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SKODA FAB IA 4376 I 2000 to 2006 (W to 06 reg) Petrol & Diesel Owners Workshop Manual step-by-step maintenance and repair The best selling car manuals in the world 00 to 2006 (W to 06 reg) Petrol & Diesel wners Workshop Manual p-bv-step maintenance and repair b e s t s e lli Skoda Fabia Owners Workshop Manual A K Legg AAE MIMI Models covered (4376 - 363) Hatchback, Saloon and Estate, including vRS and special/limited editions Petrol engines: 1.2 litre (1198cc) 3-cylinder and 1.4 litre (1397cc & 1390cc) 4-cylinder Diesel engines: 1.4 litre (1422cc) 3-cylinder and 1.9 litre (1896cc) 4-cylinder, including turbo Does not cover 1.0 litre OHV engine or 2.0 litre 16-valve petrol engines © Haynes Publishing 2006 ABODE Printed in the USA FGHIJ KLMNO A book in the Haynes Service and Repair Manual Series PQRS Haynes Publishing Sparkford, Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, Haynes North America, Inc including photocopying, recording or by any information storage or 861 Lawrence Drive, Newbury Park, California 91320, USA retrieval system, without permission in writing from the copyright holder. Editions Haynes 4, Rue de I’Abreuvoir ISBN-10: 1 84425 376 7 92415 COURBEVOIE CEDEX, France ISBN-13: 978 1 84425 376 0 British Library Cataloguing in Publication Data Haynes Publishing Nordiska AB A catalogue record for this book is available from the British Library. Box 1504, 751 45 UPPSALA, Sverige expert22 nnn http://rutracker.org Contents LIVING WITH YOUR SKODA FABIA Safety first! Page 0»5 Introduction to the Skoda Fabia Page 0«6 Roadside repairs If your car won’t start Page 0*7 Jump starting Page 0*8 Wheel changing Page 0*9 Identifying leaks Page 0»10 Towing Page 0*10 Weekly checks Introduction Page 0»11 Underbonnet check points Page 0»11 Engine oil level Page 0»13 Coolant level Page 0»14 Brake (and clutch) fluid level Page 0*14 Washer fluid level Page 0»15 Battery Page 0*15 Tyre condition and pressure Page 0*16 Electrical systems Page 0*17 Wiper blades Page 0*17 Lubricants and fluids Page 0-18 Tyre pressures Page 0»18 MAINTENANCE Routine maintenance and servicing Petrol models Page 1A»1 Servicing specifications Page 1A»2 Maintenance schedule Page 1A»3 Maintenance procedures Page 1A»8 Diesel models Page 1B«1 Servicing specifications Page 1B*2 Maintenance schedule Page 1B-2 Maintenance procedures Page 1B*6 Illegal Copying It is the policy of Haynes Publishing to actively protect its Copyrights and Trade Marks. Legal action will be taken against anyone who unlawfully copies the cover or contents of this Manual. This includes all forms of unauthorised copying including digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and in writing. Illegal copying will also be reported to the appropriate statutory authorities. expert22 .qrrn http://rutracker.orq Contents REPAIRS AND OVERHAUL Engine and associated systems 1.2 litre petrol engine in-car repair procedures Page 2A»1 1.4 litre OHV petrol engine in-car repair procedures Page 2B»1 1.4 litre DOHC engine in-car repair procedures Page 201 Diesel engine in-car repair procedures Page 2D»1 Engine removal and overhaul procedures Page 2E»1 Cooling, heating and air conditioning systems Page 3*1 Petrol engine fuel systems Page 4A»1 Diesel engine fuel system Page 4B»1 Emission control and exhaust systems Page 4C«1 Starting and charging systems Page 5A»1 Ignition system - petrol engines Page 5B»1 Preheating system - diesel engines Page 501 Transmission Clutch Page 6*1 Manual transmission Page 7A»1 Automatic transmission Page 7B»1 Driveshafts Page 8*1 Brakes and Suspension Braking system Page 9»1 Suspension and steering systems Page 10*1 Body equipment Bodywork and fittings Page 11*1 Body electrical systems Page 12*1 Wiring diagrams Page 12*21 REFERENCE Dimensions and weights Page REF»1 Conversion factors Page REF»2 Buying spare parts Page REF»3 Vehicle identification numbers Page REF«3 General repair procedures Page REF»4 Jacking and vehicle support Page REF»5 Disconnecting the battery Page REF»5 Tools and working facilities Page REF»6 MOT test checks Page REF»8 Fault finding Page REF»12 Glossary of technical terms Page REF»22 Index Page REF»30 expert22 f\nn http://rutracker.org o.4 Advanced Driving Advanced driving For many people, the process of ‘learning to these skills, all driving situations can be drive’ doesn’t go much further than learning approached and negotiated in a safe, how to pass the driving test because of a methodical way, leaving nothing to chance. common belief that good drivers are made by ‘experience’. Concentration