Motor ARV, AQV, AZE, AZF, AME, ATZ, AQW PDF

Service
Workshop Manual
FABIA 2000
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical

Components
Edition 08.99
Engine code
ARV AQV AZE
AZF AME ATZ AQW
Service Department. Technical Information
Printed in Czech Republic

S00.5305.00.20
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.
Service
Printed in Czech Republic

S00.5305.00.20
FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
List of Supplements to Workshop Manual
FABIA 2000
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Edition 08.99
Supplement
Subject
Article Number
08.99
Basic Edition
S00.5305.00.20
06.00
Supplement to Basic Edition
S00.5305.01.20
03.01
Modifications in Rep. Gr. 00, 13, 15 and 17
S00.5305.02.20
02.02
Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26
S00.5305.03.20
09.03
Modifications in Rep. Gr. 00, 13, 15 and 17
S00.5305.04.20
Edition 09.03
S00.5305.04.20
Edition
List of Supplements
List of Supplements
Edition 09.03
S00.5305.04.20
Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1
page
Removing and Installing Engine .................................................................... 10-1
page
- Removing engine ...................................................................................... 10-1
page
- Installing the engine ................................................................................... 10-1
page
- Tightening torques .................................................................................... 10-1
page
- Assembly bracket ...................................................................................... 10-1
page
Removing and installing V-ribbed belt ............................................................ 13-1
page
- Summary of components - Vehicles without air conditioning ................................... 13-1
page
- Summary of components - Vehicles with air conditioning ....................................... 13-1
page
- Removing the V-ribbed belt .......................................................................... 13-1
page
- Installing the V-ribbed belt ........................................................................... 13-1
page
Disassembling and Assembling Cylinder Block and Crankshaft ........................... 13-2
page
- Summary of components ............................................................................. 13-2
page
- Inspecting synchronous running of sprockets ..................................................... 13-2
page
- Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-2
page
- Replacing ring gear ................................................................................... 13-2
page
Disassembling and Assembling Pistons, Connecting Rod and Liner ..................... 13-3
page
Removing and installing cylinder head ........................................................... 15-1
page
page
- Removing and installing cylinder head ............................................................. 15-1
page
Repairing cylinder head .............................................................................. 15-2
page
- Inspect valve guides .................................................................................. 15-2
page
- Removing and installing valves ..................................................................... 15-2
page
- Reworking valve seats ................................................................................ 15-2
page
- Replacing valve stem seal ........................................................................... 15-2
page
- Basic setting of hydraulic valve clearance compensation ....................................... 15-2
page
- Testing the compression ............................................................................. 15-2
page
Repairing valve gear ................................................................................... 15-3
page
- Removing and installing camshaft .................................................................. 15-3
page
- Removing and installing rocker arms ............................................................... 15-3
page
- Inspecting hydraulic tappets ......................................................................... 15-3
page
Removing and installing parts of the lubrication system ..................................... 17-1
page
page
Removing and installing oil pan .................................................................... 17-2
page
- Removing and installing oil pan - for a 1.0 litre engine .......................................... 17-2
page
- Removing and installing oil pan - for a 1.4 litre engine .......................................... 17-2
page
Testing Oil Pressure and Oil Pressure Switch .................................................. 17-3
page
10 Removing and Installing Engine
13 Crankgear
15 Cylinder Head, Valve Gear
17 Lubrication
Edition 09.03
S00.5305.04.20
Table of Contents
19 Cooling
Parts of cooling system - Summary of components ........................................... 19-1
page
- Parts of the cooling system fitted to body ......................................................... 19-1
page
- Parts of cooling system engine side ................................................................ 19-1
page
- Connection diagram for coolant hoses ............................................................. 19-1
page
- Draining and filling up coolant ....................................................................... 19-1
page
- Checking the coolant system for tightness ........................................................ 19-1
page
Removing and Installing Radiator, Coolant Pump ............................................. 19-2
page
- Removing and installing radiator .................................................................... 19-2
page
- Removing and installing coolant pump ............................................................ 19-2
page
Removing and Installing Parts of the Fuel Supply System ................................... 20-1
page
- Safety precautions when working on the fuel supply system ................................... 20-1
page
- Cleanliness rules ...................................................................................... 20-1
page
Activated Charcoal Filter System .................................................................. 20-2
page
- Repairing parts of the activated charcoal filter system .......................................... 20-2
page
Removing and installing parts of the exhaust system ........................................ 26-1
page
- Aligning exhaust system free of stress ............................................................. 26-1
page
- Replacing front or rear silencer ..................................................................... 26-1
page
- Checking the exhaust system for leaks ............................................................ 26-1
page
20 Fuel Supply
26 Exhaust System
II
Table of Contents
Edition 09.03
S00.5305.04.20
00
00 Technical Data
00-1
Technical Data
Engine number
The engine number (engine identification characters
and serial number) is located on the end face of the cylinder block on the belt pulley side, at the connection to
the cylinder head -arrow-.
In addition, a sticker with engine identification and serial number is affixed to the cylinder head cover.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
Engine identification characters
Manufactured
ARV
AQV
AZE
AZF
01.01 07.02
01.01 07.02
04.00 03.03
04.00 03.03
EU-2
EU-3
EU-2
EU-4
0,997
0,997
1,397
1,397
Exhaust limits conforming to

Displacement
Power output
kW at
rpm
37/5000
37/5000
44/5000
44/5000
Torque
Nm at
rpm
84/2750
84/2750
118/2600
118/2600
Bore
mm
72
72
75,5
75,5
61,2
61,2
78,0
78,0
10 : 1
10 : 1
10 : 1
10 : 1
Stroke
mm
Compression
Fuel - RON
Fuel injection and ignition system
95
unleaded1)
95
unleaded1)
95
unleaded1)
95 unleaded1)
Simos 3PB
Simos 3PA
Simos 3PB
Simos 3PA
Knock control
yes
yes
yes
yes
Self-diagnosis
yes
yes
yes
yes
1 lambda probe
2 lambda probes
1 lambda probe
2 lambda probes
1 Catalyst
2 Catalysts
1 Catalyst
2 Catalysts
Turbocharging
no
no
no
no
Exhaust gas recirculation
no
no
no
no
Secondary air system
no
no
no
no
Camshaft adjustment
no
no
no
no
Lambda control
Catalytic converter
1)
At least 91 RON in exceptional cases; the engine output is reduced however
Edition 09.03
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Technical Data
00-1 page 1
00
Engine identification characters

Manufactured
Exhaust limits conforming to
AME
ATZ
AQW
08.99 04.03
11.99 07.00
08.00 03.03
EU-2
D4
EU-4, EU3-DDK
1,397
1,397
1,397
Displacement
Power output
kW at rpm
50/5000
50/5000
50/5000
Torque
Nm at rpm
120/2500
120/2500
120/2500
mm
75,5
75,5
75,5
mm
78,0
78,0
78,0
10 : 1
10 : 1
10 : 1
95 unleaded1)
95 unleaded1)
95 unleaded1)
Simos 3PB
Simos 3PA
Simos 3PA
Knock control
yes
yes
yes
Self-diagnosis
yes
yes
yes
1 lambda probe
2 lambda probes
2 lambda probes
1 Catalyst
2 Catalysts
2 Catalysts
Turbocharging
no
no
no
Exhaust gas recirculation
no
no
no
Secondary air system
no
no
no
Camshaft adjustment
no
no
no
Bore
Stroke
Compression
Fuel - RON
Fuel injection and ignition system
Lambda control
Catalytic converter
1)
At least 91 RON in exceptional cases; the engine output is reduced however
00-1 page 2
Technical Data
Edition 09.03
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10
10 Removing and Installing Engine

10-1
Removing and Installing

Engine
Special tools, test and measuring equipment and

auxiliary items required
Workshop crane (e.g. -V.A.G 1202 A-)
Catch pan (e.g. -V.A.G 1306-)
Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-)
Pliers for spring strap clips
Engine mount -MP 1-180 Assembly stand -MP 9-101 Lifting device -MP 9-201 Grease -G 000 100 Hot screw paste -G 052 112 A3 Wire
Adhesive tape
Removing engine
Note
The engine is removed towards the front together with
the gearbox.
Supporting points for lift platform Inspection and
Maintenance.
The hose connections are secured with screw-type
clips, spring-type clips or clamp-type clips. Always replace warm-type clamps with spring strap clips or
warm-type clamps.
Fuel hoses at the engine must only be secured with
spring-type clips. The use of clamp-type or screw-type

clips is not allowed.
Use pliers for spring strap clips to fit the spring strap
clips.
Pay attention to the correct assignment of the connec-
tors, if necessary mark.
Procedure
On models fitted with a coded radio set, pay attention

to the coding; determine if necessary.
Disconnect the earth strap from the battery with the ignition off.
Remove noise insulation -arrows-.

Unscrew the drive shaft to the right and left of the
gearbox.
Raise drive shafts and secure.
Edition 02.02
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S10-0135
Removing and Installing Engine
10-1 page 1
10
Remove front exhaust pipe with catalyst Chap. 261.
Place drip tray below the engine (e. g. -V.A.G 1306-).

Loosen the drain screw on the coolant expansion bottle.
Turn the drain plug -arrow- on the radiator to the left

and draw backwards, if necessary fit auxiliary hose
onto connection.
A10-0118
Remove engine cover -1- as follows:
3
4
Release logo -2- and carefully lever off the cap -3-.
Release nuts -4- (5 Nm).
Pull out oil dipstick -6-.
Remove engine cover -1- towards the top (do not un-
screw cap -5-).
Close the oil filler inlet on the cylinder head cover with
4
5
the cap fitted to the bottom of the engine cover (if not
available use other means).
Remove the air filter with hoses 1.0/37; 1.4/44; 1.4/

50 engine - fuel injection; Rep. Gr. 24.
Remove the cable from the starter solenoid switch
S10-0138
Electrical System; Rep. Gr. 27.
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
Release the generator cables from the battery cover

and remove the wiring loom from the holder.
Unplug connector -1- from the engine control unit.

Separate plug connection -2-.
Unclip cable clip -3- -arrows-.
1
2
S10-0142
10-1 page 2
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10
Remove coolant hoses -1- and -2- from the coolant

regulator housing.
Remove the vacuum connection from the brake servo
unit.
Caution!
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.
S10-0141
Remove the fuel presupply pipe -4- by pressing the re-
lease buttons at the separation point.
Remove coolant hoses -1- and -2- from the expansion

reservoir.
Release vacuum hose -3- from the solenoid valve

-N80-.
1
3
S10-0137
Release nut -arrow A- and tie up holder -1-.
1
A
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S34-0397
10-1 page 3
10
Disconnect the Bowden cable support from gearbox

-arrows-.
S34-0389
Detach selector cable -A-, for this step remove circlip
-arrow 1- from the relay lever.
Remove bearing bolt -arrow 2- from the reversing le-
ver of the selector cable -A-.
Remove the shift cable -B- with the gearbox shift le-
ver, for this step unscrew nut -arrow 3-.
2
B
S34-0398
Remove the hose line holder -1- from the gearbox -arrow A-.
Remove -arrow B- the slave cylinder -2- and lay aside,

secure with wire, do not open the line system.
Note
Do not depress the clutch pedal.
B
B
S34-0400
10-1 page 4
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10
Remove the earth strap -1- from the front of the gearbox.
Disconnect plug -2- from the reversing light switch

-F4-.
Separate plug connection -3-.
2
S10-0143
Remove coolant hose from the rear coolant pipe -arrow-.
S10-0139
Remove connector -1- from thermo-switch -F18- and

separate plug connections -2- on the holder of the air
duct scoop.
To do so press the latch clips.
There are 2 plug connections on vehicles fitted with air

conditioning.
Separate the coolant hose from the radiator at the top

and bottom of the connection fittings.
To do so pull the retaining clip -3- up to the stop and

remove the quick coupling towards the rear.
S19-0078
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10-1 page 5
10
Unbolt the pendulum support -arrows-.

