Service: FABIA 2000
Service: FABIA 2000
Service: FABIA 2000
Workshop Manual
FABIA 2000 ³
1.9/96 TDI Engine, Mechanics
Edition 07.03
Engine code ASZ
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The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5327.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Supple-
Edition Subject Article Number
ment
07.03 Basic Edition S00.5327.00.20
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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 page 1
Removing and installing, tightening the timing belt ........................................... 13-2 page 1
Removing and installing sealing flange and flywheel ......................................... 13-3 page 1
Crankshaft, Piston and Conrod ..................................................................... 13-4 page 1
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Valve seats, valves guides, valve stem seals .................................................... 15-4 page 1
17 – Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 page 1
- Disassembling and assembling oil filter holder ................................................... 17-1 page 2
Removing and installing oil pan .................................................................... 17-2 page 1
Testing oil pressure and oil pressure switch .................................................... 17-3 page 1
19 – Cooling
Parts of cooling system - Summary of components ........................................... 19-1 page 1
Removing and installing radiator, coolant pump and coolant thermostat ................ 19-2 page 1
20 – Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 page 1
Repairing the accelerator control .................................................................. 20-2 page 1
21 – Turbocharging
Charge air system with turbocharger I ............................................................ 21-1 page 1
- Removing and installing exhaust turbocharger with component parts ........................ 21-1 page 1
- Removing and installing parts of the charge air cooling ......................................... 21-1 page 2
- Connection diagram for vacuum hoses ............................................................ 21-1 page 2
Charge air system with turbocharger II ........................................................... 21-2 page 1
- Remove exhaust turbocharger ...................................................................... 21-2 page 1
- Checking charge pressure control .................................................................. 21-2 page 1
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 page 1
- Aligning exhaust system free of stress ............................................................. 26-1 page 2
- Procedure ............................................................................................... 26-1 page 2
- Replacing middle or rear silencer ................................................................... 26-1 page 2
- Checking the exhaust system for leaks ............................................................ 26-1 page 3
Exhaust gas recirculation system .................................................................. 26-2 page 1
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00 – Technical Data
Engine characteristics
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Engine identification characters ASZ
Manufactured 06.03 ³
Exhaust limits conforming to EU-3
Displacement l 1,896
Power output kW at rpm 96/4000
Torque Nm at rpm 310/1900
Bore ∅ mm 79,5
Stroke mm 95,5
Compression 19,0 : 1
Firing order 1-3-4-2
min. CN 49
Catalytic converter yes
Exhaust gas recirculation yes
Turbocharging yes
Charge air cooler yes
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Note
The removing of the 1.9/96 TDI Engine can differ in cer-
tain details from the removing of the 1.9/74 TDI Engine.
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13 – Crankgear
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Edition 07.03 Removing and installing, tightening the timing belt 13-2 page 1
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13 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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Edition 07.03 Removing and installing sealing flange and flywheel 13-3 page 1
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13 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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15-3 Camshaft
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15
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Edition 07.03 Valve seats, valves guides, valve stem seals 15-4 page 1
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15 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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17 – Lubrication
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!
1 - 15 Nm
2 - Bracket
T For cable to oil level and oil
temperature sender
3 - Dipstick
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T Oil level must not exceed
„max“ marking!
