1 4 63 KW MPI Engine

Service
Workshop Manual
Fabia II 2007 ➤
1.4/63 kW MPI engine
Engine ID BXW CGG
B
Edition 02.07
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
01 - Self-diagnosis
10 - Removing and installing engine
13 - Crankgear
15 - Cylinder Head, Valve Gear
17 - Lubrication
19 - Cooling
20 - Fuel Supply
24 - Fuel Formation, Injection
26 - Exhaust System
28 - Ignition system
Fabia II 2007 ➤
1.4/63 kW MPI engine - Edition 02.07
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Self diagnosis, safety measures, cleanliness regulations, directions . . . . . . . . . . . . . . . . . . 2
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Rules of cleanliness to observe when working on the fuel supply system . . . . . . . . . . . . . . 2
1.4 Safety measures to apply when working on the fuel injection and ignition system . . . . . . 3
1.5 General notes on the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 General notes on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.7 Supplementary instructions and assembly work on vehicles with an air conditioning
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
13 - Crankgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1 Removing and installing a V-ribbed belt and a toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1 Summary of components - V-ribbed belt with AC compressor . . . . . . . . . . . . . . . . . . . . . . 12
1.2 Removing and installing V-ribbed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Summary of components - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.4 Removing and installing, tightening the timing belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Checking semi automatic toothed belt tensioning pulley . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2 Removing and installing cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Aluminium cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Replacing crankshaft seal on belt pulley side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Replacing the sealing flange on the gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Summary of components of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.4 Testing the compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.5 Testinf the combustion chamber for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Replacing camshaft gasket rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Inspect valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4 Replacing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1 Removing and installing parts of the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Summary of components of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
Fabia II 2007 ➤
1.4 Testing oil pressure and oil pressure switch F1 ................................ 59
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1 Removing and installing parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.1 Summary of components of parts of the cooling system on the side next to the body . . . . 61
1.2 Summary of components of coolant regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.3 Connection diagram for coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.4 Summary of components of coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.5 Draining and filling up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.6 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.7 Checking the coolant system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Removing and installing parts of the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 Summary of components of the fuel tank with attached parts and fuel filter . . . . . . . . . . . . 71
1.2 Extract fuel from the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.3 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.4 Removing and installing the sender for fuel gauge display G . . . . . . . . . . . . . . . . . . . . . . 76
1.5 Removing and installing the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Testing parts of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Checking fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.2 Venting air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.3 Switching off the fuel delivery unit using the crash signal . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Electronic Engine Power Control (Electronic throttle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.1 Summary of components of accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 Activated charcoal container system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.1 Summary of components of activated charcoal container system . . . . . . . . . . . . . . . . . . . . 88
4.2 Checking the fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
24 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1 Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.1 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Summary of components of intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.3 Summary of components of fuel rail with injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.4 Summary of components of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.5 Checking the tightness of the injection valves and the fuel injection rate . . . . . . . . . . . . . . 94
1.6 Clean throttle valve control unit J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

1 Removing and installing parts of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Summary of components of pre-exhaust pipe with catalytic converters . . . . . . . . . . . . . . 100
1.2 Middle and rear silencer - Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3 Replacing middle silencer if necessary rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.4 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.5 Inspecting the exhaust system for leaktightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.1 Summary of components of parts of the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.2 Removing and installing ignition coils with power output stages . . . . . . . . . . . . . . . . . . . . 104
ii Contents
Fabia II 2007 ➤
00 – Technical data
1 Technical data
1.1 Engine number

The engine identification character and the engine number can
be found on the sticker -arrow- at the control box.
In addition, the engine identification characters are indicated on
the vehicle data sticker and also at the front on the cylinder block
on the connecting flange for gearbox.
The engine number consists of 9 characters. The first part (a
maximum of 3 letters) represents the “engine identification char‐
acters”, the second (the six part section) the “serial number”. If
more than 999.999 engines with the same engine identification
character were produced, then the first of the 6 digits will be re‐
placed by a letter.
1.2 Engine characteristics

Engine identification character BXW CGGB
Manufactured 02.07 ? 03.10 04.10 ?
Exhaust limit values conforming to EU-4 EU-5
Displacement l 1390 1390
Power output kW at rpm 63/5000 63/5000
Torque Nm at rpm 132 / 3800 132 / 3800
Bore ∅ mm 76,5 76,5
Stroke mm 75,6 75,6
Compression ra‐ 10,5 : 1 10,5 : 1
tio
Cylinder/number of valves per cylinder 4/4 4/4
Fuel - RON min. unleaded 95 1) unleaded 95 1)
Ignition system, fuel injection Magneti Marelli 4HV Magneti Marelli 4HV
Firing order 1-3-4-2 1-3-4-2
Knock control yes yes
Self-diagnosis yes yes
Lambda control yes yes
Catalytic converter yes yes
Balancing shaft gearbox no no
Exhaust gas recirculation no no
1) At least 91 RON in exceptional cases, although engine output

is reduced
1. Technical data 1
Fabia II 2007 ➤
01 – Self-diagnosis
1 Self diagnosis, safety measures,
cleanliness regulations, directions
1.1 Self-diagnosis
This repair group is no longer applicable.
Instead use the “Vehicle self-diagnosis”, “Measuring method” and
the “Targeted fault finding” ⇒ Vehicle diagnosis, testing and in‐
formation system VAS 5051.
1.2 Safety precautions when working on the

fuel supply system
WARNING
The fuel feed line is pressurized! Place a clean cleaning cloth

around the connection point before detaching wiring. Reduce
pressure by carefully removing the wiring.
WARNING
When undertaking all installation work, particularly in the en‐

gine compartment due to its cramped construction, please
observe the following:
♦ Lay lines of all kinds (e.g. fuel, hydraulic fluid, the activated
charcoal container system, cooling fluid and refrigerant,
brake fluid, vacuum) and electrical lines in such a way that
the original line guide is re-established.
♦ Ensure that there is adequate distance to all moving or hot
parts.
♦ The fuel pump is activated when the ignition is switched on

and by the door contact switch of the driver door. Before open‐
ing the fuel system and for reasons of safety, if the battery is
not disconnected, the connector must be disconnected from
the fuel delivery unit.
When removing and installing the fuel gauge sender or the fuel
delivery unit from a full or partly filled fuel tank, pay attention to
the following points:
♦ The extraction hose of an exhaust extraction system which is
switched on, must be positioned close to the assembly open‐
ing of the fuel tank in order to extract the released fuel vapours,
even before the work is commenced. If no exhaust extraction
system is available, a radial fan (motor not in air flow of fan)
with a delivery volume of more than 15 m3/h must be used.
♦ Avoid skin contact with fuel! Wear fuel-resistant gloves!
1.3 Rules of cleanliness to observe when

working on the fuel supply system
Pay careful attention to the following rules of cleanliness when
working on the fuel supply or fuel injection systems:
2 Rep. Gr.01 - Self-diagnosis

Fabia II 2007 ➤
♦ Thoroughly clean the connection points and their surroundings

before releasing.
♦ Place removed parts on a clean surface and cover. Do not use
fuzzy cloths!
♦ Carefully cover or seal removed or opened components if the
repair is not carried out immediately.
♦ Only install clean parts: Remove spare parts from their wrap‐
ping immediately before installing. Do not use any parts which
have been stored unwrapped (e.g. in tool boxes).
♦ When the system is opened: do no use compressed air. Do
not use the vehicle.
1.4 Safety measures to apply when working

on the fuel injection and ignition system
WARNING
The fuel system is under pressure! Before opening the system

lay cleaning cloths around the connection point. Reduce pres‐
sure by carefully releasing the connection point.
Observe the following points to prevent injury to persons and/or

damage to the injection and ignition system:
♦ Do not touch or remove ignition cables with the engine running
or when starting the engine.
♦ Do not disconnect or connect cables of the fuel injection and
ignition system, also not cables of test equipment, unless the
ignition is switched off.
♦ If the engine must be operated at start speed without the en‐
gine starting, as for example, when checking the compression
pressure: open lid of fuse carrier below the dash panel and
unplug fuse for injection valves -N30, N31, N32, N33- ⇒ Cur‐
rent flow diagrams and Fitting locations.
If test and measuring devices are required during test drives ob‐
serve the following:
♦ Always secure the test and measuring devices on the rear seat
and have a second person operate them there.
♦ If the test and measuring devices are operated from the pas‐
senger seat, the passenger can be injured by the release of
the passenger airbag in the event of an accident.
1.5 General notes on the injection system

♦ The engine control unit is equipped with a self-diagnosis sys‐
tem. Before repairs as well as for fault finding first interrogate
the fault memory ⇒ Vehicle diagnosis, testing and information
system VAS 5051.
♦ Fuel hoses in the engine compartment must be secured with
spring band clamps. The use of clamp-type or screw-type clips
is not allowed.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Do not use sealants containing silicone. Traces of silicone el‐
ements drawn in by the engine are not burnt in the engine and
damage the lambda probes.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
1. Self diagnosis, safety measures, cleanliness regulations, directions 3

Fabia II 2007 ➤
and if necessary delete ⇒ Vehicle diagnosis, testing and in‐

Safety measures ⇒ page 3
1.6 General notes on the ignition system

Setting data, spark plugs ⇒ Maintenance ; Fabia II .
Ignition system ⇒ page 104 .
♦ Switch off the ignition before disconnecting and connecting the
battery, as this may damage the 4AV control unit.
♦ The engine control unit and further components are fitted with
a self diagnosis function; check it ⇒ Vehicle diagnosis, testing
and information system VAS 5051.
♦ A minimum voltage of 11.5 V is required for perfect functioning
of the electrical components.
♦ Certain inspections may cause the control unit to detect and
store a fault. It is therefore necessary to interrogate the fault
memory after having completed all inspections and repairs,
and if necessary delete ⇒ Vehicle diagnosis, testing and in‐
Safety measures ⇒ page 3
1.7 Supplementary instructions and assem‐

bly work on vehicles with an air condi‐
tioning system
WARNING
Refrigerant circuit of the air conditioning system must not be

opened.
Caution
Risk of damaging the condenser and the refrigerant lines as

well as the refrigerant hoses.
♦ Do not over-tension, buckle or bend refrigerant lines and
refrigerant hoses.
Steps which should be taken in order to remove and install the

engine without opening the refrigerant circuit:
– Unscrew the holding clamp(s) on the refrigerent lines
– Remove V-ribbed belt ⇒ page 13 .
– Remove AC compressor ⇒ Heating, Air Conditioning ⇒ Rep.
Gr. 87 .
– Mount the air conditioning compressor and the condenser in
such a way that the refrigerent lines/hoses are not under ten‐
sion.
4 Rep. Gr.01 - Self-diagnosis

Fabia II 2007 ➤
10 – Removing and installing engine

1 Removing and installing engine
Special tools and workshop equipment required
♦ Engine / gearbox mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Lifting device for workshop crane -MP9-201 (2024 A)-
♦ Workshop crane , e.g. -VAS 6100-
♦ Catch pan , e.g. -VAS 6208-
♦ Pliers for spring strap clamps
♦ Wire
♦ Grease -G 000 100-
♦ Hot screw paste -G 052 112 A3-
1.1 Removing
Note
♦ The engine is removed towards the front together with the

gearbox.
♦ All cable straps that have been loosened or cut open when the
engine was removed must be attached again in the same lo‐
cation when the engine is installed again.
♦ Collect drained coolant in a clean container for reuse or proper
disposal.
– Observe all safety measures and notes for assembly work on

the fuel supply, injection and ignition system; as well as the
rules for cleanliness ⇒ page 2 .
WARNING
Observe measures when disconnecting the battery ⇒ Electri‐

cal System ⇒ Rep. Gr. 27 .
– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.

Gr. 27 .
– Remove air filter with air guide ⇒ page 94 .
– Remove noise insulation ⇒ Body Work ⇒ Rep. Gr. 50 .
– Remove the front wheelhouse liners ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Remove front bumper ⇒ Body Work ⇒ Rep. Gr. 63 .
– Drain coolant ⇒ page 65 .
– Separate coolant hoses from radiator and from heat exchang‐
er.
– Disconnect plugs from radiator fan -V7- and from thermos‐
witch for radiator fan -F18- .
1. Removing and installing engine 5

Fabia II 2007 ➤
– Disconnect plug of front headlights, turn signal lights, horn,

sensor for exterior temperature indicator and switch for front
flap lock.
– Remove lock carrier with headlights and radiator if necessary
also with AC condenser ⇒ Body Work ⇒ Rep. Gr. 50 .
Vehicles with air conditioning
Note
Carefully swivel the lock carrier with installed AC condenser to the

side and position on a suitable base. Do not separate refrigerant
lines.
Continued for all vehicles

– Disconnect the fuel feed line -2- and the vent line -1-.
To do so press in the securing rings.
– Seal the lines in order to prevent any dirt from penetrating into
the fuel system.
– Remove the vacuum and ventilation hoses from the engine or
from other components.
– Remove/unclamp all electrical lines from the engine, genera‐
tor, starter and gearbox and uncover them.
– Remove pre-exhaust pipe with catalytic converter
⇒ page 100 .
– Unbolt the pendulum support -arrows-.

– Remove shift mechanism from gearbox ⇒ gearbox ⇒ Rep.
Gr. 34 .
– Remove slave cylinder ⇒ Gearbox ⇒ Rep. Gr. 30 .
Note
Do not depress the clutch pedal.

– Remove AC compressor from holder ⇒ Heating, Air Condi‐
tioning ⇒ Rep. Gr. 87 .
– Secure the air-conditioning compressor with attached lines to
the assembly carrier.
– Unscrew drive shaft to the right and left of the gearbox and tie
up ⇒ Chassis ⇒ Rep. Gr. 40 .
6 Rep. Gr.10 - Removing and installing engine

Fabia II 2007 ➤
– Hang lifting device -MP9-201 (2024 A)- as follows and slightly

raise engine with the workshop crane .
Belt pulley side: 2nd hole of the attachment in Position 1.
Flywheel side: 1st hole of the attachment in Position 5.
WARNING
Use securing pins on the hooks and rig pins -arrows-.
– Unscrew the coolant expansion bottle and and lay to one side
(the hoses remain connected).
– Unscrew screws -arrows- and remove engine mount.
– Release screws -arrows- and remove gearbox mount.

– Raise the engine with gearbox and carefully pull out towards
the front.
Note
Engine with gearbox must be guided carefully when pulling out,

in order to avoid damaging the body.
1.1.1 Securing the engine to the assembly

stand
♦ Lifting device for workshop crane -MP9-201 (2024 A)-
♦ Engine mount -MP 1-202-
♦ Assembly stand -MP 9-101-
♦ Workshop crane , e.g. -VAS 6100-
Secure the engine with the holder -MP 1-202- on the assembly
stand -MP 9-101- before performing assembly work.
– Unbolt gearbox from engine ⇒ Chassis ⇒ Rep. Gr. 34 .
– Remove coolant regulator housing from the cylinder head.

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– Screw engine mount -MP 1-202- to engine and to assembly

stand -MP 9-101- .
1.2 Install
Installation is performed in the reverse order, pay attention to the
following points:
Note
♦ When performing installation work replace the self-locking

nuts.
♦ Replace screws which have been tightened to a torquing angle
as well as gasket rings and seals.
♦ When installing, the cable straps must be fastened again in
the same place as before the removal.
♦ The hose connections are secured with corresponding hose
clamps.
♦ Clean the drive shaft serration and hub serration on used
clutch discs and remove corrosion. Apply a very thin layer of
grease -G 000 100- onto the serration. Subsequently move the
hub up and down on the drive shaft until it fits smoothly on the
shaft. Remove all excess grease so that it does not get onto
the friction surfaces of the clutch.
– Inspect clutch release bearing for wear, replace if necessary.

– Grease the clutch release bearing and guide bushing for re‐
lease bearing with grease -G 000 100- .
– Check whether the dowel sleeves for centering the gearbox
have been inserted in the cylinder block, if necessary insert.

