Engines Awy, Azq, BMD, Bme

Service
Workshop Manual
FABIA 2000
Edition 08.02
Engine code
1.2/40; 1.2/47 Engine, Mechanical Components

AWY AZQ BMD BME
Service Department. Technical Information
Printed in Czech Republic S00.5322.00.20
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 S00.5322.00.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components
List of Supplements to Workshop Manual
FABIA 2000
1.2/40; 1.2/47 Engine, Mechanical Components
Edition 08.02
Supplement 1 2 3
Edition 08.02 04.03 06.04 12.04
Subject Basic Edition Changes for engine with engine identification characters AZQ Changes for engine with engine identification characters BMD Changes for engine with engine identification characters BME
Article Number S00.5322.00.20 S00.5322.01.20 S00.5322.02.20 S00.5322.03.20
Edition 12.04 S00.5322.03.20
List of Supplements
List of Supplements
Edition 12.04 S00.5322.03.20
Table of Contents
00 Technical Data
Technical Data .......................................................................................... 00-1 page 1
10 Removing and Installing Engine

Removing and Installing Engine .................................................................... 10-1 - Removing engine ...................................................................................... 10-1 - Installing the engine ................................................................................... 10-1 - Tightening torques .................................................................................... 10-1 - Assembly bracket ...................................................................................... 10-1 page page page page page 1 1 4 5 5
13 Crankgear
Removing and installing V-ribbed belt ............................................................ 13-1 - Summary of components ............................................................................. 13-1 Disassembling and assembling engine ........................................................... 13-2 - Valve control drive - summary of components ... ................................................. 13-2 - Removing and installing the timing gear cover ................................................... 13-2 Removing and installing the camshaft sprocket, setting the timing ....................... 13-3 - Inspect setting of the timing .......................................................................... 13-3 - Removing and installing the camshaft sprocket, setting the timing ............................ 13-3 Removing and installing the gasket ring and flywheel ........................................ 13-4 - Replacing gasket ring for crankshaft - on the belt pulley side .................................. 13-4 - Replacing the gasket ring for the crankshaft - flywheel side .................................... 13-4 - Replacing ring gear ................................................................................... 13-4 page page page page page page page page page page page page 1 1 1 1 5 1 1 3 1 2 2 3
15 Cylinder Head, Valve Gear

Removing and installing cylinder head ........................................................... 15-1 - Summary of components ............................................................................. 15-1 - Removing and installing cylinder head ............................................................. 15-1 - Testing the compression ............................................................................. 15-1 Repairing the valve gear - Part 1 .................................................................... 15-2 - Summary of components ............................................................................. 15-2 - Removing and installing camshaft .................................................................. 15-2 Repairing the valve gear - Part 2 .................................................................... 15-3 - Replacing valve stem seal ........................................................................... 15-3 - Inspect valve guides .................................................................................. 15-3 - Reworking valve seats ................................................................................ 15-3 page page page page page page page page page page page 1 1 4 5 1 1 3 1 1 3 4
17 Lubrication
Removing and installing parts of the lubrication system - Part 1 .......................... 17-1 - Summary of components ............................................................................. 17-1 - Dismantling and assembling the oil filter ........................................................... 17-1 Removing and installing parts of the lubrication system - Part 2 .......................... 17-2 - Removing and installing oil pan ..................................................................... 17-2 - Removing and installing oil pump ................................................................... 17-2 Testing oil pressure and oil pressure switch .................................................... 17-3 page page page page page page page 1 1 4 1 1 2 1
19 Cooling
Edition 12.04 S00.5322.03.20 Table of Contents
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Removing and installing parts of the cooling system - Summary of components .... 19-1 - Parts of the cooling system fitted to body ......................................................... 19-1 - Parts of cooling system engine side ................................................................ 19-1 - Connection diagram for coolant hoses ............................................................. 19-1 Removing and installing parts of the cooling system - Part 1 ............................... 19-2 - Draining and filling up coolant ....................................................................... 19-2 - Checking the coolant system for tightness ........................................................ 19-2 Removing and installing parts of the cooling system - Part 2 ............................... 19-3 - Removing and installing radiator .................................................................... 19-3 - Removing and installing coolant pump ............................................................ 19-3 page page page page page page page page page page 1 2 3 5 1 1 2 1 1 2
20 Fuel Supply
Removing and installing parts of the fuel supply system .................................... 20-1 - Removing and installing fuel tank with attached parts and fuel filter .......................... 20-1 - Safety precautions when working on the fuel supply system ................................... 20-1 - Rules of cleanliness ................................................................................... 20-1 - Removing and installing the fuel delivery unit .................................................... 20-1 - Removing and installing the fuel gauge sender .................................................. 20-1 - Removing and installing the fuel tank .............................................................. 20-1 - Inspecting the fuel delivery unit and fuel system ................................................. 20-1 - Inspecting the operating and holding pressure of the fuel, inspecting the non-return valve of the fuel delivery unit .............................................................................. 20-1 - Disconnecting the fuel delivery unit with crash signal ........................................... 20-1 Inspecting the electronic power control (electronic throttle) ................................ 20-2 - Summary of components ............................................................................ 20-2 Activated charcoal filter system .................................................................... 20-3 - Summary of components of activated charcoal filter system ................................... 20-3 page page page page page page page page page page page page page page 1 1 1 1 1 1 1 2 2 2 1 1 1 1
26 Exhaust System
Removing and installing parts of the exhaust system ........................................ 26-1 - Silencer with hangers ................................................................................. 26-1 - Aligning exhaust system free of stress ............................................................. 26-1 - Replacing front or rear silencer ..................................................................... 26-1 - Checking the exhaust system for leaks ............................................................ 26-1 Exhaust gas recirculation system .................................................................. 26-2 - Exhaust gas recirculation system - Summary of components .................................. 26-2 page page page page page page page 1 4 4 5 5 1 1
II
Table of Contents
Edition 12.04 S00.5322.03.20
00
00 Technical Data
00-1 Technical Data
Engine number The engine number (engine identification characters and serial number) is located in the front left on the cylinder block at the engine/gearbox joint -arrow B-. In addition, a sticker with engine identification characters and serial number is affixed to the timing gear cover -arrow A-. The engine identification characters are also indicated on the vehicle data sticker.
Pruef- und Einstellarbeiten ACHTUNG! Bei XXX 000 000 Motorkennbuchstaben:
Engine characteristics Engine identification characters Manufactured Exhaust limits conforming to Displacement Power output Torque Bore Stroke Compression Firing order Fuel - RON Fuel injection and ignition system Lambda control Catalytic converter Turbocharging Exhaust gas recirculation Secondary air system Camshaft adjustment
1) 2)
AWY 02.02 05.04 EU-4, EU-3 DDK, EU-2 DDK l 1,198 40/4750 106/3000 76,5 86,9 10,3 : 1 1-2-3 95 unleaded1) 95 Simos 3PD 2 Lambda probes2) 1 Catalyst no no no no
BMD 05.04 EU-4, EU-2 DDK 1,198 40/4750 108/3000 76,5 86,9 10,3 : 1 1-2-3 unleaded1) 95 Simos 3PG 2 Lambda probes2) 1 Catalyst no no no no
AZQ 01.03 12.04 EU-4, EU-3 DDK, EU-2 DDK 1,198 47/5400 112/3000 76,5 86,9 10,5 : 1 1-2-3 unleaded1) Simos 3PE 2 Lambda probes 1 Catalyst no yes no no
BME 12.04 EU-4, EU-2 DDK 1,198 47/5400 112/3000 76,5 86,9 10,5 : 1 1-2-3 95 unleaded1) Simos 3PG 2 Lambda probes 1 Catalyst no yes no no
kW at rpm Nm at rpm mm mm
At least 91 RON in exceptional cases; the engine output is reduced however Engine version complying with exhaust emission standard EU-2 DDK only with one lambda probe before catalyst
Edition 12.04 S00.5322.03.20
Technical Data
00-1 page 1
00
00-1 page 2
Technical Data
Edition 12.04 S00.5322.03.20
10
10 Removing and Installing Engine

10-1 Removing and Installing Engine
Special tools, test and measuring equipment and auxiliary items required
Workshop crane, e.g. -V.A.G 1202 A Catch pan e.g. - V.A.G 1306 Pliers for spring strap clips Engine mount -MP 1-202 Assembly stand -MP 9-101 Lifting device -MP 9-201 Grease -G 000 100 Hot bolt paste -G 052 112 A3 Wire Adhesive tape
Removing engine
Note
The engine is removed towards the front together with
the gearbox.
Jacking up points for raising the vehicle Inspection
and Maintenance.
Pay attention to the correct assignment of the connec-
tors, if necessary mark.
If the battery is disconnected and reconnected, carry
out certain additional operations Electrical System; Rep. Gr. 27.
Procedure
Disconnect the battery-earth strap with the ignition off. Remove noise insulation -arrows-. Unscrew the drive shaft to the right and left of the
gearbox flange Chassis; Rep. Gr. 40. Raise drive shafts and secure. Removing exhaust pipe Chapter 26-1. Drain coolant Chapter 19-2. Remove engine cover with air filter 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. Rep. Gr. 27.
S10-0135
1 2
Remove battery and battery tray Electrical System; Unplug connector -1- from the engine control unit. Separate plug connection -2-. Unclip cable clip -3- -arrows-.
S10-0142
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Removing and Installing Engine
10-1 page 1
10
The engine is removed together with the cable harness.
Disconnect all cables for the engine, gearbox, starter

motor and radiator which are will get in the way during removal.
Remove the coolant hose which connects the coolant

regulator to the heat exchanger.
Remove the vacuum hose from the brake servo unit.

WARNING! The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.
Detach the fuel feed line -5-, or fuel return line -4- and
ventilation line -3- by pressing on their release buttons.
Unplug the plug connection -2- and remove solenoid

valve for the activated charcoal filter system -N80- -1-.
Remove the cooling system ventilation hose -7- from

the coolant pipe at the front.
Remove the coolant hose -6- on the pipe behind the

expansion reservoir.
Remove Bowden cable support Manual gearbox

002; Rep. Gr. 34.
Remove the slave cylinder of the hydraulic clutch

Manual gearbox 002; Rep. Gr. 30. and bottom of the connection fittings.
Separate the coolant hose from the radiator at the top Unbolt the pendulum support -arrows-.
Vehicles without air conditioning
Removing the lock carrier Body work; Rep. Gr. 50.

