D3E802A922B-1 2 55 KW TDI CR Engine

Service
Workshop Manual
Fabia II 2007
1,2/55 kW TDI CR Engine
Engine ID
CFW
A
Edition 02.10
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Service Department. Technical Information
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling
20 - Fuel Supply
21 - Turbocharging
23 - Fuel Formation, Injection
26 - Exhaust System
28 - Glow Plug System
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2010 KODA AUTO a. s.
D3E802A922B
Fabia II 2007
1,2/55 kW TDI CR Engine - Edition 02.10
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
1.2
Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . .

Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations concerning safety precautions when working on the fuel system . . . . . . . . . .
Regulations concerning cleanliness when working on the fuel supply/fuel injection system
........................................................................
Regulations concerning cleanliness when working on the exhaust gas turbocharger . . . .
Fuel hoses in the engine compartment - removing and replacing . . . . . . . . . . . . . . . . . . . .
General instructions for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
1.4
1.5
1.6
1.7
1
1.1
1.2
1.3
1.4
1.5
2
3
4
5
6
7
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9
Removing and installing engine trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
Securing the engine to the assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installing the engine . .Protected
. . . . . by. .copyright.
. . . . .Copying
. . . . for
. . private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in. part
. . or. .in.whole,
. . . .is .not. .permitted
. . . . 16
Assembly bracket . . . . .with
. . respect
. . . . to. .the. .correctness
. . . . . .of. information
. . . . . . in. this
. . .document.
. . . . . Copyright
. . . . . .by. KODA
. . . . AUTO
. . . .A.. S.
. . . 19
13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
3
3.1
3.2
4
4.1
4.2
5
5.1
5.2
5.3
5.4
5.5
6
6.1
6.2
6.3
6.4
Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-ribbed belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing tensioning element for V-ribbed belt . . . . . . . . . . . . . . . . . . . . . .
Removing and installing crankshaft-belt pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing belt drive - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder block - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing bracket for auxiliary units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing shaft module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing balancing shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing flanges and flywheel - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the sealing flange on the belt pulley side . . . . . . . . . . . . . . . . . .
Replace sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the two-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft, Piston and Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking piston projection in TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
21
21
22
24
25
27
27
29
38
41
41
42
45
45
46
49
49
50
53
58
60
62
62
63
66
67
Fabia II 2007
15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder head cover - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the gasket rings for the injection units in the cylinder head cover
........................................................................
Cylinder head - summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve gear - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing gasket ring for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring the axial play of the camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking hydraulic balancing elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
68
69
70
71
72
73
82
82
83
83
84
85
91
91
92
95
95
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts of the lubrication system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter holder and engine oil cooler - Summary of components . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the oil filter holder with the engine oil cooler . . . . . . . . . . . . . . . .
Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
97
98
99
103
106
108
109
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1
1.1
1.2
1.3
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant lines, coolant temperature sender, coolant pumps and coolant regulator . . . . . .
Coolant pipes, coolant temperature sender and coolant recirculation pump 2 - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump and 4/2 way valve with coolant regulator - Summary of components . . . . . .
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing 4/2 way valve with coolant regulator . . . . . . . . . . . . . . . . . . . . . .
Radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator with radiator fan - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan shroud with radiator fan V7 - Summary of components . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fan shroud with radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
112
112
114
117
117
119
119
120
124
124
125
126
127
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1
Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . .

......
......
Fuel filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Behaviour in case of misfuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Fuel
tank
with component
parts
- Summary
components
with respect
to the
correctness
of information in this
document.
Copyright byof
KODA
AUTO A. S. . . . . . . . . . . . . . . . . . .
1.3
1.4
1.5
ii
Contents
130
130
132
134
134
136
Fabia II 2007
1.6
1.7
1.8
2
2.1
2.2
2.3
2.4
3
3.1
Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the voltage supply of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test feed pressure of fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the fuel flow rate of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the power consumption of the fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator pedal module - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
138
140
141
142
142
143
146
148
151
151
21 - Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust turbocharger - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil feed line and oil return-flow line for exhaust gas turbocharger - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing exhaust temperature sender 1 G235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge air system with exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge air cooling - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose connections with screw clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing left charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing right charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the charge-air system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram for vacuum hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152
152
153
154
158
160
160
162
162
163
163
164
166
168
23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1
1.1
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4
4.1
4.2
4.3
4.4
5
5.1
Diesel direct injection system - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel system - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection unit with clamping claw - Summary of components . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing, testing fuel formation, components . . . . . . . . . . . . . . . . . . . . . .
Filling and bleeding the high pressure pump and the fuel system . . . . . . . . . . . . . . . . . . . .
Check the fuel system for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . .
Installing the high pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the injection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the fuel distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and
installing
fuel
pressure
sender
G247
. . .not
. .guarantee
. . . . . .or.accept
. . . .any
. .liability
............
unless
authorised by
KODA
AUTO A. S.
KODA AUTO
A. S. does
respect to the
correctness
of information
in thispump
document.. Copyright
Removing andwith
installing
the
fuel high
pressure
. . . . . by
. .KODA
. . . .AUTO
. . . A.
. .S.
...........
Intake manifold and air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake manifold with component parts - Summary of components . . . . . . . . . . . . . . . . . . . .
Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air filter - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
170
171
173
173
174
177
179
179
180
181
183
185
187
191
193
194
198
198
198
201
202
204
204
26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1
Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Contents
iii
Fabia II 2007
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
2
2.1
2.2
2.3
Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5 standard (left-hand
drive) - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the exhaust gas temperature sender 3 G495 for vehicles according to EU 5 standard
(left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the differential pressure sender G505 for vehicles according to EU
5 standard (left-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the pre-exhaust pipe for vehicles according to EU 5 standard (lefthand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5 standard (right-hand
drive) - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the differential pressure sender G505 for vehicles according to EU
5 standard (right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the pre-exhaust pipe for vehicles according to EU 5 standard (righthand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear part of the exhaust system for vehicles according to EU 5 standard - Summary of
components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust pipe with oxidation catalytic converter for vehicles according to EU-4/BS4 standard
- Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing the pre-exhaust pipe for vehicles according to EU-4/BS-4 standard
(right-hand drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the middle and rear part of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . .
Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts of exhaust gas recirculation - Summary of components . . . . . . . . . . . . . . . . . . . . . .
Checking change-over flap for radiator for exhaust gas recirculation . . . . . . . . . . . . . . . .
Removing and installing radiator for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . .
207
208
209
209
210
214
215
215
216
217
222
223
224
226
227
227
228
228
229
230
28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

1
1.1
Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
iv
Contents
Fabia II 2007
00
Technical data
Technical data
1.1
Engine number
The engine number (engine identification character 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 timing belt guard.
The engine code is also indicated on the vehicle data sticker.
The engine identification characters have four digits starting
with the letter C.
The first 3 digits of the engine identification characters refer to
the displacement and the mechanical construction of the en
gine. They are type-punched on the cylinder block including
the serial number.
The 4th digit refers to the output and torque of the engine. It
depends upon the engine control unit.
1.2
Engine characteristics
Engine identification character
CFWA
CFWA
Manufactured
Exhaust limit values conforming to
Displacement
cm 3
04.10 ?
EU5
1199
08.10 ?
EU4 (BS4)
1199
Power output
kW at rpm
Torque
Nm at rpm
Bore
mm
Stroke
mm
Cylinder / valves per cylinder
Compression ratio
Firing order
Catalytic converter
Diesel particle filter
Exhaust gas recirculation with ra
diator
Turbocharging
Charge air cooler
Balancing shaft module
55/4000
55/4000
180/1500 3450
180/1500 3450
79,5
79,5
80,5Copying for private or commercial purposes, in part
80,5
Protected by copyright.
or in whole, is not permitted
3/4
3/4
16,5 : 1
16,5 : 1
1-2-3
1-2-3
yes
yes
yes
no
yes
yes
yes
yes
yes
yes
yes
yes
1. Technical data
Fabia II 2007
01
Self-diagnosis
Self diagnosis, safety measures,

cleanliness regulations and direc
tions
1.1
Self-diagnosis
This Rep.-Gr. is deleted.

For this use the Vehicle self-diagnosis, Measuring method and
Fault finding Vehicle diagnosis, testing and information sys
tem VAS 5051.
1.2
Supplementary instructions and assem

bly work on vehicles with an air condi
tioning system
WARNING
Risk of injury through refrigerant.

Refrigerant circuit of the air conditioning system must not
be opened.
Caution
Risk of damaging the condensor, the refrigerant lines and ho

ses.
Do not over-tension or buckle refrigerant lines and hoses.
Steps which should be taken in order to remove and install the
engine without opening the refrigerant circuit:
Unscrew the holding clamp(s) on the refrigerent lines
Remove V-ribbed
belt page 23 .
Remove AC compressor
from the bracket for auxiliary units
page 22 .
Mount the AC compressor in such a way that the refrigerant

lines/hoses are not under tension.
Rep. Gr.01 - Self-diagnosis
Fabia II 2007
1.3
Regulations concerning safety precau

tions when working on the fuel system
WARNING
When undertaking all installation work, particularly in the en

gine compartment due to its cramped construction, please
observe the following:
Lay lines of all kinds in such a way that the original line
guide is re-established.
Ensure that there is adequate free access to all moving or
hot components.
The fuel or the fuel lines in the fuel system can become
very hot (risk of burning)!
The fuel system is under pressure!
Wear safety goggles and safety clothing, in order to avoid
injuries and skin contact with fuel.
Place cleaning cloths around the connection point before
detaching cable connections. Reduce pressure by care
fully removing the wiring.
For reasons of safety the current supply to the fuel pump must
be interrupted before opening the fuel system. Otherwise the
fuel pump is activated when opening the driver's door. One of
the following options must be used to interrupt the current sup
ply:
Disconnect battery
or
Take out fuse for fuel pump relay -J17or
Disconnect the plug on the flange of the fuel delivery unit
Caution
In order to avoid the fuel high pressure pump to run dry and to
achieve a quick engine start after parts are replaced, the fol
lowing points must be observed:
If the fuel system was opened, starting with the fuel tank
through to the fuel high pressure pump, the ventilation of
the fuel system must be carried out before starting the en
gine. For this purpose, switch on the ignition and only
switch it off once the fuel pump has come to a standstill.
Repeat this procedure at least 5 times.
If the fuel high pressure pump is removed or replaced, the
initial fuel filling of the fuel high pressure pump must be
carried out before the first engine start page 179 .
If the high pressure system was opened, it must be
checked for tightness page 180 .
When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open
1. Self diagnosis, safety measures, cleanliness regulations and directions
Fabia II 2007
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
Avoid skin contact with fuel! Wear fuel-resistant gloves!
If test and measuring devices are required during test drives ob
serve 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 devices are operated from the passen
ger seat, the passenger could be injured by the release of the
passenger airbag in the event of an accident.
WARNING
Secure the diagnostic device to the rear seat and operate from
that position.
Observe the following points to prevent injury to persons and/or
damage to the injection and preheating system:
People, who have a heart pacemaker implant, should not bend
over the engine compartment when the engine is running, as
the injection units generate an output high voltage pulse.
No fuel lines must be opened when the engine is running.
Disconnect and connect wires of the preheating and injection
system as well as measuring device wires when the ignition is
switched off.
Do not carry out engine wash unless the ignition is switched
off.
If the engine must be operated at starter speed, without it
starting, unplug the connector -5- at the fuel pressure regulat
ing valve -N276- .
Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.
If the battery is connected, carry out certain additional opera
tions Electrical System; Rep. Gr. 27 .
1.4
Regulationsunless
concerning
cleanliness
authorised by KODA
AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
when working on the fuel supply/fuel in
jection system
Carefully observe the following 6 rules for cleanliness when

working on the fuel supply/injection system:
Thoroughly clean the connection points and their surroundings
before releasing.
Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
Carefully cover or close opened components if the repair is not
completed immediately.
Only install clean parts: Remove spare parts from their wrap
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
When the system is opened: do no use compressed air. Do
not use the vehicle.
Fabia II 2007
Also make sure no diesel fuel runs onto the coolant hoses. If
this is the case clean the hoses immediately. Replace imme
diately any hoses which have suffered damage.
1.5
Regulations concerning cleanliness

when working on the exhaust gas turbo
charger
Carefully observe the following 5 rules for cleanliness when

working on the exhaust gas turbocharger:
Thoroughly clean the connection points and their surroundings
before releasing.
Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
Carefully cover or close opened components if the repair is not
completed immediately.
Only install clean parts: Remove spare parts from their wrap
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. on a shelf or in a tool box).
When the system is opened: do no use compressed air. Do
not use the vehicle.
Fabia II 2007
1.6
Fuel hoses in the engine compartment removing and replacing

Note
On this engine, the nozzles for the pressurized fuel hoses have
a so-called 3-wave profile (arrows). In this way, the tightness

of the fuel system is improved.
When removing the fuel hoses, in most cases the very thin
barrier layer on the inside of the fuel hose is damaged.
This damage is not visible to the eye. However, it can lead to
leakage of the fuel system after a certain period of time.
When the fuel hoses are refitted on the nozzles, the initial po
sition of the hose on the 3 waves cannot be ensured. This

encourages the tendency to leak.
Caution
After removing the fuel hoses from nozzles with 3-wave

profile, replace these fuel hoses.
-Arrows-1-2-3-4-
3-wave profile
Return-flow line
Return line support at fuel distributor
Delivery nozzle of the high pressure pump
Quick coupling on the fuel filter
Note
For the above mentioned reasons, always disconnect the
quick coupling when removing the fuel hoses from the fuel filter
page 134 .
Do not open the spring strap clamp and detach the fuel hose
from the nozzle of the quick coupling.
If other components are only removed: Check whether it is
possible to separate the fuel system on the quick couplings at

the fuel filter or at the connection points in right of engine com
partment.
If a fuel hose cannot be disconnected from the hose nozzle by

hand:
Caution
Never push a screwdriver or a similar tool between the hose

and the hose nozzle!
Risk of damage to the nozzle - the component must be
replaced.
Turn
with respect
the correctness
information
in this
document.
the fuel
hose towith
suitableofpliers
and
detach
theCopyright
hose.by KODA AUTO A. S.
Fabia II 2007
If a fuel hose can still not be disconnected from the hose nozzle:
Only cut into the textile layer of the hose lengthwise and detach
the hose.
Do not cut through the inner rubber layer. If the nozzle is dam
aged, it is necessary to replace the complete component.
Note
Before fitting the new fuel hose, thoroughly clean the hose
nozzle from grease, oil and dirt. To do so, do not use any metal
tools which could damage the hose nozzle.
Fit the fuel hose on the nozzle without lubricant and secure
with spring strap clamp.
1.7
General instructions for charge air sys

tem
WARNING

hot components.
Caution
In case a mechanical damage to the exhaust gas turbocharger

is found, e.g. damage to the compressor wheel, it is not suffi
cient to only replace the turbocharger. In order to avoid con
sequential damage, perform the following tasks:
Clean all oil lines.
Change engine oil and oil filter.
Check air filter, air filter insert and charge air hoses as well
as charge air pipes for soiling.
Check all air guides and charge air cooler for foreign bod
ies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
The charge-air system must be tight, check page 164 .
Replace the gaskets, the sealing rings and the self-locking
nuts.
Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
Observe the instructions for installing the charge air hoses on
the fluted pipes page 160 .
Observe assembly markings on the hoses and components.
Fabia II 2007
All hose connections of the charge air system are secured with
screw clamps.
Only install approved clamps for securing the hose connec
tions Electronic Catalogue of Original Parts .
After installing the exhaust turbocharger, run engine at idling
speed for about 1 minute to ensure that oil is supplied to the
turbocharger bearing.
Fabia II 2007
10
Removing and installing engine
Removing and installing engine
1.1
Removing and installing engine trim

panel
Removing
Caution
The bracket for the engine cover on the cylinder head cover
can break off when it is incorrectly disassembled.
It is therefore necessary to remove the engine cover ac
cording to the following instruction.
Successively slacken the engine cover in the marked se
quence -1 ... 4- from the fixing points. To do so, grip the engine
cover from underneath as far as possible in the area of the
-arrows- and pull it upwards out of the attachment.
Install
Caution
Before installing the engine cover, check the correct fitting po

sition of the 4 fixing elements (ball sockets). If necessary, move
them back into the correct position. Otherwise this can lead to
damage to the engine cover.
If necessary, adjust the ball sockets of the engine cover to the
correct position.
Position the engine cover onto the fixing points and press it in
at the corners until it clicks into place.
1.2
Removing engine
Special tools and workshop equipment required

Removal tool for the inner lining of the door
panel -MP8-602/1
1. Removing and installing engine
Fabia II 2007
Engine mount -T40076 Engine/gearbox jack , e.g. -V.A.G 1383 A Catch pan , e.g. -VAS 6208 Double ladder , e. g. -VAS 5085 Pliers for spring strap clamps
Bolt M10 x 50
Nut M12
Note
The engine is removed downwards together with the gearbox.
All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo

cation when the engine is installed again.
Leave the ignition key in the ignition lock so that the steering
lock does not click into place.
Collect drained coolant in a clean container for proper disposal
or reuse.
WARNINGProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

gine compartment because of its cramped construction, please
hot components.
Observe all safety measures and notes for assembly work on the
fuel and injection system, the charge air system as well as the
rules for cleanliness page 2 .
Observe the instructions for the fuel hose in the engine compart
ment page 6 .
If present, take the adapter for the anti-theft wheel bolts out of
the luggage compartment.
Disconnect the battery-earth strap with the ignition off Elec
trical System; Rep. Gr. 27 .
Only slacken the nut of the right drive shaft.
Remove front wheels.
Remove the right and left wheelhouse liner Body Work;
Rep. Gr. 66 .
Drain coolant page 112 .
10
Rep. Gr.10 - Removing and installing engine
Fabia II 2007
Unscrew the positive cable -1- at the positive terminal on the
battery.
Remove engine cover page 9 .
Remove air intake hose.
Remove the battery with the battery tray Electrical System;
Rep. Gr. 27 .
Remove vacuum lines with brackets -1- from air filter.

Release plug -3- from charge pressure control solenoid valve
-N75- .
Unscrew bracket -2- with charge pressure control solenoid
valve -N75- .
Place the charge pressure control solenoid valve -N75 - with
vacuum lines on the engine.
Remove air filter with air mass meter -G70- and inlet hose
page 202 .
Remove shift mechanism from gearbox Gearbox; Rep. Gr.
34 .
Remove pressure line from breather/slave cylinder Gear
box; Rep. Gr. 30 .
Caution
After separating the hydraulic line, do not operate the clutch

pedal.
Unplug connector -arrow- from speedometer sender -G22- (if
available).
Detach vacuum lineProtected
at brake
servo unit.
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
Remove the engineunless
control
unit page 204 .
Unplug the plug of the engine wiring harness and disconnect

from the engine control unit.
11
Fabia II 2007
Disconnect plug connection -arrow-.
Carefully slacken the engine wiring harness on its fixing points

-arrows-.
Place the engine wiring harness on the engine.
Disconnect plug -arrow 1- from reversing light switch -F4- .

Remove connector -arrow 2- and cable -arrow 3- from the
starter.
Expose cables.
Disconnect the plug connection below the starter.
Remove the coolant hoses at the top radiator and secure to
the engine.
Collect the fuel which flows out with a cleaning cloth.
12
Fabia II 2007
Pull off fuel hoses -1, 2, 5 and 6-. To do so, push the quick
couplings onto the nozzles, press in the securing elements
(hold pressed) and detach the quick couplings.
Unplug connector -4-.
Unscrew expansion bottle -3-.
Place the expansion bottle with connected coolant hoses and
fuel hoses on the engine.
Remove fan shroud with radiator fan -V7- page 126 .
Remove right charge air pipe to throttle valve control unit
page 163 .
Remove right drive shaft Chassis; Rep. Gr. 40 .
Unscrew left drive shaft from the flange shaft of the gearbox
and tie up.
Vehicles with air conditioning
Remove V-ribbed belt page 22 .
WARNING

be opened.
Caution

ses.
Remove the AC compressor from the bracket for auxiliary
units and secure it with connected refrigerant hoses to the
body.
Continued for all vehicles
Vehicles with diesel particle filter
Remove diesel particle filter:
Left-hand drive page 210 .
Right-hand drive page 217 .
Vehicles without diesel particle filter
Remove pre-exhaust pipe page 224 .
13
Fabia II 2007
Disconnect plug connection for exhaust gas temperature
sender 1 -G235- .
Remove the coolant hoses at the heat exchanger and secure
to the engine.
Disconnect plug at oil level and oil temperature sender G266- .
Remove coolant temperature sender at radiator outlet -G83( page 117 , Pos. 26).
Remove noise insulation -2- for oil pan. To do this:

- Release screws -1-.
- Remove 2-part clips -arrows-.
- Remove cable fixings at the noise insulation.
Release screw -6-.

14
Fabia II 2007
Tighten engine mount -T40076- with nut -1- at the cylinder
block to approx. 20 Nm.
Place nut M12 -3- between engine mount -T40076- and cyl
inder block.
Fix the engine mount -T40076- with a screw M10 x 50 -2- to
the cylinder block.
Insert engine/gearbox jack -V.A.G 1383 A- in the engine
mount -T40076- and slightly raise.
Position the engine mount -T40076- in the engine/gearbox
jack -V.A.G 1383/A- .
Note
Use the double ladder to release the screws for the engine/gear
box mounting.
Successively release screws for engine mounting -arrows-.
The nut -2- must not be released.
Successively release screws for gearbox mounting -arrows-.

Note
Check whether all hose and line connections between engine,
gearbox and body are released.
When lowering carefully guide the engine with the gearbox, in
order to avoid damage.
unless
Carefully
lower
engine
with
gearbox.
During
this
procedure,
authorised
by KODA
AUTO A.
S. KODA
AUTO A.
S. does not
guarantee
or accept any liability
turn
or move
engine
with thein gearbox
depending
uponAUTO
the A. S.
with respect
to the the
correctness
of information
this document.
Copyright by KODA
constriction.
Remove the gearbox from the engine.
1.3
Securing the engine to the assembly

stand

Engine mount -MP1-202 Hook -MP1-202/10 Assembly stand -MP9-101 Lifting device -MP9-201 (2024A) Bushing -T30010 (VW 540/1B)-
15
Fabia II 2007
Workshop crane , e.g. -VAS 6100
Separate engine from gearbox.

WARNING
Use securing pins on the hooks and rig pins to prevent release.
Hook on lifting device -MP9-201 (2024A)- at engine and at
workshop crane .
Lift engine with installed engine mount -T40076- out of the
engine/gearbox jack using the workshop crane .
Remove engine mount -T40076 - .
For carrying out assembly work, attach the engine with engine
mount -MP1-202- , adapter -MP1-202/10- and sleeves T30010- to the assembly stand -MP9-101- . The figure shows
the 1.9 ltr./47 kW SDI Engine. The fixing system is identical.
1.4
Installing the engine

Grease -G 000 100
Fit engine and gearbox using engine mount to the engine/

gearbox jack .
Installation is performed in the reverse order, pay attention to the

following points:
16
Fabia II 2007
Note
If the toothed belt is replaced when carrying out engine repair
(apart from regular change interval), it should be entered in the

Service Schedule !
Observe all safety measures and notes for assembly work on
the fuel and injection system, the charge air system as well as
the rules for cleanliness page 2 .
Replace self-locking nuts.

Replace screws which have been tightened firmly to a torquing
angle.
Always replace gasket rings and seals.

All cable straps should be fastened again in the same place
when installing.
Secure all hose connections with corresponding hose clamps
Electronic Catalogue of Original Parts .

WARNING

gine compartment because of its cramped construction, please
hot components.
Note
Clean the drive shaft serration and hub serration on a used
clutch disc, remove corrosion and only apply a very thin layer
of grease -G 000 100- on the serration. Subsequently move
the clutch disc up and down on the drive shaft until the hub fits
smoothly on the shaft. Always remove excess grease.
unlessinstalling
authorised bythe
KODA
AUTO A. S.
KODA the
AUTOcentering
A. S. does notof
guarantee
After
coupling,
check
the clutch
to the correctness of information in this document. Copyright by KODA AUTO A. S.
discwith
respect
Gearbox;
Rep. Gr. 30 .
Check the clutch release bearing for wear. Replace release
bearing if worn Gearbox; Rep. Gr. 30 .
Check whether the dowel sleeves for centering the engine/

gearbox are present in the cylinder block; insert if necessary.
17
Fabia II 2007
Ensure that the intermediate plate has been inserted on the
sealing flange and is pushed onto the dowel sleeves
-arrows-.
Screw on gearbox to engine gearbox; Rep. Gr. 34 .
Insert engine/gearbox assembly in the body.
Align the engine/gearbox unit free of stress and attach firmly
page 19 .
When tightening the new screws for engine and gearbox

mounts, engine and gearbox support brackets must be resting
fully against mount.
Remove engine mount -T40076- from engine.

