Service
5
Service Department. Technical Information
Printed in Czech Republic
S00.5327.00.20
Workshop Manual
FABIA 2000 ³
1.9/96 TDI Engine, Mechanics
Edition 07.03
Engine code
ASZ
Service
5
Service Department. Technical Information
Printed in Czech Republic
S00.5327.00.20
Workshop Manual
FABIA 2000 ³
1.9/96 TDI Engine, Mechanics
Edition 07.03
Engine code
ASZ
Service
5
The Workshop Manual is intended only for use within the Organisation Škoda.
It is not permitted to pass it on to other persons.
© ŠKODA AUTO a. s.
Printed in Czech Republic
S00.5327.00.20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
List of Supplements
Edition 07.03
S00.5327.00.20
List of Supplements to Workshop Manual
FABIA 2000 ³
1.9/96 TDI Engine, Mechanics
Edition 07.03
Supple-
ment
Edition
Subject
Article Number
07.03
Basic Edition
S00.5327.00.20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
List of Supplements
Edition 07.03
S00.5327.00.20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Table of Contents
Edition 07.03
S00.5327.00.20
I
Table of Contents
00 – Technical Data
Technical Data ..........................................................................................
10 – Removing and Installing Engine
Removing and Installing Engine ....................................................................
13 – Crankgear
Removing and installing V-ribbed belt ............................................................
Removing and installing, tightening the timing belt ...........................................
Removing and installing sealing flange and flywheel .........................................
Crankshaft, Piston and Conrod .....................................................................
15 – Cylinder Head, Valve Gear
Removing and installing cylinder head ...........................................................
Repairing Valve Gear ..................................................................................
Camshaft .................................................................................................
Valve seats, valves guides, valve stem seals ....................................................
17 – Lubrication
Removing and installing parts of the lubrication system .....................................
- Disassembling and assembling oil filter holder ...................................................
Removing and installing oil pan ....................................................................
Testing oil pressure and oil pressure switch ....................................................
19 – Cooling
Parts of cooling system - Summary of components ...........................................
Removing and installing radiator, coolant pump and coolant thermostat ................
20 – Fuel Supply
Removing and installing parts of the fuel supply system ....................................
Repairing the accelerator control ..................................................................
21 – Turbocharging
Charge air system with turbocharger I ............................................................
- Removing and installing exhaust turbocharger with component parts ........................
- Removing and installing parts of the charge air cooling .........................................
- Connection diagram for vacuum hoses ............................................................
Charge air system with turbocharger II ...........................................................
- Remove exhaust turbocharger ......................................................................
- Checking charge pressure control ..................................................................
26 – Exhaust System
Removing and installing parts of the exhaust system ........................................
- Aligning exhaust system free of stress .............................................................
- Procedure ...............................................................................................
- Replacing middle or rear silencer ...................................................................
- Checking the exhaust system for leaks ............................................................
Exhaust gas recirculation system ..................................................................
00-1
page
1
10-1
page
1
13-1
page
1
13-2
page
1
13-3
page
1
13-4
page
1
15-1
page
1
15-2
page
1
15-3
page
1
15-4
page
1
17-1
page
1
17-1
page
2
17-2
page
1
17-3
page
1
19-1
page
1
19-2
page
1
20-1
page
1
20-2
page
1
21-1
page
1
21-1
page
1
21-1
page
2
21-1
page
2
21-2
page
1
21-2
page
1
21-2
page
1
26-1
page
1
26-1
page
2
26-1
page
2
26-1
page
2
26-1
page
3
26-2
page
1
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Table of Contents
Edition 07.03
S00.5327.00.20
II
- Testing mechanical exhaust gas recirculation valve ............................................. 26-2
page
2
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Technical Data
Edition 07.03
S00.5327.00.20
00-1
page
1
00
00-1
Technical Data
Engine number
The engine number („engine identification characters“
and „serial number“) is located at the engine/gearbox
joint -arrow-.
In addition, a sticker with the „engine identification char-
acters“ and „serial number“ is affixed to the timing belt
guard.
The engine identification characters are also indicated on
the vehicle data sticker.
