Motor_ARV,AQV,AZE,AZF,AME,ATZ,AQW

Service5 Workshop Manual FABIA 2000 Edition 08.99 Engine code 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components ARV AQV AZE AZF AME ATZ AQW Service Department. Technical Information Printed in Czech Republic S00.5305.00.20 5 Service The Workshop Manual is intended only for use within the Organisation Škoda. It is not permitted to pass it on to other persons. © ŠKODA AUTO a. s. Printed in Czech Republic S00.5305.00.20 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components List of Supplements to Workshop Manual FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Edition 08.99 Supplement 1 2 3 4 Edition 08.99 06.00 03.01 02.02 09.03 Subject Basic Edition Supplement to Basic Edition Modifications in Rep. Gr. 00, 13, 15 and 17 Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26 Modifications in Rep. Gr. 00, 13, 15 and 17 Article Number S00.5305.00.20 S00.5305.01.20 S00.5305.02.20 S00.5305.03.20 S00.5305.04.20 Edition 09.03 S00.5305.04.20 List of Supplements FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components List of Supplements Edition 09.03 S00.5305.04.20 ............................... 15-3 page page page page page page page page page page page page page page 1 1 2 1 1 2 3 6 6 7 1 1 2 3 17 – Lubrication Removing and installing parts of the lubrication system ................Removing the V-ribbed belt ......Summary of components ..............................................0 litre engine ....................... 15-1 Repairing cylinder head ..................... 13-1 .............................................. 15-2 ..................................... Valve Gear Removing and installing cylinder head ..Installing the engine ........... 1.................... 10-1 ...................................................... 13-2 ......................5305............... 17-1 ...............................Removing engine .........for a 1.......... 17-2 Testing Oil Pressure and Oil Pressure Switch .................03 S00... 15-2 Repairing valve gear ................................................ 15-2 ...............Summary of components ........................Replacing gasket ring for crankshaft -on the belt pulley side...............................Tightening torques . 00-1 page 1 10 – Removing and Installing Engine Removing and Installing Engine ....Inspecting synchronous running of sprockets ...... 17-2 .........................................................................................................Removing and installing valves ............................ 13-1 Disassembling and Assembling Cylinder Block and Crankshaft .........................0/37......................................Summary of components ....................................................Basic setting of hydraulic valve clearance compensation ... 15-2 .......... 13-1 ......................................................................... 15-2 ................................Summary of components ...........................................Replacing ring gear ..........................Testing the compression ........Removing and installing oil pan ...................................................................................................................Inspecting hydraulic tappets .....................................................FABIA 2000 1...................... 15-3 ............................ 17-1 Removing and installing oil pan ........................................................ Mechanical Components Table of Contents 00 – Technical Data Technical Data ....... 15-1 ................ 13-3 page page page page page page page page page page page 1 1 3 4 5 1 1 3 4 7 1 15 – Cylinder Head......4/44..............................................................................Inspect valve guides ....................................................................Removing and installing oil pan ....................... 17-3 page page page page page page 1 2 1 1 1 1 Edition 09.......04.................... 10-1 ..................................................................................for a 1................................................. 10-1 ................Summary of components ....Replacing valve stem seal .................................20 Table of Contents I ..4 litre engine ....... 10-1 ...................................................................... 10-1 page page page page page 1 1 7 9 9 13 – Crankgear Removing and installing V-ribbed belt ..............Removing and installing camshaft .................... 15-2 .......... 15-3 ......................... 13-2 ....Removing and installing cylinder head ....................................................... 15-3 ..................................................................................................... 1...Assembly bracket ......................Vehicles with air conditioning ......................................... 13-2 ............................. 15-2 .......4/50 Engine............................................................. Connecting Rod and Liner ....Removing and installing rocker arms ............. 13-2 Disassembling and Assembling Pistons........................................................................... 15-1 ....................Reworking valve seats ....................... 17-2 ........................................................................Installing the V-ribbed belt ........................................ 13-2 ........ 13-1 ........Vehicles without air conditioning .. 13-1 ........ ..Connection diagram for coolant hoses ........................ 19-2 .................................................................... 19-1 ........................ 19-2 ... 1........ 19-2 page page page page page page page page page 1 1 3 5 5 7 1 1 2 20 – Fuel Supply Removing and Installing Parts of the Fuel Supply System ............... 26-1 .................. 1.................... 19-1 .............................. 20-1 ........ 26-1 page page page page 1 2 3 3 II Table of Contents Edition 09......... 26-1 ....... Coolant Pump ........... 19-1 ....03 S00.....................Draining and filling up coolant ....................................Checking the exhaust system for leaks .........0/37.....................................Repairing parts of the activated charcoal filter system ................. 19-1 .... 19-1 Removing and Installing Radiator................................................................................Parts of the cooling system fitted to body ..................................................20 ..................Safety precautions when working on the fuel supply system ....Aligning exhaust system free of stress ................................................................................. 20-1 .......Parts of cooling system engine side .................................................Removing and installing radiator ...........................................Replacing front or rear silencer .................... 20-1 Activated Charcoal Filter System .... 26-1 .............4/50 Engine............Summary of components ............04... Mechanical Components 19 – Cooling Parts of cooling system ..........................................FABIA 2000 1..Cleanliness rules ...... 20-2 ....................................................................Removing and installing coolant pump .........Checking the coolant system for tightness .........5305................................................ 19-1 ....................................................................................... 20-2 page page page page page 1 3 3 1 1 26 – Exhaust System Removing and installing parts of the exhaust system .4/44.. 03 AZF 04.02 AZE 04.5 78. the engine output is reduced however Edition 09.02 AQV 01. 1.FABIA 2000 1.997 37/5000 84/2750 72 61.03 S00. In addition.4/50 Engine.01 07.5305. a sticker with „engine identification“ and „serial number“ is affixed to the cylinder head cover. 1.01 l 07.4/44.RON Fuel injection and ignition system Knock control Self-diagnosis Lambda control Catalytic converter Turbocharging Exhaust gas recirculation Secondary air system Camshaft adjustment 1) ARV 01.00 03.2 10 : 1 unleaded1) 95 Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no EU-2 1.03 EU-2 0. at the connection to the cylinder head -arrow-.997 37/5000 84/2750 72 61.397 44/5000 118/2600 75. Engine characteristics Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Fuel . The engine identification characters are also indicated on the vehicle data sticker.00 03.2 10 : 1 95 unleaded1) 95 Simos 3PB yes yes 1 lambda probe 1 Catalyst no no no no EU-3 0.5 78.20 Technical Data 00-1 page 1 .04.0 10 : 1 unleaded1) Simos 3PB yes yes 1 lambda probe 1 Catalyst no no no no EU-4 1. Mechanical Components 00 00 – Technical Data 00-1 Technical Data Engine number The engine number („engine identification characters“ and „serial number“) is located on the end face of the cylinder block on the belt pulley side.0/37.0 10 : 1 95 unleaded1) Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no kW at rpm Nm at rpm ∅ mm mm At least 91 RON in exceptional cases.397 44/5000 118/2600 75. 4/44.397 50/5000 120/2500 75.20 .397 50/5000 120/2500 75.00 AQW 08.0/37. 1.00 Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Fuel .04.4/50 Engine.99 04.5305.0 10 : 1 95 unleaded1) Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no 07.03 S00. 1.03 EU-2 ATZ 11. the engine output is reduced however 00-1 page 2 Technical Data Edition 09.0 10 : 1 95 unleaded1) Simos 3PB yes yes 1 lambda probe 1 Catalyst no no no no At least 91 RON in exceptional cases. EU3-DDK 1.5 78.03 EU-4.RON Fuel injection and ignition system Knock control Self-diagnosis Lambda control Catalytic converter Turbocharging Exhaust gas recirculation Secondary air system Camshaft adjustment 1) FABIA 2000 1.00 03.99 D4 1.0 10 : 1 95 unleaded1) Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no l kW at rpm Nm at rpm ∅ mm mm 1.397 50/5000 120/2500 75. Mechanical Components AME 08.5 78.5 78. – Disconnect the earth strap from the battery with the ignition off. – Unscrew the drive shaft to the right and left of the gearbox.G 1331-) ♦ Torque wrench 40 to 200 Nm (e. The use of clamp-type or screw-type clips is not allowed.A. spring-type clips or clamp-type clips. -V. pay attention to the coding. ♦ Pay attention to the correct assignment of the connec- tors. ♦ The hose connections are secured with screw-type clips.0/37.g.03. if necessary mark. ♦ Supporting points for lift platform ⇒ Inspection and Maintenance. -V. – Raise drive shafts and secure. -V. -V. Procedure – On models fitted with a coded radio set.5305. test and measuring equipment and auxiliary items required ♦ Workshop crane (e.02 S00. ♦ Use pliers for spring strap clips to fit the spring strap clips.FABIA 2000 1.g.g.A.A. ♦ Fuel hoses at the engine must only be secured with spring-type clips.G 1202 A-) ♦ Catch pan (e. Mechanical Components 10 10 – Removing and Installing Engine 10-1 Removing and Installing Engine Special tools. S10-0135 Edition 02. determine if necessary. Always replace warm-type clamps with spring strap clips or warm-type clamps. 1.4/50 Engine. 1.G 1332-) ♦ Pliers for spring strap clips ♦ Engine mount -MP 1-180♦ Assembly stand -MP 9-101♦ Lifting device -MP 9-201♦ Grease -G 000 100♦ Hot screw paste -G 052 112 A3♦ Wire ♦ Adhesive tape Removing engine Note ♦ The engine is removed towards the front together with the gearbox.A.20 Removing and Installing Engine 10-1 page 1 .g.4/44. – Remove noise insulation -arrows-.G 1306-) ♦ Torque wrench 5 to 50 Nm (e. g. Gr. 1. – Separate plug connection -2-. 1 2 3 S10-0142 10-1 page 2 Removing and Installing Engine Edition 02. Rep. – Unclip cable clip -3.20 .as follows: ♦ Release logo -2.02 S00.0/37.towards the top (do not un- 1 2 3 4 4 screw cap -5-). Gr. 27. – Turn the drain plug -arrow. – Remove the air filter with hoses ⇒ 1. Mechanical Components – Remove front exhaust pipe with catalyst ⇒ Chap. A10-0118 – Remove engine cover -1.5305.4/50 Engine. – Unplug connector -1. Rep.4/44. 1.4/44. -V. – Loosen the drain screw on the coolant expansion bottle. 27.A. ♦ Release nuts -4.fuel injection.0/37. Gr.from the engine control unit.4/ 50 engine .10 1.(5 Nm).and carefully lever off the cap -3-. 1. – Remove the cable from the starter solenoid switch ⇒ Electrical System. 1. 24. 6 5 – Close the oil filler inlet on the cylinder head cover with the cap fitted to the bottom of the engine cover (if not available use other means).-arrows-. ♦ Remove engine cover -1.03.G 1306-). Rep. 26– Place drip tray below the engine (e. ♦ Pull out oil dipstick -6-. FABIA 2000 1. – Release the generator cables from the battery cover and remove the wiring loom from the holder. S10-0138 – Remove battery and battery tray ⇒ Electrical System.on the radiator to the left and draw backwards. if necessary fit auxiliary hose onto connection. 4/50 Engine.20 Removing and Installing Engine 10-1 page 3 . – Remove the vacuum connection from the brake servo unit. Caution! The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. 1 A B S34-0397 Edition 02.and tie up holder -1-.5305. Mechanical Components 10 – Remove coolant hoses -1.03.from the expansion reservoir. 1 M 2 – Remove the fuel presupply pipe -4. – Release vacuum hose -3.0/37.from the coolant regulator housing.and -2.FABIA 2000 1. 1 3 4 S10-0137 – Release nut -arrow A.02 S00.and -2. Reduce pressure by carefully releasing the connection point.4/44. M S10-0141 2 – Remove coolant hoses -1.by pressing the release buttons at the separation point. 1.from the solenoid valve -N80-. 1. – Remove -arrow B.the slave cylinder -2.from the relay lever. Mechanical Components – Disconnect the Bowden cable support from gearbox S34-0389 – Detach selector cable -A-.4/44.03. for this step remove circlip -arrow 1.and lay aside. 1. FABIA 2000 1.02 S00. do not open the line system. 2 A B B 1 S34-0400 10-1 page 4 Removing and Installing Engine Edition 02. – Remove the shift cable -B. Note Do not depress the clutch pedal. – Remove the hose line holder -1. for this step unscrew nut -arrow 3-.10 -arrows-.with the gearbox shift lever.from the reversing lever of the selector cable -A-.20 . A 1 3 2 B S34-0398 – Remove bearing bolt -arrow 2. 1.0/37.5305. secure with wire.4/50 Engine.from the gearbox -arrow A-. To do so press the latch clips. 1 2 – Separate the coolant hose from the radiator at the top and bottom of the connection fittings.from the reversing light switch -F4-. 1.and separate plug connections -2.0/37. Mechanical Components 10 – Remove the earth strap -1.on the holder of the air duct scoop.03. 1 3 2 S10-0143 – Remove coolant hose from the rear coolant pipe -arrow-.5305. 1.from the front of the gearbox.4/50 Engine.02 S00. To do so pull the retaining clip -3. – Separate plug connection -3-. – Disconnect plug -2.FABIA 2000 1.20 Removing and Installing Engine 10-1 page 5 . 3 S19-0078 Edition 02.from thermo-switch -F18.up to the stop and remove the quick coupling towards the rear. S10-0139 – Remove connector -1. There are 2 plug connections on vehicles fitted with air conditioning.4/44. ♦ Use cloths to protect the right headlight glass from damage.5305. – Remove AC compressor with the refrigerant lines connected. Gr. 2 MP 9-201 S10-0136 Continued for all vehicles – Hook on lifting device -MP 9-201. 1. 50.0/37. Gr. – Remove the lock carrier with the radiator and con- denser ⇒ Body work. Rep.4/44. ♦ The holes in the vertical perforated bars are counted from the hook. Note 1 ♦ Do not buckle the refrigerant lines.20 . swivel to the side and position on support -2. 1. removing the headlight if necessary. 50.02 S00. – Remove connector from the AC compressor. Mechanical Components – Removing the lock carrier with radiator ⇒ Body Work. S34-0403 – Secure the AC compressor -1. On the belt pulley side: 2nd hole of the vertical perforated bar in position 1 On the flywheel side: 2nd hole of the vertical perforated bar in position 5 Warning! Use securing pins on the hooks and rig pins. 10-1 page 6 Removing and Installing Engine Edition 02. Rep.10 – Unbolt the pendulum support -arrows-. Vehicles with air conditioning Caution! Do not open the refrigerant circuit of the air conditioning system. Note ♦ The rig positions on the supporting bracket marked 1 1 2 3 4 5 6 7 8 S10-0134 to 4 point towards the belt pulley.03. – Remove the V-ribbed belt ⇒ Chapter 13-1.as follows and raise slightly with the workshop crane.in such a way that there is no risk of tilting.to the lock carrier -arrow-.4/50 Engine. Vehicles without air conditioning FABIA 2000 1. FABIA 2000 1.to the pin screws on the exhaust manifold.02 S00.0/37. 1 3 S10-0140 – Unscrew the fixing screws -arrows. Mechanical Components 10 2 – Release screws -2-.20 Removing and Installing Engine 10-1 page 7 .from the gearbox mount. 1. ♦ Always replace self-locking nuts. – Slightly lower the engine/gearbox unit and pull out carefully towards the front. ♦ Apply hot screw paste -G 052 112 A3.before performing assembly work.on the assembly support -MP 9-101. Instead of engine mount -MP 1-180.03.it is also possible to use engine mount -MP 1-202-. S10-0120 Secure the engine with engine mount -MP 1-180. ♦ Tightening torques ⇒ 10-1 page 9 ♦ Assembly bracket ⇒ 10-1 page 9 Edition 02. Note Grip the engine on the supports of the engine mount -arrows-. MP 1-180 MP 9-101 Installing the engine Note ♦ Always replace the seals and gaskets during assemS10-0082 bly work.5305.4/44. 1.4/50 Engine. 02 S00. 30. Vehicles with air conditioning – Install the AC compressor ⇒ Chapter 13-1. Rep.4/44. – Install the front exhaust pipe with catalyst and fit the exhaust pipe free of stress ⇒ Chapter 26-1. – Install coolant hoses ⇒ Chapter 19-1. 40. ⇒ Gearbox 002. 10-1 page 8 Removing and Installing Engine Edition 02. insert if necessary. Set clock. radiator or heat exchanger were not replaced. 1.0/37. – Fit V-ribbed belt ⇒ Chapter 13-1. Initialise power window lifter. Pay attention to the following points: – Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block. Rep. Continued for all vehicles – Install the drive shaft on the right and left of the gearbox ⇒ Chassis. – Inspect clutch release bearing for wear.03. – Install alternator ⇒ Electrical System. 27. Tightening torques ⇒ 10-1 page 9. – Adjust the gearshift mechanism and cable control – When installing the engine/gearbox unit make sure all adjoining components are clear. – Lubricate the drive shaft serration lightly with grease -G 000 100 -. Gr. Rep. – Electrical connections and cables ⇒ Current Flow Diagrams. – If necessary check the centering of the clutch driver disc. ⇒ Inspection and Maintenance – Check oil level before starting the engine. replace if necessary. Electrical Fault Finding and Fitting Locations. cylinder head. 1.20 . Note The drained off coolant must only be re-used if the cylinder block.10 Procedure FABIA 2000 1.5305. Gr. Gr. 34. – Align the engine/gearbox unit.4/50 Engine. Mechanical Components Installation is performed in the reverse order. Rep. – Install the slave cylinder of the hydraulic clutch ⇒ Gearbox 002. Gr. – Top up coolant ⇒ Chapter 19-1 – After connecting the battery: Code radio. ⇒ 1.0/37. phosphatized or blackened nuts and screws.40 Nm + 90° (1/4 turn) .fuel injection.fuel injection. ♦ Do not use degreased parts. Mechanical Components 10 – Adapt the engine control unit to the throttle valve control unit -J338.20 Nm + 90° (1/4 turn) . ♦ Unless otherwise indicated the following tightening torques apply: Component Screws/nuts M6 M7 M8 M10 M12 deviations: Engine to gearbox connecting screws Drive shaft to gearbox mounting flange ⇒ Manual gearbox 002. Rep.03. 1. memory ⇒ 1.0/37. 1.20 Removing and Installing Engine S10-0125 10-1 page 9 . 1.FABIA 2000 1.4/50 Engine. Gr. rep. 24. Do not use Molykote. 1. ♦ Other lubricants such as engine and gearbox oil are allowed.50 Nm + 90° (1/4 turn) .0.replace 1 1 S10-0132 2 1 1 1 Edition 02.5305.replace 2 .4/44 engine . Rep.30 Nm + 90° (1/4 turn) . – Perform a test drive and interrogate and erase fault Tightening torques Note ♦ Tightening torques apply only for lightly greased. rep.4/44. size 34 ⇒ Chassis. Gr.replace Gearbox mounting 1 .replace 2 .02 S00. 01 .4/1.4/50 engine . size 40 Torque 9 Nm 13 Nm 20 Nm 40 Nm 70 Nm 1 2 Assembly bracket Tightening torques Engine mounting 1 . 1.4/44. oiled. 4/50 Engine.30 Nm + 90° (1/4 turn) .5305.in the elongated holes of the support in such a way that the maximum permissible distance is obtained between the gearbox and the assembly carrier. Mechanical Components Tighten screws -1.replace 1 2 S10-0133 10-1 page 10 Removing and Installing Engine Edition 02.02 S00. 1.10 Hinged bracket Note FABIA 2000 1. 1 .03.20 .replace 2 .0/37. 1.4/44.40 Nm + 90° (1/4 turn) . Screw 4 .Coolant pump removing and installing ⇒ Chapter 19-2 2 .Washer Camber towards the outside 14 .100 Nm to release and tighten lock flywheel ♦ Engine removed: with -MP 1-504♦ Engine installed: with locking screw ⇒ Chapter 13-2 17 .45 Nm 10 .(Loctite 648) before inserting 15 .Generator to facilitate positioning of the generator on the holder. 1.FABIA 2000 1. ♦ Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.4/44. 1 . 1 in 13-1 page 2 removing ⇒ 13-1 page 4 Edition 02. Reversing the rotation direction of an already used belt may destroy it. drive the bushing of the retaining screw slightly backwards 7 .Vehicles without air conditioning Note ♦ Mark the rotation direction before removing the V-ribbed belt.20 Removing and installing V-ribbed belt 2 3 5 4 6 8 7 9 14 13 12 11 10 S13-0241 13-1 page 1 .20 Nm Left-hand thread coat with -AMV 154 100.Clamp 5 . Mechanical Components 13 13 – Crankgear 13-1 Removing and installing V-ribbed belt Summary of components .25 Nm coat with -AMV 105 50017 (Loctite 242) before inserting 11 .Screw 8 .03.Bracket for generator 16 15 12 .V-ribbed belt Routing of the ribbed V-belt ⇒ Fig.Guide pulley 13 .30 Nm replace 9 .5305. 1.4/50 Engine.Belt pulley for crankshaft 16 .02 S00.25 Nm replace 6 .0/37.Bracket 1 for clamp removing and installing ⇒ Chapter 15-1 3 . 4/44.5305.02 S00.coolant pump 4 3 2 S13-0242 1 13-1 page 2 Removing and installing V-ribbed belt Edition 02.0/37.20 .13 installing ⇒ 13-1 page 5 FABIA 2000 1.crankshaft Guide pulley Belt pulley .03. Mechanical Components Fig.generator Belt pulley . 1: 1234- Routing of the ribbed V-belt Belt pulley . 1.4/50 Engine. 1. FABIA 2000 1. 2 in 13-1 17 page 4 coat with -AMV 105 500(Loctite 242) before inserting 10 .Screw 14 tightening order and tightening torque ⇒ Fig.35 Nm coat with -AMV 200 000S13-0344 21 20 (Loctite 270) before inserting 14 .Bracket 8 7 for generator and AC com11 10 pressor 7 9 13 12 4 . ♦ Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.4/50 Engine. Reversing the rotation direction of an already used belt may destroy it. 1.Screw tightening order and tightening torque ⇒ Fig.45 Nm 17 .02 S00.25 Nm 20 .25 Nm 18 .Bushing 22 11 . 2 in 13-1 page 4 16 8 . 2 in 13-1 page 4 15 .Lever with tensioner 4 grease bearing points in 6 holder before fitting 5 3 .Vehicles with air conditioning Note ♦ Mark the rotation direction before removing the V-ribbed belt.10 Nm 15 7 .Dowel sleeves for AC compressor must be present in holder ⇒ item 3 in 13-1 page 3 16 .Belt pulley for crankshaft 21 .Washer 9 .Coolant pump 5 4 removing and installing 1 2 3 ⇒ Chapter 19-2 2 .Generator to facilitate the positioning of the generator on the holder drive the bushing of the retaining screw slightly backwards 19 .Washer Camber towards the outside 19 13 .4/44. 1.03.20 Nm 6 .Gasket 8 replace 9 5 .100 Nm to release and tighten lock flywheel ♦ Engine removed: with -MP 1-504♦ Engine installed: with locking screw ⇒ Chapter 13-2 Edition 02. 1 .20 Removing and installing V-ribbed belt 13-1 page 3 .5305.0/37. Mechanical Components 13 Summary of components .Guide pulley 18 12 .Screw tightening order and tightening torque ⇒ Fig. 4/50 Engine. Stage: the desired final tightening torque . test and measuring equipment and auxiliary items required ♦ Wrench for V-ribbed belt -T30022- Note The assistance of a second mechanic is required to tighten the V-ribbed belt.5305.and pivot the generator towards the engine.tighten in the same order as for the 1st stage Fig. 2. 3 in 13-1 page 4 removing ⇒ 13-1 page 4 installing ⇒ 13-1 page 6 Fig. 1.generator Belt pulley . 3. – Release securing screws -arrows.20 . Removing. S13-0245 13-1 page 4 Removing and installing V-ribbed belt Edition 02.vehicles with air conditioning Special tools. Mechanical Components 22 . 5 ♦ 2.V-ribbed belt Routing of the ribbed V-belt ⇒ Fig. 1. Stage: tighten to 2 Nm one after the other in the or- der of items: 1.coolant pump 6 5 2 Removing the V-ribbed belt Removing . 4.4/44. 2: 1234567- Tightening torques and tightening order for alternator bracket and AC compressor 23 Nm Bracket for alternator and AC compressor 45 Nm Washer 23 Nm 45 Nm 23 Nm Screws are tightened up in two stages in the following order: ♦ 1. 