Engine ATD

Service

5

Workshop ManualFABIA 2000Edition 08.00Engine code

1.9/74 TDI Engine, MechanicsATD

Service Department. Technical Information

Printed in Czech Republic S00.5313.00.20

5

Service

The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.

Printed in Czech Republic S00.5313.00.20

FABIA 2000

1.9/74 TDI Engine, Mechanics

List of Supplements to Workshop Manual

FABIA 20001.9/74 TDI Engine, MechanicsEdition 08.00Supplement 1 2 3

Edition 08.00 08.01 05.02 11.03

Subject Basic Edition Modifications in Rep. Gr. 13, 17, 20, 21 Modifications in Rep. Gr. 10, 13, 19, 20, 21 Modifications in Rep. Gr. 13, 15, 17, 19, 20, 21, 26

Article Number S00.5313.00.20 S00.5313.01.20 S00.5313.02.20 S00.5313.03.20

Edition 11.03 S00.5313.03.20

List of Supplements

FABIA 2000


List of Supplements

Edition 11.03 S00.5313.03.20

FABIA 2000


Table of Contents00 Technical DataTechnical data ........................................................................................... 00-1 page 1

10 Removing and Installing EngineRemoving and Installing Engine .................................................................... 10-1 - Removing engine ...................................................................................... 10-1 - Securing the engine to the assembly stand ....................................................... 10-1 - Installing the engine ................................................................................... 10-1 - Tightening torques .................................................................................... 10-1 - Assembly bracket ...................................................................................... 10-1 page page page page 1 1 7 9

page 11 page 11

13 CrankgearRemoving and installing V-ribbed belt ............................................................ 13-1 - Summary of components - Vehicles without air conditioning ................................... 13-1 - Summary of components - Vehicles with air conditioning ....................................... 13-1 - Removing the V-ribbed belt .......................................................................... 13-1 - Installing the V-ribbed belt ........................................................................... 13-1 Removing and installing, tightening the timing belt ........................................... 13-2 - Summary of components ............................................................................. 13-2 - Removing and installing, tightening the timing belt .............................................. 13-2 Removing and installing sealing flange and flywheel ......................................... 13-3 - Replacing gasket ring for crankshaft - on the belt pulley side - ................................ 13-3 - Removing and installing the front sealing flange ................................................. 13-3 Crankshaft, Piston and Conrod ..................................................................... 13-4 - Removing and installing crankshaft ................................................................ 13-4 - Disassembling and assembling piston and conrod .............................................. 13-4 - Checking piston projection in TDC .................................................................. 13-4 page page page page page page page page page page page page page page page 1 1 2 3 5 1 1 3 1 2 4 1 1 2 5

15 Cylinder Head, Valve GearRemoving and installing cylinder head ........................................................... 15-1 - Summary of components ............................................................................. 15-1 - Removing and installing cylinder head ............................................................. 15-1 - Testing compression .................................................................................. 15-1 Repairing Valve Gear .................................................................................. 15-2 Camshaft ................................................................................................. 15-3 - Removing and installing camshaft .................................................................. 15-3 - Removing and installing gasket ring for camshaft ................................................ 15-3 Valve Seats/Valves Guide/Valve Stem Seal ...................................................... 15-4 - Reworking valve seats ................................................................................ 15-4 - Calculating max. permissible reworking dimension .............................................. 15-4 - Inspecting valve guides .............................................................................. 15-4 - Replacing valve stem seals .......................................................................... 15-4 page page page page page page page page page page page page page 1 1 3 6 1 1 1 3 1 1 1 2 2

17 LubricationRemoving and installing parts of the lubrication system ..................................... 17-1 - Disassembling and assembling oil filter holder ................................................... 17-1 page page 1 2

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1.9/74 TDI Engine, Mechanics page page 1 1

Removing and Installing Oil Pan ................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3

19 CoolingParts of cooling system - Summary of components ........................................... 19-1 - Parts of the cooling system fitted to body ......................................................... 19-1 - Parts of cooling system engine side ................................................................ 19-1 - Connection diagram for coolant hoses ............................................................. 19-1 - Draining and filling up coolant ....................................................................... 19-1 - Checking the coolant system for tightness ........................................................ 19-1 Removing and Installing Radiator, Coolant Pump, Coolant Regulator .................... 19-2 - Removing and installing radiator .................................................................... 19-2 - Removing and installing coolant pump ............................................................ 19-2 - Removing and installing coolant regulator ........................................................ 19-2 page page page page page page page page page page 1 2 3 4 4 6 1 1 2 3

20 Fuel SupplyRemoving and installing parts of the fuel supply - Part 1 .................................... 20-1 - Fuel tank with component parts - Summary of components .................................... 20-1 - Safety precautions when working on the fuel supply system ................................... 20-1 - Rules of cleanliness ................................................................................... 20-1 - Repairing the fuel filter ................................................................................ 20-1 - Removing and installing the fuel delivery unit/fuel gauge sender unit ........................ 20-1 - Removing and installing the fuel gauge sender from the fuel delivery unit .................. 20-1 - Testing fuel pump ..................................................................................... 20-1 Removing and installing parts of the fuel supply - Part 2 .................................... 20-2 - Removing and installing the fuel tank .............................................................. 20-2 - Removing and installing fuel cooler ................................................................ 20-2 - Inspecting tandem pump ............................................................................ 20-2 - Removing and installing the tandem pump ........................................................ 20-2 Repairing the accelerator control .................................................................. 20-3 - Summary of components ............................................................................ 20-3 page page page page page page page page page page page page page page page 1 1 2 3 4 5 6 6 1 1 2 2 4 1 1

21 TurbochargingCharge-air system with exhaust turbocharger - Part 1 ........................................ 21-1 - Removing and installing exhaust turbocharger with component parts ........................ 21-1 - Removing and installing parts of the charge air cooling ......................................... 21-1 - Removing and installing charge-air cooler ........................................................ 21-1 - Connection diagram for vacuum hoses for vehicles 10.01 .................................. 21-1 .................................. 21-1 - Connection diagram for vacuum hoses for vehicles 11.01 page page page page page page page page page page 1 1 3 3 5 6 1 1 1 2

Charge-air system with exhaust turbocharger - Part 2 ........................................ 21-2 - Rules of cleanliness ................................................................................... 21-2 - Remove exhaust turbocharger ...................................................................... 21-2 - Checking charge pressure control .................................................................. 21-2

26 Exhaust SystemRemoving and installing parts of the exhaust system ........................................ 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Replacing front or rear silencer ..................................................................... 26-1 - Checking the exhaust system for leaks ............................................................ 26-1Table of Contents

page page page page

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1.9/74 TDI Engine, Mechanics page page page 1 1 2

Exhaust gas recirculation system .................................................................. 26-2 - Removing and installing parts of the exhaust gas recirculation system ...................... 26-2 - Test mechanical exhaust gas recirculation valve ................................................. 26-2

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00 Technical Data00-1 Technical data

Engine number The engine number (engine identification characters and serial number) is located in the front at the engine/ gearbox joint -arrow-. In addition, a sticker with the engine identification characters and serial number is affixed to the toothed belt guard. The engine identification characters are also indicated on the vehicle data sticker.

Engine characteristics Identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression ratio Firing order min. CN Catalytic converter Exhaust gas recirculation Turbocharging Charge air cooler l kW at rpm Nm at rpm mm mm ATD 02.00 EU -3 1,896 74/4000 240/1800-2400 79,5 95,5 19,0 1-3-4-2 49 yes yes yes yes

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Technical data

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10

10 Removing and Installing Engine10-1 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 Engine/gearbox jack (e.g. -V.A.G 1383 A-) Engine mount -T10012 Distance sleeve -T30010 Extension -10-222 A/7 Engine / gearbox mount -MP 1-202 Assembly stand -MP 9-101 Lifting device -MP 9-201 Pliers for spring strap clips Snap hook Grease -G 000 100 Hot screw paste -G 052 112 A3 Wire Adhesive tape

Removing engineNote The engine is removed towards the front together with

the gearbox. Supporting points on the lift platform Inspection

and Maintenance. The hose connections are secured with screw-type

clips, spring-type clips or clamp-type clips. Always replace warm-type clamps with spring strap clips or screw 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. If the battery is disconnected and reconnected, carry

out certain additional operations Electrical System; Rep. Gr. 27.

Procedure

On models fitted with a coded radio set, pay attentionto the coding; determine if necessary.

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Removing and Installing Engine

10-1 page 1

10 Disconnect the battery-earth strap with the ignition off. Remove noise insulation -arrows-. Remove drive shaft to the right Running gear;Rep. Gr. 40.

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Unscrew the drive shaft to the left of the gearboxflange.

Raise drive shaft on the left and secure. Remove front exhaust pipe with catalyst Chapter26-1.

Remove front bumper Body work; Rep. Gr. 63.S10-0114

Screw out screw -3-. Remove charge-air pipe at bottom -1- with connectinghose -2- -arrows-.

Remove charge-air routing from charge-air cooler Chapter 21-1.