means applying your mind to safe driving, completely excluding anything Learning to drive by ‘experience’ teaches that’s not relevant. Driving is usually the most three driving skills: dangerous activity that most of us undertake in our daily routines. It deserves our full □ Quick reactions. (Whoops, that was attention. close!) □ Good handling skills. (Horn, swerve, Observation means not just looking, but brake, horn). seeing and seeking out the information found □ Reliance on vehicle technology. (Great in the driving environment. Many people see the words ‘advanced stuff this ABS, stop in no distance even in driving' and believe that it won’t interest them the wet...) Anticipation means asking yourself what is or that it is a style of driving beyond their own happening, what you can reasonably expect abilities. Nothing could be further from the Drivers whose skills are ‘experience based’ to happen and what could happen truth. Advanced driving is straightforward generally have a lot of near misses and the unexpectedly. (One of the commonest words safe, sensible driving - the sort of driving we odd accident. The results can be seen every used in compiling accident reports is should all do every time we get behind the day in our courts and our hospital casualty ‘suddenly’.) wheel. departments. Planning is the link between seeing An average of 10 people are killed every day Advanced drivers have learnt to control the something and taking the appropriate on UK roads and 870 more are injured, some risks by controlling the position and speed of action. For many drivers, planning is the seriously. Lives are ruined daily, usually their vehicle. They avoid accidents and near missing link. because somebody did something stupid. misses, even if the drivers around them make Something like 95% of all accidents are due mistakes. If you want to become a safer and more skilful to human error, mostly driver failure. driver and you want to enjoy your driving more, Sometimes we make genuine mistakes - The key skills of advanced driving are contact the Institute of Advanced Motorists at everyone does. Sometimes we have lapses of concentration, effective all-round www.iam.org.uk, phone 0208 996 9600, or concentration. Sometimes we deliberately observation, anticipation and planning. write to IAM House, 510 Chiswick High Road, take risks. When good vehicle handling is added to London W4 5RG for an information pack. Safety First! o-s Working on your car can be dangerous. • Mains voltage is also dangerous. Make Special hazards This page shows just some of the potential sure that any mains-operated equipment is risks and hazards, with the aim of creating a correctly earthed. Mains power points should Hydrofluoric acid safety-conscious attitude. be protected by a residual current device General hazards (RCD) circuit breaker. • This extremely corrosive acid is formed when certain types of synthetic rubber, found Fume or gas intoxication in some O-rings, oil seals, fuel hoses etc, are Scalding • Exhaust fumes are exposed to temperatures above 400°C. The • Don't remove the radiator or expansion poisonous; they often rubber changes into a charred or sticky tank cap while the engine is hot. contain carbon substance containing the acid. Once formed, • Engine oil, automatic transmission fluid or monoxide, which is the acid remains dangerous for years. If it power steering fluid may also be dangerously rapidly fatal if inhaled. gets onto the skin, it may be necessary to hot if the engine has recently been running. Never run the amputate the limb concerned. engine in a • When dealing with a vehicle which has Burning confined space suffered a fire, or with components salvaged • Beware of burns from the exhaust system such as a garage from such a vehicle, wear protective gloves and from any part of the engine. Brake discs with the doors shut. and discard them after use. and drums can also be extremely hot • Fuel vapour is also The battery immediately after use. poisonous, as are the vapours from some cleaning solvents and paint thinners. • Batteries contain sulphuric acid, which Crushing attacks clothing, eyes and skin. Take care • When working under or near Poisonous or irritant substances when topping-up or carrying the battery, a raised vehicle, • Avoid skin contact with battery acid and • The hydrogen gas given off by the battery always with any fuel, fluid or lubricant, especially is highly explosive. Never cause a spark or supplement the antifreeze, brake hydraulic fluid and Diesel allow a naked light nearby. Be careful when jack with axle fuel. Don’t