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– Insert intermediate plate on sealing flange and push onto the

dowel sleeves -arrows-.
– Attach gearbox to engine ⇒ Gearbox ⇒ Rep. Gr. 34 .
– When swiveling the unit, ensure adequate clearance particu‐
larly to the drive shafts.
– Align the engine and gearbox mounting so that it is stress-free
through tapping movements.
Note
Tightening order and tightening torque of screws for assembly

bracket ⇒ page 10 .
– Install drive shafts ⇒ Chassis ⇒ Rep. Gr. 40 .

– Install exhaust pipe with catalytic converter ⇒ page 100 .
– Install AC compressor at holder ⇒ Heating, Air Conditioning
⇒ Rep. Gr. 87 .
– Install the V-ribbed belt ⇒ page 13 .
– Electrical connections and proper routing ⇒ Electrical System
⇒ Rep. Gr. 97 .
– Install slave cylinder ⇒ Gearbox ⇒ Rep. Gr. 30 .
– Attach shift mechanism ⇒ Gearbox ⇒ Rep. Gr. 34 .
– Install lock carrier with headlights and radiator if necessary al‐
so with AC condenser ⇒ Body Work ⇒ Rep. Gr. 50 .
– Install air filter ⇒ page 94 .
– Top up coolant ⇒ page 65 .
– Adapt the engine control unit to the throttle valve control unit
-J338- ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
– Interrogate fault memory, rectify any faults existing and erase
system VAS 5051.
– Perform a test drive.
system VAS 5051.
1.2.1 Tightening torques

Component Nm
Screws and nuts M6 9
M7 13
M8 20
M10 40
M12 70
deviations:
Fixing screws for engine/gearbox ⇒ Gearbox ⇒ Rep. Gr. 34
Screws for assembly bracket ⇒ page 10

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1.3 Assembly bracket
Note
♦ When installing, first of all insert all screws for bracket and
screw in by hand by at least two - three turns.
♦ Tighten screws for bracket in the sequence according to the
numerical marking in the figures.
1.3.1 Tightening torques

Assembly bracket - engine up to 03/2010
1 - 20 Nm + torque a further 90° (1/4 turn) - replace
Assembly bracket - engine as of 04/2010

Note
On engines manufactured as of 04/2010, the assembly bracket

is supplemented by a dynamic vibration damper -1-. This damper
is an inseparable component part of the assembly bracket - it is
not removed.
Assembly bracket - gearbox
Note
Tighten screws -1- in the following sequence: rear, front and then
upwards.

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Pendulum support
Note
Before tightening the screws -1- press off gearbox in the elonga‐
ted holes of the pendulum support to the front in such a way that
there is maximum distance between the gearbox and the assem‐
bly carrier.

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13 – Crankgear
1 Removing and installing a V-ribbed
belt and a toothed belt
1.1 Summary of components - V-ribbed belt with AC compressor
1 - Tensioning pulley for ribbed

V-belt
❑ Swing out the tension‐
ing pulley with ring
spanner
❑ the tensioning pulley
can be secured by in‐
serting the 4 mm hexa‐
gon socket wrench into
the fit hole
2 - Bracket for auxiliary units
3 - 50 Nm
❑ Tightening sequence:
tighten first top right bolt,
then bottom right bolt,
and last the bolts at the
left (looking in direction
of travel)
4 - 23 Nm
5 - AC generator
❑ removing and installing
⇒ Electrical System ⇒
Rep. Gr. 27
❑ to facilitate the position‐
ing of the AC generator
drive the threaded bush‐
ings of the screws on the
generator slightly back‐
wards
6 - 20 Nm + torque a further 1/
4 turn (90°)
7 - Bushing
❑ 2 pieces
8 - 25 Nm
9 - AC compressor
❑ removing and installing ⇒ Heating, Air Conditioning ⇒ Rep. Gr. 87
10 - V-ribbed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ removing and installing ⇒ page 13
❑ Routing of the ribbed V-belt ⇒ page 12
11 - Belt pulley
❑ for the V-ribbed belt
12 Rep. Gr.13 - Crankgear

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12 - 150 Nm + torque a further 1/2 turn (180°)

❑ replace
❑ Counterhold belt pulley with counterholder -T30004 (3415)- with bolt -T30004/1 (3415/1)-
❑ tightening may occur in successive stages
❑ the torquing angle can be measured with a commercially available angle measuring plate, e.g. -Hazet
6690-
Routing of the V-ribbed belt with AC compressor

1 - Belt pulley of the crankshaft
2 - Tensioning pulley
3 - Belt pulley for AC generator
4 - AC compressor
5 - V-ribbed belt
1.2 Removing and installing V-ribbed belt

♦ Clamping lever -MP1-203-
♦ Open-end wrench waf 16
♦ Locking pin -T10060A-
Vehicles without air conditioning
Removing
– Remove the noise insulation.
– Mark the rotation direction of the V-ribbed belt.
– Release fixing screws for generator.
1. Removing and installing a V-ribbed belt and a toothed belt 13

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– Position clamping lever -MP1-203- , secure by inserting the

pin and and press AC generator towards the crankshaft.
Remove the released ribbed V-belt from the AC generator - belt
pulley.
Install
– Lay the V-ribbed belt on the crankshaft - belt pulley.
– Push AC generator down and fit on belt.
Once the AC generator is released the belt is tensioned to nom‐
inal voltage.
– After fitting the ribbed V-belt, crank the engine several times
with the starter (about 10 turns) once the AC generator screws
are released.
– First tighten the bottom and then the top screw for AC gener‐
ator to 20 Nm.
– Install the noise insulation.
Removing
– Mark the rotation direction of the V-ribbed belt.
– Swivel out tensioning pulley with an open-end wrench SW 16

in -direction of arrow-.
– Remove the V-ribbed belt. If necessary the tensioning pulley
can be secured by inserting a locking pin -T10060A- or a box
spanner 4 into the fit hole.
Install
– First lay the V-ribbed belt on the belt pulley crankshaft, then
on the AC compressor belt pulley.
– Release tensioning pulley with the wrench and pull the belt
over the AC generator - belt pulley.
– Check whether the ribbed V-belt fits correctly in the ribbing of
all tensioning pulleys.
– Check V-ribbed belt when engine is idling.
Note
♦ Pay attention to the running direction when installing the V-

ribbed belt.
♦ Replace damaged V-ribbed belt.
♦ If the belt is considerably worn it must be replaced.
♦ Do not bend or buckle the belt!

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1.3 Summary of components - toothed belt
1 - Timing belt guard - top part

4 turn (90°)
❑ replace
❑ to release and tighten
use camshaft lock -
T10016-
3 - Camshaft sprocket
❑ take note of the position
when installing the tim‐
ing belt ⇒ page 16
4 - Coupling drive tensioning
pulley
❑ check ⇒ page 22
❑ Tensioning toothed belt
⇒ page 19
5 - Coupling drive-toothed belt
❑ before removing mark
running direction
❑ check for wear
❑ do not kink
❑ removing and installing,
tensioning ⇒ page 16
6 - 10 Nm
7 - Coolant pump
❑ if damage and leak
present - replace com‐
pletely
⇒ page 70
8 - Rear toothed belt guard
9 - 20 Nm
10 - 50 Nm
11 - Guide pulley
12 - Tensioning pulley
❑ Tensioning toothed belt ⇒ page 19
13 - Belt pulley of the crankshaft
❑ take note of the position when installing the timing belt ⇒ page 16
14 - Main drive-toothed belt
❑ before removing mark running direction
❑ check for wear
❑ do not kink
❑ Routing of toothed belt ⇒ page 16
❑ removing and installing, tensioning ⇒ page 16
Note

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15 - 12 Nm
❑ replace
16 - Belt pulley
❑ pay attention to locating element when installing
❑ replace
❑ Counterhold belt pulley with counterholder -T30004 (3415)- with bolt -T30004/1 (3415/1)-
6690-
18 - V-ribbed belt
❑ mark the direction of rotation with chalk or a felt-tip pen before removing
❑ check for wear
❑ Routing of the ribbed V-belt ⇒ page 12
19 - Timing belt guard - bottom part
20 - Console
21 - 50 Nm
❑ replace
Routing of toothed belt

-A- Coupling drive - Toothed belt
-B- Main drive - Toothed belt
1.4 Removing and installing, tightening the

timing belt
♦ Supporting device -MP9-200 (10-222A)-
♦ Pressure pad -T30004 (3415)- with replaceable stud -
T30004/1 (3415/1)-
♦ Camshaft lock -T10016-

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Note
If the toothed belt is replaced within the scope of engine repair

(apart from change intervals), it should be entered in the Service
Schedule!
1.4.1 Removing
– Remove timing belt guard - top part.
– Remove front right wheelhouse liner: ⇒ Body Work ⇒ Rep.
Gr. 66 .
– Position crankshaft at top dead centre of cylinder 1. The notch
on the belt pulley must be aligned with the edge of the marking
-A-.
– The locating holes in the camshaft sprockets must be aligned

with the fit holes in the cylinder head cover -arrows-.
Note
If the locating holes are positioned on the opposite side of the

toothed belt sprockets, it will be necessary to rotate the crankshaft
a further revolution.
– Install supporting device -MP9-200 (10-222A)- according to

the illustration and support engine in fitting position.
– Unscrew filler neck from windshield washer reservoir.
– Unscrew the coolant expansion bottle and and lay to one side
(the hoses remain connected).

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– Unscrew fixing screws -1- and -2- for assembly bracket on the
belt pulley side and remove the entire assembly bracket.
– Remove the engine mount on the cylinder head.
– Mark the rotation direction of the two toothed belts.
Attach the two camshaft sprockets with camshaft lock -T 10016-
as follows:
– Fully insert the two fixing pins through the locating holes of the
camshaft sprockets into the fit holes of the cylinder head cover.
Note
The two fixing pins are correctly inserted if the end parts -D- are
flush with line -A-.
– Slide the support -B- up to the stop on the camshaft timing

gear -C-.
– Release fixing screw for belt pulley and toothed belt gear.
Counterhold belt pulley with counterholder -T30004 (3415)-
and stud -T30004/1 (3415/1)- .
– Remove belt pulley. Screw in the fixing screw with 2 washers
to secure the toothed belt gear.
– Remove tensioning pulley for V-ribbed belt ⇒ page 12 .
For all vehicles
– Remove bottom part of toothed belt guard.
Remove main drive toothed belt
– Release the main drive tensioning pulley -1- and release the
toothed belt by turning the tensioning pulley anti-clockwise
-arrow-.
– Release the tensioning screw of the tensioning pulley.
– Remove tensioning pulley.
– Remove camshaft lock -T 10016- .
– Remove timing belt.
– Fix the two camshaft sprockets with camshaft lock -T 10016- .
Remove coupling drive - toothed belt

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– Release the coupling drive tensioning pulley -1- and release

the toothed belt by turning the tensioning pulley clockwise
-arrow-.
– Remove coupling drive tensioning pulley.
– Remove timing belt.
1.4.2 Install
Conditions
• The pistons must not be positioned at top dead centre.
• The toothed belt gear of the crankshaft is secured to the crank‐
shaft with the fixing screw and 2 washers.
• Camshaft sprockets are fixed with camshaft lock -T10016- in
the fit holes in the cylinder head cover and secured against
turning.
Note
When turning the camshaft the valves may touch the piston in top
dead centre.
Work procedure
– Position crankshaft at top dead centre of cylinder 1. The cham‐
fered tooth must correspond with the marking on the sealing
flange -arrow-.
– Fit the coupling drive - toothed belt. If the toothed belt has been
used pay attention to the rotation direction.
Install the coupling drive tensioning pulley as follows:
– Turn the coupling drive tensioning pulley with hexagon socket

wrench -1- clockwise in the direction of the marking window
-arrow- (tensioning pulley in released position).
– Push the bottom part of the coupling drive-toothed belt up‐
wards using the tensioning pulley and screw in the fixing screw
of the tensioning pulley.
– Tighten fixing screw manually. The peg of the base plate -2-
must engage in the bore in the cylinder head.

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– Subsequently tension the toothed belt by turning the tension‐

ing pulley anti-clockwise until the pointer -2- is positioned
above the peg -arrow- of the base plate in the marking window.
– Tighten the fixing screw on the tensioning pulley. Tightening
torque: 20 Nm
– Remove camshaft lock -T 10016- .
– Turn the crankshaft or toothed belt gear from top dead centre
half a tooth anti-clockwise (approx 1.5 mm).
– Fit the main drive - toothed belt.
– Fix the two camshaft sprockets with camshaft lock -T 10016- .
If the tensioning pulley has been removed beforehand, install ten‐
sioning pulley as follows:
– Turn tensioning pulley with Allan key anti-clockwise in the

marked position -arrow-.
– Tighten fixing screw manually. The screw in the cylinder block

-2- must lock in the recess on the base plate -1-.
– Subsequently tension the toothed belt in the direction of the
arrow by turning the tensioning pulley until the pointer -3- is
positioned above the notch -arrow- in the base plate.
– Tighten the fixing screw on the tensioning pulley. Tightening
torque: 20 Nm
– Remove the camshaft lock -T 10016- .

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– Turn crankshaft 2 turns further in the running direction of the

engine until the crankshaft is again on top dead centre of cyl‐
inder 1. The chamfered tooth must correspond with the mark‐
ing on the sealing flange -arrow- in the fig. -A-.
In this position both camshaft sprockets must lock with camshaft
lock -T 10016- fig. -B-.
– Then inspect the toothed belt setting and tensioning pulley
setting again, if necessary repeat tensioning of the two toothed
belts.
– Install bottom toothed belt guard.
– Install the crankshaft belt pulley. Pay attention to the following:
♦ The fixing screws for the belt pulley and toothed belt gear must
be replaced.
♦ Pay attention to the toothed belt gear attachment when instal‐
ling the belt pulley.
♦ The clamping surfaces of the belt pulley and the screw must
be free of grease.
♦ Tightening process for the new oiled screw: 150 Nm + torque
a further 1/2 turn (180°).
♦ Counterhold belt pulley for crankshaft with counterholder -
T30004 (3415)- with bolt -T30004/1 (3415/1)- .
– Attach engine mount to cylinder head. Tightening torque 50
Nm
– Install engine assembly bracket. Tightening torques
⇒ page 10 .
– Install the top part of the timing belt guard.
– Install the V-ribbed belt ⇒ page 13 .
Note
Pay attention to the correct position of the V-ribbed belt in the belt
pulley when installing it.
– Install the front right wheelhouse liner ⇒ Body Work ⇒ Rep.

Gr. 66 .
– Screw on coolant expansion reservoir.
– Connect hose for crankcase ventilation and install engine cov‐
er with air filter ⇒ page 94 .

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1.5 Checking semi automatic toothed belt

tensioning pulley
Check main drive tensioning pulley
– Mark the pointer position of the tensioning pulley -arrow-. Load
timing belt by firmly pressing down with thumb. The pointer
must move.
– Relieve the pressure on the toothed belt and rotate crankshaft
a further 2 revolutions in direction of rotation of engine until the
engine is again positioned at TDC of cylinder 1. When doing
this, it is important that the last 45° (1/8 turn) are rotated without
any interruption.
– Then check pointer position. The pointer must return to its in‐
itial position.
If the pointer does not return to its initial position:
– Replace tensioning pulley.
Check coupling drive tensioning pulley
– Mark the pointer position of the tensioning pulley -1-. Load

timing belt by firmly pressing down with thumb -arrows-. The
pointer must move.
– Relieve the toothed belt again.
– Turn the crankshaft twice in the running direction of the engine.
– Then check pointer position. The pointer must return to its in‐
itial position.
If the pointer does not return to its initial position:
– Replace tensioning pulley.

