Mecanica

Service
Workshop Manual
FABIA 2000
Chassis
Edition 08.99
Service Department. Technical Information
Printed in Czech Republic S00.5303.00.20
Service
The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.
Printed in Czech Republic S00.5303.00.20
FABIA 2000
Chassis
List of Supplements to Workshop Manual
FABIA 2000
Chassis
Edition 08.99
Suppleme nt 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Edition 08.99 12.99 05.00 07.00 08.00 11.00 01.01 02.01 03.01 08.01 11.01 03.02 10.02 02.03 07.03 04.04 07.04 11.04 04.05
Subject Basic Edition Supplement to Basic Edition Axles, brakes, electrical inspection ABS, ABS/EDL/TCS Steering ABS, Brake mechanics, Brake hydraulics Repairing the front axle, repairing the wheel bearing Repairing front suspension strut, repairing drive shafts Removing and installing rear axle and coil spring Chassis with Brakes FS-II and C54-II ESP and Rep.-Gr. 48, solid nut (twelve point nut), brakepressure reducer Geometrical change Changes to the text in Rep. Gr. 00, 40, 42, 46 and 48 Brake pedal switch, control unit for the ABS (fault table, coding) 1.2 ltr./47 kW Engine, Supplement to the text 1.9 ltr./96 kW TDI PD Motor, 1.4 ltr./55 kW TDI PD Engine, Supplement to the text Steering KOYO, Correction of the text, Updating of the steering coding Supplement to Rep. Gr. 40, 44, 45, 46 and 47, ABS BOSCH 8.0 Supplement to Rep. - Gr. 45 and 48 TRW/KOYO steering Text adaptation, Supplement to the coding of ABS, TCS, ESP
Article Number S00.5303.00.20 S00.5303.01.20 S00.5303.02.20 S00.5303.03.20 S00.5303.04.20 S00.5303.05.20 S00.5303.06.20 S00.5303.07.20 S00.5303.08.20 S00.5303.09.20 S00.5303.10.20 S00.5303.11.20 S00.5303.12.20 S00.5303.13.20 S00.5303.14.20 S00.5303.15.20 S00.5303.16.20 S00.5303.17.20 S00.5303.18.20
Edition 04.05 S00.5303.18.20
List of Supplements
FABIA 2000
Chassis
List of Supplements
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
Table of Contents
00 Technical Data
Chassis ................................................................................................... 00-1 - Nominal values front axle ............................................................................ 00-1 - Nominal values rear axle ............................................................................. 00-1 - Vehicle data sticker and PR number ............................................................... 00-1 Steering ................................................................................................... 00-2 Brakes ..................................................................................................... 00-3 - Brake variants and their assignment ............................................................... 00-3 - Adjusting values for the load-dependent regulator ............................................... 00-3 - Pressure value of the distributor valve ............................................................. 00-3 - Brake fluid .............................................................................................. 00-3 Wheels, Tyres ........................................................................................... 00-4 - Possible wheel-tyre combinations .................................................................. 00-4 - Tyre legend ............................................................................................. 00-4 page page page page page page page page page page page page page 1 1 2 2 1 1 1 5 5 5 1 1 2
40 Front wheel suspension

Repairing front axle .................................................................................... 40-1 - An overview of the front axle ........................................................................ 40-1 - I - Summary of components assembly carrier, console, axle link, anti-roll bar, coupling rod, bracket, pendulum support ........................................................................... 40-1 - Inspecting the steering joint .......................................................................... 40-1 - Removing and installing the steering joint ......................................................... 40-1 - Release the assembly carrier and tighten (fix) .................................................... 40-1 - Removing and installing the track control arm .................................................... 40-1 - Removing and installing the console ............................................................... 40-1 - Disconnecting and assembling the track control arm and console ............................ 40-1 - Replacing the bonded rubber bush for track control arm ........................................ 40-1 - Replacing the bonded rubber bush for console - removal version 1 .......................... 40-1 - Replacing the bonded rubber bush for console - removal version 2 .......................... 40-1 - Removing and installing the anti-roll bar ........................................................... 40-1 - Removing and installing assembly carrier ......................................................... 40-1 Repairing front suspension strut ................................................................... 40-2 - II - Summary of components of suspension strut ................................................. 40-2 - Removing and installing the suspension strut .................................................... 40-2 - Repairing the suspension strut ...................................................................... 40-2 - Inspecting the shock absorber ...................................................................... 40-2 - Disposing of the shock absorber .................................................................... 40-2 Repairing the wheel bearing ......................................................................... 40-3 - III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FSIII ......................................................................................................... 40-3 - III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FSII .......................................................................................................... 40-3 - III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake C54II .......................................................................................................... 40-3 - Removing and installing wheel bearing housing .................................................. 40-3 page page page page page page page 1 1 2 4 4 6 8
page 10 page 13 page 13 page 13 page 15 page 17 page 19 page page page page page page page page page page page 1 1 2 5 7 8 1 1 3 5 7
Edition 04.05 S00.5303.18.20
Table of Contents
FABIA 2000 - Removing and installing the wheel hub with wheel bearing with the wheel-bearing housing fitted ..................................................................................................... 40-3 Drive shafts with CV joints ........................................................................... 40-4 - Removing and installing a drive shaft .............................................................. 40-4 - Summary of components of drive shaft with CV joint ............................................ 40-4 - Repairing drive shaft with CV joint .................................................................. 40-4 - Inspecting a CV joint .................................................................................. 40-4 Drive shafts with tripod joint ........................................................................ 40-5 - Removing and installing a drive shaft .............................................................. 40-5 - V - Summary of components of drive shaft with AAR2000 tripod joint ........................ 40-5 - Inspecting outer CV joint ............................................................................. 40-5 - Repairing the drive shaft with AAR 2000 tripod joint ............................................. 40-5 - Removing and installing the outer CV joint ........................................................ 40-5
Chassis
page 10 page page page page page page page page page page page 1 1 2 5 7 1 1 1 3 3 6
42 Rear wheel suspension

Rear axle with drum brake ........................................................................... 42-1 - Summary of components of rear axle .............................................................. 42-1 - Removing and installing rear suspension ......................................................... 42-1 Servicing the rear axle with drum brakes ........................................................ 42-2 - Removing and installing coil spring ................................................................. 42-2 - Removing and installing shock absorber .......................................................... 42-2 - Disassembling and assembling shock absorber ................................................. 42-2 - Inspecting the shock absorber ...................................................................... 42-2 - Disposing of the shock absorber .................................................................... 42-2 - removing and installing rubber-metal bearing .................................................... 42-2 Rear suspension with disc brake ................................................................... 42-3 - Summary of components of rear suspension ..................................................... 42-3 - Removing and installing rear suspension ......................................................... 42-3 Servicing rear suspension with disc brake ...................................................... 42-4 Repairing the wheel bearing ......................................................................... 42-5 - Summary of components of wheel bearing - drum brake ....................................... 42-5 - Removing and installing the wheel hub with wheel bearing - drum brake .................... 42-5 - Summary of components of wheel bearing - disc brake ........................................ 42-5 - Removing and installing the wheel hub with wheel bearing - disc brake .................... 42-5 - Removing and installing axle studs ................................................................. 42-5 page page page page page page page page page page page page page page page page page page page page 1 1 3 1 1 2 3 3 3 3 1 1 3 1 1 1 1 4 4 6
44 Wheels, Tyres, Chassis Alignment

Wheels, Tyres ........................................................................................... 44-1 - General points ......................................................................................... 44-1 - Disc wheel .............................................................................................. 44-1 - Light-alloy wheel ....................................................................................... 44-1 Vehicle alignment ...................................................................................... 44-2 - General points ......................................................................................... 44-2 - Test requirements ..................................................................................... 44-2 - Measurement preliminaries .......................................................................... 44-2 - Chassis terms .......................................................................................... 44-2 - Nominal values for vehicle alignment .............................................................. 44-2 - Checking the transversal inclination of the vehicle ............................................... 44-2 page page page page page page page page page page page 1 1 2 3 1 1 2 3 4 4 4
II
Table of Contents
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis page page page page page page 4 5 5 5 6 7
- Checking the camber on the front axle, if necessary take the mean .......................... 44-2 - Checking the camber on the rear axle ............................................................. 44-2 - Checking the track on the rear axle ................................................................ 44-2 - Checking the tracking on the front axle, adjusting if necessary ................................ 44-2 - Checking the left and right steering angle ......................................................... 44-2 - Calculation of the misalignment on the rear axle ................................................. 44-2
45 Anti-Lock Brake System

Antilock braking system (ABS) ..................................................................... 45-1 - Safety precautions, basic information on fault finding and on repairing ...................... 45-1 - Instructions for repair work on Antilock braking system ........................................ 45-1 - Required technical information ...................................................................... 45-1 Distinguishing features of the ABS system ...................................................... 45-2 - General Instructions ................................................................................... 45-2 - Distinguishing features ............................................................................... 45-2 - Fitting position of the ABS systems BOSCH 5.7 and BOSCH 8.0 ............................. 45-2 Function of Self-diagnosis ........................................................................... 45-3 - General Instructions ................................................................................... 45-3 - Vehicle fitted with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 does not have an EDL function .................................................................................................. 45-3 Vehicle diagnosis, measurement and information system -VAS 5051- .................... 45-4 - Connect vehicle diagnosis, measurement and information system -VAS 5051- and select functions (ABS systems BOSCH 5.7 and BOSCH 8.0) ......................................... 45-4 Performing Self-diagnosis - ABS systems BOSCH 5.7 and BOSCH 8.0 ................... 45-5 - Test requirements ..................................................................................... 45-5 - Connecting vehicle system tester -V.A.G 1552- and selecting function ...................... 45-5 - Interrogating control unit version .................................................................... 45-5 - Overview of selectable functions .................................................................... 45-5 - Interrogating fault memory ........................................................................... 45-5 - Erasing fault memory ................................................................................. 45-5 - Ending output .......................................................................................... 45-5 - Automatic test sequence ............................................................................. 45-5 Fault table - ABS systems BOSCH 5.7 ............................................................ 45-6 Fault table - ABS systems BOSCH 8.0 ............................................................ 45-7 Code control unit - ABS systems BOSCH 5.7 ................................................... 45-8 - Table of codes ......................................................................................... 45-8 Code control unit - ABS BOSCH 8.0 .............................................................. 45-9 - Table of codes ......................................................................................... 45-9 Reading measured value block - BOSCH 5.7 page page page page page page page page page page page page page page page page page page page page page page page page page page page page 1 1 1 4 1 1 2 3 1 1 2 1 1 1 1 1 1 2 2 3 3 4 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1
................................................... 45-10 page
- Safety measures ....................................................................................... 45-10 page - Test sequence and test tables with measured values ........................................... 45-10 page Reading measured value block - BOSCH 8.0 .................................................... 45-11 page - Safety measures ....................................................................................... 45-11 page - Test sequence and test tables with measured values ........................................... 45-11 page Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 ........................ 45-12 page - Performing actuator diagnosis ....................................................................... 45-12 page Basic setting - ABS systems BOSCH 5.7 ........................................................ 45-13 page
Edition 04.05 S00.5303.18.20
Table of Contents
III
FABIA 2000
Chassis 1 3 4 6 1 1 3 5 1 1 1 1 3 4 1 1 3 6 8
- Bleeding the hydraulic unit (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ................ 45-13 page - Bleeding the hydraulic unit (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ................ 45-13 page - Null balance of the steering angle sender -G85- ................................................. 45-13 page - Perform ESP road and system test (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ...... 45-13 page Basic setting - ABS systems BOSCH 8.0 ........................................................ 45-14 page - Bleeding the hydraulic unit (vehicles with ABS/TCS/ESP BOSCH 8.0) ...................... 45-14 page - Null balance of the steering angle sender -G85- (vehicles with ABS/TCS/ESP BOSCH 8.0) 45-14 page - Perform ESP road and system test (vehicles with ABS/TCS/ESP BOSCH 8.0) ............ 45-14 page Electrical Test - ABS systems BOSCH 5.7 ....................................................... 45-15 page - Test requirements ..................................................................................... 45-15 page - Connecting test box -V.A.G 1598A- ................................................................ 45-15 page - Multi-pin connector with contact assignment ...................................................... 45-15 page - Overview of test steps ................................................................................ 45-15 page - Test table ............................................................................................... 45-15 page Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7 and BOSCH 8.0 ......................................................................................... 45-16 page - Summary of components - Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7 .................................................................................. 45-16 page - Summary of components - Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 8.0 .................................................................................. 45-16 page - Indication of faults by means of warning lights ................................................... 45-16 page - Setting, removing and installing the brake light switch -F- ...................................... 45-16 page
- Removing and installing steering angle sender -G85- - vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0 ....................................................... 45-16 page 10 - Removing and installing lateral acceleration sender -G200- and yaw rate sender -G202- or ESP sensor unit -G419- - vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0 ............................................................................................. 45-16 page 13 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo unit/Master brake cylinder ................................................................................................... 45-17 page - Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder ................................................................................................. 45-17 page - Removing and installing the hydraulic control unit ............................................... 45-17 page - Repairing the hydraulic control unit ABS or ABS/EDL/TCS BOSCH 5.7 ..................... 45-17 page 1 1 2 6
- Removing and installing brake pressure sender 1 -G201- - vehicles with ABS/EDL/TCS/ ESP BOSCH 5.7 ...................................................................................... 45-17 page 10 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo unit/Master brake cylinder ................................................................................................... 45-18 page - Summary of Components of Hydraulic Control Unit Brake Servo Unit/Master Brake Cylinder ................................................................................................. 45-18 page - Removing and installing the hydraulic control unit ............................................... 45-18 page - Removing and installing bracket for the hydraulic control unit ................................. 45-18 page - Connecting the brake lines .......................................................................... 45-18 page Removing and Installing Parts of the ABS System on the Front and Rear Axle ........ 45-19 page - Removing and installing wheel speed sensor on the front axle - Vehicles with ABS systems BOSCH 5.7 or BOSCH 8.0 .......................................................................... 45-19 page - Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH 5.7 ....................................................................................................... 45-19 page - Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH 8.0 ....................................................................................................... 45-19 page - Sensor ring for ABS on the front and rear axle ................................................... 45-19 page 1 1 3 6 7 1 1 1 4 8
IV
Table of Contents
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis 8 9
- Removing and installing wheel speed sensor on the rear axle ................................. 45-19 page - Repairing rear wheel speed sensor cables - Vehicles with ABS systems BOSCH 5.7 and BOSCH 8.0 ............................................................................................. 45-19 page
46 Brakes, Brake mechanics

Repairing the front wheel brake .................................................................... 46-1 - Repairing front brake, the floating caliper disc brake FS-III ..................................... 46-1 - Removing and installing brake pads - Floating caliper disc brake FS-III ..................... 46-1 - Repairing front brake, the floating caliper disc brake FS-III ..................................... 46-1 - Removing and installing brake pads - Floating caliper disc brake FS-II ...................... 46-1 - Repairing the front brake - the floating caliper disc brake C54-II .............................. 46-1 - Removing and installing brake pads - the floating caliper disc brake C54-II ................. 46-1 Repairing a rear brake ................................................................................. 46-2 - Removing and installing rear brake - Drum brake ................................................ 46-2 - Resetting brake ........................................................................................ 46-2 - Repairing rear brake - drum brake .................................................................. 46-2 - Removing and installing brake shoe - Drum brake ............................................... 46-2 - Setting the hand-brake - drum brake ............................................................... 46-2 - Removing and installing rear brake - Disc brake ................................................. 46-2 - Removing and installing brake pads - Disc brake ................................................ 46-2 - Setting the hand-brake - disc brake ................................................................ 46-2 Handbrake ............................................................................................... 46-3 - Summary of components of hand brake ........................................................... 46-3 - Removing and installing the hand-brake cable ................................................... 46-3 Foot Controls, Brake Pedal .......................................................................... 46-4 - Summary of Components of Foot Controls, Brake Pedal ....................................... 46-4 - Separating the brake pedal from the brake servo unit and clipping onto brake servo unit . 46-4 - Removing and installing the foot controls .......................................................... 46-4 - Removing and installing brake pedal ............................................................... 46-4 page page page page page 1 1 3 6 7
page 10 page 12 page page page page page page page 1 1 3 4 6 8 9
page 10 page 13 page page page page page page page page 1 1 2 1 1 2 3 4
47 Brake, Brake Hydraulics

Repairing the brake caliper .......................................................................... 47-1 - Summary of Components of Brake Caliper FS-III ................................................ 47-1 - Removing and installing piston of brake caliper FS-III ........................................... 47-1 - Summary of Components of Brake Caliper FS-II ................................................. 47-1 - Removing and installing piston of brake caliper FS-II ........................................... 47-1 - Summary of components of brake caliper C54-II ................................................. 47-1 - Removing and installing piston of brake caliper C54-II .......................................... 47-1 - Summary of components of rear brake caliper ................................................... 47-1 - Removing and installing the rear brake caliper piston ........................................... 47-1 Brake Servo Unit, Master Brake Cylinder ......................................................... 47-2 - Summary of Components of Brake Servo Unit, Master Brake Cylinder ...................... 47-2 - Checking the master brake cylinder for tightness ................................................ 47-2 - Removing and installing the master brake cylinder .............................................. 47-2 - Removing and installing brake servo unit .......................................................... 47-2 - Removing and installing the vacuum pump for the brake servo unit .......................... 47-2 - Removing and installing tandem pump for fuel and vacuum supply .......................... 47-2 Brake-power regulator, brake-pressure reducer ................................................ 47-3 page page page page page page page page page page page page page page page page page 1 1 2 4 4 5 5 6 7 1 1 2 3 5 7 8 1
Edition 04.05 S00.5303.18.20
Table of Contents
FABIA 2000 - Summary of Components of Brake-Power Regulator ........................................... 47-3 - Inspecting and adjusting the brake-power regulator ............................................. 47-3 - Removing and installing brake-power regulator .................................................. 47-3 - Inspecting the brake-pressure reducer ............................................................ 47-3 - Removing and installing the brake-pressure reducer ............................................ 47-3 Bleeding Brake System ............................................................................... 47-4 - Bleeding Brake System - vehicles without and with ABS, ABS/EDL/TCS or ABS/EDL/TCS/ ESP BOSCH 5.7 or ABS, ABS/TCS or ABS/ASR/ESP BOSCH 8.0 .......................... 47-4 - Bleeding the brake system of air using the brake filling and bleeding device, e. g. -ROMESS S15- ........................................................................................ 47-4 - Bleeding the brake system of air without using the brake filling and bleeding device ...... 47-4 - Changing the brake fluid ............................................................................. 47-4
Chassis page page page page page page page page page page 1 2 3 4 5 1 1 2 4 5
48 Steering
Steering column ........................................................................................ 48-1 - Summary of components ............................................................................ 48-1 Inspecting steering column .......................................................................... 48-2 - Optical inspection ..................................................................................... 48-2 - Functional test ......................................................................................... 48-2 Removing and installing steering column ....................................................... 48-3 - Removing the steering column ...................................................................... 48-3 - Installing the steering column ....................................................................... 48-3 Removing and installing ignition lock housing ................................................. 48-4 - Removing ignition lock housing ..................................................................... 48-4 - Installing ignition lock housing ....................................................................... 48-4 Frequency link, bracket ............................................................................... 48-5 - Removing and installing frequency link ............................................................ 48-5 - Removing and installing bracket .................................................................... 48-5 Steering without servo unit (mechanical steering) ............................................. 48-6 - Summary of components ............................................................................ 48-6 Removing and installing mechanical steering gear ............................................ 48-7 - Removing steering gear .............................................................................. 48-7 - Installing steering gear ............................................................................... 48-7 Inspecting and adjusting mechanical steering gear ........................................... 48-8 - Check the centre position of the gear rack of the steering gear, if necessary adjust ....... 48-8 - Adjusting the steering gear (adjusting the pressure plate clearance) ......................... 48-8 Disassembling and assembling the steering gear ............................................. 48-9 page page page page page page page page page page page page page page page page page page page page page page page 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 3 5 6 1
Track rod ends, track rods ........................................................................... 48-10 page - Play, correct attachment and joint boots ........................................................... 48-10 page - Removing and installing track rod ends ............................................................ 48-10 page - Removing and installing track rods ................................................................. 48-10 page Power-assisted steering .............................................................................. 48-11 page - Structure and function ................................................................................ 48-11 page - Summary of components of power-assisted steering (TRW) .................................. 48-11 page - Summary of components of power-assisted steering (KOYO) ................................. 48-11 page - Summary of components of pressure line (hose) - power steering TRW or KOYO ........ 48-11 page Removing and installing power-steering gear (TRW or KOYO) ............................. 48-12 page
VI
Table of Contents
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis 2 6 1 1 1 4 1 1 1 1 1 3 1 1 1 2 1 1 1 3 1 1 2 1 1 5 1 1 4 1 1 1 1 3 1 1 1 1 1 2 3 5 8 9
- Removing the power-assisted steering drive ...................................................... 48-12 page - Installing the power-assisted steering drive ....................................................... 48-12 page Power-assisted steering sensor -G250- and the hydraulic line for power steering .... 48-13 page - Check power-assisted steering sensor -G250- (TRW or KOYO) .............................. 48-13 page - Remving and installing power-assisted steering sensor -G250- (TRW or KOYO) .......... 48-13 page - Removing and installing hydraulic lines (TRW or KOYO) ....................................... 48-13 page Inspecting and adjusting the power-steering gear ............................................. 48-14 page - Check the centre position of the gear rack of the power-steering gear, if necessary adjust 48-14 page - Adjusting the power-steering gear (adjusting the pressure plate clearance) ................. 48-14 page Disassembling and assembling the power-assisted steering gear ........................ 48-15 page - Disassembling and assembling the power-assisted steering gear (TRW) ................... 48-15 page - Disassembling and assembling the power-assisted steering gear (KOYO) .................. 48-15 page Track rod ends, track rods for power steering and mechanical steering ................. 48-16 page - Inspecting play, correct attachment and boots of track rod ends .............................. 48-16 page - Removing and installing track rod ends ............................................................ 48-16 page - Removing and installing track rods ................................................................. 48-16 page Disposing of the power-steering gear ............................................................. 48-17 page Engine pump aggregate .............................................................................. 48-18 page - Summary of components of engine pump aggregate (TRW) ................................... 48-18 page - Summary of components of engine pump aggregate (KOYO) ................................. 48-18 page Inspecting engine pump aggregate ................................................................ 48-19 page - Testing function of the engine pump aggregate .................................................. 48-19 page - Check the feed pressure of the engine pump aggregate ........................................ 48-19 page Removing and installing as well as disposing of engine pump aggregate .............. 48-20 page - Removing and installing engine pump aggregate (TRW) ....................................... 48-20 page - Removing and installing engine pump aggregate (KOYO) ..................................... 48-20 page Replace reservoir of engine pump aggregate ................................................... 48-21 page - Replace reservoir of engine pump aggregate (TRW) ............................................ 48-21 page - Replace reservoir of engine pump aggregate (KOYO) .......................................... 48-21 page Checking hydraulic oil level ......................................................................... 48-22 page - Inspecting hydraulic oil level, if necessary topping up ........................................... 48-22 page Filling and bleeding the power steering system, and checking tightness ................ 48-23 page - Filling and bleeding the power steering system .................................................. 48-23 page - Checking the power steering system for leaks .................................................... 48-23 page Power steering noises ................................................................................ 48-24 page - Notes for eliminating the noises ..................................................................... 48-24 page Self-diagnosis on the power-assisted steering system ...................................... 48-25 page - Indication of faults by means of warning light for Servotronic -K92- ........................... 48-25 page - Connect vehicle system tester -V.A.G 1552- or fault read-out scan tool -V.A.G 1551- and select functions. ........................................................................................ 48-25 page - Overview of the selectable functions on the Vehicle system tester -V.A.G 1552- ........... 48-25 page - Interrogating and erasing fault memory ............................................................ 48-25 page - Fault table .............................................................................................. 48-25 page - Coding control unit .................................................................................... 48-25 page - Reading measured value block ..................................................................... 48-25 page
- Disposing of the engine pump aggregate .......................................................... 48-20 page 10
Edition 04.05 S00.5303.18.20
Table of Contents
VII
FABIA 2000
Chassis
- Connect vehicle diagnosis, measurement and information system -VAS 5051- and select functions ................................................................................................ 48-25 page 11 Electrical Test of Power Steering ................................................................... 48-26 page Checking the data BUS ............................................................................... 48-27 page - Operation ............................................................................................... 48-27 page - Test condition .......................................................................................... 48-27 page - Test sequence ......................................................................................... 48-27 page Electric/Electronic components and fitting locations ......................................... 48-28 page 1 1 1 1 1 1
VIII
Table of Contents
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
00
00 Technical Data
00-1 Chassis
Nominal values front axle

Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for
the windscreen wiper washer system, spare wheel, tool kit, jack and without driver). Spring strut type axle Standard suspension Running gear/PR No. Overall track -adjustableToe difference angle on turns of 20 of inside wheel -not adjustableToe difference angle on turns at full lock of inside wheel -not adjustableMax. wheel lock angle -not adjustableCamber 3) Max. difference between left and right side Caster angle -not adjustableMax. difference between left and right side
1) 2) 3)
Sport chassis G04
Rough road suspension 1GB G03, G06 010' 10' - 1 28' 20' 1) - 53' 20' 2) 6 50' 1) 6 50' 2) 39 34' 1) 39 34' 2) -15' 30' 30' 4 14' 30' 1) 2 42' 30' 2) 30'
1GA, 1GG G01, G02, G05 010' 10' - 1 30' 20' 6 50' 1) 4 5' 2) 39 14' 1) 36 59' 2) -30' 30'4) -28' 30' 5) 30' 4 28' 30' 1) 2 55' 30' 2) 30'
1)
Explanations concerning this PR No. 00-1 page 2 010' 10' - 1 32' 20' --6 45' --38 37' ---39' 30' 30' 4 42' 30' --30'
- 55' 20' 2)
4) 5)
with electro-hydraulic steering with mechanical steering It is possible to adjust the camber within the tolerance range by shifting the engine-gearbox assembly carrier with console. Note: Always replace the screws and washers of the engine-gearbox assembly carrier! After carrying out corrections of steering geometry, inspect position of steering wheel and alter to correct position, if necessary. up to 09.00 from 10.00
Edition 04.05 S00.5303.18.20
Chassis
00-1 page 1
00
Nominal values rear axle
FABIA 2000
Chassis
Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and water reservoir for
the windscreen wiper washer system, spare wheel, tool kit, jack and without driver). Twist-beam rear axle Standard suspension Sport chassis Rough road suspension
The allocation of the adjusting values to the relevant running gear occurs via the PR No. of the front axle damping. Overall track -not adjustableCamber -not adjustable20' 10' 1) 21' 10' 2) -1 25' 10' 3) -1 33' 10'5) 4) -1 30' 10' 6) Max. difference between left and right side Max. misalignment of the rear axle
1) 2) 3) 4) 5) 6)
26' 10' ---1 33' 10' 4) -1 30' 10' 6) 30' 20'
15' 10' 1) 16' 10' 2) -1 25' 10' 3) -1 33' 10'5) 4) -1 30' 10' 6) 30' 20'
30' 20'
up to 05.01 from 06.01 up to 12.02 up to 08.03 as of 01.03 from 09.03
Vehicle data sticker and PR number

Different running gears are fitted depending on the engine type and equipment. These running gears are identified by PR numbers. The PR number for the front axle on the vehicle data sticker indicates which type of running gear has been fitted. The vehicle data sticker is located on the floor panel of the boot and in the Service Schedule. Example of a vehicle data sticker In this example the vehicle is fitted with a standard damping running gear 1GA -arrow-. These PR numbers are required to determine the nominal values for the vehicle.
S00-0151
00-1 page 2
Chassis
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
00
00-2
Steering
electro-hydraulic (Electrically Powered Hydraulic Steering - EPHS) Rack pinion (input shaft) 2,91 370 TMS-L-10.482 A0F 063 000 04 2) 11,0 +5,0 0...0,08 Displacement of the gear rack
40 mm: Axial force 200 N over 40 mm up to the stop: Axial
1)
Steering system:
mechanical
Steering gear: Steering-wheel turns from turning angle to the next: Steering wheel diameter (mm): Grease denomination for gear rack: Grease amount for gear rack in steering gear (g): maximum clearance between pressure plate and cover (mm): authorised axial force for the displacement of the gear rack (N):
Zahnstange - Ritzel (Eingangswelle) Rack pinion (input shaft) 4,04 370 SHELL STERAK 40,0 0,04...0,09 ---
force 250 N
(Displacement speed 1 cm/s) Pinion torque (Nm): -- Steering-wheel angle 180: Pin-
ion torque = 0.8...1.3 Nm

Steering-wheel angle over 180
up to the stop: Pinion torque = 0.8...1.6 Nm Rotating force of the steering tie rods from rest position (N): Denomination of the hydraulic oil: 1,0...3,5 3) PENTOSIN CHF 11S N 052 146 00 TL 52 146 or PENTOSIN CHF 202 N 052 146 01 TL 52 146 0,80 1,0...3,5 3) ---
Hydraulic oil amount (l):

1) 2) 3)
---
applies for TRW steering applies for KOYO steering after 2 rotations
Edition 04.04 S00.5303.15.20
Steering
00-2 page 1
00
FABIA 2000
Chassis
00-2 page 2
Steering
Edition 04.04 S00.5303.15.20
FABIA 2000
Chassis
00
00-3
Brakes
Brake variants and their assignment

Engine Engine code letters: S = Manual gearbox A = Automatic gearbox Master brake cylinder - Brake booster -
Front disc brake:
litre/ kW
1,0/37 ARV, AQV S S
1,2/40 AWY, BMD 20,64 S -
1,2/47 AZQ,BME S -
mm Inch
Left-hand drive with and without ABS: Right-hand drive with and without ABS: FS-II 48,0 239,0 193,8 18,0 15,0 17,6 2,0 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0 FS-II 48,0 239,0 193,8 18,0 15,0 17,6 2,0
8,5 8,5 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0
Front brake caliper (type denomination) Front brake caliper, piston - Front brake disc - mm mm
Brake disc - average effective di- mm ameter Brake disc, thickness Brake disc, minimum thickness Pad thickness with supporting plate Minimum thickness without supporting plate
Rear disc brake:
mm mm mm mm
Rear brake caliper, piston - Rear brake disc - Rear brake disc - average effective diameter Brake disc, thickness Brake disc, minimum thickness Pad thickness with supporting plate Minimum thickness without supporting plate
Rear drum brake:
mm mm mm mm mm mm mm
Brake drum - Brake drum - maximum diameter Wheel-brake cylinder - Brake pad, width Pad thickness without supporting shoe Minimum thickness without supporting shoe
mm mm mm mm mm mm
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
Edition 04.05 S00.5303.18.20
Brakes
00-3 page 1
00
Front disc brake:
FABIA 2000
Chassis
litre/ kW
1,2/47 AZQ,BME S S
1,4/44 AZE, AZF 20,64 S -
1,4/50 AME, ATZ, AQW S -
mm Inch
Left-hand drive with and without ABS: Right-hand drive with and without ABS: FS-II 48,0 239,0 193,8 18,0 15,0 17,6 2,0 FS-II 48,0 239,0 193,8 18,0 15,0 17,6 2,0 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0
8,5 8,5 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0
Front brake caliper (type denomination) Front brake caliper, piston - Front brake disc - mm mm
Brake disc - average effective di- mm ameter Brake disc, thickness Brake disc, minimum thickness Pad thickness with supporting plate Minimum thickness without supporting plate
Rear disc brake:
mm mm mm mm
Rear drum brake:
mm mm mm mm mm mm
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
00-3 page 2
Brakes
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
00
litre/ kW 1,4/55 AUA, BBY, BKY S mm Inch A 1,4/74 AUB, BBZ S 20,64 Left-hand drive with and without ABS: Right-hand drive with and without ABS: FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0 54,0 256,0 208,0 22,0 19,0 19,6 2,0 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0 C54-II 54,0 288,0 244,0 25,0 22,0 18,6 2,0 8,5 8,5 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0 S 2,0/85 AZL S 1.9/47 SDI ASY -
Front disc brake:
Front brake caliper (type denomination) Front brake caliper, piston - Front brake disc - Brake disc - average effective diameter Brake disc, thickness Brake disc, minimum thickness Pad thickness with supporting plate Minimum thickness without supporting plate
Rear disc brake:
Rear drum brake:
38,0 232,0 196,0 9,0 7,0 16,9 2,0
38,0 232,0 196,0 9,0 7,0 16,9 2,0
mm mm mm mm mm mm
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
Edition 04.05 S00.5303.18.20
Brakes
00-3 page 3
00
Front disc brake:
FABIA 2000
Chassis
litre/ kW
1.9/74 TDI PD ATD S -
1.9/96 TDI PD ASZ S -
1.4/55 TDI PD AMF S -
mm Inch
20,64 Left-hand drive with and without ABS: Right-hand drive with and without ABS: FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0 C54-II 54,0 288,0 244,0 25,0 22,0 18,6 2,0 FS-III 54,0 256,0 208,0 22,0 19,0 19,6 2,0 8,5 8,5
Front brake caliper (type denomination) Front brake caliper, piston - Front brake disc - Brake disc - average effective diameter Brake disc, thickness Brake disc, minimum thickness Pad thickness with supporting plate Minimum thickness without supporting plate
Rear disc brake:
Rear drum brake:
38,0 232,0 196,0 9,0 7,0 16,9 2,0
38,0 232,0 196,0 9,0 7,0 16,9 2,0
mm mm mm mm mm mm
200,0 201,0 19,05 40,0 5,4 1,5
200,0 201,0 19,05 40,0 5,4 1,5
00-3 page 4
Brakes
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
00
Adjusting values for the load-dependent regulator

Note
The adjusting values apply for the vehicle ready for driving. Vehicle weight ready for driving: Weight of the vehicle with full fuel tank and full water reservoir for windscreen wip-
er/washer and headlamp cleaning system, spare wheel, tool kit, jack and driver (75 kg). The spare wheel, tool kit and jack must be located in the position prescribed by the vehicle manufacturer, the driver must be seated on the driver seat. Model/Version Vehicles without electro-hydraulic steering - drum brakes on rear axle Vehicles with electro-hydraulic steering - drum brakes on rear axle Front axle Rear axle Front axle Rear axle bar 70 38 3 70 43 3 MPa 7,0 3,8 0,3 7,0 4,3 0,3 Front axle Rear axle Front axle Rear axle bar 100 47 3 100 56 3 MPa 10,0 4,7 0,3 10,0 5,6 0,3
Pressure value of the distributor valve

1 MPa = 10 bar Pz = output pressure at the distributor valve and left or right rear wheel Pp = input pressure at the distributor valve and left or right front wheel Part no.of the distributor valve: 6Y0612151 The colour marking on the main brake cylinder is not visible.
Pz(MPa)
6 5 4 3 2 1 2,5 0 1 2 3 4 4,5 5 6 7 8 9 10 11 Pp(MPa) 3,1 2,5 4,75
B A
Pressure values
S00-0183
Initial setting Pp (MPa) Pz (MPa) 2,5 2,5
A 4,5 3,1 0,1 5 3,25 6 3,55 7 3,85 8 4,15 9 4,45
B 10 4,75 0,2 11 5,05
Brake fluid
Classification Capacity N 052 766 X0 (USA standard FMVSS 571.116 DOT4) TL 766 X0 0.500 l 0.470 l 0.430 l Replace Vehicles with rear disc brakes, with ABS Vehicles with rear drum brakes, with ABS Vehicles with rear drum brakes, without ABS
every 2 years
Edition 04.05 S00.5303.18.20
Brakes
00-3 page 5
00
FABIA 2000
Chassis
00-3 page 6
Brakes
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
00
00-4
Wheels, Tyres
Possible wheel-tyre combinations

Engine Wheel size 1) 155/80 R13 79T 3) 1.0 l/37 kW 1.2 l/40 kW 1.2 l/47 kW 1.4 l/44 kW 1.4 l/50 kW 165/70 R14 81T 185/60 R14 82T 195/50 R15 82T 185/55 R15 81T 205/45 R16 83W, V 165/70 R14 81T 185/60 R14 82T 1.4 l/55 kW 1.4 l/55 kW TDI PD 185/55 R15 81T 195/50 R15 82V, T 205/45 R16 83W, V 185/60 R14 82H 1.4 l/74 kW 1.9 l/74 kW TDI PD 195/50 R15 82V, H 185/55 R15 81H 205/45 R16 83W, V 195/50 R15 82V, H 2.0 l/85 kW 185/55 R15 81H 205/45 R16 83W, V 165/70 R14 81T 185/60 R14 82T 1.9 l/47 kW SDI 195/50 R15 82T 185/55 R15 81T 205/45 R16 83W, V 205/45 R16 83W 1.9 ltr./96 kW TDI PD
1) 2) 3) 4)
Light-alloy rim 2) 6J x 14 H2 6J x 15 H2 6J x 15 H2 6.5J x 16 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 6.5J x 16 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 6.5J x 16 H2 6J x 15 H2 6J x 15 H2 6.5J x 16 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 6.5J x 16 H2 6.5J x 16 H2 6J x 15 H2 -
Steel rim 2) 5J x 13 H2 5J x 14 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 5J x 14 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 5J x 14 H2 6J x 14 H2 6J x 15 H2 6J x 15 H2 6,5J x 16 H2

4)
Offset (mm) 35 35 43 38 43 43 42 35 43 38 43 43 42 43 38 43 43 42 43 43 42 35 43 38 43 43 42 37 43 42
Snow chains permitted yes yes yes no no yes no yes yes no yes no no yes no no yes no no yes no yes yes no no yes no no yes no
185/55 R15 84H 205/45 R16 83W, V
Tyre inflation pressure Inspection and Maintenance as well as sticker on the fuel-tank cap 5-hole fixing, diameter of the bolt circle 100 mm, diameter of the central hole 57 mm without power steering it is only fitted as a spare wheel in series
Note
Only use tyres of a same size and type on a vehicle,
however the tread pattern and manufacturer may differ per axle. It is exceptionally allowed to use a differ-
Edition 07.03 S00.5303.14.20
Wheels, Tyres
00-4 page 1
00
ent tyre temporarily in the event of breakdown. Take into account a change in driving and braking behaviour.
Use wheel bolts with spherical collar and a thread of
FABIA 2000
Chassis
M14 x 1.5 - tightening torque: 120 Nm.

Only use authorised rims on the relevant vehicle. When replacing rims always use wheel bolts that be-
long to these rims (different length and spherical cap shape).

Also observe the national legislation.
Caution! Tyres that are more than 6 years old must only be used in case of emergency and while driving very carefully.
Tyre legend
Legend, e.g. 155/80 R13 79 T 155/80 R 13 79 T Meaning Tyre width (mm) section ratio between height - width (%) Tyre type (radial) Rim diameter (inch) Load rating-index Speed symbol
Manufacturing date DOT up to 399 < DOT 0300
Meaning Manufactured during week 39 of 1999 < = denomination of the decade (1990 1999) Manufactured during week 3 of 2000 (03 = 3rd calendar week, 00 = year 2000)
79 = 437 kg Load rating-indexes (Load index) 81 = 462 kg 82 = 475 kg 83 = 500 kg T = 190 km/h Speed symbols H = 210 km/h V = 240 km/h W = 270 km/h
00-4 page 2
Wheels, Tyres
Edition 07.03 S00.5303.14.20
FABIA 2000
Chassis
40
40 Front wheel suspension

40-1 Repairing front axle
An overview of the front axle

I - Repairing front axle 40-1 page 2 II - Repairing the suspension strut Chapter 40-2 III - Repairing the wheel bearing Chapter 40-3 IV - Drive shaft with constant velocity joint Chapter 40-4 V - Drive shaft with tripod joint Chapter 40-5
II
IV
III
S40-0153
Edition 04.05 S00.5303.18.20
Repairing front axle
40-1 page 1
40
FABIA 2000
Chassis
I - Summary of components assembly carrier, console, axle link, anti-roll bar, coupling rod, bracket, pendulum support
Note
Welding and straightening work is not allowed on the bearing and wheel control components of the wheel suspen-
sion.
Always replace the self-locking nuts and screws. Always replace corroded self-locking nuts and screws.
1 - Assembly carrier 26 removing and installing 40-1 page 19 1 2 3 4 assignment Spare part 27 catalogue 2 - Nut, 40 Nm assignment Spare part catalogue 25 3 - Anti-roll bar 20 to remove and install lower assembly carrier 24 removing and installing 40-1 page 17 22 assignment Spare part catalogue 4 - Rubber bearing assignment Spare part 21 23 catalogue 5 - Clamp assignment Spare part 19 catalogue 6 - Nut, 40 Nm assignment Spare part catalogue 7 - Coupling rod 18 assignment Spare part catalogue 8 - Bracket 17 9 - Screw, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 10 - Screw, 70 Nm + torque a further 90 (1/4 turn) replace after each removal 11 - Bonded rubber bush removing and installing - removal version 1 40-1 page 13 removing and installing - removal version 2 40-1 page 15 12 - Axle link removing and installing 40-1 page 8 removing and assembling the track control arm and console 40-1 page 13 Bonded rubber bush -arrow- is a component part of the track control arm 13 - Lock washer replace after each removal 14 - Nut, self-locking, 20 Nm and torque a further 90 (1/4 turn) replace after each removal
5 6 7 8
9 10 11 12 13 14 15 10
16
S40-0201
40-1 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
15 - Steering joint check 40-1 page 4 removing and installing 40-1 page 4 16 - Screw, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 17 - Air deflector assignment Spare part catalogue 18 - Clip assignment Spare part catalogue 19 - Screw, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 20 - Console Can only be removed and fitted together with the track control arm Disconnecting and assembling the track control arm and console 40-1 page 13 21 - Screw, 50 Nm + torque a further 90 (1/4 turn) replace after each removal note the order of use of the screws: first staple Pos. 22 (manual work) then staple Pos. 21 subsequently tighten up positions 21 and 22 alternately 22 - Screw, 70 Nm + torque a further 90 (1/4 turn) replace after each removal note the order of use of the screws: first staple Pos. 22 (manual work) then staple Pos. 21 subsequently tighten up positions 21 and 22 alternately 23 - Screw, 30 Nm + torque a further 90 (1/4 turn) replace after each removal position the screws in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier 24 - Dowel screw, 40 Nm and torque a further 90 (1/4 turn) replace after each removal 25 - Hinged bracket do not disassemble position the screws in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier assignment Spare part catalogue 26 - Shield for drive shaft assignment Spare part catalogue 27 - Screw, 35 Nm
Edition 04.05 S00.5303.18.20
40-1 page 3
40
Inspecting the steering joint
Inspecting axial play
FABIA 2000
Chassis
Pull the track control arm down with force and push up
again.
S40-0286
Inspecting radial play
Forcefully push the wheel at the bottom towards the

inside and the outside. Note
For these two tests no play may be felt or be visible. Observe the steering joint during the tests. Take into account possible wheel bearing play or
play in top suspension strut bearing.

Inspect rubber bellows for damage, if necessary re-
place.
Removing and installing the steering joint

Special tools, test and measuring equipment and auxiliary items required
Engine/gearbox jack e.g. - V.A.G 1383- with
S40-0287
-V.A.G 1359/2 Fixing device -T 10096 Ball joint extractor -Matra V176 Polycarbamide grease -G 052 142 A2 Glue sealing mass -Loctite 601-
Removing
Remove the drive shaft from wheel-bearing housing

Chapter 40-4 and tie up drive shaft to body.
Swivel out the wheel-bearing housing with the suspension strut and support with wooden insert -1-. Note
Position gearbox jack with adapter, (e.g. -V.A.G 1383/
A- with -V.A.G 1359/2-, (risk of accident: due to falling parts while the steering joint is being pressed out).
To protect the thread, screw the nut a couple of thread
turns onto the steering joint.
S40-0161
40-1 page 4
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Push out the steering joint with the ball joint extractor.
Installing Note
Note the installed position of the steering joint. The castor changes if the fitting position is incorrect. Always replace plate nuts of drive shaft on both sides
Matra V176
by twelve-point nuts. Fitting position Left steering joint L - means left 3 - means 13" 4 - means 14" Right steering joint R - means right 3 - means 13" 4 - means 14" Arrow points in the driving direction on the 14" running gear.
S40-0162
Insert steering joint in the wheel-house bearing. Screw new nut onto the steering joint and tighten.
Secure against spinning while doing this. Vehicles with 13" running gear
Smear the drive shaft lightly with adhesive sealing

material -Loctite 601-. Vehicles with 14 and 15 running gear
Grease the serration on the propeller shaft with polycarbamide grease -G 052 142 A2-. Do not grease thread on the outer joint of the drive shaft.
Grease the serration in the wheel hub with polycarbamide grease -G 052 142 A2-. Continued for all vehicles
Insert the drive shaft in the wheel hub and screw on

with new twelve-point nut.
When inserting the drive shaft insert the steering joint

at the same time -1- into the track control arm -2-.
Screw the steering joint -1- and the track control arm
-2- with new screws -arrows- and new lock washer in the former position and to the marking. Note Make sure the steering joint boot is neither damaged nor twisted.
2 1
S40-0338
Fit front wheel.

