Hello Skoda drivers & fans, I am about to fit a genuine VW engine repair set to a relative's Fabia 2005 1.2 6v BMD type petrol engine (low compressions on two cylinders, and engine light on which has had a thorough fault diagnosis including a cylinder leak-down test and fault codes read/cleared) over the next couple of weeks or so.

Unfortunately, I was relieved of most of my tools that I have amassed over the past 31 years on last Friday afternoon whilst I was ill in bed with a couple of kidney stones. So, please could any knowledgeable forum member please tell me the spline tool size for the head bolts, and Allen key sizes for the inlet manifold and timing chain cover and any other special bit sizes?

I am not sure if the existence of the all-in-one-box and under a single part number, engine repair kit is well-known of in the UK, but believe me it does exist and is available from VAG, at least in Germany & Poland, I have one, and it comprises of:

1. New cylinder head assembly complete with already-fitted new valves and springs, which I may give them a very gentle valve grind using fine past before I fit it (I have been a Citroen trained, time-served mechanic since 1980 up until 2008).

2. New catalytic converter/manifold!!!

3. The correct VAG silicone sealant for the cam cover.

4. Head bolts, exhaust manifold gasket and nuts.

5. Head gasket, crankshaft pulley bolt, timing chain wheel bolt and probably a few other sundry items that I haven't mentioned.

I will give an update when I start the job and the end results regarding the before/after compression figures and road test impression (it's a very sluggish car at the moment!) if there's anyone interested?

It is, by the way, definitely in need of the VAG approved repair work and NOT down to faulty coils or any other hidden fault.

I may also fit new piston rings and a timing chain, as I am bored, owing quite severe mobility & health problems due to being too long in the motor trade, the repair is for a relative and I will have a very good & if necessary, prolonged attempt at claiming a proportion, or all of the repair bill back from VAG as I do not believe a carefully driven, genuine 27,00 miles car, that after its first service has had 6,000-mile interval full services using genuine or top-quality parts and 'Mobil 1' fully-synthetic engine oil should have compressions so low that it would be incapable of passing an MOT emissions test...

The readings are: No. 1 Cylinder 160 PSI, No. 2 110 PSI, No. 3 125 PSI.

Skoda will apparently do this work in Germany for 75% of the cost in some cases, or even free, in a few instances.

Thanks, Ian.

Edited 2 December, 201114 yr by tobytronicstereophonic

Fitted a few of these kits, pretty straight forward, you need timing tools for crank and camshafts.

Oversized valve guides cause the valve seats to wear oval and then the cylinder leaks.

Edited 2 December, 201114 yr by tobytronicstereophonic

Thanks S. God, I can borrow a timing tool set. How much do the head repair kits cost in this country?

I am asking for the tool sizes so I can just buy the minimum tools to do the job after mine were stolen.

Also God, in your experience are the 12v Fabia 1.2 engines susceptible to the same problems?

My 2004 12 valve Fabia seems to suddenly run really well for brief periods, and quite sluggish most of the time, with significantly less MPG than a year ago but with no fault codes logged and it has new NGK plugs genuine Skoda coil packs as they were a £13.00 bargain in an Ebay auction. I may do a compression/leak-down test on it over the weekend. Regards, Ian.

Edited 3 December, 201114 yr by tobytronicstereophonic

I have done the cylinder heads on both 6v and 12v engines and the bulletin we had did list kits for both models but only some engine codes can be affected, BME and BMD spring to mind but it doesn't mean all of those engines can be affected. Iirc the kits were less than £1000 and given what you get in the kit it's a pretty good price. There will be no need to strip the new head down, it can go straight on.

Tools wise you will need off the top of my head

5, 6 mm Allen key sockets

M6, M8, M10 and maybe M12 spline sockets.

19 or 21mm 12point socket for crank pulley bolt

Thanks Skoda God, I got mine for £302 of the German Ebay site, plus £28 shipping. Thanks a lot for all of the the info, Ian.

Do you have any more information on the all-in-one repair set for this engine? Or a link to one on the German eBay? I've looked myself but can't find one unfortunately. I'm facing a similar repair on a 2005 Polo (BMD engine) and am struggling to find much info on what's needed despite so many stories of people suffering this problem (I guess because most were fixed under warranty or via a goodwill gesture).

Do the new heads come complete with cam, pulley etc ready to just slot in or is there more work to do? Is it advisable to replace the timing chain too (mines on 83k) as I believe that means the sump has to come off too?

Any advice you can give would be most appreciated!