210- into the spark

plug thread and apply constant pressure of at least 0.6MPa (6 bar) in the cylinder.

– Remove valve springs with valve lever -MP 1-211-.

If valve collets are tight, slacken with slight blows of ahammer on the valve lever.

– Pull off valve stem seal with extractor for valve stem

seal -MP 1-230-.NoteNote

MP 1-230S15-0183

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsValve stem seals, valves guides, valve seats Edition 11.04S00.5134.52.20

15-4 page 2

15

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 valve stem seal

insertion tool -MP 1-233- and carefully push onto thevalve guide.

– Remove plastic sleeve.

Further installation occurs in a similar way in reverse order to removal.

After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valvetouches the piston when the engine is started.

Inspect valve guidesSpecial tools, test and measuring equipment andauxiliary items required

_ Universal dial gauge holder -MP 3-447- _ Dial gaugeIf the valve is replaced when carrying out repair work, usea new valve for the measurement.

Procedure

– Insert valve into guide. End of valve stem must end

flush with the guide (because of the different stem diameter,use only inlet valve in inlet guide and exhaustvalve in exhaust guide).

– Determine valve rock.

Wear limit: 0.6 mmIf the wear limit is exceeded, repeat measurement withnew valves. If the wear limit is again exceeded, replacecylinder head.

Reworking valve seatsIf no perfect contact pattern is achieved by grinding in thevalve seats, rework the valve seats.

Special tools, test and measuring equipment andauxiliary items required _ Depth gauge/caliper gauge _ NAC milling cutter for reworking valve seats _ Grinding paste

A

MP 1-233

B

S15-0184

NoteNote

NoteNoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Valve stem seals, valves guides, valve seatsS00.5134.52.20

15-4 page 3

15

_ When carrying out repairs on engines with leaking



valves, it is not sufficient to machine or replace thevalve seats and valves. It is also necessary to inspect the valve guides for wear, particularly on engines with

a high mileage 15-4 page 2.

_ Rework valve seats only sufficiently in order to obtaina proper contact pattern.

_ Calculate the maximum permissible reworking dimensionbefore commencing. _ If the reworking dimension is exceeded, proper operationof the hydraulic valve clearance compensation isno longer assured and the cylinder head must be replaced.

Calculating maximum permissible reworking dimension

– Insert valve and press firmly against the valve seat.

If the valve is replaced when carrying out repair work, usea new valve for the measurement.

– Measure distance -a- between the end of the valve

stem and the upper face of the cylinder head.

– Calculate max. permissible reworking dimension from

the distance -a- measured and from the minimum dimension.

Minimum dimension for inlet and exhaust valve: 31.7mm.Distance measured -a- minus minimum dimension =max. permissible reworking dimension.Example:If the max. permissible reworking dimension is 0 mm or less than 0 mm, repeat measurement with a new valve. If the measuring result is still 0 mm or less than 0 mm, replacecylinder head.NoteNoteMeasured distance 32.0 mm- Minimum dimension 31.7 mm

= max. permissible reworking dimension1)

0.3 mm1) The max. permissible reworking dimension is shown in the figuresfor reworking the valve seats as dimension „b“.

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsValve stem seals, valves guides, valve seats Edition 11.04S00.5134.52.20

15-4 page 4

15

Reworking inlet valve seatReworking exhaust valve seat

ProcedureReworking can be carried out with a machine or by hand.The following conditions must be met:

Wear limit of valve guides must not exceed the permissible

dimension 15-4 page 2.

Use NAC milling cutter with carbide metal tips (min. 90HRC).

Mill with the milling cutter using slight pressure in such



a way that an even removal of swarfs is ensured over the whole working surface.

Reworking valve seats with NAC milling cutter

– Place cylinder head on a felt base and secure to prevent

it from turning.

– Match diameter of guide drift to diameter of valve

guide.DimensionInlet valve seat

∅a mm 39,2b mm Max. permissible reworking dimensionc mm 1,8 … 2,2Z Bottom edge of cylinder head

45° Valve seat angle

30° Top correction angleS Combustion chamber floor areaDimension

Exhaust valve seat ∅a mm 32.4 mmb mm Max. permissible reworking dimensionc mm 2,2 … 2.6 mmZ Bottom edge of cylinder head

45° Valve seat angle

30° Top correction angleS Combustion chamber floor areaS15-0098

Valve guide Guide drift in mmInlet valve6,0 -0,01

Exhaust valve

Octavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsEdition 11.04 Valve stem seals, valves guides, valve seatsS00.5134.52.20

15-4 page 5

15

– Match diameter of milling cutter to diameter of valve

seat.

Milling sequence1. Machine valve seat with 90° milling tool until until aperfect contact pattern is achieved. (Do not exceedmaximum permissible reworking dimension!)

2. Initially mill top correction angle with 120° milling cutter

until the valve seat diameter -a- or valve seat width-c- is achieved 15-4 page 4.

– Grind in valve/valve seat -arrows- with fine grinding

paste so as to achieve a perfect contact pattern.

– Check contact pattern e.g. with water colour (perfect

contact pattern over entire circumference).

– Install valve springs.

– Inspect valve for leaks.



The tightness of the valve can be checked by filling petrolinto the inlet and outlet canal (no petrol must flow out atthe valve seat)

After completing the repair measure the dimension -aagainand calculate the maximum permissible reworking

dimension 15-4 page 3.

If the reworking dimension is exceeded, proper operationof the valve gear is no longer assured and the cylinder head must be replaced.Valve seat Milling cutter

90 mm

Milling cutter

120 mm

Inlet valve 41 41Exhaust valve 34 34

c

a

120 °90 °

1.

2.S15-0060

S15-0061

NoteOctavia 1997 1.6 l/75 kW Engine - Mechanical ComponentsValve stem seals, valves guides, valve seats Edition 11.04

S00.5134.52.20

15-4 page 6

15

_______ ___ _ ____ __________________________________ ________ __ _______ ___ __ _______ _____ _ _________ _____ _______ ______

____ ___ _ __

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/ _ _ _ _ _

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_ _ (

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_#.____!_________:#___$ _ +__ "_____2_____5_6_. ___&_3 _ ________7________ _ ______________________ ___ 9_______

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8 ___________________2_____5_6_. ___&_3________"_____ ____

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V.A.G 1598/31



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A20-0096

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A20-0096

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A26-0130

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Skoda Octavia Mechanical Components

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