engine coolant SKODA FABIA 2000 1.G / 6Y Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
List of SupplementsEdition 09.04
S00.5301.14.20
List of Supplements to Workshop Manual
FABIA 2000➤
Inspection and Maintenance
Edition 08.99
Supple-
mentEdition Subject Article Number
08.99 Basic Edition S00.5301.00.20
1 12.99 Supplement to Basic Edition S00.5301.01.20
2 02.00 Vehicle identification number S00.5301.02.20
3 03.00 Inspection Service every 90.000 km; exhaust-emission analysis S00.5301.03.20
4 11.00 FABIA COMBI, new engines and gearboxes, exhaust-emission
analysisS00.5301.04.20
5 12.00 Vehicle identification number, exhaust-emission analysis, text
modificationsS00.5301.05.20
6 06.01 FABIA SEDAN, text modifications S00.5301.06.20
7 11.01 Additional text S00.5301.07.20
8 02.02 Engines AWY and BBY S00.5301.08.20
9 06.02 Engine BBZ, coolant G12 Plus S00.5301.09.20
10 10.02 Additions and alterations to the text, exhaust-emission analysis S00.5301.10.20
11 04.03 AZQ Engine, additions and alterations to the text S00.5301.11.20
12 07.03 Exhaust-emission analysis according to EOBD, engine oil capacity
at oil change, engines AMF and ASZS00.5301.12.20
13 02.04 Exhaust gas, addition to text S00.5301.13.20
14 09.04 BMD, BKY engine, addition to text S00.5301.14.20

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
Table of ContentsEdition 09.04
S00.5301.14.20I Table of Contents
02 – Inspection and Maintenance
General points..........................................................................................
- Vehicle identification data ............................................................................
- Storage of ŠKODA new vehicles ....................................................................
- Vehicle handover from stock ........................................................................
- Additional customer information regarding inspection and maintenance .....................
Inspection................................................................................................
- Pre-Delivery Inspection -PDI- (Export) .............................................................
- Pre-sales Inspection - (the Czech Republic) ......................................................
- Delivery Inspection (Export) .........................................................................
- Oil Change Service every 15.000 km
1) (QG0) ....................................................
- Annual Inspection (every 12 months) (QG0) ......................................................
- Every 30 000 km (QG0) ..............................................................................
- Every 60 000 km (QG0) ..............................................................................
- Every 90 000 km (QG0) ..............................................................................
- Every 120 000 km (QG0) .............................................................................
- Every 150.000 km (QG0) .............................................................................
- Every 240 000 km (QG0) .............................................................................
- Inspection Service (QG1, QG2) .....................................................................
- Oil change (QG1, QG2)..............................................................................
Engines...................................................................................................
- Engine overview .......................................................................................
- Engine fitted ............................................................................................
- Visual inspection: Engine for leaks and damage .................................................
- Replace engine oil filter ...............................................................................
- Replacing timing belt and tensioning pulley for camshaft drive (1.9 TDI engines) ..........
- Replacing timing belt and tensioning pulley for camshaft drive (1.4 TDI engines) ..........
- Inspecting timing belt for camshaft drive for wear and running (petrol engine) ..............
- Replacing toothed belt and guide pulley for camshaft drive (1.9 SDI engines) ..............
- Inspecting engine oil level ............................................................................
- Change engine oil .....................................................................................
- Inspecting antifreeze protection, replenishing coolant additive if necessary .................
- Inspecting coolant level (volume) ...................................................................
- Ribbed V-belt: Inspect condition....................................................................
- Routing of V-ribbed belt ..............................................................................
- Replace spark plugs ..................................................................................
- Replace air filter element .............................................................................
- Replacing the fuel filter (diesel engine) ............................................................
- Draining the fuel filter (diesel engine) ..............................................................
Gearbox...................................................................................................
- Gearbox/Final drive: Check the oil level and top it if necessary ................................
- Inspecting ATF level, if necessary topping up ....................................................
Chassis...................................................................................................
- Inspecting thickness of front and rear brake pads/linings .......................................
- Inspecting brake system for leaks and damage ..................................................
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InspectionEdition 09.04
S00.5301.14.2002-2 page 1 02
02-2 Inspection
Pre-Delivery Inspection -PDI- (Export)
The operations marked with * apply to all countries; other
operations are applicable to certain countries only!
