engine SKODA FABIA 2006 2.G / 5J Repair Manual

Inspecting and Replenishing198
Opening the bonnet
– Unlock the bonnet ⇒page 197, fig. 141.
– Ensure that the arms of the windscreen wipers are correctly in
place against the windscreen before opening the bonnet other-
wise damage could occur to the paintwork.
– Press the locking button ⇒page 197, fig. 142, the bonnet unlocks
itself.
– Grip the bonnet and lift it up.
– Take the bonnet support out of its holder and set it in the opening
designed for it ⇒page 197, fig. 143.
Closing the bonnet
– Lift the bonnet slightly and unhook the bonnet support. Press the
bonnet support into the holder designed to hold it.
– Allow the bonnet to drop from a height of about 30 cm into the lock
- bonnet do not press down on it!
WARNING
•Never open the bonnet if you see that steam or coolant is flowing out of the engine compartment - risk of scalding! Wait long enough until the steam or coolant has stopped escaping.
•For safety reasons, the bonnet must always be properly closed when driving. One should therefore check that the lock has in fact engaged properly after closing the bonnet.
•Stop your vehicle immediately whil e driving if you notice that the lock is not properly engaged and close the bonnet properly - risk of an accident!
Caution
•Before opening the bonnet, ensure that the arms of the windscreen wipers are correctly in place against the windscreen. Otherwise, there is a risk of damage to the paintwork.
Working in the engine compartment
Particular care is required when carrying out any work in the
engine compartment!
There is a risk of injuries, scalding, accidents and fire when working in the engine compartment, e.g. inspecting and replenishing oil and other fluids. For this reason, it is essential to comply with the warning instructions stated below and with the general appl icable rules of safety. The engine compartment of your car is a hazardous area ⇒.
WARNING
•Never open the bonnet if you see that steam or coolant is flowing out of the engine compartment - risk of scalding! Wait long enough until the steam or coolant has stopped escaping.
•Switch off the engine and pull out the ignition key.
•Apply the handbrake firmly.
•If your vehicle is fitted with a manual gearbox, move the gearshift lever into Neutral, or if it is fitted with automatic gearbox, move the selector lever into position P.
•Allow the engine to cool down.
•Keep children clear of the engine compartment.
•Do not touch any hot engine parts - risk of burns!
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Using the systemSafetyDriving TipsGeneral MaintenanceBreakdown assistanceTechnical Data
•Never spill oil and other fluids over the hot engine. Such fluids (e.g. the antifreeze contained in the coolant) may ignite!
•Avoid short circuits in the electrical system - particularly on the battery.
•Never place your hand into the radiator fan as long as the engine is still warm. The fan might suddenly start running!
•Never open the cap of the coolant expansion bottle as long as the engine is still warm. The co oling system is pressurized!
•Cover over the cap of the coolant expansion reservoir with a large cloth when opening it as protection for your face, hands and arms from hot steam or hot coolant.
•Do not let objects, such as e.g cleaning cloth or tools lie in the engine compartment.
•If you wish to work under the vehicle, you must secure the vehicle from rolling away and support it with suitable supporting blocks: the car jack is not sufficient for this - risk of injury!
•In cases where it be necessary to carry out inspection work when the engine is running there is an additional risk from rotating parts (e.g. the V-ribbed belt, alternator, radiator fan) and from the high-voltage igni- tion system. Please observe in addition the following:
− Never touch the electrical cables of the ignition system.
− Absolutely avoid any jewellery, loose items of clothing or long hair from getting into the rotating part s of the engine - Hazard! Therefore remove any jewellery beforehand, tie up your hair and wear tight fitting clothing.
•Please also comply with the warnin g instructions stated below when carrying out any essential work on th e fuel system or on the electrical system:
− Always separate the car battery from the electrical system.
− Do not smoke.
− Never carry out any work close to naked flames.
− Always keep a working fire extinguisher at hand.
Caution
When replenishing fluids in the engine, always ensure that the fluids are on no account mixed up. This may result in ma jor operating problems and also vehicle damage!
Overview of the engine compartment
The main inspection points.
Fig. 144 Diesel engine 1.9 litre/77 kW
WARNING (continued)WARNING (continued)
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Coolant expansion bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil filler opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery (below a cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note
The location of the inspection points in the engine compartment of petrol and diesel engines is practically identical.
Engine oil
Engine oil specifications
The grade of engine oil should be selected in accordance with
precise specifications.
The engine of your vehicle has been fact ory-filled with a high-grade oil which you can use throughout the year - except in extreme climatic regions.
You can mix various oils together with ea ch other when refilling with oil. This does not, however, apply for models with flexible service intervals (QG1).