Unbolt the pendulum support -arrows-. Place a catch pan under the engine. Open the cap on the coolant expansion bottle.

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Turn the drain plug -arrow- on the radiator to the leftand draw backwards, if necessary fit auxiliary hose onto connection.

A10-0118

Also detach the front coolant hose at bottom of oilcooler -arrow- and allow remaining coolant to drain off.

S10-0116

Remove engine cover:Pull the front engine cover upwards with a sudden motion -arrow A- and pull the cover out of the rear attachment -arrow B-.

Remove air filter with intake hose 1.9/74 TDI Engine - Fuel Injection; Rep. Gr. 23.

Remove battery and battery tray Electrical System;Rep. Gr. 27.

Unscrew the generator cables from the battery coverand remove the wiring loom from the holder.

Remove the coolant hoses from the radiator. Removing the lock carrier Body work; Rep. Gr. 50.For vehicles with air conditioningInstructions and work procedures Heating, Air Conditioning; Rep. Gr. 87.

Before removing the lock carrier:

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10 Drain refrigerant. Disconnect the high and low pressure lines on the

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couplings. Remove high-pressure line from the compressor.

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For all vehicles

Disconnect the coolant hose -1- from the pipe. Disconnect the fuel-intake hose -3- and the fuel-returnhose -2- from the pipes.

3 2S10-0148

Remove charge-air pipe at the top -1- with connectinghose -2- -arrows-.

Pull off the coolant hose from the expansion bottle atthe bottom.

Disconnect the vacuum hose to the vacuum reservoirat the connecting piece.

Remove the vacuum hose -1- from the intake manifoldflap vacuum unit.

Pull off the vacuum hose -2- from the exhaust gas solenoid valve -N18-.

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1

S10-0146

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Remove the coolant intake hose -3- from the supports-4-.

Remove the coolant return hose -2- from the heat exchanger connection fittings -1-.

3

4

Pull off vacuum hose -6- from tandem pump -5-.

2 1 6 5

S10-0150

Unplug connector -1- from the engine control unit. Disconnect the plug connections -2- and -3- and remove from bracket.

Unclip cable clip -4- -arrows-.

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4

S10-0117

Remove Bowden cable support -arrows-. Pull out slave cylinder line -A- from the holder on thegearbox.

A

S10-0152

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10 Detach selector cable -1- with relay lever, for this stepremove circlip -arrow A- from the relay lever.

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1 6 B 5 3 2 A

Remove the shift cable -2- with the gearbox shift lever,for this step unscrew nut -arrow B-.

Raise control cables and secure. Disconnect plug -3- from the reversing light switch-F4-.

Release earth strap -4- from the frame side rail. Unplug connector -5- and the cable -6- from the starter.

4S10-0153

Remove slave cylinder -B-, lay aside and secure withwire. Do not open line system. Note Do not depress the clutch pedal.

A30-0048

Disconnect the plug connections -2- and -3- under thestarter and remove from bracket.

1

2 3S10-0151

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10MP 9-201 10-222A/7

Hook on lifting device -MP 9-201- with extension-10-222A/7- and snap hook -A-, as shown in the figure, hang up and take up the weight of the engine/ gearbox assembly. Caution! Use securing pins on the hooks and rig pins to prevent release.

A

S10-0155

Unscrew the engine mounting from the engine support bracket -arrows-. Note If the engine/gearbox unit drops when the screws are released raise it up again.ax m in m

S10-0149

Unscrew the gearbox mount from the gearbox supportbracket -arrows-. The note on unscrewing the engine mounting also applies for the gearbox mount.

Carefully lower the engine with gearbox and pull outcarefully towards the front. Note Carefully guide the engine and gearbox during withdrawal. Ensure adequate clearance to other neighbouring components.

Securing the engine to the assembly standTo perform the assembly work the engine must be secured to the assembly stand -MP 9-101-. Note When measuring the cylinder bore ( Chapter 13-4) the engine must not be fixed to the assembly stand.

S10-0120

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10Procedure

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Position the engine mount -T10012- in the engine/gearbox jack.

Fix engine mount -T10012- to the cylinder block usingfixing nuts and bolts M10 with a tightening torque of 40 Nm.

Raise the engine and gearbox with the engine/gearbox jack.

Dismantle the lifting device -MP 9-201-.

T10012 V.A.G 1383A With a lifting device bring the engine/gearbox unit tothe work bench.N10-0056

Lower the engine/gearbox unit in such a way that thegearbox is positioned on the support.

T 10012 Remove cover plate -A- for flywheel behind the rightflange shaft -arrows-.

V.A.G 1383/AN10-0148

Unplug the connector from the speedometer sender-G22-.

Remove engine/gearbox connecting screws. Press gearbox from engine.

A

V34 - 3005

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10MP 9-201 7 5 68

Hook on lifting device -MP 9-201- and lift out of engine/gearbox jack using the workshop crane. Caution! Use securing pins on the hooks and rig pins to prevent release.

12 3 4

S10-0175

Unscrew Engine mount -T10012-. Attach engine to the assembly stand -MP 9-101- withthe engine / gearbox mount -MP 1-202 - and distance sleeves -T30010-. (The figure shows the 1.9 l/47 kW SDI engine; the fixing system is the same).

MP 1-202

Installing the engineNote Always replace the seals and gaskets during assem-

T30010

bly work. Always replace self-locking nuts. Coat stud bolts of exhaust manifold with hot bolt paste

-G 052 112 A3- before installing. Tightening torques 10-1 page 11. Assembly bracket 10-1 page 11.

S10-0123

ProcedureInstallation is performed in the reverse order. Pay attention to the following points:

Check whether the dowel sleeves for centering theengine/gearbox are present in the cylinder block; insert if necessary.

Check whether the intermediate plate has been inserted on the sealing flange and rests on the dowel sleeves -arrows-.

If necessary check the centering of the clutch driverdisc.

Inspect clutch release bearing for wear, replace if necessary.

Grease the drive shaft serration with grease-G 000 100 -.

Assemble together the engine with gearbox Manual gearbox 02R; Rep. Gr. 34.

When installing engine/gearbox unit, ensure adequate clearance to neighbouring components.A10-0129

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10 Align the engine/gearbox unit free of stress and attachfirmly. When tightening the bolts for engine and gearbox mounts, engine and gearbox support brackets must be resting fully against mount. Tightening torques 10-1 page 11.

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Install the slave cylinder of the hydraulic clutch Gearbox 02R; Rep. Gr. 30. Gearbox 02R; Rep. Gr. 34.

Adjust the gearshift mechanism and the shift cables Install the right drive shaft and screw the left driveshaft onto the gearbox Chassis; Rep. Gr. 40.

Install the front exhaust pipe with catalytic converterand the exhaust system so that they are not under tension. Chapter 26-1.

Install the lock carrier with component parts Bodywork; Rep. Gr. 50.

For vehicles with air conditioningInstructions and work procedures Heating, Air Conditioning; Rep. Gr. 87.

Disconnect the refrigerant lines. Replacing dessicator insert. Filling the refrigerant circuit.For all vehicles

Install front bumper Body work; Rep. Gr. 63. Electrical connections and proper routing CurrentFlow Diagrams, Electrical Fault Finding and Fitting Locations.

Install the coolant hoses Chapter 19-1.Note Only re-use drained coolant if none of the following components has been replaced: Engine block, cylinder head, radiator, heat exchanger.

Top up coolant Chapter 19-1. Check oil level before starting the engine. Interrogate fault memory and erase 1.9/74 TDI Engine - Fuel Injection; Rep. Gr. 01.

Perform a test drive.

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Tightening torquesNote Tightening torques apply only for lightly greased,

oiled, phosphatized or blackened nuts and screws. Other lubricants such as engine and gearbox oil are

allowed. Do not use Molykote. Do not use degreased parts. Unless otherwise indicated the following tightening

torques apply: Component Screws/nuts M6 M7 M8 M10 M12 Nm 9 13 20 40 70

2 1

1Assembly bracket

1

S10-0154

Engine assembly bracket1 - 20 Nm + 90 (1/4 turn) - replace 2 - 30 Nm + 90 (1/4 turn) - replace

2 1 1

Gearbox assembly bracket1 - 50 Nm + 90 (1/4 turn) - replace 2 - 40 Nm + 90 (1/4 turn) - replace

1Hinged bracketNote Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier. 1 - 30 Nm + 90 (1/4 turn) - replace 2 - 40 Nm + 90 (1/4 turn) - replace

S10-0125

1 2S10-0126

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13 Crankgear13-1 Removing and installing V-ribbed belt

Summary of components - Vehicles without air conditioningNote 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 V-ribbed belt in the belt pulley when installing it.

