Skoda 2000 Fabia Instruction manual

Service 5
Service Department. Technical Information Printed in Czech Republic
S00.5306.00.20
Workshop Manual
FABIA 2000 ³
1.4/55; 1.4/74 Engine - Mechanical Components
Edition 08.99
Engine code AUA AUB BBY BBZ BKY

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
S00.5306.00.20

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
List of SupplementsEdition 05.05
S00.5306.06.20
List of Supplements to Workshop Manual
FABIA 2000 ³
1.4/55; 1.4/74 Engine - Mechanical Components
Edition 08.99
Suppleme
nt Edition Subject Article Number
08.99 Basic Edition S00.5306.00.20
1 07.00 Supplement to Basic Edition S00.5306.01.20
2 05.01 Modifications in Rep. Gr. 00, 10, 13, 15, 17 and 19 S00.5306.02.20
3 06.02 Additions to engines with the engine codes BBY, BBZ S00.5306.03.20
4 09.03 Modifications in Rep. Gr. 00, 10, 13, 15 and 17 S00.5306.04.20
5 05.04 Supplement to engine with the engine codes BBY S00.5306.05.20
6 05.05 Modifications in the Rep. Gr. 00, 13, 15, 17, 19, 20 and 26 S00.5306.06.20

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
List of Supplements Edition 05.05
S00.5306.06.20

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Table of ContentsEdition 05.05
S00.5306.06.20 I
Table of Contents
00 – Technical Data
Technical Data ..........................................................................................
- Engine number .........................................................................................
- Engine characteristics ................................................................................
10 – Removing and Installing Engine
Removing and Installing Engine ....................................................................
- Removing engine ......................................................................................
- Removing ...............................................................................................
- Attaching engine to assembly stand ................................................................
- Installing ................................................................................................
- Tightening torques ....................................................................................
13 – Crankgear
Disassembling and assembling engine ...........................................................
- Summary of components of ribbed V-belt on vehicles fitted with AC .........................
- Removing and installing V-ribbed belt ..............................................................
- Summary of components of timing belt ...........................................................
- Removing, installing and tensioning the toothed belt and inspecting the semi-automatic
toothed belt tensioning pulley ........................................................................
Removing and installing cylinder block ..........................................................
- Aluminium cylinder block .............................................................................
- Replacing gasket ring for crankshaft -on the belt pulley side- ..................................
- Removing and installing drive plate ................................................................
- Replacing the sealing flange for crankshaft - flywheel side .....................................
Disassembling and assembling piston and conrod ............................................
15 – Cylinder Head, Valve Gear
Removing and installing cylinder head ...........................................................
- Engines with engine identification characters AUA, AUB, BBY, BBZ. ........................
- Engines with engine identification letters BKY ....................................................
- removing and installing cylinder head cover ......................................................
- Removing and installing cylinder head .............................................................
- Testing the compression .............................................................................
Repairing Valve Gear ..................................................................................
- Reworking valve seats ................................................................................
- Replacing camshaft gasket rings ...................................................................
- Inspect valve guides ..................................................................................
- Replacing valve stem seals ..........................................................................
17 – Lubrication
Removing and installing parts of the lubrication system .....................................
- Lubrication system - Overview of components ...................................................
- Removing and installing oil pan .....................................................................
- Removing and installing oil pump ...................................................................
- Testing oil pressure and oil pressure switch ......................................................
19 – Cooling
00-1 page 1
00-1 page 1
00-1 page 1
10-1 page 1
10-1 page 1
10-1 page 1
10-1 page 5
10-1 page 5
10-1 page 7
13-1 page 1
13-1 page 1
13-1 page 2
13-1 page 3
13-1 page 4
13-2 page 1
13-2 page 1
13-2 page 2
13-2 page 3
13-2 page 4
13-3 page 1
15-1 page 1
15-1 page 1
15-1 page 3
15-1 page 4
15-1 page 7
15-1 page 10
15-2 page 1
15-2 page 4
15-2 page 6
15-2 page 7
15-2 page 8
17-1 page 1
17-1 page 1
17-1 page 3
17-1 page 4
17-1 page 6