Edition 04.05 S00.5303.18.20 Repairing front axle
40-1 page 5
40
Tightening torques:
FABIA 2000
Chassis
Steering joint to wheel-bearing housing

Use new nut!
20 Nm + 90
Twelve-point nut of drive shaft to wheel hub 13" running gear

Use new nut! Do not grease thread of the outer joint of the drive shaft.
50 Nm
Twelve-point nut of drive shaft to wheel hub 14" and 15" running gear
50 Nm + 45
Steering joint to track control arm

Use new screws! Use new lock washer!
20 Nm + 90
Wheel bolts
120 Nm
Release the assembly carrier and tighten (fix)

-V.A.G 1359/2 Fixing device -T 10096 Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2Removing Vehicles with exhaust pipe under the assembly carrier
Remove the front exhaust pipe with catalyst Engine

- Mechanics; Rep. Gr. 26. Continued for all vehicles
S48-0112
Unscrew screws -1- and -2- from the pendulum support.
Insert wooden insert -1- in the adapter, e.g.

-V.A.G 1359/2-.
Position gearbox jack and support assembly carrier.

Note
Note the following work steps and absolutely ensure
that you follow the sequence.

The fixing bolts for -T10096- must only be tightened to
maximum 20 Nm as otherwise the fixing bolt thread becomes damaged.
V.A.G 1359/2 V.A.G 1383A

S40-0168
40-1 page 6
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Unscrew left screw -4- for assembly carrier -3-, screw

in a fixing bolt of -T10096- and tighten to 20 Nm.
Unscrew right screw -4- for assembly carrier (not

shown in figure), screw in a fixing bolt of -T10096- and tighten to 20 Nm.
5 4 2
Release screws -1- on both sides. Unscrew the left screw -2- and remove support -5-. Screw in fixing bolts of -T10096- to 20 Nm. Unscrew the right screw -2- and remove support -5-. Screw in fixing bolts of -T10096- to 20 Nm.
The fixing of the assembly carrier is completed once all 4 screws (Pos. -2- and -4-) are consecutively replaced with the fixing bolts. Note When lowering the assembly carrier make sure that the pressure line, return hose and the line of the power-assisted steering sensor -G250- are not exposed to traction.
S48-0117
Lower assembly carrier approx. 4 cm.

Installing
Raise assembly carrier until the console touches the

body. Note
Note the following work steps and absolutely ensure
that you follow the sequence.

Unscrew the fixing bolts of -T10096- one at a time. It
should be subsequently replaced by a new bolt tightened to the recommended torque.
Unscrew fixing bolt -1- of -T10096- from the left and

screw in new bolt to the recommended tightening torque. 3 - Assembly carrier
Unscrew fixing bolt -1- of -T10096- from the right

(shown in figure) and screw in new bolt to the recommended tightening torque.
2 1 3
Unscrew fixing bolt -2- of -T10096- from the left. Install left support. Screw in new bolts for the left support and tighten at
the rear by hand.
Tighten new bolts for left console and support to the

recommended tightening torque.
S48-0197
Tighten the rear left support bolts to the recommended tightening torque.
Unscrew right fixing bolts -2- of -T10096- (shown in

figure).
Install right support.
Edition 04.05 S00.5303.18.20
40-1 page 7
40
Screw in new bolts for the right support and tighten at
the rear by hand.
FABIA 2000
Chassis
Tighten new bolts for the console and screw in to the

Tighten up the rear right support bolts to the recommended tightening torque.
Remove gearbox jack with adapter. Mount pendulum support on the gearbox and tighten
up the new screws -1-. Note Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier. Vehicles with exhaust pipe under the assembly carrier
1 2
Install the front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26. Tightening torques: Console to body
Use new screws!
S10-0133
70 Nm + 90
Support to body
Use new screws!
20 Nm + 90
Pendulum support to gearbox

Use new screws!
30 Nm + 90
Fixing bolt of -T10096-
20 Nm
Removing and installing the track control arm

Multi-purpose tool -MP 3-419-
Removing
Raise the vehicle until the front axle is free of stress. Remove front wheel.
Vehicles on which the track control arm should not be replaced
Mark fitting position of screws -arrowsfrom steering

joint -1- to track control arm -2-.
Mark installation position of the steering joint -1- for

the track control arm -2-. Continued for all vehicles
2 1
S40-0338
Turn steering to right lock (removal on the left side) or

to left lock (removal on the right side).
40-1 page 8
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Release screws -arrows-. Pull the wheel-bearing housing with steering joint out
of the track control arm.
Mark the fitting position of the screw -1-. Release screw -1-.
Note Only swivel the track control arm as far as necessary out of the assembly carrier to avoid damaging the bonded rubber mounting.
Swivelling the track control arm -2- out of the assembly carrier.
S40-0169
Pull out the track control arm -1- using the multi-purpose tool -MP 3-419- from the console. Note When pulling out the track control arm ensure that the wheehouse trim panel and the noise insulation are not damaged. Installing
MP3-419
Brush the track control arm studs with assembly sliding oil -G 294 421 A1-. Caution!
When sliding in observe that the track control
S40-0333
arm is in the correct installed position relative to the console. The surface of the track control arm must correspond with the surfaces in the console bearing 40-1 page 13.
The track control arm should form one level with
the assembly carrier.

If the fitting position is not respected, this could
lead to damage at the bonded rubber bush of the console and as a result to a shorter life of the bonded rubber bush.
Insert the track control arm by hand into the bonded

rubber bush of the console, if necessary use a rubber hammer.
Insert the track control arm -2- in the assembly carrier,

if necessary use a rubber hammer.
Insert screw -1- and tighten to the former position/

marking to a specified tightening torque.
Insert steering joint in the track control arm. If the track control arm is not replaced, tighten screws
to former position/marking. Note Use new screws and new lock washer to screw the steering joint/track control arm.
S40-0169
40-1 page 9
40
Vehicles on which the track control arm was replaced
FABIA 2000
Chassis
Position the track control arm -2- and steering joint -1relatively to each other in such a way that the holes -arrows- of the track control arm and steering joint are flush. For better fixing use two drifts with 8.3 mm or as shown in the figure, two drill bits with 8.3 mm . Continued for all vehicles Further installation occurs in reverse order.
Install and tighten the wheel Chapter 44-1.

Tightening torques:
2 1
S40-0337
Track control arm to assembly carrier

Use new screw!
70 Nm + 90

20 Nm + 90
Wheel bolts
120 Nm
Removing and installing the console

Note
If the console is to be replaced, remove it together with
the track control arm.

The bonded rubber bush in the console may also be
replaced in the vehicle, removal version 1 40-1 page 13 or removal version 2 40-1 page 15.
Removing
Removing the track control arm 40-1 page 8. Unscrew the left and right nut -1-. Pull out left and right coupling rod -3- from stabilizer
-2-.
2 1
S48-0113
40-1 page 10
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Unscrew clamp of the anti-roll bar from the console

-arrows-. Note The anti-roll bar clamp is located behind the console and is not visible in the figure shown.
S40-0165
Screw out the screws -1- and tie up the steering gear
with wire.
Release the assembly carrier and lower 40-1

page 6.
1 1
Take the console out of the assembly carrier.

Installing Note
Observe the jointing and screw sequence of the
screwed connections assembly carrier/track control arm item 21 in 40-1 page 3 and assembly carrier/ console/steering gear item 22 in 40-1 page 3.
Tighten screwed connections assembly carrier/track
1
S40-0166
control arm in unladen weight position Chapter 442. position the steering gear on the assembly carrier and insert the screws for the steering gear.
Before inserting the screws for the assembly carrier,
Insert console into the assembly carrier. Insert and tighten screws -1-. Tighten assembly carrier 40-1 page 6.
1 1
1
S40-0166
Edition 04.05 S00.5303.18.20
40-1 page 11
40
Screw the anti-roll bar to the console -arrows-.
FABIA 2000
Chassis
S40-0165
Insert left and right coupling rod -3- into the stabilizer
-2-.
Tighten the left and right nut -1-. Installing the track control arm 40-1 page 8. Perform a test drive.
Caution! If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight, perform a chassis alignment.
2 1
Carry out check of chassis alignment Chapter 44-2

Tightening torques:
S48-0113
Track control arm to assembly carrier

Use new screw! observe the order of tightening up item 22 in 40-1 page 3
70 Nm + 90
Console to body
Use new screws!
70 Nm + 90
Support to body
Use new screws!
20 Nm + 90
Console to assembly carrier/body

Use new screws! observe the order of tightening up item 21 in 40-1 page 3
50 Nm + 90
Coupling rod to anti-roll bar Clamp for anti-roll bar to console

Use new screws!
40 Nm 20 Nm + 90
40-1 page 12
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Disconnecting and assembling the track control arm and console

Two-arm extractor -Kukko 20/10 Assembly sliding oil -G 294 421 A1-
Separating the track control arm from the console
Push track control arm out of the console.

1 - Two-arm extractor -Kukko 20/10Assembling the track control arm and the console
Brush the track control arm studs with assembly sliding oil -G 294 421 A1-.
Clamp console in a vice with protective jaws.
Fitting position of the track control arm in the console bearing

The surfaces -A- of the track control arm must correspond with the surfaces -B- in the console rubber-metal bearing. 1 - Axle link 2 - Console 3 - Bonded rubber bush
S40-0343
2 1 A B
Insert the track control arm by hand up to the stop in

the bonded rubber mounting of the console.
Replacing the bonded rubber bush for track control arm

No provision is made for replacing the bonded rubber bush. In the event of damage to the bearing, the track control arm must be completely replaced together with the bearing Spare Part Catalogue.
B
S40-0171
Replacing the bonded rubber bush for console - removal version 1

Pressure plate -MP 3-413 Pressure plate -MP 3-459 Assembly device -MP 5-402 Assembly device -T10030 Pressure plate -T30035 Assembly sliding oil -G 294 421 A1-
Edition 04.05 S00.5303.18.20
40-1 page 13
40
Pulling out the bonded rubber bush
FABIA 2000
Chassis
Removing the track control arm 40-1 page 8. Screw in the screw -T10030/3- (-1-) into the console.
234567Nut of -T10030/3Washer of -T10030/3Axial bearing of -MP 5-402Pressure plate -MP 3-459Console Pressure plate -T30035-
3 1 2
Pulling out the bonded rubber bush.

Inserting the bonded rubber bush
S40-0172
Note
Never use grease! Use assembly sliding oil -G 294 421 A1 - to insert. This leaves a slightly sticky film, which ensures a tight
fit of the bearing.

Commercially available greases/oils are usually acidic
1 2
and leave behind a grease film.

This could result in a corrosion of the bearing or during
compression and rebound of the vehicle the whole bearing may turn in the track control arm and not the actual rubber in itself. Fitting position of the bonded rubber mounting in the console
The stud -1- of the bonded rubber bush must be flush
with marking -2- on the console.

At the console on the left the marking points towards
the body.
At the console on the right the marking points towards
S40-0173
the body.
Arrangement of the special tools for installation without console. 1234567Nut of -T 10030/3Axial bearing of -MP 5-402Pressure plate -T 10030/6Bonded rubber bush Pressure plate -MP 3-413Washer of -T 10030Spindle -T 10030/3-
3 4 5 6
S40-0174
40-1 page 14
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Brush the bonded rubber mounting with assembly

sliding oil -G 294 421 A1-.
Mount the bonded rubber mounting in the console using the special tools.
Align the bonded rubber mounting in the console according to the prescribed installed position 40-1 page 14. the console -4-. Note When inserting the bonded rubber mounting counterhold at spindle.
Position the bonded rubber mounting -5- parallel to
Do not twist the bonded rubber mounting and insert up

to the stop.
S40-0175
Remove the special tools. Installing the track control arm 40-1 page 8.
Replacing the bonded rubber bush for console - removal version 2

Spindle -MP 5-401/2 Pressure plate -MP 6-414/8 Pressure washer -T30047 Pressure plate -T40023 Assembly sliding oil -G 294 421 A1-
Replacing the bonded rubber bush for installed console

Removing the track control arm 40-1 page 8. Loosen underfloor trim panel -1- to approx. half. Press down the underfloor trim panel -1-. Insert the spindle -MP 5-401/2- using the pressure plate -T40023- and the washer -1- from the rear into the bush. console -arrow-, until the pressure plate -T40023- is resting against the bush.
S40-0341
1 T40023
Screw the spindle -MP 5-401/2- into the thread of the Pulling out the bonded rubber bush.
Inserting the bonded rubber bush Note
Never use grease! Use assembly sliding oil -G 294 421 A1- to insert. This leaves a slightly sticky film, which ensures a tight
MP5-401/2
S40-0334
fit of the bearing.

40-1 page 15
40
FABIA 2000
Chassis

compression and rebound of the vehicle the whole bearing may turn in the track control arm and not the actual rubber in itself. Fitting position of the bonded rubber mounting in the console
The stud -1- of the bonded rubber bush must be flush
with marking -2- on the console.

At the console on the left the marking points towards
the body.
At the console on the right the marking points towards
the body.
Transpose the position of the stud -1- on the long side

of the bonded rubber bush, in order to ensure the correct fitting position when inserting. Use e.g a marker for this purpose.
S40-0335

Insert special tools in opposite direction of travel.

2 - Washer 3 - Console When inserting pay special attention to fitting position of the bonded rubber bush -1-.
Insert the bonded rubber bush -1-. Remove the special tools. Attach the underfloor trim panel. Installing the track control arm 40-1 page 8.
Replacing the bonded rubber bush for removed console

Remove console 40-1 page 10. Separating the track control arm and the console
40-1 page 13.
Clamp console -1- in a vice with protective jaws. Insert the spindle -MP 5-401/2- using the pressure
plate -T40023- and the washer -2- from the rear into the bush.
1 MP5-401/2 T40023
Screw the spindle -MP 5-401/2- into the thread of the

console -arrow-, until the pressure plate -T40023- is resting against the bush.
Pulling out the bonded rubber bush.

Inserting the bonded rubber bush
S40-0339
40-1 page 16
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Note
Never use grease! Use assembly sliding oil -G 294 421 A1- to insert. This leaves a slightly sticky film, which ensures a tight
fit of the bearing.


compression and rebound of the vehicle the whole bearing may turn in the track control arm and not the actual rubber in itself. Fitting position of the bonded rubber mounting in the console The stud -1- of the bonded rubber bush must be flush with marking -2- on the console.
Transpose the position of the stud -1- on the long side

of the bonded rubber bush, in order to ensure the correct fitting position when inserting. Use e.g a marker for this purpose.
S40-0335

Insert special tools as shown in the figure.

1 - Console 3 - Washer When inserting pay special attention to fitting position of the bonded rubber bush -2-.
Insert the bonded rubber bush -2-. Remove the special tools. Install console 40-1 page 10.
Removing and installing the anti-roll bar

-V.A.G 1359/2 Fixing device -T10096 Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2Removing
Removing noise insulation Engine - Mechanics;

Rep. Gr. 10.
S48-0112
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40-1 page 17
40
Unscrew clamp of the anti-roll bar from the console
-arrows-. Note
The anti-roll bar clamp is located behind the console
FABIA 2000
Chassis
and is not visible in the figure shown.

The bottom screw of the right clamp can only be re-
moved once the assembly carrier has been lowered.
S40-0165
Screw out the left and right nuts -1-. Pull out left and right coupling rod -3- from stabilizer
-2-.
2 1
S48-0113
with wire.

page 6.
1 1
Remove the clamp from the anti-roll bar. Turn the anti-roll bar upwards and remove towards the
rear. Installing
Insert the anti-roll bar. Insert new screws for the clamps and tighten by hand.
Note Before inserting the screws for the assembly carrier, position the steering gear on the assembly carrier and insert the screws for the steering gear.
1
S40-0166
Raise the assembly carrier and fix 40-1 page 6.

Further installation occurs in reverse order, while paying attention to the following:
40-1 page 18
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Mount pendulum support on the gearbox and tighten

up the new screws -1-. Note Position the screws -1- in the elongated holes of the pendulum support in such a way that there is maximum distance between the gearbox and the assembly carrier. Tightening torques: Console to body
Use new screws!
70 Nm + 90
1 2
Support to body
Use new screws!
20 Nm + 90
S10-0133

Use new screws! observe the order of tightening up
50 Nm + 90
item 21 in 40-1 page 3

Use new screws!
30 Nm + 90
Coupling rod to anti-roll bar Clamp for anti-roll bar to console

Use new screws!
40 Nm 20 Nm + 90
Removing and installing assembly carrier

-V.A.G 1359/2 Fixing device -T10096 Extractor -MP 6-425 Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2 Polycarbamide grease -G 052 142 A2 Glue sealing mass -Loctite 601-
Removing

Chapter 40-4 and tie up drive shaft to body.
Swivel out the wheel-bearing housing with the suspension strut and support with wooden insert -1-.
S40-0161
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40-1 page 19
40
-2-.
FABIA 2000
Chassis
2 1
Swivel the anti-roll bar upwards.
S48-0113
with wire.

page 6. Installing Note
Before inserting the screws for the assembly carrier,
1 1
position the steering gear on the assembly carrier and insert the screws for the steering gear.
Always replace plate nuts of drive shaft on both sides
1
S40-0166
by twelve-point nuts.
Raise the assembly carrier and fix 40-1 page 6.

Further installation occurs in reverse order, while paying attention to the following: Vehicles with 13" running gear

material -Loctite 601-. Vehicles with 14 and 15 running gear

with new twelve-point nut.
Screw the steering joint and the track control arm with
new screws.
Perform a test drive.
40-1 page 20
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40

Tightening torques: Console to body
Use new screws!
70 Nm + 90
Support to body
Use new screws!
20 Nm + 90

Use new screws! observe the order of tightening up item 21 in 40-1 page 3
50 Nm + 90

50 Nm
50 Nm + 45
Coupling rod to anti-roll bar Steering joint to track control arm

40 Nm 20 Nm + 90
Wheel bolts
120 Nm
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40-1 page 21
40
FABIA 2000
Chassis
40-1 page 22
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
40-2
Repairing front suspension strut
II - Summary of components of suspension strut

Note The figure represents the wheel-bearing housing for disc brake FS-III. The different versions of the wheel-bearing housing do not influence the assembly of the suspension strut. 1 - Wheel-bearing housing 2 - Nut, 60 Nm + torque a further 90 (1/4 turn) 34replace after each removal Screw replace after each removal Shock absorber removing and installing 40-2 page 2 can be replaced individually must be replaced completely check 40-2 page 7 disposing of 40-2 page 8 assignment Spare part catalogue Stop buffer Boot Helical spring check colour coding The surface of the spring coil must not be damaged replace axle-wise per axle only use helical springs of the same make removing and installing 40-2 page 6 assignment Spare part catalogue Axial grooved ball bearing Suspension strut bearing Self-locking nut, 60 Nm replace after each removal Suspension strut dome
12
13 12 12
6 11 10 4 9 8 3 2 7 1
S40-0185
567-
8910 11 -
12 - Screw, 15 Nm + torque a further 90 (1/4 turn) replace after each removal when mounting the suspension strut, first mount the screws on the inside of the vehicle 13 - Cap clipped into suspension strut dome
Edition 04.05 S00.5303.18.20
40-2 page 1
40
Removing and installing the suspension strut
Gearbox jack with adapter e.g. - V.A.G 1383 A- with
FABIA 2000
Chassis
-V.A.G 1359/2 Spreader -3424 Extractor -MP 6-425 Extractor -Matra V176 Polycarbamide grease -G 052 142 A2 Glue sealing mass -Loctite 601-
Removing
Raise the vehicle until the front axle is free of stress. Unscrew plate nut (or the twelve-point nut) from the
drive shaft using a 19 mm Allen key.
2 1
S40-0338
Remove wheel. Mark fitting position of screws -arrowsfrom steering


the track control arm -2-.
Screw out the screws. Unscrew the nut of the coupling rod -arrows B- from
the suspension strut.
Unhook speed sensor cable from the suspension

strut.
S40-0342
Screw up nut -1- sufficiently so that the puller

-Matra V176- is supported on the nut.
Use puller -Matra V176- to press track rod/track rod

end -2- off the steering arm.
Matra V176 1
Screw off the nut from the track rod end. Pull track rod end out of steering arm. Tie up track rod. Remove the drive shaft from wheel-bearing housing Chapter 40-4 and tie up. use the removed screws and the removed lock washer.
Screw steering joint to the track control arm. To do so Position the gearbox jack with adapter (e.g. - V.A.G
1383/A- with -V.A.G 1359/2-) under the wheel-bearing housing.
S40-0177
40-2 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Separate the screwed connection wheel-bearing

housing/suspension strut -arrow-.
S40-0288
Insert the spreader -3424- in the slot on the wheelbearing housing.
Turn ratchet 90 and remove from spreader -3424-. Press the brake disc by hand towards the suspension
strut. Otherwise the shock-absorber tube may tilt in the hole of the wheel-bearing housing.
3424
Pull wheel-bearing housing downwards away from the

shock-absorber tube and lower with gearbox jack until the shock-absorber tube hangs free.
Secure the wheel-bearing housing to the console/assembly carrier.

S40-0179
Remove the gearbox jack with adapter. Unscrew the screws for the top shock-absorber fixture
-arrows-.
Remove the suspension strut.

Installing
Insert the suspension strut and secure to the suspension strut dome. First mount the screws on the inner side of the vehicle.
Tighten up the screws fully to the specified tightening

torque.
Position the gearbox jack with adapter (e.g. - V.A.G

S40-0186
Insert suspension strut in the wheel-house bearing. Loosen the wheel-bearing housing on the console/assembly carrier.
Raise up the wheel-bearing housing using the gearbox jack to the point where the screws for the suspension strut/wheel-bearing housing can be inserted. Note Never press on the steering joint with the gearbox jack.
Edition 04.05 S00.5303.18.20 Repairing front suspension strut
40-2 page 3
40
With one's hand on the brake disc press in the direction of the suspension strut making sure that the shock-absorber tube in the bore hole of the wheelbearing housing does not become tilted.
FABIA 2000
Chassis
Remove spreader -3424-. Screw on the new nuts and tighten up fully -arrow-.
Further installation occurs in reverse order, while paying attention to the following: Note Remove possible corrosion, grease or adhesive sealing material from the thread and from the serration of the outer joint as well as from the serration of the wheel hub. Vehicles with 13" running gear

material -Loctite 601-. Do not grease thread on the outer joint of the drive shaft. Vehicles with 14 and 15 running gear
S40-0288
Insert the drive shaft in the serration of the wheel hub. When inserting the drive shaft insert at the same time
the steering joint -1- into the track control arm -2- in accordance with the former positions and markings.
Secure the outer joint of the drive shaft with a new

twelve-point nut. Note
Always replace plate nuts of drive shaft on both sides
by twelve-point nuts.
Replace nut on both sides.
2 1
S40-0338
Screw the track control arm -1- with the steering joint
-2- with new screws -arrows- and new lock washer in accordance with the former positions and markings.
Tighten the new screws -arrows- in accordance with

the markings and the former positions to the specified tightening torque.
40-2 page 4
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40

Tightening torques:
Suspension strut to suspension strut dome

Use new screws!
15 Nm + 90
Wheel-bearing housing to suspension strut

Use new screws and nuts!
60 Nm + 90
Track rod end/track rod to steering arm

Use new nuts!
20 Nm + 90
The anti-roll bar on the suspension strut Twelve-point nut of drive shaft to wheel hub 13" running gear
Use new nuts! Do not grease thread of the outer joint of the drive shaft.
40 Nm 50 Nm
50 Nm + 45

20 Nm + 90
Wheel bolts
120 Nm
Repairing the suspension strut

Spring tensioning device, e.g. -V.A.G 1752/1 Spring holder with protective lining, e.g. - V.A.G 1752/
4 Socket wrench insert OK 21 -MP 6-427-
Edition 04.05 S00.5303.18.20
40-2 page 5
40
Removing the helical spring
FABIA 2000
Chassis
Removing the suspension strut 40-2 page 2 Preload the helical spring with the spring tensioner until the suspension strut bearing -3- is relieved.
V.A.G 1752/1
1 MP 6-427 2 3
Unscrew the nut from the piston rod using socket

wrench insert OK 21 -MP 6-427- and counterhold with an hexagonal wrench -2-. 1 - Ratchet or torque wrench
V.A.G 1752/4
Remove component parts of the suspension strut and

preloaded helical spring with the clamping fixture.
S40-0187
Check correct seating of the helical spring in the

spring tensioning device, e.g. -V.A.G 1752/4- -arrow-.
V.A.G 1752/1
Installing the helical spring
V.A.G 1752/4
S40-0290
Position the preloaded helical spring with spring tensioning device, e.g. -V.A.G 1752/4- on the bottom spring washer. The extremity of the spring coil must lie against the stop -arrow-. Further installation occurs in reverse order.
Tightening torque:
Nut for suspension strut bearing on the piston rod 60 Nm
Assembling the shock absorber 40-2 page 1
S40-0259
40-2 page 6
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Inspecting the shock absorber

Leaks on the shock absorber Minor oil leakage (sweating) on the piston rod seal does not entail the replacement of the shock absorber. If an oil leak is visible (but blunt, dull, possibly dried by dust) and does not propagate any further than from the top shock-absorber plug (piston rod seal) to the bottom spring cap -arrow-, the shock absorber is deemed to be O.K. Note A slight oil leak is beneficial as the gasket is lubricated and this increases the life time. This applies for shock absorbers on the front as well as the rear axle. Shock absorber noises There is reason to believe that in the event of noise complaints the shock absorbers are all too often considered as the source. Possible causes of noise may be e.g.:
Defective shock absorber Loose fixation of the suspension strut/body Defective axial grooved ball bearing Insufficient clearance of the suspension strut The outer joint is defect Defective wheel bearing Cracked welding points on body Loose parts or parts fitted under stress (exhaust sysS40-0071
tem, attachments, flaps, etc.) Note In the event of complaints about noises interpreted as knocking or cracking noises, always first perform a test drive with the customer to determine where, when and how these noises occur (preferably on a bumpy dry road). Inspecting the removed shock absorber without gas pressure Defective shock absorbers become noticeable while driving because of the knocking noises caused by wheel hopping, more specifically on poor road surfaces and they must be replaced. The main cause of defect is oil leakage. The shock absorber then compresses and/or expands in jolts. It has an idle travel before taking effect. Note Shock absorbers are maintenance-free. It is not possible to top up the shock absorber oil. Inspecting the removed shock absorber with gas pressure Defective shock absorbers with gas pressure are also noticeable because of loud knocking noises caused by
Edition 04.05 S00.5303.18.20
40-2 page 7
40
wheel hopping and externally usually exhibit considerable oil leakage. Check by hand whether or not the shock absorber is defective as follows:
FABIA 2000
Chassis
Compress the shock absorber by hand.

The piston rod must move evenly over the entire stroke without jolting.
Release the piston rod. On sufficiently pressurized

shock absorbers it will automatically return to its original position. If this is not the case, the shock absorber need not necessarily be replaced, as it will still operate as a conventional shock absorber (see instructions below). Note
The absorbing function is still fully present without suf-
ficient gas pressure as long as the oil leakage is not too large. However, the noise level may increase. On older vehicles it is possible to continue using an operational yet pressureless shock absorber without problem.
Adequate gas pressure in the shock absorber im-
proves the noise behaviour and function when driving over poor road surfaces.
Disposing of the shock absorber

Drill 3 mm (commercially available) Drill 6 mm (commercially available) Safety goggles (commercially available) Oil catch container (commercially available) Pipe cutter, e.g. Stahlwille Express -150/3- (commer-
cially available) Note There are two ways of disposing of shock absorbers. Degassing the front and rear pressurized shock absorbers Possibility A: Degassing by drilling open I - Front pressurized shock absorber II - Rear pressurized shock absorber
Clamp the pressurized shock absorber in the vice in

such a way tbat the piston points downwards. Caution! Wear safety goggles during the drilling procedure.
40-2 page 8
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
I II
Drill a hole 3 mm -arrow A- through the outer pipe

of the shock absorber. Note Gas will escape during drilling. through (approx. 25 mm deep).
20
Drill a second hole 6 mm -arrow B- through the outer and inner pipe of the shock absorber.
20
Hold the shock absorber over an oil catching pan,

move the piston rod sevral times up and down over its entire stroke until no more oil escapes. Degassing the front and rear pressurized shock absorbers Possibility B: Open with pipe cutter I - Front pressurized shock absorber II - Rear pressurized shock absorber
Clamp the pressurized shock absorber in the vice in

such a way that the piston points upwards. Caution! Wear safety goggles during the drilling procedure.
S40-0188
Drill a hole 3 mm -arrow A- through the outer pipe

of the shock absorber. Note Gas will escape during drilling.
Position a pipe cutter, e.g. Stahlwille Express -150/3-,

as shown in the figure, and cut through the outer pipe of the shock absorber.
Pull the piston rod upwards and while doing so grip the
inner pipe with pipe pliers and press it down in such a way that it remains in the outer pipe when the piston rod is slowly pulled up.
II
Pull the piston rod out of the inner pipe. Empty the shock absorber pipe.
S40-0189
Edition 04.05 S00.5303.18.20
40-2 page 9
60
Drill further until the inner pipe has been drilled
60
40
FABIA 2000
Chassis
40-2 page 10
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
40-3
Repairing the wheel bearing
III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FS-III
Note
Welding and straightening work is not allowed on the bearing and wheel control components of the front wheel
suspension.
1 - Suspension strut removing and installing 5 Chapter 40-2 1 repair Chapter 40-2 assignment Spare part 2 catalogue 6 28 2 - Drive shaft with CV joint 7 removing and installing Chapter 40-4 3 inspect Chapter 40-4 4 repair Chapter 40-4 27 26 assignment Spare part catalogue 25 24 3 - Shim assignment Spare part 23 catalogue 20 4 - Fillister head screw with inter19 nal serrations replace after each removal 22 8 assignment Spare part catalogue 9 M8 x 48 initially tighten all screws to 10 Nm, then tighten screws crosswise 17 18 Tightening torque: 40 Nm 21 M10 x 52 10 12 initially tighten all screws to 10 Nm, then tighten screws 16 crosswise 11 Tightening torque: 70 Nm 14 15 13 S40-0202 5 - Drive shaft with tripod joint removing and installing Chapter 40-5 repair Chapter 40-5 assignment Spare part catalogue 6 - Shim only replace along with a cylindrical screw with internal serrations M8 x 28 head, item 7 7 - Fillister head screw with internal serrations replace after each removal assignment Spare part catalogue M8 x 18 initially tighten all screws to 10 Nm, then tighten screws crosswise Tightening torque: 40 Nm M8 x 28
Edition 04.05 S00.5303.18.20 Repairing the wheel bearing
40-3 page 1
40
FABIA 2000
Chassis
8910 11 -
12 13 14 -
15 16 17 18 -
19 -
initially tighten all screws to 10 Nm, then tighten screws crosswise Tightening torque: 40 Nm M10 x 23 initially tighten all screws to 10 Nm, then tighten screws crosswise Tightening torque: 70 Nm Brake disc, internally ventilated Wheel bolt, 120 Nm assignment Spare part catalogue Plate nut replace after each removal against twelve-point nut item 11 50 Nm + 45 replace after each removal Do not grease thread of the outer joint of the drive shaft. assignment Spare part catalogue Screw, 4 Nm Brake pad removing and installing Chapter 46-1 Brake caliper assignment Spare part catalogue do not release brake hose when working on the front wheel suspension tie up with wire or anything similar repair Chapter 47-1 Guide bolts, 28 Nm Cap removing Screw, 10 Nm Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub The wheel hub and the wheel bearing are a single unit; it does not need servicing and is free of play; it is not possible to undertake any kind of adjustment or repair work on it. The sensor ring for ABS cannot be replaced individually replace after each removal, is destroyed during removal Removing and installing the wheel hub with wheel bearing 40-3 page 10 assignment Spare part catalogue Cover plate
20 - Nut, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 21 - Track rod and track-rod ends removing and installing Chapter 48-16 22 - Wheel-bearing housing removing and installing 40-3 page 7 assignment Spare part catalogue 23 - Nut, 60 Nm + torque a further 90 (1/4 turn) replace after each removal 24 - Screw replace after each removal the tip of bolt must point in the direction of travel 25 - Speed sensor ABS assignment Spare part catalogue 26 - Allan screw, 8 Nm for speed sensor ABS 27 - Nut, 40 Nm assignment Spare part catalogue
40-3 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
28 - Coupling rod assignment Spare part catalogue
III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FS-II
Note
suspension.
1 - Suspension strut removing and installing Chapter 40-2 repair Chapter 40-2 2 1 assignment Spare part catalogue 27 2 - Drive shaft with CV joint 3 removing and installing Chapter 40-4 26 inspect Chapter 40-4 25 repair Chapter 40-4 24 assignment Spare part 23 catalogue 3 - Shim 22 assignment Spare part 19 catalogue 4 - Fillister head screw with internal serrations replace after each removal assignment Spare part 21 catalogue M8 x 48 initially tighten all screws to 15 10 Nm, then tighten screws crosswise 20 14 Tightening torque: 40 Nm M10 x 52 initially tighten all screws to 13 10 Nm, then tighten screws crosswise 12 Tightening torque: 70 Nm 5 - Brake disc, internally ventilated 6 - Wheel bolt, 120 Nm assignment Spare part catalogue 7 - Plate nut replace after each removal against twelve-point nut item 8 8 - 50 Nm replace after each removal Do not grease thread of the outer joint of the drive shaft. assignment Spare part catalogue
18 17 16 5 6
9 10
7 8
S40-0203
11
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40
FABIA 2000
Chassis
9 - Screw, 4 Nm 10 - Brake pad removing and installing Chapter 46-1 11 - Brake caliper assignment Spare part catalogue do not release brake hose when working on the front wheel suspension tie up with wire or anything similar repair Chapter 47-1 12 - Fillister head screw with internal serrations, 25 Nm M8 x 49 13 - Fillister head screw with internal serrations, 25 Nm M8 x 59 14 - Air deflector assignment Spare part catalogue 15 - Screw, 10 Nm for air deflector 16 - Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub The wheel hub and the wheel bearing are a single unit; it does not need servicing and is free of play; it is not possible to undertake any kind of adjustment or repair work on it. The sensor ring for ABS cannot be replaced individually replace after each removal, is destroyed during removal assignment Spare part catalogue 17 - Screw, 10 Nm 18 - Cover plate 19 - Nut, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 20 - Track rod and track-rod ends removing and installing Chapter 48-16 21 - Wheel-bearing housing removing and installing 40-3 page 7 assignment Spare part catalogue 22 - Nut, 60 Nm + torque a further 90 (1/4 turn) replace after each removal 23 - Screw replace after each removal the tip of bolt must point in the direction of travel 24 - Speed sensor ABS assignment Spare part catalogue 25 - Allan screw, 8 Nm for speed sensor ABS 26 - Nut, 40 Nm assignment Spare part catalogue 27 - Coupling rod assignment Spare part catalogue
40-3 page 4
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40
III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake C54-II
Note
suspension.
1 - Suspension strut 5 removing and installing Chapter 40-2 1 repair Chapter 40-2 assignment Spare part 2 31 catalogue 6 7 2 - Drive shaft with CV joint removing and installing Chapter 40-4 3 inspect Chapter 40-4 4 repair Chapter 40-4 30 29 assignment Spare part catalogue 28 27 3 - Shim assignment Spare part 26 catalogue 23 4 - Fillister head screw with inter22 25 nal serrations 21 replace after each removal 20 assignment Spare part 24 catalogue M8 x 48 17 initially tighten all screws to 10 Nm, then tighten screws 19 crosswise 15 14 Tightening torque: 40 Nm M10 x 52 12 initially tighten all screws to 13 10 Nm, then tighten screws 18 crosswise 17 14 Tightening torque: 70 Nm 16 5 - Drive shaft with tripod joint removing and installing Chapter 40-5 repair Chapter 40-5 assignment Spare part catalogue 6 - Shim only replace along with a cylindrical screw with internal serrations M8 x 28 head, item 7 7 - Fillister head screw with internal serrations replace after each removal assignment Spare part catalogue M8 x 18 initially tighten all screws to 10 Nm, then tighten screws crosswise Tightening torque: 40 Nm M8 x 28 initially tighten all screws to 10 Nm, then tighten screws crosswise Tightening torque: 40 Nm
10 13 11
S40-0204
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40
FABIA 2000
Chassis
8910 11 -
12 13 14 -
15 16 -
17 -
18 19 20 -
21 22 -
M10 x 23 initially tighten all screws to 10 Nm, then tighten screws crosswise Tightening torque: 70 Nm Brake disc, internally ventilated Wheel bolt, 120 Nm assignment Spare part catalogue Plate nut replace after each removal against twelve-point nut item 11 50 Nm + 45 replace after each removal Do not grease thread of the outer joint of the drive shaft. assignment Spare part catalogue Screw, 4 Nm Brake pad removing and installing Chapter 46-1 Pad retaining plate always replace when changing the brake pads brake pads contained in repair kit Brake carrier with guide bolts and protective caps Heat shield always replace when changing the brake pads brake pads contained in repair kit Brake caliper assignment Spare part catalogue do not release brake hose when working on the front wheel suspension tie up with wire or anything similar repair Chapter 47-1 Screw, 30 Nm replace after each removal Track rod and track-rod ends removing and installing Chapter 48-16 Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub The wheel hub and the wheel bearing are a single unit; it does not need servicing and is free of play; it is not possible to undertake any kind of adjustment or repair work on it. The sensor ring for ABS cannot be replaced individually replace after each removal, is destroyed during removal Removing and installing the wheel hub with wheel bearing 40-3 page 10 assignment Spare part catalogue Screw, 10 Nm Cover plate
23 - Nut, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 24 - Screw, 125 Nm clean ribbing on underside each time removed 25 - Nut, 60 Nm + torque a further 90 (1/4 turn) replace after each removal 26 - Wheel-bearing housing removing and installing 40-3 page 7 assignment Spare part catalogue 27 - Screw replace after each removal the tip of bolt must point in the direction of travel
40-3 page 6
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28 - Speed sensor ABS assignment Spare part catalogue 29 - Allan screw, 8 Nm for speed sensor ABS 30 - Nut, 40 Nm assignment Spare part catalogue 31 - Coupling rod assignment Spare part catalogue
Removing and installing wheel bearing housing

Note
The running gears have different versions of wheel
bearing housings and floating caliper brakes.

The special tools, test and measuring equipment as
well as aids required for removing and installing the wheel bearing housing of running gears with FS-II, FS-III or C54-II brakes are identical. Special tools, test and measuring equipment and auxiliary items required
Gearbox jack with adapter e.g. -V.A.G 1383 A- with
-V.A.G 1359/2 Spreader -3424 Extractor -MP 6-425 Extractor -Matra V176 Polycarbamide grease -G 052 142 A2 Glue sealing mass -Loctite 601-
Removing
Raise the vehicle until the front axle is free of stress. Unscrew twelve-point nut (or the plate nut) from the
Remove wheel.
Vehicles fitted with anti-roll bar
Unscrew nut -1-. Pull out coupling rod -3- from the anti-roll bar -2-.
Vehicles with ABS
2 1
Removing the speed sensor.

Vehicles fitted with FS-III floating caliper brake
S48-0113
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40
Removing the caps from the brake caliper guide bolts. Unscrew and remove the two guide bolts -arrow- from
the brake caliper. Vehicles fitted with FS-II floating caliper brake
FABIA 2000
Chassis
Unscrew cylinder bolts with hexagon socket head

from brake caliper and take out (not shown). Vehicles fitted with C54-II floating caliper brake
S40-0176
Release screws -1-.

Continued for all vehicles
Remove brake caliper or brake carrier with brake caliper and secure with wire in such a way that the weight of the brake caliper does not pull on or damage the brake hose.

Chapter 40-4 and tie up.
Remove the track rod end from the steering-knuckle

arm with extractor -Matra V176- and tie up the track rod.
1
S40-0197
Position the gearbox jack with adapter (e.g. -V.A.G

Separate the screwed connection wheel-bearing

housing/suspension strut -arrow-.
S40-0288
40-3 page 8
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40
Insert the spreader -3424- in the slot on the wheelbearing housing.
Turn ratchet 90 and remove from spreader -3424-. Press the brake disc by hand towards the suspension
3424
Remove the wheel-bearing housing from the shockabsorber tube and lower with gearbox jack. Installing
Raise the wheel-bearing housing with gearbox jack. Insert the suspension strut/wheel-bearing housing
screw.
S40-0179
Press the brake disc by hand towards the suspension

Remove spreader -3424-.

Further installation occurs in reverse order, while paying attention to the following: Vehicles with 13" running gear


with new twelve-point nut. Note Always replace plate nuts of drive shaft on both sides by twelve-point nuts.
Screw the steering joint and track control arm with the
new screws in the former positions.
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Chassis

Tightening torques:
Wheel-bearing housing to suspension strut

60 Nm + 90

50 Nm
50 Nm + 45
Track-rod end to steering lever

Use new nuts!
20 Nm + 90

20 Nm + 90
FS-III brake caliper to wheel bearing housing FS-II brake caliper to wheel bearing housing Brake carrier with C54-II brake caliper to wheel bearing housing Coupling rod to anti-roll bar Speed sensor to wheel-bearing housing Wheel bolts
28 Nm 25 Nm 125 Nm 40 Nm 8 Nm 120 Nm
Removing and installing the wheel hub with wheel bearing with the wheel-bearing housing fitted
Note
The FS-II chassis uses another size of wheel hub with
wheel bearing compared to the FS-lll chassis or the C54-ll type.

The special tools, test and measuring equipment as
well as aids required for removing and installing the wheel bearing housing of chassis with the FS-II, FS-III or C54-II brake are identical.
When drawing in the wheel hub and wheel bearing at
the chassis fitted with an FS-II brake, pay attention to the modified installed position of the assembly device - T10064/4-. On a chassis fitted with the FS-II brake use grips -T10064/5- and on chasses with FS-III or C54-II brakes use grips -T10064/6-.
40-3 page 10
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Gearbox jack with adapter e.g. -V.A.G 1383 A- with
-V.A.G 1359/2 Assembly device -MP 6-414 Extractor -MP 6-425 Side door removal tool -MP 8-605/1- or e.g. supple-
mentary tool kit -V.A.G 1459 B/2 Assembly device -T10064 Extractor -Matra V176 Molykote grease -G 052 723 A2 Polycarbamide grease -G 052 142 A2 Glue sealing mass -Loctite 601-
2 1
Removing the wheel hub with wheel bearing
Remove wheel.
Vehicles fitted with anti-roll bar
S48-0113
Unscrew nut -1-. Pull out coupling rod -3- from the anti-roll bar -2-.
Vehicles with ABS
Removing the speed sensor.

Vehicles fitted with FS-III floating caliper brake
Removing the caps from the brake caliper guide bolts. Unscrew and remove the two guide bolts -arrowsfrom the brake caliper. Vehicles fitted with FS-II floating caliper brake
Unscrew cylinder bolts with hexagon socket head

from brake caliper and take out (not shown). Vehicles fitted with C54-II floating caliper brake
S40-0176
Release screws -1-.