For vehicles with air conditioning
S34-0403
WARNING! Do not open the refrigerant circuit of the air conditioning system.
Remove the V-ribbed belt Chapter 13-1. Remove connector from the AC compressor. Remove AC compressor with the refrigerant lines connected.
Secure the AC compressor -1- to the lock carrier -arrow-.
Remove the lock carrier with the radiator and con-
denser Body work; Rep. Gr. 50, swivel to the side and position on a suitable base -2- on which there is no risk of tilting.
S10-0136
10-1 page 2
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Note
Do not buckle the refrigerant lines. Use cloths to protect the right headlight glass from
damage, removing the headlight if necessary.
Continued for all vehicles
Hook lifting device -MP 9-201- into the engine lifting

eyes and raise slightly using the workshop crane. Caution! Use securing pins on the hooks and rig pins to prevent release.
Release screws -1-.
Unscrew the screws -arrows- from the gearbox

mount.
Slightly lower the engine with gearbox and pull out

carefully towards the front.
Remove the engine from the gearbox.
S10-0120
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Secure the engine with engine mount -MP 1-202- (using 3 screws -arrows-) on the assembly stand -MP 9-101- for performing assembly work.
Installing the engine

Note
Always replace the seals and gaskets during assem-
bly work.
Always replace self-locking nuts. Tightening torques 10-1 page 5. Assembly bracket 10-1 page 5.
Procedure
Installation is performed in the reverse order. Pay attention to the following points:
Check whether the dowel sleeves for centering the

gearbox are present in the cylinder block 2; insert if necessary.
If necessary check the centering of the clutch driver

disc.
Inspect clutch release bearing for wear, replace if necessary.
Grease the drive shaft serration with grease

-G 000 100-.
When installing engine/gearbox unit, ensure adequate clearance to neighbouring components.
Align the engine and gearbox so that they are tensionfree.
Install the slave cylinder of the hydraulic clutch

Gearbox 002; Rep. Gr. 30.
Adjust the gearshift mechanism and shift cables

Manual gearbox 002; Rep. Gr. 34.
Install the AC compressor Chapter 13-1. Install the V-ribbed belt Chapter 13-1.
Continued for all vehicles
Install the drive shaft on the right and left of the gearbox Chassis; Rep. Gr. 40.
Align the front exhaust pipe with catalyst and fit the exhaust system free of stress Chapter 26-1.
Electrical connections and proper routing Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Install coolant hoses Chapter 19-1.
10-1 page 4
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Note The drained off coolant must only be then re-used if the cylinder block, cylinder head, radiator or heat exchanger were not replaced.
Top up coolant Chapter 19-2. Check oil level before starting the engine. Adapt engine control unit to the throttle valve control
unit -J338- 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
Read the readiness code and generate it 1.2/40;

1.2/47 Engine, Fuel Injection; Rep. Gr. 01.
Perform a test drive, interrogate fault memory and delete it 1.2/40; 1.2/47, Fuel Injection; Rep. Gr. 01.
Tightening torques
Note
Tightening torques apply only for lightly greased,
oiled, phosphatized or blackened nuts and screws. allowed. Under no circumstances use Molykote.
Other lubricants such as engine and gearbox oil are Do not use degreased parts. Unless otherwise indicated the following tightening
torques apply:
Component Screws/nuts M6 M7 M8 M10 M12 deviations: Engine mounting, gearbox mount, pendulum support Engine to gearbox connecting screws M10
Nm 9 15 23 40 60 Assembly bracket 45
Assembly bracket
Tightening torques
Engine mounting 1 - 20 Nm + 90 (1/4 turn) - replace 2 - 30 Nm + 90 (1/4 turn) - replace
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Gearbox mounting 1 - 50 Nm + 90 (1/4 turn) - replace 2 - 40 Nm + 90 (1/4 turn) - replace
2 1 1
1
Hinged bracket Note Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier. 1 - 30 Nm + 90 (1/4 turn) - replace 2 - 40 Nm + 90 (1/4 turn) - replace
S10-0125
1 2
S10-0133
10-1 page 6
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13
13 Crankgear
13-1 Removing and installing V-ribbed belt
Summary of components
Note
Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used
belt may destroy it.
Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it. Vehicles without an air-conditioning system do not have an air-conditioning compressor or guide pulley.
1 - 22 Nm 2 - Belt pulley on the coolant pump 3 - Trim 4 - Tensioner with tensioning pulley do not remove the tensioning pulley. 5 - 40 Nm 6 - Generator to facilitate positioning of the generator on the cylinder block, drive the threaded bushings of the screws slightly backwards 7 - Guide pulley 8 - Washer Camber towards the outside 9 - Belt pulley for crankshaft 10 - 90 Nm + torque a further 90 (1/4 turn) replace interlock the crankshaft with a drift -T10121- for loosening and tightening it up Chapter 13-3 11 - Distance sleeve for generator 12 - 23 Nm 13 - Distance sleeve for the AC compressor 14 - Dowel sleeves for AC compressor must be inserted in the cylinder block 15 - V-ribbed belt Routing of the V-ribbed belt vehicles without air conditioning Fig. 1 in 13-1 page 2 Vehicles with air conditioning Fig. 2 in 13-1 page 3 removing and installing 13-1 page 2
Edition 08.02 S00.5322.00.20
Removing and installing V-ribbed belt
13-1 page 1
13
Removing
Mark the rotation direction of the V-ribbed belt. Lever off the cover for the tensioning roller -A-. Swing out the tensioning roller -A- with Torx key 50 -Bin the direction of travel up to the stop and remove the V-ribbed belt. Note The tensioning roller can be interlocked by inserting a rig pin.
Installing
Note
Inspect V-ribbed belt Inspection and Maintenance. Before fitting the V-ribbed belt make sure that all as-
semblies (generator, coolant pump and AC compressor) are securely mounted. guide pulley.
Check smooth operation of belt pulley, tensioning and Pay attention to the rotation direction of already used
V-ribbed belts. guide pulley.
Position the V-ribbed belt on the belt pulleys and Swing out the tensioning roller -A- with Torx key 50 -Bin the direction of travel up to the stop and lay the Vribbed belt in place.
Press on the cover of the tensioning roller -A-. Start engine and check belt run.
Fig. 1: 1234V-ribbed belt run - without an air conditioning system
Belt pulley - crankshaft Belt pulley - coolant pump Tensioning pulley Belt pulley - generator
13-1 page 2
Edition 08.02 S00.5322.00.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Fig. 2: 123456V-ribbed belt run - with an air conditioning system
13
Belt pulley - crankshaft Belt pulley - coolant pump Tensioning pulley Belt pulley - generator Belt pulley - AC compressor Guide pulley
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13
13-1 page 4
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13
13-2
Disassembling and assembling engine
Valve control drive - summary of components

WARNING! Top and bottom part of cylinder block must not be disassembled. For engine with engine identification characters AWY, BMD 1 - Cylinder head with cover removing and installing Chapter 15-1 2 - Cylinder block 2 part do not separate 3 - Crankshaft gear for balancing shaft draft Wheel position for balancing shaft gear Fig. 2 in 13-2 page 5 4 - Balancing shaft gear do not remove Wheel position for crankshaft gear Fig. 2 in 13-2 page 5 5 - Chain tensioner for the oil pump 6 - Oil pump removing and installing Chapter 17-2 7 - Guide rail 8 - Chain sprocket on the crankshaft for the camshaft drive interlocked with spring on the crankshaft 9 - Chain sprocket on the crankshaft for the oil pump drive not interlocked on the crankshaft 10 - Oil pump chain 11 - Oil pump sprocket 12 - Oil pan removing and installing Chapter 17-2 13 - 9 Nm 14 - Cover Oil pump sprocket 15 - 20 Nm + torque a further 90 (1/4 turn) replace 16 - O-ring replace if damaged replace the sealing of the housing with silicone sealant 17 - Housing Replace together with O-ring item 16 Replace silicone sealant sealing with O-ring item 16
Edition 12.04 S00.5322.03.20 Disassembling and assembling engine
13-2 page 1
13
fit onto cleaned crankshaft install only after putting the timing gear cover in place otherwise the gasket ring can be damaged 18 - Gasket ring Replace in case of damage Chap. 13-4 replace together with housing item 17 for crankshaft on the belt pulley side Neither grease nor oil sealing lip of sealing ring before installing remove grease residue on the housing with a clean cloth 19 - Belt pulley - crankshaft 20 - 90 Nm + torque a further 90 (1/4 turn) replace Interlock crankshaft with an assembly device -T10121- for removing and installing it Chapter 13-3 21 - 25 Nm 22 - 45 Nm 23 - 10 Nm if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have sealant on them 24 - To intake manifold 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24 25 - The vacuum regulating valve (PCV valve) pay attention to the spare part number 26 - O-ring replace if damaged 27 - Timing gear cover removing and installing 13-2 page 5 28 - Oil separator clipped in the steering wheel housing 29 - 20 Nm + torque a further 90 (1/4 turn) replace Interlock camshaft with an assembly device -T10120- for removing and installing it Chapter 13-3 30 - Timing chain tensioning Fig. 1 in 13-2 page 5 31 - Camshaft sprocket not interlocked on the camshaft but simply fitted onto it removing and installing, setting the timing Chapter 13-3 32 - Bolts, 18 Nm for tensioning rail or possibly also guide rail 33 - Tensioning rail interlock tensioner Fig. 1 in 13-2 page 5 34 - Hydraulic control chain tensioner tension (loosen control chain) Fig. 1 in 13-2 page 5
13-2 page 2
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components For engine with engine identification characters AZQ, BME 1 - Cylinder head with cover removing and installing Chapter 15-1 2 - Cylinder block 2 part do not separate 3 - Balancing shaft 4 - Balancing shaft gear do not remove Wheel position for crankshaft gear Fig. 2 in 13-2 page 5 5 - Oil pump removing and installing Chapter 17-2 6 - Bolts, 18 Nm for tensioning rail or possibly also guide rail 7 - Guide rail 8 - Chain sprocket on the crankshaft for the camshaft drive interlocked with spring on the crankshaft 9 - Chain sprocket on the crankshaft for the oil pump drive not interlocked on the crankshaft 10 - Oil pump chain 11 - Oil pump sprocket 12 - Oil pan removing and installing Chapter 17-2 13 - 9 Nm 14 - Cover Oil pump sprocket 15 - 20 Nm + torque a further 90 (1/4 turn) replace 16 - O-ring replace if damaged replace the sealing of the housing with silicone sealant 17 - Housing Replace together with O-ring item 16 Replace silicone sealant sealing with O-ring item 16 fit onto cleaned crankshaft install only after putting the timing gear cover in place otherwise the gasket ring can be damaged 18 - Gasket ring Replace in case of damage Chap. 13-4 replace together with housing item 17 for crankshaft on the belt pulley side Neither grease nor oil sealing lip of sealing ring before installing remove grease residue on the housing with a clean cloth 19 - Belt pulley - crankshaft
13
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13
20 - 90 Nm + torque a further 90 (1/4 turn) replace Interlock crankshaft with an assembly device -T10121- for removing and installing it Chapter 13-3 21 - 25 Nm 22 - 50 Nm 23 - 8 Nm + torque a further 90 (1/4 turn) if no blue sealant mass is left in the thread of the M6 screws, replace the screws for ones which have sealant on them 24 - To intake manifold 1.2/47 Engine, Fuel Injection; Rep. Gr. 24 25 - 10 Nm 26 - The vacuum regulating valve (PCV valve) pay attention to the spare part number 27 - O-ring replace if damaged 28 - Timing gear cover removing and installing 13-2 page 5 29 - Cover 30 - O-ring replace if damaged 31 - 50 Nm + torque a further 90 (1/4 turn) replace Interlock camshafts with a pipe section -T10123- for removing and installing it Chapter 13-3 32 - Tensioning rail interlock tensioner Fig. 1 in 13-2 page 5 33 - Hydraulic control chain tensioner 34 - 15 Nm 35 - Timing chain 36 - Camshaft sprocket removing and installing, setting the timing Chapter 13-3 37 - 15 Nm for engine with engine identification characters AZQ 38 - Sliding block for engine with engine identification characters AZQ 39 - Washer for engine with engine identification characters AZQ replace
13-2 page 4
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Fig. 1: Interlock tensioner
13
Press on the piston of the hydraulic tensioner -2- in the

-direction of travel- over the tensioning rail -1- until the piston can be interlocked with the safety drift -B- (e.g. with a 3 mm box spanner).
Fig. 2:
Set the point of installation of the gearwheel on the crankshaft
Place the marking at the gearwheel on the crankshaft

opposite to the marking at the gearwheel on the balancing shaft -arrows-.
Removing and installing the timing gear cover

