Mecanica Skoda Fabia Motor ARV, AQV, AZE, AZF, AME, ATZ, AQW PDF

Service
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
Service
The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA 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
List of Supplements
Edition 09.03 S00.5305.04.20
Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1 page 1
10 Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 - Removing engine ...................................................................................... 10-1 - Installing the engine ................................................................................... 10-1 - Tightening torques .................................................................................... 10-1 - Assembly bracket ...................................................................................... 10-1 page page page page page 1 1 7 9 9
13 Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 - Summary of components - Vehicles without air conditioning ................................... 13-1 - Summary of components - Vehicles with air conditioning ....................................... 13-1 - Removing the V-ribbed belt .......................................................................... 13-1 - Installing the V-ribbed belt ........................................................................... 13-1 Disassembling and Assembling Cylinder Block and Crankshaft ........................... 13-2 - Summary of components ............................................................................. 13-2 - Inspecting synchronous running of sprockets ..................................................... 13-2 - Replacing gasket ring for crankshaft -on the belt pulley side- .................................. 13-2 - Replacing ring gear ................................................................................... 13-2 Disassembling and Assembling Pistons, Connecting Rod and Liner ..................... 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, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 - Summary of components ............................................................................. 15-1 - Removing and installing cylinder head ............................................................. 15-1 Repairing cylinder head .............................................................................. 15-2 - Inspect valve guides .................................................................................. 15-2 - Removing and installing valves ..................................................................... 15-2 - Reworking valve seats ................................................................................ 15-2 - Replacing valve stem seal ........................................................................... 15-2 - Basic setting of hydraulic valve clearance compensation ....................................... 15-2 - Testing the compression ............................................................................. 15-2 Repairing valve gear ................................................................................... 15-3 - Removing and installing camshaft .................................................................. 15-3 - Removing and installing rocker arms ............................................................... 15-3 - Inspecting hydraulic tappets ......................................................................... 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 ..................................... 17-1 - Summary of components ............................................................................. 17-1 Removing and installing oil pan .................................................................... 17-2 - Removing and installing oil pan - for a 1.0 litre engine .......................................... 17-2 - Removing and installing oil pan - for a 1.4 litre engine .......................................... 17-2 Testing Oil Pressure and Oil Pressure Switch .................................................. 17-3 page page page page page page 1 2 1 1 1 1
Edition 09.03 S00.5305.04.20
Table of Contents
19 Cooling
Parts of cooling system - Summary of components ........................................... 19-1 - Parts of the cooling system fitted to body ......................................................... 19-1 - Parts of cooling system engine side ................................................................ 19-1 - Connection diagram for coolant hoses ............................................................. 19-1 - Draining and filling up coolant ....................................................................... 19-1 - Checking the coolant system for tightness ........................................................ 19-1 Removing and Installing Radiator, Coolant Pump ............................................. 19-2 - Removing and installing radiator .................................................................... 19-2 - Removing and installing coolant pump ............................................................ 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 ................................... 20-1 - Safety precautions when working on the fuel supply system ................................... 20-1 - Cleanliness rules ...................................................................................... 20-1 Activated Charcoal Filter System .................................................................. 20-2 - Repairing parts of the activated charcoal filter system .......................................... 20-2 page page page page page 1 3 3 1 1
26 Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Replacing front or rear silencer ..................................................................... 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 page page page page 1 2 3 3
II
Table of Contents
Edition 09.03 S00.5305.04.20
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, at the connection to the cylinder head -arrow-. In addition, a sticker with engine identification and serial number is affixed to the cylinder head cover. The engine identification characters are also indicated on the vehicle data sticker.
Engine characteristics Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Fuel - 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 01.01 07.02 EU-2 l 0,997 37/5000 84/2750 72 61,2 10 : 1 95 unleaded1) 95 Simos 3PB yes yes 1 lambda probe 1 Catalyst no no no no
AQV 01.01 07.02 EU-3 0,997 37/5000 84/2750 72 61,2 10 : 1 unleaded1) 95 Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no
AZE 04.00 03.03 EU-2 1,397 44/5000 118/2600 75,5 78,0 10 : 1 unleaded1) Simos 3PB yes yes 1 lambda probe 1 Catalyst no no no no
AZF 04.00 03.03 EU-4 1,397 44/5000 118/2600 75,5 78,0 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; the engine output is reduced however
Edition 09.03 S00.5305.04.20
Technical Data
00-1 page 1
00
Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Fuel - 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 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components AME 08.99 04.03 EU-2 l kW at rpm Nm at rpm mm mm 1,397 50/5000 120/2500 75,5 78,0 10 : 1 95 unleaded1) Simos 3PB yes yes 1 lambda probe 1 Catalyst no no no no ATZ 11.99 07.00 D4 1,397 50/5000 120/2500 75,5 78,0 10 : 1 95 unleaded1) Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no AQW 08.00 03.03 EU-4, EU3-DDK 1,397 50/5000 120/2500 75,5 78,0 10 : 1 95 unleaded1) Simos 3PA yes yes 2 lambda probes 2 Catalysts no no no no
At least 91 RON in exceptional cases; the engine output is reduced however
00-1 page 2
Technical Data
Edition 09.03 S00.5305.04.20
10
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-) Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-) Torque wrench 40 to 200 Nm (e.g. -V.A.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.
Supporting points for lift platform Inspection and
Maintenance.
The hose connections are secured with screw-type
clips, spring-type clips or clamp-type clips. Always replace warm-type clamps with spring strap clips or warm-type clamps.
Fuel hoses at the engine must only be secured with
spring-type clips. The use of clamp-type or screw-type clips is not allowed.

Use pliers for spring strap clips to fit the spring strap
clips.
Pay attention to the correct assignment of the connec-
tors, if necessary mark.
Procedure
On models fitted with a coded radio set, pay attention

to the coding; determine if necessary.
Disconnect the earth strap from the battery with the ignition off.
Remove noise insulation -arrows-. Unscrew the drive shaft to the right and left of the
gearbox.
Raise drive shafts and secure.
S10-0135
Edition 02.02 S00.5305.03.20
Removing and Installing Engine
10-1 page 1
10
1.
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 bottle.
Turn the drain plug -arrow- on the radiator to the left

and draw backwards, if necessary fit auxiliary hose onto connection.
A10-0118
Remove engine cover -1- as follows:

Release logo -2- and carefully lever off the cap -3-. Release nuts -4- (5 Nm). Pull out oil dipstick -6-. Remove engine cover -1- towards the top (do not un-
3 4 4
screw cap -5-).
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).
Remove the air filter with hoses 1.0/37; 1.4/44; 1.4/

50 engine - fuel injection; Rep. Gr. 24.
Remove the cable from the starter solenoid switch

Electrical System; Rep. Gr. 27.
S10-0138
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
Release the generator cables from the battery cover

and remove the wiring loom from the holder.
Unplug connector -1- from the engine control unit. Separate plug connection -2-. Unclip cable clip -3- -arrows-.
1 2
S10-0142
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10
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 connection point. Reduce pressure by carefully releasing the connection point.
2
Remove the fuel presupply pipe -4- by pressing the release buttons at the separation point.
S10-0141
Remove coolant hoses -1- and -2- from the expansion

reservoir.
Release vacuum hose -3- from the solenoid valve

-N80-.
1 3 4
S10-0137
Release nut -arrow A- and tie up holder -1-.
1 A
S34-0397
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10-1 page 3
10
-arrows-.
Disconnect the Bowden cable support from gearbox
S34-0389
Detach selector cable -A-, for this step remove circlip

-arrow 1- from the relay lever.
A 1 3 2 B
S34-0398
Remove bearing bolt -arrow 2- from the reversing lever of the selector cable -A-.
Remove the shift cable -B- with the gearbox shift lever, for this step unscrew nut -arrow 3-.
Remove the hose line holder -1- from the gearbox -arrow A-.
Remove -arrow B- the slave cylinder -2- and lay aside,

secure with wire, do not open the line system. Note Do not depress the clutch pedal.
2 A B B 1
S34-0400
10-1 page 4
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10
Remove the earth strap -1- from the front of the gearbox.
Disconnect plug -2- from the reversing light switch

-F4-.
Separate plug connection -3-.
1 3
2
S10-0143
Remove coolant hose from the rear coolant pipe -arrow-.
S10-0139
Remove connector -1- from thermo-switch -F18- and

separate plug connections -2- on the holder of the air duct scoop. To do so press the latch clips. There are 2 plug connections on vehicles fitted with air conditioning.
1 2
Separate the coolant hose from the radiator at the top

and bottom of the connection fittings. To do so pull the retaining clip -3- up to the stop and remove the quick coupling towards the rear.
S19-0078
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10-1 page 5
10
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 conditioning system.
Remove the V-ribbed belt Chapter 13-1. Remove connector from the AC compressor. Remove AC compressor with the refrigerant lines connected.
S34-0403
Secure the AC compressor -1- to the lock carrier -arrow-.
Remove the lock carrier with the radiator and con-
denser Body work; Rep. Gr. 50, swivel to the side and position on support -2- in such a way that there is no risk of tilting. Note
Do not buckle the refrigerant lines. Use cloths to protect the right headlight glass from
damage, removing the headlight if necessary.
2 MP 9-201
S10-0136
Continued for all vehicles
Hook on lifting device -MP 9-201- as follows and raise

slightly with the workshop crane. 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. Note
The rig positions on the supporting bracket marked 1
S10-0134
to 4 point towards the belt pulley.

