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Service

5

Workshop Manual

FABIA 2000

1.9/96 TDI Engine, Mechanics Edition 07.03 Engine code ASZ
1.9/96 TDI Engine, Mechanics
Edition 07.03
Engine code
ASZ

5

Service

The Workshop Manual is intended only for use within the Organisation Škoda. It is not permitted to pass it on to other persons.

Printed in Czech Republic

S00.5327.00.20

© ŠKODA AUTO a. s.

FABIA 2000 1.9/96 TDI Engine, Mechanics

List of Supplements to Workshop Manual

FABIA 2000

1.9/96 TDI Engine, Mechanics

Edition 07.03

Supple-

ment

Edition

Subject

Article Number

07.03

Basic Edition

S00.5327.00.20

FABIA 2000 1.9/96 TDI Engine, Mechanics

FABIA 2000 1.9/96 TDI Engine, Mechanics

Table of Contents

00

– Technical Data

Technical Data

00-1

page

1

10

– Removing and Installing Engine

Removing and Installing Engine

10-1

page

1

13

– Crankgear

Removing and installing V-ribbed belt

13-1

page

1

Removing and installing, tightening the timing belt

13-2

page

1

Removing and installing sealing flange and flywheel

13-3

page

1

Crankshaft, Piston and Conrod

13-4

page

1

15

– Cylinder Head, Valve Gear

Removing and installing cylinder head

15-1

page

1

Repairing Valve Gear

15-2

page

1

Camshaft

15-3

page

1

Valve seats, valves guides, valve stem seals

15-4

page

1

17

– Lubrication

Removing and installing parts of the lubrication system

17-1

page

1

-

Disassembling and assembling oil filter holder

17-1

page

2

Removing and installing oil pan

17-2

page

1

Testing oil pressure and oil pressure switch

17-3

page

1

19

– Cooling

Parts of cooling system - Summary of components

19-1

page

1

Removing and installing radiator, coolant pump and coolant thermostat

19-2

page

1

20

– Fuel Supply

Removing and installing parts of the fuel supply system

20-1

page

1

Repairing the accelerator control

20-2

page

1

21

– Turbocharging

Charge air system with turbocharger I

21-1

page

1

- Removing and installing exhaust turbocharger with component parts

21-1

page

1

- Removing and installing parts of the charge air cooling

21-1

page

2

- Connection diagram for vacuum hoses

21-1

page

2

Charge air system with turbocharger II

21-2

page

1

- Remove exhaust turbocharger

21-2

page

1

- Checking charge pressure control

21-2

page

1

26

– Exhaust System

Removing and installing parts of the exhaust system

26-1

page

1

- Aligning exhaust system free of stress

26-1

page

2

- Procedure

26-1

page

2

- Replacing middle or rear silencer

26-1

page

2

- Checking the exhaust system for leaks

26-1

page

3

Exhaust gas recirculation system

26-2

page

1

Edition 07.03

Table of Contents

I

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FABIA 2000 1.9/96 TDI Engine, Mechanics

- Testing mechanical exhaust gas recirculation valve

26-2

page

2

II

Table of Contents

Edition 07.03

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FABIA 2000 1.9/96 TDI Engine, Mechanics

00

00 – Technical Data

00-1

Technical Data

Engine number

The engine number („engine identification characters“ and „serial number“) is located at the engine/gearbox joint -arrow-.

In addition, a sticker with the „engine identification char- acters“ and „serial number“ is affixed to the timing belt guard.

The engine identification characters are also indicated on the vehicle data sticker.

Engine characteristics

on the vehicle data sticker. Engine characteristics Engine identification characters ASZ Manufactured

Engine identification characters

ASZ

Manufactured

06.03

Exhaust limits conforming to

EU-3

Displacement

l

1,896

Power output

kW at rpm

96/4000

Torque

Nm at rpm

310/1900

Bore

mm

79,5

Stroke

mm

95,5

Compression

19,0 : 1

Firing order

1-3-4-2

min. CN

49

Catalytic converter

yes

Exhaust gas recirculation

yes

Turbocharging

yes

Charge air cooler

yes

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Technical Data

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00

FABIA 2000 1.9/96 TDI Engine, Mechanics

00-1 page 2

Technical Data

Edition 07.03

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FABIA 2000 1.9/96 TDI Engine, Mechanics

10

10 – Removing and Installing Engine

10-1

Removing and Installing Engine

1.9/74 TDI Engine, Mechanics; Rep. Gr. 10

Gearbox 0A8; Rep. Gr. 30 und 34

Mechanics; Rep. Gr. 10 ⇒ Gearbox 0A8; Rep. Gr. 30 und 34 Note The removing of

Note

The removing of the 1.9/96 TDI Engine can differ in cer- tain details from the removing of the 1.9/74 TDI Engine.