1 - 10 Nm + torque a further 1/4 turn (90) 2 - Vibration damper/belt pulley Assembly only possible in one position - holes offset 3 - 25 Nm 4 - Tensioner for V-ribbed belt 5 - Bracket for generator Dowel sleeve for centering Fig. 1 in 13-1 page 3 6 - 45 Nm 7 - Bracket for bottom charge-air pipe 8 - 8 Nm 9 - Generator to facilitate the positioning of the generator on the holder drive the threaded bushings of the retaining screws slightly backwards 10 - 25 Nm 11 - V-ribbed belt removing 13-1 page 3 installing 13-1 page 5

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9S13-0255

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Removing and installing V-ribbed belt

13-1 page 1

13

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Summary of components - Vehicles with air conditioningNote 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 V-ribbed belt in the belt pulley when installing it.

1 - 10 Nm + torque a further 1/4 turn (90) 2 - Vibration damper/belt pulley Assembly only possible in one position - holes offset 3 - 25 Nm 4 - Generator to facilitate the positioning of the generator on the holder drive the threaded bushings of the retaining screws slightly backwards 5 - Tensioner for V-ribbed belt 6 - Bracket for generator and AC compressor Dowel sleeve for centering Fig. 1 in 13-1 page 3 7 - 25 Nm 8 - 45 Nm 9 - Bracket for bottom charge-air pipe 10 - 8 Nm 11 - 25 Nm 12 - AC compressor 13 - Dowel sleeves for AC compressor must be present in holder item 6 14 - V-ribbed belt removing 13-1 page 3 installing 13-1 page 5

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14 13 12 11S13-0257

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dowel sleeve for centering

Before installing the bracket check whether the dowelsleeve -arrow- has been fitted.

Removing the V-ribbed beltRemoving - vehicles without air conditioningS13-0256

Remove engine cover:Pull the front engine cover upwards with a sudden motion -arrow A- and pull the cover out of the rear attachment -arrow B-.

Remove charge-air pipe at the top -1- with connectinghose -2- -arrows-.

Mark the rotation direction of the V-ribbed belt.

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13-1 page 3

13 To slacken the V-ribbed belt turn the tensioning device in the direction of the arrow.

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Remove V-ribbed belt; first from the generator-beltpulley.

Removing- vehicles with air conditioning

S13-0220

Remove the noise insulation.

S10-0114

Release screw -3-. Remove charge-air pipe at the bottom -1- with connecting hose -2- -arrows-.

Mark the rotation direction of the V-ribbed belt.

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13

Swivel tensioning pulley in -direction of arrow- in orderto slacken the V-ribbed belt.

Remove V-ribbed belt; first from the air conditioningcompressor belt-pulley.

Installing the V-ribbed beltNote Inspect V-ribbed belt Inspection and Maintenance. Before fitting the V-ribbed belt make sure that all as-

semblies (generator and AC compressor) are securely mounted. Ensure belt pulley and tensioning pulley run freely.

Tension the tensioning device and lay the V-ribbedbelt on it; lay it over the generator belt pulley last.

Start engine and inspect running of belt.

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13-2

Removing and installing, tightening the timing belt

Summary of componentsNote Before removing the timing belt, mark direction of running. Reversing the rotation direction of an already used belt may destroy it. For vehicles 04.01

1 - Timing belt guard - top part 2 - Timing belt before removing mark running direction check for wear do not kink removing and installing 13-2 page 3 3 - 20 Nm + torque a further 1/8 turn (45) 4 - Tensioning pulley 5 - 100 Nm 6 - 20 Nm + torque a further 1/8 turn (45) 7 - Camshaft sprocket 8 - Hub with pulse rotor to release and tighten use counterholder -T10051 to remove use extractor -T10052removing and installing Chapter 15-3 9 - 10 Nm 10 - Rear timing belt guard 11 - Sealing sleeve replace if damaged 12 - Tensioning device for timing belt 13 - Guide pulley 14 - Coolant pump removing and installing Chapter 19-2 15 - Timing belt gear - crankshaft Contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of grease Fitting position: flats on timing belt sprocket and crankshaft must be aligned 16 - 120 Nm + torque a further 1/4 turn (90) to release and tighten use counterholder -MP 1-310 - or -T30004replace do not wet new screws with oil and do not grease them 17 - 15 Nm 18 - 20 Nm

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13-2 page 1

1319 - Timing belt guard - bottom part 20 - V-ribbed belt pulley with vibration damper Assembly only possible in one position - holes offset 21 - 10 Nm + torque a further 1/4 turn (90) 22 - Timing belt guard - middle part 23 - 45 Nm 24 - Engine support bracket

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For vehicles 05.01 1 - Timing belt guard - top part 2 - Timing belt before removing mark running direction check for wear do not kink removing and installing 13-2 page 3 3 - 20 Nm + torque a further 1/8 turn (45) 4 - Tensioning pulley

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5 - 20 Nm + torque a further 1/8 turn (45) 6 - Camshaft sprocket 7 - 100 Nm 5 8 - Hub with pulse rotor 12 to release and tighten use counterholder -T10051 13 to remove use extractor -T1005214 removing and installing 15 Chapter 15-3 23 9 22 9 - 10 Nm 10 - Rear timing belt guard 11 - Sealing sleeve replace if damaged 12 - O-ring replace 21 20 9 19 18 17 16 S13-0399 13 - Coolant pump removing and installing Chapter 19-2 14 - 15 Nm 15 - Guide pulley 16 - Timing belt gear - crankshaft Contact surface between crankshaft timing belt sprocket and crankshaft must be clean and free of grease Fitting position: flats on timing belt sprocket and crankshaft must be aligned 17 - 120 Nm + torque a further 1/4 turn (90) to release and tighten use counterholder -MP 1-310 - or -T30004replace do not wet new screws with oil and do not grease them

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18 - 20 Nm + torque a further 1/8 turn (45) 19 - Timing belt guard - bottom part 20 - V-ribbed belt pulley with vibration damper Assembly only possible in one position - holes offset 21 - 10 Nm + torque a further 1/4 turn (90) 22 - Timing belt guard - middle part 23 - 45 Nm 24 - Engine support bracket

Removing and installing, tightening the timing beltSpecial tools, test and measuring equipment and auxiliary items required Torque wrench Rig pin for injection pump -MP 1-301- or -3359 Supporting device -MP 9-200 Small locking plates -T10008 Locking device -T10050 Wrench for tensioning pulleys (e.g. -Matra V 159-,

-T10020-, -Hazet 2587 - or - Stahlwille 127-17-) Pliers for spring strap clips Liquid locking material -D 000 600 A2-

Removing

Remove the V-ribbed belt Chapter 13-1. Remove the front right wheelhouse liner BodyWork; Rep. Gr. 66.

Removing the V-ribbed belt pulley. Remove middle and bottom part of toothed belt guard. Remove charge-air pipe at the top -1- with connectinghose -2- -arrows-. WARNING! Fuel line is under pressure. Place cleaning cloths around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.

Disconnect the fuel feed line -1- and the fuel returnflow line -2-.

Remove expansion reservoir and place down to thefront with coolant hoses connected.

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13-2 page 3

13 Install supporting device -MP 9-200- and support theengine with spindle -A- in fitting position. Allow spindle -B- to hang loosely.

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Remove engine support -arrows-.Note Releasing the pendulum support brings the engine forwards and the engine mounting can be removed.

Unbolt the pendulum support from the gearbox. Remove timing belt guard - top part. Lower engine approx. 35 mm and release bottomscrew of the engine mounting.

Raise the engine approx. 45 mm relative to its normalposition and release the top screws of the engine mounting.

Swivel out the engine mounting towards the top -arrow A- and subsequently pull up at the rear -arrow B-.

Lower engine again into normal position. Position crankshaft on TDC cylinder 1.

B A

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13

Note Rotate crankshaft until the marking on the top of the toothed belt sprocket and the arrow on the rear toothed belt guard are positioned opposite the lugs on the hub of the impulse rotor -arrows A-.

Lock hub with locking pin -MP 1-301- or -3359-.Insert locking pin through the left slot into the hole at the cylinder head.

Secure crankshaft toothed belt sprocket with lockingdevice -T10050-. Insert locking device from the front of the timing belt sprocket into the teeth. To facilitate this step, it is recommended to colour the TDC marking on the crankshaft timing belt sprocket and on the locking device -T10050- with white paint -arrows B-. Note The marking on the crankshaft timing belt sprocket

and the marking on the locking device -T10050- must be positioned opposite -arrows B-. Pin of locking device must engage in the hole of the sealing flange -arrow C-. Locking device - T10050- must not be used as a coun-

terholder when releasing or tightening the bolts for the toothed belt gear - crankshaft!

Mark the rotation direction of the timing belt.For vehicles 04.01

Insert wrench fully into the hexagon socket bolt andpress in anti-clockwise direction onto the tensioning pulley -arrow- long enough until it is possible to secure the toothed belt tensioning device with the locking plate -T10008-.

Slacken nut of tensioning pulley. Unscrew bolts -1- of toothed belt tensioning deviceand remove the tensioning device.

Remove guide pulley item 13 in 13-2 page 1For vehicles 05.01

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13-2 page 5

13 Loosen the fixing nut on the tensioning roller. Loosen the eccentric of the tensioning pulley with awrench (e. g. -T10020-) anti-clockwise.