4 - Filler funnel
T Remove for extracting oil
5 - Guide tube
6 - Fitting sleeve
T For centering oil pump/cylin-
der block
7 - O-ring
T Replace
8 - Suction line
T Clean strainer if dirty
9 - Baffle
10 - Oil pan
T Before installing, coat with
silicone sealant
-D 176 404 A2- ⇒ Chapter
17-2
11 - Gasket ring
T Replace
12 - Oil drain plug, 30 Nm
13 - 10 Nm
14 - Oil level and oil temperature
sender -G266-
T Test ⇒ Electrical System;
Rep. Gr. 90
15 - Oil pump
T With pressure relief valve 1.2 MPa
T Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present
T If there is any scoring on contact surfaces and gears, replace
16 - Oil pump sprocket
T Fits onto oil pump shaft in one position only
17 - 25 Nm
Edition 07.03 Removing and installing parts of the lubrication system 17-1 page 1
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17 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
18 - Sealing flange
T Before installing, it must not be dirty
T Before installing, coat with silicone sealant -D 176 404 A2- ⇒ Chapter 13-3
T Replacing crankshaft seal ⇒ Chapter 13-3
19 - Oil pump chain
20 - Chain tensioner, 15 Nm
T When installing, pretension spring and attach
21 - Oil injection nozzle
T For piston cooling
T Pay attention to SP No. (right-angle bend)
22 - 27 Nm
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T When installing, move up
against the anti-twist lock (in
direction of tightening)
4 - Gasket
T Replace
T Insert into lugs on oil cooler
5 - Oil pressure switch -F1-, 20
Nm
T Brown
T 0.07 MPa (0.7 bar)
T Cut open gasket ring if leak-
ing and replace
T Inspect ⇒ Chapter 17-3
6 - Oil filter holder
T With integrated overpressure
valve
7 - 15 Nm + torque a further 1/4
turn (90°)
T Replace
T Before tightening, turn in by
hand first
8 - Gasket ring
T Replace
9 - Connection fitting, 30 Nm
10 - Oil feed line
T For exhaust turbocharger
T Tighten to 22 Nm
11 - O-ring
T Replace
12 - Oil filter element
T When changing oil, fit new O-rings ⇒ item 11
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Edition 07.03 Testing oil pressure and oil pressure switch 17-3 page 1
S00.5327.00.20
17 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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19 – Cooling
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Edition 07.03 Removing and installing radiator, coolant pump and coolant 19-2 page 1
S00.5327.00.20 thermostat
19 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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Removing and installing radiator, coolant pump and coolant Edition 07.03
19-2 page 2 thermostat S00.5327.00.20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics 20
20 – Fuel Supply
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Edition 07.03 Removing and installing parts of the fuel supply system 20-1 page 1
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20 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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Removing and installing parts of the fuel supply system Edition 07.03
20-1 page 2 S00.5327.00.20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics 20
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21 – Turbocharging
Note
♦ The hose connections are secured with clamps.
♦ The charge-air system must be tight.
♦ Always replace self-locking nuts.
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6- Connection fitting, 30 Nm
7- Gasket ring
T Replace
8- Gasket
T Replace
T Check fitting position
9- Support
T Exhaust turbocharger - cylin-
der block
10 - Washer
11 - 25 Nm
T Replace
T Coat stud bolts with
-G 052 112 A3-
12 - 40 Nm
13 - Connecting tube
T Between turbocharger and
air filter
14 - Flange
15 - Connecting hose
16 - Connection fitting, 40 Nm
17 - Oil return line
T To cylinder block
T Tighten to 30 Nm
18 - 15 Nm
19 - Gasket
T Replace
20 - Exhaust turbocharger
T Can only be replaced complete with exhaust manifold
T Removing and installing ⇒ Chapter 21-2
T Inspecting charge pressure control ⇒ Chapter 21-2
T Charge pressure regulating valve and vacuum unit for charge pressure regulating valve are component parts
of the exhaust turbocharger and cannot be replaced individually
T After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to
the turbocharger
21 - Vacuum line
T To the solenoid valve for charge pressure limitation -N75-
22 - 20 Nm
23 - 20 Nm
T Replace
24 - Shield
25 - Front exhaust pipe with catalytic converter
26 - Bracket
27 - Intake manifold
28 - 6 Nm
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Connection diagram for vacuum hoses
1 - Valve block
T Component parts of the
valve block are:
1 2
♦ Changeover valve for intake 3
manifold flap -N239-
♦ Solenoid valve for exhaust
gas recir culation -N18-
♦ Solenoid valve for charge
pressure control -N75-
2 - Connecting strip 4
T Pay attention to the coding
when connecting the vacu-
um hoses
3 - Connecting piece 5
4 - Vacuum unit
11
T For charge pressure control
T Components of the exhaust
gas turbocharger cannot be
replaced individually
5 - Vacuum unit
6 - To air filter
7 - Vacuum unit
T For intake manifold flap 6
8 - Mechanical exhaust gas recir-
culation valve
9 - Tandem pump
10 - Distributor part
T With non-return valve for 10
brake servo unit 9 8 7
11 - Brake servo unit
S21-0043
Test conditions
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• No fault stored in fault memory ⇒ 1.9/96 TDI Engine,
Fuel Injection; Rep. Gr. 01
• 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 ac-
cident which involves the front passenger airbag be-
ing deployed.