Compare as-delivered condition of vehicle with order form Chapter
♦Engine fitted
♦Type plate in the engine compartment
♦Vehicle data sticker (compare with stamped identification number)
♦Colour of paintwork, badges, inscriptions
♦Seats (cover, colour) interior trim (colour)
♦Radio, speakers, aerial
♦Central locking system, anti-theft alarm system
♦Wheels, tyres
♦Sun roof
♦Vehicle log book - for completion: Operating manual and service plan (in the correct lan-
guage and with the correct edition data), short introduction, technical data, support in the
case of a breakdown, other manuals (radio,...) ) - all in the vehicle log book pouch
♦Other equipment (all equipment fitted in proper condition)
* Check transport damage (bodywork, paintwork, upholstery, interior trim, carpeting, footmats,
tyres, wheels)02-5, 02-7
Vehicle (exterior)
–Check that all car keys and key number fobs have been provided; check that the sticker
for the key number for the electronic immobiliser is complete and legible
–Proper operation of door handles outside, door locks, child safety locks, door contact
switches and proper operation of all locks and keys (including spare keys), doors, boot lid/
tailgate, fuel filler cap, bonnet lock02-7
–Proper operation of anti-theft alarm system
Engine compartment (from above)
–Check battery no-load voltage, recharge battery if necessary02-6
–Check tight connection of electric cables and plug connections (in particular battery ca-
bles)
–Inspect engine, gearbox, cooling system, brake system and fuel system for leaks02-3, 02-5
–Engine oil level (in-between markings on dipstick)02-3
–Brake fluid level (at „MAX“ marking)02-5
–Coolant level (in-between marking), special equipment antifreeze down to -35°C02-3
–Fill up fluid in washer reservoir, in the winter add antifreeze
Vehicle interior
–Proper operation of seat belts, seat belt height adjuster, power windows and sun roof
–Check car tool kit, spare wheel and accessories for completeness and proper attachment
Underside of vehicle (on lift platform)
–Inspect underbody (underbody protection for damage)02-7
–Inspect for leaks and damage: Engine, gearbox, final drive, steering, brake system, axles,
joint boots. Check proper routing of the brake hoses and brake lines, fuel lines including
ventilation of the fuel system02-3, 02-5

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InspectionEdition 09.04
S00.5301.14.2002-2 page 2 02
Pre-sales Inspection - (the Czech Republic)
Compare as-delivered condition of vehicle with order form Chapter
♦Engine fitted
♦Type plate in the engine compartment
♦Vehicle data sticker (compare with stamped identification number)
♦Colour of paintwork, badges, inscriptions
♦Seats (cover, colour) interior trim (colour)
♦Radio, speakers, aerial
♦Central locking system, anti-theft alarm system
♦Wheels, tyres
♦Sun roof
♦Vehicle log book - for completion: Operating manual and service plan (in the correct lan-
guage and with the correct edition data), a list of dealers, short introduction, technical da-
ta, other manuals (radio......) ) - all in the vehicle log book pouch
♦Other equipment (all equipment fitted in proper condition)
♦Vehicles in stock for more than 6 months: Change brake fluid
Inspections and operations to be completed
Vehicle (exterior)
–Plastic and rubber parts - cleanliness and damage
–Inspect bodywork and paintwork for damage02-7
–Check that all car keys and key number fobs have been provided; check that the sticker
for the key number for the electronic immobiliser is complete and legible
–Proper operation of door handles outside, door locks, child safety locks, door contact
switches and proper operation of all locks and keys (including spare keys), doors, boot lid/
tailgate, fuel filler cap, bonnet lock02-7
–Proper operation of anti-theft alarm system
–Tighten the wheel bolts to specified torque (steel and light alloy wheels 120 Nm), fit wheel
caps02-5
–Check the tyre inflation pressure (including spare wheel), if necessary correct the tyre in-
flation pressure, fit valve caps02-5
–Fit roof aerial
Engine compartment (from above)
–Check battery no-load voltage, recharge battery if necessary02-6
–Check tight connection of electric cables and plug connections (in particular battery ca-
bles)
–Inspect engine, gearbox, cooling system, brake system and fuel system for leaks02-3, 02-5
–Engine oil level (in-between markings on dipstick)02-3
