Engine ASZ

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
List of Supplements to Workshop Manual
FABIA 2000
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
List of Supplements
Edition 07.03 S00.5327.00.20
FABIA 2000
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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page page page page page page
1 2 2 2 3 1
FABIA 2000
1.9/96 TDI Engine, Mechanics page 2
- Testing mechanical exhaust gas recirculation valve ............................................. 26-2
II
Table of Contents
Edition 07.03 S00.5327.00.20
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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
00-1 page 1
00
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00-1 page 2
Technical Data
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10
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
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10-1 page 2
Removing and Installing Engine
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13
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
13
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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
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13
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13-2 page 2
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13
13-3
Removing and installing sealing flange and flywheel
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13
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13-3 page 2
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13
13-4
Crankshaft, Piston and Conrod
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13
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13-4 page 2
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15
15 Cylinder Head, Valve Gear

15-1 Removing and installing cylinder head
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Removing and installing cylinder head
15-1 page 1
15
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15-1 page 2
Removing and installing cylinder head
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15
15-2
Repairing Valve Gear
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15
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15-2 page 2
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15
15-3
Camshaft
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Camshaft
15-3 page 1
15
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15-3 page 2
Camshaft
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15
15-4
Valve seats, valves guides, valve stem seals
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15
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15-4 page 2
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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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17
FABIA 2000
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
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17-2
Removing and installing oil pan
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17-3
Testing oil pressure and oil pressure switch
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17-3 page 2
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19 Cooling
19-1 Parts of cooling system Summary of components
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Parts of cooling system - Summary of components
19-1 page 1
19
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19-1 page 2
Parts of cooling system - Summary of components
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19
19-2
Removing and installing radiator, coolant pump and coolant thermostat
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19-2 page 1
19
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19-2 page 2
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20 Fuel Supply
20-1 Removing and installing parts of the fuel supply system
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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
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21
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
21
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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

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
21-2
Charge air system with turbocharger II
Remove exhaust turbocharger

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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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
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
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21
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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26
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
26-1 page 1
26
Aligning exhaust system free of stress
Torque wrench
FABIA 2000
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

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.
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26
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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26
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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Testing mechanical exhaust gas recirculation valve
Hand vacuum pump (e.g. -V.A.G 1390-)
FABIA 2000
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
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Service

1.9/96 TDI Engine, Mechanics

Service Department. Technical Information

Printed in Czech Republic S00.5327.00.20

Printed in Czech Republic S00.5327.00.20

1.9/96 TDI Engine, Mechanics

List of Supplements to Workshop Manual

Subject Basic Edition

Article Number S00.5327.00.20

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

10 Removing and Installing Engine

15 Cylinder Head, Valve Gear

page page page page page page

1.9/96 TDI Engine, Mechanics page 2

- Testing mechanical exhaust gas recirculation valve ............................................. 26-2

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

10 Removing and Installing Engine

Edition 07.03 S00.5327.00.20

Removing and Installing Engine

1.9/96 TDI Engine, Mechanics

Removing and Installing Engine

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

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

Edition 07.03 S00.5327.00.20

Removing and installing V-ribbed belt

1.9/96 TDI Engine, Mechanics

Removing and installing V-ribbed belt

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

Removing and installing, tightening the timing belt

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

Edition 07.03 S00.5327.00.20

Removing and installing, tightening the timing belt

1.9/96 TDI Engine, Mechanics

Removing and installing, tightening the timing belt

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

Removing and installing sealing flange and flywheel

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

Edition 07.03 S00.5327.00.20

Removing and installing sealing flange and flywheel

1.9/96 TDI Engine, Mechanics

Removing and installing sealing flange and flywheel

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

Crankshaft, Piston and Conrod

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

Edition 07.03 S00.5327.00.20

Crankshaft, Piston and Conrod

1.9/96 TDI Engine, Mechanics

Crankshaft, Piston and Conrod

Edition 07.03 S00.5327.00.20

1.9/96 TDI Engine, Mechanics

15 Cylinder Head, Valve Gear