syphon them by mouth. If such a connecting and disconnecting battery stands, or use substance is swallowed or gets into the eyes, chargers or jump leads. drive-on seek medical advice. Air bags ramps. ^(|< • Prolonged contact with used engine oil can Never cause skin cancer. Wear gloves or use a • Air bags can cause injury if they go off venture * barrier cream if necessary. Change out of oil- accidentally. Take care when removing the under a car which soaked clothes and do not keep oily rags in steering wheel and/or facia. Special storage is only supported by a jack. your pocket. instructions may apply. • Take care if loosening or tightening high- • Air conditioning refrigerant forms a Diesel injection equipment torque nuts when the vehicle is on stands. poisonous gas if exposed to a naked flame Initial loosening and final tightening should be (including a cigarette). It can also cause skin • Diesel injection pumps supply fuel at very done with the wheels on the ground. burns on contact. high pressure. Take care when working on the fuel injectors and fuel pipes. Fire Asbestos • Fuel is highly flammable; fuel vapour is • Asbestos dust can cause cancer if inhaled A Warning: Never expose the hands, explosive. or swallowed. Asbestos may be found in face or any other part of the body • Don’t let fuel spill onto a hot engine. gaskets and in brake and clutch linings. to injector spray; the fuel can • Do not smoke or allow naked lights When dealing with such components it is penetrate the skin with potentially fatal (including pilot lights) anywhere near a safest to assume that they contain asbestos. results. vehicle being worked on. Also beware of creating sparks (electrically or by use of tools). Remember... • Fuel vapour is heavier than air, so don’t work on the fuel system with the vehicle over DO DON’T an inspection pit. • Another cause of fire is an electrical • Do use eye protection when using power • Don’t attempt to lift a heavy component overload or short-circuit. Take care when tools, and when working under the vehicle. which may be beyond your capability - get repairing or modifying the vehicle wiring. assistance. • Do wear gloves or use barrier cream to • Keep a fire extinguisher handy, of a type protect your hands when necessary. • Don’t rush to finish a job, or take suitable for use on fuel and electrical fires. unverified short cuts. • Dq get someone to check periodically Electric shock that all is well when working alone on the • Don’t use ill-fitting tools which may slip • Ignition HT vehicle. and cause injury. voltage can be • Do keep loose clothing and long hair well • Don’t leave tools or parts lying around dangerous, out of the way of moving mechanical parts. where someone can trip over them. Mop especially to up oil and fuel spills at once. people with heart • Do remove rings, wristwatch etc, before problems or a working on the vehicle - especially the • Don’t allow children or pets to play in or pacemaker. Don’t electrical system. near a vehicle being worked on. work on or near the • Do ensure that any lifting or jacking ignition system with ' equipment has a safe working load rating the engine running or ' j W \ adequate for the job. the ignition switched on. 06 Introduction Hatchback, 4-door Saloon and 5-door Estate bodystyles. Fully-independent front suspension is fitted, with the components attached to a subframe assembly; the rear suspension is semi independent, with a torsion beam and trailing arms. A five-speed manual gearbox is fitted, with a four-speed automatic gearbox available as an option for 1.4 litre 16-valve petrol engine models. Note; At the time of writing, no information was available for the 6-speed gearbox (code 0A8) fitted to vRS models. A wide range of standard and optional equipment is available within the model range to suit most tastes, including anti-lock braking, traction control and air conditioning. For the home mechanic, Skoda Fabia models are straightforward vehicles to maintain, and most of the items requiring frequent attention are easily accessible. Your Skoda Fabia Manual The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage). It will also provide information on routine maintenance The Skoda Fabia models covered by this 16-valve petrol engines are not covered in this and servicing, and give a logical course of manual were manufactured between March Manual. 