1
S40-0197
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40-3 page 11
40
Remove brake caliper or brake carrier with brake caliper and secure with wire in such a way that the weight of the brake caliper does not pull on or damage the brake hose.
FABIA 2000
Chassis

Chapter 40-4 and tie up.
Swivel out the wheel-bearing housing with the suspension strut and support with wooden insert -1-.
Remove the track rod end from the steering-knuckle

arm with extractor -Matra V176- and tie up the track rod.
Screw out the Phillips head screws of the brake disc

and remove brake disc.
Remove the cover plate of the brake disc. Place the gearbox jack with adapter, e.g. -V.A.G
1383/A- with -V.A.G 1359/2- below (danger of having an accident): from parts which are falling when pulling out the wheel hub).
S40-0161
Note
The illustration shows the process of pulling out the
wheel hub and wheel bearing at a wheel bearing housing for vehicle fitted with an FS-III brake.
The procedure for pulling out the wheel hub and wheel
bearing of the chassis fitted with an FS-II or C54-II brake is similar to that for a chassis fitted with an FSIII brake even when the wheel bearing housing has a different appearance.
Mount the assembly device -MP 6-414- at right angles
to the centre axle of the wheel hub with wheel bearing. Do not tilt the wheel hub with wheel bearing when removing and installing.
Three different variants are described below for pull-
ing out the wheel bearing with wheel hub.
Insert the side door removal tool -3- between the

wheel-bearing housing and the wheel hub as support for the assembly device -2-.
3 2 4 1
Pull the wheel hub with wheel bearing out of the

wheel-bearing housing. 12345-MP 6-414/2- with -MP 6-414/5-MP 6-414/1-MP 8-605/1-MP 6-414/10-MP 6-414/6Note
Instead of the side door removal tool -MP 8-605/1-
S40-0181
use 2 bases with a thickness of approx. 25 mm, a height of approx. 40 mm and a length of approx. 220 mm between the wheel-bearing housing and the
40-3 page 12
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40
3 2 4 1
wheel hub as support for the assembly device -MP 6-414-. The arrangement is similar to separating device - E-37- 40-3 page 13.
If the separating device -E-37- from the supplementa-
ry tool kit -V.A.G 1459 B/2- is available then this can also be used as a support. Please note the correct installed position while doing this. The straight surfaces of the cutting edges must point towards the wheel hub.
Insert separating device -3- between the wheel-bearing housing and the wheel hub and take up the weight.
Pull the wheel hub with wheel bearing out of the

wheel-bearing housing. 12345-MP 6-414/2- with -MP 6-414-MP 6-414/1Separating device -E-37- from -V.A.G 1459 B/2-MP 6-414/10-MP 6-414/6-
S40-0182
Inserting a wheel hub with wheel bearing Note

Figure S40-0180 shows the wheel bearing housing for
the chassis with the FS-III brake. The procedure for cleaning and greasing the holes on wheel bearing housings for a chassis with FS-II or C54-II brakes is similar to that on a chassis with an FS-III brake.
Clean the bore holes on the wheel bearing housing. Coat the bore with molykote grease -G 052 723 A2-
over the entire surface.

Screw the grippers -1- to the wheel hub with wheel
S40-0180
bearing -2-. Grippers -1Chassis with an FS-II brake Chassis with an FS-III or C54-II brake -T10064/5-T10064/6-
1 3
Note The wheel bolts -3- must not protrude from the rear of the grippers -1-. Chassis with an FS-II brake Note Do not tilt the wheel hub with wheel bearing while inserting.
2
S40-0194
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40
Pull the wheel hub with wheel bearing into the wheelbearing housing. 12345-MP 6-414/5-T10064/1-T10064/5-MP 6-414/10-T10064/4-
FABIA 2000
Chassis
3 4 2 1 5
S40-0195
Chassis with an FS-III or C54-II brake Note

Figure S40-0183 shows the procedure for pulling in
the wheel hub and wheel bearing on a wheel bearing housing for a chassis fitted with an FS-III brake.
The selection and arrangement of special tools for
pulling in the wheel hub with wheel bearing into the wheel bearing housing of a chassis fitted with an C54II brake is similar to that for a chassis fitted with an FSIII brake.
Do not tilt the wheel hub with wheel bearing while in-
serting.
3 4 2 1 5
S40-0183
Pull the wheel hub with wheel bearing into the wheelbearing housing. 12345-MP 6-414/5-T10064/1-T10064/6-MP 6-414/10-T10064/4-
Pull in the wheel hub with wheel bearing until the circlip is heard to click into position.
Screw out the grippers -1- from the wheel hub with
wheel bearing -2-. 3 - Wheel bolts Further installation occurs in reverse order, while paying attention to the following: Vehicles with 13" running gear
1 3 2 1

S40-0196
Grease the serration on the propeller shaft with polycarbamide grease -GG 052 142 A2-. Do not grease thread on the outer joint of the drive shaft.
Grease the serration in the wheel hub with polycarbamide grease -G 052 142 A2-.
40-3 page 14
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with new twelve-point nut. Note Always replace plate nuts of drive shaft on both sides by twelve-point nuts.
Screw the steering joint and track control arm with the
new screws in the former positions.


Tightening torques:
Cover plate to wheel-bearing housing Phillips head screw of brake disc to wheel hub with wheel bearing Twelve-point nut of drive shaft to wheel hub 13" running gear
10 Nm 4 Nm 50 Nm
50 Nm + 45
Track rod/track rod end to steering lever

Use new nuts!
20 Nm + 90

20 Nm + 90
FS-III brake caliper to wheel bearing housing FS-II brake caliper to wheel bearing housing Brake carrier with C54-II brake caliper to wheel bearing housing Coupling rod to anti-roll bar Wheel bolts
28 Nm 25 Nm 125 Nm 40 Nm 120 Nm
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FABIA 2000
Chassis
40-3 page 16
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FABIA 2000
Chassis
40
40-4
Drive shafts with CV joints
Removing and installing a drive shaft

Extractor -MP 6-425 Polycarbamide grease -G 052 142 A2 Glue sealing mass -Loctite 601 A steel cylinder - max. 18 mm, length 20 mm
Removing
Removing noise insulation Engine - Mechanics;

Rep. Gr. 10.
Unscrew the drive shaft from the flange shaft - gearbox, if necessary remove the heat shield below the inner joint.
Remove front wheel. Mark fitting position of screws -arrowsfrom steering
2 1
S40-0338

the track control arm -2-.
Release screws -arrows-. Press out drive shaft with -MP 6-425-. Remove the drive shaft.
Installing Note Remove possible corrosion, grease or adhesive sealing material from the thread and from the serration of the outer joint as well as from the serration of the wheel hub. Vehicles with 13" running gear
Smear the gearing of the outer joint of the drive shaft

lightly with adhesive sealing material -Loctite 601-. Do not grease thread on the outer joint of the drive shaft. Vehicles with 14 and 15 running gear
MP 6-425
S40-0178
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40
Insert the drive shaft in the serration of the wheel hub. When inserting the drive shaft insert at the same time
the steering joint -1- into the track control arm -2- in accordance with the former positions and markings.
FABIA 2000
Chassis
Screw the drive shaft onto the flange shaft - gearbox

and initially tighten to 10 Nm.
Secure the outer joint of the drive shaft with a new

twelve-point nut. Note Always replace plate nuts of drive shaft on both sides by twelve-point nuts. Replace nut on both sides.
2 1
S40-0338
Tighten the drive shaft on the flange shaft - gearbox to

the prescribed torque.
Screw the track control arm -1- with the steering joint
-2- with new screws -arrows- and new lock washer in accordance with the former positions and markings.
Tighten the new screws -arrows- in accordance with

the markings and the former positions to the specified tightening torque. Further installation occurs in reverse order. Tightening torques:
Drive shaft to flange shaft/gearbox

Use new screws!
M 8 = 40 Nm M 10 = 70 Nm 50 Nm

50 Nm + 45

20 Nm + 90
Wheel bolts
120 Nm
Summary of components of drive shaft with CV joint

Grease quality and grease quantity Note
The outer joints of the drive shaft are filled with grease
for operating at normal temperatures, e.g. -N 052 738 00-.

Only use the appropriate high-temperature grease
from the relevant repair kit for the grease filling of the CV joint Spare Parts catalogue.
40-4 page 2
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40
of which in: Joint [g] 80 +10 100 +10 Joint boot [g] -----
Grease Outer joint mm 90 100 Inner joint mm 90 100 80 +10 110 +10 Total amount [g] 80 +10 100 +10
40 +5 55 +5
40 +5 55 +5
Note
Assignment of the drive shafts Spare part catalogue. Grease joint if necessary, when replacing the joint boot. Spread the grease mass evenly in the joint boot.
1 - Right joint boot (tubular shaft) assignment Spare part catalogue 2 - Screw replace after each removal initially tighten to 10 Nm, subsequently tighten crosswise to final torque: M 10 = : For vehicles 04.03 70 Nm For vehicles 05.03 Tighten 50 Nm + 45 M8=: For vehicles 04.03 40 Nm For vehicles 05.03 Tighten 20 Nm + 90 assignment Spare part catalogue 3 - Shim assignment Spare part catalogue 4 - Warm-type clamp replace tensioning 40-4 page 5 5 - Joint boot for inner CV joint Material: Hytrel (Polyelastomere) inspect for tears and chafing points remove from CV joint with drift before installation coat the inside of the cap with sealant -D 454 300 A2assignment Spare part catalogue
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40-4 page 3
40
FABIA 2000
Chassis
6 - Disc spring Fitting position 40-4 page 6 7 - Inner CV joint must be replaced completely pressing off 40-4 page 6 pressing on 40-4 page 6 grease 40-4 page 2 check 40-4 page 8 assignment Spare part catalogue 8 - Gasket The adherend must be free of grease and oil! replace Pull off protective foil and stick in housing assignment Spare part catalogue 9 - Circlip replace use circlip pliers, e.g. -VW 161 A- for removing and installing assignment Spare part catalogue 10 - Left drive shaft (solid shaft) assignment Spare part catalogue 11 - Warm-type clamp replace tensioning 40-4 page 5 12 - Joint boot Material: Hytrel (Polyelastomere) inspect for tears and chafing points 13 - Warm-type clamp replace tension with tensioning pliers, e.g. -V.A.G 1682 - 40-4 page 5 14 - Disc spring Fitting position 40-4 page 5 15 - Thrust ring Fitting position 40-4 page 5 16 - Circlip replace insert in the shaft groove 17 - Outer CV joint must be replaced completely removing 40-4 page 5 before installing grease the serration with polycarbamide grease -G 052 142 A2Installing: drive onto the shaft with a plastic hammer until the compressed circlip expands grease 40-4 page 2 check 40-4 page 7 assignment Spare part catalogue 18 - Thrower ring 13" chassis - black 14" and 15" chassis - white 19 - Twelve-point nut 13" chassis - black, 50 Nm 14" and 15" chassis - silvery, 50 Nm + 45 replace after each removal
40-4 page 4
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Repairing drive shaft with CV joint

Pressure plate -MP 3-406 Pressure plate -MP 3-407 Thrust piece -MP 3-448 Strutting bushing -MP 6-428 Clamping device -MP 6-429 Workshop press, e.g. -V.A.G 1290 A Tensioning pliers, e.g. -V.A.G 1682 Sealant -D 454 300 A2-
Removing outer CV joint
Removing drive shaft 40-4 page 1. Remove the joint boot. Drive the CV joint off the drive shaft with a strong blow
of a plastic hammer.
Remove circlip item 16 in 40-4 page 4. Remove the disc spring and thrust ring from the drive
shaft. Installing the inner CV joint
Push the new joint boot onto the drive shaft. Fit the disc spring -1- and the thrust ring -2- onto the
drive shaft. Check fitting position.
Insert new circlip in the groove of the drive shaft. Carefully drive CV joint onto the drive shaft with a
plastic hammer until the compressed circlip expands.
Grease the CV joint and the joint boot 40-4

page 2.
Fit joint boot on the outer joint. Install drive shaft 40-4 page 1.
Note
In view of the hard material (as opposed to rubber) of
the joint boot, which requires the use of a stainless steel-open warm-type clamp, the latter can only be tightened with tensioning pliers, e.g. -V.A.G 1682-.
Tightening torque 20 Nm. Make sure the thread of spindle -A- of the pliers is
smooth. If necessary grease with molykote grease, e.g. MoS2.

If it is not smooth, e.g. if the thread is dirty, the neces-
sary clamping force of the open warm-type clamp is not reached at the given torque.
Tighten the open warm-type clamp on the outer joint

(at the large diameter).
Edition 04.05 S00.5303.18.20
40-4 page 5
40
Apply tensioning pliers, e.g. -V.A.G 1682- as shown.
Make sure the cutting edges of the pliers are positioned in the corners -arrows B- of the warm-type clamp.
FABIA 2000
Chassis
Tighten the warm-type clamp by turning the spindle

with a torque wrench. Do not tilt the pliers during this process. A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers
V.A.G 1682 A
Tighten the warm-type clamp at the small diameter Apply tensioning pliers, e.g. -V.A.G 1682- as shown.
Make sure the cutting edges of the pliers are positioned in the corners -arrows B- of the warm-type clamp.
Tighten the warm-type clamp by turning the spindle

with a torque wrench. Do not tilt the pliers during this process. A - Spindle of tensioning pliers B - Cutting edges of tensioning pliers C - Torque wrench Removing inner CV joint
S40-0078
MP 3-448
Removing drive shaft 40-4 page 1. Open warm-type clamp. Remove joint boot from CV joint with drift. Remove the circlip from the drive shaft. Press CV joint off the drive shaft. Do this while supporting the ball joint. Remove the disc spring from the drive shaft.
MP 3-407
S40-0098
Installing the inner CV joint
Fit the disc spring -1- onto the drive shaft.

Check fitting position.
40-4 page 6
Edition 04.05 S00.5303.18.20
FABIA 2000
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Push the new joint boot onto the drive shaft. Press CV joint onto the drive shaft up to the stop.
Note Chamfer on inner diameter of the ball hub (serration) must point towards the bearing collar of the drive shaft.
MP 6-428
MP 6-429
Fit new circlip on the drive shaft. For this use e.g. the
circlip pliers -VW 161 A-.
Coat the edge of the inner joint boot cap with sealant
-D 454 300 A2-.
MP 3-407
MP 3-406
Fit joint boot on the constant velocity joint.

Note
In view of the hard material (as opposed to rubber) of
S40-0099
the joint boot, which requires the use of a stainless steel-open warm-type clamp, the latter can only be tightened with tensioning pliers, e.g. -V.A.G 1682-.
Tightening torque 20 Nm. Make sure the thread of spindle -A- of the pliers is
smooth. If necessary grease with molykote grease, e.g. MoS2.

If it is not smooth, e.g. if the thread is dirty, the neces-
sary clamping force of the open warm-type clamp is not reached at the given torque.
Inspecting a CV joint
Disassembling and inspecting the outer CV joint Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected for wear and damage.
With an electric stylus or rubstone mark the position of

the ball hub relatively to the ball cage and housing before disassembling -arrow-.
Rotate the ball hub and ball cage. Remove the balls one after the other.
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40
Turn the cage until two rectangular cage windows -arrow- rest on the joint part.
FABIA 2000
Chassis
Remove cage with hub.
Turn the hub segment in opening of the cage. Tilt hub out of cage.
Note
The 6 balls of each joint belong to a tolerance group.
Inspect the axle studs, hub, cage and balls for small depressions (pitting = point erosion) and seizing marks. Load alteration shocks indicate too much torsional clearance in the joint. If this is the case, replace the joint. Smoothing and bearing marks do not justify a joint replacement.
Inspect the cage for tears.
Assembling the outer CV joint
Install drive shaft 40-4 page 1. Press the required grease mass into the joint part
40-4 page 2
Insert the cage and hub in the joint body.

Note The cage must be inserted in the correct position.
Press in opposite balls one after the other, during this

process observe the prior position of the ball hub relatively to the ball cage and to the joint part.
Insert new circlip in the groove of the shaft. Spread any residual grease in the joint boot 40-4
page 2.
Installing the joint boot 40-4 page 5.

Disassembling and inspecting the inner CV joint Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected for wear and damage.
40-4 page 8
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Note The ball hub and joint piece are paired and must be marked before disassembly. Do not interchange the bearing track assignment.
Rotate the ball hub and ball cage. Press the ball hub and ball cage out of the joint part in
the direction of the arrow.
Press out the balls from the cage.
Tilt the ball hub out of the ball cage over the ball bearing track -arrows-.
Inspect the joint part, ball hub, ball cage and balls for
small broken out depressions (pitting = point corrosion) and seizing marks. Note Load alteration shocks indicate too much torsional clearance in the joint. If this is the case, replace the joint. Smoothing and bearing marks do not justify a joint replacement. Assembling the inner CV joint
Insert the ball hub in the ball cage over the two chamfers. The fitting location is random. Press the balls into the cage.
Insert the hub with cage upright into the joint part.
Edition 04.05 S00.5303.18.20
40-4 page 9
40
Note When inserting make sure the greatest distance -a- on the joint part is close to the short distance -b- on the hub after it has been swivelled in -arrow-.
FABIA 2000
Chassis
Swivel in the ball hub, to do so swivel the hub out of

the cage -arrows- until the balls are at bearing track distance.
Lock the hub with the balls into position by exerting

considerable pressure on the cage -arrow-. Inspecting the operation of the CV joint The CV joint is correctly assembled if the ball hub can be rolled by hand up and down the entire linear compensation.
Install drive shaft 40-4 page 5. Press the required grease mass into the joint part
40-4 page 2 page 2.
Spread any residual grease in the joint boot 40-4 Installing the joint boot 40-4 page 5.
40-4 page 10
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40
40-5
Drive shafts with tripod joint
Removing and installing a drive shaft

Chapter 40-4
V - Summary of components of drive shaft with AAR2000 tripod joint

Grease quality and grease quantity
Note
The outer joints of the drive shaft must be filled with
grease for operating at normal temperatures, e.g. -N 052 738 00-.

Only use high-temperature grease from the relevant
repair kit for filling the CV joint Spare Parts catalogue. Grease of which in: Joint [g] 100
+10
Outer joint mm 100 Tripod joint mm 108
Total amount [g] 100

+10
Joint boot [g] ---
110 +5
110 +5
---
Note
Assignment of the drive shafts Spare part cata-
logue
Grease joint if necessary, when replacing the joint
boot.
On tripod joints only apply grease in the joint; the
grease should never let in the grease boot. Of all of the grease used, half should be pressed into the front side of the joint and the other half on the rear side of the tripod joint.
Edition 04.05 S00.5303.18.20
40-5 page 1
40
1 - Joint boot for the joint inspect for tears and chafing points assignment Spare part catalogue 2 - Warm-type clamp replace tensioning Chapter 40-4 3 - Screw replace after each removal initially tighten to 10 Nm, subsequently tighten crosswise to final torque: M 10 = : For vehicles 04.03 70Nm For vehicles 05.03 Tighten 50 Nm + 45 M8=: For vehicles 04.03 40Nm For vehicles 05.03 Tighten 20 Nm + 90 assignment Spare part catalogue 4 - Shim assignment Spare part catalogue 5 - Joint part grease 40-5 page 1 assignment Spare part catalogue 6 - Tripod spider with rollers Chamfer -arrow- points towards the drive shaft serration 7 - Circlip replace insert in the shaft groove 8 - O-ring seal replace 9 - Cover replace 10 - Hose clamp for tripod joint replace tensioning 40-5 page 5 11 - Joint boot for tripod joint inspect for tears and chafing points assignment Spare part catalogue 12 - Drive shaft assignment Spare part catalogue 13 - Warm-type clamp replace tensioning Chapter 40-4
FABIA 2000
Chassis
40-5 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
14 - Disc spring Fitting location Chapter 40-4 15 - Thrust ring Fitting location Chapter 40-4 16 - Circlip replace insert in the shaft groove 17 - Outer CV joint must be replaced completely removing Chapter 40-4 Installing: carefully drive onto the shaft with a plastic hammer until the compressed circlip expands greasing Chapter 40-4 inspect Chapter 40-4 Do not grease thread of the outer joint of the drive shaft. assignment Spare part catalogue 18 - Thrower ring 13" chassis - black 14" and 15" chassis - white 19 - Twelve-point nut 13" chassis - black, 50 Nm 14" and 15" chassis - silvery, 50 Nm + 45 replace after each removal
Inspecting outer CV joint

Chapter 40-4
Repairing the drive shaft with AAR 2000 tripod joint

Pressure plate -MP 3-406 Pressure plate -MP 3-407 Thrust piece -MP 3-408 Distance sleeve -MP 3-458/2 Thrust piece -MP 6-405 Strutting bushing -MP 6-428 Clamping device -MP 6-429 Pliers -3340 Circlip pliers (commercially available) Workshop press, e.g. -V.A.G 1290 A-
Disassembling the AAR 2000 tripod joint
Removing the drive shaft Chap. 40-4. Open hose clamp on joint part.
Edition 04.05 S00.5303.18.20
40-5 page 3
40
Straighten the metal tabs -arrows- with a screwdriver
and lever off cover.
FABIA 2000
Chassis
S40-0145
Remove O-ring seal -arrow- from the slot. Mark the fitting position of parts -1...3-.
1 - Joint part 2 - Tripod spider 3 - Drive shaft Note
If parts -1...3- are not marked and if they are not fitted
in their original position again this could cause noises during driving at a later stage.
Use a waterproof marker for marking.
Clamp the drive shaft in a vice with protective jaws. Removing the circlip.
1 - Circlip pliers (commercially available)
S40-0148
40-5 page 4
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
40
Hold the joint part and remove drive shaft from the
vice.
Insert the drive shaft in the press. Hold the drive shaft and push tripod spider off the
drive shaft.
MP 6-405
Remove the tripod spider with rollers and lay aside on

a clean surface.
Remove the joint part from the drive shaft. Remove the joint boot from the drive shaft. Clean the drive shaft and the joint part.
Assembling the AAR 2000 tripod joint
MP 3-406
Insert the joint boot on the drive shaft. Insert the joint part on the drive shaft.
MP 6-428
Note Chamfer on the tripod spider must point towards the drive shaft. Chamfer serves as an assembly aid item 6 in 40-5 page 2.
S40-0144
Position the tripod spider on the drive shaft according

to the markings and press on up to the stop.
Insert new circlip and pay attention to correct position. Slide the joint part over the rollers and hold down. Remove the drive shaft from the special tool and
clamp in the vice.
MP 3-408 MP 3-458/2
MP 3-407 MP 3-406 MP 6-429
S40-0143
Edition 04.05 S00.5303.18.20
40-5 page 5
40
Press 60 grams of -Hochtemperaturfett- from the repair kit into the tripod joint (on the tripod spider side) -arrow A-.
FABIA 2000
Chassis
Press 60 grams of -Hochtemperaturfett- from the repair kit in the rear of the tripod joint -arrow B-.
Installing the joint boot.

Note The bead in the joint boot must fit into the groove of the joint part.
Remove drive shaft from the vice and clamp the joint
part.
S40-0106
Insert new gasket ring -arrow- from the repair kit in the
groove.
Fit the new cover on the joint part.

Note The bores of the cover and joint part must be flush.
Fit the hose clamp.
Removing and installing the outer CV joint

Chapter 40-4
40-5 page 6
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
42
42 Rear wheel suspension

42-1 Rear axle with drum brake
Summary of components of rear axle

Note
Welding and straightening on axle body and axle studs not allowed. Always replace the self-locking nuts and bolts. Always replace corroded self-locking nuts and screws. Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
1 - Wheel bolt, 120 Nm Allocation Spare parts catalogue 30 2 - Screw, 4 Nm 3 - Brake drum reset brake before removing the brake drum Chapter 46-2 29 4 - Cap replace after each removal pressing off and inserting Chapter 42-5 5 - Twelve-point nut, self-locking, 70 Nm and turn a further 30 (1/12 turn) 15 replace after each removal 6 - Wheel hub with wheel bearing for vehicles with ABS the 14 sensor ring is built into the wheel hub 13 wheel hub and wheel bearing form one unit; it does not need servicing. the sensor ring for ABS cannot be replaced individually removing and installing Chapter 42-5 Allocation Spare parts catalogue 7 - Screw, 30 Nm + torque a fur10 ther 90 (1/4 turn) replace after each removal 8 - Brake carrier with brake shoe repairing Chapter 46-2 9 - Holder for hand-brake cable replace after each removal Fitting location Chapter 46-3 10 - Hand-brake cable removing and installing Chapter 46-3
32 31 28 27 23 26 25 24
33 34
22 20
21 19
12 16 12 11
18 17 8 7
1 9 6 5 4 3
S42-0122
Edition 03.02 S00.5303.11.20
Rear axle with drum brake
42-1 page 1
42
FABIA 2000
Chassis
11 - Bracket for brake-power regulator attached to the vehicle body 12 - Screw, 20 Nm 13 - Brake-power regulator load dependent for vehicles without ABS inspecting and setting Chapter 47-3. 14 - Screw, 16 Nm 15 - Screw, 16 Nm 16 - Holder for hand-brake cable 17 - Bonded rubber bush removing and installing Chapter 42-2 18 - Axle body Allocation Spare parts catalogue The locating face and the threaded holes for axle studs must be free from enamel and dirt removing and installing 42-1 page 3 19 - Axle stud Straightening work is not allowed! Re-cutting the thread is not allowed! removing and installing Chapter 42-5 20 - Brake line Tightening torque of the pipe screws: 14 Nm 21 - Axle body Allocation Spare parts catalogue The locating face and the threaded holes for axle studs must be free from enamel and dirt 22 - Self-locking nut replace after each removal 23 - Screw, 40 Nm + torque a further 90 (1/4 turn) replace after each removal insert from the inside of the vehicle For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight Chapter 44-2, then place a weight of 90 kg in the luggage compartment, immediately behind the rear seat. This operation can be skipped if the shock absorber and rear suspension are preassembled Chapter 42-2. 24 - Speed sensor ABS Allocation Spare parts catalogue 25 - Plug for vehicles without ABS to plug the hole in the axle stud 26 - Allan screw, 8 Nm for speed sensor ABS 27 - Bottom spring base inspect for damage (visual inspection) 28 - Screw, 45 Nm + torque a further 90 (1/4 turn) replace after each removal insert from the outside of the vehicle For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight Chapter 44-2, then place a weight of 90 kg in the luggage compartment, immediately behind the rear seat. 29 - Self-locking nut replace after each removal 30 - Mount for rear axle attached to the vehicle body
42-1 page 2
Edition 03.02 S00.5303.11.20
FABIA 2000
Chassis
42
31 - Helical spring removing and installing Chapter 42-2 check for paint damage, if necessary eliminate paint damage check colour coding Allocation Spare parts catalogue replace axle-wise per rear axle only use helical springs of the same make 32 - Top spring base installing Chapter 42-2 33 - Screw, 30 Nm + torque a further 90 (1/4 turn) replace after each removal 34 - Shock absorber removing and installing Chapter 42-2 inspecting Chapter 40-2 disposal Chapter 40-2 can be replaced individually Allocation Spare parts catalogue per rear axle only use shock absorbers of the same make
Fitting location of the shock absorber on the rear axle

If shock absorber -1- is preassembled to the rear ax-
les -2-, pay attention to the installed angle -- = 97.

torque.
It is not necessary to initially tighten the bolt and to
place a weight of 90 kg in the vehicle.
Removing and installing rear suspension

Torque wrench Brake pedal arrester, e.g. -V.A.G 1238 B- or brake
pedal load-V.A.G 1869/2 Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
-V.A.G 1359/2 Spring tensioning device, e. g. -V.A.G 1752/1 Spring holder with protective lining, e. g. -V.A.G 1752/
2
S42-0145
3 Securing strap, e. g. -T10038 Brake filling and bleeding device, e. g.
-ROMESS S15 Wooden block 490 x 270 x 50 mm for attachment
-V.A.G 1359/2 Assembly paste -G052 150 A2-
Removing
Remove wheels.
Edition 03.02 S00.5303.11.20 Rear axle with drum brake
42-1 page 3
42
Removing the centre console Body Work;
Rep. Gr. 68.
FABIA 2000
Chassis
Actuate the brake pedal and insert the brake pedal depressor. This prevents the brake line and the ABS hydraulic unit from running empty of brake fluid.
Release adjusting nut -arrow- and unhook hand-brake

cable from compensating clamp.
Pull hand-brake cables out of guide tubes.

Caution!
Before removing the rear suspension, the vehicle
must be lashed securely on both sides at the supporting arms of the lift platform.
If the vehicle is not lashed, there is a risk of the
S46-0096
vehicle toppling off the lift platform.
Remove the plugs from the frame side rail and the pull
in the securing strap 1 - Supporting arm of lift platform 2 - Securing strap, e. g. -T10038-
1 2 1
Lash the vehicle on both sides to the supporting arms
of the lift platform.
Pull out the plug connector from the oil pressure

switch.
N42-0390
Unclip cable for wheel speed sensor from the fixture. Unhook handbrake cable from the holders -arrows-. Detach clip -2- from brake hose fixture. Separate brake line. Note
Seal brake lines with plugs.
1
Only on vehicles equipped with Xenon headlights
Disconnect the tension rod for the sender at the rear

of the assembly carrier Electrical System; Rep. Gr. 94.
S42-0147
42-1 page 4
Edition 03.02 S00.5303.11.20
FABIA 2000
Chassis
42
Only on vehicles fitted with load-sensitive brake pressure regulator (without ABS)
Screw out bolt -1-.
Remove coil spring Chapter 42-2. Slacken the front attachment of the wheelhouse liner
at the rear Body Work; Rep. Gr. 66. - V.A.G 1359/2-.
S42-0148
Insert wooden block -A- into attachment, e. g. Support rear axle with gearbox jack and attachment.
Note A second person is required for the further removal operations.
V.A.G 1359/2 A
Unbolt rear suspension from shock absorbers -arrows-.
Secure rear suspension at attachment, e. g. with strap

of attachment V.A.G 1359/2.
V.A.G 1383 A
N42-0130
Screw out the bolts -1- of the bearing bracket of the

rear axle and lower the rear axle.
Installing
Installation is carried out in the reverse order. Pay attention to the following:
Before inserting the rear suspension, grease the kidney-shaped cavities of the bonded rubber bushes with assembly paste - G052 150 A2 -.
S42-0147
Edition 03.02 S00.5303.11.20
42-1 page 5
42
Note
The bolts of the bearing bracket of the rear suspen-
FABIA 2000
Chassis
sion must not be inserted into the profiles of the inner core -arrows- of the bonded rubber bush. If this is done, the rear suspension will be installed skewed and the bush will be damaged. In this case, the bush must be replaced.
To provide a clearer illustration, the bonded rubber
bush is shown with the rear suspension removed.

The axle beam should be moved into the horizontal
position when tightening the bolts and nuts of the bearing bracket of the rear suspension and the shock absorber. Place the vehicle onto its wheels for this step, ensure vehicle is at unladen weight Chapter 44-2 and place a weight of 90 kg in the luggage compartment, immediately behind the rear seat.
S42-0150
Install shock absorber Chapter 42-2. Install new nuts and bolts on the front axle mounting
but do not tighten up completely.
Install coil spring Chapter 42-2. Install a new clamp for attaching the brake line. Adjust handbrake Chapter 42-2. Bleed brake system Chapter 47-4. If fitted, inspect the load-sensitive brake pressure regulator and set if necessary Chapter 47-3. such a way before tightening up so that the sender lever points towards the rear when whipping the rear axle and does not turn upwards.
If fitted, adjust the upper position of the tension rod in
Tighten up the screw of the bearing bracket of the rear

axle fully to the specified tightening torque. Place vehicle onto its wheels and ensure it is at its unladen weight Chapter 44-2. Then place a 90 Kg weight in the luggage compartment immediately behind the rear seat.

Tightening torques:
Brake line to brake hose Shock absorber to rear suspension
14 Nm 40 Nm +90
Rear suspension to bearing bracket

45 Nm +90
Brake pressure regulator to rear suspension The sender at the rear on the rear axle Wheel bolts
16 Nm 16 Nm 120 Nm
42-1 page 6
Edition 03.02 S00.5303.11.20
FABIA 2000
Chassis
42
42-2
Servicing the rear axle with drum brakes
Removing and installing coil spring

Spring tensioning device, e. g. -V.A.G 1752/1 Spring holder with protective lining, e. g. -V.A.G 1752/
3-
Removing
Note The rear silencer must be taken off in order to remove the left coil spring.
V.A.G 1752/1
Removing the rear silencer Engine - Mechanics;

Rep. Gr. 26. Note
Ensure that the spring holders are positioned as close
as possible to the spring coils -arrow-.

During the tensioning operation, ensure that the
V.A.G 1752/3 2 1 V.A.G 1752/3
S42-0149
spring holder is correctly located at the spring coils.

Do not use impact screw drivers.
Insert spring tensioning device. Tension coil spring sufficiently until it can be removed. Remove coil spring.
1 - top base 2 - Mount for top base
Installing
Check to ensure that the zinc base (bottom base) is

not damaged. Replace if necessary.
V.A.G 1752/1
S42-0146
Install the helical spring along with the top base.

The beginning of the spring -arrow- must be positioned at the stop at the top of the base.
Release the tension of the coil spring and remove the

spring tensioner (do not damage surface protection for the coil spring).
Edition 04.04 S00.5303.15.20
42-2 page 1
42
Removing and installing shock absorber
Torque wrench Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
FABIA 2000
Chassis
-V.A.G 1359/2-
Removing
Remove wheel. Place gearbox jack with attachment below and support rear suspension at shock absorber mounting.
Only on vehicles equipped with an Xenon headlights

of the assembky carrier Electrical System; Rep. Gr. 94.
Remove bolts -1- and -2-. Take out shock absorber.

Installing
Installation is carried out in the reverse order. Pay attention to the following:
Install a bolt on the shock absorber for the rear axle

and tighten by hand.
If fitted, adjust the upper position of the tension rod in

such away before tightening up so that the sender lever points towards the rear when whipping the rear axle and does not turn upwards.
Place vehicle onto its wheels and ensure it is at its unladen weight Chapter 44-2.
Then place a 90 kg weight in the luggage compartment immediately behind the rear seat bench.

torque.
V.A.G 1383A
30 Nm + 90
V.A.G 1359/2
S42-0040
Tightening torques:
Shock absorber to body
Use new screws!
Shock absorber to rear suspension

40 Nm + 90
Wheel bolts
120 Nm
42-2 page 2
Edition 04.04 S00.5303.15.20
FABIA 2000
Chassis
42
Disassembling and assembling shock absorber

Note The shock absorbers must not be disassembled and repaired. 1 - Shock absorber can be replaced individually removing and installing 42-2 page 2 assignment Spare part catalogue disposal Chapter 40-2 inspect Chapter 40-2 2 - Protective cap 3 - Protective tube 4 - Stop buffer 5 - Shock absorber bushing 6 - Self-locking nut, 25 Nm replace after each removal counterhold the piston rod of the shock absorber at the tip in order to slacken and tighten the nut 7 - Cover
7 6
3 1 2
S42-0152
Inspecting the shock absorber

Chapter 40-2
Disposing of the shock absorber

Chapter 40-2
removing and installing rubber-metal bearing

Universal tool -MP 3-419 Axial bearing -MP 5-402-
Edition 04.04 S00.5303.15.20
42-2 page 3
42
Assembly device, e. g. -MP 5-400 Assembly device, e. g. -MP 5-401 Assembly device, e. g. -MP 6-430 Torque wrench Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
FABIA 2000
Chassis
-V.A.G 1359/2 Wooden block 490 x 270 x 50 mm for attachment
-V.A.G 1359/2 Securing strap, e. g. -T10038-
Removing
Note It is only possible to replace the bonded rubber bush when the rear suspension is lowered.
Remove wheels.
Caution!
Before removing the rear suspension, the vehicle
must be lashed securely on both sides at the supporting arms of the lift platform.
If the vehicle is not lashed, there is a risk of the
vehicle toppling off the lift platform.
Remove the plugs from the frame side rail and the pull
in the securing strap 1 - Supporting arm of lift platform 2 - Securing strap, e. g. - T10038-
Lash the vehicle on both sides to the supporting arms

of the lift platform.
Unhook handbrake cable from the holders -arrows-. Detach clip -2- from brake hose fixture. Release brake line from fixture, on no account separate.
Only on vehicles equipped with an Xenon headlights

of the assembky carrier Electrical System; Rep. Gr. 94.
S42-0147
42-2 page 4
Edition 04.04 S00.5303.15.20
FABIA 2000
Chassis
42
Only on vehicles fitted with load-sensitive brake pressure regulator (without ABS)
Release screw -1-. Slacken the front attachment of the wheelhouse liner
at the rear Body Work; Rep. Gr. 66.
Remove coil spring 42-2 page 1.

Insert wooden block into attachment, e. g.

-V.A.G 1359/2-.
Support rear axle with gearbox jack and attachment.

S42-0148
Note A second person is required for the further removal operations.
Secure the rear axle with the strap of the attachment. Screw out bolts -1- on the bearing bracket of the rear
axle.
Swivel rear suspension on both sides down and out of

the bearing brackets. Note
When lowering the rear axle, ensure that the brake
lines and handbrake cables are not tensioned.

Lower rear suspension only sufficiently to gain clear
access to the rubber-metal bearing.
S42-0147
Lower rear suspension. Insert special tools as shown and pull out rubber-metal bearing. Note A second mechanic must counterhold at the rear axle when pulling out the rubber-metal bearing.
MP 5-400/2
MP 3-419
S42-0143
Edition 04.04 S00.5303.15.20
42-2 page 5
42
Installing
Fabia RS The axle -1- must be aligned with the edge -arrow- of the trailing arm -2-.
FABIA 2000
Chassis
2
Other vehicles (except Fabia RS) The rubber-metal bearing has a marking -1- on the inside. This marking must be aligned with the edge -arrow- of the trailing arm -2-.
S42-0160
Mark the position of the marking -1- on the rubbermetal bearing.
2
Fabia RS
1
S42-0151
Insert special tools together with rubber-metal bearing

as shown.
42-2 page 6
Edition 04.04 S00.5303.15.20
FABIA 2000
Chassis
42
Other vehicles (except Fabia RS)
Insert special tools together with rubber-metal bearing

as shown. For all vehicles
Ensure that the marking or the axle is aligned with the

edge of the trailing arm.
Pull the rubber-metal bearing -2- onto the spindle by

turning.
Verify the installed position of the mounting once the

installation is complete. If the marking or the axle is not aligned with the edge of the trailing arm, it is then necessary to repeat removal and installation. Further installation occurs in reverse order. Pay attention to the following:
Before inserting the rear suspension, grease the kidney-shaped cavities of the rubber-metal bearing with assembly paste -G 052 150 A2-. Note
The bolts of the bearing bracket of the rear suspen-
sion must not be inserted into the profiles of the inner core -arrows- of the rubber-metal bearing. If this is done, the rear suspension will be installed skewed and the bush will be damaged. In this case, the rubber-metal bearing must be replaced.
To provide a clearer illustration, the rubber-metal
bearing is shown with the rear suspension removed.
Install new nuts and bolts on bearing bracket of the

rear axle and tighten by hand. Note The axle beam should be moved into the horizontal position when tightening the bolts and nuts. Place the vehicle onto its wheels for this step, ensure vehicle is at unladen weight Chapter 44-2 and place a weight of 90 kg in the luggage compartment, immediately behind the rear seat bench.
S42-0150
Install coil spring 42-2 page 1. If fitted, adjust the upper position of the tension rod in
such away before tightening up so that the sender lever points towards the rear when whipping the rear axle and does not turn upwards.
Install a new clamp for attaching the brake line. Tighten up the screw of the bearing bracket of the rear
axle fully to the specified tightening torque. Place vehicle onto its wheels and ensure it is at its unladen weight Chapter 44-2. Then place a 90 kg weight in the luggage compartment immediately behind the rear seat bench.
Edition 04.04 S00.5303.15.20
42-2 page 7
42
Tightening torques:
Rear suspension to bearing bracket
FABIA 2000
Chassis
45 Nm + 90
Brake pressure regulator to rear suspension The sender at the rear on the rear axle Wheel bolts
16 Nm 16 Nm 120 Nm
42-2 page 8
Edition 04.04 S00.5303.15.20
FABIA 2000
Chassis
42
42-3
Rear suspension with disc brake
Summary of components of rear suspension

Note
Welding and straightening on axle beam and axle stubs not allowed. Always replace the self-locking nuts and bolts. Always replace corroded self-locking nuts and bolts. Always tighten pipe connections of brake lines to a torque of 14 Nm.
1 - Brake caliper repairing Chap. 47-1 2 - Wheel bolt, 120 Nm 25 Assignment Spare part catalogue 3 - Cross-head screw, 4 Nm 4 - Brake disc 24 5 - Cap replace each time removed pressing off and inserting Chap. 42-5 6 - Twelve-point nut, self-locking, 70 Nm + torque a further 30 (1/12 turn) replace each time removed 7 - Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub Wheel hub and wheel bearing form one unit. The unit is maintenance-free. Adjusting and repairs are not possible. The sensor ring for ABS cannot be replaced individually removing and installing Chap. 42-5 Assignment Spare part catalogue 8 - Hexagon bolt + washer, 30 Nm + torque a further 90 (1/4 turn) replace each time removed 9 - Cover plate 10 - Fixture for handbrake cable replace each time removed Fitting location Chap. 46-3 11 - Handbrake cable removing and installing Chap. 46-3 12 - Fixture for handbrake cable 13 - Bonded rubber bush removing and installing Chap. 42-2 14 - Axle beam Assignment Spare part catalogue
Edition 02.01 S00.5303.07.20
27 26 23 22 21 20 19
28 29
18 17 16 15
14 12 13 1
2 11 10 9 8 7 6 5 4 3
S42-0123
42-3 page 1
42
FABIA 2000
Chassis
The locating face and the threaded holes for axle stubs must be free from enamel and dirt 15 - Axle stub Straightening work is not allowed! Re-cutting the thread is not allowed! removing and installing Chap. 42-5 16 - Hexagon bolt, 30 Nm + torque a further +30 (1/12 turn) 17 - Brake line with connection, banjo bolt and seals must not be disassembled, must be replaced completely Tightening torque of banjo bolt: 35 Nm do not unscrew when replacing the brake pad 18 - Self-locking hexagon nut replace each time removed 19 - Hexagon bolt, 40 Nm + torque a further 90 (1/4 turn) replace each time removed insert from the inside of the vehicle For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight Chap. 44-2, then place a weight of 90 kg in the luggage compartment, immediately behind the rear seat. This operation can be deleted if shock absorber and rear suspension are preassembled, while maintaining the correct installation angle Chap. 42-2. 20 - Speed sensor ABS Assignment Spare part catalogue 21 - Hexagon socket bolt, 8 Nm for speed sensor ABS 22 - Bottom spring base inspect for damage (visual inspection) 23 - Hexagon bolt, 45 Nm + torque a further 90 (1/4 turn) replace each time removed insert from the outside of the vehicle For tightening fully, place vehicle onto its wheels and ensure it is at unladen weight Chap. 44-2, then place a weight of 90 kg in the luggage compartment, immediately behind the rear seat. 24 - Self-locking hexagon nut replace each time removed 25 - Mount for rear suspension welded to body 26 - Coil spring removing and installing Chap. 42-4 check for paint damage, if necessary eliminate paint damage check colour coding Assignment Spare part catalogue always replace on both sides of axle use only coil springs of the same make on an axle 27 - Top spring base installing Chap. 42-4 28 - Hexagon bolt, 30 Nm + torque a further 90 (1/4 turn) replace each time removed 29 - Shock absorber removing and installing Chap. 42-4 inspecting Chap. 40-2 disposal Chap. 40-2 can be replaced individually Assignment Spare part catalogue use only shock absorbers of the same make on an axle
42-3 page 2
Edition 02.01 S00.5303.07.20
FABIA 2000
Chassis
42
Fitting location of shock absorber of rear suspension

Chap. 42-1
Removing and installing rear suspension

Chap. 42-1
Edition 02.01 S00.5303.07.20
42-3 page 3
42
FABIA 2000
Chassis
42-3 page 4
Edition 02.01 S00.5303.07.20
FABIA 2000
Chassis
42
42-4
Servicing rear suspension with disc brake
Chap. 42-2
Edition 02.01 S00.5303.07.20
42-4 page 1
42
FABIA 2000
Chassis
42-4 page 2
Edition 02.01 S00.5303.07.20
FABIA 2000
Chassis
42
42-5
Summary of components of wheel bearing - drum brake

1 - Phillips screw, 4 Nm 2 - Brake drum 3 - Cap replace after each removal extracting and inserting 42-5 page 1 4 - Self-locking twelve-point nut, 70 Nm and tighten a further 30 replace after each removal 5 - Wheel hub with wheel bearing Wheel hub with wheel bearing form one unit. The unit is maintenance-free. Adjusting and repairs are not possible. removing and installing 42-5 page 1 Assignment Spare Part Catalogue 6 - Axle body 7 - Brake carrier with brake shoe removing and installing Chap. 46-2 8 - Tighten combination hexagon screw 30 Nm and 90 replace after each removal 9 - Axle stud Straightening work is not allowed! Re-cutting the thread is not allowed! removing and installing 42-5 page 6
8 9
2 1
S42-0124
Removing and installing the wheel hub with wheel bearing - drum brake
Drive bushing -MP 3-427 Hub cap extractor -MP 5-404 Torque wrench (40...200 Nm), e.g. -V.A.G 1332 Torque wrench (4...20 Nm), e.g. -V.A.G 1410 Torque wrench, e.g. - V.A.G 1756-
Removing
Raise vehicle.
Edition 11.00 S00.5303.05.20
42-5 page 1
42
Unscrew rear wheel. Resetting brake. To this end use a screwdriver to push the wedge up
through a hole for the wheel screws in the brake drum.
FABIA 2000
Chassis
Unscrew the Phillips head screws of the drum brake

and remove drum brake.
S42-0031
Release cap from its position by gently tapping the

claw of the hub cap extractor.
MP 5-404
S42-0125
Press off cap. Release twelve-point nut. Remove wheel hub with wheel bearing from axle stud.
Caution! On vehicles with ABS make sure the sensor ring is not damaged.
MP 5-404
Installing
Carefully slide the wheel hub with wheel bearing onto

the axle stud up to the stop.
S42-0126
42-5 page 2
Edition 11.00 S00.5303.05.20
FABIA 2000
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42
Caution! On vehicles with ABS make sure the sensor ring is not damaged. Note
Do not tilt the wheel hub with wheel bearing on the
axle stud.
Use new twelve-point nuts. Replace cap after each removal. Damaged caps allow moisture to penetrate.
Further installation occurs in reverse order.
Drive in new cap.

