Engines Awy,Azq,Bmd,Bme

Service 5

Service Department. Technical Information Printed in Czech RepublicS00.5322.00.20

Workshop ManualFABIA 2000 1.2/40; 1.2/47 Engine, Mechanical ComponentsEdition 08.02Engine code AWY AZQ BMD BME

Service5

The Workshop Manual is intended only for use within the Organisation koda.It is not permitted to pass it on to other persons.

KODA AUTO a. s.

Printed in Czech RepublicS00.5322.00.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

List of SupplementsEdition 12.04S00.5322.03.20

List of Supplements to Workshop Manual

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical ComponentsEdition 08.02

Supple-ment Edition Subject Article Number

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


List of Supplements Edition 12.04S00.5322.03.20


Table of ContentsEdition 12.04S00.5322.03.20

I

Table of Contents

00 Technical DataTechnical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Removing and Installing EngineRemoving and Installing Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing engine ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installing the engine ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Tightening torques ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Assembly bracket ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CrankgearRemoving and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Valve control drive - summary of components ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing the timing gear cover .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing the camshaft sprocket, setting the timing . . . . . . . . . . . . . . . . . . . . . . .

- Inspect setting of the timing ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing the camshaft sprocket, setting the timing ........ . . . . . . . . . . . . . . . . . . . .

Removing and installing the gasket ring and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing gasket ring for crankshaft - on the belt pulley side ........ . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing the gasket ring for the crankshaft - flywheel side .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing ring gear ..... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 Cylinder Head, Valve GearRemoving and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


- Removing and installing cylinder head ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Testing the compression ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the valve gear - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


- Removing and installing camshaft ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the valve gear - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing valve stem seal ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Inspect valve guides .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Reworking valve seats .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 LubricationRemoving and installing parts of the lubrication system - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . .


- Dismantling and assembling the oil filter ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing parts of the lubrication system - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing oil pan ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing oil pump .... .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 Cooling

00-1 page 1

10-1 page 110-1 page 110-1 page 410-1 page 510-1 page 5

13-1 page 113-1 page 1

13-2 page 113-2 page 113-2 page 5

13-3 page 113-3 page 113-3 page 3

13-4 page 113-4 page 213-4 page 213-4 page 3


15-2 page 115-2 page 115-2 page 3


17-1 page 117-1 page 117-1 page 4

17-2 page 117-2 page 117-2 page 2

17-3 page 1


Table of Contents Edition 12.04S00.5322.03.20

II

Removing and installing parts of the cooling system - Summary of components . . . .

- Parts of the cooling system fitted to body .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Parts of cooling system engine side ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connection diagram for coolant hoses ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing parts of the cooling system - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Draining and filling up coolant . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking the coolant system for tightness ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing parts of the cooling system - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing radiator ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing coolant pump ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Fuel SupplyRemoving and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing and installing fuel tank with attached 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 ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Inspecting the fuel delivery unit and fuel system ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Inspecting the operating and holding pressure of the fuel, inspecting the non-return valve of the fuel delivery unit .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Disconnecting the fuel delivery unit with crash signal .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting the electronic power control (electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Summary of components ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Summary of components of activated charcoal filter system ......... . . . . . . . . . . . . . . . . . . . . . . . . . .

26 Exhaust SystemRemoving and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Silencer with hangers ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Aligning exhaust system free of stress ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Replacing front or rear silencer ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking the exhaust system for leaks ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Exhaust gas recirculation system - Summary of components ........ . . . . . . . . . . . . . . . . . . . . . . . . . .


19-2 page 119-2 page 119-2 page 2

19-3 page 119-3 page 119-3 page 2

20-1 page 120-1 page 120-1 page 120-1 page 120-1 page 120-1 page 120-1 page 120-1 page 2

20-1 page 220-1 page 2

20-2 page 120-2 page 1

20-3 page 120-3 page 1

26-1 page 126-1 page 426-1 page 426-1 page 526-1 page 5

26-2 page 126-2 page 1


Technical DataEdition 12.04S00.5322.03.20

00-1 page 1

00

00-1 Technical DataEngine number

The engine number (engine identification characters and serial number) is located in the front left on the cyl-inder block at the engine/gearbox joint -arrow B-.

