belt SKODA FABIA 2000 1.G / 6Y Workshop Manual

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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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Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
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
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Delivery Inspection (Export)
–Proper operation of seat belts, seat belt height adjuster, power windows and sun roof
–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, set clock, encode02-6
–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
–Fit net in luggage compartment (if available)
–Check the car tool kit, spare wheel and accessories, that they have all been supplied and
are properly secured
–Install the carpets supplied in the vehicle
–Perform a test drive
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
–Interrogate fault memory of all systems, if necessary erase02-6
–Remove protective seat covers
–Remove recharging table (if affixed)
–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„Next Service Date“ sticker
and affix to the side of the dash panel on the driver's side, hand the card „Škoda Assist-
ance“ to the customer02-7
–Final inspection to ensure proper condition for handover to the customer
Inspections and operations to be completed Chapter
Vehicle (exterior)
–Plastic and rubber parts: Inspect for cleanliness and damage
–Inspect bodywork and paintwork for damage02-7
–Check operation of the tailgate lock and the fuel filler cap, door contact switch, operation
of the door handles, door locks and safety buttons, central locking from outside as well as
inside, child safety locks, ability to close all locks on the vehicle using all keys (including
the spare key)02-7
–Check operation of the 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
–Vehicles in stock for more than 6 months: Change brake fluid02-5

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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
S00.5301.14.2002-2 page 7 02
Every 60 000 km (QG0)
Includes: Inspection every 30 000 km and additional operations stated in the table below
Every 90 000 km (QG0)
Includes: Inspection every 30 000 km and additional operations stated in the table below
Every 120 000 km (QG0)
Includes: Inspection every 60 000 km and additional operations stated in the table below
Every 150.000 km (QG0)
Includes: Inspection every 60 000 km and additional operations stated in the table below
Work involvedChapter
–Air filter: Clean housing, replace filter element02-3
–Fuel filter: replace (vehicles with diesel engine)02-3
–Ribbed V-belt: Inspect condition and for vehicles without tensioning pulley also the ten-
sion02-3
–Spark plugs: replace02-3
–Automatic gearbox: Inspect ATF1) level, if necessary top up
1)Automatic transmission fluid for the automatic gearbox
02-4
Work involvedChapter
–Timing belt for camshaft drive: replace (ASY diesel engines up to 04.2001)02-3
–Timing belt and tensioning pulley for camshaft drive: replace (PD diesel engine up to
07.03)02-3
–Timing belt for camshaft drive: inspect (petrol engines) - every 90 000 km, then every 30
000 km02-3
Work involvedChapter
–Timing belt and tensioning pulley (038 109 244 H)1) for camshaft drive: replace (diesel en-
gines other than the PD engine) - vehicles as of 05.2001 to 04.2002
1)When the tensioning pulley Spare Part No. 038 109 244 M is mounted after 120 000 km. on vehicles with a diesel engine during replacement of
the timing belt and the tensioning pulley the change interval of the timing belt should be altered from 120 000 km to 150 000 km. The customer
should be informed about the new service interval when the tensioning pulley is first replaced by a new tensioning pulley Spare Part No. 038
109 244 M by making an entry in the service plan, in the section „Workshop entries“. Only the timing belt will be replaced at each next service
interval at 150 000 km.
02-3
–Timing belt for camshaft drive: replace (PD diesel engine as of 08.03)02-3
Work involvedChapter
–Timing belt: replace (diesel engines other than the PD engine) - vehicles as of 05.200202-3

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InspectionEdition 09.04
S00.5301.14.2002-2 page 8 02
Every 240 000 km (QG0)
Includes: Inspection every 120 000 km and additional operations stated in the table below
Inspection Service (QG1, QG2)
♦Vehicles with WIV (QG1) must be filled with oils which conform to the VW standard 503 00 (petrol engines) VW
506 00 (SDI, TDI diesel engines) or VW 506 01 (TDI PD diesel engines), possibility of damage when using other
oils.
♦Vehicles with WIV which have been filled with oils which do not conform to the VW standard 503 00 or VW 506 00
or VW 506 01, must be coded in the WIV with a fixed oil change limitation (QG2) ⇒Chapter 02-6. Work involvedChapter
–Replace tensioning pulley (PD diesel engine as of 08.03)02-3
♦Every 2 years - in addition change brake fluid
♦Every 4 years - replace contents set for tyre repair
♦Every 90 000 km - replace the guide pulley and the tensioning pulley (PD diesel engine up to 07.03)
♦Every 120 000 km - replace the timing belt and the guide pulley (038 109 244 H) (diesel engines as of 05.01 to
04.02 except the PD engine)
♦Every 120 000 km - Replace the timing belt (PD Diesel engine as of 08.03)
♦Every 150 000 km - replace the timing belt (diesel engines as of 05.02 and with the guide pulleyr 038 109 244
M) - except on the TDI PD engine
♦Every 240 000 km - Replace the tensioning pulley (PD Diesel engine as of 08.03)
♦Exhaust-emission analysis (EEA). Expiry date - see EEA tag on the vehicle identification plate (only valid for
some countries)
♦At each inspection - check the 'use by date' of the first aid kit
♦Recommendation: Replace windscreen wiper blades every 2 years
Note
Work involvedChapter
–Interrogate fault memory of all systems, if necessary erase02-6
–Visual inspection: Engine and components in the engine compartment for leaks and dam-
age02-3
–Change the engine oil, replace the oil filter02-3
–Conduct a visual inspection of the airbag units for external damage02-7
–Reset service interval display02-6
–Inspecting brake system for leaks and damage02-5
–Check the thickness of the brake pads on all wheels02-5
–Check gearbox, final drive, drive shafts and joint boots for leaks and damage
–Axle joints: Inspect boots for leaks and damage
–Track rod ends: Inspect play and correct attachment of boots