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2 Removing and installing cylinder

block
2.1 Aluminium cylinder block
WARNING
The crankshaft must not be removed. Merely releasing the

crankshaft bearing cover will result in deformations of the bear‐
ing seats of the cylinder block.
If the bearing cover screws have been released, replace the
complete cylinder block together with the crankshaft.
1 - 10 Nm
2 - Suction line
3 - Cylinder block
4 - Knock sensor
5 - 20 Nm
❑ The tightening torque in‐
fluences the knock sen‐
sor function
4 turn (90°)
❑ replace
7 - Flywheel
❑ for removing and instal‐
ling secure the flywheel
using -MP1-223 (3067)-
8 - Intermediate plate
❑ must be positioned on
dowel sleeves
❑ do not damage/bend
during assembly work
9 - 12 Nm
❑ replace
10 - Sealing flange on the
gearbox side
❑ with rotor and gasket
ring
❑ always replace com‐
plete with gasket ring
and rotor
⇒ page 25
11 - Engine speed sender -G28-
12 - 5 Nm
13 - Gasket
❑ replace
2. Removing and installing cylinder block 23

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14 - Oil pump
❑ must be replaced completely
❑ when fitting pay attention to the driver on the crankshaft ⇒ Item 16 (page 24)
❑ must be positioned on dowel sleeves
15 - Sealing ring
❑ replace ⇒ page 24
16 - Driver
❑ coat with oil before installing the oil pump
2.2 Replacing crankshaft seal on belt pulley

side
♦ Gasket ring extractor -T30003 (3240)-
♦ Bushing -T10022-
♦ Pressure plate -T10022/1-
♦ Spindle -T10022/2-
Removing
– Remove main drive toothed belt ⇒ page 16 .
– Remove the toothed belt sprocket of the crankshaft.
– To guide the gasket ring extractor screw in fixing screw for
toothed belt gear in the crankshaft up to the stop.
– Unscrew inner part of the gasket ring extractor -T30003- 2
turns (approx. 3 mm) out of the outer part and lock with knurled
screw.
– Oil the thread head of the gasket ring extractor, position and
forcely screw into the gasket ring as far as possible.
– Release knurled screw and turn the inner side against the
crankshaft until the gasket ring is pulled out.
Install
– Lightly oil the sealing lip of the gasket ring.
– Position the bushing -T10022- on the crankshaft stub and

screw in with spindle -T10022/2 - up to the stop.
– Slide gasket ring over the bushing -T10022- .

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– Press in gasket ring with pressure plate -T10022/1- up to the

stop.
2.3 Replacing the sealing flange on the

gearbox side
♦ Assembly tool -T10134-
♦ 3 hexagon screws M6 x 35
♦ Feeler gauges
♦ Steel straightedge
2.3.1 Removing
Note
In order to better represent the work sequences, these sequences

are performed with the engine removed. The work sequences are
identical with the engine installed and gearbox removed.
– Remove the flywheel ⇒ Item 7 (page 23) .

– Remove the intermediate plate.
– Position engine at top dead centre of cylinder 1 ⇒ page 16 .
– Removing the oil pan ⇒ page 55 .
– Remove engine speed sender -arrow-.
– Unscrew the fixing screws of the sealing flange.

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– Screw 3 screws M6 x 35 into the threaded bores of the sealing

flange -arrows-.
– Press sealing flange together with rotor from the crankshaft To
do so, turn the screws alternatively into the sealing flange.
2.3.2 Install
Note
♦ The sealing flange with PTFE gasket ring is provided with

sealing lip supporting ring. This supporting ring is intended as
an assembly sleeve. It must not be removed before installing.
♦ Do not separate or turn the sealing flange and rotor after re‐
moving them from the spare part package.
♦ The rotor is given its fitting location by fixing the assembly de‐
vice -T10134- to the positioning pin.
♦ The sealing flange and sealing ring form one unit. It must only
be replaced together with the rotor.
♦ The rotor has an elastomer layer on its sealing surface with
the crankshaft. This layer must not be brought into contact with
dirt or grease.
♦ The assembly device -T10134- is given its fitting location to
the crankshaft by means of a guide bolt, which is guided into
the threaded bore of the crankshaft.
A - Mounting the sealing flange with rotor on the assembly device

-T10134-
A - Hexagon nut
B - Clamping surface
C - Assembly cup
D - Allan screw
E - Guide bolts (with red handle - for fuel engine)
F - Positioning pin
G - Guide bolts (with black handle - for diesel engine)

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– Grip assembly device on clamping surface -B- of the threaded

spindle in a vice.
– Remove the securing clip -arrow- from the new sealing flange.
Note
Do not remove or turn the rotor from the sealing flange.
– Lay the front side of the sealing flange on a clean and level
surface.
– Press the sealing lip supporting ring -A- -arrows-, until it rests
on the level surface.
Note
The top edge of the rotor and the front edge of the sealing flange
must be flush.
The locating hole -B- on the rotor -C- must be flush with the mark‐
ing -A- on the sealing flange.

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– Lay the sealing flange with the front side on the assembly de‐
vice in such a way that the positioning pin -A- engages in the
hole -B- of the rotor.
Note
Make sure the sealing flange lies flat on the assembly device.
– When tightening the knurled screws -A- press the sealing lip
supporting ring -B- on the surface of the assembly device -
T10134- in such a way that the positioning pin can no longer
slide out of the rotor hole.
B - Mounting the assembly device -T10134- with sealing flange
on the crankshaft flange
• The crankshaft flange must be free of grease and oil
• The crankshaft is at top dead centre of cylinder 1
– Unscrew hexagon nut -B- up to the end of the threaded spin‐
dle.
– Screw assembly device with Allan screws -A- up to the stop

onto the crankshaft flange.
– Screw in 2 screws M6 x 35 mm -A- by about 3 thread turns for

the sealing flange guide into the cylinder block.

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– Move the assembly cup -C- by hand in the

-direction of the arrow- until the rotor -B- rests on the crank‐
shaft flange -A-. Subsequently insert the guide bolt with red
ball -F- fully into the threaded bore of the crankshaft. If the
guide bolt is correctly seated, the ball is approx. 10 mm from
the assembly cup -C-. This gives the rotor its final fitting loca‐
tion.
– Screw in hexagon nut -E- by hand onto the threaded spindle
until it rests against the assembly cup -C-.
C - Pressing the rotor onto the crankshaft flange
– Tighten the hexagon nut of the assembly device using a torque

wrench with adapter. Tightening torque: 35 Nm.
Note
After tightening the nut to 35 mm there must still be a narrow air

gap between the cylinder block and the sealing flange.
D - Inspecting the fitting position of the rotor on the crankshaft
– Unscrew hexagon nut -E- up to the end of the threaded spin‐

dle.
– Unscrew 2 screws M6 x 35 -A- from the cylinder block.
– Release 3 knurled screws -B- from the sealing flange.
– Unscrew 2 Allan screws and remove assembly device.
– Remove sealing lips supporting ring.
The fitting position of the rotor on the crankshaft is accurate if

there is a distance -a- of 0.5 mm between the crankshaft flange
-A- and the rotor -B-.

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– Position the steel striaghtedge onto the crankshaft flange.

– Measure the distance between the steel straightedge and the
rotor with a feeler gauge.
If the measured distance is less than 0.5 mm:
– Press down rotor ⇒ page 30 .
If the dimension is correct:
– Tighten the new fixing screws of the sealing flange crosswise.
Tightening torque: 12 Nm.
– Install engine speed sender -G28- -arrow-. Tightening torque:

5 Nm.
– Installing the oil pan ⇒ page 55 .
– Installing intermediate plate.
– Install flywheel with new screws. Tighten fixing bolts to 60 Nm
and torque a further 1/4 turn (90°).
E - Pressing down the rotor
– Screw assembly device -T 10134- with Allan screws up to the

stop onto the crankshaft flange.
– Screw in 3 knurled screws -A- into the flange.
– Subsequently insert the guide bolt with red ball -E- fully into
the threaded bore of the crankshaft. If the guide bolt is correctly
seated, the ball is approx. 10 mm from the assembly cup -B-.
– Screw in hexagon nut -D- by hand onto the threaded spindle
until it rests against the assembly cup -B-.
– Tighten the hexagon nut of the assembly device using a torque

wrench with adapter. Tightening torque: 40 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 29 .
If the dimension -a- is again too small:
– Tighten the hexagon nut of the assembly device to 45 Nm.
– Again inspect the fitting position of the rotor on the crankshaft
⇒ page 29 .

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3 Pistons and conrods
1 - Circlip
2 - Piston pin
❑ if stiff, heat piston to ap‐
prox. 60°C
with bracket -T10014-
3 - Piston
❑ mark installation posi‐
tion and matching cylin‐
der
❑ arrow on piston crown
faces towards the belt
pulley
❑ ∅ Piston = 76.47 mm
4 - Piston rings
❑ Offset joint 120°
❑ use piston ring pliers for
removing and installing
❑ remove and install 3-
part oil scraper rings by
hand
❑ marking -TOP- must
face towards piston
crown
❑ Inspect gap clearance
⇒ page 32
❑ Inspect end clearance
⇒ page 32
5 - Conrod
❑ always replace as a set
only
❑ mark matching cylinder
-A-
❑ Fitting position: Markings -B- point towards the belt pulley side
❑ located axially by pistons
6 - Conrod bearing cap
❑ Check fitting position
❑ cracked cover fits only in one position at the relevant conrod
7 - Conrod bolt
❑ M7 x 0.75: 20 Nm + torque a further 1/4 turn (90°)
❑ M8 x 1: 30 Nm + torque a further 1/4 turn (90°)
❑ replace
❑ Oil thread and contact surface
8 - Cylinder block
❑ inspect cylinder bore ⇒ page 33
❑ ∅ Cylinder = 76.51 mm
9 - Bearing shell
❑ do not mix up used bearing shells (mark)
3. Pistons and conrods 31

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❑ insert bearing shells in the centre
Inspecting piston ring gap clearance

– Push in ring at right angles to the cylinder wall from the top
through to the bottom cylinder opening, about 15 mm from the
cylinder edge.
Piston ring new Wear limit
dimensions in mm
1. Compression ring 0,20 ... 0,50 1,0
Oil scraper ring 0,25 ... 0,50 __1)
1) cannot be measured
Inspect piston ring end clearance

– Clean annular groove before measurement is taken.
Piston ring new Wear limit
dimensions in mm
Oil scraper ring cannot be measured
Inspecting pistons

♦ External micrometer 75...100 mm
– Measure about 10 mm from the lower edge, offset at right an‐
gles to the piston pin shaft.

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♦ Variation compared to nominal diameter max. 0.04 mm

Inspecting cylinder bore

♦ Internal precision measuring instrument 50...100 mm
– Measure at 3 points crosswise in a transverse direction -A- and
lengthwise -B-.
♦ Variations compared to nominal dimension max. 0.08 mm
Note
Do not measure the cylinder bore if the cylinder block is fixed to

the assembly stand with the engine mount -MP 1-202- , as this
may result in incorrect measurements.
3. Pistons and conrods 33

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15 – Cylinder Head, Valve Gear

1 Removing and installing cylinder
head
1.1 Summary of components of cylinder

head
Testing compression pressure ⇒ page 42 .
Note
♦ When installing a replacement cylinder head, all the contact

surfaces between the hydraulic supporting elements, roller
rocker arms and the cam tracks must be oiled before installing
the cylinder head cover.
♦ Do not remove the plastic bases supplied as a protection for
the open valves until just before fitting on the cylinder head.
♦ If the cylinder head is replaced, the system must also be com‐
pletely filled with fresh coolant.
♦ Before assembly moisten all bearing points and contact sur‐
faces with oil.
♦ Disassembling and assembling intake manifold ⇒ page 92 .
34 Rep. Gr.15 - Cylinder Head, Valve Gear

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running direction
❑ check for wear
❑ do not kink
❑ Routing of toothed belt
⇒ page 15
running direction
❑ check for wear
❑ do not kink
4 - 10 Nm
5 - Protective housing
6 - Line
❑ tighten at cylinder head
cover to 8 Nm
7 - Hall sender -G40-
8 - O-ring
❑ replace
9 - Roller rocker arm
❑ Check smooth opera‐
tion of cylindrical-roller
bearings
❑ oil contact surfaces
❑ to install clip onto the supporting element with the locking clips
10 - Lifting eye
11 - 20 Nm
12 - Dowel pins
13 - hydraulic balancing element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ oil the contact surfaces before installing
❑ before installing check axial play of the camshaft ⇒ page 44
14 - Cylinder head bolt
❑ replace
❑ observe the mounting instructions and sequence for loosening and tightening ⇒ page 39
15 - Oil pressure switch -F1- , 25 Nm
❑ Switching pressure 0.03 ... 0.07 MPa (0.3 ... 0.7 bar)
❑ Cut open gasket ring if leaking and replace
16 - Cylinder head gasket
❑ replace
❑ metal gasket
1. Removing and installing cylinder head 35

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17 - Cylinder head
❑ check for distortion ⇒ page 36
❑ Sealing surfaces on the cylinder head cover must be free of oil and grease
❑ after replacing fill entire system with fresh coolant
18 - Coupling drive tensioning pulley
19 - 20 Nm
21 - Cylinder head cover
❑ when installing, fit onto pin screws and dowel pins vertically from above
❑ replace
❑ tighten from inside to outside
Inspecting the cylinder head for distortion

Max. permissible distortion: 0.05 mm
1.2 Removing and installing cylinder head

cover
♦ Pressure pad -T30004 (3415)- with replaceable stud -
T30004/1-
♦ Extractor -T10094 A-
♦ Sealant remover gasket stripper (bearing code GST, bearing
article no. R 34402), manufacturer Retech s.r.o.
♦ Cleaning agent and grease remover e.g. -D 000 401 04-
♦ Sealant -D 188 003 A1-
♦ Protective gloves and safety goggles

Fabia II 2007 ➤
Removing
Note
♦ The camshafts are located in the cylinder head cover. This is

why the cylinder head cover must only be removed once the
two toothed belts have been removed.
♦ Do not rework the sealing surface of the cylinder head cover.
♦ Removing and installing camshafts ⇒ page 44 .
– Disconnect the battery-earth strap with the ignition off.

– Removing both timing belts ⇒ page 16 .
– Unscrew the earth line from the cylinder head cover.
– Removing oil filler inlet.
– Removing ignition coils ⇒ page 104 .
– Remove cable guide with wiring loom from cylinder head cov‐
er.
– Remove coolant ventilation line from cylinder head cover.
– Disconnect the 3-pin plug connection from the hall sender.
– Release the fixing screw for the rear toothed belt guard near
the right lifting eye.
– Slacken the fixing screws of the cylinder head cover crosswise
from outside to inside and unscrew.
– Carefully remove the cylinder head cover.
– Remove the roller rocker arms together with the hydraulic bal‐
ancing elements and lay aside on a clean surface. Make sure
the roller rocker arm and the hydraulic supporting elements
are not interchanged.
Install
• The toothed belt gear of the crankshaft is secured to the crank‐
shaft with the fixing screw and 2 washers.
• Camshaft sprockets are fixed with camshaft lock -T10016- in
the fit holes in the cylinder head cover and secured against
turning.
Note
When turning the camshaft the valves may touch the piston in top
dead centre.
WARNING
Wear protective gloves when working with sealant and grease

remover!
– Remove residual sealant on the cylinder head and cylinder

head cover with a chemical sealant remover.
– Ensure that no dirt and sealant residues get into the cylinder
head.

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– Degrease the sealing surfaces.

– Apply a thin coating of sealant -D 188 003 A1- uniformly on
the clean sealing surface of the cylinder head cover (see grid
surface in the fig.).
Note
The sealant must not be applied too thickly, as otherwise excess

sealant may penetrate into the oil bores and possibly cause en‐
gine damage.
– Make sure all roller rocker arms are correctly positioned on the
end of valve stems -1- and on the relevant hydraulic supporting
elements -2-.
– When installing, screw 2 pin screws (M6 x 70) into the cylinder
head in order to guide the cylinder head cover.
– Carefully place the cylinder head cover at right angles to the

cylinder wall onto the pin screws -arrows- and dowel pins of
the cylinder head.