Install pre-exhaust pipe with diesel particle filter:
Install pre-exhaust pipe page 224 .
Install the right drive shaft and attach the left drive shaft to the
flange shaft Chassis; Rep. Gr. 40 .
Connect hydraulic line to breather/clutch slave cylinder and
bleed the clutch hydraulic Gearbox; Rep. Gr. 30 .
Attach shift mechanism to gearbox and adjust Gearbox;
Rep. Gr. 34 .
Attach AC compressor to holder for auxiliary units
page 22 .
Install the V-ribbed belt page 23 .
Connect all hoses to the engine.
Connect electrical connections and attach cables Current
flow diagrams and Fitting locations.
Check oil level, top up oil if necessary Maintenance ; Fabia
II .
Connect vehicle diagnosis system, measurement and infor
mation system -VAS 505X- and carry out the targeted function
filling and bleeding the high pressure pump and the fuel sys
tem Vehicle diagnosis, testing and information system VAS
5051.
Top up coolant page 112 .
Install the noise insulation Body Work; Rep. Gr. 50 .
Install the left and right wheelhouse liner Body Work; Rep.
Gr. 66 .
Protected
by copyright.
Carry out cohesive work when reconnecting
the battery
Copying for private or commercial purposes, in part or in whole, is not permitted
Electrical System; Rep. Gr. 27 .
Perform a test drive.
Interrogate all fault memories, if necessary rectify any faults

existing and erase the fault memory Vehicle diagnosis, test
ing and information system VAS 5051.
18
Fabia II 2007
Note
After deleting the fault memory of the engine control unit the read
iness code must be checked, if necessary re-generated.
Tightening torques
Component
Nm
Screws or nuts
M6
M7
M8
M10
M12
9
13
20
40
70
deviations:
Engine/gearbox connecting screws Gearbox; Rep. Gr. 34
Screws for assembly bracket page 19
1.5
Assembly bracket
1 - Screw
replace
tightening order and
tightening torque
page 20
2 - Engine support bracket
removing and installing
page 38
3 - Screw
replace
tightening torque
page 20
4 - 20 Nm + torque a further 90
(1/4 turn)
replace
5 - Engine mounting
(1/4 turn)
replace
7 - Pendulum support
Fitting position
page 20
(1/4 turn)
replace
(1/4 turn)
replace
19
Fabia II 2007
10 - 40 Nm + torque a further 90 (1/4 turn)
replace
replace
12 - Gearbox mount
13 - 25 Nm
Nut of bracket for diesel particle filter/pre-exhaust pipe
replace
Engine support - tightening order and tightening torque
Tighten the new screws in 3 stages in the sequence shown:
Stage
Screws
Tightening torque/torquing angle
1
2
3
-1 3-1 3-1 3-
7 Nm
40 Nm
torque a further 180
Fitting position - pendulum support

Position the screws -A- in the elongated holes of the pendulum
support in such a way that there is maximum distance between
the gearbox and the assembly carrier.
The screw -arrow- must not be loosened.
20
Fabia II 2007
13
Crankgear
Removing and installing V-ribbed belt
1.1
V-ribbed belt drive - Summary of com

ponents
1.1.1
Vehicles without air conditioning
1 - Crankshaft-belt pulley
with vibration damper
page 25
2 - 25 Nm
3 - Generator
Electrical System;
Rep. Gr. 27
4 - Bracket for auxiliary units
page 42
5 - V-ribbed belt
page 22
replace
pay attention to the cor
rect position on the belt
pulley when installing it.
1. Removing and installing V-ribbed belt
21
Fabia II 2007
1.1.2
page 25
2 - 25 Nm
3 - Generator
Electrical System;
Rep. Gr. 27
page 42
5 - 20 Nm + torque a further
180 (1/2 turn)
replace
6 - Tensioning element
for the V-ribbed belt
page 24
7 - AC compressor
Heating, Air Condi
tioning; Rep. Gr. 87
8 - 45 Nm
9 - Dowel sleeves
pay attention to correct
fit in the holder
10 - V-ribbed belt
page 23
check for wear
mark the direction of rotation with chalk or a felt-tip pen before removing
do not kink
pay attention to the correct position on the belt pulley when installing it.
1.2
1.2.1

for vehicles without air conditioning sys
tem
Note
The repair kit for the V-ribbed belt includes the assembly tool T10367- and an illustrated work procedure .
22
Rep. Gr.13 - Crankgear
Fabia II 2007
Removing
Remove the sound dampening system Body Work; Rep.
Gr. 50 .
Remove the right wheelhouse liner Body Work; Rep. Gr.
66 .
Cut through the V-ribbed belt.
Install
following points:
The following work procedure is described in the illustrated
work procedure .
Start engine and check ribbed V-belt run.
1.2.2

for vehicles with air conditioning system

Locking pin -T10060 ARemoving
66 .
Remove right charge air pipe page 163 .
Caution
Risk of damage through reversing the rotation direction of an

already used V-ribbed belt.
If it is intended to re-install the V-ribbed belt, mark the di
rection of rotation with chalk or a felt-tip pen before re
moving it.
Loosen the V-ribbed belt by swivelling the tensioning element
in -the direction of the arrow-.
23
Fabia II 2007
Align the holes -arrows- and lock the tensioning element using
the locking pin -T10060 A- .
Remove the V-ribbed belt.
Install
following points:
Note
Before fitting the V-ribbed belt make sure that all assemblies
(generator and AC compressor) are securely mounted.
Lay the V-ribbed belt onto the V-ribbed belt pulleys.
1-
Crankshaft belt pulley with vibration damper
2-
Tensioning element
3-
Generator
4-
AC compressor
Hold the tensioning element with the ring spanner and pull out
the locking pin -T10060 A- .
Release the tensioning element.
Check correct positioning of the V-ribbed belt.
Start engine and check ribbed V-belt run.
1.3
Removing and installing tensioning ele

ment for V-ribbed belt
Removing
24
Fabia II 2007
Release screws of coolant lines -arrows-.
WARNING

be opened.
Caution

ses.
body.
Release the screw -2- and remove the tensioning element for
V-ribbed belt -1-.
Install
following points:
Replace the screw for the tensioning element.
Tightening torque: 20 Nm + torque a further 180 (1/2 turn)
Attach AC compressor to holder for auxiliary units
page 22 .
Install the V-ribbed belt page 23 .
1.4
Removing and installing crankshaft-belt

pulley
Removing
Remove
V-ribbed
22 purposes,
.
Protected
by copyright.
Copying forbelt
privateorpage
commercial
in part or in whole, is not permitted
with respect
Release
coolant inlines
-arrows-.
to the screws
correctnessof
of information
this document.
Copyright by KODA AUTO A. S.
Lay the coolant lines a little to the side.
25
Fabia II 2007
Loosen the screws -arrows- for the crankshaft belt pulley. To
do so, counterhold with a ring spanner at the screw for the
crankshaft timing belt sprocket.
Release screws and remove crankshaft-belt pulley.

Install
following points:
Install the crankshaft belt pulley with new screws Electronic
Catalogue of Original Parts . The assembly is only possible in
one position.
26
Fabia II 2007
Removing and installing toothed belt
2.1
Timing belt drive - Summary of components
1 - Toothed belt
before removing mark
running direction
check for wear
do not kink
page 29
Note
90 (1/4 turn)
replace
Neither oil nor grease
thread or collar.
by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
tighteningunless
mayauthorised
occur in
successive stages
3 - Toothed belt gear
at the crankshaft
4 - 20 Nm
5 - Guide pulley, bottom
(1/8 turn)
7 - Tensioning pulley
for removing and instal
ling, remove engine
support page 38
8 - 25 Nm
replace
on the camshaft
10 - 25 Nm
11 - 100 Nm
to release and tighten use counterholder -T10051 12 - Hub
for camshaft
to remove use extractor -T10052 removing and installing page 85
13 - Rear toothed belt guard
replace
for attaching the high pressure pump
2. Removing and installing toothed belt
27
Fabia II 2007
15 - 10 Nm
replace
16 - Guide pulley, top
attached to the bracket for auxiliary units
replace
for guide pulley, middle (without position number)
screwed into the bracket for auxiliary units
18 - Hub
for high pressure pump
to release and tighten use counterholder -T10051 to remove use extractor -T40064 removing and installing page 194
19 - 95 Nm
on the high pressure pump
replace
22 - Coolant pump
removing and installing page 119
23 - 15 Nm
24 - Timing belt guard - top part
25 - Timing belt guard - bottom part
26 - 10 Nm
insert using locking agent -D 000 600 A227 - 10 Nm + torque a further 90 (1/4 turn)
replace
29 - 5 Nm
30 - Protection plate
31 - Screw
replace
tightening order and tightening torque page 38
28
Fabia II 2007
Attach toothed belt guard - bottom part
Insert screws with locking agent -D 000 600 A2- .
Tighten screws -arrows- to 9 Nm.
2.2
Removing and installing toothed belt

Rig pin for diesel injection pump -3359 - (2x)
Crankshaft arrester -T10050 Locking pin -T10060 A Counterholder -T10172 - with bolts -T10172/4- and bolts T10172/8 Offset screwdriver -T10264 Rig tool -T10265 Socket insert XZN 10 -T10385 Pliers for spring strap clamps
2.2.1
Removing
WARNING

gine
compartment due to its cramped construction, please
observe
the tofollowing:
with respect
the correctness of information in this document. Copyright by KODA AUTO A. S.
hot components.
29
Fabia II 2007
Note
If the toothed belt is replaced beyond the change interval, it
should be entered in the Service Schedule !
Observe safety measures when working on the fuel system
page 3 .
Observe rules for cleanliness page 4 .

The engine support does not have to be removed in order to
remove the camshaft sprocket.
Put the shift lever into Neutral in order to turn the crankshaft.
Switch off ignition and withdraw ignition key.
Gr. 66 .
Remove crankshaft-belt pulley page 25 .
Note
Do not lock tensioning element for V-ribbed belt.

Remove top part of toothed belt guard; to do so release re
taining clips -arrows-.
Release screws -arrows-.

Remove bottom part of toothed belt guard.
Note
The engine support must be removed to replace the tensioning

pulley page 38 .
30
Fabia II 2007
Rotate the crankshaft on TDC in direction of rotation of the
engine, secure the crankshaft timing belt sprocket with the
crankshaft arrester -T10050- . Slide the crankshaft arrester
from the front side of the crankshaft timing belt sprocket into
its teeth.
Note
The markings on the crankshaft - toothed belt sprocket -2- and on

the crankshaft arrester -T10050- -1- must be aligned. The bolt of
the crankshaft arrester -T10050- must engage at the same time
in the hole of the sealing flange.
The arrow on the camshaft sprocket must be close to the 12

o'clock position.
If the arrow is close to the 6 o'clock position, torque the
crankshaft by 1 turn (360).
Successively release screws -1- for camshaft sprocket, re

place screws and do not fully screw in the new screws.
Successively unscrew the screws -2- of the toothed belt

sprocket of the high pressure pump with the socket insert XZN
10 -T10385- , replace the screws and do not fully screw in the
new screws.
Loosen nut -1- for tensioning pulley.

Turn the eccentric of the tensioning pulley with the offset
screwdriver -T10264- in -direction of arrow- (anti-clockwise)
until the tensioning pulley can be interlocked with the rig tool
-T10265- .
31
Fabia II 2007
Then turn the eccentric of the tensioning pulley with the offset
screwdriver -T10264- in the -direction of arrow- up to the stop
and tighten the nut -1- by hand.
Caution
Risk of damage through reversing the rotation direction of an

already used toothed belt.
If the toothed belt is re-installed, mark the direction of ro
tation with chalk or a felt-tip pen before removing it.
First of all remove the toothed belt from the large guide pulley
and then from the remaining toothed belt gears.
2.2.2
Installing (set the timing)
Note
Adjusting work on the timing belt must only be performed on
a cold engine, as the position of the pointer at the tensioning

element is temperature dependent.
If it is intended to replace the tensioning pulley, the engine
support must be removed page 38 .
Conditions
Tensioning pulley locked with rig tool -T10265- and fixed with
nut up to right stop.
Lock the crankshaft with the crankshaft arrester -T10050- .
The screws for the camshaft sprocket and the toothed belt
gear on the high pressure pump are replaced and loosely
tightened. It must still be possible to just turn the toothed belt
sprockets, however they must not tilt.
32
Fabia II 2007
Note
If necessary, turn the hub of the camshaft using the counterholder

-T10172- with bolts -T10172/4- until it can be locked. To do so
tighten at least one fixing screw -1- by hand.
Lock hub for camshaft with rig pin for injection pump -3359- .
To do so, slide the rig pin through the open elongated hole on
the outside of the cylinder head.
Loosen again the screws which were tightened by hand.
Lock hub for high pressure pump with rig pin for injection pump
-3359- . To do so, insert the rig pin into the hole of the timing
belt gear from the outside.
Note
If necessary, use a screwdriver to turn the hub of the high pres

sure pump at the screw heads -1- until the hub can be locked with
the rig pin.
33
Fabia II 2007
Turn the camshaft sprocket -3- and the toothed belt sprocket
on the high pressure pump -5- clockwise in their elongated
holes as far as the stop.
Fit the timing belt in the following order.
1-
Crankshaft - toothed belt sprocket
2-
Tensioning pulley
3-
Camshaft sprocket
4-
Timing belt gear on the coolant pump
5-
Toothed belt gear on the high pressure pump
6-
Guide pulley
Loosen nut -1- for tensioning pulley and remove rig tool T10265- .
Note
Pay attention to correct fitting of the tensioning pulley in the rear

toothed belt guard -arrow-.
Fit counterholder -T10172- with bolts -T10172/4 - onto cam

shaft sprocket.
Push the counterholder in -direction of arrow- and keep it pre
tensioned.
First of all tighten the screws -1- for the camshaft sprocket and
the screws -2- for the toothed belt gear on the high pressure
pump in this position to 20 Nm.
Note
The screws must be further turned after the setting and testing of
the timing have been carried out page 37 .
34
Fabia II 2007
Turn the eccentric of the tensioning pulley with the offset
screwdriver -T10264- clockwise -arrow- until the pointer -2- is
in the centre of the base plate in front of the gap.
The nut -1- must not turn along.
Hold tensioning pulley in this position and tighten nut.

Remove rig pins for diesel injection pump -3359- and crank
shaft arrester -T10050- .
Test timing
Turn the crankshaft at the central screw for crankshaft toothed
belt sprocket by 2 turns in the direction of rotation of the engine
until the crankshaft is positioned shortly before TDC.
Position the crankshaft arrester -T10050- on the crankshaft
toothed belt sprocket.
Turn the crankshaft in the direction of rotation of the engine
until the bolt -arrow- of the crankshaft arrester engages during
this rotary movement in the sealing flange.
Note
The removal of the crankshaft and camshaft is limited in the fol

lowing test. The removal point of the hub of the high pressure
pump is always difficult to find again. A slight difference -arrowdoes not influence the engine running.
Conditions
35
Fabia II 2007
The hub of the camshaft must be locked with the rig pin for
diesel injection pump -3359- .
The pointer of the tensioning pulley -2- must be in the area

-a- of the base plate -1-.
If the conditions are not fulfilled:

Correct timing page 36 .
If the conditions are fulfilled:
Continued if the timing is correctly set page 37 .
Correct timing
Push the crankshaft arrester -T10050- until its locking bolt
pushes out of the hole in the sealing flange.
Turn the crankshaft against the running direction of the engine
slightly before the TDC.
Now slowly turn with the crankshaft in the running direction of
the engine, until the hub of the camshaft can be locked during
this rotary movement with the rig pin for the injection pump
-3359- .
Slacken the fixing screws of the pulley when the hub of the
camshaft sprocket is locked.
36
Fabia II 2007
Check the position of the bolt -arrow- of the crankshaft arrester
-T10050- to the hole in the sealing flange:
If the bolt -arrow- of the crankshaft arrester -T10050- is positioned
to the left of the hole:
Slowly turn the crankshaft in the direction of rotation of the
engine until the bolt of the crankshaft arrester -T10050- en
gages into the hole in the sealing flange.
Pre-tighten the fixing screws for the camshaft sprocket to 20
Nm.
Note
The screws must be further turned according to the setting of the

timing page 37 .
If the bolt of the crankshaft arrester -T10050- is positioned to the
right behind the hole:
First of all turn the crankshaft slightly against the direction of
rotation of engine until the bolt is positioned to the left in front
of the hole.
Slowly turn the crankshaft in the direction of rotation of the
engine until the bolt of the
crankshaft
arrester
en purposes, in part or in whole, is not permitted
Protected
by copyright.
Copying for-T10050private or commercial
unless
authorisedflange.
gages into the hole in the
sealing
Pre-tighten the fixing screws for the camshaft sprocket to 20

Nm.
Note
The screws must be further turned according to the setting of the

timing page 37 .
Procedure if the timing is correctly set
Remove rig pin -3359- and crankshaft arrester -T10050- .
Once again test timing page 35 .
If the hub of the camshaft sprocket can now be secured:
Tighten fixing screws of toothed belt sprockets with a rigid
wrench as follows:
Camshaft sprocket:
45 (torque a further 45 (1/8 turn). Counterhold with counter
holder -T10172- with bolts -T10172/4 - .
Toothed belt sprocket on the high pressure pump:
37
Fabia II 2007
90 (torque a further 45 (1/4 turn). Counterhold with counter
holder -T10172- with bolts -T10172/8 - .
Further installation occurs in reverse order to removal.
Tightening torques: page 27
2.3
Removing and installing engine support

Supporting device -MP9-200 (10-222A) Adapter -MP9-200/3 (10-222A/3)
Removing
Note
Do not open fuel lines and coolant lines. The coolant expansion
reservoir remains closed.
Gr. 50 .
unless authorised
by KODA
A. S. KODA
AUTO
A. S. does
guarantee
Unscrew
screws
-2 andAUTO
3- and
remove
holder
fornotdiesel
parti
with respect
cle filter
at theto top.

Unscrew screws -4- and nuts -5- and remove bracket for preexhaust pipe at the bottom.
Unclip hoses at coolant expansion reservoir.
Disconnect plug from coolant expansion reservoir.
38
Fabia II 2007
Disconnect plug -1- at differential pressure sender -G505 Unscrew differential pressure sender -G505- from bracket and
lay to the side.
Disconnect plug -2- at fuel temperature sender -G81- .
Unbolt the coolant expansion bottle.
Remove the fuel filter -1- upwards out of the bracket.

Lay coolant expansion reservoir and fuel filter with lines to the
side.
Fit supporting device -MP9-200- . For this purpose, position

the supports -A- next to the screw -arrow 1- and the support
of the front flap -arrow 2- as shown.
Note
The assembly bracket must only be removed if the engine is
supported with the supporting device -MP9-200- !
Only release the engine support if the assembly bracket is re
moved.
39
Fabia II 2007
Unscrew securing bolts -arrows-.
Caution
The nut -2- must not be released.

Remove the complete engine mounting.
WARNING
Make sure that no components/hoses are damaged, over

stretched or torn off when lifting and lowering the engine with
the supporting device -MP9-200- .
Slacken screws of engine support in the sequence -3 1-.
Remove the engine support upwards.
Install
Place the engine support from the top.
Caution
The tightening sequence and the tightening torque of the

screws for the engine support must definitely be respected.
Otherwise stress of the engine support occurs, which results
in the breaking of the engine support.
Screw in new screws and tighten in 3 stages in the sequence
shown.
Stage
Screws
1
2
3
-1 3-1 3-1 3-
7 Nm
40 Nm
180 (torque a further 90 (1/2 turn)

Tightening torque of the engine mounting: page 19
40
Fabia II 2007
Cylinder block
3.1
Cylinder block - Summary of components
1 - Cylinder block
Removing and installing
sealing flanges and fly
wheel page 49
Removing and installing
crankshaft, piston and
conrod page 62
2 - Knock sensor -G613 - 20 Nm
the tightening torque in
fluences the knock sen
sor function
4 - Engine speed sender -G28 removing and installing
page 60
5 - 5 Nm
6 - Gasket
replace
7 - Oil filter holder
disassembling and as
sembling page 98
8 - Screws for balancing shaft
module
page 46
(1/4 turn)
replace
tighten crosswise
10 - 15 Nm
11 - 4/2 way valve with coolant regulator
12 - O-ring
replace
13 - Balancing shaft module
14 - Oil pan
15 - 15 Nm
16 - Screw
for bracket for auxiliary units Item 19 (page 42)
replace
loosen and tighten page 42
3. Cylinder block
41
Fabia II 2007
17 - Screw
replace
18 - Screw
replace
for engine support, guide pulleys of timing belt, AC generator, AC compressor and tensioning element
of the V-ribbed belt
pay attention to the dowel sleeves between the bracket for auxiliary units and the cylinder block
20 - 25 Nm
21 - Lifting eye
22 - Screw
replace
23 - Screw
replace
25 - Bracket for pre-exhaust pipe
26 - 23 Nm
unless
authorised
27
- 40
Nm by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
28 - Heat shield
for right drive shaft
3.2
Removing and installing bracket for aux

iliary units
Removing
Remove the high pressure pump page 194 .
42
Fabia II 2007
Remove alternator Electrical System; Rep. Gr. 27 .
WARNING

be opened.
Caution

ses.
body.
Remove guide pulleys -1 and 2- and release the screw
-arrow- of the rear timing belt guard.
Release screw -1- of engine support.
3. Cylinder block
43
Fabia II 2007
Release screws in the sequence -6 1- and remove bracket
for auxiliary units.
Install
following points:
Note
A dowel sleeve must be located between the bracket for aux
iliary units and the cylinder block in the screw hole -6-.
Replace all the screws of the bracket for auxiliary units and the
engine support, which have been tightened to a torquing an

gle.
Before tightening the fixing screws of the bracket for auxiliary
units, screw in the screw of the engine support by hand.
Screw in the new screws of the bracket for auxiliary units.

Screws -1- and -2- M10 x 52
screws -3- and -4- M10 x 30
screws -5- and -6- M10 x 60
Gradually tighten the new fixing screws for auxiliary units in
the sequence -16-:
1.
Screw in all the screws by hand.
2.
Tighten all bolts initially to 40 Nm.
3.
Torque the screws with a rigid wrench as follows:

Torque screws -1 and 2- a further 90 (1/4 turn.)
Tighten the new screw of the engine support -3-.

Install high pressure pump page 194 .
Install alternator Electrical System; Rep. Gr. 27 .
Install AC compressor page 22 .
Fill up the fuel system page 179 .
44
Fabia II 2007
Balancing shaft module
4.1
Balancing shaft module - Summary of components

Note
The balancing shaft module with oil pump can only be replaced completely.
1 - Cover
clean if soiled
2 - 8 Nm
180 (1/2 turn)
tighten crosswise from
the inside outwards in
several stages
180 (1/2 turn)
5 - Balancing shaft module with
oil pump
must be replaced com
pletely
before installing, check
whether the dowel
sleeve is present for
centering in the cylinder
block and the O-ring is
inserted in the balancing
shaft module
page 46
6 - O-ring
replace
check for correct posi
tion, is inserted in the
balancing shaft module
lightly oil for assembly
7 - Cylinder block
8 - Fitting sleeve
9 - Chain tensioner with ten
sioning rail
to remove lock with locking pin -T40011 removing and installing page 46
replace
11 - Assembly aid
Rig pin -T4001112 - Chain
check fitting position 4.2 Removing and installing balancing shaft module, page 46
4. Balancing shaft module
45
Fabia II 2007
13 - 23 Nm
14 - Deflection chain sprocket
4.2
Removing and installing balancing shaft

module
Locking pin -T40011 Socket insert -T10061Removing

Removing toothed belt page 29 .
Removing the oil pan page 99 .
Remove sealing flange on belt pulley side page 50 .
Remove cover of balancing shaft module.
Lock the chain tensioner with the locking pin -T40011-arrow-.
Release screw from deflection chain sprocket -1- and remove
deflection chain sprocket.
Release screws -2- from chain tensioner and remove chain
tensioner.
Remove chain from chain sprockets and place on a clean sur
face.
Unscrew balancing shaft module
from cylinder block and place
down on a clean surface.
Install
Check all the components of the chain drive for wear.

Note
When installing the balancing shaft module, ensure that the dowel
sleeve is inserted in the cylinder block and the O-ring in the bal
ancing shaft module.
Tighten the balancing shaft module to the cylinder block by
hand.
46
Fabia II 2007
Align the balancing shaft module in such a way that it is flush
with the outer edge of the cylinder block on the belt pulley side.
Caution
Under no circumstances the balancing shaft module must be

installed as shown in the picture detail with -arrow 1 and 2-.
Replace the screws of the balancing shaft module and tighten
crosswise from the inside outwards in several stages.
Clean the chain with a non-fluffing cleaning cloth.
Fit the chain onto the chain sprocket of the crankshaft, the oil
pump and the balancing shaft as shown.
While doing so, the marking on the chain sprocket of the

crankshaft must be opposite the individual colour-marked
chain link -top arrow-.
The marking on the chain sprocket of the balancing shaft must

be between the 2 colour-marked chain links -bottom arrow-.
Protected
copyright.
Copying
The colour markings are only located
onbythe
outer
tabsforofprivate
the or commercial purposes, in part or in whole, is not permitted
unless authorised
by KODA
AUTO
A. S. KODA AUTO A. S. does not guarantee or accept any liability
chain. They must point to the outside.
Thus the
original
direc
tion of rotation of the chain is ensured.
Insert the deflection chain sprocket into the chain and tighten
at the balancing shaft module to 23 Nm.
Install chain tensioner.
Replace screws -2- and tighten as follows.
1.
2.
3.
4.
middle screw
Screw to oil pump
Screw to guide rail
middle screw
8 Nm
8 Nm
8 Nm
90 (torque a further
90 (1/4 turn)
5.
Screw to oil pump
90 (1/4 turn)
6.
Screw to guide rail
90 (1/4 turn)
Remove the locking pin -T40011- from the chain tensioner.
4. Balancing shaft module
47
Fabia II 2007
Check, if the markings on the chain sprocket of the crankshaft
and the balancing shaft are correctly positioned to the colourmarked chain links -arrows-.
48
Fabia II 2007
Removing and installing sealing

flange and flywheel
5.1
Sealing flanges and flywheel - Summary of components

Note
The sealing flange on the belt pulley side -2- is made of plastic. The sealing ring -1- and a circumferential silicone
seal for the cylinder block and for the oil pan is integrated in it page 50 .
1 - Sealing ring
Only possible to replace
complete with sealing
flange page 50
Do not additionally lubri
cate or grease sealing
lip of the gasket ring
before installing, re
move oil residues on
crankshaft journal and
cylinder block with a
clean cloth
2 - Sealing flange
on belt pulley side
replace
page 50
3 - Cylinder block
4 - The two-mass flywheel
page 58
Assembly is only possi
ble in one position
through offset holes.
(1/4 turn)
replace
6 - Intermediate plate
must be positioned on
dowel sleeves
do not damage/bend
during assembly work
hang on the sealing
flange page 50
7 - 15 Nm
replace
8 - Sealing flange
on gearbox side
can only be replaced complete with gasket ring and with rotor of engine speed sender -G28 replace page 53
5. Removing and installing sealing flange and flywheel
49
Fabia II 2007
9 - Engine speed sender -G28 removing and installing page 60
Sealing flange on the belt pulley side with silicone seal and seal
ing ring
The sealing flange on the belt pulley side with integrated sealing
ring and integrated silicone seal can only be replaced completely
page 50 .
-1-: Sealing ring
-Arrows-: circumferential silicone seal for the cylinder block
and the oil pan
Installing intermediate plate

Insert intermediate plate on sealing flange and push onto the
dowel sleeves -arrows-.
5.2
Removing and installing the sealing

flange on the belt pulley side

Counterholder -T30004 (3415) Assembly device -T10053 Socket insert -T10058 Old oil collecting and suction equipment , e.g. -V.A.G 1782 Silicone sealant -D 176 501 A1 Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
Cleaning and degreasing agent , e.g. -D 000 unless
401 authorised
04-
Protective goggles and gloves

Removing
Engine installed.
50
Fabia II 2007
Remove crankshaft - toothed belt sprocket. To this end lock
the toothed belt gear with counterholder -T30004 (3415)- .
Unscrew the sealing flange on the belt pulley side, if necessary
release by applying slight blows with a rubber-headed ham
mer.
Install
following points:
WARNING
Use protective gloves and protective googles when working

with sealant and grease remover!
Remove the remaining sealant on the cylinder block and on
the oil pan with chemical sealant remover.
Degrease the sealing surfaces.
Slide the guide bushing -T10053/1- onto the crankshaft.
Fit sealing flange and lightly tighten all screws.
Tighten the screws of the sealing flange alternately and cross
wise to 15 Nm.
Installing the oil pan page 51 .
Installing the oil pan
51
Fabia II 2007
Note
The following description for the installation of the oil pan only
applies if the sealing flange on the belt pulley side was re

placed.
If the silicone seal -arrows- is damaged, it must be replaced.
Then the work procedure page 99 must be carried out.
Pay attention to the use by date of the silicone sealant -D 176
501 A1- .
Cut off nozzle tube at the front marking ( of nozzle approx.

3 mm).
Apply the silicone sealant -D 176 501 A1- to the clean sealing
surface of the oil pan, as shown. The sealant bead must be:
Run past the area around the bolt holes on the inside
-arrows-.
Caution
Risk of blockage of the lubrication system through excess seal

ant.
Do not apply a thicker sealant bead than indicated.
Thickness of sealant bead: 23 mm

Note
After applying the sealant, install the oil pan within 5 minutes.
Position oil pan.
Note
The oil pan must be flush to the gearbox flange at the inter
mediate plate.
When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.
52
Fabia II 2007
Tighten the screws of the oil pan in 3 stages as follows.
Stage
Screws
1
2
3
-1 16-Arrows-1 16-
Tightening torque
crosswise to 5 Nm
40 Nm
crosswise to 15 Nm
The further assembly is carried out in the reverse order, while

paying attention to the following:
After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
Installing the timing belt page 29 .
Fill with engine oil and check the oil level Maintenance ;
Fabia II .
5.3
Replace sealing flange on the gearbox

side

Assembly device -T10134 Feeler gauges
Steel straightedge
Screw M6 x 35 (3x)
Screw M7 x 35 (2x)
5.3.1
Removing
Gearbox is removed.
Remove the two-mass flywheel page 58 .