Tightening torques:
Twelve-point nut to axle stud
Use new nut!
70 Nm + 30
Drum brake to wheel hub Wheel bolts
4 Nm 120 Nm
MP 3-427
S42-0127
Edition 11.00 S00.5303.05.20
42-5 page 3
42
Summary of components of wheel bearing - disc brake
1 - Phillips screw, 4 Nm 2 - Brake disc 3 - Cap replace after each removal extracting and inserting 42-5 page 4 4 - Self-locking twelve-point nut, 70 Nm and tighten a further 30 replace after each removal 5 - Wheel hub with wheel bearing Wheel hub with wheel bearing form one unit. The unit is maintenance-free. Adjusting and repairs are not possible. removing and installing 42-5 page 4 Assignment Spare Part Catalogue 6 - Axle body 7 - Allan screw, 30 Nm +30 8 - Cover plate 9 - Brake carrier with brake caliper 10 - Axle stud Straightening work is not allowed! Re-cutting the thread is not allowed! removing and installing 42-5 page 6 11 - Tighten combination hexagon screw 30 Nm and 90 replace after each removal
FABIA 2000
Chassis
10 11
2 1
S42-0128
Removing and installing the wheel hub with wheel bearing - disc brake
Removing
Raise vehicle. Unscrew rear wheel.
42-5 page 4
Edition 11.00 S00.5303.05.20
FABIA 2000
Chassis
42
Release cap from its position by gently tapping the

claw of the hub cap extractor.
MP 5-404
S42-0060
Press off cap.
MP 5-404
S42-0061
Unscrew screws -A-, remove brake caliper and tie up

with wire or anything similar. Note Do not unscrew the brake hose to remove the brake caliper.
Unscrew the Phillips head screws of the brake disc

and remove brake disc.
Unscrew the twelve-point nut. Remove wheel hub with wheel bearing from axle stud.
S42-0062
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42-5 page 5
42
Caution! On vehicles with ABS make sure the sensor ring is not damaged.
FABIA 2000
Chassis
Installing
Carefully slide the wheel hub with wheel bearing onto

the axle stud up to the stop. Caution! On vehicles with ABS make sure the sensor ring is not damaged. Note
Do not tilt the wheel hub with wheel bearing on the
axle stud.
Use new twelve-point nuts. Replace cap after each removal. Damaged caps allow moisture to penetrate.
Further installation occurs in reverse order.
Drive in new cap.

Tightening torques:
Brake carrier with brake caliper to axle body Twelve-point nut to axle stud
Use new nut!
30 Nm +30 70 Nm +30
Brake disc to wheel hub Wheel bolts
4 Nm 120 Nm
MP 3-427
S42-0129
Removing and installing axle studs

The following special tools and aids are only required for vehicles with drum brakes.
Vehicle system tester -V.A.G 1552- (only for vehicles
with ABS/TCS)
Diagnostic cable -V.A.G 1551/3 Brake pedal arrester, e.g. -V.A.G 1238 B- or brake
pedal load device, e.g. -V.A.G 1238 B-
42-5 page 6
Edition 11.00 S00.5303.05.20
FABIA 2000
Chassis
42
Brake filling and bleeding device. -ROMESS S15 Bleeding bottle (commercially available) Brake fluid Chap. 00-3
Note
Straightening work on axle studs is not allowed! Re-cutting the axle stud thread is not allowed!
Removing and installing the axle stud - Drum brake
Removing the wheel hub with wheel bearing 42-5

page 1.
Release hexagon screws -arrows-. Removing the brake carrier with brake shoe Chap.
46-2.
Remove the axle stud.

The installation occurs in reverse order.
Bleeding brake system Chap. 47-4.

Tightening torques:
Axle stud to axle body
Use new screws!
30 Nm + 90
S42-0130

Use new nut!
70 Nm + 30
Drum brake to wheel hub Brake line to wheel brake cylinder Wheel bolts
4 Nm 14 Nm 120 Nm
Removing and installing the axle stud - Disc brake
Removing the wheel hub with wheel bearing 42-5

page 4.
Release hexagon screws -arrows-. Remove cover plate and axle stud.
S42-0131
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42-5 page 7
42
Tightening torques:
Axle stud to axle body
Use new screws!
FABIA 2000
Chassis
30 Nm + 90

Use new nut!
70 Nm + 30
Brake disc to wheel hub Brake carrier with brake caliper to axle body Wheel bolts
4 Nm 30 Nm +30 120 Nm
42-5 page 8
Edition 11.00 S00.5303.05.20
FABIA 2000
Chassis
44
44 Wheels, Tyres, Chassis Alignment

44-1 Wheels, Tyres
Wheel/tyre combinations Chap. 00-4 Further information can be found in the instructions for use.
General points
For safety reasons never change tyres individually but at least in axle pairs. Tyres with the greatest tread depth must always be fitted at the rear. It is recommended to fit tyres of the same make, same type and tread pattern on all wheels. When replacing the disc wheel or the tyre always replace the rubber valve. Note Before installing the wheel, coat the centering of the hub with grease -G 052 753 A2-. Mount the tyre with the DOT marking pointing towards the outside of the wheel. This applies only to the left side of the vehicle for directional tyres. For directional tyres mount a wheel/tyre combination for the right side of the vehicle as spare wheel.
Edition 04.04 S00.5303.15.20
Wheels, Tyres
44-1 page 1
44
Disc wheel
Note
FABIA 2000
Chassis
Because of design variations the disc wheel and wheel trim cap may differ from the figure. When using anti-theft wheel bolts, the anti-theft bolt must be as close as possible to the valve.
1 - Tyres 2 - Wheel rims 5J x 13, ET 35 5J x 14, ET 35 6J x 14, ET 43 6J x 15, ET 43 3 - Wheel bolt, 120 Nm Note When using anti-theft wheel bolts for steel rims, the anti-theft bolt must be mounted in direction of the valve. 4 - Remove wheel trim cap remove with pull-off hook item 5. Note When using anti-theft wheel bolts for steel rims, first assemble the wheel trim cap onto the anti-theft bolt (at valve). Pull-off hook included in tool kit Wheel bolt key 7 8 included in tool kit Balancing weights max. 60 g allowed per rim flange Retaining spring for balancing weights Valve only use valve in accordance with spare part catalogue
1 2 3 4 5
567-
89-
S44-0010
44-1 page 2
Wheels, Tyres
Edition 04.04 S00.5303.15.20
FABIA 2000
Chassis
44
Light-alloy wheel
Light-alloy rim 6J x 14, ET 43
Note Because of design variations the light alloy rim and wheel trim cap may differ from the figure. 1 - Tyres 2 - Light-alloy rim 6J x 14, ET 43 3 - Anti-theft wheel bolt, 120 Nm 4 - Cap for anti-theft wheel bolt item 3 Remove with pull-off hook item 5. 5 - Pull-off shackle included in tool kit 6 - Wheel bolt key 7 - Adapter for anti-theft wheel bolt included in tool kit 8 - Wheel trim cap can only be removed once the wheel has been removed removing and installing Note Do not use a pull-off hook or other tools, e.g. screwdriver as this could damage the wheel trim cap. 11 12 Removing: Push the wheel trim cap towards the outside from the inside of the rim. Installing: Push-in the wheel trim cap from the outside of the rim, it clicks audibly. Cap for wheel bolt item 10 Remove with pull-off hook item 5. Wheel bolt, 120 Nm Balancing weights max. 60 g allowed per rim flange Retaining spring for balancing weights Valve only use valve in accordance with spare part catalogue
1 2 3
8 13 12 11 10 9
S44-0011
9-
10 11 12 13 -
Edition 04.04 S00.5303.15.20
Wheels, Tyres
44-1 page 3
44
Light-alloy rim 6J x 15, ET 43
Note
FABIA 2000
Chassis
Because of design variations the light alloy rim and wheel trim cap may differ from the figure. 1 - Tyres 2 - Light-alloy rim 6J x 15, ET 43 3 - Anti-theft wheel bolt, 120 Nm 4 - Adapter for anti-theft wheel bolt included in tool kit 5 - Wheel bolt, 120 Nm 6 - Wheel trim cover remove with pull-off hook item 7. 7 - Pull-off hook included in tool kit 8 - Wheel bolt key 9 - Balancing weights max. 60 g allowed per rim flange 10 - Retaining spring for balancing weights 11 - Valve only use valve in accordance with spare part catalogue
1 2 3
10
11
10
S44-0012
44-1 page 4
Wheels, Tyres
Edition 04.04 S00.5303.15.20
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44
44-2
Vehicle alignment
General points
The vehicle must only be aligned using an alignment gauge released by the manufacturer! We recommend you align both the front and rear axles during each chassis alignment procedure. Otherwise correct vehicle driving behaviour cannot be guaranteed! Note
Only perform a vehicle alignment after the first 1000 to
2000 km to allow the helical springs to fully settle.

During adjustment work try to approximate the nomi-
nal values. If the fitting position of the rear axle and hence the running direction of the vehicle are not considered this could result in a skew steering wheel. Note
Before removing mark the steering wheel position rel-
atively to the steering column.

This position must not be changed! Otherwise the
central position of the gear rack cannot be guaranteed!

Steering columns supplied as spare parts do not have
dotting marks. These steering columns must be dot marked after chassis alignment and a subsequent test drive.
vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 If the
steering wheel is offset on these vehicles, a null balance of the steering angle sender -G85- is carried out (either using the vehicle system tester -V.A.G 1552 Chapter 45-13 or using the vehicle diagnosis, measurement and information system -VAS 5051 Chapter 45-4).
vehicles with ABS//TCS/ESP BOSCH 8.0 If the steer-
ing wheel is offset on these vehicles, a null balance of the steering angle sender -G85- is carried out (either usng the vehicle system tester -V.A.G 1552 Chapter 45-14or using the vehicle diagnosis, measurement and information system -VAS 5051 Chapter 45-4).
Edition 07.04 S00.5303.16.20
Vehicle alignment
44-2 page 1
44
It is necessary to perform a vehicle alignment in the event of:
incorrect driving behaviour damage caused by accident and if parts have been replaced axle parts have been removed there is unilateral tyre wear
FABIA 2000
Chassis
Front axle part replaced
Chassis alignment required yes no X X X X X X X X
Rear axle part replaced
Chassis alignment required yes no X X X
Axle link Wheel-bearing housing Track rod/track-rod ends Steering gear Assembly carrier Suspension strut or shock absorber or helical spring Console for engine-gearbox assembly carrier Anti-roll bar
Shock absorber Helical spring Complete rear axle
Test requirements
Determining the running gear version according to the
vehicle data sticker Chap. 00-1.
Check the wheel suspension, steering and steering

linkage for unauthorised clearance and damage, if necessary repair.
Check tyre inflation pressure, if necessary correct
Inspection and Maintenance or fuel-tank cap sticker. the left and right tyres on an axle must not exceed 2 mm.
Check the tyre tread depth. The difference between The unladen weight of the vehicle must correspond
with the vehicle documents. Unladen weight: Weight of the vehicle with full fuel tank and full water reservoir for windscreen wiper/washer and headlamp cleaning system, spare wheel, tool kit, jack and without driver. The spare wheel, tool kit and jack must be located in the position prescribed by the vehicle manufacturer.
Vehicle must be aligned, with the springs having been

repeatedly deflected and having returned to their original position.
Make sure that during alignment no sliding base and

no rotating plate touches the limit stop. Note!
The measuring device must be positioned and adjusted in compliance with the specifications; follow the manufacturer's instructions!
44-2 page 2
Vehicle alignment
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44
If necessary obtain information on your alignment gauge from the manufacturer. In the course of time the alignment platform and alignment gauge/alignment computer may deviate from their original adjustment/setting. The alignment platform and alignment gauge/alignment computer must be tested and adjusted during a maintenance operation at least once a year or following the manufacturer's instructions and if necessary be adjusted! Treat these precision instruments with great care.
Measurement preliminaries
Brake pedal arrester, e.g. -V.A.G 1238/B- or
-V.A.G 1869/2 Open-jawed wrench insert waf 22, e.g. -V.A.G 1332/
12 Alignment/measuring gauge Weights, e.g. sand bags approx. 10 kg
The lateral runout on the rims must be balanced (compensated). Otherwise the alignment result will be distorted. Correct toe-in adjustment is impossible if the rim runout has not been compensated! To this end comply with the instructions of the alignment gauge manufacturer.
Perform a rim runout compensation. Lower vehicle and deflect the springs. Fit Brake pedal arrester, e.g. -V.A.G 1238/B- or
-V.A.G 1869/2- and activate the brake pedal with Brake pedal arrester. Overview of the work sequence for vehicle alignment The following sequence of work steps must always be respected! 1 - Find out what chassis has been mounted in the vehicle. This information can be found on the vehicle data sticker Chap. 00-1 2 - Check camber on front axle, if necessary take the mean 44-2 page 4 3 - Check camber on rear axle 44-2 page 5 4 - Check track on rear axle 44-2 page 5 5 - Check track on front axle, if necessary adjust 44-2 page 5 The following always applies! Always check the transversal inclination of the vehicle before adjustment if one of the measuring values is outside the tolerance 44-2 page 4.
S45-0016
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Vehicle alignment
44-2 page 3
44
Chassis terms
Chapter 00-1
FABIA 2000
Chassis
Nominal values for vehicle alignment

Front axle nominal values Chap. 00-1. Rear axle nominal values Chap. 00-1.
Checking the transversal inclination of the vehicle

Transversal inclination of the vehicle: Straightahead position It is possible the vehicle is skew if the measured values lie outside the tolerance for the front and rear axle nominal values Chap. 00-1. RHD vehicles or e. g. vehicles with an automatic gearbox may be slightly skew. This is normal and is due to the fitting locations of the assemblies and the related weight transfer.
Deflect the vehicle repeatedly and allow the springs to

return to their original position. Note Only determine dimension -a- on the rear axle. Determining dimension -a- for the left and right vehicle side. aleft - left vehicle side aright - right vehicle side = 90
Compare dimensions aleft and aright.

The deviation between aleft and aright must neither exceed nor fall short of 5.0 mm.
Correct any deviations outside tolerance 5.0 mm.

If the deviation is exceeded, e.g. +8.0 mm, correct the difference on the rear axle on the relevant side by placing weights in the boot. If the deviation falls short of e.g. -8.0 mm, correct the difference on the front axle by placing weights on the relevant suspension strut dome. Suitable weights are e.g. sand bags approx. 10 kg
S44-0013
Checking the camber on the front axle, if necessary take the mean
The camber cannot be adjusted, it can only be centered.
44-2 page 4
Vehicle alignment
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
44
If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted 44-2 page 1. It is only possible to evenly center the camber within the tolerance range by shifting the complete engine-gearbox assembly carrier.
Release screws -1- and -2-. Move the engine-gearbox assembly carrier with console until the camber is equal on both sides.
Subsequently check the castor.

When moving the engine-gearbox assembly carrier with console the castor may change.
Tighten the console with the engine-gearbox assembly carrier with new screws. Tightening torque: Console for engine-gearbox assembly carrier on body.
Use new screws!
Tighten 70 Nm + 90
1
S44-0014
Checking the camber on the rear axle

The camber cannot be adjusted. If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted 44-2 page 1. If the measured values still lie outside the tolerance, check the axle body for damage and if necessary replace.
Checking the track on the rear axle

The track cannot be adjusted. If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted 44-2 page 1. If the measured values still lie outside the tolerance, check the axle body for damage and if necessary replace.
Checking the tracking on the front axle, adjusting if necessary

If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted 44-2 page 1.
Release counternut -1 -. Adjust track by turning the left and/or right track rod.
Use an open-jawed spanner on the hexagon bolt -arrow- of the track rod. Check that the bellows have not become twisted after turning the track rods!
S44-0015
Edition 07.04 S00.5303.16.20
Vehicle alignment
44-2 page 5
44
Twisted bellows wear fast.
FABIA 2000
Chassis
Tighten counternut -1- with 50 Nm and again check

track value. After tightening counternut -1- the set value may change slightly. Make sure this value remains within the tolerance for the nominal value. If this is not the case repeat the track adjustment operation.
Checking the left and right steering angle

This check is only required if
the steering angles differ by more than 2 from the
steering centre.
at full steering angle the tyres come into contact with
components on the front axle or body on one side,

the left/right turning clearance circle differs.
The distance between the components on the front axle and the tyres -arrow- must be the same on both sides at maximum steering angle. If the distance is unequal it is possible to correct the distance by turning the left and right track rod. Example: The distance between the front axle components and the tyres is smaller on the left than on the right.
Release the counternuts on the track rods. Turn the track rod on the left (unscrew from track-rod
end).
Turn the track rod on the right to the same extent

(screw into track-rod end).
S44-0016
Check overall track.

After this adjustment procedure the overall track must correspond with the specified nominal value!
Tighten counternuts with 50 Nm.

After tightening the counternuts the set value may change slightly. Make sure this value remains within the tolerance for the nominal value. If this is not the case repeat the overall track adjustment operation. Check that the bellows have not become twisted after turning the track rods!
44-2 page 6
Vehicle alignment
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
44
Calculation of the misalignment on the rear axle

Note The indicated values are only given as an example.
For track values with the same preceding sign (+/+ or -/-) subtract the smaller value from the greater value and
divide by 2. Track value on the rear left wheel +15' 15' - 5' = 10' 10' : 2 = 5' Deviation from the running direction = 5' Track value on the rear right wheel +5'
Value with a different preceding sign (+/-) are added up and the sum is divided by 2.
Track value on the rear left wheel +15' 15' + 5' = 20' 20' : 2 = 10' Deviation from the running direction = 10' The relevant result is the actual deviation of the running direction from the longitudinal vehicle axis. Track value on the rear right wheel -5'
Edition 07.04 S00.5303.16.20
Vehicle alignment
44-2 page 7
44
FABIA 2000
Chassis
44-2 page 8
Vehicle alignment
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
45 Anti-Lock Brake System

45-1 Antilock braking system (ABS)
Safety precautions, basic information on fault finding and on repairing

The ABS and ESP are vehicle safety systems; de-
tailed system knowledge is required for working on such systems.

Testing and replacement or repairs should be carried
out only by personnel specially trained for ABS. Dash panel insert up to model year 2004
4 1 2 3
S45-0184
Dash panel insert as of model year 2005

Faults are indicated by the ABS warning light -K47-
(-3-), the red dual circuit and hand brake system warning light -K7- (-4-) and the traction control system warning light -K86- or ESP and TCS warning light -K155- (-2-). Certain faults are not detected until after a minimum speed of 20 km/h has been exceeded (conduct a road test).
The brake pad warning light -K32- (-1-) indicates the
condition of the brake pads. If the warning light does not go out after the ignition is switched on or it comes on when driving, the brake pads could be worn down.
If the ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- do not light up and if in spite of this the brake system is not fully operational, look for the fault in the conventional brake system Chap. 46-1 and Chap. 47-1.
Notes on rectifying sudden faults Technical Service
4 1 2 3
S45-0187
Handbook.
Instructions for repair work on Antilock braking system

ABS systems BOSCH 5.7 and BOSCH 8.0
The hydraulic unit of the systems ABS, ABS/EDL/TCS
BOSCH 5.7 and ABS, ABS/TCS BOSCH 8.0 can be disassembled and repaired.
The hydraulic unit ABS/EDL/TCS/ESP BOSCH 5.7
and ABS/TCS/ESP BOSCH 8.0 must not be disassembled and repaired. In the event of faults or defects, replace the complete hydraulic control unit.
A repair of the hydraulic control unit is only possible in
an unmounted condition.
Edition 07.04 S00.5303.16.20
Antilock braking system (ABS)
45-1 page 1
45
The separation of the hydraulic unit for ABS -N55- and
FABIA 2000
Chassis
the return flow pump for ABS -V39- (-a-) from the ABS control unit -J104- (-b-) is possible.
The separation of the return flow pump for ABS -V39-
from the hydraulic unit for ABS -N55- is not permitted. ABS BOSCH 5.7
b
S45-0068
ABS, ABS/TCS BOSCH 8.0
S45-0181
ABS/TCS/ESP BOSCH 8.0 Continued for ABS systems BOSCH 5.7 and BOSCH 8.0
Carefully cover or close opened components if the re-
pair is not completed immediately (use plugs repair kit -1H0 698 311 A-).
After separating the control unit/hydraulic unit use the
transport protection for valve domes.

Before commencing work on the ABS systems it is
necessary to interrogate the fault memory in order to check complaints and conduct specific fault finding.
The interrogation of the fault memory can be per-
formed within the framework of:

S45-0182
the self diagnosis with the vehicle system tester -V.A.G 1552- or with the vehicle diagnosis, measurement and information system -VAS 5051-.
45-1 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Do not separate plug connections unless the ignition
is switched off.
Before commencing work on the ABS systems, switch
off the ignition and disconnect the earth strap at the battery Electrical System; Rep. Gr. 27. On models fitted with a coded radio set, pay attention to the coding; determine if necessary.
Welding work using electric welding equipment may
affect the ABS or ESP systems.

Before commencing welding work using electrical
welding tool:
Disconnect the cable form the negative terminal of the

battery and cover the negative terminal.
Connect the earth connection of the electric welding

tool directly to the part to be welded. There must not be any electrically insulated parts between the earth connection and the welding point.
Electronic control units and electrical wiring must not

touch the earth connection or the welding electrode.
During paintwork, the electronic control unit can be
loaded for a short time at a maximum of 95 C and for longer period (approx. 2 hours) at a maximum of 85 C. from the control unit.
Do not drive the vehicle if the connector is unplugged When carrying out work on the antilock brake system,
ensure scrupulous cleanliness, on no account use agents containing mineral oils, such as oil, greases, etc.
Thoroughly clean connection points and the surround-
ing area before disconnecting, but do not use any aggressive cleaning agents, such as brake cleaner, petroleum, thinner or similar.
Place removed parts on a clean surface and cover. Carefully cover or seal opened components if the re-
pairs are not carried out immediately (use plugs from repair kit 1HO 698 311 A).
Do not use fluffy clothes. Remove spare parts from their wrapping immediately
before fitting.
Use only genuine wrapped parts. If the system is opened, avoid working with com-
pressed air and avoid moving the vehicle.

Ensure that no brake fluid is able to flow into the con-
nectors.
Observe the relevant instructions when handling
brake fluid Chap. 47-4.
After completing work which involved opening the
brake system, bleed brake system with brake filling and bleeding device, e. g. -ROMESS S15-, Chap. 47-4.
During the subsequent road test, ensure that at least
one controlled brake application is performed (pulsing must be felt on the brake pedal).
Edition 07.04 S00.5303.16.20
45-1 page 3
45
Required technical information
Binder Current Flow Diagrams, Electrical Fault Find-
FABIA 2000
Chassis
ing and Fitting Locations

Self-study programme ABS or ESP Technical Service Handbook Operating instructions for the vehicle diagnosis,
measuring and information system -VAS 5051-
45-1 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
45-2
Distinguishing features of the ABS system
General Instructions
The ABS prevents the wheels from locking during a
brake application initiated by the driver.

The electronic differential lock (EDL) is a starting-off
aid. A supporting torque is created for the differential by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus available for the gripping wheel with the better adhesion. This also applies when reversing.
The traction control system (TCS) prevents the driving
wheels from slipping when accelerating while reducing the engine power output. This is possible over the entire vehicle speed range. EDL and TCS are mutually supportive when accelerating the vehicle.
The engine drag torque control (EDC) prevents that
the drive gears are blocked by the engine because of the braking ratio, if suddenly the accelerator pedal is released or when braking with a gear engaged.
The electronic stability program (ESP) recognizes crit-
ical driving conditions and stabilizes the vehicle by individual wheel braking and by intervention in the engine control. This occurs independently of the brake or accelerator pedal activation.
The ESP is active over the entire speed range. If the
ESp is in regulating mode the ESP warning lamp flashes three times per second.
The description of the structure and function of the
ESP can be found in self-study programme No. 42.

The brake system is split diagonally. Brake servo as-
sistance is provided pneumatically by the vacuum brake servo unit.

Vehicles fitted with ABS, ABS/EDL/TCS or ABS/EDL/
TCS/ESP BOSCH 5.7 as well as vehicles with ABS, or ABS/TCS or ABS/TCS/ESP BOSCH 8.0 do not have a mechanical brake pressure regulator. Specifically matched software in the control unit, the electronic brake pressure distribution (EBD) regulates the brake pressure on the rear axle.
The return flow pump for ABS -V39-, the hydraulic unit
for ABS -N55- and the ABS control unit -J104- form the hydraulic control unit.
New control units supplied through the Parts Division
are not coded. They must be coded after installation.

Code ABS systems BOSCH 5.7 with the vehicle sys-
tem tester -V.A.G 1552- Chap. 45-8 or with the vehicle diagnosis, measurement and information system -VAS 5051- Chap. 45-4. tem tester -V.A.G 1552- Chap. 45-9 or with the vehicle diagnosis, measurement and information system - VAS 5051- Chap. 45-4.
Code ABS systems BOSCH 8.0 with the vehicle sys-
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45-2 page 1
45
Distinguishing features
Note Identification and assignment of the ABS systems Spare parts catalogue. ABS BOSCH 5.7
Dimension -a-: 102 mm 8 valve domes: The protective sleeves for the valves
FABIA 2000
Chassis
are visible if the control unit is separated from the hydraulic unit Chap. 45-17.
Control unit identification: The control unit version can
be displayed with the -V.A.G 1552- via the function 01 Interrogating control unit version Chapter 45-5 or with the vehicle diagnosis system, measurement and information system -VAS 5051- Chapter 45-4.
List of available functions Chap. 45-5.
S45-0108
ABS/EDL/TCS BOSCH 5.7

Dimension -a-: 127 mm 12 valve domes: The protective sleeves for the valves
are visible if the control unit is separated from the hydraulic unit Chap. 45-17.
S45-0114
ABS/EDL/TCS/ESP BOSCH 5.7

Dimension -a-: 130 mm 12 valve domes Brake pressure sender 1 -G201- (-1-) Control unit identification: The control unit version can
Note
S45-0105
45-2 page 2
Edition 07.04 S00.5303.16.20
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Chassis
45

Dimension -a-: 80 mm Inscription ABS on the hydraulic unit for ABS -N55 8 valve domes: The protective sleeves for the valves
are visible if the control unit is separated from the hydraulic unit.
S45-0175
ABS/TCS/ESP BOSCH 8.0 The hydraulic control unit ABS/TCS/ESP BOSCH 8.0 must not be disassembled. It must be replaced as a complete unit in the case of repairs.
Dimension -a-: 103 mm Inscription ESP on the hydraulic unit for ABS -N55 12 valve domes Control unit identification: The control unit version can
Fitting position of the ABS systems BOSCH 5.7 and BOSCH 8.0
ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 In the engine compartment, to the right on the lateral part of the engine compartment Note The Fig. shows the ABS or ABS/EDL/TCS BOSCH 5.7 hydraulic control unit.
S45-0176
S45-0104
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45
ABS, ABS/TCS or ABS/TCS/ESP BOSCH 8.0 In the engine compartment, to the right on the lateral part of the engine compartment Note The Fig. shows the ABS or ABS/TCS BOSCH 8.0 hydraulic control unit.
FABIA 2000
Chassis
S45-0183
45-2 page 4
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FABIA 2000
Chassis
45
45-3
Function of Self-diagnosis
General Instructions
ABS systems BOSCH 5.7 and BOSCH 8.0 As the control units are interlinked over two data BUS lines, always start fault finding by interrogating the contents of the fault memories of all the control units fitted to the vehicle. The interrogation of the fault memory can be performed with the vehicle system tester -V.A.G 1552- by the automatic test sequence (activation with the key function 0 0 ) Chap. 45-5 or with the vehicle diagnosis system, measurement and information system -VAS 5051 Chap. 45-4. When doing so check whether a possibly stored fault might affect the ABS system. The ABS control unit -J104- together with the hydraulic unit for ABS -N55- forms a compact unit. The unit is located in the right of the engine compartment. The control unit is equipped with a fault memory. The connection for self-diagnosis is located in the storage compartment on the driver's side. Self-diagnosis relates to the electrical/electronic part of the ABS, i. e. faults are detected only over the electrical connection to the control unit, e.g. open circuit of a wheel speed sensor. The control unit detects faults during the operation of the vehicle and stores them in a permanent memory, whose information is retained even if the battery voltage is disconnected. Faults which occur sporadically (isolated) are likewise detected and stored. If this fault no longer occurs during 40 vehicle starts and driving-off procedures, it is erased from the fault memory (fault delete counter), with the exception of the fault Control unit defective. After the ignition is switched on the ABS warning light -K47-, the red dual circuit and hand brake system warning light -K7- and the traction control system warning light -K86- or the ESP and TCS warning light -K155- light up for approx. 2 seconds. During this period a test sequence (self-check) is performed in the control unit with the following functions:
Test of supply voltage, min. 11.0 Volts. Test of control unit including valve coils. Electrical test of wheel speed sensors, not fully com-
pleted until vehicle reaches 20 km/h.

Check of control unit coding. Test of electric motor for the return flow pump (hy-
draulic pump). Before starting fault finding, always initiate self-diagnosis and retrieve the stored information using vehicle system
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tester -V.A.G 1552- Chap. 45-5 or using vehicle diagnosis system, measurement and information system -VAS 5051- Chap. 45-4. Note
The description Chap. 45-5 only relates to the ve-
FABIA 2000
Chassis
hicle system tester -V.A.G 1552- using the current program card.
The use of fault reader -V.A.G 1551- with integrated
printer is similar. A minor deviation on the display read-out is possible.
Vehicle fitted with ABS/EDL/TCS or ABS/ EDL/TCS/ESP BOSCH 5.7 does not have an EDL function
Complaint: Vehicle EDS system does not operate When dealing with this complaint a possible fault cause may be that the brake light switch is incorrectly set or is not operating Chap. 45-10, read measured value block, display group numbers 002 and 004.
45-3 page 2
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45-4
Vehicle diagnosis, measurement and information system -VAS 5051-
Connect vehicle diagnosis, measurement and information system -VAS 5051and select functions (ABS systems BOSCH 5.7 and BOSCH 8.0)
The self-diagnosis of the ABS systems BOSCH 5.7 and BOSCH 8.0 can be performed using the vehicle diagnosis, measurement and information system -VAS 5051-. Special tools, test and measuring equipment and auxiliary items required
Vehicle diagnosis, measurement and information sys-
tem -VAS 5051 Diagnostic cable -VAS 5051/5A- or Diagnostic cable
-VAS 5051/6A-
WARNING!
For test drives, test and measuring equipment
must always be fastened to the rear seat.

The equipment must be operated by an assist-
ant during test drives.
Mount the plug of the diagnostic cable -VAS 5051/5Aor the diagnostic cable -VAS 5051/6A- on the diagnostic connection in the storage compartment on the driver's side.
Switch on the vehicle diagnosis, measurement and information system -VAS 5051- -arrow-. The vehicle diagnosis, measurement and information system -VAS 5051- is operational, if it shows the keyboards of its operating modes.
Switch on ignition. On the screen, select the Gefhrte Fehlersuche . Select the following one after the other:
Brand Type Model year Variant Engine identification characters
Confirm the data entered.

Wait until the vehicle diagnosis, measurement and information system -VAS 5051- has communicated with all the control units in the vehicle (vehicle system test).
Press the
Sprung and choose the Selected Functions/Components option.
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Select on the display chassis Select on the display brake system Select on the display the indicated 01-self-diagnosable system.
FABIA 2000
Chassis
Select on the display the indicated Antilock braking

system . Now all possible components and functions of the antilock braking system in the vehicle are indicated.
Select on the display the desired component or the

desired function.
45-4 page 2
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45
45-5
Performing Self-diagnosis - ABS systems BOSCH 5.7 and BOSCH 8.0
Test requirements
Approved tyre size fitted to all wheels; tyres inflated to
the specified pressure.
Mechanical/hydraulic part of the brake system together with the brake light switch and brake lights operating properly.
No leaks in hydraulic connections and lines (visual inspection of hydraulic unit, brake calipers, wheel brake cylinders, tandem brake master cylinder).
Wheel bearings and wheel bearing play O.K. Control unit correctly bolted to the hydraulic unit. Plug connection on ABS control unit -J104- correctly
plugged in (lock is engaged).
Inspect plug contacts of ABS components for damage

and correct fitting.
All fuses must be OK in compliance with the current

flow diagram.
Battery voltage at least 11 V.
Connecting vehicle system tester -V.A.G 1552- and selecting function

Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3-, -V.A.G 1551/3A-,
-V.A.G 1551/3B- or -V.A.G 1551/3CNote

During self-diagnosis the ABS function is disconnect-
ed in the control unit.

TheWarning lights -K47-, -K7- and -K86/K155- light up
during self-diagnosis. The diagnostic connection is located in the storage compartment on the driver's side.
V.A.G 1552 V.A.G 1551/3

S01-0087
Connect vehicle system tester -V.A.G 1552- with the

diagnostic cable -V.A.G 1551/3-.
Switch on the ignition.
Interrogating control unit version

Readout on display:
Vehicle system test Enter address word XX HELP
Press
0 and 3 for the address word brake electron6Q0614117 ABS 5.7 Coding 00036 FRONT X00 -> WSC xxxxx
ics and confirm the entry with Q . After approx. 5 seconds the display will show:
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The display shows:
the control unit identification number, e.g. 6Q0614117 the system designation, e. g. ABS 5.7 Front the version number, e.g. X00 the code No. of the control unit, e.g. 00036 the workshop code (WSC Operatinginstructions
FABIA 2000
Chassis
vehicle system tester V.A.G. 1552) Assignment of the control unit Spare part catalogue If the control unit identification number is not displayed: 45-5 page 2.
Press
. Vehicle system test Select function XX HELP
Readout on display:
Overview of selectable functions

01 02 03 04 05 06 07 08 Interrogating control unit version 45-5 page 1 Interrogating fault memory 45-5 page 2 Final control diagnosis Chap. 45-12 Basic setting BOSCH 5.7 Chap. 45-13, BOSCH 8.0 Chap. 45-14 1) Erasing fault memory 45-5 page 3 Ending output 45-5 page 3 Code control unit BOSCH 5.7 Chap. 45-8, BOSCH 8.0 Chap. 45-9 Reading measured value block BOSCH 5.7 Chap. 45-10, BOSCH 8.0 Chap. 45-11
Interrogating fault memory

Readout on display:
Vehicle system test Select function XX HELP
Press
0 and 2 for the function Interrogate fault X faults detected!
memory and confirm with Q . The number of faults stored appears on the display or Eventuell gespeicherte Fehler eines Systems werden nacheinander angezeigt.
No fault detected!
->
Press
The stored faults are displayed in sequence.
Note the fault message displayed and refer to the fault

table for the corresponding ABS system BOSCH 5.7 Chap. 45-6, BOSCH 8.0 Chap. 45-7. If No fault detected appears the program returns to its initial setting after key is pressed. Readout on display:
End output (Function 06) 45-5 page 3.

1)
only required for vehicles with ABS/EDL/TCS (BOSCH 5.7), ABS/EDL/TCS/ESP (BOSCH 5.7) or ABS/TCS/ESP (BOSCH 8.0)
45-5 page 2
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Switch off ignition and disconnect the diagnostic plug

connection. Note
If a fault is detected: 1. Rectify fault (repair) 2. Interrogate fault memory (Function 02) 3. Erase fault memory (Function 05) 4. End output (function 06) 5. Road test 6. Interrogate the fault memory again
Erasing fault memory

Requirements:
Fault memory interrogated 45-5 page 2. All faults rectified.

After interrogating the fault memory: Readout on display:
Press
0 and 5 for the function Erase fault memory and confirm with Q . Vehicle system test Fault memory erased! ->
Readout on display: The fault memory is now erased.
Press
Readout on display: Note

If the following message is displayed the test se-
quence is incorrect.
Carefully follow the test sequence step by step: first
Vehicle system test Fault memory was not interrogated
->
interrogate the fault memory, if necessary rectify faults and then erase the fault memory.
Ending output
Press
0 and 6 for the function End output and confirm with Q . Vehicle system test Enter address word XX HELP
Readout on display:
Switch off ignition. Disconnect plug connections from vehicle system

tester -V.A.G 1552-.
Switch on ignition.
The warning lights -K47-, -K7- and -K86/K155- must go out after approx. 2 seconds.
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Automatic test sequence
Note
During testing and installation other control units may
FABIA 2000
Chassis
also detect faults, e.g. pulled-out connectors. This is why you must conclude the self-diagnosis by interrogating and erasing the fault memories of all control units.
With the automatic test sequence all fault memory
contents of the control units are interrogated. Readout on display:

Press
0 twice for address word Automatic test sequence and confirm with Q .
After this all the control unit identifications with possible entries from the fault memories appear in the display in the order of the address words. The automatic test sequence is completed when the following read-out appears on the display:
45-5 page 4
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Chassis
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45-6
Note
Fault table - ABS systems BOSCH 5.7
As the control units are interlinked over two data BUS lines, always start fault finding by activating the function Au-
tomatic test sequence Chap. 45-5 on all control units fitted to the vehicle This allows to interrogate all the control units fitted on the vehicle to determine their possible faults. system tester -V.A.G 1552- during interrogation of the fault memory content, are listed below.
All the possible faults which can be detected by the ABS control unit -J104- and which can be displayed on vehicle The fault table is ordered according to the 5-digit fault code on the left. The fault table may also display the fault type. The column Fault elimination refers to certain test steps in the electrical test. Before replacing acomponent fault to be faulty test all corresponding plug connections, lines and earth connection
according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
After carrying out the repair always interrogate and erase the fault memory using vehicle system tester
-V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
After the test drive interrogate the fault memory again.
Read-out on display -V.A.G 1552no fault detected
Rectifying fault If after repair No fault detected is displayed, the self-diagnosis is completed. If in spite of display read-out No fault detected the ABS does not operate without fault, proceed as follows: 1. Perform a test drive at a speed above 20 km/h, 2. interrogate the fault memory again, if still no fault is stored, 3. continue fault finding without self-diagnosis and run through the Electrical Test completely Chapter 45-15.
00257 ABS FL- N101 inlet valve 00259 ABS FR -N99 inlet valve 00265 ABS FL- N102 outlet valve 00267 ABS FR- N100 outlet valve 00273 ABS RR -N133 inlet valve 00274 ABS RL -N134 inlet valve 00275 ABS RR -N135 outlet valve 00276 ABS RL -N136 outlet valve
Performing a final control diagnosis, function 03

Chapter 45-12.
Check wiring and plug connections to the ABS control

unit -J104- according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. If none of the above measures results in elimination of the fault:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17.
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Read-out on display -V.A.G 155200283 Speed sensor vl-G47 Open circuit/Short circuit to positive Implausible signal Rectifying fault
FABIA 2000
Chassis
Read the measured value block Chapter 45-10, display group 001.
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. for damage.
Check the front left speed sensor -G47- and sensor ring Replace the speed sensor -G47- or the sensor ring as required Chapter 45-19. If the fault occurs again:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. play group 001. 00285 Speed sensor vr-G45 Open circuit/Short circuit to positive Implausible signal
Read the measured value block Chapter 45-10, dis Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Check the front right speed sensor -G45- for damage. Replace the speed sensor -G45- or the sensor ring as required Chapter 45-19. If the fault occurs again:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. play group 001. 00287 Speed sensor hr-G44 Open circuit/Short circuit to positive Implausible signal
Check the rear right speed sensor -G44- for damage. Replace the speed sensor -G44- or the sensor ring as required Chapter 45-19. If the fault occurs again:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. play group 001. 00290 Speed sensor hl-G46 Open circuit/Short circuit to positive Implausible signal
Check the rear left speed sensor -G46- for damage. Replace the speed sensor -G46- or the sensor ring as required Chapter 45-19. If the fault occurs again:
45-6 page 2
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Chassis Rectifying fault
45
Read the measured value block Chapter 45-10, display group 002 or 006 .
Read-out on display -V.A.G 155200301 Return flow pump for ABS - V39 Open circuit
Erasing fault memory (05) Chapter 45-5. Ending output (06) Chapter 45-5. Switch off ignition. Switch on ignition.
If the fault occurs again:
00302 ABS solenoid valve relay J106
Open circuit
Replace hydraulic control unit Chapter 45-17. Read the measured value block Chapter 45-10, display group 006.

Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. play group 002. 00526 Brake light switch -F Open circuit
Read the measured value block Chapter 45-10, dis Carry out the Electrical Test, test step no. 4 Chapter
45-15.
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
00532 Supply voltage Note:

This fault is related to
Signal outside tolerance Signal too low
Replacing brake light switch Chapter 45-16. Carry out the Electrical Test, test step no. 1 Chapter
45-15.
Determine and eliminate open circuit in voltage supply Test battery, AC generator and voltage regulator
the voltage supply of the control unit.

This fault is only stored
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
if it occurs at a vehicle speed above 6 km/h.
The ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP system is switched on again as soon as the vehicle voltage exceeds 10 volts and the warning lights go out.
Test earth connections.

If no fault is found in the voltage supply:
00597 Different wheel speed pulses
Replace hydraulic control unit Chapter 45-17. Test wheels and tyre pressures Chapter 00-4. Check the fitting position of the speed sensor and wheel
bearing with sensor ring and replace if necessary Chapter 40-3 or Chapter 42-3.
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Read-out on display -V.A.G 155200753 Electr. connections wheel speed pulses 00778 Steering angle sender G85 Electrical fault in the circuit Rectifying fault
FABIA 2000
Chassis

unit -J104- according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
defective
Read the measured value block Chapter 45-10, display groups 005 and 125.
Perform null balance of the steering angle sender -G85 Chapter 45-13.
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Chap. 45-16.
If necessary replace steering angle sender -G85Balance not performed Implausible signal
Check fitting position of the steering angle sender -G85 Chapter 45-16.
Carry out check of chassis alignment Chapter 44-2 Perform null balance of the steering angle sender -G85 Chapter 45-13. 01044 Control unit wrongly coded 01119 Signal for gear recognition 01197 Data bus drive: wrong software version 01200 Power supply for ABS valves Note:
Coding ABS with EDL control unit -J104- Chapter 458.
Performing automatic test sequence Chapter 45-5. Performing automatic test sequence Chapter 45-5.
Carry out the Electrical Test, test step no. 2 Chapter

45-15.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Chapter 45-10, display groups 002 or 006.
the voltage supply to the hydraulic unit -N55and the return flow pump motor -V39-.
Test relay for solenoid valves, read measured value block


Chapter 45-12.
45-6 page 4
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1)
45
Read-out on display -V.A.G 155201312 Drive databus defective
Test the control unit coding Engine - Fuel Injection;

Rep. Gr. 01.
Testing data BUS Electrical system; Rep. Gr. 90 Carry out the Electrical Test, test step no. 6 Chapter
45-15. defect sporadic 1)
Erasing fault memory Chapter 45-5. No further measures required. Inform customer.
1)
The fault does not result in the ABS warning lamp -K47- or the dual circuit and hand brake system warning lamp -K7 - lighting up. The ABS function is fully maintained.
Read-out on display -V.A.G 155201314 Engine control unit No communication
Rectifying fault

45-15.
Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis of the engine control unit
Engine - Fuel Injection; Rep. Gr. 01. Engine - Fuel Injection; Rep. Gr. 01. play group 125. please read out fault memory 01315 Gearbox control unit No communication
Read out fault memory of the engine control unit Read the measured value block Chapter 45-10, dis Carry out the Electrical Test, test step no. 6 Chapter
45-15.
Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis of the gearbox control unit
automatic gearbox 001; Rep. Gr. 01. please read out fault memory 01316 Brake control unit 01317 Control unit with display in dash panel insert -J285 No communication No communication
Read out the fault memory of the automatic gearbox control unit Automatic Gearbox; Rep. Gr. 01.
Testing data BUS Electrical system; Rep. Gr. 90 Read the measured value block Chapter 45-10, display group 125.

