2000 SKODA FABIA gearbox

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
InspectionEdition 09.04
S00.5301.14.2002-2 page 7 02
Every 60 000 km (QG0)
Includes: Inspection every 30 000 km and additional operations stated in the table below
Every 90 000 km (QG0)
Includes: Inspection every 30 000 km and additional operations stated in the table below
Every 120 000 km (QG0)
Includes: Inspection every 60 000 km and additional operations stated in the table below
Every 150.000 km (QG0)
Includes: Inspection every 60 000 km and additional operations stated in the table below
Work involvedChapter
–Air filter: Clean housing, replace filter element02-3
–Fuel filter: replace (vehicles with diesel engine)02-3
–Ribbed V-belt: Inspect condition and for vehicles without tensioning pulley also the ten-
sion02-3
–Spark plugs: replace02-3
–Automatic gearbox: Inspect ATF1) level, if necessary top up
1)Automatic transmission fluid for the automatic gearbox
02-4
Work involvedChapter
–Timing belt for camshaft drive: replace (ASY diesel engines up to 04.2001)02-3
–Timing belt and tensioning pulley for camshaft drive: replace (PD diesel engine up to
07.03)02-3
–Timing belt for camshaft drive: inspect (petrol engines) - every 90 000 km, then every 30
000 km02-3
Work involvedChapter
–Timing belt and tensioning pulley (038 109 244 H)1) for camshaft drive: replace (diesel en-
gines other than the PD engine) - vehicles as of 05.2001 to 04.2002
1)When the tensioning pulley Spare Part No. 038 109 244 M is mounted after 120 000 km. on vehicles with a diesel engine during replacement of
the timing belt and the tensioning pulley the change interval of the timing belt should be altered from 120 000 km to 150 000 km. The customer
should be informed about the new service interval when the tensioning pulley is first replaced by a new tensioning pulley Spare Part No. 038
109 244 M by making an entry in the service plan, in the section „Workshop entries“. Only the timing belt will be replaced at each next service
interval at 150 000 km.
02-3
–Timing belt for camshaft drive: replace (PD diesel engine as of 08.03)02-3
Work involvedChapter
–Timing belt: replace (diesel engines other than the PD engine) - vehicles as of 05.200202-3

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
InspectionEdition 09.04
S00.5301.14.2002-2 page 8 02
Every 240 000 km (QG0)
Includes: Inspection every 120 000 km and additional operations stated in the table below
Inspection Service (QG1, QG2)
♦Vehicles with WIV (QG1) must be filled with oils which conform to the VW standard 503 00 (petrol engines) VW
506 00 (SDI, TDI diesel engines) or VW 506 01 (TDI PD diesel engines), possibility of damage when using other
oils.
♦Vehicles with WIV which have been filled with oils which do not conform to the VW standard 503 00 or VW 506 00
or VW 506 01, must be coded in the WIV with a fixed oil change limitation (QG2) ⇒Chapter 02-6. Work involvedChapter
–Replace tensioning pulley (PD diesel engine as of 08.03)02-3
♦Every 2 years - in addition change brake fluid
♦Every 4 years - replace contents set for tyre repair
♦Every 90 000 km - replace the guide pulley and the tensioning pulley (PD diesel engine up to 07.03)
♦Every 120 000 km - replace the timing belt and the guide pulley (038 109 244 H) (diesel engines as of 05.01 to
04.02 except the PD engine)
♦Every 120 000 km - Replace the timing belt (PD Diesel engine as of 08.03)
♦Every 150 000 km - replace the timing belt (diesel engines as of 05.02 and with the guide pulleyr 038 109 244
M) - except on the TDI PD engine
♦Every 240 000 km - Replace the tensioning pulley (PD Diesel engine as of 08.03)
♦Exhaust-emission analysis (EEA). Expiry date - see EEA tag on the vehicle identification plate (only valid for
some countries)
♦At each inspection - check the 'use by date' of the first aid kit
♦Recommendation: Replace windscreen wiper blades every 2 years
Note
Work involvedChapter
–Interrogate fault memory of all systems, if necessary erase02-6
–Visual inspection: Engine and components in the engine compartment for leaks and dam-
age02-3
–Change the engine oil, replace the oil filter02-3
–Conduct a visual inspection of the airbag units for external damage02-7
–Reset service interval display02-6
–Inspecting brake system for leaks and damage02-5
–Check the thickness of the brake pads on all wheels02-5
–Check gearbox, final drive, drive shafts and joint boots for leaks and damage
–Axle joints: Inspect boots for leaks and damage
–Track rod ends: Inspect play and correct attachment of boots

