Self-Study Programme 27 Octavia 1.4 L engine and gearbox 002.pdf

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Š
KODA is enlarging its range of petrol engines in the
OCTAVIA with a new 1.4-ltr. OHV engine.
This compact and lightweight engine is a
Š
KODA
development and is based on tried-and-tested
components of the 1.3-ltr. light-alloy engine.
The engine is classified as conforming with the EU II
emission standard.
SP15_02
SP27_18
You can find out more regarding design and operation of this
new engine in this Self Study Programme.
2
Contents
Part I – 1.4-ltr./44 kW Engine
Summary of New Features
The technical data
The engine characteristics
Mechanical Components
Valve gear
Valve timing
Crankshaft
Crankshaft bearings
Survey of Systems
Simos 3PB engine management
Engine speed sensor G28
Camshaft position sensor G163
Simos 3PB system function
Fuel injection
Electronic Throttle Function
Electrically operated throttle flap
Accelerator pedal
Self-diagnosis/emergency running to accelerator pedal
Throttle flap control unit
Function positions of throttle flap control unit
Basic setting of throttle flap control unit
Self-diagnosis/emergency running to throttle flap control unit
Fault lamp for electronic throttle
Sensors
Function Diagram
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10
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Part II – 5-Speed Manual Gearbox 002
Technical Data
Technical features
Gearbox diagram
Engine/Gearbox Mounting
Engine mount
Gearbox mount
Pendulum support
Clutch Mechanism
External Shift
Final Drive/Speedometer Drive
Service
Service
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You will find notes on inspection and maintenance,
setting and repair instructions in the Workshop
Manual.
3
Summary of New Features
The technical data
New!
SP27_61
AMD
Petrol engine
Type:
4-cylinder in-line engine
1397 cm
3
Displacement:
Bore:
75.5 mm
Stroke:
78 mm
Compression ratio: 10.0 : 1
Rated output:
44 kW (60 HP)
at 4500 rpm
Max. torque:
120 Nm at 2500 rpm
Engine management: Simos 3PB
(electronically
controlled sequential
fuel injection and fully
mapped ignition with
cylinder-selective knock
control)
Valves per cylinder: 2
Emission control:
Lambda control,
1 catalytic converter
Emission standard: Complies with EU II
Fuel:
95 RON unleaded
Code letter:
The basic design of the 1.4-ltr. engine is
derived from the tried-and-tested 1.3-ltr. light-
alloy engine fitted to the FELICIA.
–
Cross-flow cylinder head with 2 valves for
each cylinder.
Bottom-mounted camshaft driven by a
duplex roller chain.
Valves driven by tappets, tappet rods and
rocker arms.
Replaceable cylinder liners, cooled directly
by coolant.
Crankshaft mounted in 3 bearings.
Oil pump driven by camshaft.
–
–
–
–
–
Note:
The engine can also be operated with
91 RON unleaded fuel although this
results in torque and power losses as
a result of the knock control.
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The engine characteristics
New!
1000
2000
3000
n (1/min)
4000
5000
6000
SP27_17
The technical highlights
–
The displacement has been increased as a
result of enlarging the stroke to 78 mm
while maintaining the original bore of
75.5 mm.
The valve tappets of the valve gear have
been replaced by hydraulic valve tappets
which ensure automatic compensation of
the valve clearance. This makes it possible
to eliminate the setting of the valve
clearance as part of the service interval.
At the same time, a reduction in valve gear
noise has been achieved.
The following measures have been
implemented with the aim of reducing
vibrations and improving the noise
characteristics:
Forged crankshaft with eight balancing
weights for achieving optimal mass
balance.
The stiffness of the crankshaft mounting in
the housing is enhanced by combining the
bearing caps in a ladder frame (bearing
unit).
The oscillating masses of the crank gear
have been reduced by opting for a smaller
size of piston pins (Ø 17 mm) and lighter
weight pistons.
The stiffness of the crankcase has also
been enhanced by new type of ribbing.
The flexural stiffness of the engine-gear-
box connection has been enhanced by a
new stiffening to the oil pan flange.
– The Simos 3PB system with sequential fuel
injection and electronic throttle flap control
(electronic throttle) has been used for the
first time as the engine management
system in a
Š
KODA engine.
–
–
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Mechanical Components
Valve gear
Rocker arm
Rocker arm adjusting
bolt
Tappet rod
New!
Oil feed from engine
oil circuit
Hydraulic tappet
(tappet for hydraulic valve
clearance compensation)
Camshaft
203/3.3
The valves of the 1.3-ltr. engine are driven by
the bottom-mounted camshaft through tappet
rods.
Valve clearance compensation is achieved by
the hydraulic system in the tappet, while
incorporating the engine oil pressure.
After replacing parts of the valve gear, a basic
setting of the hydraulic tappet should be
performed.
This is done by means of the rocker arm
adjusting bolt. Please refer to the Workshop
Manual OCTAVIA, 1.4-ltr./44 kW Engine for
further information on this step.
Advantage
The valve clearance remains constant during
the entire engine operating life, which has a
positive impact in reducing exhaust emissions.
It is not necessary to re-set the valve clearance
during service work.
Note:
For repair work, always stop the
tappets in the installed position in
order to retain the oil supply.
Scrupulous cleanliness is essential for
all work.
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