Edition 07.03

Removing and Installing Engine

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10-1 page 1

10

FABIA 2000 1.9/96 TDI Engine, Mechanics

10-1 page 2

Removing and Installing Engine

Edition 07.03

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FABIA 2000 1.9/96 TDI Engine, Mechanics

13

13 – Crankgear

13-1

Removing and installing V-ribbed belt

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

Edition 07.03

Removing and installing V-ribbed belt

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13-1 page 1

13

FABIA 2000 1.9/96 TDI Engine, Mechanics

13-1 page 2

Removing and installing V-ribbed belt

Edition 07.03

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FABIA 2000 1.9/96 TDI Engine, Mechanics

13

13-2

Removing and installing, tightening the timing belt

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

Edition 07.03

Removing and installing, tightening the timing belt

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13-2 page 1

13

FABIA 2000 1.9/96 TDI Engine, Mechanics

13-2 page 2

Removing and installing, tightening the timing belt

Edition 07.03

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13

13-3

Removing and installing sealing flange and fly- wheel

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

Edition 07.03

Removing and installing sealing flange and flywheel

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13-3 page 1

13

FABIA 2000 1.9/96 TDI Engine, Mechanics

13-3 page 2

Removing and installing sealing flange and flywheel

Edition 07.03

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13

13-4

Crankshaft, Piston and Conrod

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

Edition 07.03

Crankshaft, Piston and Conrod

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13-4 page 1

13

FABIA 2000 1.9/96 TDI Engine, Mechanics

13-4 page 2

Crankshaft, Piston and Conrod

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FABIA 2000 1.9/96 TDI Engine, Mechanics

15

15 – Cylinder Head, Valve Gear

15-1

Removing and installing cylinder head

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

Edition 07.03

Removing and installing cylinder head

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15-1 page 1

15

FABIA 2000 1.9/96 TDI Engine, Mechanics

15-1 page 2

Removing and installing cylinder head

Edition 07.03

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15

15-2

Repairing Valve Gear

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

Edition 07.03

Repairing Valve Gear

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15-2 page 1

15

FABIA 2000 1.9/96 TDI Engine, Mechanics

15-2 page 2

Repairing Valve Gear

Edition 07.03

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15

15-3

Camshaft

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

Edition 07.03

Camshaft

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15

FABIA 2000 1.9/96 TDI Engine, Mechanics

15-3 page 2

Camshaft

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15

15-4

Valve seats, valves guides, valve stem seals

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

Edition 07.03

Valve seats, valves guides, valve stem seals

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15-4 page 1

15

FABIA 2000 1.9/96 TDI Engine, Mechanics

15-4 page 2

Valve seats, valves guides, valve stem seals

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17

17 – Lubrication

17-1

Note

Removing and installing parts of the lubrication system

If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs, carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.

Testing oil pressure and oil pressure switch Chapter 17-3.

The oil level must never exceed the „max“ marking - risk of damage to catalytic converter!

Check the oil level, amount of oil and oil specification:

Inspection and Maintenance

1

-

15 Nm

2

- Bracket For cable to oil level and oil temperature sender

3

- Dipstick Oil level must not exceed „max“ marking!

