engine SKODA ROOMSTER 2010 1.G Repair Manual

Inspecting and replenishing
162
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, acci dents 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 safe ty. 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!

Never spill oil and other fluids over the hot engine. Such fluids (e.g. the anti-
freeze 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 expans ion 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.

Do not let objects, such as e.g cleaning cloth or tools lie in the engine
compartment.

If you wish to work under the vehicl e, 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 fr om 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 cabl es of the ignition system.
 Absolutely avoid any jewellery, loose it ems 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 warnin g instructions stated below when
carrying out any essential work on the fuel system or on th e 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 oper ating problems and also vehicle damage!
WARNING (continued)
s16g.4.book Page 162 Wednesday, February 10, 2010 3:53 PM

Inspecting and replenishing163
Using the system
Safety
Driving Tips
General Maintenance
Breakdown assistance
Praktik
Technical Data
Overview of the engine compartment
The main inspection points.Fig. 136 Diesel engine 1.6 ltr./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 th e engine compartment of petrol and diesel
engines is practically identical.
Engine oilCheck engine oil level
The dipstick indicates the le vel 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 162.
– Wait a few minutes and pull out the oil dipstick .
– Wipe off the dipstick with a clea n 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 .
A1
166
A2
172
A3
164
A4
163
A5
167
A6
168
Fig. 137 Dipstick
AaAb
Aa
Ab
s16g.4.book Page 163 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing
164
Oil level within range
–You must top up the oil. It is sufficient, once th is 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 hi gher 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 duri ng 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 28 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 162, “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 professional
assistance from a specialist garage, otherwise it could lead to severe engine damage.
Replenishing engine oil– Inspect the oil level page 163.
– Unscrew the cap of the engine oil filler opening. – Wipe off the oil from the sealing surface of the cover and on the counterpart using
a clean cloth.
– Pour in a suitable grade of oi l in portions of 0.5 litres page 208.
– Inspect the oil level page 163.
– 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 162, “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 163. Oil will otherwise
be drawn in through the cr ankcase 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 17.
WARNING

Only carry out the engine oil change, if you have the required professional
knowledge!

Read and observe the warning notes page 162, “Working in the engine
compartment” before working in the engine compartment.

First of all, let the engine cool down, we ar an eye protection and gloves - risk
of caustic burns due to hot oil.
Ac
Ab
AbAa
Aa
s16g.4.book Page 164 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing165
Using the system
Safety
Driving Tips
General Maintenance
Breakdown assistance
Praktik
Technical Data
Caution
You must not pour any additives into the en gine 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 prop erly 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 an authorised Škoda Service Partner.Note
After your skin has come in contact with th e oil, you must thoroughly wash your skin.Cooling systemCoolant
The job of the coolant is to cool the engine.The cooling system does not require any maintenance under normal operating condi-
tions. 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 mo nths 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 prot ection 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 antifr eeze agent G13 (purple in colour).
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.
Coolant capacity
Caution

Other coolant additives may cause operational problems which, in particular,
involves significantly reduci ng the anticorrosion effect.

Any faults or problems resulting from corrosion may cause a loss of coolant
and, as a consequenc e of this, result in major engine damage.Petrol engines
Content
1.2 ltr./51 kW - EU5 / EU2 DDK
5,5
1.2 ltr./63 kW TSI - EU5
7,7
1.2 ltr./77 kW TSI - EU5
7,7
Diesel engines
Content
1.6 ltr./66 kW TDI CR DPF - EU5
8,4
1.6 ltr./77 kW TDI CR DPF - EU5
8,4
s16g.4.book Page 165 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing
166
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 162.
– Check the level of coolant in the coolant expansion bottle fig. 138 . The coolant
level when the engine is cold must lie between the “MIN” and “MAX” mark-
ings. The level may also rise slightly above the “MAX” marking when the engine is
warm.
If the coolant level in the reservoir is too lo w, this is indicated by the warning light in
the instrument cluster
  page 28. 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 162, “Working in the engine
compartment” before working in the engine compartment.
Caution
One should contact a specialist garage as s oon as possible if the source of overheating
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 fig. 138 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 165, “Coolant”. Do not use an al ternative additive if the coolant
additive G12 PLUS - 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 orig-
inal container out of the reach of children - risk of poisoning!
Fig. 138 Engine compartment: Coolant
expansion bottle
AB
AA
s16g.4.book Page 166 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing167
Using the system
Safety
Driving Tips
General Maintenance
Breakdown assistance
Praktik
Technical Data

If any splashes of coolant get into yo ur 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.
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 igni tion 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 workin g 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 162.
– Inspect the brake fluid level in the reservoir fig. 139 . 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 brak e 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. If the
brake fluid level is too low, this is indicated by the warning light
 lighting up in the
instrument cluster page 31. In this case stop immediately and do not drive any
further! Obtain professional assistance.
WARNING

Read and observe the warning notes page 162, “Working in the engine
compartment” before working in the engine compartment.
WARNING (continued)
Fig. 139 Engine compartment: Brake
fluid reservoir
s16g.4.book Page 167 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing
168

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 brake fluid approved by Škoda Auto. The brake fluid must
comply with one of the following standards or specifications:
VW 501 14,

FMVSS 116 DOT4,

DIN ISO 4925 CLASS 4.
We recommend that you have the brake fluid replaced by an authorised Škoda
Service Partner 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 br ake system. This greatly impairs the
braking efficiency and thus also the safety of your vehicle.