Engine oils are, of course, undergoing continuous further development. Thus the information stated in this Owner's Manual is only correct at the time of publication.
Škoda Service Partners are informed by Škoda Auto a.s. about current changes. We recommend having this oil change undertaken by a Škoda Service Partner.
Engine oil specifications for vehicles with fixed service intervals (QG0, QG2)
Engine oil specifications for models with flexible service intervals (QG1)
Caution
Only the above-mentioned oils may be used on vehicles with flexible service intervals (QG1). We recommend always re filling with oil of the same specifica- tion since this will maintain the properti es of the oil. In exceptional cases, you must top up only once engine oil complying with Specification VW 502 00 (only for petrol engines) or Specification VW 505 01 (only for diesel engines) to maximum 0.5 litres. You must not use other engine oils - risk of engine damage!
A1204A2211
A3202
A4201
A5206
A6207
Engine oil specifications
Petrol engines
VW 501 01 VW 502 00 VW 504 00
ACEA A2 a) or A3 a)
a)Only to be used in exceptional cases if the oils specified above are not available.
Diesel enginesVW 505 01b)
VW 507 00 c)
b)Only for engines without diesel particle filter ⇒page 36.c)Only for engines with diesel particle filter ⇒page 36.
Engine oil specifications
Petrol enginesVW 504 00 alternative VW 503 00
Diesel enginesVW 507 00
alternative VW 506 01 a)
a)Only for engines without diesel particle filter ⇒page 36.
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Using the systemSafetyDriving TipsGeneral MaintenanceBreakdown assistanceTechnical Data
Note
•Before a long drive we recommend that you purchase and carry with you engine oil which complies with the specif ication for your vehicle. Consequently, you will always have the correct engine oil for refilling.
•We recommend using a preservative fr om the Škoda original accessories offered by your Škoda dealer.
•For further information - see Service shedule.
Check engine oil level
The dipstick indicates the level of oil in the engine.
Checking the oil level
– Park the vehicle on a horizontal surface.
– Switch the engine off.
– Open the bonnet ⇒ in “Working in the engine compartment”
on page 198.
– Wait a few minutes and pull out the oil dipstick ⇒.
– Wipe off the dipstick with a clean cloth and insert it again fully.
– Then withdraw the dipstick again and read off the oil level.
Oil level within range
– You must not top up the oil.
Oil level within range
– You may top up the oil. It is possible that the oil level may then be
within range after doing this.
Oil level within range
– You must top up the oil. It is sufficient, once this is done, to keep
the oil level is within range .
It is normal for the engine to consume oil. The oil consumption may be as much as 0.5 l/1 000 km depending on your style of driving and the conditions under which you operate your vehicle. The oi l consumption may be slightly higher than this during the first 5 000 kilometres.
One should therefore check the oil level at regular intervals, preferably every time after the fuel tank is filled or after driving for long stretches.
We recommend maintaining the oil level within the range if the engine has been operating at high loads, for ex ample during a lengthy motorway trip during the summer months, towing a tr ailer or negotiating a high mountain pass, but not above this.
Fig. 145 Dipstick
Aa
Ab
Aa
Ac
Ab
Ab
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The warning light in the instrument cluster* will indicate ⇒page 31 whether the oil level is too low. In this case, check the oil level as soon as possible. Top up with an appropriate quantity of oil.
WARNING
Read and observe the warning notes ⇒page 198, “Working in the engine compartment” before working in the engine compartment.
Caution
•Always check the oil level on vehicles with engine 1.2 l/47 kW when the engine is warm. Otherwise the measuring result is incorrect und oil could be incorrectly replenished - risk of engine damage!
•The oil level must on no account ex tend beyond the range . Danger of damaging the catalytic converter.
•Do not continue your journey if for some reason it is not possible under the conditions prevailing to top up with oil. Switch the engine off and obtain professional assistance from a specialist garage, otherwise it could lead to severe engine damage.
Replenishing engine oil
– Inspect the oil level ⇒page 201.
– Unscrew the cap of the engine oil filler opening.
– Pour in a suitable grade of oil in portions of 0.5 litres ⇒page 200,
“Engine oil specifications”.
– Inspect the oil level ⇒page 201.
– Carefully screw on the cap of the filler opening and push the
dipstick in fully.
WARNING
•Avoid dripping oil onto hot parts of the engine when topping up will oil - a risk of fire!
•Read and observe the warning notes ⇒page 198, “Working in the engine compartment” before work ing in the engine compartment.
For the sake of the environment
The oil level must on no account be above the range ⇒page 201. Oil will otherwise be drawn in through the cran kcase ventilation and may pass through the exhaust system to atmosphere. The oil may combust in the catalytic converter and damage it.