4

- Filler funnel Remove for extracting oil

5

- Guide tube

6

- Fitting sleeve For centering oil pump/cylin- der block

7

- O-ring Replace

8

- Suction line Clean strainer if dirty

9

- Baffle

 

10

- Oil pan Before installing, coat with silicone sealant -D 176 404 A2- Chapter

 

17-2

11

- Gasket ring Replace

12

- Oil drain plug, 30 Nm

13

-

10 Nm

14

- Oil level and oil temperature sender -G266- Test Electrical System; Rep. Gr. 90

15

- Oil pump

 

With pressure relief valve 1.2 MPa

Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present If there is any scoring on contact surfaces and gears, replace

16

- Oil pump sprocket Fits onto oil pump shaft in one position only

17

-

25 Nm

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Removing and installing parts of the lubrication system

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17

FABIA 2000 1.9/96 TDI Engine, Mechanics

18 - Sealing flange

Before installing, it must not be dirty

Before installing, coat with silicone sealant -D 176 404 A2- Chapter 13-3

Replacing crankshaft seal Chapter 13-3

19 - Oil pump chain

20 - Chain tensioner, 15 Nm When installing, pretension spring and attach

21 - Oil injection nozzle For piston cooling

22 -

27 Nm

Pay attention to SP No. (right-angle bend)

Disassembling and assembling oil filter holder

1

2

3

4

5

- Cap, 25 Nm - Gasket Replace

- Oil cooler When installing, move up against the anti-twist lock (in direction of tightening)

- Gasket Replace Insert into lugs on oil cooler

- Oil pressure switch -F1-, 20 Nm Brown

0.07 MPa (0.7 bar)

Cut open gasket ring if leak-

ing and replace Inspect Chapter 17-3

6

7

- Oil filter holder With integrated overpressure valve

- 15 Nm + torque a further 1 / 4 turn (90°) Replace Before tightening, turn in by hand first

8 - Gasket ring Replace

9

- Connection fitting, 30 Nm

10 - Oil feed line

For exhaust turbocharger

Tighten to 22 Nm

Oil feed line For exhaust turbocharger Tighten to 22 Nm 11 - O-ring Replace 12 -

11 - O-ring Replace

12

- Oil filter element When changing oil, fit new O-rings item 11

17-1 page 2

Removing and installing parts of the lubrication system

Edition 07.03

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FABIA 2000 1.9/96 TDI Engine, Mechanics

17

17-2

Removing and installing oil pan

1.9/74 TDI Engine, Mechanics; Rep. Gr. 17

Edition 07.03

Removing and installing oil pan

S00.5327.00.20

17-2 page 1

17

FABIA 2000 1.9/96 TDI Engine, Mechanics

17-2 page 2

Removing and installing oil pan

Edition 07.03

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17

17-3

Testing oil pressure and oil pressure switch

1.9/74 TDI Engine, Mechanics; Rep. Gr. 17

Edition 07.03

Testing oil pressure and oil pressure switch

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17-3 page 1

17

FABIA 2000 1.9/96 TDI Engine, Mechanics

17-3 page 2

Testing oil pressure and oil pressure switch

Edition 07.03

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FABIA 2000 1.9/96 TDI Engine, Mechanics

19

19 – Cooling

19-1

Parts of cooling system - Summary of components

1.9/74 TDI Engine, Mechanics; Rep. Gr. 19

Edition 07.03

Parts of cooling system - Summary of components

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19

FABIA 2000 1.9/96 TDI Engine, Mechanics

19-1 page 2

Parts of cooling system - Summary of components

Edition 07.03

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19

19-2

Removing and installing radiator, coolant pump and coolant thermostat

1.9/74 TDI Engine, Mechanics; Rep. Gr. 19

Edition 07.03

Removing and installing radiator, coolant pump and coolant

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thermostat

19-2 page 1

19

FABIA 2000 1.9/96 TDI Engine, Mechanics

19-2 page 2

Removing and installing radiator, coolant pump and coolant

Edition 07.03

thermostat

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FABIA 2000 1.9/96 TDI Engine, Mechanics

20

20 – Fuel Supply

20-1

Removing and installing parts of the fuel supply system

1.9/74 TDI Engine, Mechanics; Rep. Gr. 20

Edition 07.03

Removing and installing parts of the fuel supply system

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20-1 page 1

20

FABIA 2000 1.9/96 TDI Engine, Mechanics

20-1 page 2

Removing and installing parts of the fuel supply system

Edition 07.03

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20

20-2

Repairing the accelerator control

1.9/74 TDI Engine, Mechanics; Rep. Gr. 20

Edition 07.03

Repairing the accelerator control

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20-2 page 1

20

FABIA 2000 1.9/96 TDI Engine, Mechanics

20-2 page 2

Repairing the accelerator control

Edition 07.03

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21

21 – Turbocharging

21-1

Charge air system with turbocharger I

Removing and installing exhaust turbocharger with component parts

Pay attention to rules for cleanliness 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21.