Engine installed in the vehicle
Supporting device -MP 9-200 Hand-held power drill with plastic brush insert Flat scraper Silicone sealant -AMV 174 003-
Removing
If necessary remove engine cover with air filter 1.2/

40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
Mount supporting device -MP 9-200- and take up the

weight of the engine/gearbox assembly at the spindles.
Remove the V-ribbed belt Chapter 13-1. Remove the right engine mounting Chap. 10-1. Remove pulley wheel of the coolant pump Chapter
19-1.
Remove the guide pulley (only on vehicles with air

conditioning) Chapter 13-1. Chapter 13-1.
Remove the tensioner with tensioning roller Remove alternator Electrical System; Rep. Gr. 27. Remove the ventilation pipe of the cooling system
Chapter 19-1.
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13-2 page 5
13
Interlock the crankshaft with an assembly device
-T10121- Chapter 13-3, screw out the screw of the crankshaft and pull off the belt pulley - crankshaft. possibly also the sender for the oil level/temperature -G266- (vehicles with WIV) Chapter 17-1/17-2.
Remove the oil pan, guide pipe of the oil dipstick anbd Remove the connection for the vacuum regulating
valve (PCV valve).
Screw out all screws on the timing gear cover. Remove the timing gear cover. Use slight knocks with
a rubber-headed hammer from outside to loosen the cover as necessary (the timing gear cover sits on the fitting sleeves).
Use a flat scraper to remove plastic sealant residues

from the engine. Note Cover the area around the sealing surfaces so that no sealant residues can find their way into the timing gear drive.
Remove sealant residues on the timing gear cover

with a rotating brush, e.g. a hand drill with plastic brush attachment (wear protective goggles).
Clean the sealing surfaces on the timing gear cover

and engine. They must be free of oil and grease.
Installing
Note
Install housing item 17 in 13-2 page 1, item 17
in 13-2 page 3 only after putting the timing gear cover in place otherwise the gasket ring can be damaged.
Remove sealant residues of silicone sealant applied
inside the housing and insert a new O-ring item 16 in 13-2 page 1, item 16 in 13-2 page 3 into the housing. while removing (e.g. broken off wings).
Check whether the oil scraper has been damaged Pay attention to the 'use by date' on sealant. The timing gear cover must be installed within 5 min-
utes after applying the silicone sealant.
if no blue sealant mass is left in the thread of the M6
screws, replace the screws for ones which have sealant on them.
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
Apply silicone sealant to the clean sealing surface of

the timing gear cover, according to the illustration -arrows A-.
13-2 page 6
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13
Note Apply silicone sealant to the separation point of the cylinder head/cylinder block according to the parting plane -arrows C-. For engine with engine identification characters AWY, BMD
For engine with engine identification characters AZQ, BME Continued for all engines B - Position of the fitting sleeves
Thickness of sealant bead: 23 mm.
Note The sealant bead must not be thicker than 3 mm otherwise excess sealant may get into the oil pan and clog the strainer in the oil pump.
Fit timing gear cover immediately and lightly tighten all

bolts.
Tighten all bolts fully in the given sequence: Tightening torques 13-2 page 8.
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13
For engine with engine identification characters AWY, BMD
For engine with engine identification characters AZQ, BME Continued for all engines
Install the housing item 17 in 13-2 page 1,

item 17 in 13-2 page 3. Note The sealing of the housing must be carried out with an Oring item 16 in 13-2 page 1, item 16 in 13-2 page 3.
Size of screws and the tightening torque

For engine with engine identification characters AWY, BMD Position 3 1, 2 22, 23 others
1)
Size of bolt M10x162 M10x142 M8x55 M6x401)
Torque 45 Nm 45 Nm 25 Nm 10 Nm
if no blue sealant mass is left in the thread of the screws, replace the screws for ones which have sealant on them.
For engine with engine identification characters AZQ, BME
13-2 page 8
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Position 1, 2, 3 4, 5 6, 7, 8, 11, 14, 15 others
1)
13
Size of bolt M10x120 M8x55 M6x401) M6x221)
Torque 50 Nm 25 Nm 8 Nm + torque a further 90 (1/4 turn)
if no blue sealant mass is left in the thread of the screws, replace the screws for ones which have sealant on them.
Continued for all engines Further installation occurs in reverse order. Pay attention to the following:
Replace crankshaft screw.
Tightening torque: 90 Nm + torque a further 90 (1/4 turn)
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13-2 page 10
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13
13-3
Removing and installing the camshaft sprocket, setting the timing
Inspect setting of the timing

For engine with engine identification characters AWY, BMD Special tools, test and measuring equipment and auxiliary items required
Assembly device -T10120 Assembly device -T10121 Extractor -T10094-
Note
The crankshaft is at TDC of the piston for cylinder 1 for
mixture ignition only then when the camshaft is standing atTDC of the piston for cylinder 1 (both devices must be interlocked). time as a fixing lever to loosen and tighten up the crankshaft screws. have been removed.
The assembly device -T10121- also serve at the same
The engine can be easily turned once the spark plugs

Remove camshaft position sensor -G163- at cylinder

head cover.
Remove engine speed sender -G28- on the cylinder

block.
Insert assembly device -T10120- according to the illustration into the hole.
Rotate crankshaft in direction of rotation of engine

long enough until the assembly device -T10120- can be inserted down to the stop.
Interlock crankshaft, press the assembly -T10121into the hole in the flywheel. Note If the assembly device -T10121- cannot be inserted, remove the assembly device -T10120- out of the camshaft. Rotate crankshaft in direction of rotation of engine (360 ) and repeat the procedure. If both devices cannot be inserted:
Setting the timing 13-3 page 3.

If both devices can be inserted:
Remove the devices from the holes and install camshaft position sensor as well as engine speed sender. Further installation occurs in reverse order.
Edition 12.04 S00.5322.03.20
13-3 page 1
13
For engine with engine identification characters AZQ, BME Special tools, test and measuring equipment and auxiliary items required
Pipe section -T10123 Assembly device -T10121 Extractor -T10094-
Note
The crankshaft is at TDC of the piston for cylinder 1 for
mixture ignition only then when the camshaft is standing atTDC of the piston for cylinder 1 (both devices must be interlocked). time as a fixing lever to loosen and tighten up the crankshaft screws. have been removed.
The assembly device -T10121- also serve at the same

Remove caps at cylinder head cover -arrows-. Remove engine speed sender -G28- on the cylinder
block.
Rotate crankshaft in direction of rotation of engine

long enough until the grooves are positioned horizontally in both camshafts.
Pipe sections -T10123- must be lightly pushed into the

camshafts.
Fasten both devices with screws (M6).
T10123
Interlock crankshaft, press the assembly device
-T10121- into the hole in the flywheel. Note If the assembly device -T10121- cannot be inserted, remove the pipe sections -T10123- out of the camshaft. Rotate crankshaft in direction of rotation of engine (360 ) and repeat the procedure. If both devices cannot be inserted:
Setting the timing 13-3 page 3.

If both devices can be inserted:
Remove the devices from the holes and install caps

as well as engine speed sender. Further installation occurs in reverse order.
13-3 page 2
Edition 12.04 S00.5322.03.20
13

Pressure pad -MP 1-216-
Removing the camshaft sprocket

Interlock camshaft and crankshaft at TDC for cylinder

1 13-3 page 1.
Remove the timing gear cover Chapter 13-2. Interlock the control chain tensioner Chapter 13-2. Remove the camshaft screw and take out the camshaft sprocket.
Screw in the crankshaft screw with housing and belt

pulley - crankshaft. Tightening torque: 90 Nm + torque a further + 45 (1/8 turn)
Remove the assembly device -T10121- and turn the
crankshaft 45 in the opposite direction of rotation of the engine.
Work can be performed on the valve drive while it is in this position.
Installing the camshaft sprocket, setting the timing

The pistons must not be positioned at top dead centre.

Note
To turn the camshaft when the sprocket has been re-
moved one can screw in a screw with two washers to a maximum of 20 Nm + 45 (1/8 turns) into the camshaft and turn the camshaft. The pistons must not be at TDC. whenever the camshaft is removed
The central screw of the camshaft is to be replaced The assembly device -T10120- also serves at the
same time as a fixing lever to loosen and tighten up the camshaft screws. have been removed.
Position camshaft to TDC of cylinder 1 and lock into

place 13-3 page 1. One should not be able to move the camshaft in any direction after interlocking.
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13-3 page 3
13
Screw out the camshaft screws. Remove oil residues on the camshaft studs and camshaft sprocket in the points of contact using a clean cloth.
Place the camshaft sprocket with the control chain laid

on it on the camshaft and screw in the new camshaft screw so that the camshaft sprocket can still turn.
Tension control chain Chapter 13-2 Turn the crankshaft through a further 45 in the direction of rotation of the engine to TDC for cylinder 1 and interlock. Note
If the crankshaft is turned beyond TDC for cylinder 1
(observe the marking on the flywheel) then it should turned back and the TDC for cylinder 1 set again. piston on the valves.
If the crankshaft is turned further it will collide with the
Turn the camshaft sprocket -1- with pressure pad

-MP1-216- opposite the direction of rotation of the engine -arrow- up to the stop, hold the camshaft sprocket in this position and tighten up the screw -2-. Tightening torque: 20 Nm + torque a further 90 (1/4 turn) Note The assistance of a 2nd mechanic is required for this work.
Carefully crank engine at least 2 revolutions to ensure

that no valve touches the piston when the engine is started, check timing again 13-3 page 1. Further installation occurs in reverse order.
Check position of camshaft to crankshaft in the dis-
play group 012 display field 3 and 4 1.2/40, 1.2/47 Engine, Fuel Injection; Rep. Gr. 01.
Removing the camshaft sprockets

Interlock camshafts and crankshaft at TDC for cylinder 1 13-3 page 1.
Remove the timing gear cover Chapter 13-2. Interlock the control chain tensioner Chapter 13-2. Remove the camshaft screws and take out the camshaft sprockets.
Screw in the crankshaft screw with housing and belt

pulley - crankshaft. Tightening torque: 90 Nm + torque a further + 45 (1/8 turn)
13-3 page 4
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13
Remove the assembly device -T10121- and turn the
crankshaft 45 in the opposite direction of rotation of the engine.
Work can be performed on the valve drive while it is in this position.
Installing the camshaft sprockets, setting the timing


Note
To turn the camshaft when the sprocket has been re-
moved one can screw in a screw with two washers to a maximum of 50 Nm + 45 (1/8 turns) into the camshaft and turn the camshaft. The pistons must not be at TDC. of the sprockets on engine with engine identification characters AZQ are to be replaced when the camshafts are removed.
The central screws of the camshafts and the washers
The pipe section -T10123- also serves at the same
time as a fixing lever to loosen and tighten up the camshaft screws. have been removed.
Position camshafts to TDC of cylinder 1 and lock into

place 13-3 page 1.
Screw out the camshaft screws. Remove oil residues on the camshaft studs and camshaft sprockets in the points of contact using a clean cloth.
Place the camshaft sprockets with the control chain

laid on it on the camshafts and screw in the new camshaft screws so that the camshaft sprockets can still turn.
T10123
Tension control chain Chapter 13-2 Turn the crankshaft through a further 45 in the direction of rotation of the engine to TDC for cylinder 1 and interlock. Note
If the crankshaft is turned beyond TDC for cylinder 1
(observe the marking on the flywheel) then it should turned back and the TDC for cylinder 1 set again. piston on the valves.
If the crankshaft is turned further it will collide with the
Edition 12.04 S00.5322.03.20
13-3 page 5
13
(to do so use the pressure pad -MP1-216-).
Tighten screws -2- of camshaft sprockets -1- to 50 Nm Then, torque the bolts a further 90 (1/4 turn) with a rigid wrench. Tightening torque: 50 Nm + torque a further 90 (1/4 turn) Note The assistance of a 2nd mechanic is required for this work.

