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Service

Workshop Manual
FABIA 2000
Edition 07.03
Engine code

1.9/96 TDI Engine, Mechanics


ASZ

Service Department. Technical Information

Printed in Czech Republic S00.5327.00.20

Service

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

Printed in Czech Republic S00.5327.00.20

FABIA 2000

1.9/96 TDI Engine, Mechanics

List of Supplements to Workshop Manual

FABIA 2000
1.9/96 TDI Engine, Mechanics
Edition 07.03
Supplement

Edition 07.03

Subject Basic Edition

Article Number S00.5327.00.20

Edition 07.03 S00.5327.00.20

List of Supplements

FABIA 2000

1.9/96 TDI Engine, Mechanics

List of Supplements

Edition 07.03 S00.5327.00.20

FABIA 2000

1.9/96 TDI Engine, Mechanics

Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1 page 1

10 Removing and Installing Engine


Removing and Installing Engine .................................................................... 10-1 page 1

13 Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 Removing and installing, tightening the timing belt ........................................... 13-2 Removing and installing sealing flange and flywheel ......................................... 13-3 Crankshaft, Piston and Conrod ..................................................................... 13-4 page page page page 1 1 1 1

15 Cylinder Head, Valve Gear


Removing and installing cylinder head ........................................................... 15-1 Repairing Valve Gear .................................................................................. 15-2 Camshaft ................................................................................................. 15-3 Valve seats, valves guides, valve stem seals .................................................... 15-4 page page page page 1 1 1 1

17 Lubrication
Removing and installing parts of the lubrication system ..................................... 17-1 - Disassembling and assembling oil filter holder ................................................... 17-1 Removing and installing oil pan .................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3 page page page page 1 2 1 1

19 Cooling
Parts of cooling system - Summary of components ........................................... 19-1 Removing and installing radiator, coolant pump and coolant thermostat ................ 19-2 page page 1 1

20 Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 Repairing the accelerator control .................................................................. 20-2 page page 1 1

21 Turbocharging
Charge air system with turbocharger I ............................................................ 21-1 - Removing and installing exhaust turbocharger with component parts ........................ 21-1 - Removing and installing parts of the charge air cooling ......................................... 21-1 - Connection diagram for vacuum hoses ............................................................ 21-1 Charge air system with turbocharger II ........................................................... 21-2 - Remove exhaust turbocharger ...................................................................... 21-2 - Checking charge pressure control .................................................................. 21-2 page page page page page page page 1 1 2 2 1 1 1

26 Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Procedure ............................................................................................... 26-1 - Replacing middle or rear silencer ................................................................... 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Exhaust gas recirculation system .................................................................. 26-2
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- Testing mechanical exhaust gas recirculation valve ............................................. 26-2

II

Table of Contents

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00

00 Technical Data
00-1 Technical Data

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

Engine characteristics Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Firing order min. CN Catalytic converter Exhaust gas recirculation Turbocharging Charge air cooler l kW at rpm Nm at rpm mm mm ASZ 06.03 EU-3 1,896 96/4000 310/1900 79,5 95,5 19,0 : 1 1-3-4-2 49 yes yes yes yes

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Technical Data

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00

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00-1 page 2

Technical Data

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10 Removing and Installing Engine


10-1 Removing and Installing Engine

1.9/74 TDI Engine, Mechanics; Rep. Gr. 10 Gearbox 0A8; Rep. Gr. 30 und 34 Note The removing of the 1.9/96 TDI Engine can differ in certain details from the removing of the 1.9/74 TDI Engine.