45-15.
Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis of the dash panel insert
Electrical System; Rep. Gr. 90. 01321 Airbag control unit -J234 No communication
Testing data BUS Electrical system; Rep. Gr. 90 Read out fault memory of the airbag control unit Body
Work; Rep. Gr. 01
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45
Read-out on display -V.A.G 155201418 Vehicle stability program switch valve -1- N225 01419 Vehicle stability program switch valve -2- N226 01420 Vehicle stability program high pressure valve -1N227 01421 Vehicle stability program high pressure valve -2N228 Rectifying fault
FABIA 2000
Chassis

45-6 page 6
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FABIA 2000
45
Read-out on display -V.A.G 155201423 Lateral acceleration sender -G200
Check fitting position of the lateral acceleration sender

-G200- Chapter 45-16.
Read measured value block Chapter 45-10, display

group 005; replace lateral acceleration sender -G200- if necessary Chapter 45-16. If none of the above measures results in elimination of the fault:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. Electrical fault in the circuit

group 005; replace lateral acceleration sender -G200- if necessary Chapter 45-16. If none of the above measures results in elimination of the fault:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. play group 005. Implausible signal
Read the measured value block Chapter 45-10, dis Check attachment of the lateral acceleration sender
-G200- Chapter 45-16.
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. and again interrogate fault memory Chapter 45-5.
Erase fault memory Chapter 45-5, perform test drive

Replacing lateral acceleration sender -G200 Chap. 45-16. If none of the above measures results in elimination of the fault:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. 01424 Yaw rate sender -G202, signal line 01425 Yaw rate sender -G202, reference line Electrical fault in the circuit Electrical fault in the circuit

group 005; replace yaw rate sender -G202- if necessary Chapter 45-16. If none of the above measures results in elimination of the fault:
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Read-out on display -V.A.G 155201435 Brake pressure sender 1 G201 Rectifying fault
FABIA 2000
Chassis
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. 17. If none of the above measures results in elimination of the fault:
Replacing brake pressure sender 1 -G201- Chap. 45-
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. Electrical fault in the circuit
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. play group 005.
Read the measured value block Chapter 45-10, dis Replacing brake pressure sender 1 -G201- Chap. 4517. If none of the above measures results in elimination of the fault:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. Implausible signal
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. group 005; replace brake pressure sender 1 -G201- if necessary Chapter 45-17. If none of the above measures results in elimination of the fault:
45-6 page 8
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FABIA 2000
45
Read-out on display -V.A.G 155201542 Yaw rate sender -G202 defective

group 005; replace yaw rate sender -G202- if necessary Chapter 45-16. If the fault has still not been corrected:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. play group 005. Implausible signal
Read the measured value block Chapter 45-10, dis Check attachment of the yaw rate sender -G202 Chapter 45-16.
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. and again interrogate fault memory. If the fault occurs again:
Erase fault memory Chapter 45-5, perform test drive
Replacing yaw rate sender -G202- Chap. 45-16.

If none of the above measures results in elimination of the fault:
Replacing control unit ABS with EDL control unit -J104 Chapter 45-17. 01826 (Information in the literature) Note:
This fault concerns the
Test fuse 1. Test wiring and plug connections to the steering angle
sender -G85- according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
voltage supply of the steering angle sender -G85-. 18055 Inspect coding/variants of the control units in the drive train
Test battery, charge if necessary Electrical System;

Rep. Gr. 27.

Rep. Gr. 01.
Check coding of the gearbox control unit automatic

gearbox 001; Rep. Gr. 01. 18256 Please read out fault memory of the engine CU 18263 Data bus drive Software status monitoring
Read out fault memory of the engine control unit

Engine - Fuel Injection; Rep. Gr. 01.
Performing automatic test sequence Chapter 45-5. Make sure the control units connected to the data BUS
cables have no entry in the fault memory.
Check whether the correct engine control unit and the

right ABS with EDL control unit -J104- (spare part number) have been fitted.
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Read-out on display -V.A.G 155218265 Load signal 65535 Control unit defective Rectifying fault
FABIA 2000
Chassis

Engine - Fuel Injection; Rep. Gr. 01. Chapter 45-17.
Replacing control unit ABS with EDL control unit -J104-
45-6 page 10
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FABIA 2000
Chassis
45
45-7
Note
As the control units are interlinked over two data BUS lines, always start fault finding by activating the function Au-
tomatic test sequence Chap. 45-5 on all control units fitted to the vehicle This allows to interrogate all the control units fitted on the vehicle to determine their possible faults. system tester -V.A.G 1552- during interrogation of the fault memory content, are listed below.
All the possible faults which can be detected by the ABS control unit -J104- and which can be displayed on vehicle The fault table is ordered according to the 5-digit fault code on the left. The fault table may also display the fault type. Before replacing acomponent fault to be faulty test all corresponding plug connections, lines and earth connection
according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
After carrying out the repair always interrogate and erase the fault memory using vehicle system tester
-V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
After the test drive interrogate the fault memory again.
Read-out on display -V.A.G 1552no fault detected
Rectifying fault If after repair No fault detected is displayed, the self-diagnosis is completed. If in spite of display read-out No fault detected the ABS does not operate without fault, proceed as follows: 1. Perform a test drive at a speed above 20 km/h, 2. interrogate the fault memory again, if still no fault is stored,
00003 Control unit defective 00257 ABS FL- N101 inlet valve 00259 ABS FR -N99 inlet valve 00265 ABS FL- N102 outlet valve 00267 ABS FR- N100 outlet valve 00273 ABS RR -N133 inlet valve 00274 ABS RL -N134 inlet valve 00275 ABS RR -N135 outlet valve 00276 ABS RL -N136 outlet valve
Replacing hydraulic control unit Chap. 45-18.

Chapter 45-12.

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45
Read-out on display -V.A.G 155200283 Speed sensor vl-G47 Implausible signal Electrical fault in the circuit Mechanical fault Rectifying fault
FABIA 2000
Chassis
Check the front left speed sensor -G47- and sensor ring Replace the speed sensor -G47- or the sensor ring as required Chapter 45-19. If the fault occurs again:
00285 Speed sensor vr-G45
Mechanical fault Implausible signal Electrical fault in the circuit
Replacing hydraulic control unit Chap. 45-18. Read the measured value block Chapter 45-11, display group 001.
Check the front right speed sensor -G45- and sensor ring Replace the speed sensor -G45- or the sensor ring as required Chapter 45-19. If the fault occurs again:
00287 Speed sensor hr-G44
Check the rear right speed sensor -G44- and sensor ring Replace the speed sensor -G44- or the sensor ring as required Chapter 45-19. If the fault occurs again:
00290 Speed sensor hl-G46
Check the rear left speed sensor -G46- and sensor ring Replace the speed sensor -G46- or the sensor ring as required Chapter 45-19. If the fault occurs again:
45-7 page 2
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45
Read-out on display -V.A.G 155200301 Return flow pump for ABS - V39 Implausible signal
Perform actuator diagnosis Chapter 45-12. Check fuse, wiring and plug connections according to the
current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
00493 ESP sensor unit -G419
no signal/communication Implausible signal
Replacing hydraulic control unit Chap. 45-18. Read the measured value block Chapter 45-11, display groups 005 or 126.

Replacing ESP sensor unit -G419- Chapter 45-16.

00526 Brake light switch -F Open circuit Implausible signal
00532 Supply voltage Note:

Signal too low
Replacing brake light switch -F- Chap. 45-16. Read the measured value block Chapter 45-11, display group 006.
the voltage supply of the control unit.

This fault is only stored
if it occurs at a vehicle speed above 6 km/h.
The ABS, ABS/TCS or ABS/TCS/ESP system is switched on again as soon as the vehicle voltage exceeds 10 volts and the warning lights go out.
Test earth connections.

00597 Different wheel speed pulses 00753 Electr. connections wheel speed pulses
Mechanical fault
Replacing hydraulic control unit Chap. 45-18. Test wheels and tyre pressures Chapter 00-4. Check the fitting position of the speed sensor and wheel
Short circuit to positive Electrical fault in the circuit

Edition 07.04 S00.5303.16.20
45-7 page 3
45
Read-out on display -V.A.G 155200778 Steering angle sender G85 defective Rectifying fault
FABIA 2000
Chassis
Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Chap. 45-16.
If necessary replace steering angle sender -G85No or incorrect basic setting/adaption no signal/communication
Perform null balance of the steering angle sender -G85 Chapter 45-14. play group 125.
Read the measured value block Chapter 45-11, dis Check wiring and plug connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. play group 005.
Implausible signal
Read the measured value block Chapter 45-11, dis Check fitting position of the steering angle sender -G85 Chapter 45-16.
Carry out check of chassis alignment Chapter 44-2 Perform null balance of the steering angle sender -G85 Chapter 45-14. 01044 Control unit wrongly coded 01119 Signal for gear recognition 01130 ABS operation
Performing automatic test sequence Chapter 45-5.

Erasing fault memory (05) Chapter 45-5. Ending output (06) Chapter 45-5. Switch off ignition. Switch on ignition. Interrogating fault memory (02) Chap. 45-5.
01200 Power supply for ABS valves Note:

Replacing hydraulic control unit Chap. 45-18. Test relay for solenoid valves, read measured value block
Chapter 45-11, display group 006.
voltage supply of the valves of the hydraulic unit -N55-.

Chapter 45-12.
45-7 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
45
Read-out on display -V.A.G 155201201 Power supply for ABS pump Note:
Test relay for return flow pump for ABS -V39-, read
measured value block Chapter 45-11, display group 006. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
voltage supply of the return flow pump for ABS -V39-.

Chapter 45-12. 9. 01312 Drive databus defective 1)
Coding ABS with EDL control unit -J104- Chapter 45 Test the control unit coding Engine - Fuel Injection;
Rep. Gr. 01.
defect sporadic 1)
Testing data BUS Electrical system; Rep. Gr. 90 Erasing fault memory Chapter 45-5. No further measures required. Inform customer.
1)
The fault does not result in the ABS warning lamp -K47- or the dual circuit and hand brake system warning lamp -K7- lighting up. The ABS function is fully maintained.
Read-out on display -V.A.G 155201314 Engine control unit no signal/communication
Rectifying fault
Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis of the engine control unit
Engine - Fuel Injection; Rep. Gr. 01. Engine - Fuel Injection; Rep. Gr. 01. play group 125. please read out fault memory 01315 Gearbox control unit no signal/communication
Read out fault memory of the engine control unit Read the measured value block Chapter 45-11, dis Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis of the gearbox control unit
automatic gearbox 001; Rep. Gr. 01.
please read out fault memory 01317 Control unit with display in dash panel insert -J285 no signal/communication
Read out the fault memory of the automatic gearbox control unit Automatic Gearbox; Rep. Gr. 01. play group 125.
Read the measured value block Chapter 45-11, dis Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis of the dash panel insert
Electrical System; Rep. Gr. 90.
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45-7 page 5
45
Read-out on display -V.A.G 155201321 Airbag control unit -J234 no signal/communication Rectifying fault
FABIA 2000
Chassis
Testing data BUS Electrical system; Rep. Gr. 90 Perform self-diagnosis for airbag system Body Work;
Rep. Gr. 01 01418 Vehicle stability program switch valve -1- N225 01419 Vehicle stability program switch valve -2- N226 01420 Vehicle stability program high pressure valve -1N227 01421 Vehicle stability program high pressure valve -2N228 01435 Brake pressure sender 1 G201 Implausible signal


Chapter 45-12.
01486 System function test activated 01683 Wheel speed signals/ speed
Replacing hydraulic control unit Chap. 45-18. Perform or end ESP road and system test Chap. 4514
Test wheels and tyre pressures Chapter 00-4. Check the fitting position of the speed sensor and wheel
Check wiring and plug connections for the speed sensor

01765 Engine control unit control difference
according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Engine - Fuel Injection; Rep. Gr. 01.
Perform self-diagnosis of the engine control unit
45-7 page 6
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FABIA 2000
45
Perform ESP road and system test Chap. 45-14 Erasing fault memory (05) Chapter 45-5. Ending output (06) Chapter 45-5. Switch off ignition. Switch on ignition.
Read-out on display -V.A.G 155201766 Brake control unit control difference Implausible signal
Perform self-diagnosis of the engine control unit

Engine - Fuel Injection; Rep. Gr. 01. 01826 Steering angle sender G85, voltage supply KL30 Note:
This fault is stored, if
Test wiring and plug connections to the steering angle

sender -G85- according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Test battery, AC generator and voltage regulator
the steering angle sender -G85- is separated from the voltage supply or the onboard voltage is NOK.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. sender -G85- Chapter 45-14.
Perform test drive or null balance of the steering angle

01827 Control unit with display in dash panel insert -J285, wheel circumference implausible 16347 Control unit defective 18055 Inspect coding/variants of the control units in the drive train
Replace steering angle sender -G85- Chap. 45-16. Perform self-diagnosis of the dash panel insert
Replacing hydraulic control unit Chap. 45-18. Coding ABS with EDL control unit -J104- Chapter 459.

Rep. Gr. 01.
Check coding of the gearbox control unit automatic

gearbox 001; Rep. Gr. 01. 18265 Load signal

Engine - Fuel Injection; Rep. Gr. 01.
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45-7 page 7
45
FABIA 2000
Chassis
45-7 page 8
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
45-8
Code control unit - ABS systems BOSCH 5.7
Vehicle system tester -V.A.G 1552- or vehicle diagno-
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3, 3A, 3B, 3C-,
-VAS 5051/5A- or -VAS 5051/6AThe control unit built into the vehicle is coded. New control units supplied through the spares warehouse are not coded and must be coded after being installed. Perform coding with the vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform coding with the vehicle system tester -V.A.G 1552Precondition for coding Coding is only then possible if the workshop code (WSC) has been entered into the vehicle system tester -V.A.G 1552- and when function 11 Coding 2 was also successfully performed on vehicles with ABS/EDL/TCS/ ESP. Test sequence
Determine the engine identification characters and the

type of ABS hydraulic control unit fitted on the vehicle.
Connect up vehicle system tester -V.A.G 1552- and

enter the control unit for brake electronics with the ignition switched on (address word 03) Chapter 45-5. Readout on display:
Select function
firm with Q .
0 7 code the control unit and conCoding control unit Enter code number XXXXX
Readout on display:
Enter the relevant code number of the vehicle and

confirm with
Q.
Table of codes 45-8 page 1
Table of codes
Engine Engine identification characters ABS control unit iden- ABS version tification number 6Q0614117 1.0 litre/37 kW AQV, ARV 6Q0907379 6Q0907379C 6Q0907379G 1.2 ltr./40 kW AWY 6Q0907379G ABS ABS ABS ABS ABS Code number 00036 00044 00044 00044 00044 Gearbox Gearbox Gearbox
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45-8 page 1
45
Engine Engine identification characters AZQ AZF, AZE ABS control unit iden- ABS version tification number 6Q0907379G 6Q0907379 1.4 ltr./44 kW 6Q0907379C 6Q0907379G 6Q0614117 6Q0614417 6Q0907379 1.4 ltr./50 kW AQW, AME, ATZ 6Q0907379A 6Q0907379C 6Q0907379D 6Q0907379G 6Q0907379H 6Q0614117 6Q0614417 6Q0907379 6Q0907379A 6Q0907379C 6Q0907379C 1.4 ltr./55 kW AUA, BBY 6Q0907379D 6Q0907379D 6Q0907379G 6Q0907379G 6Q0907379H 6Q0907379H 6Q0907379Q 6Q0907379Q 6Q0614117 6Q0614417 6Q0907379 6Q0907379A 1.4 ltr./74 kW AUB, BBZ 6Q0907379C 6Q0907379D 6Q0907379G 6Q0907379H 6Q0907379Q ABS ABS ABS ABS ABS TCS ABS TCS ABS TCS ABS TCS ABS TCS ABS TCS ABS ABS TCS TCS ABS ABS TCS TCS ESP ESP ABS TCS ABS TCS ABS TCS ABS TCS ESP Code number 00044 00044 00044 00044 00036 00052 00044 00060 00044 00060 00044 00060 00036 00116 00044 00124 00044 00045 00124 00125 00044 00045 00124 00125 03453 03485 00036 00116 00044 00124 00044 00124 00044 00124 03386
FABIA 2000 Gearbox
Chassis
1.2 ltr./47 kW
Gearbox Gearbox
Gearbox
Gearbox
Gearbox Automatic gearbox Gearbox Automatic gearbox Gearbox Automatic gearbox Gearbox Automatic gearbox Gearbox Automatic gearbox
Gearbox
45-8 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000 Engine
Chassis Engine identification characters ABS control unit iden- ABS version tification number 6Q0907379 6Q0907379A 6Q0907379C 6Q0907379D 6Q0907379G ABS TCS ABS TCS ABS TCS ESP ESP ESP ESP ABS ABS ABS TCS ABS TCS ABS TCS ABS TCS ESP ESP ABS TCS ESP ABS TCS Code number 00044 00188 00044 00188 00044 00188 033381) 033412) 033443) 03338 00044 00044 00044 00180 00044 00188 00044 00188 00044 00188 03411 03479 00044 00188 03357 00044 00188 Gearbox Gearbox Gearbox Gearbox Gearbox Gearbox
45
2.0 ltr./85 kW
AZL
6Q0907379H 6Q0907379M 6Q0907379M 6Q0907379M 6Q0907379Q 6Q0907379
1.9 ltr./47 kW SDI
ASY
6Q0907379C 6Q0907379G 6Q0614417 6Q0907379 6Q0907379A 6Q0907379C 6Q0907379D 6Q0907379G 6Q0907379H 6Q0907379Q 6Q0907379Q
1.9 ltr./74 kW TDI PD
ATD
AMF
6Q0907379G 6Q0907379H 6Q0907379Q

1) 2) 3)
ASZ
6Q0907379G 6Q0907379H
Fabia Fabia Sedan Fabia estate car
The control unit coding is shown in the display, example 00116:
6Q0614117 TCS 5.7 Coding 00116 Vehicle system test Select function XX
Front
X00 -> WSC XXXXX HELP
Press
Readout on display: Only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
Select function
1 1 Coding 2 and confirm with Q . Coding 2 Enter code number XXXXX
Readout on display: Note The steering wheel must be in the straight ahead position before executing the function Coding 2.
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45-8 page 3
45
Enter code number 40168 and confirm with
Readout on display:
Q. Vehicle system test Select function XX
FABIA 2000
Chassis
HELP
Select function
0 4 initiate basic setting and conInitiating basic setting Enter display group number XXX Q.
firm entry with Q . Readout on display:
Select display group 0 0 1 and confirm with Switch off the ignition for about 2 seconds. Switch on ignition.
Note
The vehicle system tester -V.A.G 1552- must remain connected up while the ignition is switched off. Readout on display: Continued for all vehicles
Press
0 6 for the function End output and confirm Vehicle system test Enter address word XX HELP
with Q . Readout on display: Note

The ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- will light up and will remain lit up if the control unit is incorrectly coded.
At the same time, an entry is recorded in the fault
memory Chap. 45-5.
45-8 page 4
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FABIA 2000
Chassis
45
45-9
Code control unit - ABS BOSCH 8.0
-VAS 5051/5A- or -VAS 5051/6AThe control unit built into the vehicle is coded. New control units supplied through the spares warehouse are not coded and must be coded after being installed. Perform coding of vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform coding with the vehicle system tester -V.A.G 1552Coding requirements Coding is only then possible if the workshop code (WSC) has been entered into the vehicle system tester -V.A.G 1552- and when function 16 access authorisation was also successfully performed. Test sequence
Determine the engine identification characters and the

type of ABS hydraulic control unit fitted on the vehicle.

Select function
firm with Q .
0 7 code the control unit and conCoding control unit Enter code number XXXXXXX
Readout on display:

confirm with Q . Table of codes 45-9 page 2
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45-9 page 1
45
Table of codes
Engine Engine identification characters ABS control unit identification number 6Q0907379R 6Q0907379R 1.2 ltr./40 kW AWY, BMD 6Q0907379AA 6Q0907379AA 6Q0907379AF 6Q0907379AF 6Q0907379R 6Q0907379AA 6Q0907379AF 6Q0907379AF 1.2 ltr./47 kW AZQ, BME 6Q0907379S 6Q0907379AB 6Q0907379AG 6Q0907379AG 6Q0907379AH 6Q0907379T 6Q0907379R 6Q0907379AA 6Q0907379AF 6Q0907379S 6Q0907379AB 6Q0907379AG 6Q0907379T 1.4 ltr./55 kW AUA, BBY, BKY 6Q0907379AH 6Q0907379R 6Q0907379AA 6Q0907379AF 6Q0907379S 6Q0907379AB 6Q0907379AG 6Q0907379T 6Q0907379AH ABS version ABS ABS ABS ABS ABS ABS ABS ABS ABS ABS TCS TCS TCS TCS ESP ESP ABS ABS ABS TCS TCS TCS ESP ESP ABS ABS ABS TCS TCS TCS ESP ESP Brakes at the front axle 13 FS-II 14 FS-III 13 FS-II 14 FS-III 13 FS-II 14 FS-III 14 FS-III 14 FS-III 13 FS-II 14 FS-III 14 FS-III 14 FS-III 13 FS-II 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III Brakes at the rear axle
FABIA 2000
Chassis
Code number
Gearbox
Drum brake 0000005 Drum brake 0000005 Drum brake 0000005 Drum brake 0000005 Drum brake 0002058 Drum brake 0002100 Drum brake 0000005 Drum brake 0000005 Drum brake 0002061 Drum brake 0002103 Drum brake 0000005 Drum brake 0000005 Drum brake 0002061 Drum brake 0002103 Drum brake 0000428 Drum brake 0000428 Drum brake 0000005 Drum brake 0000005 Drum brake 0002106 Drum brake 0000005 Drum brake 0000005 Drum brake 0002106 Drum brake 0000425 Drum brake 0000425 Drum brake 0000011 Drum brake 0000011 Drum brake 0002127 Drum brake 0000011 Drum brake 0000011 Drum brake 0002127 Drum brake 0000440 Drum brake 0000440 Automatic gearbox Gearbox Gearbox Gearbox
45-9 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000 Engine
Chassis Engine identification characters ABS control unit identification number 6Q0907379R 6Q0907379AA 6Q0907379AF 6Q0907379AF 6Q0907379S 6Q0907379AB 6Q0907379AG 6Q0907379AG 6Q0907379AH 6Q0907379T 6Q0907379AA 6Q0907379R 6Q0907379AB ABS version ABS ABS ABS ABS TCS TCS TCS TCS ESP ESP ABS ABS TCS TCS TCS ESP ESP ABS ABS ABS ABS TCS TCS TCS TCS ESP ESP ESP ABS ABS ABS ABS ABS ABS ABS TCS TCS TCS TCS ESP ESP Brakes at the front axle 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III 14 FS-III Brakes at the rear axle Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Code number Gearbox
45
0000005 0000005 0002178 0000005 0000005 0002178 0000329 0000329 0000008 0000008 0000008 0002226 0000008 0000275 0000275 Gearbox Manual gearbox
Drum brake 0002109
1.4 ltr./74 kW
AUB, BBZ
Drum brake 0002109
2.0 ltr./85 kW
AZL
6Q0907379AG 6Q0907379S 6Q0907379T 6Q0907379AH 6Q0907379R 6Q0907379AA 6Q0907379AF 6Q0907379AF 6Q0907379S
Drum brake 0000008 Drum brake 0000008 Drum brake 0002148 Drum brake 0002151 Drum brake 0000008 Drum brake 0000008 Drum brake 0002148 Drum brake 0002151 Drum brake 0000431 Drum brake 0000431 Drum brake 0000437 Drum brake 0000008 Drum brake 0002142 Drum brake 0000008 Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake 0000008 0000008 0002196 0000008 0000008 0002196 0000365 0000365 Gearbox Gearbox
AMF
6Q0907379AB 6Q0907379AG 6Q0907379AG 6Q0907379T 6Q0907379AH 6Q0907379AH 6Q0907379R
1.9 ltr./47 kW SDI
ASY
6Q0907379AF 6Q0907379AA 6Q0907379R 6Q0907379AA 6Q0907379AF 6Q0907379AF 6Q0907379S 6Q0907379AB 6Q0907379AG 6Q0907379AG 6Q0907379T 6Q0907379AH
Drum brake 0002154 Gearbox
ATD
Drum brake 0002154
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45-9 page 3
45
Engine Engine identification characters ABS control unit identification number 6Q0907379AF 6Q0907379AA 6Q0907379R 1.9 ltr./96 kW TDI PD ASZ 6Q0907379S 6Q0907379AB 6Q0907379AG 6Q0907379AH 6Q0907379T ABS version ABS ABS ABS TCS TCS TCS ESP ESP Brakes at the front axle 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II 15 C54-II Brakes at the rear axle Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake Disc brake
FABIA 2000 Code number Gearbox
Chassis
0002229 0000008 0000008 0000008 0000008 0002229 0000296 0000296 Gearbox
The read-out on display is the control unit coding, e.g. 0000365):
6Q0907379T ESP 8.0 Coding 0000365 Vehicle system test Select function XX
front
X00 WSC XXXXX HELP
Press
Readout on display: only on vehicles with ABS/TCS/ESP BOSCH 8.0
Function
1 6 select access authorisation and conAccess authorisation Enter code number XXXXX
firm with Q . Readout on display: Note The steering wheel must be in the straight ahead position before executing the function access authorisation.
Enter code number 40168 and confirm with

Readout on display:
Q. Vehicle system test Select function XX HELP
Select function
0 4 initiate basic setting and conInitiating basic setting Enter display group number 0 0 1 and confirm with Q . Basic setting 1 EIN <8-OFF> Bal. steer. angl. send. O.K.
firm entry with Q . Readout on display: Readout on display:

XXX
Select display group

Readout on display:
Null balance steering angle sender -G85- is performed successfully.
Switch off the ignition for about 2 seconds. Switch on ignition.

Note The vehicle system tester -V.A.G 1552- must remain connected up while the ignition is switched off.
Check straight-ahead position using function 8 read
measured value block Chap. 45-11, display group number 005.
45-9 page 4
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
45
Press
with Q . Readout on display: Note

The ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- will light up and will remain lit up if the control unit is incorrectly coded.
At the same time, an entry is recorded in the fault
memory Chap. 45-5.
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45-9 page 5
45
FABIA 2000
Chassis
45-9 page 6
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FABIA 2000
Chassis
45
45-10 Reading measured value block - BOSCH 5.7

-VAS 5051/5A- or -VAS 5051/6AThe control unit can transmit many measured values. These measured values provide information about the operating condition of the system or the connected sensors. In many cases the transmitted measured values are useful for fault finding and fault elimination. As all measured values cannot be analysed simultaneously they are concentrated in individual display groups, which can be selected via display group numbers.
Safety measures
If test and measuring devices are required during test drives observe 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 passenger seat, the passenger could be injured by the release of the passenger airbag in the event of an accident.
Test sequence and test tables with measured values

Perform with the vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform with the vehicle system tester -V.A.G 1552-
Connect Vehicle system tester -V.A.G 1552- and select the control unit for brake electronics with the ignition switched on (address word 03) Chap. 45-5. Readout on display:
Press
0 and 8 for the function Read measured value block and confirm with Q . Reading measured value block Enter display group number XXX
Readout on display:
Enter display group number 45-10 page 2.

What now appears in the display is the measured value block selected in standardised form. Note To switch to another display group proceed as follows:
Edition 07.04 S00.5303.16.20
Reading measured value block - BOSCH 5.7
45-10 page 1
45
Display group number higher lower skip -V.A.G 1551Press 3 Press 1 Press C -V.A.G 1552Press Press Press C
FABIA 2000
Chassis
If the specifications are achieved in all the display

fields, press
.
Press
0 and 6 for the function End output and con-
firm with Q . Display group number 001: The current wheel speeds are displayed. They serve to check the speed sensor assignment relatively to the wheel (to this end raise the vehicle and turn the wheel by hand).
Reading measured value block 1 0 km/h 0 km/h 0 km/h
0 km/h
Readout on display Rear right wheel speed (km/h)
Rear left wheel speed (km/h) Front right wheel speed (km/h) Front left wheel speed (km/h)
Display group number 002: vehicles with ABS, ABS/EDL/TCS BOSCH 5.7
Reading measured value block 2 0 0 1
Readout on display not assigned
Relay for solenoid valves of ABS -J106 0 - Not allowed during the function Read measured value block. The
relay was not activated with ignition on.

1 - Specified value; with ignition on the relay was activated by the ABS
with EDL control unit -J104-. Return flow pump for ABS -V39 0 - Specified value; no voltage on return flow pump motor. 1 - Not allowed during the function Read measured value block. Voltage present on
return flow pump motor. Brake light switch -F 0 - Brake pedal not actuated 1 - Brake pedal operated, if deviation carry out electrical test, test step No. 4 Chap. 45-15.
45-10 page 2
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FABIA 2000
Chassis
45
vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
Reading measured value block 2 0 0 activated
Readout on display TCS and ESP push-button -E256 0 - Switch not operated operated - switch operated, if deviation: Carry out electrical
test, test step No. 5 Chap. 45-15
Switch for hand-brake control -F9 0 - Hand brake not appied operated - hand brake applied, if deviation: Carry out electrical test, test
step No. 7 Chap. 45-15
Brake light switch -F 0 - Brake pedal not actuated operated - brake pedal operated, if deviation: Carry out electrical test, test step No. 4
Chap. 45-15
Brake pedal switch -F47 0 - Brake pedal not actuated operated - brake pedal operated, if deviation: Carry out electrical test, test step No. 4 Chap. 45-
15
Display group number 003: vehicles with ABS/EDL/TCS BOSCH 5.7 Note Readout of the display group number must occur while the engine is running.
Reading measured value block 3 800 rpm 10 % 1
Switch for the Traction Control System -E132 0 - Switch not actuated 1 - Button operated, if deviation: Carry out electrical test, test step No. 5
Chap. 45-15
current engine torque

Display range 0100 %
Engine speed
Display range 08000 rpm
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45-10 page 3
45
FABIA 2000
Chassis
Reading measured value block 3 770 rpm 33 Nm 33 Nm
0%
Readout on display Throttle valve angle

Engine loss torque

Display range 0630 Nm

Engine speed
Display group number 004: vehicles with ABS/EDL/TCS BOSCH 5.7
Reading measured value block 4 2:50 h 0 0
Disregard display EDL disconnected because of increased brake temperature

0 - none 1 - yes
Stationary time information

too great ERROR invalid
45-10 page 4
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FABIA 2000
Chassis
45
Reading measured value block 4 2:50 h on/off
not assigned EDL disconnected because of increased brake temperature Stationary time information
too great ERROR invalid
Display group number 005: vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
Reading measured value block 5 0,00 0.00/s 1.3 bar
0.00 m/s2
Readout on display Lateral acceleration sender -G200 Specified value for vehicle at standstill: -0,70.7 m/s2 Specified value at full steering angle and at a speed of 20
km/h: -6,06.0 m/s2 Brake pressure sender 1 -G201 Specified value for not-operated brake: -7,07.0 bar
Yaw rate sender -G202 Specified value for vehicle at standstill: -3,03.0 /s
Steering angle sender -G85 Specified value when driving straight ahead: -2,52,51)
1)
If a speed of 20 km/h is exceeded self-diagnosis is discontinued by the ABS with EDL control unit -J104-.
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45-10 page 5
45
FABIA 2000
Chassis
Reading measured value block 6 12.7 V on off
WSC XXXXX
Readout on display Workshop code operating instructions vehicle system tester -V.A.G 1552-
Return flow pump for ABS -V39 off - Specified value; no voltage on return flow pump motor. on - Not allowed during the function Read measured value block. Volt-
age present on return flow pump motor. Relay for solenoid valves of ABS -J106 on - Specified value; with ignition on the relay was activated by the ABS with EDL
control unit -J104-.

off - Not allowed during the function Read measured value block. The relay was not
activated with ignition on. Voltage supply of the ABS with EDL control unit -J104 Specified value: 11,014.5 V
Reading measured value block 125 Steering angle 1 Engine 1 Gearbox 1
Combi 1
Readout on display
Data BUS for dash panel insert

1 - Data BUS connection is present 0 - Data BUS connection is not present1)
Data BUS for gearbox control unit2)

Data BUS for engine control unit

Data BUS for steering angle sender

1)
2)
The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine control unit or gearbox control unit or dash panel insert defective. Only on vehicles equipped with an automatic gearbox.
45-10 page 6
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FABIA 2000
Chassis
45
45-11 Reading measured value block - BOSCH 8.0

-VAS 5051/5A- or -VAS 5051/6A The control unit can transmit many measured values. These measured values provide information about the operating condition of the system or the connected sensors. In many cases the transmitted measured values are useful for fault finding and fault elimination. As all measured values cannot be analysed simultaneously they are concentrated in individual display groups, which can be selected via display group numbers.
Safety measures
If test and measuring devices are required during test drives observe 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 equipment is operated from
the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
Test sequence and test tables with measured values

Perform with the vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform with the vehicle system tester -V.A.G 1552-

Select function
0 8 Read measured value block Reading measured value block Enter display group number
and confirm the entry with key Q . Readout on display: Readout on display:
XXX
Enter display group 45-11 page 2.

What now appears in the display is the measured value block selected in standardised form.
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45-11 page 1
45
Note Proceed according to the following table to switch to another display group: Display group number higher lower skip -V.A.G 1551Press 3 Press 1 Press C -V.A.G 1552Press Press Press C
FABIA 2000
Chassis
If the nominal values are reached in all display fields,

press the key .
Press
0 6 for the function End output and confirm
with Q . Display group number 001: The current wheel speeds are displayed. They serve to check the speed sensor assignment relatively to the wheel (to this end raise the vehicle and turn the wheel by hand).
Reading measured value block 1 0 km/h 0 km/h 0 km/h
0 km/h
Readout on display Rear right wheel speed (km/h)
Rear left wheel speed (km/h) Front right wheel speed (km/h) Front left wheel speed (km/h)
45-11 page 2
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Display group number 002: vehicles with ABS, ABS/TCS BOSCH 8.0
Reading measured value block 2 0 0 1
Relay for solenoid valves of ABS -J106 0 - Not allowed during the function Read measured value block. The
relay was not activated with ignition on.

1 - Specified value; with ignition on the relay was activated by the ABS
with EDL control unit -J104-. Return flow pump for ABS -V39 0 - Specified value; no voltage on return flow pump motor. 1 - Not allowed during the function Read measured value block. Voltage present on
return flow pump motor. Brake light switch -F 0 - Brake pedal not actuated 1 - Brake pedal actuated
Vehicles with ABS//TCS/ESP BOSCH 8.0
Reading measured value block 2 0 0 activated
Readout on display TCS and ESP push-button -E256 0 - Switch not operated operated - switch operated
Switch for hand-brake control -F9 0 - Hand brake not appied operated - hand brake applied
Brake light switch -F 0 - Brake pedal not actuated operated - brake pedal operated
Brake pedal switch -F47 0 - Brake pedal not actuated operated - brake pedal operated
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45-11 page 3
45
Display group number 003: vehicles with ABS/TCS BOSCH 8.0 Note Readout of the display group number must occur while the engine is running.
FABIA 2000
Chassis
Reading measured value block 3 800 rpm 10 % 1
TCS switch -E132 0 - Switch not actuated 1 - Switch actuated

Engine speed
Reading measured value block 3 770 rpm 33 Nm 33 Nm
0%
Readout on display Throttle valve angle

Engine loss torque


Engine speed
45-11 page 4
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Display group number 004: vehicles with ABS/TCS BOSCH 8.0
Reading measured value block 4 2:50 h on/off 0
Disregard display EDL disconnected because of increased brake temperature

off - no EDL disconnected, EDL system operational on - EDL disconnected because of increased brake temperature, EDL system not op-
erational Stationary time information (cooling time for brakes)

Display range 0:0255:59 - Stationary time of the vehicle after ignition off until the next ignition
on
ERROR - missing message from combiinstrument
Reading measured value block 4 2:50 h on/off
not assigned EDL disconnected because of increased brake temperature

off - no EDL disconnected, EDL system operational on - EDL disconnected because of increased brake temperature, EDL system not op-
erational Stationary time information (cooling time for brakes)

Display range 0:0255:59 - Stationary time of the vehicle after ignition off until the next ignition
on
ERROR - missing message from combiinstrument
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45-11 page 5
45
Display group number 005: Vehicles with ABS//TCS/ESP BOSCH 8.0
FABIA 2000
Chassis
Reading measured value block 5 0,00 0.00/s 1.3 bar
0.00 m/s2
Readout on display Lateral acceleration sender -G200-1)

Specified value for vehicle at standstill: -0,70.7 m/s2 Specified value at full steering angle and at a speed of 20
km/h: -6,06.0 m/s2 Brake pressure sender 1 -G201-2)

Specified value for not-operated brake: -7,07.0 bar
Yaw rate sender -G202-1)

Specified value for vehicle at standstill: -3,03.0 /s
Steering angle sender -G85 Specified value when driving straight ahead: -2,52,53)
1) 2) 3)
The sender is located in the ESP sensor unit -G419-. The sender is located in the hydraulic control unit. If a speed of 20 km/h is exceeded self-diagnosis is discontinued by the ABS with EDL control unit -J104-.
Reading measured value block 6 12.7 V on off
WSC XXXXX
Readout on display Workshop code operating instructions vehicle system tester -V.A.G 1552-
Return flow pump for ABS -V39 off - Specified value; no voltage on return flow pump motor. on - Not allowed during the function Read measured value block. Volt-
age present on return flow pump motor. Relay for solenoid valves of ABS -J106 on - Specified value; with ignition on the relay was activated by the ABS with EDL

off - Not allowed during the function Read measured value block. The relay was not
activated with ignition on. Supply voltage of the ABS control unit -J104 Specified value: 11,014.5 V
45-11 page 6
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Display group number 007 (not fitted to all vehicles) The vehicle must be raised and the respective wheel must be turned by hand, in order to check the fitting position of the speed sensor.
Reading measured value block 7 o.k. o.k. o.k.
o.k.
Readout on display Fitting position of speed sensor RR

o.k. - fitting position OK n.o.k. - fitting position N.O.K. invalid - wheel does not turn
Fitting position of the speed sensor RL

Fitting position of the speed sensor FR

Fitting position of the speed sensor FL

Reading measured value block 9 0 0 1.3 bar
Brake pressure sender 1 -G201-1)

Specified value for not-operated brake: -7,07.0 bar
Brake light switch -F 0 - Brake pedal not actuated operated - brake pedal operated
Brake pedal switch -F47 0 - Brake pedal not actuated operated - brake pedal operated
1)
The sender is located in the hydraulic control unit.
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45-11 page 7
45
Display group number 125 (for all vehicles):
FABIA 2000
Chassis
Reading measured value block 125 Steering angle 1 1 Engine 1 Gearbox 1
Combi 1
Readout on display
Data BUS for dash panel insert

Data BUS for gearbox control unit2)

Data BUS for engine control unit

Data BUS for steering angle sender

1)
2)
The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine control unit or gearbox control unit or dash panel insert defective. Only on vehicles fitted with automatic gearbox.
Reading measured value block 126
ESP sensors 1
Readout on display
Data BUS ESP sensor unit -G419 1 - Data BUS connection is present 0 - Data BUS connection is not present1)
not assigned not assigned not assigned

1)
The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine control unit or gearbox control unit or dash panel insert defective.
45-11 page 8
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Display group number 127 (for all vehicles):
Reading measured value block 127 Airbag 1
not assigned Data BUS for airbag control unit

not assigned
1)
The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine control unit or gearbox control unit or dash panel insert defective.
Edition 04.05 S00.5303.18.20
45-11 page 9
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FABIA 2000
Chassis
45-11 page 10
Edition 04.05 S00.5303.18.20
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45-12 Final control diagnosis ABS system BOSCH 5.7 and BOSCH 8.0
-VAS 5051/5A- or -VAS 5051/6AThe final control diagnosis is a part of the electrical test. Final control diagnosis is used to test the pump motor. It is also used to check the correct operation of the hydraulic circuits (assignment of brake pressure lines to the wheel brakes, and also the operation of the valves) to ensure they are correctly connected and are not leaking. Note
The vehicle must be raised so that the wheels are
clear of the ground (2nd mechanic required for rotating the wheels).
It is possible to quit the test procedure at any time by pressing C After depressing the brake pedal several times, the
vacuum in the brake servo unit is reduced. Greater effort is then required to operate the brake pedal in order to achieve the same fluid pressure in the brake system as with vacuum assistance.
Once the vacuum in the brake servo unit has been re-
duced, it is possible that the wheels do not lock start engine in order to build up vacuum in the brake servo unit. tions on the display, i.e. carry out all self-diagnosis working steps in the prescribed sequence.
Operate vehicle system tester following the indica-
During actuator diagnosis do not exceed a maximum
wheel speed of 10 km/h. At a higher speed the ABS with EDL control unit -J104- interrupts the actuator diagnosis. Example (only for vehicle system tester -V.A.G 1552-): Read-out on display of V.A.G. 1552 during final control diagnosis: IFL = Inlet valve front left VBAT = V-Battery voltage, voltage present on valve OFL = Outlet valve front left OV = O Volt; no voltage on valve locked/free = Wheel status; must be checked by 2nd mechanic Hydr-P = Hydraulic pump (Return flow pump)
Final control diagnosis - -> EDL valves/Hydr.p:V BAT Wheel FL/FR lock Final control diagnosis IFL: VBAT OFL: 0V - -> Wheel FL locked
Edition 07.04 S00.5303.16.20
Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0
45-12 page 1
45
Performing actuator diagnosis
With the vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 With the vehicle system tester -V.A.G 1552-
FABIA 2000
Chassis
Press
0 and 3 for the function actuator diagnosis
and confirm with Q . Return flow pump for ABS -V39- must run. Note
On vehicles with ABS, ABS/EDL/TCS the ABS warn-
ing light -K47- flashes 2x and the dual circuit and hand brake system warning light -K7- flashes 4x per second during the next working steps.
On vehicles with ABS/EDL/TCS/ESP the ABS warn-
ing light -K47- flashes 2x per second during the next working steps . Readout on display:
Final control diagnosis Hydraulic pump ABS -V64 Final control diagnosis Operate brake ->
Press
within the next 60 seconds. ->
Readout on display:
Operate brake pedal Press

. Final control diagnosis - -> IFL: OV OFL: 0V Wheel FL locked
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel

by hand. If the wheel does not lock, it is possible that there is a fault in the mechanical/hydraulic part of the brake system.
Press
. Final control diagnosis IFL: VBAT OFL: 0V - -> Wheel FL locked
Readout on display:
Press
Return flow pump for ABS -V39- must run. Brake pedal must not yield. If the brake pedal yields, there is a fault in the hydraulic unit. In that case replace the hydraulic unit BOSCH 5.7 Chap. 45-17, BOSCH 8.0 Chap. 45-18. Readout on display:
Final control diagnosis IFL: VBAT OFL: VBAT - -> Wheel FL free

by hand. If the wheel locks, it is possible that the brake pressure lines to the wheel brakes are wrongly connected.
45-12 page 2
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Press
Return flow pump for ABS -V39- no longer runs. Readout on display:
Final control diagnosis IFL: VBAT OFL: 0V - -> Wheel FL free
Press
Brake pedal must be felt to yield. If the brake pedal does not yield, there is a fault in the hydraulic unit. In that case replace the hydraulic unit BOSCH 5.7 Chap. 45-17, BOSCH 8.0 Chap. 4518. Readout on display:
Final control diagnosis - -> IFL: OV OFL: 0V Wheel FL locked

Press
. Final control diagnosis Release brake ->
Readout on display:
Take your foot off the brake pedal. Press

. Final control diagnosis Operate brake ->
Readout on display:

. Final control diagnosis - -> IFR: 0V OFR: 0V Wheel FR locked
Readout on display:

Press
. Final control diagnosis IFR: VBAT OFR: 0V - -> Wheel FR locked
Readout on display:
Press
Final control diagnosis IFR: VBAT OFR: VBAT - -> Wheel FR free

Press
Return flow pump for ABS -V39- no longer runs.
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45-12 page 3
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Readout on display:
Final control diagnosis IFR: VBAT OFR: 0V
FABIA 2000
Chassis
Press
- -> Wheel FR free
Final control diagnosis - -> IFR: 0V OFR: 0V Wheel FR locked

Press
Readout on display:

Readout on display:

. Final control diagnosis - -> IRL: 0V ORL: 0V Wheel RL locked
Readout on display:

Press
. Final control diagnosis IRL: VBAT ORL: 0V - -> Wheel RL locked
Readout on display:
Press
Final control diagnosis IRL: VBAT ORL: VBAT - -> Wheel RL free

Press
Final control diagnosis IRL: VBAT ORL: 0V - -> Wheel RL free
Press
45-12 page 4
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Final control diagnosis - -> IRL: 0V ORL: 0V Wheel RL locked

Press
Readout on display:

Readout on display:

. Final control diagnosis - -> IRR: 0V ORR: 0V Wheel RR locked
Readout on display:

Press
. Final control diagnosis IRR: VBAT ORR: 0V - -> Wheel RR locked
Readout on display:
Press
Final control diagnosis IRR: VBAT ORR: VBAT - -> Wheel RR free

Press
Final control diagnosis IRR: VBAT ORR: 0V - -> Wheel RR free
Press
Brake pedal must be felt to yield. If the brake pedal does not yield, there is a fault in the hydraulic unit. In that case replace the hydraulic unit
Edition 07.04 S00.5303.16.20 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0
45-12 page 5
45
BOSCH 5.7 Chap. 45-17, BOSCH 8.0 Chap. 4518. Readout on display:
FABIA 2000
Chassis
Final control diagnosis - -> IRR: 0V ORR: 0V Wheel RR locked

Press
Readout on display:

. Final control diagnosis - -> EDL valves/Hydr. p: VBAT Wheel FL/FR lock
Read-out on display (for vehicles with EDL):
Instruct the 2nd mechanic to rotate the relevant

wheels by hand.
If the wheels do not lock, there is a fault in the hydraulic part of the ABS system. In this case replace the hydraulic unit BOSCH 5.7 Chap. 45-17, BOSCH 8.0 Chap. 45-18.
Press
The warning light goes out. Read-out on display (for vehicles with EDL): The final control diagnosis is ended.
Function unknown or cannot be executed at this moment ->
Press
Readout on display: Note

If the ABS warning light -K47- does not go out, there
is a fault in the system.

