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Workshop Manual
FABIA 2000
Edition 07.03
Engine code
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.
FABIA 2000
FABIA 2000
1.9/96 TDI Engine, Mechanics
Edition 07.03
Supplement
Edition 07.03
List of Supplements
FABIA 2000
List of Supplements
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Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1 page 1
13 Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 Removing and installing, tightening the timing belt ........................................... 13-2 Removing and installing sealing flange and flywheel ......................................... 13-3 Crankshaft, Piston and Conrod ..................................................................... 13-4 page page page page 1 1 1 1
17 Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 - Disassembling and assembling oil filter holder ................................................... 17-1 Removing and installing oil pan .................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3 page page page page 1 2 1 1
19 Cooling
Parts of cooling system - Summary of components ........................................... 19-1 Removing and installing radiator, coolant pump and coolant thermostat ................ 19-2 page page 1 1
20 Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 Repairing the accelerator control .................................................................. 20-2 page page 1 1
21 Turbocharging
Charge air system with turbocharger I ............................................................ 21-1 - Removing and installing exhaust turbocharger with component parts ........................ 21-1 - Removing and installing parts of the charge air cooling ......................................... 21-1 - Connection diagram for vacuum hoses ............................................................ 21-1 Charge air system with turbocharger II ........................................................... 21-2 - Remove exhaust turbocharger ...................................................................... 21-2 - Checking charge pressure control .................................................................. 21-2 page page page page page page page 1 1 2 2 1 1 1
26 Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Procedure ............................................................................................... 26-1 - Replacing middle or rear silencer ................................................................... 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Exhaust gas recirculation system .................................................................. 26-2
Edition 07.03 S00.5327.00.20 Table of Contents
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Table of Contents
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00 Technical Data
00-1 Technical Data
Engine number The engine number (engine identification characters and serial number) is located at the engine/gearbox joint -arrow-. In addition, a sticker with the engine identification characters and serial number is affixed to the timing belt guard. The engine identification characters are also indicated on the vehicle data sticker.
Engine characteristics Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Firing order min. CN Catalytic converter Exhaust gas recirculation Turbocharging Charge air cooler l kW at rpm Nm at rpm mm mm ASZ 06.03 EU-3 1,896 96/4000 310/1900 79,5 95,5 19,0 : 1 1-3-4-2 49 yes yes yes yes
Technical Data
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Technical Data
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1.9/74 TDI Engine, Mechanics; Rep. Gr. 10 Gearbox 0A8; Rep. Gr. 30 und 34 Note The removing of the 1.9/96 TDI Engine can differ in certain details from the removing of the 1.9/74 TDI Engine.
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13 Crankgear
13-1 Removing and installing V-ribbed belt
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13-2
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13-3
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13-4
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15-2
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15-3
Camshaft
Camshaft
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Camshaft
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15-4
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17 Lubrication
17-1
Note
If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs,
carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.
Testing oil pressure and oil pressure switch Chapter 17-3. The oil level must never exceed the max marking - risk of damage to catalytic converter!
Check the oil level, amount of oil and oil specification: Inspection and Maintenance 1 - 15 Nm 2 - Bracket For cable to oil level and oil temperature sender 3 - Dipstick Oil level must not exceed max marking! 4 - Filler funnel Remove for extracting oil 5 - Guide tube 6 - Fitting sleeve For centering oil pump/cylinder block 7 - O-ring Replace 8 - Suction line Clean strainer if dirty 9 - Baffle 10 - Oil pan Before installing, coat with silicone sealant -D 176 404 A2- Chapter 17-2 11 - Gasket ring Replace 12 - Oil drain plug, 30 Nm 13 - 10 Nm 14 - Oil level and oil temperature sender -G266Test Electrical System; Rep. Gr. 90 15 - Oil pump With pressure relief valve 1.2 MPa Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present If there is any scoring on contact surfaces and gears, replace 16 - Oil pump sprocket Fits onto oil pump shaft in one position only 17 - 25 Nm
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18 - Sealing flange Before installing, it must not be dirty Before installing, coat with silicone sealant -D 176 404 A2- Chapter 13-3 Replacing crankshaft seal Chapter 13-3 19 - Oil pump chain 20 - Chain tensioner, 15 Nm When installing, pretension spring and attach 21 - Oil injection nozzle For piston cooling Pay attention to SP No. (right-angle bend) 22 - 27 Nm
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17-2
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17-3
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19 Cooling
19-1 Parts of cooling system Summary of components
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19-2
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20 Fuel Supply
20-1 Removing and installing parts of the fuel supply system
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21 Turbocharging
21-1 Charge air system with turbocharger I
12345678-
9-
10 11 -
12 13 -
14 15 16 17 -
18 19 20 -
Oil feed line 22 Nm Sealing sleeve 5 Nm 10 Nm Connection fitting, 30 Nm Gasket ring Replace Gasket Replace Check fitting position Support Exhaust turbocharger - cylinder block Washer 25 Nm Replace Coat stud bolts with -G 052 112 A340 Nm Connecting tube Between turbocharger and air filter Flange Connecting hose Connection fitting, 40 Nm Oil return line To cylinder block Tighten to 30 Nm 15 Nm Gasket Replace Exhaust turbocharger Can only be replaced complete with exhaust manifold Removing and installing Chapter 21-2 Inspecting charge pressure control Chapter 21-2 Charge pressure regulating valve and vacuum unit for charge pressure regulating valve are component parts of the exhaust turbocharger and cannot be replaced individually
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After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharger Vacuum line To the solenoid valve for charge pressure limitation -N7520 Nm 20 Nm Replace Shield Front exhaust pipe with catalytic converter Bracket Intake manifold 6 Nm
5 11
10 9 8 7
S21-0043
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21-2
Test conditions
No leaks on the intake and exhaust side No fault on the engine/fuel injection system Engine oil temperature at least 80 C
Test sequence
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
Connect up the Vehicle system tester -V.A.G 1552and select the address word 01 Engine electronics (the engine must be idling at the time) 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.