The holes in the vertical perforated bars are counted
from the hook.
10-1 page 6
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10
2
Release screws -2-.
3
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 assembly work. Note Grip the engine on the supports of the engine mount -arrows-. Instead of engine mount -MP 1-180- it is also possible to use engine mount -MP 1-202-.
MP 1-180 MP 9-101
Installing the engine

Note
Always replace the seals and gaskets during assemS10-0082
bly work.
Always replace self-locking nuts. Apply hot screw paste -G 052 112 A3- to the pin
screws on the exhaust manifold.

Tightening torques 10-1 page 9 Assembly bracket 10-1 page 9
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10-1 page 7
10
Procedure
Installation is performed in the reverse order. Pay attention to the following points:
Check whether the dowel sleeves for centering the

engine/gearbox are present in the cylinder block; insert if necessary.
If necessary check the centering of the clutch driver

disc.
Inspect clutch release bearing for wear, replace if necessary.
Lubricate the drive shaft serration lightly with grease

-G 000 100 -.
Install the slave cylinder of the hydraulic clutch

Gearbox 002; Rep. Gr. 30. Gearbox 002; Rep. Gr. 34.
Adjust the gearshift mechanism and cable control When installing the engine/gearbox unit make sure all
adjoining components are clear.
Align the engine/gearbox unit.

Tightening torques 10-1 page 9.
Install the AC compressor Chapter 13-1. Install alternator Electrical System; Rep. Gr. 27. Fit V-ribbed belt Chapter 13-1.
Continued for all vehicles
Install the drive shaft on the right and left of the gearbox Chassis; Rep. Gr. 40.
Install the front exhaust pipe with catalyst and fit the
exhaust pipe free of stress Chapter 26-1.
Electrical connections and cables Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Install coolant hoses Chapter 19-1.

Note The drained off coolant must only be re-used if the cylinder block, cylinder head, radiator or heat exchanger were not replaced.
Top up coolant Chapter 19-1 After connecting the battery:

Code radio. Set clock. Initialise power window lifter. Inspection and Maintenance
Check oil level before starting the engine.
10-1 page 8
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10
Adapt the engine control unit to the throttle valve control unit -J338- 1.4/1.0; 1.4/44 engine - fuel injection; Rep. Gr. 24. memory 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01 .
Perform a test drive and interrogate and erase fault
Tightening torques
Note
Tightening torques apply only for lightly greased,
oiled, phosphatized or blackened nuts and screws.

Other lubricants such as engine and gearbox oil are
allowed. Do not use Molykote.

Do not use degreased parts. 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. size 34 Chassis; rep. size 40 Torque 9 Nm 13 Nm 20 Nm 40 Nm 70 Nm
Assembly bracket
Tightening torques
Engine mounting 1 - 20 Nm + 90 (1/4 turn) - replace 2 - 30 Nm + 90 (1/4 turn) - replace Gearbox mounting 1 - 50 Nm + 90 (1/4 turn) - replace 2 - 40 Nm + 90 (1/4 turn) - replace
S10-0132
2 1 1
1
Edition 02.02 S00.5305.03.20 Removing and Installing Engine
S10-0125
10-1 page 9
10
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 (1/4 turn) - replace 2 - 40 Nm + 90 (1/4 turn) - replace
1 2
S10-0133
10-1 page 10
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13
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.

Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.
1 - Coolant pump removing and installing Chapter 19-2 2 - Bracket 1 for clamp removing and installing Chapter 15-1 3 - Screw 4 - Clamp 5 - 25 Nm replace 6 - Generator to facilitate positioning of the generator on the holder, drive the bushing of the retaining screw slightly backwards 7 - Screw 8 - 30 Nm replace 9 - 45 Nm 10 - 25 Nm coat with -AMV 105 50017 (Loctite 242) before inserting 11 - Bracket for generator 16 15 12 - Guide pulley 13 - Washer Camber towards the outside 14 - 20 Nm Left-hand thread coat with -AMV 154 100- (Loctite 648) before inserting 15 - Belt pulley for crankshaft 16 - 100 Nm to release and tighten lock flywheel Engine removed: with -MP 1-504 Engine installed: with locking screw Chapter 13-2 17 - V-ribbed belt Routing of the ribbed V-belt Fig. 1 in 13-1 page 2 removing 13-1 page 4
Edition 02.02 S00.5305.03.20 Removing and installing V-ribbed belt
2 3
4 6
7 9
14 13 12 11 10
S13-0241
13-1 page 1
13
installing 13-1 page 5
Fig. 1: 1234-
Routing of the ribbed V-belt
Belt pulley - generator Belt pulley - crankshaft Guide pulley Belt pulley - coolant pump
4 3 2
S13-0242
13-1 page 2
Removing and installing V-ribbed belt
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13
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.

Pay attention to the correct position of the ribbed V-belt in the belt pulley when installing it.
1 - Coolant pump 5 4 removing and installing 1 2 3 Chapter 19-2 2 - Lever with tensioner 4 grease bearing points in 6 holder before fitting 5 3 - Bracket 8 7 for generator and AC com10 11 pressor 7 9 13 12 4 - Gasket 8 replace 9 5 - 20 Nm 6 - 10 Nm 15 7 - Screw 14 tightening order and tightening torque Fig. 2 in 13-1 page 4 16 8 - Washer 9 - Screw tightening order and tightening torque Fig. 2 in 13-1 17 page 4 coat with -AMV 105 500(Loctite 242) before inserting 10 - Bushing 22 11 - Guide pulley 18 12 - Washer Camber towards the outside 19 13 - 35 Nm coat with -AMV 200 000S13-0344 21 20 (Loctite 270) before inserting 14 - Screw tightening order and tightening torque Fig. 2 in 13-1 page 4 15 - Dowel sleeves for AC compressor must be present in holder item 3 in 13-1 page 3 16 - 45 Nm 17 - 25 Nm 18 - Generator to facilitate the positioning of the generator on the holder drive the bushing of the retaining screw slightly backwards 19 - 25 Nm 20 - Belt pulley for crankshaft 21 - 100 Nm to release and tighten lock flywheel Engine removed: with -MP 1-504 Engine installed: with locking screw Chapter 13-2
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13-1 page 3
13
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: 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. Stage: tighten to 2 Nm one after the other in the or-
der of items: 1, 2, 3, 4, 5
2. Stage: the desired final tightening torque - tighten in
the same order as for the 1st stage Fig. 3: 123456Routing of the V-ribbed belt
Belt pulley - AC compressor Guide pulley Belt pulley - generator Belt pulley - crankshaft Tensioning pulley Belt pulley - coolant pump
5 2
Removing the V-ribbed belt

Removing - vehicles without air conditioning
3
S13-0244
Mark the routing of the V-ribbed belt. Release securing screws -arrows- and pivot the generator towards the engine.
Remove the V-ribbed belt.

Removing- vehicles with air conditioning
Wrench for V-ribbed belt -T30022-
Note The assistance of a second mechanic is required to tighten the V-ribbed belt.
S13-0245
13-1 page 4
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13
Remove noise insulation -arrows-. Mark the routing of the V-ribbed belt.
S10-0135
Release screw -1- from the tensioner -3-. Remove camshaft position sensor -2-. Insert wrench for ribbed V-belt -T30022 - in the tensioner -3- up to the stop.
T30022 1 3 2
Loosen tensioning pulley (tighten tensioner -3-). To

this end rotate wrench in the direction of the arrow.
Remove the V-ribbed belt from the tensioning pulley

and pivot tensioning pulley back.
Installing the V-ribbed belt

Note
Check V-ribbed belt for wear Inspection and MainS13-0246
tenance.
Before fitting the V-ribbed belt make sure that all as-
semblies (generator, coolant pump, AC compressor) are securely mounted.

Check smooth operation of belt pulley, tensioning and
guide pulley.
Pay attention to the rotation direction of already used
V-ribbed belts.
Installing- Vehicles without air conditioning

Torque wrench V-ribbed belt tensioning tool (e.g. NP 002 manufac-
tured by Nolt)
Belt tension measuring tool (e.g. of the firm Optibelt or
Clavis)
Replace self-locking nuts -arrows- and tighten while

making sure the generator can still be rotated.
Fit the ribbed V-belt.

