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Skoda FABIA 2000 Workshop Manual

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Service
Workshop Manual
FABIA 2000
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical
Components
Edition 08.99
Engine code
Service Department. Technical Information
ARV AQV AZE
AZF AME ATZ AQW
5
Printed in Czech Republic
S00.5305.00.20

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  • Page 1 Service Workshop Manual FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Edition 08.99 Engine code ARV AQV AZE AZF AME ATZ AQW Service Department. Technical Information Printed in Czech Republic S00.5305.00.20...
  • Page 2 Service The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic S00.5305.00.20 It is not permitted to pass it on to other persons. © ŠKODA AUTO a. s.
  • Page 3 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 Supple- Edition Subject Article Number ment 08.99 Basic Edition S00.5305.00.20 06.00 Supplement to Basic Edition S00.5305.01.20 03.01...
  • Page 4 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components List of Supplements Edition 09.03 S00.5305.04.20...

  • Page 5: Table Of Contents

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Table of Contents 00 – Technical Data Technical Data ..................00-1 page 10 – Removing and Installing Engine Removing and Installing Engine ..............10-1 page - Removing engine ..................10-1 page - Installing the engine ...................
  • Page 6 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 19 – Cooling Parts of cooling system - Summary of components ........... 19-1 page - Parts of the cooling system fitted to body ............19-1 page - Parts of cooling system engine side ..............

  • Page 7: Technical Data

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 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 cyl- inder block on the belt pulley side, at the connection to the cylinder head -arrow-.
  • Page 8 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Engine identification characters Manufactured 08.99 04.03 11.99 07.00 08.00 03.03 Exhaust limits conforming to EU-2 EU-4, EU3-DDK Displacement 1,397 1,397 1,397 Power output kW at rpm 50/5000 50/5000 50/5000 Torque Nm at rpm...

  • Page 9: Removing And Installing Engine

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 10 – Removing and Installing Engine 10-1 Removing and Installing Engine Special tools, test and measuring equipment and auxiliary items required ♦ Workshop crane (e.g. -V.A.G 1202 A-) ♦ Catch pan (e.g. -V.A.G 1306-) ♦...
  • Page 10 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Remove front exhaust pipe with catalyst ⇒ Chap. 26- – Place drip tray below the engine (e. g. -V.A.G 1306-). – Loosen the drain screw on the coolant expansion bot- tle.
  • Page 11 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Remove coolant hoses -1- and -2- from the coolant regulator housing. – 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 connec- tion point.
  • Page 12 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Disconnect the Bowden cable support from gearbox -arrows-. S34-0389 – Detach selector cable -A-, for this step remove circlip -arrow 1- from the relay lever. – Remove bearing bolt -arrow 2- from the reversing le- ver of the selector cable -A-.
  • Page 13 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Remove the earth strap -1- from the front of the gear- box. – Disconnect plug -2- from the reversing light switch -F4-. – Separate plug connection -3-. S10-0143 – Remove coolant hose from the rear coolant pipe -ar- row-.
  • Page 14 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Unbolt the pendulum support -arrows-. Vehicles without air conditioning – Removing the lock carrier with radiator ⇒ Body Work; Rep. Gr. 50. Vehicles with air conditioning Caution! Do not open the refrigerant circuit of the air condi- tioning system.

  • Page 15: Installing The Engine

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Release screws -2-. S10-0140 – Unscrew the fixing screws -arrows- from the gearbox mount. – Slightly lower the engine/gearbox unit and pull out carefully towards the front. S10-0120 Secure the engine with engine mount -MP 1-180- on the assembly support -MP 9-101- before performing assem- bly work.
  • Page 16 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Procedure Installation is performed in the reverse order. Pay atten- tion to the following points: – Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; in- sert if necessary.

  • Page 17: Tightening Torques

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Adapt the engine control unit to the throttle valve con- trol unit -J338- ⇒ 1.4/1.0; 1.4/44 engine - fuel injec- tion; Rep. Gr. 24. – Perform a test drive and interrogate and erase fault memory ⇒...
  • Page 18 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Hinged bracket Note Tighten screws -1- 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. 1 - 30 Nm + 90° ( turn) - replace 2 - 40 Nm + 90°...