Carefully follow the test sequence step by step: first
interrogate the fault memory then erase.
End output (function 06) Chap. 45-5.
45-12 page 6
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45-13 Basic setting - ABS systems BOSCH 5.7

The function basic setting performs the following tasks:
On vehicles with ABS/EDL/TCS and ABS/EDL/TCS/
ESP BOSCH 5.7 the bleeding of the hydraulic unit is performed via display group 10.
On vehicles with ABS/EDL/TCS/ESP additionally the
null balance of the steering angle sender -G85- is performed via display group 001.
Bleeding the hydraulic unit (vehicles with ABS/EDL/

TCS/ESP BOSCH 5.7) 45-13 page 1. TCS/ESP BOSCH 5.7) 45-13 page 3. 45-13 page 4.
Bleeding the hydraulic unit (vehicles with ABS/EDL/ Null balance of the steering angle sender -G85 Perform vehicle and system test (vehicles with ABS/
EDL/TCS/ESP BOSCH 5.7) 45-13 page 6.
Bleeding the hydraulic unit (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7)

-VAS 5051/5A- or -VAS 5051/6A Brake filling and bleeding device, e. g.
-ROMESS S15 Brake fluid Chapter 00-3
It is only necessary to carry out the basic setting if at least one chamber of the brake fluid reservoir has run completely empty, or after completing repairs to the brake system because of leaks. Perform basic setting of vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform basic setting of the vehicle system tester -V.A.G 1552Note Operate the vehicle system tester -V.A.G 1552- by referring to the read-out on the display:
WARNING! When replenishing brake fluid with a brake filling and bleeding appliance, e.g. ROMESS S15, it is important to ensure a minimum filling pressure of 0.2 MPa (2 bar).
Edition 07.04 S00.5303.16.20
Basic setting - ABS systems BOSCH 5.7
45-13 page 1
45
If the filling pressure of 0.2 MPa (2 bar) is not reached, proper bleeding of the hydraulic unit is no longer assured.
FABIA 2000
Chassis
Connect brake filling and bleeding appliance, e. g.

ROMESS S15.
Bleed brake system Chapter 47-4. Connect Vehicle system tester -V.A.G 1552- and select the control unit for brake electronics with the ignition switched on (address word 03) Chap. 45-5. Readout on display:
Press
0 and 4 for the function basic setting and confirm with Q . Basic setting Enter display group number XXX
Readout on display:
First actuate the brake pedal 10x and hold brake

down.
Press
0 , 1 and 0 and confirm with Q .
Note If you are using V.A.G. 1551 a <3> appears instead of <>. Readout on display:
System in basic setting 10 Rel. pedal;FR+FL bleeder screws OPEN <> System in basic setting Actuate pedal 10x; wait System in basic setting Actuate pedal 10x; wait System in basic setting Bleeder screw CLOSED 11
Press
Readout on display:
Return flow pump for ABS -V39- runs.
Readout on display:
12
Readout on display:
13 <>
Press
. System in basic setting 14 Rel. pedal;RR+RL bleeder screws OPEN <> System in basic setting Actuate pedal 10x; wait System in basic setting Bleeder screw CLOSED System in basic setting Part bleeding ended... Vehicle system test Select function XX 15
Readout on display:
Press
Readout on display:
Readout on display:
16 <> 17
Press
Readout on display:
Press
. HELP
Readout on display:
Press
0 and 6 for the function End output and conVehicle system test Enter address word XX HELP
firm the entry with Q . Readout on display:
Switch off ignition.
45-13 page 2
Edition 07.04 S00.5303.16.20
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Separate plug connection to V.A.G. 1552. Bleed brake system Chapter 47-4. Perform test drive with at least one ABS adjustment.
Bleeding the hydraulic unit (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7)

It is only necessary to carry out the basic setting if at least one chamber of the brake fluid reservoir has run completely empty, or after completing repairs to the brake system because of leaks. Perform basic setting of vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform basic srtting of the vehicle system tester -V.A.G 1552Note Operate the vehicle system tester by referring to the read-out on the display:
WARNING! When replenishing brake fluid with a brake filling and bleeding appliance, e.g. ROMESS S15, it is important to ensure a minimum filling pressure of 0.2 MPa (2 bar). If the filling pressure of 0.2 MPa (2 bar) is not reached, proper bleeding of the hydraulic unit is no longer assured.
Connect brake filling and bleeding appliance, e. g.

ROMESS S15.
Press
0 and 4 for the function basic setting and Basic setting Enter display group number XXX
confirm with Q . Readout on display:
Edition 07.04 S00.5303.16.20
45-13 page 3
45
down.
FABIA 2000
Chassis
Press
0 , 1 and 0 and confirm with Q . Basic setting 10 EIN <8-OFF> Rel. pedal;FR+FL bleeder screws OPEN <8> Basic setting 10 Actuate pedal 10x; wait Basic setting 10 Actuate pedal 10x; wait Basic setting 10 Bleeder screw CLOSED <8-OFF>
Readout on display:
Press
8.
Readout on display:
Readout on display:
<8-OFF>
Readout on display:
<8-OFF> <8>
Press
8. Basic setting 10 <8-OFF> Rel. pedal;RR+RL bleeder screws OPEN <8> Basic setting 10 Actuate pedal 10x; wait Basic setting 10 Bleeder screw CLOSED Basic setting 10 Part bleeding ended... Vehicle system test Select function XX <8-OFF>
Readout on display:
Press
8.
Readout on display:
Readout on display:
<8-OFF> <8> <8-OFF>
Press
8.
Readout on display:
Press
. HELP
Readout on display:
Press
firm the entry with Q . Readout on display: Steering angle sender

Switch off ignition. Separate plug connection to V.A.G. 1552. Bleed brake system Chapter 47-4. Perform test drive with at least one ABS adjustment.
Null balance of the steering angle sender -G85Null balance of the steering angle sender -G85- is required if:
The ABS control unit -J104- of the steering angle
sender -G85- or the steering column are replaced.

Settings have been changed on the running gear with-
in the scope of a chassis alignment.

If as a result of a fault entry in the fault memory of the
ABS control unit -J104- the fault table indicates a fault, perform null balance.
45-13 page 4
Edition 07.04 S00.5303.16.20
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-V.A.G 1551/3B- or -V.A.G 1551/3CNote For the null balance of the steering angle sender -G85first perform function 11 coding 2. To do so first enter the workshop code in the vehicle system tester -V.A.G 1552-.
Start the engine. Turn the steering column one turn to the right and one
turn to the left.
Perform a short test drive on an even surface. Drive

straight ahead and no faster than 20 km/h, pay specific attention to the following two points:
If the steering wheel is off straight, correct within the
scope of a chassis alignment. After the alignment again perform null balance.
If during the test drive the steering wheel is straight,
stop the vehicle in its straight ahead position. Make sure the steering wheel is not moved. Do not switch off the ignition!
Press
1 and 1 for the function Coding 2 and conCoding 2 Enter code number Q. Vehicle system test Select function XX HELP
firm with Q . Readout on display:

XXXXX
Enter code number 40168 and confirm entry with

Readout on display:
Press
0 and 4 for the function basic setting and confirm with Q .
Readout on display:
Basic setting Enter display group number XXX Function unknown or cannot be carried out at the moment Basic setting 1 ON <8-OFF> Bal. steer. angl. send. O.K. ->
Press
If this appears on the display, function 11 coding 2 was not successfully performed. Readout on display:

Basic setting 1 ON <8-OFF> Bal. steer. angl. send. N.O.K. -
or: Readout on display: or:

Edition 07.04 S00.5303.16.20 Basic setting - ABS systems BOSCH 5.7
45-13 page 5
45
Readout on display: 1. Interrogate fault memory (Function 02) 2. Erase fault memory (Function 05) 3. End output (function 06) 4. Switch off the ignition. 5. Switch on the ignition. 6. Again perform null balance.
FABIA 2000
Basic setting 1 ON <8-OFF> Bal. steer. angl. send. locked
Chassis
-
Press
. Vehicle system test Enter address word XX HELP
Readout on display:
Press
firm with Q .
Perform ESP road and system test (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7)
The ESP road test is a plausibility test of the signals from the lateral acceleration sender -G200-, yaw rate sender -G202- (both senders are integrated in one housing) and the brake pressure sender 1 -G201-. The ESP road test should be performed after each replacement of the electrical components of the ESP system. If the ESP road test is initiated, it can no longer be interrupted and must be performed. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3B- or -V.A.G 1551/3C-
Press
0 and 4 for the function basic setting and Basic setting Enter display group number XXX System in basic setting 3 System test activated O.K. ->
Press
Readout on display: The ESP road and system test is activated, ESP and TCS warning light -K155- lights up.
Press
Readout on display:
Press
with Q . Readout on display:
45-13 page 6
Edition 07.04 S00.5303.16.20
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Disconnect vehicle system tester -V.A.G 1552-. Start the engine. Depress the brake pedal forcefully until the ESP and
TCS warning light -K155- goes out, at the same time the ABS warning light -K47- lights up.
Now perform the ESP road test.

WARNING!
Observing the rules of the road traffic regula-
tions as well as paying attention to the traffic conditions must be given top priority.
Drive a right or a left curve. Subsequently carry out a

change of direction and drive a left or a right curve.
After cornering, drive straight ahead for a certain period of time. Note
A curve with a radius of 10 to 12 meters and a speed
of 15 to 20 km/h must be driven in approx 4 seconds during cornering.

It must be driven in such a way, that no ABS, EDL,
TCS or ESP control is activated.

If there are other traffic dependent driving manoeu-
vres between cornerings, they will have no influence on the ESP road test. If the ABS warning light -K47- goes out, the ESP road and system test was successfully performed and ended, the system is OK. If the ABS warning light -K47- does not go out, the ESP road and system test was not successfully performed.
Repeat the ESP road and system test 45-13

page 6. If the ABS warning light -K47- and the ESP and TCS warning light -K155- light up, there are faults in the system.
Interrogate fault memory Chap. 45-5.
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45-13 page 8
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45-14 Basic setting - ABS systems BOSCH 8.0

The function basic setting performs the following tasks:
On vehicles with ABS/TCS/ESP BOSCH 8.0 the
bleeding of the hydraulic unit is performed via display group 10.

On vehicles with ABS/TCS/ESP BOSCH 8.0 the null
balance of the steering angle sender -G85- is performed via display group 001.
On vehicles with ABS/TCS/ESP BOSCH 8.0 the ESP
road and syystem test is performed via display group 003.
Bleeding the hydraulic unit (vehicles with ABS/TCS/

ESP BOSCH 8.0) 45-14 page 1.
Null balance of the steering angle sender -G85- (vehicles with ABS/TCS/ESP BOSCH 8.0) 45-14 page 3. TCS/ESP BOSCH 8.0) 45-14 page 5.
Perform road and system test (vehicles with ABS/
Bleeding the hydraulic unit (vehicles with ABS/TCS/ESP BOSCH 8.0)

It is only necessary to carry out the basic setting if at least one chamber of the brake fluid reservoir has run completely empty, or after completing repairs to the brake system because of leaks. Perform basic setting of vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform basic setting of vehicle system tester -V.A.G 1552Note Operate the vehicle system tester by referring to the read-out on the display:
Edition 07.04 S00.5303.16.20
45-14 page 1
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FABIA 2000
Chassis
WARNING! When replenishing brake fluid with a brake filling and bleeding appliance, e.g. -ROMESS S15-, it is important to ensure a minimum filling pressure of 0.2 MPa (2 bar). If the filling pressure of 2 MPa (2 bar) is not reached, proper bleeding of the hydraulic unit is no longer assured.
Connect brake filling and bleeding device, e.g.

-ROMESS S15-.
Press
0 and 4 for the function basic setting and Basic setting Enter display group number XXX

down.
Press
0 , 1 and 0 and confirm with Q . Basic setting 10 EIN <8-OFF> Rel. pedal;FR+FL bleeder screws OPEN <8> Basic setting 10 Actuate pedal 10x; wait Basic setting 10 Actuate pedal 10x; wait Basic setting 10 Bleeder screw CLOSED <8-OFF>
Readout on display:
Press
8.
Readout on display:
Readout on display:
<8-OFF>
Readout on display:
<8-OFF> <8>
Press
8. Basic setting 10 <8-OFF> Rel. pedal;RR+RL bleeder screws OPEN <8> Basic setting 10 Actuate pedal 10x; wait Basic setting Bleeder screw CLOSED 10 <8> <8-OFF> <8-OFF>
Readout on display:
Press
8.
Readout on display:
Readout on display:
<8-OFF>
Press
8. Basic setting 10 Part bleeding ended... Vehicle system test Select function XX
Readout on display:
Press
. HELP
Readout on display:
Press
firm the entry with Q .
45-14 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Readout on display:
Switch off ignition. Separate plug connection to V.A.G. 1552. Bleed brake system Chapter 47-4. Perform test drive with at least one ABS adjustment.
Null balance of the steering angle sender -G85- (vehicles with ABS/TCS/ESP BOSCH 8.0)
Null balance of the steering angle sender -G85- is required if:
the ABS control unit -J104- or the steering angel send-
er -G85- is replaced and the control unit is coded subsequently.

the steering column is replaced. Settings have been changed on the running gear with-
in the scope of a chassis alignment.

if as a result of a fault entry in the fault memory of the
ABS control unit -J104- the fault table indicates a fault, perform null balance. Special tools, test and measuring equipment and auxiliary items required
-VAS 5051/5A- or -VAS 5051/6APerform basic setting of vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform basic sitting of the vehicle system tester -V.A.G 1552Note For the null balance of the steering angle sender -G85first perform function 16 access authorisation. To do so first enter the workshop code in the vehicle system tester -V.A.G 1552-.
Start the engine. Turn the steering column one turn to the right and one
turn to the left.
Perform a short test drive on an even surface. Drive

straight ahead and no faster than 20 km/h, pay specific attention to the following two points:
If the steering wheel is off straight, correct within the
scope of a chassis alignment. After the alignment again perform null balance.
If during the test drive the steering wheel is straight,
stop the vehicle in its straight ahead position.
Edition 07.04 S00.5303.16.20
45-14 page 3
45
Make sure the steering wheel is not moved. Do not switch off the ignition!
FABIA 2000
Chassis
Press
1 and 6 for the function access authorisaAccess authorisation Enter code number XXXXX Q. Vehicle system test Select function XX HELP
tion and confirm with Q . Readout on display:
Enter code number 40168 and confirm entry with

Readout on display:
Press
0 and 4 for the function basic setting and Basic setting Enter display group number XXX Function unknown or cannot be carried out at the moment Basic setting 1 ON <8-OFF> Bal. steer. angl. send. O.K. ->
Press
If this appears on the display, function 16 access authorisation was not successfully performed. Readout on display: Null balance steering angle sender -G85- is performed successfully.
->

Basic setting 1 ON <8-OFF> Bal. steer. angl. send. N.O.K. ->
or: Readout on display: Null balance steering angle sender -G85- is not performed successfully.
Switch off ignition then switch on again after 10 seconds.
Repeat the null balance of the steering angle sender

-G85-. or: Readout on display: Null balance of the steering angle sender -G85- was not performed, because the steering wheel with the steering angle sender -G85- was not yet moved (steered).
Basic setting 1 ON <8-OFF> Bal. steer. angl. send. locked -
Switch off ignition then switch on again after 10 seconds.
Repeat the null balance of the steering angle sender

-G85-.
Press
. Vehicle system test Enter address word XX HELP
Readout on display:
Press
firm with Q .
45-14 page 4
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FABIA 2000
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45
Perform ESP road and system test (vehicles with ABS/TCS/ESP BOSCH 8.0)
The ESP road test is a plausibility test of the signals from the lateral acceleration sender -G200-, yaw rate sender -G202- (both senders in the ESP sensor unit -G419-) and the brake pressure sender 1 -G201- (in the hydraulic control unit). The ESP road test should be performed after each replacement of the electrical components of the ESP system. If the ESP road test is initiated, it can no longer be interrupted and must be performed. Special tools, test and measuring equipment and auxiliary items required
-VAS 5051/5A- or -VAS 5051/6APerform basic setting of vehicle diagnosis, measurement and information system -VAS 5051-. Chapter 45-4 Perform basic setting of vehicle system tester -V.A.G 1552-
Press
0 and 4 for the function basic setting and Basic setting Enter display group number XXX System in basic setting 3 System test activated O.K. ->
Press
Readout on display: The ESP road and system test is activated, ESP and TCS warning light -K155- lights up.
Press
Readout on display:
Press
with Q . Readout on display:
Disconnect vehicle system tester -V.A.G 1552-. Start the engine. Depress the brake pedal forcefully until the ESP and
TCS warning light -K155- goes out, at the same time the ABS warning light -K47- lights up.
Edition 07.04 S00.5303.16.20
45-14 page 5
45
Now perform the ESP road test.
WARNING!
Observing the rules of the road traffic regula-
FABIA 2000
Chassis
tions as well as paying attention to the traffic conditions must be given top priority.
Drive a right or a left curve. Subsequently carry out a

change of direction and drive a left or a right curve.
After cornering, drive straight ahead for a certain period of time. Note
A curve with a radius of 10 to 12 meters and a speed
of 15 to 20 km/h must be driven in approx 4 seconds during cornering.

It must be driven in such a way, that no ABS, EDL,
TCS or ESP control is activated.

If there are other traffic dependent driving manoeu-
vres between cornerings, they will have no influence on the ESP road test. If the ABS warning light -K47- goes out, the ESP road and system test was successfully performed and ended, the system is OK. If the ABS warning light -K47- does not go out, the ESP road and system test was not successfully performed.
Repeat the ESP road and system test 45-14

page 5. If the ABS warning light -K47- and the ESP and TCS warning light -K155- light up, there are faults in the system.
Interrogate fault memory Chap. 45-5.
45-14 page 6
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FABIA 2000
Chassis
45
45-15 Electrical Test - ABS systems BOSCH 5.7

Test box -V.A.G 1598A Adapter -V.A.G 1598/34 Adapter -V.A.G 1598/34R Measuring tool set, e.g. -V.A.G 1594 A Hand multimeter, e.g. -V.A.G 1526 A-
The test steps 45-15 page 4 apply for:

Vehicles for which the final control diagnosis does not
indicate the fault source. In this case the full electric inspection must be carried out.
Vehicles for which the final control diagnosis does
give a direct indication of the fault source. Then only perform the test steps recommended in the test table (targeted approach).
Test requirements
Fuses according to current flow diagram O.K.
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. trical consumers (headlights, lighting, blowers etc.).
Before starting the test switch off the ignition and elec-
Connecting test box -V.A.G 1598A Unlatch the multi-pin connector -arrow 1- and disconnect from the ABS with EDL control unit -J104- by pulling upwards -arrow 2-.
S45-0074
Connect the test box -V.A.G 1598A- with adapter

-V.A.G 1598/34- -1- to the multi-pin connector on the wiring loom -2-. Use adapter -V.A.G 1598/34R- for RH drive vehicles. Do not connect the multi-pin connector of the adapter -V.A.G 1598/34- -3-. The nominal values are specific to V.A.G 1526A and do not necessarily apply for other measuring tools. After the electrical test:
3 1
V.A.G 1598A V.A.G 1598/34 2

S45-0034
Insert the multi-plug connector on the ABS with EDL

control unit -J104- and lock.
Multi-pin connector with contact assignment

Note All unlisted contacts are not yet assigned and must under no circumstances be connected to other components!
Edition 07.04 S00.5303.16.20 Electrical Test - ABS systems BOSCH 5.7
45-15 page 1
45
Contact assignment of 42-pin plug connection -T42wiring loom/ABS control unit -J104-
FABIA 2000
Chassis
10
11
26
Contact 1 2 5 6 81) 91) 101) 12 13 14 15 16 192) 211) 23 24 251) 261) 27 28 30 31 32 342) 371) 381) 391) Wiring to component Earth terminal 31 Voltage supply of battery + (terminal 30) Earth terminal 31 Voltage supply of battery + (terminal 30) Lateral acceleration sender -G200- (signal line)
42
27
S45-0031
Lateral acceleration sender -G200- and yaw rate sender -G202Lateral acceleration sender -G200- and yaw rate sender -G202Speed sensor front left -G47Speed sensor rear left -G46Speed sensor rear left -G46Speed sensor front right -G45Speed sensor front right -G45Rear right speed sensor output Lateral acceleration sender -G200- and yaw rate sender -G202- (earth cable) Voltage supply (terminal 15) Data BUS cable (CAN-R) Current Flow Diagrams, Electrical Fault Finding and Fitting Locations Brake pressure sender 1 -G201- (earth cable) Brake pressure sender 1 -G201- (signal line) Traction control system switch -E132- or TCS and ESP button -E256Speed sensor front left -G47Speed sensor rear right -G44Speed sensor rear right -G44Brake light switch -FRear left speed sensor output Brake pedal switch -F47Handbrake warning switch -F9Voltage supply for:
Steering angle sender -G85 Lateral acceleration sender -G200 Yaw rate sender -G202-
45-15 page 2
Electrical Test - ABS systems BOSCH 5.7
Edition 07.04 S00.5303.16.20
FABIA 2000 Contact 40 411) 421)

1) 2)
Chassis Wiring to component
45
Data BUS cable (CAN-L) Current Flow Diagrams, Electrical Fault Finding and Fitting Locations Yaw rate sender -G202- (signal line) Brake pressure sender 1 -G201- (voltage line)
only assigned on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 only assigned on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 and navigation system
Overview of test steps

Component to be tested Voltage supply for the ABS return flow pump -V39- to the ABS control unit -J104Voltage supply of the valves in the hydraulic unit for ABS -N55- to the ABS control unit -J104Voltage supply (terminal 15) to the ABS control unit -J104Function of the brake light switch -FFunction of the traction control system switch -E132- or TCS and ESP button -E256Test of the data BUS cables Handbrake warning switch -F91)
Test steps in test table 45-15 page 4
Perform test step 1 Perform test step 2 Perform test step 3 Perform test step 4 Perform test step 5 Perform test step 6 Perform test step 7
1)
Test can only be performed on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7.
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45-15 page 3
45
Test table
Note
FABIA 2000
Chassis
The denominations of the bushes of the test box -V.A.G 1598A- with the adapter -V.A.G 1598/34- are identical to
the contact denominations of the ABS with EDL control unit -J104- in the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. part of the table.
If the measured values deviate from the nominal values perform the fault eliminating measures listed in the right Once these values are reached, additionally check the cable for short-circuit to positive and earth. If the measured values only differ slightly from the nominal values, clean the bushes and plugs of the test devices
and measuring cables (with contact spray -G 000 700 04-) and repeat the test. Before replacing the relevant components test the cables and connectors; more specifically for nominal values below 10 repeat the resistance measurement on the component. Switch on measuring range: Voltage measurement (20V=) Test step Test box -V.A.G 1598Awith adapter -V.A.G 1598/341+2 5+2 Test covers
Test conditions
additional
Specification
Measures for deviations from nominal value
works 1 Voltage supply for the ABS return flow pump -V39- to the ABS control unit -J104-
Ignition off
approx. battery voltage
Test cable from contact 1 or 5 to earth.
Test cable from contact 2 via fuse to battery + Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
1+6 5+6
Voltage supply for the valves in the ABS return flow pump -V39to the ABS control unit -J104-
Ignition off
Test cable from contact 6 via fuse to battery + Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
23 + 1 23 + 5
Voltage supply (terminal 15) to the ABS control unit -J104-
Ignition on
Test cable from contact 23 to the connector of terminal 15 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
45-15 page 4
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Test conditions
additional
Switch on measuring range: Voltage measurement (20V=) Test step Test box -V.A.G 1598Awith adapter -V.A.G 1598/345 + 32 Test covers Specification Measures for deviations from nominal value
works 4 Function of the brake light switch -F-
Ignition off Brake pedal

not actuated
< 1.0 V
Test brake light

switch -F- and read measured value block Chap. 4510, display group number 003.
Test cable from contact 5 to earth.
Test cable from

contact 32 to the brake light switch -F Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Actuate brake
pedal
Test brake light Test fuse.
switch -F- Chap. 45-16.
5 + 27
Function of the traction control system switch -E132- or TCS and ESP button -E256-
Ignition on Traction control approx. batsystem switch or TCS and ESP button pressed. system switch or TCS and ESP button not pressed. tery voltage
Test cable from contact 5 to earth.
Test cable fom

contact 27 to traction control system switch -E132- or TCS and ESP button -E256-.
Traction control < 1.0 V
Check traction control system switch -E132- or TCS and ESP button -E256-
Edition 07.04 S00.5303.16.20
45-15 page 5
45
Switch on measuring range: Resistance measurement (200 /20 M) Test step Test box -V.A.G 1598Awith adapter -V.A.G 1598/3424 + 40 Test covers
FABIA 2000
Chassis
Test conditions
additional works
Specification
Data BUS cables
Ignition off Measuring range

200 set
Disconnect control
units on the data BUS drive Electrical System; Rep. Gr. 90
Connect Test box

-V.A.G 1598A- with adapter -V.A.G 1598/ 34-
Check the data BUS

cable for open circuit.
max. 1.5
Check data BUS
Chapter 48-27. ing to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Ignition off Measuring range 20

M set
Check wiring accord-
Check cables for

short-circuit between the cables or for short-circuit to positive term. or earth.
Switch on measuring range: Voltage measurement (20V=) Test step Test box -V.A.G 1598Awith adapter -V.A.G 1598/3438 + 2 Test covers
Test conditions
additional works
Specification
71)
Switch for handbrake control -F9-
Ignition off Handbrake not applied
< 1.0 V
Reading measured
value block Chap. 45-10, display group number 002. tact 2 via fuse to battery +.
Apply handbrake.
Test cable from con Test cable from

contact 38 to the handbrake warning switch -F9 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
1)
This test sequence can only be performed on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7.
45-15 page 6
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45
45-16 Electrical/electronic components and fitting locations - ABS/ ESP systems BOSCH 5.7 and BOSCH 8.0
Summary of components - Electrical/electronic components and fitting locations ABS/ESP systems BOSCH 5.7
All components marked with 1) can be tested using the vehicle system tester -V.A.G 1552- or the fault read-out scan tool -V.A.G 1551- with the self-diagnosis or using the vehicle diagnosis, measurement and information system -VAS 5051-. 1 - Hydraulic control unit BOSCH 5.71) 9 1 2 3 4 5 6 7 8 fitted until CW 21/2004 different versions: for ABS and ABS/EDL/TCS BOSCH 5.7 without brake pressure sender 1 -G201 for ABS/EDL/TCS/ESP BOSCH 5.7 with brake pressure sender 1 -G201 Distinguishing features Chapter 45-2 Fitting location: in right of engine compartment removing and installing Chapter 45-17 disassembling and assembling Chapter 45-17 ABS/EDL/TCS/ESP BOSCH 5.7 must not be disassembled and repaired 10 2 - Brake pressure sender 1 11 -G201- 1) only on vehicles with ABS/ 12 EDL/TCS/ESP BOSCH 5.7 Fitting location: screwed into 13 the hydraulic control unit removing and installing Chapter 45-17 15 14 must only be replaced, but 17 not repaired 16 3 - Brake servo unit with master S45-0186 brake cylinder and brake fluid reservoir 4 - Traction control system switch -E132 - or TCS and ESP button -E256Fitting location: Centre part of dash panel above radio Operation: Switching off the TCS or ESP function can be inspected in the measured value block Chapter 45-10 and during the Electrical Test Chapter 45-15 removing and installing Electrical System; Rep. Gr. 96; Switches in the dash panel and in the doors, removing and installing switches in the centre console 5 - Traction control system warning light -K86- or ESP and TCS warning light -K155Fitting location: in the dash panel insert Operation: the warning light lights up:
Edition 11.04 S00.5303.17.20
Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7 and BOSCH 8.0
45-16 page 1
45
for about 2 seconds after ignition is switched on if fault is detected in TCS or ESP operation after switching the traction control system switch or TCS and ESP button to OFF
FABIA 2000
Chassis
45-16 page 6 the warning light flashes: during TCS/ESP control 6 - ABS warning light -K47Fitting location: in the dash panel insert Operation: the ABS warning light lights up: for about 2 seconds after the ignition is switched on or the engine is started if a fault is detected, e.g. open circuit to wheel speed sensor 45-16 page 6 7 - Dual circuit and hand brake system warning light -K7Fitting location: in the dash panel insert Operation: Dual circuit and hand brake system warning light: lights up if hand-brake is applied flashes if low brake fluid level lights up for about 2 seconds after ignition is switched on lights up if the electronic brake pressure distribution fails, i.e. when the ABS warning light -K47- comes on 45-16 page 6 8 - Dash panel insert fitted up to model year 2004 9 - Steering angle sender -G85-1) only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 Fitting location: on steering column between the steering wheel and the steering column switch can be tested in the measured value block Chapter 45-10 removing and installing 45-16 page 10 10 - Diagnostic connection Fitting location: in the storage area on the driver's side 11 - Wheel hub with wheel bearing Sensor ring for ABS is built into the wheel hub removing and installing: can only be replaced together with wheel hub and wheel bearing Chapter 42-5 12 - Rear right and rear left wheel speed sensors -G44/G46-1) removing and installing (disc brake or drum brake) Chapter 45-19 Rear wheel speed sensor cables removing and installing (disc brake or drum brake) Chapter 45-19 13 - Switch for hand-brake control -F9Fitting location: on handbrake lever can be inspected in the measured value block Chapter 45-10 and during the Electrical Test Chapter 45-15. removing and installing Chapter 46-3 14 - Lateral acceleration sender -G200- and yaw rate sender -G202-1) only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 Fitting location: under left front seat both senders are integrated in one housing can be tested in the measured value block Chapter 45-10 removing and installing 45-16 page 13 15 - Brake light switch -F-1) assignment Spare part catalogue is open in the off position adjust 45-16 page 8 removing and installing 45-16 page 8
45-16 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
replace after each removal
can be inspected in the measured value block Chapter 45-10 and during the Electrical Test Chapter 4515 16 - Wheel hub with wheel bearing Sensor ring for ABS is built into the wheel hub removing and installing: can only be replaced together with wheel hub and wheel bearing Chapter 40-3 17 - Front right and front left wheel speed sensors -G45/G47-1) removing and installing Chapter 45-19 Front wheel speed sensor cables removing and installing Chapter 45-19
Summary of components - Electrical/electronic components and fitting locations ABS/ESP systems BOSCH 8.0
All components marked with 1) can be tested using the vehicle system tester -V.A.G 1552- or the fault read-out scan tool -V.A.G 1551- with the self-diagnosis or using the vehicle diagnosis, measurement and information system -VAS 5051-. 1 - Hydraulic control unit BOSCH 2 3 4 5 1 8.01) fitted as of CW 22/2004 different versions: ABS ABS/TCS assignment Spare part catalogue Distinguishing features Chapter 45-2 Fitting location: in right of engine compartment removing and installing Chapter 45-18 2 - Traction control system 21 switch -E132- or TCS and ESP button -E256-1) Fitting location: Centre part of dash panel above radio Operation: Switching off the TCS or ESP function removing and installing Electrical System; Rep. Gr. 96; Switches in the dash panel and in the doors, 20 removing and installing switches in the centre console 3 - Traction control system warning light -K86- or ESP and TCS 17 warning light -K15519 18 Fitting location: in the dash panel insert item 6 Operation: the warning light lights up: for about 2 seconds after ignition is switched on if fault is detected in TCS or ESP operation after switching the traction control system switch or TCS and ESP button to OFF
Edition 11.04 S00.5303.17.20 Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7 and BOSCH 8.0
9 10
11
12 13 14 16 15
S45-0185
45-16 page 3
45
FABIA 2000
Chassis
4-
5-
67-
8-
9-
10 -
45-16 page 6 the warning light flashes: during TCS/ESP control ABS warning light -K47Fitting location: in the dash panel insert item 6 Operation: the ABS warning light lights up: for about 2 seconds after the ignition is switched on or the engine is started if a fault is detected, e.g. open circuit to wheel speed sensor 45-16 page 6 Dual circuit and hand brake system warning light -K7Fitting location: in the dash panel insert item 6 Operation: Dual circuit and hand brake system warning light: lights up if hand-brake is applied flashes if low brake fluid level lights up for about 2 seconds after ignition is switched on lights up if the electronic brake pressure distribution fails, i.e. when the ABS warning light -K47- comes on 45-16 page 6 Dash panel insert fitted up to model year 2004 Traction control system warning light -K86- or ESP and TCS warning light -K155Fitting location: in the dash panel insert item 10 Operation: the warning light lights up: for about 2 seconds after ignition is switched on if fault is detected in TCS or ESP operation after switching the traction control system switch or TCS and ESP button to OFF 45-16 page 6 the warning light flashes: during TCS/ESP control ABS warning light -K47Fitting location: in the dash panel insert item 10 Operation: the ABS warning light lights up: for about 2 seconds after the ignition is switched on or the engine is started if a fault is detected, e.g. open circuit to wheel speed sensor 45-16 page 6 Dual circuit and hand brake system warning light -K7Fitting location: in the dash panel insert item 10 Operation: Dual circuit and hand brake system warning light: lights up if hand-brake is applied flashes if low brake fluid level lights up for about 2 seconds after ignition is switched on lights up if the electronic brake pressure distribution fails, i.e. when the ABS warning light -K47- comes on 45-16 page 6 Dash panel insert fitted as of model year 2005
11 - Steering angle sender -G85-1) only on vehicles with ABS/TCS/ESP BOSCH 8.0 Fitting location: on steering column between the steering wheel and the steering column switch removing and installing 45-16 page 10
45-16 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
12 - Diagnostic connection Fitting location: in the storage area on the driver's side 13 - Rear right and rear left wheel speed sensors -G44/G46-1) removing and installing (disc brake or drum brake) Chapter 45-19 Rear wheel speed sensor cables removing and installing (disc brake or drum brake) Chapter 45-19 14 - Wheel hub with wheel bearing Sensor ring for ABS is built into the wheel hub removing and installing: can only be replaced together with wheel hub and wheel bearing Chapter 42-5 15 - Handbrake warning switch -F9-1) Fitting location: on handbrake lever removing and installing Chapter 46-3 16 - ESP sensor unit -G419-1) only on vehicles with ABS/TCS/ESP BOSCH 8.0 Fitting location: under left front seat removing and installing 45-16 page 13 Lateral acceleration sender -G200- and yaw rate sender -G202- are combined in a common housing with the ESP sensor unit -G419 there are no separate fault codes 17 - Brake light switch -F-1) assignment Spare part catalogue is open in the off position adjust 45-16 page 8 removing and installing 45-16 page 8 replace after each removal 18 - Wheel hub with wheel bearing Sensor ring for ABS is built into the wheel hub removing and installing: can only be replaced together with wheel hub and wheel bearing Chapter 40-3 19 - Brake servo unit with master brake cylinder and brake fluid reservoir 20 - Front right and front left wheel speed sensors -G45/G47-1) removing and installing Chapter 45-19 Front wheel speed sensor cables removing and installing Chapter 45-19 21 - Hydraulic control unit BOSCH 8.01) fitted as of CW 22/2004 ABS/TCS/ESP assignment Spare part catalogue Distinguishing features Chapter 45-2 Fitting location: in right of engine compartment removing and installing Chapter 45-18 ABS/TCS/ESP BOSCH 8.0 must not be disassembled and repaired
Edition 11.04 S00.5303.17.20
45-16 page 5
45
Indication of faults by means of warning lights
Vehicle system tester -V.A.G 1552- or fault read-out
FABIA 2000
Chassis
scan tool -V.A.G 1551- or vehicle diagnosis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3-, -V.A.G 1551/3A-,
-V.A.G 1551/3B-, -V.A.G 1551/3C- or Diagnostic cable -VAS 5051/5A- or -VAS 5051/6A Note
When using the fault reader -V.A.G 1551- a minor de-
viation in the display is possible.

When using the vehicle diagnosis, measurement and
information system -VAS 5051- the electrical test is integrated in the Targeted fault finding. Dash panel insert up to model year 2004 Dash panel insert as of model year 2005 Warning lights Pos. 1 2 3 4 Denomination Brake pad warning light -K32Traction control system warning light -K86ESP and TCS warning light -K155ABS warning light -K47Dual circuit and hand brake system warning light -K70
4 1 2 3
S45-0184
Brake pad warning light -K32- (-1-)

If the brake pad warning light -K32- (-1-) does not go
4 1 2 3
S45-0187
out after switching the ignition on or glows during the driving operation, the following can be the causes of the fault: a - The brake pads could be worn down. Check the brake pads on the front and rear axles. Replace the brake pads if they are worn down Chapter 46-1 and Chapter 46-2. b - There is a fault in the wiring Current Flow Diagrams, Electrical Fault Finding and Fitting Locations ABS warning light -K47- (-3-)
If the ABS warning light -K47- (-3-) does not go out af-
ter the ignition is switched on and after completion of the test sequence, the causes of the fault may be: a - Voltage supply is less than 11 volts. b - An ABS fault is present. If an ABS fault is present, the anti-lock brake system remains switched off while the conventional brake system remains fully operational.
45-16 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
WARNING! If an ABS fault -b- is present, the anti-lock brake system remains switched off while the conventional brake system remains fully operational. c - A fault existed on a wheel speed sensor after the last vehicle start (sporadic fault). If there is a fault on a vehicle speed sensor, the ABS warning light -K47goes out automatically after restarting the vehicle and after a speed above 20 km/h is reached. d - The connection form the dash panel insert to the ABS control unit -J104- (databus) is interrupted Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. e - The dash panel insert is defective. ABS warning light -K47- (-3-) and dual circuit and hand brake system warning light -K7- (-4-)
If the ABS warning light -K47- (-3-) goes out or the
dual circuit and hand brake system warning light -K7(-4-) lights up or flashes, the causes of the fault may be: a - The hand-brake is still applied (warning light lights up). b - The brake fluid level is too low (warning light flashes). c - There is a fault in the wiring between dash panel insert and brake fluid level warning contact -F34 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the ABS warning light -K47- (-3-) and the dual circuit
and hand brake system warning light -K7- (-4-) do not go out, then the ABS and EBD (Electronic Brake pressure Distribution) have failed. One must reckon with a somewhat changed braking characteristic.
WARNING! Once the ABS warning light -K47- and the dual circuit and hand brake system warning light -K7have lit up then one can expect the rear wheels to lock quite early on when braking. ABS warning light -K47- (-3-), dual circuit and hand brake system warning light -K7- (-4-), traction control system warning light -K86- (-2-) and ESP and TCS warning light -K155- (-2-)
If the ABS warning light -K47- (-3-) and the dual circuit
and hand brake system warning light -K7- (-4-) goes out, but the traction control system warning light -K86(-2-) or the ESP and TCS warning light -K155- (-2-) remain lit, the causes of the fault may be: a - Fault relates only to TCS or ESP.
Edition 11.04 S00.5303.17.20
45-16 page 7
45
b - ASR is switched off with traction control system switch -E132- or ESP with TCS and ESP button -E256-. c - TCS or ESP is in regulating mode (flashing rhythm 3x per second). d - Short-circuit to positive in traction control system switch -E132- or in TCS and ESP switch -E256(warning light goes out after approx. 5 minutes).
FABIA 2000
Chassis
1
Display overview of the warning lights -K7-, -K47-, -K86- or -K 155Warning lights 1 - Dual circuit and hand brake system warning light -K72 - ABS warning light -K473 - Traction control system warning light -K86- or ESP and TCS warning light -K155For the warning lights of the pos. 3 there are two different symbols, Dash panel insert as of model year 2004 and dash panel insert as of model year 2005. Display overview System condition Dual circuit and hand brake system warning light -K7lights up ABS warning light -K47Traction control system warning light -K86- or ESP and TCS warning light -K155lights up Traction control system switch -E132- or TCS and ESP button -E256not actuated
2 3
S45-0203
Ignition on test of the lights(-K7is only indicated for the test in the dash panel insert) System o.k. ESP/TCS or ABS/ TCS -in recess ESP/TCS or ABS/ TCS are switched off ESP/TCS or ABS/ TCS are switched on again via TCS and ESP button -E256- or traction control system switch -E132-(were switched off)
lights up
does not light up does not light up does not light up does not light up
does not light up does not light up does not light up does not light up
does not light up flashes (3x/seconds) lights up does not light up
not actuated not actuated activated activated
Setting, removing and installing the brake light switch -FSpecial tools, test and measuring equipment and auxiliary items required
Polycarbamide grease -G 052 142 A2-
45-16 page 8
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
Note The brake light switch must be removed for setting.
Remove the storage area on the driver's side Body

Work; Rep. Gr. 70.
Unplug connector from brake light switch.

For vehicles up to 07.01
Turn brake light switch -1- 90 to the left and remove

from its bracket -2-. Note
Carry out installation of the brake light switch only af-
ter attaching the ball head of the pushrod fron the brake servo unit to the brake pedal Chapter 46-4.
The contact surface which the tappet is to touch on
the brake pedal should be greased using polycarbamide grease - G 052 142 A2- before installing the brake light switch.
To adjust, pull out the plunger of the brake light switch

fully.
S45-0062
Press down brake pedal as far as possible by hand. Guide the brake light switch through the assembly
opening and install again by turning 90 to the right.
Release brake pedal.

For vehicles from 08.01
Turn brake light switch -1- 45 to the left and remove

from its bracket -2-. Note
The brake light switch may only be installed once to
ensure that it has an adequately tight fit.

Carry out installation of the brake light switch only af-
ter attaching the ball head of the pushrod fron the brake servo unit to the brake pedal Chapter 46-4.
The contact surface which the tappet is to touch on
the brake pedal should be greased using polycarbamide grease -G 052 142 A2- before installing the brake light switch.
S45-0101
Guide the brake light switch through in the assembly

opening and install by turning it 45 to the right. Pull the brake light switch tappet out completely up to its stop before assembly since it will be automatically adjusted and set during assembly. Brake pedal always remains in the off position in this case (not actuated).
After installing the brake light switch, check whether

brake pedal is in the end position (release position). Continued for all vehicles
Insert plug into brake light switch.

Edition 11.04 S00.5303.17.20 Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7 and BOSCH 8.0
45-16 page 9
45
Inspecting operation of the brake light switch BOSCH
5.7 Chap. 45-10 BOSCH 8.0 Chap. 45-11. Actuate brake pedal all brake lights must light up. Release brake pedal all brake lights must go out.
FABIA 2000
Chassis
Install the storage area on the driver's side Body

Work; Rep. Gr. 70.
Removing and installing steering angle sender -G85- - vehicles with ABS/EDL/ TCS/ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0
The description of the structure and function of the steering angle sender -G85- can be found in self-study programme No. 42. Special tools, test and measuring equipment and auxiliary items required
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3-, -V.A.G 1551/3A-,
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6ARemoving
WARNING! Disconnect earth strap from the battery before commencing work on the electrical system. If the battery earth strap is disconnected and connected, carry out additional operations Electrical System; Rep. Gr. 27.
Disconnect battery Electrical System; Rep. Gr. 27. Check whether the front wheels are in the straightahead position.
Remove steering wheel Body Work; Rep. Gr. 69. Removing steering column trim Body Work;
Rep. Gr. 70. The steering angle sender -G85- is fitted together with the coil spring -2- in housing -1-. They must not be separated or disassembled. When removing pay attention to the steering angle sender -G85- to obtain correct re-installation:
S48-0188
45-16 page 10
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
1
Position the steering angle sender -G85- in the middle
position as shown: A yellow dot must be visible in the window -1-. The markings -arrows- must be flush. Make sure this correct position is maintained.
S48-0189
Secure the coil spring -2- against unintentional turning
by covering it with adhesive tape -1-. -3- Housing for steering angle sender -G85-
2
Disconnect plugs -1- and -2-.
S48-0190
S45-0199
Edition 11.04 S00.5303.17.20
45-16 page 11
45
Carefully release catch hooks -arrows-, remove housing -1- with steering angle sender -G85- and coil spring. Installing
FABIA 2000
Chassis
Slide housing -1- with steering angle sender -G85and coil spring onto the steering column and lock into position with steering column switch -arrows-.
Connect both plug connections.

