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SP45_11
A new 3-cylinder petrol engine will in future form the entry-level engine
for Škoda models. It is a completely new development and will be
available in the ŠkodaFabia.
Initially, it will be available as a 6-V engine version with 2 valves for each
cylinder; at a later date a 12-V version with 4 valves for each cylinder and
increased power output will be available.
Essentially, the engine has been designed in conformity with the proven
design principles which exist within the Group. Cylinder block and
cylinder head are light-alloy components. The camshaft and the oil pump
are both driven by means of a chain. The valve gear is equipped with
hydraulic valve clearance compensation elements.
2 GB
Contents
Introduction 4
Technical highlights 4
Specifications 5
Cooling System 17
Overview 17
Engine Management 18
System overview 18
Single-spark ignition coils with power output stage 20
Two-probe lambda control 21
Overview of system components 22
Simos 3PD/3PE engine management system 24
Function Diagram 26
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GB 3
Introduction
Technical highlights
The 1.2-ltr. inline engine available with
2 valves, and also with 4 valves per cylinder,
opens up a new chapter in the range of Škoda
engines and enlarges the choice for Škoda
models.
SP45_48 SP45_49
... with 2 valves per cylinder ... with 4 valves per cylinder
– Crankshaft with 6 balance weights running – Crankcase ventilation with fresh air flow into
in 4 bearings ventilation system, PCV (Positive Crankcase
– Camshaft driven by crankshaft by means of Ventilation) control valve
a chain; oil pump likewise chain-driven – Oil level/temperature sender installed into
– Timing chain tensioned by hydraulic oil pan from above through timing case
tensioning device, chain for oil pump drive (extended service interval)
tensioned mechanically – Plastic intake manifold
– Cylinder block split at level of middle of – Electronic Power Control
crankshaft – Single-spark ignition coils
– Balance shaft for reducing vibrations – Post-treatment of exhaust gases with
– Cross-flow cooling in cylinder head 2 step-type lambda probes on 2-V engine,
– 4-valve engine without fuel return-flow catalytic converter close to engine
line, fuel filter with integrated fuel pressure – Post-treatment of exhaust gases with
regulator 1 broadband lambda probe as upstream-cat
– 2-valve engine with fuel return-flow line, probe and one step-type probe as
fuel pressure regulator at fuel distribution downstream-cat probe on 4-V engine,
pipe catalytic converter close to engine
– Upright oil filter located at exhaust side in – Electric exhaust gas recirculation valve on
top part of cylinder block, filter element 4-V engines
replaceable from above – Air filter with integrated control for blending
of warm air
4 GB
Specifications
Engine characteristic - AWY Engine characteristic - AZQ
50 50
40
40
110
110
100
100
30
30
90
90
80
80
20 70
20 70
10 10
1000 2000 3000 4000 5000 SP45_15 1000 2000 3000 4000 5000 SP45_29
n (1/min) n (1/min)
GB 5
Engine Mechanical Components
Upstream-cat Coolant
Warm air inlet Vacuum valve
lambda probe thermostat
connection (crankcase ventilation)
housing
Tensioning pulley
Intake manifold
Alternator
Clutch flange
Alternator Coolant AC compressor
pump
SP45_06 SP45-07
The cylinder block is split at the level of the Exhaust manifold and catalytic converter form
middle of the crankshaft. The bottom part is a a compact single assembly. The upstream-cat
bearing bridge which is particularly stable in lambda probe is installed from above into the
design and consists of a single part. This also exhaust manifold directly upstream of the
performs the task of the otherwise usual catalytic converter.
bearing caps and, as a result of its compact The downstream-cat lambda probe is located
design, contributes to good mounting of the in the exhaust pipe downstream of the
crankshaft. catalytic converter.
The bottom part also integrates a balance
shaft which is responsible for ensuring low- Warm air is inducted from the area between
vibration running of the engine. exhaust manifold/catalytic converter and the
matching cover through the warm air inlet
The ventilation of the crankcase features a connection to the air filter.
PCV control valve.
The ratio of cold and warm inducted air is
Ignition in the respective cylinder is controlled by means of regulating flap in
performed by individual ignition modules combination with a thermostat. The control
(single-spark ignition coils). mechanism is integrated in the air filter.
6 GB
Main components of engine Note:
Please refer to the Workshop
housing Manual for more detailed
information regarding the sealing.
Cylinder head cover, cylinder head, cylinder
block (top and bottom part) and the timing
case (side housing cover for camshaft drive/oil
pump drive) are aluminium die castings.