3: 123456Routing of the V-ribbed belt 1 Belt pulley .13 FABIA 2000 1.vehicles without air conditioning 4 3 S13-0244 – Mark the routing of the V-ribbed belt.crankshaft Tensioning pulley Belt pulley . – Remove the V-ribbed belt.AC compressor Guide pulley Belt pulley .03.0/37.02 S00. – Insert wrench for ribbed V-belt -T30022 . AC compressor) are securely mounted.4/44. test and measuring equipment and auxiliary items required ♦ Torque wrench ♦ V-ribbed belt tensioning tool (e. NP 002 manufac- tured by Nolt) ♦ Belt tension measuring tool (e.Vehicles without air conditioning Special tools. – Remove camshaft position sensor -2-. Mechanical Components 13 – Remove noise insulation -arrows-.in the tensioner -3. Installing.03.02 S00.FABIA 2000 1. S10-0135 – Release screw -1. tensioning and guide pulley.and tighten while making sure the generator can still be rotated.up to the stop. ♦ Before fitting the V-ribbed belt make sure that all as- semblies (generator. ♦ Pay attention to the rotation direction of already used V-ribbed belts.5305. T30022 1 3 2 – Loosen tensioning pulley (tighten tensioner -3-). – Fit the ribbed V-belt. of the firm Optibelt or Clavis) – Replace self-locking nuts -arrows. To this end rotate wrench in the direction of the arrow. coolant pump.from the tensioner -3-.0/37. – Mark the routing of the V-ribbed belt. Installing the V-ribbed belt Note ♦ Check V-ribbed belt for wear ⇒ Inspection and MainS13-0246 tenance. – Remove the V-ribbed belt from the tensioning pulley and pivot tensioning pulley back.20 Removing and installing V-ribbed belt 13-1 page 5 . ♦ Check smooth operation of belt pulley.4/50 Engine. 1. S13-0245 Edition 02.g. 1.g. 25 Nm 2 .4/44. 1.30 Nm 1 2 – Check belt tension again. NP 002 S27-0014 – Position the belt tension measuring tool (in the figure of the firm Optibelt) on the V-ribbed belt and read off the belt tension value -arrow. run engine for approximately 1 minute in idle and re-adjust the belt tension. – Start engine and check belt run. 3 Installing .5305. 13-1 page 6 Removing and installing V-ribbed belt Edition 02.13 FABIA 2000 1. Nominal values for the tension of the V-ribbed belt: ♦ New ribbed V-belt (run in for 1 minute): 400 ♦ Used V-ribbed belt: 400 +50 +80 N S13-0240 N – Once the nominal value has been reached. 1. – Position the V-ribbed belt on the belt pulleys and guide pulley.02 S00. test and measuring equipment and auxiliary items required ♦ Wrench for ribbed V-belt -T30022S13-0249 Note The assistance of a second mechanic is required to loosen the V-ribbed belt.20 .0/37.25 Nm 3 . tighten the nuts of the generator mounting: 1 .on the scale ⇒ Operating Instructions for the relevant measuring tool. Mechanical Components – Insert V-ribbed belt tensioning tool NP 002 in the clamp and tension the V-ribbed belt by screwing out the handle -in direction of the arrow-.Vehicles with air conditioning Special tools. correct if necessary.4/50 Engine.03. Note Tighten the new ribbed V-belt with 500 +100 N. – Fit noise insulation -arrows-.02 S00.4/44. 1. 3 – Tighten screw -1.4/50 Engine.up to the stop. 1.0/37. S10-0135 Edition 02. To this end rotate wrench in the direction of the arrow.on the tensioner -3-.03. – Loosen tensioning pulley (tighten tensioner -3-).20 Removing and installing V-ribbed belt 13-1 page 7 . – Position the V-ribbed belt on the tensioning pulley and pivot tensioning pulley back. Tightening torque: 10 Nm – Fit camshaft position sensor -2-.in the tensioner -3.5305. Tightening torque: 8 Nm S13-0246 – Start engine and check belt run. Mechanical Components 13 T30022 1 2 – Insert wrench for V-ribbed belt -T30022 .FABIA 2000 1. 02 S00.5305.0/37. 1.20 .13 FABIA 2000 1.4/44. 1. Mechanical Components 13-1 page 8 Removing and installing V-ribbed belt Edition 02.4/50 Engine.03. 1 (marking of belt pulley crankshaft is positioned opposite marking „0“ at timing gear cover) ♦ only one installed position is possible for the 1.to carry out removal and installation work. 1. Gr.5305.0 litre engine ⇒ 13-2 page 3 Note ♦ The design of the 1.Flywheel with rotor for engine speed sender -G28lock with -MP 1-504. Repairing the clutch.75 Nm 2 .Thrust washer for middle bearing lubricating grooves point outwards 4 .4 litre engine (since the bore holes are varying distances apart) 1 2 29 28 27 26 25 3 4 5 6 13 24 23 22 21 20 7 8 9 10 11 12 14 15 6 .Crankshaft bearing unit 3 .Gasket ring replace remove when removing the sealing flange lightly oil sealing lip and outer edge before installing 19 18 17 16 S13-0170 Edition 09.for removing and installing replace ring gear ⇒ 13-2 page 7 installation position to crankshaft: ♦ on the 1. 1 .30 Nm + torque a further 1/4 turn (90°) replace coat with -AMV 200 000.4/44.on the engine holder -MP 9-101.0/37.4/50 Engine.03 S00.0 ltr.(Loctite 270) before inserting 7 . ♦ Repairing the clutch ⇒ Manual Gearbox 002. engine. 30. engine 1. 1.or -MP 1-202 .0 litre engine is essentially identical to that of the 1.4 ltr.8 Nm coat with -AMV 188 520(Loctite 574) before inserting 5 .4 ltr. Differences exist only in the version of the crankshaft and its mounting ⇒ 13-2 page 3.FABIA 2000 1.20 Disassembling and Assembling Cylinder Block and Crankshaft 13-2 page 1 . Mechanical Components 13 13-2 Disassembling and Assembling Cylinder Block and Crankshaft Summary of components 1.04. ♦ The engine should be attached to the engine repair stand -MP 1-180. Rep. engine the 2 »missing« teeth of the rotor must face forward when crankshaft position at TDC of cyl. 1 in 13-2 page 3 Woodruff key check tightness Crankshaft Axial play when new: 0.(Loctite 242) before inserting Gasket replace Camshaft sprocket after replacing. inspect synchronous running of chain sprockets ⇒ Fig.0/37.20 .13 8- FABIA 2000 1.5305.26 mm Bearing shell for crankshaft bearing unit without lubricating groove do not mix up used bearing shells (mark) 13-2 page 2 Disassembling and Assembling Cylinder Block and Crankshaft Edition 09. inspect synchronous running of chain sprockets ⇒ 13-2 page 3 Camshaft setting ⇒ Fig.13 mm Wear limit: 0.04. 1. 1 in 13-2 page 3 Helical gear for oil pump drive 25 Nm coat with -AMV 154 100.4/44. Mechanical Components 910 11 12 13 14 15 16 17 18 - 19 20 21 22 23 24 - 25 - 26 - 27 28 - 29 - press into the sealing flange Sealing flange not available as replacement part (only together with cylinder block) coat with -AMV 188 520. 1. conrod and liner ⇒ Chapter 13-3 8 Nm Timing gear cover Gasket ring replace ⇒ 13-2 page 4 Belt pulley for crankshaft 100 Nm to release and tighten lock flywheel ♦ Engine removed: with -MP 1-504♦ Engine installed: with locking screw ⇒ 13-2 page 4 7 Nm coat with -AMV 105 500.(Loctite 574) before inserting Shield for knock sensor -G615 Nm 20 Nm The tightening torque influences the knock sensor function Knock sensor -G61Cylinder block disassembling and assembling pistons.03 S00.4/50 Engine.03 to 0.(Loctite 648) before inserting Timing chain mark running direction (installed position) before removing always replace complete with crankshaft sprocket and camshaft sprocket Bearing shell for cylinder block with lubricating groove do not mix up used bearing shells (mark) Crankshaft sprocket after replacing. Inspecting synchronous running of sprockets This inspection should be carried out if the sprockets have been replaced.(from marking to marking -arrows-) is 12 chain pins.Bearing caps Bearing cap 1: on the belt pulley side Bearing cap 2: with recesses for thrust washers 2 . test and measuring equipment and auxiliary items required ♦ Straightedge ♦ Feeler gauge a= 12 2 3 S15-0028 The crankshaft sprocket is available in 3 different widths.Bearing shell for cylinder block with lubricating groove do not mix up used bearing shells (mark) 1 2 3 4 5 S13-0209 Fig.20 Disassembling and Assembling Cylinder Block and Crankshaft 13-2 page 3 .13 mm Wear limit: 0. Mechanical Components 13 Modifications of the 1.FABIA 2000 1. 1.so that the distance -a.4/44.26 mm 5 .4 litre engine 1 .Crankshaft Axial play when new: 0.2 mm with letters „E“. marked with the letter „F“. The wheel with an average thickness. 1: Camshaft setting 1 – Insert chain sprockets -2. Special tools.into the timing chain -1.04.03 S00.Bearing shell for bearing cap without lubricating groove do not mix up used bearing shells (mark) 3 . 1.Thrust washer for bearing cap 2 check for firm seating 4 . is supplied together with the camshaft sprocket Edition 09.4/50 Engine.0 litre engine compared to the 1. graduations: marked 0.0/37.03 to 0.5305.and -3. „F“ or „G“. 2 2 2 Replacing gasket ring for crankshaft -on the belt pulley sideSpecial tools.is carried out with the letters „E“.11 mm (crankshaft sprocket is positioned further out) I 1 a II 1 b III 1 c – If the size of the gap is not within the tolerance range.20 . Mechanical Components in a set.= 0.4/50 Engine.Nominal dimension -a. tolerance -c.2 mm II .04.03 S00.Camshaft sprocket 2 . 1.Crankshaft sprocket Pfeil-points towards flywheel side I .4/44. 1.for the timing pointing outwards. order crankshaft sprocket with same „code letter“ and check synchronous running of chain sprockets. test and measuring equipment and auxiliary items required ♦ Pressure plate -MP 6-401/1♦ Supporting device -MP 9-200♦ Two-arm extractor -Kukko 20-10♦ Removal hooks -T10040/1♦ Pressure plate -T10041- S13-0171 13-2 page 4 Disassembling and Assembling Cylinder Block and Crankshaft Edition 09. Marking of the crankshaft sprocket radially in the area of the slot for the Woodruff key -arrow.13 FABIA 2000 1. with the markings -arrows.5305.= 0.min.= -0. Note If chain sprockets are replaced.0/37. S15-0027 Position of chain sprockets 1 . install crankshaft sprocket of a different width and repeat the inspection.max. „F“ or „G“. tolerance -b.09 ± 0.29 mm III . the wheels marked with the letters „E“ and „G“ are only supplied individually ⇒ Spare Part Catalogue. * Test sequence S13-0172 – Press the chain sprockets until they make contact. – Place straightedge flat onto the camshaft sprocket and measure size of gap at crankshaft sprocket. 2 1 3 S10-0140 – Remove noise insulation -arrows-.0/37. – Remove the V-ribbed belt ⇒ Chapter 13-1.5305. – Remove right wheel-well inner panel. S10-0135 Edition 09.FABIA 2000 1.03 S00. Mechanical Components 13 ♦ Flywheel lock -MP 1-504♦ Torque wrench ♦ Screw M 6x40 (grade: 8.4/44. – Lower engine approximately 50 mm.4/50 Engine.8) – make a 60° point at the extremity of the bolt (locking screw) ♦ Nut M6 Removing – Removing engine cover ⇒ Chapter 10-1.20 Disassembling and Assembling Cylinder Block and Crankshaft 13-2 page 5 .04. – Unscrew bolts -2-. 1. – Mount supporting device -MP 9-200.and take up the weight of the engine/gearbox assembly at the spindles. 1. Note If the engine has been removed use a flywheel lock -MP 1-504. A Installing • Crankshaft is locked with flywheel lock -MP 1-504 -.04.(Kukko -20-10-). – Tighten central screw with 100 Nm. Tightening torque: 10 Nm Note Do not start engine as long as the locking screw is located in the gearbox housing! T10041 N13-0425 – Install the V-ribbed belt ⇒ Chapter 13-1. Note Use to press in the central screw. – Pull out gasket ring with two-arm extractor -A.0/37. – Attaching the double clamp of the exhaust system 13-2 page 6 Disassembling and Assembling Cylinder Block and Crankshaft Edition 09. – Install the crankshaft belt pulley.20 . – Installing pendulum support and attaching engine mounting ⇒ Chapter 10-1. – Release locking screw and install engine speed sender. – Slightly rotate the crankshaft on the central screw until the locking screw can be fully tightened (screw tip is located between 2 teeth of the ring gear).5305.instead. 1.to lock the crankshaft.and pressure plate -MP 6-401/1-. 1. 1 a S13-0173 – Remove the central screw and belt pulley crankshaft. extractor hook -T10040/1 .13 FABIA 2000 1. 1 2 – Tighten up the screw and secure in place with the counternut -2-. T10040/1 T10040/1 MP 6-401/1 S13-0175 – Lightly oil the sealing lip of the gasket ring.4/44. or locking bolt. Mechanical Components – To lock the crankshaft remove the engine speed sender and screw in the locking screw -1.4/50 Engine. – Press down gasket ring with pressure plate -T10041 up to the stop into the bushing.03 S00. ⇒ Chapter 26-1. 4/50 Engine. Edition 09. Heat ring gear if stiff. 150 °C and fit onto the flywheel.5305. Installing – Heat ring gear to approx. if necessary. 1.FABIA 2000 1. knock on as far as the stop evenly with a drift over the entire circumference. 1. Mechanical Components 13 Replacing ring gear • Flywheel removed Removing – Fit on flywheel flat and position ring gear in stages by striking over the entire circumference.4/44.04.0/37.03 S00.20 Disassembling and Assembling Cylinder Block and Crankshaft 13-2 page 7 . 20 .4/44. 