Vehicles without air conditioning
Removing the lock carrier with radiator Body Work;

Rep. Gr. 50.
Vehicles with air conditioning

Caution!
Do not open the refrigerant circuit of the air conditioning system.
S34-0403
Remove the V-ribbed belt Chapter 13-1.

Remove connector from the AC compressor.
Remove AC compressor with the refrigerant lines connected.
Secure the AC compressor -1- to the lock carrier -arrow-.
Remove the lock carrier with the radiator and con-
denser Body work; Rep. Gr. 50, swivel to the side

and position on support -2- in such a way that there is
no risk of tilting.
Note
Do not buckle the refrigerant lines.

Use cloths to protect the right headlight glass from
damage, removing the headlight if necessary.
S10-0136
Continued for all vehicles
Hook on lifting device -MP 9-201- as follows and raise
MP 9-201
slightly with the workshop crane.

On the belt pulley side:
2nd hole of the vertical perforated bar in position 1
On the flywheel side:
2nd hole of the vertical perforated bar in position 5
Warning!
Use securing pins on the hooks and rig pins.
Note
S10-0134
The rig positions on the supporting bracket marked 1
to 4 point towards the belt pulley.

The holes in the vertical perforated bars are counted
from the hook.
10-1 page 6
Edition 02.02
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10
Release screws -2-.
3
S10-0140
Unscrew the fixing screws -arrows- from the gearbox

mount.
Slightly lower the engine/gearbox unit and pull out

carefully towards the front.
S10-0120
Secure the engine with engine mount -MP 1-180- on the

assembly support -MP 9-101- before performing assembly work.
Note
Grip the engine on the supports of the engine mount -arrows-.
MP 1-180
Instead of engine mount -MP 1-180- it is also possible to

use engine mount -MP 1-202-.
MP 9-101
Installing the engine

Note
S10-0082
Always replace the seals and gaskets during assem-
bly work.
Always replace self-locking nuts.
Apply hot screw paste -G 052 112 A3- to the pin
screws on the exhaust manifold.

Tightening torques 10-1 page 9
Assembly bracket 10-1 page 9
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10-1 page 7
10
Procedure
Installation is performed in the reverse order. Pay attention to the following points:
Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; insert if necessary.
If necessary check the centering of the clutch driver

disc.
Inspect clutch release bearing for wear, replace if necessary.
Lubricate the drive shaft serration lightly with grease

-G 000 100 -.
Install the slave cylinder of the hydraulic clutch

Gearbox 002; Rep. Gr. 30.
Adjust the gearshift mechanism and cable control

Gearbox 002; Rep. Gr. 34.
When installing the engine/gearbox unit make sure all

adjoining components are clear.
Align the engine/gearbox unit.

Tightening torques 10-1 page 9.
Install the AC compressor Chapter 13-1.

Install alternator Electrical System; Rep. Gr. 27.
Fit V-ribbed belt Chapter 13-1.
Continued for all vehicles
Install the drive shaft on the right and left of the gearbox Chassis; Rep. Gr. 40.
Install the front exhaust pipe with catalyst and fit the
exhaust pipe free of stress Chapter 26-1.
Electrical connections and cables Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Install coolant hoses Chapter 19-1.

Note
The drained off coolant must only be re-used if the cylinder block, cylinder head, radiator or heat exchanger were
not replaced.
Top up coolant Chapter 19-1

After connecting the battery:
Code radio.
Set clock.
Initialise power window lifter.
Inspection and Maintenance
Check oil level before starting the engine.
10-1 page 8
Edition 02.02
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10
Adapt the engine control unit to the throttle valve control unit -J338- 1.4/1.0; 1.4/44 engine - fuel injection; Rep. Gr. 24.
Perform a test drive and interrogate and erase fault
memory 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01 .
Tightening torques
Note
Tightening torques apply only for lightly greased,
oiled, phosphatized or blackened nuts and screws.

Other lubricants such as engine and gearbox oil are
allowed. Do not use Molykote.

Do not use degreased parts.
Unless otherwise indicated the following tightening
torques apply:
Component
Screws/nuts
Torque
M6
9 Nm
M7
13 Nm
M8
20 Nm
M10
40 Nm
M12
70 Nm
deviations:
Engine to gearbox connecting
screws
Manual gearbox
002; rep. size 34
Drive shaft to gearbox mounting flange
Chassis; rep. size

40
Assembly bracket
Tightening torques
Engine mounting
S10-0132
1 - 20 Nm + 90 (1/4 turn) - replace

2 - 30 Nm + 90 (1/4 turn) - replace
Gearbox mounting
1 - 50 Nm + 90 (1/4 turn) - replace
2 - 40 Nm + 90 (1/4 turn) - replace
1
Edition 02.02
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S10-0125
10-1 page 9
10
Hinged bracket
Note
Tighten screws -1- in the elongated holes of the support
in such a way that the maximum permissible distance is
obtained between the gearbox and the assembly carrier.
1 - 30 Nm + 90 (1/4 turn) - replace
2 - 40 Nm + 90 (1/4 turn) - replace
1
2
10-1 page 10
S10-0133
Edition 02.02
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13
13 Crankgear
13-1
Removing and installing V-ribbed belt
Summary of components - Vehicles without air conditioning

Note
Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used
belt may destroy it.

Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.
1 - Coolant pump
T removing and installing
Chapter 19-2
2 - Bracket
1
T for clamp
Chapter 15-1
3 - Screw
4 - Clamp
5 - 25 Nm
T replace
6 - Generator
T to facilitate positioning of the
generator on the holder,
drive the bushing of the retaining screw slightly backwards
7 - Screw
8 - 30 Nm
T replace
9 - 45 Nm
10 - 25 Nm
T coat with -AMV 105 50017
(Loctite 242) before inserting
11 - Bracket
T for generator
16 15
12 - Guide pulley
13 - Washer
T Camber towards the outside
14 - 20 Nm
T Left-hand thread
T coat with -AMV 154 100- (Loctite 648) before inserting
15 - Belt pulley
T for crankshaft
16 - 100 Nm
T to release and tighten lock flywheel
Engine removed: with -MP 1-504 Engine installed: with locking screw Chapter 13-2
17 - V-ribbed belt
T Routing of the ribbed V-belt Fig. 1 in 13-1 page 2
T removing 13-1 page 4
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2
3
4
7
9
14 13 12
11
10
S13-0241
13-1 page 1
13

T installing 13-1 page 5
Fig. 1:
1234-
Routing of the ribbed V-belt
Belt pulley - generator

Belt pulley - crankshaft
Guide pulley
Belt pulley - coolant pump
4
3
2
13-1 page 2
S13-0242
Edition 02.02
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13
Summary of components - Vehicles with air conditioning

Note
Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used
belt may destroy it.

Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.
1 - Coolant pump
5
4
1 2 3
Chapter 19-2
2 - Lever with tensioner
4
T grease bearing points in
6
holder before fitting
5
3 - Bracket
8
7
T for generator and AC com10
11
pressor
7
9
13 12
4 - Gasket
8
T replace
9
5 - 20 Nm
6 - 10 Nm
15
7 - Screw
14
T tightening order and tightening torque Fig. 2 in 13-1
page 4
16
8 - Washer
9 - Screw
T tightening order and tightening torque Fig. 2 in 13-1
17
page 4
T coat with -AMV 105 500(Loctite 242) before inserting
10 - Bushing
22
11 - Guide pulley
18
12 - Washer
T Camber towards the outside
19
13 - 35 Nm
T coat with -AMV 200 000S13-0344
21
20
(Loctite 270) before inserting
14 - Screw
T tightening order and tightening torque Fig. 2 in 13-1 page 4
15 - Dowel sleeves for AC compressor
T must be present in holder item 3 in 13-1 page 3
16 - 45 Nm
17 - 25 Nm
18 - Generator
T to facilitate the positioning of the generator on the holder drive the bushing of the retaining screw slightly backwards
19 - 25 Nm
20 - Belt pulley
T for crankshaft
21 - 100 Nm
Engine removed: with -MP 1-504 Engine installed: with locking screw Chapter 13-2
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13-1 page 3
13
22 - V-ribbed belt
T Routing of the ribbed V-belt Fig. 3 in 13-1 page 4
T removing 13-1 page 4
T installing 13-1 page 6
Fig. 2:
1234567-
Tightening torques and tightening order for

alternator bracket and AC compressor
23 Nm
Bracket for alternator and AC compressor
45 Nm
Washer
23 Nm
45 Nm
23 Nm
Screws are tightened up in two stages in the following order:

1. Stage: tighten to 2 Nm one after the other in the or-
der of items: 1, 2, 3, 4, 5
2. Stage: the desired final tightening torque - tighten in
the same order as for the 1st stage

Fig. 3:
123456-
Routing of the V-ribbed belt
Belt pulley - AC compressor

Guide pulley
Belt pulley - generator
Belt pulley - crankshaft
Tensioning pulley
Belt pulley - coolant pump
5
2
Removing the V-ribbed belt

Removing - vehicles without air conditioning
3
S13-0244
Mark the routing of the V-ribbed belt.

Release securing screws -arrows- and pivot the generator towards the engine.
Remove the V-ribbed belt.

Removing- vehicles with air conditioning
Wrench for V-ribbed belt -T30022-
Note
The assistance of a second mechanic is required to tighten the V-ribbed belt.
13-1 page 4
S13-0245
Edition 02.02
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13

Mark the routing of the V-ribbed belt.
S10-0135
Release screw -1- from the tensioner -3-.

Remove camshaft position sensor -2-.
Insert wrench for ribbed V-belt -T30022 - in the ten-
T30022
1
sioner -3- up to the stop.
Loosen tensioning pulley (tighten tensioner -3-). To
this end rotate wrench in the direction of the arrow.
Remove the V-ribbed belt from the tensioning pulley

and pivot tensioning pulley back.
Installing the V-ribbed belt

Note
Check V-ribbed belt for wear Inspection and Main-
S13-0246
tenance.
Before fitting the V-ribbed belt make sure that all as-
semblies (generator, coolant pump, AC compressor)

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.
Installing- Vehicles without air conditioning

Torque wrench
V-ribbed belt tensioning tool (e.g. NP 002 manufac-
tured by Nolt)
Belt tension measuring tool (e.g. of the firm Optibelt or
Clavis)
Replace self-locking nuts -arrows- and tighten while

making sure the generator can still be rotated.
Fit the ribbed V-belt.

S13-0245
Edition 02.02
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13-1 page 5
13
Insert V-ribbed belt tensioning tool NP 002 in the

clamp and tension the V-ribbed belt by screwing out
the handle -in direction of the arrow-.
NP 002
S27-0014
Position the belt tension measuring tool (in the figure

of the firm Optibelt) on the V-ribbed belt and read off
the belt tension value -arrow- on the scale Operating Instructions for the relevant measuring tool.
Note
Tighten the new ribbed V-belt with 500 +100 N, run engine
for approximately 1 minute in idle and re-adjust the belt
tension.
Nominal values for the tension of the V-ribbed belt:
New ribbed V-belt (run in for 1 minute): 400
Used V-ribbed belt: 400
+50
+80
N
S13-0240
Once the nominal value has been reached, tighten the

nuts of the generator mounting:
1 - 25 Nm
2 - 25 Nm
3 - 30 Nm
Check belt tension again, correct if necessary.