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
InspectionEdition 09.04
S00.5301.14.2002-2 page 9 02
–Check the tyre inflation pressure (including spare wheel), correct if necessary02-5
–Inspect tyre wear (including spare wheel)02-5
–Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., RL...,
SP...)02-5
–Inspect exhaust system for leaks, damage and attachment
–Brake fluid volume: Check level, if necessary top up02-5
–Battery: test02-6
–Check the anti-freeze in the cooling system and record ...... °C, check for leaks, top up
coolant if necessary02-3
–Flap lock for the engine bonnet: grease
–Inspect operation of all switches, all electrical components, gauges/indicators and con-
trols for proper operation02-6
–Windscreen wiper and washer system: Inspect condition of wiper blades, wiper operation,
washer system: if necessary top up fluid02-7
–Inspect plenum chamber for dirt, clean if necessary02-7
–Inspect operation of tilting roof and grease the runners02-7
–Headlights: Inspect, if necessary adjust02-6
–Gear oil: Inspect level and top up if necessary (manual gearbox)02-4
–Draining the fuel filter (diesel engine)
–Inspect trailer coupling (with removable arm - manufacturer Profsvar)02-7
–Check underbody protection and body paintwork for damage02-7
–Dust and odour filter element for the passenger compartment: replace02-7
–Air filter: Clean the housing, replace the insert every 4 years or 60.000 km.02-3
–Replace the fuel filter (diesel engine with fuel operation, which does not comply with DIN
EN 590-standard)
–Ribbed V-belt: Inspect condition and for vehicles without tensioning pulley also the ten-
sion - every 60.000 km02-3
–Replace the fuel filter (diesel engine) - every 60.000 km
–Spark plugs: replace - every 60.000 km.02-3
–Automatic gearbox: Check the ATF level, and top up if necessary, every 60.000 km
–Check the timing belt for the camshaft on a 4-cylinder petrol engine at 90.000 km and
then every 30.000 km after that
–Replace the emergency battery for the alarm system - every five years02-6
After each inspection
–Complete the „Next Service“ sticker and affix sticker to the side of the dash panel (on the
driver's side)
–Perform road test including inspection of proper operation of footbrakes and handbrake,
gearshift and steering, final inspection02-9
–„Mirror tag“ - complete and attach to interior mirror
–Hand customer the completed and signed form Work involvedChapter

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
EnginesEdition 09.04
S00.5301.14.2002-3 page 4 02
Engine fitted
The engine identification characters and serial number
are located in the front at the engine/gearbox joint.
In addition, a sticker with the engine identification charac-
ters and serial number is affixed to the timing belt guard.
Engine with identification characters ARV, AQV, AZE,
AZF, AME, ATZ and AQW.
Engine with identification characters AUA, AUB, BBY,
BBZ, BKY.Compression 19 19 10,5 10,3 10,5
Hydraulic valve clearance
compensationXX X X X
Mixture formation Bosch PDE -
injectorsBosch PDE -
injectorsBosch ME 7.5 Simos 3PG Magneti Marelli
4TV
Fuel RON (minimum) - -
unleaded 95
1)unleaded 951)unleaded 951)
Fuel CN (minimum) 49 49 - - -
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-2-3 1-3-4-2
Exhaust gas recirculation X X - - X
Ignition system/fuel injection Bosch PDE -
injectorsBosch PDE -
injectorsBosch ME 7.5 Simos 3PG Magneti Marelli
4TV
Self-diagnosis X X X X X
Catalytic converter X X X X X
Turbocharging X X - - -
Charge air cooler X X - - -
Lambda probe - - X X X
Camshaft adjustment - - - - -
1)Regular grade unleaded petrol (min. 91 ROZ) can be used although engine power output is slightly reduced.
Engine identification char-
actersAT D A S Z A Z L B M D B K Y