that no valve touches the piston when the engine is started, check timing again 13-3 page 1. Further installation occurs in reverse order.
Check position of camshaft to crankshaft in the dis-
play group 012 display field 3 and 4 1.2/40, 1.2/47 Engine, Fuel Injection; Rep. Gr. 01.
13-3 page 6
Edition 12.04 S00.5322.03.20
13
13-4
Note
Removing and installing the gasket ring and flywheel
Repairs on the clutch Manual gearbox 002; Rep. Gr. 30. The engine should be attached to the engine repair stand with the engine holder -MP 1-202- for carrying out re-
moval and installation work.
1 - 90 Nm + torque a further 90 (1/4 turn) replace Interlock crankshaft with a fixing bolt -T10121- for removing and installing it Chapter 13-3 2 - Belt pulley - crankshaft 3 - Housing Replace together with O-ring item 4 Replace silicone sealant sealing with O-Ring item 4 fit onto cleaned crankshaft 4 - O-ring replace if damaged replace the sealing of the housing with silicone sealant 5 - Gasket ring for crankshaft on the belt pulley side Neither grease nor oil sealing lip of sealing ring before installing remove grease residue on the housing with a clean cloth replace if damaged 13-4 page 2 Replace together with housing item 3 6 - Cylinder block 7 - 60 Nm + torque a further 90 (1/4 turn) replace tighten up in two steps: Step I = 60 Nm Step II = 90 (1/4 turn) 8 - Flywheel assembly only possible in one position -holes offset Interlock crankshaft flywheel with a fixing bolt -T10121- for removing and installing it Chapter 13-3 replace ring gear 13-4 page 3 9 - Intermediate plate must be positioned on dowel sleeves do not damage/bend during assembly work 10 - Gasket ring for crankshaft on the flywheel side Neither grease nor oil sealing lip of sealing ring
Edition 04.03 S00.5322.01.20
13-4 page 1
13
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components before installing remove grease residue on crankshaft journal with a clean cloth replace 13-4 page 2
Replacing gasket ring for crankshaft - on the belt pulley side

Removing
Remove the V-ribbed belt Chapter 13-1. Remove belt pulley - crankshaft and housing
Chapter 13-2. -A-. Note The adhesive surface must not get damaged when removing the gasket ring.
Remove the gasket ring carefully using a screwdriver
Installing
Pressure plate -T40008-
Note The sealing lips of the gasket ring must be neither oiled nor greased.
Position the gasket ring on the steering wheel housing

and drive in using a pressure piece -T40008- down to the stop on the device.
Carefully place a new grease and oil free housing into

the gasket ring Chapter 13-2. Further installation occurs in reverse order.
Replacing the gasket ring for the crankshaft - flywheel side

Assembly fixture -T10122-
Gearbox removed Remove the flywheel item 8 in 13-4 page 1. Remove the gasket ring carefully using a screwdriver
-A-. Note The adhesive surface must not get damaged when removing the gasket ring.
13-4 page 2
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13
Installing
Note The sealing lips of the gasket ring must be neither oiled nor greased.
Push the assembly device -T10122/1- into the assembly device -T10122/2- and gasket ring -A-, then push onto the assembly device -T10122/2-, as shown.
Remove assembly device -T10122/1-. Remove oil residue on the crankshaft stub with a
clean cloth.
Insert the gasket ring with assembly device -T10122/

2 -.
Drive in gasket ring with assembly device -T10122/3up to the stop. Further installation occurs in reverse order.
Replacing ring gear

Flywheel removed
Removing
Fit on flywheel flat and position ring gear in stages by

striking over the entire circumference. Heat ring gear if stiff.
Installing
Heat ring gear to approx. 150 C and fit onto the fly-
wheel evenly; knock on as far as the stop with a drift over the entire circumference, if necessary. Note
Lay the flywheel in place so that the rotor for the engine speed is not damaged.
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13
13-4 page 4
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15
15 Cylinder Head, Valve Gear

15-1 Removing and installing cylinder head
Testing compression pressure 15-1 page 5.
Note
Removing and installing intake manifold 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. Removing and installing exhaust manifold Chapter 26-1 Removing and installing coolant regulator housing Chapter 19-1. If the cylinder head is replaced, the system must be completely filled with fresh coolant.
For engine with engine identification characters AWY, BMD 1 - Cylinder head with cover check for distortion Fig. 1 in 15-1 page 4 removing and installing 15-1 page 4 after replacing fill entire system with fresh coolant repair the valve gear Chapter 15-2/15-3 2 - Collar for engine with engine identification characters AWY 3 - Gasket replace if damaged 4 - Cap 5 - 20 Nm 6 - Lifting eye - on the left 7 - Cylinder head bolt replace observe the mounting instructions and sequence for loosening and tightening 15-1 page 4 8 - From connecting hose for engine with engine identification characters BMD 9 - Ventilation hose with non-return valve for engine with engine identification characters BMD 10 - From air filter for engine with engine identification characters AWY 11 - Ventilation hose for engine with engine identification characters AWY 12 - Camshaft position sensor -G16313 - 8 Nm
Edition 12.04 S00.5322.03.20
Removing and installing cylinder head
15-1 page 1
15
14 - Gasket ring replace if damaged 15 - Bracket for the cable harness 16 - 0.045 MPa (0.45 bar) oil pressure switch -F1-, 25 Nm inspect Chapter 17-3 17 - Gasket ring replace 18 - Cylinder head gasket replace check fitting position: The spare part number must be legible 19 - Bolts, 18 Nm for tensioning rail or possibly also guide rail 20 - 20 Nm + torque a further 90 (1/4 turn) replace 21 - Camshaft sprocket removing and installing Chapter 13-3 22 - Lifting eye - on the right
For engine with engine identification characters AZQ, BME 1 - 10 Nm + torque a further 90 (1/4 turn) replace 2 - O-ring replace if damaged 3 - Camshaft position sensor -G1634 - 8 Nm 5 - 10 Nm 6 - Bracket for the cable harness 7 - Cap 8 - Exhaust camshaft inspect axial play Chapter 15-2 9 - Bearing cap for camshaft When installing pay attention to the smooth operation of the camshafts inspect axial play Chapter 15-2 10 - Roller rocker arm do not get them confused with each other. inspect roller bearings oil contact surface for installing, clip onto hydraulic supporting element with locking clip
15-1 page 2
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components 11 - Supporting element do not get them confused with each other. with hydraulic valve clearance compensation oil contact surface 12 - Valve collets 13 - Valve spring retainer 14 - Valve spring removing and installing Chapter 15-3; replacing the valve stem seal 15 - Valve stem seal replacing Chapter 15-3 16 - 0.045 MPa (0.45 bar) oil pressure switch -F1-, 25 Nm inspect Chapter 17-3 17 - Valve do not rework, only grinding in is permissible Valve dimensions Chapter 15-2 18 - Cylinder head bolt replace observe the mounting instructions and sequence for loosening and tightening 15-1 page 4 19 - Cylinder head Inspect valve guides Chapter 15-3 check for distortion Fig. 1 in 15-1 page 4 20 - Gasket ring Clean strainer if dirty 21 - 20 Nm 22 - Lifting eye 23 - Camshaft sprocket 24 - 50 Nm + torque a further 90 (1/4 turn) replace Interlock camshafts with a pipe section -T10121- for removing and installing it Chapter 13-3 Washer for engine with engine identification characters AZQ replace Inlet camshaft 15 Nm for engine with engine identification characters AZQ Sliding block for engine with engine identification characters AZQ Cylinder head cover sealing surfaces must not be reworked. removing and installing Chapter 15-2, removing and installing the camshaft
15
25 -
26 27 28 29 -
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15-1 page 3
15
Fig. 1:
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Inspecting the cylinder head for distortion
Straightedge Feeler gauge
Max. permissible distortion: 0.05 mm (minimum clearance of straightedge base: 100 mm) If the distortion is greater than 0.05 mm, replace cylinder head.

Removing
Remove the timing gear cover Chapter 13-2. Remove the camshaft sprocket, if necessary the camshaft sprockets Chapter 13-3.
Remove cylinder head cover Chapter 15-2. Loosen the cylinder head screws in two stages and remove in the known order. For engine with engine identification characters AWY, BMD
For engine with engine identification characters AZQ, BME Continued for all engines
Carefully remove the cylinder head.

Note Do not lay the cylinder head on the surface with the head combustion chamber - danger of damaging the spark plugs.
Installing

Note
Always replace the cylinder head bolts. There must not be any oil or coolant present in the
holes for the cylinder head bolts. immediately before fitting.
Remove the new cylinder head seal from its wrapping
15-1 page 4
Edition 12.04 S00.5322.03.20

When conducting repairs sealant residues should be
15
removed from the contact surface of the cylinder head using a chemical cleaner. will result in leaks.
Treat the new seal with the utmost care. Any damage
Check whether both sleeves which are intended for

the guide of the cylinder head, are inserted into the cylinder block above; insert if necessary.
Fit on new cylinder head gasket. The legend (spare

part no.) must be legible.
Insert the cylinder head. Insert new cylinder head screws into the screw contact surface lightly oiled and tighten by hand.
Tighten cylinder head in three stages in the following

order: For engine with engine identification characters AWY, BMD For engine with engine identification characters AZQ, BME Continued for all engines 1. Pre-tighten with torque wrench: Step I = 30 Nm 2. Tighten further with a rigid wrench: Stage II = 1/4 turn (90) Stage III = 1/4 turn (90) Further installation occurs in reverse order. Pay attention to the following:
that no valve touches the piston when the engine is started.
Testing the compression

Test condition
Engine oil temperature at least 30 C

Compression tester e.g. -1763 Spark plug wrench e.g. -3122 B Extractor -T10094-
Test sequence

Disconnect the 4-pin plug plug connector from ignition

coils with a power output stage -N70-, -N127-, - N291-
Edition 12.04 S00.5322.03.20
15-1 page 5
15
1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24 if necessary pull the ignition coils out slighty.
Pull out with extractor -T10094- ignition coils with a
power output stage -N70-, -N127-, -N291- 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
Disconnect all plug connections of the injection valves Unscrew the spark plugs. Test compression with compression tester,
e.g.-V.A.G 1763Note Use of tester Operating Instructions.
Operate starter until the tester no longer indicates a

pressure rise.
Compression readings
new min. 15 bar (1.5 MPa) Wear limit 11 bar (1.1 MPa) Difference between cylinders max. 3 bar (0.3 MPa)
Screw in the spark plug and then tighten fully to 30

Nm.
Install ignition coils with a power output stage -N70-,

-N127-, -N291- 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. power output stage and the injectors.
Plug in the plug connector for the ignition coils with the Install engine cover with air filter 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24.
Interrogate fault memory and erase 1.2/40; 1.2/47

Engine, Fuel Injection; Rep. Gr. 01. Note Separating the plug connections causes faults to be stored.
15-1 page 6
Edition 12.04 S00.5322.03.20
15
15-2
Repairing the valve gear - Part 1
Note 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. For engine with engine identification characters AWY, BMD 1 - Cylinder head cover sealing surfaces must not be reworked. with integrated camshaft bearings removing and installing 15-2 page 3, removing and installing the camshaft 2 - 6 Nm + torque a further 90 (1/ 4 turn) replace 3 - Camshaft removing and installing 15-2 page 3 Pay attention to the marking Fig. 2 in 15-2 page 2 4 - Roller rocker arm do not get them confused with each other. inspect roller bearings oil contact surface for installing, clip onto hydraulic supporting element with locking clip 5 - Supporting element do not get them confused with each other. with hydraulic valve clearance compensation oil contact surface 6 - Valve collets 7 - Valve spring retainer 8 - Valve spring replace springs as a set only removing and installing Removing and installing and valves for a removed cylinder head Chapter 15-3 With cylinder head installed Chapter 15-3, remove the valve stem seal 9 - Valve stem seal replacing Chapter 15-3 10 - Cylinder head sealing surfaces on the camshaft side must not be reworked. Inspect valve guides Chapter 15-3 11 - Valve do not re-mill, only grinding with the valve seat is permissible Valve dimensions Fig. 3 in 15-2 page 2
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15-2 page 1
15
reworking valve seats Chapter 15-3
Fig. 1:
Inspecting axial play of camshaft
Universal dial gauge holder -MP 3-447 Dial gauge
MP 3-447
Perform measurement with the supporting elements removed and the cylinder head cover removed.
Load camshaft at the middle camshaft bearing cap.