1.04.0/37.03 S00.5305. Mechanical Components 13-2 page 8 Disassembling and Assembling Cylinder Block and Crankshaft Edition 09. 1.4/50 Engine.13 FABIA 2000 1. 01. 1. 1 in 13-3 page 2 inspecting piston ring end clearance ⇒ Fig. 2 in 13-3 11 A page 3 offset gap 120° relative to top 10 piston ring 9 3 . 1 in 13-3 page 2 12 inspecting piston ring end clearance ⇒ Fig.or -MP 1-202. test and measuring equipment and aids required ♦ Liner extractor 75. Connecting Rod and Liner Secure the engine with engine holder -MP 1-180.5305. Connecting Rod and Liner 13-3 page 1 . 2 in 13-3 4 15 page 3 2 .FABIA 2000 1.before performing assembly work. Mechanical Components 13 13-3 Note Disassembling and Assembling Pistons.on the assembly stand -MP 9-101.on piston crown) available as replacement part only as a set with liners (4 in total) 5 . Special tools.4/44. engine check fitting position press out to replace Edition 06.Piston mark installation position and matching liner arrow on piston crown faces S13-0210 towards the camshaft side use piston ring tensioning strap for installing install pistons of the same weight class only (+ pr .points towards camshaft side.5 mm -MP 1-105♦ Piston pin drift -T10046- 1 .Piston ring (chrome-plated) use piston ring pliers for re1 moving and installing 2 marking „TOP“ faces piston crown inspecting piston ring gap 3 clearance ⇒ Fig.Piston ring (grey) 5 14 use piston ring pliers for re6 moving and installing marking „TOP“ faces piston 13 B crown inspecting piston ring gap 11 clearance ⇒ Fig. mark if necessary Oil drilling -arrow B.0/37.for piston pin lubrication available as replacement part only in set (4 conrods with 4 conrod caps) 6 . 1.Conrod Check fitting position: engraved number („1“ to „4“ for appropriate cylinder) -arrow A.4 ltr.4/50 Engine. 3 in 13-3 8 page 3 7 4 .Oil scraper ring (3 part) remove and install by hand installing ⇒ Fig.Conrod bolt only 1.20 Disassembling and Assembling Pistons.00 S00. 0 ltr. 1.13 FABIA 2000 1. new Piston ring dimensions in mm 1.0..20.01.. 1: Inspecting piston ring gap clearance Special tools.4/50 Engine. Mechanical Components 7 . engine ensure tightly located in retaining lugs 12 . Connecting Rod and Liner Edition 06.Liner remove with -MP 1-105available as replacement part only as a set with pistons (4 in total) check pretension ⇒ Fig.72 Wear limit 1.1.1.Conrod cap check fitting position ⇒ item 5 in 13-3 page 1 11 .0 ---1) no specification possible for wear limit 13-3 page 2 Disassembling and Assembling Pistons.Conrod bolt.0 ltr.5305..4/44.40.. engine 0.40.30.40 1. Piston ring (grey) Oil scraper ring 1) 1.40 0.20 . do not use emery paper. heat piston to 60 °C Fig. 1. Piston ring (chrome-plated) 2.40.00 S00.. engine oil thread and head contact surface 10 .Gasket ring replace different thicknesses are available to correct the liner pretension 13 .Circlip 15 . 4 in 13-3 page 3 14 .0 ltr.0.. if stiff..40 Nm only 1..0/37.0 S13-0006 0. at right angles about 15 mm away from top edge of liner.50 1. 20 Nm + torque a further 1/4 turn (90°) only 1. engine insert in middle 1. engine replace oil thread and head contact surface 9 . test and measuring equipment and auxiliary items required ♦ Feeler gauge – Push in ring.4 ltr.0.0.50 0.62 0.Piston pin remove and install with -T10046-.Bearing shell do not mix up used bearing shells 1.. flat scraper or similar 8 . engine 0..20..4 ltr.4 ltr..Cylinder block seat surfaces for liners must be clean and flat remove contamination on seat surfaces of the liners by cleaning only. FABIA 2000 Fig. 2: 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 13 Inspecting piston ring end clearance Special tools, test and measuring equipment and auxiliary items required ♦ Feeler gauge Clean ring groove before inspecting. Piston ring dimensions in mm 1. Piston ring (chrome-plated) 2. Piston ring (grey) Oil scraper ring Fig. 3: new Wear limit 0,04...0,08 0,04...0,08 0,15 0,15 V13 - 0687 cannot be measured Installing oil scraper ring The oil scraper ring consists of a shaped spring ring and a top and bottom metal ring. Installation steps: – Insert spring ring into the groove. Position joint so that there is no hole behind it. – Compress joint of spring ring and insert top metal ring. The joint of the top metal ring should be positioned 45°...90° to the left of the joint of the spring ring. – Compress joint of spring ring and insert bottom metal ring. The joint of the bottom metal ring should be positioned 45°...90° to the right of the joint of the spring ring. Fig. 4: Inspecting pretension of liners S13-0008 Special tools, test and measuring equipment and auxiliary items required ♦ Measuring tool for liner pretension -MP 1-107♦ Dial gauge MP 1-107 The seat surfaces of the liners and of the cylinder block must be clean and flat. Remove contamination on seat surfaces of the liners by cleaning only; do not use emery paper, flat scraper or similar – Insert liners with seal firmly into the cylinder block up to the stop. S13-0128 – Measure projection (preload) of liners to top edge of cylinder block. The projection must be 0.07...0.12 mm; if necessary adjust to correct projection by fitting seals of different thicknesses. Edition 06.00 S00.5305.01.20 Disassembling and Assembling Pistons, Connecting Rod and Liner 13-3 page 3 13 Note FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components ♦ Seals are available in thicknesses of 0.10; 0.12 and 0.14 mm. ♦ The difference in the projections of the liners to each other must not exceed 0.04 mm. ♦ The liners must not touch at the flattened points -ar- rows-. 13-3 page 4 Disassembling and Assembling Pistons, Connecting Rod and Liner Edition 06.00 S00.5305.01.20 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 15 15 – Cylinder Head, Valve Gear 15-1 Removing and installing cylinder head Summary of components – Testing compression pressure ⇒ Chap. 15-2 Note ♦ Removing and installing intake manifold: ⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24 ♦ Removing and installing exhaust manifold ⇒ Chapter 26-1 ♦ If the cylinder head is replaced, the system must be completely filled with fresh coolant. 1 - 3 Nm 2 - Seal replace 3 - Cylinder head bolt moisten with oil before screwing in tightening order and tightening torque ⇒ 15-1 page 4 4 - Washer 5 - Lifting eye - on the left 6 - Rocker arm shaft removing and installing rocker arms ⇒ Chapter 15-3 performing basic setting of hydraulic valve clearance compensation ⇒ Chap. 15-2 7 - Bracket for ignition terminal 8 - Shim 9 - 23 Nm do not tighten fully until cylinder head bolts have been tightened 10 - 20 Nm self-locking, replace do not tighten fully until cylinder head bolts have been tightened 11 - 20 Nm wet with -AMV 105 500(Loctite 242) before screwing in do not tighten fully until cylinder head bolts have been tightened 12 - Bracket for generator support 13 - Cylinder head gasket Observe installation position; with part no. marking faces up replace 14 - Cylinder head check for distortion ⇒ Fig. 1 in 15-1 page 2 Edition 09.03 S00.5305.04.20 Removing and installing cylinder head 15-1 page 1 15 FABIA 2000 removing and installing ⇒ 15-1 page 2 after replacing fill entire system with fresh coolant Oil deflector 25 Nm Lifting eye - on the right Gasket for cylinder head cover replace if damaged Cylinder head cover Cap fit on during installation work 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 15 16 17 18 19 20 - Fig. 1: Inspecting the cylinder head for distortion Special tools, test and measuring equipment and auxiliary items required ♦ Straightedge ♦ Feeler gauge Max. permissible distortion: 0.05 mm (minimum clearance of straightedge base: 100 mm) If the distortion is greater than 0.05 mm, replace cylinder head, do not rework. Removing and installing cylinder head • Engine installed Special tools, test and measuring equipment and auxiliary items required ♦ Catch pan (e.g. -V.A.G 1306-) ♦ Torque wrench ♦ Pliers for spring strap clips ♦ Flat scraper ♦ Braking agent -AMV 105 500- (Loctite 242) V15 - 0673 Removing – On models fitted with a coded radio set, first determine the coding. – Disconnect the battery-earth strap with the ignition off. Note When the battery is disconnected and reconnected, carry out rework ⇒ Electrical System; Rep. Gr. 27. 1 2 3 4 4 6 5 – Remove front exhaust pipe with catalyst ⇒ Chapter 26-1. – Drain coolant ⇒ Chapter 19-1. – Removing engine cover ⇒ Chapter 10-1. S10-0138 15-1 page 2 Removing and installing cylinder head Edition 09.03 S00.5305.04.20 – Release ventilation hose -3.FABIA 2000 1.from the thermo regulator housing.from the expansion reservoir. Caution! The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point.and -2.5305. 8 7 6 S15-0157 – Remove vacuum line from the brake servo unit. S10-0137 – Remove the push rods and lay aside according to – Carefully remove the cylinder head. – Then unscrew the remaining cylinder head bolts/nuts.N30 bis N33- 1 4 3 5 – Unclip edge connector -4.and -8-.and remove wiring loom from holders.from the solenoid valve.from the intake manifold pressure sender -G71. – Release the cylinder head bolts/nuts (do not yet fully unscrew). 1.04. 1 M – Remove ignition terminal. Reduce pressure by carefully releasing the connection point. their fitting position. Remove intake hose -5-. Mechanical Components 15 2 – Disconnect plug: 2 . Edition 09. – Unscrew the guide tube for the oil dipstick from the exhaust manifold. 1. – Remove the cylinder head cover. – Remove the generator support bracket ⇒ item 12 in 15-1 page 1 – Prior to this remove the V-ribbed belt on vehicles with air conditioning ⇒ Chapter 13-1. M 2 2 S10-0141 – Remove the fuel presupply pipe -4. – – – – Remove ventilation hoses -1.from the throttle valve control unit -J3383 .from the injector cylinders . 1 3 4 – First remove the rocker arm shaft.03 S00.4/50 Engine.G726 .-arrows.from the coolant temperature sender -G627 . Disconnect air hose from hot air collector.20 Removing and installing cylinder head 15-1 page 3 .by pressing the release buttons at the separation point. – Remove pipe supports for intake manifold. Remove coolant hoses -1.0/37.4/44.with intake manifold temperature sender . – Remove the coolant hose -2. Make sure this does not cause any extended scoring or scratching. Any damage will result in leaks. – Insert the cylinder head. ♦ There must not be any oil or coolant present in the blind holes for the cylinder head bolts.4/44. 6. Note Before inserting the cylinder head make sure all liners are correctly fitted in the cylinder block. 9 10 Bolt length 168 mm 185 mm 132 mm Washer yes no yes 10 9 13 6 5 11 2 1 12 4 3 8 14 7 N15-0221 15-1 page 4 Removing and installing cylinder head Edition 09. 1. 3.03 S00. While doing so the liners must no be pushed out. marking is at the top.4/50 Engine.0/37.04. cylinder block and liners using a flat scraper or using a suitable chemical device for this purpose. 2. 8. ♦ Treat the seal with the utmost care. Observe the following bolt length and installation with/without washers: Position 1. Wrongly inserted push rods (with ball head on the edge of the tappet or with the edge on the ball head of the adjusting screw) result in faults in the basic setting of the valve gear or damage when the engine is started. – Insert the push rods with the ball socket from the top in accordance with their original location. – Position the new cylinder head gasket in such a way that the part no. if necessary press down. – Moisten the thread of the cylinder head bolts with oil. – Insert a clean cleaning cloth in the liners and in the openings for the push rods to ensure no dirt contaminates the liners or tappets. Mechanical Components ♦ Remove the new cylinder head seal from its wrapping immediately before fitting. Note When inserting the push rods carefully introduce them in the ball socket of the tappet and in the ball knobs of the adjusting screws. 5. 1.5305.20 . – Turn the crankshaft in such a way that all pistons are at the same height. 7 4. – Carefully clean the sealing surfaces of the cylinder head. – Fit the rocker arm shaft and tighten the fixing screws by hand. – Carefully remove old residual seal and the cleaning cloths.15 Installing Note FABIA 2000 1. – Insert the other cylinder head bolts/nuts and tighten by hand. 4/44. Rep. 24.0/37. Note The basic setting of the hydraulic valve clearance compensation must not be carried out again.0/37.04. Rep. – Perform basic setting of hydraulic valve clearance compensation ⇒ Chapter 15-2. ory ⇒ 1. 1. 