FABIA 2000


Remove guide pulley item 15 in 13-2 page 2For all vehicles

Remove timing belt.Installing and tensioningNote Tensioning work at the timing belt must only be carried out when engine is cold.

Slacken bolts of camshaft sprocket -1- sufficiently sothat the camshaft sprocket can be turned in the area of the slots.

Turn camshaft sprocket clockwise in the slots -arrowas far as the stop. For vehicles 04.01

Carefully turn eccentric in clockwise direction with thewrench for tensioning pulleys -C- sufficiently until the lug on the eccentric is right in front of stop -B-.

Fit timing belt onto camshaft sprocket, tensioning pulley, crankshaft timing belt sprocket and onto the timing belt sprocket of the coolant pump.

Install the tensioning device for toothed belt. Install guide pulley item 13 in 13-2 page 1 Carefully turn eccentric in an anti-clockwise directionwith a wrench for tensioning rollers -C- (the lug on the eccentric moves toward the stop -A-) until it is possible to move the locking plate -T10008- away slightly.

Turn wrench in clockwise direction long enough untilgap size -a- is achieved. (The lug on the eccentric moves toward the stop -B-). Specification -a-: 4 1 mm.

13-2 page 6


Edition 11.03 S00.5313.03.20

FABIA 2000


13

Note Use e.g. a 4 mm drill bit to adjust gap size -a-. Gap size -a- becomes smaller after the tensioning pul-

ley is tightened. This fact should therefore be taken into account when setting with 4 mm drill bit. On a warm engine dimension -a- can decrease to 1

mm.

Hold tensioning pulley in this position and tighten nutof tensioning pulley as follows: 20 Nm + torque a further 1/8 turn (45) For vehicles 05.01

Fit timing belt onto crankshaft timing belt sprocket,tensioning pulley, camshaft sprocket and onto the timing belt sprocket of the coolant pump.

Install guide pulley item 15 in 13-2 page 2 Check the correct catch fitting of the tensioning pulleyin the hole in the rear timing belt guard -arrow-.

A13-0053

Turn the eccentric of the tensioning pulley with awrench (e. g. -T10020-) clockwise in such a way until the pointer -2- stands in the centre of the gap size of the base plate. Note Ensure that the fixing nut does not turn at the same time.

Hold the tensioning pulley in this position and tightenthe nut of the tensioning pulley to 20 Nm + torque a further 45 (1/8 turn).

Note When tightening the fixing nut, the pointer turns -arrowmax. 5 mm to the right from the gap of the base plate. This position must not be corrected, because the toothed belt settles when running-in. For all vehicles

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13-2 page 7

13 Tighten bolts of camshaft sprocket -1- to tighteningtorque of 25 Nm + torque a further 45 (1/8 turn).

FABIA 2000


Test timing

Remove locking pin -MP 1-301- or -3359- and lockingdevice -T10050-.

Tighten crankshaft two revolutions in the direction ofrotation of engine and position again to TDC of piston for cylinder 1. Note Pin for locking device - T10050 - must engage in the

sealing flange. (Locking device should be inserted just ahead of TDC on toothed belt sprocket.) If the crankshaft is positioned after TDC of piston for

cylinder 1 and the pin of the locking device does not engage in the sealing flange, rotate the crankshaft back no more than 1/4 revolution and again set the crankshaft to the TDC of the piston for cylinder 1 by turning in direction of rotation of engine. It is not permitted to carry out the correction by turning

in the opposite direction of rotation of the engine in order to insert the locking device.

After inserting the pin for locking device -T10050check and determine whether the hub can be secured with locking pin -MP 1-301- or -3359-. If the hub cannot be arrested:

Remove bolt for locking device from the hole at thesealing flange and rotate the crankshaft until the hub can be locked with locking pin.

Slacken bolts of camshaft sprocket -1-. Rotate crankshaft in opposite direction of rotation ofengine long enough until the pin for locking device in the sealing flange is positioned close to the hole -arrow-.

Rotate crankshaft in direction of rotation of enginelong enough until the pin for locking device engages in the sealing flange.

Tighten bolts of camshaft sprocket to a tighteningtorque of 25 Nm. 20 Nm + torque a further 1/8 turn (45) For vehicles 04.01

After inserting the pin for locking device -T10050-

check dimension -a- 4 1 mm and determine whether the hub can be secured with rig pin - MP 1-301- or -3359-.

If dimension -a- is not reached:

Tighten the tensioning pulley.

13-2 page 8


Edition 11.03 S00.5313.03.20

FABIA 2000


13

Hold the tensioning pulley with the wrench, slacken the nut, and turn the wrench clockwise until dimension -a- is achieved. Specification -a-: 4 1 mm. If nominal dimension -a- is obtained and if the hub can be arrested:

Again tighten the nut:20 Nm + torque a further 1/8 turn (45) For vehicles 05.01 The pointer of the tensioning pulley stands in the centre or max. 5 mm to the right from the gap of the base plate. For all vehicles

Remove locking pin and locking device -T10050-. Rotate crankshaft on a further two revolutions in direction of rotation of the engine until the crankshaft is again positioned at TDC of piston of cylinder 1. Note Pin for locking device -T10050- must engage in seal-

ing flange when this is done.

If the crankshaft is positioned after TDC of piston for cylinder 1 and the pin of the locking device does not engage in the sealing flange, rotate the crankshaft back no more than 1/4 revolution and again set the crankshaft to the TDC of the piston for cylinder 1 by turning in direction of rotation of engine. in the opposite direction of rotation of the engine in order to insert the locking device.

It is not permitted to carry out the correction by turning

Repeat check.Further installation occurs in reverse order. Tightening torque of the engine support bracket on the vehicle body: 45 Nm. Tightening torque of the engine support and pendulum support: Chapter 10-1.

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13-2 page 9

13

FABIA 2000


13-2 page 10


Edition 11.03 S00.5313.03.20

FABIA 2000


13

13-3Note

Removing and installing sealing flange and flywheel

Repairing the clutch Manual gearbox 02R; Rep. Gr. 30 Secure the engine with engine mount -MP 1-202- and distance sleeves -T30010- on the assembly stand before

performing assembly work. 1 - PTFE gasket ring replace 13-3 page 3 only install PTFE gasket ring (pay attention to different versions Fig. 1 in 13-3 page 2) 2 - Front sealing flange must be positioned on dowel sleeves removing and installing 13-3 page 4 3 - Cylinder block removing and installing crankshaft Chapter 13-4 disassembling and assembling pistons and conrod Chapter 13-4 4 - Flywheel Assembly only possible in one position - holes offset lock using -MP 1-504- for removing and installing with the fixture Fig. 2 in 13-3 page 2 5 - 60 Nm + torque a further 90 (1/4 turn)

2

3

1

7 4 5

replace 6 - Intermediate plate must be positioned on dowel sleeves do not damage/bend during 8 7 6 N13-0488 assembly work hang on the sealing flange Fig. 3 in 13-3 page 2 7 - 15 Nm 8 - Sealing flange with PTFE gasket ring to remove and install, take off oil pan Chapter 17-2 must be replaced completely only install sealing flange with PTFE gasket ring (pay attention to different versions Fig. 1 in 13-3 page 2) install gasket ring dry, the crankshaft stub must be free of grease fit new sealing flange with guide bushing (do not pull guide bushing out of gasket ring before fitting)

Edition 05.02 S00.5313.02.20


13-3 page 1

13Fig. 1: I II Gasket ring versions

FABIA 2000


IElastomer gasket ring sealing lip -1-; with garter spring PTFE gasket ring multiple sealing lips -2-; without garter spring

II 1 2

Note When installing PTFE gasket ring do not moisten with oil. The shaft must also be free from oil and grease.

S13-0190

Fig. 2:

Lock the flywheel

Position the assembly fixture -MP 1-504- on the ringgear and turn until it rests against spacer bush -T30010-.

MP 1-202

T30010 MP 1-504

T30010S13-0191

Fig. 3:

Installing intermediate plate

Insert intermediate plate on sealing flange and pushonto the dowel sleeves -arrows-.

Replacing gasket ring for crankshaft - on the belt pulley side Special tools, test and measuring equipment and auxiliary items required Torque wrench Gasket ring extractor -MP 1-226 Pressure bushing -T10053 Guide bushing -T10053/1 Bolt (M16 x 1.5 x 60) -T10053/2 Counterholder -T30004- or -MP 1-310 A10-0129

13-3 page 2


Edition 05.02 S00.5313.02.20

FABIA 2000


13

Removing

Remove the timing belt Chapter 13-2. Remove crankshaft timing belt sprocket. To this endlock the toothed belt gear with counterholder -T30004or -MP 1-310-. Note When screwing on the counterholder -MP 1-310- place 2 washers between the toothed belt gear and the counterholder.

T 30004

MP 1-310

S13-0166

Screw the bolt by hand into the crankshaft as far asthe stop.

Unscrew inner part of the gasket ring extractor-MP 1-226- nine turns (approx. 17 mm) out of the outer part and lock with knurled screw.

A13-0067

Oil the thread head of the gasket ring extractor-MP 1-226 -, position and forcefully screw it into the gasket ring as far as possible.