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– Tighten the new fixing screws of the cylinder head cover cross‐
wise and evenly from the inside to the outside. Tightening
torque 10 Nm + torque a further 1/4 turn (90°).
WARNING
Do not tilt the cylinder head cover!
Note
♦ After installing the cylinder head cover, allow the sealant to dry
for about 30 minutes.
♦ After installing new hydraulic supporting elements, the engine
must not be started for about 30 minutes. The hydraulic sup‐
porting elements must “settle” (otherwise valves would strike
the pistons).
♦ If the battery earth strap is disconnected and reconnected,
carry out additional operations ⇒ Electrical System; Rep. Gr.
27 .
The further assembly is carried out in reverse order to disassem‐

bly.
1.3 Removing and installing cylinder head

♦ Pressure pad -T30004 - with replaceable stud -T30004/1-
♦ Support -T10014-
♦ Extractor -T10094-
♦ Catch pan , e.g. -V.A.G 1306-
♦ Protective gloves and safety goggles
♦ Sealant -D 188 003 A1-
Requirements
• Engine temperature should not exceed 35 °C, because the
cylinder head could be twisted when slackening the screws.
1.3.1 Removing
– Remove air filter ⇒ page 94 .
– Remove cylinder head cover ⇒ page 36 .
WARNING
Hot steam may escape when the compensation bottle is

opened. Cover the cap with a cloth and open carefully.

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– Open and close the cap of the expansion reservoir to reduce

the pressure in the cooling system.
– Release spring strap clamps and disconnect coolant hoses of
the coolant regulator housing.
– Remove the guide tube for the oil dipstick.
WARNING
The fuel system is under pressure! Place a clean cleaning cloth

around the connection point before detaching hose connec‐
tions. Then reduce the pressure by carefully removing the
hose.
– Remove fuel feed line -2-. To do so press the release buttons.

– Seal the lines so that no dirt can get into the fuel system.
– Observe rules for cleanliness ⇒ page 2 .
– Release or disconnect the following components:
♦ Hose to activated charcoal container system of intake mani‐
fold.
♦ Vacuum hose to brake servo unit from intake manifold.
♦ Plug connection of knock sensor (rear cylinder block) and in‐
take manifold pressure sender with intake manifold tempera‐
ture sender.
♦ Plug connection of engine speed sender.
♦ Plug connection of coolant temperature sender, oil pressure
switch and exhaust gas recirculation valve.
♦ Plug connection of the throttle valve control unit.
♦ Plug connections of the injection valves.
♦ Plug connection of heated vacuum valve at oil separator.
♦ Crankcase ventilation hose at intake manifold.
– Remove/unclamp all other necessary electrical cables from
the engine.
– Unscrew the pre-exhaust pipe from the exhaust manifold and
hook up ⇒ page 100 .
Note
Both lifting eyes are located on the cylinder head. An additional

holder must be fitted on the cylinder block to support the engine.

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– Install supporting device -MP 9-200- with positioned spindles

as shown and support the engine with spindle -B-.
– Carefully raise engine with spindle -B-.
– Removing toothed belt ⇒ page 16 .
– Remove guide pulley ⇒ page 15 .
– Screw in bracket -T10014- in the location of the removed guide
pulley. Tightening torque: 20 Nm
– Support the engine and carefully raise with spindle -A- and
through this release the spindle -B-.
– Remove spindle -B-.
– Remove the clips on the coolant regulator housing, which se‐
cure the coolant pipe to the coolant pump.
– Slacken cylinder head bolts in the order shown and unscrew.

– Carefully remove the cylinder head.
1.3.2 Install
Note
♦ There must be no oil or coolant in the blind holes for the cyl‐
inder head bolts in the cylinder block.
♦ Remove the new cylinder head seal from its wrapping imme‐
diately before fitting.
♦ Treat the new gasket with the utmost care. Any damage will
result in leaks.
♦ Replace cylinder head bolts.
– Make sure that when cleaning the cylinder head and cylinder
block no impurities can get into the cylinder or into the oil and
coolant galleries.
WARNING

remover!
– When conducting repairs sealant residues should be removed

from the contact surface of the cylinder head/cylinder block
using a chemical sealant remover.
– Position piston of cylinder 1 to top dead centre ⇒ page 16 .

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– Lock the camshaft sprockets with -T10016- .

– Position the new cylinder heads. The marking (spare part no.)
must be legible.
– Insert the cylinder head. Pay attention to the centering pins in
the cylinder block.
– Insert new cylinder head bolts and tighten by hand.
– Tighten the cylinder head bolts in the order shown.
– First of all tighten all bolts to 30 Nm.
– Torque all bolts 1/4 turn (90°) with a rigid wrench.
– Subsequently again torque all bolts 1/4 turn (90°) with a rigid
wrench.
– Insert the hydraulic supporting elements in the cylinder head
and position the relevant roller rocker arm on the valve stem
ends.
– Install cylinder head cover ⇒ page 36 .
– Remove both toothed belts ⇒ page 16 .
Further installation occurs in reverse order.
Note
If the battery earth strap is disconnected and reconnected, carry

out additional operations ⇒ Electrical System ⇒ Rep. Gr. 27 .
1.4 Testing the compression

♦ Spark plug wrench , e.g. -3122 B-
♦ Compression tester , e.g. -V.A.G 1763-
♦ Extractor -T10094 A-
Test conditions
• Engine oil temperature at least 30°C
Work procedure
– Remove ignition coils with extractor -T10094- .
– Unscrew the spark plugs with spark plug wrench.

Fabia II 2007 ➤
– Remove the fuse for the voltage supply of the injection valves
from the E box in the dash panel ⇒ Current flow diagrams and
Fitting locations.
– Check compression pressure using the compression tester.
Note
The use of the tester is described in the relevant operating in‐

structions.
– Leave engine running until the tester no longer indicates a

pressure rise.
Compression readings
New engine Wear limit Difference between
cylinders
1 … 1.5 MPa (10… 0.7 MPa (7 bar) 0.3 MPa (3 bar)
15 bar)
If the specified values are not reached, test the combustion cham‐
ber for tightness ⇒ page 43 .
– Screw in the spark plug with spark plug wrench and then tight‐
en fully to 30 Nm.
Further installation occurs in reverse order.
system VAS 5051.
1.5 Testinf the combustion chamber for

tightness
♦ Pressure hose -MP1-210 (VW 653/3)- (replace gasket ring
with a spark plug gasket ring)
♦ Spark plug wrench
Test sequence
– Release the spark plugs.
– Position the piston of the relevant cylinder to top dead centre.
– Screw the pressure hose MP 1-210 into the spark plug thread.
– Connect pressure hose to compressed air.
– With the assistance of a second mechanic, lock the screw at
the crankshaft in order to avoid the displacement of the piston
from top dead centre after pressure build-up.
– Build up a pressure of approx. 0.3 MPa (3 bar) in the com‐
bustion chamber.
– Determine how the pressure escapes:
1- Via the inlet valve(s) - the pressure enters the throttle valve.
2- Via the outlet valve(s) - the pressure enters the exhaust
system.
3- Via the piston rings - pressure enters the engine block.

Fabia II 2007 ➤
2 Valve gear
1 - 10 Nm
2 - Protective housing
3 - Line
❑ tighten at the cylinder
head cover to 8 Nm
4 turn (90°)
❑ replace
❑ to release and tighten
use camshaft lock -
T10016- ⇒ page 46
5 - Camshaft sprocket
❑ pay attention to position
of toothed belt when in‐
stalling ⇒ page 16
6 - Sealing ring
❑ only replace with the
camshaft installed
❑ Lightly oil the sealing lip
of the gasket ring
running direction
❑ check for wear
❑ do not kink
4 turn (90°)
❑ replace
❑ tighten from inside to outside
9 - Cylinder head cover
❑ when installing, fit onto pin screws and dowel pins vertically from above
10 - Screw cap
11 - 10 Nm
12 - Roller rocker arm
❑ Check smooth operation of cylindrical-roller bearings
❑ to install clip onto the supporting element with the locking clips
13 - Valve collets

Fabia II 2007 ➤
14 - Screw cap
15 - 20 Nm
16 - Lifting eye
17 - Non-return valve, 6 Nm
❑ Clean thread and install with sealant -D 154 102 A1-
❑ do not tighten excessively as the valve may clamp
18 - hydraulic balancing element
❑ do not interchange
❑ with hydraulic valve clearance compensation
❑ before installing check axial play of the camshafts ⇒ page 46
19 - Valve spring retainer
20 - Valve spring
❑ removing and installing with bracket -MP1-229 (3362)-
21 - Valve stem seal
22 - Valve guide
23 - Oil pressure switch -F1- , 25 Nm
❑ Switching pressure 0.03 ... 0.07 MPa (0.3 ... 0.7 bar)
❑ Cut open gasket ring if leaking and replace
24 - Valves
❑ do not rework, only grinding in is permissible
❑ Valve dimensions ⇒ page 46
25 - Cylinder head
❑ reworking a valve seat ⇒ page 47
❑ reworking sealing surface ⇒ page 47
26 - 20 Nm
27 - Coupling drive tensioning pulley
28 - Screw plug, 45 Nm
❑ install with sealant -D 154 102 A1-
❑ must not be screwed in too far
❑ maximum permissible countersink: 2 mm
29 - Camshafts
❑ Inspecting axial play ⇒ page 46
❑ oil before installing
❑ after installation replace gasket rings ⇒ page 50
30 - O-ring
❑ replace
❑ moisten with oil before inserting
2. Valve gear 45
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Locking both camshaft sprockets with the camshaft lock -T10016-

– Fully insert the two fixing pins through the locating holes of the
camshaft sprockets into the fit holes of the cylinder head cover.
Note
The two fixing pins are correctly inserted if the end parts -D- are
flush with line -A-.
– Slide the bracket -B- up to the stop on the inlet camshaft

sprocket -C-.
– If both camshaft sprockets are locked in the fit holes, it is pos‐
sible to slacken or screw them down.
Checking the axial play of the camshaft

♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Carry out measurement with the cylinder head cover removed
and the end covers installed ⇒ Item 10 (page 44) and
⇒ Item 14 (page 44) .
Wear limit: 0.40 mm
Valve dimensions
Note
Valves must not be reworked. Only grinding in with grinding paste

in the valve seats is permissible.
Dimension Inlet valve Exhaust valve

∅a mm 29,5 26,0
∅b mm 5,973 5,953
c mm 100,9 100,5
α ∠° 45 45

Fabia II 2007 ➤
Reworking lower cylinder head sealing surface

Permissible reworking dimension of cylinder head: a = at least
108.25 mm.
2.1 Reworking valve seats

♦ Depth gauge
♦ NAC milling cutter for reworking valve seats
Note
♦ When carrying out repairs on engines with leaking valves, it is

not sufficient to machine or replace the valve seats and valves.
It is also necessary to inspect the valve guides for wear, par‐
ticularly on engines with a high mileage ⇒ page 51 .
♦ Rework valve seats only sufficiently in order to obtain a proper
contact pattern. Calculate the maximum permissible rework‐
ing dimension before commencing. If the reworking dimension
is exceeded, the proper operation of the hydraulic valve clear‐
ance compensation is no longer ensured. If this is the case
replace the cylinder head.
Calculating maximum permissible reworking dimension

– Insert valve into the guide and press firmly against the valve
seat.
Note
If the valve is replaced when carrying out repair work, use a new
valve for the measurement.
2. Valve gear 47
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– Measure distance between the valve stem end and the upper
face of the cylinder head.
– Calculate max. permissible reworking dimension from the dis‐
tance measured and the minimum dimension.
Minimum dimension: inlet valve 7.6 mm
Minimum dimension: outlet 7.6 mm
valve
“Measured distance” - “minimum dimension” = “max. permissible
reworking dimension”.
Example:
Measured distance 8.0 mm
- Minimum dimension 7.6 mm
= max. permissible reworking dimension 2) 0.4 mm
2) The max. permissible reworking dimension is shown in the figure for reworking
the valve seats as dimension “b”.
Reworking valve seats
Reworking inlet valve seat

a = ∅ 28.7 mm
b = max. permissible reworking dimension
c = 1.5…1.8 mm
Z = Bottom edge of cylinder head
α = 45° valve seat angle
β = 30° top correction angle
γ = 60° bottom correction angle
Reworking exhaust valve seat

a = ∅ 25.0 mm
b = max. permissible reworking dimension
c = approx. 1.8 mm
Z = Bottom edge of cylinder head
α = 45° valve seat angle
β = 30° top correction angle
γ = 60° bottom correction angle
Work procedure
Reworking can be carried out by hand while complying with the
following conditions:
• Wear limit of valve guides must not exceed the permissible
dimension ⇒ page 51 .
• Use NAC milling cutter with carbide metal tips (min. 90 HRC).
• Mill with the milling cutter using slight pressure in such a way
that an even removal of swarfs is ensured over the whole
working surface.

Fabia II 2007 ➤
Reworking valve seats with NAC milling cutter

– Place cylinder head on a felt base and secure to prevent it from
turning.
– Match diameter of guide drift to diameter of valve guide.
Valve guide ∅ Guide drift in mm
Inlet valve 6,0 - 0,01
Exhaust valve
– Match diameter of milling cutter to diameter of valve seat.
Valve seat ∅ Milling ∅ Milling cut‐ ∅ Milling
cutter 90 ter 120 cutter 60
mm mm mm
Inlet valve 32 32 21/34
Exhaust valve 30 30 21/34
Milling sequence
1 - Mill valve seat with 90° milling cutter until a perfect contact
pattern is achieved. (Do not exceed maximum permissible re‐
working dimension!)
2 - Mill top correction angle with 120° milling cutter until valve seat
diameter -a- ( ⇒ page 48 ) is achieved.
3 - Rework bottom correction angle with 60° milling cutter until
valve seat width -c- ( ⇒ page 48 ) is achieved.
– Grind in valve/valve seat -arrows- with fine grinding paste so

as to achieve a perfect contact pattern.
– Check contact pattern e.g. with water colour (perfect contact
pattern over entire circumference).
– Install valve springs.
– Inspect the valves for tightness.
The tightness of the valves can be checked by filling petrol into
the inlet and outlet canal (no petrol must flow out at the valve
seat).
After completing the repair measure once again the distances
between the valve stem ends and the upper face of the cylinder
head and calculate the maximum permissible reworking dimen‐
sion ⇒ page 47 .
Note
If the maximum permissible reworking dimension is exceeded,

proper operation of the valve gear is no longer assured and the
cylinder head must be replaced.
2. Valve gear 49
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2.2 Replacing camshaft gasket rings

♦ Pressure pad -T30004- with replaceable stud -T30004/1-
♦ Inserting device -T10015-
♦ Gasket ring extractor -T10018-
♦ Torque wrench
Removing
– First remove the two toothed belts ⇒ page 16 .
– Turn crankshaft slightly back.
Note
Camshaft sprockets are fixed with camshaft lock -T10016- in the

fit holes in the cylinder head cover and secured against turning.
– Remove camshaft sprockets. To release the screws hold the

camshaft sprockets with camshaft lock -T10016- .
– Unscrew inner part of the gasket ring extractor -T10018- 2
turns (approx. 3 mm) out of the outer part and lock with knurled
screw.
– Oil the theaded head of the gasket ring extractor.
– Forcefully screw in gasket ring extractor -T10018- as far as
possible in the gasket ring.
– Release knurled screw and turn the inner side against the
camshaft until the gasket ring is pulled out.
Install
– Lightly oil the sealing lip of the gasket ring.

Fabia II 2007 ➤
– Insert guide bushing -T10015/2- on the camshaft stub.

– Slide gasket ring over the guide bushing.
– Press in the gasket ring with pressure bushing -T10015/1- and
screw -T10015/3- up to the stop.
– Install camshaft sprockets.
Note
Pay attention to the position of the camshaft sprockets relatively

to the cotter nuts in the camshafts.
– Hold the relevant camshaft timing gear with -T10016- .