Start engine and check belt run.
3
Installing - Vehicles with air conditioning
S13-0249
Wrench for ribbed V-belt -T30022-
Note
The assistance of a second mechanic is required to loosen the V-ribbed belt.
Position the V-ribbed belt on the belt pulleys and

guide pulley.
13-1 page 6
Edition 02.02
S00.5305.03.20
13
Insert wrench for V-ribbed belt -T30022 - in the ten-
T30022
sioner -3- up to the stop.
Loosen tensioning pulley (tighten tensioner -3-). To

this end rotate wrench in the direction of the arrow.
Position the V-ribbed belt on the tensioning pulley and

pivot tensioning pulley back.
Tighten screw -1- on the tensioner -3-.

Tightening torque: 10 Nm
Fit camshaft position sensor -2-.

S13-0246
Start engine and check belt run.

Fit noise insulation -arrows-.
S10-0135
Edition 02.02
S00.5305.03.20
13-1 page 7
13
13-1 page 8
Edition 02.02
S00.5305.03.20
13
13-2
Disassembling and Assembling Cylinder Block

and Crankshaft
Summary of components
1.4 ltr. engine
1.0 litre engine 13-2 page 3
Note
The design of the 1.0 litre engine is essentially identical to that of the 1.4 ltr. engine. Differences exist only in the
version of the crankshaft and its mounting 13-2 page 3.
Repairing the clutch Manual Gearbox 002; Rep. Gr. 30; Repairing the clutch.
The engine should be attached to the engine repair stand -MP 1-180- or -MP 1-202 - on the engine holder
-MP 9-101- to carry out removal and installation work.

1 - 75 Nm
2 - Crankshaft bearing unit
3 - Thrust washer
T for middle bearing
T lubricating grooves point outwards
4 - 8 Nm
T coat with -AMV 188 520(Loctite 574) before inserting
5 - Flywheel
T with rotor for engine speed
sender -G28T lock with -MP 1-504- for removing and installing
T replace ring gear 13-2
page 7
T installation position to crankshaft:
on the 1.0 ltr. engine the 2
missing teeth of the rotor
must face forward when
crankshaft position at TDC of
cyl. 1 (marking of belt pulley crankshaft is positioned opposite marking 0 at timing
gear cover)
only one installed position is
possible for the 1.4 litre engine (since the bore holes
are varying distances apart)
4
5
29
28
27
26
25
13
24 23 22 21 20
6 - 30 Nm + torque a further 1/4

turn (90)
T replace
7 - Gasket ring
T replace
T remove when removing the sealing flange
T lightly oil sealing lip and outer edge before installing
Edition 09.03
S00.5305.04.20
7
8
9
10
11
12
14
15
19 18 17 16
Disassembling and Assembling Cylinder Block and Crankshaft
S13-0170
13-2 page 1
13
8-
910 11 12 13 14 15 16 17 18 -
19 20 21 22 23 24 -
25 -
26 -
27 28 -
29 -

T press into the sealing flange
Sealing flange
T not available as replacement part (only together with cylinder block)
Shield
T for knock sensor -G615 Nm
20 Nm
T The tightening torque influences the knock sensor function
Knock sensor -G61Cylinder block
T disassembling and assembling pistons, conrod and liner Chapter 13-3
8 Nm
Timing gear cover
Gasket ring
T replace 13-2 page 4
Belt pulley
T for crankshaft
100 Nm
Engine removed: with -MP 1-504 Engine installed: with locking screw 13-2 page 4
7 Nm
Gasket
T replace
Camshaft sprocket
T after replacing, inspect synchronous running of chain sprockets Fig. 1 in 13-2 page 3
Helical gear
T for oil pump drive
25 Nm
Timing chain
T mark running direction (installed position) before removing
T always replace complete with crankshaft sprocket and camshaft sprocket
Bearing shell
T for cylinder block with lubricating groove
T do not mix up used bearing shells (mark)
Crankshaft sprocket
T after replacing, inspect synchronous running of chain sprockets 13-2 page 3
T Camshaft setting Fig. 1 in 13-2 page 3
Woodruff key
T check tightness
Crankshaft
T Axial play when new: 0.03 to 0.13 mm
T Wear limit: 0.26 mm
Bearing shell
T for crankshaft bearing unit without lubricating groove
T do not mix up used bearing shells (mark)
13-2 page 2
Edition 09.03
S00.5305.04.20
13
Modifications of the 1.0 litre engine compared to the 1.4 litre engine
1 - Bearing caps
T Bearing cap 1: on the belt
pulley side
T Bearing cap 2: with recesses
for thrust washers
2 - Bearing shell
T for bearing cap without lubricating groove
T do not mix up used bearing
shells (mark)
3 - Thrust washer
T for bearing cap 2
T check for firm seating
4 - Crankshaft
T Axial play when new: 0.03 to
0.13 mm
T Wear limit: 0.26 mm
5 - Bearing shell
T for cylinder block with lubricating groove
T do not mix up used bearing
shells (mark)
5
S13-0209
Fig. 1:
Camshaft setting
Insert chain sprockets -2- and -3- into the timing chain
Inspecting synchronous running of

sprockets
a=
12
-1- so that the distance -a- (from marking to marking

-arrows-) is 12 chain pins.
This inspection should be carried out if the sprockets

have been replaced.

Straightedge
S15-0028
Feeler gauge
The crankshaft sprocket is available in 3 different widths;

graduations: marked 0.2 mm with letters E, F or G.
The wheel with an average thickness, marked with the
letter F, is supplied together with the camshaft sprocket
Edition 09.03
S00.5305.04.20
13-2 page 3
13
in a set, the wheels marked with the letters E and G

are only supplied individually Spare Part Catalogue.
Marking of the crankshaft sprocket radially in the area of
the slot for the Woodruff key -arrow- is carried out with the
letters E, F or G.
Note
If chain sprockets are replaced, order crankshaft sprocket with same code letter and check synchronous running of chain sprockets.
S13-0172
Test sequence
Press the chain sprockets until they make contact,

with the markings -arrows- for the timing pointing outwards.
Place straightedge flat onto the camshaft sprocket

and measure size of gap at crankshaft sprocket.
S15-0027
Position of chain sprockets

1 - Camshaft sprocket
2 - Crankshaft sprocket
Pfeil-points towards flywheel side
I - Nominal dimension -a- = 0.09 0.2 mm
II - max. tolerance -b- = 0.29 mm
III - min. tolerance -c- = -0.11 mm (crankshaft sprocket
is positioned further out)
If the size of the gap is not within the tolerance range,
II
III
1
a
1
b
1
c
install crankshaft sprocket of a different width and repeat the inspection.
Replacing gasket ring for crankshaft -on

the belt pulley side-
S13-0171

Pressure plate -MP 6-401/1 Supporting device -MP 9-200 Two-arm extractor -Kukko 20-10 Removal hooks -T10040/1 Pressure plate -T10041-
13-2 page 4
Edition 09.03
S00.5305.04.20
13

Flywheel lock -MP 1-504 Torque wrench
Screw M 6x40 (grade: 8.8)
make a 60 point at the extremity of the bolt (locking

screw)
Nut M6
Removing
Removing engine cover Chapter 10-1.

Mount supporting device -MP 9-200- and take up the
weight of the engine/gearbox assembly at the spindles.
Unscrew bolts -2-.

Remove right wheel-well inner panel.
3
S10-0140

Lower engine approximately 50 mm.
Remove the V-ribbed belt Chapter 13-1.
S10-0135
Edition 09.03
S00.5305.04.20
13-2 page 5
13
To lock the crankshaft remove the engine speed

sender and screw in the locking screw -1- instead.
Slightly rotate the crankshaft on the central screw until
the locking screw can be fully tightened (screw tip is

located between 2 teeth of the ring gear).
Tighten up the screw and secure in place with the

counternut -2-.
Note
If the engine has been removed use a flywheel lock

-MP 1-504- to lock the crankshaft.
S13-0173
Remove the central screw and belt pulley crankshaft.

Pull out gasket ring with two-arm extractor -A- (Kukko
-20-10-), extractor hook -T10040/1 - and pressure
plate -MP 6-401/1-.
Installing
Crankshaft is locked with flywheel lock -MP 1-504 -, or
T10040/1
locking bolt.
T10040/1
MP 6-401/1
S13-0175
Lightly oil the sealing lip of the gasket ring.

Press down gasket ring with pressure plate -T10041 up to the stop into the bushing.
Note
Use to press in the central screw.
Install the crankshaft belt pulley.

Tighten central screw with 100 Nm.
Release locking screw and install engine speed send-
T10041
er.
Note
N13-0425
Do not start engine as long as the locking screw is located in the gearbox housing!
Install the V-ribbed belt Chapter 13-1.

Installing pendulum support and attaching engine
mounting Chapter 10-1.
Attaching the double clamp of the exhaust system

Chapter 26-1.
13-2 page 6
Edition 09.03
S00.5305.04.20
13
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 flywheel; knock on as far as the stop evenly with a drift
over the entire circumference, if necessary.
Edition 09.03
S00.5305.04.20
13-2 page 7
13
13-2 page 8
Edition 09.03
S00.5305.04.20
13-3
13
Disassembling and Assembling Pistons, Connecting Rod and

Liner
Note
Secure the engine with engine holder -MP 1-180- or -MP 1-202- on the assembly stand -MP 9-101- before performing
assembly work.
Special tools, test and measuring equipment and aids required
Liner extractor 75.5 mm -MP 1-105 Piston pin drift -T10046-
1 - Piston ring (chrome-plated)

T use piston ring pliers for re1
moving and installing
2
T marking TOP faces piston
crown
T inspecting piston ring gap
3
clearance Fig. 1 in 13-3
page 2
T inspecting piston ring end
4
15
page 3
2 - Piston ring (grey)
5
14
T use piston ring pliers for re6
moving and installing
T marking TOP faces piston
13
B
crown
T inspecting piston ring gap
11
page 2
12
T inspecting piston ring end
11
A
page 3
T offset gap 120 relative to top
10
piston ring
9
3 - Oil scraper ring (3 part)
T remove and install by hand
T installing Fig. 3 in 13-3
8
page 3
7
4 - Piston
T mark installation position and
matching liner
T arrow on piston crown faces
S13-0210
towards the camshaft side
T use piston ring tensioning strap for installing
T install pistons of the same weight class only (+ pr - on piston crown)
T available as replacement part only as a set with liners (4 in total)
5 - Conrod
T Check fitting position: engraved number (1 to 4 for appropriate cylinder) -arrow A- points towards camshaft
side, mark if necessary
T Oil drilling -arrow B- for piston pin lubrication
T available as replacement part only in set (4 conrods with 4 conrod caps)
6 - Conrod bolt
T only 1.4 ltr. engine
T check fitting position
T press out to replace
Edition 06.00
S00.5305.01.20

Liner
13-3 page 1
13
7 - Cylinder block
T seat surfaces for liners must be clean and flat
T remove contamination on seat surfaces of the liners by cleaning only; do not use emery paper, flat scraper or
similar
8 - Conrod bolt, 20 Nm + torque a further 1/4 turn (90)
T replace
T oil thread and head contact surface
9 - 40 Nm
T oil thread and head contact surface
10 - Conrod cap
T check fitting position item 5 in 13-3 page 1
11 - Bearing shell
T do not mix up used bearing shells
T 1.0 ltr. engine insert in middle
T 1.4 ltr. engine ensure tightly located in retaining lugs
12 - Gasket ring
T replace
T different thicknesses are available to correct the liner pretension
13 - Liner
T remove with -MP 1-105T available as replacement part only as a set with pistons (4 in total)
T check pretension Fig. 4 in 13-3 page 3
14 - Circlip
15 - Piston pin
T remove and install with -T10046-, if stiff, heat piston to 60 C
Fig. 1:
Inspecting piston ring gap clearance

Feeler gauge
Push in ring, at right angles about 15 mm away from

top edge of liner.
new
Piston ring
dimensions
in mm
1.0 ltr. engine
1.4 ltr. engine
Wear limit
1. Piston ring
(chrome-plated)
0,20...0,50
0,40...0,72
1,0
2. Piston ring
(grey)
0,20...0,50
0,30...0,62
1,0
Oil scraper
ring
0,40...1,40
0,40...1,40
---1)
1)
S13-0006
no specification possible for wear limit
13-3 page 2

Liner
Edition 06.00
S00.5305.01.20
13

Fig. 2:
Inspecting piston ring end clearance

Feeler gauge
Clean ring groove before inspecting.