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Table of Contents Edition 05.05
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II
Parts of the Cooling System .........................................................................
- Parts of the cooling system fitted to body .........................................................
- Coolant regulator - Summary of components .....................................................
- Coolant pump - Summary of components .........................................................
- Connection diagram for coolant hoses .............................................................
- Draining and filling up coolant .......................................................................
- Removing and installing radiator ....................................................................
- Removing and installing coolant pump ............................................................
20 – Fuel Supply
Removing and installing parts of the fuel supply system ....................................
- Removing and installing fuel tank with attached parts and fuel filter ..........................
- Safety precautions when working on the fuel supply system ...................................
- Rules of cleanliness ...................................................................................
- Removing and installing the fuel delivery unit ....................................................
- Removing and installing the fuel gauge sender ..................................................
- Removing and installing the fuel tank ..............................................................
- Inspecting the fuel pump and fuel system .........................................................
- Inspecting the operating and holding pressure of the fuel, inspecting the non-return valve
of the fuel pump .......................................................................................
- Disconnecting the fuel delivery unit with crash signal ...........................................
Inspecting Electronic Power Control (Electronic throttle) ....................................
- Summary of components ............................................................................
Activated Charcoal Filter System ..................................................................
- Summary of components of activated charcoal filter system ...................................
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................
- Exhaust manifold with pre-catalytic converter, front exhaust pipe with catalyst and
component parts - Engines with engine identification characters AUA, AUB, BBY, BBZ .
- Exhaust manifold, front exhaust pipe with pre-catalytic converter and catalyst and
component parts - Engine with engine identification characters BKY ........................
- Silencer with hangers .................................................................................
- Testing the catalyst ...................................................................................
Exhaust gas recirculation system .................................................................
- Summary of components of exhaust gas recirculation - engines with engine identification
characters AUA, AUB, BBY, BBZ. ..................................................................
- Summary of components of . exhaust gas recirculation - engine with engine identification
characters BKY ³05.05 .............................................................................
- Check exhaust gas recirculation potentiometer -G212- .........................................
19-1 page 1
19-1 page 1
19-1 page 3
19-1 page 4
19-1 page 5
19-1 page 5
19-1 page 6
19-1 page 7
20-1 page 1
20-1 page 1
20-1 page 3
20-1 page 3
20-1 page 4
20-1 page 5
20-1 page 5
20-1 page 6
20-1 page 11
20-1 page 14
20-2 page 1
20-2 page 1
20-3 page 1
20-3 page 1
26-1 page 1
26-1 page 1
26-1 page 3
26-1 page 4
26-1 page 4
26-2 page 1
26-2 page 1
26-2 page 2
26-2 page 2

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Technical DataEdition 05.05
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00-1 page 1
00
00-1 Technical Data
Engine number
The engine number („engine identification characters“
and „serial number“) is indicated on the end face of the
cylinder block at the gearbox side below the coolant ther-
mostat housing.
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
00 – Technical Data
Engine identification
characters
AUA BBY BKY AUB BBZ
Manufactured 05.00 ³03.02 04.02 ³05.04 05.04 ³08.99 ³05.02 05.02 ³
Displacement l 1,390 1,390 1,390 1,390 1,390
Valves per cyl-
inder
44444
Power output kW at rpm 55/5000 55/5000 55/5000 74/6000 74/6000
Torque Nm at
rpm
126/3800 126/3800 126/3800 126/4400 126/4400
Bore ∅mm 76,5 76,5 76,5 76,5 76,5
Stroke mm 75,6 75,6 75,6 75,6 75,6
Compression 10,5 10,5 10,5 10,5 10,5
Fuel - RON min. 95 unleaded1)
1) At least 91 RON in exceptional cases, although engine output is reduced.
95 unleaded1) 95 unleaded1) 98 unleaded2)
2) At least 95 RON in exceptional cases, although engine output is reduced.
98 unleaded2)
Ignition system, fuel injec-
tion
4LV 4MV 4TV 4LV 4MV
Knock control yes yes yes yes yes
Self-diagnosis yes yes yes yes yes
Lambda control 2 Lambda
probes
2 Lambda
probes
2 Lambda
probes
2 Lambda
probes
2 Lambda
probes
Exhaust gas recirculation yes yes yes yes yes
Catalytic converter 2 Catalysts 2 Catalysts 2 Catalysts 2 Catalysts 2 Catalysts
Turbocharging no no no no no
Exhaust limits conforming
to
EU-4, EU-3
DDK, EU-2
DDK
EU-4, EU-3
DDK, EU-2
DDK
EU-4, EU-2
DDK
EU-4, EU-3
DDK, EU-2
DDK
EU-4, EU-2
DDK