Wear limit: max. 0.20 mm
S15-0178
Fig. 2:
Camshaft identification
Identification Engine identification characters Camshaft AWY 03D K, 03D N BMD 03D P
Fig. 3:
Valve dimensions
Note The valves must not be reworked. Only grinding in with grinding paste in the related valve seat is permissible. For engine with engine identification characters AWY, BMD Dimension a b c mm mm mm Inlet valve 34,5 5,98 99,25 45 Exhaust valve 28 5,96 99,25 45
15-2 page 2
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Dimension a b c mm mm mm Inlet valve 29,5 5,973 100,9 45 Exhaust valve 26 5,953 100,57 45
15
Removing and installing camshaft

Sealant -D 154 103 A1 Grease -G 052 735 A2-
Removing
Remove the timing gear cover Chapter 13-2. Remove the camshaft sprocket Chapter 13-3. Remove assembly device -T10120-. Unscrew screws from the cylinder head cover. Remove the cylinder head cover and use slight knocks from above to loosen as necessary (the cylinder head cover sits on the fitting sleeves). surface.
Carefully lift out camshaft and place down on a clean Remove the roller rocker arm together with the hydraulic supporting elements and lay aside on a clean surface. Ensure that the roller rocker arm and the supporting element is not mixed up.
Cover the bore holes for the hydraulic supporting elements and valve springs with clean cloth.
Cover or close the oil channel for camshaft bearings. Remove residual sealant on the cylinder head and on
the cylinder head cover using flat scraper. Note Sealant residues must not remain in the cylinder head.
Clean the camshaft bearings on the cylinder head and

on the cylinder head cover.
Installing
Sealing surfaces must be free of oil and grease. The pistons must not be positioned at top dead centre.
Edition 12.04 S00.5322.03.20
15-2 page 3
15
Oil the hydraulic supporting elements and insert at the

same location together with the corresponding roller arms as when removing into the cylinder head. Make sure all roller rocker arms -1- are correctly positioned on the end of valve stems -2- and on the corresponding hydraulic supporting elements -3-.
Coat the camshaft bearing -A- on the cylinder head

and the cylinder head cover with a constant layer of grease -G 052 735 A2-.
Cut off nozzle of tube of the sealant -D 154 103 A1- at

the front marking ( of nozzle approx. 2 mm). cylinder head, as shown in the illustration.
Thickness of sealant bead -B-: 23 mm. Be careful how you apply sealant in the areas of -ar-
Apply sealant bead to the clean sealing surface of the
rows- so that excess sealant is not pushed into the bearing and thus the camshaft is not glued solid by this. of the bolt holes. Note
The sealant must be run past on the inside in the area
The sealant bead must not be thicker than 3 mm oth-
erwise excess sealant may get into the oil pan and clog the strainer in the oil pump. minutes after applying the silicone sealant.
The cylinder head cover must be installed within 15
Place the camshaft in such a way that the opening of

the OT -arrow- points forwards towards exhaust gas channels.
Place the cylinder head cover so that the sleeves -Ain the bore holes grip in the cylinder head.
15-2 page 4
Edition 12.04 S00.5322.03.20
15
Insert new fixing screws and tighten in the direction

given. Tightening torque: 6 Nm + torque a further 90 (1/4 turn)
Wipe away exuded sealant particularly in the area

steering wheel cover. Further installation occurs in reverse order. For engine with engine identification characters AZQ, BME Special tools, test and measuring equipment and auxiliary items required
Sealant -D 154 103 A1 Grease -G 052 735 A2 Extractor -T10094-
Removing
Remove cylinder head cover Note Sealing surfaces of cylinder head must not be reworked.
Remove the timing gear cover Chapter 13-2. Remove the camshaft sprockets Chapter 13-3. Remove pipe sections -T10123Pull out with extractor -T10094- ignition coils with a power output stage -N70-, -N127-, -N291- 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. from outside to inside and remove.
Slacken the bolts of the cylinder head cover crosswise Carefuelly remove the cylinder head cover and apply
slight knocks with a rubber-headed hammer from above to loosen as necessary (the cylinder head cover sits on the fitting sleeves).
Remove residual sealant on the cylinder head and on

the cylinder head cover using flat scraper. Note Sealant residues must not remain in the cylinder head. Remove the camshafts
Slacken the screws of the camshaft bearing in the given sequence and remove.
Carefully remove camshaft bearing cap. Carefully lift out camshafts and place down on a clean
surface.
Installing
Install camshafts
Edition 12.04 S00.5322.03.20
15-2 page 5
15
Note
Lug of inlet camshaft must be positioned on the hole for the hall sender.
Coat the camshaft bearing on the cylinder head and

on the camshaft covers with a constant layer of grease -G 052 735 A2-.
Carefully insert camshafts into the cylinder head cover.
Fit on camshaft bearing cap. Install screws of camshaft bearing in given sequence
and tighten by hand. Make sure that the camshaft bearing caps are not tilted. Tightening torque: 10 Nm + torque a further 90 (1/4 turn) Pay attention to smooth operation of the camshafts. Install cylinder head cover
Sealing surfaces must be free of oil and grease. The pistons must not be positioned at top dead centre.
Note When turning the camshaft the valves may touch the piston in TDC.
Cut off nozzle of tube of the sealant -D 154 103 A1- at

the front marking ( of nozzle approx. 2 mm). ing surface of the cylinder head.
Thickness of sealant bead: 23 mm. The sealant must be run past on the inside in the area
Apply a narrow even sealant bead on the clean seal-
of the bolt holes. Note
The sealant bead must not be thicker than 3 mm oth-
erwise excess sealant may get into the oil ducts and can cause engine damage. minutes after applying the silicone sealant.
The cylinder head cover must be installed within 15
Make sure all roller rocker arms are correctly positioned on the end of valve stems -1- and on the relevant hydraulic supporting elements -2-.
15-2 page 6
Edition 12.04 S00.5322.03.20
15
Carefully fit cylinder head cover onto the fitting sleves

-arrows- vertically from above into the cylinder head.
Insert the new fixing screws and tighten diagonally

and evenly from the inside to the outside. Make sure that the cylinder head cover is not tilted. Tightening torque: 10 Nm + torque a further 90 (1/4 turn)
Wipe away exuded sealant particularly in the area

steering wheel cover. Note After installing the cylinder head cover, allow the sealant to dry for about 30 minutes. Further installation occurs in reverse order.
Edition 12.04 S00.5322.03.20
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15
15-2 page 8
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15
15-3
Repairing the valve gear Part 2
Replacing valve stem seal

Removing
Valve spring assembly lever -MP 1-211 Valve supporting plate -MP 1-218 Assembly device -MP 1-213 Gasket ring extractor -MP 1-230 Insertion tool -MP 1-233-
Cylinder head and camshaft removed Components removed (intake manifold, exhaust manifold, spark plugs etc.) (with cylinder head removed) Note Build up pressure with installed cylinder head, see procedure for engine with engine identification characters AZQ, BME.
Fit cylinder head onto the valve supporting plate. Screw on assembly device -MP 1-213-.
Always use cylinder head cover screws (M7) -1- with 4 M8 washers -2-.
Place the valve spring assembly lever -MP 1-211- on

the valve spring and press the valve springs together.
Remove the safety valve collets.

Note Release collets that are tight by striking with light blows of a hammer on the valve lever.
Edition 12.04 S00.5322.03.20
15-3 page 1
15
seal -MP 1-230-.
Pull off valve stem seal with extractor for valve stem
Press sleeve -1- down slightly during this step.
Installing
In order to avoid damage to the new valve stem seals,

fit the supplied plastic sleeve -A- onto the valve stem.
Oil valve stem seal -B-, insert into the insertion tool
-MP 1-233- and carefully push onto the valve guide.
Remove plastic sleeve.

Further installation occurs in reverse order.
Removing
For engine with engine identification characters AZQ, BME Special tools, test and measuring equipment and auxiliary items required
Supporting device -MP 9-200 Spark plug wrench, e.g. -3122B Assembly device -MP 1-229- with pressure plate
- MP 1-229/1-
Gasket ring extractor -MP 1-230 Insertion tool -MP 1-233 Pressure pad -T 30004- with replaceable stud
-T30004/1-
Counterholder -MP 1-216 Pressure hose -MP 1-210 Extractor -T10094-
(with cylinder head installed) Note Use valve supporting plate -MP 1-218- with cylinder head removed, see procedure for engine with engine identification characters AWY, BMD.
Remove the V-ribbed belt Chapter 13-1. Remove cylinder head cover Chapter 15-2. Unscrew the spark plugs with spark plug wrench
-3122B-.
15-3 page 2
Edition 12.04 S00.5322.03.20
15
MP1-229/1
Remove roller rocker arm and place on a clean surface. Make sure that you do not mix up the roller rocker arms.
MP1-229
Position piston of the relevant cylinder in bottom dead

centre.
Screw on assembly device -MP 1-229- with pressure

plate -MP 1-229/1-.
Screw the pressure hose -MP 1-210- in the spark plug

thread.
Connect pressure hose to compressed air (min. 0.6

MPa (6 bar) overpressure) and remove the valve springs with device -MP 1-229-.
Pull off valve stem seals with extractor -MP 1-230-.
Installing
Insert the supplied plastic bushings on the relevant

valve stem. This will prevent any damage to the new valve stem seals.
MP1-210
S15-0158
Insert the new valve stem seal -B- in the insertion tool
-MP 1-233-.
MP1-233
Oil the sealing lip of the valve stem seal and carefully
slide onto the valve guide -A-. Install cylinder head cover Chapter 15-2. Installing the camshaft sprockets and setting the timing Chapter 13-3. Further installation occurs in reverse order.
B A
Inspect valve guides

Cylinder head and valve spring removed
S15-0161
Universal dial gauge holder -MP 3-447 Dial gauge
Procedure
Note If the valve is replaced when carrying out repair work, use a new valve for the measurement.
Insert valve into guide. End of valve stem must be

flush with end of guide (without valve stem seal). Because of the different stem diameters only use inlet valve in inlet guide or outlet valve in outlet guide.
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15-3 page 3
15
Determine valve rock.
Wear limit
Inlet valve guide 0,5 mm
Exhaust valve guide 0,55 mm
Note If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded - replace cylinder head.
Reworking valve seats

Universal dial gauge holder -MP 3-447 Dial gauge Micrometer or caliper gauge NAC milling cutter for reworking valve seats Grinding paste
Note
When carrying out repairs on engines with leaking
valves, it is not sufficient to machine or replace the valve seats and valves. It is also necessary to inspect the valve guides for wear, particularly on engines with a high mileage 15-3 page 3. If the wear limit is exceed, replace cylinder head. the valve with the corresponding valve seat with grinding paste is permissible, in order to obtain a proper contact pattern. Calculate the maximum permissible reworking dimension before commencing 15-3 page 4. If the reworking dimension is exceeded, proper operation of the valve gear is no longer assured and the cylinder head must be replaced.
Do not re-mill valve seats. Only opposite grinding in of
Calculating maximum permissible reworking dimension
Insert valve and press firmly against the valve seat.

Note
If the valve is replaced when carrying out repair work,
use a new valve for the measurement. thoroughly cleaned.
If no new valve is used, then the valve disc must be
Attach universal dial gauge holder with bolt to cylinder

head.
15-3 page 4
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15
Measure distance -h- from the bottom edge of the cylinder head to the bottom edge of the valve disc. Measure in the immediate vicinity of the recess from the valve disc center -arrows-.
Measure valve length -c-.

Note Measure dimension -c- in the immediate vicinity of the recess from the valve disc center.
Calculate max. permissible reworking dimension from

the distances -c, h- measured and from the maximum dimension. Maximum dimension for both valves: 103.7 mm The maximum permissible reworking dimension = 103.7 - (c + h).
Example:
Maximum dimension for both valves - (Valve length -c- + measured distance -h-) = max. permissible reworking dimension1)
1)
103,7 mm (99,2 + 4,35) mm 0,15 mm
The max. permissible reworking dimension is shown in the figures for reworking the valve seats as dimension b.
Measure distance between the valve stem end and

the upper face of the cylinder head.
Calculate max. permissible reworking dimension from

the distance measured and the minimum dimension. Minimum dimension: for inlet and exhaust valve 7.6 mm
Measured distance - minimum dimension = max. permissible reworking dimension. Example:
Edition 12.04 S00.5322.03.20
15-3 page 5
15
Measured distance - Minimum dimension = max. permissible reworking dimension 1)
1)
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components 8.0 mm 7.6 mm 0.4 mm
The max. permissible reworking dimension is shown in the figures for reworking the valve seats as dimension b.
Continued for all engines Note If the max. permissible reworking dimension is 0 mm, if necessary repeat measurement with a new valve. If the max. permissible reworking dimension is again 0 mm, replace cylinder head.
Reworking inlet valve seat

For engine with engine identification characters AWY, BMD Dimen sion a b c Z S mm mm mm Inlet valve seat
33,4 Max. permissible reworking dimension 1,5...1,7 Bottom edge of cylinder head 45 valve seat angle 30 top correction angle 60 bottom correction angle Combustion chamber floor area
For engine with engine identification characters AZQ, BME Dimen sion a b c Z S mm mm mm Inlet valve seat
Reworking exhaust valve seat

15-3 page 6
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components Dimen sion a b c Z S mm mm mm Exhaust valve seat
15
For engine with engine identification characters AZQ, BME Dimen sion a b c Z S mm mm mm Exhaust valve seat
25,0 Max. permissible reworking dimension approx. 1.8 Bottom edge of cylinder head 45 valve seat angle 30 top correction angle 60 bottom correction angle Combustion chamber floor area
Procedure
Reworking can be carried out by hand while complying with the following conditions:
Wear limit of valve guides must not exceed the permissible dimension 15-3 page 3. HRC).
Use NAC milling cutter with carbide metal tips (min. 90 Mill with the milling cutter using slight pressure in such
a way that an even removal of swarfs is ensured over the whole working surface.
Reworking valve seats with NAC milling cutter
Place cylinder head on a felt base and secure to prevent it from turning.
Match diameter of guide drift to diameter of valve

guide. Valve guide Inlet valve Exhaust valve
S15-0098
Guide drift in mm 6,0 - 0,01
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15-3 page 7
15
seat. Valve seat Milling cutter 90 mm 36 Milling cutter 120 mm 38
Match diameter of milling cutter to diameter of valve

Milling cutter 60 mm 21/34
Inlet valve
AWY, BMD engine AZQ, BME engine AWY, BMD engine AZQ, BME engine
90
32
32
21/34
1.
120
30
30
21/34
Exhaust valve
30
30
21/34
2.
Milling sequence
1 - Machine valve seat with 90 milling tool until until a perfect contact pattern is achieved. (Do not exceed maximum permissible reworking dimension!) 2 - Chamfer top correction angle with 120 milling cutter until the valve seat diameter -a- ( 15-3 page 6) is achieved. 3 - Chamfer bottom correction angle with 60 milling cutter until valve seat width -c- ( 15-3 page 6) is achieved.
60
3.
c
S15-0062
Grind in valve/valve seat -arrows- with fine grinding

paste so as to achieve a perfect contact pattern.
Check contact pattern e.g. with water colour (perfect

contact pattern over entire circumference).
Install valve springs. Inspect valve for leaks.

The tightness of the valve can be checked by filling petrol into the inlet and outlet canal (no petrol must flow out at the valve seat) After completing the repair measure the dimension -hagain and calculate the maximum permissible reworking dimension 15-3 page 4. Note If the reworking dimension is exceeded, proper operation of the valve gear is no longer assured and the cylinder head must be replaced.
S15-0063
15-3 page 8
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17
17 Lubrication
17-1 Removing and installing parts of the lubrication system - Part 1
Note
If considerable quantities of metal swarf or abrasion (caused by rubbing damage such as damage to the crankshaft
and conrod bearings) is found in the engine oil when carrying out engine repairs, it is necessary to determine the cause of the rubbing damage and replace the damaged parts, then carefully clean the oil galleries in order to avoid consequential damage. verter!
The oil level must lie between the markings and not be above the "max" marking - risk of damage to catalytic con-
Check the engine oil, amount of oil, oil specification Inspection and Maintenance 1 - 0.045 MPa (0.45 bar) oil pressure switch - F1-, 25 Nm green insulation inspect Chapter 17-3 cut open gasket ring if leaking and replace 2 - Dowel sleeves 3 - Oil pump with the overpressure valve removing and installing Chapter 17-2 4 - 24 Nm 5 - Oil pan clean sealing surface before installing before installing, coat with silicone sealant -D 176 404 A2- Chapter 17-2 6 - 9 Nm 7 - Gasket ring replace 8 - Oil drain plug, 30 Nm 9 - 8 Nm 10 - Cover for oil pump chain 11 - 20 Nm + torque a further 90 (1/4 turn) replace 12 - Oil pump sprocket check fitting position 13 - Oil pump chain 14 - Chain tensioner for the oil pump drive
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Removing and installing parts of the lubrication system - Part 1
17-1 page 1
17
15 - Guide bolts, 15 Nm for chain tensioner for the oil pump drive 16 - Chain sprocket on the crankshaft for the oil pump drive not interlocked on the crankshaft 17 - O-ring replace if damaged replace the sealing of the housing with silicone sealant 18 - Housing Replace together with O-ring item 17 Replace silicone sealant sealing with O-Ring item 17 fit onto cleaned crankshaft install only after putting the timing gear cover in place otherwise the gasket ring can be damaged 19 - Gasket ring Replace in case of damage Chap. 13-4. Replace together with housing item 18 for crankshaft on the belt pulley side Neither grease nor oil sealing lip of sealing ring before installing remove grease residue on the housing with a clean cloth 20 - Belt pulley - crankshaft 21 - 90 Nm + torque a further 90 (1/4 turn) replace Interlock crankshaft with a fixing bolt -T10121- for removing and installing it Chapter 13-3 O-ring replace if damaged Oil level and oil temperature sender -G266 only for vehicles with WIV check Current Flow Diagrams, Electrical Fault Finding and Fitting Locations Gasket ring replace if damaged Guide tube Dipstick the oil level must not be above the max marking! Inspect engine oil level Inspection and Maintenance Timing gear cover removing and installing Chapter 13-2 Support for engine with engine identification characters AWY for the oil filter Oil filter removing and installing oil filter insert 17-1 page 3 disassembling and assembling 17-1 page 4 24 Nm
22 23 -
24 25 26 -
27 28 -
29 -
30 -
17-1 page 2
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17
Removing and installing oil filter insert
Screw out the screw plug from the nose elevation -a-arrow- and leave in this position for at least one minute to allow the oil to run out of the oil filter insert. Note If the screw plug is removed completely without waiting a while the oil will flow into the DC generator.
Remove the screw plug with the oil filter insert holder. Lightly knock the screw plug with the oil filter insert
holder -1- on a fixed base -3- (e.g. wooden plate) -arrow-. This loosens the oil filter insert -2-.
Place the screwdriver carefully in the groove -arrowof the screw plug and plug off the O-ring.
Insert the new O-ring. Insert the new oil filter insert and tighten screw plug to
25 Nm.
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17
Dismantling and assembling the oil filter

1 - Screw plug with the oil filter insert holder, 25 Nm do not separate 2 - Gasket ring replace delivered with the oil filter insert 3 - Oil filter element removing and installing 17-1 page 3 4 - 8 Nm 5 - Support for engine with engine identification characters AWY 6 - Gasket replace if damaged 7 - 24 Nm 8 - Oil filter holder 9 - O-rings replace if damaged
17-1 page 4
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17
17-2
Removing and installing oil pan

Silicone sealant -D 176 404 A2 Hand-held power drill with plastic brush insert Flat scraper Protective goggles
Removing
Remove lower engine guard -arrows-. Drain engine oil. Release the oil pan's fixing screws. Remove oil pan, if necessary release by applying slight blows with a rubber-headed hammer. crankcase.
S10-0135
Use a flat scraper to remove sealant residues on the Use a rotating plastic brush to remove sealant residues on the oil pan (wear protective goggles).
Clean sealing surfaces, they must be free of oil and

grease. Installing Note
Pay attention to the 'use by date' on sealant. The oil pan must be installed within 5 minutes after apN17-0012
plying the silicone sealant.
Cut off nozzle tube at the front marking ( of nozzle

approx. 3 mm).
A17-0081
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17
of the oil pan, as shown in the illustration.
Thickness of sealant bead: 24 mm
Apply silicone sealant -A- to the clean sealing surface
Note The sealant bead must not be thicker than 4 mm otherwise excess sealant may get into the oil pan and clog the strainer in the oil pump.
Fit oil pan immediately and lightly tighten all bolts. Tighten all bolts fully in the given sequence:
Tightening torque: 9 Nm Note After installing the oil pan, allow the sealant to dry for about 30 minutes. Only then may engine oil be filled in. Further installation occurs in reverse order.
Removing and installing oil pump

Removing
Removing the oil pan 17-2 page 1. Screw out screw -1- and unclip the chain guard for the
oil pump -2- in the area of -arrow-.
Release screw -2-. Swing the chain tensioner for the oil pump drive -4- in
the -direction of the arrow- and remove the sprocket for the oil pump from the oil pump. The sprocket for the oil pump stays in the chain for the oil pump.
Screw out screws -1- and remove the oil pump from
the cylinder block.
Installing
Installation is carried out in the reverse order. Pay attention to the following:
The oil pump must sit in the sleeves then tighten to 24
Nm.
Replace the sprocket screw for the oil pump, tighten-
ing torque: 20 Nm + torque a further 90 (1/4 turn)
17-2 page 2
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17
17-3
Testing oil pressure and oil pressure switch
Oil pressure tester (e.g. - V.A.G 1342-) Diode test lamp (e.g. -V.A.G 1527 B-) Adapter cable set (e.g. -V.A.G 1594 A- or
-V.A.G 1594 C -)
Current flow diagram
Function of dynamic oil pressure warning system if oil pressure low The oil pressure switch is opened when pressureless and closed when the switching pressure is reached. The oil pressure warning is activated for about 10 seconds after the ignition is switched on (terminal 15 on). Activation delay of oil pressure warning: approx. 3 s. Off delay of oil pressure warning: approx. 5 s. Test pressure warning light After the ignition is switched on and engine not running, the oil pressure warning light in the dash panel insert must come on for about 3 seconds and then go out. The check is ended when the engine is started. Warning criteria The visual oil pressure warning is switched on (oil pressure warning light flashes) and the buzzer sounds 3 times as an audible warning if one of the following conditions exists:
Ignition on, engine not running, oil pressure switch
closed
Engine speed greater than 1500 rpm, oil pressure
switch opened
At an engine speed greater than 5000 rpm, the oil

pressure warning is not cancelled, also not if the oil pressure switch is closed. The oil pressure warning is cancelled once engine speed is below 5000 rpm.
If the oil pressure switch is opened for only 0.5 3

seconds at an engine speed of more than 1500 rpm, this is stored in the dash panel insert. If this situation occurs 3 times when the engine is running, the oil pressure warning is immediately activated and is also not cancelled below an engine speed of 1500 rpm. The oil pressure warning is cancelled once the oil pressure switch is closed for more than 5 seconds at an engine speed of more than 1500 rpm, or if the ignition is switched off. Test conditions
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17
Inspect engine oil level to ensure that it is OK
Inspection and Maintenance
Oil pressure warning light -K3- must come on for

must have run at least once).
about 3 seconds when the ignition is switched on.
Engine oil temperature at least 80 C (radiator fan

Testing oil pressure switch Detach cable from oil pressure switch.
Unscrew oil pressure switch and screw in oil pressure

tester e.g. -V.A.G 1342-).
V.A.G 1342
Screw oil pressure switch -2- into -V.A.G 1342 -. Connect brown cable -1- of tester to earth (-). Connect diode test lamp (e.g. -V.A.G 1527 B-) to oil
pressure switch -2- and battery positive (+). The LED must not light up.
If the LED lights up, replace the oil pressure switch. Start engine and slowly increase engine speed. At 0.030.06 MPa (0.30.6 bar) the LED must light
up, if not replace oil pressure switch. Testing oil pressure
2
A17-0025
Unscrew oil pressure switch and -V.A.G 1342- scew

in.
Screw oil pressure switch into -V.A.G 1342-. Start engine (engine oil temperature at least 80 C). Oil pressure at 2000 rpm: at least 0.2 MPa (2 bar) At a higher engine speed the oil pressure must not be
greater than 0.6 MPa (6 bar). If the specified value is not reached:
Eliminate any mechanical damage, e.g. bearing damage.
Replace oil pump with pressure relief valve

Chapter 17-2. If the specified pressure is exceeded:
Inspect oil galleries. Replace oil pump with pressure relief valve if necessary Chapter 17-2.
17-3 page 2
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19
19 Cooling
19-1 Removing and installing parts of the cooling system - Summary of components
Note
When the engine is warm the cooling system is under
pressure. Reduce pressure before repairs.
The hose connections are secured with spring-type
clips. In the event of repairs only use spring-type clips. strap clips.
Use pliers for spring strap clips for installing the spring Always replace seals and gasket rings. When installing fit the coolant hoses free of stress,
without them touching any other components (pay attention to the marking on the coolant connection and hose).
Parts of the cooling system fitted to body 19-1 page 2. Parts of cooling system engine side 19-1 page 3 connection diagram for coolant hoses 19-1 page 5 Draining coolant and filling up Chap. 19-2 Coolant mixing ratios Chapter 19-2.
Edition 12.04 S00.5322.03.20
Removing and installing parts of the cooling system - Summary of components
19-1 page 1
19
Parts of the cooling system fitted to body

1 - Radiator removing and installing Chapter 19-3 after replacing fill entire system with fresh coolant 2 - O-ring replace 3 - Top coolant hose attached to radiator by a spring strap clamp connection diagram for coolant hoses 19-1 page 5 4 - Cap Check pressure Chapter 19-2 5 - Connector 6 - Double screw, 2 Nm 7 - Fan shroud 8 - 5 Nm 9 - 5 Nm 10 - Expansion reservoir Inspect cooling system for leaks Chapter 19-2 connection diagram for coolant hoses 19-1 page 5 11 - Retaining clip for ventilator cable check tightness 12 - Auxiliary fan on vehicles with air conditioning, or additional equipment 13 - Fan holder 14 - Fan for radiator 15 - Bottom coolant hose attached to radiator by a spring strap clamp connection diagram for coolant hoses 19-1 page 5 16 - Bracket for fan connector 17 - Thermoswitch for radiator fan -F18-, 35 Nm for electric fan switching temperatures: 1. Stage on: 9197 C off: 8491 C 2. Stage on: 99105 C off: 9198 C 18 - Bottom radiator bearing black 19 - 5 Nm
19-1 page 2
Edition 12.04 S00.5322.03.20
FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components 20 - Top radiator bearing white
19
Parts of cooling system engine side

Coolant regulator housing
1 - Sender for the coolant temperature -G622 - O-ring replace if damaged 3 - Retaining clip 4 - 8 Nm 5 - Coolant regulator housing with coolant regulator must be replaced completely The function of the coolant regulator cannot be checked 6 - Coolant pipe 7 - Gasket ring replace if damaged 8 - To connection fitting on the heat exchanger connection on the duct on the right (in the direction of travel) connection diagram for coolant hoses 19-1 page 5 9 - From connection fitting on the heat exchanger connection on the duct on the left (in the direction of travel) connection diagram for coolant hoses 19-1 page 5 10 - From bottom radiator connection connection diagram for coolant hoses 19-1 page 5 11 - To top radiator connection connection diagram for coolant hoses 19-1 page 5
Edition 12.04 S00.5322.03.20
19-1 page 3
19
Coolant pump
1 - 22 Nm Hold the belt pulley with Vribbed belt attached for loosening and fixing it 2 - Belt pulley for the V-ribbed belt 3 - 24 Nm 4 - Coolant pump check smooth operation Inspect the plastic screw for tears the pump should be replaced completely if the seal on it is damaged removing and installing Chapter 19-3 5 - 24 Nm do not mix up with other screws cement should be spread on the thread
19-1 page 4
Edition 12.04 S00.5322.03.20
19
Connection diagram for coolant hoses

For engine with engine identification characters AWY, BME 1 - Radiator after replacing fill entire system with fresh coolant removing and installing Chapter 19-3 2 - Ventilation tube 3 - Crankcase 4 - Coolant pump removing and installing Chapter 19-3 check smooth operation 5 - Expansion reservoir 6 - Coolant pipe 7 - Heat exchanger 8 - Coolant regulator housing with coolant regulator removing and installing 19-1 page 3 9 - Quick coupling for radiator connections replace the gaskets if damaged then wet with coolant additive before inserting
Edition 12.04 S00.5322.03.20
19-1 page 5
19
For engine with engine identification characters BMD 1 - Ventilation hose 2 - PCV ventilation pipe with heating through coolant 3 - Coolant pipe 4 - Heat exchanger 5 - Coolant regulator housing with coolant regulator removing and installing 19-1 page 3 6 - Quick coupling for radiator connections replace the gaskets if damaged then wet with coolant additive before inserting 7 - Radiator after replacing fill entire system with fresh coolant removing and installing Chapter 19-3 8 - Crankcase 9 - Coolant pump removing and installing Chapter 19-3 check smooth operation 10 - Expansion reservoir
19-1 page 6
Edition 12.04 S00.5322.03.20
19
19-2
Removing and installing parts of the cooling system - Part 1
Information concerning the mixture ratios 19-2 page 1
Draining and filling up coolant

Coolant capacity approx. 5.0 ltr. Special tools, test and measuring equipment and auxiliary items required
Catch pan e.g. - V.A.G 1306 antifreeze tester
Draining
WARNING! Hot steam may escape when the expansion reservoir is opened. Cover the cap with a cloth and open carefully.
Open the coolant cap on the coolant expansion bottle. Remove noise insulation -arrows-. Place a catch pan under the engine. Turn the drain plug -arrow- on the radiator to the left and draw backwards; fit auxiliary hose onto connection if necessary. Note
S10-0135
Observe the disposal instructions for coolant.
Filling up
Select the appropriate coolant additive from the original spare parts catalogue KODA or from the list of allowed coolant additives Inspection and Maintenance. Recommended mixture ratios: Antifreeze pro- Antifreeze contection down to centration1)2) -25 C -35 C
1)
A10-0118
Drinking water2) 60 % (3.0 litres) 50 % (2.5 litres)
40 % (2,0 ltr.) 50 % (2.5 litres)
2)
In order to obtain adeqaute corrosion protection the antifreeze concentration must not be less than 30% and not more than 60 %; the antifreeze protection and cooling efficiency are reduced as the concentration increases. The coolant amount may differ according to the version of the vehicle.
Insert and tighten the coolant drain plug. Remove the coolant temperature sender.
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19-2 page 1
19
coolant temperature is visible in the filler neck.
Fill up with with coolant slowly until the sender for the Install the coolant temperature sender Fill up coolant gradually up to max marking on the
expansion reservoir.
Close expansion bottle. Run engine until fan starts.

G1 2
Check the level of coolant and top up if necessary.

When engine is at operating temperature the coolant level must be at the max marking, when engine is cold between the min and max markings.
S19-0077
Checking the coolant system for tightness

Coolant system tester, e.g. -V.A.G 1274 Adapter, e.g. -V.A.G 1274/8 Adapter, e.g. -V.A.G 1274/9 -
Test condition
Engine must be warm

Test sequence
Open the cap of the coolant expansion reservoir. Position coolant system tester, e.g. -V.A.G 1274- with
adapter, e.g. - V.A.G 1274/8- on the coolant expansion bottle.
V.A.G 1274
Using the hand pump of the tester generate an overpressure of approx. 0.14 Mpa (1.4 bar).
If the pressure drops determine location of the leaks

and repair them.
Testing the pressure relief valve in the cap
V.A.G 1274/8
G1 2
Screw cap onto the tester using an adapter, e.g.

-V.A.G 1274/9 -.
S19-0082
19-2 page 2
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19
Using the hand pump of the tester generate an overpressure of approx. 0.16 Mpa (1.6 bar).
The pressure relief valve should open at a pressure of

0.140.16 MPa (1.4 1.6 bars).
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19
19-2 page 4
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19
19-3
Removing and installing radiator

Catch pan e.g. - V.A.G 1306-
Removing
Drain coolant Chapter 19-2. Remove connector -1- from thermo-switch for the
coolant fan -F18- and disconnect plug connection -2on the holder of the air duct scoop. To do so press the latch clips. There are 2 plug connections on vehicles fitted with air conditioning.
1 2 3
Separate the coolant hose from the radiator at the top

and bottom of the connection fittings. To do so pull the retaining clip -3- up to the stop and remove the quick coupling towards the rear.
Remove the lock carrier with component parts

Body work; Rep. Gr. 50.
S19-0078

WARNING! Do not open the refrigerant circuit of the air conditioning system.
Attach the condenser with the radiator to the engine or

support. Note
Do not suspend the condenser to the wires. Do not fold the condenser wires.
Release the bolts securing the condenser -arrowsand remove radiator with fan. Tightening torque: 5 Nm
S19-0081
Installing
Top up coolant Chapter 19-2.
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19-3 page 1
19
Removing and installing coolant pump

Components and tightening torques Chapter 19-1
Removing
Drain coolant Chapter 19-2. Only slacken the bolts of the coolant pump belt pulley,
do not remove them.
Remove the V-ribbed belt Chapter 13-1. Remove belt pulley from the coolant pump. Unscrew coolant pump.
Installing
Inspect the plastic screw for the coolant pump for
tears.
Top up coolant Chapter 19-2.
19-3 page 2
Edition 08.02 S00.5322.00.20
20
20 Fuel Supply
20-1 Removing and installing parts of the fuel supply system
For engine with engine identification characters AWY 2.0/85 TDI Engine, Mechanical Components; Rep. Gr. 20 For engine with engine identification characters AZQ, BMD, BME 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
Removing and installing fuel tank with attached parts and fuel filter
For engine with engine identification characters AWY 2.0/85 kW Engine, Mechanics; Rep. Gr. 20 For engine with engine identification characters AZQ, BMD, BME 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
Safety precautions when working on the fuel supply system

2.0/85 kW Engine, Mechanics; Rep. Gr. 20
Rules of cleanliness
2.0/85 Engine, Mechanical Components; Rep. Gr. 20
Removing and installing the fuel delivery unit

Removing and installing the fuel gauge sender

Removing and installing the fuel tank

For engine with engine identification characters AWY 2.0/85 Engine, Mechanical Components; Rep. Gr. 20 For engine with engine identification characters AZQ, BMD, BME
Edition 12.04 S00.5322.03.20
Removing and installing parts of the fuel supply system
20-1 page 1
20
1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
Inspecting the fuel delivery unit and fuel system

For engine with engine identification characters AWY 2.0/85 Engine, Mechanical Components; Rep. Gr. 20 For engine with engine identification characters AZQ, BMD, BME 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
Inspecting the operating and holding pressure of the fuel, inspecting the nonreturn valve of the fuel delivery unit
1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24
Disconnecting the fuel delivery unit with crash signal

20-1 page 2
Removing and installing parts of the fuel supply system
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20
20-2
Inspecting the electronic power control (electronic throttle)
2.0/85 kW Engine - Mechanics; Rep. Gr. 20
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20-2 page 1
20
20-2 page 2
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20
20-3
Activated charcoal filter system
Summary of components of activated charcoal filter system

2.0/85 kW Engine - Mechanics; Rep. Gr. 20
Edition 08.02 S00.5322.00.20
20-3 page 1
20
20-3 page 2
Edition 08.02 S00.5322.00.20
26
26 Exhaust System
26-1 Removing and installing parts of the exhaust system
Note Always replace gaskets and self-locking nuts. For engine with engine identification characters AWY, AZQ 1 - Hot air collector/shield 2 - 8 Nm 3 - Exhaust manifold with integrated catalytic converter Check catalytic converter 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 01 4 - Lambda probe -G39-, 50 Nm pay attention to the spare part number in front of the catalytic converter 4-pin connector for engine with engine identification characters AWY 6-pin connector for engine with engine identification characters AZQ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body Check Lambda probe before catalyst -G39- und lambda control 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. 5 - Gasket replace 6 - Shield plate - short for vehicles without air conditioning 7 - Shield plate - extended for vehicles with an air conditioning system 8 - 23 Nm 9 - Front exhaust pipe for engines complying with exhaust emission standard EU-4, EU-3 DDK for engines with engine identification characters AZQ complying with exhaust emission standard EU-2 DDK 10 - Clamping sleeve align exhaust system free of stress before fitting on 26-1 page 4 Fitting position: bolts at bottom and horizontal Tighten bolted connections evenly
Edition 12.04 S00.5322.03.20
Removing and installing parts of the exhaust system
26-1 page 1
26
11 - Front exhaust pipe for engines with engine identification characters AWY complying with exhaust emission standard EU-2 DDK 12 - Retaining strap replace if damaged 13 - 20 Nm 14 - Support 15 - 40 Nm replace coat stud bolts of exhaust manifold with hot bolt paste -G 052 112 A3- before installing. 16 - Lambda probe downstream of catalytic converter -G130-, 50 Nm coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body Check Lambda probe after catalyst -G130- und lambda control 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. 17 - Gasket replace 18 - 25 Nm replace coat stud bolts of exhaust manifold with hot bolt paste -G 052 112 A3- before installing.
For engine with engine identification characters BMD, BME 1 - Shield 2 - 8 Nm 3 - Exhaust manifold with integrated catalytic converter pay attention to the spare part number Check catalytic converter 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 01 4 - Lambda probe -G39-, 50 Nm pay attention to the spare part number in front of the catalytic converter coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body Check Lambda probe before catalyst -G39- und lambda control 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. 5 - Gasket replace 6 - Shield plate - short for vehicles without air conditioning 7 - Shield plate - extended for vehicles with an air conditioning system 8 - 22 Nm 9 - 23 Nm
26-1 page 2
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10 - Front exhaust pipe for engines with engine identification characters BMD complying with exhaust emission standard EU-4 for engines with engine identification characters BME complying with exhaust emission standard EU-4 and EU-2 DDK 11 - Clamping sleeve align exhaust system free of stress before fitting on 26-1 page 4 Fitting position: bolts at bottom and horizontal Tighten bolted connections evenly 12 - Front exhaust pipe for engines with engine identification characters BMD complying with exhaust emission standard EU-2 DDK 13 - Retaining strap replace if damaged 14 - 20 Nm 15 - Support 16 - 40 Nm replace coat stud bolts of exhaust manifold with hot bolt paste -G 052 112 A3- before installing. 17 - Lambda probe downstream of catalytic converter -G130-, 50 Nm coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body Check Lambda probe after catalyst -G130- und lambda control 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 24. 18 - Gasket replace 19 - 25 Nm replace coat stud bolts of exhaust manifold with hot bolt paste -G 052 112 A3- before installing. 20 - Shield for engines with engine code BME for nordic countries
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Silencer with hangers
1 - 23 Nm 2 - Hanger retaining strap made of silicone pay attention to the spare part number 3 - Hanger retaining strap made of EPDM pay attention to the spare part number 4 - Hanger retaining strap made of EPDM 5 - Separation point Disconnect the front and rear silencers when conducting repairs 26-1 page 5 6 - Front and rear silencer Replace individually when carrying out repairs 26-1 page 5 Align exhaust system free of stress 26-1 page 4
Aligning exhaust system free of stress

The exhaust system is aligned when cold. Slacken bolted connections of clamping sleeve between catalytic converter and front silencer and replace nuts.
Position clamping sleeve at the distance -a- = 5 mm

from the marking on the front exhaust pipe (bolts at bottom and horizontal) and tighten front bolted connection slightly.
S26-0064
26-1 page 4
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26
Push front silencer -1- sufficiently far forward into the

clamping sleeve until the dimension -b- of 3...7 mm is achieved between hanger of body and hanger of front silencer. -Arrow- points in direction of travel.
Tighten bolted connections on the clamping sleeve in

this position. Tightening torque: 23 Nm Note After tightening the clamping sleeve, inspect dimension -b- and adjust if necessary.
b
S26-0065
Replacing front or rear silencer

Body saw (e.g. -V.A.G 1523-)
A separation point is provided for repair purposes for replacing the front silencer or rear silencer.
Separate exhaust pipe with body saw at right angles

at the separation point -arrow 1-.
When installing clamping sleeve -4- position on the

side markings -arrow 2 and 3-.
Align exhaust system free of stress 26-1 page 4. Align rear silencer horizontally. Tighten bolted connections of the clamping sleeve
evenly to 23 Nm. Installation position of clamping sleeve: Bolts positioned vertically at front of exhaust pipe.
3 2 1
Checking the exhaust system for leaks

Start engine and run in idle. Seal off tail pipe for the duration of the leak check (e.g.
with cloth or plug).
S26-0063
Check the connection points for leaks by listening:

Cylinderhead/exhaust manifold, exhaust manifold/exhaust pipe with catalytic converter, etc.
Eliminate any leak found.
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26-1 page 6
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26-2
Exhaust gas recirculation system
Exhaust gas recirculation system - Summary of components

For engine with engine identification characters AZQ, BME 1 - EGR valve -N18- with EGR potentiometer -G212 Inspect exhaust gas recirculation valve -N18- 1.2/40; 1.2/47 Engine, Fuel Injection; Rep. Gr. 01 2 - Gasket replace 3 - Adapter 4 - 20 Nm 5 - 10 Nm 6 - 10 Nm 7 - Connecting tube 8 - 20 Nm 9 - Vacuum hose To air filter
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26-2 page 2
Edition 12.04 S00.5322.03.20

Engines Awy, Azq, BMD, Bme

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Service

1.2/40; 1.2/47 Engine, Mechanical Components

Service Department. Technical Information

Printed in Czech Republic S00.5322.00.20

Printed in Czech Republic S00.5322.00.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

List of Supplements to Workshop Manual

Edition 08.02 04.03 06.04 12.04

Article Number S00.5322.00.20 S00.5322.01.20 S00.5322.02.20 S00.5322.03.20

Edition 12.04 S00.5322.03.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

Edition 12.04 S00.5322.03.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

10 Removing and Installing Engine

15 Cylinder Head, Valve Gear

Edition 12.04 S00.5322.03.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

Edition 12.04 S00.5322.03.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

Edition 12.04 S00.5322.03.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

10 Removing and Installing Engine

Jacking up points for raising the vehicle Inspection

Pay attention to the correct assignment of the connec-

tors, if necessary mark.

If the battery is disconnected and reconnected, carry

out certain additional operations Electrical System; Rep. Gr. 27.

Edition 04.03 S00.5322.01.20

Removing and Installing Engine

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

The engine is removed together with the cable harness.

Disconnect all cables for the engine, gearbox, starter

Remove the coolant hose which connects the coolant

Remove the vacuum hose from the brake servo unit.

Unplug the plug connection -2- and remove solenoid

Remove the cooling system ventilation hose -7- from

Remove the coolant hose -6- on the pipe behind the

Remove Bowden cable support Manual gearbox

Remove the slave cylinder of the hydraulic clutch

Removing the lock carrier Body work; Rep. Gr. 50.

Secure the AC compressor -1- to the lock carrier -arrow-.

Remove the lock carrier with the radiator and con-

Removing and Installing Engine

Edition 04.03 S00.5322.01.20

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

damage, removing the headlight if necessary.

Continued for all vehicles

Hook lifting device -MP 9-201- into the engine lifting

Release screws -1-.

Unscrew the screws -arrows- from the gearbox

Slightly lower the engine with gearbox and pull out

Remove the engine from the gearbox.

Edition 04.03 S00.5322.01.20

Removing and Installing Engine

FABIA 2000 1.2/40; 1.2/47 Engine, Mechanical Components

Installing the engine

Check whether the dowel sleeves for centering the

If necessary check the centering of the clutch driver

Inspect clutch release bearing for wear, replace if necessary.

Grease the drive shaft serration with grease

When installing engine/gearbox unit, ensure adequate clearance to neighbouring components.

Align the engine and gearbox so that they are tensionfree.