– Tighten new screws to tightening torque 20 Nm and torque a
further 1/4 turn (90°).
Installing the timing belt ⇒ page 16 .
bly.
2.3 Inspect valve guides

♦ Universal dial gauge holder -MP 3-447 (VW 387)-
♦ Dial gauge
Note
If the valve is replaced when carrying out repair work, use a new
valve for the measurement.
Work procedure
– Insert valve into guide. End of valve stem must be flush with
guide. Because of the different stem diameters only use inlet
valve in inlet guide or outlet valve in outlet guide.
– Determine valve rock.
Wear limit: 0.8 mm.
Note
If the wear limit is exceeded, repeat measurement with new

valves.
If the valve rock is exceeded:

– Replace the cylinder head.
2.4 Replacing valve stem seals

With cylinder head installed:
♦ Spark plug wrench , e.g. -3122B-
2. Valve gear 51
Fabia II 2007 ➤
♦ Blank holder -MP1-229 (3362)- with pressure plate -

MP1-229/1 (3362/1)-
♦ Extractor -MP1-230 (3364)-
♦ Valve stem seal insertion tool -MP1-233 (3365)-
♦ Pressure pad -T30004 (3415)- with replaceable stud -T
30004/1-
♦ Pressure hose -MP1-210 (VW 653/3)-
Note
With cylinder head removed, place cylinder head onto the valve
supporting plate -MP 1-218- .
Removing
– Remove cylinder head cover ⇒ page 36 .
– Remove roller rocker arm and place on a clean surface. Make
sure that you do not mix up the roller rocker arms.
– Unscrew the spark plugs with spark plug wrench -3122B- .
– Position piston of the relevant cylinder in bottom dead centre.
– Screw on assembly device -MP1-229 (3362)- with pressure
plate -MP1-229/1 (3362/1)- .
– Screw the pressure hose -MP1-210 (VW 653/3)- in the spark
plug thread.
– Connect pressure hose to compressed air (min. 0.6 MPa (6
bar) overpressure) and remove the valve springs with device
-MP1-229 (3362)- .
– Pull off valve stem seals with extractor -MP1-230 (3364)- .
Install
– Insert the supplied plastic bushings on the relevant valve stem.
This will prevent any damage to the new valve stem seal.
– Insert the new valve stem seal -B- in the insertion tool -
MP1-233 (3365)- .
– Oil the sealing lip of the valve stem seal and carefully slide
onto the valve guide -A-.
bly.
– Install cylinder head cover ⇒ page 36 .
– Install toothed belt and set the timing ⇒ page 16 .

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17 – Lubrication
1 Removing and installing parts of the
lubrication system
1.1 Summary of components of lubrication system
Note
♦ If considerable quantities of metal swarf or abrasion is found in the engine oil when carrying out engine
repairs, it is not sufficient to replace the oil filter. Carefully clean all oil galleries in order to avoid consequential
damage.
♦ The oil level must not be above the max. marking - risk of damage to catalytic converter!
Check the oil level, amount of oil and oil specification ⇒ Mainte‐
nance ; Fabia II .
Inspecting oil pressure ⇒ page 59
1 - Connector
2 - Oil pressure switch -F1- , 25
Nm
❑ Switching pressure
0.03 ... 0.07 MPa (0.3 ...
0.7 bar)
❑ Cut open gasket ring if
leaking and replace
3 - 20 Nm
4 - Oil filler inlet
5 - Dipstick
❑ Oil level must not ex‐
ceed the max. marking!
6 - Hopper
❑ Remove for extracting
oil
7 - Guide tube
running direction
❑ check for wear
❑ do not kink
⇒ page 15
9 - Guide pulley
❑ for main drive toothed
belt
1. Removing and installing parts of the lubrication system 53

Fabia II 2007 ➤
10 - Oil filter
❑ slacken at hexagon
❑ tighten by hand
❑ pay attention to installation instructions on oil filter
11 - Oil pump
❑ must be replaced completely
❑ with pressure relief valve, it opens at an overpressure of approx. 0.45 MPa (4.5 bar)
❑ when fitting pay attention to the driver on the crankshaft ⇒ Item 27 (page 54)
12 - 12 Nm
❑ replace
13 - Toothed belt sprocket of crankshaft
14 - Sealing ring
15 - Gasket
❑ replace
16 - 20 Nm
17 - Gasket
❑ replace
18 - 10 Nm
19 - Intake manifold
❑ Clean strainer if dirty
20 - Main drive tensioning pulley
21 - Oil level and oil temperature sender -G266-
❑ replace if damaged
❑ check ⇒ Current flow diagrams and Fitting locations
22 - Sealing ring
❑ replace
23 - Oil pan
❑ clean sealing surface before installing
❑ install with sealant -D 176 600 A1-
24 - Oil drain plug, 30 Nm
❑ with captive seal
❑ replace
25 - Fixing screws, 13 Nm
❑ replace
❑ slacken or tighten only the screws at the flywheel side with socket insert, e.g. -T10058-
26 - 45 Nm
27 - Driver
❑ coat with oil before installing the oil pump
54 Rep. Gr.17 - Lubrication

Fabia II 2007 ➤
28 - Sealing ring
❑ replace
29 - Oil separator
❑ with heated vacuum regulating valve (PCV valve)
❑ Resistance of heating element at 25 °C: 2.5 - 5.9 Ω
30 - O-ring
31 - for crankcase ventilation preheating
1.2 Removing and installing oil pan

♦ Wrench , e.g. -T10058 -
♦ Cleaning agent and grease remover e.g. -D 000 401 04-
♦ Silicone sealant -D 176 600 A1-
♦ Torque wrench
Removing
– Unscrew pre-exhaust pipe from exhaust manifold
⇒ page 100 .
– Disconnect plug from oil level and oil temperature sender -
G266- .
– Unscrew 2 fixing screws from the gearbox flange and the oil
pan.
– Drain engine oil.

Fabia II 2007 ➤
– Release screws -arrows- and remove cover plate from gear‐

box housing.
– Unscrew the sealed oil pan with silicone sealant.
– Remove oil pan. If necessary release the oil pan by gently
tapping it with a rubber hammer.
WARNING

remover!
– Clear sealing surface on cylinder block and on the oil pan from
gasket residues with chemical sealant remover.
Install
Note
♦ Pay attention to the use by date on sealant.

♦ The oil pan must be installed within 5 minutes after applying
the silicone sealant.
♦ The oil pan can be easier and more securely installed if M6
pin screws are inserted as guides in 2 locations on the cylinder
block flange.
– Cut off nozzle tube at the front marking (∅ of nozzle tube ap‐
prox. 3 mm).
– Apply silicone sealant to the clean sealing surface of the oil
pan, as shown in the illustration. The sealant bead must be:
♦ be 2...3 mm thick
♦ run past the area around the bolt holes on the inside
-arrows-
Note
The sealant bead must not be thicker otherwise excess sealant

may get into the oil pan and clog the strainer in the oil suction
pipe.
– Fit oil pan immediately and lightly tighten all oil pan screws.
– Tighten the oil pan screws to tightening torque: 13 Nm
– Tighten up the bolts on the oil pan/gearbox to a torque of 45
Nm.

Fabia II 2007 ➤
– Position cover plate on gearbox housing and tighten the fixing

screws -arrows- to 40 Nm.
Note
After installing the oil pan, allow the sealant to dry for about 30
minutes. Only then may engine oil be filled in.
1.3 Removing and installing oil pump

♦ Bushing -T10022-
♦ Inserting device for gasket ring -MP1-207-
♦ Cleaning agent and grease remover -D 000 401 04-
♦ Torque wrench
Removing
– Secure toothed belt sprocket of the crankshaft -1- to the crank‐
shaft with fixing screw -2-.
– Position crankshaft at top dead centre of cylinder 1.
• The chamfered tooth of the toothed belt must correspond with
the marking on the oil pump -arrow-.
– Turn the crankshaft or the toothed belt sprocket from top dead
centre 3 teeth anti-clockwise.
• The third tooth -arrow- of the toothed belt sprocket on the right
next to the chamfered tooth -A- must be flush with the marking
of the top dead centre at the oil pump housing.

Fabia II 2007 ➤
Note
Turning will give the crankshaft the fitting position for the oil pump.
One of the 4 polygonal cams -arrow- must be positioned on the
crankshaft at the top.
– Remove main drive tensioning pulley.

– Removing the oil pan ⇒ page 55 .
– Removing the intake manifold ⇒ page 92 .
– Remove the toothed belt sprocket of the crankshaft.
– Remove oil pump.
– Remove gasket ring.
WARNING

remover!
– Clear sealing surface on cylinder block and on the oil pump

from gasket residues with chemical sealant remover.
Install
• One of the 4 polygonal cams -arrow- must be positioned on

the crankshaft at the top.
– Position the bushing -T10022- on the crankshaft and tighten

the Allan screw of the inserting device -MP 1-207- by hand.
– Insert new seal on the dowel sleeves -A-.

Fabia II 2007 ➤
– Position the marking -arrow A- of the inside rotor of the oil

pump to the marking for the fitting position -arrow B- of the oil
pump housing cover.
– Coat the polygonal cam of the crankshaft with oil.
– Lightly oil the gasket ring of the oil pump.
– Carefully push the oil pump onto the polygonal cams of the
crankshaft.
– If necessary align the pump rotor to the polygonal cams of the
crankshaft by turning slightly.
– Subsequently, carefully slide the oil pump over the dowel
sleeves.
– Tighten the oil pump with new screws. Tightening torque: 12
Nm
– Removing the bushing -T10022- .
– Installing the intake manifold ⇒ page 92 .
– Installing the oil pan ⇒ page 55 .
– Install main drive tensioning pulley, install timing belt and ten‐
sion ⇒ page 16 .
1.4 Testing oil pressure and oil pressure

switch -F1-
♦ Oil pressure tester , e.g. -V.A.G 1342-
♦ Voltage tester , e. g. -V.A.G 1527-
♦ Measuring tool set , e.g. -V.A.G 1594 C-
Test sequence
– Remove oil pressure switch -F1 - and screw into testing de‐
vice.
– Screw tester in the cylinder head instead of the oil pressure
switch.
– Connect brown cable of tester to earth (-).
– Connect voltage tester to battery positive (+) and to oil pres‐
sure switch.
If the LED lights up:
– Replace oil pressure switch -F1- .
If the LED does not light up:
– Start engine and slowly increase engine speed.
Given an oil pressure of 0.03...0.07 MPa (0.3...0.7 bar) the
LED must light up, otherwise replace the oil pressure switch.
– Increase engine speed further.
Atan engine speed of 2000 rpm and an oil temperature of 80°
C the oil pressure should be at least 0.2 MPa (2 bar).
At a higher engine speed the oil pressure must not be greater than
0.7 MPa (7 bar).

Fabia II 2007 ➤
19 – Cooling
cooling system
WARNING
Hot steam or hot coolant may escape when the compensation

bottle is opened. Cover the cap with a cloth and open carefully.
Note
♦ When the engine is warm the cooling system is under pres‐

sure. If necessary reduce pressure before repairs.
♦ The hose connections are secured with spring-type clips. In
the event of repairs only use spring-type clips.
♦ Use pliers for spring strap clips to fit the spring strap clips.
♦ Always replace seals and gasket rings.
♦ When installing fit the coolant hoses free of stress, without
them touching any other components (pay attention to the
markings on the coolant connections and hoses).
♦ The arrows affixed to the coolant pipes and the coolant hoses
must stand opposite to each other.
60 Rep. Gr.19 - Cooling

Fabia II 2007 ➤
1.1 Summary of components of parts of the cooling system on the side next to
the body
1 - Radiator
❑ only complete with radi‐
ator fan
⇒ Item 9 (page 61)
⇒ page 66
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 65
2 - O-ring
❑ replace
3 - Top coolant hose
❑ check tightness
❑ connection diagram for
coolant hoses
⇒ page 64
4 - Coolant hose
❑ for crankcase ventila‐
tion preheating at intake
manifold
5 - Screw cap
❑ with the overpressure
valve
❑ Test pressure
0.14...0.16 MPa
(1.4...1.6 bar)
6 - Connector
7 - Double screw, 2 Nm
8 - Expansion reservoir
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling system for tightness ⇒ page 68
9 - Radiator fan -V7-
❑ screwed onto radiator
❑ can be replaced separately
10 - 5 Nm
11 - Bottom coolant hose
❑ check tightness
❑ connection diagram for coolant hoses ⇒ page 64
12 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ switching temperatures
1. Stage
♦ on: 92 ... 97 °C
♦ off: 84 ... 91 °C
2. Stage
♦ on: 99 ... 105 °C
1. Removing and installing parts of the cooling system 61

Fabia II 2007 ➤
♦ off: 91 ... 98 °C
1 - Radiator
⇒ page 66
❑ after replacing fill entire
system with fresh cool‐
ant ⇒ page 65
2 - O-ring
❑ replace
❑ check tightness
❑ connection diagram for
coolant hoses
⇒ page 64
4 - Coolant hose
tion preheating at intake
manifold
5 - Air duct scoop
6 - 5 Nm
7 - Screw cap
❑ with the overpressure
valve
❑ Test pressure
0.14...0.16 MPa
(1.4...1.6 bar)
8 - Connector
9 - Double screw, 2 Nm
❑ with coolant shortage
warning light sender -
G32-
❑ Check the cooling system for tightness ⇒ page 68
11 - Radiator fan -V7-
12 - Support
❑ for fan
13 - Retaining clip
❑ for fan cable
14 - Support
❑ for plug of fan
❑ check tightness
❑ connection diagram for coolant hoses ⇒ page 64
16 - Thermo-switch for radiator fan -F18- , 35 Nm
❑ switching temperatures
1. Stage

Fabia II 2007 ➤
♦ on: 92 ... 97 °C
♦ off: 84 ... 91 °C
2. Stage
♦ on: 99 ... 105 °C
♦ off: 91 ... 98 °C
17 - Bottom radiator bearing
❑ black
18 - Top radiator bearing
❑ white
1.2 Summary of components of coolant regulator
1 - Connection fittings
2 - Self-tapping screw, 7 Nm
3 - O-ring
❑ replace
4 - Coolant regulator
❑ check: heat up regulator
in a water bath
❑ Start of opening approx.
84 °C
❑ End of opening: approx.
98 °C
❑ Opening stroke: at least
7 mm
5 - to heat exchanger
❑ Connection diagram for
coolant hoses
⇒ page 64 .
6 - Coolant regulator housing
7 - from heat exchanger
❑ Connection diagram for
coolant hoses
8 - Coolant pipe
9 - Sealing ring
❑ replace
10 - Cooling pump housing at
cylinder block
11 - Retaining clip
❑ check tightness
12 - 10 Nm
13 - Cap
❑ before removing, reduce pressure in cooling system if necessary
14 - Coolant temperature sender -G62-
❑ before removing, reduce pressure in cooling system if necessary
15 - Retaining clip
❑ check tightness

Fabia II 2007 ➤
16 - to bottom radiator
❑ Connection diagram for coolant hoses ⇒ page 64 .
17 - from top radiator
❑ Connection diagram for coolant hoses ⇒ page 64 .
1.3 Connection diagram for coolant hoses
2 - Coolant hose
❑ from heated vacuum
regulating valve
3 - Intake manifold
4 - Preheating for crankcase
ventilation
5 - Heat exchanger for heating
7 - Radiator
9 - Cylinder head/cylinder
block
10 - Coolant hose

Fabia II 2007 ➤
1.4 Summary of components of coolant pump

running direction
❑ check for wear
❑ do not kink
⇒ page 15
2 - Coolant pump
❑ check smooth operation
❑ if damage and leak
present, replace com‐
plete
⇒ page 70
3 - 10 Nm
6 - Timing belt guard - bottom
part
7 - 12 Nm
❑ replace
8 - Belt pulley
⇒ page 16
❑ pay attention to locating
element when installing
❑ Removing and installing
ribbed V-belt ⇒ page 13
9 - 150 Nm + torque a further
1/ turn (180°)
2
❑ replace
6690-
10 - 20 Nm
11 - Toothed belt sprocket of crankshaft
1.5 Draining and filling up coolant

♦ antifreeze tester -T 10007-

Fabia II 2007 ➤
Draining
WARNING

opened. Cover the cap with a cloth and open carefully.
– Open the cap of the coolant expansion reservoir.

