Self-Study Programme 19 1.6L 1.8L petrol engines.pdf

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SP19-1
SKODA now offers the option of two powerful petrol engines
of a new engine generation.
You can get to know the engineering of these engines, their
common features and other highlights in this booklet.
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Contents
Engine Series EA 113
Development objectives
Common features
Engine Cooling System
Coolant pump/Coolant thermostat
The coolant circuit
Engine Lubrication System
Engine lubrication
Oil circuit
Dynamic oil pressure warning system
Fuel System
Fuel system (block diagram)
Fuel injection system
Fuel pump relay
Fuel tank ventilation system
Self-Diagnosis
1.6-ltr. Engine AEH
The technical data
The engine characteristics
Overview of system
Position of components
Simos 2 engine management system
The variable intake manifold
Simos 2 function diagram
1.8-ltr. Engine AGN
The technical data
The engine characteristics
Motronic 3.8.2. function diagram
Overview of system
Position of components
Camshaft adjustment
The camshaft adjustment valve
Hall sender G40
Motronic 3.8.2. function diagram
Test Your Knowledge
Service
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You will find notes on inspection and
maintenance, setting and repair instructions in
the Workshop Manual.
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Engine Series EA 113
Development objectives
Both petrol engines
1.6-ltr. 2-valve
code letter
AEH
1.8-ltr. 5-valve
code letter
AGN
have been developed from components of the group engine range.
They are part of a new generation of four-cylinder engines mounted transversely.
In addition to the engineering demands, the requirements profile which the development engineers had to
meet were also decisively influenced by production aspects.
The development objectives
– new, powerful engines for transverse installation
– good fuel economy and low emission levels
– extensive parts communality
were achieved by incorporating proven design details of engineering and using lightweight materials.
Engineering design details
– Maintenance-free ignition system with rotorless
high-voltage distribution
– Variable intake manifold (1.6-ltr. engine)
– Camshaft with adjustment feature
(1.8-ltr. engine)
– Oil circuit with dynamic oil pressure warning
– Oil pump designed as internal gear pump
– Thermostat integrated in cylinder block
– Coolant pump integrated in cylinder block
– Engine management system with 16-bit
processor
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Weight reduction
Die-cast aluminium oil pan
Plastic intake manifold
Plastic coolant pump impeller
Light alloy ancillaries bracket
Light alloy cylinder block (1.6-ltr. engine)
Valves with 7 mm stem diameter
The limits of current exhaust emission legislation have been met by adopting the following engineering
solutions
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Map-controlled, cylinder-selective knock control
Adaptive idle speed cylinder charge control
Fuel shut-off on overrun
Three-way catalytic converter and heated Lambda sensor.
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Common features
Common design features and common parts in the different engines offer a multiple range of benefits:
– The engines can be manufactured on a single production line (integrated production)
– The high number of engines produced offer lower manufacturing costs
– Simplification in the service sector
The common features:
– The crankcase of both engines, light alloy
on the 1.6-ltr. engine cast iron on the
1.8-ltr. engine, are geometrically identical.
– The cylinder head is a cross-flow type.
– Oil pump - internal gear pump driven by
chain from the crankshaft, eliminates the
need for separate drive shafts.
– Dynamic oil pressure warning system.
– The coolant pump does not have its own
housing, but is integrated in the crankcase
and driven by the toothed belt.
– The valve gear is optimally designed
(valve stem diameter 7 mm, single valve
spring), which in turn reduces the moving
masses.
– Weight-reduced hydraulic tappets.
– Potential-free Lambda sensor.
– Stiffened engine-gearbox assembly
through the use of die-cast aluminium oil
pan with multiple transmission bolted con-
nections.
– Rotorless high-voltage ignition distribu-
tion operating free of contacts, crankshaft
position detected by sensor at crankshaft
(reference marks), camshaft position is
detected by phase sensor at the cam-
shaft.
– The engine control modules of the elec-
tronic engine management system have
an identical housing.
The connector is a double design.
– Identical ancillary mounting brackets,
compact arrangement of the ancillaries at
engine block.
– The activated charcoal filter has the pulse
valve directly in the filter. Hose system
with quick-coupling.
– The engine-gearbox assembly is sus-
pended in a pendulum mounting in the
vehicle.
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Engine Cooling System
Coolant pump/Coolant thermostat
The coolant pump
does not have its own housing but is inserted in the
cylinder block.
It is driven by the toothed belt.
The pump impeller is made of plastic.
The advantages of this design are:
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reduced number of components
reduced weight
Coolant pump
Toothed belt
SP19-58
The coolant thermostat
is integrated in the cylinder block.
It is held in position by the connection fitting of the
coolant hose in the cylinder block.
Coolant thermostat
SP182-32
Note:
The coolant in these engines is also composed of a mixture of water, antifreeze and
anti-corrosion agent in order to prevent frost and corrosion damage. Consequently,
the cooling system is filled all year round. If the radiator, heat exchanger or cylinder
head is replaced, the system should be refilled with fresh coolant in order to ensure,
in particular, adequate corrosion protection.
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