Manual Service Skoda Octavia 1997
Manual Service Skoda Octavia 1997
Manual Service Skoda Octavia 1997
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Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Supple-
Edition Subject Article Number
ment
01.01 Basic Edition S00.5134.50.20
1 08.02 Changes for engine BFQ S00.5134.51.20
2 11.04 Modifications in Rep. Gr. 10, 13 and 15 S00.5134.52.20
Table of Contents
00 – Technical Data
Technical Data .......................................................................................... 00-1 page 1
13 – Crankgear
Disassembling and assembling engine ........................................................... 13-1 page 1
- Removing and installing V-ribbed belt .............................................................. 13-1 page 1
Removing and installing, tightening the timing belt ........................................... 13-2 page 1
- Summary of components ............................................................................. 13-2 page 1
- Removing toothed belt ................................................................................ 13-2 page 2
- Installing toothed belt, tensioning (setting timing) ................................................ 13-2 page 5
- Inspecting the semi-automatic timing belt tensioning pulley .................................... 13-2 page 6
Removing and installing sealing flange and pressure plate ................................. 13-3 page 1
- Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-3 page 2
- Removing and installing the front sealing flange ................................................. 13-3 page 4
- Removing and installing drive plate ................................................................ 13-3 page 6
Removing and installing crankshaft ............................................................... 13-4 page 1
Disassembling and assembling piston and conrod ............................................ 13-5 page 1
17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1
- Disassembling and assembling the oil filter holder .............................................. 17-1 page 3
Removing and installing oil pan .................................................................... 17-2 page 1
Testing oil pressure and oil pressure switch .................................................... 17-3 page 1
19 – Cooling
Parts of cooling system - Summary of components ........................................... 19-1 page 1
- Parts of the cooling system fitted to body ......................................................... 19-1 page 1
- Parts of cooling system engine side ................................................................ 19-1 page 2
- Connection diagram for coolant hoses ............................................................. 19-1 page 3
- Draining and filling up coolant ....................................................................... 19-1 page 3
- Removing and installing radiator .................................................................... 19-1 page 5
- Removing and installing coolant pump ............................................................ 19-1 page 8
Electronically controlled cooling system ......................................................... 19-2 page 1
- Operation ............................................................................................... 19-2 page 1
- Testing electronically controlled cooling system .................................................. 19-2 page 1
- Disassembling and assembling coolant distributor housing .................................... 19-2 page 3
- Testing thermostat for map-controlled engine cooling ........................................... 19-2 page 3
20 – Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 page 1
- Removing and installing the fuel tank with component parts and fuel filter .................. 20-1 page 2
- Safety precautions when working on the fuel supply system ................................... 20-1 page 3
- Rules of cleanliness ................................................................................... 20-1 page 3
- Removing and installing the fuel delivery unit .................................................... 20-1 page 4
- Removing and installing the fuel gauge sender .................................................. 20-1 page 5
- Removing and installing the fuel tank .............................................................. 20-1 page 5
- Connecting remote control ........................................................................... 20-1 page 6
- Disconnecting the fuel delivery unit with crash signal ........................................... 20-1 page 7
- Testing fuel pump ..................................................................................... 20-1 page 7
- Inspecting fuel flow rate .............................................................................. 20-1 page 8
Inspecting the electronic power control (electronic throttle) ................................ 20-2 page 1
Activated charcoal filter system .................................................................... 20-3 page 1
- Operation ............................................................................................... 20-3 page 1
- Repairing parts of the activated charcoal filter system .......................................... 20-3 page 2
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Exhaust manifold, exhaust pipe with catalytic converter and attached parts ................ 26-1 page 1
- Silencer with hanger .................................................................................. 26-1 page 3
- Removing and installing front exhaust pipe ....................................................... 26-1 page 3
- Removing and installing exhaust manifold ........................................................ 26-1 page 4
- Replacing front or rear silencer ..................................................................... 26-1 page 5
- Aligning exhaust system free of stress ............................................................. 26-1 page 5
- Checking the exhaust system for leaks ............................................................ 26-1 page 7
Secondary air system ................................................................................. 26-2 page 1
- Removing and installing parts of the secondary air injection system ......................... 26-2 page 1
Exhaust gas recirculation system .................................................................. 26-3 page 1
- Exhaust gas recirculation system - summary of components .................................. 26-3 page 1
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Note
♦ Always replace the seals and gaskets during assem-
bly work.
♦ Replace the self-locking nuts and screws.
♦ Clean all threaded holes into which self-locking bolts
are inserted, with a thread tap to remove residues of
the locking fluid.
♦ Coat stud bolts of exhaust manifold with hot bolt paste
-G 052 112 A3- before installing.
♦ Tightening torques µ 10-2 page 3.
♦ Assembly bracket µ 10-2 page 4.
♦ If the battery is disconnected and reconnected, carry
out certain additional operations µ Electrical System;
Rep. Gr. 27.
Procedure
Installation is performed in the reverse order. Pay atten-
tion to the following points:
Note
The drained off coolant must only be then re-used if the
cylinder head, cylinder block, radiator or heat exchanger
were not replaced.
Caution!
Before slackening the bolts, the unit must be se-
cured with the supporting device -MP 9-200-.
Engine mounting
a = 14.0 mm
b = at least 10.0 mm
Both bolt heads -1- must end flush with the edge -c-.
Gearbox mounting
The edges -a- and -b- must be positioned parallel to each
other.
Tightening torques
Note
♦ Tightening torques apply only for lightly greased,
oiled, phosphatized or blackened nuts and screws.
♦ Other lubricants such as engine and gearbox oil are
allowed. Under no circumstances use Molykote.
♦ Do not use degreased parts.
♦ Unless otherwise indicated the following tightening
torques apply:
Component Nm
Screws and nuts M6 9
M7 13
M8 20
M10 40
M12 70
In variation of this:
Engine mounting, gearbox µ Assembly
mount, pendulum support bracket
Driver plate on the torque converter 60
Connecting bolts for the engine/the gearbox
µ 5-speed manual gearbox 02K; Rep. Gr. 34
µ Automatic gearbox; Rep. Gr. 37.
Assembly bracket
Tightening torques
Engine assembly bracket
Hinged bracket
1 - 40 Nm +45° 3)
2 - 40 Nm +45°3)
3 - 20 Nm + 90° (1/4 turn)3)
1) Replace bolts
2) Replace bolts
3) Replace bolts
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Summary of components
Special tools, test and measuring equipment and aids required
♦ Torque wrench
♦ Pressure pad -T30004-
♦ Two-hole nut turner -T10020-
♦ Supporting device -MP 9-200-
Note
Before removing the timing belt, mark direction of running. Reversing the rotation direction of an already used belt may
destroy it.
Edition 11.04 Removing and installing, tightening the timing belt 13-2 page 1
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Note
When engine removed, position vibration damper to TDC
cylinder 1 -arrows-.
Edition 11.04 Removing and installing, tightening the timing belt 13-2 page 3
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
S13-0104
Note
♦ To slacken the front bolt of the engine support, raise
engine slightly with spindle of supporting device
-MP 9-200-.
♦ To take off engine support, raise or lower engine, re-
spectively with the supporting device -MP 9-200-.
Note
♦ Also when carrying out repairs which necessitate tak-
ing the toothed belt only off the camshaft sprocket, it
is then necessary to carry out the installation of the
toothed belt as follows.
♦ When rotating the camshaft, the crankshaft must not
be positioned at TDC. Risk of damaging valves and
piston crowns.
Condition
Note
When engine removed, after this, install bottom toothed
belt guard and vibration damper. Position crankshaft to
TDC of cylinder 1 -arrows-.
Edition 11.04 Removing and installing, tightening the timing belt 13-2 page 5
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Note
Before installing engine support, insert bolts into engine
support.
Fitting position
• The angle bracket -arrow- must engage in the recess
at the cylinder head.
Test condition
• Toothed belt fitted on and tensioned.
• Engine temperature not above 30 °C.
Test sequence
– Position engine on TDC cylinder 1.
– Load timing belt by firmly pressing down with thumb.
The pointer -2- must move.
– Relieve the pressure again on the timing belt and ro-
tate crankshaft a further two revolutions in direction of
rotation of engine and position again at TDC of cylin-
der 1.
Note
For the inspection use a mirror.
Edition 11.04 Removing and installing, tightening the timing belt 13-2 page 7
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Note
♦ Repairs to clutch µ 5-Speed Manual Gearbox 02K; Rep. Gr. 30.
♦ Secure the engine with engine mount -MP 1-202- and distance sleeves -T30010- on the assembly stand before
performing assembly work.
1 - 15 Nm
2 - Gasket ring
s do not oil sealing lip of gasket 1 2 3 4 5 6 7
ring
s replace µ 13-3 page 2
3 - Front sealing flange
s must be positioned on dowel
sleeves
s removing and installing
µ 13-3 page 4
s remove oil pan for removing
and installing
4 - Threaded pin, 10 Nm
s replace
s unscrew for attaching engine
holder -T10012-
5 - Cylinder block
s removing and installing
crankshaft µ Chapter 13-4
s disassembling and assem-
bling pistons and conrod
µ Chapter 13-5
6 - Gasket ring
s replace
7 - 100 Nm
8 - 60 Nm + torque a further 90°
(1/4 turn)
s replace
12 1 11 10 9 8
9 - Washer
s Check fitting position
S13-0281
10 - Pressure plate/driver disc
s remove and install flywheel
and pressure plate µ 5-Speed Manual Gearbox 02K; Rep. Gr. 30
s removing and installing drive plate µ 13-3 page 6
11 - Intermediate plate
s hang on the sealing flange µ Fig. 1 in 13-3 page 2
s must be positioned on dowel sleeves
s do not damage/bend during assembly work
12 - Rear sealing flange with gasket ring
s must be replaced completely
s use supporting sleeve supplied for installing
s remove oil pan for removing and installing
s Neither grease nor oil sealing lip of sealing ring
s before installing remove grease residue from crankshaft journal with a clean cloth
s supporting sleeve must not be removed until after pushing sealing flange onto the crankshaft journal
Edition 11.04 Removing and installing sealing flange and pressure plate 13-3 page 1
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Removing
– Remove the V-ribbed belt µ Chapter 13-1.
– Remove tensioning element for V-ribbed belt.
T 30004
– Remove the timing belt µ Chapter 13-2.
– Remove crankshaft toothed belt sprocket. To this end
lock the toothed belt gear with counterholder -T30004-
or -MP 1-310-.
Note
When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and counter-
holder.
MP 1-310
S13-0156
Removing and installing sealing flange and pressure plate Edition 11.04
13-3 page 2 S00.5134.52.20
Octavia 1997 1.6 l/75 kW Engine - Mechanical Components 13
– Oil the thread head of the gasket ring extractor
-MP 1-226-, position and forcefully screw it into the
gasket ring as far as possible.
– Release knurled screw and turn the inner side against
the crankshaft until the gasket ring is pulled out.
Installing
Note
Do not oil sealing lip of the gasket ring.
MP 1-226
Note
If the bolt -T10053/2- (M16x1.5x60) is not available, the
old central bolt for the crankshaft toothed belt sprocket
can be used.
Edition 11.04 Removing and installing sealing flange and pressure plate 13-3 page 3
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
♦ Torque wrench
♦ Assembly device -T10053-
♦ Counterholder -T30004 - or -MP 1-310-
♦ Hand-held power drill with plastic brush insert
♦ Flat scraper
♦ Silicone sealant -D 176 404 A2-
Removing
– Remove the V-ribbed belt µ Chapter 13-1.
– Remove tensioning element for V-ribbed belt.
T 30004
– Remove the timing belt µ Chapter 13-2.
– Remove crankshaft toothed belt sprocket. To this end
lock the toothed belt gear with counterholder -T30004-
or -MP 1-310-.
Note
When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and counter-
holder.
Removing and installing sealing flange and pressure plate Edition 11.04
13-3 page 4 S00.5134.52.20
Octavia 1997 1.6 l/75 kW Engine - Mechanical Components 13
– Use a rotating plastic brush to remove sealant resi-
dues on the sealing flange (wear protective goggles).
– Clean the sealing surfaces. They must be free of oil
and grease.
Installing
– Cut off nozzle tube at the front marking (∅ of nozzle
approx. 3 mm).
– Apply silicone sealant to the clean sealing surface of
the sealing flange, as shown in the illustration.
♦ Thickness of sealant bead -arrows-: 2…3 mm
Note
♦ Before applying the sealant bead cover over the gas-
ket ring with a clean cloth.
♦ The sealant bead must not be thicker otherwise ex-
cess sealant can clog the strainer in the oil suction
pipe.
♦ Pay attention to the 'use by date' on sealant.
♦ The sealing flange must be installed within 5 minutes
after applying the silicone sealant.
♦ When installing the sealing flange with the gasket ring
fitted use guide sleeve -T10053/1-.
♦ After installing, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
Edition 11.04 Removing and installing sealing flange and pressure plate 13-3 page 5
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Note
♦ Thread and collar must be free of oil and grease.
♦ When attaching the counterholder -MP 1-310- place
2 washers between toothed belt sprocket and coun-
terholder. MP 1-310
♦ Replace central screw for crankshaft toothed belt
gear.
B
Releasing and tightening the drive plate
MP 1-221
– Attach counterholder -MP 1-221- with M8x45 bolt to
the drive plate. Place two M10 nuts -arrow- between
the counterholder and the driver disc.
Fitting position of the counterholder: S13-0280
A - for slackening A
B - for tightening
S13-0282
Removing and installing sealing flange and pressure plate Edition 11.04
13-3 page 6 S00.5134.52.20
Octavia 1997 1.6 l/75 kW Engine - Mechanical Components 13
– Inspect installed dimension of drive plate at the 3
mounting holes for the torque converter and calculate
mean value.
Specification -a-: 19,5…21.1 mm
Note
The measurement is made through the hole of the drive
plate to the milled surface of the cylinder block. a
If the specified value is not reached:
S13-0197
S13-0285
Edition 11.04 Removing and installing sealing flange and pressure plate 13-3 page 7
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Removing and installing sealing flange and pressure plate Edition 11.04
13-3 page 8 S00.5134.52.20
Octavia 1997 1.6 l/75 kW Engine - Mechanical Components 13
Note
♦ Before removing the crankshaft, ensure a suitable place is available for placing it down so that the sensor rotor
µ item 7 in 13-4 page 1 does not rest on anything or get damaged.
♦ To carry out removal and installation operations, attach the engine with the engine holder -MP 1-202- and the
sleeves -T30010- to the assembly stand -MP 9-101- µ Chapter 10-1.
♦ Pay attention to colour coding when inserting bearing shells µ Fig. 2 in 13-4 page 2
1 - Oil pump
s removing and installing
1 2 3 4 5 6 4 7 8
µ Chapter 17-1
2 - 15 Nm
3 - Sprocket
s for oil pump drive
4 - Bearing shells 1, 2, 3, 4 and 5 5
s Identification for ordering re- 4
placement parts µ Fig. 2 in 3
13-4 page 2 2
1
s for bearing cap without lubri-
cating groove
s for cylinder block with lubri-
cating groove
s do not mix up used bearing
shells (mark)
5 - 40 Nm + torque a further 90° 9
(1/4 turn)
4
s replace
s tighten thread
6 - Bearing caps
s Bearing cap 1: on the belt
4 10
pulley side
s retaining lugs of the bearing
shells of the cylinder block/
bearing cap must be on top
of one another
7 - Rotor
s for engine speed sender
-G28-
s assembly only possible in S13-0288
one position -holes offset-
s replace sensor rotor each time the bolts are slackened
s removing and installing µ Fig. 1 in 13-4 page 2
8 - 10 Nm + torque a further 90° (1/4 turn)
s replace
9 - Crankshaft
s Axial play when new: 0,07…0.23 mm
Wear limit: 0.30 mm
s Crankshaft bearing journal: ∅ 48.00 mm
s Conrod bearing journal: ∅ 42.00 mm
10 - Thrust washer
s for bearing 3
s Fitting position: Oil grooves point to the crank webs
Note
♦ After being attached a second time, the attachment
point of the recess head screws in the sensor rotor is
sufficiently misshapen that the bolt heads rest against
crankshaft -3- -arrows- and the sensor rotor is posi-
tioned loosely below the screws.
♦ It is only possible to install the sensor rotor in one po-
sition, the holes are offset.
Note
2
Bearing 1 points toward belt pulley.
Colour coding of bearing shells matches the letters
on the cylinder block
3
S = black
R = red
G = yellow
B = blue 4
W = white
Note
For carrying out removal and installation operation, attach the engine with the engine holder -MP 1-202- and the
sleeves -T30010- to the assembly stand -MP 9-101-.
1 - Circlip
2 - Piston pin 1 2 3 1 4
s if stiff, heat piston to 60°C
s use drift -VW 222A- for re-
moving and installing
3 - Piston
s check µ Fig. 3 in 13-5
page 3
s mark installation position rel-
ative to conrod and mark
matching cylinder with felt
pen
s arrow on piston crown faces
towards the belt pulley side 6 5
s use piston ring tensioning
strap for installing
s Piston 80.965 mm
4 - Piston ring (compression
ring) 11 12
s Offset joint 120°
s use piston ring pliers for re- A B
moving and installing com-
pression rings
s marking „TOP“ must face to-
wards piston crown
s inspect gap clearance
µ Fig. 1 in 13-5 page 2 7
s inspect end clearance
µ Fig. 2 in 13-5 page 2
5 - Piston ring (oil scraper ring)
s carefully remove and install 10 9 8
by hand S13-0283
s marking „TOP“ must face to-
wards piston crown
s inspect gap clearance µ Fig. 1 in 13-5 page 2
s inspect end clearance µ Fig. 2 in 13-5 page 2
6 - Conrod
s replace as a set only
s mark assignment to cylinder -B-
s Fitting position:
Markings -A- must be positioned one above the other and point to the belt pulley side
s with oil drilling for lubricating piston pin
7 - Conrod bearing cap
s as a result of the conrod separated in the cracking process, the cover fits only in one position and only to the
relevant conrod
s mark assignment to cylinder -B-
s Fitting position:
Markings -A- must be positioned one above the other and point to the belt pulley side
Edition 11.04 Disassembling and assembling piston and conrod 13-5 page 1
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Gap clearance
Piston ring new Wear limit
(mm) (mm)
Compression ring 0,20…0,40 0,80
Oil scraper ring 0,25…0,50 0,80
End clearance
Piston ring new Wear limit
(mm) (mm)
Compression ring 0,06…0,09 0,20
Oil scraper ring 0,03…0,06 0,15
Test sequence
Note
Do not measure the cylinder bore if the cylinder block is
fixed to the assembly stand with the engine mount
-MP 1-202-, as this may result in incorrect measure-
ments.
Edition 11.04 Disassembling and assembling piston and conrod 13-5 page 3
S00.5134.52.20
13 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Note
♦ Always replace cylinder head bolts.
♦ Always replace self-locking nuts.
♦ Always replace the seals and gaskets during assem-
bly work.
♦ When installing a cylinder head, all the contact surfac-
es between the hydraulic tappets, roller rocker arms
and the cam tracks must be oiled before installing the
cylinder head cover.
♦ Do not remove the plastic bases supplied as a protec-
tion for the open valves until just before fitting on the
cylinder head.
♦ If the cylinder head is replaced, the system must be
completely filled with fresh coolant.
♦ Disassembling and assembling intake manifold
µ 1.6-litre/75 kW Engine, Fuel Injection and Ignition
System; Rep. Gr. 24.
Requirements
• Engine temperature not above 30 °C.
Note
♦ If the battery is disconnected and reconnected, carry
out certain additional operations µ Electrical System;
Rep. Gr. 27.
♦ All cable straps which are detached or cut open when
removing, should be fitted on again in the same place
when installing.
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
– Remove fuel feed line -1- and fuel feed line -2-, to do
so press latch clips. Lines and line connections are
colour-coded.
– Detach hose -3- at the ACF tank.
– Remove inlet line and pressure line of secondary air
pump.
Note
Seal the intake passages in the bottom part of the intake
manifold with a clean cloth.
Note
♦ There must not be any oil or coolant present in the
holes for the cylinder head bolts.
♦ Remove the new cylinder head seal from its wrapping
immediately before fitting.
♦ Treat the new seal with the utmost care. Any damage
will result in leaks.
Test sequence
– Inspect cylinder head at several points for distortion
using a knife-edge straightedge and feeler gauge.
♦ Max. permissible distortion: 0.1 mm (minimum clear-
ance of straightedge base: 100 mm)
Procedure
– Reworking of the sealing surface of the cylinder head
(face-grinding) is only permissible up to minimum di-
mension -a-.
♦ Minimum dimension -a-: 132.6 mm
Note
If the sealing surface is reworked, the valves should be
set lower by the same amount (rework valve seat rings)
otherwise the valves will strike the pistons. When doing
this, ensure that the permissible maximum dimension -
µ Chap. 15-4 - is not exceeded.
Test condition
• Engine oil temperature must be at least 30°C.
Test sequence
– Unplug 4-pin plug (-1-) from ignition transformer
-N152- (-2-).
– Disconnect the connector of the injection valves.
Note
Use of tester µ Operating instructions
Compression readings
Note
♦ Cylinder head and ladder frame must always be replaced together.
♦ After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touch-
es the piston when the engine is started.
1 - 100 Nm
s to release and tighten use
counterholder -T30004-
2 - Camshaft sprocket
s to remove and install, re-
move toothed belt
µ Chapter 13-2
s installation position fixed by
parallel key µ item 4
s for engines with engine iden-
tification characters AVU
with rotor for hall sender
-G40-
3 - Gasket ring
s do not oil sealing lip of gasket
ring
s replacing µ Chapter 15-3
4 - Parallel key
5 - 20 Nm
6 - Ladder frame
s Reworking of sealing surfac-
es not permissible
s with integrated camshaft
bearing
s Bearing 1 for camshaft
sprocket
s pay attention to tightening or-
der of camshaft bearings
µ Chapter 15-3
s Apply sealant
-D 188 800 A1- carefully in
the sealant groove and to the
bottom sealing surface
7 - Camshaft
s The rework of the camshaft is not permissible
s inspecting axial play µ Fig. 1 in 15-2 page 2
s removing and installing µ Chapter 15-3
s Slack: max. 0.01 mm
s for engines with engine identification characters AVU without rotor for hall sender -G40-
8 - Roller rocker arm
s do not interchange
s inspect roller bearings
s oil contact surface
s for installing, clip onto hydraulic supporting element with locking clip
9 - Supporting element
s do not interchange
s with hydraulic valve clearance compensation
s oil contact surface
10 - Valve collets
11 - Valve spring retainer
12 - Valve spring
s removing and installing
– with cylinder head removed:
with -MP 1-211- and -MP 1-213- with valve supporting plate -MP 1-218-
– with cylinder head installed µ Chapter 15-4
13 - Valve stem seal
s replacing µ Chapter 15-4
14 - Cap
s insert flush
s for removal, only push the rubber through the middle using a screwdriver and release
15 - Valve guide
s inspect µ Chapter 15-4
16 - Cylinder head
s reworking valve seats µ Chapter 15-4
17 - Valve
s do not rework, only grinding in is permissible
s Valve dimensions µ Fig. 2 in 15-2 page 2
Note
The valves must not be reworked. Only grinding in is per-
missible.
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Note
With cylinder head removed, place cylinder head onto the
valve supporting plate -MP 1-218-.
Removing
– Removing camshaft µ Chap. 15-3.
– Remove the roller rocker arm together with the sup-
porting element. Lay aside on a clean surface.
– Ensure that the roller rocker arm and the supporting
element is not mixed up.
– Use assembly tool -T10112- to unplug spark plug con-
nector and unscrew spark plugs with spark plug
wrench.
– Put the piston of the relevant cylinder at „bottom dead
centre“.
– Insert assembly device -MP 1-213- and adjust bearing
to stay bolt height.
– Screw the pressure hose -MP 1-210- into the spark
plug thread and apply constant pressure of at least 0.6
MPa (6 bar) in the cylinder.
– Remove valve springs with valve lever -MP 1-211-.
MP 1-230
Note
If valve collets are tight, slacken with slight blows of a
hammer on the valve lever.
– Pull off valve stem seal with extractor for valve stem
seal -MP 1-230-.
S15-0183
Edition 11.04 Valve stem seals, valves guides, valve seats 15-4 page 1
S00.5134.52.20
15 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Installing
– In order to avoid damage to the new valve stem seals,
fit the supplied plastic sleeve -A- onto the valve stem. MP 1-233
– Oil valve stem seal -B-, insert into the valve stem seal
insertion tool -MP 1-233- and carefully push onto the A B
valve guide.
– Remove plastic sleeve.
Further installation occurs in a similar way in reverse or-
der to removal.
Note
After carrying out work on the valve gear, carefully crank
engine at least 2 revolutions to ensure that no valve
S15-0184
touches the piston when the engine is started.
Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
Procedure
– Insert valve into guide. End of valve stem must end
flush with the guide (because of the different stem di-
ameter, use only inlet valve in inlet guide and exhaust
valve in exhaust guide).
– Determine valve rock.
Wear limit: 0.6 mm
Note
If the wear limit is exceeded, repeat measurement with
new valves. If the wear limit is again exceeded, replace
cylinder head.
Note
If no perfect contact pattern is achieved by grinding in the
valve seats, rework the valve seats.
Note
♦ When carrying out repairs on engines with leaking
valves, it is not sufficient to machine or replace the
valve seats and valves. It is also necessary to inspect
the valve guides for wear, particularly on engines with
a high mileage µ 15-4 page 2.
♦ Rework valve seats only sufficiently in order to obtain
a proper contact pattern.
♦ Calculate the maximum permissible reworking dimen-
sion before commencing.
♦ If the reworking dimension is exceeded, proper oper-
ation of the hydraulic valve clearance compensation is
no longer assured and the cylinder head must be re-
placed.
Note
If the valve is replaced when carrying out repair work, use
a new valve for the measurement.
Note
If the max. permissible reworking dimension is 0 mm or
less than 0 mm, repeat measurement with a new valve. If
the measuring result is still 0 mm or less than 0 mm, re-
place cylinder head.
Edition 11.04 Valve stem seals, valves guides, valve seats 15-4 page 3
S00.5134.52.20
∅
∅
15 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
Procedure
Reworking can be carried out with a machine or by hand.
The following conditions must be met:
S15-0098
Note
If the reworking dimension is exceeded, proper operation
of the valve gear is no longer assured and the cylinder
head must be replaced.
Edition 11.04 Valve stem seals, valves guides, valve seats 15-4 page 5
S00.5134.52.20
15 Octavia 1997 1.6 l/75 kW Engine - Mechanical Components
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