– Open the drain valve at coolant hose below the radiator
-arrow-.
Note
Observe the disposal instructions for coolant!
Filling up
– Close the drain valve at coolant hose below the radiator.
Select the appropriate coolant additive from the Electronic Cata‐
logue of Original Parts Škoda or from the list of allowed coolant
additives ⇒ Maintenance ; Fabia II .
– First of all prepare required quantity of coolant mixed to the
correct ratio in a suitable vessel ⇒ Maintenance ; Fabia II .
– Top up coolant in the expansion reservoir, until the “max.

marking” of the coolant level is reached.
– Switch off the heating, and if present, the air conditioning sys‐
tem.
– Start engine, run for not more than 3 minutes at approx. 2000
rpm and while doing so top up coolant in the expansion res‐
ervoir.
– Tighten cap at expansion reservoir.
– Run engine until radiator fan starts.
WARNING

opened.
♦ Wear safety goggles and safety clothing, in order to avoid
eye injuries and scalding.
♦ Cover the cap with cloths and open carefully.
– Check the level of coolant when the expansion reservoir is

closed and top up if necessary when the engine is cooled
down.
• When engine is at operating temperature the coolant level
must be at the “max. marking”, when engine is cold between
the “min. marking” and the “max. marking”.
1.6 Removing and installing radiator


Fabia II 2007 ➤

Removing
– Remove front bumper ⇒ Body Work ⇒ Rep. Gr. 63 .
Note
Collect drained coolant in a clean container for proper disposal or

reuse.

– Pull off coolant hose at the top and bottom of the radiator.
– Disconnect plug -1- from thermoswitch for radiator fan -F18-
and plug -2- from radiator fan -V7- .
WARNING
Refrigerant circuit of the air conditioning system must not be

opened.
– Remove headlights ⇒ Electrical System ⇒ Rep. Gr. 94 .

– Unscrew screws of brackets for the refrigerant lines at the fan
shroud and at the radiator.
– Release screws -arrows- and remove fan shroud with fan.
Caution
Risk of damaging the condenser, the refrigerant lines and the

refrigerant hoses.
♦ Do not over-tension, buckle or bend refrigerant lines and
hoses.
– Unscrew fixing screws for AC compressor -arrows- and sus‐

pend condenser laterally.
– Unscrew fixing screws for radiator bearing on right and left.
– Incline the radiator slightly backwards and pull out upwards.
– Unscrew fixing screws for radiator bearing on front right and
left.
– Incline the radiator slightly backwards and pull out upwards.
Install
Installation is carried out in the reverse order. Pay attention to the
following:

Fabia II 2007 ➤
1.7 Checking the coolant system for leak‐

tightness
1.7.1 Inspecting coolant system with cooling

system testing device -V.A.G 1274- for
tightness
♦ Cooling system testing device , e.g. -V.A.G 1274-
♦ Adapter for cooling system testing device , e.g. -V.A.G 1274/8-
Test condition
• The engine is at operating temperature.
Test sequence
WARNING

opened.
♦ Cover the cap with a cloth and open carefully.
– Open compensation bottle.

– Position the cooling system testing device -V.A.G 1274- with
adapter -V.A.G 1274/8- on the coolant expansion reservoir.
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0.1 MPa (1.0 bar).
If the pressure drops:
– Determine position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Position the cooling system testing device -V.A.G 1274- with

adapter -V.A.G 1274/9- on the cap.
– Operate the handpump.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve opens too early or too late:
– Replace cap.

Fabia II 2007 ➤
1.7.2 Inspecting coolant system with cooling

system testing device -V.A.G 1274 B-
for tightness
♦ Cooling system testing device , e.g. -V.A.G 1274 B-
Test condition
• The engine is at operating temperature.
Test sequence
WARNING

opened.
♦ Cover the cap with a cloth and open carefully.
– Open compensation bottle.

– Screw the adapter for cooling system testing device -V.A.G
1274/8- into the coolant expansion bottle.
– Clamp the connecting piece -V.A.G 1274 B/1- in the adapter
for cooling system testing device -V.A.G 1274/8- .
– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Using the hand pump of the testing device generate an over‐
pressure of approx. 0.1 MPa (1.0 bar).
WARNING
Risk of burning!
♦ Before the cooling system testing device -V.A.G 1274 B-
is separated from the connecting hose or the connecting
piece -V.A.G 1274 B/1- , the existing pressure must ab‐
solutely be released.
♦ For this step, press the pressure relief valve on the cooling
system testing device -V.A.G 1274 B- until the pressure
gauge indicates the value “0”.
If the pressure drops:

– Determine position of the leak and repair fault.
Testing the pressure relief valve in the cap
– Screw the screw cap into the adapter for cooling system test‐
ing device -V.A.G 1274/9- .
– Clamp the connecting piece -V.A.G 1274 B/1- in the adapter
for cooling system testing device -V.A.G 1274/9- .

Fabia II 2007 ➤
– Connect the connecting piece -V.A.G 1274 B/1- via the deliv‐
ered connecting hose to the cooling system testing device -
V.A.G 1274 B- .
– Operate the handpump.
• The pressure relief valve should open at a pressure of
0.14...0.16 MPa (1.4...1.6 bar).
If the pressure relief valve opens too early or too late:
– Replace cap.
1.8 Removing and installing coolant pump

♦ antifreeze tester
Removing
Note
♦ The integrated gasket of the coolant pump must not be re‐

moved from the pump.
♦ If leak and damage present, replace the coolant pump with
gasket completely.
♦ Cover the toothed belt with a cloth before removing the coolant
pump in oder to protect it from the coolant.

– Unscrew the fixing screw of the toothed belt guard at rear.
– Release fixing screws of coolant pump and remove toothed
belt guard at rear and coolant pump ⇒ page 65 .
Install
Installation is performed in the reverse order, pay attention to the
following points:
– Insert coolant pump 3 in the cylinder block and install fixing
screws 4 together with rear toothed belt guard.
– Tighten fixing screws Pos. 10 ⇒ page 65 to 20 Nm.
– Tighten fixing screw Pos. 3 ⇒ page 65 to 10 Nm.
– Install timing belt and tension ⇒ page 16 .

Fabia II 2007 ➤
20 – Fuel Supply
fuel supply system
Note
♦ The fuel lines are connected with quick-release fittings, which

are loosened by pressing in the circlip.
♦ Fuel hoses must be secured only with spring strap clips. The
use of clamp-type or screw-type clips is not allowed.
♦ The fuel supply system must be bled after removal of the fuel
filter, fuel delivery unit and the fuel rail ⇒ page 85 .
Observe safety measures ⇒ page 2 .

Observe rules for cleanliness ⇒ page 2 .
1.1 Summary of components of the fuel tank with attached parts and fuel filter
1 - Fuel tank
❑ support with engine/
gearbox jack -
V.A.G 1383 A- when re‐
moving
⇒ page 77
❑ after replacing the fuel
tank, bleed the fuel sup‐
ply with the valve on the
fuel strip ⇒ page 85
2 - 25 Nm
3 - Tensioning strap
4 - Vent line
❑ to activated charcoal fil‐
ter solenoid valve -N80-
in engine compartment.
5 - Fuel feed line
❑ black
❑ to fuel rail at intake
manifold
6 - Fuel filter
❑ with integrated fuel
pressure regulator 0.4
MPa (4 bar)
❑ blue return-flow line in
the middle and black
feed line on the edge
❑ after replacing the fuel
filter, bleed the fuel sup‐
ply with the vent valve
on the fuel strip
⇒ page 85
1. Removing and installing parts of the fuel supply system 71

Fabia II 2007 ➤
❑ Fitting location: Pin at fil‐
ter housing must engage in the recess of the guide for the fixing clamp
❑ the direction of flow is marked by arrow
7 - 5 Nm
❑ for collar clamp for fuel filter
8 - Sealing ring
❑ moisten with fuel before installing
9 - Fuel gauge sender -G-
10 - Fuel delivery unit
❑ inspecting fuel pump ⇒ page 80
❑ Clean strainer if dirty
❑ Fitting position of the flange of the fuel delivery unit on engine with the identification characters BXW
⇒ page 73
❑ Fitting position of the flange of the fuel delivery unit on engine with the identification characters CGGB
⇒ page 73
11 - Return-flow line
❑ from fuel filter to fuel delivery unit
❑ blue
12 - Feed line
❑ from the fuel delivery unit to the fuel filter
❑ black
13 - Union nut
❑ removing and installing with wrench for union nut -MP1-227 (3217)- ⇒ page 74
14 - 10 Nm
15 - Vent valve
❑ to remove, unclip valve at side and take out of filler neck.
❑ before installing, unscrew cap ⇒ Item 16 (page 72)
16 - Screw cap
17 - Sealing ring
18 - Fuel tank lid unit
❑ with rubber bowl
❑ removing and installing ⇒ Body Work ⇒ Rep. Gr. 55
19 - Gravity valve
❑ to remove, unclip valve at top and lift out of filler neck
❑ inspect valve for blockage:
♦ Valve in a vertical position: open
♦ Valve tilted 45°: closed
20 - Vent line
❑ between activated charcoal filter ⇒ Item 21 (page 72) and vent line ⇒ Item 4 (page 71)
21 - Activated charcoal filter
❑ Pay attention to part number - different version for engine identification characters BXW and CGGB
❑ Summary of components of activated charcoal container system ⇒ page 88
❑ Checking the fuel tank venting ⇒ page 89
72 Rep. Gr.20 - Fuel Supply

Fabia II 2007 ➤
22 - 10 Nm
23 - Vent line
❑ attached to the fuel tank
Fitting position of the flange of the fuel delivery unit on engine with
the identification characters BXW
Marking on the flange must be aligned with marking on the fuel
tank -arrows-.
Connect blue or blue marked return-flow line -1- to the connection
with the marking -R-.
Connect black feed line -2- to the connection with the marking
-V-.
Fitting position of the flange of the fuel delivery unit on engine with
the identification characters CGGB
Marking on the flange must be aligned with marking on the fuel
tank.
The -arrow- shows the direction of travel.
Connect blue or blue marked return-flow line -1- to the connection
with the marking -R-.
Connect black feed line -2- to the connection with the marking
-V-.
Inspect vent valve

Lever in off position: valve closed.
Lever pushed in direction of arrow: valve open.
Note
Unscrew cap of fuel tank before installing the vent valve.
1.2 Extract fuel from the fuel tank

♦ Hose adapter , e.g. -V.A.G 1318-16 -
♦ Adapter , e.g. -V.A.G 1318-17-
♦ Battery
♦ Fuel tank

Fabia II 2007 ➤
Note
If the fuel pump is defective, suction off fuel using a fuel suction
device , e.g. -VAS 5190- .
Work procedure
Condition
• The ignition must be switched off and the ignition key must be
withdrawn.
– Fold back right rear seat vertically ⇒ Body Work ⇒ Rep. Gr.
72 .
– Remove the cover from the fuel delivery unit.
WARNING
The fuel feed line is pressurized! Wear safety goggles and

safety clothing, in order to avoid injuries and skin contact. Place
cleaning cloths around the connection point before detaching
cable connections. Reduce pressure by carefully removing the
wiring.
– Pull off the fuel feed line and gather residual fuel in a cloth.
– Connect the adapter -V.A.G 1318/17- and -V.A.G 1318/16- to
the fuel delivery unit and hold it in the fuel tank .
– Disconnect connector for fuel pump.
– Using auxiliary cables -A- from the measuring tool set -V.A.G
1594/C- connect up the battery through contacts of the fuel
delivery unit as follows:
Battery positive (+) to contact -1- of the fuel delivery unit
Engine with the identification characters BXW
Battery minus (-) to contact -4- of the fuel delivery unit
Engine with the identification characters CGGB
Battery minus (-) to contact -5- of the fuel delivery unit
The fuel delivery unit runs and suctions off fuel.
WARNING
In order to avoid fuel overflow due to the fuel tank not being
sufficiently large enough, the fuel pump must not run unatten‐
ded.
1.3 Removing and installing fuel delivery

unit
♦ Wrench for union nut -MP1-227 (3217)-
Condition
withdrawn.

Fabia II 2007 ➤
• The fuel tank must not be more than 1/2 full.

Removing
Note
♦ Observe the safety instructions before starting fitting work

⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 2 .
♦ Empty the fuel tank if necessary ⇒ page 73 .
72 .
– Disconnect the plug, the feed and return flow line from the
flange of the fuel delivery unit.
Note
Always press in the securing ring in order to unlock the fuel lines.
WARNING

tions. Reduce pressure by carefully releasing the connection
point.

Fabia II 2007 ➤
– Unscrew union nut with wrench -MP1-227 (3217)- .

– Pull the fuel delivery unit and the gasket ring out of the opening
of the fuel tank.
Note
You must empty the old fuel delivery unit before disposing of it if
you wish to replace it.
Install
Installation of the fuel delivery unit occurs in reverse order to re‐
moval. Pay attention to the following:
Note
♦ Make sure that the sender for fuel gauge display -G- is not bent
when installing.
♦ Insert dry gasket ring of the fuel delivery unit into the opening
of the fuel tank.
♦ Only moisten gasket ring with fuel before assembly of the fuel
delivery unit.
♦ Observe fitting position of flange of fuel delivery unit:
♦ Fitting position of the flange of the fuel delivery unit on engine
with the identification characters BXW ⇒ page 73
♦ Fitting position of the flange of the fuel delivery unit on engine
with the identification characters CGGB ⇒ page 73
♦ Do not interchange feed line and return-flow line.
♦ Make sure the fuel hoses fit tightly.
♦ After installing the fuel delivery unit, check whether the feed,
return-flow and vent lines are clipped in place on the fuel tank.
1.4 Removing and installing the sender for

fuel gauge display -G-
Note
In the vehicles there are 2 types of senders for fuel gauge display
-G- installed.
Sender for fuel gauge display -G- type 1

Removing
– Remove fuel delivery unit ⇒ page 74 .

Fabia II 2007 ➤
– Unlatch and disconnect lines -3- and -4-.

– Raise catches -1- and -2- with a screwdriver and remove the
sender for fuel gauge display -G- from the bottom -arrow-.
Install
– Insert the sender for the fuel gauge display -G- in the guides
at the fuel delivery unit and press upwards until it latches into
position.
– Connect plug of lines and check for correct position of the
sender.
– Install fuel delivery unit ⇒ page 74 .
Sender for fuel gauge display -G- type 2
Removing
– Remove fuel delivery unit ⇒ page 74 .
– Unlock the catches -arrows- using a screwdriver and pull out

the sender for fuel gauge display -G- towards the top.
– Unlatch and disconnect the plug connection of the lines -1-

(brown), -2- (blue) and -3- (black).
Install
– Connect the lines and check the connector for secure catch.
– Insert the sender for fuel gauge display -G- in the guide at the
fuel delivery unit and press downwards until it latches into po‐
sition.
– Install fuel delivery unit ⇒ page 74 .
1.5 Removing and installing the fuel tank

♦ Engine and gearbox jack e.g. -V.A.G 1383 A-
Condition
withdrawn.

Fabia II 2007 ➤
Removing
Note
♦ Observe the safety instructions before starting fitting work

⇒ page 2 .
♦ Observe rules for cleanliness ⇒ page 2 .
♦ Empty the fuel tank if necessary ⇒ page 73 .
– Open fuel tank flap and unscrew fuel tank cap.

– Remove the rear right plastic wheelhouse liner ⇒ Body Work
⇒ Rep. Gr. 66 .
– Unscrew fixing screws at tank filler neck -arrows-.
– Remove both vent lines from activated charcoal filter.
72 .
– Disconnect the plug from the flange of the fuel delivery unit.
– Remove rear axle ⇒ Chassis ⇒ Rep. Gr. 42 .
WARNING

point.
Note
Always press in the securing ring in order to unlock the caps of

the fuel lines.
– Disconnect the feed line -1- and the vent line -2-.
– Unscrew tensioning strap.
– Support the fuel tank using the engine/gearbox jack -V.A.G
1383 A- .
– Unscrew the fixing screws from the fuel tank.
– Slightly lower the lever and remove the fuel tank with the as‐
sistance of a second mechanic.
Install
– Check if the earth lead shows traces of oxidation on both con‐
nections, remove if necessary.

Fabia II 2007 ➤
– Check fitting position of the earth lead -1-.

• The plug -1- must tightly fit on the plate ring -2-.
• The contact tab -4- must be hung in the fuel tank -3- and se‐
cured with the spacer bush -5-.
The installation occurs in reverse order, while paying attention to
the following:
♦ Check vent and fuel hoses for damage.
♦ Do not mix-up the feed, return-flow and vent lines (the return-
flow line is blue or has a blue marking, the feed line is black).
♦ Make sure the caps of the fuel hoses fit tightly.
♦ After replacing the fuel tank, bleed the fuel supply with the
valve on the fuel strip ⇒ page 85
Note
After installing the fuel tank, check whether the feed, return-flow
and vent lines are clipped in place on the fuel tank.