Piston ring dimensions
in mm
new
Wear limit
1. Piston ring
(chrome-plated)
0,04...0,08
0,15
2. Piston ring (grey)
0,04...0,08
0,15
Oil scraper ring

Fig. 3:
cannot be measured
V13 - 0687
Installing oil scraper ring
The oil scraper ring consists of a shaped spring ring and

a top and bottom metal ring.
Installation steps:
Insert spring ring into the groove. Position joint so that

there is no hole behind it.
Compress joint of spring ring and insert top metal ring.

The joint of the top metal ring should be positioned
45...90 to the left of the joint of the spring ring.
Compress joint of spring ring and insert bottom metal

ring. The joint of the bottom metal ring should be positioned 45...90 to the right of the joint of the spring
ring.
Fig. 4:
S13-0008
Inspecting pretension of liners

MP 1-107
Measuring tool for liner pretension -MP 1-107 Dial gauge
The seat surfaces of the liners and of the cylinder block

must be clean and flat.
Remove contamination on seat surfaces of the liners by
cleaning only; do not use emery paper, flat scraper or
similar
Insert liners with seal firmly into the cylinder block up

to the stop.
S13-0128
Measure projection (preload) of liners to top edge of

cylinder block.
The projection must be 0.07...0.12 mm; if necessary adjust to correct projection by fitting seals of different thicknesses.
Edition 06.00
S00.5305.01.20

Liner
13-3 page 3
13
Note
Seals are available in thicknesses of 0.10; 0.12 and
0.14 mm.
The difference in the projections of the liners to each
other must not exceed 0.04 mm.

The liners must not touch at the flattened points -ar-
rows-.
13-3 page 4

Liner
Edition 06.00
S00.5305.01.20
15
15 Cylinder Head, Valve Gear

15-1
Removing and installing cylinder head
Testing compression pressure Chap. 15-2
Note
Removing and installing intake manifold: 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24
Removing and installing exhaust manifold Chapter 26-1
If the cylinder head is replaced, the system must be completely filled with fresh coolant.
1 - 3 Nm
2 - Seal
T replace
3 - Cylinder head bolt
T moisten with oil before
screwing in
T tightening order and tightening torque 15-1 page 4
4 - Washer
5 - Lifting eye - on the left
6 - Rocker arm shaft
T removing and installing rocker arms Chapter 15-3
T performing basic setting of
hydraulic valve clearance
compensation Chap. 15-2
7 - Bracket
T for ignition terminal
8 - Shim
9 - 23 Nm
T do not tighten fully until cylinder head bolts have been
tightened
10 - 20 Nm
T self-locking, replace
T do not tighten fully until cylinder head bolts have been
tightened
11 - 20 Nm
T wet with -AMV 105 500(Loctite 242) before screwing
in
T do not tighten fully until cylinder head bolts have been tightened
12 - Bracket
T for generator support
13 - Cylinder head gasket
T Observe installation position; with part no. marking faces up
T replace
14 - Cylinder head
T check for distortion Fig. 1 in 15-1 page 2
Edition 09.03
S00.5305.04.20
15-1 page 1
15
15 16 17 18 19 20 -

T removing and installing 15-1 page 2
T after replacing fill entire system with fresh coolant
Oil deflector
25 Nm
Lifting eye - on the right
Gasket for cylinder head cover
T replace if damaged
Cylinder head cover
Cap
T fit on during installation work
Fig. 1:
Inspecting the cylinder head for distortion

Straightedge
Feeler gauge
Max. permissible distortion: 0.05 mm (minimum clearance of straightedge base: 100 mm)
If the distortion is greater than 0.05 mm, replace cylinder
head, do not rework.
V15 - 0673
Engine installed
Torque wrench
Pliers for spring strap clips
Flat scraper
Braking agent -AMV 105 500- (Loctite 242)
Removing
On models fitted with a coded radio set, first determine the coding.
Disconnect the battery-earth strap with the ignition off.
3
4
Note
When the battery is disconnected and reconnected, carry
out rework Electrical System; Rep. Gr. 27.
Remove front exhaust pipe with catalyst Chapter

26-1.
4
5
Drain coolant Chapter 19-1.

Removing engine cover Chapter 10-1.
S10-0138
15-1 page 2
Edition 09.03
S00.5305.04.20
15
Disconnect plug:
2 - from the throttle valve control unit -J3383 - from the intake manifold pressure sender -G71- with
intake manifold temperature sender - G726 - from the coolant temperature sender -G627 - from the injector cylinders - N30 bis N33-
1
4
Unclip edge connector -4- -arrows- and remove wiring

loom from holders.
Remove ventilation hoses -1- and -8-.

Remove intake hose -5-.
Disconnect air hose from hot air collector.
6
S15-0157
Remove coolant hoses -1- and -2- from the thermo

regulator housing.
Remove vacuum line from the brake servo unit.

Remove pipe supports for intake manifold.
Unscrew the guide tube for the oil dipstick from the ex-
haust manifold.
Remove ignition terminal.

Caution!
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.
S10-0141
Remove the fuel presupply pipe -4- by pressing the re-
lease buttons at the separation point.
Remove the coolant hose -2- from the expansion reservoir.
Release ventilation hose -3- from the solenoid valve.

Remove the cylinder head cover.
Release the cylinder head bolts/nuts (do not yet fully
unscrew).
First remove the rocker arm shaft.

Then unscrew the remaining cylinder head bolts/nuts.
Remove the generator support bracket item 12 in
15-1 page 1
Prior to this remove the V-ribbed belt on vehicles with
S10-0137
air conditioning Chapter 13-1.
Remove the push rods and lay aside according to

their fitting position.
Carefully remove the cylinder head.
Edition 09.03
S00.5305.04.20
15-1 page 3
15
Installing
Note
Remove the new cylinder head seal from its wrapping
immediately before fitting.

Treat the seal with the utmost care. Any damage will
result in leaks.
There must not be any oil or coolant present in the
blind holes for the cylinder head bolts.
Insert a clean cleaning cloth in the liners and in the

openings for the push rods to ensure no dirt contaminates the liners or tappets.
Carefully clean the sealing surfaces of the cylinder

head, cylinder block and liners using a flat scraper or
using a suitable chemical device for this purpose.
Make sure this does not cause any extended scoring
or scratching.
Carefully remove old residual seal and the cleaning

cloths.
Turn the crankshaft in such a way that all pistons are

at the same height. While doing so the liners must no
be pushed out; if necessary press down.
Position the new cylinder head gasket in such a way

that the part no. marking is at the top.
Note
Before inserting the cylinder head make sure all liners are
correctly fitted in the cylinder block.
Insert the cylinder head.

Insert the push rods with the ball socket from the top
in accordance with their original location.
Note
When inserting the push rods carefully introduce them in
the ball socket of the tappet and in the ball knobs of the
adjusting screws. Wrongly inserted push rods (with ball
head on the edge of the tappet or with the edge on the
ball head of the adjusting screw) result in faults in the basic setting of the valve gear or damage when the engine
is started.
Moisten the thread of the cylinder head bolts with oil.

Fit the rocker arm shaft and tighten the fixing screws
by hand.
Insert the other cylinder head bolts/nuts and tighten by

hand. Observe the following bolt length and installation with/without washers:
Position
Bolt length
Washer
1, 2, 3, 6, 7
168 mm
yes
4, 5, 8, 9
185 mm
no
10
132 mm
yes
15-1 page 4
10
9
5
13
2
1
11
4
12
8
14
N15-0221
Edition 09.03
S00.5305.04.20
15
Tighten the cylinder head bolts/nuts in the following

sequence:
Position
1 to 10
Tightening method
Stage I:
20 Nm
Stage ll:
1/
4 turn (90) with a rigid

wrench
Stage lll:
1/
11 to 14
turn (90) with a rigid

wrench
4
20 Nm
Install the generator support bracket item 12 in

15-1 page 1
Insert bolt item 11 in 15-1 page 1 with locking
agent -AMV 105 500-.
Tighten the rocker arm shaft screws crosswise evenly

to 25 Nm.
Perform basic setting of hydraulic valve clearance

compensation Chapter 15-2.
Note
The basic setting of the hydraulic valve clearance compensation must not be carried out again, if only the cylinder head gasket is replaced.
Install the V-ribbed belt on vehicles with air conditioning Chapter 13-1.
Further installation occurs in a similar way in reverse order to removal. Pay attention to the following:
Install front exhaust pipe with catalyst Chapter 261.
Top up coolant Chapter 19-1.

Adapt the engine control unit to the throttle valve control unit -J338- 1.0/37; 1.4/44; 1.4/50 engine - fuel
injection; Rep. Gr. 24.
Perform a test drive, interrogate and erase fault memory 1.0/37; 1.4/44; 1.4/50 engine - fuel injection;
Rep. Gr. 01
Edition 09.03
S00.5305.04.20
15-1 page 5
15
15-1 page 6
Edition 09.03
S00.5305.04.20
15
15-2
Repairing cylinder head
1 - Valve collets
2 - Valve spring retainer
3 - Valve spring
15-2 page 2
4 - Valve stem seal
T replace 15-2 page 6
5 - Cylinder head
T reworking valve seats
15-2 page 3
T inspecting valve guides
15-2 page 1
6 - Valves
T do not rework, only grinding
in is permissible
15-2 page 2
T Valve dimensions 15-2
page 3
7 - Cylinder head marking
8 - Plug
T installing Fig. 1 in 15-2
page 1
1
2
3
4
7
6
S15-0148
Fig. 1:
Knocking plug into cylinder head

Injection drift pin -MP 1-173 Sealant -AMV 200 000- (Loctite 270)
Coat outer circumference of plug with -AMV 200 000-.

Use -MP 1-173- to knock in plug.
Inspect valve guides

MP 1-173
S15-0011
Universal dial gauge holder -MP 3-447 Dial gauge
Edition 09.03
S00.5305.04.20
15-2 page 1
15
Procedure
Insert valve into guide. End of valve stem must be

flush with guide.
Determine valve rock.