–Brake fluid level (at „MAX“ marking)02-5
–Coolant level (in-between marking)02-3
–Fill up fluid in washer reservoir, in the winter add antifreeze
–Windscreen wiper/washer system and headlamp cleaning system: Check for proper oper-
ation02-7
Vehicle interior

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InspectionEdition 09.04
S00.5301.14.2002-2 page 4 02
–Fit roof aerial
Engine compartment (from above)
–Check battery no-load voltage; recharge if necessary02-6
–Check tight connection of electric cables and plug connections (in particular battery ca-
bles)
–Brake fluid level (at „MAX“ marking)02-5
–Check the engine oil level (to be in-between the marking on the dipstick)02-3
–Check the coolant level (in-between marking), for special equipment antifreeze down to -
35 °C02-3
–Fill up fluid in washer reservoir, in the winter add antifreeze
–Check windscreen wiper and washer system, the spray nozzle adjustment and the resting
position of the windscreen wipers02-7
Vehicle interior
–Inspect upholstery, interior trim, carpeting and footmats for cleanliness and damage
–Inspect all switches, all electrical components, gauges/indicators and controls02-6
–Radio: Inspect for proper operation, store stations, encode, set clock02-6
–Fit net in luggage compartment (if available)
–Vehicle log book - for completion: Operating manual and service plan (in the correct lan-
guage and with the correct edition data), short introduction, technical data, support in the
case of a breakdown, other manuals (radio,...) ) - all in the vehicle log book pouch
–Reset service interval display02-6
–Power windows: Inspecting positioning02-6
–Key switch for airbag deactivation, front passenger side: Check function „ON/OFF“ and
switch-over to the position „ON“02-7
Underside of vehicle (on lift platform)
–Inspect underbody (underbody protection for damage)02-7
–Inspect for leaks and damage: Engine, gearbox, final drive, steering, brake system, axles,
joint boots. Check proper routing of the brake hoses and brake lines, fuel lines including
ventilation of the fuel system02-3, 02-5
–Inspect tyres and wheels for damage02-5
Concluding operations
–Perform a test drive02-9
–Interrogate fault memory of all systems, if necessary erase02-6
–Complete the service schedule, affix the vehicle data sticker in the Service Schedule to
the floor of the luggage compartment next to the spare wheel, complete the „Next Service
Date“ sticker and affix to the side of the dash panel on the driver's side02-7
–Remove recharging table (if affixed)
–Remove protective seat covers
–Install the carpets supplied in the vehicle
–Final inspection to ensure proper condition for handover to customer

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InspectionEdition 09.04
S00.5301.14.2002-2 page 6 02
Every 30 000 km (QG0)
Includes: Annual inspection and additional operations stated in the table below
–Track rod ends: Inspect play and correct attachment of boots
–Check the tyre inflation pressure (including spare wheel), correct if necessary02-5
–Inspect tyre wear (including spare wheel)02-5
–Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., RL...,
SP...)02-5
–Inspect exhaust system for leaks, damage and attachment
–Brake fluid volume: Check level, if necessary top up02-5
–Battery: test02-6
–Check the anti-freeze in the cooling system and record ...... °C, check for leaks, top up
coolant if necessary02-3
–Flap lock for the engine bonnet: grease
–Inspect operation of all switches, all electrical components, gauges/indicators and con-
trols for proper operation02-6
–Windscreen wiper and washer system: Inspect condition of wiper blades, wiper opera-
tion, washer system: if necessary top up fluid02-7
–Inspect plenum chamber for dirt, clean if necessary02-7
–Fuel filter: Drain away water (vehicles with diesel engine with fuel operation, which does
not comply with DIN EN 590-standard)02-3
–Inspect trailer coupling (with removable arm - manufacturer Profsvar)02-7
After each inspection
–Complete the „Next Service“ sticker and affix sticker to the side of the dash panel (on the
driver's side)
–Perform road test including inspection of proper operation of footbrakes and handbrake,
gearshift and steering, final inspection02-9
–„Mirror tag“ - complete and attach to interior mirror
–Hand customer the completed and signed form
Work involvedChapter
–Headlights: Inspect, if necessary adjust02-6