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Technical Data Edition 05.05
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00-1 page 2
00

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing EngineEdition 09.03
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10-1 page 1
10
10-1 Removing and Installing
Engine
Removing engine
Special tools, test and measuring equipment and
auxiliary items required
♦Lifting device, e.g. -MP 9-201-
♦Tensioning block -MP 9-101-
♦Engine mount -MP 1-202-
♦Workshop crane, e.g. - V.A.G 1202 A-
♦Catch pan, e.g. -V.A.G 1306 -
♦Grease -G 000 100- (for vehicles with gearbox)
♦Cable strap
Removing
All cable straps that have been loosened or cut open
when the engine was removed must be fitted again in the
same location when the engine is installed again.
–First check whether a radio set with anti-theft coding
has been fitted. If this is the case obtain coding.
–Disconnect the earth strap from the battery with the ig-
nition off.
–Disconnect positive cable in fuse holder at battery -ar-
row-.
–Remove cable from battery to fuse holder at battery
and place to the side.
–Remove battery tray and take battery out of battery
box.
–Remove battery box -arrows-.
–Disconnect the positive wire from the battery to the
starter (is removed together with the engine/gearbox
unit).
10 – Removing and Installing Engine
Note
S10-0110
S27-0064

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
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10
–Pull off hose -1- (for engines as of 04.02) and remove
the engine guard -2- with air filter upwards -arrows-.
–Open cap of expansion reservoir to release pressure
in the cooling system.
–Release the screws at the bottom of the engine cover
-arrows- and remove cover.
–Unscrew front exhaust pipe from the exhaust manifold
⇒Chapter 26-1 and tie to body member.
–Remove pendulum support -arrows-.
–Unscrew drive shaft to the right and left of the gearbox
and tie up ⇒Body; Rep. Gr. 40.
–Drain coolant ⇒Chapter 19-1.
–Pull off coolant hose at the top and bottom of the radi-
ator.
When disconnecting hoses the residual coolant flows out!
Make sure a catch pan is positioned underneath.
–Disconnect the plug connections on the connector be-
low the starter:
♦Plug connection for lambda probe cable
♦Plug connection to AC compressor cable
♦Plug connection to generator cable
–Disconnect plug connection of the reverse gear switch
from the gearbox.
–Remove front bumper ⇒Body work; Rep. Gr. 63.
–Disconnect the following plug connections:
S10-0101
S10-0100
Note

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing EngineEdition 09.03
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10
♦Plug connection of the electric wiring to the radiator
fans
♦Plug connection of the thermo-switch -F18-
♦Plug connection of the electric wiring to the main
headlights and fog lights
Vehicles with air conditioning
To avoid damaging the condenser, wiring and air condi-
tioning hoses make sure the lines and hoses are not ex-
cessively expanded, buckled or bent.
–Release the retaining clips of the AC system line.
–Remove the V-ribbed belt ⇒Chapter 13-1.
–Remove connector from the AC compressor.
–Remove AC compressor ⇒Heating, Air Conditioning;
Rep. Gr. 87.
–Tie up AC compressor to lock carrier.
Continued for all vehicles
–Removing lock carrier ⇒Body Work; Rep. Gr. 50 and
lay aside.
–Disconnect the starter plug connection.
–Disconnect the plug from the engine control unit -ar-
row-.
–Disconnect 10-pin plug connection in left of engine
compartment and lay wiring loom aside.
The assembly is removed together with the cable har-
ness.
Vehicles fitted with a manual gearbox
–Remove shift cables of shift mechanism from gearbox
and place down to the side ⇒Manual Gearbox 02T;
Rep. Gr. 34.
–Remove clutch cylinder and lay aside ⇒Gearbox
02T; Rep. Gr. 30.
Clutch pedal must not be depressed.
Vehicles with automatic gearbox
–Remove selector lever tension rod from the gearbox
and lay aside ⇒Automatic Gearbox 001; Rep. Gr. 37.
WARNING!
Do not open the refrigerant circuit of the air condi-
tioning system. Therefore, when laying aside the
lock carrier pay special attention to the air condi-
tioning hoses, that must not be folded or exposed
to stress.
Note
S10-0128
S10-0111
Note
Note