Remove the intermediate plate from the dowel sleeves and
unhook from sealing flange -arrows-.
Position crankshaft to TDC for cylinder 1 page 29 .
Remove engine
with respect-G28to the correctness
of information in this document. Copyright by KODA AUTO A. S.
speed sender
-Pos. 1-.
Unscrew the fixing screws of the sealing flange.
53
Fabia II 2007
Screw 3 screws M6 x 35 mm into the threaded bores of the
sealing flange -arrows-.
Remove the sealing flange together with rotor from the crank
shaft by alternately screwing in the press-off screws.
5.3.2
Install
Note
The sealing flange with PTFE gasket ring is provided with
sealing lip supporting ring. This supporting ring is intended as

an assembly sleeve and must not be removed before instal
ling.
Do not separate or turn the sealing flange and rotor after re
moving them from the spare part package.
The rotor is given its fitting location by fixing the assembly de
vice -T10134- to the positioning pin.
The sealing flange and gasket ring form one unit and must be
replaced together with the rotor.
The rotor has an elastomer layer on its sealing surface with
the crankshaft. This layer must not be brought into contact with
dirt or grease.
The assembly device -T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into

the threaded bore of the crankshaft.
A - Mounting sealing flange with rotor on the assembly device T10134A - Hexagon nut
B - Clamping surface
C - Assembly cupProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
D - Allan screw
E - Guide bolts (with red handle - for fuel engine)

F - Positioning pin
G - Guide bolts (with black handle - for diesel engine)
54
Fabia II 2007
Grip assembly device -T10134- on clamping surface -B- of the
threaded spindle in a vice.
Push assembly cup -C- down until it rests on the hexagon nut
-A-, -arrow-.
The inner part of the assembly device and the assembly cup
must be flush.
Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
Lay the front side of the sealing flange on a clean and level
surface.
by copyright.
Press down sealing lips supportingProtected
ring -Ain
by surface.
KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
-direction of the arrow-, until it restsunless
on authorised
the level
Note
The top edge of the rotor and the front edge of the sealing flange
must be flush.
The locating hole -B- on the rotor -C- must be flush with the mark
ing -A- on the sealing flange.
55
Fabia II 2007
Lay the sealing flange with the front side on the assembly de
vice -T10134- in such a way that the positioning pin -A- en
gages into the hole -B- of the rotor.
Note
Make sure the sealing flange lies flat on the assembly device.
When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly device T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly device -T10134- with sealing flange
on the crankshaft flange
The crankshaft flange must be free of grease and oil
Crankshaft is at TDC for cylinder 1
Unscrew hexagon nut up to the end of the threaded spindle.
Screw assembly device -T10134- with Allan screws -A- up to

the stop onto the crankshaft flange.
Screw in 2 screws M7 x 35 mm -A- by about 3 thread turns for

the sealing flange guide into the cylinder block.
56
Fabia II 2007
Move the assembly cup -C- by hand in the
-direction of the arrow- until the rotor -B- rests on the crank
shaft flange -A-. Subsequently insert the guide bolt with black
handle -D- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly pushed in, then the handle has a dis
tance of approx. 10 mm from the assembly cup -C-. This gives
the rotor its final fitting location.
Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
Note
The guide bolt for petrol engines (red handle) -F- must not be fitted
into the threaded hole of the crankshaft.
C - Pressing the rotor onto the crankshaft flange
Tighten the hexagon nut of the assembly device -T10134 using a torque wrench with adapter.
Tightening torque: 35 Nm
Note
After tightening the hexagon nut to 35 mm there must still be a

narrow air gap between the cylinder block and the sealing flange.
D - Inspecting the fitting position of the rotor on the crankshaft
Unscrew hexagon nut -E- up to the end of the threaded spin
dle.
Release 2 screws -A- to the guide from the cylinder block.
Release 3 knurled screws -B- from the sealing flange.
Unscrew 2 Allan screws and remove assembly device.
Remove sealing lips supportingProtected
ring. by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- = 0.5 mm between the crankshaft flange
-A- and the rotor -B-.
57
Fabia II 2007
Position the steel striaghtedge onto the crankshaft flange.
Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
Press down rotor page 58 .
If the dimension is correct:
Tighten the new fixing screws of the sealing alternately cross
wise.
Install engine speed sender -G28- -Pos. 1-.
Installing the oil pan page 99 .
Fit intermediate plate.
Install two-mass flywheel with new screws.
Tighten fixing screws to 60 Nm + torque a further 90 (1/4 turn).
E - Pressing down the rotor
Screw assembly device -T10134- with Allan screws up to the

stop onto the crankshaft flange.
Screw in 3 knurled screws -B- into the flange.
Insert the guide bolt with black handle -D- fully into the threa
ded bore of the crankshaft.
If the guide bolt is correctly positioned, then the handle has a

distance of approx. 10 mm from the assembly cup -C-.
Screw in hexagon nut -E- by hand onto the threaded spindle

until it rests against the assembly cup.
unless authorised
by KODA
A. S. KODA AUTO A. S. does not guarantee or accept any liability
Tighten the hexagon nut of the assembly
device
usingAUTO
a torque
wrench with adapter.
Again inspect the fitting position of the rotor on the crankshaft
page 57 .
If the dimension -a- is again too small:
Tighten the hexagon nut of the assembly device to 45 Nm.
Again inspect the fitting position of the rotor on the crankshaft
page 57 .
5.4
Removing and installing the two-mass

flywheel

Counterholder -MP1-223 (3067)or
58
Fabia II 2007
Engine mount -MP1-202 (VW 540) Bushing -T30010 (VW 540/1B) Flywheel lock -MP1-504Removing
Gearbox is removed.
Engine installed
Insert the counterholder -MP1-223 (3067)- into the bore hole
on the cylinder block.
Fitting position of the counterholder:
A - for tightening
B - for slackening
Engine removed
Position the flywheel lock -MP1-504- on the starter ring gear
and turn crankshaft until it rests against the sleeve -T30010 - .
59
Fabia II 2007
Continued for all engines
Rotate the secondary side -A- of the two-mass flywheel in such
a way that the screws -B- are positioned in the middle of the
holes -arrows-.
Caution
When unscrewing the screws -B-, ensure that no screw head

catches on the secondary side -A- of the two-mass flywheel,
otherwise it will be damaged.
Release screws -B- and remove two-mass flywheel.
Install
Installation occurs in reverse order to removal. Pay attention to
the following:
Note
Use new screws for attaching.

Rotate the secondary side -A- of theunless
two-mass
flywheel in such
a way that the fixing screws -B- are positioned in the middle of
the holes -arrows-.
1.
Screw in all the screws -B- by hand.
2.
First of all tighten all the screws -B- crosswise to 60 Nm.
3.
Then torque all the screws -B- crosswise a further 90 (1/4

turn.)
5.5
Removing and installing engine speed

sender -G28-

Socket insert -T10370 Assembly device -T10118 Remove the sound dampening system Body Work; Rep.
Gr. 50 .
Disconnect plug -1- at engine speed sender -G28- with as
sembly device -T10118- .
60
Fabia II 2007
Release the screw -arrow- and pull out the engine speed
sender -G28- .
Installation occurs in reverse order to removal. Pay attention to
the following:
Tightening torque for screw of engine speed sender -G28- : 5
Nm
61
Fabia II 2007
Crankshaft, Piston and Conrod
6.1
Crankshaft - Summary of components
1 - Bearing shells 1, 2 and 4

for bearing cap without
lubricating groove
for cylinder block with lu
bricating groove
do not mix up used bear
ing shells (mark)
(1/4 turn)
replace
3 - Bearing caps
Bearing cap 1: on belt
pulley side
4 - Crankshaft
with chain sprocket for
balancing shaft and oil
pump drive
Axial play when new:
0.070.17 mm
Wear limit: 0,37 mm
Crankshaft bearing
pins: 54.00 mm
Conrod bearing:
47.80 mm
5 - Bearing shell 3
for bearing cap without
lubricating groove
for cylinder block with lu
bricating groove
6 - Thrust washers
Fitting position for bear
ing 3 page 62
Fitting position of thrust washer for bearing 3
62
Fabia II 2007
6.2
Disassembling and assembling pistons and conrods
1 - Piston rings
Offset joint 120
use piston ring pliers for
marking TOP faces
piston crown
Inspect gap clearance
page 64
Inspect end clearance
page 65
2 - Piston
with combustion cham
ber
Mark the installation po
sition and the assign
ment to cylinder
page 64
arrow on piston crown
faces towards the belt
pulley
replace the piston if
there is any sign of crack
formation
Inspecting piston
page 65
Piston dimension:
79.45 mm
use piston ring tension
ing strap for installing
inspect piston projection
at TDC page 66
unless authorised
3 - Piston
pin by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
if stiff, heat piston to ap
prox. 60C
use drift -VW 222A- for removing and installing
4 - Circlip
replace
5 - Conrod
always replace as a set only
mark matching cylinder -A Fitting position: Markings -B- point towards the belt pulley side
with a split bearing cap
separate new conrod page 67
Axial play wear limit: 0.37 mm
6 - Bearing shell
Fitting position page 66
mark used bearing shells for reinstalling, however do not mark the contact surface
Observe version: top bearing shell (towards the piston) must be made from a long lasting material, rec
ognition feature for new bearing shells: black marking on the contact surface near the separation point
insert in middle page 66
check for firm seating
6. Crankshaft, Piston and Conrod
63
Fabia II 2007
7 - Cylinder block
Inspect cylinder page 65
Cylinder dimension: 79.50 mm
8 - Conrod bearing cap
Check fitting position
cracked cover fits only in one position at the relevant conrod
9 - Oil injection nozzle
for piston cooling
10 - Pressure valve, 27 Nm
replace without sealant
replace
Oil thread and contact surface
Installation position and assignment of piston/cylinder
The arrow on the piston crown -arrows- faces towards the belt
pulley side.
Inspecting piston ring gap clearance

Feeler gauges
64
Fabia II 2007
Insert ring at right angles from above down into lower cylinder
opening, about 15 mm away from edge of cylinder. To insert
use piston without rings.
Piston ring
(dimensions in mm)
New
Wear limit
1. Compression ring
2. Compression ring
Oil scraper ring
0,20 0,40
0,20 0,40
0,25 0,50
1,00
1,00
1,00
Inspect piston ring end clearance

Feeler gauges
Clean before inspecting the annular grooves of the piston.
Piston ring
(dimensions in mm)
New
Wear limit
1. Compression ring
2. Compression ring
Oil scraper ring
0,06 0,09
0,05 0,08
0,03 0,06
0,25
0,25
0,15
Inspecting pistons

External micrometer
Measure about 10 mm from the lower edge, offset at right an
gles to the piston pin shaft.
Max. deviation from specified dimension: 0,04 mm.
Inspecting cylinder bore

Internal precision measuring instrument
Measure cylinder at 3 points crosswise in transverse direction
-A- and lengthwise -B-.
65
Fabia II 2007
Max. deviation from specified dimension: 0.10 mm
Fitting position of the bearing shells in the conrods

Insert bearing shell in the conrod or in the centre of the conrod
bearing cap.
Dimension -a- = 2.5 mm
Oil spray nozzle and pressure valve

1-
Screw with pressure valve
2-
Oil spray nozzle (for cooling piston)
Fitting position: Align the guide edge of the oil spray nozzle to
the edge of the cylinder block being worked on.
Note
The oil injection nozzles must not be bent.

Replace the oil injection nozzles if they are bent.
6.3
Checking piston projection in TDC

Measuring tool for liner pretension -MP1-107Test sequence
Attach the measuring tool for liner pretension -MP1-107- to the
cylinder block as shown in the illustration.
Measure the projection for each cylinder at 2 points.
Note
When fitting new pistons or a partial engine, check the piston
projection in TDC on all pistons.
If different values are measured during the projection meas
urement of the piston, the greatest dimension applies for the

seal assignment.
the piston
projection
fit theofrelevant
cylinder
head
with respect
to the correctness
information in
this document.
Depending on
seal in accordance with the table below.
66
Piston projection over

cylinder block - top side
mm
Marking
number of bores
0,91 1,00
1,01 1,10
1,11 1,20
1
2
3
Fabia II 2007
Identification of the cylinder head gasket
-Arrow 1-: part number
-Arrow 2-: bores
-Arrow 3-: ignore
6.4
Separating new conrod
It can happen that on new conrods, the provided separation point

is not completely cracked. If the conrod bearing cap cannot be
removed by hand, then proceed as follows:
Mark the assignment of the conrod to the cylinder.
Slightly tension the conrod, as shown in the illustration, in a
vice provided with aluminium protective jaws.
Note
Only tension the conrod slightly in order to avoid damage.
The conrod is clamped beyond the breaking point, which is
shown in the figure with a broken line.
Unscrew both screws -arrows- by approx. 5 turns.

Protected
by copyright.
Copying
for private
or commercial
in part
in whole,hammer
is not permitted
Knock
against
the
conrod
bearingpurposes,
cap with
a orplastic
unless authorised
by KODA
A. S.in
KODA
AUTO
S. does not
in -direction
ofAUTO
arroworder
to A.
loosen
it. guarantee or accept any liability
67
Fabia II 2007
15
Cylinder Head, Valve Gear
Cylinder head
1.1
Cylinder head cover - Summary of components
1 - 5 Nm
2 - Heat shield
3 - Crankcase ventilation hose
to suction hose
page 201
4 - Rubber grommet
for screw for clamping
claw
replace
5 - Sealing ring
for injection unit
replace
replace without tool
Observe fitting location
of the pegs
page 70
6 - Gasket
for cylinder head cover
replace if damaged or
leaking
7 - Screw, 10 Nm
Replace seal if dam
aged
tightening torque
page 68
8 - Cylinder head cover
page 69
Cylinder head cover - tightening torque and tightening order
Tighten the screws for the cylinder head cover in the sequence
-1 ... 6- to 10 Nm.
68
Rep. Gr.15 - Cylinder Head, Valve Gear
Fabia II 2007
1.2
Removing and installing cylinder head

cover
fuel supply and injection system as well as the rules for cleanli
ness page 2 .
Removing
Remove the injection units page 187 .
Detach vacuum lines with bracket from the cylinder head cover
-arrows-.
Remove top part

of toothed belt guard, to do so release clips
-arrows-.
Slacken fixing screws of cylinder head cover in the sequence

-6 ... 1-.
Remove cylinder head cover.
Install
following points:
Note
Replace all the gaskets.
1. Cylinder head
69
Fabia II 2007
-16- by hand.
-1 ... 6- to 10 Nm.
Check fuel system for tightness page 180 .
1.3
Removing and installing the gasket

rings for the injection units in the cylinder
head cover

Key set for lambda probe -3337 Set of tools -T10055 Assembly device -T10208/2Observe all safety measures and notes for assembly work on the
fuel supply and injection system as well as the rules for cleanli
ness page 2 .
Removing
Remove the injection units on which the gasket ring should be
replaced page 187 .
Lay the concerned return lines slightly to the side.
Caution
Pay particular attention in order to avoid unnecessary installa

tion work or consequential damage.
Pay attention to cleanliness.
by copyright.
Copying
private or commercial
in part
NoProtected
dirt must
get into
theforremoved
return purposes,
lines and
the
unless authorisedof
bythe
KODA
AUTO A. S.
KODA AUTO A. S. does not guarantee or accept any liability
connections
injection
units.
No dirt must get into the holes for the injection units in the
cylinder head cover.
Remove the concerned gasket ring of the injection unit.
Check if the spring ring is still present on the removed old
gasket ring.
Note
If the spring ring is no longer present on the old gasket ring, make
sure the spring ring does not remain in the hole for the injection
unit.
Install
following points:
70
Fabia II 2007
Check the cylinder head cover for damage.
Insert new gasket ring by hand.
Observe fitting location of the pegs of the gasket ring.
1.4
Cylinder head - summary of components

Note
Do not remove the plastic bases supplied as a protection for the open valves until just before fitting on the
cylinder head.
When replacing the cylinder head, replace all the coolant page 112 .
1 - 25 Nm
2 - Lifting eye
3 - Gasket
replace
4 - Vacuum pump
WARNING
The vacuum pump must

on no account be disas
sembled, otherwise the
proper operation of the
pump vacuum part is no
longer assured. This will
result in a failure of the
brake booster.

page 82
5 - 9 Nm
6 - 9 Nm
7 - Coolant temperature send
er -G628 - Connection fittings
for coolant
9 - Sealing ring
replace
10 - Clamp
check tightness
11 - 23 Nm
12 - Support
13 - Cylinder head gasket
replace
Pay attention to the marking page 72
14 - Cylinder head
after replacing fill entire system with fresh coolant
1. Cylinder head
71
Fabia II 2007
15 - Pencil type glow plug, 17 Nm
16 - Cylinder head bolt
pay attention to sequence for loosening and tightening page 73
before fitting insert washers in the cylinder head
17 - Oil pressure switch -F1- , 22 Nm
Marking: green
Switching pressure 0.03 ... 0.06 MPa (0.3 ... 0.6 bar)
Cut open gasket ring if leaking and replace
check page 108
Inspecting the cylinder head for distortion
Inspect cylinder head at several points for distortion using a
knife-edge straightedge and feeler gauge.
Max. permissible distortion: 0.05 mm

Note
It is not permissible to rework the cylinder heads of diesel engines.
Identification of the cylinder head gasket

Part number -arrow 1 Control code -arrow 2- (ignore)
Bores -arrow 3Note
Differing thicknesses of cylinder head gaskets are inserted
according to the piston projection. If only the gasket is re

placed, then it must be replaced
a new
gasket
withor the
Protected with
by copyright.
Copying
for private
commercial purposes, in part or in whole, is not permitted
same marking.
When installing new pistons or a partial engine, determine the
piston projection at TDC page 66 .
1.5
Removing and installing Hall sender G40-
Removing
72
Fabia II 2007
Disconnect the plug -arrow- from the hall sender -G40- .
Unscrew the bracket -arrow- for the plug of the Hall sender G40- , remove the plug from the bracket and place down the
cable.
Loosen the retaining lugs of the cable guide with a screwdriver

and remove the cover of the repair opening -arrows-.
Unscrew the Hall sender -G40- -arrow- from the cylinder head
and guide its plug through the repair opening in the toothed
belt guard.
Install
following points:
Close the repair opening in the toothed belt guard with a rubber
plug Electronic Catalogue of Original Parts .
install toothed belt and set the timing page 29 .
1.6
Removing and installing cylinder head

Guide bolt -MP1-208 (3070) Rig pin for diesel injection pump -3359 - (2x)
Crankshaft arrester -T10050 Counterholder -T10051 1. Cylinder head
73
Fabia II 2007
Extractor -T10052 Set of tools 17 mm -T10395 Tensioning strap -T10038- (2x)
Open ring spanner 17 mm
Catch pan , e.g. -VAS 6208 Old oil collecting and suction equipment , e.g. -V.A.G 1782 Sealant remover gasket stripper (bearing code GST, bearing
WARNING

hot components.
1.6.1
Removing
fuel and injection system, the charge air system as well as the
rules for cleanliness page 2 .
ment page 6 .
Remove left charge air pipe page 163 .
Remove the plenum chamber cover and partition panel
Body work; Rep. Gr. 66 .
Detach vacuum line at brake servo unit.
unlessdampener
Screw out screws -arrows- and remove pulsation
-2-.
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Fabia II 2007
Disconnect plug -1- at oil pressure switch -F1- .
Detach vacuum line -2- and release screw -arrow- of vacuum
line.
Disconnect plug -4- at the coolant temperature sender -G62- .
Remove the coolant hoses from the connection fitting, to do

so slacken the hose clamps -1- and -2Vehicles with diesel particle filter
Left-hand drive: page 210 .
Note
Support assembly carrier on right and left with tensioning strap T10038- .
Release screws of coolant return-flow line -arrows- and lay the
coolant return-flow line to the side.
Note

1. Cylinder head
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Fabia II 2007
Detach fuel hoses -2 and 5-. To do so, push the quick cou
plings onto the nozzles, press in the securing elements (hold
pressed) and detach the quick couplings.
Remove cylinder head cover page 69 .
Note
Remove high pressure line -2- between fuel distributor and

high pressure pump.
Unclip the engine pre-wiring from the holder -arrow-.

Disconnect all the remaining plug connections at the engine.
Lay the engine pre-wiring to the side.
Release screw -arrow- for oil dipstick.
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Fabia II 2007
Remove the connection pipes -A- for exhaust gas recircula
tion.
Collect escaping engine oil with the old oil collecting and suc
tion equipment -V.A.G 1782- .
Slacken union nut -1- with open ring spanner 17 mm -A-.

Release screws -2, 3, 5 and 6-.
Remove oil feed line -7-.
Remove the support for exhaust turbocharger -4- from the oil
return-flow line -8-.
Disconnect the plug -arrow- from the hall sender -G40- .

Remove the toothed belt from the camshaft sprocket and from
the toothed belt gear of the high pressure pump
2.2 Removing and installing toothed belt, page 29 .
Remove camshaft sprocket.
Counterhold the hub with the counterholder -T10051- and

slacken the fixing screw -1- of the hub.
Turn bolt attaching the hub out about 2 turns.
1. Cylinder head
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Fabia II 2007
Position the extractor -T10052- and align it with the hub bores.
Tighten fixing screws -1-.
Slacken the hub of the toothed belt sprocket from the camshaft
cone by uniformly tightening the screw of the extractor -2-.
Note
Hold the extractor firmly using a wrench SW 30.

Remove hub from cone of camshaft.
Unscrew the fixing screw -arrow- of the rear toothed belt
guard.
Unscrew nut -1- for tensioning pulley.

Release cylinder head screws.
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Fabia II 2007
Follow the sequence -1 8- for loosening the cylinder head
screws.
Note
The assistance of a second mechanic is required for removing
the cylinder head.
The timing belt tensioning pulley is removed from the pin screw
when lifting out the cylinder head.
First of all raise the cylinder head on the gearbox side and
thread it out of the rear toothed belt guard. Make sure that the
timing belt tensioning pulley does not fall down.
Caution
Risk of damage to the glow plugs when placing down the cyl
inder head.
If the cylinder head is removed with installed glow plugs,
do not place it down on the sealing surface since the glow
plugs protrude slightly beyond the sealing surface.
Place down the cylinder head in such a way that the oil return
flow line does not bend, if necessary place a wooden wedge
under the exhaust manifold.
1.6.2
Install
Note
There must not be any oil or coolant present in the threaded
holes for the cylinder head bolts.
Always replace the cylinder head bolts.

Remove the new cylinder head gasket from its wrapping im
mediately before fitting.
Treat the seal with the utmost care. Damage to the silicone
layer and in the surrounding area result in leakages.
Stuff clean cloth into the cylinders to avoid any dirt getting in
between cylinder wall and piston.
WARNING
Wear protective gloves when

working
with
sealant
unless
authorised
by KODA
AUTOand
A. S. grease
KODA AUTO A. S. does not guarantee or accept any liability
remover!
Note
Make sure that when cleaning the cylinder head and cylinder
block no foreign bodies can get into the cylinder, the oil and cool
ant galleries or into the threaded holes.
Carefully remove old sealant residue from the cylinder head
and cylinder block using a chemical sealant remover.
1. Cylinder head
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Fabia II 2007
Remove the crankshaft arrester -T10050- before placing on
the cylinder head and turn the crankshaft in the opposite di
rection of rotation of engine until all the pistons are almost
evenly positioned at the same height.
Pay attention to the identification of the cylinder head gasket:
-Arrow 1-: part number
-Arrow 2-: bores
-Arrow 3-: ignore
Note
Install new cylinder head gasket with the same identification
-arrow 2-.
If parts of the crankshaft drive were replaced, then the new
cylinder head gasket must be redefined by measuring the pro

trusion of the piston in TDC page 66 .
Position the cylinder head gasket with the marking to the top.
For centering, screw in guide bolts -MP1-208 (3070)- into the

outer holes on the suction side.
Note
The assistance of a 2nd mechanic is required for fitting on the
cylinder head.
Guide the cylinder head Protected

into thebytoothed
belt guard.
copyright. Copying
for private or commercial purposes, in part or in whole, is not permitted
By doing so, the cylinder head

must not grind down the dowel
sleeves -A-.
The tensioning roller must be fitted onto the pin screw when
placing on the cylinder head.
Insert the cylinder head.

Insert the 6 cylinder head bolts and tighten by hand.
Remove the guide bolts by screwing out with a bolt tightener
from MP1-208 through the screw holes and screw in the 2 re
maining cylinder head screws.
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Fabia II 2007
Tighten the cylinder head in four stages in the indicated tight
ening sequence:
Stage
I
II
III
IV
Tightening torque
Pre-tighten with the torque wrench to 30 Nm.
Pre-tighten with the torque wrench to 50 Nm.
Using a rigid wrench torque a further 90 (1/4
turn).
Using a rigid wrench torque a further 90 (1/4
turn).
Attach rear toothed belt guard at cylinder head.

Install the hub and the camshaft sprocket.
Lock the camshaft and the high pressure pump with the rig
pins for diesel injection pump -3359- .
Rotate the crankshaft on TDC in direction of rotation of the
engine, interlock with the crankshaft arrester -T10050- .
Further installation occurs in reverse order for removal, while
paying attention to the
following:
Protected
Note

The tightening torques can be found in the corresponding
summaries of components.
Install cylinder head cover page 69 .

Install the oil feed line and the support for the exhaust turbo
charger page 153 .
Install diesel particle filter page 210 .
Install pre-exhaust pipe page 224 .
Check oil level, top up oil if necessary Maintenance ; Fabia
II .
ment page 6 .
Fill up the fuel system page 179 .
Note
If the cylinder head was replaced, refill the entire system with
coolant.
1. Cylinder head
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Fabia II 2007
1.7
Removing and installing the vacuum

pump
WARNING
The vacuum pump must on no account be disassembled, oth

erwise the proper operation of the pump vacuum part is no
longer assured. This will result in a failure of the brake booster.
Removing
page 202 .
Detach the vacuum line -1- from the vacuum pump -2-.
Unscrew the fixing screws of the left charge air pipe and af
terwards press the left charge air pipe slightly downwards in
order to reach the rear bolted connection of the vacuum pump.
Unscrew securing bolts -arrows-.

Remove vacuum pump -2- from cylinder head.
Install
following points:
Note
Ensure that the coupling of the vacuum
pump is correctly seat
ed in the camshaft.
Replace the gasket of the vacuum pump.

Install vacuum pumps and tighten fixing screws to 10 Nm.
Connect the vacuum line of the brake servo unit to the nozzle
-1- of the vacuum pump.
1.8
Testing the compression
Connect the vehicle diagnosis, measurement and information

system -VAS 505X- and select the function Self-diagnosable
systems in the Targeted fault finding Vehicle diagnosis,
testing and information system VAS 5051.
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Fabia II 2007
Valve gear
2.1
Valve gear - Summary of components

Note
Cylinder heads with cracks between the valve seats may continue to be used without any reduction in the
life time provided the cracks are slight and max. 0.5 mm wide.
After installing the camshafts, the engine must not be cranked or started for about 30 minutes. The hydraulic
clearance compensation elements must settle (otherwise the valves would strike the pistons).
After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no
valve touches the piston when the engine is started.