Note ♦ The hose connections are secured with clamps. ♦ The charge-air system must be
Note
♦ The hose connections are secured with clamps.
♦ The charge-air system must be tight.
♦ Always replace self-locking nuts.
1
- Oil feed line
2
-
22 Nm
3
- Sealing sleeve
4
-
5 Nm
5
-
10 Nm
6
- Connection fitting, 30 Nm
7
- Gasket ring
Replace
8
- Gasket
Replace
Check fitting position
9
- Support
Exhaust turbocharger - cylin-
der block
10
- Washer
11
-
25 Nm
Replace
Coat stud bolts with
-G 052 112 A3-
12
-
40 Nm
13
- Connecting tube
Between turbocharger and
air filter
14
- Flange
15
- Connecting hose
16
- Connection fitting, 40 Nm
17
- Oil return line
To cylinder block
Tighten to 30 Nm
18
-
15 Nm

19 - Gasket Replace

20 - Exhaust turbocharger Can only be replaced complete with exhaust manifold

Removing and installing Chapter 21-2

Inspecting charge pressure control Chapter 21-2

Charge pressure regulating valve and vacuum unit for charge pressure regulating valve are component parts of the exhaust turbocharger and cannot be replaced individually

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Charge air system with turbocharger I

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21

FABIA 2000 1.9/96 TDI Engine, Mechanics

After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharger

21 - Vacuum line To the solenoid valve for charge pressure limitation -N75-

22

23 -

-

20 Nm

20 Nm

Replace

24 - Shield

25 - Front exhaust pipe with catalytic converter

26 - Bracket

27 - Intake manifold

28 -

6 Nm

Removing and installing parts of the charge air cooling

1.9/74 TDI Engine, Mechanics; Rep. Gr. 21

Connection diagram for vacuum hoses

1

- Valve block Component parts of the valve block are:

Changeover valve for intake manifold flap -N239-

Solenoid valve for exhaust gas recir culation -N18-

Solenoid valve for charge pressure control -N75-

2

- Connecting strip Pay attention to the coding when connecting the vacu- um hoses

3

- Connecting piece

4

- Vacuum unit

For charge pressure control

Components of the exhaust

 

gas turbocharger cannot be replaced individually

5

- Vacuum unit

6

- To air filter

7

- Vacuum unit For intake manifold flap

8

- Mechanical exhaust gas recir- culation valve

9

- Tandem pump

10

- Distributor part With non-return valve for brake servo unit

11

- Brake servo unit

1 2 3 4 5 11 6 10 9 8 7
1
2
3
4
5
11
6
10
9
8
7

21-1 page 2

Charge air system with turbocharger I

Edition 07.03

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21

21-2

Charge air system with turbocharger II

Remove exhaust turbocharger

1.9/74 TDI Engine, Mechanics; Rep. Gr. 21

Checking charge pressure control

Special tools, test and measuring equipment and auxiliary items required

Hand vacuum pump (e.g. -V.A.G 1390-)

Hand multimeter (e.g. -V.A.G 1715-)

Vehicle system tester -V.A.G 1552-

Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3C-

Adapter cable set (e.g. -V.A.G 1594 C-)

Test box -V.A.G 1598/31-

Test conditions

No fault stored in fault memory 1.9/96 TDI Engine, Fuel Injection; Rep. Gr. 01

No leaks on the intake and exhaust side

No fault on the engine/fuel injection system

Engine oil temperature at least 80 °C

Test sequence

If test and measuring devices are required during test drives observe the following:

Always secure the test and measuring devices on the rear seat and have a second person operate them there.

If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an ac- cident which involves the front passenger airbag be- ing deployed.

The charge pressure is measured with vehicle system tester -V.A.G 1552- when the engine is idling and dur- ing a road test.

Connect up the Vehicle system tester -V.A.G 1552- and select the address word 01 „Engine electronics“ (the engine must be idling at the time) 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.