Release knurled screw and turn the inner side againstthe crankshaft until the gasket ring is pulled out.

InstallingNote Only fit PTFE gasket rings. Do not fit elastomer gasket

rings with a garter spring. The sealing lips of the PTFE gasket ring must neither

be oiled nor greased.

MP 1-226

S13-0078

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13-3 page 3

13 Use a clean cloth to remove oil residues on the crankshaft journal.

FABIA 2000


Insert guide bushing -T10053/1- on the crankshaftstub.

Slide gasket ring over the guide bushing onto thecrankshaft stub.

T10053/1 Press in the gasket ring with pressure bushing-T10053- and screw -T10053/2- up to the stop.

S13-0194

T10053/2

T10053 Install timing belt gear on the crankshaft and lock withcounterholder -T30004- or -MP 1-310-. Note When screwing on the counterholder -MP 1-310-

S13-0266

place 2 washers between the toothed belt gear and the counterholder. Replace central screw for toothed belt gear - crank-

T 30004

shaft.

Tighten new central screw for toothed belt gear crankshaft to 120 Nm and turn a further 90 (1/4 turn).

Install the timing belt Chapter 13-2.

Removing and installing the front sealing flangeSpecial tools, test and measuring equipment and auxiliary items required Torque wrench Guide bushing -T10053/1 Counterholder -T30004- or -MP 1-310 Hand-held power drill with plastic brush insertS13-0166

MP 1-310

13-3 page 4


Edition 05.02 S00.5313.02.20

FABIA 2000 Flat scraper


13

Silicone sealant -D 176 404 A2-

Removing

Remove the timing belt Chapter 13-2. Remove crankshaft timing belt sprocket. To this endlock the toothed belt gear with counterholder -T30004or -MP 1-310 -. Note When screwing on the counterholder -MP 1-310- place 2 washers between the toothed belt gear and the counterholder.

T 30004

Drain engine oil. Remove oil pan Chapter 17-2. Unscrew front sealing flange. Remove sealing flange, if necessary release by applying slight blows with a rubber-headed hammer.S13-0166

MP 1-310

Use a flat scraper to remove sealant residues on thecylinder block.

Use a rotating plastic brush to remove sealant residues on the sealing flange (wear protective goggles).

Clean sealing surfaces, they must be free of oil andgrease.

InstallingNote Pay attention to the 'use by date' on sealant. The sealing flange must be installed within 5 minutes

after applying the silicone sealant.

Cut off nozzle of tube of silicone sealant-D 176 404 A2- at the front marking ( of nozzle approx. 3 mm).

N17-0019

Edition 05.02 S00.5313.02.20


13-3 page 5

13 Apply silicone sealant bead to the clean sealing surface of the sealing flange, as shown in the illustration. Thickness of sealant bead -arrow-: 23 mm Note The sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.

FABIA 2000


Fit sealing flange immediately and lightly tighten allbolts.

A17-0028

Note When installing the sealing flange with the gasket ring fitted use guide bushing -T10053/1-:

Tighten the fixing screws of the sealing flange crosswise. Tightening torque: 15 Nm

Install oil pan Chapter 17-2.Note After installing, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in.

Install the timing belt Chapter 13-2.

T10053/1

S13-0194

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FABIA 2000


13

13-4

Crankshaft, Piston and Conrod

Removing and installing crankshaft1 - Bearing shells 1, 2, 4 and 5 for bearing cap without lubricating groove for cylinder block with lubricating groove do not mix up used bearing shells (mark) 2 - 65 Nm + torque a further 1/4 turn (90) replace tighten thread 3 - Bearing caps Bearing cap 1: on the belt pulley side Bearing cap 3: with recesses for thrust washers retaining lugs of the bearing shells of the cylinder block/ bearing cap must be on top of one another 4 - Bearing shell 3 for bearing cap without lubricating groove for cylinder block with lubricating groove 5 - Thrust washer for bearing cap 3 pay attention to locating element 6 - Rotor for engine speed sender -G287 - 10 Nm + torque a further 1/4 turn (90) replace 8 - Fit pin Checking projection from crankshaft Fig. 1 in 13-4 page 2 9 - Crankshaft Crankshaft bearing journal: 54.00 mm Conrod bearing journal: 47.80 mm Axial play when new: 0,070.17 mm Wear limit: 0.37 mm 10 - Thrust washer for cylinder block, bearing 3

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13-4 page 1

13Fig. 1: Checking projection of fit pin from crankshaft

FABIA 2000


1

2

a

Special tools, test and measuring equipment and auxiliary items required Depth gauge

Test sequence:

Use depth gauge to inspect projection -a- of dowel pinwhen pulse rotor -1- is removed. 1 - Pulse rotor 2 - Fixing screw 3 - Projection of the fit pin -3- from crankshaft -a- = 2.53.0 mm

3

2

2N13-0554

Disassembling and assembling piston and conrod1 - Piston rings Offset joint 120 use piston ring pliers for removing and installing Marking TOP faces up inspect gap clearance Fig. 2 in 13-4 page 3 inspect end clearance Fig. 3 in 13-4 page 4 2 - Piston with combustion chamber mark installation position and matching cylinder Installation position and assignment of piston/cylinder Fig. 5 in 13-4 page 4 arrow on piston crown faces towards the belt pulley side use piston ring tensioning strap for installing if cracks present on piston stem - replace piston inspect piston projection at TDC 13-4 page 5 Pistons: 79.47 mm 3 - Piston pin if stiff, heat piston to 60C use drift -VW 222A- for removing and installing 4 - Circlip 5 - Conrod replace as a set only mark assignment to cylinder, refer to -AFitting position: Markings -B- point towards the belt pulley side 6 - Bearing shell Check fitting position pay attention to different version:

13-4 page 2


Edition 11.03 S00.5313.03.20

FABIA 2000


13

7-

8-

9-

10 -

Top bearing shell (on piston side) is subject to less stress Distinguishing feature: black marking on the contact surface near the separation point insert bearing shell in the middle of the conrod bearing cap do not mix up used bearing shells (mark) check for firm seating Axial clearance: Wear limit: 0.37 mm Cylinder block Inspect cylinder block Fig. 4 in 13-4 page 4 Cylinder: 79.51 mm Conrod cap as a result of the conrod separated in the cracking process, the cover fits only in one position and only to the relevant conrod Oil injection nozzle For piston cooling Pay attention to SP No. (right-angle bend) Pressure relief valve, 27 Nm opens at an overpressure of 2.5 to 3.2 bar (0.25 to 0.32 MPa) replace without sealant

11 - Conrod bolt, 30 Nm + torque a further 1/4 turn (90) replace oil thread and head contact surface

Fig. 2:

Inspecting piston ring gap clearance

Special tools, test and measuring equipment and auxiliary items required Feeler gauge

Test sequence

Push in ring at right angles to the cylinder wall from thetop through to the bottom cylinder opening, about 15 mm from the cylinder edge. To insert use piston without rings. Piston ring 1. Compression ring 2. Compression ring Oil scraper ring new (mm) 0,200,40 0,200,40 0,250,50 Wear limit (mm) 1,0 1,0 1,0

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13-4 page 3

13Fig. 3: Inspect piston ring end clearance

FABIA 2000


Special tools, test and measuring equipment and auxiliary items required Feeler gauge

Clean ring groove before inspecting.Piston ring 1. Compression ring 2. Compression ring Oil scraper ring new (mm) 0,060,09 0,050,08 0,030,06 Wear limit (mm) 0,25 0,25 0,15V13 - 0687

Fig. 4:

Inspecting cylinder bore

Special tools, test and measuring equipment and auxiliary items required Internal precision measuring instrument 50 to 100 mm

Piston dimenston item 2 in 13-4 page 2. Cylinder dimenston item 7 in 13-4 page 3. Test sequence

Measure at 3 points crosswise in a transverse direction -A- and lengthwise -B-. Deviations from specified dimension: max. 0.10 mm Note Do not measure the cylinder bore if the cylinder block is fixed to the assembly stand with the engine mount -MP 1-202-, as this may result in incorrect measurements.

Fig. 5:

Piston fitting position and assignment of the piston/cylinder

Special tools, test and measuring equipment and auxiliary items required e. g. electric stylus

Procedure

1/2

1/2

3/4

3/4

Mark installation position and assignment on inside ofpiston (not on piston crown), e.g. with an electric stylus. Pistons in cylinders 1 and 2: Large piston relief for inlet valve to flywheel side -arrowsPistons in cylinders 3 and 4:

13-4 page 4


Edition 11.03 S00.5313.03.20

FABIA 2000


13

Large piston relief for inlet valve to belt pulley side -arrowsNote For new pistons the cylinder assignment is colour-

coded on the piston crown. Pistons in cylinders 1 and 2: Identification 1/2 Pistons in cylinders 3 and 4: Identification 3/4

Checking piston projection in TDCSpecial tools, test and measuring equipment and auxiliary items required Measuring tool for piston projection -MP 1-107-

Procedure

When installing new pistons or a short engine, inspectthe piston projection at TDC. Depending on the piston projection fit the relevant cylinder head seal in accordance with the table below: Piston projection over cylinder block - top side 0.91 mm1.00 mm 1.01 mm1.10 mm 1.11 mm1.20 mm Identification of the cylinder head seal Spare parts No. = -arrow 1 Control code = -arrow 2- (ignore) Bore = -arrow 3-

Marking of bore 1 2 3

Note If different values are measured during the piston projection measurement, the greatest dimension applies for the seal assignment.