  • Page 19: Crankgear

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 13 – Crankgear 13-1 Removing and installing V-ribbed belt Summary of components - Vehicles without air conditioning Note ♦ Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it.
  • Page 20 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components installing ⇒ 13-1 page 5 Fig. 1: Routing of the ribbed V-belt 1 - Belt pulley - generator 2 - Belt pulley - crankshaft 3 - Guide pulley 4 - Belt pulley - coolant pump...

  • Page 21: Summary Of Components - Vehicles With Air Conditioning

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Summary of components - Vehicles with air conditioning Note ♦ Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it. ♦...

  • Page 22: Removing The V-Ribbed Belt

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 22 - V-ribbed belt Routing of the ribbed V-belt ⇒ Fig. 3 in 13-1 page 4 removing ⇒ 13-1 page 4 installing ⇒ 13-1 page 6 Fig. 2: Tightening torques and tightening order for...

  • Page 23: Installing The V-Ribbed Belt

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Remove noise insulation -arrows-. – Mark the routing of the V-ribbed belt. S10-0135 – Release screw -1- from the tensioner -3-. T30022 – Remove camshaft position sensor -2-. – Insert wrench for ribbed V-belt -T30022 - in the ten- sioner -3- up to the stop.
  • Page 24 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, 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-. 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- on the scale ⇒...
  • Page 25 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Insert wrench for V-ribbed belt -T30022 - in the ten- T30022 sioner -3- up to the stop. – Loosen tensioning pulley (tighten tensioner -3-). To this end rotate wrench in the direction of the arrow.
  • Page 26 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Removing and installing V-ribbed belt Edition 02.02 13-1 page S00.5305.03.20...

  • Page 27: Disassembling And Assembling Cylinder Block And Crankshaft

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 13-2 Disassembling and As- sembling Cylinder Block and Crankshaft Summary of components 1.4 ltr. engine 1.0 litre engine ⇒ 13-2 page 3 Note ♦ The design of the 1.0 litre engine is essentially identical to that of the 1.4 ltr. engine. Differences exist only in the version of the crankshaft and its mounting ⇒...
  • Page 28 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components press into the sealing flange 8 - Sealing flange not available as replacement part (only together with cylinder block) coat with -AMV 188 520- (Loctite 574) before inserting 9 - Shield for knock sensor -G61-...

  • Page 29: Inspecting Synchronous Running Of Sprockets

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Modifications of the 1.0 litre engine compared to the 1.4 litre engine 1 - Bearing caps Bearing cap 1: on the belt pulley side Bearing cap 2: with recesses for thrust washers...

  • Page 30: Replacing Gasket Ring For Crankshaft -On The Belt Pulley Side

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components in a set, the wheels marked with the letters „E“ and „G“ are only supplied individually ⇒ Spare Part Catalogue. Marking of the crankshaft sprocket radially in the area of the slot for the Woodruff key -arrow- is carried out with the letters „E“, „F“...
  • Page 31 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components ♦ Flywheel lock -MP 1-504- ♦ Torque wrench ♦ Screw M 6x40 (grade: 8.8) – make a 60° point at the extremity of the bolt (locking screw) ♦ Nut M6 Removing –...
  • Page 32 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – To lock the crankshaft remove the engine speed sender and screw in the locking screw -1- instead. – 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).

  • Page 33: Replacing Ring Gear

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Replacing ring gear • Flywheel removed Removing – Fit on flywheel flat and position ring gear in stages by striking over the entire circumference. Heat ring gear if stiff. Installing – Heat ring gear to approx. 150 °C and fit onto the fly- wheel;...
  • Page 34 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Disassembling and Assembling Cylinder Block and Crankshaft Edition 09.03 13-2 page S00.5305.04.20...