Note After removing the transport protection or the adhesive tape do not turn the coil spring, only the positioning of the steering angle sender -G85- in centre position is allowed.
S48-0191
Removing transport protection or adhesive tape. Position the steering angle sender in the centre position: A yellow dot must be visible in the window -1-. The markings -arrows- must be flush. Make sure this correct position is maintained.
Fitting steering column trim Body Work;

Rep. Gr. 70.
Install steering wheel Body Work; Rep. Gr. 69. Connect battery Electrical System; Rep. Gr. 27. Perform null balance of the steering angle sender
-G85-. vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
using the vehicle diagnosis, measurement and inforS48-0189
mation system -VAS 5051- Chapter 45-4.
or
using the vehicle system tester -V.A.G 1552-
Chapter 45-13.

If a fault is stored in the fault memory:
Eliminating fault Chapter 45-6. Erasing fault memory Chapter 45-5.

using the vehicle diagnosis, measurement and infor-
mation system -VAS 5051- Chapter 45-4.
or
using the vehicle system tester -V.A.G 1552-
Chapter 45-14.

Eliminating fault Chapter 45-7.
45-16 page 12
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
Erasing fault memory Chapter 45-5.
Removing and installing lateral acceleration sender -G200- and yaw rate sender -G202- or ESP sensor unit -G419- - vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0
Note
The lateral acceleration sender -G200- and the yaw
rate sender -G202- are combined in one housing for the ABS/EDS/ASR/ESP BOSCH 5.7.
Only the ESP sensor unit -G419- for the ABS/ASR/
ESP BOSCH 8.0 exists. The lateral acceleration sender -G200- and the yaw rate sender -G202- are integrated in it.
The removed unit is sensitive to strong vibrations. If the unit was exposed to strong vibrations or blows,
its function cannot be guaranteed. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6ARemoving
WARNING!
Disconnect earth strap from the battery before
commencing work on the electrical system.

If the battery earth strap is disconnected and
connected, carry out additional operations Electrical System; Rep. Gr. 27.
Disconnect battery Electrical System; Rep. Gr. 27. Remove the driver's seat Body Work; Rep. Gr. 72.
Note
The unit is located under the base of the left front seat
2 1
before the cross member.

-Arrow- in Fig. S45-0113 points in the travel direction.
Unplug plug -1- from the unit -3-. Unscrew hexagon nuts -2- and remove unit -3-.
Installing Installation is performed in the reverse order. Pay attention to the following points:
Connect battery Electrical System; Rep. Gr. 27.
S45-0113
Edition 11.04 S00.5303.17.20
45-16 page 13
45
Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. If a fault is stored in the fault memory: vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
FABIA 2000
Chassis


Tightening torques: Sender -G200/G202 - on body (ABS/EDL/ TCS/ESP BOSCH 5.7) ESP sensor unit -G419- on body (ABS/TCS/ ESP BOSCH 8.0) 6 Nm 6 Nm
45-16 page 14
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
45
45-17 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo unit/Master brake cylinder
Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
Note
Removing and installing the hydraulic control unit completely 45-17 page 2. Repairing the hydraulic control unit 45-17 page 6. Mount bracket before assembling the brake lines. Do not bend brake lines when assembling or when connecting. Install brake hoses without transposition. Brake hoses must not come into contact with other components during operating condition. Do not remove the plugs on the connection threads and the holes in the parts carrying brake fluid until just before
assembling.
Tighten all the brake line pipe screws to a tightening torque of 14 Nm.
1 - Hydraulic control unit ABS BOSCH 5.7 ABS/EDL/TCS BOSCH 5.7 assignment Spare part 2 catalogue fitted until CW 21/2004 2 - Brake line 1 identification marking of the hydraulic unit VL to front left brake caliper 3 - Brake line identification marking of the hydraulic unit VR to front right brake caliper 4 - Brake line 21 identification marking of the hydraulic unit HZ2 Master brake cylinder/floating piston circuit to hydraulic control unit 5 - Brake line 19 identification marking of the hydraulic unit HZ1 18 Master brake cylinder/pressure rod piston circuit to hy17 draulic control unit 6 - Brake line identification marking of the hydraulic unit HL to wheel brake cylinder/rear left brake caliper 16 7 - Brake line identification marking of the hydraulic unit HR to wheel brake cylinder/rear right brake caliper 8 - Brake pressure sender 1 -G201removing and installing 45-17 page 10 inspect Chapter 45-10
Edition 07.04 S00.5303.16.20
3 3 4 5 2
4 5 8 6
11
10 12
20 19 13
13 12 15 14
S45-0107
Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo unit/Master brake cylinder
45-17 page 1
45
9must only be replaced, but not repaired Line ABS/EDL/TCS/ESP BOSCH 5.7 to ABS control unit Hydraulic control unit ABS/EDL/TCS/ESP BOSCH 5.7 must not be repaired, replace completely in the event of faults Brake pressure sender 1 -G201- must be replaced, but not repaired assignment Spare part catalogue fitted until KW 21/2004 Line holder for brake line assignment Spare part catalogue Bracket for brake line 2 units assignment Spare part catalogue Bracket for brake line 3 units assignment Spare part catalogue Brake servo unit inspect Chapter 47-2 removing and installing Chapter 47-2 Master brake cylinder cannot be repaired, replace completely in the event of faults Tightness test Chapter 47-2 removing and installing Chapter 47-2 Brake fluid reservoir Self-locking nuts, 20 Nm replace after each removal Bracket for ABS, ABS/ABS/EDL or ABS/EDL/TCS/ESP BOSCH 5.7 Screw, 8 Nm Bracket for ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 Hexagon collar nut, self-locking, 20 Nm replace after each removal
FABIA 2000
Chassis
10 -
11 -
12 -
13 -
14 -
15 -
16 17 18 19 20 21 -
Removing and installing the hydraulic control unit

The removal and installation of the relevant hydraulic control unit is described according to the example of the ABS system BOSCH 5.7. Removal and installation is similar for the ABS/EDL/TCS or ABS/EDL/TCS/ ESP system BOSCH 5.7.
45-17 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
WARNING!
Make absolutely sure that no brake fluid gets
into the plug connector housing of the hydraulic control unit. This may result in the corrosion of the contacts and to system failure.
Carefully clean out the plug connector housing
with compressed air if it gets dirty.

Do not bend the brake lines around the hydrau-
lic control unit. Special tools, test and measuring equipment and auxiliary items required
Brake pedal arrester, e.g. -V.A.G 1238 B- or brake
pedal load -V.A.G 1869/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A Brake filling and bleeding device, e. g.
-ROMESS S15 Bleeding bottle (commercially available) Repair kit SP-No. 1H0 698 311 A Brake fluid Chapter 00-3
Removing Note Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
2 1
Disconnect battery Electrical System; Rep. Gr. 27. Remove engine cover Engine, Mechanics;
Rep. Gr. 10. Vehicles with TDI PD Turbocharger engines
S45-0193
Remove top charge-air pipe -1- with connecting hose

-2- TDI Engine, Mechanics; Rep. Gr. 21. Continued for all vehicles
Actuate brake pedal and arrest with brake pedal arrester.
Attach the bleeder hose of the bleeding bottle onto the

vent valve of the front left brake caliper and open bleeder valve.
Shut the vent valve once the brake fluid has flown out. Disconnect the bleeder hose from the vent valve. Place sufficient non-fluffing cloths under and around
the hydraulic control unit.
S45-0016
Edition 07.04 S00.5303.16.20
45-17 page 3
45
Unlatch the multi-pin connector -arrow 1- and pull off
upwards from the control unit -arrow 2-.
FABIA 2000
Chassis
Close the plug connector housing of the control unit

with a cap.
If necessary remove the brake lines from the line holder.
Mark brake lines. Unscrew brake lines from hydraulic control unit. Close off immediately brake lines. Shut off immediately threaded bores (brake line connections) on the hydraulic control unit with plugs from repair kit SP No. 1 H0 698 311 A.
vehicles with ABS/EDL/TCS/ESP BOSCH 5.7 Note To avoid overvoltage and static discharge do not touch the plug contacts of the brake pressure sender 1 -G201-.
S45-0065
Unplug connector from brake pressure sender 1

-G201-. Continued for all vehicles
Remove right drive shaft from the flange shaft and tie
up. Avoid damaging the paintwork on the drive shaft during this operation.
Drive shaft with constant velocity joint Chapter 40-4 Drive shaft with tripod joint Chapter 40-5
Remove shield from the assembly carrier Chap.

40-1.
Unscrew the nuts of the two hydraulic control unit

brackets.
Remove hydraulic control unit with brackets from the

threaded bores at the body.
2 1
S45-0067
Remove the hydraulic control unit downwards from

the vehicle.
Separate bracket -1- from the fixing bolt of the bracket

-2-.
Release the screws -arrows- and remove hydraulic

control unit from bracket -2-. Installing Note
New hydraulic control units are filled with hydraulic oil
and bleed.
Only then remove plugs from the hydraulic unit when
the relevant brake line is installed.

If the plugs were already removed from the hydraulic
2 1
S45-0067
unit before the brake line is installed, then brake fluid may escape and adequate filling and bleeding can no longer be guaranteed.
Screw bracket -2- onto the hydraulic control unit.
45-17 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Tighten up the screws -arrows- fully to the specified

tightening torque.
Insert bracket -1- onto the fixing bolt of the bracket -2-.
Note Do not immediately tighten the nuts for securing the hydraulic control unit to the body. This facilitates the screwing of the individual brake lines onto the hydraulic control unit.
Install the hydraulic control unit and screw on nuts as

well as collar nut. vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
Mount plug on brake pressure sender 1 -G201-.

Remove plugs from the brake lines to be installed.

WARNING! Pay attention to the correct channel assignment of the brake lines. Interchanging the brake lines will result in dangerous brake control actions.
Connect the brake line to the hydraulic control unit

and tighten 45-17 page 1.
Tighten the collar nut and nuts for securing the hydraulic control unit to the specified tightening torque.
Fit drive shaft to flange shaft.

Drive shaft with constant velocity joint Chapter 40-4 Drive shaft with tripod joint Chapter 40-5
If necessary install shield on the assembly carrier

Chap. 40-1. lock. Further installation occurs in reverse order. Vehicles with TDI PD Turbocharger engines
Insert the multi-plug connector on the control unit and
Install top charge-air pipe -1- with connecting hose -2 TDI Engine, Mechanics; Rep. Gr. 21. Continued for all vehicles
Installing engine cover Engine, Mechanics;

Rep. Gr. 10.
2 1
Connect battery Electrical System; Rep. Gr. 27. Bleed brake system Chapter 47-4. Coding control unit Chap. 45-8 Perform null balance of the steering angle sender -G85- (only for vehicles with ABS/EDL/TCS/ESP) Chap. 45-13.
S45-0193
Edition 07.04 S00.5303.16.20
45-17 page 5
45
Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. If a fault is stored in the fault memory:
FABIA 2000
Chassis

Note For vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 perform a test drive after bleeding with at least one ABS control! Tightening torques: Hydraulic control unit to bracket Bracket to hydraulic control unit and to body
Use new nuts and new hexagon
8 Nm 20 Nm
collar nut! Brake line to hydraulic control unit Drive shaft to flange shaft - gearbox
Use new screws!
14 Nm M8 = 40 Nm M10 = 70 Nm 35 Nm
Shield to assembly carrier
Repairing the hydraulic control unit ABS or ABS/EDL/TCS BOSCH 5.7

The hydraulic control units ABS and ABS/EDL/TCS BOSCH 5.7 must be repaired, while the hydraulic control units ABS/EDL/TCS/ESP BOSCH 5.7 must not be disassembled. It must be replaced in case of repairs. For ABS/EDL/TCS/ESP only the brake pressure sender 1 -G201- must be replaced 45-17 page 10. Note
Inspecting and repairs of the hydraulic control unit
must only be performed by skilled personnel in approved automobile workshops (Bosch service centres or contract dealers of the vehicle manufacturer).
Observe the notes in the manufacturer's instructions
for the replacement of hydraulic control units. Special tools, test and measuring equipment and auxiliary items required
Caliper gauge (commercially available)
45-17 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Note
The sealing surface on the hydraulic control unit must
be clean and undamaged. It must never be reworked, e.g. with files, scrapers etc. If necessary replace the hydraulic unit.
The gasket on the control unit must not be removed, it
cannot be replaced.
The screws (inner Torx T20) of the hydraulic unit/con-
trol unit must be replaced after each disassembling. Use the screws included in the parts kit. Tightening must occur in the prescribed sequence and in steps.
If the control unit is being replaced tentatively tighten
the fixing screws only slightly Tighten the screws to the specified torque once the control unit is correctly positioned on the hydraulic control unit.
Maximum 5 tightening procedures (hydraulic unit)
may be carried out throughout the entire life of the hydraulic control unit. Pay attention to the colour markings (approx. 3 mm wide red lines) on the hydraulic control unit. Replace the complete hydraulic control unit if more than 5 tightening procedures have been performed (-arrow- area for colour markings).
The threads in the hydraulic unit for securing the con-
trol unit must not be rethreaded. If the thread is damaged (screws are hard to tighten by hand or they cannot be tightened to the prescribed torque) replace the hydraulic control unit.
Blowing out of the control unit or the hydraulic unit with
compressed air to secure an oily or aqueous film on and between the valve domes or the solenoid coils is not permissible. Only use moisture-free and oil-free compressed air, e.g. from a spray. Cleaning with hydrocarbon solvents is not allowed.
If the hydraulic control unit is open protect the valve
S45-0111
domes, solenoid coils, contact springs against damage and soiling.

If the hydraulic control unit is open it is not permissible
to apply a voltage to the contact springs of the hydraulic pump. Risk of contact arcing.
Repair is only possible with the hydraulic control unit
removed.
Disassembly and assembly of the hydraulic control
unit is described on an ABS unit BOSCH 5.7. The procedure for the ABS/EDL/TCS unit BOSCH 5.7 is identical. The ABS/EDL/TCS/ESP unit BOSCH 5.7 must not be disassembled. It must be replaced in case of repairs. Only the brake pressure sender 1 -G201must be replaced 45-17 page 10.
Remove hydraulic control unit with bracket 45-17

page 2 Disassembling the hydraulic control unit Hydraulic unit for ABS -N55- with return flow pump for ABS -V39- (-a-):
b
S45-0068
Edition 07.04 S00.5303.16.20
45-17 page 7
45
Hydraulic unit: The valve block includes the control
FABIA 2000
Chassis
valve and the contact springs of the hydraulic pump.

Do not separate the return flow pump for ABS -V39-
from the hydraulic unit for ABS -N55-. ABS control unit -J104- (-b-):
Contact assignment Chap. 45-15
Note The hydraulic control unit ABS/EDL/TCS/ESP BOSCH 5.7 must not be disassembled. It must be replaced as a complete unit in the case of repairs. Only the brake pressure sender 1 -G201- must be replaced 45-17 page 10.
Release inner Torx screws T20 -Postions 1 through to

6-.
S45-0071
When tightening the control unit -b- of the hydraulic unit -a- make sure the valve domes -1- are not tilted along with the solenoid coils -4-. 3 - Silicone seal
Cover the solenoid coils of the control unit. Protect the valve domes and contact springs -2- of the
return flow pump for ABS -V39- against damage and soiling. Do not use fluffing cloths or a transport protection of an already installed spare part hydraulic pump. This is a requirement for possible guarantee claims. Assembling the hydraulic control unit vehicles with ABS/EDL/TCS BOSCH 5.7
2
S45-0070
If new or removed control units -1- are installed again, inspect the heat conduction posts -3-.
Inspect the end faces of the heat conduction posts for

good heat conduction properties. The faces must not exhibit any deposit, e.g. oxidation.
Check projection of the posts using a gauge.

Dimension must be of 0.81.0 mm between the top side of the heat conduction posts and the seal -2-.
3 2 1
Press the end face of the heat conduction posts with

your thumb, they must give. If faults are found during one of the 3 test steps, the control unit must be replaced. Continued for all vehicles
S45-0110
45-17 page 8
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Inspect the sealing surface on the hydraulic unit for

soiling, if necessary clean with white spirits and a nonfluffing paper or linen cloth.
If an oily or aqueous film appears on the surface of the

hydraulic unit, clean with white spirits and a non-fluffing paper or linen cloth.
If there is a considerable oily and aqueous film between the valves use moisture-free and oil-free compressed air to blow it out.
If damage is noticed on the hydraulic unit, e.g. scoring

or scratching etc., near the seal, replace the hydraulic unit.
Inspect the contact springs of the hydraulic pump for

burning points and oxidation. Reworking or cleaning is not possible, replace the hydraulic unit. Note
Before fitting the control unit to the hydraulic unit make
sure the seal protrudes by min. 0.1 mm from the control unit housing.
When assembling the control unit and the hydraulic
unit make sure the valve domes of the hydraulic unit do not tilt along with the solenoid coils of the control unit.
Place the control unit on the hydraulic unit and guide

the solenoid coils over the valves by exerting a slight pressure. While doing so center the control unit relatively to the hydraulic unit. The edge of the control unit must engage in the groove of the hydraulic unit.
Press by hand on the control unit until it fixes in place

with the two centre screws. Note
Screw on the hydraulic unit and the control unit in the
prescribed sequence and in steps. Tightness will not be guaranteed if this is not observed.
Only use new inner Torx screws from the parts kit. When screwing together make sure the left and right
gap between the control unit and the hydraulic unit is always the same.
First screw in the inner Torx screws and tighten them

by hand in the alternating sequence 1 - 2, 3 - 4, 5 - 6.
Tighten all inner Torx screws in the alternating sequence 1 - 2, 3 - 4, 5 - 6 to the prescribed torque.
S45-0071
Edition 07.04 S00.5303.16.20
45-17 page 9
45
Indicate each fitting of the hydraulic unit with the control unit in the area -arrowwith a permanent mark approx. 3 mm wide. Colour: red For this use e.g. lead seal enamel.
FABIA 2000
Chassis
Install hydraulic control unit with bracket 45-17

page 2. Tightening torque: Control unit to hydraulic unit
Use new screws!
3 Nm
Removing and installing brake pressure sender 1 -G201- - vehicles with ABS/EDL/ TCS/ESP BOSCH 5.7
A description of the structure and function of the brake pressure sender 1 -G201- can be found in self-study programme no. 42. Special tools, test and measuring equipment and auxiliary items required
S45-0111
-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A Hexagon socket wrench insert, e. g. -900S Lg 24-
Note
Repair of the brake pressure sender 1 -G201- is not
allowed. Only the brake pressure sender 1 -G201must be replaced.

No additional seals or lubricants may be used when
sealing the sender/hydraulic unit. A thread moistened with brake fluid is allowed.
The sealing surfaces of the conical seat on the sender
and on the hydraulic unit must not be damaged,e.g. small surfaces, grooves.
The threads on the sender and on the hydraulic unit
must not be damaged. Re-cutting the thread is not allowed. Replace the complete hydraulic unit if the thread is damaged (sender difficult to screw in).
Replacement of the brake pressure sender 1 -G201-
is limited to a maximum of 4 repeat screwing procedures (torque connections). Pay attention to the colour markings (approx. 3 mm wide green lines) on the hydraulic control unit (-arrow- for colour markings). If more than 4 tightening procedures are performed the complete hydraulic unit must be replaced Removing
Remove the hydraulic control unit 45-17 page 2. Unscrew brake pressure sender 1 -G201-
S45-0112
45-17 page 10
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Check the ball sealing surface of the hydraulic unit for

damage. Teplace the hydraulic unit if they are damaged (e.g. small surfaces, grooves). Reworking of the sealing surface is not allowed. Installing
Screw in the brake pressure sender 1 -G201- by hand

up to the stop and tighten to the prescribed torque.
Indicate each fitting of the sender brake pressure

sender -G201- with the control unit in the area -arrowwith a permanent mark approx. 3 mm wide (green).
Installing the hydraulic control unit 45-17 page 2. Inspect the tightness on the connection of the brake
pressure sender 1 -G201- under pressure (brake pedal pressed). If brake fluid escapes:
Tighten up the sender fully to the specified tightening

torque. If brake fluid still escapes:
S45-0112
Replace the brake pressure sender 1 -G201- or hydraulic unit and check tightness.
Bleed brake system Chapter 47-4. Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. If faults are stored in the fault memory:

Note For vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 perform a test drive after bleeding with at least one ABS control! Tightening torque: Brake pressure sender 1 -G201- on hydraulic unit 20 Nm
Edition 07.04 S00.5303.16.20
45-17 page 11
45
FABIA 2000
Chassis
45-17 page 12
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
45-18 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo unit/Master brake cylinder
Summary of Components of Hydraulic Control Unit Brake Servo Unit/Master Brake Cylinder
Note
Removing and installing the hydraulic control unit completely 45-18 page 3. Mount bracket before assembling the brake lines. Do not bend brake lines when assembling or when connecting. Install brake hoses without transposition. Brake hoses must not come into contact with other components during operating condition. Do not remove the plugs on the connection threads and the holes in the parts carrying brake fluid until just before
assembling.
Tighten all the brake line pipe screws to a tightening torque of 14 Nm. The repair of the hydraulic control unit ABS/ASR/ESP BOSCH 8.0 is not permissible.
1 - Hydraulic control unit ABS BOSCH 8.0 removing and installing 45-18 page 3 5 ABS/TCS BOSCH 8.0 4 assignment Spare part 3 catalogue 2 identification marking of the hydraulic unit ABS 1 fitted as of CW 22/2004 2 - Brake line identification marking of the hydraulic unit VR to front right brake caliper Connect 45-18 page 7 20 3 - Brake line identification marking of the hydraulic unit HL to wheel brake cylinder/rear left brake caliper Connect 45-18 page 7 4 - Brake line 19 identification marking of the 18 hydraulic unit HR to wheel brake cylinder/rear 17 right brake caliper Connect 45-18 page 7 5 - Brake line identification marking of the hydraulic unit VL to front left brake caliper 16 Connect 45-18 page 7 6 - Hydraulic control unit ABS/TCS/ESP BOSCH 8.0 removing and installing 45-18 page 3 assignment Spare part catalogue
3 2 6
8 21 10 12
11 12
9 10
13
13 12 15 14
S45-0168
Edition 07.04 S00.5303.16.20
45-18 page 1
45
identification marking of the hydraulic unit ESP fitted as of CW 22/2004 Brake line identification marking of the hydraulic unit HZ2 Master brake cylinder/floating piston circuit to hydraulic control unit Connect 45-18 page 7 Brake line identification marking of the hydraulic unit HZ1 Master brake cylinder/pressure rod piston circuit to hydraulic control unit Connect 45-18 page 7 Bracket for hydraulic control unit ABS/TCS/ESP BOSCH 8.0 removing and installing 45-18 page 6 Screws, 8 Nm for holder to hydraulic control unit Line holder for brake line assignment Spare part catalogue Bracket for brake line 2 units assignment Spare part catalogue Bracket for brake line 3 units assignment Spare part catalogue Brake servo unit inspect Chapter 47-2 removing and installing Chapter 47-2 Master brake cylinder cannot be repaired, replace completely in the event of faults Tightness test Chapter 47-2 removing and installing Chapter 47-2 Brake fluid reservoir Self-locking nuts, 20 Nm replace after each removal for bracket to body Bracket for ABS, ABS/TCS, ABS/TCS/ESP BOSCH 8.0 removing and installing 45-18 page 6 Hexagon collar nut, 20 Nm replace after each removal for bracket to body Bracket for hydraulic control unit ABS, ABS/TCS BOSCH 8.0 removing and installing 45-18 page 6 Bracket for brake line 2 units assignment Spare part catalogue
FABIA 2000
Chassis
7-
8-
9-
10 11 -
12 -
13 -
14 -
15 -
16 17 -
18 -
19 -
20 -
21 -
45-18 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Removing and installing the hydraulic control unit

WARNING!
Make absolutely sure that no brake fluid gets
into the plug connector housing of the hydraulic control unit. This may result in the corrosion of the contacts and to system failure.
Carefully clean out the plug connector housing
with compressed air if it gets dirty.

Do not bend the brake lines around the hydrau-
lic control unit. Special tools, test and measuring equipment and auxiliary items required
pedal load -V.A.G 1869/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-,
-ROMESS S15 Bleeding bottle (commercially available) Repair kit SP-No. 1H0 698 311 A Brake fluid Chapter 00-3

2 1
S45-0193
Edition 07.04 S00.5303.16.20
45-18 page 3
45
Actuate brake pedal and arrest with brake pedal arrester.
FABIA 2000
Chassis
Attach the bleeder hose of the bleeding bottle onto the

vent valve of the front left brake caliper and open bleeder valve.
Shut the vent valve once the brake fluid has flown out. Disconnect the bleeder hose from the vent valve. Place sufficient non-fluffing cloths under and around
the hydraulic control unit. Unlatch the multi-pin connector The unlatching of the multi-pin connector is described according to the example of the ABS system BOSCH 8.0. On the ABS/TCS and ABS/TCS/ESP systems BOSCH 8.0 the unlatching is identical.
S45-0016
Release multi-pin connector -1-. Insert red fuse -2- up to the stop in -direction of the arrow-.
1
Swivel the clamp downwards -1- up to the stop in the
-direction of arrow-.
S45-0169
Pull out multi-pin connector -2- from ABS control unit

-J104-.
Close the plug connector of the ABS control unit

-J104- with a cap. Unscrew brake lines from hydraulic control unit.
S45-0170
45-18 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
1 2 3 4 5
Mark brake lines -16-. Unscrew brake lines -16- from hydraulic control
unit.
Close off immediately brake lines. Shut off immediately threaded bores (brake line connections) on the hydraulic control unit with plugs from repair kit SP No. 1 H0 698 311 A.
6
S45-0171
ABS/TCS/ESP BOSCH 8.0
4 5
Mark brake lines -16-. Unscrew brake lines -16- from hydraulic control
unit.
Close off immediately brake lines. Shut off immediately threaded bores (brake line connections) on the hydraulic control unit with plugs from repair kit SP No. 1 H0 698 311 A. Remove the hydraulic control unit The removal of the hydraulic control unit is described on an ABS/TCS/ESP unit. The removal of an ABS or an ABS/TCS unit occurs in the same way as for the ABS/ TCS/ESP unit.
6
S45-0172
Unscrew nuts -4- from bracker -3-. Unscrew hexagon collar nut -6-. Remove the hydraulic control unit ABS, ABS/TCS or
ABS/TCS/ESP BOSCH 8.0 -1- with bracket -2- and -3- upwards out of the vehicle. 5 - Threaded bores welded to the body 7 - Threaded bores welded to the body Installing Note
New hydraulic control units are filled with hydraulic oil
1 7
2 3 6 5 4 4
S45-0178
and bleed.
Only then remove plugs from the hydraulic unit when
the relevant brake line is installed.

If the plugs were already removed from the hydraulic
unit before the brake line is installed, then brake fluid may escape and adequate filling and bleeding can no longer be guaranteed. Installation is performed in the reverse order. Pay attention to the following points:
Edition 07.04 S00.5303.16.20
45-18 page 5
45
FABIA 2000
Chassis
WARNING! Pay attention to the correct channel assignment of the brake lines. Interchanging the brake lines will result in dangerous brake control actions.
Connecting the brake lines 45-18 page 7 Make sure that the multi-pin connector latches correctly with the ABS control unit -J104-.
Remove brake pedal arrester, e.g. -V.A.G 1238 B- or

brake pedal load -V.A.G 1869/2-
Bleed brake system Chapter 47-4. Code ABS control unit -J104-:
using vehicle system tester -V.A.G 1552- Chapter
45-9.
using vehicle diagnosis, measurement and informa-
tion system -VAS 5051- Chapter 45-4. one ABS adjustment.
Perform test drive after the bleeding of air with at least

Tightening torques: Brake line to hydraulic control unit Bracket with hexagon collar nut to body
Use new nut!
14 Nm 20 Nm
Bracket with nuts to body

Use new nuts!
20 Nm
Removing and installing bracket for the hydraulic control unit

Removing and installing bracket for ABS or ABS/TCS BOSCH 8.0 Removing
Removing the hydraulic control unit ABS or ABS/TCS

BOSCH 8.0 45-18 page 3. -2-.
Separate bracket -4- from the fixing bolt of the bracket Release screws -3- (2x). Remove bracket -2- from hydraulic control unit -1-.
Installing Installation is carried out in the reverse order. Tightening torque: Bracket to hydraulic control unit 8 Nm
2 3 3
4
S45-0179
45-18 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
1
Removing and installing bracket for ABS/TCS/ESP BOSCH 8.0 Removing
Removing the hydraulic control unit ABS/TCS/ESP

BOSCH 8.0 45-18 page 3. -2-.
Separate bracket -4- from the fixing bolt of the bracket Release screws -3- (3x). Remove bracket -2- from hydraulic control unit -1-.
Installing Installation is carried out in the reverse order. Tightening torque: Bracket to hydraulic control unit 8 Nm
3 4
S45-0180
Connecting the brake lines

Note
Mount braket before assembling the brake lines. Do not bend brake lines when assembling or when
connecting.
Install brake hoses without transposition. Brake hoses must not come into contact with other
components during operating condition.

Do not remove the plugs on the connection threads
and the holes in the parts carrying brake fluid until just before assembling.
Tightening torque of pipe screws for brake lines of 14
Nm.
WARNING! Pay attention to the correct channel assignment of the brake lines. Interchanging the brake lines will result in dangerous brake control actions. vehicles with ABS or ABS/TCS BOSCH 8.0 Connecting the brake lines to the master brake cylinder Pos. 1 2 Denomination HZ1 HZ2 Connecting points Master brake cylinder/push rod piston circuit Master brake cylinder/floating piston circuit
1 2
S45-0173
Edition 07.04 S00.5303.16.20
45-18 page 7
45
Connecting the brake lines to the hydraulic control unit Pos. 1 2 3 4 5 6 Denomination FR RL RR FL HZ2 HZ1 Connecting points Front right brake caliper Wheel brake cylinder/rear left brake caliper Wheel brake cylinder/rear right brake caliper Front left brake caliper Master brake cylinder/floating piston circuit Master brake cylinder/push rod piston circuit
FABIA 2000
Chassis
4 5
6
S45-0171
Vehicles with ABS//TCS/ESP BOSCH 8.0 Connecting the brake lines to the master brake cylinder Pos. 1 2 Denomination HZ1 HZ2 Connecting points Master brake cylinder/push rod piston circuit Master brake cylinder/floating piston circuit
1 2
Note
When tightening the pipe screw to the brake line in the
area of the crimping -arrow A- counterhold by hand.

When tightening the pipe screw to the brake line in the
S45-0174
area of the crimp -arrow B- counterhold by hand. Connecting the brake lines to the hydraulic control unit Pos. 1 2 3 4 5 6 Denomination FR RL RR FL HZ2 HZ1 Connecting points Front right brake caliper Wheel brake cylinder/rear left brake caliper Wheel brake cylinder/rear right brake caliper Front left brake caliper Master brake cylinder/floating piston circuit Master brake cylinder/push rod piston circuit
4 5
6
S45-0172
45-18 page 8
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
45-19 Removing and Installing Parts of the ABS System on the Front and Rear Axle
Removing and installing wheel speed sensor on the front axle - Vehicles with ABS systems BOSCH 5.7 or BOSCH 8.0
Removing
Raise vehicle. Separate plug connection -1- wheel speed sensor cable/wheel speed sensor.
3 2
Release Allan screw -3-. Remove wheel speed sensor -2- from the wheel-bearing housing. Installing
Insert the wheel speed sensor in the bore of the

wheel-bearing housing and tighten the Allan screw -3to 8 Nm.
Connect plug connection -1- wheel speed sensor cable/wheel speed sensor.
S45-0125
Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH 5.7
Wiring loom repair kit, e.g. Skoda Car Tool Kit koda,
Order No.: S 504 500 V

-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6ARemoving Note

It is prohibited to repair shielded leads of the ABS sys-
tem.
Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
Edition 07.04 S00.5303.16.20
Removing and Installing Parts of the ABS System on the Front and Rear Axle
45-19 page 1
45
FABIA 2000
Chassis
2 1
S45-0193
Unlatch the multi-pin connector -arrow 1- and disconnect from the control unit -arrow 2-.
S45-0074
Lever off the cap of the multi-pin connector on both

sides with a screwdriver and remove cap.
Open cable strap.
S45-0075
45-19 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Release secondary lock (purple) with a small screwdriver in the direction of the arrow.
S45-0076
Contact assignment for multipin plug connector T42a wiring loom/ABS control unit -J104Contact 15 + 16 12 + 28 30 + 31 13 + 14 Wiring to component Speed sensor front right -G45Speed sensor front left -G47Speed sensor rear right -G44Speed sensor rear left -G46-
10
11
Open wiring loom. Using a suitable ejection tool from the wiring loom repair kit press out the relevant contacts.
Raise vehicle. Remove wheel. Release plug connection on speed sensor and separate plug connector.
26
42
27
S45-0031
Remove defective speed sensor cable.

Installing
Draw in new speed sensor cable. Connect speed sensor cable to speed sensor. Clip on speed sensor cable -arrows- and mount in
bracket -1-.
Actuate steering from left to right up to the stop and

check for free movement of the speed sensor cable. Note When assembling the speed sensor cable make sure it is not twisted when installed in the wheelhouse.
S45-0078
Edition 07.04 S00.5303.16.20
45-19 page 3
45
Mount wheel. Lower the vehicle. Insert contact in the plug housing and insert the single
cable seal with a suitable plug-in tool from the wiring loom repair kit up to the stop.
FABIA 2000
Chassis
Secure contacts with the secondary lock. Mount new cable strap for wiring loom on multi-pin
connector.
Position the cap on the multi-pin connector and lock

into position.
Insert the multi-plug connector on the control unit and

lock. Vehicles with TDI PD Turbocharger engines
VW AG 6Q0 973 042 B00 1928 404 293
R
1 928 403 931
S45-0079

Rep. Gr. 10.
Connect battery Electrical System; Rep. Gr. 27. Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. If faults are stored in the fault memory:
2 1
S45-0193
Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH 8.0

-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6ARemoving Note

It is prohibited to repair shielded leads of the ABS sys-
tem.
45-19 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45

2 1
S45-0193
Release multi-pin connector -1-. Insert red fuse -2- up to the stop in -direction of the arrow-. 2 - Hydraulic control unit
1
Swivel the clamp downwards -1- up to the stop in the
-direction of arrow-.
S45-0169
Pull out multi-pin connector -2- from hydraulic control

unit.
S45-0170
Edition 07.04 S00.5303.16.20
45-19 page 5
45
Open cable straps -2-. Lever off the cap -1- of the multi-pin connector on both
sides from the catches -arrowwith a screwdriver.
FABIA 2000
Chassis
Remove cap -1- from the bottom part of the multi-pin

connector.
D E L PH
S45-0194
Slide secondary lock (purple) -1- with a small screwdriver in the -direction of the arrow-. At the same time the contacts are released.
S45-0195
Contact assignment for multipin plug connector wiring loom/ABS control unit -J104Contact 6 + 18 22 +34 19 + 31 20 + 33 Wiring to component Speed sensor front right -G45Speed sensor front left -G47Speed sensor rear right -G44Speed sensor rear left -G46-
13
12
Open wiring loom. Using a suitable ejection tool from the wiring loom repair kit press out the relevant contacts.
38
37
24
14
26
25
S45-0196
Raise vehicle. Remove wheel. Release plug connection on speed sensor and separate plug connector.
Remove defective speed sensor cable.

Installing
Draw in new speed sensor cable. Connect speed sensor cable to speed sensor.
45-19 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Clip on speed sensor cable -arrows- and mount in

bracket -1-.
Actuate steering from left to right up to the stop and

check for free movement of the speed sensor cable. Note When assembling the speed sensor cable make sure it is not twisted when installed in the wheelhouse.
Mount wheel. Lower the vehicle. Insert contact in the plug housing and insert the single
cable seal with a suitable plug-in tool from the wiring loom repair kit up to the stop.
S45-0078
Secure contacts by sliding the secondary lock (purple).
DELPHI
S45-0197
Insert catch -arrow A- of the cap -1- into the recess

-arrow B- of the bottom part -2- of the multi-pin connector.
1 B 2 A
Swivel cover -1- in -direction of the arrow- and lock

into position with the bottom part -2- of the multi-pin connector.
Mount new cable strap for wiring loom on multi-pin

connector.
Insert the multi-plug connector on the ABS with EDL

control unit -J104- and lock. Vehicles with TDI PD Turbocharger engines
DELPHI
S45-0198
Edition 07.04 S00.5303.16.20
45-19 page 7
45
FABIA 2000
Chassis

Rep. Gr. 10.
Connect battery Electrical System; Rep. Gr. 27. Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. If faults are stored in the fault memory:
2 1
S45-0193
Sensor ring for ABS on the front and rear axle

The sensor ring -1- is fitted in the wheel hub with wheel bearing -2- and cannot be replaced individually. In the event of damage or defect of the sensor ring, replace wheel hub with wheel bearing. I - Removing and installing wheel hub and wheel bearing for front axle Chap. 40-3 II - Removing and installing wheel hub and wheel bearing for rear axle Chap. 42-5
I 1
II 1
Removing and installing wheel speed sensor on the rear axle

Vehicles with disc brakes Removing
2
S45-0073
Raise vehicle. Separate plug connection -1- wheel speed sensor cable - wheel speed sensor.
Release Allan screw -2-. Pull the wheel speed sensor from the axle stud and
brake carrier. Installing
Insert the wheel speed sensor in the bore of the axle

stud and tighten the Allan screw -2- to 8 Nm.
Connect plug connection -1- wheel speed sensor cable - wheel speed sensor. Vehicles with drum brakes
S45-0200
45-19 page 8
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
45
Removing and installing the wheel speed sensor occurs in the same way as for the disc brake version 45-19 page 8. 1 - Plug connection wheel speed sensor cable/wheel speed sensor 2 - Allan screw for fixing the wheel speed sensor
Repairing rear wheel speed sensor cables - Vehicles with ABS systems BOSCH 5.7 and BOSCH 8.0

-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6ARemoving Note Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
S45-0201
Disconnect battery Electrical System; Rep. Gr. 27. Release plug connection on speed sensor and separate plug connector.
Unclip wheel speed sensor cable on rear axle and

body.
Removing the seat bench Body Work; Rep. Gr. 72. Removing trim panel at bottom of pillar C Body
Work; Rep. Gr. 70.
Removing the entrance plate Body Work;

Rep. Gr. 68.
Fold back the floor covering around the seat bench. Release the rubber grommet -1- and pull the wheel
speed sensor cable -2- into the vehicle interior.
Separate the wheel speed sensor cable between

crimp connection -arrow A- and sheathing -arrow B-. Installing
1 2 A B
Draw in the new wheel speed sensor cable and attach

the rubber grommet.
Insulate the two cable extremities with a 67 mm wire

stripper.
Twist the two cable extremities.

S45-0080
Edition 07.04 S00.5303.16.20
45-19 page 9
45
Note
The insulation of the cable extremities must not be
FABIA 2000
Chassis
pinched together.
Make sure the correct red crimp connector for 0.5
mm2 is selectd.
Slide the crimp connector on the cable extremities and

crimp it together at both sides with the stop pliers. Note
The crimp connector must be heated from the centre
towards the outside until it is fully sealed and the adhesive flows out.
Set the hot-air blower to the relevant temperature ac-
cording to the operating instructions.

During shrinking make sure the hot nozzle does not
S45-0081
damage any other cables, plastic parts or insulating materials.
After crimping shrink the crimp connector with the hotair blower. To do so use the hot-air blower from the wiring loom repair kit.
If the repair cable was initially wrapped, you must rewrap this point with yellow insulating tape, or if necessary again attach the cable with a cable strap. Further installation occurs in reverse order.
Installing the entrance plate Body Work;

Rep. Gr. 68.
Installing trim panel at bottom of pillar C Body

Work; Rep. Gr. 70.
S45-0202
Installing the seat bench Body Work; Rep. Gr. 72. Connect battery Electrical System; Rep. Gr. 27. Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. If faults are stored in the fault memory: ABS systems BOSCH 5.7

ABS systems BOSCH 8.0
Eliminating fault Chapter 45-7. Erase fault memory.
45-19 page 10
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
46
46 Brakes, Brake mechanics

46-1 Repairing the front wheel brake
Repairing front brake, the floating caliper disc brake FS-III

Piston jig -MP 9-403 Brake pedal load, e.g. -V.A.G 1869/2 Torque wrench Brake filling and bleeding device, e. g.
-ROMESS S15 Bleeding bottle (commercially available) Brake fluid Chapter 00-3
Note
After replacing the brake pads forcefully apply the
brake pedal repeatedly to ensure the brake pads go into their normal operating position.
Use brake pedal load, e.g. -V.A.G 1869/2 - or
-V.A.G 1238 B-, before removing a brake caliper or separating a brake hose from the brake caliper
Use a bleeding bottle, that only comes into contact
with the brake fluid, to drain brake fluid from the brake fluid reservoir. Brake fluid is toxic and must never be sucked up by mouth!
Already used brake fluid must never be used again. Tightening torque of the wheel screws: 120 Nm.
Edition 02.03 S00.5303.13.20
Repairing the front wheel brake
46-1 page 1
46
1 - Brake disc Thickness: 22 mm Wear limit: 19 mm always replace axle-wise Unscrew the brake caliper before removing Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent; as you could otherwise damage the brake discs. 2 - Screw, 4 Nm 3 - Brake pads with wear indicator with a corresponding wear (limit 2 to 3 mm) the warning lamp in the dash panel insert lights up Thickness: 19.6 mm (including the support plate) Wear limit: 2.0 mm without supporting plate 8 Check thickness Inspection and Mainte7 nance always replace axle-wise do not unscrew the brake hose when replacing the brake pad removing and installing 46-1 page 3 do not interchange the inside and outside brake pads 46-1 page 3 4 - Brake caliper removing: Remove the brake pads 46-1 page 3
FABIA 2000
Chassis
14 13 12 11 10 1
6 5
6 5 4 3
S46-0087
Use brake pedal load Unscrew brake hose from brake caliper Screw the brake hose onto the brake caliper Remove brake pedal load Bleed the brake system Chapter 47-4
repair Chapter 47-1 5 - Guide bolts, 28 Nm 6 - Cap removing 7 - Tensioning sleeve 8 - Brake hose with supports, hollow screw and gasket rings must be replaced completely, do not dismantle Tightening torque: 35 Nm do not unscrew when replacing the brake pad 9 - Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub Installing: Installing brake pads 46-1 page 3
46-1 page 2
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
10 11 12 13 14 -
replace after each removal, is destroyed during removal removing and installing Chapter 40-3 assignment Spare part catalogue Screw, 10 Nm Cover plate Wheel-bearing housing Speed sensor ABS Allan screw, 8 Nm for speed sensor ABS
Removing and installing brake pads Floating caliper disc brake FS-III
Piston jig -MP 9-403 Torque wrench Brake filling and bleeding device, e. g.
Removing
Remove wheel.
Note
When removing mark the brake pads you intend to
keep using. Install in the same location, as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the
brake pad.
Disconnect the plug connection for the brake pad

wear indicator (where the vehcile is fitted with this).
S46-0088
Remove caps -1-. Unscrew and remove the two guide bolts -arrow- from
the brake caliper.
S46-0089
Edition 02.03 S00.5303.13.20
46-1 page 3
46
Remove the brake caliper -1- and secure with wire in
such a way that the weight of the brake caliper does not burden or damage the brake hose.
FABIA 2000
Chassis
1 3
Remove brake pads -2- and -3- from the brake caliper.
Installing
Note Drain brake fluid from the brake fluid reservoir using a ventilation bottle before pushing the piston back in. Caution! Brake fluid is toxic and must never be sucked off by mouth. Note Use alcohol only to clean the brake caliper housing.
S46-0090
MP 9-403
Clean the brake caliper. Push piston back with piston jig -MP 9-403-.
Note Do not interchange the inside and outside brake pads. Pay attention to identification.
S46-0074
Insert the brake pads with the white marking on the

rear side piston side in the piston.
Insert the brake pads with the black three-finger clip in

the brake caliper housing.
Kolbenseite
M46-0001
46-1 page 4
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
First position the brake caliper at the bottom. Mount the brake caliper with brake pads onto the
wheel bearing housing. The brake caliper pin -arrow- must be located behind the guide of the wheel bearing housing!
FS -
S46-0101
Screw the brake caliper with both guide bolts -arrowsonto the wheel bearing housing. Tightening torque: 28 Nm
Connect up the plug connection for the brake pad

Insert the caps of the guide bolts. Attach the wheel.