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13-4 page 5

13

FABIA 2000


13-4 page 6


Edition 11.03 S00.5313.03.20

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15

15 Cylinder Head, Valve Gear15-1 Removing and installing cylinder head

Summary of componentsRemoving and installing toothed belt Chap. 13-2 Testing compression pressure 15-1 page 6. Note When installing a replacement cylinder head with fitted crankshaft moisten the contact surfaces between the buck-

et tappet and the cam slide with engine oil. Factory-fitted plastic washers intended to protect the open valves must only be removed shortly before inserting

the cylinder head. If the cylinder head is replaced, the system must be completely filled with fresh coolant. Reworking of cylinder heads on diesel engines is not allowed.

1 - Cylinder head cover before inserting thoroughly clean the contact surface of the cylinder head with a clean cloth. 2 - Pressure control valve for crankcase ventilation 3 - to exhaust turbocharger 4 - Closing cover replace seal if damaged 5 - Sealing cup replace if damaged 6 - Hexagon collar bolt with guide bushing, 10 Nm first tighten all screws by hand 7 - Gasket for cylinder head cover replace if damaged 8 - 20 Nm 9 - Lifting eye 10 - Central socket connector for pump-nozzle unit 11 - 10 Nm 12 - from brake servo unit 13 - Tandem pump for fuel and vacuum supply removing and installing Chap. 20-2 inspecting 20-2 14 - 25 Nm 15 - intake hose from fuel filter Chap. 20-1 white markingEdition 08.00 S00.5313.00.20

1

2

3

4

5

6

12 13 7 8 9 28 27 11 17 16 10 11 14 15

26 20 25 19 18

24

23

22 21 19

S15-0164

Removing and installing cylinder head

15-1 page 1

15

FABIA 2000


16 -

17 18 19 20 21 22 23 -

24 25 -

26 -

27 28 -

check tightness secure with spring band clamps Return-flow hose to fuel filter Chap. 20-1 blue marking check tightness secure with spring band clamps Gasket replace 20 Nm Ball knob screw, 8 Nm Bracket for engine cover Lifting eye with bracket for engine cover Bracket for coolant hose Cylinder head gasket replace Pay attention to identification Fig. 2 in 15-1 page 3 20 Nm Cylinder head check for distortion Fig. 1 in 15-1 page 2 removing and installing 15-1 page 3 after replacing, fill entire system with fresh coolant Glow plug 15 Nm inspecting 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 28 pump-nozzle unit removing and installing 1.9/74 TDI engine, Fuel Injection; Rep. Gr. 23 Cylinder head bolt replace Sequence for loosening and tightening 15-1 page 3 with the camshaft bearing caps removed insert the special washers in the cylinder block before fitting the cylinder head screws Chap. 15-2

Fig. 1:

Inspecting cylinder head for distortion

Special tools, test and measuring equipment and auxiliary items required Feeler gauge Knife-edge straightedge

Max. permissible distortion: 0.1 mm Note Reworking of cylinder heads on diesel engines is not allowed.V15 - 0673

15-1 page 2


Edition 08.00 S00.5313.00.20

FABIA 2000 Fig. 2:


15

Cylinder head seal identification

Spare part No. = -arrow 1 Control code = -arrow 2- (disregard!) Orifices = -arrow 3-

Note Cylinder head seals of different thicknesses are fitted depending on the piston projection from the cylinder block. If only the seal is replaced the new seal must bear the same identification.

Removing and installing cylinder headSpecial tools, test and measuring equipment and auxiliary items required Catch pan (e.g. -V.A.G 1306-) Lifting device -MP 9-200 Bracket -T10014 Torque wrench 5...50 Nm (e.g. -V.A.G 1331-) Torque wrench 40...200 Nm (e.g. -V.A.G 1332-) Pliers for spring strap clips Snap hook Workshop crane

Removing

On models fitted with a coded radio set, pay attentionto the coding; determine if necessary.

Disconnect the earth strap from the battery with the ignition off.

Removing engine cover Chap. 10-1. Remove air filter with intake hose 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23.

Remove battery and battery tray Electrical System;Rep. Gr. 27.

Removing charge air pipe at the rear Chap. 21-1. Unplug connector with glow plugs. Remove front exhaust pipe with catalyst -6-. Remove hoses -1- and -2- from the exhaust turbocharger. First unscrew the charge air pipe at the bottom of the engine bracket - risk of fracture! block Chap. 21-1.

1 3 7

2 4

Unscrew the oil return-flow line -5- on the cylinder Release screw -3- of the support, release screw -4and swivel the support down.

Remove the vacuum hose -7- from the vacuum unitfor boost-pressure control.

5 6S21-0022

Drain coolant Chap. 19-1.

Edition 08.00 S00.5313.00.20


15-1 page 3

15 Unscrew the induction pipe from the intake manifoldand lay aside with the hoses connected 1.9/74 TDI Engine - Fuel Injection; Rep. Gr. 23.

FABIA 2000


Release screws from the cylinder head cover. Extract the fuel with a manual vacuum pump and ventilation reservoir from the return hose of the tandem pump Chap. 20-2.

1 5 2 4

Remove fuel hoses -1- and -4-. Remove coolant hose -5-. Remove plug -2- for the central socket connector forthe pump-nozzle unit.

3S15-0165

Disconnect plug -3- from the fuel temperature sender-G81-.

Unscrew the oil feed line on the oil filter holder, the exhaust turbocharger and brackets.

Disconnect coolant hose -1- from T-piece and thecoolant hoses -2- and -3- from the connection fittings.

Disconnect plug -4- from the coolant temperaturesender -G62-.

1

2

3

4S15-0166

Remove the coolant hose -3- from the supports -4-. Pull off vacuum hose -6- from tandem pump -5-. Removing the toothed belt Chap. 13-2. Turn the crankshaft slightly back from the TDC position. Chap. 15-3.

3

4

Remove the camshaft timing gear and the hub Removing coolant pump Chap. 19-2. Removing camshaft position sensor -G40- andtoothed belt guard at rear Chap. 13-2.

2 1 6 5

S10-0150

15-1 page 4


Edition 08.00 S00.5313.00.20

FABIA 2000


15MP 9-200 A B

Screw holder -T10014- with snap hook -A- into thefront threaded bore of the removed engine support bracket above the coolant pump and take up engine weight with workshop crane -B-.

Dismantle supporting device -MP 9-200-.

T10014S15-0167

Release the cylinder head bolts in the given sequenceand remove.

Carefully remove the cylinder head.Note The assistance of a second mechanic is required to remove and install the cylinder head.

InstallingNote Always replace the cylinder head bolts. There must be no oil or coolant in the blind holes of the

cylinder head bolts in the cylinder block. Remove the new cylinder head seal from its wrapping

immediately before fitting. In the event of repairs carefully remove residual seal-

ant from the cylinder head and cylinder block. Make sure this does not cause any extended scoring or scratching. When using emery paper the grain must not be less than 100. Carefully remove lubrication and grinding residues. Treat the new seal with the utmost care. Any damage

will result in leaks.

Before fitting the cylinder head position the crankshafton TDC marking.

Turn crankshaft back against the running direction ofthe engine until all pistons are almost evenly at TDC.

Check whether the 2 dowel sleeves -1- that guide thecylinder head are located in the cylinder block, if necesarry insert.

Position the new cylinder heads. The legend (sparepart No.) must be legible.

1

1

Position cylinder head, insert new cylinder head boltsand tighten by hand.S15-0154

Edition 08.00 S00.5313.00.20


15-1 page 5

15 Screw down the cylinder head in four stages in the indicated tightening sequence: 1. Pre-tighten with torque wrench: Stage I = 40 Nm stage II = 60 Nm 2. Tighten further with a rigid wrench: Stage III = 1/4 turn (90) Stage IV = 1/4 turn (90)

FABIA 2000


After securing the cylinder head or the camshaft timing gear turn the camshaft in such a way that the cams for cylinder 1 point upwards evenly. The further assembly is carried out in reverse order to disassembly.

Installing the toothed belt, tightening Chap. 13-2. Top up coolant Chap. 19-1. Interrogate fault memory and erase 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 01.

Testing compressionTest condition

Engine oil temperature min. 30 CSpecial tools, test and measuring equipment and auxiliary items required Torque wrench 5...50 Nm (e.g. -V.A.G 1331-) Compression pressure gauge, (e.g. -V.A.G 1763-) Adapter (e.g. -V.A.G 1381/12-) Flexible-head wrench for glow plugs

Test sequence

Removing engine cover Chap. 10-1. Remove central socket connector for pump-nozzleunit.