–Gear oil: Inspect level and top up if necessary (manual gearbox)02-4
–Fuel filter: Drain away water (vehicles with diesel engine with fuel operation, which does
not comply with DIN EN 590-standard)02-3
–Check underbody protection and body paintwork for damage02-7
–Dust and odour filter element for the passenger compartment: replace02-7
–Inspect operation of tilting roof and grease the runners02-7
–Inspect timing belt (petrol engines) - every 90 000 km, then every 30 000 km02-3

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InspectionEdition 09.04
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–Check the tyre inflation pressure (including spare wheel), correct if necessary02-5
–Inspect tyre wear (including spare wheel)02-5
–Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., RL...,
SP...)02-5
–Inspect exhaust system for leaks, damage and attachment
–Brake fluid volume: Check level, if necessary top up02-5
–Battery: test02-6
–Check the anti-freeze in the cooling system and record ...... °C, check for leaks, top up
coolant if necessary02-3
–Flap lock for the engine bonnet: grease
–Inspect operation of all switches, all electrical components, gauges/indicators and con-
trols for proper operation02-6
–Windscreen wiper and washer system: Inspect condition of wiper blades, wiper operation,
washer system: if necessary top up fluid02-7
–Inspect plenum chamber for dirt, clean if necessary02-7
–Inspect operation of tilting roof and grease the runners02-7
–Headlights: Inspect, if necessary adjust02-6
–Gear oil: Inspect level and top up if necessary (manual gearbox)02-4
–Draining the fuel filter (diesel engine)
–Inspect trailer coupling (with removable arm - manufacturer Profsvar)02-7
–Check underbody protection and body paintwork for damage02-7
–Dust and odour filter element for the passenger compartment: replace02-7
–Air filter: Clean the housing, replace the insert every 4 years or 60.000 km.02-3
–Replace the fuel filter (diesel engine with fuel operation, which does not comply with DIN
EN 590-standard)
–Ribbed V-belt: Inspect condition and for vehicles without tensioning pulley also the ten-
sion - every 60.000 km02-3
–Replace the fuel filter (diesel engine) - every 60.000 km
–Spark plugs: replace - every 60.000 km.02-3
–Automatic gearbox: Check the ATF level, and top up if necessary, every 60.000 km
–Check the timing belt for the camshaft on a 4-cylinder petrol engine at 90.000 km and
then every 30.000 km after that
–Replace the emergency battery for the alarm system - every five years02-6
After each inspection
–Complete the „Next Service“ sticker and affix sticker to the side of the dash panel (on the
driver's side)
–Perform road test including inspection of proper operation of footbrakes and handbrake,
gearshift and steering, final inspection02-9
–„Mirror tag“ - complete and attach to interior mirror
–Hand customer the completed and signed form Work involvedChapter

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EnginesEdition 09.04
S00.5301.14.2002-3 page 10 02
Only use engine oils:
QGO, QG2
Specification VW 505 01 or VW 505 00 (oil according
to VW 505 00 cannot be used for TDI PD - engines)
Oils may be intermixed when topping up.
In exceptional cases:
Multigrade oils according to ACEA B3 or B4. Such oils
must only be used once for topping up within the speci-
fied oil change interval if, in exceptional cases, no ap-
proved engine oil is available.
QG1
Specification VW 506 01 or VW 506 00 (oil according
to VW 506 00 cannot be used for TDI PD - engines)
–Close the oil filler opening again.
–Start engine and check for leaks.
–Check the engine oil level again and top up with oil if
necessary.
–Wait at least 3 minutes after topping up the oil again
before inspecting the oil level again.
–Install the noise insulation.
The oil level must not be above the -max- marking to
avoid damage to the catalytic converter. See Inspecting
engine oil level ⇒02-3 page 8.
Inspecting antifreeze protection, replen-
ishing coolant additive if necessary
♦Collect drained coolant for proper disposal.
♦Observe the disposal instructions for the drained cool-
ant.
Special tools, test and measuring equipment and
auxiliary items required
♦Refractomer -T10007-
Inspecting antifreeze protection of the coolant
♦The refractometer -T10007- may, for example, be
used for inspecting the antifreeze protection of the
coolant.