1 - Sealing ring
Do not additionally lubri
cate or grease sealing
lip of the gasket ring
before fitting remove oil
residues on the cam
shaft studs with a clean
cloth
page 84
2 - 10 Nm
pay attention to se
quence for loosening
and tightening
2.3 Removing and in
stalling camshafts,
page 85
3 -unless
Dowel
pins, 10 Nm
4 - Bearing frame
seal with silicone seal
ant -D 176 501 A15 - Camshaft
for exhaust valves
page 85
6 - Camshaft
for inlet valves
page 85
7 - Roller rocker arm
with locking clip
Mark installation position
do not interchange
Check smooth operation of cylindrical-roller bearings
oil contact surfaces
2. Valve gear
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Fabia II 2007
8 - Hydraulic balancing element
Mark installation position
oil the contact surfaces before installing
check page 91
9 - Cylinder head
pay attention to the notes page 83
check for distortion page 71
after replacing fill entire system with fresh coolant page 112
10 - Hall sender -G40 removing and installing page 72
11 - Valve
do not rework, only grinding in is permissible
mark the fitting position for re-installation
Valve dimensions page 95
inspecting valve guides page 95
12 - Pin screw, 15 Nm
13 - Valve stem seal
replace page 92
14 - Valve spring
15 - Valve spring retainer
16 - Collets
17 - Screw cap
replace
removing: plunge into the installed bearing frame using a screwdriver and lever out
installing:
inCopying
without
sealant
using purposes,
a suitable
piece
flush
Protected by drive
copyright.
for private
or commercial
in partthrust
or in whole,
is notuntil
permitted
2.2
Removing and installing gasket ring for

camshaft

Insertion tool -MP1-214 (10-203) Gasket ring extractor -T30003 (3240) Screw M12 x 1.5 x 75 from the insertion tool -MP1-214
(10-203)Removing
Detach the toothed belt from the camshaft sprocket and from
the toothed belt gear of the high pressure pump page 29 .
Remove camshaft sprocket and hub page 85 .
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Fabia II 2007
Insert thrust piece -3240/1- into the camshaft.
Turn inner part of gasket ring extractor -3240- 2 turns (approx.
3 mm) out of the outer part and lock with knurled screw.
Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
Install
Note
by copyright.
The sealing lip of this gasket ring must Protected
be neither
oiledCopying
nor for private or commercial purposes, in part or in whole, is not permitted
greased.
Remove oil residue on the camshaft stud with a clean cloth.

Fit the guide bushing from -MP1-214 (10-203)- onto the cam
shaft as shown in the illustration.
Carefully slide the gasket ring -1- over the guide bushing onto
the camshaft.
Press in the gasket ring with the thrust piece of the insertion
tool -MP1-214 (10-203)- and the screw M12 x 1.5 x 75 up to
the stop.
Install the hub and the camshaft sprocket page 85 .
2.3
Removing and installing camshafts

Counterholder -T10051 Extractor -T10052-
2. Valve gear
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Fabia II 2007
Camshaft-insertion tool -T40094 Support -T40095 Tensioning tool -T40096/1 Silicone sealant -D 176 501 A1 Sealant remover gasket stripper (bearing code GST, bearing
Cleaning and degreasing agent , e.g. -D 000 401 04 Protective goggles and gloves
Removing
Cylinder head fitted.
Detach the toothed belt from the camshaft sprocket and from
the toothed belt gear of the high pressure pump page 29 .
Screw out the fixing screws -1- of the camshaft sprocket.
Remove camshaft sprocket from the hub.
Slacken screw -1- for the hub of the camshaft, to do so coun

terhold with counterholder -T10051- .
Release screw by about 2 turns.
Position the extractor -T10052- at the hub of the camshaft and

screw the screws -1- into the hub.
Slacken the hub of the toothed belt sprocket from the camshaft
cone by uniformly tightening the screw of the extractor -2-.
Note
While doing so, hold the extractor firmly using a wrench SW 30.
Remove hub of toothed belt sprocket from cone of camshaft.
Remove vacuum pump page 82 .
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Fabia II 2007
Loosen the screws for the bearing frame in the sequence
-20...1-.
Unscrew screws and carefully separate the bearing frame
from the cylinder head.
Mark the camshafts for reinstalling and remove.
Install
WARNING

Remove residual sealant on the bearing frame and cylinder
head using a chemical sealant remover.
Clean sealing surfaces, they must be free of oil and grease.
Oil contact surfaces of camshafts.
Caution
The camshafts must only be installed using the camshaft-in

sertion tool -T40094- as described below. Otherwise the axial
bearing in the bearing frame can be destroyed and the cylinder
head must be replaced.
Set up the camshaft-insertion tool -T40094- as follows:
Remove the supports -T40094/3- , -T40094/4- and -T40094/5
Protected by
- from the base plate. The screws are located
atcopyright.
the bottom.
Note
If the components of the camshaft-insertion tool -T40094- are not

yet marked, they must be marked for the subsequent refitting. For
this use e.g. blow counts.
Tighten the supports -T40094/9- and -T40094/12- (with bear

ing bracket -T40094/11- ) to the base plate as shown in the
illustration.
2. Valve gear
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Fabia II 2007
Place the support -T40094/2- on the position -A- and the sup
port -T40094/1- on the position -D-.
Insert the inlet camshaft in the supports -T40094/1- and T40094/2- .
The recess -arrow- for the cylinder head screw must point to
the outside.
Fit on a feeler gauge of 0.50 mm and slide the support T40094/8- into the groove of the inlet camshaft.
Insert the outlet camshaft in the supports -T40094/9 - and T40094/12- and lock with serration of detent bracket T40094/11
The peg on the detent bracket -T40094/11- must engage in

the groove of the camshaft.
Position the tensioning tool -T40096/1- on the pinions of the

outlet camshaft in such a way that each clamping arm engages
in a pinion.
The wider clamping arm must engage in the wider pinion.
Tension the tensioning tool -T40096/1- with the knurled wheel

until the tooth flanks of both wheels are aligned.
Slide the outlet camshaft to the inlet camshaft until the serra
tions are in mesh.
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Fabia II 2007
Position the bearing frames onto the camshafts.
All of the camshaft bearings must rest on the camshafts.
Position the holder -T40095- , as shown in the figure, and fix

the camshafts in the bearing frame.
Remove the detent bracket -T40094/11- and push the support
-T40094/8 - out of the groove of the inlet camshaft.
Note
Pay attention to the use by date on sealant.

2 mm).
Caution
Risk of contamination of the camshaft bearings through excess

sealant.
Do not apply thicker sealant beads than indicated.
Apply sealant onto the clean sealing surface of the cylinder
head as shown in the illustration.
Thickness of the sealant beads: 23 mm
Pay attention that the oil supply hole for the bearing frame is
not closed through excess sealant.
Note
The bearing frame with camshafts must be installed within 5 mi

nutes after applying the silicone sealant.
Install new screw cap ( page 83 , Pos. 17) on cylinder head
until flush.
Remove the camshafts together with the bearing frame, holder
-T40095- and tensioning tool -T40096/1- from the camshaftinsertion tool -T40094- and carefully insert into the bearings in
the cylinder head.
2. Valve gear
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Fabia II 2007
Insert the screws of the bearing frame and first tighten in the
sequence -1 20- by hand.
The ladder frame must rest on the cylinder head with its com
plete contact surface.
Tighten the screws of the bearing frame in the sequence

-120-.
Remove bracket -T40095- and tensioning tool -T40096/1- .
Replacing camshaft gasket ring page 84 .
Install the hub for the camshaft timing gear and tighten the
screw -1- to 100 Nm. To do so, counterhold with counterholder
-T10051- .
Push camshaft sprocket onto the hub.

Note
While doing so, the arrow on the camshaft sprocket must be close
to the 12 o'clock position.
Screw in screws -1- by hand.
Lock hub with locking pin -3359- .

Install vacuum pump page 82 .
Install cylinder head cover page 69 .
Note
After installing the camshafts, the engine must not be cranked
or started for about 30 minutes. The hydraulic clearance com

pensation elements must settle (otherwise the valves would
strike the pistons).
After carrying out work on the valve gear, carefully crank en
gine at least 2 revolutions to ensure that no valve touches the

piston when the engine is started.
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Fabia II 2007
2.4
Measuring the axial play of the cam

shafts

Universal dial gauge holder -MP3-447 (VW 387) Dial gauge, e.g. -VAS 6079Work procedure
Remove bearing frame page 85 .
Attach the dial gauge with the universal dial gauge holder MP3-447 (VW 387)- to the bearing frame as shown in the
illustration.
Press the camshaft by hand against the dial gauge.
Position dial gauge to 0.
Press the camshaft off the dial gauge and read the value.
Axial play of inlet and outlet camshaft:
Wear limit 0.17 mm
2.5
Checking hydraulic balancing elements

Note
The hydraulic balancing elements cannot be repaired.

Irregular valve noises when starting engine are normal.
If the irregular valve noises disappear but occur regularly dur
ing short journeys, then the oil pressure must be checked

page 108 .
The valve for oil pressure control is integrated in the oil pump.
Feeler gauges
Work procedure
Start engine and allow to run until the radiator fan starts.
Increase speed to about 2500 rpm for 2 minutes and under
take a test drive if necessary.
If the valve noises occur irregularly, determine the defective hy
draulic balancing element as follows:
Turn the crankshaft until the cam of the hydraulic balancing
element to be tested is positioned on top.
2. Valve gear
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Fabia II 2007
Press down the hydraulic balancing element using a wooden
or plastic wedge.
Determine the play between the cam and the roller of the valve
lever.
If a 0.20 mm feeler gauge can be slipped between the cam and
the roller of the valve lever, the hydraulic balancing element is
defective:
Replace the hydraulic balancing element. To do so, remove
camshafts page 85 .
Note
After installing the camshafts, the engine must not be started
for about 30 minutes. The hydraulic clearance compensation

elements must settle (otherwise valves would strike the pis
tons).
After carrying out work on the valve gear, carefully crank en
gine at least 2 revolutions to ensure that no valve touches the

piston when the engine is started.
2.6
Replacing valve stem seals

Valve stem seal extractor -MP1-230 (3364) Valve stem seal insertion tool -MP1-233 (3365) Disassembly and assembly device for valve collets -VAS
5161- with knurled spacer ring -VAS 5161/23-1- and guide
plate -VAS 5161/23 Screw M6 x 30 (2 pieces)
Work procedure
Remove all glow plugs page 232 .
Remove the camshafts page 85 .
Copying
forrocker
private or commercial purposes, in part or in whole, is not permitted
When installing again, mark the assignment
of the
roller
arms and the hydraulic clearance
compensation elements.
Remove the roller rocker arms together with the hydraulic bal
ancing elements and lay aside on a clean surface.
Put the piston of the relevant cylinder at bottom dead centre.

Position the guide plate -VAS 5161/23 - onto the cylinder head.
Screw the guide plate at the side of the intake manifold with
the knurled screw -VAS 5161/12- to the cylinder head and with
2 screws M6 x 30 -1- by hand until it fits on tightly.
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Fabia II 2007
Screw the sealing bolt -VAS 5161/10- into the guide plate.
Screw adapter -VAS 5161/11 - into the threaded hole of the
glow plug by hand.
Insert the impact drift -VAS 5161/3 - into the guide plate and
slacken the tightly fitted valve collets using a plastic hammer.
Screw the detent part -VAS 5161/6- and the interlocking fork
-VAS 5161/5- into the guide plate.
Slide the knurled spacer ring -VAS 5161/23-1- onto the as
sembly cartridge -VAS 5161/8- .
Connect the adapter -VAS 5161/11 - to the compressed air
with a commercially available intermediate piece and apply
constant pressure.
Minimum pressure: 0.6 MPa (6 bar)
Hook the pressure fork -VAS 5161/2 - onto the detent part and
push the assembly cartridge downwards.
Turn simultaneously the knurled screw of the assembly car
tridge to the right, until the tips click into the valve collets.
Rotate the knurled screw to the left and to the right, by doing
so the valve collets are pressed apart and are installed in the
assembly cartridge.
Release the pressure fork.
Remove the assembly cartridge with the knurled spacer ring.

Remove the valve spring with the valve spring retainer.
2. Valve gear
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Fabia II 2007
Pull off valve stem seal with extractor for valve stem seal
-3364- .
Fit the plastic protective sleeve -A-, which is attached to the

new valve stem seals -B-, onto the valve stem.
Lightly oil the sealing lip of the new valve stem seal.
Slide the valve stem seal onto the plastic bushing.
Carefully press the valve stem seal with the valve stem seal
insertion tool -3365 - onto the valve guide.
Remove plastic sleeve.
If the valve collets were removed from the assembly cartridge,

first of all they must be inserted into the insertion device VAS 5161/18- .
The large diameter of the valve collets points to the top.
Insert the valve spring and theunless
valve
spring retainer.
Press the assembly cartridge -VAS
5161/8- from the top onto
the insertion device for valve collets -VAS 5161/18- and lift up
the valve collets.
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Fabia II 2007
Re-insert the assembly cartridge into the guide plate VAS 5161/23- .
Press down the pressure fork and turn the knurled screw to
the left while pulling it upwards by doing so the valve collets
are inserted.
Release the pressure fork on tightened knurled screw.
Repeat the procedure for each valve.
Assembling together
following points:
Note
Ensure that all the roller arms are correctly positioned on the valve
stem ends and are clipped in place on the relevant hydraulic bal
ancing elements.
Install camshafts page 85 .
Install glow plugs page 232 .
2.7
Valve dimensions
Note
Valves must not be reworked. Only grinding in is permissible.

Dimension
a
b
c
2.8
mm
mm
mm
Inlet valve
Exhaust valve
26,50 26,70
5,968 5,982
99,30
45
24,4 24,60
5,958 5,972
99,10
45
Inspect valve guides

Universal dial gauge holder -MP3-447 (VW 387) Dial gauge, e.g. -VAS 6079-
2. Valve gear
95
Fabia II 2007
Test sequence
Note
If the valves are replaced when carrying out repair work, use
new valves for the measurement.
Because of the different stem diameters only use inlet valve
in inlet guide or outlet valve in outlet guide.
Insert valve into valve guide. The end of valve stem must be
flush with 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 exceeded, replace cylinder head.
The valve guides cannot be replaced.
96
Fabia II 2007
17
Lubrication
Removing and installing parts of the

lubrication system
Note
The oil level must not be above the max. marking - risk of
damage to catalytic converter!
If considerable quantities of metal swarf as well as abrasion is
found in the engine oil when carrying out engine repairs, care
fully clean the oil galleries in order to avoid consequential
damage and additionally replace the engine oil cooler as well
as the oil filter element.
Check the engine oil, amount of oil and oil specification Main
tenance ; Fabia II .
1.1
Parts of the lubrication system - Summary of components
1 - Cylinder block
2 - Gasket
replace
must not be oiled
insert in the grooves at
the oil filter holder
3 - Oil filter holder with engine
oil cooler
Summary of compo
nents page 98
(1/4 turn)
replace
5 - Dipstick
with guide pipe
oil level must not exceed
max. marking
6 - 9 Nm
7 - Noise insulation
8 - 9 Nm
9 - 8 Nm
10 - Left charge air pipe
11 by
- Oil
pan Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
copyright.
removing
and installing
page 99
12 - Bracket for coolant pipe

13 - 10 Nm
1. Removing and installing parts of the lubrication system
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Fabia II 2007
14 - Oil level and oil temperature sender -G266 check Vehicle diagnosis, testing and information system VAS 5051
15 - O-ring
replace
16 - 15 Nm
17 - Oil drain plug, 30 Nm
with captive seal
replace
18 - 5 Nm
19 - Cover
for balancing shaft module
clean if soiled
20 - Balancing shaft module
with oil pump
must be replaced completely
21 - 15 Nm
22 - Sealing flange
on belt pulley side
replace
must be positioned on dowel sleeves
1.2
Oil filter holder and engine oil cooler - Summary of components

Caution
The gaskets Item 8 (page 99) and Item 11 (page 99)

are made out of various materials depending on the medium
to be sealed (coolant or oil).
98
They must not be oiled. The sealing area for coolant would
otherwise swell up.
Rep. Gr.17 - Lubrication
Fabia II 2007
Oil pressure switch -F1- page 71 , Pos. 17.
1 - Screw cap, 25 Nm
with oil filter recircula
tion valve
slacken and tighten with
oil filter wrench -34172 - O-ring
replace
3 - O-ring
replace
4 - O-ring
replace
5 - Oil filter element
remove from the cap
Item 1 (page 99)
replace O-rings
Item 2 (page 99) ,
Item 3 (page 99) ,
Item 4 (page 99) if oil
filter element is changed
Keep to change inter
vals Maintenance ;
Fabia II
6 - Engine oil cooler
connection diagram for
coolant hoses
page 112
page 106
7 - 11 Nm
tighten crosswise
8 - Gasket
replace
do not oil
insert in the grooves at the oil filter holder
replace
tighten crosswise
10 - Oil filter holder
with integrated return-flow check tube
11 - Gasket
replace
do not oil
insert in the grooves at the oil filter holder
1.3
Removing and installing oil pan

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Fabia II 2007
Socket insert -T10058 Old oil collecting and suction equipment , e.g. -V.A.G 1782 Silicone sealant -D 176 501 A1 Sealant remover gasket stripper (bearing code GST, bearing
Removing
Gr. 50 .
66 .
Disconnect plug -arrow- at oil level and oil temperature sender
-G266- .
Remove noise insulation -2- for oil pan.

To do this:
Unscrew bolts -1-.
Remove 2-part clips -arrows-.
Remove the attachment of the cable on the noise insulation.
Release screw -3-.
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Fabia II 2007
Screw out screws -arrows- for oil dipstick guide pipe.
Pull out the oil dipstick guide pipe upwards.
Screw out screws -arrows- of oil pan/gearbox.

Release the screws -1 16- of the oil pan with the socket
insert -T10058- crosswise.
Remove oil pan, if necessary release by applying slight blows
with a rubber-headed hammer.
Install
The sealing flange on the belt pulley side was not replaced.
Install oil pan, if the sealing flange on the belt pulley side was
replaced page 50 .
Caution
The sealing flange on the belt pulley side is made of plastic and
has an integrated silicone seal. In order to reliably seal the oil
pan on the sealing flange, from which the silicone seal was
removed, the following work procedure must absolutely be
kept.
WARNING

Remove residual sealant from the sealing surfaces on the cyl
inder block and on the oil pan with chemical sealant remover.
101
Fabia II 2007
Remove residual sealant and silicone seal -arrows- at the old
sealing flange on the belt pulley side with chemical sealant
remover.
Note
Pay attention to the use by date of the silicone sealant -D 176 501
A1- .
3 mm).
Apply the silicone sealant -D 176 501 A1- to the clean sealing
surface of the oil pan, as shown.
The sealant must be run past on the inside in the area of the
bolt holes -arrows-.
Caution
Risk of blockage of the lubrication system through excess seal

ant.
Do not apply a thicker sealant bead than indicated.
Note
The bottom surface of the sealing flange on the belt pulley side
has a displacement of approx. 1 mm to the bottom cylinder block
surface after removing the old silicone seal, which must be com
pensated for by applying the required sealant on the correspond
ing area of the oil pan sealing surface.
102
Fabia II 2007
Thickness of sealant beads on the oil pan:
In the area of the sealing surfaces of the cylinder block and
the sealing flange on the gearbox side -between arrows 1-:
2 3 mm
In the area of the sealing surface of the sealing flange on the
belt pulley side -between arrows 2-: 3 4 mm
The old silicone seal, which is no longer present, must be re

placed in the area of the sealing flange on the belt pulley side
with the sealant bead equal to the height and width of the sil
icone seal.
Note
After applying the sealant, install the oil pan within 5 minutes.
Position oil pan.
Note
The oil pan must be flush to the gearbox flange at the inter
mediate plate.
When installing the oil pan with the engine removed, ensure
that the oil pan is flush with the cylinder block at the flywheel
side.
Tighten the screws of Protected

the oil by
pan
in 3 Copying
stagesforas
follows.
copyright.
private
or commercial purposes, in part or in whole, is not permitted
with respect to the
correctness of information in this document. Copyright by KODA AUTO A. S.
Tightening
torque
Stage
Screws
-1 16-Arrows-
crosswise to 5 Nm
40 Nm
-1 16-
crosswise to 15 Nm
21
3
1) When installing the oil pan on a removed engine, this work step
is not carried out. Make sure however that the pan is flush with
the cylinder block on the flywheel side.
Note
After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
Fill with engine oil and check the oil level Maintenance ;
Fabia II .
1.4
Removing and installing the oil filter

holder with the engine oil cooler

Removal tool for the inner lining of the door panel -MP8-602/1
Catch pan , e.g. -VAS 6208 Old oil collecting and suction equipment , e.g. -V.A.G 1782 -
103
Fabia II 2007
Pliers for spring strap clamps
Removing
Remove 4/2 way valve with coolant regulator page 120 .
Remove oil filter insert -3-.
Release screws -arrows- from the connection for the oil dip
stick guide pipe.
Pull out the oil dipstick guide pipe upwards.
104
Fabia II 2007
Remove coolant hose, to do so detach hose clamp -arrow-.
Place an old oil collecting and suction equipment -V.A.G 1782under the engine.
Screw out screws -arrows- and remove oil filter holder with
engine oil cooler.
Install
following points:
Note
Replace gaskets, gasket rings and O-rings.

Replace screws which have been tightened firmly to a torquing
angle.
Hose connections as well as charge air pipes and charge air
hoses must be free of oil and grease before being installed.
Only install approved clamps for securing the hose connec
tions Electronic Catalogue of Original Parts .
Insert the new gasket in the grooves at the oil filter holder.
Insert new screws -arrows- of oil filter holder.
Tighten the screws crosswise in 2 stages as follows:
First the screw at the top left, then the screw at the bottom right
and subsequently tighten the screws crosswise.
Stage
1
2
14 Nm
90 (torque a further 90 (1/4 turn)
Install oil filter insert, fill with engine oil and check the oil level
Maintenance ; Fabia II .
Note
If the engine oil cooler was replaced, refill the entire system with
coolant.
105
Fabia II 2007
1.5
Removing and installing engine oil cool

er

Catch pan , e.g. -VAS 6208 Old oil collecting and suction equipment , e.g. -V.A.G 1782 Pliers for spring strap clamps
Removing
Remove connecting hose from right charge air pipe to throttle
valve control unit.
Remove oil filter insert -3-.
Remove coolant hose, to do so detach hose clamp -arrow-.

Place an old oil collecting and suction equipment -V.A.G 1782under the engine.
106
Fabia II 2007
Release screws -arrows-.
Remove engine oil cooler from oil filter holder.
Install
following points:
Insert the new gasket -1- in the grooves at the oil filter holder.
Carefully position the engine oil cooler on the centering pins.
Press the engine oil cooler onto the flange of the oil filter holder
in such a way that it lies flat and the ends of the centering pins
-1- protrude out of the guide bores.
Insert the screws -arrows-, first fully screw in by hand, then

gradually
tighten crosswise in 2 stages, as described in the
following:
Stage
Tightening torque
1
2
5 Nm
11 Nm
Install oil filter insert, fill with engine oil and check the oil level
Maintenance ; Fabia II .
Note
If the engine oil cooler was replaced, refill the entire system with
coolant.
107
Fabia II 2007
1.6
Testing oil pressure and oil pressure

switch

Oil pressure tester , e.g. - V.A.G 1342 Voltage tester , e. g. -V.A.G 1527 B Measuring tool set , e.g. -V.A.G 1594 C Test conditions
Oil level o.k.
Coolant temperature approx. 80C
Test preparations
Remove oil pressure switch -F1- page 109 .
108
Fabia II 2007
Screw the connection of the oil pressure tester -V.A.G 1342into the hole for the oil pressure switch.
Screw the oil pressure switch -2- into the oil pressure tester.
Testing oil pressure switch
Connect brown cable -1- of oil pressure tester to earth (-).
Unclamp the voltage tester with its auxiliary cables out of the
measuring tool set on the oil pressure switch and plus (+) ter
minal on the battery.
The LED must not light up.
If the LED lights up:

Replace oil pressure switch.
If the LED does not light up:
Start engine.
Note
Observe the testing equipment and the LED while actuating the
starter since the switching point of the oil pressure switch can
already be exceeded when starting up.
At a pressure of 0.03...0.06 MPa (0.3...0.6 bar) the LED should

light up.
If the LED does not light up:

Replace oil pressure switch.
Testing oil pressure
Start engine.
Oil pressure when engine idling: at least 0,08 MPa (0,8 bar).
Oil pressure at 2000 rpm: min. 0.15 MPa (1.5 bar).
If the specified values are not reached: Oil pump defective.

Replace balancing shaft module with oil pump.
Oil pressure at a higher engine speed: max. 0,5 MPa (5,0 bar).
If the specified value is exceeded, the pressure control valve is

defective.
Replace balancing shaft module
with oil pump.
Note
After testing the oil pressure switch -F1 - or checking the oil
pressure, remove the oil pressure tester -V.A.G 1342- and re

install the oil pressure switch -F1- with a new gasket ring.
The tightening torque of the oil pressure switch -F1- is 22 Nm.
1.7
Removing and installing oil pressure

switch -F1-
Removing
109
Fabia II 2007
Remove the hose for the crankcase ventilation -3-, to do so
press together the release buttons.
Detach vacuum hose -2- with bracket from suction hose -1-'.
Detach suction hose -1- from air mass meter -G70- .
Unscrew screw -4- (captive), swivel suction hose -1- with con
nection fitting towards the rear and detach from exhaust gas
turbocharger.
Unscrew screws -2- and -3- and remove engine lifting eye
-1-.
Disconnect plug -arrow-.
Screw out oil pressure switch -F1- .
Install
following points:
Note
Replace gasket ring.

Tighten oil pressure switch -F1- to 20 Nm.
Install suction hose page 202 .
110
Fabia II 2007
19
Cooling
Cooling system
WARNING
Hot steam or hot coolant may escape when the compensation

bottle is opened. Cover the cap with a cloth and open carefully.
Note
When the engine is warm the cooling system is under pres
sure. If necessary reduce pressure before repairs.
Secure all hose connections with spring strap clamps.

Use pliers for spring strap clamps to fit the spring strap clips.
Always replace seals and gasket rings.
The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.
1. Cooling system
111
Fabia II 2007
1.1
Connection diagram for coolant hoses
1 - Expansion reservoir
with cap
Testing the pressure re
lief valve in the cap
page 115
2 - Coolant recirculation pump
2 -V1783 - Radiator for exhaust gas re
circulation
after replacing fill entire
system with fresh cool
ant page 112
page 230
4 - Heat exchanger of heating
system
with quick couplings
ant page 112
5 - Cylinder head and cylinder
block
ant page 112
6 - Engine oil cooler
ant page 112
page 106
7 - Top coolant hose
to ATF radiator
8 - Radiator
after replacing fillProtected
entirebysystem
with fresh
coolant
page
112in part or in whole, is not permitted
copyright. Copying
for private
or commercial
purposes,
9 - Bottom coolant hose with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
to ATF radiator
11 - Coolant pump
after replacing fill entire system with fresh coolant page 112
1.2
Draining and filling up coolant

Catch pan , e.g. -VAS 6208 Pliers for spring strap clamps
112
Rep. Gr.19 - Cooling
Fabia II 2007
antifreeze tester
Draining
Note
Collect drained coolant in a clean container for proper disposal or

reuse.
WARNING
Hot steam may escape when the compensation bottle is

opened.
eye injuries and scalding.
Cover the cap with a cloth and open carefully.
Open the cap of the coolant expansion reservoir.
Gr. 50 .
Remove the left charge air hose, to do so slacken the screw
clamps -arrows-.
Caution
Shut off the opening of the charge air cooler, e.g. with a clean
foam piece, so that no coolant can penetrate.
Place a catch pan under the engine.
Detach coolant hoses -arrows-.
1. Cooling system
113
Fabia II 2007
Detach the bottom coolant hose from the radiator.
Filling up
Re-connect all the coolant hoses and the left charge air hose.
Select the appropriate coolant additive from the Electronic
Catalogue of Original Parts or from the list of allowed coolant ad
ditives Maintenance ; Fabia II .
In a clean reservoir mix drinking water and coolant additive in
the correct mixing ratio Maintenance ; Fabia II .
Top up coolant in the expansion reservoir, until the max. mark

ing of the coolant level is reached.
Switch off the heating, and if present, the air conditioning sys
tem.
Start engine, run for not more than 3 minutes at approx. 2000
rpm and while doing so continuously top up coolant in the ex
pansion reservoir.
Tighten cap at expansion reservoir.
Run engine until radiator fan starts.
WARNING
Hot steam may escape when the compensation bottle is

opened.
Check the level of coolant when the expansion reservoir is
closed and top up if necessary when the engine is cooled
down.
When the engine is at operating temperature the coolant level

must be at the -max- marking, while the level must lie in the
middle of the criss-crossed field if the engine is cold (between
the -min- and -max- markings).
1.3
1.3.1
Checking the coolant system for leak

tightness
Checking with the cooling system test
ing device -V.A.G 1274-
Cooling system testing device , e.g. -V.A.G 1274 Adapter , e.g. -V.A.G 1274/8 Adapter , e.g. -V.A.G 1274/9 Test condition
The engine is at operating temperature.
114
Fabia II 2007
Test sequence
WARNING

bottle is opened.
Open compensation bottle.
Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/8- on the coolant expansion reservoir.
Generate a pressure of approx. 0.1 MPar (1.0 bar) for testing
the cooling system.
If the pressure drops:
Determine position of the leak and repair fault.
Testing the pressure relief valve in the cap
Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/9- on the cap.
Generate a pressure for testing the pressure valve in the screw
cap.
The pressure valve should open at a pressure of 0.14...0.16

MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:

Replace cap.
1.3.2
Checking with the cooling system test

ing device -V.A.G 1274 B-

Cooling system testing device , e.g. -V.A.G 1274 B Adapter , e.g. -V.A.G 1274/8 Adapter , e.g. -V.A.G 1274/9Test condition
The engine is at operating temperature.
1. Cooling system
115
Fabia II 2007
Test sequence
WARNING

bottle is opened.
Open compensation bottle.
Screw the adapter -V.A.G 1274/8- into the coolant expansion
reservoir.
Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/8- .
Connect the connecting piece -V.A.G 1274 B/1- via the deliv
ered connecting hose to the cooling system testing device V.A.G 1274 B- .
Using the hand pump of the testing device generate a pressure
of approx. 0.1 MPa (1.0 bar).
WARNING
Risk of scalding!
Before the cooling system testing device -V.A.G 1274 Bis separated from the connecting hose or the connecting
piece -V.A.G 1274 B/1- , the existing pressure must ab
solutely be released.
For this step, press the pressure relief valve on the cooling
system testing device -V.A.G 1274 B- and hold it pressed
until the pressure gauge indicates the value 0.
If the pressure drops:
Search position of the leak and repair fault. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Test the pressure valve in the cap
Screw the screw cap into the adapter -V.A.G 1274/9- .

Connect the connecting piece -V.A.G 1274 B/1- to the adapter
-V.A.G 1274/9- .
Connect the connecting piece -V.A.G 1274 B/1- via the deliv
ered connecting hose to the cooling system testing device V.A.G 1274 B- .
Generate a pressure for testing the pressure valve in the screw
cap.
The pressure valve should open at a pressure of 0.14...0.16

MPa (1.4...1.6 bar).
If the valve does not open in the prescribed pressure range:

Replace cap.
116
Fabia II 2007
Coolant lines, coolant temperature

sender, coolant pumps and coolant
regulator
2.1
Coolant pipes, coolant temperature sender and coolant recirculation pump

2 - Summary of components
1 - Coolant hose
from the expansion res
ervoir
2 - Coolant hose
to the expansion reser
voir
3 - 8 Nm
4 - Coolant return-flow line
5 - Coolant return hose
6 - Bypass line
to 4/2 way valve
7 - Coolant hose
from heat exchanger of
heating system
8 - Coolant hose
to heat exchanger of
heating system
9 - 15 Nm
10 - 9 Nm
11 - Coolant temperature
sender -G6212 - O-ring
replace
by copyright.
13Protected
- Retaining
clipCopying for private or commercial purposes, in part or in whole, is not permitted
withcheck
respect totightness
14 - Coolant connection fitting

at cylinder head
15 - O-ring
replace
16 - Connecting hose
to coolant recirculation pump 2
2. Coolant lines, coolant temperature sender, coolant pumps and coolant regulator
117
Fabia II 2007
17 - Coolant recirculation pump 2 -V17818 - 8 Nm
19 - Spacer
20 - 8 Nm
21 - Washer
to radiator for exhaust gas recirculation
23 - Radiator for exhaust gas recirculation
24 - Coolant pipe
with bracket for coolant recirculation pump 2 -V17825 - Connecting hose
26 - Coolant temperature sender at radiator outlet -G8327 - 8 Nm
to coolant pipe to radiator for exhaust gas recirculation
29 - Coolant hose
Feed line and return line to coolant radiator
30 - 15 Nm
pageCopying
120 for private or commercial purposes, in part or in whole, is not permitted
32 - O-ring
replace
118
Fabia II 2007
2.2
Coolant pump and 4/2 way valve with coolant regulator - Summary of com
ponents
1 - 15 Nm
2 - Coolant pump
page 119
3 - O-ring
replace
4 - O-ring
replace
5 - 4/2 way valve with coolant
regulator
check Vehicle diagno
sis, testing and informa
tion system VAS 5051
-A-: Return line from heat
exchanger of heating sys
tem
-B-: Bypass line to cooler
feed line
-C-: Return line from ex
pansion reservoir
-D-: Cooler return-flow line
6 - 15 Nm
2.3
Removing and installing coolant pump
Removing
119
Fabia II 2007
Release screws -1- and remove coolant pump -2-.
Remove O-ring -3-.
Install
following points:
Note
Replace O-ring.
Clean sealing surface for O-ring, if necessary smoothen.
Moisten the new O-ring -3- with coolant.
Attach the coolant pump -2-.
Fitting position: Plug in housing points down.
Tighten screws -1- of coolant pump to 15 Nm.

2.4
Removing and installing 4/2 way valve

with coolant regulator

Flexible-head wrench SW 10 -3185 Refractometer -T10007- or -T10007A Socket insert -T10058 Catch pan , e.g. -VAS 6208 Pliers for spring strap clamps
Removing
Remove left charge air pipe page 163 .
Note
Utmost care should be taken to guide the generator past the ra

diator, in order not to damage it.
120
Fabia II 2007
Remove alternator Electrical System; Rep. Gr. 27 .
Release screws of coolant return-flow line -arrows-.
Disconnect the plug -5- from the throttle valve control unit J338 - .
Remove throttle valve control unit -J338- -arrows-.
121
Fabia II 2007
Disconnect plugs -1- from hall sender -G40 - .
Disconnect plug -2- from knock sensor -G61- .
Unscrew bracket -arrow- of hall sender -G40- .
Detach coolant hose -arrow-.
Detach coolant hoses -B-, -C- and -D-.
122
Fabia II 2007
Slacken the screws -3- of the 4/2 way valve -2- with the flexi
ble-head wrench SW 10 -3185- and unscrew them with the
socket insert -T10058- .
Turn 4/2 way valve -2- with O-ring -1- 90 to the left and re
move from the connection fitting.
Install
Clean sealing surface for O-ring, if necessary smoothen.
Moisten the new O-ring -1- with coolant.
Insert the hose -A- behind the oil filter holder.

Apply only slight force when carrying out the next 2 working steps.
Make sure that no damage occurs.
Insert 4/2 way valve in -direction of arrow- between bracket for

auxiliary units and oil filter holder.
Insert the connection fitting -2- of the 4/2 way valve with O-ring
-1- in the cylinder block with slight rotary movements.
Screw in fixing screws -3- with flexible-head wrench SW 10
-3185- and tighten to 15 Nm.
Install throttle valve control unit -J338- and tighten the screws
to 10 Nm.
123
Fabia II 2007
Radiator and radiator fan
3.1
Radiator with radiator fan - Summary of components
1 - Clamp
2 - Top coolant hose
connection diagram for
coolant hoses
page 112
3 - Expansion reservoir
Check the cooling sys
tem for tightness
page 114
4 - Screw cap
Check pressure relief
valve page 114
5 - 2 Nm
6 - Connector
7 - Coolant hose
8 - Radiator bearing
9 - 8 Nm
10 - Clamp
11 - Radiator
page 127
ant page 112
12 - Fan shroud with radiator
fan -V7 Summary of compo
nents page 125
page 126
13 - Bottom coolant hose
14 - Charge air cooler
can only be removed and installed together with the radiator page 127
15 - Bottom bearing
16 - Clamp
17 - Connector
for radiator fan -V718 - Thermo-switch for radiator fan -F18- , 35 Nm
switching temperatures:
1. Stage on: 92 ... 97 C; off: 84 ... 91 C
2. Stage on: 99 ... 105 C; off: 91 ... 98 C
19 - Sealing ring unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
replace
124
Fabia II 2007
20 - Condenser
removing and installing Heating, Air Conditioning; Rep. Gr. 87
3.2
Fan shroud with radiator fan -V7- - Summary of components
1 - 8 Nm
replace
2 - Supporting sleeve
3 - Fan shroud
4 - Radiator fan -V75 - The fan ring
attached to the fan
shroud by means of in
tegrated expanding riv
ets -arrow-
3. Radiator and radiator fan
125
Fabia II 2007
3.3
Removing and installing fan shroud with

radiator fan -V7-
Removing
Screw out screws -arrows- for connection fitting -1-. Remove
connecting hose -2- to air filter.
Gr. 50 .
Remove right charge air hose and left charge air hose
page 160 .
Disconnect plug for radiator fan -V7- Item 17 (page 124) .
Release the fan shroud with the radiator fan -V7- on the right
and left catch hooks using a suitable tool.
Push the fan shroud with the radiator fan -V7- upwards out of
the supports and remove downwards.
Remove the radiator fan from the fan shroud
Disconnect the plug connection for the radiator fan -V7- from
the holder.
Push the pins back out of the expanding rivets -arrows page 125 .
Carefully slacken the fan ring on the reverse side of the shroud
using a suitable tool.
Remove fan ring.
126
Fabia II 2007
Unscrew the nuts -arrows- and remove the radiator fan -V7from the shroud.
Install
following points:
Tightening torque of nuts for radiator fan -V7- page 125 .
Insert the fan shroud with radiator fan -V7- from below and
slide into all 4 supports on the radiator from above.
The fan shroud must click audibly into place in the supports
on the top right and left.
Check that the fan shroud with the radiator fan -V7- catches
correctly in the installation position.
3.4
Removing and installing radiator

Catch pan , e.g. -VAS 6208 Broad cross-head screwdriver
Removing
Remove front bumper Body Work; Rep. Gr. 63 .
Disconnect plug from thermo-switch for radiator fan -F18- .
Detach top coolant hose from connection fitting of radiator.
Press off filler neck for windscreen
system
fromorbrack
Protected by washer
copyright. Copying
for private
et.
Remove bracket for windscreen washer system.
To do so, press in the catch in -direction of arrow 1- and at the

same time push the bracket upwards in
-direction of arrow 2-.
127
Fabia II 2007
Release the screw -2- for the radiator bearing on the right and
left.
Push the radiator to the rear and remove the right and left ra
diator bearing Item 8 (page 124) .
Vehicles without air conditioning
Push the radiator together with the charge air cooler upwards
out of the lower rubber bearings and remove it laterally down.
WARNING

be opened.
Caution

ses.
body.
Mark the installation position of the screws -1- on the right and
left and only slacken them.
Push the radiator together with the charge air cooler and the
condensor upwards out of the lower rubber bearings.
To do so, pull the plastic housing of the lock carrier down
wards. There is little space on the right between the refrigerant
line and the body.
Lay the radiator with the condensor to the rear.
Release the screws -arrows- of the condensor -2- from the

radiator -1-.
Draw the condensor forwards and attach to the lock carrier.
Remove the radiator together with the charge air cooler later
ally down.
Separate the charge air cooler from the radiator.
Caution
To prevent damage to the charge air cooler, the separation of

the charge air cooler from the radiator must be carried out by
2 mechanics.
128
Fabia II 2007
Slide a broad cross-head screwdriver into the left catch from
the front and the rear. Carefully open the catch of the charge
air cooler -1- at the radiator by turning the screwdriver.
Pull the left charge air cooler slightly down in this position.
Push the charge air cooler -1- to the right out of the catch of
the radiator -2-.
Install
following points:
On vehicles with air conditioning system, push the plastic

housing of the lock carrier upwards into the initial position and
tighten the screws -1- on the right and left.
129
Fabia II 2007
20
Fuel Supply

fuel supply system
Note
Fuel lines are secured with quick-release couplings.

Fuel hoses must only be secured with spring-type clips
electronic catalogue of original parts .
Use pliers for spring strap clips to fit the spring strap clips.
Observe safety measures page 3 .
ment page 6 .
1.1
Behaviour in case of misfuelling

Caution
Fueling with incorrect fuel can result in irreversible damage to

the high pressure components, in particular to the fuel high
pressure pump, because of inadequate fuel lubricity and the
dirt contained in the fuel.
The initial damage is caused by the rubbing of the moving
parts, which results in the formation of a large quantity of
fine metal swarf.
Thus, free metal particles contaminate the injection sys
tem and quickly damage other parts, especially the fuel
pressure regulating valve and the injection units.
Here are 2 examples which show the consequences of misfuel
ing.
Example 1
Misfueling was noticed BEFORE starting the engine, the engine
was NOT started.
Example 2
Misfueling was noticed AFTER starting the engine. Contaminated
or incorrect fuel was drawn in and is present in the high pressure
components.
Note
Collect the incorrect fuel which was drained from the fuel tank and
the diesel fuel which was used for cleaning the fuel tank and dis
pose.
130
Rep. Gr.20 - Fuel Supply
Fabia II 2007
Behaviour in case of example 1
Caution
Do not switch on the ignition.

The engine must not be started.
Completely empty the fuel tank page 134 .
Fill the fuel tank with 5 ltr. of diesel fuel and empty it again.
Completely fill up the fuel tank with diesel fuel.
Perform a test drive.
Behaviour in case of example 2
Completely empty the fuel tank page 134 .
Remove fuel delivery unit page 138 .
Check the fuel tank for dirt and fine metal swarf, if necessary
clean with great care.
Install fuel delivery unit page 138 .
Fill the fuel tank with 5 ltr. of diesel fuel and empty it again.
Replace fuel filter in engine compartment page 141 .
Replace the following high pressure components:
High pressure pump page
194
High pressure lines page 185
Fuel distributor page 191

Fuel pressure regulating valve -N276 - page 183
Fuel pressure sender -G247- page 193
Injection units page 187
Fuel return-flow lines
2.2 Fuel system - Summary of components, page 174
Completely fill up the fuel tank with diesel fuel.
Filling and bleeding the high pressure pump and the fuel sys
tem page 179 .
1. Removing and installing parts of the fuel supply system
131
Fabia II 2007
1.2
Fuel tank with component parts - Summary of components
1 - Screw cap
2 - 2 Nm
3 - Fuel tank lid unit
with rubber bowl
Body Work; Rep. Gr.
55
4 - Earth connection
5 - Gravity valve
to remove, unclip valve
at top and lift out of filler
neck.
inspect valve for block
age:
Valve in a horizontal posi
tion: valve open
Valve tilted 45: valve
closed
6 - 8 Nm
7 - Vent line
clipped in place on fuel
tank
8 - Fuel tank
when removing, support
with the engine/gearbox
jack e.g. -V.A.G 1383 A
page 136
(1/4 turn)
replace
10 - Tensioning strap
11 - Additional fuel filter
if present
the side with the 2 connections must point to the rear
Position the connection with the dummy nozzle upwards
12 - Support
for additional fuel filter
if present
13 - Fuel delivery unit
note the installed position of the fuel tank page 138
removing and installing page 138 unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
inspecting fuel pump page 142
with sender for fuel gauge display -G Removing and installing the sender for fuel gauge display -G- page 138
Clean strainer if dirty
132
Fabia II 2007
14 - Sealing ring
replace if damaged
insert dry into the opening of the fuel tank
only moisten from the inside the seal of the flange with fuel for installation purposes
15 - Union nut, 80 Nm
use wrench -MP1-227 (3217)- for removing and installing
16 - Bypass return line
if present
17 - Feed line
to fuel filter
black
clipped in place on fuel tank
18 - Return-flow line
from the high pressure pump
blue
clipped in place on fuel tank
19 - Vent valve
to remove, unclip valve at side and take out of filler neck.
before installing, unscrew cap Item 1 (page 132)
check page 133
20 - O-ring
replace
Inspect vent valve
Lever in off position: valve closed
Lever pushed in direction of arrow: valve open
Note
Before installing the vent valve, unscrew the cap from the filler
neck.
133
Fabia II 2007
1.3
Fuel filter - Summary of components

Note
The feed lines Item 2 (page 134) and Item 3 (page 134) must only be separated at the quick couplings.
Do not detach the hoses from the quick couplings. Otherwise the feed lines must be replaced page 6 .
1 - Fuel filter
the arrows engraved on
the filter identify the fuel
inlet and the fuel outlet
page 141
Change intervals
Maintenance ; Fabia
ll
pay attention to part
number Electronic
catalogue of original
parts
on vehicles complying
with exhaust emission
standard EU-4/BS-4
with drain plug, tighten
ing torque 2 Nm
Drain fuel filter Main
tenance ; Fabia II
2 - Feed line
from the fuel delivery
unit
white marking
detach at the quick cou
pling
3 - Feed line
to fuel high pressure
pump
white marking
detach at the quick cou
pling
4 - O-ring
replace
5 - O-ring
replace, included in the scope
of delivery
of AUTO
the fuel
temperature
-G81- or accept any liability
unless authorised
by KODA
A. S. KODA
AUTO A. S.sender
does not guarantee
6 - Fuel temperature sender -G817 - Support

for fuel filter
8 - 20 Nm
1.4
Extract fuel from the fuel tank

Hose adapter , e.g. -V.A.G 1318/16-
134
Fabia II 2007
Adapter , e.g. -V.A.G 1318/17 Measuring tool set , e.g. -V.A.G 1594 C Battery
Fuel tank
Note
If the fuel delivery unit is defective, suction off fuel using a fuel
suction device , e.g. -VAS 5190- .
Work procedure
Note
page 3 .

Switch off ignition and withdraw ignition key.
Position right rear seat vertically Body Work; Rep. Gr. 72 .
Lift cover of fuel delivery unit.
Note
On vehicles with auxiliary heating, the plug connection for the

dosing pump -V54- must be disconnected additionally.
Unplug the 5-pin connector -1- and the black feed line -2-.
Note
Press in the securing ring in order to unlock the lines.
135
Fabia II 2007
Connect the adapter set -V.A.G 1318/17- to the hose adapter
-V.A.G 1318/16- and attach the suction line thus prepared to
the feed support of the fuel pump.
Keep suction line in a suitable fuel tank.
Connect the battery and the contacts of the fuel pump with
cables -A- from the measuring tool set as follows:
Battery positive terminal (+) to contact -1- of the fuel pump.
Battery negative terminal (+) to contact -5- of the fuel pump.
The fuel pump runs and suctions off fuel.
WARNING
In order to prevent an overflow of fuel, the fuel pump must not

run unattended.
1.5
Removing and installing the fuel tank

Engine/gearbox jack , e.g. -V.A.G 1383 AConditions
All electrical components are switched off and the ignition key
is withdrawn.
The fuel tank must not be more than 1/4 full page 134 .
Removing
Note
Protected
by copyright.
Copying
for private
Observe safety measures
when
working
on the
fuelorsystem
page 3 .

Unscrew the cap from the filler neck.

136
Fabia II 2007
Remove rear axle Chassis; Rep. Gr. 42 .
Remove rear part of exhaust system page 222 .
Remove the rear right wheelhouse liner Body Work; Rep.
Gr. 66 .
Remove left heat shield.
Disconnect the fuel feed line -1- and the front right fuel returnflow line -2- at the fuel tank.
Note
Unscrew bolts on filler neck -arrows-.

Support fuel tank using the engine/gearbox jack V.A.G 1383 A - .
Release the securing bolts of the fuel tank -arrows-.

Pull the filler neck out of the rubber bowl and lower the fuel
tank.
Install
Protected
following
points:
Note
Lay the fuel lines avoiding any kinks.
Do not mix-up the fuel feed line (black) and the fuel return-flow
line (blue).
Make sure the fuel line connections fit tightly.

Check feed line and return-flow line at fuel tank for firm seating.
137
Fabia II 2007
Check earth connection of fuel tank/body at filler neck and if
necessary remove corrosion.
Check the fitting position of the earth lead:
The plug -1- on the metal plate ring -2- must be pushed on
firmly.
The contact tab -4- must be hung on the fuel tank -3- and se
cured with the spacer bush -5-.
Tightening torques: page 132

Before starting the engine, the fuel system must be bled as fol
lows:
Switch on the ignition and only switch it off once the fuel pump
has come to a standstill. Repeat this procedure at least 5
times.
1.6
Removing and installing fuel delivery

unit

Wrench for union nut -MP1-227 (3217) Fuel extraction device , e. g. -VAS 5190Conditions
All electrical components are switched off and the ignition key
is withdrawn.
The fuel tank must not be more than 3/4 full page 134 .
Removing
Note
page 3 .

138
Fabia II 2007
First of all check the plug -arrow- for firm seating. Pull on the
plug without pressing the locking mechanism. If the plug was
not correctly plugged in, it may have caused a fault.
Detach the fuel feed line -4- and the fuel return-flow line -2-.
Note

Remove the bypass return line -3- (if present) from the fuel
delivery unit. To do so, open the warm-type clamp.
Unscrew union nut with wrench for union nut -MP1-227 - .

Pull the fuel delivery unit and the gasket ring out of the opening
of the fuel tank.
Note
The old delivery unit must be emptied before disposing of it if it

should be replaced.
Install
If the fuel delivery unit is replaced on the fuel system with bypass
return line:
Cut off the tip -2- on the marking -arrow-.
Dimension -a-: 25 mm
Remove
-1-. AUTO A. S. does not guarantee or accept any liability
unless
authorised byprotective
KODA AUTO caps
A. S. KODA

following points:
139
Fabia II 2007
Note
Do not damage the sender for fuel gauge display when instal
ling it.
Insert the new dry gasket ring into the opening of the fuel tank
and moisten only from the inside with fuel for installing the fuel
delivery unit.
Pay attention to the installed position of the fuel delivery unit:
The marking on the flange must be aligned with the marking

on the fuel tank -arrows-.
Make sure the fuel lines fit tightly.

The bypass return line is attached to the support -1- with a
spring strap clamp.
After installing the fuel delivery unit, check whether the lines
are also clipped in place on the fuel tank.
Before starting the engine, the fuel system must be bled as fol
lows:
Switch on the ignition and only switch it off once the fuel pump
has come to a standstill. Repeat this procedure at least 5
times.
1.7
Removing and installing the sender for

fuel gauge display -G-
Removing
Protected
by copyright. the
Copying
for private
or commercial
purposes,
in part
Unlatch and
disconnect
plugs
of the
electrical
cables
-1unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
(black), -2(blue)
and
-3(brown).
Press together the securing tabs -arrows- and remove the

sender for fuel gauge display -G- upwards.
Install
Insert the sender for fuel gauge display -G- in the guides at the
fuel delivery unit and press downwards until it latches into po
sition.
Connect the lines -1, 2 and 3- and fix in the holding slots.
Install fuel delivery unit page 138 .
140
Fabia II 2007
1.8
Removing and installing fuel filter
Removing
Disconnect the fuel feed lines at the quick couplings from the
fuel filter -1-. To do so, push the quick couplings onto the noz
zles, press in the securing elements (hold pressed) and detach
the quick couplings.
Unclip the fuel filter -1- from the bracket.
Remove fuel filter from the top.
Install
Installation is carried out in the reverse order. Pay attention to the
following:
Pay attention to the fitting position of the fuel filter. The arrows
engraved on the filter identify the fuel inlet and the fuel outlet.
Lay the fuel hoses avoiding any kinks.
Make sure the quick couplings fit tightly. Check for secure
catch by tightening it in the opposite direction.
Connect vehicle diagnosis, measurement and information
system -VAS 505x- and carry out the function filling/bleeding
the high pressure pump and the fuel system Vehicle diag
nosis, testing and information system VAS 5051.
141
Fabia II 2007
Testing fuel pump
2.1
Testing the voltage supply of the fuel

pump

Vehicle diagnosis, measurement and information system VAS 505x Hand multimeter , e.g. -V.A.G 1526 D Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565Test conditions
Battery voltage at least 12 V.
Fuses o.k. Current flow diagrams and Fitting locations.
All electrical consumers such as the lights and rear window

heater must be switched off.
Test sequence
Connect the adapter for measuring method/DSO (5-pin) -VAS
5565- between the plug and the flange.
142
Fabia II 2007
Connect the handheld multimeter -V.A.G 1526 D- to the test
contacts -1- and -5- of the adapter.
system -VAS 505x- and carry out the function check the high
pressure pump.
Note
The fuel pump is actuated for 30 seconds.

Read off voltage value at handheld multimeter -V.A.G 1526
D- .
Specified value: battery voltage - 0.5 V
If voltage is not present:

Test control of fuel pump relay Vehicle diagnosis, testing
and information system VAS 5051.
Test cable connections for open circuit and for short circuit
Current flow diagrams and Fitting locations.
Voltage supply is O.K.:
Check power consumption of the fuel pump page 148 .
2.2
Test feed pressure of fuel pump

Pressure gauge , e.g. -VAS 6551 Hose adapter , e.g. -VAS 6551/1 Hose adapter , e.g. -VAS 6551/2 Vehicle diagnosis, measurement and information system VAS 505xTest conditions
Battery voltage at least 12 V.
Fuses o.k. Current flow diagrams and Fitting locations.
Fuel tank at least 3/4 full.
Horizontal position of the vehicle.
Flow path in the fuel
hoses and the lines in the engine com
partment and at the
underbody
not interrupted due to damage
(kinks).
All electrical consumers such as the lights and rear window

heater must be switched off.
Test sequence
Note
page 3 .