Select function
0 4 Initiate basic setting and disBasic setting 11 1400 rpm OFF -> 99 %
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Note After selecting display group number 011, the idling speed is increased by the engine control unit in display block 1 to 13801420 rpm. The display in display field 2 must switch between off and on every 10 seconds. The following readouts must fluctuate in display fields 3 and 4: Display field 2: off.
Specification in display field 3: Atmospheric pressure
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in mbar
Specification in display field 4: 98100%
Read function
Reading measured value block 11 3090 rpm 2346 mbar 2281 mbar
-> 6
Charge pressure control solenoid valve must operate for this test. While doing so the linkage of the charge pressure control vacuum unit at the bottom of the turbocharger must move back and forward. This linkage must move at least 34 times as long as a vacuum is present in the vacuum system. If the linkage moves and the nominal charge pressure is not reached:
Replace turbocharger.
If the linkage does not move because the charge pressure control solenoid valve is not operating:
Inspect charge pressure control solenoid valve -N75 1.9/96 (TDI) Engine, Mechanics; Rep. Gr. 23.
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Replace turbocharger.
V.A.G 1390
N21-0078
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26 Exhaust System
26-1 Removing and installing parts of the exhaust system
Note
The exhaust manifold is a component part of the ex-
haust turbocharger and therefore must not be replaced individually; removing and installing Chap. 21-2.
Always replace gaskets and self-locking nuts. After performing installation work on the exhaust sys-
tem, make sure the exhaust system is not mounted under tension, the individual components have adequate clearance from the vehicle body and the weight of the exhaust system is evenly distributed over the hangers. 1 - Gasket Replace 2 - Front exhaust pipe with catalytic converter 3 - 25 Nm Replace Coat stud bolts of exhaust turbocharger with hot bolt paste -G 052 112 A3- before installing. 4 - Retaining loop Press off from cross member item 5 to remove front exhaust pipe with catalytic converter 5 - Cross member 6 - 25 Nm 7 - Double clamp Align exhaust system free of stress before tightening 26-1 page 2 Fitting position: bolts at bottom and horizontal Tighten bolted connections evenly 8 - 40 Nm Replace 9 - Spring hanger Pay attention to part number 10 - Separation point For repairs 26-1 page 2 11 - Middle and rear silencer Replace individually when carrying out repairs 26-1 page 2 Align exhaust system free of stress 26-1 page 2
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Aligning exhaust system free of stress
Special tools, test and measuring equipment and auxiliary items required
Torque wrench
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Procedure
The exhaust system is aligned when cold. Slacken bolted connections of double clamp between
front silencer with catalytic converter and middle and rear silencer and replace nuts.
S26-0064
A separation point is provided for repair purposes for replacing the middle silencer or rear silencer.
Separate exhaust pipe at right angles at the separation point -arrow 1- with body saw.
Align exhaust system free of stress 26-1 page 2. Align rear silencer horizontally. Tighten bolted connections of the double clamp evenly to 40 Nm. Installation position of double clamp: Bolts positioned vertically at front of exhaust pipe.
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26-2
Note
the diesel direct injection system control unit -J248via the EGR valve -N18- to the mechanical exhaust gas recirculation valve.
Inspecting exhaust gas recirculation 1.9/96 (TDI)
Engine, Fuel Injection; Rep. Gr. 23 and exhaust gas recirculation valve -N18- 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.
The mechanical exhaust gas recirculation valve with
conically shaped valve tappet makes it possible to achieve different opening cross-sections at different valve strokes.
Connection diagram for vacuum hoses Chap. 21-1.
1 - Intake manifold 2 - O-ring Replace 3 - Vacuum setting element 4 - 5 Nm 5 - Mechanical exhaust gas recirculation valve Component part of the induction pipe Must be replaced together with the induction pipe Check 26-2 page 2 6 - Induction pipe With mechanical exhaust gas recirculation valve and control flap 7 - 10 Nm 8 - Gasket Replace 9 - 25 Nm 10 - Connecting tube 11 - Gasket Replace Check fitting position 12 - 6 Nm 13 - Sealing sleeve
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Testing mechanical exhaust gas recirculation valve
Special tools, test and measuring equipment and auxiliary items required
Hand vacuum pump (e.g. -V.A.G 1390-)
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Test sequence
V.A.G 1390
S13-0161
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