– Select function 0 4 play group 0 1 1 . Readout on display:
– Select function
0
4
play group
0
1
1
.
Readout on display:

„Initiate basic setting“ and dis-

. Readout on display: „Initiate basic setting“ and dis- Basic setting 11   -> 1400 rpm

Basic setting 11

 

->

1400 rpm

OFF

982 mbar

99 %

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Charge air system with turbocharger II

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21

FABIA 2000 1.9/96 TDI Engine, Mechanics

21 FABIA 2000 1.9/96 TDI Engine, Mechanics Note After selecting display group number 011, the idling

Note

After selecting display group number 011, the idling speed is increased by the engine control unit in display block 1 to 1380…1420 rpm.

The display in display field 2 must switch between „off“ and „on“ every 10 seconds.

The following readouts must fluctuate in display fields 3 and 4:

Display field 2: off.

Specification in display field 3: Atmospheric pressure in mbar

Specification in display field 4: 98…100%

Display field 2: on.

Specification in display field 3: Atmospheric pressure in mbar + 100…250 mbar

Specification in display field 4: 0…2%

Continue the test as follows:

Press → . – Read function 0 8
Press
.
– Read function
0
8

„Read measured value block“

and select display group

0 1 1 .
0
1
1
.

Accelerate vehicle in 2nd gear from about 1000 rpm to 3200 rpm. While doing so the accelerator pedal must be fully pressed down.

At about 3000 rpm read off value indicated in display block.

Specification in display field 3: 2100…2600 mbar

If the specified value is not reached:

Conduct final control diagnosis for charge pressure control solenoid valve -N75- 1.9ltr./96 (TDI) En- gine, Fuel Injection; Rep. Gr. 01.

Charge pressure control solenoid valve must operate for this test. While doing so the linkage of the charge pres- sure control vacuum unit at the bottom of the turbocharg- er must move back and forward. This linkage must move at least 3…4 times as long as a vacuum is present in the vacuum system.

If the linkage moves and the nominal charge pressure is not reached:

Replace turbocharger.

If the linkage does not move because the charge pres- sure control solenoid valve is not operating:

Inspect charge pressure control solenoid valve -N75- 1.9/96 (TDI) Engine, Mechanics; Rep. Gr. 23.

Inspect vacuum hoses Chapter 21-1 .

If the linkage does not move although the charge pres- sure control solenoid valve is operating:

the charge pres- sure control solenoid valve is operating: Reading measured value block 11 3090 rpm

Reading measured value block 11

3090 rpm

2281 mbar

2346 mbar

->

6

21-2 page 2

Charge air system with turbocharger II

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21

Connect hand vacuum pump to vaccum unit for charge pressure control valve and inspect linkage for unobstructed movement.

If the linkage only moves with difficulty or does not move at all:

Replace turbocharger.

or does not move at all: – Replace turbocharger. V.A.G 1390 N21-0078 Edition 07.03 Charge air
V.A.G 1390 N21-0078
V.A.G 1390
N21-0078

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Charge air system with turbocharger II

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FABIA 2000 1.9/96 TDI Engine, Mechanics

21-2 page 4

Charge air system with turbocharger II

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26

26 – Exhaust System

26-1

Note

Removing and installing parts of the exhaust sys- tem

The exhaust manifold is a component part of the ex- haust turbocharger and therefore must not be re- placed individually; removing and installing Chap.

21-2.

Always replace gaskets and self-locking nuts.

After performing installation work on the exhaust sys- tem, make sure the exhaust system is not mounted under tension, the individual components have ade- quate clearance from the vehicle body and the weight of the exhaust system is evenly distributed over the hangers.

1

- Gasket

 
 

Replace

2

- Front exhaust pipe with cata- lytic converter

3

-

25 Nm Replace Coat stud bolts of exhaust turbocharger with hot bolt paste -G 052 112 A3- be- fore installing.

4

- Retaining loop Press off from cross member

 

item 5 to remove front ex-

haust pipe with catalytic con- verter

5

- Cross member

6

-

25 Nm

 

7

- Double clamp

 

Align exhaust system free of stress before tightening

 

26-1 page 2

 

Fitting position: bolts at bot-

tom and horizontal Tighten bolted connections evenly

8

-

40 Nm

 
 

Replace

9

- Spring hanger Pay attention to part number

10

- Separation point For repairs 26-1 page 2

11

- Middle and rear silencer

Replace individually when carrying out repairs 26-1 page 2

Align exhaust system free of stress 26-1 page 2

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Removing and installing parts of the exhaust system

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FABIA 2000 1.9/96 TDI Engine, Mechanics

Aligning exhaust system free of stress

Special tools, test and measuring equipment and auxiliary items required

Torque wrench

Procedure

The exhaust system is aligned when cold.