Changing engine oil
The engine oil must be changed at the intervals stated in the Service schedule or according to the service interval indicator ⇒page 16.
WARNING
•Only carry out the engine oil change, if you have the required profes- sional knowledge!
•Read and observe the warning notes ⇒page 198, “Working in the engine compartment” before work ing in the engine compartment.
•Let the engine cool down - risk of burning from hot oil.
•Wear an eye protection - risk of caustic burns due to oil splashes.
Aa
Aa
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•Oil is toxic! Store old oil in a safe place out of the reach of children and unauthorized persons until you dispose of it properly.
Caution
You must not pour any additives into th e engine oil - risk of engine damage! Damage, which results from such product, are excluded from the warranty.
For the sake of the environment
•You must on no account pour oil into the ground or into the sewage system.
•In view of the problems involved in properly disposing of old oil, the mate- rial, equipment and the knowledge required for such work, we recommend that you have the oil and oil filter change ca rried out by your Škoda Service Partner.
Note
After your skin has come in contact with the oil, you must thoroughly wash your skin.
Cooling system
Coolant
The job of the coolant is to cool the engine.
The cooling system does not require an y maintenance under normal operating conditions. The coolan t consists of water with a concentration of coolant addi- tive of 40 %. This mixture not only provid es antifreeze protection down to -25°C but also protects the cooling and heat ing system from corrosion. It also
prevents the formation of scale and significantly increases the boiling point of the coolant.
You must therefore not reduce the concentration of antifreeze agent in the coolant by adding water, also not duri ng the summer months or in countries with a warm climate. The concentration of coolant additive in the coolant must be at least 40%.
You can increase the amount of antifreeze in the coolant if a higher concentra- tion of antifreeze is necessary for clim atic reasons but only up to 60% (anti- freeze protection down to approx. -40° C). The antifreeze protection tails off above that concentration.
Vehicles exported to co untries with a cold climate (e.g. Sweden, Norway, Finland) are already factory-filled with a coolant which offers antifreeze protec-tion down to about -35°C. In these countries the concentration of coolant addi- tive should be at least 50 %.
Coolant
The cooling system is filled at the works with coolant (purple in colour), which complies with the specification TL-VW 774 F.
We recommend that you use the antifreeze agent - G12 PLUS (purple in colour).
We recommend that you contact your Šk oda Service Partner if you have any questions regarding the coolant or if you wish to fill up with a different coolant.
Your Škoda Service Partner can also supp ly you with the correct coolant addi- tives.
Caution
•Other coolant additives may cause operational problems which, in particular, involves significantly reducing the anticorrosion effect.
•Any faults or problems resulting from corrosion may cause a loss of coolant and, as a consequence of th is, result in major engine damage.
WARNING (continued)
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Inspecting the coolant level
The coolant expansion bottle is located in the engine compartment on
the right.
– Switch the engine off.
– Open the bonnet ⇒ in “Working in the engine compartment”
on page 198.
– Check the level of coolant in the coolant expansion bottle
⇒ fig. 146. The coolant level when the engine is cold must lie
between the “MIN” and “MAX” markings. The level may also
rise slightly above the “MAX” ma rking when the engine is warm.
If the coolant level in the reservoir is too low, this is indicated by the warning light in the instrument cluster  ⇒page 30. We nevertheless recommend inspecting the coolant level directly at the reservoir from time to time.
Loss of coolant
A loss of coolant is first and foremost an indication of a leak in the system. You should not merely top up the coolant in the reservoir. It is also important to have the cooling system inspected without delay by a specialist garage.
Losses can only occur through the pressure relief in the cap of the coolant expansion bottle which is completely free of leaks if the coolant boils as a result of overheating and is forced out of the cooling system.
WARNING
Read and observe the warning notes ⇒page 198, “Working in the engine compartment” before working in the engine compartment.
Caution
One should contact a specialist garage as soon as possible if the source of over- heating itself cannot be determined an d removed, since there may be grave damage to the engine.
Replenishing the coolant
– Switch the engine off.
– Allow the engine to cool down.
– Place a cloth over the cap of the coolant expansion reservoir
⇒ fig. 146 and unscrew the cap carefully by turning it to the left
⇒ .
– Top up the coolant.
– Screw the cap tight until it is heard to lock.
Fig. 146 Engine compartment: Coolant expansion bottle
ABAA
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The coolant which you use for replenishing the system, must comply with one specific specification ⇒page 203, “Coolant”. Do not use an alternative additive if the coolant additive G12 PLUS is not available in exceptional cases. Just top up the system with water and as soon as possible arrange adjustment to correct the mixing ratio of water and coolant a dditive again by a specialist garage.
Only use fresh coolant for topping up the system.
Do not fill up over the “MAX” marking! Excess coolant which is heated up is forced out of the cooling system through the pressure relief valve in the cap of the coolant compensation bottle.
Wait until the engine has cooled down for a system which has suffered a major loss of coolant before pouring in cool ant. This is necessary to avoid engine damage.
WARNING
•The cooling system is pressurized! Do not open the cap of the coolant expansion bottle if the engine is still hot - risk of scalding!
•The coolant additive and thus all of the coolant is harmful to your health. Avoid contact with the coolan t. Coolant vapours are also harmful to the health. It is important, therefore, to always safely store any coolant additive in its original container out of the reach of children - risk of poisoning!
•If any splashes of coolant get into your eyes, rinse out your eyes immediately with clear water and cont act a doctor as soon as possible.
•You should also consult a doctor without delay if you have inadvert- ently swallowed coolant.
Caution
Do not continue your journey if for some reason it is not possible under the conditions prevailing to top up with coolant. Switch the engine off and obtain professional assistance from a specialist garage, otherwise it could lead to severe engine damage.
For the sake of the environment
Do not re-use coolant if it is necessary to drain the coolant in the system. It should be collected and disposed of in compliance with environmental protec- tion regulations.
Radiator fan
The radiator fan may switch on suddenly.
The radiator fan is driven by an electr ic motor and controlled by a thermostat according to the coolant temperature.
The radiator fan may continue running fo r up to 10 minutes after the engine has been switched off - even if the ignition is also off. It may also switch on suddenly after a certain time, if:
•the coolant temperature has risen beca use of an accumulation of heat or
•the warm engine compartment is heated up additionally by strong sunlight.
WARNING
You must therefore be aware when working in the engine compartment that the fan may switch on suddenly - risk of injury!
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Brake fluid
Inspecting the brake fluid level
The brake fluid reservoir is located on the left of the engine compart-
ment. The brake fluid reservoir on right-hand steering models is posi-
tioned on the other side of the engine compartment.
– Switch the engine off.
– Open the bonnet ⇒ in “Working in the engine compartment”
on page 198.
– Inspect the brake fluid level in the reservoir ⇒fig. 147. The level
must be between the “MIN” and “MAX” markings.
A slight drop in the fluid level results when driving due to normal wear-and-tear and automatic adjustment of the br ake pads, and is perfectly normal.
There may be an indication of a leak in the brake system, however, if the fluid level drops significantly within a short time or if it drops below the “MIN” marking. A situation where the brake flui d level is too low is indicated by the warning light  lighting up in th e instrument cluster ⇒page 34. In this case stop the car immediately and do not drive any further! Contact a Škoda Dealer to obtain professional assistance.
WARNING
•Read and observe the warning notes ⇒page 198, “Working in the engine compartment” before work ing in the engine compartment.
•If the fluid level has dropped below the MIN marking, do not drive any further - risk of accident! Contact a Škoda dealer to obtain profes- sional assistance.
Replacing brake fluid
Brake fluid absorbs moisture. This causes the fluid to absorb moisture from the surrounding air over a period of time. Excessive water in the brake fluid may be the cause of corrosion in the brake syst em. The water content also lowers the boiling point of the brake fluid. This is why brake fluid must be replaced every two years.
One may only use new genuine brake fluid from Škoda Auto a.s. The specifica- tion for the brake fluid is “FMVSS 116 DOT 4”.
We recommend that you have th e brake fluid replaced by a Škoda Service Par tner as part of an Inspection Service.
Fig. 147 Engine compartment: Brake fluid reservoir
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WARNING
•Using old brake fluid can result in severe stress on the brakes because of the formation of vapour bubbles in the brake system. This greatly impairs the braking efficiency and thus also the safety of your vehicle.
•Brake fluid is toxic! It must therefore be kept safely in closed original containers and well away from children and unauthorized persons.
Caution
Brake fluid damages the paintwork of the vehicle.
For the sake of the environment
In view of the problems involved with prop er disposal of brake fluid, the special tools and the professional knowledge required, we recommend you have the brake fluid replaced by a Škoda Service Partner.
Battery
Working on the battery
The battery is located in the engine compartment below a plastic box.
– Unlock the interlock on the positi ve terminal side of the battery
⇒ fig. 148.
– Open the cover in direction of arrow.
– The installation of the battery co ver on the positive terminal side
takes place in the reverse order.
Removal and installation of the battery is not recommended since it can, under certain circumstances, lead to major da mage to the battery and fuse boxes. Contact a specialist garage.
Fig. 148 The battery: Open up the cover
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