Engine characteristics
00 – Technical Data
Engine identification characters
ASZ
Manufactured
06.03 ³
Exhaust limits conforming to
EU-3
Displacement
l
1,896
Power output
kW at rpm
96/4000
Torque
Nm at rpm
310/1900
Bore
∅ mm
79,5
Stroke
mm
95,5
Compression
19,0 : 1
Firing order
1-3-4-2
min. CN
49
Catalytic converter
yes
Exhaust gas recirculation
yes
Turbocharging
yes
Charge air cooler
yes
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Technical Data
Edition 07.03
S00.5327.00.20
00-1
page
2
00
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and Installing Engine
Edition 07.03
S00.5327.00.20
10-1
page
1
10
10-1
Removing and Installing
Engine
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 10
⇒ Gearbox 0A8; Rep. Gr. 30 und 34
The removing of the 1.9/96 TDI Engine can differ in cer-
tain details from the removing of the 1.9/74 TDI Engine.
10 – Removing and Installing Engine
Note
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and Installing Engine
Edition 07.03
S00.5327.00.20
10-1
page
2
10
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing V-ribbed belt
Edition 07.03
S00.5327.00.20
13-1
page
1
13
13-1
Removing and installing
V-ribbed belt
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 13
13 – Crankgear
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing V-ribbed belt
Edition 07.03
S00.5327.00.20
13-1
page
2
13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing, tightening the timing belt
Edition 07.03
S00.5327.00.20
13-2
page
1
13
13-2
Removing and installing,
tightening the timing belt
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing, tightening the timing belt
Edition 07.03
S00.5327.00.20
13-2
page
2
13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing sealing flange and flywheel
Edition 07.03
S00.5327.00.20
13-3
page
1
13
13-3
Removing and installing
sealing flange and fly-
wheel
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing sealing flange and flywheel
Edition 07.03
S00.5327.00.20
13-3
page
2
13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Crankshaft, Piston and Conrod
Edition 07.03
S00.5327.00.20
13-4
page
1
13
13-4
Crankshaft, Piston and
Conrod
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Crankshaft, Piston and Conrod
Edition 07.03
S00.5327.00.20
13-4
page
2
13
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing cylinder head
Edition 07.03
S00.5327.00.20
15-1
page
1
15
15-1
Removing and installing
cylinder head
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15
15 – Cylinder Head, Valve Gear
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing cylinder head
Edition 07.03
S00.5327.00.20
15-1
page
2
15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Repairing Valve Gear
Edition 07.03
S00.5327.00.20
15-2
page
1
15
15-2
Repairing Valve Gear
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Repairing Valve Gear
Edition 07.03
S00.5327.00.20
15-2
page
2
15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Camshaft
Edition 07.03
S00.5327.00.20
15-3
page
1
15
15-3
Camshaft
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Camshaft
Edition 07.03
S00.5327.00.20
15-3
page
2
15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Valve seats, valves guides, valve stem seals
Edition 07.03
S00.5327.00.20
15-4
page
1
15
15-4
Valve seats, valves
guides, valve stem seals
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Valve seats, valves guides, valve stem seals
Edition 07.03
S00.5327.00.20
15-4
page
2
15
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the lubrication system
Edition 07.03
S00.5327.00.20
17-1
page
1
17
17-1
Removing and installing parts of the lubrication system
♦
If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine repairs,
carefully clean the oil galleries in order to avoid consequential damage and additionally replace the oil cooler.
♦
Testing oil pressure and oil pressure switch
⇒ Chapter 17-3.
♦
The oil level must never exceed the „max“ marking - risk of damage to catalytic converter!
Check the oil level, amount of oil and oil specification:
⇒ Inspection and Maintenance
1 - 15 Nm
2 - Bracket
T
For cable to oil level and oil
temperature sender
3 - Dipstick
T
Oil level must not exceed
„max“ marking!
