Skoda 2000 Fabia Instruction manual

Service 5
Service Department. Technical Information Printed in Czech Republic
S00.5305.00.20
Workshop Manual
FABIA 2000 ³
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical
Components
Edition 08.99
Engine code ARV AQV AZE AZF AME ATZ AQW
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Service
5
The Workshop Manual is intended only for use within the Organisation Škoda.
It is not permitted to pass it on to other persons.
© ŠKODA AUTO a. s.
Printed in Czech Republic
S00.5305.00.20
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
List of SupplementsEdition 09.03
S00.5305.04.20
List of Supplements to Workshop Manual
FABIA 2000 ³
1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Edition 08.99
Supple-
ment Edition Subject Article Number
08.99 Basic Edition S00.5305.00.20
1 06.00 Supplement to Basic Edition S00.5305.01.20
2 03.01 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.02.20
3 02.02 Modifications in Rep. Gr. 00, 13, 15, 17, 19 and 26 S00.5305.03.20
4 09.03 Modifications in Rep. Gr. 00, 13, 15 and 17 S00.5305.04.20
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
List of Supplements Edition 09.03
S00.5305.04.20
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Table of ContentsEdition 09.03
S00.5305.04.20 I
Table of Contents
00 – Technical Data
Technical Data ..........................................................................................
10 – Removing and Installing Engine
Removing and Installing Engine ....................................................................
- Removing engine ......................................................................................
- Installing the engine ...................................................................................
- Tightening torques ....................................................................................
- Assembly bracket ......................................................................................
13 – Crankgear
Removing and installing V-ribbed belt ............................................................
- Summary of components - Vehicles without air conditioning ...................................
- Summary of components - Vehicles with air conditioning .......................................
- Removing the V-ribbed belt ..........................................................................
- Installing the V-ribbed belt ...........................................................................
Disassembling and Assembling Cylinder Block and Crankshaft ...........................
- Summary of components .............................................................................
- Inspecting synchronous running of sprockets .....................................................
- Replacing gasket ring for crankshaft -on the belt pulley side- ..................................
- Replacing ring gear ...................................................................................
Disassembling and Assembling Pistons, Connecting Rod and Liner .....................
15 – Cylinder Head, Valve Gear
Removing and installing cylinder head ...........................................................
- Summary of components .............................................................................
- Removing and installing cylinder head .............................................................
Repairing cylinder head ..............................................................................
- Inspect valve guides ..................................................................................
- Removing and installing valves .....................................................................
- Reworking valve seats ................................................................................
- Replacing valve stem seal ...........................................................................
- Basic setting of hydraulic valve clearance compensation .......................................
- Testing the compression .............................................................................
Repairing valve gear ...................................................................................
- Removing and installing camshaft ..................................................................
- Removing and installing rocker arms ...............................................................
- Inspecting hydraulic tappets .........................................................................
17 – Lubrication
Removing and installing parts of the lubrication system .....................................
- Summary of components .............................................................................
Removing and installing oil pan ....................................................................
- Removing and installing oil pan - for a 1.0 litre engine ..........................................
- Removing and installing oil pan - for a 1.4 litre engine ..........................................
Testing Oil Pressure and Oil Pressure Switch ..................................................
00-1 page 1
10-1 page 1
10-1 page 1
10-1 page 7
10-1 page 9
10-1 page 9
13-1 page 1
13-1 page 1
13-1 page 3
13-1 page 4
13-1 page 5
13-2 page 1
13-2 page 1
13-2 page 3
13-2 page 4
13-2 page 7
13-3 page 1
15-1 page 1
15-1 page 1
15-1 page 2
15-2 page 1
15-2 page 1
15-2 page 2
15-2 page 3
15-2 page 6
15-2 page 6
15-2 page 7
15-3 page 1
15-3 page 1
15-3 page 2
15-3 page 3
17-1 page 1
17-1 page 2
17-2 page 1
17-2 page 1
17-2 page 1
17-3 page 1
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Table of Contents Edition 09.03
S00.5305.04.20
II
19 – Cooling
Parts of cooling system - Summary of components ...........................................
- Parts of the cooling system fitted to body .........................................................
- Parts of cooling system engine side ................................................................
- Connection diagram for coolant hoses .............................................................
- Draining and filling up coolant .......................................................................
- Checking the coolant system for tightness ........................................................
Removing and Installing Radiator, Coolant Pump .............................................
- Removing and installing radiator ....................................................................
- Removing and installing coolant pump ............................................................
20 – Fuel Supply
Removing and Installing Parts of the Fuel Supply System ...................................
- Safety precautions when working on the fuel supply system ...................................
- Cleanliness rules ......................................................................................
Activated Charcoal Filter System ..................................................................
- Repairing parts of the activated charcoal filter system ..........................................
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................
- Aligning exhaust system free of stress .............................................................
- Replacing front or rear silencer .....................................................................
- Checking the exhaust system for leaks ............................................................
19-1 page 1
19-1 page 1
19-1 page 3
19-1 page 5
19-1 page 5
19-1 page 7
19-2 page 1
19-2 page 1
19-2 page 2
20-1 page 1
20-1 page 3
20-1 page 3
20-2 page 1
20-2 page 1
26-1 page 1
26-1 page 2
26-1 page 3
26-1 page 3
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Technical DataEdition 09.03
S00.5305.04.20
00-1 page 1
00
00-1 Technical Data
Engine number
The engine number („engine identification characters“
and „serial number“) is located on the end face of the cyl-
inder block on the belt pulley side, at the connection to
the cylinder head -arrow-.
In addition, a sticker with „engine identification“ and „seri-
al number“ is affixed to the cylinder head cover.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
00 – Technical Data
Engine identification charac-
ters
ARV AQV AZE AZF
Manufactured 01.01 ³07.02 01.01 ³07.02 04.00 ³03.03 04.00 ³03.03
Exhaust limits conforming to EU-2 EU-3 EU-2 EU-4
Displacement l 0,997 0,997 1,397 1,397
Power output kW at
rpm
37/5000 37/5000 44/5000 44/5000
Torque Nm at
rpm
84/2750 84/2750 118/2600 118/2600
Bore ∅mm 72 72 75,5 75,5
Stroke mm 61,2 61,2 78,0 78,0
Compression 10 : 1 10 : 1 10 : 1 10 : 1
Fuel - RON 95 unleaded1)
1) At least 91 RON in exceptional cases; the engine output is reduced however
95 unleaded1) 95 unleaded1) 95 unleaded1)
Fuel injection and ignition sys-
tem
Simos 3PB Simos 3PA Simos 3PB Simos 3PA
Knock control yes yes yes yes
Self-diagnosis yes yes yes yes
Lambda control 1 lambda probe 2 lambda probes 1 lambda probe 2 lambda probes
Catalytic converter 1 Catalyst 2 Catalysts 1 Catalyst 2 Catalysts
Turbocharging no no no no
Exhaust gas recirculation no no no no
Secondary air system no no no no
Camshaft adjustment no no no no
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Technical Data Edition 09.03
S00.5305.04.20
00-1 page 2
00
Engine identification characters AME ATZ AQW
Manufactured 08.99 ³04.03 11.99 ³07.00 08.00 ³03.03
Exhaust limits conforming to EU-2 D4 EU-4, EU3-DDK
Displacement l 1,397 1,397 1,397
Power output kW at rpm 50/5000 50/5000 50/5000
Torque Nm at rpm 120/2500 120/2500 120/2500
Bore ∅mm 75,5 75,5 75,5
Stroke mm 78,0 78,0 78,0
Compression 10 : 1 10 : 1 10 : 1
Fuel - RON 95 unleaded1)
1) At least 91 RON in exceptional cases; the engine output is reduced however
95 unleaded1) 95 unleaded1)
Fuel injection and ignition system Simos 3PB Simos 3PA Simos 3PA
Knock control yes yes yes
Self-diagnosis yes yes yes
Lambda control 1 lambda probe 2 lambda probes 2 lambda probes
Catalytic converter 1 Catalyst 2 Catalysts 2 Catalysts
Turbocharging no no no
Exhaust gas recirculation no no no
Secondary air system no no no
Camshaft adjustment no no no
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing EngineEdition 02.02
S00.5305.03.20
10-1 page 1
10
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
♦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 re-
place 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 ig-
nition off.
–Remove noise insulation -arrows-.
–Unscrew the drive shaft to the right and left of the
gearbox.
–Raise drive shafts and secure.
10 – Removing and Installing Engine
Note
S10-0135
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing Engine Edition 02.02
S00.5305.03.20
10-1 page 2
10
–Remove front exhaust pipe with catalyst ⇒Chap. 26-
1.
–Place drip tray below the engine (e. g. -V.A.G 1306-).
–Loosen the drain screw on the coolant expansion bot-
tle.
–Turn the drain plug -arrow- on the radiator to the left
and draw backwards, if necessary fit auxiliary hose
onto connection.
–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-
screw cap -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.
–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-.
A10-0118
S10-0138
1
64
5
3
4
2
1
2
S10-0142
3
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing EngineEdition 02.02
S00.5305.03.20
10-1 page 3
10
–Remove coolant hoses -1- and -2- from the coolant
regulator housing.
–Remove the vacuum connection from the brake servo
unit.
–Remove the fuel presupply pipe -4- by pressing the re-
lease buttons at the separation point.
–Remove coolant hoses -1- and -2- from the expansion
reservoir.
–Release vacuum hose -3- from the solenoid valve
-N80-.
–Release nut -arrow A- and tie up holder -1-.
M
M
1
2
S10-0141
Caution!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
2
1
3 4
S10-0137
B
1
S34-0397
A
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing Engine Edition 02.02
S00.5305.03.20
10-1 page 4
10
–Disconnect the Bowden cable support from gearbox
-arrows-.
–Detach selector cable -A-, for this step remove circlip
-arrow 1- from the relay lever.
–Remove bearing bolt -arrow 2- from the reversing le-
ver of the selector cable -A-.
–Remove the shift cable -B- with the gearbox shift le-
ver, for this step unscrew nut -arrow 3-.
–Remove the hose line holder -1- from the gearbox -ar-
row A-.
–Remove -arrow B- the slave cylinder -2- and lay aside,
secure with wire, do not open the line system.
Do not depress the clutch pedal.
S34-0389
A
1
3
B
2
S34-0398
2
A
B1
B
S34-0400
Note
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing EngineEdition 02.02
S00.5305.03.20
10-1 page 5
10
–Remove the earth strap -1- from the front of the gear-
box.
–Disconnect plug -2- from the reversing light switch
-F4-.
–Separate plug connection -3-.
–Remove coolant hose from the rear coolant pipe -ar-
row-.
–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.
–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.
1
3
2
S10-0143
S10-0139
1
2
3
S19-0078
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing Engine Edition 02.02
S00.5305.03.20
10-1 page 6
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
–Remove the V-ribbed belt ⇒Chapter 13-1.
–Remove connector from the AC compressor.
–Remove AC compressor with the refrigerant lines con-
nected.
–Secure the AC compressor -1- to the lock carrier -ar-
row-.
–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.
♦Do not buckle the refrigerant lines.
♦Use cloths to protect the right headlight glass from
damage, removing the headlight if necessary.
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
♦The rig positions on the supporting bracket marked 1
to 4 point towards the belt pulley.
♦The holes in the vertical perforated bars are counted
from the hook.
S34-0403
Caution!
Do not open the refrigerant circuit of the air condi-
tioning system.
2
1
S10-0136
Note
MP 9-201
S10-0134
23478
156
Warning!
Use securing pins on the hooks and rig pins.
Note
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing EngineEdition 02.02
S00.5305.03.20
10-1 page 7
10
–Release screws -2-.
–Unscrew the fixing screws -arrows- from the gearbox
mount.
–Slightly lower the engine/gearbox unit and pull out
carefully towards the front.
Secure the engine with engine mount -MP 1-180- on the
assembly support -MP 9-101- before performing assem-
bly work.
Grip the engine on the supports of the engine mount -ar-
rows-.
Instead of engine mount -MP 1-180- it is also possible to
use engine mount -MP 1-202-.
Installing the engine
♦Always replace the seals and gaskets during assem-
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
3
2
1
S10-0140
S10-0120
MP 1-180
MP 9-101
S10-0082
Note
Note
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing Engine Edition 02.02
S00.5305.03.20
10-1 page 8
10
Procedure
Installation is performed in the reverse order. Pay atten-
tion to the following points:
–Check whether the dowel sleeves for centering the
engine/gearbox are present in the cylinder block; in-
sert if necessary.
–If necessary check the centering of the clutch driver
disc.
–Inspect clutch release bearing for wear, replace if nec-
essary.
–Lubricate the drive shaft serration lightly with grease
-G 000 100 -.
–Install the slave cylinder of the hydraulic clutch
⇒Gearbox 002; Rep. Gr. 30.
–Adjust the gearshift mechanism and cable control
⇒Gearbox 002; Rep. Gr. 34.
–When installing the engine/gearbox unit make sure all
adjoining components are clear.
–Align the engine/gearbox unit.
Tightening torques ⇒10-1 page 9.
Vehicles with air conditioning
–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 gear-
box ⇒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 Di-
agrams, Electrical Fault Finding and Fitting Locations.
–Install coolant hoses ⇒Chapter 19-1.
The drained off coolant must only be re-used if the cylin-
der 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.
Note
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing EngineEdition 02.02
S00.5305.03.20
10-1 page 9
10
–Adapt the engine control unit to the throttle valve con-
trol unit -J338- ⇒1.4/1.0; 1.4/44 engine - fuel injec-
tion; Rep. Gr. 24.
–Perform a test drive and interrogate and erase fault
memory ⇒1.0/37; 1.4/44; 1.4/50 engine - fuel injec-
tion; Rep. Gr. 01 .
Tightening torques
♦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:
Assembly bracket
Tightening torques
Engine mounting
1 - 20 Nm + 90°(1/4turn) - replace
2 - 30 Nm + 90°(1/4turn) - replace
Gearbox mounting
1 - 50 Nm + 90°(1/4turn) - replace
2 - 40 Nm + 90°(1/4turn) - replace
Note
Component Torque
Screws/nuts M6 9 Nm
M7 13 Nm
M8 20 Nm
M10 40 Nm
M12 70 Nm
deviations:
Engine to gearbox connecting
screws
⇒Manual gearbox
002; rep. size 34
Drive shaft to gearbox mount-
ing flange
⇒Chassis; rep. size
40
2
1
11
S10-0132
2
11
1
1
S10-0125
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and Installing Engine Edition 02.02
S00.5305.03.20
10-1 page 10
10
Hinged bracket
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- 30Nm+90°(1/4turn) - replace
2- 40Nm+90°(1/4turn) - replace
2
1
S10-0133
Note
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and installing V-ribbed beltEdition 02.02
S00.5305.03.20
13-1 page 1
13
13-1 Removing and installing V-ribbed belt
Summary of components - Vehicles without air conditioning
♦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
Tremoving and installing
⇒Chapter 19-2
2 - Bracket
Tfor clamp
Tremoving and installing
⇒Chapter 15-1
3- Screw
4- Clamp
5- 25Nm
Treplace
6- Generator
Tto facilitate positioning of the
generator on the holder,
drive the bushing of the re-
taining screw slightly back-
wards
7- Screw
8- 30Nm
Treplace
9- 45Nm
10 - 25 Nm
Tcoat with -AMV 105 500-
(Loctite 242) before inserting
11 - Bracket
Tfor generator
12 - Guide pulley
13 - Washer
TCamber towards the outside
14 - 20 Nm
TLeft-hand thread
Tcoat with -AMV 154 100- (Loctite 648) before inserting
15 - Belt pulley
Tfor crankshaft
16 - 100 Nm
Tto release and tighten lock flywheel
♦Engine removed: with -MP 1-504-
♦Engine installed: with locking screw ⇒Chapter 13-2
17 - V-ribbed belt
TRouting of the ribbed V-belt ⇒Fig. 1 in 13-1 page 2
Tremoving ⇒13-1 page 4
13 – Crankgear
Note
1
S13-0241
17
7
9
10
12
1314
1516 11
3
2
5
6
4
8
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FABIA 2000 ³1.0/37; 1.4/44; 1.4/50 Engine, Mechanical Components
Removing and installing V-ribbed belt Edition 02.02
S00.5305.03.20
13-1 page 2
13
Tinstalling ⇒13-1 page 5
Fig. 1: Routing of the ribbed V-belt
1 - Belt pulley - generator
2 - Belt pulley - crankshaft
3 - Guide pulley
4 - Belt pulley - coolant pump
1
2
3
4
S13-0242
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