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Removing and Installing Engine

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10-1 page 2

Removing and Installing Engine

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13 Crankgear
13-1 Removing and installing V-ribbed belt

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

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Removing and installing V-ribbed belt

13-1 page 1

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13-1 page 2

Removing and installing V-ribbed belt

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13

13-2

Removing and installing, tightening the timing belt

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

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Removing and installing, tightening the timing belt

13-2 page 1

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13-2 page 2

Removing and installing, tightening the timing belt

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13

13-3

Removing and installing sealing flange and flywheel

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

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Removing and installing sealing flange and flywheel

13-3 page 1

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13-3 page 2

Removing and installing sealing flange and flywheel

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13

13-4

Crankshaft, Piston and Conrod

1.9/74 TDI Engine, Mechanics; Rep. Gr. 13

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Crankshaft, Piston and Conrod

13-4 page 1

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13-4 page 2

Crankshaft, Piston and Conrod

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15

15 Cylinder Head, Valve Gear


15-1 Removing and installing cylinder head

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

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Removing and installing cylinder head

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15-1 page 2

Removing and installing cylinder head

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15-2

Repairing Valve Gear

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

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Repairing Valve Gear

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15-2 page 2

Repairing Valve Gear

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15

15-3

Camshaft

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

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Camshaft

15-3 page 1

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15-3 page 2

Camshaft

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15

15-4

Valve seats, valves guides, valve stem seals

1.9/74 TDI Engine, Mechanics; Rep. Gr. 15

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Valve seats, valves guides, valve stem seals

15-4 page 1

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15-4 page 2

Valve seats, valves guides, valve stem seals

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17

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

Removing and installing parts of the lubrication system

carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.
Testing oil pressure and oil pressure switch Chapter 17-3. The oil level must never exceed the max marking - risk of damage to catalytic converter!

Check the oil level, amount of oil and oil specification: Inspection and Maintenance 1 - 15 Nm 2 - Bracket For cable to oil level and oil temperature sender 3 - Dipstick Oil level must not exceed max marking! 4 - Filler funnel Remove for extracting oil 5 - Guide tube 6 - Fitting sleeve For centering oil pump/cylinder block 7 - O-ring Replace 8 - Suction line Clean strainer if dirty 9 - Baffle 10 - Oil pan Before installing, coat with silicone sealant -D 176 404 A2- Chapter 17-2 11 - Gasket ring Replace 12 - Oil drain plug, 30 Nm 13 - 10 Nm 14 - Oil level and oil temperature sender -G266Test Electrical System; Rep. Gr. 90 15 - Oil pump With pressure relief valve 1.2 MPa Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present If there is any scoring on contact surfaces and gears, replace 16 - Oil pump sprocket Fits onto oil pump shaft in one position only 17 - 25 Nm

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Removing and installing parts of the lubrication system

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18 - Sealing flange Before installing, it must not be dirty Before installing, coat with silicone sealant -D 176 404 A2- Chapter 13-3 Replacing crankshaft seal Chapter 13-3 19 - Oil pump chain 20 - Chain tensioner, 15 Nm When installing, pretension spring and attach 21 - Oil injection nozzle For piston cooling Pay attention to SP No. (right-angle bend) 22 - 27 Nm

Disassembling and assembling oil filter holder


1 - Cap, 25 Nm 2 - Gasket Replace 3 - Oil cooler When installing, move up against the anti-twist lock (in direction of tightening) 4 - Gasket Replace Insert into lugs on oil cooler 5 - Oil pressure switch -F1-, 20 Nm Brown 0.07 MPa (0.7 bar) Cut open gasket ring if leaking and replace Inspect Chapter 17-3 6 - Oil filter holder With integrated overpressure valve 7 - 15 Nm + torque a further 1/4 turn (90) Replace Before tightening, turn in by hand first 8 - Gasket ring Replace 9 - Connection fitting, 30 Nm 10 - Oil feed line For exhaust turbocharger Tighten to 22 Nm 11 - O-ring Replace 12 - Oil filter element When changing oil, fit new O-rings item 11

17-1 page 2

Removing and installing parts of the lubrication system

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17-2

Removing and installing oil pan

1.9/74 TDI Engine, Mechanics; Rep. Gr. 17

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Removing and installing oil pan

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17-2 page 2

Removing and installing oil pan

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17-3

Testing oil pressure and oil pressure switch

1.9/74 TDI Engine, Mechanics; Rep. Gr. 17

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Testing oil pressure and oil pressure switch