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing Engine Edition 09.03
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10-1 page 4
10
Continued for all vehicles
–Disconnect earth strap of the gearbox.
–Release spring strap clamps and disconnect hoses of
the coolant regulator housing:
♦Heater intake hose
♦Hose of the expansion reservoir
♦Heater return-flow hose
When disconnecting hoses the residual coolant flows out!
Make sure a catch pan is positioned underneath.
–Disconnect the hose of the vent line from the throttle
valve.
–Disconnect the fuel feed line from the fuel rail -arrow-.
–Disconnect the coolant reservoir ventilation hose from
the ventilation tube.
–Remove vacuum hose from the brake servo unit.
–Attach lifting device -MP 9-201- as shown in the figure
and raise slightly using the workshop crane.
♦On the belt pulley side: 4. Hole of vertical perforated
bar in position 1.
♦On the flywheel side: 2. Hole of vertical perforated bar
in position 8.
♦The hole of supporting bracket -1- points towards the
belt pulley.
♦The holes in the vertical perforated bars are counted
from the hook.
Note
S10-0099
WARNING!
Fuel line is under pressure! Place clean cleaning
cloths around the connection point before detach-
ing hose connections. Reduce pressure by careful-
ly removing the hose.
S10-0103
MP 9 - 201
WARNING!
Use securing pins on the hooks and rig pins to
prevent release.
Note

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing EngineEdition 09.03
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10
–Release screws -arrows- from engine mounting -A-
and from the gearbox mount -B-.
–Lower engine/gearbox unit and push towards the
front.
The engine/gearbox unit must be guided carefully so as
not to damage the body.
Attaching engine to assembly stand
Secure the engine with engine mount -MP 1-202- on the
tensioning block -MP 9-101 - before performing assem-
bly work.
–Unscrew gearbox from engine.
Vehicles with automatic gearbox
–After disconnecting the engine from the gearbox se-
cure torque converter against „dropping out“.
Continued for all vehicles
–Screw engine on engine mount -MP 1-202- -arrows-
secured to tensioning block -MP 9-101-.
Because of the different bore distances in the engine
mount and bores in the engine flange the engine can only
be supported in three points.
Installing
–Check whether dowel sleeves for centering have been
inserted in the cylinder block, if necessary insert.
–Insert intermediate plate on sealing flange and push
onto the dowel sleeves -arrows-.
–Pay attention to correct fit of the intermediate plate.
–Check the centering of the clutch driver disc.
–Inspect clutch release bearing for wear, replace if nec-
essary.
–Slightly grease the clutch release bearing, guide
bushing for clutch release bearing and serration of the
gearbox drive shaft with grease -G 000 100-.
–Assemble engine with gearbox ⇒Gearbox 02T;
Rep. Gr. 34 or ⇒Automatic Gearbox 001;
Rep. Gr. 37.
S10-0109
A
B
Note
MP1-202
MP9-101
S10-0129
Note
N10-0160

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing Engine Edition 09.03
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10-1 page 6
10
–Secure engine/gearbox unit in the engine and gear-
box mount -arrows- and tighten the screws to the indi-
cated tightening torque ⇒10-1 page 7.
–Position the vent hose for the coolant reservoir on the
ventilation tube and draw together with retaining clips.
–Position the vacuum hose of the brake servo unit and
draw together with retaining clips.
–Connect the fuel feed line to the fuel rail.
–Fit the hose of the vent line to the throttle valve and
draw together with retaining clips.
–Connect the hoses to the coolant regulator housing:
♦Heater intake hose
♦Hose of the expansion reservoir
♦Heater return-flow hose
–Screw on earth strap of the gearbox.
Vehicles fitted with a manual gearbox
–Installing the master cylinder ⇒Gearbox 02T;
Rep. Gr. 30.
–Installing the control cables of the gearshift mecha-
nism ⇒Gearbox 02T; Rep. Gr. 34.
Vehicles with automatic gearbox
–Check attachment of the torque converter.
–Install or adjust selector lever tension rod to the gear-
box ⇒Automatic Gearbox 001; Rep. Gr. 37.
Continued for all vehicles
–Pull in wiring loom and connect the ten-pin plug con-
nection in left of engine compartment.
–Connect the plug connection for the engine control
unit.
–Connect the starter plug connection.
–Install the lock carrier ⇒Body Work; Rep. Gr. 50.
Vehicles with air conditioning
To avoid damaging the condenser, wiring and air condi-
tioning hoses make sure the lines and hoses are not ex-
cessively expanded, buckled or bent.
–Install AC compressor ⇒Heating, Air Conditioning;
Rep. Gr. 87.
–Connect the AC compressor plug connection.
–Install the V-ribbed belt ⇒Chapter 13-1.
Continued for all vehicles
–Connect the following plug connections:
S10-0109
A
B
S10-0111
Note