Collect the fuel which flows out with a cloth.
2. Testing fuel pump
143
Fabia II 2007
Disconnect the push-fit coupling of the fuel feed line to the high
pressure pump ( page 134 , Pos. 3) at the fuel filter outlet.
Incorporate the pressure gauge -VAS 6551- with the lines VAS 6551/1- and -VAS 6551/2- in the fuel circuit.
Switch on the pressure gauge -VAS 6551- by pressing the
button On/Off .
Open the shut-off cocks A and B of the pressure gauge VAS 6551- , close the shut-off cock C.
system -VAS 505x- and carry out the function filling/bleeding
the high pressure pump and the fuel system.
Read the pressure on the pressure gauge:
Specified value: min. 0.45 MPa (4.5 bar)
Start engine and run in idle.

Position the pressure gauge -VAS 6551- on the windscreen in

such a way that it is legible from inside.
Increase the idling speed to 2500 rpm.
Repeat the test at the feed line to the fuel filter if the specified
value is not reached. This will determine whether the fuel filter is
not clogged.
Re-connect the fuel feed line to the high pressure pump at the
fuel filter outlet.
Disconnect the push-fit coupling of the fuel feed line
( page 134
, Pos. 2) at the fuel filter inlet.
144
Fabia II 2007
Connect the pressure gauge -VAS 6551- with the lines -VAS
6551/1- and -VAS 6551/2- to the open ends.
The pressure measurement is carried out in the same way as
the previous test.
Now the pressure value must be at least 0.46 MPa (4.6 bar).
If the prescribed pressure values are reached, the difference

however of the measured pressure values upstream and down
stream of the filter is 0.04 MPa (0.4 bar) or higher:
Replace the fuel filter page 141 .
If the prescribed pressure value is not reached:
If present, check the additional fuel filter ( page 132 , Pos. 11)
at the fuel tank.
To do so, carry out a measurement directly at the fuel delivery unit
as described below:
Re-connect fuel feed line at fuel filter inlet.
Disconnect the fuel feed line -4- from the fuel delivery unit.
145
Fabia II 2007
Connect the connection -A- of the pressure gauge -VAS 6551with the line -VAS 6551/1- to the open nozzles of the fuel
delivery unit.
Close the shut-off cocks B and C of the pressure gauge VAS 6551- .
Switch on the pressure gauge -VAS 6551- by pressing the
button On/Off .
pressure pump.
Note

Specified value: 0,670,77 MPa (6,77,7 bar)
If the specified pressure is reached:

Replace the additional fuel filter with the integrated pressure
regulator.
Note
On this fuel system, the additional fuel filter only fulfills the
function of a pressure regulator.
The fuel is not filtered.

Check fitting position. An incorrect installation can cause the
following problems:
Impermissible increase in the fuel pressure.

Lifetime reduction of the fuel delivery unit.
Noises of the fuel delivery unit.
If the specified pressure is not reached, the pressure is interrup

ted again, the following faults may have occurred:
Battery voltage too low.
Voltage supply of fuel pump not O.K., check page 142 .
Fuel flow rate of fuel pump too low, check page 146 .
Power consumption of fuel pump too low, check
page 148 .
Filter strainer of fuel delivery unit soiled. Remove, in order to
check the fuel delivery unit page 138 .
Quick coupling in the fuel delivery unit faulty. Remove, in order
to check the fuel delivery unit page 138 .
2.3
Checking the fuel flow rate of the fuel

pump

Pressure gauge , e.g. -VAS 6551 Hose adapter , e.g. -VAS 6551/1-
146
Fabia II 2007
Hose adapter , e.g. -VAS 6551/2 Vehicle diagnosis, measurement and information system VAS 505x Measuring vessel, 3 litres or more
Test conditions
Feed pressure of fuel pump tested page 143 .
Battery voltage at least 12,5 V.
Fuel filter O.K.
Fuel tank at least 3/4 full.
Ignition off.
Test sequence
Note
page 3 .

Disconnect the fuel feed line -4- from the fuel delivery unit.
147
Fabia II 2007
Connect the connection -A- of the pressure gauge -VAS 6551with the line -VAS 6551/1- to the open nozzles of the fuel
delivery unit.
Close the shut-off cocks B and C of the pressure gauge VAS 6551- .
Starting at the connection B, guide the hose adapter -VAS
6551/2- in a measuring vessel and hold it in position.
pressure pump.
Note

Read the pressure on the pressure gauge.
Set a pressure of 0.4 ... 0.6 MPa (4 ... 6 bar) by carefully closing
and opening the shut-off cock.
Empty measuring vessel.
Repeat the function Test fuel pump and collect the delivered
fuel in the measuring vessel:
Specified value of fuel flow rate in 30 seconds: min. 1 000 ml
If the specified value is not reached, this may be due to the fol
lowing causes:
Battery voltage too low.
Fuel lines crimped, carry out a visual inspection.
Voltage supply of fuel pump not O.K., check page 142 .

Power consumption of fuel pump too low, check
page 148 .
There is a leak in the fuel system, check for tightness.
Filter strainer of fuel delivery unit soiled. Remove, in order to

check the fuel delivery unit page 138 .
2.4
Checking the power consumption of the

fuel pump

Vehicle diagnosis, measurement and information system VAS 505x Hand multimeter , e.g. -V.A.G 1526 D Amps clamp , e.g. -V.A.G 1526B/2 Adapter for measuring method/DSO (5-pin) , e.g. -VAS 5565Note
The battery voltage as well as the temperature of the diesel
fuel have a major influence on the power consumption of the

fuel pump. For this reason it is necessary to ensure that the
battery voltage is at least 12.5 V when testing.
Depending on the season, it is necessary to ensure that the
vehicle is fueled with winter diesel.
148
Fabia II 2007
Test conditions
Battery voltage at least 12.5 volts
Fuel temperature above 10 C

149
Fabia II 2007
Connect the adapter for measuring method/DSO (5-pin) -VAS
5565- to the plug and to the fuel delivery unit.
Connect the current probe -A- on the red cable with the in
scription current probe of the adapter for measuring method/
DSO (5-pin) -VAS 5565- .
Note
The current probe of the hand-held multimeter -V.A.G 1715- can

also be used.
pressure pump.
Note

Read off power consumption at handheld multimeter -V.A.G
1526 D- .
Specified value: 8.0 ... 14.0 A
unless
authorised
by KODA
AUTO
A. S. KODA
A. S. does
not guarantee or accept any liability
If the measured
value
is outside
the
range
of theAUTO
nominal
value:
Check whether the electric wiring between the flange and fuel
pump is connected and test for continuity.
If there is no open circuit in the wiring:
Replace fuel delivery unit page 138 .
150
Fabia II 2007
Accelerator control
3.1
Accelerator pedal module - Summary of components
1 - Bearing bracket
Chassis; Rep. Gr. 46
2 - Connector
6-pin, black
3 - Accelerator pedal module
with accelerator pedal
position sender -G79and accelerator pedal
position sender 2 G185 to remove the sender re
move the bottom part of
the dash panel on the
driver's side
not adjustable
check Vehicle diagno
sis, testing and informa
tion system VAS 5051
4 - 9 Nm
3. Accelerator control
151
Fabia II 2007
21
Turbocharging
Exhaust gas turbocharger
1.1
Exhaust turbocharger - Summary of components

Note

Observe general instructions for charge-air system page 7 .
Oil feed line and oil return-flow line for exhaust gas turbocharger - Summary of components page 153 .
1 - Inlet connection
2 - 9 Nm
captive at the inlet con
nection
3 - O-ring
replace
4 - 15 Nm
5 - Support
for electrical cable
6 - Heat shield
7 - Gasket
replace
8 - Exhaust gas turbocharger
can only be replaced
complete with exhaust
manifold
and vacuum
setting with
element
respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
page 154
9 - 24 Nm
replace
10 - Exhaust gas temperature
sender 1 -G235- , 45 Nm
the thread of a new
sender must be coated
with assembly paste
coat thread with hot bolt
paste -G 052 112 A3before installing a used
sender
installing page 158
11 - Connection fittings
for oil feed line
must not be released, when removing the union nut of the oil feed line counterhold at the hexagon of the
connection fitting with adapted lateral wrench 14 mm
152
Rep. Gr.21 - Turbocharging
Fabia II 2007
12 - 24 Nm
replace
13 - Heat shield
14 - Retaining loop
can only be installed in one position
15 - O-ring
replace
16 - 9 Nm
17 - Pulsation dampener
1.2
Oil feed line and oil return-flow line for exhaust gas turbocharger - Summary
of components
Note

1-
Oilwith
return-flow
line
respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Caution
Before installing, check

whether the bellows of
the oil return-flow line is
not bent or overstretch
ed. If this is the case, mi
crocracks might occur
which can result in leaks.
Replace damaged oil re
turn-flow line or support
for exhaust gas turbo
charger.
replace if damaged
2 - Gasket
replace
3 - 20 Nm
4 - O-rings
replace
5 - 20 Nm
6 - Support for exhaust gas tur
bocharger
for oil return-flow line
replace if damaged
7 - 9 Nm
8 - O-rings
different diameters, ob
serve fitting position
1. Exhaust gas turbocharger
153
Fabia II 2007
replace
9 - Hollow screw, 60 Nm
replace
10 - Gasket rings
replace
11 - Hollow screw, 30 Nm
replace
12 - Gasket
replace
13 - Connecting pipe
Caution
Pay attention that the

bellows of the connec
tion pipe is not bent or
overstretched. There is a
risk of crack formation.
14 - 23 Nm
replace
15 - 9 Nm
16 - Gasket
replace
17 - Oil feed line
check continuity
before installing, fill the bearing housing of the exhaust gas turbocharger on the connection fitting with
engine oil
Tighten the union nut using the wrench -T40055 - , tightening torque 22 Nm
1.3
Removing and installing exhaust gas

turbocharger

Set of tools 17 mm -T10395 Tensioning strap -T10038- (2x)
Old oil collecting and suction equipment , e.g. -V.A.G 1782-
154
Fabia II 2007
Removing
Caution
In case of mechanical damage to the exhaust gas turbocharg

er, e.g. damage of the compressor wheel, it is not sufficient to
only replace the exhaust gas turbocharger. In order to prevent
consequential damage to the engine, perform the following
tasks:
Clean all oil lines.
Change engine oil and oil filter.
Check air filter, air filter insert and charge air hoses as well
as charge air pipes for soiling.
Check all air guides and charge air cooler for foreign bod
ies.
If foreign bodies are detected in the charge air system, the
complete charge-air routing must be cleaned and if necessary
the charge air cooler must also be replaced.
Note
Observe general instructions for charge-air system
page 7 .

Note
Support assembly carrier on right and left with tensioning strap T10038- .
Disconnect plug -1- from position sender for charge pressure
regulator -G581- .
Remove air filter with air

mass
meter
-G70-AUTO
andA.inlet
hose
unless
authorised
by KODA
S. KODA
AUTO A. S. does not guarantee or accept any liability
page 202 .
155
Fabia II 2007
Loosen the clamp -1- from the connecting hose to the pulsa
tion dampener.
Unscrew the screws -arrows- from the charge air pipe (cap
tive).
Detach the connecting hose to the pulsation dampener as far
as possible.
Remove pulsation dampener -1-.
Remove connection pipe -2- to exhaust gas recirculation ra

diator.
Remove exhaust temperature sender 1 -G235- -1-.

156
Fabia II 2007
Slacken union nut -1- with open ring spanner 17 mm -A-. To
do so, counterhold the connection on the hexagon with the
adapted fixed spanner 14 mm.
Remove heat shield ( page 152 , Pos. 13) at exhaust mani
fold.
Release nuts of exhaust manifold.
157
Fabia II 2007
Turn exhaust gas turbocharger -1- as shown and remove be
tween body and assembly carrier. If necessary, lower the
assembly carrier on the right side a further 2 cm.
Caution
If the assembly carrier is lowered further, there is the risk that
the hydraulic hoses of the power-assisted steering are dam
aged.
Pay attention when removing the exhaust gas turbocharger
that the oil return-flow line is not bent.
Install
following points:
Caution
Before installing, check whether the bellows of the oil returnflow line is not bent or overstretched. If this is the case, micro
cracks might occur which can result in leaks.
Replace damaged oil return-flow line or support for exhaust
gas turbocharger.
Note
nuts.
Fill exhaust turbocharger with engine oil through the connec
tion fitting of the oil feed line.
Remove oil and grease from the charge air pipes and hoses
and from their connections before installing.
Secure all hose connections with screw clamps.
unless
Only install approved clamps for securing
theauthorised
hose connec
tions Electronic Catalogue of Original Parts
.
Tightening torques page 152 and page 153 .

Checking the oil level Maintenance ; Fabia II .
Note
After installing the exhaust turbocharger, run engine at idling

speed for about 1 minute to ensure that oil is supplied to the tur
bocharger bearing.
1.4
Installing exhaust temperature sender 1

-G235-

Key -T10395/7-
158
Fabia II 2007
Caution
In this case, the setting of the torque wrench must be 28

Nm.
The correct tightening torque of 45 Nm is achieved by the ex

tension of the torque wrench using the wrench -T10395/7 - .
Grease the thread of the sender with hot bolt paste -G 052 112
A3- .
Screw in exhaust gas temperature sender 1 -G235- by hand.
Tighten sender with torque wrench together with wrench T10395/7- to 28 Nm.
159
Fabia II 2007
Charge air system with exhaust gas

turbocharger
2.1
Charge air cooling - Summary of components

Note

Observe tightening torques of screw clamps for hose connections page 162 .
Charge air cooling - Overview
Charge air cooling - Summary of components
160
Fabia II 2007
1 - Charge air cooler
can only be removed to
gether with the radiator
page 127
2 - Right charge air hose
3 - Screw clamp
Caution
A too low, but also a too

high tightening torque,
may result in the charge
air hose slipping off the
fluted tube of the charge
air pipe while driving.
Tightening torque
page 162
4 - 5 Nm
5 - Intake air temperature
sender -G426 - 8 Nm
7 - Right charge air pipe
8 - Rubber grommet
replace if damaged
9 - Connecting hose
to throttle valve control
unit -J33810 - Connecting hose
toauthorised
pulsation
dampener
unless
by KODA
11 - Left charge air pipe
12 - Left charge air hose
2. Charge air system with exhaust gas turbocharger
161
Fabia II 2007
2.2
Hose connections with screw clamps

Note
Connections, charge air pipes and hoses of charge air system
must be free of oil and grease before being installed.
Only install approved screw clamps for securing the hose con
nections Electronic Catalogue of Original Parts .
In order to secure the charge air hoses on their connection
fittings, the threads must be treated with rust solvent if the

screw clamps have been used beforehand.
After a repair, check all the charge air pipes, charge air hoses
and vacuum lines for tight connection and leaktightness.

Caution
The screw clamps -A- on the charge air hoses must definitely
be precisely tightened in accordance with the specifications
page 162 .
A too low or on the contrary, a too high
tightening torque
of the screw clamps, may result in thewith
charge
respect toair
thehose
slipping off the fluted pipe or the charge air pipe while
driving.
Tightening torques of screw clamps

1-
Screw clamp -a- = 12 mm: 5.5 Nm
2-
Screw clamp -b- = 9 mm: 3 Nm
2.3
Removing and installing charge air cool

er
The charge-air cooler is located below the radiator:

The charge-air cooler can only be removed together with the ra
diator page 127 .
162
Fabia II 2007
2.4
Removing and installing left charge air

pipe
Removing
Remove the battery with the battery tray Electrical System;
Rep. Gr. 27 .
page 202 .
Gr. 50 .
Remove the left charge air hose, to do so slacken the screw
clamps -arrows-.
Remove coolant hoses and wiring looms from left charge air
pipe
Loosen the clamp -1- from the connecting hose to the pulsa
tion dampener.
Unscrew the screws (captive) -arrows- from the left charge air
pipe.
Remove bottom left charge air pipe.
Install
following points:
unlessand
authorised
Replace damaged cable straps
clips.
Tightening torque of left charge air pipe: 8 Nm
2.5
Removing and installing right charge air

pipe
Removing
Disconnect plug -3- from intake air temperature sender -G42- .
Gr. 50 .
163
Fabia II 2007
Remove right charge air hose -arrows-.
Loosen clamp -2-.

Unscrew the screws (captive) -arrows- from the right charge
air pipe.
Remove right charge air pipe.
Install
following points:
Tightening torque of right charge air pipe: 8 Nm
2.6
Checking the charge-air system for

leaktightness

Charge-air system testing device , e. g. -V.A.G 1687 Adapter , e.g. -V.A.G 1687/10
Test sequence
Remove the intake hose -1- from the air filter.
Fit adapter -1687/10- into the intake hose -1- and secure with
a hose clamp.
Prepare tester -V.A.G 1687- as follows:
164
Fabia II 2007
Unscrew pressure control valve -2- fully and close the valves
-3- and -4-.
Note
The rotary knob must be pulled to the top in order to rotate the
pressure control valve -2-.
Connect tester for charge-air system -V.A.G 1687- to adapter

-1687/10 - as shown.
165
Fabia II 2007
Connect the feed hose for the compressed air -1- to the tester.
Note
If there is water in the inspection glass, drain water via the drain
plug -6-.
Open valve -3-.
Set the pressure to 0.05 MPa (0.5 bar) with the pressure con
trol valve -2-.
Caution
The pressure must not be greater than 0.05 MPa (0.5 bar)! A
too high pressure can damage the engine.
Open valve -4- and wait until the test circuit is filled. If neces
sary regulate the pressure to 0.05 MPa (0.5 bar).
Charge-air system:
by looking,
by listening,
by touching,with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
with a commercially available leak search spray, or
with ultrasonic measuring device , e.g. -V.A.G 1842- ,
check for leak points.
Note
Minor leaks are permissible on the suction side of the turbo
charger, because the intake hoses are not designed for over
pressure.
A small amount of air penetrates via the inlet valves into the
engine. For this reason no pressure test is possible.
Use of ultrasonic measuring device -V.A.G 1842- operating
instructions .
In case of a leak point, observe the instructions for charge air
system page 7 during the installation.
Before removing the adapter -1687/10- by loosening the hose
clamp, release the pressure in the test circuit.
2.7
Connection diagram for vacuum hoses

Caution
When routing the vacuum lines, make sure that the lines are
not kinked, twisted or crimped. Otherwise this can lead to
breakdown.
166
Fabia II 2007
Note
Blue = vacuum control line for exhaust gas recirculation
Grey = ventilation line to air filter
Green = vacuum control line for exhaust gas turbocharger
Red = vacuum supply line of the vacuum pump
1 - Vacuum setting element
at exhaust gas turbo
charger
with position sender for
charge pressure regula
tor -G5812 - Vacuum line
To the brake servo unit
3 - Air intake hose
with connecting piece
for ventilation line
4 - Solenoid valve for charge
pressure control -N75 removing page 168
5 - Vacuum pump
6 - Ventilation line
To intake hose
7 - Changeover valve for radi
ator of exhaust gas recircula
tion -N345 Check change-over
page 229
8 - Vacuum line
to cylinder head cover
with vacuum reservoir
9 - Vacuum line
to vacuum setting ele
ment at radiator for ex
haust gas recirculation
10 - Vacuum setting element
the radiator flap for ex
11 - Vacuum line
to vacuum setting element at exhaust gas turbocharger
12 - Vacuum connection
at the cylinder head cover with vacuum reservoir
167
Fabia II 2007
Remove charge pressure control solenoid valve -N75 Disconnect plug -arrow-.
Unscrew nuts -1 and 2-.
Remove vacuum lines complete with bracket -1- from air filter.
2.8
Inspect the vacuum system

Caution
When routing the vacuum lines, make sure that the lines are
not kinked, twisted or crimped. Otherwise this can lead to
breakdown.
Hand vacuum pump , e.g. -VAS 6213Work procedure
Check all the vacuum lines in the complete vacuum system
for:
tears
marten bites
Crimps and deformations
porous points and other leaks
Check vacuum lines to solenoid valves as well as from sole
noid valves to the corresponding vacuum setting elements.
168
Fabia II 2007
Note
In order to generate vacuum, push the ring -1- for the hand vac
uum pump -VAS 6213- into position -A-.
In the event of a fault memory entry, check the vacuum lines
to the mentioned component and also the remaining vacuum
lines to the other components.
If it is not possible to build up vacuum using the hand vacuum
pump -VAS 6213- or the vacuum drops immediately:
Check hand vacuum pump and connecting hoses for tight
ness.
169
Fabia II 2007
23
Fuel Formation, Injection
Diesel direct injection system - fitting

locations
The control unit is equipped with a fault memory. Before repairs,

setting operations and fault finding, interrogate the fault memory
and execute a self-diagnosis Vehicle diagnosis, testing and in
formation system VAS 5051.
Note
Faults can be detected by the control unit as checking and
adjustment work is being undertaken and then saved. It is

therefore absolutely necessary to delete the fault memory af
ter completing all checking and adjustment work Vehicle
diagnosis, testing and information system VAS 5051
page 3 .
Observe the instructions for the fuel hose in the engine com
partment page 6 .
170
Rep. Gr.23 - Fuel Formation, Injection
Fabia II 2007
1.1
Overview of fitting locations
1 - Differential pressure sender

-G505 only for vehicles with
diesel particle filter
2 - Coolant recirculation pump
2 -V1783 - Connector
for exhaust gas temper
ature sender 1 -G235 for exhaust gas temper
ature sender 3 -G495(only on vehicles with
diesel particle filter)
for exhaust gas temper
ature sender 4 -G648(only on vehicles with
for lambda probe -G39(only on vehicles with
4 - Hall sender -G40- (cam
shaft position sensor)
sender 4 -G648 only for vehicles with
diesel particle filter
6 - lambda probe -G39- with
heating for lambda probe -Z197 - Injection units (solenoid in
jectors)
Injection valve for cylin
der 1 -N30 Injection valve for cylin
der 2 -N31 Injection valve for cylinder 3 -N328 - Exhaust gas temperature sender 1 -G2359 - Position sender for charge pressure regulator -G581 10 - Exhaust gas return valve -N18 consists of:
mechanical valve (electrically operated)
EGR control motor -V338Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
EGR potentiometer -G212unless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
1. Diesel direct injection system - fitting locations
171
Fabia II 2007
11 - Oil pressure switch -F112 - Air mass meter -G7013 - Engine control unit -J62314 - Solenoid valve for charge pressure control -N75 15 - Control valve for fuel pressure -N27616 - Coolant temperature sender -G6217 - Intake manifold flap motor -V15718 - Thermoswitch for radiator fan -F1819 - Engine speed sender -G2820 - Glow plugs
Glow plug 1 -Q10 Glow plug 2 -Q11 Glow plug 3 -Q1221 - Charge pressure sender -G3122 - Throttle valve control unit -J33823 - Changeover valve for radiator of exhaust gas recirculation -N34524 - Knock sensor 1 -G6125 - Coolant temperature sender at radiator outlet -G8326 - Fuel high pressure pump with fuel dosage valve -N29027 - Intake air temperature sender -G4228 - Fuel pressure sender -G24729 - Fuel temperature sender -G81-
172
Fabia II 2007
Fuel system - Overview
2.1
System overview
WARNING
Absolutely observe the safety precautions when working on

the fuel system page 3 .
1 - Fuel dosage valve -N290 do not open

2 - Fuel high pressure pump
page 194
3 - Fuel pressure sender G247 removing and installing
page 193
4 - Fuel distributor
page 191
5 - Control valve for fuel pres
sure -N276 replace after each re
moval
check page 181
page 183
6 - Injection units (solenoid in
jectors)
page 187
7 - Fuel return-flow lines
must not be disassem
bled
8 - Fuel tank
with fuel pump for pre
delivery -G6-
9 - Fuel filter
Fuel filter - Summary of
components page 134
Change intervals Maintenance ; Fabia ll
pay attention to part number Electronic catalogue of original parts
on vehicles according to BS-4 standard with drain plug, tightening torque 2 Nm
Drain fuel filter Maintenance ; Fabia II
10 - Fuel temperature sender -G81-
2. Fuel system - Overview
173
Fabia II 2007
2.2
Fuel system - Summary of components

Caution
In order to avoid the fuel high pressure pump to run dry and to
achieve a quick engine start after parts are replaced, the fol
lowing points must be observed:
If the fuel system was opened, starting with the fuel tank
through to the fuel high pressure pump, the basic setting
Test fuel pump must be carried out once before the
engine start Vehicle diagnosis, testing and information
system VAS 5051.
If the high pressure system was opened, it must be
checked for tightness page 180 .
ment page 6 .
1 - O-ring
replace if damaged
page 176
2 - Fuel return-flow lines
to high pressure pump
they must not be kinked,
damaged or blocked
do not disassemble
after an exchange, the
engine must run at idling
speed for approx. 2 mi
nutes in order to vent the
fuel system; afterwards
check the fuel returnflow lines for tightness
3 - High pressure lines, 15 Nm
+ torque a further 60 (1/6 turn)
between fuel distributor
and injection units
do not interchange
Note
The sealing cone of the rel

evant high pressure line is
not deformed or cracked.
The line boring is not de

formed, constricted or dam
aged.
Corroded lines must no lon

ger be installed.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
install free ofunless
stress
174
Fabia II 2007
4 - Connecting hose
replace page 6
5 - Spring strap clamp
6 - Fuel pressure regulating valve -N276- , 80 Nm
replace after each removal
check page 181
7 - Fuel distributor
8 - 9 Nm
9 - 22 Nm
10 - Fuel pressure sender -G247- , 100 Nm
11 - Fuel return-flow line
to fuel feed
12 - High pressure line, 15 Nm + torque a further 60 (1/6 turn)
between the high pressure pump and the fuel distributor
Note
The sealing cone of the high pressure line is not deformed or cracked.
The line boring is not deformed, constricted or damaged.
A corroded high pressure line must not be reinstalled.

install free of stress
13 - Fuel high pressure pump
with fuel dosage valve -N290- (do not open)
after the installation, an initial fuel filling must be carried out (absolutely avoid it to run dry) page 179
replace
1/ turn)
Protected
by copyright.
15 - 20 Nm + torque
a further
45 (Copying
8 for private or commercial purposes, in part or in whole, is not permitted
replace
16 - 25 Nm
on the high pressure pump
18 - 95 Nm
19 - Hub
to release and tighten use counterholder -T10051 to remove use extractor -T4006420 - Copper disc
replace
21 - Clamping claw
replace
175
Fabia II 2007
23 - Injection unit (solenoid injector)
List of parts and gaskets or O-rings which must be replaced each time when removing and installing:
copper disc, O-ring of bore for injection unit, O-ring for fuel return-flow line.
List of parts and gaskets or O-rings which must be replaced each time when replacing the injection unit:
clamping claw, copper disc, O-ring of bore for injection unit, O-ring for fuel return-flow line.
before re-using the high pressure line carry out a visual inspection of the sealing cones for damage,
e.g. cross chamfers and corrosion, always replace if damaged
Injection units, high pressure lines and clamping claws, which are re-installed, may only be mounted
again at the same cylinder.
2.2.1
Replacing O-rings for fuel return-flow

line
Removing
Note
Proceed with utmost care. Avoid damage to the fuel return-flow

line.
Carefully remove the old O-rings from the connections of the
fuel return-flow line. While doing so, do not work with sharpedged tools.
Install
Note
When cleaning, do not use any solvent or anything similar
which damages the graphite coating on connections of the fuel

return-flow line.
Proceed with utmost care in order to avoid damage to the O-
rings or the fuel return-flow line.
The O-rings must not be twisted in the slots of the fuel return-
flow line.
Clean the seating surfaces for the O-rings on the connections

of the fuel return-flow line with great care.
Carefully push new O-rings into the slots on the connections
of the fuel return-flow line.
176
Fabia II 2007
2.3
Injection unit with clamping claw - Summary of components
1 - Injection unit (solenoid in

jector)
page 187
List of parts and gaskets
or O-rings which must
be replaced each time
when removing and in
stalling: copper disc,
O-ring of bore for injec
tion unit, O-ring for fuel
return-flow line.
List of parts and gaskets
or O-rings which must
be replaced each time
when replacing the in
jection unit: clamping
claw, copper disc, Oring of bore for injection
unit, O-ring for fuel re
turn-flow line.
before re-using the
high pressure line car
ry out a visual inspection
of the sealing cones for
damage, e.g. cross
chamfers and corrosion,
always replace if dam
aged
Injection units, high
pressure lines and
clamping claws, which
are re-installed, may on
ly be mounted again at
the same cylinder.
2 - O-ring
replace if damaged
replace page 176
3 - Fuel return-flow line
to high pressure pump
it must not be kinked, damaged or blocked
do not disassemble
after an exchange, the engine must run at idling speed for approx. 2 minutes in order to vent the fuel
system; afterwards check the fuel return-flow line for tightness
4 - gasket in the connector
replaceProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
5 - Connector with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
if the plug is disconnected, replace gasket Item 4 (page 177)
6 - Copper disc
replace
7 - O-ring
replace
8 - Clamping claw
177
Fabia II 2007
replace
10 - Threaded neck
for injection unit
178
Fabia II 2007
Removing and installing, testing fuel

formation, components
Note
If there are any complaints about the engine behaviour and
the engine performance, the primary cause may be insufficient

fuel pressure in the low pressure area of the fuel system. Fuel
pressure-related faults in the high pressure area of the fuel
system may result from a too low fuel pressure in the low
pressure area.
The fuel pressure in the high pressure area of the fuel system
is determined with the diagnosis of the engine control unit

Vehicle diagnosis, testing and information system VAS
5051.
The fuel pressure in the low pressure area of the fuel system
is measured with the pressure gauge -VAS 6551 page 142 .
Components of the fuel high pressure system must be
checked with the vehicle diagnosis, measurement and infor

mation system -VAS 505x- in the Targeted functions.
3.1
Filling and bleeding the high pressure

pump and the fuel system

Vehicle diagnosis, measurement and information system VAS 505xCaution
Risk of damage to the high pressure pump through running dry.