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17-3 page 2

Testing oil pressure and oil pressure switch

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19 Cooling
19-1 Parts of cooling system Summary of components

1.9/74 TDI Engine, Mechanics; Rep. Gr. 19

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Parts of cooling system - Summary of components

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19-1 page 2

Parts of cooling system - Summary of components

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19-2

Removing and installing radiator, coolant pump and coolant thermostat

1.9/74 TDI Engine, Mechanics; Rep. Gr. 19

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Removing and installing radiator, coolant pump and coolant thermostat

19-2 page 1

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19-2 page 2

Removing and installing radiator, coolant pump and coolant thermostat

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20 Fuel Supply
20-1 Removing and installing parts of the fuel supply system

1.9/74 TDI Engine, Mechanics; Rep. Gr. 20

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Removing and installing parts of the fuel supply system

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20-1 page 2

Removing and installing parts of the fuel supply system

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20-2

Repairing the accelerator control

1.9/74 TDI Engine, Mechanics; Rep. Gr. 20

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Repairing the accelerator control

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20-2 page 2

Repairing the accelerator control

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21 Turbocharging
21-1 Charge air system with turbocharger I

Removing and installing exhaust turbocharger with component parts


Pay attention to rules for cleanliness 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21. Note
The hose connections are secured with clamps. The charge-air system must be tight. Always replace self-locking nuts.

12345678-

9-

10 11 -

12 13 -

14 15 16 17 -

18 19 20 -

Oil feed line 22 Nm Sealing sleeve 5 Nm 10 Nm Connection fitting, 30 Nm Gasket ring Replace Gasket Replace Check fitting position Support Exhaust turbocharger - cylinder block Washer 25 Nm Replace Coat stud bolts with -G 052 112 A340 Nm Connecting tube Between turbocharger and air filter Flange Connecting hose Connection fitting, 40 Nm Oil return line To cylinder block Tighten to 30 Nm 15 Nm Gasket Replace Exhaust turbocharger Can only be replaced complete with exhaust manifold Removing and installing Chapter 21-2 Inspecting charge pressure control Chapter 21-2 Charge pressure regulating valve and vacuum unit for charge pressure regulating valve are component parts of the exhaust turbocharger and cannot be replaced individually

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Charge air system with turbocharger I

21-1 page 1

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21 22 23 24 25 26 27 28 -

After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to the turbocharger Vacuum line To the solenoid valve for charge pressure limitation -N7520 Nm 20 Nm Replace Shield Front exhaust pipe with catalytic converter Bracket Intake manifold 6 Nm

Removing and installing parts of the charge air cooling


1.9/74 TDI Engine, Mechanics; Rep. Gr. 21

Connection diagram for vacuum hoses


1 - Valve block Component parts of the valve block are: Changeover valve for intake manifold flap -N239 Solenoid valve for exhaust gas recir culation -N18 Solenoid valve for charge pressure control -N752 - Connecting strip Pay attention to the coding when connecting the vacuum hoses 3 - Connecting piece 4 - Vacuum unit For charge pressure control Components of the exhaust gas turbocharger cannot be replaced individually 5 - Vacuum unit 6 - To air filter 7 - Vacuum unit For intake manifold flap 8 - Mechanical exhaust gas recirculation valve 9 - Tandem pump 10 - Distributor part With non-return valve for brake servo unit 11 - Brake servo unit

5 11

10 9 8 7
S21-0043

21-1 page 2

Charge air system with turbocharger I

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21-2

Charge air system with turbocharger II

Remove exhaust turbocharger


1.9/74 TDI Engine, Mechanics; Rep. Gr. 21

Checking charge pressure control


Special tools, test and measuring equipment and auxiliary items required
Hand vacuum pump (e.g. -V.A.G 1390-) Hand multimeter (e.g. -V.A.G 1715-) Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3C Adapter cable set (e.g. -V.A.G 1594 C-) Test box -V.A.G 1598/31-

Test conditions

No fault stored in fault memory 1.9/96 TDI Engine,


Fuel Injection; Rep. Gr. 01

No leaks on the intake and exhaust side No fault on the engine/fuel injection system Engine oil temperature at least 80 C
Test sequence
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the

rear seat and have a second person operate them there. If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.