Note
WARNING!
Coolant additives are toxic!
Do not inhale coolant vapours, do not swallow
coolant, avoid contact with skin and eyes; haz-
ardous if consumed!
Note

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EnginesEdition 09.04
S00.5301.14.2002-3 page 11 02
–Extract a small quantity of coolant with the pipette and
place on the measuring glass. Hold unit against a light
source and read off the temperature down to which
antifreeze protection exists on the scale for ethylene
glycol.
♦Antifreeze protection must be ensured down to about
-25 C.
♦Down to about -35 C in countries with an arctic cli-
mate.
♦If a greater antifreeze concentration is required for cli-
matic reasons, the concentration may be increased up
to 60 % (i.e. antifreeze protection down to about -40
C). Any further increase in concentration increase
would reduce the antifreeze protection and impair
cooling efficiency.
Replenishing coolant additive
♦Coolant additive G12 - red in colour, complying with
standard TL VW 774 D, must not be mixed with other
coolant additives which comply with standard TL VW
774 C(B) -bluish-green in colour-. If these two coolant
additives are mixed the coolant will turn brown. Brown
coolant must be drained immediately, the cooling sys-
tem flushed out with drinking water and filled with
fresh coolant. If this is not done the engine and cooling
system may suffer damage.
♦Coolant additives complying with standard TL VW 774
C (G11) -bluish-green in colour-, must only be used
for topping up on vehicles fitted with a cooling system
which is already filled with this coolant.
♦Vehicles produced as of MJ 03 are filled with coolant
additive G12 PLUS which has a lilac colour and con-
forms with the standard TL VW 774 F.
♦Coolant additive G12 PLUS must only be mixed with
coolant additives G12 and G11.
♦Coolant additive G12 PLUS is recommended for use
on all vehicles when changing the coolant.
If the vehicle is filled with the recommended coolant and
the antifreeze protection is not adequate, drain part of the
coolant from the cooling system.
–After this, fill the cooling system with concentrated
coolant additive.
The coolant capacity is:
Note
Note

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EnginesEdition 09.04
S00.5301.14.2002-3 page 12 02
–Perform a test drive and again check the coolant anti-
freeze protection.
Inspecting coolant level (volume)
–The coolant expansion reservoir is located on the right
of the engine compartment.
–Inspect coolant level only when the engine is not run-
ning.
Specified coolant level for the Inspection Service:
•Engine cold: between„MAX“ and „MIN“ marking.
•Engine warm: slightly above the „MAX“ marking.
♦The cooling system is filled all year round with a mix-
ture of water and antifreeze/anti-corrosion agent.
Coolant additives prevent damage from frost and cor-
rosion and the accumulation of lime scale while also
raising the boiling point of the coolant. For these rea-
sons the cooling system must always be filled all year
round with radiator antifreeze and anti-corrosion
agent offering these properties.
♦Coolant additive G12 - red in colour, complying with
standard TL VW 774 D, must not be mixed with other
coolant additives which comply with standard TL VW
774 C(B) -bluish-green in colour-. If these two coolant
additives are mixed the coolant will turn brown. Brown
coolant must be drained immediately, the cooling sys-
tem flushed out with drinking water and filled with
fresh coolant. If this is not done the engine and cooling
system may suffer damage. Engine Coolant capacity
1.2 ltr./40 kW and 1.2
ltr./47 kWapprox. 5.1 ltr.
1.4 ltr./55 kW and 1.4
ltr./74 kWapprox. 5.5 ltr.
1.0 ltr./37 kW; 1.4 ltr/
44 kW and 1.4 ltr./50
kWapprox. 6.0 ltr.
1.4 ltr./55 TDI PD approx. 6.2 ltr.
1.9 ltr./47 kW SDI approx. 6.6 ltr.
1.9 ltr./74 kW TDI PD
and 1.9 ltr./96 kW TDI
PDapprox. 6.8 ltr.
2.0 ltr./85 kW approx. 6.9 ltr.
S02-0303
WARNING!
Coolant additives are toxic!
Do not inhale coolant vapours, do not swallow
coolant, avoid contact with skin and eyes; haz-
ardous if consumed!
Note