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2 Testing parts of the fuel system
2.1 Checking fuel delivery unit

♦ Multimeter , e.g. -V.A.G 1526 A -
♦ Multimeter with current probe
♦ Remote control e.g. -V.A.G 1348/3A-
♦ Diagnostic unit VAS 505X
♦ Wrench for union nut -MP1-227 (3217)-
♦ Pressure gauge appliance , e.g. -V.A.G 1318-
♦ Adapter , e.g. -V.A.G 1318/1-
♦ Adapter , e.g. -V.A.G 1318/11-
♦ Adapter , e.g. -V.A.G 1318/17-
♦ Adapter , e.g. -V.A.G 1318/23-
♦ Measuring vessel
♦ Current flow diagram
2.1.1 Inspecting proper operation and power

supply
Test conditions
• Battery voltage at least 11.5 volts
• Fuse for injection valves in fuse holder below the dash panel
O.K.
72 .
– Switch on ignition. The fuel delivery unit must be heard to start.
– Switch off ignition.
If the fuel delivery unit does not run:
– Remove cover from the fuse holder.

Fabia II 2007 ➤
– Remove the fuse for the injection valves (according to the cur‐
rent flow diagram) from the fuse holder below the dash panel
⇒ Current flow diagrams and Fitting locations.
– Connect remote control -V.A.G 1348/3A- with the auxiliary ca‐
bles from the measuring tool set at fuse socket of the relevant
fuse and to battery positive (+).
– Activate remote control.
If the fuel delivery unit runs:
– Testing fuel pump relay -J17- ⇒ Vehicle diagnosis, testing and
information system VAS 5051.
If the fuel delivery unit does not run:
– Disconnect the plug from the flange at the fuel delivery unit.
Engine with the identification characters BXW
– Connect multimeter for voltage measurement to contacts 1

and 4.
Engine with the identification characters CGGB
– Connect multimeter for voltage measurement to contacts 1
and 5.
For all vehicles
– Activate remote control.
Specified value: approx. battery voltage.
If the specified value of the voltage is not reached:
– Determine and remove open circuit in the wiring according to
the current flow diagram ⇒ Current flow diagrams and Fitting
locations.
If the specified value of the voltage is reached:
– Unscrew union nut with wrench -MP1-227 (3217)- .

– Remove fuel delivery unit and check whether the electric wir‐
ing between the flange and fuel delivery unit is connected.
If no open circuit was detected:
– Replace fuel delivery unit ⇒ page 74 .
2.1.2 Check fuel flow rate

Test conditions
• Supply voltage o.k.
• Remote control -V.A.G 1348/3A - is connected.
Test sequence
– Unscrew the fuel tank cap from the filler neck.
2. Testing parts of the fuel system 81

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– Pull out the fuel feed line -2- and catch the fuel which flows out
with a cleaning cloth.
WARNING

point.
– Connect pressure gauge -V.A.G 1318- with adapter -

V.A.G 1318/23 - and -V.A.G 1318/17- to the fuel feed line.
– Connect hose -V.A.G 1318/1- to adapter -V.A.G 1318/11- of
the pressure gauge and hold in the measuring vessel.
– Open shut-off cock of the pressure gauge appliance. The lever
points in the direction of flow -A-.
– Activate remote control -V.A.G 1348/3A- . While doing so,
slowly close the shut-off cock until the pressure gauge dis‐
plays 0.3 MPa (3 bar) pressure. Now do not change the
position of the shut-off cock.
– Empty measuring vessel.
– The fuel flow rate of the fuel delivery unit is dependent on the
battery voltage. Therefore connect the multimeter with the
adapter cable to the vehicle battery.
– Activate the remote control for 30 seconds while measuring
the battery voltage.
– Compare the fuel rate with the specified value.

*) Minimum flow rate in cm3/30 s
**) Voltage at fuel delivery unit when engine not running and de‐
livery unit operating (approx. 2 volts less than battery voltage).
Read out examples:
During the test a voltage of 12.5 V was measured on the battery.
The voltage at the fuel delivery unit is about 2 V less than the
battery voltage. Thereby a minimum flow rate of 540 cm3/30 s is
shown in the diagram.
If the minimum flow rate is not reached:
– Check the fuel lines for possible restrictions (kinks) or block‐
ing.

Fabia II 2007 ➤
– Disconnect the hose -1- of the feed line from the fuel filter inlet
(filter version with integrated fuel pressure regulator).
– Connect pressure gauge -V.A.G 1318- with the adapter -
V.A.G 1318/17 - to the hose -1-.
– Repeat fuel flow rate test.
If the minimum flow rate is now reached:
– Replace fuel filter.
If the minimum flow rate is again not reached:
– Remove the fuel delivery unit and check whether the pump
strainer is not clogged up.
If no fault was detected until now:
– Replace fuel delivery unit.
The fuel flow rate was reached but a fault in the fuel supply system
is suspected (e.g. temporary failure of the fuel supply system).
– Check the power consumption of the fuel delivery unit as fol‐
lows:
– Connect all released fuel lines.
– Connect multimeter with current probe on the line from contact

-1- of the connector of the fuel delivery unit.
– Start engine and run in idle.
– Measure power consumption of the fuel delivery unit.
Specified value: max. 8 A
Note
If the failure in the fuel supply is occasional the test may be per‐
formed during a test drive. The assistance of a 2nd mechanic is
required.
If the power consumption is exceeded:

– Replace fuel delivery unit.
2.1.3 Inspecting the operating and holding

pressure of the fuel, checking the non-
return valve of the fuel pump
Inspecting the fuel operating pressure
WARNING

around the connection point before detaching wiring. Reduce
pressure by carefully removing the wiring.
Note
The fuel pressure regulator is a component part of the fuel filter It

regulates the fuel pressure in the system to approx 0.4 MPa (4
bar).

Fabia II 2007 ➤
– Pull out the fuel feed line -2- and catch the fuel which flows out
with a cleaning cloth.
– Connect the pressure gauge -V.A.G 1318- with adapter -

V.A.G 1318/11 - and -V.A.G 1318/17- to the fuel feed line, the
shut-off cock on the measuring device must be in position
-A-.
– Start engine.
Specified value 0.39 ... 0.42 MPa (3.9 ... 4.2 bar).
If the specified value is higher than 0.42 bar (4.2 MPa):
– Check fuel return-flow line between the fuel filter and the fuel
pump for continuity or replace fuel pressure regulator.
If the specified value is lower than 0.39 bar (3.9 MPa):
– Check lines and fuel rail for leaktightness.
Inspecting the holding pressure and the non-return valve of the
fuel delivery unit.
Note
This test simultaneously checks the leaktightness of the fuel feed

line from the fuel delivery unit through to the connecting point of
the pressure gauge -V.A.G 1318- .

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– Connect the pressure gauge -V.A.G 1318- with the adapter -

V.A.G 1318/23- and -V.A.G 1318/17- to the fuel feed line.
– Close shut-off cock of the pressure measuring device.
The lever then points in the position -B-.
– Switch the ignition on and off so often until the fuel pressure
on the pressure gauge does no longer rise.
– Read off fuel pressure on the pressure gauge.
Specified value: at least 0.37 MPa (3.7 bar).
WARNING
Danger of liquid spraying out when opening the shut-off valve;

hold the container in front of the free connection to the pressure
gauge.
– Lower the pressure to 0.3 MPa (3 bar) by carefully opening the

shutoff cock.
– Observe pressure drop at pressure gauge.
The pressure must not drop below 0.25 MPa (2.5 bar) within
10 minutes.
If the pressure keeps dropping:
– Check line connections for leaktightness.
If the lines are not found to be faulty, the fuel delivery unit is de‐
fective.
– Replace fuel delivery unit ⇒ page 74 .
2.2 Venting air from the fuel system

♦ Remote control , e.g. -V.A.G 1348/3A- with adapter cable -
V.A.G 1348/3-2-
♦ Adapter -V.A.G 1318/20-
♦ Adapter -V.A.G 1318/20-1-
– Remove cover from the fuse holder.
– Connect remote control -V.A.G 1348/3A- with the auxiliary ca‐
bles from the measuring tool set at fuse socket of the relevant
fuse and to battery positive (+).
– Remove air filter ⇒ page 94 .

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– Unscrew the ventilation valve cap -arrow- on the fuel strip.
– Screw adapter -V.A.G 1318/20-1- onto adapter -V.A.G

1318/20- (T-piece).
– Turn the valve at T-piece anti-clockwise, until it is fully opened.
– Screw adapter -V.A.G 1318/20- fully onto the vent valve on the
fuel strip.
– Connect hose with catch pan to adapter -V.A.G 1318/20-1- .
– Screw valve at T-piece clockwise up to the stop into the vent
valve.
– Check the adapter and hose connections for leaktightness.
– Activate remote control -V.A.G 1348/3A- .
– As soon as fuel flows out of the hose without bubbles, unscrew
valve at T-piece anti-clockwise, until no more fuel escapes.
– Wrap the vent valve with a clean cloth.
– Press together the bleeder hose and pull off from adapter -
V.A.G 1318/20-1- .
– Unscrew adapter -V.A.G 1318/20- (T-piece) from the vent
valve on the fuel strip.
– Screw cap onto the vent valve on the fuel strip.
– Install air filter ⇒ page 94 .
2.3 Switching off the fuel delivery unit using

the crash signal
Operation
The vehicles with airbag are equipped with a crash signal fuel
shut-off system. If while driving the airbag units are triggered, the
fuel pump relay -J17- opens and deactivates the fuel delivery unit.
This also enhances the starting behaviour of the engine. When
the door is opened, the fuel pump is operated for about 2 seconds
so that pressure is built up in the fuel system.
– Testing fuel pump relay ⇒ Current flow diagrams and Fitting
locations.

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3 Electronic Engine Power Control

(Electronic throttle)
3.1 Summary of components of accelerator pedal module
1 - Bracket
⇒ Chassis ⇒ Rep. Gr.
46
2 - Connector
❑ black
❑ 6-pin
3 - Accelerator pedal module
❑ with accelerator pedal
position sender -G79-
and accelerator pedal
position sender 2 -
G185-
❑ to remove the sender re‐
move the bottom part of
the dash panel insert on
the driver's side
4 - 10 Nm
3. Electronic Engine Power Control (Electronic throttle) 87

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4 Activated charcoal container system
4.1 Summary of components of activated charcoal container system
Note
♦ The hose connections are secured with spring-type clips.


1 - Intake manifold
2 - Ventilation hose
3 - Solenoid valve -N80-
❑ attached with bracket to
the intake manifold
❑ valve is actuated
(pulsed) by engine con‐
trol unit
❑ check ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
5 - Vent line
❑ from activated charcoal
filter system solenoid
valve 1 -N80-
6 - Vent line
❑ from gravity valve to fuel
tank
7 - Activated charcoal filter
❑ Fitting location: in rear
right wheelhouse
❑ attached to the vehicle
body
❑ Pay attention to part
number - different ver‐
sion for engine identifi‐
cation characters BXW
and CGGB
❑ Checking the fuel tank
venting ⇒ page 89
❑ removing:
– Removing the rear right wheel.
– Remove the rear right plastic wheelhouse liner ⇒ Body Work ⇒ Rep. Gr. 66 .
– Disconnect lines -5- and -6-.
– Remove screw -8-.
– Push filter down.

Fabia II 2007 ➤
❑ Installing:
– Installation is carried out in the reverse order.
8 - 10 Nm
4.2 Checking the fuel tank venting

♦ Hand vacuum pump , e.g. -VAS 6213-
Test condition
• The ignition must be switched off.
– Remove the ventilation line -1- from the activated charcoal fil‐
ter on the activated charcoal filter system solenoid valve 1 -
N80- -2-.
– Connect hand vacuum pump -VAS 6213- to vent line -1- as
shown.
– Operate the hand vacuum pump several times. No vacuum
should build up.
If a vacuum builds up.
– Check the ventilation opening -3- on the activated charcoal
filter -4- for dirt and clean as required.
If no vacuum builds up:
– Shut off ventilation opening -3- on the activated charcoal filter
and once again operate the hand vacuum pump several times.
A vacuum should build up.
If no vacuum builds up:
– Replace activated charcoal filter.
4. Activated charcoal container system 89

Fabia II 2007 ➤
24 – Fuel Formation, Injection

1 Fuel Injection System
General notes on the injection system ⇒ page 3
1.1 Overview of fitting locations

The components marked with -A- and -B- are not shown in the
fig.
A - Accelerator pedal position

sender -G79- and accelerator
pedal position sender 2 -G185-
❑ in footwell on the accel‐
erator pedal (both send‐
ers integrated into a
housing)
B - lambda probe downstream
of catalytic converter -G130-
❑ downstream of catalytic
converter ⇒ page 100
1 - Electric heated vacuum reg‐
ulating valve (PCV valve)
❑ at oil scraper
⇒ page 53
2 - Injection valves
❑ Injection valve for cylin‐
der 1 -N30-
der 2 -N31-
der 3 -N32-
der 4 -N33-
❑ at fuel distributor
⇒ page 93
3 - Intake manifold pressure
sender -G71- and intake air
temperature sender -G42-
❑ on the intake manifold
⇒ Item 17 (page 92)
4 - Knock sensor 1 -G61-
❑ at rear cylinder block
5 - Solenoid valve 1 for activated charcoal filter -N80-
❑ on the intake manifold ⇒ Item 6 (page 92)
6 - Throttle valve control unit -J338-
❑ with throttle valve drive for electronic power control -G186- , angle sensor 1 for throttle valve drive for
electronic power control -G187- and angle sensor 2 for throttle valve drive for electronic power control -
G188-
❑ on the intake manifold ⇒ Item 4 (page 92)
90 Rep. Gr.24 - Fuel Formation, Injection

Fabia II 2007 ➤
7 - Engine speed sender -G28-

❑ at rear crankshaft sealing flange, on the suction side
❑ on cylinder head cover ⇒ page 34
9 - Coolant temperature sender -G62-
❑ in coolant regulator housing ⇒ page 63
10 - Motronic engine control unit -J623- with atmospheric charge pressure sender
11 - Thermoswitch for radiator fan -F18-
❑ at bottom left coolant fitting ⇒ page 61
12 - 4-pin plug
❑ for lambda probe -G39- and lambda probe heating before catalyst
❑ at plug holder at starter
13 - Lambda probe -G39-
❑ in front of the catalytic converter ⇒ page 100
14 - Ignition coils with a power output stage
❑ Ignition coil 1 with a power output stage -N70-
1. Fuel Injection System 91

Fabia II 2007 ➤
1.2 Summary of components of intake manifold
1 - Intake manifold
2 - Sealing ring
❑ replace
3 - 7 Nm
4 - Throttle valve control unit -
J338-
❑ when replacing, adapt
the engine control unit to
the throttle valve control
unit ⇒ Vehicle diagno‐
sis, testing and informa‐
tion system VAS 5051
❑ from the activated char‐
coal filter system
⇒ page 88
6 - Solenoid valve 1 for activa‐
ted charcoal filter -N80-
❑ attached with bracket to
the intake manifold
8 - 20 Nm
9 - Vacuum hose
❑ To the brake servo unit
10 - O-ring
11 - Coolant hose
tion preheating
12 - Spring strap clamp
13 - Preheating for crankcase ventilation
❑ remove intake manifold for removing and installing
14 - 3 Nm
15 - Hose
❑ to vacuum regulating valve for crankcase ventilation (for oil separator)
16 - O-ring
❑ replace
17 - Intake manifold pressure sender -G71- with intake air temperature sender -G42-

Fabia II 2007 ➤
1.3 Summary of components of fuel rail with injection valves
1 - Fuel intake hose

❑ from fuel filter
❑ secure with spring strap
clamps
❑ check for firm seating
2 - 7 Nm
3 - Retaining clip
❑ pay attention to correct
position
4 - Cable guide
❑ clipped in place on fuel
distributor
5 - Fuel distributor
6 - Vent valve
❑ for fuel system
❑ Vent fuel system
⇒ page 85
7 - Protective cap
❑ for vent valve
8 - Retaining clip
❑ check for correct seat‐
ing on injector
9 - O-ring
❑ replace
❑ before fitting moisten
lightly with clean engine
oil
10 - Injection valves -N30 …
N33-
❑ Resistance: 12.0 …
17.0 Ω (at room temperature)

Fabia II 2007 ➤
1.4 Summary of components of air filter
1 - 3 Nm
❑ Air filter top part and air
filter bottom part are
connected with self-cut‐
ting screws. If these
screws are released or
tightened with a screw‐
driver, the connected
components can be
damaged.
❑ For this reason, only use
a screwdriver if:
❑ the screwdriver speed is
max 200 rpm,
❑ the tightening torque is
max. 3 Nm.
2 - Air filter top part
3 - Sealing ring
4 - One-way valve
5 - Hose
❑ to cylinder head cover
6 - Air intake hose
7 - Spring strap clamp
❑ to remove and install
use pliers for spring
strap clips
8 - Sealing ring
9 - Rubber grommet
10 - Air filter bottom part
11 - Filter insert
1.5 Checking the tightness of the injection

valves and the fuel injection rate
♦ Remote control e.g. -V.A.G 1348/3 A-
♦ Adapter cable , e.g. -V.A.G 1348/3-2-
♦ Hand multimeter , e.g. -V.A.G 1602-
1.5.1 Checking the tightness of the injection

valves
WARNING
The fuel system is under pressure! Before opening the system

lay cleaning cloths around the connection point. Reduce pres‐
sure by carefully releasing the connection point.