Note
After selecting display group number 011, the idling
speed is increased by the engine control unit in display
block 1 to 1380…1420 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
in mbar
♦ Specification in display field 4: 98…100%
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Press → .
– Replace turbocharger.
If the linkage does not move because the charge pres-
sure control solenoid valve is not operating:
– Replace turbocharger.
V.A.G 1390
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N21-0078
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26 – Exhaust System
Note
♦ The exhaust manifold is a component part of the ex-
haust turbocharger and therefore must not be re-
placed 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 ade-
quate clearance from the vehicle body and the weight
of the exhaust system is evenly distributed over the
hangers.
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1 - Gasket
T Replace
2 - Front exhaust pipe with cata-
lytic converter
3 - 25 Nm
T Replace
T Coat stud bolts of exhaust
turbocharger with hot bolt
paste -G 052 112 A3- be-
fore installing.
4 - Retaining loop
T Press off from cross member
⇒ item 5 to remove front ex-
haust pipe with catalytic con-
verter
5 - Cross member
6 - 25 Nm
7 - Double clamp
T Align exhaust system free of
stress before tightening
⇒ 26-1 page 2
T Fitting position: bolts at bot-
tom and horizontal
T Tighten bolted connections
evenly
8 - 40 Nm
T Replace
9 - Spring hanger
T Pay attention to part number
10 - Separation point
T For repairs ⇒ 26-1 page 2
11 - Middle and rear silencer
T Replace individually when carrying out repairs ⇒ 26-1 page 2
T Align exhaust system free of stress ⇒ 26-1 page 2
Edition 07.03 Removing and installing parts of the exhaust system 26-1 page 1
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26 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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.
– Position double clamp at the distance -a- = 5 mm from a
the marking on the pipe of the catalytic converter S26-0064
(bolts at bottom and horizontal) and tighten front bolt-
ed connection slightly.
– Push middle silencer -1- sufficiently far forward into
the double clamp until the dimension -b- of 3...7 mm is
achieved between hanger of body and hanger of mid-
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dle silencer.
-Arrow- points in direction of travel.
Note
After tightening the double clamp, inspect dimension -b-
and adjust if necessary.
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Edition 07.03 Removing and installing parts of the exhaust system 26-1 page 3
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26 FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
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1 - Intake manifold
2 - O-ring
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T Replace
3 - Vacuum setting element
4 - 5 Nm
5 - Mechanical exhaust gas recir-
culation valve
T Component part of the induc-
tion pipe
T Must be replaced together
with the induction pipe
T Check ⇒ 26-2 page 2
6 - Induction pipe
T With mechanical exhaust
gas recirculation valve and
control flap
7 - 10 Nm
8 - Gasket
T Replace
9 - 25 Nm
10 - Connecting tube
11 - Gasket
T Replace
T Check fitting position
12 - 6 Nm
13 - Sealing sleeve
Test sequence
– Remove engine cover -arrows-.
– Disconnect vacuum hose on mechanical exhaust-gas
recirculation valve.
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– Detach hose of hand vacuum pump from mechanical
exhaust gas recirculation valve.
The diaphragm rod must move back to its original po-
sition against the -direction of the arrow-.
S13-0161