1. Mechanical Components 15 – Tighten the cylinder head bolts/nuts in the following sequence: Position 1 to 10 Stage I: Stage ll: Stage lll: 11 to 14 Tightening method 20 Nm 4 turn (90°) with a rigid wrench 1/ turn (90°) with a rigid wrench 4 1/ 20 Nm – Install the generator support bracket ⇒ item 12 in 15-1 page 1 Insert bolt ⇒ item 11 in 15-1 page 1 with locking agent -AMV 105 500-. interrogate and erase fault mem- Edition 09. – Adapt the engine control unit to the throttle valve control unit -J338. 1.20 Removing and installing cylinder head 15-1 page 5 .4/44. 1.4/50 engine .FABIA 2000 1. if only the cylinder head gasket is replaced.⇒ 1. 1.0/37.4/50 Engine. Further installation occurs in a similar way in reverse order to removal. 01 – Perform a test drive. – Tighten the rocker arm shaft screws crosswise evenly to 25 Nm.03 S00.fuel injection. Gr. Pay attention to the following: – Install front exhaust pipe with catalyst ⇒ Chapter 261. 1.5305.4/44.4/50 engine .fuel injection. – Install the V-ribbed belt on vehicles with air conditioning ⇒ Chapter 13-1. Gr. – Top up coolant ⇒ Chapter 19-1. 4/50 Engine.0/37. 1.15 FABIA 2000 1.5305. 1.03 S00.04.20 . Mechanical Components 15-1 page 6 Removing and installing cylinder head Edition 09.4/44. Valve stem seal replace ⇒ 15-2 page 6 5 . – Use -MP 1-173.(Loctite 270) – Coat outer circumference of plug with -AMV 200 000-.Cylinder head marking 8 .Valves do not rework. 1. Mechanical Components 15 15-2 Repairing cylinder head 1 2 3 4 1 .03 S00.Cylinder head reworking valve seats ⇒ 15-2 page 3 inspecting valve guides ⇒ 15-2 page 1 6 . 1 in 15-2 page 1 8 7 6 6 5 S15-0148 Fig. 1: Knocking plug into cylinder head Special tools.Plug installing ⇒ Fig.to knock in plug.FABIA 2000 1. test and measuring equipment and auxiliary items required ♦ Injection drift pin -MP 1-173♦ Sealant -AMV 200 000.5305.4/50 Engine.04. Inspect valve guides Special tools.4/44. test and measuring equipment and auxiliary items required ♦ Universal dial gauge holder -MP 3-447♦ Dial gauge MP 1-173 S15-0011 Edition 09.Valve spring removing and installing ⇒ 15-2 page 2 4 .20 Repairing cylinder head 15-2 page 1 . only grinding in is permissible removing and installing ⇒ 15-2 page 2 Valve dimensions ⇒ 15-2 page 3 7 .0/37.Valve collets 2 .Valve spring retainer 3 . 1. onto the cylinder head. Wear limit Inlet valve 0. If the wear limit is again exceeded . use a new valve for the measurement.replace cylinder head.4/44.together with threaded connector -1.5305.03 S00. ♦ If the valve is replaced when carrying out repair work. 2 1 MP 1-114 – Press down assembly lever -2-.5 mm Exhaust valve 0. – Attach valve spring assembly lever -MP 1-114. test and measuring equipment and auxiliary items required ♦ Valve supporting plate -MP 1-113♦ Valve spring assembly lever -MP 1-114♦ Insert for conical spring -MP 1-114/1♦ Threaded connector M8x40 MP 1-113 S15-0008 – Fit cylinder head onto the valve supporting plate .20 .04. – Pull out valves.4/50 Engine.15 Procedure FABIA 2000 1. Mechanical Components – Insert valve into guide. MP 1-113 MP 1-114/1 S15-0124 15-2 page 2 Repairing cylinder head Edition 09. End of valve stem must be flush with guide. Removing and installing valves Removing Special tools. Note Release collets that are tight by striking light blows with a hammer on the assembly lever.0/37. 1.MP 1-113-. – Determine valve rock. 1.and insert -MP 1-114/1.6 mm Note ♦ If the wear limit is exceeded. repeat measurement with new valve. – Take out collets. 7 42. permissible reworking dimension from the distance measured and the maximum dimension. Only grinding in is permissible.03 S00.0 7. 1.0 101.4/50 Engine.0 1. It is also necessary to inspect the valve guides for wear.0 ltr. Maximum dimensions in mm Inlet valve Exhaust valve Edition 09. Note If the valve is replaced when carrying out repair work.0 7.0 104.1 43.between the valve stem and the seat surface for valve spring. proper operation of the valve gear is no longer assured and the cylinder head must be replaced.4 ltr 30.5305. – Measure distance -a. particularly on engines with a high mileage.20 a 1.FABIA 2000 1. Calculate the maximum permissible reworking dimension before commencing.0 7. Inlet valve Dimension ∅a ∅b c α mm mm ∠° 1. If the reworking dimension is exceeded. test and measuring equipment and auxiliary items required ♦ Depth gauge/caliper gauge ♦ NAC milling cutter for reworking valve seats ♦ Grinding paste Note ♦ When carrying out repairs on engines with leaking valves.4 ltr. ♦ Rework valve seats only sufficiently in order to obtain a proper contact pattern.4 ltr 34.4/44.8 Repairing cylinder head S15-0093 15-2 page 3 .0/37.0 ltr 27.0 Reworking valve seats Special tools.0 101. engine 42. it is not sufficient to machine or replace the valve seats and valves. engine 43. Mechanical Components 15 Valve dimensions Note Valves must not be reworked.0 7.0 ltr 34. Calculating maximum permissible reworking dimension – Insert valve and press firmly against the valve seat.0 45 Exhaust valve 1. 1. use a new valve for the measurement.0 45 1.0 45 1.0 45 mm 104. – Calculate max.04. 4 ± 0. permissible reworking dimension S15-0058 1.inlet and exhaust valve 1. 1.7 mm 0.5305. engine: ∅a mm Valve seat diameter: 33.45 up to 1. The following conditions must be met: • Wear limit of valve guides must not exceed the permissible dimension ⇒ 15-2 page 2. replace cylinder head. engine: ∅a b mm mm Valve seat diameter: 32.6 -0. repeat measurement with a new valve. permissible reworking dimension 43.exhaust valve Max. Reworking valve seats Dimension 1.9 -0.04.65 up to 1.4 ltr.4/50 Engine. If the max. permissible reworking dimension is 0 mm.1 .4 ltr.75 .1 .6 .inlet valve 1. Example: Maximum dimension = Measured distance Max.inlet valve 29.20 .1 mm 42. Mechanical Components Maximum dimension less distance measured = max.03 S00. HRC).1 . permissible reworking dimension.1 .0 ltr.0/37. 1.95 .0 ltr.exhaust valve Valve seats Z a b 45° 60° 30° 1.3 up to 1.exhaust valve Valve seat angle Top correction angle Bottom correction angle Z 45° 30° 60° Bottom edge of cylinder head Procedure Reworking can be carried out with a machine or by hand. 90 15-2 page 4 Repairing cylinder head c Edition 09.4 mm Note If the max.4 ± 0. permissible reworking dimension is again 0 mm. • Use NAC milling cutter with carbide metal tips (min.4/44. engine: c mm Valve seat width: 1. engine: c mm Valve seat width: 1.inlet valve 26.15 FABIA 2000 1. (Do not exceed maximum permissible reworking dimension!) 2 .0/37. engine 1.with fine grinding paste so as to achieve a perfect contact pattern. Note After installing the cylinder head.4 ltr. 1.4/50 Engine. Milling sequence 1 .03 S00. 301) 21/34 S15-0098 Inlet valve 1.4 ltr. 60° 3. engine 90° 1. Mechanical Components 15 Reworking valve seats with NAC milling cutter – Place cylinder head on a felt base and secure to prevent it from turning.Rework bottom correction angle with 60° milling cutter until valve seat width „c“ (⇒ 15-2 page 4) is achieved. Valve guide Inlet valve Exhaust valve Guide drift ∅ mm 7. – Match diameter of guide drift to diameter of valve guide.Machine valve seat with 90° milling tool until until a perfect contact pattern is achieved. 1.01 – Match diameter of milling cutter to diameter of valve seat. engine 1. carry out basic setting of the hydraulic valve clearance compensation. The inspection can be carried out with water colour (perfect contact pattern over entire circumference) or by filling fuel into the combustion chamber (no fuel must flow out at the valve seat). 3 . c S15-0062 – Grind in valve/valve seat -arrows.FABIA 2000 1.0 -0.0 ltr. 2.4/44.04.0 ltr. engine 1.20 Repairing cylinder head 15-2 page 5 .Chamfer top correction angle with 120° milling cutter until valve seat diameter „a“ (⇒ 15-2 page 4) is achieved.5305. S15-0063 Edition 09. 120° a Exhaust valve 1) May not yet be contained in NAC milling cutter kit. Valve seat ∅ Milling cutter 90° mm 36 36 30 32 ∅ Milling cutter 120° mm 38 38 30 32 ∅ Milling cutter 60° mm 21/34 21/34 max. – Check valve for tightness. 5305. it is necessary to carry out the basic setting of the hydraulic valve clearance compensation as follows: Note The basic setting of the hydraulic valve clearance compensation must not be carried out again. Check the gradual reduction of the play through swinging movements of the adjusting rocker arm. test and measuring equipment and auxiliary items required ♦ Valve stem seal insertion tool -MP 1-212♦ Valve supporting plate -MP 1-113- – Carefully lever off valve stem seal -arrow-.20 . if only the cylinder head gasket is replaced. turn back the adjusting bolts in the rocker arms until play can be felt between rocker arm and valve. turn adjusting bolts in a further two turns. then carefully fit onto the valve stem and press onto the valve guide.0/37. 1. – From this point.04. place into insertion tool -A-. – At cylinder 1. 1. After completing repair work on the cylinder head/valve gear. A Basic setting of hydraulic valve clearance compensation The hydraulic valve clearance compensation is maintenance-free. – Turn adjusting bolts of both rocker arms slightly against the valves until valve gear has no play.03 S00. The point with no play which has appeared determines the exact contact location. S15-0016 – Oil valve stem seal. 15-2 page 6 Repairing cylinder head Edition 09. Mechanical Components Special tools.4/50 Engine.15 Replacing valve stem seal FABIA 2000 1. however. the setting must not be changed. slacken the lock nuts for the adjusting bolts of the rocker arms.4/44. test and measuring equipment and auxiliary items required ♦ Torque wrench S15-0110 Procedure – Rotate crankshaft until the valves of cylinder 4 overlap (inlet valve opens and exhaust valve closes). Special tools. – Then. – Insert valve into guide. Screw in lock nut and then tighten fully to 13 Nm. g. g. – Remove the fixing screws of the ignition terminal and detach ignition terminal from the park plugs.0/37.04.G 1381. 1.from the ignition terminal.g. Testing the compression Test conditions • Engine oil temperature at least 30 °C Special tools. N15-0219 – Use compression tester (e.A. Note Removing fuse 35 interrupts the voltage supply of the injectors. – Unscrew spark plugs with spark plug wrench (e. Note Use of tester ⇒ Operating Instructions.G 1381 .G 1763-) ♦ Spark plug wrench (e.A.or -V.3122 B-) ♦ Torque wrench Test sequence – Remove engine cover.FABIA 2000 1. – Have a second mechanic fully depress the accelerator pedal. -V.5305.4/44.A. Hydraulic compensation elements must settle (otherwise valves may remain constantly open and strike the piston). Mechanical Components 15 – Carry out the setting operations on the other cylinders according to the table below: Setting Cylinder 1 Cylinder 3 Cylinder 4 Cylinder 2 Valve overlap Cylinder 4 Cylinder 2 Cylinder 1 Cylinder 3 Note After installing new hydraulic tappets.A.or -V. . – Remove fuse 35.4/50 Engine.03 S00. test and measuring equipment and auxiliary items required ♦ Compression tester (e. 1. – Unplug 4-pin connector -arrow.G 1763 -) to test compression. Edition 09. the engine must not be started for about 30 minutes.20 Repairing cylinder head 15-2 page 7 . g. -V. -3122 B-). Note Separating the plug connections causes faults to be stored.5305. – Install spark plugs.04. 1.4/44. 1.75 MPa) Difference between cylinders max. fuse 35 and engine cover.4/50 Engine. 01. ignition terminal. FABIA 2000 1. Gr.5 bar (0.3 MPa) – Plug connectors into the ignition strip. 3 bar (0.2 MPa) Wear limit 7.15 pressure rise.0/37.4/44. 12 bar (1. 1. Fuel Injection System.4/50 Engine. 1. Rep.20 .03 S00.0/37. Mechanical Components – Operate starter until the tester no longer indicates a Compression readings New engine min. Tightening torques Component Spark plugs in cylinder head Ignition terminal to bracket Nm 30 9 15-2 page 8 Repairing cylinder head Edition 09. – Interrogate fault memory and erase ⇒ 1. O-ring 5 . 1 in 15-3 page 1 do not interchange lay aside with contact surface facing down oil contact surface 3 .Cylinder block Removing and installing cylinder block ⇒ Chap. 1.1. 2 in 15-3 page 2 8 . 13-2 4 .Camshaft position sensor -G1636 .20 Repairing valve gear 15-3 page 1 .5 Nm 1 2 3 4 5 6 7 8 10 9 S15-0149 Fig.0/37.4/50 Engine. 2 a S15-0130 Edition 03.as shown in illustration.Tappet rod pay attention to correct installation position do not interchange 2 . 1.01 S00.Woodruff key check tightness 9 .4/44.8 to 1. 