Fabia II 2007 ➤
Test condition
• Fuel pressure must be OK, test ⇒ page 83
– Disconnect plug -arrows- of all injection valves.
– Release the wiring loom of the injection valves.
– Unscrew the fuel distributor from the intake manifold.
– Remove the fuel distributor with injectors from the inlet mani‐
fold. (Hose remains connected).
– Connect a terminal fof the fuse socket for the relevant fuse and
battery positive (+) with adapter cables from the measuring
tool set , so that the fuel delivery unit runs.
Note
This step is only intended to ensure that the fuel delivery unit runs
when the engine is switched off.
– Test the tightness of the injection valves (visual inspection).

• With the fuel delivery unit running, maximum 2 drops may drip
out per minute at each valve.
If the fuel loss is greater than this:
– Replace the leaky injector ⇒ page 93 .
Note
Use new gasket rings.
1.5.2 Testing fuel injection rate

Test conditions:
• Fuel pressure must be OK, test ⇒ page 83
• Injection valves must be installed in the fuel rail and fuel line
connected
• Fuel temperature 15…20°C, fuel must be according to the
valid standards
– Place the injection valve to be tested in a measuring glass -
V.A.G 1602- of the injection rate tester.

Fabia II 2007 ➤
– Connect a terminal fof the fuse socket for the relevant fuse and
battery positive (+) with adapter cables from the measuring
tool set , so that the fuel delivery unit runs.
Note
This step is only intended to ensure that the fuel delivery unit runs
when the engine is switched off.
– Connect a contact of the injection valve on the engine mass

using adapter cables from the mesuring tool set .
– Connect the second contact of the injection valve using an
auxiliary cable to the remote control -V.A.G 1348/3 A- with the
adapter cable e.g. -V.A.G 1348/3-2- .
– Connect alligator clip to battery positive (+).
– Activate the remote control -V.A.G 1348/3 A- for 30 seconds.
Also perform a visual inspection of the jet formation.
– Repeat the test at the other injectors in sequence. To do so
always use a new measuring glass.
– After all the injectors have been operated, place the measuring
glasses on a flat surface and compare the quantities of fuel
injected.
Specified value: 61 ... 69 ml (per injection valve)
The injection rate must be the same for all injection valves.
If the measurement obtained for one or several injectors is below
or above the specification:
– Replace the faulty injector ⇒ page 93 .
The injectors are installed in the reverse order for removal. Pay
attention to the following:
♦ Replace the O-rings on all the injectors and moisten lightly with
clean engine oil.
♦ Fit the fuel rail with the installed injection valves to the intake
manifold and tighten screws uniformly to 7 Nm.
1.6 Clean throttle valve control unit -J338-
Note
♦ If a new engine control unit -J623- is fitted, the throttle valve

control unit -J338- must be adapted. The adaptation must only
be carried out with a new or cleaned throttle valve control unit
-J338- . Otherwise dirt/carbon deposits in the end stop of the
throttle valve can lead to incorrect adaptation values.
♦ The throttle valve support must not be scratched when clean‐
ing.
– Remove the air filter housing ⇒ page 94 .

– Remove the throttle valve control unit ⇒ page 92 .

Fabia II 2007 ➤
– Open the throttle valve manually and block the throttle valve
in the opened position with a suitable object (e.g. plastic or
wooden wedge)-arrow-.
WARNING
Acetone is easily inflammable. Please observe the accident

prevention regulations and the safety instructions when han‐
dling easily inflammable fluids. Do not use compressed air
when cleaning the throttle valve. Wear safety goggles and
safety clothing, in order to avoid injuries and skin contact.
– Thoroughly clean the throttle valve support, in particular the

area of the closed throttle valve -arrows-, with commercially
available acetone in accordance with DIN 53247 and a paint
brush.
– Wipe the throttle valve support with a fluffy cloth.
– Let the acetone dry off completely and re-install the cleaned
throttle valve control unit.
– Adapting the engine control unit -J623- to the throttle valve
control unit -J338- ⇒ Vehicle diagnosis, testing and information
system VAS 5051.

Fabia II 2007 ➤
2 Engine control unit
2.1 Removing and installing engine control

unit -J623-
Note
♦ Before replacing the engine control unit -J623- first the control
unit identification and hence the coding of the previous control
unit must be interrogated ⇒ Vehicle diagnosis, testing and in‐
♦ If replacing, the throttle valve control unit -J338- must be
cleaned ⇒ page 96 before adapting a new control unit.

♦ Body saw e.g. -V.A.G 1523/A-
Removing
– Switch off ignition.
– Press bracket -arrows- outwards and pull the engine control
unit out sideways.
For vehicles with protective cover

Fabia II 2007 ➤
– Cut with body saw a slot for the cross-head screwdriver in the
heads of the pull-off screws.
Note
♦ It must be sawed 2x with the body saw, so that the slot is wide
enough, in order to be able to unscrew the screws with a suit‐
able screwdriver.
♦ The pull-off screws until are inserted with locking agent.
– Screw out the screws.

– Remove protective cover of control unit.
For all vehicles
– Disconnect plug at engine control unit and unplug.
Install
Connect both plugs and lock.
For vehicles with protective cover
– Insert protective cover and fix with new pull-off screws at en‐
gine control unit.
For all vehicles
Insert the control unit into the pressure retaining clips on the body.
– When replacing the control unit, adapt the engine control unit
⇒ Vehicle diagnosis, testing and information system VAS
5051.
2. Engine control unit 99

Fabia II 2007 ➤
26 – Exhaust System
exhaust system
Note
♦ When performing installation work on the exhaust system,

make sure the exhaust system is not mounted under tension
and has adequate clearance from the vehicle body. If neces‐
sary slacken the clamping sleeves and collar clamp and align
the silencer and exhaust pipe so as to create adequate clear‐
ance between these components and the vehicle body, and
that the weight of the exhaust system is evenly distributed over
the hangers.
♦ Always replace self-locking nuts.
1.1 Summary of components of pre-exhaust pipe with catalytic converters
1 - Hot air collector/heat shield

2 - 10 Nm
3 - Lambda probe upstream of
catalytic converter -G39- , 50
Nm
❑ the thread of new lamb‐
da probes must be coat‐
ed with assembly paste
❑ for re-used lambda
probe, only coat the
thread with hot bolt
paste -G 052 112 A3-
❑ the hot bolt paste -G 052
112 A3- must not come
into contact with the
slots of the probe body
❑ 4-pin plug in holder at
starter
4 - Exhaust manifold
❑ with pre-catalytic con‐
verter
❑ protect against shocks
and blows
5 - Gasket
❑ replace
6 - 25 Nm
❑ replace
❑ Coat stud bolts on the
exhaust manifold with
hot bolt paste -G 052
112 A3- before installing
7 - Lambda probe downstream
of catalytic converter -G130- ,
50 Nm
❑ the thread of new lambda probes must be coated with assembly paste
100 Rep. Gr.26 - Exhaust System

Fabia II 2007 ➤
❑ for re-used lambda probe, only coat the thread with hot bolt paste -G 052 112 A3-
❑ the hot bolt paste -G 052 112 A3- must not come into contact with the slots of the probe body
❑ 4-pin plug in the cover below the right base of the vehicle trim panel
8 - Clamping sleeve, 25 Nm
❑ Before tightening, align the exhaust system in cold condition free of stress ⇒ page 103
❑ Tighten bolted connections evenly
9 - Tunnel bridge (strut)
10 - 25 Nm
11 - Pre-exhaust pipe
❑ with catalytic converter
❑ protect against shocks and blows
12 - Retaining strap
13 - 20 Nm
14 - 40 Nm
❑ replace
❑ Coat stud bolts of pre-catalytic converter with hot bolt paste -G 052 112 A3- before installing.
15 - Support
16 - Wiring harness bracket
1. Removing and installing parts of the exhaust system 101

Fabia II 2007 ➤
1.2 Middle and rear silencer - Summary of components
1 - Clamping sleeve, 25 Nm
❑ Before tightening, align
the exhaust system in
cold condition free of
stress ⇒ page 103
❑ Tighten bolted connec‐
tions evenly
2 - Middle and rear silencer
❑ for first version a build‐
ing unit
❑ Replace individually
when carrying out re‐
pairs
❑ Separation point
⇒ page 102
❑ Align exhaust system
free of stress
⇒ page 103
3 - Rear retaining strap
❑ Pay attention to the part
number
4 - 25 Nm
5 - Retaining strap
❑ Pay attention to the part
number
1.3 Replacing middle silencer if necessary

rear silencer
♦ A separation point is provided for repair purposes for replacing
the middle silencer, if necessary the rear silencer.
♦ The separation point is marked by indentation on the circum‐
ference of the exhaust pipe.
♦ Body saw e.g. V.A.G 1523
♦ Protective goggles
WARNING
Wear safety goggles.
102 Rep. Gr.26 - Exhaust System

Fabia II 2007 ➤
– Separate exhaust pipe at right angles at the separation point

-arrow 2-.
– When installing, position clamping sleeve -4- between the side
markings -arrow 1- and -arrow 3-.
– Install clamping sleeve in such a way that the ends of the
screws do not protrude beyond the bottom edge of the clamp‐
ing sleeve.
– Align exhaust system in cold condition free of stress
⇒ page 103 .
1.4 Aligning exhaust system free of stress

Condition
• The exhaust system is aligned when cold.
– Slacken clamping sleeve between pre-exhaust pipe and mid‐
dle and rear silencer.
– Push the middle and rear silencer forward until the dimension
-a- = 3 ... 7mm is obtained on the retaining strap/middle si‐
lencer.
– Tighten bolted connections of clamping sleeve evenly to 25
Nm.
1.5 Inspecting the exhaust system for leak‐

tightness
– Start engine and run in idle.
– Seal off tail pipe for the duration of the leak check (e.g. with
cloth or plug).
– Inspect connection points of cylinder head/exhaust manifold/
pre-exhaust pipe etc. for leaktightness by listening and visual
inspection.
– Eliminate any leak found.
1. Removing and installing parts of the exhaust system 103

Fabia II 2007 ➤
28 – Ignition system
1 Ignition system
General notes on the ignition system ⇒ page 4 .
1.1 Summary of components of parts of the ignition system
1 - Connector
❑ black, 4 pin
❑ release with assembly
device -T10118-
2 - Ignition coil with power out‐
put stage -N70, N127, N291 a
N292-
⇒ page 104
3 - Connector
❑ black, 2 pin
❑ for knock sensor 1 -
G61-
❑ contacts gold-plated
4 - Knock sensor 1 -G61-
❑ Contacts of connector
gold-plated
5 - 20 Nm
❑ The tightening torque in‐
fluences the knock sen‐
sor function
6 - Connector
❑ black, 3 pin
❑ for hall sender -G40-
8 - O-ring
9 - 10 Nm
10 - Spark plug, 30 Nm
❑ Pay attention to part
number, model and electrode spacing ⇒ Maintenance ; Fabia II
❑ removing and installing with spark plug wrench -3122 B-
11 - Cable guide
12 - Earth connection
13 - 10 Nm
❑ only loosen or tighten with the ignition off
1.2 Removing and installing ignition coils

with power output stages
104 Rep. Gr.28 - Ignition system

Fabia II 2007 ➤
♦ Assembly tool -T10118-

♦ Extractor -T10094A-
Removing
– Position extractor -T10094A- onto the ignition coil with power
output stage in the -direction of the arrow-.
– Slightly pull out the ignition coil with power output stage.
– Position the assembly device -T10118- as shown.
– Carefully release the connector catch and unplug the connec‐
tor.
Install
– Position extractor -T10094A- onto the ignition coil with power
output stage.
– Loosely insert ignition coil in the cylinder head.
– Push connector onto the ignition coil with power output stage
until it audibly locks into place.
– Press the ignition coil with power output stage with extractor -
T10094A- onto the spark plug in the cylinder head.
1. Ignition system 105

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Service

Service Department. Technical Information

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

15 - Cylinder Head, Valve Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.4 Testing oil pressure and oil pressure switch F1 ................................ 59

24 - Fuel Formation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

26 - Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

1.1 Engine number

1.2 Engine characteristics

1) At least 91 RON in exceptional cases, although engine output

1.2 Safety precautions when working on the

The fuel feed line is pressurized! Place a clean cleaning cloth

When undertaking all installation work, particularly in the en‐

♦ The fuel pump is activated when the ignition is switched on

1.3 Rules of cleanliness to observe when

2 Rep. Gr.01 - Self-diagnosis

♦ Thoroughly clean the connection points and their surroundings

1.4 Safety measures to apply when working

The fuel system is under pressure! Before opening the system

Observe the following points to prevent injury to persons and/or

1.5 General notes on the injection system

1. Self diagnosis, safety measures, cleanliness regulations, directions 3

and if necessary delete ⇒ Vehicle diagnosis, testing and in‐

1.6 General notes on the ignition system

1.7 Supplementary instructions and assem‐

Refrigerant circuit of the air conditioning system must not be

Risk of damaging the condenser and the refrigerant lines as

Steps which should be taken in order to remove and install the

4 Rep. Gr.01 - Self-diagnosis

10 – Removing and installing engine

♦ The engine is removed towards the front together with the

– Observe all safety measures and notes for assembly work on

Observe measures when disconnecting the battery ⇒ Electri‐

– Remove battery and battery tray ⇒ Electrical System ⇒ Rep.

1. Removing and installing engine 5

– Disconnect plug of front headlights, turn signal lights, horn,

Carefully swivel the lock carrier with installed AC condenser to the

Continued for all vehicles

– Unbolt the pendulum support -arrows-.

Do not depress the clutch pedal.

Vehicles with air conditioning

6 Rep. Gr.10 - Removing and installing engine

– Hang lifting device -MP9-201 (2024 A)- as follows and slightly

Use securing pins on the hooks and rig pins -arrows-.

– Unscrew screws -arrows- and remove engine mount.

– Release screws -arrows- and remove gearbox mount.

Engine with gearbox must be guided carefully when pulling out,

1.1.1 Securing the engine to the assembly

1. Removing and installing engine 7

– Screw engine mount -MP 1-202- to engine and to assembly

♦ When performing installation work replace the self-locking

– Inspect clutch release bearing for wear, replace if necessary.

8 Rep. Gr.10 - Removing and installing engine

– Insert intermediate plate on sealing flange and push onto the

Tightening order and tightening torque of screws for assembly

– Install drive shafts ⇒ Chassis ⇒ Rep. Gr. 40 .

1.2.1 Tightening torques

1. Removing and installing engine 9

1.3 Assembly bracket

1.3.1 Tightening torques

2 - 30 Nm + torque a further 90° (1/4 turn) - replace

Assembly bracket - engine as of 04/2010

3 - 30 Nm + torque a further 90° (1/4 turn) - replace