The oil pan is manufactured from sheet steel. The illustrations show the 2-valve engine version
The cast-in-place liners for the pistons are
manufactured of grey cast iron.
2
1
3
Timing case
Top part of
cylinder block
Parts sealed by
means of:
Bottom part of
cylinder block
1 Liquid gasket
(bearing bridge)
1
2 Metal gasket
GB 7
Engine Mechanical Components
8 GB
The main difference between the inertia Inertia effects can be influenced by:
effects mentioned consist in the fact that the
rotating inertia forces at a particular rotational – Number and arrangement of cylinders
speed have a constant magnitude but – Type of throws of the crankshaft
different directions. The directions are fixed – Balance weights fitted to the crankshaft
by the throws of the crankshaft. – Use of one or several balance shafts
Crankshaft star
Note:
The crankshaft must not be
SP45_43
removed or detached.
Please refer to the descriptions
in the Workshop Manual.
Crankshaft of
4-cylinder engine
GB 9
Engine Mechanical Components
Hydraulic tensioning
device for timing chain
Chain sprocket of
crankshaft for camshaft
drive Crankshaft
Chain sprocket of
crankshaft for oil pump
SP45_08
drive
The camshaft is driven by the crankshaft via The oil pump integrated in the oil pan is
the timing chain. driven by the crankshaft by means of a chain.
The tensioning rail and guide rail in The oil pump extracts the oil through a
combination with the hydraulic tensioning suction strainer. This strainer forms the
device ensure that the timing chain is always bottom part of the oil pump.
correctly tensioned and guided.
The chain for driving the oil pump is
The camshaft controls the valves by means of tensioned by mechanical chain tensioner.
roller-type rocket arms/cam rollers. Hydraulic A leaf spring ensures that the chain is
supporting elements ensure proper correctly tensioned.
compensation of the valve clearance.
10 GB
GB 11
Engine Mechanical Components
Air filter
Non-return valve
Oil return-flow
galleries
Fresh air supply
hose
PCV control
Inlet downstream valve
of throttle valve
Oil separator
Plastic hose
12 GB
4-valve engine version
Air filter
Non-return valve
Inlet downstream
of throttle valve
PCV control valve
Plastic hose
Oil return-flow
galleries
SP45_47
Air inlet into
crankcase
Note:
The non-return valve prevents oil from
being combusted out of the cylinder head
cover into the oil filter (is also applicable
for the 2-valve engine version).
The air supply for the crankcase is produced The crankcase fresh air supply reduces the
by means of fresh air which flows along the quantity of water vapour in the crankcase.
hose from the air filter to the engine.
The fresh air is inducted by the vacuum in the The mixture is then passed through the
intake manifold and flows along the oil return- crankcase ventilation system to the
flow galleries into the crankcase. This combustion.
produces a pressure balance and blending
with the gases from the combustion chamber.
GB 13
Engine Mechanical Components
Crankcase ventilation
The gases are drawn out of the crankcase by The 2-valve engine version features a
the vacuum in the intake manifold. labyrinth oil separator system.
This consists of a special moulded part at
In the oil separation system the oil is which the oil is separated while the remaining
separated from the gases by means of gases flow onto the PCV control valve.
condensation and drips back into the oil pan. The extracted gases flow on from the PCV
control valve along an external plastic line.
The gases flow through the PCV control valve They flow directly into the induction system
into the intake manifold where they are mixed downstream of the throttle valve control unit
with the inducted air and supplied to the and are blended with the inducted air.
combustion chambers of the cylinders for
combustion.
SP45_50
14 GB
The 4-valve engine version, in contrast to the Note:
2-valve version, has an enlarged oil separator Whereas the PCV valve ensures a
system. uniform vacuum in the crankcase,
This consists of a labyrinth oil separator in the the pressure limiting valve opens if
form of ribbing in the timing case and a an overpressure exists in the
cyclone oil separator. crankcase. This is produced, for
example, as a result of wear at the
The extracted gases first of all flow through piston rings and cylinder walls. In
the PCV control valve and then continue along this case, there is an increased
an external plastic line to the intake manifold flow of gases from the cylinder
and on through a gallery in the inside of intake into the crankcase. The oil
manifold until just before the throttle valve separation system is thus affected.
control unit.
The gases flow into the intake manifold via an
internal opening and are blended with the
inducted air.