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
EnginesEdition 09.04
S00.5301.14.2002-3 page 6 02
Engine with identification characters AWY, AZQ, BMD.
Engine with identification characters ASZ.
Engine with identification characters AMF.
Visual inspection: Engine for leaks and
damage
–Inspect engine for leaks and damage.
–Inspect all lines, hoses and connections of the fuel
system and of the cooling and heating system for
leaks, chafing points, porous and brittle joints.
–Inspect gearbox or final drive for leaks (e.g. drain plug,
drive shafts, shift linkage etc.).
–Inspect steering, sealing boots of track rod ends as
well as steering boots for damage and correct instal-
lation.
–Inspect boots of steering joints for damage, leaks and
correct installation.
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Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
GearboxEdition 07.03
S00.5301.12.2002-4 page 1 02
02-4 Gearbox
Gearbox/Final drive: Check the oil level
and top it if necessary
5 speed gearbox 002
Gearbox oil specification: G50 SAE 75W90 (synthetic oil)
–Unscrew plug for inspecting gear oil -arrow-.
The oil is at the correct level if the gear is filled up to the
lower edge of the oil filler hole.
–Tighten plug -arrow-, 25 Nm.
When topping up, pay attention to the following
points:
–Unscrew plug for inspecting gear oil -arrow-.
–Pour in gear oil up to lower edge of the filler hole.
–Screw in plug -arrow-.
–Start engine, engage a gear and allow gearbox to ro-
tate for about 2 minutes.
–Switch off engine, unscrew plug -arrow- and top up
gear oil to lower edge of the filler hole.
–Tighten plug -arrow-, 25 Nm.
5 speed gearbox 02R
Gearbox oil specification: G50 SAE 75W90 (synthetic oil)
–Remove noise insulation panel -arrows-.
–Unscrew plug for inspecting gear oil -arrow-.
The oil is at the correct level if the gear is filled up to the
lower edge of the oil filler hole.
–Tighten plug -arrow-, 30 Nm.
When topping up, pay attention to the following
points:
–Unscrew plug for inspecting gear oil -arrow-.
–Pour in gear oil up to lower edge of the filler hole.
–Screw in plug -arrow-.
–Start engine, engage a gear and allow gearbox to ro-
tate for about 2 minutes.
–Switch off engine, unscrew plug -arrow- and top up
gear oil to lower edge of the filler hole.
–Tighten plug -arrow-, 30 Nm.
5 speed gearbox 02T
Special tools, test and measuring equipment and
auxiliary items required
♦Socket wrench insert -T30023 (3357)-
S34-0408
S10-0101
S34-0498

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
GearboxEdition 07.03
S00.5301.12.2002-4 page 2 02
Gearbox oil specification: G50 SAE 75W90 (synthetic
oil).
–Unscrew plug for inspecting gear oil -arrow-.
The oil is at the correct level if the gear is filled up to the
lower edge of the oil filler hole.
–Tighten plug -arrow-, 25 Nm.
When topping up, pay attention to the following
points:
–Unscrew plug for inspecting gear oil -arrow-.
–Pour in gear oil up to lower edge of the filler hole.
–Screw in plug -arrow-.
–Start engine, engage a gear and allow gearbox to ro-
tate for about 2 minutes.
–Switch off engine, unscrew plug -arrow- and top up
gear oil to lower edge of the filler hole.
–Tighten plug -arrow-, 25 Nm.
6 speed gearbox 0A8
Gearbox oil specification: G51 SAE 75W90 (synthetic
oil).
–Unscrew plug for inspecting gear oil -arrow-.
The oil is at the correct level if the gear is filled up to the
lower edge of the oil filler hole.
–Tighten plug -arrow-, 30 Nm.
When topping up, pay attention to the following
points:
–Unscrew plug for inspecting gear oil -arrow-.
–Pour in gear oil up to lower edge of the filler hole.
–Screw in plug -arrow-.
–Start engine, engage a gear and allow gearbox to ro-
tate for about 2 minutes.
–Switch off engine and unscrew plug -arrow-.
–Pour in gear oil again up to lower edge of the filler
hole.
–Tighten plug -arrow-, 30 Nm.
Inspecting ATF level, if necessary top-
ping up
Special tools, test and measuring equipment and
auxiliary items required
♦Torque wrench (5 to 50 Nm), e.g. -V.A.G 1331-
♦Diagnostic cable -V.A.G 1551/3-
♦Vehicle system tester -V.A.G 1552-
♦ATF filling system e.g. -V.A.G 1924-

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
GearboxEdition 07.03
S00.5301.12.2002-4 page 3 02
If ATF is added, use ATF with spare part number -G 052
990 A2-.
–The gasket ring -arrow- for the ATF screw plug must
always be replaced.
Inspecting ATF level
Test conditions
•Gearbox not in emergency running mode, ATF tem-
perature not above 30°C.
•Vehicle on level ground
•Selector lever in „P“
–Attach the reservoir of the ATF filling system, e.g.
-V.A.G 1924- to the vehicle.
–Connect vehicle system tester -V.A.G 1552- with di-
agnostic cable -V.A.G 1551/3- ⇒Chap. 02-6.
–Select address word 02 „gearbox electronics“ and
move forward until „select function XX“ appears in the
display.
–Start engine.
–Raise vehicle.
–Position the catch pan under the gearbox.
Readout on display:
–Enter function for „Read measured value block“
and confirm the entry with the key .
– Enter function for „display group number
002“ and confirm the entry with the key .
Readout on display:
The third display field indicates the ATF temperature.
The ATF temperature must not exceed 30 C at the start
of the test.
N38-0037
S37-0078
V.A.G 1924
V.A.G 1552
Vehicle system test HELP
Select function XX
Reading measured value block
Enter display group number XXX 08
Q
002
Q
Reading measured value block 2 ->
0% 4% 30 C 12.9 V
Note