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing EngineEdition 09.03
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10-1 page 7
10
♦Plug connection of the electric wiring to the radiator
fans
♦Plug connection of the thermo-switch -F18-
♦Plug connection of the electric wiring to the main
headlights and fog lights
–Connect plug connection of the reverse gear switch
from the gearbox.
–Connect the plug connections on the connector below
the starter:
♦Plug connection for lambda probe cable
♦Plug connection to AC compressor cable
♦Plug connection to generator cable
–Position the coolant hose at the top and bottom of the
radiator and draw together with retaining clips.
–Installing the drive shaft right and left of the gearbox
⇒Running Gear; Rep. Gr. 40.
–Install pendulum support and tighten the screws to the
recommended torque ⇒10-1 page 7.
–Install front exhaust pipe to exhaust manifold
⇒Chapter 26-1.
–Install front bumper ⇒Body work; Rep. Gr. 63.
–Install the noise insulation.
–Top up coolant ⇒Chapter 19-1.
–Install engine cover with air filter.
–Connect the positive wire in the fuse box to the bat-
tery.
–Install battery box.
–Insert battery in battery box and connect.
–Adapt 4AV control unit to throttle valve control unit
⇒1.4/55; 1.4/74 Engine, Fuel Injection; Rep. Gr. 24.
–Perform test drive and interrogate fault memory
⇒1.4/55, 1.4/74 Engine, Fuel Injection; Rep. Gr. 01.
♦All cable straps that have been loosened or cut open
when the engine was removed must be fitted again in
the same location when the engine is installed again.
♦If the battery earth strap is disconnected and connect-
ed, carry out additional operations ⇒Electrical Sys-
tem; Rep. Gr. 27.
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.
Note
Note

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
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10
♦Do not use degreased parts.
♦Unless otherwise indicated the following tightening
torques apply:
Assembly bracket
Engine mount:
1 - 20 Nm + 90°(1/4turn) - replace
2 - 30 Nm + 90°(1/4turn) - replace
Gearbox mount:
1 - 50 Nm + 90°(1/4turn) - replace
2 - 40 Nm + 90°(1/4turn) - replace
Pendulum support:
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°(1/4turn) - replace
2 - 40 Nm + 90°(1/4turn) - replace
Component Torque
Bolts, nuts M 6 9 Nm
M 7 13 Nm
M 8 20 Nm
M10 40 Nm
M 12 70 Nm
deviations:
Engine to gearbox connecting
screws
⇒Manual gearbox
02T; rep. size 34
Drive shaft to gearbox mount-
ing flange
⇒Chassis; rep. size
40
2
1
11
S10-0124
2
11
1
1
S10-0125
1
2
S10-0126
Note

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Disassembling and assembling engineEdition 05.05
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13-1 page 1
13
13-1 Disassembling and assembling engine
Summary of components of ribbed V-belt on vehicles fitted with AC
1 - Tensioning pulley for ribbed
V-belt
TSwing out the tensioning pul-
ley with ring spanner
TThe tensioning pulley can be
secured by inserting the
socket wrench into the fit
hole
2- Compactholder
Tfor AC generator, AC com-
pressor and tensioning pul-
ley for ribbed V-belt
3- 50Nm
TTightening sequence: first
top right bolt, then bottom
right bolt, and last the bolts at
the left (looking in direction of
travel)
4- 23Nm
5 - AC generator
Tremoving and installing
⇒Electrical System;
Rep. Gr. 27
Tto facilitate the positioning of
the AC generator drive the
threaded bushings of the
screws on the generator
slightly backwards
6 - 20 Nm + torque a further 1/4
turn (90 °)
7- Bushing
T2 pieces
8- 25Nm
9 - AC compressor
Tremoving and installing ⇒Heating, Air Conditioning; Rep. Gr. 87
10 - V-ribbed belt
Tbefore removing mark running direction
Tcheck for wear
Tremoving and installing ⇒13-1 page 2
TRouting of toothed belt ⇒13-1 page 2
11 - V-ribbed belt pulley
12 - 90 Nm + torque a further 1/4turn (90 °)
Treplace
Ttightening may occur in successive stages
Tthe torquing angle can be measured with a commercially available angle measuring plate, e.g. -Hazet 6690-
13 – Crankgear

