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
S00.5306.06.20
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
S00.5306.06.20
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
S00.5306.06.20
00-1 page 2
00

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components
Removing and Installing EngineEdition 09.03
S00.5306.04.20
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
Removing and Installing Engine Edition 09.03
S00.5306.04.20
10-1 page 2
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