15-1 Removing and installing timing gear cover and sprockets ⇒ Chap.02. -a.8 Nm 7 .9 mm 1 – Inset shop-made tool -2. tilt slightly and pull tappet out of the guide in the cylinder block.Camshaft with timing segment for camshaft position sensor -arrowCamshaft setting ⇒ Fig.FABIA 2000 1.Retaining plate of camshaft 10 .Hydraulic tappets with hydraulic valve clearance compensation check ⇒ 15-3 page 3 use auxiliary tool to pull out of cylinder block ⇒ Fig.in the tappet bore -1-.5305. Mechanical Components 15 15-3 Repairing valve gear Removing and installing camshaft 1 . 1: Removing hydraulic tappet – Make auxiliary tool (wire) -2. on inside for M11 cylinder head bolt 11 . 1.Spring washer 5 . 15-1 2 .into the timing chain -1.15 Fig.and -3.20 .Tensioning ring 12 . on outside for M11 cylinder head bolt 4 .Rocker arm bracket.(from marking to marking -arrows-) is 12 chain pins.02.Rocker arm bracket for M8 bolt 9 .Adjusting screw performing basic setting of hydraulic valve clearance compensation ⇒ Chap. 3 in 15-3 page 3 10 .4/50 Engine.0/37.Spring S15-0028 1 9 11 9 9 5 6 7 10 5 8 3 11 12 9 8 S15-0150 8 2 2 4 9 3 9 10 8 15-3 page 2 Repairing valve gear Edition 03.4/44. 1 a= 12 2 3 Removing and installing rocker arms 1 . Mechanical Components – Insert chain sprockets -2. 1.Circlip 3 .5305.Rocker arm shaft removing and installing ⇒ Chap.Rocker arm 6 .so that the distance -a.Rocker arm bracket. 15-2 7 .Rocker arm pay attention to different version ⇒ Fig.Lock nut 13 Nm 8 .01 S00. 2: Camshaft setting FABIA 2000 1. If it is possible to insert a feeler gauge between rocker arm and valve and the tappet at the same time moves down.between rocker arm and valve. 1. If the hydraulic tappets are still loud. Mechanical Components 15 Arrangement of rocker arms and rocker arm brackets Straight rocker arm Inclined rocker arm. S15-0189 Edition 03. 1. replace the tappet. Test sequence – Start engine and allow to run until the radiator fan has cut in once. – Inspect tappets at the other cylinders by carrying out the same procedure.FABIA 2000 Fig.5305. determine the faulty tappet as follows: – Remove cylinder head cover. on outside Rocker arm bracket for M8 bolt Rocker arm bracket for M11 bolt. – Attempt to insert a 0.0/37.2 mm feeler gauge -arrow.4/50 Engine. If play was measured only between rocker arm and valve (tappet does not move down).02. carry out basic setting of the hydraulic valve clearance compensation ⇒ Chap. after the setting. 152.20 Repairing valve gear 15-3 page 3 . – Apply a load to the hydraulic tappet by pressing slightly several times on the adjusting screw with a wooden or plastic wedge. – Rotate crankshaft until the valves of cylinder 4 overlap (inlet valve opens and exhaust valve closes). repeat the inspection. ♦ Irregular valve noises when starting engine are nor- mal.4/44. on inside Note 1 2 3 2 3 2 3 1 The rocker arms for the inlet valves are shown in dark in the illustration. to the left Inclined rocker arm. – Increase engine speed to about 2500 rpm for 2 minutes. test and measuring equipment and auxiliary items required ♦ Feeler gauge ♦ Wooden or plastic wedge Note ♦ Always replace hydraulic tappet complete (cannot be adjusted or repaired). 3: 123ABC- 1.01 S00. A B C B B C B S15-0132 A Inspecting hydraulic tappets Special tools. to the right Rocker arm bracket for M11 bolt. 15 Inspection Cylinder 1 Cylinder 3 Cylinder 4 Cylinder 2 FABIA 2000 Valve overlap Cylinder 4 Cylinder 2 Cylinder 1 Cylinder 3 1.4/44. 15-3 page 4 Repairing valve gear Edition 03. 1. Hydraulic compensation elements must settle (otherwise valves may remain constantly open and strike the piston).01 S00. 1.0/37. Mechanical Components Note After installing new hydraulic tappets. the engine must not be started for about 30 minutes.02.4/50 Engine.5305.20 . 1. 1.4/44.4/50 Engine. Edition 02. do not mix up! Oil capacity and oil specification: ⇒ Inspection and Maintenance.03.20 Removing and installing parts of the lubrication system 17-1 page 1 .0 ltr. carefully clean the oil galleries in order to avoid consequential damage. at front ⇒ item 12 in 17-1 page 2 pay attention to these bolts.risk of damage to catalytic converter! ♦ For 1. engine only: longer oil pan bolts on bracket for coolant pipe.02 S00.0/37.FABIA 2000 1. ♦ The oil level must not be above the max.5305. Mechanical Components 17 17 – Lubrication 17-1 Removing and installing parts of the lubrication system Note ♦ If considerable quantities of metal swarf or abrasion (caused by rubbing damage such as damage to the crankshaft and conrod bearings) is found in the engine oil when carrying out engine repairs. marking . 45 Nm for 1.5305.20 Nm 15 .Split pin 6 .09 MPa) oil pressure switch .10 Nm 14 .4 litre engine only: 16 .17 Summary of components FABIA 2000 1.4 ltr.Oil drain plug.0.0 ltr.Oil pan removing and installing ⇒ Chapter 17-2 19 . 3 in 17-1 page 4 20 . 1.03.Bracket for middle coolant pipe for 1.4 litre engine only: 12 .Cap fit on during installation work 2 .Intermediate plate clamped onto oil pan support of 1. 45 Nm grey inspecting ⇒ Chapter 17-3 cut open seal if leaking and replace 4 .Gasket for 1.Gasket replace 18 .02 S00. 1. engine only: 2 bolts M6x22 (different colour and shape).before installing the oil pan with gasket ⇒ Fig.Gasket replace if damaged on the engine cover 3 . knock in slightly with aluminium drift so that the seat of the ball is smoothened 7 .Oil filter slacken with tensioning strap moisten seal with oil tighten by hand pay attention to installation instructions on oil filter pay attention to change intervals 5 .F1-. engine 11 .8 Nm 17-1 page 2 Removing and installing parts of the lubrication system Edition 02.8 Nm S17-0081 10 . do not mix up with other bolts (M6x20) 13 .Pressure spring for pressure relief valve 9 .40 Nm 8 .4/44.0 litre engine only replace coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520. 30 Nm 17 .Oil pan support for 1.Ball for pressure relief valve when installing.0/37. Mechanical Components 1 .20 .9 bar (0.4/50 Engine. replace timing gear cover ⇒ Chapter 13-2 S17-0038 ♦ If no axial play is present. – When installing replace seal -3-. 1: Oil pump . 4.Gasket replace install only if insufficient axial play of oil pump gears ⇒ Fig.Dipstick oil level must not exceed "max" marking! Inspect engine oil level ⇒ Inspection and Maintenance Fig.13 mm Note ♦ If the wear limit is reached.0/37. – Tighten new self-locking nut -1.46 MPa) overpressure clean strainer if dirty 22 .10 mm wear limit: 0. 1. Fig.up and out.4/44.Guide tube removing and installing ⇒ Fig.6 bar (0. ♦ Inspect unrestricted running of the oil pump in assem- bled state with timing gear cover installed. 2 in 17-1 page 3 25 .FABIA 2000 1.5305. 1 2 3 S17-0039 Edition 02. install gasket ⇒ item 22 in 17-1 page 3. 1.02 S00.on the exhaust manifold and lift guide tube -2.20 Removing and installing parts of the lubrication system 17-1 page 3 .03.Oil pump cover with pressure relief valve opening pressure: approx. test and measuring equipment and auxiliary items required ♦ Feeler gauge ♦ Straightedge Axial clearance for new part: 0. 2: Removing and installing dipstick guide tube – Unscrew nut -1. Mechanical Components 17 21 . 1 in 17-1 page 3 24 .Gears inspecting axial play ⇒ Fig.to 20 Nm.inspect axial play Special tools. 1 in 17-1 page 3 23 .4/50 Engine.02 through 0. 02 S00. Mechanical Components – Coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520.0/37.0 litre engine 1. 1. 17-1 page 4 Removing and installing parts of the lubrication system Edition 02.03. 1.before installing the oil pan with gasket -arrows-.17 Fig.4/50 Engine.5305. 3: FABIA 2000 Apply sealant for a 1.20 .4/44. 1.20 Removing and installing oil pan 17-2 page 1 . test and measuring equipment and auxiliary items required ♦ Hand drill with plastic brush attachment ♦ Flat scraper ♦ Torque wrench ♦ Silicone sealant -D 176 404 A2.(M6x22). and 1. engine is identical ⇒ 17-2 page 1.03 S00.and -6. – Unbolt front coolant pipe (below oil pan) at the 2 fixtures at the cylinder block. test and measuring equipment and auxiliary items required ♦ Torque wrench ♦ Sealant -AMV 188 520- – Coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520. Installing Special tools. Tightening torque: 10 Nm Note The bracket for the front coolant pipe is also attached with bolts -2. – Tighten securing bolts in the specified order.FABIA 2000 1. 12 16 19 8 4 1 5 9 13 17 18 Removing and installing oil pan . if necessary release by applying slight blows with a rubber-headed hammer.for a 1.04.4/50 Engine. Do not interchange with the other bolts (M6x20).before installing the oil pan with gasket -arrows-. 1.0 litre engine Removing The procedure for removing the oil pan on a 1. – Unbolt oil pan together with oil pan support. Mechanical Components 17 17-2 Removing and installing oil pan Removing and installing oil pan .for a 1.5305. – Lay on the gasket for the oil pan. Edition 09.4 litre engine Special tools.or . – Drain engine oil.0/37. – Remove oil pan.4 ltr.4/44.0 ltr. Press the coolant pipe slightly towards the outside for this step.047 198 049- 20 15 11 7 3 2 6 10 N17-0079 14 (THREE BOND 1215 J) ♦ Counterholder -T30008- Removing – Remove noise insulation below engine. they must be free of oil and grease. – Clean sealing surfaces.17 cylinder block. -b. If -D 176 404 A2.0/37. 1. ♦ The oil pan must be installed immediately after apply- ing the silicone sealant -047 198 049.(THREE BOND 1215 J) . – Cut off nozzle tube at the front marking (∅ of nozzle approx.20 .= 15 mm.4/50 Engine. 3 mm). FABIA 2000 1. as shown in the illustration.04. Installing Note ♦ Pay attention to the 'use by date' on sealant. A 17-2 page 2 Removing and installing oil pan Edition 09. 1. Note ♦ It is particularly important to maintain the specified ap- plication pattern for the bead in the area of the sealing flange to the flywheel -arrows A-.03 S00. ♦ The assistance of a second mechanic is required to N17-0012 install the oil pan. which must be reliably sealed off by an accumulation of sealant -a.5305.4/44. ♦ There is an opening in the cylinder block -arrow B.∅ A A B b a S17-0040 13 mm.= 4 mm. N17-0019 – Apply silicone sealant to the clean sealing surface of the oil pan. ♦ Thickness of sealant bead: 2 to 3 mm Note The sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.is used installation must be performed within 5 minutes. Press the front coolant pipe slightly towards the outside. Mechanical Components – Use a flat scraper to remove sealant residues on the – Use a rotating plastic brush to remove sealant residues on the oil pan (wear protective goggles). The flat side of the counterholders -T30008.Tighten all the bolts of the oil pan/cylinder block only very slightly in the given sequence. 5 .Tighten all the bolts of the oil pan/cylinder block slightly in the given sequence. – Position oil pan together with oil pan support immediately against the cylinder block and tighten the bolts as follows: 1 .must touch the cylinder block for this step.20 Removing and installing oil pan 17-2 page 3 .FABIA 2000 1. S17-0041 – Position oil pan together with oil pan support immediately against the cylinder block and tighten the bolts as follows: 1 .gearbox.Tighten all the bolts of the oil pan/cylinder block only very slightly in the given sequence. 12 16 19 13 17 18 20 15 11 7 3 2 6 10 N17-0079 14 Engine removed (Gearbox disconnected) T30008 – To ensure clearance of intermediate plate when installing the engine .tight to cylinder block (M10) as shown in the illustration. 2 . Relevant tightening sequence of the bolts: as described in „engine installed“. 1. 1. 12 16 19 8 4 1 5 9 13 17 18 20 15 11 7 3 2 6 10 N17-0079 14 Continuation for both installation descriptions Further installation occurs in a similar way in reverse order to removal.Tighten all bolts to the prescribed torque in the given sequence: M6 = 10 Nm.03 S00. M8 = 20 Nm. if necessary slacken oil pan bolts again and correct position of the oil pan.5305. 2 . Note A gearbox housing or a gearbox can also be fitted instead of the counterholders -T30008-. bolt counterholders -T30008. 4 .4/50 Engine. There must not be any gap between the oil pan support and counterholders -T30008-. For this step press oil pan support against the counterholders -T30008-.Tighten two bolts of oil pan support/gearbox to 45 Nm.4/44. Edition 09.Slightly tighten two bolts of oil pan support/gearbox. M8 = 20 Nm. 3 .04.Tighten all the bolts of the oil pan/cylinder block to the prescribed torque in the given sequence: M6 = 10 Nm.0/37. Mechanical Components 17 8 4 1 5 9 Engine installed – Fit intermediate plate onto oil pan support. 20 . Mechanical Components After installing the oil pan. 1.04.0/37.4/50 Engine.03 S00. Only then may engine oil be filled in. 1. allow the sealant to dry for about 30 minutes.17 Note FABIA 2000 1.4/44. 