4 - Filler funnel
T
Remove for extracting oil
5 - Guide tube
6 - Fitting sleeve
T
For centering oil pump/cylin-
der block
7 - O-ring
T
Replace
8 - Suction line
T
Clean strainer if dirty
9 - Baffle
10 - Oil pan
T
Before installing, coat with
silicone sealant
-D 176 404 A2-
⇒ Chapter
17-2
11 - Gasket ring
T
Replace
12 - Oil drain plug, 30 Nm
13 - 10 Nm
14 - Oil level and oil temperature
sender -G266-
T
Test
⇒ Electrical System;
Rep. Gr. 90
15 - Oil pump
T
With pressure relief valve 1.2 MPa
T
Before installing, check whether both dowel sleeves for centering oil pump/cylinder block are present
T
If there is any scoring on contact surfaces and gears, replace
16 - Oil pump sprocket
T
Fits onto oil pump shaft in one position only
17 - 25 Nm
17 – Lubrication
Note
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the lubrication system
Edition 07.03
S00.5327.00.20
17-1
page
2
17
18 - Sealing flange
T
Before installing, it must not be dirty
T
Before installing, coat with silicone sealant -D 176 404 A2-
⇒ Chapter 13-3
T
Replacing crankshaft seal
⇒ Chapter 13-3
19 - Oil pump chain
20 - Chain tensioner, 15 Nm
T
When installing, pretension spring and attach
21 - Oil injection nozzle
T
For piston cooling
T
Pay attention to SP No. (right-angle bend)
22 - 27 Nm
Disassembling and assembling oil filter holder
1 - Cap, 25 Nm
2 - Gasket
T
Replace
3 - Oil cooler
T
When installing, move up
against the anti-twist lock (in
direction of tightening)
4 - Gasket
T
Replace
T
Insert into lugs on oil cooler
5 - Oil pressure switch -F1-, 20
Nm
T
Brown
T
0.07 MPa (0.7 bar)
T
Cut open gasket ring if leak-
ing and replace
T
Inspect
⇒ Chapter 17-3
6 - Oil filter holder
T
With integrated overpressure
valve
7 - 15 Nm + torque a further
1
/
4
turn (90
°)
T
Replace
T
Before tightening, turn in by
hand first
8 - Gasket ring
T
Replace
9 - Connection fitting, 30 Nm
10 - Oil feed line
T
For exhaust turbocharger
T
Tighten to 22 Nm
11 - O-ring
T
Replace
12 - Oil filter element
T
When changing oil, fit new O-rings
⇒ item 11
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing oil pan
Edition 07.03
S00.5327.00.20
17-2
page
1
17
17-2
Removing and installing
oil pan
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 17
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing oil pan
Edition 07.03
S00.5327.00.20
17-2
page
2
17
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Testing oil pressure and oil pressure switch
Edition 07.03
S00.5327.00.20
17-3
page
1
17
17-3
Testing oil pressure and
oil pressure switch
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 17
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Testing oil pressure and oil pressure switch
Edition 07.03
S00.5327.00.20
17-3
page
2
17
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Parts of cooling system - Summary of components
Edition 07.03
S00.5327.00.20
19-1
page
1
19
19-1
Parts of cooling system -
Summary of components
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 19
19 – Cooling
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Parts of cooling system - Summary of components
Edition 07.03
S00.5327.00.20
19-1
page
2
19
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing radiator, coolant pump and coolant
thermostat
Edition 07.03
S00.5327.00.20
19-2
page
1
19
19-2
Removing and installing
radiator, coolant pump
and coolant thermostat
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 19
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing radiator, coolant pump and coolant
thermostat
Edition 07.03
S00.5327.00.20
19-2
page
2
19
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the fuel supply system
Edition 07.03
S00.5327.00.20
20-1
page
1
20
20-1
Removing and installing
parts of the fuel supply
system
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 20
20 – Fuel Supply
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the fuel supply system
Edition 07.03
S00.5327.00.20
20-1
page
2
20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Repairing the accelerator control
Edition 07.03
S00.5327.00.20
20-2
page
1
20
20-2
Repairing the accelerator
control
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Repairing the accelerator control
Edition 07.03
S00.5327.00.20
20-2
page
2
20
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Charge air system with turbocharger I
Edition 07.03
S00.5327.00.20
21-1
page
1
21
21-1
Charge air system with turbocharger I
Removing and installing exhaust turbocharger with component parts
Pay attention to rules for cleanliness
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21.
♦
The hose connections are secured with clamps.
♦
The charge-air system must be tight.
♦
Always replace self-locking nuts.