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InspectionEdition 09.04
S00.5301.14.2002-2 page 9 02
–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 4 02
Engine fitted
The engine identification characters and serial number
are located in the front at the engine/gearbox joint.
In addition, a sticker with the engine identification charac-
ters and serial number is affixed to the timing belt guard.
Engine with identification characters ARV, AQV, AZE,
AZF, AME, ATZ and AQW.
Engine with identification characters AUA, AUB, BBY,
BBZ, BKY.Compression 19 19 10,5 10,3 10,5
Hydraulic valve clearance
compensationXX X X X
Mixture formation Bosch PDE -
injectorsBosch PDE -
injectorsBosch ME 7.5 Simos 3PG Magneti Marelli
4TV
Fuel RON (minimum) - -
unleaded 95
1)unleaded 951)unleaded 951)
Fuel CN (minimum) 49 49 - - -
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-2-3 1-3-4-2
Exhaust gas recirculation X X - - X
Ignition system/fuel injection Bosch PDE -
injectorsBosch PDE -
injectorsBosch ME 7.5 Simos 3PG Magneti Marelli
4TV
Self-diagnosis X X X X X
Catalytic converter X X X X X
Turbocharging X X - - -
Charge air cooler X X - - -
Lambda probe - - X X X
Camshaft adjustment - - - - -
1)Regular grade unleaded petrol (min. 91 ROZ) can be used although engine power output is slightly reduced.
Engine identification char-
actersAT D A S Z A Z L B M D B K Y

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EnginesEdition 09.04
S00.5301.14.2002-3 page 7 02
Replace engine oil filter
Vehicles with petrol engine
Special tools, test and measuring equipment and
auxiliary items required
♦Oil filter wrench
–Release oil filter (e.g. Würth, Hazet) and remove.
–Clean sealing surface at engine.
–Oil rubber seal slightly.
–Screw in new filter and tighten by hand.
–After filling with oil, run engine until it is at operating
temperature and inspect for leaks.
Vehicles with diesel engine
Special tools, test and measuring equipment and
auxiliary items required
♦Oil filter wrench -3417- or wrench 36
–Release cap -1-.
–Replace O-rings -2- and -3- as well as oil filter element
-4-.
–Tighten cap -1-.
Tightening torque of the cap: 25 Nm
Replacing timing belt and tensioning
pulley for camshaft drive (1.9 TDI en-
gines)
–Removing and installing the timing belt
⇒Rep. Gr. 13; 1.9/74 TDI Engine, Mechanics, or
⇒Rep. Gr. 13; 1.9/96 TDI Engine, Mechanics.
Replacing timing belt and tensioning
pulley for camshaft drive (1.4 TDI en-
gines)
–Removing and installing the toothed belt
⇒Rep. Gr. 13; 1.4/55 TDI Engine, Mechanics.
Inspecting timing belt for camshaft drive
for wear and running (petrol engine)
Check timing belt for:
♦Tears or splits -A-, cross-sectional fractures
♦Lateral catches -B-
♦Fraying or chunking -C-
♦Crack in the base tooth -D-
♦Separation of layers (timing belt housing, cords)
♦Traces of oil and grease
S02-0339
2
1
4
3

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EnginesEdition 09.04
S00.5301.14.2002-3 page 8 02
The timing belt must most definitely be replaced if any
shortcomings are found. This will help prevent any fail-
ures or operational problems. Replacing the timing belt is
a repair measure.
Replacing toothed belt and guide pulley
for camshaft drive (1.9 SDI engines)
–Removing and installing the toothed belt
⇒Rep. Gr. 13; 1.9/47 SDI engine, Mechanics.
Inspecting engine oil level
When inspecting, pay attention to the following points:
Before inspecting, warm up the engine to normal temper-
ature.
Wait at least 3 minutes after switching off the engine to al-
low the oil to flow back into the oil pan.
–Withdraw dipstick, wipe off with a clean cloth and re-
insert dipstick fully.
–Withdraw dipstick once again and read off oil level.
Fig. 1: Oil dipstick version I
Fig. 2: Oil dipstick version ll
The oil level in area -a-
–The oil must be topped up. It is sufficient when the oil
level rises to the area -b-.
The oil level in area -b-
–The oil can be topped up. It is possible that the oil level
will rise to the area -c-.
The oil level in area -c-
–The oil must not be topped up.
♦The oil level must not, under any circumstances, be
above area -a- - danger of damage to the catalytic
converter.
♦The vehicle must be standing on level ground when
measuring the oil level. Wait a few minutes after
switching off the engine to allow the oil to flow back
into the oil pan.
Change engine oil
♦The engine oil should always be changed, if possible,
when the engine is at normal operating temperature.
♦If the engine oil is drained, replace the seal of the oil
drain plug.
Note
Note
Note