17-2 page 4 Removing and installing oil pan Edition 09.5305. or at „Ignition off“. 1. The oil pressure warning is cancelled if the oil pressure switch is closed for more than 5 s at a speed of more than 1500 rpm. Activation delay of oil pressure warning: approx.FABIA 2000 1. 1. the oil pressure warning is immediately activated and is not cancelled below 1500 rpm.G 1594 A-) ♦ Current flow diagram Function of dynamic oil pressure warning system The oil pressure switch is opened when pressureless and closed when the switching pressure is reached.01..A. – If the oil pressure switch is open for only 0.G 1527 B-) ♦ Adapter cable set (e.5. -V. Test conditions • Engine oil at correct level. The check is ended when the engine is started.3 s at an engine speed above 1500 rpm. -V. The oil pressure warning is activated for about 10 s after the ignition is switched on („terminal 15 on“).A. this is stored in the combination processor of the dash panel insert.A.0/37. -V. Test sequence Edition 06. Mechanical Components 17 17-3 Testing Oil Pressure and Oil Pressure Switch Special tools. not even if the oil pressure switch is closed. test and measuring equipment and auxiliary items required ♦ Oil pressure tester (e.g.g. Warning criteria The visual oil pressure warning (oil pressure warning lamp flashes) is activated and the audible warning buzzer sounds 3 times if one of the following conditions exists: • „Ignition on“. 3 s Off delay of oil pressure warning: approx. oil pressure switch open – At an engine speed above 5000 rpm.5305. engine not running.G 1342-) ♦ Diode test lamp (e.20 Testing Oil Pressure and Oil Pressure Switch 17-3 page 1 . If this condition occurs 3 times when the engine is running. g. oil pressure switch closed • Engine speed greater than 1500 rpm.. the oil pressure warning is not cancelled. the oil pressure warning lamp in the dash panel insert must light up for about 3 s and then go out.4/50 Engine. 5 s Check warning lamp After the ignition is switched on and engine not running. • Engine oil temperature at least 80 °C (radiator fan must have cut in once). 17-1 • Oil pressure warning lamp (-K3-) must light up for about 3 s when ignition is switched on.00 S00. Oil pressure switch cancelled below 5000 rpm.4/44. inspecting ⇒ Chap. A.5305.4/44.g.and battery positive (+). The LED must not light up. If the nominal value is not reached: – Inspect axial play of oil pump ⇒ Chap.17 FABIA 2000 1. -V.105 MPa overpressure.G 1342-. At 2000 rpm and an oil temperature of 80 °C the oil pressure should be at least 0. replace oil pressure switch. If necessary. 0. At higher engine speeds the oil pressure must not be lower than 0.4/50 Engine.G 1342-). – Connect diode test lamp (e. 17-3 page 2 Testing Oil Pressure and Oil Pressure Switch Edition 06.G 1527 B-) to oil pressure switch -2.. – The LED must light up at 0.7 MPa. Mechanical Components – Unplug connector from oil pressure switch.A. replace the oil pressure switch. replace oil pump cover together with pressure relief valve. g. – Start engine and slowly increase engine speed. – Connect brown cable -1. 17-1.A. 1 2 A17-0025 – Increase engine speed further.0/37. – Unscrew oil pressure switch and screw in oil pressure tester (e. + - – If the LED lights up.20 . 1..00 S00. -V. if not.A.01. 1.into -V.G 1342 – Screw oil pressure switch -2.of tester to earth (-).075 .2 MPa. V. fill entire system with fresh coolant 2 . 2 Nm 7 .4/44. 1.Radiator removing and installing ⇒ Chapter 19-2 after replacing.03.Expansion bottle check the coolant system for tightness ⇒ 19-1 page 7 connection diagram for coolant hoses ⇒ 19-1 page 5 11 . ♦ The hose connections are secured with spring-type clips.5 Nm 10 .Retaining clip for fan cable check tightness 12 . In the event of repairs only use spring-type clips.Auxiliary fan for vehicles with air conditioning system or additional equipment 1 2 3 4 7 8 9 G12 5 6 20 19 18 10 11 17 5 5 12 16 13 9 2 15 5 14 8 S19-0074 Edition 02.0/37.02 S00. without them touching any other components (pay attention to the marking on the coolant connection and hose).Top coolant hose attached to radiator with retaining clips Connection diagram for coolant hoses ⇒ 19-1 page 5 4 .5 Nm 9 . If necessary reduce pressure before repairs.Double screw.Connector 6 .Cover plate check pressure ⇒ 19-1 page 7 5 .O-ring replace 3 .5305.20 Parts of cooling system . 1.Air duct scoop 8 . ♦ When installing fit the coolant hoses free of stress.FABIA 2000 1.Summary of components 19-1 page 1 . ♦ Always replace seals and gasket rings.4/50 Engine. Mechanical Components 19 19 – Cooling 19-1 Note ♦ When the engine is warm the cooling system is under Parts of cooling system Summary of components pressure. Coolant mixing ratios ⇒ 19-1 page 6 Parts of the cooling system fitted to body 1 . 5305.Bottom radiator bearing black 19 .5 Nm 20 . Stage ♦ on: 99 through 105 °C ♦ off: 91 through 98 °C 18 .Bottom coolant hose attached to radiator by retaining clips connection diagram for coolant hoses ⇒ 19-1 page 5 16 .02 S00.19 FABIA 2000 1. 35 Nm or for both fans switching temperatures: 1. Stage ♦ on: 91 through 97 °C ♦ off: 84 through 91 °C 2.Thermoswitch for radiator fan -F18-. 1.4/44.Fan for radiator 15 .4/50 Engine.Top radiator bearing white 19-1 page 2 Parts of cooling system . Mechanical Components 13 .The fan ring 14 .03.Bracket for fan connector 17 .20 . 1.0/37.Summary of components Edition 02. Towards the top expansion reservoir 2 . 19-1 1 .Summary of components 19-1 page 3 .O-ring replace 5 .Towards top radiator 3 .20 Nm 8 . 1.FABIA 2000 1.03. Mechanical Components 19 Parts of cooling system engine side coolant regulator housing Note Draining coolant and filling up ⇒ Chap.Sender for the coolant temperature -G626 . 88 °C Opening end: approx.coolant regulator housing Opening start: approx. 103 °C 4 .To heat exchanger 2 3 4 5 4 6 7 8 1 7 S19-0115 Edition 02. 1.5305.02 S00.Retaining clip 7 .4/50 Engine.0/37.4/44.20 Parts of cooling system . Summary of components Edition 02.Coolant hose insert up to stop on coolant pump/front coolant pipe 9 .to bottom radiator 13 .10 Nm 6 .02 S00. 1.20 .4/44.Front coolant pipe 10 . Mechanical Components 1 2 3 4 5 6 7 13 10 12 11 10 S19-0085 8 9 19-1 page 4 Parts of cooling system .20 Nm 8 .to connection fitting for heat exchanger 12 .20 Nm 11 .0/37.03. replace 4 . front coolant pipe 1 .to bottom expansion reservoir FABIA 2000 1. 1.4/50 Engine.5305.Belt pulley for the V-ribbed belt 5 .Coolant pump check smooth operation if damage and leak present replace completely removing and installing ⇒ Chapter 19-2 3 .Gasket replace 2 .20 Nm self-locking.19 Coolant pump.V-ribbed belt before removing mark running direction do not kink check for wear removing and installing ⇒ Chapter 13-1 7 . Expansion bottle 6 . 1. Cover the cap with a cloth and open carefully.Coolant hose with heat protection 10 . fill entire system with fresh coolant removing and installing ⇒ Chapter 19-2 2 . Special tools.Cylinder block 4 .Coolant pipe for ventilation line 7 . – Open the coolant cap. Mechanical Components 19 Connection diagram for coolant hoses 1 .Summary of components S10-0135 19-1 page 5 .Quick coupling for radiator connections Replace gasket rings.Connection fittings for heat exchanger 9 .20 Parts of cooling system .5305.G 1306-) ♦ antifreeze tester Draining Caution! Hot steam may escape when the expansion reservoir is opened.FABIA 2000 1.02 S00. – Remove noise insulation -arrows-.g. Edition 02.coolant regulator housing with coolant regulator removing and installing ⇒ 19-1 page 3 11 .Heat exchanger 8 . -V.Coolant pump removing and installing ⇒ Chapter 19-2 check smooth operation 5 . test and measuring equipment and auxiliary items required ♦ Catch pan (e.A. moisten with coolant additives 5 6 7 8 9 4 3 10 2 11 1 S19-0087 Draining and filling up coolant Coolant capacity approx. 1.4/44.0/37.Front coolant pipe 3 .6 ltr.4/50 Engine.Radiator after replacing.03. 5. Rep.4/50 Engine.20 .02 S00. Cover the cap with a cloth and open carefully.8 ltr. Gr.Antifreeze contection down to centration1)2) -25 °C -35 °C 1) A10-0118 Drinking water2) 50 % (2. Mechanical Components – Place a catch pan under the engine. Note Observe the disposal instructions for coolant.Summary of components Edition 02. Caution! Hot steam may escape when the expansion reservoir is opened.8 ltr. if necessary fit auxiliary hose onto connection. – Install sender for coolant temperature.and remove sender for coolant temperature -1.0/37. – Pull out retaining clip -2.) 1 2 40 % (2. S19-0077 19-1 page 6 Parts of cooling system .“ mark. 02 Recommended mixture ratios: Antifreeze pro. 1. If the engine is cold the coolant level must between the „min“ and the „max. 1.03.35 litres) 50 % (2. – Close expansion bottle.) 2) The antifreeze concentration must not exceed 60 %. If the engine is warm the coolant level must be on the „max. the antifreeze protection and cooling efficiency are reduced as the concentration increases.25 litres) 60 % (3. 2 G1 – Check the level of coolant and top up if necessary.19 FABIA 2000 1. S19-0086 – Fill with coolant gradually up to „max“ marking on the expansion bottle. – Turn the drain plug -arrow.5305.4/44.“ mark. – Run engine until the fan on the radiator starts. Filling up Select the appropriate coolant additive from the original spare parts catalogue ŠKODA or from the list of allowed coolant additives ⇒ Inspection and Maintenance.on the radiator to the left and draw backwards. – Insert and tighten the coolant drain plug. The coolant amount may differ according to the version of the vehicle.from the coolant regulator housing. G 1274-) with adapter (e.g. -V.15 MPa.FABIA 2000 1.A.12 to 0. V. g. – With the hand pump of the tester generate an overpressure of approx.g.G 1274/8 G12 – Screw cap onto tester with adapter (e. 0.Summary of components 19-1 page 7 . -V.02 S00.4/44.A. – Position coolant system tester (e. S19-0082 – The pressure relief valve must open for an overpressure of 0. 0.A. 1. -V. Cover the cap with a cloth and open carefully.G 1274-) ♦ Adapter (e.G 1274/8-) on the coolant expansion bottle.A.1 MPa.G 1274 – With the hand pump of the tester generate an overpressure of approx.G 1274/8-) ♦ Adapter (e.0/37.5305.V. Mechanical Components 19 Checking the coolant system for tightness Special tools.A.03.A. g. test and measuring equipment and auxiliary items required ♦ Coolant system tester (e.20 Parts of cooling system . – Open the cap of the coolant expansion reservoir.g.G 1274/ 9-). 1. -V.A.G 1274/9-) Test condition • Engine must be warm Test sequence Caution! Hot steam may escape when the expansion reservoir is opened. – If the pressure drops determine location of the leaks and repair them. g. Edition 02.4/50 Engine. Testing the pressure relief valve in the cap V. -V. .15 MPa.A. 4/44.03.4/50 Engine.19 FABIA 2000 1. 1.20 .Summary of components Edition 02.5305.02 S00. 1.0/37. Mechanical Components 19-1 page 8 Parts of cooling system . 1.20 Removing and Installing Radiator. 1.00 S00.g.5305. To do so pull the retaining clip -3. – Unscrew bolts for radiator bearing -arrows-. 63.4/50 Engine. Torque: 5 Nm – Pull radiator with fan backwards and remove downwards. 50. ♦ Do not fold the condenser wires. Attach the condenser with the radiator to the engine or support.A.up to the stop and remove the quick coupling towards the rear.G 1331-) Removing 1 2 – Drain coolant ⇒ Chap. Rep.01. 19-1. There are 2 plug connections on vehicles fitted with air conditioning. -V. Gr. Gr. Coolant Pump Removing and installing radiator Special tools.g.FABIA 2000 1.from thermo-switch -F18. 3 – Separate the coolant hose from the radiator at the top and bottom of the connection fittings.and separate plug connection -2.on the holder of the air duct scoop. -V.4/44. Note ♦ Do not suspend the condenser to the wires. S19-0080 – Unscrew bolts for radiator bearing -arrows-. Rep..G 1306-) ♦ Torque wrench 5. S19-0078 Vehicles without air conditioning – Removing front bumper ⇒ Body Work. Torque: 5 Nm – Removing the lock carrier with component parts ⇒ Body Work. To do so press the latch clips.0/37. Vehicles with air conditioning Caution! Do not open the refrigerant circuit of the air conditioning system.A.. test and measuring equipment and auxiliary items required ♦ Catch pan (e. Mechanical Components 19 19-2 Removing and Installing Radiator. – Remove connector -1. Coolant Pump 19-2 page 1 . S19-0083 Edition 06.50 Nm (e. A. 10-1 S10-0138 – Mount lifting device -MP 9-200.00 S00. -V.A.19 and remove radiator with fan.4/50 Engine.50 Nm (e. – Removing engine cover ⇒ Chap. 19-2 page 2 Removing and Installing Radiator.200 Nm (e...and take up the weight of the engine/gearbox unit at the spindles. test and measuring equipment and auxiliary items required ♦ Lifting device -MP 9-200♦ Catch pan (e.4/44. – Re-adjust headlights on vehicles fitted with air conditioning.20 .0/37.G 1332-) S19-0081 1 2 3 4 4 6 5 Removing – Drain coolant ⇒ Chap. Removing and installing coolant pump Special tools. -V.. Pay attention to the following: – Top up coolant ⇒ Chap.. 19-1. Torque: 5 Nm FABIA 2000 1. Coolant Pump Edition 06.g. Mechanical Components – Release the bolts securing the condenser -arrows- Installing The installation occurs in reverse order.01.G 1306-) ♦ Torque wrench 5. 1.A. 19-1.G 1331-) ♦ Torque wrench 40.g.5305. 1. -V.g. 13-1. – Remove belt pulley from the coolant pump.4/44. – First install ribbed V-belt ⇒ Chap.and -3-. 19-1. 1 – Release clamp from coolant pump and disconnect coolant hose. 1. – Unscrew coolant pump.FABIA 2000 1.00 S00. To this end release bolts -2. Mechanical Components 19 2 – Remove engine mounting -1-.5305. Edition 06. Bolts must be on top. then tighten the belt pulley bolts of the coolant pump. turn crankshaft. – Removing the ribbed V-belt ⇒ Chap. – Unscrew front coolant pipe from front and rear cylinder block. – Top up coolant ⇒ Chap. 10-1. Torque: 10 Nm – Tightening torques of the engine mounting ⇒ Chap.20 Removing and Installing Radiator.0/37.01. 1. 13-1. – Only slacken the bolts of the coolant pump belt pulley. Coolant Pump 19-2 page 3 . Installing Installation occurs in reverse order to removal.4/50 Engine. Pay attention to the following: 3 S10-0140 – Replace seal for coolant pump. 19 FABIA 2000 1. 1. Coolant Pump Edition 06.00 S00.5305. Mechanical Components 19-2 page 4 Removing and Installing Radiator.4/50 Engine.01.20 .4/44.0/37. 1. 1. 1 . Observe rules for cleanliness ⇒ 20-1 page 3.G 1383 A. Repairing parts of the activated charcoal filter system ⇒ Chap. ♦ Fuel hoses in the engine must only be secured with spring strap clamps.00 S00.4/44. Mechanical Components 20 20 – Fuel Supply 20-1 Note ♦ Fuel lines are secured by plug connectors.Fuel tank support with engine/gearbox 15 jack -V.A. The use of collar clamps or screw clamps Removing and Installing Parts of the Fuel Supply System is not allowed.when removing 14 2 .0/37. 20-2.5305.FABIA 2000 1.20 Removing and Installing Parts of the Fuel Supply System 20-1 page 1 .Vent line to solenoid valve 1 for activated charcoal filter in engine 12 compartment 6 . Observe safety measures ⇒ 20-1 page 3.Fuel delivery unit clean strainer if dirty pay attention to installation position of flange of fuel delivery unit ⇒ Fig.4/50 Engine. 1.3 Nm screw for collar clamp for fuel filter 9 .25 Nm 13 4 .01.Feed line 11 black to fuel rail (at intake mani10 fold) 9 7 .25 Nm 3 . 1 in 20-1 page 2 11 .Return-flow line between fuel delivery unit and fuel filter blue 12 .Gasket ring moisten with fuel before installing 16 17 18 19 20 21 22 23 2 1 2 6 5 4 3 S20-0084 Edition 06.Fuel level sender 10 .Tensioning strap 5 .Fuel filter 8 with integrated fuel pressure regulator line connections: 7 ♦ feed (black): in middle ♦ return flow (blue): on outside 8 .Feed line between fuel delivery unit and fuel filter black 13 . 10 Nm 23 . 2: Inspecting vent valve Lever in off position: closed Lever pushed in direction of arrow: open Note Unscrew cap of fuel tank before installing the vent valve.Union nut use wrench -MP 1-227.to connection marked -V-.Activated charcoal filter 22 .for removing and installing 15 .5 Nm 18 . before installing. inspect valve for blockage: ♦ valve vertical: open ♦ valve tilted 45°: closed 20 . 1.4/50 Engine.01. Note After installing the flange of the fuel delivery unit. check whether the feed. Mechanical Components 14 . unclip valve at top and lift out of filler neck.1.0/37.Vent line clipped in place on fuel tank Fig.Gravity valve to remove.4/44.Vent valve to remove. 2 in 20-1 page 2 16 .00 S00.20 FABIA 2000 1. 2 V R 1 A20-0096 Fig. Black feed line -2.End cover 17 . return-flow and vent lines are still clipped in place on the fuel tank. Blue return-flow line -1. V20-1040 20-1 page 2 Removing and Installing Parts of the Fuel Supply System Edition 06. 1: Installation position of flange of fuel delivery unit Marking on the flange must be aligned with marking on the fuel tank -arrows-.Fuel filler flap unit with rubber bowl 19 . unscrew cap check ⇒ Fig.5305.20 .to connection marked -R-.Vent line between activated charcoal filter ⇒ item 21 in 20-1 page 2 and vent line ⇒ item 5 in 20-1 page 1 21 . 1. unclip valve at side and take out of filler neck. Do not use parts which have been stored unwrapped (e.g. 1. Edition 06.5305.20 Removing and Installing Parts of the Fuel Supply System 20-1 page 3 . If no exhaust extraction system is available. Mechanical Components 20 Safety precautions when working on the fuel supply system Caution! The fuel feed line is pressurized! Place cleaning cloths around the connection point before detaching hose connections.4/44. ♦ Only install clean parts: Remove spare parts from their wrapping immediately before fitting. even before the work is commenced. a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m3/h must be used. Pay attention to the following points when removing and installing the fuel gauge sender or the fuel pump (fuel delivery unit) on a fuel tank that is filled or partially filled: ♦ The extraction hose of an exhaust extraction system which is switched on. Do not use fuzzy cloths! ♦ Carefully cover or close opened components if the re- pair is not completed immediately.00 S00. Avoid moving the vehicle. 1. Reduce pressure by carefully removing the hose. must be positioned close to the assembly opening of the fuel tank in order to extract the released fuel gases. ♦ When the system is open: Avoid using compressed air.4/50 Engine. ♦ Place removed parts on a clean surface and cover. in tool boxes and the like).FABIA 2000 1. ♦ Avoid skin contact with fuel! Wear fuel-resistant gloves! Cleanliness rules Carefully observe the following „5 rules“ for cleanliness when working on the fuel supply/injection system: ♦ Thoroughly clean the connection points and their sur- roundings before releasing.01.0/37. 0/37.5305.4/44. 1.20 .20 FABIA 2000 1.00 S00. Mechanical Components 20-1 page 4 Removing and Installing Parts of the Fuel Supply System Edition 06.01. 1.4/50 Engine. Mechanical Components 20 20-2 Activated Charcoal Filter System Repairing parts of the activated charcoal filter system Note ♦ The hose connections are secured with spring strap or collar clamps. 1.FABIA 2000 1. 20-1. ♦ Collar clamps must always be replaced with spring strap clamps. Observe the rules for cleanliness ⇒ Chap. Rep.00 S00.Throttle valve control unit 4 . 1.0/37.Solenoid valve 1 -N80in right of engine compartment valve is actuated (pulsed) by engine control unit when engine is warm testing ⇒ 1. Observe the safety precautions ⇒ Chap.01.10 Nm 3 .0/37. Fuel Injection. 2 pin for solenoid valve 1 -N806 . 1.4/44.5305.Vent line from solenoid valve 1 -N80(in engine compartment) 2 . Gr.Connector black.4/50 Engine. 20-1. Final Control 5 . 1 .Activated charcoal filter Fitting location: in rear right wheelhouse attached to body 7 . 01.20 Activated Charcoal Filter System 20-2 page 1 .Vent line from gravity valve to fuel tank 1 7 6 2 3 5 4 S20-0088 Edition 06.4/44 Engine. 5305.20 FABIA 2000 1.4/44.4/50 Engine.20 . Mechanical Components 20-2 page 2 Activated Charcoal Filter System Edition 06.0/37. 1.00 S00. 1.01. Double clamp align exhaust system free of stress before tightening ⇒ 26-1 page 2 fitting position: bolts at bottom and horizontal tighten bolted connections evenly 12 .FABIA 2000 1. Rep.fuel injection.Gasket replace fitting position: notch faces down 3 . Rep.fuel injection. hot screw paste must not get into the slot of the probe body use lambda probe wrench for removing and installing testing ⇒ 1. 1.0/37.4/44. 24 13 .Exhaust manifold to remove take off intake manifold ⇒ 1. Gr. 24.Cross member 10 .4/44.4/50 engine . 1.4/44.0/37. 1.4/50 Engine.0/37.Retaining strap made of silicone press off from cross member ⇒ item 9 to remove front exhaust pipe with catalytic converter 9 . 1. 1. Tightening torque: 2 Nm Removing and installing parts of the exhaust system 1 . ♦ Use a screwdriver to slacken and tighten the clamps of the heat shields. only on engines complying with D4-/EU4 exhaust-emission standard only coat thread with hot screw paste G 052 112 A3.03.20 Nm replace 6 . 5 .5305.Hot air collector/shield 7 .4/50 engine .4/44.Guide tube for the oil dipstick 8 .02 S00.Gasket replace 2 . Gr. 1.25 Nm 11 . 1. Mechanical Components 26 26 – Exhaust System 26-1 Note ♦ Always replace gaskets and self-locking nuts.Lambda probe downstream of catalytic converter -G130-.20 Removing and installing parts of the exhaust system 26-1 page 1 .0/37.4/50 engine . 1.25 Nm replace 14 . Gr.Hanger retaining strap made of EPDM Edition 02.25 Nm coat with hot screw paste G 052 112 A3 before inserting 4 . 50 Nm. 01 test lambda control and lambda probe heater ⇒ 1.fuel injection. Rep. – Position double clamp at the distance -a.Hanger retaining strap made of EPDM pay attention to the spare part number 16 .0/37. a S26-0064 26-1 page 2 Removing and installing parts of the exhaust system Edition 02.4/50 engine .Front and rear silencer replace individually when carrying out repairs ⇒ 26-1 page 3 align exhaust system free of stress ⇒ 26-1 page 2 19 . 01 test lambda control and lambda probe heater ⇒ 1.Lambda probe 1 downstream of catalytic converter -G39-.02 S00.A.5305.4/44. – Slacken bolted connections of double clamp between catalytic converter and front silencer and replace nuts.Separation point for repairs ⇒ 26-1 page 3 17 . 1. Gr. 1. hot screw paste must not get into the slot of the probe body use lambda probe wrench for removing and installing testing ⇒ 1.0/37. 1. Rep.4/44.4/50 engine .Front exhaust pipe with catalytic converter only on engines complying with EU2 exhaust-emission standard 22 .G 1331-) Procedure • The exhaust system is aligned when cold.Hanger retaining strap made of silicone pay attention to the spare part number 18 . Mechanical Components 15 .fuel injection.Front exhaust pipe with catalytic converter only on engines complying with D4-/EU4 exhaust-emission standard with 2 catalytic converters 20 .20 . Rep.fuel injection. -V. Gr. test and measuring equipment and auxiliary items required ♦ Torque wrench 5 to 50 Nm (e.4/44.0/37.26 FABIA 2000 1.= 5 mm from the marking on the pipe of the catalytic converter (bolts at bottom and horizontal) and tighten front bolted connection slightly. 1. 1. 50 Nm only coat thread with hot screw paste G 052 112 A3.03. 24 21 .g. 1.40 Nm replace coat stud bolts with hot bolt paste G 052 112 A3 Aligning exhaust system free of stress Special tools.4/50 Engine. 03.sufficiently far forward into the double clamp until the dimension -b. – Separate exhaust pipe at right angles at the separation point -arrow 1.of 3 to 7 mm is achieved between hanger and the body and the hanger and the front silencer. S26-0063 – Check the connection points for leaks by listening: Cylinderhead/exhaust manifold. – Tighten bolted connections of the double clamp evenly to 25 Nm. test and measuring equipment and auxiliary items required ♦ Torque wrench 5 to 50 Nm (e. etc. -V. with cloth or plug).G 1523 -) A separation point is provided for repair purposes for replacing the front silencer or rear silencer.A. b S26-0065 Replacing front or rear silencer Special tools.02 S00. exhaust manifold/exhaust pipe with catalytic converter. Installation position of double clamp: bolts positioned vertically at front of exhaust pipe.g.4/50 Engine.FABIA 2000 1.g. 1 – Tighten bolted connections on the double clamp in this position. 1.G 1331-) ♦ Body saw (e.position on the side markings -arrows 2 and 3-. 1.g. Edition 02. 4 – Align exhaust system free of stress ⇒ 26-1 page 2. – Seal off tail pipe for the duration of the leak check (e.20 Removing and installing parts of the exhaust system 26-1 page 3 . – When installing double clamp -4.points in direction of travel. -V. – Eliminate any leak found. Mechanical Components 26 – Push front silencer -1. -Arrow.4/44. Tightening torque: 25 Nm Note After tightening the double clamp. 3 2 1 Checking the exhaust system for leaks – Start engine and run in idle.with body saw.5305. – Align rear silencer horizontally.A.0/37. inspect dimension -band adjust if necessary. 20 . Mechanical Components 26-1 page 4 Removing and installing parts of the exhaust system Edition 02.26 FABIA 2000 1. 1.03.0/37.02 S00. 1.4/50 Engine.5305.4/44.