  • Page 35: Disassembling And Assembling Pistons, Connecting Rod And Liner

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 13-3 Disassembling and Assembling Pistons, Connecting Rod and Liner Note Secure the engine with engine holder -MP 1-180- or -MP 1-202- on the assembly stand -MP 9-101- before performing assembly work. Special tools, test and measuring equipment and aids required ♦...
  • Page 36 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 7 - Cylinder block seat surfaces for liners must be clean and flat remove contamination on seat surfaces of the liners by cleaning only; do not use emery paper, flat scraper or...
  • Page 37 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Fig. 2: Inspecting piston ring end clearance Special tools, test and measuring equipment and auxiliary items required ♦ Feeler gauge Clean ring groove before inspecting. Piston ring dimen- Wear limit sions in mm 1.
  • Page 38 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Note ♦ 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-.

  • Page 39: Cylinder Head, Valve Gear

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 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 ♦...
  • Page 40 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components removing and installing ⇒ 15-1 page 2 after replacing fill entire system with fresh coolant 15 - Oil deflector 16 - 25 Nm 17 - Lifting eye - on the right 18 - Gasket for cylinder head cover...
  • Page 41 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Disconnect plug: 2 - from the throttle valve control unit -J338- 3 - from the intake manifold pressure sender -G71- with intake manifold temperature sender - G72- 6 - from the coolant temperature sender -G62- 7 - from the injector cylinders - N30 bis N33- –...
  • Page 42 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Installing Note ♦ Remove the new cylinder head seal from its wrapping immediately before fitting. ♦ Treat the seal with the utmost care. Any damage will result in leaks. ♦ There must not be any oil or coolant present in the blind holes for the cylinder head bolts.
  • Page 43 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Tighten the cylinder head bolts/nuts in the following sequence: Position Tightening method 1 to 10 Stage I: 20 Nm Stage ll: turn (90°) with a rigid wrench Stage lll: turn (90°) with a rigid...
  • Page 44 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Removing and installing cylinder head Edition 09.03 15-1 page S00.5305.04.20...

  • Page 45: Repairing Cylinder Head

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 15-2 Repairing cylinder head 1 - Valve collets 2 - Valve spring retainer 3 - Valve spring removing and installing ⇒ 15-2 page 2 4 - Valve stem seal replace ⇒ 15-2 page 6...

  • Page 46: Removing And Installing Valves

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Procedure – Insert valve into guide. End of valve stem must be flush with guide. – Determine valve rock. Wear limit Inlet valve Exhaust valve 0.5 mm 0.6 mm Note ♦ If the wear limit is exceeded, repeat measurement with new valve.

  • Page 47: Reworking Valve Seats

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Valve dimensions Note Valves must not be reworked. Only grinding in is permis- sible. Inlet valve Exhaust valve Dimension 1.0 ltr 1.4 ltr 1.0 ltr 1.4 ltr ∅ a 34,0 34,0 27,0 30,0 ∅...
  • Page 48 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Maximum dimension less distance measured = max. per- missible reworking dimension. Example: Maximum dimension 43,1 mm Measured distance 42,7 mm Max. permissible reworking di- 0,4 mm mension Note If the max. permissible reworking dimension is 0 mm, re- peat measurement with a new valve.
  • Page 49 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Reworking valve seats with NAC milling cutter – Place cylinder head on a felt base and secure to pre- vent it from turning. – Match diameter of guide drift to diameter of valve guide.

  • Page 50: Replacing Valve Stem Seal

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Replacing valve stem seal Special tools, 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-.

  • Page 51: Testing The Compression

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Carry out the setting operations on the other cylinders according to the table below: Setting Valve overlap Cylinder 1 Cylinder 4 Cylinder 3 Cylinder 2 Cylinder 4 Cylinder 1 Cylinder 2...
  • Page 52 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Operate starter until the tester no longer indicates a pressure rise. Compression readings New engine Wear limit Difference be- tween cylinders min. 12 bar (1.2 7.5 bar (0.75 max. 3 bar (0.3...

  • Page 53: Repairing Valve Gear

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 15-3 Repairing valve gear Removing and installing camshaft 1 - Tappet rod pay attention to correct in- stallation position do not interchange 2 - Hydraulic tappets with hydraulic valve clear- ance compensation check ⇒...

  • Page 54: Removing And Installing Rocker Arms

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Fig. 2: Camshaft setting – Insert chain sprockets -2- and -3- into the timing chain -1- so that the distance -a- (from marking to marking -arrows-) is 12 chain pins. S15-0028 Removing and installing rocker arms...

  • Page 55: Inspecting Hydraulic Tappets

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Fig. 3: Arrangement of rocker arms and rocker arm brackets 1 - Straight rocker arm 2 - Inclined rocker arm, to the left 3 - Inclined rocker arm, to the right A - Rocker arm bracket for M11 bolt, on outside...
  • Page 56 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Inspection Valve overlap Cylinder 1 Cylinder 4 Cylinder 3 Cylinder 2 Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 Note After installing new hydraulic tappets, the engine must not be started for about 30 minutes. Hydraulic compensa- tion elements must settle (otherwise valves may remain constantly open and strike the piston).

  • Page 57: Lubrication

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 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 en-...

  • Page 58: Summary Of Components

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Summary of components 1 - Cap fit on during installation work 2 - Gasket replace if damaged on the engine cover 3 - 0.9 bar (0.09 MPa) oil pres- sure switch - F1-, 45 Nm grey inspecting ⇒...
  • Page 59 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 21 - Oil pump cover with pressure relief valve opening pressure: approx. 4.6 bar (0.46 MPa) overpressure clean strainer if dirty 22 - Gasket replace install only if insufficient axial play of oil pump gears ⇒ Fig. 1 in 17-1 page 3 23 - Gears inspecting axial play ⇒...
  • Page 60 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Fig. 3: Apply sealant for a 1.0 litre engine – Coat the joints between the timing gear cover/cylin- derblock with sealant -AMV 188 520- before installing the oil pan with gasket -arrows-.

  • Page 61: Removing And Installing Oil Pan

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 17-2 Removing and installing oil pan Removing and installing oil pan - for a 1.0 litre engine Removing The procedure for removing the oil pan on a 1.0 ltr. and 1.4 ltr. engine is identical ⇒ 17-2 page 1.
  • Page 62 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Use a flat scraper to remove sealant residues on the cylinder block. – Use a rotating plastic brush to remove sealant resi- dues on the oil pan (wear protective goggles). –...
  • Page 63 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Engine installed – Fit intermediate plate onto oil pan support. – Position oil pan together with oil pan support immedi- ately against the cylinder block and tighten the bolts as follows: 1 - Tighten all the bolts of the oil pan/cylinder block only very slightly in the given sequence.
  • Page 64 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Note After installing the oil pan, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in. Removing and installing oil pan Edition 09.03 17-2 page...

  • Page 65: Testing Oil Pressure And Oil Pressure Switch

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 17-3 Testing Oil Pressure and Oil Pressure Switch Special tools, test and measuring equipment and auxiliary items required ♦ Oil pressure tester (e. g. -V.A.G 1342-) ♦ Diode test lamp (e.g. -V.A.G 1527 B-) ♦...
  • Page 66 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Unplug connector from oil pressure switch. – Unscrew oil pressure switch and screw in oil pressure V.A.G 1342 tester (e.g. -V.A.G 1342-). – Screw oil pressure switch -2- into -V.A.G 1342-.

  • Page 67: Cooling

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 19 – Cooling 19-1 Parts of cooling system - Summary of components Note ♦ When the engine is warm the cooling system is under pressure. If necessary reduce pressure before re- pairs.
  • Page 68 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 13 - The fan ring 14 - Fan for radiator 15 - Bottom coolant hose attached to radiator by retaining clips connection diagram for coolant hoses ⇒ 19-1 page 5 16 - Bracket...

  • Page 69: Parts Of Cooling System Engine Side

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Parts of cooling system engine side coolant regulator housing Note Draining coolant and filling up ⇒ Chap. 19-1 1 - Towards the top expansion reservoir 2 - Towards top radiator 3 - coolant regulator housing Opening start: approx.
  • Page 70 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Coolant pump, front coolant pipe 1 - Gasket replace 2 - Coolant pump check smooth operation if damage and leak present - replace completely removing and installing ⇒ Chapter 19-2 3 - 20 Nm...