S13-0245
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13-1 page 5
13
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 Operating Instructions for the relevant measuring tool. Note Tighten the new ribbed V-belt with 500 +100 N, run engine for approximately 1 minute in idle and re-adjust the belt tension. 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
Once the nominal value has been reached, tighten the

nuts of the generator mounting: 1 - 25 Nm 2 - 25 Nm 3 - 30 Nm
Check belt tension again, correct if necessary. Start engine and check belt run.
3
Installing - Vehicles with air conditioning
Wrench for ribbed V-belt -T30022S13-0249
Note The assistance of a second mechanic is required to loosen the V-ribbed belt.
Position the V-ribbed belt on the belt pulleys and

guide pulley.
13-1 page 6
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13
T30022 1 2
Insert wrench for V-ribbed belt -T30022 - in the tensioner -3- up to the stop.
Loosen tensioning pulley (tighten tensioner -3-). To

this end rotate wrench in the direction of the arrow.
Position the V-ribbed belt on the tensioning pulley and

pivot tensioning pulley back.
Tighten screw -1- on the tensioner -3-.

Tightening torque: 10 Nm
Fit camshaft position sensor -2-.

Tightening torque: 8 Nm
S13-0246
Start engine and check belt run. Fit noise insulation -arrows-.
S10-0135
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13-1 page 7
13
13-1 page 8
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13
13-2
Disassembling and Assembling 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 13-2 page 3.
Repairing the clutch Manual Gearbox 002; Rep. Gr. 30; Repairing the clutch. The engine should be attached to the engine repair stand -MP 1-180- or -MP 1-202 - on the engine holder
-MP 9-101- to carry out removal and installation work. 1 - 75 Nm 2 - Crankshaft bearing unit 3 - Thrust washer for middle bearing lubricating grooves point outwards 4 - 8 Nm coat with -AMV 188 520(Loctite 574) before inserting 5 - Flywheel with rotor for engine speed sender -G28 lock with -MP 1-504- for removing and installing replace ring gear 13-2 page 7 installation position to crankshaft: on the 1.0 ltr. engine the 2 missing teeth of the rotor must face forward when crankshaft position at TDC of cyl. 1 (marking of belt pulley crankshaft is positioned opposite marking 0 at timing gear cover) only one installed position is possible for the 1.4 litre engine (since the bore holes are varying distances apart)
29 28 27 26 25 3
4 5 6
13 24 23 22 21 20
7 8 9 10 11 12 14 15
6 - 30 Nm + torque a further 1/4 turn (90) replace coat with -AMV 200 000- (Loctite 270) before inserting 7 - Gasket ring replace remove when removing the sealing flange lightly oil sealing lip and outer edge before installing
19 18 17 16
S13-0170
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13-2 page 1
13
8-
FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components press into the sealing flange Sealing flange not available as replacement part (only together with cylinder block) coat with -AMV 188 520- (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, 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 242) before inserting Gasket replace Camshaft sprocket after replacing, inspect synchronous running of chain sprockets Fig. 1 in 13-2 page 3 Helical gear for oil pump drive 25 Nm coat with -AMV 154 100- (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, inspect synchronous running of chain sprockets 13-2 page 3 Camshaft setting Fig. 1 in 13-2 page 3 Woodruff key check tightness Crankshaft Axial play when new: 0.03 to 0.13 mm Wear limit: 0.26 mm Bearing shell for crankshaft bearing unit without lubricating groove do not mix up used bearing shells (mark)
910 11 12 13 14 15 16 17 18 -
19 20 21 22 23 24 -
25 -
26 -
27 28 -
29 -
13-2 page 2
Edition 09.03 S00.5305.04.20
13
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 2 - Bearing shell for bearing cap without lubricating groove do not mix up used bearing shells (mark) 3 - Thrust washer for bearing cap 2 check for firm seating 4 - Crankshaft Axial play when new: 0.03 to 0.13 mm Wear limit: 0.26 mm 5 - Bearing shell for cylinder block with lubricating groove do not mix up used bearing shells (mark)
5
S13-0209
Fig. 1:
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.
Inspecting synchronous running of sprockets

This inspection should be carried out if the sprockets have been replaced. Special tools, test and measuring equipment and auxiliary items required
Straightedge Feeler gauge
a= 12
S15-0028
The crankshaft sprocket is available in 3 different widths; graduations: marked 0.2 mm with letters E, F or G. The wheel with an average thickness, marked with the letter F, is supplied together with the camshaft sprocket
Edition 09.03 S00.5305.04.20
13-2 page 3
13
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 or G. Note If chain sprockets are replaced, order crankshaft sprocket with same code letter and check synchronous running of chain sprockets.
Test sequence
S13-0172
Press the chain sprockets until they make contact,

with the markings -arrows- for the timing pointing outwards.
Place straightedge flat onto the camshaft sprocket

and measure size of gap at crankshaft sprocket.
S15-0027
Position of chain sprockets

1 - Camshaft sprocket 2 - Crankshaft sprocket Pfeil-points towards flywheel side I - Nominal dimension -a- = 0.09 0.2 mm II - max. tolerance -b- = 0.29 mm III - min. tolerance -c- = -0.11 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,

install crankshaft sprocket of a different width and repeat the inspection.
Replacing gasket ring for crankshaft -on the belt pulley sideSpecial tools, 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
Edition 09.03 S00.5305.04.20

Flywheel lock -MP 1-504 Torque wrench Screw M 6x40 (grade: 8.8)
13
make a 60 point at the extremity of the bolt (locking

screw)
Nut M6
Removing
Removing engine cover Chapter 10-1. Mount supporting device -MP 9-200- and take up the
weight of the engine/gearbox assembly at the spindles.
Unscrew bolts -2-. Remove right wheel-well inner panel.
3
S10-0140
Remove noise insulation -arrows-. Lower engine approximately 50 mm. Remove the V-ribbed belt Chapter 13-1.
S10-0135
Edition 09.03 S00.5305.04.20
13-2 page 5
13
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).
1 2
Tighten up the screw and secure in place with the

counternut -2-. Note If the engine has been removed use a flywheel lock -MP 1-504- to lock the crankshaft.
S13-0173
Remove the central screw and belt pulley crankshaft. Pull out gasket ring with two-arm extractor -A- (Kukko
-20-10-), extractor hook -T10040/1 - and pressure plate -MP 6-401/1-.
Installing
Crankshaft is locked with flywheel lock -MP 1-504 -, or

locking bolt.
T10040/1 T10040/1 MP 6-401/1
S13-0175
Lightly oil the sealing lip of the gasket ring. Press down gasket ring with pressure plate -T10041 up to the stop into the bushing. Note Use to press in the central screw.
Install the crankshaft belt pulley. Tighten central screw with 100 Nm. Release locking screw and install engine speed sender. 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. Installing pendulum support and attaching engine
mounting Chapter 10-1. Chapter 26-1.
Attaching the double clamp of the exhaust system
13-2 page 6
Edition 09.03 S00.5305.04.20
13
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 flywheel; knock on as far as the stop evenly with a drift over the entire circumference, if necessary.
Edition 09.03 S00.5305.04.20
13-2 page 7
13
13-2 page 8
Edition 09.03 S00.5305.04.20
13
13-3
Note
Disassembling and Assembling Pistons, Connecting Rod and Liner
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
Liner extractor 75.5 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. 1 in 13-3 page 2 inspecting piston ring end clearance Fig. 2 in 13-3 4 15 page 3 2 - 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. 1 in 13-3 page 2 12 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 - Oil scraper ring (3 part) remove and install by hand installing Fig. 3 in 13-3 8 page 3 7 4 - 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 - on piston crown) available as replacement part only as a set with liners (4 in total) 5 - Conrod Check fitting position: engraved number (1 to 4 for appropriate cylinder) -arrow A- points towards camshaft side, mark if necessary Oil drilling -arrow B- for piston pin lubrication available as replacement part only in set (4 conrods with 4 conrod caps) 6 - Conrod bolt only 1.4 ltr. engine check fitting position press out to replace
Edition 06.00 S00.5305.01.20 Disassembling and Assembling Pistons, Connecting Rod and Liner
13-3 page 1
13
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 similar 8 - Conrod bolt, 20 Nm + torque a further 1/4 turn (90) only 1.0 ltr. engine replace oil thread and head contact surface 9 - 40 Nm only 1.4 ltr. engine oil thread and head contact surface 10 - Conrod cap check fitting position item 5 in 13-3 page 1 11 - Bearing shell do not mix up used bearing shells 1.0 ltr. engine insert in middle 1.4 ltr. engine ensure tightly located in retaining lugs 12 - Gasket ring replace different thicknesses are available to correct the liner pretension 13 - Liner remove with -MP 1-105 available as replacement part only as a set with pistons (4 in total) check pretension Fig. 4 in 13-3 page 3 14 - Circlip 15 - Piston pin remove and install with -T10046-, if stiff, heat piston to 60 C
Fig. 1:
Inspecting piston ring gap clearance
Feeler gauge
Push in ring, at right angles about 15 mm away from

top edge of liner. new Piston ring dimensions in mm 1. Piston ring (chrome-plated) 2. Piston ring (grey) Oil scraper ring
1)
1.0 ltr. engine 0,20...0,50
1.4 ltr. engine 0,40...0,72
Wear limit
1,0
S13-0006
0,20...0,50 0,40...1,40
0,30...0,62 0,40...1,40
1,0 ---1)
no specification possible for wear limit
13-3 page 2
Edition 06.00 S00.5305.01.20
FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Fig. 2: Inspecting piston ring end clearance
13
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
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
13-3 page 3
13
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-.
13-3 page 4
Edition 06.00 S00.5305.01.20
15
15 Cylinder Head, Valve Gear