Wear limit
Inlet valve
Exhaust valve
0.5 mm
0.6 mm
Note
If the wear limit is exceeded, repeat measurement
with new valve. If the wear limit is again exceeded - replace cylinder head.
If the valve is replaced when carrying out repair work,
use a new valve for the measurement.
Removing and installing valves

Removing
Valve supporting plate -MP 1-113 Valve spring assembly lever -MP 1-114 Insert for conical spring -MP 1-114/1-
MP 1-113
Threaded connector M8x40
S15-0008
Fit cylinder head onto the valve supporting plate

- MP 1-113-.
Attach valve spring assembly lever -MP 1-114- and insert -MP 1-114/1- together with threaded connector
-1- onto the cylinder head.
Press down assembly lever -2-.

Take out collets.
MP 1-114
Note
Release collets that are tight by striking light blows with a
hammer on the assembly lever.
Pull out valves.
MP 1-113
MP 1-114/1
15-2 page 2
S15-0124
Edition 09.03
S00.5305.04.20
15
Valve dimensions
Note
Valves must not be reworked. Only grinding in is permissible.
Inlet valve
Dimension
Exhaust valve
1.0 ltr
1.4 ltr
1.0 ltr
1.4 ltr
mm
34,0
34,0
27,0
30,0
mm
7,0
7,0
7,0
7,0
mm 104,0
101,0
104,0
101,0
45
45
45
45
Reworking valve seats

Depth gauge/caliper gauge
NAC milling cutter for reworking valve seats
Grinding paste
Note
When carrying out repairs on engines with leaking
valves, it is not sufficient to machine or replace the

valve seats and valves. It is also necessary to inspect
the valve guides for wear, particularly on engines with
a high mileage.
Rework valve seats only sufficiently in order to obtain
a proper contact pattern. Calculate the maximum permissible reworking dimension before commencing. If
the reworking dimension is exceeded, proper operation of the valve gear is no longer assured and the cylinder head must be replaced.
Calculating maximum permissible reworking dimension
Insert valve and press firmly against the valve seat.

Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
Measure distance -a- between the valve stem and the

seat surface for valve spring.
Calculate max. permissible reworking dimension from

the distance measured and the maximum dimension.
Maximum dimensions
in mm
1.0 ltr. engine
1.4 ltr. engine
Inlet valve
43,1
42,7
Exhaust valve
43,0
42,8
Edition 09.03
S00.5305.04.20
S15-0093
15-2 page 3
15
Maximum dimension less distance measured = max. permissible reworking dimension.

Example:
Maximum dimension
43,1 mm
Measured distance
42,7 mm
Max. permissible reworking dimension
0,4 mm
Note
If the max. permissible reworking dimension is 0 mm, repeat measurement with a new valve. If the max. permissible reworking dimension is again 0 mm, replace
cylinder head.
Reworking valve seats

Dimension
Z
a
Valve seats
1.0 ltr. engine:

mm
Valve seat
diameter:
33,4 0.1 - inlet valve

26.4 0.1 - exhaust valve
32.9 -0.1 - inlet valve

29.6 -0.1 - exhaust valve
1.4 ltr. engine:

a
mm
Valve seat
diameter:
mm
Max. permissible reworking dimension
1.0 ltr. engine:

c
mm
30
45
60
S15-0058
Valve seat
width:
1.3 up to 1.6 - inlet and exhaust valve
Valve seat
width:
1.45 up to 1.75 - inlet

valve
1.65 up to 1.95 - exhaust
valve
1.4 ltr. engine:

c
mm
Bottom edge of cylinder head
45
Valve seat angle
30
Top correction angle
60
Bottom correction angle
Procedure
Reworking can be carried out with a machine or by hand.
The following conditions must be met:
Wear limit of valve guides must not exceed the permissible dimension 15-2 page 2.
Use NAC milling cutter with carbide metal tips (min. 90

HRC).
15-2 page 4
Edition 09.03
S00.5305.04.20
15
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.
Valve guide
Guide drift mm
Inlet valve
7,0 -0,01
Exhaust valve
Match diameter of milling cutter to diameter of valve

seat.
Milling cutter 90
mm
Milling
cutter
120
mm
Milling cutter 60
mm
1.0 ltr.
engine
36
38
21/34
1.4 ltr.
engine
36
38
21/34
1.0 ltr.
engine
30
30
max. 301)
1.4 ltr.
engine
32
32
21/34
Valve seat
Inlet
valve
Exhaust
valve
1)
S15-0098
90
1.
2.
May not yet be contained in NAC milling cutter kit.
120
a
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 cutter until valve seat diameter a ( 15-2 page 4) is
achieved.
3 - Rework bottom correction angle with 60 milling cutter until valve seat width c ( 15-2 page 4) is
achieved.
60
3.
c
S15-0062
Grind in valve/valve seat -arrows- with fine grinding

paste so as to achieve a perfect contact pattern.
Check valve for tightness.

The inspection can be carried out with water colour (perfect contact pattern over entire circumference) or by filling
fuel into the combustion chamber (no fuel must flow out
at the valve seat).
Note
After installing the cylinder head, carry out basic setting
of the hydraulic valve clearance compensation.
S15-0063
Edition 09.03
S00.5305.04.20
15-2 page 5
15
Replacing valve stem seal

Valve stem seal insertion tool -MP 1-212 Valve supporting plate -MP 1-113-
Carefully lever off valve stem seal -arrow-.

Insert valve into guide.
S15-0016
Oil valve stem seal, place into insertion tool -A-, then
carefully fit onto the valve stem and press onto the
valve guide.
Basic setting of hydraulic valve clearance compensation

The hydraulic valve clearance compensation is maintenance-free; the setting must not be changed.
After completing repair work on the cylinder head/valve
gear, however, it is necessary to carry out the basic setting of the hydraulic valve clearance compensation as follows:
S15-0110
Note
The basic setting of the hydraulic valve clearance compensation must not be carried out again, if only the cylinder head gasket is replaced.
Torque wrench
Procedure
Rotate crankshaft until the valves of cylinder 4 overlap

(inlet valve opens and exhaust valve closes).
At cylinder 1, slacken the lock nuts for the adjusting

bolts of the rocker arms.
Then, turn back the adjusting bolts in the rocker arms

until play can be felt between rocker arm and valve.
Turn adjusting bolts of both rocker arms slightly

against the valves until valve gear has no play. Check
the gradual reduction of the play through swinging
movements of the adjusting rocker arm. The point with
no play which has appeared determines the exact
contact location.
From this point, turn adjusting bolts in a further two

turns. Screw in lock nut and then tighten fully to 13
Nm.
15-2 page 6
Edition 09.03
S00.5305.04.20
15
Carry out the setting operations on the other cylinders

according to the table below:
Setting
Valve overlap
Cylinder 1
Cylinder 4
Cylinder 3
Cylinder 2
Cylinder 4
Cylinder 1
Cylinder 2
Cylinder 3
Note
After installing new hydraulic tappets, the engine must
not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves may remain
constantly open and strike the piston).
Testing the compression

Test conditions
Engine oil temperature at least 30 C

Compression tester (e. g. -V.A.G 1381- or
-V.A.G 1763-)
Spark plug wrench (e.g. - 3122 B-)
Torque wrench
Test sequence
Remove engine cover.

Unplug 4-pin connector -arrow- from the ignition terminal.
Remove the fixing screws of the ignition terminal and

detach ignition terminal from the park plugs.
Unscrew spark plugs with spark plug wrench (e. g.

-3122 B-).
Remove fuse 35.

Note
Removing fuse 35 interrupts the voltage supply of the injectors.
Have a second mechanic fully depress the accelerator
N15-0219
pedal.
Use compression tester (e. g. -V.A.G 1381 - or

-V.A.G 1763 -) to test compression.
Note
Use of tester Operating Instructions.
Edition 09.03
S00.5305.04.20
15-2 page 7
15
Operate starter until the tester no longer indicates a

pressure rise.
Compression readings
New engine
Wear limit
Difference between cylinders
min. 12 bar (1.2

MPa)
7.5 bar (0.75

MPa)
max. 3 bar (0.3

MPa)
Plug connectors into the ignition strip.

Install spark plugs, ignition terminal, fuse 35 and engine cover.
Interrogate fault memory and erase 1.0/37; 1.4/44;

1.4/50 Engine, Fuel Injection System; Rep. Gr. 01.
Note
Separating the plug connections causes faults to be
stored.
Tightening torques
Component
Nm
Spark plugs in cylinder head
30
Ignition terminal to bracket
15-2 page 8
Edition 09.03
S00.5305.04.20
15
15-3
Repairing valve gear
Removing and installing camshaft

1 - Tappet rod
T pay attention to correct installation position
T do not interchange
2 - Hydraulic tappets
T with hydraulic valve clearance compensation
T check 15-3 page 3
T use auxiliary tool to pull out
of cylinder block Fig. 1 in
15-3 page 1
T do not interchange
T lay aside with contact surface facing down
T oil contact surface
3 - Cylinder block
T Removing and installing cylinder block Chap. 15-1
T Removing and installing timing gear cover and sprockets
Chap. 13-2
4 - O-ring
5 - Camshaft position sensor
-G1636 - 8 Nm
7 - Camshaft
T with timing segment for camshaft position sensor -arrowT Camshaft setting Fig. 2 in
15-3 page 2
8 - Woodruff key
T check tightness
9 - Retaining plate of camshaft
10 - 5 Nm
Fig. 1:
3
4
5
6
7
8
10
9
S15-0149
Removing hydraulic tappet
Make auxiliary tool (wire) -2- as shown in illustration.
-a- 1.8 to 1.9 mm
Inset shop-made tool -2- in the tappet bore -1-, tilt

slightly and pull tappet out of the guide in the cylinder
block.
2
a
S15-0130
Edition 03.01
S00.5305.02.20
15-3 page 1
15
Fig. 2:

Camshaft setting
Insert chain sprockets -2- and -3- into the timing chain
a=
12
-1- so that the distance -a- (from marking to marking

-arrows-) is 12 chain pins.
S15-0028
3
Removing and installing rocker arms
1 - Rocker arm shaft
Chap. 15-1
2 - Circlip
3 - Rocker arm bracket, on outside
T for M11 cylinder head bolt
4 - Spring washer
5 - Rocker arm
6 - Adjusting screw
T performing basic setting of
hydraulic valve clearance
compensation Chap. 15-2
7 - Lock nut
T 13 Nm
8 - Rocker arm bracket
T for M8 bolt
9 - Rocker arm
T pay attention to different version Fig. 3 in 15-3 page 3
10 - Rocker arm bracket, on inside
T for M11 cylinder head bolt
11 - Tensioning ring
12 - Spring
1
9
11
9
9
2
10
5
9
3
11
12
10
8
S15-0150
15-3 page 2
Edition 03.01
S00.5305.02.20
15

Fig. 3:
123ABC-
Arrangement of rocker arms and rocker arm

brackets
Straight rocker arm

Inclined rocker arm, to the left
Inclined rocker arm, to the right
Rocker arm bracket for M11 bolt, on outside
Rocker arm bracket for M8 bolt
Rocker arm bracket for M11 bolt, on inside
Note
The rocker arms for the inlet valves are shown in dark in
the illustration.
S15-0132
Inspecting hydraulic tappets

Feeler gauge
Wooden or plastic wedge
Note
Always replace hydraulic tappet complete (cannot be
adjusted or repaired).
Irregular valve noises when starting engine are nor-
mal.
Test sequence
Start engine and allow to run until the radiator fan has
cut in once.
Increase engine speed to about 2500 rpm for 2 minutes.