1.9 litre diesel engines are available action and diagnosis when random faults 2000 and December 2005. in normally-aspirated and turbocharged occur. However, it is hoped that you will use Models included in this Manual are available versions. All petrol engines use multi-point fuel the manual by tackling the work yourself. with 1.2 litre 3-cylinder SOHC 6-valve, 1.2 litre injection, and are fitted with a wide range of On simpler jobs it may even be quicker than 3-cylinder DOHC 12-valve, 1.4 litre 4-cylinder emission control systems. All the engines are booking the car into a garage and going there 8-valve, and 1.4 litre 4-cylinder 16-valve of a well-proven design and, provided regular twice, to leave and collect it. Perhaps most petrol engines. The diesel engines available maintenance is carried out, are unlikely to give important, a lot of money can be saved by are 1.4 litre 3-cylinder (6-valve) and 1.9 litre trouble. avoiding the costs a garage must charge to 4-cylinder (8-valve). 1.0 litre OHV and 2.0 litre Skoda Fabia models are available in 5-door cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence. References to the ‘left’ and ‘right’ of the vehicle are in the sense of a person in the driver’s seat facing forward. Acknowledgements Thanks are due to Draper Tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. This manual is not a direct reproduction of the vehicle manufacturer’s data, and its publication should not be taken as implying any technical approval by the vehicle manufacturers or importers. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given. Roadside repairs 0.7 The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters. Sf your car won't start and If your car won't start even the starter motor doesn’t though the starter motor turn turns as normal □ If it’s a model with automatic transmission, make sure the selector □ Is there fuel in the tank? is in P or N. □ Is there moisture on electrical components under the bonnet? □ Open the bonnet and make sure that the battery terminals are Switch off the ignition, then wipe off any obvious dampness with clean and tight. a dry cloth. Spray a water-repellent aerosol product (WD-40 or □ Switch on the headlights and try to start the engine. If the equivalent) on ignition and fuel system electrical connectors like headlights go very dim when you're trying to start, the battery is those shown in the photos. (Note that diese) engines don’t usually probably flat. Get out of trouble by jump starting (see next page) suffer from damp). using a friend’s car. Ill M l j J*:r- . A Check the condition and security of the Check the fuses and fusible links in the C Check the wiring to the ignition coils battery connections (remove the cover 1 fusebox located on top of the battery beneath the engine top cover (petrol first) models only) Check that electrical connections are secure (with the ignition switched off) and spray them with Check that all engine wiring is secure a water-dispersant spray like WD-40 if you suspect a problem due to damp U o-8 Roadside repairs Jump starting KBSff-f-l Jump starting will get you out of trouble, but you must correct [HllUTj When jump-starting a car using a booster ✓ Make sure that the booster battery is the whatever made the battery go battery, observe the following precautions: same voltage as the discharged one in flat in the first place. There are the vehicle. three possibilities: ✓ Before connecting the booster battery, t The battery has been drained by make sure that the ignition is switched repeated attempts to start, or by off. ✓ If the battery is being jump-started from leaving the lights on. the battery in another vehicle, the two vehicles MUST NOT TOUCH each other. 2The charging system is not working ✓ Ensure that all electrical equipment properly (alternator drivebelt slack (lights, heater, wipers, etc) is switched off. or broken, alternator wiring fault or ✓ Make sure that the transmission is in alternator itself faulty). ✓ Take note of any special precautions neutral (or PARK, in the case of automatic 3The battery itself is at fault printed on the battery case. transmission). (electrolyte low, or battery worn out). 1 F 1 B B ii Jr M I Connect one end of the red jump lead to Connect the other end of the red lead to Connect one end of the black jump lead ithe positive (+) terminal of the flat the positive (+) terminal of the booster to the negative (-) terminal of the booster I battery battery. battery wA j Connect the other end of the black jump | lead to a suitable metal part of the engine Ion the vehicle to be started Make sure that the jump leads will not come into contact with the fan, drive- belts or other moving parts of the engine. Start the engine using the booster battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc.