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

Disassembling and assembling engineEdition 12.04S00.5322.03.20

13-2 page 1

13

13-2 Disassembling and assembling engine

Valve control drive - summary of components

For engine with engine identification characters AWY, BMD

1 - Cylinder head with cover❑ removing and installing

⇒ Chapter 15-1

2 - Cylinder block❑ 2 part❑ do not separate

3 - Crankshaft gear❑ for balancing shaft draft❑ Wheel position for balancing

shaft gear ⇒ Fig. 2 in 13-2 page 5

4 - Balancing shaft gear❑ do not remove❑ Wheel position for crankshaft

gear ⇒ Fig. 2 in 13-2 page 5

5 - Chain tensioner for the oil pump

6 - Oil pump❑ removing and installing

⇒ Chapter 17-2

7 - Guide rail8 - Chain sprocket on the crank-

shaft for the camshaft drive❑ interlocked with spring on the

crankshaft

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

shaft

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

❑ removing and installing ⇒ Chapter 17-2

13 - 9 Nm14 - Cover

❑ Oil pump sprocket

15 - 20 Nm + torque a further 90 (1/4 turn)

❑ replace

16 - O-ring❑ replace if damaged❑ replace the sealing of the housing with silicone sealant

17 - Housing❑ Replace together with O-ring ⇒ item 16❑ Replace silicone sealant sealing with O-ring ⇒ item 16

WARNING!

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

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

Disassembling and assembling engine Edition 12.04S00.5322.03.20

13-2 page 2

13

❑ fit onto cleaned crankshaft❑ install only after putting the timing gear cover in place otherwise the gasket ring can be damaged

18 - Gasket ring❑ Replace in case of damage ⇒ Chap. 13-4❑ replace together with housing ⇒ item 17❑ for crankshaft on the belt pulley side❑ Neither grease nor oil sealing lip of sealing ring❑ before installing remove grease residue on the housing with a clean cloth

19 - Belt pulley - crankshaft

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

❑ replace❑ Interlock crankshaft with an assembly device -T10121- for removing and installing it ⇒ Chapter 13-3

21 - 25 Nm22 - 45 Nm23 - 10 Nm

❑ if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have sealant on them

24 - To intake manifold❑ ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24

25 - The vacuum regulating valve (PCV valve)❑ pay attention to the spare part number

26 - O-ring❑ replace if damaged

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

28 - Oil separator❑ clipped in the steering wheel housing

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

❑ replace❑ Interlock camshaft with an assembly device -T10120- for removing and installing it ⇒ Chapter 13-3

30 - Timing chain❑ tensioning ⇒ Fig. 1 in 13-2 page 5

31 - Camshaft sprocket❑ not interlocked on the camshaft but simply fitted onto it❑ removing and installing, setting the timing ⇒ Chapter 13-3

32 - Bolts, 18 Nm❑ for tensioning rail or possibly also guide rail

33 - Tensioning rail❑ interlock tensioner ⇒ Fig. 1 in 13-2 page 5

34 - Hydraulic control chain tensioner❑ tension (loosen control chain) ⇒ Fig. 1 in 13-2 page 5

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

Disassembling and assembling engineEdition 12.04S00.5322.03.20

13-2 page 3

13

For engine with engine identification characters AZQ, BME

1 - Cylinder head with cover❑ removing and installing

⇒ Chapter 15-1

2 - Cylinder block❑ 2 part❑ do not separate

3 - Balancing shaft4 - Balancing shaft gear

❑ do not remove❑ Wheel position for crankshaft

gear ⇒ Fig. 2 in 13-2 page 5

5 - Oil pump❑ removing and installing

⇒ Chapter 17-2

6 - Bolts, 18 Nm❑ for tensioning rail or possibly

also guide rail

7 - Guide rail8 - Chain sprocket on the crank-

shaft for the camshaft drive❑ interlocked with spring on the

crankshaft

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

shaft

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

❑ removing and installing ⇒ Chapter 17-2

13 - 9 Nm14 - Cover

❑ Oil pump sprocket

15 - 20 Nm + torque a further 90 (1/4 turn)

❑ replace

16 - O-ring❑ replace if damaged❑ replace the sealing of the housing with silicone sealant

17 - Housing❑ Replace together with O-ring ⇒ item 16❑ Replace silicone sealant sealing with O-ring ⇒ item 16❑ fit onto cleaned crankshaft❑ install only after putting the timing gear cover in place otherwise the gasket ring can be damaged

18 - Gasket ring❑ Replace in case of damage ⇒ Chap. 13-4❑ replace together with housing ⇒ item 17❑ for crankshaft on the belt pulley side❑ Neither grease nor oil sealing lip of sealing ring❑ before installing remove grease residue on the housing with a clean cloth

19 - Belt pulley - crankshaft

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

Disassembling and assembling engine Edition 12.04S00.5322.03.20

13-2 page 4

13

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

❑ replace❑ Interlock crankshaft with an assembly device -T10121- for removing and installing it ⇒ Chapter 13-3

21 - 25 Nm22 - 50 Nm

23 - 8 Nm + torque a further 90 (1/4 turn)

❑ if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have sealant on them

24 - To intake manifold❑ ⇒ 1.2/47 Engine, Fuel Injection; Rep. Gr. 24

25 - 10 Nm26 - The vacuum regulating valve (PCV valve)

❑ pay attention to the spare part number

27 - O-ring❑ replace if damaged

28 - Timing gear cover❑ removing and installing ⇒ 13-2 page 5

29 - Cover30 - O-ring

❑ replace if damaged

31 - 50 Nm + torque a further 90 (1/4 turn)

❑ replace❑ Interlock camshafts with a pipe section -T10123- for removing and installing it ⇒ Chapter 13-3

32 - Tensioning rail❑ interlock tensioner ⇒ Fig. 1 in 13-2 page 5

33 - Hydraulic control chain tensioner34 - 15 Nm35 - Timing chain36 - Camshaft sprocket

❑ removing and installing, setting the timing ⇒ Chapter 13-3

37 - 15 Nm❑ for engine with engine identification characters AZQ

38 - Sliding block❑ for engine with engine identification characters AZQ

39 - Washer❑ for engine with engine identification characters AZQ❑ replace

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

Disassembling and assembling engineEdition 12.04S00.5322.03.20

13-2 page 5

13

Fig. 1: Interlock tensioner

– Press on the piston of the hydraulic tensioner -2- in the -direction of travel- over the tensioning rail -1- until the piston can be interlocked with the safety drift -B- (e.g. with a 3 mm box spanner).

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

– Place the marking at the gearwheel on the crankshaft opposite to the marking at the gearwheel on the bal-ancing shaft -arrows-.

Removing and installing the timing gear cover

• Engine installed in the vehicle

Special tools, test and measuring equipment and auxiliary items required

♦ Supporting device -MP 9-200-

♦ Hand-held power drill with plastic brush insert

♦ Flat scraper

♦ Silicone sealant -AMV 174 003-

Removing

– If necessary remove engine cover with air filter ⇒ 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.

– Mount supporting device -MP 9-200- and take up the weight of the engine/gearbox assembly at the spin-dles.

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

– Remove the right engine mounting ⇒ Chap. 10-1.

– Remove pulley wheel of the coolant pump ⇒ Chapter 19-1.

– Remove the guide pulley (only on vehicles with air conditioning) ⇒ Chapter 13-1.

– Remove the tensioner with tensioning roller ⇒ Chapter 13-1.

– Remove alternator ⇒ Electrical System; Rep. Gr. 27.

– Remove the ventilation pipe of the cooling system ⇒ Chapter 19-1.

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

Disassembling and assembling engine Edition 12.04S00.5322.03.20

13-2 page 6

13

– Interlock the crankshaft with an assembly device -T10121- ⇒ Chapter 13-3, screw out the screw of the crankshaft and pull off the belt pulley - crankshaft.

– Remove the oil pan, guide pipe of the oil dipstick anbd possibly also the sender for the oil level/temperature -G266- (vehicles with WIV) ⇒ Chapter 17-1/17-2.

– Remove the connection for the vacuum regulating valve (PCV valve).

– Screw out all screws on the timing gear cover.

– Remove the timing gear cover. Use slight knocks with a rubber-headed hammer from outside to loosen the cover as necessary (the timing gear cover sits on the fitting sleeves).

– Use a flat scraper to remove plastic sealant residues from the engine.

Cover the area around the sealing surfaces so that no sealant residues can find their way into the timing gear drive.

– Remove sealant residues on the timing gear cover with a rotating brush, e.g. a hand drill with plastic brush attachment (wear protective goggles).

– Clean the sealing surfaces on the timing gear cover and engine. They must be free of oil and grease.

Installing

♦ Install housing ⇒ item 17 in 13-2 page 1, ⇒ item 17 in 13-2 page 3 only after putting the timing gear cover in place otherwise the gasket ring can be damaged.

♦ Remove sealant residues of silicone sealant applied inside the housing and insert a new O-ring ⇒ item 16 in 13-2 page 1, ⇒ item 16 in 13-2 page 3 into the housing.

♦ Check whether the oil scraper has been damaged while removing (e.g. broken off wings).

♦ Pay attention to the 'use by date' on sealant.

♦ The timing gear cover must be installed within 5 min-utes after applying the silicone sealant.

♦ if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have seal-ant on them.

– Cut off nozzle tube at the front marking (∅ of nozzle approx. 3 mm).

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

Note

Note

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

Disassembling and assembling engineEdition 12.04S00.5322.03.20

13-2 page 7

13

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

For engine with engine identification characters AWY, BMD

For engine with engine identification characters AZQ, BME

Continued for all engines

B - Position of the fitting sleeves

♦ Thickness of sealant bead: 2…3 mm.

The sealant bead must not be thicker than 3 mm other-wise excess sealant may get into the oil pan and clog the strainer in the oil pump.

– Fit timing gear cover immediately and lightly tighten all bolts.

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

Note

Note

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

Disassembling and assembling engine Edition 12.04S00.5322.03.20

13-2 page 8

13

For engine with engine identification characters AWY, BMD

For engine with engine identification characters AZQ, BME

Continued for all engines

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

The sealing of the housing must be carried out with an O-ring ⇒ item 16 in 13-2 page 1, ⇒ item 16 in 13-2 page 3.

Size of screws and the tightening torque

For engine with engine identification characters AWY, BMD

For engine with engine identification characters AZQ, BME

Note

Position Size of bolt Torque

3 M10x162 45 Nm

1, 2 M10x142 45 Nm

22, 23 M8x55 25 Nm

others M6x401) 10 Nm

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

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

Disassembling and assembling engineEdition 12.04S00.5322.03.20

13-2 page 9

13

Continued for all engines

Further installation occurs in reverse order. Pay attention to the following:

♦ Replace crankshaft screw.

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

Position Size of bolt Torque

1, 2, 3 M10x120 50 Nm

4, 5 M8x55 25 Nm

6, 7, 8, 11, 14, 15

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

turn)others M6x221)

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