After installing a new high pressure pump, the high pres
sure pump must be filled up with fuel before the first engine
start. Avoid the high pressure pump to run dry.
Note
When installing the high pressure pump, ensure that no dirt
penetrates the fuel system.
Only remove the screw plug immediately before installing the
fuel lines.
Conditions
The vehicle must be filled up.
Temperature of the fuel system 15 C.
Work procedure
system -VAS 505x- .
Switch on ignition.
3. Removing and installing, testing fuel formation, components
179
Fabia II 2007
Select the Engine electronics in the self-diagnosis.
Then select 006 - Basic setting.
Then select Test fuel pump.
Subsequently press on Start.
The fuel pump starts running for approx. 60 seconds.
Repeat this work procedure 3x.
This ensures that the fuel high pressure pump is adequately
filled up with fuel.
WARNING
Wear protective gloves and protective googles when working

with grease remover!
Degrease the union nuts -1- and -5- of the high pressure pipe
and their surroundings at the pump as well as at the fuel dis
tributor.
Start the engine and let it run at an average speed for a few
minutes.
Carry out a visual inspection of the fuel system for leaks after
switching off the engine.
If there is leakage despite the correct tightening torque:
Replace the related component part and repeat the filling/
bleeding procedure.
If no leaks are found:
Carry out a test drive with minimum one full load acceleration
up to max. speed.
Afterwards, once again carry out a visual inspection of the fuel
system for leaks.
Replace the related component part and once again repeat
the filling/bleeding procedure.
memory
of engine
with respect
to the correctness of information in this document. Copyright by KODA AUTO A. S.
Interrogate and if necessary erase fault

control unit Vehicle diagnosis, testing and information sys
tem VAS 5051.
After deleting the fault memory of the engine control unit the
readiness code must be checked, if necessary re-generated
5051.
3.2
Check the fuel system for tightness

Vehicle diagnosis, measurement and information system VAS 505x-
180
Fabia II 2007
Work procedure
WARNING

Degrease all fuel connections.
Let the engine run at idling speed for a few minutes.
Carry out a visual inspection of the complete fuel system for
leaks after switching off the engine.
Replace the related component part and repeat the leak
check.
Carry out a test drive with minimum one full load acceleration
up to max. speed.
Then once again carry out a visual inspection of the complete
fuel system for leaks.
Replace the related component part and once again repeat
the leak check.
Interrogate and if necessary erase fault memory of engine
control unit Vehicle diagnosis,
testing
and Copying
information
Protected
by copyright.
for privatesys
or commercial purposes, in part or in whole, is not permitted
tem VAS 5051.
After deleting the fault memory of the engine control unit the
readiness code must be checked, if necessary re-generated
5051.
3.3
Check fuel pressure regulating valve N276-
The fuel pressure regulating valve -N276- -5- is located in the fuel
distributor.
On this engine, the fuel pressure regulating valve -N276- has 2
functions:
At cold start, it opens at a certain low temperature. The
warmed fuel from the fuel distributor is then led back into the
feed line in front of the fuel filter. This prevents the fuel filter
from clogging at low temperatures.
During vehicle over-run conditions, it regulates the fuel pres
sure in the fuel distributor.

Suitable auxiliary hose for connection to the fuel return-flow
line.
Fuel tank, approx. 200 ml.
Test condition
If necessary, allow engine to run until fuel temperature is at

least 20 C.
181
Fabia II 2007
Determine fuel temperature:
system -VAS 505x- .
Select the correct vehicle in the Targeted fault finding.
Press button Skip.
Press Selected Functions/Components.
Select Drive.
Select Engine CFWA (Rep. Gr. 01; 10-28).
Select 23 - fuel formation, injection.
Select Electrical Components.
Select fuel temperature sender -G81 - .
The fuel temperature is displayed.
Work procedure
Caution
The test sequence must be absolutely observed.
Fuel temperature at least 20 C.
The engine must only be idling. Otherwise the fuel pres

sure regulating valve -N276- can open and in turn the test
will be inaccurate.
Observe the rules for cleanliness and the instructions when un

dertaking all work on the fuel system page 2 .
ment page 6 .
182
Fabia II 2007
Detach the hose -1- from the fuel return-flow line -2 page 6 .
Close off the open hose end -arrow- with a suitable screw plug.
The hose connection must withstand a pressure of at least 1

MPa (10 bar).
Start engine and run for at least 3 minutes at idling speed. In

the event that fuel flows out of the fuel return-flow line, imme
diately switch off the engine.
No fuel must flow out of the fuel return-flow line -2-.

Note
If the engine is switched off, the fuel pressure regulating valve
-N276- opens.
The high pressure in the fuel distributor is removed via the fuel
return-flow line and the fuel flows out. This fuel must be col
lected.
After the test:

Firmly connect an auxiliary hose to the fuel return-flow line
-2- when the engine is running at idling speed.
Hold the auxiliary hose in a suitable fuel tank.
WARNING
Danger of liquid spraying out from the auxiliary hose of the fuel
return-flow line after switching off the engine!
Switch off engine.
If fuel has flown out of the fuel return-flow line when the engine
was running, the fuel pressure regulating valve -N276- is defec
tive:
Replace fuel pressure regulating valve -N276- page 183 .
Note
Replace fuel hose to fuel return-flow line page 6 .

3.4
Removing and installing the fuel pres

sure regulating valve -N276-

Open-end wrench 36 mm
Cleaning and degreasing agent , e.g. -D 000 401 04-
Protective goggles and gloves
183
Fabia II 2007
The fuel pressure regulating valve -N276- -5- is located in the fuel
distributor.
Note
The fuel pressure regulating valve -N276- is not reusable.

Removing
WARNING

Note
No grease remover must get into the plug connection, carefully

clean.
Also clean the thread area of the fuel pressure regulating valve
-N276- with a grease remover. No dirt must get into the hole
of the fuel distributor.
Dry fuel pressure regulating valve -N276 Disconnect the plug at the fuel pressure regulating valve N276- .
Counterhold the fuel pressure regulating valve -N276- on the
hexagon and slacken the screwed connection using a wrench.
unless authorised
by KODA AUTO
A. S. KODA
AUTO A. S.
does
not guarantee or accept any liability
Unscrew the screwed
connection
by hand
and remove
the
fuel
with respect
to the
correctness
of information
this document. Copyright by KODA AUTO A. S.
pressure regulating
valve
-N276from
the fuelin distributor.
Remove dirt from the thread, the sealing surface and the hole
in the fuel distributor. To do so do not use any mechanical
tools.
Note
Close the fuel distributor hole immediately with a suitable screw

plug in order to prevent dirt from penetrating.
184
Fabia II 2007
Install
Note
The fuel pressure regulating valve -N276- does not have a
gasket ring but a biting edge.
The fuel pressure regulating valve -N276- is not reusable.

The O-ring seals the high-pressure side from the low-pressure
side and must be replaced.
Before installing, moisten the O-ring and the hole in the fuel
distributor with diesel fuel.
Pay attention to damage of the biting edge and the thread of
the new fuel pressure regulating valve -N276- .
Also check the sealing surface in the fuel distributor.

Screw in the screwed connection and tighten by hand.
Align the fuel pressure regulating valve -N276- in such a way
that the connecting line is routed tension-free after fitting on
the plug.
Counterhold the fuel pressure regulating valve -N276- on the
hexagon and tighten the screwed connection to 80 Nm using
a wrench.
with respect
to the
correctness
of information
After installing,
start
the
engine
and let itin this
rundocument.
at an average
speed for a few minutes.
Switch off the engine and check the fuel system for tightness
page 180 .
Note
If the fuel pressure regulating valve -N276- was replaced, the in

itialisation values of the regulating valve must be reset Vehicle
diagnosis, testing and information system VAS 5051, Targeted
functions; Reset initialisation values of the regulating valve for
the fuel pressure.
3.5
Installing the high pressure lines

Socket wrench insert -T40055 Assembly sleeve -T10411 Cleaning and degreasing agent , e.g. -D 000 401 04 Protective goggles and gloves
185
Fabia II 2007
Caution
For easier installation of the fuel high pressure pipe, re

lease the tension of the fuel distributor. If necessary,
slightly push the fuel distributor.
For easier installation of the injection pipes, release the
tension of the fuel distributor as well as the clamping claws
of the injection units. If necessary, slightly push the fuel
distributor and slightly twist the relevant injection unit.
The pipes must on no account be bent or installed when
under tension. The installation tension can lead to fracture
of the fuel high pressure pipe.
Note
It is not allowed to use tools for aligning the fuel distributor/the
injection units.
Pay attention to the cylinder specific marking when re-using
the high pressure lines.
The high pressure lines can be re-used if:
The sealing cone of the relevant high pressure line is not de

formed or cracked.
The line boring is not deformed, constricted or damaged.
Corroded lines must no longer be installed.

Suction off dirt from the sealing cones of the supports at the
fuel distributor.
WARNING

Clean fuel lines and line connections and blow-dry with com
pressed air.
Coat threads of union nuts with fuel.
Mounting sequence
First position the injection lines from the fuel distributor to the
injection units free of tension and only tighten the union nuts
by hand.
Tighten the screws for the clamping claws of the injection units
to 8 Nm and torque a further 180 (1/2 turn).
Use the socket wrench insert 17 mm -T40055- to tighten the
union nuts of the high pressure lines first on the injection units
and then on the fuel distributor to 15 Nm and torque a further
60 (1/6 turn).
186
Fabia II 2007
For installing the high pressure line between the high pressure
pump and the fuel distributor, slide the assembly sleeve T10411 - onto the fuel pressure sender -G247- .
Note
The bracket for the engine mounting must be movable in order
to position the union nut on the high pressure pump, to do so

slacken the screws -4-.
The assembly sleeve -T10411- ensures the correct distance
between the fuel pressure sender -G247- and the high pres
sure line.
Install the highProtected

pressure
line from
highorpressure
pump to
by copyright.
Copyingthe
for private
commercial purposes,
in part or in whole, is not permitted
unless authorised
by KODA
A. S.nuts
KODA
AUTOby
A. S.
does not guarantee or accept any liability
the fuel distributor
and tighten
theAUTO
union
only
hand.
Use the socket wrench insert 17 mm -T40055- to tighten the

union nuts of the high pressure line -2- between the high pres
sure pump and the fuel distributor first at the high pressure
pump -5- and then at the fuel distributor -1- to 15 Nm and tor
que a further (1/6 turn).
Tighten the screws of the fuel distributor to 22 Nm.
Tighten the screws -3 and 4- of the brackets for the fuel high
pressure line to 9 Nm.
Tighten the fixing screws of the bracket for the engine mount
ing to 23 Nm.
Remove assembly device -T10411- .
Fit the plug on the fuel pressure sender -G247- .
3.6
Removing and installing the injection

units

Extractor -T10055 Assembly sleeve -T10377 Socket wrench insert -T40055 Assembly sleeve -T10411 Extractor -T10426Removing
187
Fabia II 2007
Disconnect plug -1- from position sender for charge pressure
regulator -G581- .
Caution
Pay attention to cleanliness.
Under no circumstances dirt must get into the removed

return lines and the connections of the injection units.
It is absolutely necessary to protect the opened fuel con

nections from dirt with suitable means.
Open return-flow line connection. To do so, release the catch

-1-.
Detach the fuel return-flow line from the injection unit in
-direction of arrow-.
Disconnect the plug -1- at the injection units to be removed.

Replace the connector gasket ( page 177 , Pos. 4) of the
connectors -1- Electronic Catalogue of Original Parts .
Release the screw of the clamping claw for the injection unit
to be removed.
Caution

188
Fabia II 2007
Position the extractor -T10055- with the extractor -T10426- as
shown.
Always pull out the injection unit together with the clamping
claw towards the top by tapping it.
Note
Place the removed injection units on a clean cloth.

Remove the soot particles on the sealing surface of the injec
tion unit in the cylinder head and the dirt in the opening with a
cloth soaked in engine oil or in rust solvent, if necessary.
Caution
Make sure the sealing surfaces are not damaged in the proc
ess.
Important instructions for the replacement of parts
When reinstalling the injection unit, the following parts must be
replaced:
Copper seal
O-ring of bore for injection unit
Screw for clamping claw
When installing the new injection unit, the following must also be
replaced:
Clamping claw
Injection unit for cylinder
Instructions for reinstalling the injection units
Note
When
reinstalling,
the
injection
units,
the injection
lines
Protected
by copyright.
Copying
for private
or commercial
purposes, in
part orand
in whole, is not permitted
the clamping
claws
mustAUTO
onlyA. be
installed
the
pointor accept any liability
unless authorised
by KODA
S. KODA
AUTO at
A. S.
doessame
not guarantee
respect
to the
where with
they
were
removed.
The reinstalled injection units or injection lines must not be
damaged.
Spray the tip of the injection unit with a rust solvent spray. Re
move the soot and grease particles with a cloth after approx.
5 minutes.
189
Fabia II 2007
Remove the old copper seal from the injection unit; to do so,
carefully tighten the copper seal with pliers until the copper
seal does no longer turn. Then pull the injection unit out of the
copper seal with slight turning and pulling movements of the
hand.
Check the injection units and the fitting positions for cleanli
ness before installing.
Mounting sequence
Note
All the O-rings must be coated with engine oil before installing.
Insert a new copper seal on the injection unit with plastic bush
ing.
Replace the gasket ring of the bore for the injection unit, for
this step use the assembly sleeve -T10377 - .
Slide the clamping claw onto the injection unit. Check fitting
position page 177 .
Carefully insert the injection unit with the clamping claw into
the bore in the cylinder head.
Caution

Screw in the new screw of the clamping claw and first tighten
only by hand.
Note
For a tension-free installation of the injection line, it is essential to

align the position of the injection unit by twisting.
Install high pressure lines page 185 .
Further assembly occurs in reverse order.
Check gasket rings of fuel return-flow lines for wear, if neces
sary replace page 176 .
Carefully press the connections of the return-flow lines into the
injection units.
The cap must click audibly into place.

Note
After replacing the injection units, carry out Adaptation of cor

rection values in the Targeted functions Vehicle diagnosis,
190
Fabia II 2007
3.7
Removing and installing the fuel distrib

utor

Socket wrench insert -T40055Removing
ment page 6 .
Release the screws -3 and 4- of the brackets for the fuel high
pressure.
Remove fuel high pressure line -2-, to do so slacken the union
nut -5- at the high pressure pump and unscrew the union nut
-1- at the fuel distributor.
Open the catches -arrows- of the cable guide and expose the
wiring loom.
Disconnect the plugs at the glow plugs page 232 .
Disconnect plugs -1 ... 6-.

Replace the connector gasket of the connectors -2, 3 and 4 Electronic Catalogue of Original Parts .
191
Fabia II 2007
Release screws -arrows- of fuel return-flow line.
The fuel return-flow line remains attached to the fuel distribu
tor.
Caution
Mark the assignment of the high pressure lines to the cyl

inders, they must only be re-used on the same cylinder.
Rules of cleanliness when working on the injection sys
tem.
Immediately close the open connections with a suitable
screw cap.
Remove high pressure line between fuel distributor and injec
tion units.
Place the removed high pressure lines on a clean cloth.
Remove the fuel distributor, to do so release both screws
-arrows-.
Install
following points:
Screw in the fixing screws -arrows- of the fuel distributor and

first tighten only by hand.
The fuel distributor must be moved in order to ensure the

stress-free assembly of the high pressure lines.
Install high pressure lines page 185 .

Tightening torques
2.2 Fuel system
- Summary
components,
page
174not. guarantee or accept any liability
unless authorised
by KODAof
AUTO
A. S. KODA AUTO
A. S. does
192
Fabia II 2007
3.8
Removing and installing fuel pressure

sender -G247-
The fuel pressure sender -G247- -6- is located in the fuel distrib
utor. It measures the current fuel pressure in the high pressure
system and delivers a voltage signal to the engine control unit J623- .
If the sender fails, the pressure regulation is controlled by the en
gine control unit via a characteristic diagram.
In the emergency running mode, the maximum engine speed is
limited to approx. 3000 rpm.

Removing
WARNING

Note
No grease remover must get into the plug connection, carefully

clean.
Before removing the fuel pressure sender -G247 - , clean the
thread area with a grease remover (no dirt must get into the
hole of the fuel distributor).
Dry the fuel pressure sender -G247- .
Disconnect plug at fuel pressure sender -G247- .
Caution
Do not slacken the fuel pressure sender using the open-end

wrench or the open ring spanner - Risk of damage!
unlessinsert.
Use lengthened socket

Unscrew the fuel pressure sender -G247- .
Remove dirt from the threaded hole and the sealing surface in
the fuel distributor. To do so do not use any mechanical tools.
193
Fabia II 2007
Note
Close the fuel distributor hole immediately with a suitable screw

plug in order to prevent dirt from penetrating.
Install
Note
The fuel pressure sender -G247- has no gasket ring but a bit
ing edge for sealing.
Pay attention to damage of the sealing surfaces (biting edge
seal) and the thread of the new fuel pressure sender -G247- .
It is possible to use the fuel pressure sender -G247- again.
Also check the sealing surface of the hole of the fuel distribu
tor.
The thread of the fuel pressure sender -G247- is coated with
a lubricating lacquer. The thread must always be free of oil and

grease.
Caution
Do not tighten the fuel pressure sender using the open-end

wrench or the open ring spanner - Risk of damage!
Use lengthened socket insert.
Screw in the fuel pressure sender -G247- by hand.
Tighten the fuel pressure sender -G247- .
Tightening torque: 100 Nmunless authorised by KODA AUTO A. S. KODA AUTO A. S. does not guarantee or accept any liability
3.9
Removing and installing the fuel high

pressure pump

Counterholder -T10051 Extractor -T40064 Thrust piece -T40064/1 Bolt -T40064/2Removing
ment page 6 .
Gr. 50 .
194
Fabia II 2007
Caution
Make sure that no cable connection is damaged when discon

necting the plugs.
Otherwise, the complete wiring loom must be replaced.
Disconnect plugs -10, 11 and 12-.
10 - Hall sender -G4011 - Fuel dosage valve -N29012 - Fuel temperature sender -G81- in the fuel feed line
Release screws of coolant return-flow line -arrows-.

Lay coolant return-flow line to the side.
Way of proceeding if the high pressure pump is not replaced
Detach the fuel hoses -1 and 6- at the quick couplings. To do

so, push the quick couplings onto the nozzles, press in the
securing elements (hold pressed) and detach the quick cou
plings.
If the fuel hoses are not detached from the high pressure
pump, they must not be replaced.
Way of proceeding if the high pressure pump is replaced
Observe the instructions for the fuel hose in the engine com
partment page 6 .
Detach the fuel hoses -arrows- at the high pressure pump.

Continue as follows for both procedures
195
Fabia II 2007
Carefully unlock the fuel return-flow line -arrow- at the high
pressure pump.
Carefully remove the fuel return-flow line from the high pres
sure pump.
Unscrew high pressure line -2- between fuel distributor and

high pressure pump.
Remove the toothed belts from the toothed belt sprockets of
the camshaft and the high pressure pump page 29 .
Release screws -1- and remove timing belt gear from the high
pressure pump.
Hold the hub of the fuel high pressure pump with the counter
holder -T10051- and unscrew the fixing nut -1-.
Note
Replace the basic pressure plate with the pressure plate by copyright.
T40064/1- on the extractorProtected
-T40064. Copying for private or commercial purposes, in part or in whole, is not permitted
196
Fabia II 2007
Position extractor -T40064- with pressure plate -T40064/1 and bolt -T40064/2- as shown.
Detach the hub from the high pressure pump. If necessary
counterhold with an open-end wrench 24 mm.
Release the fixing screws -arrows- of the high pressure pump.

Remove the high pressure pump.
Install
Caution
Risk of damage to the high pressure pump through running dry.

Note
When installing the high pressure pump, ensure that no dirt
penetrates the fuel system.
Only remove the screw plug immediately before installing the
fuel lines.
Installation occurs in reverse order for removal, while paying at

tention to the following:
The screws for the high pressure pump must be replaced.
Tightening torques of fuel system page 174 .
Tightening torques of toothed belt drive page 27 .
If the fuel hoses -arrows- were removed at the high pressure
pump, they must be replaced page 6 .
Note
If the high pressure pump was replaced, the initialisation values

of the fuel pressure regulating valve -N276- must be reset Ve
hicle diagnosis, testing and information
system VAS 5051, Tar
geted functions; Reset initialisation values
of tothe
with respect
the regulating
valve for the fuel pressure.
Filling and bleeding the high pressure pump and the fuel sys
tem page 179 .
197
Fabia II 2007
Intake manifold and air filter
4.1
Intake manifold with component parts - Summary of components
1 - Changeover valve for radi

ator of exhaust gas recircula
tion -N3452 - 8 Nm
3 - 8 Nm
4 - Charge pressure sender G315 - Gasket
replace
6 - Connecting pipe
to cylinder head/radiator
for exhaust gas recircu
lation
Caution

7 - 9 Nm
8 - Warm-type clamp, 4 Nm
replace
9 - Throttle valve control unit J33810 - 10 Nm
11 - Gasket
replace
single gaskets can also
be installed
12 - Intake manifold
with intake manifold flap motor -V157 with intake air-intrinsic optimisation
must not be disassembled
13 - 8 Nm
4.2
Removing and installing intake manifold

Socket insert Torx T 30 -T10405-
198
Fabia II 2007
Removing
Note
page 3 .

Caution
Make sure that no cable connection is damaged when discon

necting the plugs.
Otherwise, the complete wiring loom must be replaced.
Release screws -arrows- of fuel return-flow line.
Carefully unlock the fuel return-flow line -arrow- at the high

pressure pump.
Carefully remove the fuel return-flow line from the high pres
sure pump.
wiring loom.
Disconnect the plugs at the glow plugs page 232 .
4. Intake manifold and air filter
199
Fabia II 2007
Release screw -arrow- and lay the changeover valve for radi
ator of exhaust gas recirculation -N345- to the side.
Disconnect plugs -6,7,9,11-.

6 - Intake manifold flap motor -V1577 - Charge pressure sender -G319 - Throttle valve control unit -J33811 - Fuel dosage valve -N290-
Release screws of coolant return-flow line -arrows- and lay the

return line to the side.
unless
authorised
by KODA
A. S.
KODA
Remove
fuel
distributor
AUTO
page
191
. AUTO A. S. does not guarantee or accept any liability
Slacken clamps -1- and -3-.

Release the fixing screws of the intake manifold
( page 198 , Pos. 13) crosswise from the outside inwards.
Carefully remove intake manifold.
Install
following points:
Replace gasket.
Before installing, insert the fixing screws in the holes of the
intake manifold.
Tighten screws from inside to outside and crosswise to 8 Nm.
200
Fabia II 2007
4.3
Air filter - Summary of components
with captive screw,
9 Nm
2 - Clamp
3 - Heating for crankcase ven
tilation
for vehicles in cold cli
matic zones
4 - Bleeder hose
to charge pressure con
trol solenoid valve -N75 2.7 Connection dia
gram for vacuum ho
ses, page 166
6 - Suction hose
to exhaust gas turbo
charger
7 - Hose
for crankcase ventila
tion
to remove, press re
lease buttons
8 - 2 Nm
9 - Air mass meter -G7010 - O-ring
replace if damaged
11 - 8 Nm
12 - Air filter top part
13 - Hose
for preheating
for vehicles in cold climatic zones
14
- Filter element
to remove, turn 1/4 turn to the left
pay attention to change intervals Maintenance ; Fabia II

15 - 8 Nm
16 - Rubber bearing
replace if damaged
17 - Air filter bottom part
screwed onto lock carrier
19 - 2 Nm
20 - Air intake hose
21 - Drain pipe
201
Fabia II 2007
22 - Rubber bearing
replace if damaged
4.4
Removing and installing air filter
Remove air filter

Unplug connector -2- from air mass meter -G70- .
Open clamp -1- and detach suction hose to exhaust gas tur
bocharger.
If present, detach hose for preheating.
Remove vacuum lines with bracket

-1from Copying
air filter.
Protected by
copyright.
for private or commercial purposes, in part or in whole, is not permitted
Slacken screw -arrow- at air filter.

