Skoda 2000 Fabia Gebrauchsanweisung

Service 5

Service Department. Technical Information Printed in Czech Republic

S00.5306.00.20

Workshop Manual

FABIA 2000 ³

1.4/55; 1.4/74 Engine - Mechanical Components

Edition 08.99

Engine code AUA AUB BBY BBZ BKY

Service

The Workshop Manual is intended only for use within the Organisation Škoda.

It is not permitted to pass it on to other persons.

Printed in Czech Republic

S00.5306.00.20

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

List of SupplementsEdition 05.05

S00.5306.06.20

List of Supplements to Workshop Manual

FABIA 2000 ³

1.4/55; 1.4/74 Engine - Mechanical Components

Edition 08.99

Suppleme

nt Edition Subject Article Number

08.99 Basic Edition S00.5306.00.20

1 07.00 Supplement to Basic Edition S00.5306.01.20

2 05.01 Modifications in Rep. Gr. 00, 10, 13, 15, 17 and 19 S00.5306.02.20

3 06.02 Additions to engines with the engine codes BBY, BBZ S00.5306.03.20

4 09.03 Modifications in Rep. Gr. 00, 10, 13, 15 and 17 S00.5306.04.20

5 05.04 Supplement to engine with the engine codes BBY S00.5306.05.20

6 05.05 Modifications in the Rep. Gr. 00, 13, 15, 17, 19, 20 and 26 S00.5306.06.20

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

List of Supplements Edition 05.05

S00.5306.06.20

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

Table of ContentsEdition 05.05

S00.5306.06.20 I

Table of Contents

00 – Technical Data

Technical Data ..........................................................................................

- Engine number .........................................................................................

- Engine characteristics ................................................................................

10 – Removing and Installing Engine

Removing and Installing Engine ....................................................................

- Removing engine ......................................................................................

- Removing ...............................................................................................

- Attaching engine to assembly stand ................................................................

- Installing ................................................................................................

- Tightening torques ....................................................................................

13 – Crankgear

Disassembling and assembling engine ...........................................................

- Summary of components of ribbed V-belt on vehicles fitted with AC .........................

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

- Summary of components of timing belt ...........................................................

- Removing, installing and tensioning the toothed belt and inspecting the semi-automatic

toothed belt tensioning pulley ........................................................................

Removing and installing cylinder block ..........................................................

- Aluminium cylinder block .............................................................................

- Replacing gasket ring for crankshaft -on the belt pulley side- ..................................

- Removing and installing drive plate ................................................................

- Replacing the sealing flange for crankshaft - flywheel side .....................................

Disassembling and assembling piston and conrod ............................................

15 – Cylinder Head, Valve Gear

Removing and installing cylinder head ...........................................................

- Engines with engine identification characters AUA, AUB, BBY, BBZ. ........................

- Engines with engine identification letters BKY ....................................................

- removing and installing cylinder head cover ......................................................

- Removing and installing cylinder head .............................................................

- Testing the compression .............................................................................

Repairing Valve Gear ..................................................................................

- Reworking valve seats ................................................................................

- Replacing camshaft gasket rings ...................................................................

- Inspect valve guides ..................................................................................

- Replacing valve stem seals ..........................................................................

17 – Lubrication

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

- Lubrication system - Overview of components ...................................................

- Removing and installing oil pan .....................................................................

- Removing and installing oil pump ...................................................................

- Testing oil pressure and oil pressure switch ......................................................

19 – Cooling

00-1 page 1

10-1 page 1

10-1 page 5

10-1 page 7

13-1 page 1

13-1 page 2

13-1 page 3

13-1 page 4

13-2 page 1

13-2 page 2

13-2 page 3

13-2 page 4

13-3 page 1

15-1 page 1

15-1 page 3

15-1 page 4

15-1 page 7

15-1 page 10

15-2 page 1

15-2 page 4

15-2 page 6

15-2 page 7

15-2 page 8

17-1 page 1

17-1 page 3

17-1 page 4

17-1 page 6

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

Table of Contents Edition 05.05

S00.5306.06.20

Parts of the Cooling System .........................................................................

- Parts of the cooling system fitted to body .........................................................

- Coolant regulator - Summary of components .....................................................

- Coolant pump - Summary of components .........................................................

- Connection diagram for coolant hoses .............................................................

- Draining and filling up coolant .......................................................................

- Removing and installing radiator ....................................................................

- Removing and installing coolant pump ............................................................

20 – Fuel Supply

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

- Removing and installing fuel tank with attached parts and fuel filter ..........................

- Safety precautions when working on the fuel supply system ...................................

- Rules of cleanliness ...................................................................................

- Removing and installing the fuel delivery unit ....................................................

- Removing and installing the fuel gauge sender ..................................................

- Removing and installing the fuel tank ..............................................................

- Inspecting the fuel pump and fuel system .........................................................

- Inspecting the operating and holding pressure of the fuel, inspecting the non-return valve

of the fuel pump .......................................................................................

- Disconnecting the fuel delivery unit with crash signal ...........................................

Inspecting Electronic Power Control (Electronic throttle) ....................................

- Summary of components ............................................................................

Activated Charcoal Filter System ..................................................................

- Summary of components of activated charcoal filter system ...................................

26 – Exhaust System

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

- Exhaust manifold with pre-catalytic converter, front exhaust pipe with catalyst and

component parts - Engines with engine identification characters AUA, AUB, BBY, BBZ .

- Exhaust manifold, front exhaust pipe with pre-catalytic converter and catalyst and

component parts - Engine with engine identification characters BKY ........................

- Silencer with hangers .................................................................................