15-1 Removing and installing cylinder head
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 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 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
15 16 17 18 19 20 -
Fig. 1:
Inspecting the cylinder head for distortion
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
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.
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
Edition 09.03 S00.5305.04.20
15
2
Disconnect plug:
2 - from the throttle valve control unit -J3383 - from the intake manifold pressure sender -G71- with intake manifold temperature sender - G726 - from the coolant temperature sender -G627 - from the injector cylinders - N30 bis N33-
1 4
Unclip edge connector -4- -arrows- and remove wiring

loom from holders.
Remove ventilation hoses -1- and -8-. Remove intake hose -5-. Disconnect air hose from hot air collector. Remove coolant hoses -1- and -2- from the thermo regulator housing.
6
S15-0157
Remove vacuum line from the brake servo unit. Remove pipe supports for intake manifold. Unscrew the guide tube for the oil dipstick from the exhaust manifold.
Remove ignition terminal.

Caution! The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.
M
2 2
S10-0141
Remove the fuel presupply pipe -4- by pressing the release buttons at the separation point.
Remove the coolant hose -2- from the expansion reservoir.
Release ventilation hose -3- from the solenoid valve. Remove the cylinder head cover. Release the cylinder head bolts/nuts (do not yet fully
unscrew).
1 3 4
First remove the rocker arm shaft. Then unscrew the remaining cylinder head bolts/nuts. 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. their fitting position.
S10-0137
Remove the push rods and lay aside according to Carefully remove the cylinder head.
Edition 09.03 S00.5305.04.20
15-1 page 3
15
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.
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.
Carefully clean the sealing surfaces of the cylinder

head, cylinder block and liners using a flat scraper or using a suitable chemical device for this purpose. Make sure this does not cause any extended scoring or scratching.
Carefully remove old residual seal and the cleaning

cloths.
Turn the crankshaft in such a way that all pistons are

at the same height. While doing so the liners must no be pushed out; if necessary press down.
Position the new cylinder head gasket in such a way

that the part no. marking is at the top. Note Before inserting the cylinder head make sure all liners are correctly fitted in the cylinder block.
Insert the cylinder head. Insert the push rods with the ball socket from the top
in accordance with their original location. 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. 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.
Moisten the thread of the cylinder head bolts with oil. Fit the rocker arm shaft and tighten the fixing screws
by hand.
Insert the other cylinder head bolts/nuts and tighten by

hand. Observe the following bolt length and installation with/without washers: Position 1, 2, 3, 6, 7 4, 5, 8, 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
N15-0221
15-1 page 4
Edition 09.03 S00.5305.04.20
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

1/ 4
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-.
Tighten the rocker arm shaft screws crosswise evenly

to 25 Nm.
Perform basic setting of hydraulic valve clearance

compensation Chapter 15-2. Note The basic setting of the hydraulic valve clearance compensation must not be carried out again, if only the cylinder head gasket is replaced.
Install the V-ribbed belt on vehicles with air conditioning Chapter 13-1. Further installation occurs in a similar way in reverse order to removal. Pay attention to the following:
Install front exhaust pipe with catalyst Chapter 261.
Top up coolant Chapter 19-1. Adapt the engine control unit to the throttle valve control unit -J338- 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24. ory 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01
Perform a test drive, interrogate and erase fault mem-
Edition 09.03 S00.5305.04.20
15-1 page 5
15
15-1 page 6
Edition 09.03 S00.5305.04.20
15
15-2
Repairing cylinder head

1 2 3 4
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 5 - Cylinder head reworking valve seats 15-2 page 3 inspecting valve guides 15-2 page 1 6 - Valves do not rework, only grinding in is permissible removing and installing 15-2 page 2 Valve dimensions 15-2 page 3 7 - Cylinder head marking 8 - Plug installing Fig. 1 in 15-2 page 1
7 6 6
S15-0148
Fig. 1:
Knocking plug into cylinder head
Injection drift pin -MP 1-173 Sealant -AMV 200 000- (Loctite 270)
Coat outer circumference of plug with -AMV 200 000-. Use -MP 1-173- to knock in plug.
Inspect valve guides

Universal dial gauge holder -MP 3-447 Dial gauge
MP 1-173
S15-0011
Edition 09.03 S00.5305.04.20
15-2 page 1
15
Procedure
Insert valve into guide. End of valve stem must be

flush with guide.
Determine valve rock.

Wear limit
Inlet valve 0.5 mm Exhaust valve 0.6 mm
Note
If the wear limit is exceeded, repeat measurement
with new valve. If the wear limit is again exceeded - replace cylinder head.
If the valve is replaced when carrying out repair work,
use a new valve for the measurement.
Removing and installing valves

Removing
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

- MP 1-113-.
Attach valve spring assembly lever -MP 1-114- and insert -MP 1-114/1- together with threaded connector -1- onto the cylinder head.
2 1
MP 1-114
Press down assembly lever -2-. Take out collets.

Note Release collets that are tight by striking light blows with a hammer on the assembly lever.
Pull out valves.
MP 1-113 MP 1-114/1
S15-0124
15-2 page 2
Edition 09.03 S00.5305.04.20
15
Valve dimensions
Note Valves must not be reworked. Only grinding in is permissible. Inlet valve Dimension a b c mm mm 1.0 ltr 34,0 7,0 45 1.4 ltr 34,0 7,0 101,0 45 Exhaust valve 1.0 ltr 27,0 7,0 104,0 45 1.4 ltr 30,0 7,0 101,0 45
mm 104,0
Reworking valve seats

Depth gauge/caliper gauge NAC milling cutter for reworking valve seats Grinding paste
Note
When carrying out repairs on engines with leaking
valves, it is not sufficient to machine or replace the valve seats and valves. It is also necessary to inspect the valve guides for wear, particularly on engines with a high mileage.
Rework valve seats only sufficiently in order to obtain
a proper contact pattern. Calculate the maximum permissible reworking dimension before commencing. If the reworking dimension is exceeded, proper operation of the valve gear is no longer assured and the cylinder head must be replaced.
Calculating maximum permissible reworking dimension
Insert valve and press firmly against the valve seat.

Note If the valve is replaced when carrying out repair work, use a new valve for the measurement.
Measure distance -a- between the valve stem and the

seat surface for valve spring.
Calculate max. permissible reworking dimension from

the distance measured and the maximum dimension. Maximum dimensions in mm Inlet valve Exhaust valve
Edition 09.03 S00.5305.04.20
1.0 ltr. engine 43,1 43,0
1.4 ltr. engine 42,7 42,8

S15-0093
15-2 page 3
15
Maximum dimension less distance measured = max. permissible reworking dimension. Example: Maximum dimension = Measured distance Max. permissible reworking dimension 43,1 mm 42,7 mm 0,4 mm
Note If the max. permissible reworking dimension is 0 mm, repeat measurement with a new valve. If the max. permissible reworking dimension is again 0 mm, replace cylinder head.
Reworking valve seats

Dimension 1.0 ltr. engine: a mm Valve seat diameter: 33,4 0.1 - inlet valve 26.4 0.1 - exhaust valve Valve seats
Z a b 45 60 30
1.4 ltr. engine: a b mm mm Valve seat diameter: 32.9 -0.1 - inlet valve 29.6 -0.1 - exhaust valve
Max. permissible reworking dimension

S15-0058
1.0 ltr. engine: c mm Valve seat width: 1.3 up to 1.6 - inlet and exhaust valve
1.4 ltr. engine: c mm Valve seat width: 1.45 up to 1.75 - inlet valve 1.65 up to 1.95 - 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. The following conditions must be met:
Wear limit of valve guides must not exceed the permissible dimension 15-2 page 2. HRC).
Use NAC milling cutter with carbide metal tips (min. 90
15-2 page 4
c
Edition 09.03 S00.5305.04.20
15
Reworking valve seats with NAC milling cutter
Place cylinder head on a felt base and secure to prevent it from turning.
Match diameter of guide drift to diameter of valve

guide. Valve guide Inlet valve Exhaust valve Guide drift mm 7,0 -0,01
Match diameter of milling cutter to diameter of valve

seat. 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. 301) 21/34
S15-0098
Inlet valve
1.0 ltr. engine 1.4 ltr. engine 1.0 ltr. engine 1.4 ltr. engine
90
1.
120 a
Exhaust valve
1)
May not yet be contained in NAC milling cutter kit.
2.
Milling sequence
1 - Machine valve seat with 90 milling tool until until a perfect contact pattern is achieved. (Do not exceed maximum permissible reworking dimension!) 2 - Chamfer top correction angle with 120 milling cutter until valve seat diameter a ( 15-2 page 4) is achieved. 3 - Rework bottom correction angle with 60 milling cutter until valve seat width c ( 15-2 page 4) is achieved.
60
3.
c
S15-0062
Grind in valve/valve seat -arrows- with fine grinding

paste so as to achieve a perfect contact pattern.
Check valve for tightness.

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). Note After installing the cylinder head, carry out basic setting of the hydraulic valve clearance compensation.
S15-0063
Edition 09.03 S00.5305.04.20
15-2 page 5
15
Replacing valve stem seal
Valve stem seal insertion tool -MP 1-212 Valve supporting plate -MP 1-113-
Carefully lever off valve stem seal -arrow-. Insert valve into guide.
S15-0016
Oil valve stem seal, place into insertion tool -A-, then
carefully fit onto the valve stem and press onto the valve guide.
Basic setting of hydraulic valve clearance compensation

The hydraulic valve clearance compensation is maintenance-free; the setting must not be changed. After completing repair work on the cylinder head/valve gear, however, 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, if only the cylinder head gasket is replaced. Special tools, 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).
At cylinder 1, slacken the lock nuts for the adjusting

bolts of the rocker arms.
Then, turn back the adjusting bolts in the rocker arms

until play can be felt between rocker arm and valve.
Turn adjusting bolts of both rocker arms slightly

against the valves until valve gear has no play. Check the gradual reduction of the play through swinging movements of the adjusting rocker arm. The point with no play which has appeared determines the exact contact location.
From this point, turn adjusting bolts in a further two

turns. Screw in lock nut and then tighten fully to 13 Nm.
15-2 page 6
Edition 09.03 S00.5305.04.20
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, the engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves may remain constantly open and strike the piston).
Testing the compression

Test conditions
Engine oil temperature at least 30 C

Compression tester (e. g. -V.A.G 1381- or
-V.A.G 1763-)
Spark plug wrench (e.g. - 3122 B-) Torque wrench
Test sequence
Remove engine cover. Unplug 4-pin connector -arrow- from the ignition terminal.
Remove the fixing screws of the ignition terminal and

detach ignition terminal from the park plugs.
Unscrew spark plugs with spark plug wrench (e. g.

-3122 B-).
Remove fuse 35.

Note Removing fuse 35 interrupts the voltage supply of the injectors.
Have a second mechanic fully depress the accelerator

pedal.
N15-0219
Use compression tester (e. g. -V.A.G 1381 - or

-V.A.G 1763 -) to test compression. Note Use of tester Operating Instructions.
Edition 09.03 S00.5305.04.20
15-2 page 7
15
pressure rise.
Operate starter until the tester no longer indicates a

Compression readings
New engine min. 12 bar (1.2 MPa) Wear limit 7.5 bar (0.75 MPa) Difference between cylinders max. 3 bar (0.3 MPa)
Plug connectors into the ignition strip. Install spark plugs, ignition terminal, fuse 35 and engine cover.
Interrogate fault memory and erase 1.0/37; 1.4/44;

1.4/50 Engine, Fuel Injection System; Rep. Gr. 01. Note Separating the plug connections causes faults to be stored.
Tightening torques
Component Spark plugs in cylinder head Ignition terminal to bracket Nm 30 9
15-2 page 8
Edition 09.03 S00.5305.04.20
15
15-3
Repairing valve gear
Removing and installing camshaft

1 - Tappet rod pay attention to correct installation position do not interchange 2 - Hydraulic tappets with hydraulic valve clearance compensation check 15-3 page 3 use auxiliary tool to pull out of cylinder block Fig. 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. 15-1 Removing and installing timing gear cover and sprockets Chap. 13-2 4 - O-ring 5 - Camshaft position sensor -G1636 - 8 Nm 7 - Camshaft with timing segment for camshaft position sensor -arrow Camshaft setting Fig. 2 in 15-3 page 2 8 - Woodruff key check tightness 9 - Retaining plate of camshaft 10 - 5 Nm
3 4 5 6
7 8 10 9
S15-0149
Fig. 1:
Removing hydraulic tappet
Make auxiliary tool (wire) -2- as shown in illustration.

-a- 1.8 to 1.9 mm
Inset shop-made tool -2- in the tappet bore -1-, tilt

slightly and pull tappet out of the guide in the cylinder block.
2 a
S15-0130
Edition 03.01 S00.5305.02.20
15-3 page 1
15
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.
a= 12
3
Removing and installing rocker arms
1 - Rocker arm shaft removing and installing Chap. 15-1 2 - Circlip 3 - Rocker arm bracket, on outside for M11 cylinder head bolt 4 - Spring washer 5 - Rocker arm 6 - Adjusting screw performing basic setting of hydraulic valve clearance compensation Chap. 15-2 7 - Lock nut 13 Nm 8 - Rocker arm bracket for M8 bolt 9 - Rocker arm pay attention to different version Fig. 3 in 15-3 page 3 10 - Rocker arm bracket, on inside for M11 cylinder head bolt 11 - Tensioning ring 12 - Spring
S15-0028
1 9 11 9 9 5 6 7 10 5 8 3 11 12 9 8
S15-0150
8 2
9 3 9 10 8
15-3 page 2
Edition 03.01 S00.5305.02.20
FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Fig. 3: 123ABCArrangement of rocker arms and rocker arm brackets
15
Straight rocker arm Inclined rocker arm, to the left Inclined rocker arm, to the right Rocker arm bracket for M11 bolt, on outside Rocker arm bracket for M8 bolt Rocker arm bracket for M11 bolt, on inside Note
The rocker arms for the inlet valves are shown in dark in the illustration.
B
S15-0132
Inspecting hydraulic tappets

Feeler gauge Wooden or plastic wedge
Note
Always replace hydraulic tappet complete (cannot be
adjusted or repaired).
Irregular valve noises when starting engine are nor-
mal.
Test sequence
Start engine and allow to run until the radiator fan has
cut in once.
Increase engine speed to about 2500 rpm for 2 minutes. If the hydraulic tappets are still loud, determine the faulty tappet as follows:
Remove cylinder head cover. Rotate crankshaft until the valves of cylinder 4 overlap
(inlet valve opens and exhaust valve closes).
Apply a load to the hydraulic tappet by pressing slightly several times on the adjusting screw with a wooden or plastic wedge.
Attempt to insert a 0.2 mm feeler gauge -arrow- between rocker arm and valve. If it is possible to insert a feeler gauge between rocker arm and valve and the tappet at the same time moves down, replace the tappet. If play was measured only between rocker arm and valve (tappet does not move down), carry out basic setting of the hydraulic valve clearance compensation Chap. 152, after the setting, repeat the inspection.
Inspect tappets at the other cylinders by carrying out

the same procedure.
S15-0189
Edition 03.01 S00.5305.02.20
15-3 page 3
15
Inspection Cylinder 1 Cylinder 3 Cylinder 4 Cylinder 2
FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Valve overlap Cylinder 4 Cylinder 2 Cylinder 1 Cylinder 3
Note After installing new hydraulic tappets, the engine must not be started for about 30 minutes. Hydraulic compensation elements must settle (otherwise valves may remain constantly open and strike the piston).
15-3 page 4
Edition 03.01 S00.5305.02.20
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, carefully clean the oil galleries in order to avoid consequential damage.
The oil level must not be above the max. marking - risk
of damage to catalytic converter!

For 1.0 ltr. engine only: longer oil pan bolts on bracket
for coolant pipe, at front item 12 in 17-1 page 2 pay attention to these bolts, do not mix up!
Oil capacity and oil specification: Inspection and Maintenance.
Edition 02.02 S00.5305.03.20
Removing and installing parts of the lubrication system
17-1 page 1
17
1 - Cap fit on during installation work 2 - Gasket replace if damaged on the engine cover 3 - 0.9 bar (0.09 MPa) oil pressure switch - F1-, 45 Nm grey inspecting Chapter 17-3 cut open seal if leaking and replace 4 - 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 - Split pin 6 - Ball for pressure relief valve when installing, knock in slightly with aluminium drift so that the seat of the ball is smoothened 7 - 40 Nm 8 - Pressure spring for pressure relief valve 9 - 8 Nm S17-0081 10 - Intermediate plate clamped onto oil pan support of 1.4 ltr. engine 11 - Oil pan support for 1.4 litre engine only: 12 - Bracket for middle coolant pipe for 1.0 ltr. engine only: 2 bolts M6x22 (different colour and shape); do not mix up with other bolts (M6x20) 13 - 10 Nm 14 - 20 Nm 15 - 45 Nm for 1.4 litre engine only: 16 - Oil drain plug, 30 Nm 17 - Gasket replace 18 - Oil pan removing and installing Chapter 17-2 19 - Gasket for 1.0 litre engine only replace coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing the oil pan with gasket Fig. 3 in 17-1 page 4 20 - 8 Nm
17-1 page 2
Edition 02.02 S00.5305.03.20
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 Fig. 1 in 17-1 page 3 24 - Guide tube removing and installing Fig. 2 in 17-1 page 3 25 - Dipstick oil level must not exceed "max" marking! Inspect engine oil level Inspection and Maintenance
17
Fig. 1:
Oil pump - inspect axial play
Feeler gauge Straightedge
Axial clearance for new part: 0.02 through 0.10 mm wear limit: 0.13 mm Note
If the wear limit is reached, replace timing gear cover
Chapter 13-2
S17-0038
If no axial play is present, install gasket item 22 in
17-1 page 3.
Inspect unrestricted running of the oil pump in assem-
bled state with timing gear cover installed. Fig. 2: Removing and installing dipstick guide tube
Unscrew nut -1- on the exhaust manifold and lift guide

tube -2- up and out.
When installing replace seal -3-. Tighten new self-locking nut -1- to 20 Nm.
2 3
S17-0039
Edition 02.02 S00.5305.03.20
17-1 page 3
17
Fig. 3:
FABIA 2000 1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components Apply sealant for a 1.0 litre engine
Coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing the oil pan with gasket -arrows-.
17-1 page 4
Edition 02.02 S00.5305.03.20
17
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.
Installing
Torque wrench Sealant -AMV 188 520-
Coat the joints between the timing gear cover/cylinderblock with sealant -AMV 188 520- before installing the oil pan with gasket -arrows-.
Lay on the gasket for the oil pan. Tighten securing bolts in the specified order.
Tightening torque: 10 Nm Note The bracket for the front coolant pipe is also attached with bolts -2- and -6- (M6x22). Do not interchange with the other bolts (M6x20).
12 16 19
13 17 18
Removing and installing oil pan - for a 1.4 litre engine

Hand drill with plastic brush attachment Flat scraper Torque wrench Silicone sealant -D 176 404 A2- or - 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. Drain engine oil. Unbolt front coolant pipe (below oil pan) at the 2 fixtures at the cylinder block.
Unbolt oil pan together with oil pan support. Remove oil pan, if necessary release by applying
slight blows with a rubber-headed hammer. Press the coolant pipe slightly towards the outside for this step.
Edition 09.03 S00.5305.04.20 Removing and installing oil pan
17-2 page 1
17
cylinder block.
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).
Clean sealing surfaces, they must be free of oil and

grease.
Installing
Note
Pay attention to the 'use by date' on sealant. The oil pan must be installed immediately after apply-
ing the silicone sealant -047 198 049- (THREE BOND 1215 J) . If -D 176 404 A2- is used installation must be performed within 5 minutes.
The assistance of a second mechanic is required to
N17-0012
install the oil pan. Press the front coolant pipe slightly towards the outside.
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
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.
N17-0019
Apply silicone sealant to the clean sealing surface of

the oil pan, as shown in the illustration. 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-.
There is an opening in the cylinder block -arrow B-
A A B
b a
S17-0040
13 mm, which must be reliably sealed off by an accumulation of sealant -a- = 15 mm; -b- = 4 mm.
17-2 page 2
Edition 09.03 S00.5305.04.20
17
8 4 1 5 9
Engine installed
Fit intermediate plate onto oil pan support. Position oil pan together with oil pan support immediately 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. 2 - Slightly tighten two bolts of oil pan support/gearbox. 3 - Tighten all the bolts of the oil pan/cylinder block slightly in the given sequence. 4 - Tighten two bolts of oil pan support/gearbox to 45 Nm. 5 - Tighten all the bolts of the oil pan/cylinder block to the prescribed torque in the given sequence: M6 = 10 Nm; M8 = 20 Nm.
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 - gearbox, bolt counterholders -T30008- tight to cylinder block (M10) as shown in the illustration. The flat side of the counterholders -T30008- must touch the cylinder block for this step.
S17-0041
Position oil pan together with oil pan support immediately 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. For this step press oil pan support against the counterholders -T30008-. 2 - Tighten all bolts to the prescribed torque in the given sequence: M6 = 10 Nm; M8 = 20 Nm. There must not be any gap between the oil pan support and counterholders -T30008-; if necessary slacken oil pan bolts again and correct position of the oil pan. Note A gearbox housing or a gearbox can also be fitted instead of the counterholders -T30008-. Relevant tightening sequence of the bolts: as described in engine installed.
12 16 19
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.
Edition 09.03 S00.5305.04.20
17-2 page 3
17
Note
After installing the oil pan, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in.
17-2 page 4
Edition 09.03 S00.5305.04.20
17
17-3
Testing Oil Pressure and Oil Pressure Switch
Oil pressure tester (e. g. -V.A.G 1342-) Diode test lamp (e.g. -V.A.G 1527 B-) Adapter cable set (e.g. -V.A.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. The oil pressure warning is activated for about 10 s after the ignition is switched on (terminal 15 on). Activation delay of oil pressure warning: approx. 3 s Off delay of oil pressure warning: approx. 5 s Check warning lamp After the ignition is switched on and engine not running, the oil pressure warning lamp in the dash panel insert must light up for about 3 s and then go out. The check is ended when the engine is started. 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, engine not running, oil pressure switch

closed
Engine speed greater than 1500 rpm, oil pressure

switch open
At an engine speed above 5000 rpm, the oil pressure

warning is not cancelled; not even if the oil pressure switch is closed. Oil pressure switch cancelled below 5000 rpm.
If the oil pressure switch is open for only 0.5...3 s at an

engine speed above 1500 rpm, this is stored in the combination processor of the dash panel insert. If this condition occurs 3 times when the engine is running, the oil pressure warning is immediately activated and is not cancelled below 1500 rpm. 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, or at Ignition off. Test conditions
Engine oil at correct level, inspecting Chap. 17-1 Oil pressure warning lamp (-K3-) must light up for
about 3 s when ignition is switched on.
Engine oil temperature at least 80 C (radiator fan

must have cut in once). Test sequence
Edition 06.00 S00.5305.01.20
17-3 page 1
17
Unplug connector from oil pressure switch. Unscrew oil pressure switch and screw in oil pressure
tester (e.g. -V.A.G 1342-).
V.A.G 1342
Screw oil pressure switch -2- into -V.A.G 1342-. Connect brown cable -1- of tester to earth (-). Connect diode test lamp (e. g. -V.A.G 1527 B-) to oil
pressure switch -2- and battery positive (+). The LED must not light up.
If the LED lights up, replace the oil pressure switch. Start engine and slowly increase engine speed. The LED must light up at 0.075 ... 0.105 MPa overpressure, if not, replace oil pressure switch.
2
A17-0025
Increase engine speed further. At 2000 rpm and an oil

temperature of 80 C the oil pressure should be at least 0.2 MPa.
If the nominal value is not reached:
Inspect axial play of oil pump Chap. 17-1.

At higher engine speeds the oil pressure must not be lower than 0.7 MPa. If necessary, replace oil pump cover together with pressure relief valve.
17-3 page 2
Edition 06.00 S00.5305.01.20
19
19 Cooling
19-1
Note
When the engine is warm the cooling system is under
Parts of cooling system Summary of components
pressure. If necessary reduce pressure before repairs.

The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips.

Always replace seals and gasket rings. When installing fit the coolant hoses free of stress,
without them touching any other components (pay attention to the marking on the coolant connection and hose). Coolant mixing ratios 19-1 page 6
Parts of the cooling system fitted to body

1 - Radiator removing and installing Chapter 19-2 after replacing, fill entire system with fresh coolant 2 - O-ring replace 3 - Top coolant hose attached to radiator with retaining clips Connection diagram for coolant hoses 19-1 page 5 4 - Cover plate check pressure 19-1 page 7 5 - Connector 6 - Double screw, 2 Nm 7 - Air duct scoop 8 - 5 Nm 9 - 5 Nm 10 - Expansion bottle check the coolant system for tightness 19-1 page 7 connection diagram for coolant hoses 19-1 page 5 11 - Retaining clip for fan cable check tightness 12 - Auxiliary fan for vehicles with air conditioning system or additional equipment
3 4 7 8 9
G12
20
19 18
10 11
17
5 12 16 13 9
15 5
14
S19-0074
Edition 02.02 S00.5305.03.20
Parts of cooling system - Summary of components
19-1 page 1
19
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 for fan connector 17 - Thermoswitch for radiator fan -F18-, 35 Nm or for both fans switching temperatures: 1. Stage on: 91 through 97 C off: 84 through 91 C 2. Stage on: 99 through 105 C off: 91 through 98 C 18 - Bottom radiator bearing black 19 - 5 Nm 20 - Top radiator bearing white
19-1 page 2
Edition 02.02 S00.5305.03.20
19
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. 88 C Opening end: approx. 103 C 4 - O-ring replace 5 - Sender for the coolant temperature -G626 - Retaining clip 7 - 20 Nm 8 - To heat exchanger
5 4 6
7 8 1 7
S19-0115
Edition 02.02 S00.5305.03.20
19-1 page 3
19
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 self-locking, replace 4 - Belt pulley for the V-ribbed belt 5 - 10 Nm 6 - V-ribbed belt before removing mark running direction do not kink check for wear removing and installing Chapter 13-1 7 - 20 Nm 8 - Coolant hose insert up to stop on coolant pump/front coolant pipe 9 - Front coolant pipe 10 - 20 Nm 11 - to connection fitting for heat exchanger 12 - to bottom radiator 13 - to bottom expansion reservoir
7 13 10 12 11 10
S19-0085
19-1 page 4
Edition 02.02 S00.5305.03.20
19
Connection diagram for coolant hoses

1 - Radiator after replacing, fill entire system with fresh coolant removing and installing Chapter 19-2 2 - Front coolant pipe 3 - Cylinder block 4 - Coolant pump removing and installing Chapter 19-2 check smooth operation 5 - Expansion bottle 6 - Coolant pipe for ventilation line 7 - Heat exchanger 8 - Connection fittings for heat exchanger 9 - Coolant hose with heat protection 10 - coolant regulator housing with coolant regulator removing and installing 19-1 page 3 11 - Quick coupling for radiator connections Replace gasket rings, moisten with coolant additives
7 8
4 3 10
2 11
S19-0087
Draining and filling up coolant

Coolant capacity approx. 5.6 ltr. Special tools, test and measuring equipment and auxiliary items required
Catch pan (e.g. -V.A.G 1306-) antifreeze tester
Draining
Caution! Hot steam may escape when the expansion reservoir is opened. Cover the cap with a cloth and open carefully.
Open the coolant cap. Remove noise insulation -arrows-.

Edition 02.02 S00.5305.03.20 Parts of cooling system - Summary of components
S10-0135
19-1 page 5
19
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.
Filling up
Select the appropriate coolant additive from the original spare parts catalogue KODA or from the list of allowed coolant additives Inspection and Maintenance; Rep. Gr. 02 Recommended mixture ratios: Antifreeze pro- Antifreeze contection down to centration1)2) -25 C -35 C
1)
A10-0118
Drinking water2) 50 % (2.8 ltr.)
40 % (2.25 litres) 60 % (3.35 litres) 50 % (2.8 ltr.)
2)
The antifreeze concentration must not exceed 60 %; the antifreeze protection and cooling efficiency are reduced as the concentration increases. The coolant amount may differ according to the version of the vehicle.
Insert and tighten the coolant drain plug. Pull out retaining clip -2- and remove sender for coolant temperature -1- from the coolant regulator housing.
S19-0086
Fill with coolant gradually up to max marking on the

expansion bottle.
Install sender for coolant temperature. Close expansion bottle. Run engine until the fan on the radiator starts.
2 G1
Check the level of coolant and top up if necessary. If

the engine is warm the coolant level must be on the max. mark. If the engine is cold the coolant level must between the min and the max. mark.
S19-0077
19-1 page 6
Edition 02.02 S00.5305.03.20
19
Checking the coolant system for tightness

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
Engine must be warm

Test sequence
Open the cap of the coolant expansion reservoir. Position coolant system tester (e. g. -V.A.G 1274-)
with adapter (e. g. - V.A.G 1274/8-) on the coolant expansion bottle.
V.A.G 1274
With the hand pump of the tester generate an overpressure of approx. 0.1 MPa.
If the pressure drops determine location of the leaks

and repair them.
Testing the pressure relief valve in the cap
V.A.G 1274/8
G12
Screw cap onto tester with adapter (e.g. -V.A.G 1274/

9-).
With the hand pump of the tester generate an overpressure of approx. 0.15 MPa.
S19-0082
The pressure relief valve must open for an overpressure of 0.12 to 0.15 MPa.
Edition 02.02 S00.5305.03.20
19-1 page 7
19
19-1 page 8
Edition 02.02 S00.5305.03.20
19
19-2
Removing and Installing Radiator, Coolant Pump
Removing and installing radiator

Catch pan (e.g. -V.A.G 1306-) Torque wrench 5...50 Nm (e.g. -V.A.G 1331-)
Removing
1 2
Drain coolant Chap. 19-1. Remove connector -1- from thermo-switch -F18- and
separate plug connection -2- on the holder of the air duct scoop. To do so press the latch clips. There are 2 plug connections on vehicles fitted with air conditioning.
Separate the coolant hose from the radiator at the top

and bottom of the connection fittings. To do so pull the retaining clip -3- up to the stop and remove the quick coupling towards the rear.
S19-0078
Vehicles without air conditioning
Removing front bumper Body Work; Rep. Gr. 63. Unscrew bolts for radiator bearing -arrows-.
Torque: 5 Nm
Pull radiator with fan backwards and remove downwards.

Caution! Do not open the refrigerant circuit of the air conditioning system.
S19-0080
Unscrew bolts for radiator bearing -arrows-.

Torque: 5 Nm
Removing the lock carrier with component parts

Body Work; Rep. Gr. 50. Attach the condenser with the radiator to the engine or support. Note
Do not suspend the condenser to the wires. Do not fold the condenser wires.
S19-0083
Edition 06.00 S00.5305.01.20
19-2 page 1
19
and remove radiator with fan. Torque: 5 Nm
Release the bolts securing the condenser -arrows-
Installing
The installation occurs in reverse order. Pay attention to the following:
Top up coolant Chap. 19-1. Re-adjust headlights on vehicles fitted with air conditioning.
Removing and installing coolant pump

Lifting device -MP 9-200 Catch pan (e.g. -V.A.G 1306-) Torque wrench 5...50 Nm (e.g. -V.A.G 1331-) Torque wrench 40...200 Nm (e.g. -V.A.G 1332-)
S19-0081
3 4 4
6 5
Removing
Drain coolant Chap. 19-1. Removing engine cover Chap. 10-1

S10-0138
Mount lifting device -MP 9-200- and take up the

weight of the engine/gearbox unit at the spindles.
19-2 page 2
Edition 06.00 S00.5305.01.20
19
2
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.
Removing the ribbed V-belt Chap. 13-1. Unscrew front coolant pipe from front and rear cylinder block.
Release clamp from coolant pump and disconnect

coolant hose.
Remove belt pulley from the coolant pump. Unscrew coolant pump.
Installing
Installation occurs in reverse order to removal. Pay attention to the following:
3
S10-0140
Replace seal for coolant pump. First install ribbed V-belt Chap. 13-1, then tighten
the belt pulley bolts of the coolant pump. Torque: 10 Nm
Tightening torques of the engine mounting Chap.

10-1.
Top up coolant Chap. 19-1.
Edition 06.00 S00.5305.01.20
19-2 page 3
19
19-2 page 4
Edition 06.00 S00.5305.01.20
20
20 Fuel Supply
20-1
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
Removing and Installing Parts of the Fuel Supply System
is not allowed. Observe safety measures 20-1 page 3. Observe rules for cleanliness 20-1 page 3. Repairing parts of the activated charcoal filter system Chap. 20-2. 1 - Fuel tank support with engine/gearbox 15 jack -V.A.G 1383 A- when removing 14 2 - 25 Nm 3 - 25 Nm 13 4 - Tensioning strap 5 - Vent line to solenoid valve 1 for activated charcoal filter in engine 12 compartment 6 - Feed line 11 black to fuel rail (at intake mani10 fold) 9 7 - Fuel filter 8 with integrated fuel pressure regulator line connections: 7 feed (black): in middle return flow (blue): on outside 8 - 3 Nm screw for collar clamp for fuel filter 9 - Fuel level sender 10 - Fuel delivery unit clean strainer if dirty pay attention to installation position of flange of fuel delivery unit Fig. 1 in 20-1 page 2 11 - Return-flow line between fuel delivery unit and fuel filter blue 12 - Feed line between fuel delivery unit and fuel filter black 13 - Gasket ring moisten with fuel before installing
16 17 18 19 20 21 22 23
2 1 2
5 4 3
S20-0084
Edition 06.00 S00.5305.01.20
20-1 page 1
20
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 Fig. 2 in 20-1 page 2 16 - End cover 17 - 1.5 Nm 18 - Fuel filler flap unit with rubber bowl 19 - Gravity valve to remove, unclip valve at top and lift out of filler neck. inspect valve for blockage: valve vertical: open valve tilted 45: closed 20 - Vent line between activated charcoal filter item 21 in 20-1 page 2 and vent line item 5 in 20-1 page 1 21 - Activated charcoal filter 22 - 10 Nm 23 - Vent line clipped in place on fuel tank
Fig. 1:
Installation position of flange of fuel delivery unit
Marking on the flange must be aligned with marking on the fuel tank -arrows-. Blue return-flow line -1- to connection marked -R-. Black feed line -2- to connection marked -V-. Note After installing the flange of the fuel delivery unit, check whether the feed, return-flow and vent lines are still clipped in place on the fuel tank.
1
A20-0096
Fig. 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.
V20-1040
20-1 page 2
Edition 06.00 S00.5305.01.20
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. Reduce pressure by carefully removing the hose. 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, must be positioned close to the assembly opening of the fuel tank in order to extract the released fuel gases, even before the work is commenced. If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a delivery volume of more than 15 m3/h must be used.
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.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts: Remove spare parts from
their wrapping immediately before fitting. Do not use parts which have been stored unwrapped (e.g. in tool boxes and the like).
When the system is open: Avoid using compressed
air. Avoid moving the vehicle.
Edition 06.00 S00.5305.01.20
20-1 page 3
20
20-1 page 4
Edition 06.00 S00.5305.01.20
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. Collar clamps must always be replaced with spring strap clamps.
Observe the safety precautions Chap. 20-1. Observe the rules for cleanliness Chap. 20-1. 1 - Vent line from solenoid valve 1 -N80(in engine compartment) 2 - 10 Nm 3 - Throttle valve control unit 4 - Solenoid valve 1 -N80 in right of engine compartment valve is actuated (pulsed) by engine control unit when engine is warm testing 1.0/37; 1.4/44 Engine, Fuel Injection; Rep. Gr. 01; Final Control 5 - Connector black, 2 pin for solenoid valve 1 -N806 - Activated charcoal filter Fitting location: in rear right wheelhouse attached to body 7 - Vent line from gravity valve to fuel tank
2 3
5 4
S20-0088
Edition 06.00 S00.5305.01.20
20-2 page 1
20
20-2 page 2
Edition 06.00 S00.5305.01.20
26
26 Exhaust System
26-1
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
Removing and installing parts of the exhaust system
1 - Gasket replace 2 - Gasket replace fitting position: notch faces down 3 - 25 Nm coat with hot screw paste G 052 112 A3 before inserting 4 - Exhaust manifold to remove take off intake manifold 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24. 5 - 20 Nm replace 6 - Hot air collector/shield 7 - Guide tube for the oil dipstick 8 - Retaining strap made of silicone press off from cross member item 9 to remove front exhaust pipe with catalytic converter 9 - Cross member 10 - 25 Nm 11 - 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 - Lambda probe downstream of catalytic converter -G130-, 50 Nm. only on engines complying with D4-/EU4 exhaust-emission standard only coat thread with hot screw paste G 052 112 A3; 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; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01 test lambda control and lambda probe heater 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24 13 - 25 Nm replace 14 - Hanger retaining strap made of EPDM
Edition 02.02 S00.5305.03.20 Removing and installing parts of the exhaust system
26-1 page 1
26
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 pay attention to the spare part number 18 - 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 - Front exhaust pipe with catalytic converter only on engines complying with D4-/EU4 exhaust-emission standard with 2 catalytic converters 20 - Lambda probe 1 downstream of catalytic converter -G39-, 50 Nm only coat thread with hot screw paste G 052 112 A3; 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; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 01 test lambda control and lambda probe heater 1.0/37; 1.4/44; 1.4/50 engine - fuel injection; Rep. Gr. 24 21 - Front exhaust pipe with catalytic converter only on engines complying with EU2 exhaust-emission standard 22 - 40 Nm replace coat stud bolts with hot bolt paste G 052 112 A3
Aligning exhaust system free of stress

Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-)
Procedure
The exhaust system is aligned when cold. Slacken bolted connections of double clamp between
catalytic converter and front silencer and replace nuts.
Position double clamp at the distance -a- = 5 mm from

the marking on the pipe of the catalytic converter (bolts at bottom and horizontal) and tighten front bolted connection slightly.
S26-0064
26-1 page 2
Edition 02.02 S00.5305.03.20
26
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 hanger and the front silencer. -Arrow- points in direction of travel.
Tighten bolted connections on the double clamp in

this position. Tightening torque: 25 Nm Note After tightening the double clamp, inspect dimension -band adjust if necessary.
b
S26-0065
Replacing front or rear silencer

Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-) Body saw (e.g. -V.A.G 1523 -)
A separation point is provided for repair purposes for replacing the front silencer or rear silencer.
Separate exhaust pipe at right angles at the separation point -arrow 1- with body saw.
When installing double clamp -4- position on the side

markings -arrows 2 and 3-.
Align exhaust system free of stress 26-1 page 2. Align rear silencer horizontally. Tighten bolted connections of the double clamp evenly to 25 Nm. Installation position of double clamp: bolts positioned vertically at front of exhaust pipe.
3 2 1
Checking the exhaust system for leaks

Start engine and run in idle. Seal off tail pipe for the duration of the leak check (e.g.
with cloth or plug).
S26-0063
Check the connection points for leaks by listening:

Cylinderhead/exhaust manifold, exhaust manifold/exhaust pipe with catalytic converter, etc.
Eliminate any leak found.
Edition 02.02 S00.5305.03.20
26-1 page 3
26
26-1 page 4
Edition 02.02 S00.5305.03.20

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Service

1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components

Service Department. Technical Information

Printed in Czech Republic S00.5305.00.20

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

Edition 08.99 06.00 03.01 02.02 09.03

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

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

Edition 09.03 S00.5305.04.20

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

10 Removing and Installing Engine

15 Cylinder Head, Valve Gear

Edition 09.03 S00.5305.04.20

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

Edition 09.03 S00.5305.04.20

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

At least 91 RON in exceptional cases; the engine output is reduced however

Edition 09.03 S00.5305.04.20

At least 91 RON in exceptional cases; the engine output is reduced however

Edition 09.03 S00.5305.04.20

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

10 Removing and Installing Engine

spring-type clips. The use of clamp-type or screw-type clips is not allowed.

tors, if necessary mark.

On models fitted with a coded radio set, pay attention

Raise drive shafts and secure.

Edition 02.02 S00.5305.03.20

Removing and Installing Engine

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

Turn the drain plug -arrow- on the radiator to the left

Remove engine cover -1- as follows:

screw cap -5-).

Remove the air filter with hoses 1.0/37; 1.4/44; 1.4/

Remove the cable from the starter solenoid switch

Remove battery and battery tray Electrical System;

Release the generator cables from the battery cover

Removing and Installing Engine

Edition 02.02 S00.5305.03.20

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

Remove coolant hoses -1- and -2- from the coolant

Remove the vacuum connection from the brake servo

Remove coolant hoses -1- and -2- from the expansion

Release vacuum hose -3- from the solenoid valve

Release nut -arrow A- and tie up holder -1-.

Edition 02.02 S00.5305.03.20

Removing and Installing Engine

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

Disconnect the Bowden cable support from gearbox

Detach selector cable -A-, for this step remove circlip

Remove -arrow B- the slave cylinder -2- and lay aside,

Removing and Installing Engine

Edition 02.02 S00.5305.03.20

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

Disconnect plug -2- from the reversing light switch

Separate plug connection -3-.

Remove coolant hose from the rear coolant pipe -arrow-.

Remove connector -1- from thermo-switch -F18- and

Separate the coolant hose from the radiator at the top

Edition 02.02 S00.5305.03.20

Removing and Installing Engine