Brake fluid is toxic! It must therefor e 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 batteryFig. 140 The battery: Pull up the cove r (automatic gearbox) / (manual gearbox)The battery is located in the engine compartment below a plastic box.
– Unlock the interlock on the positive terminal side of the battery fig. 140 .
– Pull up the cover in direction of arrow  fig. 140 (automatic gearbox) or fig. 140
(manual gearbox).
– The installation of the battery cover on th e 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 ma jor 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 th is 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 prot ective 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
WARNING (continued)
s16g.4.book Page 168 Wednesday, February 10, 2010 3:53 PM

Inspecting and replenishing169
Using the system
Safety
Driving Tips
General Maintenance
Breakdown assistance
Praktik
Technical Data
acid corrodes dental enamel and create
s 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 glas ses or a shield! There is
the danger of suffering blindness! If an y battery electrolyte gets into your eye,
rinse out your eye immediately with cl ear 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 swal low 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 cabl e 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, explo-
sion 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. Avoi d creating sparks when working with
cables and electrical devices. Strong sparking represents a risk of injury.

Before carrying out any work on the el ectrical 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 th e 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 other-
wise damage could occur to the paintwork.

Do not place the battery in direct daylight in order to protect the battery housing
from the effects of ultra-violet light.For the sake of the environment
A removed battery is a special type of wa ste which is harmful to the environment -
contact your specialist garage regarding disposing of the battery.
Note

Please also refer to the guidelines page 171, “Disconnectin g and reconnecting
the battery”, also after connecting the battery.
Battery with a two-tone indicator
WARNING (continued)
Fig. 141 The battery: Show
s16g.4.book Page 169 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing171
Using the system
Safety
Driving Tips
General Maintenance
Breakdown assistance
Praktik
Technical Data
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 temper-
atures.
A discharged battery may already freez e 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 essentia l for reliably starting the engine.– Read the warning notes  in “Working on the battery” on page 168 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 th e 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 “negative”).
It is not normally necessary to disconnect th e 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”. “Quick-charging” a battery is
dangerous  in “Working on the battery” on
page 168. It requires a special charger an d appropriate knowledge. We therefore
recommend that you have your battery quick- charged only by your specialist garage.
A discharged battery may already freeze at temperatures just below 0°C . We
recommend that you no longer use a battery which has thawed out because the casing
of the battery may be cracked through the formation of ice and this would allow
battery electrolyte to flow out.
The vent plugs of the battery should not be opened for charging.
WARNING
Never charge a frozen or thawed battery - risk of explosion and caustic burns!
Replace a frozen battery.Disconnecting and reconnecting the batteryOn disconnecting and reconnecting the battery the following functions are initially
deactivated or are no longer able to operate fault-free.
We recommend having the vehicle checked by a specialist garage to ensure full func-
tionality of all electrical systems.Replacing the batteryYou should only replace a battery with a ne w battery of the same capacity, voltage (12
V), amperage and of the same size. Specialist garages have a range of suitable batteries
available.Operation
Operating measure
Electrical power window (operational faults)
 page 44
Enter radio code number
see Radio Operating Instructions
Set hours
page 18
Data in the multi-functional indicator* are
deleted.
page 18
s16g.4.book Page 171 Wednesda y, February 10, 2010 3:53 PM

Inspecting and replenishing
172
We recommend that you only have an old ba ttery disposed of by a specialist garage
since it does require special disposal.
For the sake of the environment
Batteries contain poisonous substances such as sulphuric acid and lead. They must be
disposed of in accordance with local environmental protection regulations and on no
account as domestic waste.Windshield washer systemThe windshield washer reservoir contains the cleaning fluid for the windscreen or rear
window and for the headlamp cl eaning system*. The reservoir is located in the front of
the engine compartment on the right side of the vehicle fig. 142 . On some vehicles,
the reservoir is located on the left side of the vehicle next to the battery.
The filling level of the container is about 3.5 litres and about 5.4 litres on vehicles
which have a headlight washing system.
Clear water is not sufficient to intensively clean the windscreen and headlights. We
therefore recommend using clean washing water together with the screen cleaner
from Škoda genuine accessories (in winter additionally with antifreeze) which is
capable of removing stubborn dirt. Follow the instructions for use on the packaging
when using screen cleaning products.
You should always add antifreeze to the cleani ng water in winter even if your vehicle is
fitted with heated wind screen washer nozzles*. It is also possible in exceptional cases to use methylated spirits when no screen cleaner
with antifreeze is available. The concentration of methylated spirits must not be more
than 15 %. Please note, however, that the anti
freeze protection at this concentration is
only adequate down to -5°C.
WARNING
Read and observe the warning notes page 162, “Working in the engine
compartment” before working in the engine compartment.
Caution

On no account should you add radiator an tifreeze or other additives to the wind-
screen washer fluid.

If the vehicle is fitted wi th a headlight cleaning system, you should only add
cleaning products which do not attack the polycarbonate coating of the headlights to
the windscreen washer fluid. Please contac t your specialist garage, who will tell you
which cleaning agent you can use.Note
Do not take the filter out of the windscreen wash container when filling it up again with
liquid otherwise dirt can get into the liquid transportation system and can lead to faults
in operation of the windscreen wash system.
Fig. 142 Engine compartment: Wind-
shield washer fluid reservoir
s16g.4.book Page 172 Wednesda y, February 10, 2010 3:53 PM