1 - Oil feed line
2 - 22 Nm
3 - Sealing sleeve
4 - 5 Nm
5 - 10 Nm
6 - Connection fitting, 30 Nm
7 - Gasket ring
T
Replace
8 - Gasket
T
Replace
T
Check fitting position
9 - Support
T
Exhaust turbocharger - cylin-
der block
10 - Washer
11 - 25 Nm
T
Replace
T
Coat stud bolts with
-G 052 112 A3-
12 - 40 Nm
13 - Connecting tube
T
Between turbocharger and
air filter
14 - Flange
15 - Connecting hose
16 - Connection fitting, 40 Nm
17 - Oil return line
T
To cylinder block
T
Tighten to 30 Nm
18 - 15 Nm
19 - Gasket
T
Replace
20 - Exhaust turbocharger
T
Can only be replaced complete with exhaust manifold
T
Removing and installing
⇒ Chapter 21-2
T
Inspecting charge pressure control
⇒ Chapter 21-2
T
Charge pressure regulating valve and vacuum unit for charge pressure regulating valve are component parts
of the exhaust turbocharger and cannot be replaced individually
21 – Turbocharging
Note
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Charge air system with turbocharger I
Edition 07.03
S00.5327.00.20
21-1
page
2
21
T
After installing the turbocharger, run engine at idling speed for about 1 minute to ensure that oil is supplied to
the turbocharger
21 - Vacuum line
T
To the solenoid valve for charge pressure limitation -N75-
22 - 20 Nm
23 - 20 Nm
T
Replace
24 - Shield
25 - Front exhaust pipe with catalytic converter
26 - Bracket
27 - Intake manifold
28 - 6 Nm
Removing and installing parts of the
charge air cooling
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21
Connection diagram for vacuum hoses
1 - Valve block
T
Component parts of the
valve block are:
♦
Changeover valve for intake
manifold flap -N239-
♦
Solenoid valve for exhaust
gas recir culation -N18-
♦
Solenoid valve for charge
pressure control -N75-
2 - Connecting strip
T
Pay attention to the coding
when connecting the vacu-
um hoses
3 - Connecting piece
4 - Vacuum unit
T
For charge pressure control
T
Components of the exhaust
gas turbocharger cannot be
replaced individually
5 - Vacuum unit
6 - To air filter
7 - Vacuum unit
T
For intake manifold flap
8 - Mechanical exhaust gas recir-
culation valve
9 - Tandem pump
10 - Distributor part
T
With non-return valve for
brake servo unit
11 - Brake servo unit
S21-0043
1
2
3
4
5
7
8
9
10
11
6
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Charge air system with turbocharger II
Edition 07.03
S00.5327.00.20
21-2
page
1
21
21-2
Charge air system with
turbocharger II
Remove exhaust turbocharger
⇒ 1.9/74 TDI Engine, Mechanics; Rep. Gr. 21
Checking charge pressure control
Special tools, test and measuring equipment and
auxiliary items required
♦
Hand vacuum pump (e.g. -V.A.G 1390-)
♦
Hand multimeter (e.g. -V.A.G 1715-)
♦
Vehicle system tester -V.A.G 1552-
♦
Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3C-
♦
Adapter cable set (e.g. -V.A.G 1594 C-)
♦
Test box -V.A.G 1598/31-
Test conditions
•
No fault stored in fault memory
⇒ 1.9/96 TDI Engine,
Fuel Injection; Rep. Gr. 01
•
No leaks on the intake and exhaust side
•
No fault on the engine/fuel injection system
•
Engine oil temperature at least 80
°C
Test sequence
If test and measuring devices are required during test
drives observe the following:
♦
Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
If the test and measuring equipment is operated from
the front passenger seat, this can result in injuries to
the persons sitting on that seat in the event of an ac-
cident which involves the front passenger airbag be-
ing deployed.
–
The charge pressure is measured with vehicle system
tester -V.A.G 1552- when the engine is idling and dur-
ing a road test.
–
Connect up the Vehicle system tester -V.A.G 1552-
and select the address word 01 „Engine electronics“
(the engine must be idling at the time)
⇒ 1.9/96 (TDI)
Engine, Fuel Injection; Rep. Gr. 01.
–
Select function „Initiate basic setting“ and dis-
play
group .
Readout on display:
0 4
0 1 1
Basic setting 11 ->
1400 rpm OFF 982 mbar 99 %
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Charge air system with turbocharger II
Edition 07.03
S00.5327.00.20
21-2
page
2
21
After selecting display group number 011, the idling
speed is increased by the engine control unit in display
block 1 to 1380…1420 rpm.