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
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13
Removing and installing V-ribbed belt
Special tools, test and measuring equipment and
auxiliary items required
♦Clamping lever -MP 1-203-
Vehicles with air conditioning
Routing of the V-ribbed belt
Belt drive with AC compressor:
1 - AC generator - belt pulley
2 - AC compressor - belt pulley
3 - Crankshaft toothed belt sprocket
4 - Tensioning pulley
Removing
–Remove the noise insulation.
–Mark the rotation direction of the V-ribbed belt.
–Swivel out tensioning pulley with a wrench in -direc-
tion of arrow-.
–Remove the V-ribbed belt. If necessary the tensioning
pulley can be secured by inserting the socket wrench
into the lock opening.
Installing
–First lay the V-ribbed belt on the crankshaft timing belt
sprockett, then on the AC compressor belt pulley.
–Release tensioning pulley with the wrench and pull the
belt over the AC generator - belt pulley.
–Check whether the ribbed V-belt fits correctly in the
ribbing of all tensioning pulleys.
–Check belt with the engine running in idle.
–Install the noise insulation.
♦Pay attention to the running direction when installing
the V-ribbed belt.
♦Replace damaged V-ribbed belt.
♦If the belt is considerably worn it must be replaced.
♦Do not fold or buckle the belt when handling it!
Vehicles without air conditioning
Removing
–Remove the noise insulation.
–Release fixing screws for AC generator.
S13-0206
34
2
1
S13-0205
Note

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13
–Position clamping lever -MP 1-203-, secure by insert-
ing a pin and and push AC generator towards the
crankshaft.
Remove the released ribbed V-belt from the AC genera-
tor - belt pulley.
Installing
–Lay the V-ribbed belt on the toothed belt sprocket
crankshaft.
–Push AC generator down and fit on belt.
Once the AC generator is released the belt is tensioned
to nominal voltage.
–After fitting the ribbed V-belt, crank the engine several
times with the starter (about 10 turns) once the AC
generator screws are released.
–First tighten the bottom and then the top screw for AC
generator to 20 Nm.
–Install the noise insulation.
Summary of components of timing belt
1 - Top toothed belt guard
2- 20Nm
3 - Tensioning pulley
Tcheck ⇒13-1 page 4
TTensioning toothed belt
⇒13-1 page 4
4 - Timing belt
Tbefore removing mark run-
ning direction
Tcheck for wear
Tdo not kink
TRouting of toothed belt
⇒Fig. 1 in 13-1 page 4
Tremoving and installing, ten-
sioning ⇒13-1 page 4
5 - Rear timing belt guard
6- 10Nm
7 - Lifting eye
8- 25Nm
9 - Guide pulley
10 - Bracket
11 - 50 Nm
12 - Coolant pump
Twith integrated gasket -
warning - it must not be re-
moved from the pump, re-
place completely if leaking or
damaged
Tremoving and installing
⇒Chapter 19-1

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Disassembling and assembling engine Edition 05.05
S00.5306.06.20
13-1 page 4
13
13 - Crankshaft toothed belt sprocket
Tpay attention to position of toothed belt when installing ⇒13-1 page 4
14 - 12 Nm
Treplace
15 - V-ribbed belt pulley
Tpay attention to locating element when installing
Tremoving and installing ⇒13-1 page 4
16 - 90 Nm + torque a further 1/4turn (90 °)
Treplace
Ttightening may occur in successive stages
Tthe torquing angle can be measured with a commercially available angle measuring plate, e.g. -Hazet 6690-
17 - V-ribbed belt
Tbefore removing mark running direction
Tremoving and installing ⇒13-1 page 2
TRouting of the ribbed V-belt ⇒13-1 page 2
18 - Bottom toothed belt guard
19 - Console
Fig. 1: Routing of toothed belt
A - Coupling drive - Toothed belt
B - Main drive - Toothed belt
Removing, installing and tensioning the
toothed belt and inspecting the semi-au-
tomatic toothed belt tensioning pulley
Special tools, test and measuring equipment and
auxiliary items required
♦Supporting device -MP 9-200-
♦Pressure pad -T 30004- with replaceable stud
-T 30004-
♦Camshaft lock -T 10016-