If the hydraulic tappets are still loud, determine the faulty
tappet as follows:
Remove cylinder head cover.

Rotate crankshaft until the valves of cylinder 4 overlap
(inlet valve opens and exhaust valve closes).
Apply a load to the hydraulic tappet by pressing slightly several times on the adjusting screw with a wooden
or plastic wedge.
Attempt to insert a 0.2 mm feeler gauge -arrow- between rocker arm and valve.
If it is possible to insert a feeler gauge between rocker
arm and valve and the tappet at the same time moves
down, replace the tappet.
If play was measured only between rocker arm and valve
(tappet does not move down), carry out basic setting of
the hydraulic valve clearance compensation Chap. 152, after the setting, repeat the inspection.
Inspect tappets at the other cylinders by carrying out
S15-0189
the same procedure.
Edition 03.01
S00.5305.02.20
15-3 page 3
15

Inspection
Valve overlap
Cylinder 1
Cylinder 4
Cylinder 3
Cylinder 2
Cylinder 4
Cylinder 1
Cylinder 2
Cylinder 3
Note
After installing new hydraulic tappets, the engine must
not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves may remain
constantly open and strike the piston).
15-3 page 4
Edition 03.01
S00.5305.02.20
17
17 Lubrication
17-1
Removing and installing

parts of the lubrication
system
Note
If considerable quantities of metal swarf or abrasion
(caused by rubbing damage such as damage to the

crankshaft and conrod bearings) is found in the engine oil when carrying out engine repairs, carefully
clean the oil galleries in order to avoid consequential
damage.
The oil level must not be above the max. marking - risk
of damage to catalytic converter!

For 1.0 ltr. engine only: longer oil pan bolts on bracket
for coolant pipe, at front item 12 in 17-1 page 2

pay attention to these bolts, do not mix up!
Oil capacity and oil specification:

Inspection and Maintenance.
Edition 02.02
S00.5305.03.20
Removing and installing parts of the lubrication system
17-1 page 1
17
1 - Cap
T fit on during installation work
2 - Gasket
T replace if damaged
T on the engine cover
3 - 0.9 bar (0.09 MPa) oil pressure switch - F1-, 45 Nm
T grey
T inspecting Chapter 17-3
T cut open seal if leaking and
replace
4 - Oil filter
T slacken with tensioning strap
T moisten seal with oil
T tighten by hand
T pay attention to installation
instructions on oil filter
T pay attention to change intervals
5 - Split pin
6 - Ball
T for pressure relief valve
T when installing, knock in
slightly with aluminium drift
so that the seat of the ball is
smoothened
7 - 40 Nm
8 - Pressure spring
T for pressure relief valve
9 - 8 Nm
S17-0081
10 - Intermediate plate
T clamped onto oil pan support of 1.4 ltr. engine
11 - Oil pan support
T for 1.4 litre engine only:
12 - Bracket
T for middle coolant pipe
T for 1.0 ltr. engine only: 2 bolts M6x22 (different colour and shape); do not mix up with other bolts (M6x20)
13 - 10 Nm
14 - 20 Nm
15 - 45 Nm
T for 1.4 litre engine only:
16 - Oil drain plug, 30 Nm
17 - Gasket
T replace
18 - Oil pan
T removing and installing Chapter 17-2
19 - Gasket
T for 1.0 litre engine only
T replace
T coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing the
oil pan with gasket Fig. 3 in 17-1 page 4
20 - 8 Nm
17-1 page 2
Edition 02.02
S00.5305.03.20
17

21 - Oil pump cover with pressure relief valve
T opening pressure: approx. 4.6 bar (0.46 MPa) overpressure
T clean strainer if dirty
22 - Gasket
T replace
T install only if insufficient axial play of oil pump gears Fig. 1 in 17-1 page 3
23 - Gears
T inspecting axial play Fig. 1 in 17-1 page 3
24 - Guide tube
T removing and installing Fig. 2 in 17-1 page 3
25 - Dipstick
T oil level must not exceed "max" marking!
T Inspect engine oil level Inspection and Maintenance
Fig. 1:
Oil pump - inspect axial play

Feeler gauge
Straightedge
Axial clearance for new part: 0.02 through 0.10 mm

wear limit: 0.13 mm
Note
If the wear limit is reached, replace timing gear cover
Chapter 13-2
S17-0038
If no axial play is present, install gasket item 22 in
17-1 page 3.
Inspect unrestricted running of the oil pump in assem-
bled state with timing gear cover installed.

Fig. 2:
Removing and installing dipstick guide tube
Unscrew nut -1- on the exhaust manifold and lift guide

tube -2- up and out.
When installing replace seal -3-.

Tighten new self-locking nut -1- to 20 Nm.
2
3
Edition 02.02
S00.5305.03.20
S17-0039
17-1 page 3
17
Fig. 3:

Apply sealant for a 1.0 litre engine
Coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing
the oil pan with gasket -arrows-.
17-1 page 4
Edition 02.02
S00.5305.03.20
17
17-2
Removing and installing

oil pan
Removing and installing oil pan - for a

1.0 litre engine
Removing
The procedure for removing the oil pan on a 1.0 ltr. and
1.4 ltr. engine is identical 17-2 page 1.
Installing
Torque wrench
Sealant -AMV 188 520-
Coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing
the oil pan with gasket -arrows-.
Lay on the gasket for the oil pan.

Tighten securing bolts in the specified order.
Note
12
16
19
13
17
18
20
14
The bracket for the front coolant pipe is also attached with
bolts -2- and -6- (M6x22). Do not interchange with the
other bolts (M6x20).
Removing and installing oil pan - for a

1.4 litre engine
15 11
10
N17-0079
Hand drill with plastic brush attachment

Flat scraper
Torque wrench
Silicone sealant -D 176 404 A2- or - 047 198 049-
(THREE BOND 1215 J)

Counterholder -T30008-
Removing
Remove noise insulation below engine.

Drain engine oil.
Unbolt front coolant pipe (below oil pan) at the 2 fixtures at the cylinder block.
Unbolt oil pan together with oil pan support.

Remove oil pan, if necessary release by applying
slight blows with a rubber-headed hammer. Press the
coolant pipe slightly towards the outside for this step.
Edition 09.03
S00.5305.04.20
Removing and installing oil pan
17-2 page 1
17
Use a flat scraper to remove sealant residues on the

cylinder block.
Use a rotating plastic brush to remove sealant residues on the oil pan (wear protective goggles).
Clean sealing surfaces, they must be free of oil and

grease.
Installing
Note
Pay attention to the 'use by date' on sealant.
The oil pan must be installed immediately after apply-
ing the silicone sealant -047 198 049- (THREE BOND

1215 J) . If -D 176 404 A2- is used installation must be
performed within 5 minutes.
N17-0012
The assistance of a second mechanic is required to
install the oil pan. Press the front coolant pipe slightly
towards the outside.
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
Thickness of sealant bead: 2 to 3 mm
Note
The sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clogg
the strainer in the oil suction pipe.
N17-0019
Apply silicone sealant to the clean sealing surface of

the oil pan, as shown in the illustration.
Note
It is particularly important to maintain the specified ap-
plication pattern for the bead in the area of the sealing

flange to the flywheel -arrows A-.
There is an opening in the cylinder block -arrow B-
13 mm, which must be reliably sealed off by an accumulation of sealant -a- = 15 mm; -b- = 4 mm.
a
S17-0040
17-2 page 2
Edition 09.03
S00.5305.04.20
17
Engine installed
Fit intermediate plate onto oil pan support.

Position oil pan together with oil pan support immediately against the cylinder block and tighten the bolts
as follows:
1 - Tighten all the bolts of the oil pan/cylinder block only
very slightly in the given sequence.
2 - Slightly tighten two bolts of oil pan support/gearbox.
3 - Tighten all the bolts of the oil pan/cylinder block
slightly in the given sequence.
4 - Tighten two bolts of oil pan support/gearbox to 45
Nm.
5 - Tighten all the bolts of the oil pan/cylinder block to
the prescribed torque in the given sequence:
M6 = 10 Nm; M8 = 20 Nm.
12
16
19
13
17
18
20
14
15 11
10
N17-0079
T30008
Engine removed
(Gearbox disconnected)
To ensure clearance of intermediate plate when installing the engine - gearbox, bolt counterholders
-T30008- tight to cylinder block (M10) as shown in the
illustration.
The flat side of the counterholders -T30008- must
touch the cylinder block for this step.
S17-0041
Position oil pan together with oil pan support immediately against the cylinder block and tighten the bolts
as follows:
1 - Tighten all the bolts of the oil pan/cylinder block only
very slightly in the given sequence. For this step
press oil pan support against the counterholders
-T30008-.
2 - Tighten all bolts to the prescribed torque in the given
sequence: M6 = 10 Nm; M8 = 20 Nm.
There must not be any gap between the oil pan support
and counterholders -T30008-; if necessary slacken oil
pan bolts again and correct position of the oil pan.
12
16
19
13
17
18
20
14
15 11
Note
10
N17-0079
A gearbox housing or a gearbox can also be fitted instead

of the counterholders -T30008-. Relevant tightening sequence of the bolts: as described in engine installed.
Continuation for both installation descriptions

Further installation occurs in a similar way in reverse order to removal.
Edition 09.03
S00.5305.04.20
17-2 page 3
17
Note
After installing the oil pan, allow the sealant to dry for
about 30 minutes. Only then may engine oil be filled in.
17-2 page 4
Edition 09.03
S00.5305.04.20
17-3
17
Testing Oil Pressure and

Oil Pressure Switch

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

The oil pressure switch is opened when pressureless and
closed when the switching pressure is reached.
The oil pressure warning is activated for about 10 s after
the ignition is switched on (terminal 15 on). Activation
delay of oil pressure warning: approx. 3 s Off delay of oil
pressure warning: approx. 5 s
Check warning lamp
After the ignition is switched on and engine not running,
the oil pressure warning lamp in the dash panel insert
must light up for about 3 s and then go out. The check is
ended when the engine is started.
Warning criteria
The visual oil pressure warning (oil pressure warning
lamp flashes) is activated and the audible warning buzzer
sounds 3 times if one of the following conditions exists:
Ignition on, engine not running, oil pressure switch

closed
Engine speed greater than 1500 rpm, oil pressure

switch open
At an engine speed above 5000 rpm, the oil pressure

warning is not cancelled; not even if the oil pressure
switch is closed. Oil pressure switch cancelled below
5000 rpm.
If the oil pressure switch is open for only 0.5...3 s at an

engine speed above 1500 rpm, this is stored in the
combination processor of the dash panel insert. If this
condition occurs 3 times when the engine is running,
the oil pressure warning is immediately activated and
is not cancelled below 1500 rpm. The oil pressure
warning is cancelled if the oil pressure switch is closed
for more than 5 s at a speed of more than 1500 rpm,
or at Ignition off.
Test conditions
Engine oil at correct level, inspecting Chap. 17-1

Oil pressure warning lamp (-K3-) must light up for
about 3 s when ignition is switched on.
Engine oil temperature at least 80 C (radiator fan

must have cut in once).
Test sequence
Edition 06.00
S00.5305.01.20
Testing Oil Pressure and Oil Pressure Switch
17-3 page 1
17
Unplug connector from oil pressure switch.