The charge pressure is measured with vehicle system


tester -V.A.G 1552- when the engine is idling and during a road test.

Connect up the Vehicle system tester -V.A.G 1552and select the address word 01 Engine electronics (the engine must be idling at the time) 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.

Select function

0 4 Initiate basic setting and disBasic setting 11 1400 rpm OFF -> 99 %

play group 0 1 1 . Readout on display:


982 mbar

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Charge air system with turbocharger II

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Note After selecting display group number 011, the idling speed is increased by the engine control unit in display block 1 to 13801420 rpm. The display in display field 2 must switch between off and on every 10 seconds. The following readouts must fluctuate in display fields 3 and 4: Display field 2: off.
Specification in display field 3: Atmospheric pressure

FABIA 2000

1.9/96 TDI Engine, Mechanics

in mbar
Specification in display field 4: 98100%

Display field 2: on.


Specification in display field 3: Atmospheric pressure

in mbar + 100250 mbar


Specification in display field 4: 02%

Continue the test as follows: Press .

Read function

0 8 Read measured value block 1 1.

and select display group 0

Accelerate vehicle in 2nd gear from about 1000 rpm to


3200 rpm. While doing so the accelerator pedal must be fully pressed down.

At about 3000 rpm read off value indicated in display


block. Specification in display field 3: 21002600 mbar If the specified value is not reached:

Reading measured value block 11 3090 rpm 2346 mbar 2281 mbar

-> 6

Conduct final control diagnosis for charge pressure


control solenoid valve -N75- 1.9ltr./96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.

Charge pressure control solenoid valve must operate for this test. While doing so the linkage of the charge pressure control vacuum unit at the bottom of the turbocharger must move back and forward. This linkage must move at least 34 times as long as a vacuum is present in the vacuum system. If the linkage moves and the nominal charge pressure is not reached:

Replace turbocharger.
If the linkage does not move because the charge pressure control solenoid valve is not operating:

Inspect charge pressure control solenoid valve -N75 1.9/96 (TDI) Engine, Mechanics; Rep. Gr. 23.

Inspect vacuum hoses Chapter 21-1 .


If the linkage does not move although the charge pressure control solenoid valve is operating:

21-2 page 2

Charge air system with turbocharger II

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Connect hand vacuum pump to vaccum unit for


charge pressure control valve and inspect linkage for unobstructed movement. If the linkage only moves with difficulty or does not move at all:

Replace turbocharger.

V.A.G 1390

N21-0078

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Charge air system with turbocharger II

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21-2 page 4

Charge air system with turbocharger II

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26 Exhaust System
26-1 Removing and installing parts of the exhaust system

Note
The exhaust manifold is a component part of the ex-

haust turbocharger and therefore must not be replaced individually; removing and installing Chap. 21-2.
Always replace gaskets and self-locking nuts. After performing installation work on the exhaust sys-

tem, make sure the exhaust system is not mounted under tension, the individual components have adequate clearance from the vehicle body and the weight of the exhaust system is evenly distributed over the hangers. 1 - Gasket Replace 2 - Front exhaust pipe with catalytic converter 3 - 25 Nm Replace Coat stud bolts of exhaust turbocharger with hot bolt paste -G 052 112 A3- before installing. 4 - Retaining loop Press off from cross member item 5 to remove front exhaust pipe with catalytic converter 5 - Cross member 6 - 25 Nm 7 - Double clamp Align exhaust system free of stress before tightening 26-1 page 2 Fitting position: bolts at bottom and horizontal Tighten bolted connections evenly 8 - 40 Nm Replace 9 - Spring hanger Pay attention to part number 10 - Separation point For repairs 26-1 page 2 11 - Middle and rear silencer Replace individually when carrying out repairs 26-1 page 2 Align exhaust system free of stress 26-1 page 2

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Removing and installing parts of the exhaust system

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Aligning exhaust system free of stress
Special tools, test and measuring equipment and auxiliary items required
Torque wrench

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Procedure
The exhaust system is aligned when cold. Slacken bolted connections of double clamp between
front silencer with catalytic converter and middle and rear silencer and replace nuts.