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

00 Technical Data

Mot ork enn bu chs tab en : X X

X 00 0 000A C

HTU

NG

! Bei Pr ue f- u nd Ein ste llar bei ten

Engine identification characters

AWY BMD AZQ BME

Manufactured 02.02 05.04 05.04 01.03 12.04 12.04 Exhaust limits conforming to

EU-4, EU-3 DDK, EU-2 DDK

EU-4, EU-2 DDK EU-4, EU-3 DDK, EU-2 DDK

EU-4, 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 76,5Stroke 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)

1) At least 91 RON in exceptional cases; the engine output is reduced however

95 unleaded1) 95 unleaded1) 95 unleaded1)

Fuel injection and ignition system

Simos 3PD Simos 3PG Simos 3PE Simos 3PG

Lambda control 2 Lambda probes2)

2) Engine version complying with exhaust emission standard EU-2 DDK only with one lambda probe before catalyst

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


Technical Data Edition 12.04S00.5322.03.20

00-1 page 2

00


Removing and Installing EngineEdition 04.03S00.5322.01.20

10-1 page 1

10

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

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.

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. Drain coolant Chapter 19-2. 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.

Unplug connector -1- from the engine control unit.

Separate plug connection -2-.

Unclip cable clip -3- -arrows-.

10 Removing and Installing Engine

Note

S10-0135

12

S10-0142

3


Removing and Installing Engine Edition 04.03S00.5322.01.20

10-1 page 2

10

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.

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

Remove the V-ribbed belt Chapter 13-1. Remove connector from the AC compressor.

Remove AC compressor with the refrigerant lines con-nected.

Secure the AC compressor -1- to the lock carrier -ar-row-.

Remove the lock carrier with the radiator and con-denser Body work; Rep. Gr. 50, swivel to the side and position on a suitable base -2- on which there is no risk of tilting.

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.

S34-0403

WARNING!

Do not open the refrigerant circuit of the air condi-tioning system.

2

1

S10-0136



10-1 page 3

10

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.

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.

Note

Caution!

Use securing pins on the hooks and rig pins to pre-vent release.

S10-0120



10-1 page 4

10

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

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.

For vehicles with air conditioning

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.

Note



10-1 page 5

10

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

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:

Assembly bracket

Tightening torques

Engine mounting

1 - 20 Nm + 90 (1/4 turn) - replace2 - 30 Nm + 90 (1/4 turn) - replace

Note

Note

Component Nm

Screws/nuts M6 9

M7 15

M8 23

M10 40

M12 60

deviations:

Engine mounting, gearbox mount, pendulum support

Assembly bracket

Engine to gearbox connect-ing screws

M10 45



10-1 page 6

10

Gearbox mounting


Hinged bracket

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.


2

11

1

1 S10-0125

2

1

S10-0133

Note


Removing and installing V-ribbed beltEdition 08.02S00.5322.00.20

13-1 page 1

13

13-1 Removing and installing V-ribbed belt

Summary of components

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 Nm2 - Belt pulley

on the coolant pump3 - Trim4 - Tensioner with tensioning

pulley do not remove the tensioning

pulley.

5 - 40 Nm6 - Generator

to facilitate positioning of the generator on the cylinder block, drive the threaded bushings of the screws slightly backwards

7 - Guide pulley8 - Washer

Camber towards the outside9 - Belt pulley

for crankshaft10 - 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 Nm13 - Distance sleeve

for the AC compressor14 - Dowel sleeves for AC compressor

must be inserted in the cylinder block15 - V-ribbed belt

Routing of the V-ribbed beltvehicles without air conditioning Fig. 1 in 13-1 page 2Vehicles with air conditioning Fig. 2 in 13-1 page 3

removing and installing 13-1 page 2

13 Crankgear

Note


Removing and installing V-ribbed belt Edition 08.02S00.5322.00.20

13-1 page 2

13

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.

The tensioning roller can be interlocked by inserting a rig pin.

Installing

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

Note

Note


Removing and installing V-ribbed beltEdition 08.02S00.5322.00.20

13-1 page 3

13

Fig. 2: V-ribbed belt run - with an air conditioning system


2 - Belt pulley - coolant pump

3 - Tensioning pulley

4 - Belt pulley - generator

5 - Belt pulley - AC compressor

6 - Guide pulley


Removing and installing V-ribbed belt Edition 08.02S00.5322.00.20

13-1 page 4

13


Disassembling and assembling engineEdition 12.04S00.5322.03.20

13-2 page 1

13

13-2 Disassembling and assembling engine

Valve control drive - summary of components

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 removing and installing Chapter 17-2

7 - Guide rail8 - Chain sprocket on the crank-

shaft for the camshaft drive interlocked with spring on the

crankshaft

9 - Chain sprocket on the crank-shaft for the oil pump drive not interlocked on the crank-

shaft

10 - Oil pump chain11 - Oil pump sprocket12 - Oil pan

removing and installing Chapter 17-213 - 9 Nm14 - Cover

Oil pump sprocket15 - 20 Nm + torque a further 90 (1/4 turn)

replace16 - 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

WARNING!

Top and bottom part of cylinder block must not be disassembled.


Disassembling and assembling engine Edition 12.04S00.5322.03.20

13-2 page 2

13

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


20 - 90 Nm + torque a further 90 (1/4 turn) replace Interlock crankshaft with an assembly device -T10121- for removing and installing it Chapter 13-3

21 - 25 Nm22 - 45 Nm23 - 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 replace if damaged

27 - Timing gear cover removing and installing 13-2 page 5

28 - Oil separator clipped in the steering wheel housing

29 - 20 Nm + torque a further 90 (1/4 turn) 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



13-2 page 3

13

For engine with engine identification characters AZQ, BME

1 - Cylinder head with cover removing and installing Chapter 15-1

2 - Cylinder block 2 part do not separate

3 - Balancing shaft4 - Balancing shaft gear

do not remove Wheel position for crankshaft

gear Fig. 2 in 13-2 page 5

5 - Oil pump removing and installing Chapter 17-2

6 - Bolts, 18 Nm for tensioning rail or possibly

also guide rail

7 - Guide rail8 - Chain sprocket on the crank-

shaft for the camshaft drive interlocked with spring on the

crankshaft

9 - Chain sprocket on the crank-shaft for the oil pump drive not interlocked on the crank-

shaft

10 - Oil pump chain11 - Oil pump sprocket12 - Oil pan

removing and installing Chapter 17-2

13 - 9 Nm14 - Cover

Oil pump sprocket15 - 20 Nm + torque a further 90 (1/4 turn)

replace16 - 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 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




13-2 page 4

13

20 - 90 Nm + torque a further 90 (1/4 turn) replace Interlock crankshaft with an assembly device -T10121- for removing and installing it Chapter 13-3

21 - 25 Nm22 - 50 Nm

23 - 8 Nm + torque a further 90 (1/4 turn) 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 Nm26 - The vacuum regulating valve (PCV valve)

pay attention to the spare part number27 - O-ring

replace if damaged28 - Timing gear cover

removing and installing 13-2 page 529 - Cover30 - O-ring

replace if damaged31 - 50 Nm + torque a further 90 (1/4 turn)

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 tensioner34 - 15 Nm35 - Timing chain36 - Camshaft sprocket

removing and installing, setting the timing Chapter 13-337 - 15 Nm

for engine with engine identification characters AZQ38 - Sliding block

for engine with engine identification characters AZQ39 - Washer

for engine with engine identification characters AZQ replace



13-2 page 5

13

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 vehicleSpecial tools, test and measuring equipment and auxiliary items required

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 V-ribbed belt Chapter 13-1. 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.



13-2 page 6

13

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.

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

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-.

Note

Note



13-2 page 7

13

Apply silicone sealant to the separation point of the cylin-der head/cylinder block according to the parting plane -arrows C-.



Continued for all engines

B - Position of the fitting sleeves

Thickness of sealant bead: 23 mm.

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.

Note

Note



13-2 page 8

13




Install the housing item 17 in 13-2 page 1, item 17 in 13-2 page 3.

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



Note

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.



13-2 page 9

13


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)

Position Size of bolt Torque

1, 2, 3 M10x120 50 Nm

4, 5 M8x55 25 Nm

6, 7, 8, 11, 14, 15

M6x401) 8 Nm + torque a further 90 (1/4

turn)others M6x221)

1) if no blue sealant mass is left in the thread of the screws, replace the screws for ones which have sealant on them.



13-2 page 10

13


Removing and installing the camshaft sprocket, setting the timingEdition 12.04S00.5322.03.20

13-3 page 1

13

13-3 Removing and installing the camshaft sprocket, setting the timing

Inspect setting of the timing



Assembly device -T10120- Assembly device -T10121- Extractor -T10094-

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.

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.

Note

Note


Removing and installing the camshaft sprocket, setting the timing Edition 12.04S00.5322.03.20

13-3 page 2

13



Pipe section -T10123- Assembly device -T10121- Extractor -T10094-

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.



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).

Interlock crankshaft, press the assembly device -T10121- into the hole in the flywheel.

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.


Note

T10123

Note



13-3 page 3

13

Removing and installing the camshaft sprocket, setting the timing


Pressure pad -MP 1-216-

Removing the camshaft sprocket


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


The pistons must not be positioned at top dead centre.

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.


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.

Note



13-3 page 4

13

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.

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-.

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

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 Engine, Fuel Injection; Rep. Gr. 01.

Removing the camshaft sprockets


Interlock camshafts and crankshaft at TDC for cylin-der 1 13-3 page 1.

Remove the timing gear cover Chapter 13-2. 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)

Note

Note



13-3 page 5

13

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



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.


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-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.

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.

Note

T10123

Note



13-3 page 6

13

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.


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 Engine, Fuel Injection; Rep. Gr. 01.

Note


Removing and installing the gasket ring and flywheelEdition 04.03S00.5322.01.20

13-4 page 1

13

13-4 Removing and installing the gasket ring and flywheel

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

replace Interlock crankshaft with a

fixing bolt -T10121- for re-moving and installing it Chapter 13-3

2 - Belt pulley - crankshaft3 - Housing

Replace together with O-ring item 4

Replace silicone sealant sealing with O-Ring item 4

fit onto cleaned crankshaft4 - O-ring

replace if damaged 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 block7 - 60 Nm + torque a further 90

(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 Neither grease nor oil sealing lip of sealing ring

Note


Removing and installing the gasket ring and flywheel Edition 04.03S00.5322.01.20

13-4 page 2

13

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 the V-ribbed belt Chapter 13-1. Remove belt pulley - crankshaft and housing Chapter 13-2.

Remove the gasket ring carefully using a screwdriver -A-.

The adhesive surface must not get damaged when re-moving the gasket ring.

Installing


Pressure plate -T40008-

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-.

The adhesive surface must not get damaged when re-moving the gasket ring.

Note

Note

Note


Removing and installing the gasket ring and flywheelEdition 04.03S00.5322.01.20

13-4 page 3

13

Installing

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.

Lay the flywheel in place so that the rotor for the engine speed is not damaged.

Note

Note


Removing and installing the gasket ring and flywheel Edition 04.03S00.5322.01.20

13-4 page 4

13


Removing and installing cylinder headEdition 12.04S00.5322.03.20

15-1 page 1

15

15-1 Removing and installing cylinder head


Testing compression pressure 15-1 page 5.

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.For engine with engine identification characters AWY, BMD

1 - Cylinder head with cover check for distortion Fig. 1

in 15-1 page 4 removing and installing 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 replace if damaged

4 - Cap5 - 20 Nm6 - Lifting eye - on the left7 - Cylinder head bolt

replace observe the mounting in-

structions and sequence for loosening and tightening 15-1 page 4

8 - From connecting hose for engine with engine identi-

fication characters BMD

9 - Ventilation hose with non-re-turn valve for engine with engine identi-

fication characters BMD

10 - From air filter for engine with engine identi-

fication characters AWY

11 - Ventilation hose for engine with engine identification characters AWY

12 - Camshaft position sensor -G163-13 - 8 Nm

15 Cylinder Head, Valve Gear

Note


Removing and installing cylinder head Edition 12.04S00.5322.03.20

15-1 page 2

15

14 - Gasket ring replace if damaged

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

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

21 - Camshaft sprocket removing and installing Chapter 13-3

22 - Lifting eye - on the right



replace2 - O-ring

replace if damaged3 - Camshaft position sensor

-G163-4 - 8 Nm5 - 10 Nm6 - Bracket

for the cable harness7 - Cap8 - 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



15-1 page 3

15

11 - Supporting element do not get them confused with each other. with hydraulic valve clearance compensation oil contact surface

12 - Valve collets13 - Valve spring retainer14 - Valve spring

removing and installing Chapter 15-3; replacing the valve stem seal15 - Valve stem seal

replacing Chapter 15-316 - 0.045 MPa (0.45 bar) oil pressure switch -F1-, 25 Nm

inspect Chapter 17-317 - 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 Nm22 - Lifting eye23 - Camshaft sprocket

24 - 50 Nm + torque a further 90 (1/4 turn) replace Interlock camshafts with a pipe section -T10121- for removing and installing it Chapter 13-3

25 - Washer for engine with engine identification characters AZQ replace

26 - Inlet camshaft27 - 15 Nm

for engine with engine identification characters AZQ28 - Sliding block

for engine with engine identification characters AZQ29 - Cylinder head cover

sealing surfaces must not be reworked. removing and installing Chapter 15-2, removing and installing the camshaft



15-1 page 4

15

Fig. 1: Inspecting the cylinder head for distortion


Straightedge Feeler gaugeMax. 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 timing gear cover Chapter 13-2. 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.




Carefully remove the cylinder head.

Do not lay the cylinder head on the surface with the head combustion chamber - danger of damaging the spark plugs.

Installing


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.

Note

Note



15-1 page 5

15

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:




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 that no valve touches the piston when the engine is started.

Testing the compression

Test condition

Engine oil temperature at least 30 CSpecial tools, test and measuring equipment and auxiliary items required

Compression tester e.g. -1763- Spark plug wrench e.g. -3122 B- Extractor -T10094-

Test sequence


Disconnect the 4-pin plug plug connector from ignition coils with a power output stage -N70-, -N127-, - N291-



15-1 page 6

15

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; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.

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-

Use of tester Operating Instructions. Operate starter until the tester no longer indicates a

pressure rise.

Compression readings

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 Engine, Fuel Injection; Rep. Gr. 01.

Separating the plug connections causes faults to be stored.

Note

new Wear limit Difference be-tween cylinders

min. 15 bar (1.5 MPa)

11 bar (1.1 MPa)

max. 3 bar (0.3 MPa)

Note


Repairing the valve gear - Part 1Edition 12.04S00.5322.03.20

15-2 page 1

15

15-2 Repairing the valve gear - Part 1


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 removing and installing 15-2 page 3, removing and installing the camshaft


replace3 - Camshaft

removing and installing 15-2 page 3

Pay attention to the marking Fig. 2 in 15-2 page 2

4 - 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

5 - Supporting element do not get them confused

with each other. with hydraulic valve clear-

ance compensation oil contact surface

6 - Valve collets7 - Valve spring retainer8 - Valve spring

replace springs as a set only removing and installing 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

Note


Repairing the valve gear - Part 1 Edition 12.04S00.5322.03.20

15-2 page 2

15

reworking valve seats Chapter 15-3

Fig. 1: Inspecting axial play of camshaft


Universal dial gauge holder -MP 3-447- Dial gaugePerform 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

Fig. 2: Camshaft identification

Identification

Fig. 3: Valve dimensions

The valves must not be reworked. Only grinding in with grinding paste in the related valve seat is permissible.



MP 3-447

S15-0178

Engine identifica-tion characters

AWY BMD

Camshaft 03D K, 03D N

03D P

Note

Dimension Inlet valve Exhaust valve

a mm 34,5 28 b mm 5,98 5,96c mm 99,25 99,25

45 45



15-2 page 3

15

Removing and installing camshaft



Sealant -D 154 103 A1- Grease -G 052 735 A2-

Removing

Remove the timing gear cover Chapter 13-2. 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.

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

Dimension Inlet valve Exhaust valve

a mm 29,5 26 b mm 5,973 5,953c mm 100,9 100,57

45 45

Note



15-2 page 4

15

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-: 23 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.

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.

Note



15-2 page 5

15

Insert new fixing screws and tighten in the direction given.


Wipe away exuded sealant particularly in the area steering wheel cover.




Sealant -D 154 103 A1- Grease -G 052 735 A2- Extractor -T10094-

Removing

Remove cylinder head cover

Sealing surfaces of cylinder head must not be reworked.

Remove the timing gear cover Chapter 13-2. 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; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.

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.

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

Note

Note



15-2 page 6

15

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.


Pay attention to smooth operation of the camshafts.

Install cylinder head cover

Sealing surfaces must be free of oil and grease. The pistons must not be positioned at top dead centre.

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: 23 mm. The sealant must be run past on the inside in the area

of the bolt holes.

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-.

Note

Note

Note



15-2 page 7

15

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.


Wipe away exuded sealant particularly in the area steering wheel cover.

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


Note



15-2 page 8

15



15-3 page 1

15

15-3 Repairing the valve gear - Part 2

Replacing valve stem seal

Removing



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)

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.

Release collets that are tight by striking with light blows of a hammer on the valve lever.

Note

Note



15-3 page 2

15

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



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- Extractor -T10094-(with cylinder head installed)

Use valve supporting plate -MP 1-218- with cylinder head removed, see procedure for engine with engine identifi-cation characters AWY, BMD.

Remove the V-ribbed belt Chapter 13-1. Remove cylinder head cover Chapter 15-2. Unscrew the spark plugs with spark plug wrench

-3122B-.

Note



15-3 page 3

15

Remove roller rocker arm and place on a clean sur-face. Make sure that you do not mix up the roller rock-er arms.

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

Insert the supplied plastic bushings on the relevant valve stem. This will prevent any damage to the new valve stem seals.

Insert the new valve stem seal -B- in the insertion tool -MP 1-233-.

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 Chapter 13-3.Further installation occurs in reverse order.

Inspect valve guides

Cylinder head and valve spring removedSpecial tools, test and measuring equipment and auxiliary items required

Universal dial gauge holder -MP 3-447- Dial gauge

Procedure

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.

MP1-229

MP1-210

MP1-229/1

S15-0158

S15-0161

MP1-233

A

B

Note



15-3 page 4

15

Determine valve rock.

Wear limit

If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded - replace cylinder head.

Reworking valve seats


Universal dial gauge holder -MP 3-447- Dial gauge Micrometer or caliper gauge NAC milling cutter for reworking valve seats Grinding paste

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.

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.


Attach universal dial gauge holder with bolt to cylinder head.

Inlet valve guide Exhaust valve guide

0,5 mm 0,55 mm

Note

Note

Note



15-3 page 5

15

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-.

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:


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.

Measured distance - minimum dimension = max. per-missible reworking dimension.

Example:

Note

Maximum dimension for both valves

103,7 mm

- (Valve length -c- + measured distance -h-)

(99,2 + 4,35) mm

= max. permissible reworking di-mension1)

0,15 mm

1) The max. permissible reworking dimension is shown in the figures for reworking the valve seats as dimension b.

Minimum dimension: for inlet and exhaust valve

7.6 mm



15-3 page 6

15


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



Reworking exhaust valve seat


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

Di-mension

Inlet valve seat

a mm 33,4b mm Max. permissible reworking dimension

c mm 1,5...1,7

Z Bottom edge of cylinder head

45 valve seat angle 30 top correction angle 60 bottom correction angleS Combustion chamber floor area

Di-mension

Inlet valve seat


c mm 1,5...1,8





15-3 page 7

15


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.

Di-mension

Exhaust valve seat


c mm 1,6...1,8



Di-mension

Exhaust valve seat


c mm approx. 1.8



S15-0098

Valve guide Guide drift in mmInlet valve 6,0 - 0,01

Exhaust valve



15-3 page 8

15

Match diameter of milling cutter to diameter of valve seat.

Milling sequence

1 - Machine valve seat with 90 milling tool until until a perfect contact pattern is achieved. (Do not exceed maximum permissible reworking dimension!)

2 - Chamfer top correction angle with 120 milling cut-ter until the valve seat diameter -a- ( 15-3 page 6) is achieved.

3 - Chamfer bottom correction angle with 60 milling 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.

If the reworking dimension is exceeded, proper operation of the valve gear is no longer assured and the cylinder head must be replaced.

Valve seat Mill-ing cut-ter 90

mm

Milling cutter 120 mm

Mill-ing cut-ter 60

mm

Inlet valve

AWY, BMD

engine

36 38 21/34

AZQ, BME en-

gine

32 32 21/34

Exhaust valve

AWY, BMD

engine

30 30 21/34

AZQ, BME en-

gine

30 30 21/34

c

120

90

1.

2.

S15-0062

60

3.

a

S15-0063

Note


Removing and installing parts of the lubrication system - Part 1Edition 04.03S00.5322.01.20

17-1 page 1

17

17-1 Removing and installing parts of the lubrication system - Part 1


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 specif

Engines Awy,Azq,Bmd,Bme

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