Take out air intake hose -4-.
Take out air filter completely.
Remove suction hose
Note
Due to the poor access of the pliers for spring strap clamps to the
bottom suction hose it is preferable to remove the inlet connection
from the exhaust turbocharger.
202
Fabia II 2007
Remove the hose for crankcase ventilation -3-.
Detach vacuum hose -2- from suction hose -1- and expose.
Unclip bracket.
Completely unscrew screw -4- (captive).
Swivel the inlet connection to the right and remove the suction
hose -1-.
Install suction hose
following points:
When installing the inlet connection at the exhaust gas turbo
charger make sure that the inlet connection is correctly seated
on the bolt of the exhaust gas turbocharger -arrow-.
Install air filter
following points:
Pull through the drain pipe -arrow- between the gearbox and
the body.
Check if the drain pipe is correctly routed by looking under the

wing.
Tightening torques page 201 .
203
Fabia II 2007
Engine control unit
5.1
Removing and installing engine control

unit -J623Note
If the engine control unit should be replaced, connect the vehicle

diagnosis, measurement and information system -VAS 505x- and
in the Targeted fault finding carry out replace engine control
unit.
Removing
Switch off ignition.
Remove air filter with air mass meter -G70- page 202 .
Open the catches -arrows- and remove the engine control unit.
Vehicles without protective cover
Disconnect both plugs at the engine control unit -J623- and
remove.
Vehicles with protective cover
204
Fabia II 2007
Cut with body saw slots for the cross-head screwdriver in the
heads of the pull-off screws.
Note
It must be sawed twice with the body saw, so that the slot is
wide enough, in order to be able to unscrew the screws with

a suitable screwdriver.
A locking agent is applied to the pull-off screws.

Disconnect both plugs at the engine control unit -J623- and
remove.
Install
Connect both plugs and lock.
Vehicles with protective cover
Fasten protective cover with new pull-off screws.
Tighten pull-off screws evenly until the heads are pulled off.
Insert engine control unit -J623- in the bracket and lock se
curely.
Note
After replacing the engine control unit -J623 - , the initialisation

values of the differential pressure sender -G505 - must be reset
Vehicle diagnosis, testing and information system VAS 5051.
5. Engine control unit
205
Fabia II 2007
26
Exhaust System

exhaust system
Note
The decoupling element in the pre-exhaust pipe should not be
bent by more than 10 - risk of damage.
Replace the gaskets and the self-locking nuts.

When performing installation work on the exhaust system,
make sure the exhaust system is not mounted under tension

and has adequate clearance from the vehicle body. If neces
sary slacken the double clamp and align the exhaust system
so as to create adequate clearance between these compo
nents and the vehicle body, and that the weight of the exhaust
system is evenly distributed over the hangers.
206
Rep. Gr.26 - Exhaust System
Fabia II 2007
1.1
Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5

standard (left-hand drive) - Summary of components
Note
If the particle filter or the differential pressure sender -G505- is replaced, the differential pressure sender -
G505- must be adapted Vehicle diagnosis, testing and information system VAS 5051; Targeted func
tions; adapt differential pressure sender -G505- .
The exhaust turbocharger and the exhaust manifold are one component part, remove and install
page 154 .
Double clamp between pre-exhaust pipe and rear part of exhaust system page 222 .
1 - Differential pressure sender
-G505Caution
Risk of damage!
The
differential pressure
indicator -G505- is very
sensitive. It must not
touch somewhere when
laying it down with the ho
ses connected.
Only
detach the hoses
from the differential pres
sure sender -G505- if it
must be replaced.
page 209
2 - 3 Nm
3 - Control line
sender 4 -G648- , 45 Nm
the thread of the new
temperature sender
must be coated with as
sembly paste
coat only the thread with
hot bolt paste -G 052
112 A3- for re-used tem
perature sender
ling, use wrench
T10395/6
installing page 209
6 - Lambda probe -G39- , 50 Nm
the thread of new lambda probes must be coated with assembly paste
for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3 the hot bolt paste -G 052 112 A3- must not come into contact with the slots of the probe body
1. Removing and installing
parts of the exhaust system
207
Fabia II 2007
7 - Heat shield
8 - 9 Nm
9 - Pre-exhaust pipe
with oxidation catalytic converter and diesel particle filter
10 - Gasket
replace
replace
12 - 23 Nm
13 - 23 Nm
14 - Support
bolted to engine support
15 - Exhaust gas temperature sender 3 -G495- , 45 Nm
the thread of the new temperature sender must be coated with assembly paste
coat only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender
for removing and installing, use wrench T10395/6
installing page 208
16 - Support
17 - 23 Nm
18 - Support
for differential pressure sender -G505-
1.2
Installing the exhaust gas temperature

sender 3 -G495- for vehicles according
to EU 5 standard (left-hand drive)

Key -T10395/6Grease the thread of the sender with hot bolt paste -G 052 112
A3- .
Tighten the sender with a torque wrench and the wrench T10395/6- .
Caution

Nm.
respect to the
The correct tightening torque of 45 Nm iswith
achieved
bycorrectness
the exof information in this document. Copyright by KODA AUTO A. S.
208
Fabia II 2007
1.3

to EU 5 standard (left-hand drive)

A3- .
Note
The illustration differs from the vehicle. The arrangement of the

wrenches is correct.
Caution

Nm.

1.4
Removing and installing the differential

pressure sender -G505- for vehicles ac
cording to EU 5 standard (left-hand
drive)
The differential pressure sender -G505- is connected to the meas

uring point in front of the diesel particle filter via a pipe.
The differential pressure sender -G505- determines the volumet
ric efficiency of the particle filter volume.
Caution
The differential pressure sender -G505 - is very sensitive to

shock load and leaks.
Therefore the hoses of the sender must only be removed
if the sender is damaged.
Furthermore there is the risk that the hose connections
break off when the hoses are removed.
1. Removing and installing parts of the exhaust system
209
Fabia II 2007
Removing
Disconnect plug -2- at differential pressure sender -G505Note
Pull off the hoses carefully and only straight from the connection
fittings. Otherwise the connection fittings of the differential pres
sure sender -G505- break off easily.
Pull off hoses.
Unscrew screw -3- and remove differential pressure sender G505- .
Install
following points:
Check hoses for soiling.
If the cross section of the hoses is clearly constricted through

soot deposition, the complete assembly part must be re
placed. It consists of the sender with the hoses connected.
Note
Blow out the control line from the differential pressure sender
-G505- to the diesel particle filter before installing (blocked or

iced up by condensation water).
Pay attention to the tight connection and leaktightness of the
hoses.
Perform an adaptation after replacing the differential pressure

sender -G505The work procedure for the adaptation is described in the Tar
geted fault finding. It is also described under Targeted func
tions.
Press button Skip.
Select Drive.
Select 01 - Self-diagnosable systems.
Select 01 - Engine electronics J623.
Select 01 - Engine electronics, functions.
Select 01 - Erase initialisation values (Rep. Gr. 21 - 28).
1.5
Removing and installing the pre-exhaust

pipe for vehicles according to EU 5
standard (left-hand drive)

Ring spanner set for lambda probe
Set of tools 17 mm -T10395
Transport device -T10404
210
Fabia II 2007
Hot screw paste -G 052 112 A3Removing
Disconnect the following plug connections and expose the ca
bles:
-1- Plug connection exhaust gas temperature sender 1 -G235(black)
-2- Plug connection exhaust gas temperature sender 3 -G495(brown)
-3- Plug connection exhaust gas temperature sender 4 -G648(orange)
-4- Plug connection lambda probe -G39- (grey)
Disconnect plug -2- at differential pressure sender -G505 Release screw -3-.
Caution
Risk of damage!
The differential pressure indicator -G505- is very sensi
tive. It must not touch somewhere when laying it down.
Attach the differential pressure sender -G505- to the diesel
particle filter with the hoses connected.
Release Lambda probe -G39- .
Release exhaust gas temperature sender 3 -G495- using the
wrench -T10395/6- .
Release screw -2-.
Slacken screw -3- and swivel the bracket towards the front.
Remove warm-type clamp -1- between pre-exhaust pipe and
exhaust turbocharger.
Lower the assembly carrier Chassis; Rep. Gr. 40 ; slacken
the assembly carrier in the service position and align.
Note
Deviating from the specifications provided in the Chassis
Workshop Manual, lower the assembly carrier 6 ... 7 cm.
While doing so, the hydraulic lines for the steering must not be
exposed to tension.
211
Fabia II 2007
Release screws -1- and remove cover for right drive shaft.
Unscrew the exhaust gas temperature sender 4 -G648- -1from the pre-exhaust pipe using the wrench -T10395/6- .
First release the screws -1-, then unscrew the nuts -2-.
Remove bracket for pre-exhaust pipe.
Note
If the pre-exhaust pipe should be reinstalled, the transport de
vice -T10404- -arrow- must be attached to the decoupling

element.
212
Fabia II 2007
Slacken the nuts -arrows- of the double clamp and slide back
wards.
Unhook the pre-exhaust pipe from the retaining straps on the
assembly carrier.
Carefully remove pre-exhaust pipe. To do so, turn the pre-ex

haust pipe -arrow- 180 in -direction of arrow-.
Install
Note
Neither bend nor expose the decoupling element to tension.

Do not damage the wire mesh of the decoupling element.
Secure the decoupling element with the transport device -
T10404- against overtensioning.

Note
Replace gasket and warm-type clamp.

When installing the pre-exhaust pipe with diesel particle filter, ob
serve the following sequence:
1.
2.
Position diesel particle filter on exhaust gas turbocharger

and loosely fasten clamp -1-.
Loosely screw in screws and nuts -2 5- by hand.
It must still be possible to move the diesel particle filter
and the bracket.
3.
4.
5.
Tighten clamp -1- to 7 Nm.
with 3
respect
theto
correctness
TIghten screws and nuts -2,
andto523 Nm.of information in this document. Copyright by KODA AUTO A. S.
Tighten screws -4- to 23 Nm
After replacing the diesel particle filter, the following work must
still be carried out:
Set adaptation of ash mass balance to 0 Vehicle diagnosis,
Adapt differential pressure sender -G505- page 209 .
Align exhaust system free of stress page 227 .
213
Fabia II 2007
1.6
Pre-exhaust pipe with diesel particle filter for vehicles according to EU 5

standard (right-hand drive) - Summary of components
Note
If the particle filter or the differential pressure sender -G505- is replaced, the differential pressure sender -
G505- must be adapted Vehicle diagnosis, testing and information system VAS 5051; targeted functions;
adapt differential pressure sender -G505- .
The exhaust turbocharger and the exhaust manifold are one component part, remove and install
page 154 .
Double clamp between pre-exhaust pipe and rear part of exhaust system page 222 .
1 - Lambda probe -G39- , 50
Nm
the thread of new lamb
da probes must be coat
ed with assembly paste
for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3 the hot bolt paste -G 052
112 A3- must not come
into contact with the
slots of the probe body
2 - Gasket
replace
replace
sender 4 -G648- , 45 Nm
the thread of the new
temperature sender
must be coated with as
sembly paste
coat only the thread with
hot bolt paste -G 052
112 A3- for re-used tem
perature sender
ling, use wrench
T10395/6
unless
installing
page
215
authorised
by KODA

sender 3 -G495 the thread of the new temperature sender must be coated with assembly paste
coat only the thread with hot bolt paste -G 052 112 A3- for re-used temperature sender
for removing and installing, use wrench T10395/6
installing page 215
6 - Support
for differential pressure sender -G505-
214
Fabia II 2007
8 - Control line
9 - Differential pressure sender -G505 removing and installing page 216
10 - 5 Nm
11 - 23 Nm
12 - 23 Nm
13 - Support
screwed onto the cylinder block
14 - Pre-exhaust pipe
with oxidation catalytic converter and diesel particle filter
1.7

to EU 5 standard (right-hand drive)

Key -T10395/6Grease
the thread of the sender with hot bolt paste -G 052 112
A3- unless
.

Caution

Nm.

1.8

to EU 5 standard (right-hand drive)

A3- .
215
Fabia II 2007
Caution

Nm.

1.9
Removing and installing the differential

pressure sender -G505- for vehicles ac
cording to EU 5 standard (right-hand
drive)
The differential pressure sender -G505- is connected to the meas

uring point in front of the diesel particle filter via a pipe.
The differential pressure sender -G505- determines the volumet
ric efficiency of the particle filter volume.
Caution
unless authorised
KODA AUTO
A. S. KODA
AUTO A.to
S. does not guarantee or accept any liability
The differential pressure
sender by-G505
- is very
sensitive
shock load and leaks. with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.
Therefore the hoses of the sender must only be removed

if the sender is damaged.
Furthermore there is the risk that the hose connections
break off when the hoses are removed.
216
Fabia II 2007
Removing
Disconnect plug -3- at differential pressure sender -G505Note
Pull off the hoses carefully and only straight from the connection
fittings. Otherwise the connection fittings of the differential pres
sure sender -G505- break off easily.
Pull off hoses.
Release nut -1- and remove differential pressure sender G505- -2-.
Install
following points:
Check hoses for soiling.
If the cross section of the hoses is clearly constricted through

soot deposition, the complete assembly part must be re
placed. It consists of the sender with the hoses connected.
Note
Blow out the control lines from the differential pressure sender
-G505- to the diesel particle filter before installing (blocked or

iced up by condensation water).
Pay attention to the tight connection and leaktightness of the
hoses.
Protected
Perform an adaptation after replacing the differential pressure
sender -G505The work procedure for the adaptation is described in the Tar
geted fault finding. It is also described under Targeted func
tions.
Press button Skip.
Select Drive.
Select 01 - Self-diagnosable systems.
Select 01 - Engine electronics J623.
Select 01 - Engine electronics, functions.
Select 01 - Erase initialisation values (Rep. Gr. 21 - 28).
1.10

pipe for vehicles according to EU 5
standard (right-hand drive)

Set of tools 17 mm -T10395 Transport device -T10404 -
217
Fabia II 2007
Hot screw paste -G 052 112 A3Removing
bles:
Plug connection -1- exhaust gas temperature sender 1 -G235 Plug connection -2- lambda probe -G39-
Unscrew lambda probe -G39- -1-.

Remove warm-type clamp -2- between pre-exhaust pipe and
exhaust turbocharger.
Gr. 50 .

bles:
-2- Plug connection differential

pressure
sender -G505with respect
to the correctness
of information in this document. Copyright by KODA AUTO A. S.
-3- Plug connection exhaust gas temperature sender 3 -G495 Unscrew nut -1-.
Caution
Risk of damage!
The differential pressure indicator -G505- is very sensi
tive. It must not touch somewhere when laying it down.
Attach the differential pressure sender -G505- to the diesel
particle filter with the hoses connected.
Note
exposed to tension.
218
Fabia II 2007
Unscrew the exhaust gas temperature sender 3 -G495- -1from the pre-exhaust pipe using the wrench -T10395/6- . The
figures show how to tighten the sender.
Remove the right underfloor trim panel Body Work; Rep.

Gr. 66 .
Remove the cover of the plug connection for the exhaust gas
temperature sender 4 -G648- .
219
Fabia II 2007
Disconnect plug connection for exhaust gas temperature
sender 4 -G648- .
wards.
Unhook the pre-exhaust

pipe
from AUTO
the retaining
thenot guarantee or accept any liability
unless authorised
by KODA
A. S. KODAstraps
AUTO A. on
S. does
assembly carrier.with respect to the correctness of information in this document. Copyright by KODA AUTO A. S.

Install
220
Fabia II 2007
Note


element.

Note
Replace gasket and warm-type clamp.

When installing the pre-exhaust pipe with diesel particle filter, ob
serve the following sequence:
1.
2.
3.
4.
4.
5.
5.
Position the pre-exhaust pipe with diesel particle filter

-1- at the exhaust gas turbocharger and loosely fasten
the clamp -2-.
It must still be possible to move the diesel particle filter
and the bracket.
Tighten nut -6- to 23 Nm.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Tighten nut -4- to 23 Nm.
Tighten screw -7- to 23 Nm.

After replacing the diesel particle filter, the following work must
still be carried out:
Set adaptation of ash mass balance to 0 Vehicle diagnosis,
Adapt differential pressure sender -G505- page 209 .
221
Fabia II 2007
1.11
Rear part of the exhaust system for vehicles according to EU 5 standard Summary of components
1 - Rear part of exhaust system

Individually replace the
exhaust pipe and the si
lencer when carrying
out repairs page 226
The separation point is
marked by indentations
on the exhaust pipe
Align exhaust system
free of stress
page 227
2 - Retaining strap
23 Nm
replace if damaged
3 - 20 Nm
4 - Tunnel bridge
5 - Double clamp
installing page 222
Double clamp between pre-exhaust pipe and rear part of exhaust

system
Push the double clamp -1- to the dimension -a- = 5 mm in front
of the marking at the exhaust pipe -2- and tighten the bolted
connections evenly to 23 Nm.
222
Fabia II 2007
1.12
Exhaust pipe with oxidation catalytic converter for vehicles according to

EU-4/BS4 standard - Summary of components
Note
The exhaust turbocharger and the exhaust manifold are one component part, remove and install page 154 .
1 - Lambda probe -G39- , 50
Nm
the thread of new lamb
da probes must be coat
ed with assembly paste
for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3 the hot bolt paste -G 052
112 A3- must not come
into contact with the
slots of the probe body
2 - Exhaust pipe
with oxidation catalytic
converter
page 224
3 - Gasket
replace
replace
5 - 23 Nm
6 - Retaining strap
replace if damaged
Pay attention to the part
number
7 - Retaining strap
replace if damaged
Pay attention to the part
number
8 - Separation point
9 - Tunnel bridge
10 - 23 Nm
11 - Retaining strap
replace if damaged
Pay attention to the part number
12 - 23 Nm
13 - 23 Nm
14 - Support
bolted to engine support
223
Fabia II 2007
1.13

pipe for vehicles according to EU-4/
BS-4 standard (right-hand drive)

Set of tools 17 mm -T10395 Transport device -T10404 Hot screw paste -G 052 112 A3Removing
bles:
Plug connection -1- exhaust gas temperature sender 1 -G235 Plug connection -2- lambda probe -G39-
Unscrew lambda probe -G39- -1-.

Remove
warm-type
clamp
between
pre-exhaust
pipe
and is not permitted
Protected
by copyright. Copying
for -2private
or commercial
purposes, in part
or in whole,
unless authorised
exhaust
turbocharger.

Gr. 50 .

Note
exposed to tension.
224
Fabia II 2007
wards.
Note
If no double clamp is mounted, separate the exhaust pipe at the

front separation point Item 8 (page 223) , page 226 .
Unhook the pre-exhaust pipe from the retaining straps on the
assembly carrier.

Install
Note


element.

Note
Replace gasket and
warm-type clamp.
225
Fabia II 2007
When installing the pre-exhaust pipe, observe the following se
quence:
1.
2.
Position the pre-exhaust pipe -1- at the exhaust gas tur

bocharger and loosely fasten the clamp -2-.
It must still be possible to move the pre-exhaust pipe
and the bracket.
3.
4.
4.
5.
5.

1.14
Replacing the middle and rear part of the

exhaust system

Body saw e.g. -V.A.G 1523 A Protective goggles
Work procedure
For separating the exhaust pipe and the silencer, a separation
point is provided in the rear part of the exhaust system, which is
marked with recesses.
WARNING
Wear safety goggles.

Separate exhaust pipe at right angles at the separation point
-arrow 1- with body saw.
When installing, position double clamp -4- at the side markings
-arrow 2- and -arrow 3-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
226
Fabia II 2007
Install double clamps in such a way that the ends of the screws
do not protrude beyond the bottom edge of the double clamp.
The bolted connection points to the right.
Tighten bolted connections of the double clamp evenly to 23

Nm.
1.15
Aligning exhaust system free of stress
Condition
The exhaust gas system must be cold for aligning.
Slacken double clamp -1- and align to pre-exhaust pipe -2(-arrow- points in direction of travel).
-a- = 5 mm
The fixing screws must be located on the right. They must not
protrude beyond the bottom edge of the double clamp.
Tighten the front nut by hand.
Push the rear part of the exhaust system so far forward until
the initial load -dimension a- on the retaining strap is 3 ... 7
mm.
Tighten nuts of double clamp evenly to 23 Nm.
1.16
Inspecting the exhaust system for leak

tightness
Start engine and run in idle.

Seal off exhaust tailpipe for the duration of the leak check (e.g.
with cloths, plugs).
Connection points: inspect cylinder head/exhaust manifold,
exhaust gas turbocharger/pre-exhaust pipe etc. for leaktight
ness by listening.
Eliminate any leak found.
with respect to the correctness of information in this document.1.Copyright
by KODA
AUTO A. S.
Removing
and installing
parts of
the exhaust system
227
Fabia II 2007
Exhaust gas recirculation system
2.1
Parts of exhaust gas recirculation - Summary of components
1 - 9 Nm
2 - Connecting pipe
to cylinder head
Caution

3 - 9 Nm
4 - Gasket
replace
5 - Vacuum line
do not change bending
form
Connection diagram for
vacuum hoses
page 166
6 - 9 Nm
7 - Gasket
replace
8 - Connecting pipe
To intake manifold
Caution

9 - 9 Nm
11 - Radiator
for exhaust gas recirculation
with bypass flap
with integrated exhaust gas recirculation valve -N18- and with exhaust gas recirculation potentiometer G212 Check change-over page 229
12 - 9 Nm
13 - Gasket
replace
228
Fabia II 2007
14 - Gasket
replace
15 - Connecting pipe
from exhaust manifold
Caution

16 - 22 Nm
17 - 9 Nm
18 - Gasket
replace
2.2
Checking change-over flap for radiator

for exhaust gas recirculation

Hand vacuum pump , e.g. -VAS 6213
Work procedure
Gr. 50 .
Remove heat shield collar.
Note
In order to generate vacuum, push the ring -1- for the hand vac
uum pump -VAS 6213- into position -A-.
2. Exhaust gas recirculation system
229
Fabia II 2007
Detach hose from vacuum setting element of change-over flap
and connect the hand vacuum pump -VAS 6213- instead.
Generate vacuum with the hand vacuum pump.
The linkage on the vacuum setting element for the changeover flap for radiator of exhaust gas recirculation must move
-arrows-.
If the linkage does not move or only moves with a sudden motion:
The vacuum setting element for the change-over flap for radi
ator of exhaust gas recirculation is defective.
Change-over flap for radiator of exhaust gas recirculation is
sluggish.
Replace radiator for exhaust gas recirculation page 230 .
Note
The heat shield collar should be fitted on again in the same place
when installing.
2.3
Removing and installing radiator for ex


Hose clamps up to 25 mm -MP7-602 (3094) Catch pan , e.g. -VAS 6208 Pliers for spring strap clamps
Old oil collecting
and suction equipment , e.g. -V.A.G 1782Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Removingunless
page 202 .
Release screw -1-.
Unclip the vacuum line -2- from the bracket -arrow- and place
downwards.
Remove right front wheel.
Remove the front right wheelhouse liner Body Work; Rep.
Gr. 66 .
Gr. 50 .
Left-hand drive page 210
Right-hand drive page 217
230
Fabia II 2007
Remove connection pipe -2- to exhaust gas recirculation ra
diator.
Only unscrew connecting pipe -1- at radiator for exhaust gas
recirculation -arrows-.
Slacken union nut -1- with open ring spanner 17 mm -A-.

Remove heat protective cover at vacuum setting element.
Detach hose from vacuum setting element.
Disconnect the plug on the exhaust gas recirculation valve N18- .
Pinch off coolant hoses to radiator for exhaust gas recircula
tion with hose clamps up to 25 mm -MP7-602- .
Collect escaping coolant with the catch pan -VAS 6208- .
Detach coolant hoses from radiator for exhaust gas recircula
tion.
Release screws and remove radiator for exhaust

with respectgas
to therecircu
lation.
Install
following points:
nuts.
Secure all hose connections with corresponding hose clamps
Electronic Catalogue of Original Parts .
Tightening torques page 228 .
Inspect coolant level, top up with coolant if necessary
page 112 .
2. Exhaust gas recirculation system
231
Fabia II 2007
28
Glow Plug System
Glow Plug System

Note
Check glow plugs Vehicle diagnosis, testing and information

system VAS 5051.
1.1
Removing and installing glow plugs

Flexible-head wrench SW 10 , e.g. -3220 Cleaning and degreasing agent , e.g. -D 000 401 04 Protective goggles and gloves
Test conditions
Engine is cold
Ignition is switched off
Work procedure
wiring loom.
Disconnect plug -6- at fuel pressure sender -G247- .

Caution
Carefully disconnect the plug from the glow plugs.

If the plug is damaged when disconnecting it, the complete
wiring loom including the plugs must be replaced (plugs
cannot be replaced separately).
232
Rep. Gr.28 - Glow Plug System
Fabia II 2007
Carefully disconnect the plug from the glow plugs. Use the
assembly spanner SW 12 for help.
WARNING

Clean the glow plug and the hole in the cylinder head with
great care.
Note
No dirt must get into the cylinder.

When cleaning, for example:
1.
Suction off heavy dirt using a vacuum cleaner.
2.
Spray grease remover and cleaning agent onto the glow

plug and into the hole around the plug, let it take effect for a
short period of time and blow out with compressed air.
3.
Clean the glow plug and the channel around the plug with a
cloth soaked in oil.
Slacken the glow plug with a flexible-head wrench 10 -3220 and release.
Install
following points:
Note
Before installing the glow plug, remove dirt and deposits from
the bore in the cylinder head and from the thread.
Do not oil or grease the threaded bore in the cylinder head as
well as the pencil type glow plug thread.
Screw the glow plugs into the cylinder head by hand using the
flexible-head wrench -3220- .
Tighten glow plugs to 16 - 18 Nm.
Fit the plug again onto the relevant glow plug and check for
firm seating.
Interrogating and erasing fault memory of engine control unit
5051.
Note
After deleting the fault memory of the engine control unit the read
iness code must be checked, if necessary re-generated.
1. Glow Plug System
233

D3E802A922B-1 2 55 KW TDI CR Engine

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Service

1,2/55 kW TDI CR Engine

Service Department. Technical Information

Self diagnosis, safety measures, cleanliness regulations and directions . . . . . . . . . . . . . .

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . .

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust gas turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Diesel direct injection system - fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

28 - Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

The engine number (engine identification character and serial

Engine identification character

Self diagnosis, safety measures,

This Rep.-Gr. is deleted.

Supplementary instructions and assem

Risk of injury through refrigerant.

Risk of damaging the condensor, the refrigerant lines and ho

Mount the AC compressor in such a way that the refrigerant

Rep. Gr.01 - Self-diagnosis

Regulations concerning safety precau

When undertaking all installation work, particularly in the en

Take out fuse for fuel pump relay -J17or

Disconnect the plug on the flange of the fuel delivery unit

Carefully observe the following 6 rules for cleanliness when

Rep. Gr.01 - Self-diagnosis

Regulations concerning cleanliness

Carefully observe the following 5 rules for cleanliness when

1. Self diagnosis, safety measures, cleanliness regulations and directions

Fuel hoses in the engine compartment removing and replacing

a so-called 3-wave profile (arrows). In this way, the tightness

barrier layer on the inside of the fuel hose is damaged.

This damage is not visible to the eye. However, it can lead to

leakage of the fuel system after a certain period of time.

sition of the hose on the 3 waves cannot be ensured. This

After removing the fuel hoses from nozzles with 3-wave

from the nozzle of the quick coupling.

If other components are only removed: Check whether it is

possible to separate the fuel system on the quick couplings at

If a fuel hose cannot be disconnected from the hose nozzle by

Never push a screwdriver or a similar tool between the hose

Rep. Gr.01 - Self-diagnosis

with spring strap clamp.

General instructions for charge air sys

When undertaking all installation work, particularly in the en

In case a mechanical damage to the exhaust gas turbocharger

1. Self diagnosis, safety measures, cleanliness regulations and directions

Rep. Gr.01 - Self-diagnosis

Removing and installing engine

Removing and installing engine

Removing and installing engine trim

Before installing the engine cover, check the correct fitting po

Special tools and workshop equipment required

1. Removing and installing engine

engine was removed must be attached again in the same lo