engine SKODA ROOMSTER 2009 1.G Repair Manual

Inspecting and replenishing185
Using the system
Safety
Driving Tips
General Maintenance
Breakdown assistance
Praktik
Technical Data
– Pull on the locking lever ⇒page 184, fig. 175, the bonnet is then
unlocked.
– 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 184, fig. 176.
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 prop-
erly after closing the bonnet.
•
Stop your vehicle immediately while 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 applicable rules of safety. The engine compart-
ment 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!
•
Never spill oil and other fluids over the hot engine. Such fluids (e.g. the
antifreeze contained in the wash liquid) 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 cooling 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.
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Inspecting and replenishing 186•
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 ignition
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 parts of the engine - Hazard! Therefore
remove any jewellery beforehand, tie up your hair and wear tight fitting
clothing.
•
Please also comply with the warning instructions stated below when
carrying out any essential work on the 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 major operating problems and also vehicle
damage!
Overview of the engine compartment
The main inspection pointsFig. 177 Diesel engine 1.9 litre/77 kW
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.
WARNING (continued)
A1
189
A2
196
A3
188
A4
187
A5
191
A6
192
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Inspecting and replenishing187
Using the system
Safety
Driving Tips
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Breakdown assistance
Praktik
Technical Data
Engine oilCheck engine oil level
The dipstick indicates the level of oil in the engine.Checking the oil level
– Ensure that the vehicle is positioned on a level surface and the engine
has reached its operating temperature.
– Switch the engine off.
– Open the bonnet ⇒ in “Working in the engine compartment” on
page 185.
– 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. The optimum lies in the middle of the
range .
Oil level within range
–You must top up the oil. It is sufficient, once this is done, to keep the
oil level 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 oil 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 example during a lengthy motorway trip during the
summer months, towing a trailer or negotiating a high mountain pass, but not
above this.
The warning light in the instrument cluster* will indicate ⇒page 33 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 185, “Working in the engine
compartment” before working in the engine compartment.
Caution
•
The oil level must on no account extend 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 profes-
Fig. 178 Dipstick
Aa
Ab
Aa
Ab
AcAb
Ab
Aa
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Inspecting and replenishing 188sional assistance from a specialist garage, otherwise it could lead to severe engine
damage.Replenishing engine oil– Inspect the oil level ⇒page 187.
– Unscrew the cap of the engine oil filler opening.
– Wipe off the oil from the sealing surface of the cover and on the coun-
terpart using a clean cloth.
– Pour in a suitable grade of oil in portions of 0.5 litres ⇒page 236.
– Inspect the oil level ⇒page 187.
– 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 185, “Working in the engine
compartment” before working in the engine compartment.For the sake of the environment
The oil level must on no account be above the range ⇒page 187. Oil will other-
wise be drawn in through the crankcase ventilation and may pass through the
exhaust system to atmosphere. The oil may combust in the catalytic converter and
damage it.Changing engine oilThe engine oil must be changed at the intervals stated in the Service schedule or
according to the service interval indicator ⇒page 20.
WARNING
•
Only carry out the engine oil change, if you have the required profes-
sional knowledge!
•
Read and observe the warning notes ⇒page 185, “Working in the engine
compartment” before working 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.
•
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 the 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 necessary
special tools and the knowledge required for such work, we recommend that you
have the oil and oil filter change carried out by a specialist garage.Note
After your skin has come in contact with the oil, you must thoroughly wash your
skin.
Aa
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Inspecting and replenishing189
Using the system
Safety
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Praktik
Technical Data
Cooling systemCoolant
The job of the coolant is to cool the engine.The cooling system does not require any maintenance under normal operating
conditions. The coolant consists of water with a concentration of coolant additive
of 40 %. This mixture not only provides antifreeze protection down to -25°C but
also protects the cooling and heating 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 during 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 concentration
of antifreeze is necessary for climatic reasons but only up to 60% (antifreeze
protection down to approx. -40°C). The antifreeze protection tails off above that
concentration.
Vehicles exported to countries with a cold climate (e.g. Sweden, Norway, Finland)
are already factory-filled with a coolant which offers antifreeze protection down to
about -35°C. In these countries the concentration of coolant additive should be at
least 50 %.
Coolant
The cooling system is factory-filled with coolant (purple in colour), which complies
with the specification TL-VW 774 G.
We recommend that you use the antifreeze agent G12 PLUS - PLUS (purple in
colour) for topping up the system.
We recommend that you contact a specialist garage if you have any questions
regarding the coolant or if you wish to fill up with a different coolant.
A specialist garage can also supply you with the correct coolant additives.
Caution
•
Other coolant additives may cause operational problems which, in partic-
ular, involves significantly reducing the anticorrosion effect.
•
Any faults or problems resulting from corrosion may cause a loss of
coolant and, as a consequence of this, result in major engine damage.
Inspecting the coolant levelThe 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 185.
– Check the level of coolant in the coolant expansion bottle ⇒fig. 179.
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” marking when the engine is warm.
Fig. 179 Engine compart-
ment: Coolant expansion
bottle
AB
AA
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Inspecting and replenishing 190If the coolant level in the reservoir is too low, this is indicated by the warning light
in the instrument cluster
 ⇒page 32. 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 expan-
sion bottle which is completely free of leaks if the coolant boils as a result of over-
heating and is forced out of the cooling system.
WARNING
Read and observe the warning notes ⇒page 185, “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 and 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
⇒page 189, fig. 179 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.
The coolant which you use for replenishing the system, must comply with one
specific specification ⇒page 189, “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 additive 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 coolant. 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 coolant. 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 immedi-
ately with clear water and contact a doctor as soon as possible.
•
You should also consult a doctor without delay if you have inadvertently
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.
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Inspecting and replenishing191
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Safety
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Praktik
Technical Data
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 protection
regulations.Radiator fan
The radiator fan may switch on suddenly.The radiator fan is driven by an electric motor and controlled by a thermostat
according to the coolant temperature.
The radiator fan may continue running for 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 because 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!
Brake fluidInspecting the brake fluid levelThe brake fluid reservoir is located on the left of the engine compartment.
The brake fluid reservoir on right-hand steering models is positioned on
the other side of the engine compartment.
– Switch the engine off.
– Open the bonnet ⇒ in “Working in the engine compartment” on
page 185.
– Inspect the brake fluid level in the reservoir ⇒fig. 180. 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 brake 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 situ-
ation where the brake fluid level is too low is indicated by the warning light

lighting up in the instrument cluster ⇒page 36. In this case stop immediately and
do not drive any further! Obtain professional assistance.
Fig. 180 Engine compart-
ment: Brake fluid reservoir
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Inspecting and replenishing 192
WARNING
•
Read and observe the warning notes ⇒page 185, “Working in the engine
compartment” before working in the engine compartment.
•
If the fluid level has dropped below the MIN marking, do not drive any
further - risk of accident! Obtain professional assistance.
Replacing brake fluidBrake 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 system. 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. The specification for
the brake fluid is “FMVSS 116 DOT 4”.
We recommend that you have the brake fluid replaced by a specialist garage as
part of an Inspection Service.
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 proper disposal of brake fluid, the special
tools and the professional knowledge required, we recommend you have the brake
fluid replaced by a specialist garage.BatteryWorking on the batteryThe battery is located in the engine compartment below a plastic box.
Fig. 181 The battery: pull up
the cover (automatic
gearbox)Fig. 182 The battery: pull up
the cover (manual gearbox)
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Inspecting and replenishing193
Using the system
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Technical Data
– Unlock the interlock on the positive terminal side of the battery
⇒page 192, fig. 181.
– Pull up the cover in direction of arrow ⇒page 192, fig. 181 (automatic
gearbox) or ⇒page 192, fig. 182 (manual gearbox).
– The installation of the battery cover 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 damage to the battery and fuse boxes. Contact
a specialist garage.
There is a risk of injuries, scalding, accidents and burns when carrying out any work
on the battery and on the electrical system. For this reason, it is essential to comply
with the warning instructions ⇒ stated below and with the general applicable
rules of safety.
WARNING
•
The battery acid is strongly corrosive and must, therefore, be handled
with the greatest of care. Always wear protective gloves, eye and skin
protection when handling batteries. Corrosive fumes in the air irritate the
air passages and lead to conjunctivitis and inflammation of the air passages
in the lungs. Battery acid corrodes dental enamel and creates deep wounds
after contact with the skin which take a long time to heal. Repeated contact
with diluted acids causes skin diseases (inflammations, ulcers, slin cracks).
Acids coming into contact with water are diluted accompanied by significant
development of heat.
•
Do not tilt the battery otherwise battery electrolyte may flow out of the
battery vent openings. Protect the eyes with safety glasses or a shield! There
is the danger of suffering blindness! If any battery electrolyte gets into your
eye, rinse out your eye immediately with clear water for several minutes.
Contact a doctor without delay.
•
Splashes of acid on your skin or clothes should be neutralised as soon as
possible using soap suds and then rinsed with plenty of water. Contact a
doctor immediately if you swallow battery electrolyte.
•
Keep batteries out of the reach of children.
•
Hydrogen is released when you charge a battery and a highly explosive
gas mixture is produced. An explosion can be caused through sparkling over
during unclamping or loosening of the cable plug while the ignition is on.
•
Bridging of the poles will create a short circuit (e.g. through metal
objects, cables). Possible consequences of a short circuit: Melting of lead
struts, explosion and burning of the battery, jets of acid spurting out.
•
It is prohibited to work with a naked flame and light, to smoke or to carry
out any activities which produce sparks. Avoid creating sparks when
working with cables and electrical devices. Strong sparking represents a risk
of injury.
•
Before carrying out any work on the electrical system, switch off the
engine, the ignition as well as all electrical components and disconnect the
negative cable (-) on the battery. If you wish to replace a bulb it is sufficient
to switch off the appropriate light.
•
Never charge a frozen or thawed battery - risk of explosion and caustic
burns! Replace a frozen battery.
•
Never use a battery which is damaged - risk of explosion! Immediately
replace a damaged battery.Caution
•
You must only disconnect the battery if the ignition is switched off, otherwise
the electrical system (electronic components) of the vehicle may be damaged.
When disconnecting the battery from the electrical system of the vehicle, first
disconnect the negative terminal (-) of the battery. Then disconnect the positive
terminal (+).
•
When reconnecting the battery, first connect the positive terminal (+) and only
then the negative terminal (-) of the battery. You must on no account connect the
cables wrongly - risk of a cable fire.
•
Ensure that battery acid does not come into contact with the vehicle body
otherwise damage could occur to the paintwork.WARNING (continued)
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Breakdown assistance
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Caution
If the vehicle has not been driven for more than 3 to 4 weeks, the battery will
discharge because certain electrical components consume electricity (e.g. control
units) also in idle state. You can prevent the discharging of the battery by discon-
necting the negative terminal or charging the battery constantly with a very low
charging current. Please also refer to the notes when working on the battery ⇒
in “Working on the battery” on page 192.
Note
•
Batteries with three-tone indicator, which are mounted as of factory, are
marked with a code which always begins with 1J0, 7N0 or 3B0. The exact marking
can be e.g. 1J0 915 105 AC.
•
Replacement batteries with three-tone indicator, which were obtained from
Škoda original accessories, are marked with the code 000 915 105 Ax, whereby
“x” stands for a variable. The exact marking can be e.g. 000 915 105 AB.
Inspecting the electrolyte levelThe battery is practically maintenance-free under normal operating conditions.
We do, however, recommend that you have the electrolyte level inspected from
time to time by a specialist garage when outside temperatures are high or when
driving on long trips. You should also have the electrolyte level ⇒page 195
checked each time the battery is charged.
The electrolyte level of the battery will also be checked as part of the Inspection
Service.Operation in winterThe battery has to provide greater amounts of electricity during the winter. It also
has only part of the initial power output at low temperatures that it has at normal
temperatures.
A discharged battery may already freeze at temperatures just below 0°C.We therefore recommend that you have the battery checked by a specialist garage
before the start of the winter, and recharged if necessary.
Charging the battery
A properly charged battery is essential for reliably starting the
engine.– Read the warning notes ⇒ in “Working on the battery” on
page 192 and ⇒.
– Switch the ignition and all electrical components off.
– Only for “quick-charging”: Disconnect both battery cables (first of all
“negative”, then “positive”).
– Carefully attach the terminal clamps of the charger to the battery
terminals (red = “positive”, black = “negative”).
– You can now plug the mains cable of the charger into the power socket
and switch on the charger.
– When charging is completed: switch the charger off and unplug the
mains cable from the power socket.
– Only then should you disconnect the terminal clamps of the charger.
– Reconnect the cables to the battery (first of all “positive”, then “nega-
tive”).It is not normally necessary to disconnect the cables of the battery if you recharge
the battery using low amperages (as for example from a mini-charger). Please also
refer to the instructions from the charger manufacturer.
A charging current of 0.1 of the total battery capacity (or lower) is that which should
be used until full charging is achieved.
It is, however, necessary to disconnect both cables before charging the battery with
high amperages, so-called “quick-charging”.
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