The display in display field 2 must switch between „off“
and „on“ every 10 seconds.
The following readouts must fluctuate in display fields 3
and 4:
Display field 2: off.
♦
Specification in display field 3: Atmospheric pressure
in mbar
♦
Specification in display field 4: 98…100%
Display field 2: on.
♦
Specification in display field 3: Atmospheric pressure
in mbar + 100…250 mbar
♦
Specification in display field 4: 0…2%
Continue the test as follows:
Press .
–
Read function „Read measured value block“
and select display group
.
–
Accelerate vehicle in 2nd gear from about 1000 rpm to
3200 rpm. While doing so the accelerator pedal must
be fully pressed down.
–
At about 3000 rpm read off value indicated in display
block.
Specification in display field 3: 2100…2600 mbar
If the specified value is not reached:
–
Conduct final control diagnosis for charge pressure
control solenoid valve -N75-
⇒ 1.9ltr./96 (TDI) En-
gine, Fuel Injection; Rep. Gr. 01.
Charge pressure control solenoid valve must operate for
this test. While doing so the linkage of the charge pres-
sure control vacuum unit at the bottom of the turbocharg-
er must move back and forward. This linkage must move
at least 3…4 times as long as a vacuum is present in the
vacuum system.
If the linkage moves and the nominal charge pressure is
not reached:
–
Replace turbocharger.
If the linkage does not move because the charge pres-
sure control solenoid valve is not operating:
–
Inspect charge pressure control solenoid valve -N75-
⇒ 1.9/96 (TDI) Engine, Mechanics; Rep. Gr. 23.
–
Inspect vacuum hoses
⇒ Chapter 21-1 .
If the linkage does not move although the charge pres-
sure control solenoid valve is operating:
Note
→
0 8
0 1 1
Reading measured value block 11 ->
3090 rpm 2346 mbar 2281 mbar 6
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Charge air system with turbocharger II
Edition 07.03
S00.5327.00.20
21-2
page
3
21
–
Connect hand vacuum pump to vaccum unit for
charge pressure control valve and inspect linkage for
unobstructed movement.
If the linkage only moves with difficulty or does not move
at all:
–
Replace turbocharger.
N21-0078
V.A.G 1390
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Charge air system with turbocharger II
Edition 07.03
S00.5327.00.20
21-2
page
4
21
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the exhaust system
Edition 07.03
S00.5327.00.20
26-1
page
1
26
26-1
Removing and installing
parts of the exhaust sys-
tem
♦
The exhaust manifold is a component part of the ex-
haust turbocharger and therefore must not be re-
placed individually; removing and installing
⇒ Chap.
21-2.
♦
Always replace gaskets and self-locking nuts.
♦
After performing installation work on the exhaust sys-
tem, make sure the exhaust system is not mounted
under tension, the individual components have ade-
quate clearance from the vehicle body and the weight
of the exhaust system is evenly distributed over the
hangers.
1 - Gasket
T
Replace
2 - Front exhaust pipe with cata-
lytic converter
3 - 25 Nm
T
Replace
T
Coat stud bolts of exhaust
turbocharger with hot bolt
paste -G 052 112 A3- be-
fore installing.
4 - Retaining loop
T
Press off from cross member
⇒ item 5 to remove front ex-
haust pipe with catalytic con-
verter
5 - Cross member
6 - 25 Nm
7 - Double clamp
T
Align exhaust system free of
stress before tightening
⇒ 26-1 page 2
T
Fitting position: bolts at bot-
tom and horizontal
T
Tighten bolted connections
evenly
8 - 40 Nm
T
Replace
9 - Spring hanger
T
Pay attention to part number
10 - Separation point
T
For repairs
⇒ 26-1 page 2
11 - Middle and rear silencer
T
Replace individually when carrying out repairs
⇒ 26-1 page 2
T
Align exhaust system free of stress
⇒ 26-1 page 2
26 – Exhaust System
Note
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the exhaust system
Edition 07.03
S00.5327.00.20
26-1
page
2
26
Aligning exhaust system free of stress
Special tools, test and measuring equipment and
auxiliary items required
♦
Torque wrench
Procedure
•
The exhaust system is aligned when cold.
–
Slacken bolted connections of double clamp between
front silencer with catalytic converter and middle and
rear silencer and replace nuts.
–
Position double clamp at the distance -a- = 5 mm from
the marking on the pipe of the catalytic converter
(bolts at bottom and horizontal) and tighten front bolt-
ed connection slightly.
–
Push middle silencer -1- sufficiently far forward into
the double clamp until the dimension -b- of 3...7 mm is
achieved between hanger of body and hanger of mid-
dle silencer.
-Arrow- points in direction of travel.
–
Tighten bolted connections on the double clamp in
this position.
Tightening torque: 40 Nm
After tightening the double clamp, inspect dimension -b-
and adjust if necessary.
Replacing middle or rear silencer
Special tools, test and measuring equipment and
auxiliary items required
♦
Torque wrench
♦
Body saw (e.g. -V.A.G.1523-)
A separation point is provided for repair purposes for re-
placing the middle silencer or rear silencer.
–
Separate exhaust pipe at right angles at the separa-
tion point -arrow 1- with body saw.
–
When installing, position double clamp -4- at the side
markings -arrow 2- and -arrow 3-.
–
Align exhaust system free of stress
⇒ 26-1 page 2.
–
Align rear silencer horizontally.
–
Tighten bolted connections of the double clamp even-
ly to 40 Nm.
Installation position of double clamp: Bolts positioned
vertically at front of exhaust pipe.
S26-0064
a
Note
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the exhaust system
Edition 07.03
S00.5327.00.20
26-1
page
3
26
Checking the exhaust system for leaks
–
Start engine and run in idle.
–
Seal off tail pipe for the test duration with suitable
plugs.
–
Check the connection points for leaks by listening:
Cylinder head/exhaust manifold, exhaust turbocharg-
er/front exhaust pipe with catalytic converter, double
clamp at middle or also at rear silencer.
–
Rectify any fault found.
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Removing and installing parts of the exhaust system
Edition 07.03
S00.5327.00.20
26-1
page
4
26
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Exhaust gas recirculation system
Edition 07.03
S00.5327.00.20
26-2
page
1
26
26-2
Exhaust gas recirculation
system
♦
The exhaust gas recirculation system is operated by
the diesel direct injection system control unit -J248-
via the EGR valve -N18- to the mechanical exhaust
gas recirculation valve.
♦
Inspecting exhaust gas recirculation
⇒ 1.9/96 (TDI)
Engine, Fuel Injection; Rep. Gr. 23 and exhaust gas
recirculation valve -N18-
⇒ 1.9/96 (TDI) Engine, Fuel
Injection; Rep. Gr. 01.
♦
The mechanical exhaust gas recirculation valve with
conically shaped valve tappet makes it possible to
achieve different opening cross-sections at different
valve strokes.
♦
Connection diagram for vacuum hoses
⇒ Chap. 21-1.
1 - Intake manifold
2 - O-ring
T
Replace
3 - Vacuum setting element
4 - 5 Nm
5 - Mechanical exhaust gas recir-
culation valve
T
Component part of the induc-
tion pipe
T
Must be replaced together
with the induction pipe
T
Check
⇒ 26-2 page 2
6 - Induction pipe
T
With mechanical exhaust
gas recirculation valve and
control flap
7 - 10 Nm
8 - Gasket
T
Replace
9 - 25 Nm
10 - Connecting tube
11 - Gasket
T
Replace
T
Check fitting position
12 - 6 Nm
13 - Sealing sleeve
Note
FABIA 2000 ³ 1.9/96 TDI Engine, Mechanics
Exhaust gas recirculation system
Edition 07.03
S00.5327.00.20
26-2
page
2
26
Testing mechanical exhaust gas recircu-
lation valve
Special tools, test and measuring equipment and
auxiliary items required
♦
Hand vacuum pump (e.g. -V.A.G 1390-)
Test sequence
–
Remove engine cover -arrows-.
–
Disconnect vacuum hose on mechanical exhaust-gas
recirculation valve.
–
Connect hand vacuum pump to valve and operate
pump.
The diaphragm rod must move in the direction of the
vacuum connection -Pfeil-.
–
Detach hose of hand vacuum pump from mechanical
exhaust gas recirculation valve.
The diaphragm rod must move back to its original po-
sition against the -direction of the arrow-.
V.A.G 1390
S13-0161