- Testing the catalyst ...................................................................................

Exhaust gas recirculation system .................................................................

- Summary of components of exhaust gas recirculation - engines with engine identification

characters AUA, AUB, BBY, BBZ. ..................................................................

- Summary of components of . exhaust gas recirculation - engine with engine identification

characters BKY ³05.05 .............................................................................

- Check exhaust gas recirculation potentiometer -G212- .........................................

19-1 page 1

19-1 page 3

19-1 page 4

19-1 page 5

19-1 page 6

19-1 page 7

20-1 page 1

20-1 page 3

20-1 page 4

20-1 page 5

20-1 page 6

20-1 page 11

20-1 page 14

20-2 page 1

20-3 page 1

26-1 page 1

26-1 page 3

26-1 page 4

26-2 page 1

26-2 page 2

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

Technical DataEdition 05.05

S00.5306.06.20

00-1 page 1

00-1 Technical Data

Engine number

The engine number („engine identification characters“

and „serial number“) is indicated on the end face of the

cylinder block at the gearbox side below the coolant ther-

mostat housing.

In addition, a sticker with the „engine identification char-

acters“ and „serial number“ is affixed to the timing belt

guard.

The engine identification characters are also indicated on

the vehicle data sticker.

Engine characteristics

00 – Technical Data

Engine identification

characters

AUA BBY BKY AUB BBZ

Manufactured 05.00 ³03.02 04.02 ³05.04 05.04 ³08.99 ³05.02 05.02 ³

Displacement l 1,390 1,390 1,390 1,390 1,390

Valves per cyl-

inder

44444

Power output kW at rpm 55/5000 55/5000 55/5000 74/6000 74/6000

Torque Nm at

rpm

126/3800 126/3800 126/3800 126/4400 126/4400

Bore ∅mm 76,5 76,5 76,5 76,5 76,5

Stroke mm 75,6 75,6 75,6 75,6 75,6

Compression 10,5 10,5 10,5 10,5 10,5

Fuel - RON min. 95 unleaded1)

1) At least 91 RON in exceptional cases, although engine output is reduced.

95 unleaded1) 95 unleaded1) 98 unleaded2)

2) At least 95 RON in exceptional cases, although engine output is reduced.

98 unleaded2)

Ignition system, fuel injec-

tion

4LV 4MV 4TV 4LV 4MV

Knock control yes yes yes yes yes

Self-diagnosis yes yes yes yes yes

Lambda control 2 Lambda

probes

2 Lambda

probes

2 Lambda

probes

2 Lambda

probes

2 Lambda

probes

Exhaust gas recirculation yes yes yes yes yes

Catalytic converter 2 Catalysts 2 Catalysts 2 Catalysts 2 Catalysts 2 Catalysts

Turbocharging no no no no no

Exhaust limits conforming

EU-4, EU-3

DDK, EU-2

DDK

EU-4, EU-3

DDK, EU-2

DDK

EU-4, EU-2

DDK

EU-4, EU-3

DDK, EU-2

DDK

EU-4, EU-2

DDK

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

Technical Data Edition 05.05

S00.5306.06.20

00-1 page 2

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

Removing and Installing EngineEdition 09.03

S00.5306.04.20

10-1 page 1

10-1 Removing and Installing

Engine

Removing engine

Special tools, test and measuring equipment and

auxiliary items required

♦Lifting device, e.g. -MP 9-201-

♦Tensioning block -MP 9-101-

♦Engine mount -MP 1-202-

♦Workshop crane, e.g. - V.A.G 1202 A-

♦Catch pan, e.g. -V.A.G 1306 -

♦Grease -G 000 100- (for vehicles with gearbox)

♦Cable strap

Removing

All cable straps that have been loosened or cut open

when the engine was removed must be fitted again in the

same location when the engine is installed again.

–First check whether a radio set with anti-theft coding

has been fitted. If this is the case obtain coding.

–Disconnect the earth strap from the battery with the ig-

nition off.

–Disconnect positive cable in fuse holder at battery -ar-

row-.

–Remove cable from battery to fuse holder at battery

and place to the side.

–Remove battery tray and take battery out of battery

box.

–Remove battery box -arrows-.

–Disconnect the positive wire from the battery to the

starter (is removed together with the engine/gearbox

unit).

10 – Removing and Installing Engine

Note

S10-0110

S27-0064

FABIA 2000 ³1.4/55; 1.4/74 Engine - Mechanical Components

Removing and Installing Engine Edition 09.03

S00.5306.04.20

10-1 page 2

–Pull off hose -1- (for engines as of 04.02) and remove

the engine guard -2- with air filter upwards -arrows-.

–Open cap of expansion reservoir to release pressure

in the cooling system.

–Release the screws at the bottom of the engine cover

-arrows- and remove cover.

–Unscrew front exhaust pipe from the exhaust manifold

⇒Chapter 26-1 and tie to body member.

–Remove pendulum support -arrows-.

–Unscrew drive shaft to the right and left of the gearbox

and tie up ⇒Body; Rep. Gr. 40.

–Drain coolant ⇒Chapter 19-1.

–Pull off coolant hose at the top and bottom of the radi-

ator.

When disconnecting hoses the residual coolant flows out!

Make sure a catch pan is positioned underneath.

–Disconnect the plug connections on the connector be-

low the starter:

♦Plug connection for lambda probe cable

♦Plug connection to AC compressor cable

♦Plug connection to generator cable

–Disconnect plug connection of the reverse gear switch

from the gearbox.

–Remove front bumper ⇒Body work; Rep. Gr. 63.

–Disconnect the following plug connections:

S10-0101

S10-0100

Note

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