Slacken bolted connections of double clamp between front silencer with catalytic converter and middle and rear 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 bolt- ed connection slightly.

Push middle silencer -1- sufficiently far forward into

– Push middle silencer -1- sufficiently far forward into

the double clamp until the dimension -b- of 3

7

mm is

achieved between hanger of body and hanger of mid- dle silencer.

 

-Arrow- points in direction of travel.

 

Tighten bolted connections on the double clamp in this position.

 

Tightening torque: 40 Nm

 
Note

Note

After tightening the double clamp, inspect dimension -b- and adjust if necessary.

 

Replacing middle or rear silencer

 

Special tools, test and measuring equipment and auxiliary items required

 

Torque wrench

 

Body saw (e.g. -V.A.G.1523-)

A separation point is provided for repair purposes for re- placing the middle silencer or rear silencer.

A separation point is provided for repair purposes for re- placing the middle silencer or rear

Separate exhaust pipe at right angles at the separa- tion point -arrow 1- with body saw.

When installing, position double clamp -4- at the side markings -arrow 2- and -arrow 3-.

Align exhaust system free of stress 26-1 page 2.

Align rear silencer horizontally.

Tighten bolted connections of the double clamp even- ly to 40 Nm.

Installation position of double clamp: Bolts positioned vertically at front of exhaust pipe.

a S26-0064
a
S26-0064
positioned vertically at front of exhaust pipe. a S26-0064 26-1 page 2 Removing and installing parts
positioned vertically at front of exhaust pipe. a S26-0064 26-1 page 2 Removing and installing parts
positioned vertically at front of exhaust pipe. a S26-0064 26-1 page 2 Removing and installing parts

26-1 page 2

Removing and installing parts of the exhaust system

Edition 07.03

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26

Checking the exhaust system for leaks

Start engine and run in idle.

Seal off tail pipe for the test duration with suitable plugs.

Check the connection points for leaks by listening:

Cylinder head/exhaust manifold, exhaust turbocharg- er/front exhaust pipe with catalytic converter, double clamp at middle or also at rear silencer.

Rectify any fault found.

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FABIA 2000 1.9/96 TDI Engine, Mechanics

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Removing and installing parts of the exhaust system

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26-2

Note

Exhaust gas recirculation system

The exhaust gas recirculation system is operated by the diesel direct injection system control unit -J248- via the EGR valve -N18- to the mechanical exhaust gas recirculation valve.

Inspecting exhaust gas recirculation 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 23 and exhaust gas recirculation valve -N18- 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.

The mechanical exhaust gas recirculation valve with conically shaped valve tappet makes it possible to achieve different opening cross-sections at different valve strokes.

Connection diagram for vacuum hoses Chap. 21-1.

1

- Intake manifold

2

- O-ring Replace

3

- Vacuum setting element

4

-

5 Nm

5

- Mechanical exhaust gas recir- culation valve

 

Component part of the induc- tion pipe

Must be replaced together with the induction pipe

Check 26-2 page 2

6

- Induction pipe With mechanical exhaust gas recirculation valve and control flap

7

-

10 Nm

8

- Gasket Replace

9

-

25 Nm

10

- Connecting tube

11

- Gasket Replace Check fitting position

12

-

6 Nm

13

- Sealing sleeve

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FABIA 2000 1.9/96 TDI Engine, Mechanics

Testing mechanical exhaust gas recircu- lation valve

Special tools, test and measuring equipment and auxiliary items required

Hand vacuum pump (e.g. -V.A.G 1390-)

Test sequence

Remove engine cover -arrows-.

Disconnect vacuum hose on mechanical exhaust-gas recirculation valve.

Connect hand vacuum pump to valve and operate pump.

The diaphragm rod must move in the direction of the vacuum connection -Pfeil-.

Detach hose of hand vacuum pump from mechanical exhaust gas recirculation valve.

The diaphragm rod must move back to its original po- sition against the -direction of the arrow-.

V.A.G 1390 S13-0161
V.A.G 1390
S13-0161

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Exhaust gas recirculation system

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