Remove all glow plugs with the flexible-head wrenchfor glow plugs.

Screw in adapter instead of the glow plugs. Check compression pressure with the compressiongauge. Note Use of tester Operating Instructions.

V.A.G 1381/12

Operate starter until the tester no longer indicates apressure rise. Compression readings:

Zyl

bar

V.A.G 1763ZylinderPRINT

V.G73 .A18

!

C

N15-0227

15-1 page 6


Edition 08.00 S00.5313.00.20

FABIA 2000 new engine 2,53.1 MPa

1.9/74 TDI Engine, Mechanics Wear limit 1.9 MPa Pressure difference between cylinders max. 0.5 MPa

15

Screw in glow plugs with flexible-head wrench.Tightening torque: 15 Nm

Interrogate fault memory and erase: 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 01 Note Faults are stored when the plug connection is separated from the pump-nozzle unit.

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15-2Note

Repairing Valve Gear

Cylinder heads with cracks between the valve seats may continue to be used without any reduction in life provided these are slight incipient cracks which are not more than 0.5 mm wide. 1 - 20 Nm + torque a further 1/4 1 turn (90) replace Pay attention to tightening and release sequence Chapter 15-3 19 2 - Valve-lever shaft do not interchange 3 - Cylinder head bolt Pay attention to tightening and release sequence Chapter 15-1 18 before fitting insert washers item 4 in the cylinder head 16 4 - Washer for cylinder head screws 17 insert in cylinder head before fitting the bearing cap 16 5 - Bucket tappets do not interchange with hydraulic valve clearance compensation lay aside with contact surface facing down before installing check axial play of the camshaft Fig. 1 in 15-2 page 2 oil contact surface before removing remove the camshaft bearing shells 6 - Collets 7 - Valve spring retainer 8 - Valve spring outside removing and installing: Cylinder head removed: with - MP 1-218-, - MP 1-211-, -MP 1-213 Cylinder head fitted: Chapter 15-4 9 - Valve spring inside removing and installing: Cylinder head removed: with - MP 1-218-, - MP 1-211-, -MP 1-213 Cylinder head fitted: Chapter 15-4 10 - Valve stem seal replacing Chapter 15-4 11 - Valve guide inspect Chapter 15-4 if the wear limit is exceed, replace cylinder head 12 - Unit injector removing and installing 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23

2

3 4 5 6 7 8 9 10 11 12 13 14 15N15-0231

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13 - Cylinder head pay attention to note 15-2 page 1 14 - PTFE gasket ring Do not additionally lubricate or grease the sealing lips of the PTFE gasket ring before fitting remove oil residues on the camshaft studs with a clean cloth to fit cover slot on the camshaft cone with commercially available adhesive tape (e.g. with Sellotape) removing and installing Chapter 15-3 15 - Valves Valve dimensions Fig. 3 in 15-2 page 3 16 - Bearing shell do not mix up used bearing shells (mark) check correct fit of the retaining lugs in the bearing caps and cylinder head 17 - Camshaft inspecting axial play Fig. 1 in 15-2 page 2 removing and installing Chapter 15-3 check radial clearance with Plastigage Wear limit: 0.11 mm Slack: max. 0.04 mm Identification, timing Fig. 4 in 15-2 page 3 18 - Bearing caps Fitting sequence Chap. 15-3 seal contact surface of bearing caps 1 and 5 with sealant -AMV 174 004 01- Fig. 2 in 15-2 page 3 19 - 8 Nm + torque a further 1/4 turn (90) replace

Fig. 1:

inspect camshaft, axial play

Special tools, test and measuring equipment and auxiliary items required Universal dial gauge holder -MP 3-447 Dial gauge

MP 3-447

Perform measurement with the bucket tappets removed and the first, third and last bearing cap fitted. Wear limit: max. 0.15 mm

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FABIA 2000 Fig. 2:


151

Seal contact surface of bearing caps 1 and 5 with sealant -AMV 174 004 01-

Apply a thin layer of sealant -AMV 174 004 01- evenlyto the sealing surfaces -1-. Note Make sure no sealant penetrates into the slots -arrows-.

N15-0270

Fig. 3:

Valve dimensions

Note Valves must not be reworked. Only grinding in is permissible. Dimension a b c mm mm mm Inlet valve Exhaust valve

35,95 6,980 89,95 45

31,45 6,956 89,95 45

Fig. 4:

Camshaft identification, timing

Camshaft identification Base circle of the valve cams: a = 52.8 mm Identification with digits and characters stamped in on

the end face of the cam for outlet valve on 4th cylinder. Cylinder 4 -arrow038 R or 858 R

a

N15-0258

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15-3

Camshaft

Removing and installing camshaftSpecial tools, test and measuring equipment and auxiliary items required Pressure pad -T10051 Extractor -T10052 Torque wrench Sealant -AMV 174 004 01-

Removing

Remove the timing belt Chapter 13-2. Unscrew fixing screws -1- for camshaft sprocket. Pull camshaft sprocket off the hub. Loosen fixing screw -1- of the hub. Use counterholder -T10051-.

1

T10051N15-0271

Turn bolt attaching the hub out about 2 turns. Position extractor -T10052- and align it with the hubbores.

T10052

Put the hub under tension by uniformly tightening theextractor until the hub is released from the camshaft cone. Note Hold the extractor firmly using a wrench SW 30.

Remove the hub from the cone of the camshaft. Remove cylinder head cover. Remove the valve-lever shafts.Note First release the two outer and then the inner fixingN15-0267

screws. Mark the valve-lever shafts to avoid mixing them up

and to avoid having to perform a basic setting of the pump-nozzle units.

Remove tandem pump Chap. 20-2.

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Camshaft

15-3 page 1

15 First remove bearing caps 5, 1 and 3. Detach bearingcaps 2 and 4 alternately (diagonally across).

FABIA 2000


InstallingNote When fitting the camshaft the cams of cylinder 1 must

point upwards. Do not mix up used bearing shells (mark) When installing the camshaft, ensure it is correctly lo-

cated in the retaining lugs of the bearing shells in the bearing caps and the cylinder head. Before installing the bearing caps make sure the

washers for the cylinder head screws have been inserted in the cylinder head.

Oil the contact surfaces of the bearing shells. Tighten bearing caps 2 and 4 alternately crosswiseand tighten to 8 Nm and torque a further 1/4 turn (90) (replace screws).

Install bearing caps 5, 1 and 3 and likewise tighten to8 Nm and torque a further 1/4 turn (90) (replace screws). Note Seal the separator surfaces of bearing caps 1 and 5

1 2

with sealant -AMV 174 004 01- Chap. 15-2

Bearing cap 5 -1- must fit flush -arrows- with the outer

side of the cylinder head -2-, as this may otherwise cause leaks on the tandem pump.

Install camshaft seal 15-3 page 3. Install valve-lever shafts and first tighten the insideand then the outside fixing screws evenly and crosswise. Tightening torque: 20 Nm + torque a further 1/4 turn (90)S15-0174

Position hub onto camshaft. Tighten fixing screw -1- of the hub.Tightening torque: 100 Nm Use counterholder -T10051-.

1

T10051N15-0271

15-3 page 2

Camshaft

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Push camshaft sprocket onto the hub.Note Tooth segment -arrow- of camshaft sprocket must be facing up.

Align the camshaft timing gear in middle position inthe elongated holes.

Insert the fixing screws -1- by hand and clearance freerelatively to the camshaft timing gear.

Lock hub with locking pin - MP 1-301-. Installing the timing belt, tightening Chapter 13-2. Install tandem pump Chap. 20-2.Note After installing new bucket tappets, the engine must not be started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).

Removing and installing gasket ring for camshaftSpecial tools, test and measuring equipment and auxiliary items required Inserting device - MP 1-214 Gasket ring extractor -T30003 Torque wrench Screw -M12x65-

Removing

Remove the timing belt Chapter 13-2. Remove camshaft sprocket and hub 15-3 page 1. Turn inner part of gasket ring extractor -T30003- twoturns (approx. 3 mm) out of the outer part and lock with knurled screw.

Oil the thread head of the gasket ring extractor, position and forcefully screw into the gasket ring as far as possible.

T30003

Slacken knurled screw and turn inner part of seal extractor against the camshaft until the seal is pulled out.

InstallingNote The sealing lips of the PTFE gasket ring must neither be oiled nor greased.

Remove oil residue on the camshaft stud with a cleancloth.

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Camshaft

15-3 page 3

15 Cover the slot on the camshaft cone with commercially available adhesive tape (e.g. with sellotape).

FABIA 2000


Carefully fit seal onto camshaft. Press in the gasket ring with inserting device-MP 1-214- and screw -M12x65- up to the stop.

MP 1-214

Installing the timing belt, tightening Chapter 13-2.

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Camshaft

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15-4

Valve Seats/Valves Guide/ Valve Stem Seal

Reworking valve seatsNote Do not remill valve. Only grinding in of valves is per-

missible. inspecting valve guides 15-4 page 2. If the wear

limit is exceeded, repeat measurement with new valves. If the wear limit is again exceed, replace cylinder head.