Unscrew oil pressure switch and screw in oil pressure
V.A.G 1342
tester (e.g. -V.A.G 1342-).
Screw oil pressure switch -2- into -V.A.G 1342-.

Connect brown cable -1- of tester to earth (-).
Connect diode test lamp (e. g. -V.A.G 1527 B-) to oil
pressure switch -2- and battery positive (+).
The LED must not light up.
If the LED lights up, replace the oil pressure switch.

Start engine and slowly increase engine speed.
The LED must light up at 0.075 ... 0.105 MPa over-
pressure, if not, replace oil pressure switch.
2
A17-0025
Increase engine speed further. At 2000 rpm and an oil

temperature of 80 C the oil pressure should be at
least 0.2 MPa.
If the nominal value is not reached:
Inspect axial play of oil pump Chap. 17-1.

At higher engine speeds the oil pressure must not be lower than 0.7 MPa. If necessary, replace oil pump cover together with pressure relief valve.
17-3 page 2
Testing Oil Pressure and Oil Pressure Switch
Edition 06.00
S00.5305.01.20
19
19 Cooling
19-1
Parts of cooling system Summary of components
Note
When the engine is warm the cooling system is under
pressure. If necessary reduce pressure before repairs.

The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.

Always replace seals and gasket rings.
When installing fit the coolant hoses free of stress,
without them touching any other components (pay attention to the marking on the coolant connection and
hose).
Coolant mixing ratios 19-1 page 6
Parts of the cooling system fitted to body
Edition 02.02
S00.5305.03.20
3
4
7
20
G12
1 - Radiator
Chapter 19-2
T after replacing, fill entire system with fresh coolant
2 - O-ring
T replace
3 - Top coolant hose
T attached to radiator with retaining clips
T Connection diagram for coolant hoses 19-1 page 5
4 - Cover plate
T check pressure 19-1
page 7
5 - Connector
6 - Double screw, 2 Nm
7 - Air duct scoop
8 - 5 Nm
9 - 5 Nm
10 - Expansion bottle
T check the coolant system for
tightness 19-1 page 7
T connection diagram for coolant hoses 19-1 page 5
11 - Retaining clip
T for fan cable
T check tightness
12 - Auxiliary fan
T for vehicles with air conditioning system or additional
equipment
19 18
10
11
17
5
12
16
13
9
14
15
5
Parts of cooling system - Summary of components
S19-0074
19-1 page 1
19
13 - The fan ring

14 - Fan for radiator
15 - Bottom coolant hose
T attached to radiator by retaining clips
T connection diagram for coolant hoses 19-1 page 5
16 - Bracket
T for fan connector
17 - Thermoswitch for radiator fan -F18-, 35 Nm
T or for both fans
T switching temperatures:
1. Stage
on: 91 through 97 C
off: 84 through 91 C
2. Stage
on: 99 through 105 C
off: 91 through 98 C
18 - Bottom radiator bearing
T black
19 - 5 Nm
20 - Top radiator bearing
T white
19-1 page 2
Edition 02.02
S00.5305.03.20
19
Parts of cooling system engine side

coolant regulator housing
Note
Draining coolant and filling up Chap. 19-1
1 - Towards the top expansion
reservoir
2 - Towards top radiator
3 - coolant regulator housing
T Opening start: approx. 88 C
T Opening end: approx. 103 C
4 - O-ring
T replace
5 - Sender for the coolant temperature -G626 - Retaining clip
7 - 20 Nm
8 - To heat exchanger
5
4
6
7
8
1
S19-0115
Edition 02.02
S00.5305.03.20
19-1 page 3
19
Coolant pump, front coolant pipe

1 - Gasket
T replace
2 - Coolant pump
T check smooth operation
T if damage and leak present replace completely
Chapter 19-2
3 - 20 Nm
T self-locking, replace
4 - Belt pulley
T for the V-ribbed belt
5 - 10 Nm
6 - V-ribbed belt
T before removing mark running direction
T do not kink
T check for wear
Chapter 13-1
7 - 20 Nm
8 - Coolant hose
T insert up to stop on coolant
pump/front coolant pipe
9 - Front coolant pipe
10 - 20 Nm
11 - to connection fitting for heat
exchanger
12 - to bottom radiator
13 - to bottom expansion reservoir
19-1 page 4
7
13
10
9
12
11
10
S19-0085
Edition 02.02
S00.5305.03.20
19
Connection diagram for coolant hoses

1 - Radiator
T after replacing, fill entire system with fresh coolant
Chapter 19-2
2 - Front coolant pipe
3 - Cylinder block
4 - Coolant pump
Chapter 19-2
T check smooth operation
5 - Expansion bottle
6 - Coolant pipe
T for ventilation line
7 - Heat exchanger
8 - Connection fittings
T for heat exchanger
9 - Coolant hose with heat protection
10 - coolant regulator housing
T with coolant regulator
19-1 page 3
11 - Quick coupling
T for radiator connections
T Replace gasket rings, moisten with coolant additives
7
8
4
10
11
S19-0087
Draining and filling up coolant

Coolant capacity approx. 5.6 ltr.
antifreeze tester
Draining
Caution!
Hot steam may escape when the expansion reservoir is opened. Cover the cap with a cloth and
open carefully.
Open the coolant cap.

Edition 02.02
S00.5305.03.20
S10-0135
19-1 page 5
19
Place a catch pan under the engine.

Turn the drain plug -arrow- on the radiator to the left
and draw backwards, if necessary fit auxiliary hose
onto connection.
Note
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original
spare parts catalogue KODA or from the list of allowed
coolant additives Inspection and Maintenance;
Rep. Gr. 02
A10-0118
Recommended mixture ratios:

Antifreeze pro- Antifreeze contection down to centration1)2)
Drinking
water2)
-25 C
40 % (2.25 litres) 60 % (3.35 litres)
-35 C
50 % (2.8 ltr.)
1)
2)
50 % (2.8 ltr.)
The antifreeze concentration must not exceed 60 %; the antifreeze

protection and cooling efficiency are reduced as the concentration
increases.
The coolant amount may differ according to the version of the vehicle.
Insert and tighten the coolant drain plug.

Pull out retaining clip -2- and remove sender for coolant temperature -1- from the coolant regulator housing.
S19-0086
Fill with coolant gradually up to max marking on the

expansion bottle.
Install sender for coolant temperature.

Close expansion bottle.
Run engine until the fan on the radiator starts.
G1
Caution!
open carefully.
Check the level of coolant and top up if necessary. If

the engine is warm the coolant level must be on the
max. mark. If the engine is cold the coolant level
must between the min and the max. mark.
19-1 page 6
S19-0077
Edition 02.02
S00.5305.03.20
19
Checking the coolant system for tightness

Coolant system tester (e. g. -V.A.G 1274-)
Adapter (e.g. -V.A.G 1274/8-)
Adapter (e.g. -V.A.G 1274/9-)
Test condition
Engine must be warm

Test sequence
Caution!
open carefully.
Open the cap of the coolant expansion reservoir.

Position coolant system tester (e. g. -V.A.G 1274-)
with adapter (e. g. - V.A.G 1274/8-) on the coolant expansion bottle.
V.A.G 1274
With the hand pump of the tester generate an overpressure of approx. 0.1 MPa.
If the pressure drops determine location of the leaks

and repair them.
Testing the pressure relief valve in the cap
V.A.G 1274/8
Screw cap onto tester with adapter (e.g. -V.A.G 1274/

G12
9-).
With the hand pump of the tester generate an overpressure of approx. 0.15 MPa.
S19-0082
The pressure relief valve must open for an overpressure of 0.12 to 0.15 MPa.
Edition 02.02
S00.5305.03.20
19-1 page 7
19
19-1 page 8
Edition 02.02
S00.5305.03.20
19
19-2
Removing and Installing

Radiator, Coolant Pump
Removing and installing radiator

Torque wrench 5...50 Nm (e.g. -V.A.G 1331-)
Removing
Drain coolant Chap. 19-1.

Remove connector -1- from thermo-switch -F18- and
separate plug connection -2- on the holder of the air

duct scoop.
To do so press the latch clips.

There are 2 plug connections on vehicles fitted with air
conditioning.
Separate the coolant hose from the radiator at the top

and bottom of the connection fittings.
S19-0078
To do so pull the retaining clip -3- up to the stop and

remove the quick coupling towards the rear.
Vehicles without air conditioning
Removing front bumper Body Work; Rep. Gr. 63.

Unscrew bolts for radiator bearing -arrows-.
Torque: 5 Nm
Pull radiator with fan backwards and remove downwards.

S19-0080
Caution!
Do not open the refrigerant circuit of the air conditioning system.
Unscrew bolts for radiator bearing -arrows-.

Torque: 5 Nm
Removing the lock carrier with component parts

Body Work; Rep. Gr. 50.
Attach the condenser with the radiator to the engine or

support.
Note
Do not suspend the condenser to the wires.
Do not fold the condenser wires.
Edition 06.00
S00.5305.01.20
S19-0083
Removing and Installing Radiator, Coolant Pump
19-2 page 1
19
Release the bolts securing the condenser -arrowsand remove radiator with fan.
Torque: 5 Nm
Installing
The installation occurs in reverse order. Pay attention to
the following:
Top up coolant Chap. 19-1.

Re-adjust headlights on vehicles fitted with air conditioning.
Removing and installing coolant pump

S19-0081
3
4
Lifting device -MP 9-200 Catch pan (e.g. -V.A.G 1306-)

4
5
Removing
Drain coolant Chap. 19-1.

Removing engine cover Chap. 10-1
S10-0138
Mount lifting device -MP 9-200- and take up the

weight of the engine/gearbox unit at the spindles.
19-2 page 2
Edition 06.00
S00.5305.01.20
19
Remove engine mounting -1-.
To this end release bolts -2- and -3-.
Only slacken the bolts of the coolant pump belt pulley.

Bolts must be on top, turn crankshaft.
Removing the ribbed V-belt Chap. 13-1.

Unscrew front coolant pipe from front and rear cylin-
der block.
Release clamp from coolant pump and disconnect

coolant hose.
Remove belt pulley from the coolant pump.

Unscrew coolant pump.
3
S10-0140
Installing
Installation occurs in reverse order to removal. Pay attention to the following:
Replace seal for coolant pump.

First install ribbed V-belt Chap. 13-1, then tighten
the belt pulley bolts of the coolant pump.
Torque: 10 Nm
Tightening torques of the engine mounting Chap.

10-1.
Top up coolant Chap. 19-1.
Edition 06.00
S00.5305.01.20
19-2 page 3
19
19-2 page 4
Edition 06.00
S00.5305.01.20
20
20 Fuel Supply
20-1
Removing and Installing Parts of the Fuel Supply System
Note
Fuel lines are secured by plug connectors.
Fuel hoses in the engine must only be secured with spring strap clamps. The use of collar clamps or screw clamps
is not allowed.
Observe safety measures 20-1 page 3.
Observe rules for cleanliness 20-1 page 3.
Repairing parts of the activated charcoal filter system Chap. 20-2.
1 - Fuel tank
T support with engine/gearbox
15
jack -V.A.G 1383 A- when
removing
14
2 - 25 Nm
3 - 25 Nm
13
4 - Tensioning strap
5 - Vent line
T to solenoid valve 1 for activated charcoal filter in engine
12
compartment
6 - Feed line
11
T black
T to fuel rail (at intake mani10
fold)
9
7 - Fuel filter
8
T with integrated fuel pressure
regulator
T line connections:
7
feed (black): in middle
return flow (blue): on outside
8 - 3 Nm
T screw for collar clamp for fuel
filter
9 - Fuel level sender
10 - Fuel delivery unit
T clean strainer if dirty
T pay attention to installation
position of flange of fuel delivery unit Fig. 1 in 20-1
page 2
11 - Return-flow line
T between fuel delivery unit and fuel filter
T blue
12 - Feed line
T between fuel delivery unit and fuel filter
T black
13 - Gasket ring
T moisten with fuel before installing
Edition 06.00
S00.5305.01.20
16
17
18
19
20
21
22
23
2
1
S20-0084
20-1 page 1
20
14 - Union nut
T use wrench -MP 1-227- for removing and installing
15 - Vent valve
T to remove, unclip valve at side and take out of filler neck.
T before installing, unscrew cap
T check Fig. 2 in 20-1 page 2
16 - End cover
17 - 1.5 Nm
18 - Fuel filler flap unit
T with rubber bowl
19 - Gravity valve
T to remove, unclip valve at top and lift out of filler neck.
T inspect valve for blockage:
valve vertical: open
valve tilted 45: closed
20 - Vent line
T between activated charcoal filter item 21 in 20-1 page 2 and vent line item 5 in 20-1 page 1
21 - Activated charcoal filter
22 - 10 Nm
23 - Vent line
T clipped in place on fuel tank
Fig. 1:
Installation position of flange of fuel delivery unit
Marking on the flange must be aligned with marking on

the fuel tank -arrows-.
Blue return-flow line -1- to connection marked -R-.

Black feed line -2- to connection marked -V-.
V
Note
After installing the flange of the fuel delivery unit, check
whether the feed, return-flow and vent lines are still
clipped in place on the fuel tank.
1
A20-0096
Fig. 2:
Inspecting vent valve
Lever in off position: closed

Lever pushed in direction of arrow: open
Note
Unscrew cap of fuel tank before installing the vent valve.
V20-1040
20-1 page 2
Edition 06.00
S00.5305.01.20
20
Safety precautions when working on the

fuel supply system
Caution!
The fuel feed line is pressurized! Place cleaning
cloths around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.
Pay attention to the following points when removing and
installing the fuel gauge sender or the fuel pump (fuel delivery unit) on a fuel tank that is filled or partially filled:
The extraction hose of an exhaust extraction system
which is switched on, must be positioned close to the

assembly opening of the fuel tank in order to extract
the released fuel gases, even before the work is commenced. If no exhaust extraction system is available,
a radial fan (motor not in air flow of fan) with a delivery
volume of more than 15 m3/h must be used.
Avoid skin contact with fuel! Wear fuel-resistant
gloves!
Cleanliness rules
Carefully observe the following 5 rules for cleanliness
when working on the fuel supply/injection system:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use

parts which have been stored unwrapped (e.g. in tool
boxes and the like).
When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
Edition 06.00
S00.5305.01.20
20-1 page 3
20
20-1 page 4
Edition 06.00
S00.5305.01.20
20
20-2
Activated Charcoal Filter System
Repairing parts of the activated charcoal filter system

Note
The hose connections are secured with spring strap or collar clamps.
Collar clamps must always be replaced with spring strap clamps.
Observe the safety precautions Chap. 20-1.

Observe the rules for cleanliness Chap. 20-1.
1 - Vent line
T from solenoid valve 1 -N80(in engine compartment)
2 - 10 Nm
3 - Throttle valve control unit
4 - Solenoid valve 1 -N80T in right of engine compartment
T valve is actuated (pulsed) by
engine control unit when engine is warm
T testing 1.0/37; 1.4/44 Engine, Fuel Injection;
Rep. Gr. 01; Final Control
5 - Connector
T black, 2 pin
T for solenoid valve 1 -N806 - Activated charcoal filter
T Fitting location: in rear right
wheelhouse
T attached to body
7 - Vent line
T from gravity valve to fuel tank
2
3
5
4
S20-0088
Edition 06.00
S00.5305.01.20
20-2 page 1
20
20-2 page 2
Edition 06.00
S00.5305.01.20
26
26 Exhaust System
26-1
Removing and installing parts of the exhaust system
Note
Always replace gaskets and self-locking nuts.
Use a screwdriver to slacken and tighten the clamps of the heat shields. Tightening torque: 2 Nm
1 - Gasket
T replace
2 - Gasket
T replace
T fitting position: notch faces
down
3 - 25 Nm
T coat with hot screw paste G
052 112 A3 before inserting
4 - Exhaust manifold
T to remove take off intake
manifold 1.0/37; 1.4/44;
1.4/50 engine - fuel injection;
Rep. Gr. 24.
5 - 20 Nm
T replace
6 - Hot air collector/shield
7 - Guide tube
T for the oil dipstick
8 - Retaining strap
T made of silicone
T press off from cross member
item 9 to remove front exhaust pipe with catalytic converter
9 - Cross member
10 - 25 Nm
11 - Double clamp
T align exhaust system free of
stress before tightening
26-1 page 2
T fitting position: bolts at bottom and horizontal
T tighten bolted connections evenly
12 - Lambda probe downstream of catalytic converter -G130-, 50 Nm.
T only on engines complying with D4-/EU4 exhaust-emission standard
T only coat thread with hot screw paste G 052 112 A3; hot screw paste must not get into the slot of the probe
body
T use lambda probe wrench for removing and installing
T testing 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01
T test lambda control and lambda probe heater 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24
13 - 25 Nm
T replace
14 - Hanger
T retaining strap made of EPDM
Edition 02.02
S00.5305.03.20
26-1 page 1
26
15 - Hanger
T retaining strap made of EPDM
T pay attention to the spare part number
16 - Separation point
T for repairs 26-1 page 3
17 - Hanger
T retaining strap made of silicone
T pay attention to the spare part number
18 - Front and rear silencer
T replace individually when carrying out repairs 26-1 page 3
T align exhaust system free of stress 26-1 page 2
19 - Front exhaust pipe with catalytic converter
T only on engines complying with D4-/EU4 exhaust-emission standard
T with 2 catalytic converters
20 - Lambda probe 1 downstream of catalytic converter -G39-, 50 Nm
T only coat thread with hot screw paste G 052 112 A3; hot screw paste must not get into the slot of the probe
body
T use lambda probe wrench for removing and installing
T testing 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01
T test lambda control and lambda probe heater 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24
21 - Front exhaust pipe with catalytic converter
T only on engines complying with EU2 exhaust-emission standard
22 - 40 Nm
T replace
T coat stud bolts with hot bolt paste G 052 112 A3
Aligning exhaust system free of stress

Procedure
The exhaust system is aligned when cold.

Slacken bolted connections of double clamp between
catalytic converter and front silencer and replace nuts.
Position double clamp at the distance -a- = 5 mm from

the marking on the pipe of the catalytic converter
(bolts at bottom and horizontal) and tighten front bolted connection slightly.
26-1 page 2
S26-0064
Edition 02.02
S00.5305.03.20
26
Push front silencer -1- sufficiently far forward into the

double clamp until the dimension -b- of 3 to 7 mm is
achieved between hanger and the body and the hanger and the front silencer.
-Arrow- points in direction of travel.
Tighten bolted connections on the double clamp in

this position.
Note
After tightening the double clamp, inspect dimension -band adjust if necessary.
b
S26-0065
Replacing front or rear silencer

Body saw (e.g. -V.A.G 1523 -)
A separation point is provided for repair purposes for replacing the front silencer or rear silencer.
Separate exhaust pipe at right angles at the separa-
tion point -arrow 1- with body saw.
When installing double clamp -4- position on the side

markings -arrows 2 and 3-.
Align exhaust system free of stress 26-1 page 2.

Align rear silencer horizontally.
Tighten bolted connections of the double clamp evenly to 25 Nm.
3
2
Installation position of double clamp: bolts positioned vertically at front of exhaust pipe.
1
Checking the exhaust system for leaks
S26-0063
Start engine and run in idle.

Seal off tail pipe for the duration of the leak check (e.g.
with cloth or plug).
Check the connection points for leaks by listening:

Cylinderhead/exhaust manifold, exhaust manifold/exhaust pipe with catalytic converter, etc.
Eliminate any leak found.
Edition 02.02
S00.5305.03.20
26-1 page 3
26
26-1 page 4
Edition 02.02
S00.5305.03.20

Motor ARV, AQV, AZE, AZF, AME, ATZ, AQW PDF

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Service

1.0/37; 1.4/44; 1.4/50 Engine, Mechanical

ARV AQV AZE

AZF AME ATZ AQW

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components

List of Supplements to Workshop Manual

Supplement to Basic Edition

Modifications in Rep. Gr. 00, 13, 15 and 17

Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26

Modifications in Rep. Gr. 00, 13, 15 and 17

FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components

FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components

Removing and Installing Engine .................................................................... 10-1

- Removing engine ...................................................................................... 10-1

- Installing the engine ................................................................................... 10-1

- Tightening torques .................................................................................... 10-1

- Assembly bracket ...................................................................................... 10-1

Removing and installing V-ribbed belt ............................................................ 13-1

- Summary of components - Vehicles without air conditioning ................................... 13-1

- Summary of components - Vehicles with air conditioning ....................................... 13-1

- Removing the V-ribbed belt .......................................................................... 13-1

- Installing the V-ribbed belt ........................................................................... 13-1

Disassembling and Assembling Cylinder Block and Crankshaft ........................... 13-2

- Summary of components ............................................................................. 13-2

- Inspecting synchronous running of sprockets ..................................................... 13-2

- Replacing ring gear ................................................................................... 13-2

Removing and installing cylinder head ........................................................... 15-1

- Summary of components ............................................................................. 15-1

- Removing and installing cylinder head ............................................................. 15-1

Repairing cylinder head .............................................................................. 15-2

- Inspect valve guides .................................................................................. 15-2

- Removing and installing valves ..................................................................... 15-2

- Reworking valve seats ................................................................................ 15-2

- Replacing valve stem seal ........................................................................... 15-2

- Basic setting of hydraulic valve clearance compensation ....................................... 15-2

- Testing the compression ............................................................................. 15-2

Repairing valve gear ................................................................................... 15-3

- Removing and installing camshaft .................................................................. 15-3

- Removing and installing rocker arms ............................................................... 15-3

- Inspecting hydraulic tappets ......................................................................... 15-3

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

- Summary of components ............................................................................. 17-1

Removing and installing oil pan .................................................................... 17-2

Testing Oil Pressure and Oil Pressure Switch .................................................. 17-3

10 Removing and Installing Engine

15 Cylinder Head, Valve Gear

FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components

- Parts of the cooling system fitted to body ......................................................... 19-1

- Parts of cooling system engine side ................................................................ 19-1

- Connection diagram for coolant hoses ............................................................. 19-1

- Draining and filling up coolant ....................................................................... 19-1

- Checking the coolant system for tightness ........................................................ 19-1

Removing and Installing Radiator, Coolant Pump ............................................. 19-2

- Removing and installing radiator .................................................................... 19-2

- Removing and installing coolant pump ............................................................ 19-2

- Cleanliness rules ...................................................................................... 20-1

Activated Charcoal Filter System .................................................................. 20-2

- Repairing parts of the activated charcoal filter system .......................................... 20-2

Removing and installing parts of the exhaust system ........................................ 26-1

- Aligning exhaust system free of stress ............................................................. 26-1