Position double clamp at the distance -a- = 5 mm from


the marking on the pipe of the catalytic converter (bolts at bottom and horizontal) and tighten front bolted connection slightly.

S26-0064

Push middle silencer -1- sufficiently far forward into


the double clamp until the dimension -b- of 3...7 mm is achieved between hanger of body and hanger of middle silencer. -Arrow- points in direction of travel.

Tighten bolted connections on the double clamp in


this position. Tightening torque: 40 Nm Note After tightening the double clamp, inspect dimension -band adjust if necessary.

Replacing middle or rear silencer


Special tools, test and measuring equipment and auxiliary items required
Torque wrench Body saw (e.g. -V.A.G.1523-)

A separation point is provided for repair purposes for replacing the middle silencer or rear silencer.

Separate exhaust pipe at right angles at the separation point -arrow 1- with body saw.

When installing, position double clamp -4- at the side


markings -arrow 2- and -arrow 3-.

Align exhaust system free of stress 26-1 page 2. Align rear silencer horizontally. Tighten bolted connections of the double clamp evenly to 40 Nm. Installation position of double clamp: Bolts positioned vertically at front of exhaust pipe.

26-1 page 2

Removing and installing parts of the exhaust system

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Checking the exhaust system for leaks


Start engine and run in idle. Seal off tail pipe for the test duration with suitable
plugs.

Check the connection points for leaks by listening:


Cylinder head/exhaust manifold, exhaust turbocharger/front exhaust pipe with catalytic converter, double clamp at middle or also at rear silencer.

Rectify any fault found.

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Removing and installing parts of the exhaust system

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26-1 page 4

Removing and installing parts of the exhaust system

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26-2
Note

Exhaust gas recirculation system

The exhaust gas recirculation system is operated by

the diesel direct injection system control unit -J248via the EGR valve -N18- to the mechanical exhaust gas recirculation valve.
Inspecting exhaust gas recirculation 1.9/96 (TDI)

Engine, Fuel Injection; Rep. Gr. 23 and exhaust gas recirculation valve -N18- 1.9/96 (TDI) Engine, Fuel Injection; Rep. Gr. 01.
The mechanical exhaust gas recirculation valve with

conically shaped valve tappet makes it possible to achieve different opening cross-sections at different valve strokes.
Connection diagram for vacuum hoses Chap. 21-1.

1 - Intake manifold 2 - O-ring Replace 3 - Vacuum setting element 4 - 5 Nm 5 - Mechanical exhaust gas recirculation valve Component part of the induction pipe Must be replaced together with the induction pipe Check 26-2 page 2 6 - Induction pipe With mechanical exhaust gas recirculation valve and control flap 7 - 10 Nm 8 - Gasket Replace 9 - 25 Nm 10 - Connecting tube 11 - Gasket Replace Check fitting position 12 - 6 Nm 13 - Sealing sleeve

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Exhaust gas recirculation system

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Testing mechanical exhaust gas recirculation valve
Special tools, test and measuring equipment and auxiliary items required
Hand vacuum pump (e.g. -V.A.G 1390-)

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Test sequence

Remove engine cover -arrows-. Disconnect vacuum hose on mechanical exhaust-gas


recirculation valve.

Connect hand vacuum pump to valve and operate


pump. The diaphragm rod must move in the direction of the vacuum connection -Pfeil-.

V.A.G 1390

Detach hose of hand vacuum pump from mechanical


exhaust gas recirculation valve. The diaphragm rod must move back to its original position against the -direction of the arrow-.

S13-0161

26-2 page 2

Exhaust gas recirculation system

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