Calculating max. permissible reworking dimension

15-4 page 1. If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceed, replace cylinder head.

Calculating max. permissible reworking dimension Insert valve and press firmly against the valve seat.Note If the valve is replaced when carrying out repair work, use a new valve for the measurement.

Measure distance -a- between the end of the valvestem and the upper face of the cylinder head.

Calculate max. permissible reworking dimension fromthe distance -a- measured and the minimum dimension. Minimum dimension: Inlet valve: 43.4 mm Exhaust valve: 43.2 mm

a

Measured distance less minimum dimension = max. permissible reworking dimension. Example:N15-0253

Measured distance = Minimum dimension Max. permissible reworking dimension

44.1 mm 43.4 mm 0.7 mm

Note If the max. permissible reworking dimension is 0 mm, repeat the measurement with a new valve. If the max. permissible reworking dimension is once again 0 mm, replace cylinder head.

Edition 08.00 S00.5313.00.20

Valve Seats/Valves Guide/Valve Stem Seal

15-4 page 1

15Inspecting valve guidesSpecial tools, test and measuring equipment and auxiliary items required Universal dial gauge holder -MP 3-447 Dial gauge

FABIA 2000


Work sequence

Insert valve into guide. End of valve stem must beflush with guide. Because of the different stem diameters only use inlet valve in inlet guide or outlet valve in outlet guide. Valve rock: max. 1.3 mm Note If the wear limit is exceeded, repeat measurement

with new valves. If the wear limit is again exceed, replace cylinder head. If the valve is replaced when carrying out repair work,

use a new valve for the measurement.

Replacing valve stem seals Cylinder head fittedSpecial tools, test and measuring equipment and auxiliary items required Assembly lever with pressure plate -MP 1-211 Assembly device -MP 1-213 Extractor -MP 1-206 Insertion tool -MP 1-306-

Removing

Removing camshaft Chap. 15-3. Remove bucket tappets (do not interchange) and layaside with the contact surface facing down.

Put the piston of the relevant cylinder in top dead centre (TDC).

Insert assembly device -MP 1-213- and adjust bearingto stay bolt height.

MP 1-213

Remove valve springs with assembly lever and pressure plate -MP 1-211-. Note The valves rest on the piston crown.

MP 1-211

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Pull off valve stem seals with -MP 1-206-.To do so press bushing -1- slightly downwards.

MP 1-206 1

Installing

S15-0172

To avoid damaging the new valve stem seals insertplastic bushing -A- on the valve stem.

MP 1-306 B A

Insert valve stem seal -B- in the insertion tool-MP 1-306-, oil sealing lip and carefully push onto the valve guide. Note After working on the valve gear carefully rotate the en-

gine at least 2 turns to ensure no valve strikes when the engine is started. After installing the camshaft, the engine must not be

started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise valves would strike the pistons).

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17 Lubrication17-1Note If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs,

Removing and installing parts of the lubrication system

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 oil specifications, capacity and oil level Inspection and Maintenance; Chap. 02-3 1 - 15 Nm 2 - 15 Nm 3 - Bracket at top For cable to oil level/oil temperature sender 4 - Sprocket 5 - Dipstick the oil level must not be above the max marking! Inspecting engine oil level 6 - Filler funnel Remove for extracting oil 7 - Guide tube 8 - Oil injection nozzle For piston cooling Pay attention to SP No. (right-angle bend) 9 - Pressure relief valve, 27 Nm opens at 0.25 to 0.32 MPa overpressure replace without sealant 10 - O-ring replace 11 - Suction line Clean strainer if dirty 12 - Baffle 13 - Oil pan Before installing, coat with silicone sealant - D 176 404 A2 - Chapter 17-2 14 - Oil drain plug, 30 Nm with gasket replace 15 - 10 Nm 16 - Oil level/oil temperature sensor -G266check Current Flow Diagrams, Electrical Fault Finding and Fitting Locations 17 - Gasket ring replace

7

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18 - 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 19 - Oil pump sprocket Check fitting position Fits onto oil pump shaft in one position only 20 - Bracket at bottom For cable to oil level/oil temperature sender 21 - 15 Nm 22 - 25 Nm 23 - Oil pump chain 24 - Sealing flange Before installing, coat with silicone sealant - D 176 404 A2 - Chapter 13-3 Replacing crankshaft seal Chapter 13-3 25 - Chain tensioner, 15 Nm When installing, pretension spring and attach

Disassembling and assembling oil filter holder1 - Screw plug, 25 Nm 2 - Gasket replace 3 - Oil cooler when installing, move up against anti-twist lock up to the stop (in direction of tightening) 4 - Gasket replace Insert into lugs on oil cooler 5 - Screw plug, 10 Nm with gasket do not slacken, otherwise replace 6 - 0.07 MPa Oil pressure switch - F1Brown Tighten to 20 Nm Cut open gasket ring if leaking and replace inspect Chapter 17-3 7 - Oil filter holder with integrated pressure relief valve (0.5 MPa) 8 - 15 Nm + torque a further 1/4 turn (90) replace Before tightening, turn in by hand first 9 - Gasket replace

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8

9 10 11 12

13

14

6 5 4 3

15

16 2 1

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10 - Gasket ring replace 11 - Connection fitting, 30 Nm 12 - Oil feed line For exhaust turbocharger Tighten to 22 Nm 13 - Screw plug, 25 Nm 14 - O-ring replace 15 - Oil filter element if oil filter changed, replace O-rings item 14 and item 16 16 - O-ring replace

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17-2

Removing and Installing Oil Pan

Special tools, test and measuring equipment and auxiliary items required Hinged wrench -3185 Socket insert -3249 Hand drill with plastic brush attachment Flat scraper Torque wrench 5...50 Nm (e.g. -V.A.G 1331-) Silicone sealant D 176 404 A2

Removing

Remove noise insulation -arrows-. Drain engine oil. Unbolt oil pan.Note Slacken oil pan bolts at flywheel side with hinged wrench -3185- and unscrew with wrench socket -3249-.S10-0114

Remove oil pan, if necessary release by applyingslight blows with a rubber-headed hammer.

Use a flat scraper to remove sealant residues on thecylinder block.

Use a rotating plastic brush to remove sealant residues on the oil pan (wear protective goggles).

Clean sealing surfaces. They must be free of oil andgrease. Installing Note The oil pan must be installed within 5 minutes after ap-

plying the silicone sealant. Use wrench socket -3249- to insert the oil pan bolts at

N17-0012

flywheel side and tighten with hinged wrench -3185-.

Cut off nozzle tube of the silicone sealant D 176 404A2 at the front marking ( of nozzle approx. 3 mm). Thickness of sealant bead: 23 mm Run past the area around the bolt holes on the inside

-arrows-. Note The sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clogg the strainer in the oil suction pipe.

N17-0019

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17 Apply silicone sealant to the clean sealing surface ofthe oil pan, as shown in the illustration. Note Take particular care when applying sealant bead in the area of the sealing flange at the rear -arrows-.

FABIA 2000


Fit on oil pan immediately and tighten the bolts as follows: 1 - Tighten all the bolts of oil pan/cylinder block slightly. 2 - Tighten the three bolts of oil pan/cylinder block slightly. 3 - Tighten all the bolts of oil pan/cylinder block slightly diagonally across. 4 - Tighten the three bolts of the oil pan/gearbox fully to 45 Nm. 5 - Tighten all the bolts of the oil pan/cylinder block fully to 15 Nm diagonally across. Note When installing the oil pan with the engine removed,

S17-0045

ensure that the oil pan is flush with the cylinder block at the flywheel side. After installing the oil pan, allow the sealant to dry for

about 30 minutes. Only then may engine oil be filled in.

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17-3

Testing oil pressure and oil pressure switch

Special tools, test and measuring equipment and auxiliary items required Oil pressure tester (e. g. -V.A.G 1342-) Diode test lamp (e.g. -V.A.G 1527 B-) Adapter cable set (e.g. -V.A.G 1594 A-) Current flow diagram

Function of dynamic oil pressure warning system The oil pressure switch is opened when pressureless and closed when the switching pressure is reached. The oil pressure warning is activated for about 10 s after the ignition is switched on (terminal 15 on). Activation delay of oil pressure warning: approx. 3 s Off delay of oil pressure warning: approx. 5 s Check warning lamp After the ignition is switched on and engine not running, the oil pressure warning lamp in the dash panel insert must light up for about 3 s and then go out. The check is ended when the engine is started. Warning criteria The visual oil pressure warning (oil pressure warning lamp flashes) is activated and the audible warning buzzer sounds 3 times if one of the following conditions exists:

Ignition on, engine not running, oil pressure switchclosed

Engine speed greater than 1500 rpm, oil pressureswitch open

At an engine speed above 5000 rpm, the oil pressurewarning is not cancelled; not even if the oil pressure switch is closed. Oil pressure switch cancelled below 5000 rpm-1.

If the oil pressure switch is open for only 0.5...3 s at anengine speed above 1500 rpm, this

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