  • Page 71: Connection Diagram For Coolant Hoses

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Connection diagram for coolant hoses 1 - Radiator after replacing, fill entire sys- tem with fresh coolant removing and installing ⇒ Chapter 19-2 2 - Front coolant pipe 3 - Cylinder block...
  • Page 72 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Place a catch pan under the engine. – Turn the drain plug -arrow- on the radiator to the left and draw backwards, if necessary fit auxiliary hose onto connection. Note Observe the disposal instructions for coolant.

  • Page 73: Checking The Coolant System For Tightness

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Checking the coolant system for tight- ness Special tools, test and measuring equipment and auxiliary items required ♦ Coolant system tester (e. g. -V.A.G 1274-) ♦ Adapter (e.g. -V.A.G 1274/8-) ♦ Adapter (e.g. -V.A.G 1274/9-) Test condition •...
  • Page 74 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Parts of cooling system - Summary of components Edition 02.02 19-1 page S00.5305.03.20...

  • Page 75: Removing And Installing Radiator, Coolant Pump

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 19-2 Removing and Installing Radiator, Coolant Pump Removing and installing radiator Special tools, test and measuring equipment and auxiliary items required ♦ Catch pan (e.g. -V.A.G 1306-) ♦ Torque wrench 5...50 Nm (e.g. -V.A.G 1331-) Removing –...
  • Page 76 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Release the bolts securing the condenser -arrows- and remove radiator with fan. Torque: 5 Nm Installing The installation occurs in reverse order. Pay attention to the following: – Top up coolant ⇒ Chap. 19-1.
  • Page 77 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Remove engine mounting -1-. To this end release bolts -2- and -3-. – Only slacken the bolts of the coolant pump belt pulley. Bolts must be on top, turn crankshaft. –...
  • Page 78 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Removing and Installing Radiator, Coolant Pump Edition 06.00 19-2 page S00.5305.01.20...

  • Page 79: Fuel Supply

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 20 – Fuel Supply 20-1 Removing and Installing Parts of the Fuel Supply System Note ♦ Fuel lines are secured by plug connectors. ♦ Fuel hoses in the engine must only be secured with spring strap clamps. The use of collar clamps or screw clamps is not allowed.
  • Page 80 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 14 - Union nut use wrench -MP 1-227- for removing and installing 15 - Vent valve to remove, unclip valve at side and take out of filler neck. before installing, unscrew cap check ⇒...

  • Page 81: Safety Precautions When Working On The Fuel Supply System

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Safety precautions when working on the fuel supply system Caution! The fuel feed line is pressurized! Place cleaning cloths around the connection point before detach- ing hose connections. Reduce pressure by careful- ly removing the hose.
  • Page 82 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Removing and Installing Parts of the Fuel Supply System Edition 06.00 20-1 page S00.5305.01.20...

  • Page 83: Activated Charcoal Filter System

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 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. ♦ Collar clamps must always be replaced with spring strap clamps.
  • Page 84 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Activated Charcoal Filter System Edition 06.00 20-2 page S00.5305.01.20...

  • Page 85: Exhaust System

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 26 – Exhaust System 26-1 Removing and installing parts of the exhaust system Note ♦ Always replace gaskets and self-locking nuts. ♦ Use a screwdriver to slacken and tighten the clamps of the heat shields. Tightening torque: 2 Nm...

  • Page 86: Aligning Exhaust System Free Of Stress

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components 15 - Hanger retaining strap made of EPDM pay attention to the spare part number 16 - Separation point for repairs ⇒ 26-1 page 3 17 - Hanger retaining strap made of silicone...

  • Page 87: Replacing Front Or Rear Silencer

    FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components – Push front silencer -1- sufficiently far forward into the double clamp until the dimension -b- of 3 to 7 mm is achieved between hanger and the body and the hang- er and the front silencer.
  • Page 88 FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Removing and installing parts of the exhaust system Edition 02.02 26-1 page S00.5305.03.20...

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