Pressure limiting
valve
To intake
manifold
Timing case
SP45_51
GB 15
Engine Mechanical Components
The PCV control valve ensures a constant Depending on whether the vacuum in the
vacuum in the crankcase and a good intake manifold is high or low, the flow cross-
ventilation of the crankcase. It is split into two section to the intake manifold is varied by
chambers by a spring-mounted diaphragm. means of the diaphragm and in this way a
One chamber is connected to the outside air uniform pressure level is assured in the
while the other is connected to the intake crankcase.
manifold and to the crankcase.
From
crankcase
Atmospheric
pressure
Spring force
Atmospheric pressure
Diaphragm
Inlet from
atmosphere
From
crankcase
Spring force
16 GB
Cooling System
Overview
Expansion reservoir
Heating system Coolant distributor
heat exchanger housing with thermostat
2
1
3
4
Coolant pump
SP45_27
5 6
4 5
2 To top of radiator
Radiator 2
3 From bottom of radiator
3
4 To coolant pump
5 To heat exchanger
GB 17
Engine Management System
System overview
Simos 3PD/3PE
Engine speed sender G28 control unit
AN
in C
ine
Accelerator pedal position sender G79
tra
Kl
and G185
ve
Dri
Clutch pedal switch F36
Additional signals:
Alternator terminal DF
Vehicle speed signal
CCS switch (ON/OFF)*
18 GB
Fuel pump relay J17
Fuel pump G6
SP45_10
* Only on 4-valve engine versions with optional equipment
** Only on 4-valve engine versions
GB 19
Engine Management System
SP45_28
SP45_04
Spark plug
20 GB
Two-probe lambda control
The engine control unit calculates correction Exhaust pipe Lambda probe G130
values for the fuel injection system from the (downstream of catalytic
signal supplied by lambda probe G39. converter)
This first control circuit is superposed by a
second control circuit with the downstream Note:
cat probe G130. You can obtain more detailed
information on the different
This control circuit makes it possible to correct versions of the two-probe lambda
the shift of the voltage curve of the probe control, particularly also the
upstream of the catalytic converter within a control using the broadband
defined frame (adaption), which assures a lambda probes, in the Self Study
stable and optimal mixture composition over Programme 39.
long periods.
Legend:
GB 21
Engine Management System
Note:
Familiar function components
which have already been described
in detail in earlier Self Study
Programmes are used for
controlling the 1.2-ltr. engine.
The table refers to the relevant Self
Study Programmes. Please make
use of this detailed information.
SP45_17
SP45_18
22 GB
Function component Function
description
SP45_23
SP45_24
GB 23
Engine Management System
24 GB
Illustration shows example
of 2-valve engine version
N70/ N127/ N291
G163
B
Colour coding
N30
…
N32 = Input signal
= Output signal
G28
D Legend:
A Fuel tank
B Fuel pressure regulator
C Catalytic converter
A
SIMOS 3PD D Activated charcoal filter
E Fuel filter
F Diagnostic connection
J361 G EPC fault lamp
G6
H Exhaust warning lamp
SP45_02
GB 25
Function Diagram
J519
- 80 3 62 23 53 63 65 61
J338
A B M
31
Components
A Battery G163 Camshaft position sender
F Brake light switch G185 Accelerator pedal position sender 2
F36 Clutch pedal switch G186 Throttle valve drive (EPC)
F47 Brake pedal switch G187 Angle sender -1- for throttle valve drive (EPC)
G6 Fuel pump G188 Angle sender -2- for throttle valve drive (EPC)
G28 Engine speed sender (Hall sender) J17 Fuel pump relay
G39 Lambda probe J361 Simos control unit
G42 Intake air temperature sender J363 Power supply relay for Simos control unit
G61 Knock sensor J519 Vehicle electrical system control unit
G62 Coolant temperature sender J533 Databus diagnostic interface
G71 Intake manifold pressure sender N30 - 32 Injectors cylinders 1 - 3
G79 Accelerator pedal position sender N70 Ignition coil 1 with power output stage
G130 Lambda probe downstream of catalytic N80 Solenoid valve 1 for activated charcoal filter
converter system
26 GB
J533
+30
+15
G79 G185
CAN - H
CAN - L
λ λ
21 20 31 14 4 16 35 5 17 88 87 85 50 51 18 19 64 45
J361
1 111 89 105 106 99 102 109 101 120 112 113 100
-
- -
G163 G28 G61
Q Q Q
31
SP45_16
N127 Ignition coil 2 with power output stage
N291 Ignition coil 3 with power output stage in out
Q Spark plugs
S, SB... Fuses
Z19 Lambda probe heater
Z29 Heater for lambda probe downstream of
catalytic converter
Diagnostic connectionel
Diagnostic connection:
B Alternator terminal DF