Note
After each brake pad replacement forcefully apply the
Check brake fluid level after replacing the brake pads,
S46-0089
if necessary top up with brake fluid.
Edition 02.03 S00.5303.13.20
46-1 page 5
46
Repairing front brake, the floating caliper disc brake FS-III
Special tools, test and measuring equipment and aids required
46-1 page 1
FABIA 2000
Chassis
Note 46-1 page 1 1 - Brake disc Thickness: 18 mm Wear limit: 15 mm 22 always replace axle-wise 21 Unscrew the brake caliper before removing Do not use force to separate the brake discs from the wheel hub, if necessary use 20 rust solvent; as you could otherwise damage the brake discs. 2 - Screw, 4 Nm 3 - Brake pads with wear indicator with a corresponding wear (limit:2 to 3 mm) the warning lamp in the dash panel insert 16 lights up 15 10 with riveted retaining spring 11 12 Install brake pad with a 13 14 smaller pad surface on the piston side Thickness: 17.6 mm (including the support plate) Wear limit: 2.0 mm without 9 supporting plate Check thickness 8 7 Inspection and Mainte6 5 nance always replace axle-wise do not unscrew the brake hose when replacing the brake pad removing and installing 46-1 page 7 do not interchange the inside and outside brake pads 46-1 page 7 4 - Brake caliper removing: Remove the brake pads 46-1 page 7
19 18 17
3 4
S46-0091
Use brake pedal load Unscrew brake hose from brake caliper
Installing: Installing brake pads 46-1 page 7 Screw the brake hose onto the brake caliper Remove brake pedal load Bleed the brake system Chapter 47-4 repair Chapter 47-1
46-1 page 6
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
5 - The rubber bush below before screwing in coat thread with lithium grease -G 052 150 A26 - Bottom bushing with slits on one side before screwing in coat thread with lithium grease -G 052 150 A27 - Bottom distance sleeve before screwing in coat thread with lithium grease -G 052 150 A28 - Fillister head screw with internal serrations bottom, 25 Nm M8 x 48 9 - Air deflector 10 - Screw, 10 Nm for air deflector 11 - Fillister head screw with internal serrations top, 25 Nm M8 x 59 12 - Top distance sleeve before screwing in coat thread with lithium grease -G 052 150 A213 - Top bushing with slits on one side before screwing in coat thread with lithium grease -G 052 150 A214 - The rubber bush above before screwing in coat thread with lithium grease -G 052 150 A215 - Tensioning sleeve 16 - Brake hose with supports, hollow screw and gasket rings must be replaced completely, do not dismantle Tightening torque: 35 Nm do not unscrew when replacing the brake pad 17 - Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub replace after each removal, is destroyed during removal removing and installing Chapter 40-3 assignment Spare part catalogue 18 - Screw, 10 Nm 19 - Cover plate 20 - Wheel-bearing housing 21 - Speed sensor ABS 22 - Allan screw, 8 Nm for speed sensor ABS
Removing and installing brake pads Floating caliper disc brake FS-II
46-1 page 3
Removing
Remove wheel.
Edition 02.03 S00.5303.13.20
46-1 page 7
46
Note
FABIA 2000
Chassis
brake pad.

Release fillister head screw with internal serrations -1and -2-. Note Figure shows floating caliper disc brake FS-II with removed air deflector.
S46-0102
Remove the brake caliper -1- and secure with wire in

1 3
Remove brake pads -2- and -3- from the brake caliper.
Installing
Note Drain brake fluid from the brake fluid reservoir using a ventilation bottle before pushing the piston back in. Caution! Brake fluid is toxic and must never be sucked off by mouth. Note Only use alcohol to clean the brake caliper housing.
S46-0090
Clean the brake caliper. Push piston back with piston jig -MP 9-403-. Install brake pad with a smaller pad surface on the piston side.
MP 9-403
Install brake pads with a greater pad surface in the

brake caliper housing.
S46-0074
46-1 page 8
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
First position the brake caliper at the bottom. Mount the brake caliper with brake pads onto the
wheel bearing housing. The brake caliper pin -arrow- must be located behind the guide of the wheel bearing housing!
S46-0103
Screw the brake caliper to the wheel bearing housing

with fillister head screws with internal serrations -1and -2Tightening torque: 25 Nm
Connect up the plug connection for the brake pad

Attach the wheel.

Note
S46-0102
Edition 02.03 S00.5303.13.20
46-1 page 9
46
Repairing the front brake - the floating caliper disc brake C54-II
46-1 page 1
FABIA 2000
Chassis
Note 46-1 page 1 1 - Brake disc the max. wheel run-out is not marked released combination of a brake disc without marking and a wheel hub with marking with a fixing hole for the wheel hub Thickness: 25 mm Wear limit: 22 mm always replace axle-wise for removing, first of all unbolt brake caliper complete from wheel bearing housing Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent, as you could otherwise damage the brake discs. 2 - Screw, 4 Nm 3 - Brake disc with a roughly 5 mm marking for marking the maximum wheel run-out released combination of a brake disc with marking and a wheel hub without marking with 5 fixing holes for the wheel hub Thickness: 25 mm Wear limit: 22 mm always replace axle-wise for removing, first of all unbolt brake caliper complete from wheel bearing housing Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent, as you could otherwise damage the brake discs. 4 - Pad retaining plate always replace when changing the brake pads brake pads contained in repair kit fit on before installing brake pads 5 - Brake pads with wear indicator with a corresponding wear (limit 2 to 3 mm) the warning lamp in the dash panel insert lights up Thickness: 18.6 mm (including the support plate) Wear limit: 2.0 mm without supporting plate Check thickness Inspection and Maintenance always replace axle-wise
46-1 page 10
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
6-
7-
89-
10 -
do not unscrew the brake hose when replacing the brake pad removing and installing 46-1 page 12 Brake carrier is supplied as replacement part assembled with guide pin and protective caps as well as adequate quantity of grease on guide pins if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed grease packing to lubricate the guide bolts) also use grease packing for greasing the slot on the guide pin and brake caliper for attaching the protective cap Protective cap contained in repair kit insert into the slot of the brake carrier and of the guide pin; grease the slot first using grease packing from the repair kit Guide bolts contained in repair kit Heat shield always replace when changing the brake pads contained in repair kit insert into piston Fitting position: insert plate at heat shield into opening (slot) of the brake caliper Brake caliper removing: Use brake pedal load
Unscrew brake hose from brake caliper Unbolt brake caliper from brake carrier Screw the brake hose onto the brake caliper Remove brake pedal load Bleed the brake system Chapter 47-4
11 12 13 repair Chapter 47-1 Screw, 30 Nm replace after each removal Tensioning sleeve Brake hose with supports, hollow screw and gasket rings must be replaced completely, do not dismantle Tightening torque: 35 Nm do not unscrew when replacing the brake pad Screw, 125 Nm clean ribbing on underside each time removed Allan screw, 8 Nm for speed sensor ABS Speed sensor ABS Wheel-bearing housing Cover plate Screw, 10 Nm Wheel hub with wheel bearing with and without marking of the maximum wheel run-out one can combine a wheel hub without marking of the maximum wheel run-out with a brake disc with marking of the maximum wheel run-out; the total wheel run-out of the floating caliper disc brake C54-II will not be reduced for vehicles with ABS the sensor ring is built into the wheel hub replace after each removal, is destroyed during removal Installing: Bolt brake caliper onto brake carrier
14 15 16 17 18 19 20 -
Edition 02.03 S00.5303.13.20
46-1 page 11
46
removing and installing Chapter 40-3 assignment Spare part catalogue
FABIA 2000
Chassis
Removing and installing brake pads - the floating caliper disc brake C54-II
46-1 page 3
Removing
Remove wheel.
Note
brake pad.
If brake pads are changed, replace heat shield in the
caliper and pad retaining plates.

Detach brake line from fixture at wheel bearing housing.
1
S46-0122
Screw out bolt -1-. Remove brake caliper -2- and secure with wire in such
a way that the weight of the brake caliper does not pull on or damage the brake hose.
Remove heat shield -2-. Take out brake pad -1-. Swivel brake pad -4- out to the side in -direction of
arrow A- and at the same time take out to the front in -direction of arrow B-.
Remove pad retaining plates -3- and -5-.

Installing
Installation is carried out in the reverse order. Pay attention to the following: Note Drain brake fluid from the brake fluid reservoir using a ventilation bottle before pushing the piston back in.
1 A B
Caution! Brake fluid is toxic and must never be sucked off by mouth.
4 5
S46-0123
46-1 page 12
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
Note Only use white spirits to clean the brake caliper housing and brake carrier.
Clean the brake caliper. Clean contact surfaces for pad retaining plates at the
brake carrier, remove any corrosion present.
Push piston back with piston setting and timing device

-MP 9-403 -.
Install the heat shield.

Fitting position: insert plate at heat shield into opening (slot) of the brake caliper.
MP 9-403
Install the pad retaining plate. Insert brake pads. Fit brake caliper to the brake carrier.
Do this while using new collar screws from the repair set.
Attach brake line to fixture and secure with new clip. Connect up the plug connection for the brake pad
S46-0124
Attach the wheel.

Note
Tightening torques:
Brake caliper to brake carrier
Use new screws!
30 Nm
Wheel bolts
120 Nm
Edition 02.03 S00.5303.13.20
46-1 page 13
46
FABIA 2000
Chassis
46-1 page 14
Edition 02.03 S00.5303.13.20
FABIA 2000
Chassis
46
46-2
Repairing a rear brake
Removing and installing rear brake Drum brake

Torque wrench Torque wrench with angle indicator Brake pedal load, e.g. -V.A.G 1869/2 Brake filling and bleeding device, e. g.
Note
After replacing the wheel-brake cylinder, brake carrier
and the rear brake shoes, forcefully apply the brake pedal once to ensure the brake shoes go into their normal operating position.
Generally tighten the brake line pipe screws to a tight-
ening torque of 14 Nm.

Use a bleeding bottle, that only comes into contact
with the brake fluid, to drain brake fluid from the brake fluid reservoir. Brake fluid is toxic and must never be sucked up by mouth!
Use brake pedal loader, e. g. -V.A.G 1869/2- before
removing a brake cylinder, a brake carrier or before separating a brake line from the brake cylinder.
Edition 04.05 S00.5303.18.20
46-2 page 1
46
1 - 4 Nm 2 - Brake drum Brake drum diameter 200 mm Wear limit: 201 mm clean carefully, and check for wear, damage, dimensional accuracy and perfect brake surface 3 - Cap replace after each removal pressing off and inserting Chapter 42-5 4 - Self-locking twelve-point nut, 70 Nm and tighten a further 30 replace after each removal 5 - Wheel hub with wheel bearing for vehicles with ABS the sensor ring is built into the wheel hub must be replaced completely removing and installing Chapter 42-5 assignment Spare part catalogue 6 - turn 30 Nm and 90 replace after each removal 7 - Brake carrier with brake shoe removing: Reset brake 46-2 page 3
FABIA 2000
Chassis
15 14 12 11 13 10 9
8 6
7 1
S46-0092
Remove the brake drum Use brake pedal load Unscrew the brake line Remove the brake carrier unhook the hand brake cable if necessary Installing: Install the brake carrier hook on the hand brake cable if necessary Screw on the brake line Remove brake pedal load Install the brake drum
8910 11 12 -
Bleed the brake system Chapter 47-4 repairing 46-2 page 4 Hand-brake cable Setting the hand-brake 46-2 page 8 Axle stud removing and installing Chapter 42-5 Brake line Tightening torque of the pipe screws: 14 Nm Speed sensor ABS Plug for vehicles without ABS
46-2 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46
to plug the hole for the speed sensor in the axle stud 13 - Allan screw, 8 Nm for speed sensor ABS 14 - Axle body assignment Spare part catalogue 15 - Axle body assignment Spare part catalogue
Resetting brake
Use a screwdriver to push the wedge up through a
hole for the wheel screws in the brake drum.
S42-0031
Edition 04.05 S00.5303.18.20
46-2 page 3
46
Repairing rear brake - drum brake
Torque wrench Brake pedal load, e.g. -V.A.G 1869/2-. Plastic wedge -3409 Brake filling and bleeding device, e. g. -ROMESS S15 Hook (commercially available) Brake fluid Chapter 00-3 Solid lubricant paste -G 000 650-
FABIA 2000
Chassis
Note
Use brake pedal loader, e. g. -V.A.G 1869/2- before removing a brake cylinder, a brake carrier or before separating
a brake line from the brake cylinder.

Generally tighten the brake line pipe screws to a tightening torque of 14 Nm. After working on the rear axle brake: Release hand-brake; forcefully activate the brake pedal repeatedly.
1 - Spring cap to remove push against pressure spring and turn 90 2 - Pressure spring 3 - Locating spring 4 - Pressure rod Grease the contact points with solid lubricant paste -G 000 6505 - Wedge when removing and installing the brake drum push up through a hole for wheel screws (reset brake) 46-2 page 3 6 - Wheel-brake cylinder check the system for tightness 46-2 page 5 Repairs not allowed removing: Remove the brake shoe 46-2 page 6 Use brake pedal load
5 9 8
10 11 12 1 16 15 1 2 14
S46-0093
Unscrew the brake line Remove the wheel-brake

cylinder Installing: Install the wheel-brake cylinder Screw on the brake line
13
Remove brake pedal load Install the brake shoe 46-2 page 6 Bleed the brake system Chapter 47-4
7 - Allen screw, 8 Nm 8 - Tensioning pin 9 - Brake carrier
46-2 page 4
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46
10 - Cap remove to check brake pad thickness 11 - Sliding block Cover the whole contact surface of the brake shoe with solid lubricant paste -G 000 65012 - Brake shoe removing and installing 46-2 page 6 Minimum pad thickness without supporting shoe: 1.5 mm Check the brake pad thickness Inspection and Maintenance Visual checking of the brake pad thickness through the inspection hole in the brake carrier 46-2 page 5. always use equivalent pad quality per axle Brake pads can also be supplied without supporting shoe 13 - Tension spring 14 - Bottom retractor spring Grease the contact points with solid lubricant paste -G 000 65015 - Top retractor spring 16 - Brake shoe with lever for hand-brake removing and installing 46-2 page 6 Setting the hand-brake 46-2 page 8
Checking the wheel-brake cylinder for tightness
3409
Lift off dust cup.

To this end use demounting key -3409-.
If there is any brake fluid in the dust cup, replace

wheel-brake cylinder. Make sure the dust cup is not damaged when lifting it off.
S46-0079
Checking the brake pad thickness through the inspection hole in the brake carrier.
Unclip cap -1- from the brake carrier-2-. Checking the brake pad thickness through the inspection hole in the brake carrier. Minimum pad thickness without supporting shoe (wear dimension) 1.5 mm. Note The brake pads must not be soiled with brake fluid or grease.
S46-0094
Edition 04.05 S00.5303.18.20
46-2 page 5
46
Removing and installing brake shoe Drum brake
Torque wrench Hook (commercially available) Solid lubricant paste -G 000 650-
FABIA 2000
Chassis
Removing
Remove wheel. Remove the brake drum. Remove spring cap with pressure springs. Use a screwdriver to lever off the brake shoes from the bottom support in the direction of the arrow.
S46-0070
Unhook the retractor spring at the bottom. Unhook the hand-brake cable. Carefully guide the brake shoes out between the
wheel hub and the brake carrier.
Tighten the brake shoe in the vice. Remove the tension spring -1- for wedge -2-. Unhook the retractor spring at the top -3- with hook
-A-.
1 A
S46-0071
Unhook the locating spring -1- with hook -A-. Remove the pressure rod -2- and the wedge -3- from
the brake shoe.
2 A
S46-0072
46-2 page 6
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46
2 1
Installing
Grease the contact point of the pressure rod using solid lubricant paste -G 000 650-.
Insert the locating spring -1- in the brake shoe -2- and
position the brake shoe on the pressure rod -3-
3
S46-0095
Hook locating spring -1- with hook -A- in the pressure

rod -2-.
Insert wedge -3-.

Note Pay attention to the fitting position of the wedge. The raised part of the wedge -arrow- must remain visible during installation.
2 A
S46-0073
Grease the contact point of the pressure rod using solid lubricant paste -G 000 650-.
Insert the brake shoe with brake lever in the pressure

rod.
Hook on the retractor spring at the top -3- with hook

-A-.
Hook on the tension spring -1- for wedge -2-. Carefully guide the brake shoes in between the wheel
hub and the brake carrier.
1 A
Position the brake shoe on the brake cylinder piston. Hook the hand-brake cable onto the brake lever. Grease the contact points of the bottom retractor
spring on the brake shoe with solid lubricant paste -G 000 650-.
S46-0071
Insert the bottom retractor spring and lift the brake

shoe onto the bottom bracket.
Insert the pressure spring with spring cap. Install the brake drum. Activate the foot pedal forcefully once; this causes the
rear wheel-brake to be adjusted.
Setting the hand-brake 46-2 page 8.

Edition 04.05 S00.5303.18.20 Repairing a rear brake
46-2 page 7
46
Attach the wheel.
FABIA 2000
Chassis
Setting the hand-brake - drum brake

Note
Resetting of the hand-brake is not required after reset-
ting of the rear brake due to automatic resetting of the rear wheel-brake.
Resetting is only required after replacing the hand-
brake cable, the brake carrier or the brake pads/brake shoes.
Remove the centre console Body Work;

Rep. Gr. 68.
Release the hand-brake. Forcefully apply the foot brake repeatedly. Pull the handbrake on and release it three times.
This sets the components into position.
Put the hand-brake lever into the 1st catch position

(after being in the release position).
Tighten adjusting nut -arrow- until both wheels are

hard to turn by hand. Note The adjusting nut must be screwed over the end of the tension rod (self-locking effect).
Release hand-brake and check whether both wheels

rotate freely, if necessary release adjusting nut slightly.
Put the hand-brake lever into the 4th catch position

(after being in the release position). No wheel should be rotatable; tighten the adjusting nut if necessary.
S46-0096
Release hand-brake and check whether both wheels

rotate freely, if necessary release adjusting nut slightly.

and release the hand-brake. The hand-brake must automatically return into the release position below the 1st catch.
Install the centre console Body Work; Rep. Gr. 68.
46-2 page 8
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46
Removing and installing rear brake - Disc brake

Torque wrench Torque wrench with angle indicator Brake pedal load, e.g. -V.A.G 1869/2 Brake filling and bleeding device, e. g. -ROMESS S15 Bleeding bottle (commercially available) Brake fluid Chapter 00-3
Note
After replacing the brake pads forcefully apply the brake pedal repeatedly to ensure the brake pads go into their
normal operating position.

Generally tighten the brake line pipe screws to a tightening torque of 14 Nm. Use the brake pedal load, e.g. -V.A.G 1869/2- before removing a brake caliper or separating a brake hose from the
brake caliper.
1 - 4 Nm 2 - Brake disc Thickness: 9 mm 13 Wear limit: 7 mm if worn replace axle-wise 3 - Cap replace after each removal pressing off and inserting Chapter 42-5 4 - Self-locking twelve-point nut, 12 70 Nm and tighten a further 30 11 replace after each removal 5 - Wheel hub with wheel bearing must be replaced completely 10 removing and installing Chapter 42-5 9 assignment Spare part catalogue 6 - turn 30 Nm and 90 replace after each removal 7 - Cover plate 8 8 - Axle stud 9 - ABS speed sensor 10 - Allen screw, 8 Nm for speed sensor ABS 11 - Axle body 12 - Hand-brake cable Setting the hand-brake 46-2 page 13 13 - Allan screw, tighten to 30 Nm and then turn by a further 30 14 - Brake line with supports, hollow screw and seal must be replaced completely, do not dismantle
14 15 16
17 18 19
1 7 6 5 4 3 2
S46-0097
Edition 04.05 S00.5303.18.20
46-2 page 9
46
Tightening torque of the hollow screws: 35 Nm do not unscrew when replacing the brake pad 15 - Self-locking hexagon screw, 35 Nm replace after each removal 16 - Brake caliper removing: Use brake pedal load
FABIA 2000
Chassis
Unscrew brake line from brake caliper

Installing: Screw the brake line onto the brake caliper Remove brake pedal load Bleed the brake system Chapter 47-4 repair Chapter 47-1 One must first adjust the hand-brake cable after undertaking repair or replacement work Setting the hand-brake 46-2 page 13
17 - Brake pads Thickness: 16.9 mm (including the support plate) Wear limit: 2.0 mm without supporting plate Check thickness Inspection and Maintenance always replace axle-wise removing and installing 46-2 page 10 18 - Pad retaining spring always replace when changing the pads 19 - Brake carrier with guide bolts and protective caps must be assembled with sufficient grease on the guide bolt, supplied as a spare part fit a repair set if there is any damage to the protective caps or guide bolts; (use the enclosed grease packing to lubricate the guide bolts)
Removing and installing brake pads Disc brake

Resetting and turning out tool -MP 9-401 Torque wrench Bleeding bottle (commercially available) Brake fluid Chapter 00-3
Note
Do not unscrew the brake line on the brake caliper
when replacing the brake pad.
Removing
Remove wheel.
46-2 page 10
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46

wear indicator (where the vehcile is fitted with this only right vehicle side).
Lift off the clip -1- with a screwdriver and pull down to
remove.
Push the brake lever -2- in the direction of the arrow

and unhook the hand-brake cable -3-.
Unscrew the fixing screws of the brake carrier while

counterholding the guide bolts.
Remove the brake caliper and secure with wire in

S46-0098
Remove the brake pads and pad retaining springs -arrows-. Note
Only use alcohol to clean the brake caliper housing. The adherend for the brake pads must be free from
glue residues and grease.
Clean the brake caliper.

Installing
Note Drain brake fluid from the brake fluid reservoir using a ventilation bottle before pushing the piston back in. Caution! Brake fluid is toxic and must never be sucked off by mouth.
S46-0104
Edition 04.05 S00.5303.18.20
46-2 page 11
46
Note
Only use the resetting and turning out tool to reset the
FABIA 2000
Chassis
B A
piston.
When resetting the piston with a piston resetting de-
vice the automatic reset in the brake caliper is destroyed.
Insert theresetting and turning out tool -MP 9-401-,

the tool collar -arrow B- must be located on the brake caliper.
Place an open-jawed spanner SW 13 on a suitable

spanner surface -arrow A- if the piston is difficult to move.
MP 9-401
S47-0039
Screw in the piston by turning the knurled wheel clockwise on the resetting and turning out tool -MP 9-401-.
Insert the new pad retaining springs -arrows- and

brake pads in the brake carrier.
Remove the protective foil from the supporting plate of

the brake pad. Note There are four self-locking hexagon screws in the repair set, which must be fitted.
S46-0104
Secure the brake caliper to the brake carrier using

new self-locking screws. Hold the guide bolts while tightening the screws. Tightening torque: 35 Nm
S46-0098
46-2 page 12
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46

and hook on the hand-brake cable -3-.
Fit clip -1-. Setting the hand-brake 46-2 page 13 Connect up the plug connection for the brake pad
wear indicator (where the vehcile is fitted with this only right vehicle side).
Attach the wheel.

Note
Setting the hand-brake - disc brake

Note
Resetting of the hand-brake is not required after reset-
ting of the rear brake due to automatic resetting of the rear wheel-brake.
Resetting is only required after replacing the hand-
brake cable, the brake caliper or after replacing the brake pads or the brake disc.
The brake pedal must be ventilated and fully function-
al.
Remove the centre console Body Work;

Rep. Gr. 68.
Release the hand-brake. Forcefully apply the foot brake repeatedly. Tighten adjusting nut -arrow A- so far that the levers
-arrow B- rise from the stops on the brake calipers. Note The adjusting nut must be screwed over the end of the tension rod (self-locking effect).
S46-0099
Edition 04.05 S00.5303.18.20
46-2 page 13
46
Check distance -a- between the lever and stop on the
left and right brake caliper using a feeler gauge. With the hand-brake released the total distance -a(between the lever and the stop) on the left and right brake caliper must not be less than or exceed a minimum of 1 mm and a maximum of 4mm; the maximum distance of 3 mm on a brake must not be exceeded.
FABIA 2000
Chassis
Pull the handbrake on and release it three times. This

sets the components into position.
With the hand-brake released check whether the two

wheels turn freely, release the adjusting nut slightly and check distance -a- again if necessary.

and release the hand-brake. The hand-brake must automatically return into the release position below the 1st catch.
Install the centre console Body Work; Rep. Gr. 68.
46-2 page 14
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
46
46-3
Handbrake
Summary of components of hand brake

1 - Hand-brake lever removing and installing: Removing the centre console Body Work; Rep. Gr. 68 Assignment Spare part catalogue 2 - Cover removing: Press down the catch pegs at the bottom of the trim panel with a small screwdriver and pull off the trim towards the front. Installing: Slide the trim panel until the catch peg catches onto the hand-brake lever. Check trim panel catch. Assignment Spare part catalogue 3 - Compensating clamp 4 - Adjusting nut Setting the hand-brake Chap. 46-2 5 - Grommet removing: Pull hand-brake cable from guide tube. Release grommet.
3 2
11 1 11 10 5 6 7
8 9 5
S46-0106
Pull grommet from guide
678-
910 -
11 -
tube. Installing: The installation occurs in reverse order. After installing make sure the grommet fits correctly in the body recess. Right guide tube for hand-brake cable Left guide tube for hand-brake cable Hand-brake cable removing and installing 46-3 page 2 Check fitting position: The positioning ring of the hand-brake cable must be located in the recess of the retaining clip. Hand-brake lever support welded to the body tunnel Switch for hand-brake control -F9clipped onto hand-brake lever replace if defective Tighten self-locking hexagon nut 20 Nm and 90 replace after each removal
Edition 08.00 S00.5303.04.20
Handbrake
46-3 page 1
46
Removing and installing the hand-brake cable
Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
FABIA 2000
Chassis
Removing
Removing the centre console Body Work;

Rep. Gr. 68.
Raise vehicle. Remove wheel. Release the hand-brake. Release adjusting nut -arrow- and unhook hand-brake cable from compensating clamp. Note
The retaining clip for the hand-brake cable must be replaced each time it is removed.
Remove the retaining clip of the rear axle. Unhook hand-brake cable from brackets.
Vehicles with drum brakes
Removing brake drum Chap. 46-2. Unhook the hand-brake cable from the brake lever. Pull hand-brake cable out of brake carrier.
Vehicles with disc brakes
S46-0096
Lift off the clip -1- with a screwdriver and pull down to
remove.

and unhook the hand-brake cable -3-.
3 2
Pull hand-brake cable out of guide tube.

Installing
Insert new retaining clip on the hand-brake cable.

The positioning ring must be located in the recess of the retaining clip.
N46-0176
Setting the hand-brake:

Vehicles with drum brakes Chap. 46-2 Vehicles with disc brakes Chap. 46-2
46-3 page 2
Handbrake
Edition 08.00 S00.5303.04.20
FABIA 2000
Chassis
46
46-4
Foot Controls, Brake Pedal
Summary of Components of Foot Controls, Brake Pedal

Caution! The travel of the brake pedal must not be shortened by additional floor coverings. Note
Replace self-locking nuts each time they are removed. Grease all bearing points and contact surface of the brake light switch tappet before assembly with polycarbamide
grease -G 052 142 A2-. 1 - Bracket for foot controls Crash strut cannot be removed, as it is welded to bracket removing and installing 46-4 page 3 2 - Hexagonal screw 3 - Self-locking hexagon nut, 28 Nm replace after each removal 4 pieces for securing the brake servo unit to the bracket 2 pieces for securing the bracket to the assembly plate 4 - Brake light switch assignment Spare part catalogue before assembling the brake light switch clip brake pedal to the pressure rod of the brake servo unit Setting, removing and installing the brake light switch Chap. 45-16 Inspecting function of the brake light Chap. 45-16 5 - Accelerator pedal with sender -G79- and -G185removing and installing Engine, Mechanics; Rep. Gr. 20 6 - Brake pedal removing and installing 46-4 page 4 7 - Bushing 8 - Cap 9 - Bearing bolt 10 - Self-locking hexagon nut, 25 Nm replace after each removal 11 - Brake servo unit removing and installing Chapter 47-2 assignment Spare part catalogue
Edition 07.04 S00.5303.16.20
11
12
13 14 15
1 2 3 10 9 7 8 7 6
3 4 5
S46-0113
46-4 page 1
46
12 - Front wall 13 - Module carrier 14 - Bracket for crash strut 15 - Self-locking hexagon screw, 10 Nm replace after each removal
FABIA 2000
Chassis
Separating the brake pedal from the brake servo unit and clipping onto brake servo unit
Release tool -T30021- or -T10006 A-
Separating the brake pedal from the brake servo unit
Remove the cover with storage area Body Work;

Rep. Gr. 70.
Removing the brake light switch Chap. 45-16.

Note Fig. shows the separation of the brake pedal from the brake servo unit with the foot controls removed for clarity.
Press brake pedal -1- towards the brake servo unit

and hold in position.
T30021 2
Insert release tool -T30021- or -T10006 A- and pull towards the driver's seat while counterholding the brake pedal. (At this moment the pedal must not move backwards.) This causes the retaining lugs -3- of the support to be pressed off the spherical head of the push rod -2-.
Pull the release tool and brake pedal jointly towards

the driver's seat. (This causes the brake pedal to be drawn off the ball knob of the pressure rod). Clipping the brake pedal onto the brake servo unit
1 3
S46-0114
Hold the ball knob of the pressure rod -2- before the
support and press the brake pedal -1- towards the brake servo unit so that the ball knob is heard to catch. 3 - Bracket
Setting and installing the brake light switch Chap.

45-16.
Install the cover with storage area Body Work;

Rep. Gr. 70.
Check operation of the brake lights.
1
S46-0115
46-4 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
46
Removing and installing the foot controls

-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A Release tool -T30021- or -T10006 A-
Disconnect battery Electrical System; Rep. Gr. 27. Remove the cover with storage area Body Work;
Rep. Gr. 70. Vehicles without air conditioning
Removing the left footwell vent Heating, Air Conditioning; Rep. Gr. 80. Vehicles with air conditioning
Removing the left footwell vent Heating, Air Conditioning; Rep. Gr. 87. Vehicles with Convenience system central control unit -J393-
Remove the convenience system central control unit

-J393- Body Work; Rep. Gr. 70. Continued for all vehicles
Unscrew plastic nuts -1-. Remove cover -2-. Removing brake light switch Chap. 45-16. Pull out plug of accelerator pedal position sender -G79-. 46-4 page 2.
S48-0106
Edition 07.04 S00.5303.16.20
46-4 page 3
46
Unscrew the hexagon nuts for securing the foot controls -arrows-. The top hexagon nut for securing the foot controls is not visible in the figure. It is located at the bulkhead behind the crash strut.
FABIA 2000
Chassis
Remove foot controls.

Installing Installation is carried out in the reverse order.

45-16.
Connect battery Electrical System; Rep. Gr. 27. Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-. Tightening torque: Foot controls on brake servo unit and on assembly plate
Use new nuts!
28 Nm
S46-0116
Removing and installing brake pedal

-V.A.G 1551/3B-, -V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A Release tool -T30021- or -T10006 A Internal extractor (10.014.0 mm) -Kukko 21/02 Polycarbamide grease -G 052142 A2-
Disconnect battery Electrical System; Rep. Gr. 27. Remove the cover with storage area Body Work;
Rep. Gr. 70. Vehicles without air conditioning
46-4 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
46

-J393- Body Work; Rep. Gr. 70. Continued for all vehicles
Removing brake light switch Chap. 45-16. Pull out plug of accelerator pedal position sender
-G79-.

46-4 page 2.
1 2
Unscrew hexagon nut -1-.

Note In the Fig. hexagon screw for bearing bolt is covered by the bracket.
Remove hexagon screw for bearing bolt -arrow-. Remove brake pedal -2-. Pull bearing bolt -1- out of the casing tube -3- of the
brake pedal. Note Replace all removed bushings.
S46-0117
1 2 2 KUKKO 21/02 3
Insert and tension interior extractor -Kukko 21/2- on

the bushing -2-.
Pull out bushing by hand from the casing tube.

Installing Installation is carried out in the reverse order.
S46-0118
Note Do not tilt bushings when installing.
Insert new bushings in the brake pedal if they were removed. Press in bushings up to stop.
Grease bearing points of the brake pedal (bearing

bolts and bushings) with polycarbamide grease -G 052 142 A2-.

45-16.
Connect battery Electrical System; Rep. Gr. 27. Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis, measurement and information system -VAS 5051-.
Edition 07.04 S00.5303.16.20
46-4 page 5
46
Tightening torque: Brake pedal to bracket
Use new nut!
FABIA 2000
Chassis
25 Nm
46-4 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
47 Brake, Brake Hydraulics

47-1 Repairing the brake caliper
Summary of Components of Brake Caliper FS-III

Note
When repairing install complete repair set. New brake calipers are filled with brake fluid and are pre-bled. Thinly coat brake cylinder, piston and gasket ring with lithium grease -G 052 150 A2-.
1 - Dust cap 2 - Vent valve, 10 Nm before screwing in thinly coat thread with lithium grease -G 052 150 A23 - Bushing insert in brake caliper housing 4 - Guide bolts, 28 Nm 5 - Caps insert in bushing 6 - Brake caliper housing 7 - Seal removing and installing 47-1 page 2 8 - Piston removing and installing 47-1 page 2 9 - Protective cap removing and installing 47-1 page 2 when inserting piston do not damage
4 1 2 3
S47-0068
Edition 03.01 S00.5303.08.20
Repairing the brake caliper
47-1 page 1
47
Removing and installing piston of brake caliper FS-III
Piston jig -MP 9-403 Disassembly wedge -3409 Lithium grease -G 052 150 A2-
FABIA 2000
Chassis
Removing
Insert wooden plate in the channel to avoid damaging

the piston when it is ejected.
Press out piston from the brake caliper housing with

compressed air -arrow-. Note When removing the gasket ring make sure the cylinder surface is not damaged.
S47-0051
3409
Remove gasket ring with disassembly wedge -3409-.

Installing
Clean the piston and gasket ring surfaces with alcohol

and subsequently dry.
Before installing the piston and gasket ring in the

brake caliper housing thinly coat with lithium grease -G 052 150 A2-.
Insert new gasket ring in the groove of the brake caliper housing.
S47-0031
Position the new protective cap with the outer sealing

lip on the piston.
S47-0032
47-1 page 2
Edition 03.01 S00.5303.08.20
FABIA 2000
Chassis
47
3409
Insert inner sealing lip of the protective cap with disassembly wedge -3409- in the groove of the cylinder. To do so hold the piston in front of the brake caliper housing.
S47-0033
Press the piston in the brake caliper housing with the

piston jig -MP 9-403-. Note The outer sealing lip of the protective cap will fall in the piston groove.
MP 9-403
S47-0050
Edition 03.01 S00.5303.08.20
47-1 page 3
47
Summary of Components of Brake Caliper FS-II
Note
FABIA 2000
Chassis
1 - Brake caliper housing 2 - Dust cap 3 - Vent valve, 10 Nm before screwing in thinly coat thread with lithium grease -G 052 150 A24 - Top distance sleeve insert with Lithium grease -G 052 150 A25 - Top bushing slotted insert with Lithium grease -G 052 150 A26 - Top bush insert with Lithium grease -G 052 150 A27 - Bottom bush insert with Lithium grease -G 052 150 A28 - Bottom bushing slotted insert with Lithium grease -G 052 150 A29 - Bottom distance sleeve insert with Lithium grease -G 052 150 A210 - Seal 12 removing and installing 47-1 page 2 11 - Piston removing and installing 47-1 page 2 12 - Protective cap removing and installing 47-1 page 2 when inserting piston do not damage
4 2 1 3
6 7
11
10
8
S47-0069
Removing and installing piston of brake caliper FS-II

Removing and installing the piston occurs in the same way as for the piston of the brake caliper of the FS-III brake 47-1 page 2.
47-1 page 4
Edition 03.01 S00.5303.08.20
FABIA 2000
Chassis
47
Summary of components of brake caliper C54-II

Note
1 - Dust cap 2 - Vent valve, 10 Nm before screwing in thinly coat 1 2 thread with lithium grease -G 052 150 A23 - Hexagon collar bolt, 30 Nm replace each time removed 4 - Guide bolts 5 - Protective cap insert into slot of the brake carrier and of guide pin; grease slot first of all, use grease packing of repair kit 6 - Brake carrier with guide bolt and protective cap is supplied as replacement part assembled with guide pin and protective caps as well as adequate quantity of 3 grease on guide pins if there is any damage to the protective caps or guide bolts fit a repair set; use the enclosed grease packing to lubricate the guide bolts 7 - Protective cap removing and installing 47-1 page 2 when inserting piston do not damage 8 - Piston removing and installing 47-1 page 2 9 - Seal removing and installing 47-1 page 2 10 - Brake caliper housing
4 5 6
10 9 8 7
S47-0078
Removing and installing piston of brake caliper C54-II

Removing and installing the piston occurs in the same way as for the piston of the brake caliper of the FS-III brake 47-1 page 2.
Edition 03.01 S00.5303.08.20
47-1 page 5
47
Summary of components of rear brake caliper
Note
When repairing always install complete repair set. New brake calipers are filled with brake fluid and are pre-bled.
FABIA 2000
Chassis
In the event of repair it is absolutely necessary to pre-bleed the brake calipers before installing them in the vehicle
(without brake pads) 47-1 page 8.
Thinly coat brake cylinder, piston and gasket ring with lithium grease -G 052 150 A2-.
1 - Self-locking hexagon screw, 35 Nm replace each time removed counterhold at guide bolt 2 1 when releasing and tigtening 2 - Dust cap 3 3 - Vent valve, 10 Nm before screwing in thinly coat thread with lithium grease -G 052 150 A24 - Guide bolts grease before fitting protective cap item 5 to grease use the grease supplied with the repair set 5 - Protective cap pull onto brake carrier and guide bolt 1 6 - Brake carrier with guide bolt and protective cap must be assembled with sufficient grease on the guide bolts, supplied as a spare part if there is any damage to the protective caps or guide bolts fit a repair set; use the en10 9 8 closed grease packing to lubricate the guide bolts 7 - Protective cap removing and installing 47-1 page 7 when inserting piston do not damage 8 - Piston with automatic adjusting device removing and installing 47-1 page 7 9 - Seal removing and installing 47-1 page 7 10 - Brake caliper housing with lever for hand-brake cable replace brake caliper housing if the lever for the hand-brake cable is not tight after repair pre-bleed brake caliper housing 47-1 page 8
4 5 6
S47-0070
47-1 page 6
Edition 03.01 S00.5303.08.20
FABIA 2000
Chassis
47
Removing and installing the rear brake caliper piston

Resetting and turning out tool -MP 9-401 Disassembly wedge -3409 Bleeding bottle (commercially available) Lithium grease -G 052 150 A2 Brake fluid Chap. 00-3
Removing
Insert resetting and turning out tool -MP 9-401 -.

Collar -arrow B- must be located before the piston.
B
Note If there is a resistance in the piston position open-end wrench waf 13 on the provided wrench surfaces -arrow A-.
MP 9-401
S47-0035
Release the piston from the brake caliper housing by

turning the knurled wheel to the left. Note When removing the gasket ring make sure the cylinder surface is not damaged.
3409
Remove gasket ring with disassembly wedge -3409-.

Installing
Clean the piston and gasket ring surfaces with alcohol

and subsequently dry.
Before installing the piston and gasket ring in the

brake caliper housing thinly coat with lithium grease -G 052 150 A2-.
S47-0036
Insert new gasket ring in the brake caliper housing. Position the new protective cap with the outer sealing
lip on the piston.
S47-0037
Edition 03.01 S00.5303.08.20
47-1 page 7
47
Insert inner sealing lip with disassembly wedge
-3409 - in the groove of the cylinder. To do so hold the piston in front of the brake caliper housing.
FABIA 2000
Chassis
3409
S47-0038
Insert resetting and turning out tool -MP 9-401 -.

The collar -arrow B- must rest on the brake caliper. Note
If there is a resistance in the piston position open-end
B A
wrench waf 13 on the provided wrench surfaces -arrow A-.

When adjusting the piston with a piston jig or by actu-
ating the foot brake the automatic adjustment in the brake caliper is destroyed.
Screw in piston by turning the knurled wheel to the

right.
MP 9-401
S47-0039
Insert brake pads.

Pre-bleeding the brake caliper
Note Set up brake caliper for pre-bleeding.
Open vent valve -arrow A-. Using a commercially available ventilation reservoir fill
brake fluid until bubble-free brake fluid drips out of the threaded bore (brake hose connection) -arrow B-.
Close vent valve.
A B
S47-0049
47-1 page 8
Edition 03.01 S00.5303.08.20
FABIA 2000
Chassis
47
47-2
Brake Servo Unit, Master Brake Cylinder
Summary of Components of Brake Servo Unit, Master Brake Cylinder

Note The complete master brake cylinder and brake servo unit can be replaced independently of one another. 1 - Brake servo unit removing and installing 47-2 page 5 assignment Spare part 3 catalogue on petrol engines the re1 2 quired negative pressure is drawn from the induction pipe 14 Diesel engines are fitted with MA X a vacuum pump or tandem MI pump for fuel and negative N pressure supply Functional test: 4 With the engine off press down brake pedal repeatedly 5 5 with force (this reduces the 13 12 pressure already present in the device). 6 Now hold the brake pedal in brake position using a medi7 um foot pressure and start the engine. If the brake servo unit operates perfectly the brake pedal must yield noticeably under your foot (servo boost takes effect). 8 10 9 6 if there are faults replace completely disconnect from brake pedal 11 or clip onto brake pedal Chap. 46-4 Non-return valve in vacuum S47-0071 hose of the vacuum pump 47-2 page 7 Non-return valve in the vacuum hose of the tandem pump for fuel and vacuum supply 47-2 page 8 Functional test: It must be possible to blow through the valve in the direction of the arrow.
Against the direction of the arrow the valve must be closed.

2 - Brake fluid level warning contact -F34cannot be removed or repaired 3 - Cap 4 - Brake fluid reservoir removing: Drain brake fluid.
Press out retaining pin from the lateral catches of the brake fluid reservoir and master brake cylinder. Pull brake fluid reservoir upwards out of the sealing plugs.
Installing: Installation is carried out in the reverse order.
Edition 07.04 S00.5303.16.20
47-2 page 1
47
FABIA 2000
Chassis
567-
8910 11 12 13 14 -
Chapter 47-4. On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 perform basic setting: using vehicle system tester -V.A.G 1552- Chapter 45-13 using vehicle diagnosis, measurement and information system -VAS 5051- Chapter 45-4. On vehicles with ABS//TCS/ESP BOSCH 8.0 perform basic setting: using vehicle system tester -V.A.G 1552- Chapter 45-14. using vehicle diagnosis, measurement and information system -VAS 5051- Chapter 45-4. Sealing plugs moisten with brake fluid and press in brake fluid reservoir Self-locking nut, 20 Nm replace after each installation Master brake cylinder cannot be repaired, replace completely in the event of faults Tightness test 47-2 page 2 removing and installing 47-2 page 3 assignment Spare part catalogue Retaining pin to secure brake fluid reservoir at brake master cylinder Gasket ring replace after disassembling the master brake cylinder Sealing plugs Vacuum hose insert with brake servo unit Cap check for firm seating Self-locking nut, 28 Nm replace after each removal Gasket for brake servo unit
Fill up with new brake fluid. On vehicles without ABS or with ABS BOSCH 5.7 or ABS, ABS/TCS BOSCH 8.0 bleed brake system
Checking the master brake cylinder for tightness

Brake-power regulator or brake system tester, e.g.
-V.A.G 1310- or -V.A.G 1310 A Lithium grease -G 052 150 A2-
Inspection requirement
Function and tightness of the brake system (hydraulic

control unit or load-dependent brake-power regulator, brake lines, brake hoses, brake calipers and wheelbrake cylinder) O.K. Test
Release the vent valve on one of the front brake calipers.
47-2 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
Connect the pressure gauge of the tester -V.A.G

1310 - or -V.A.G 1310 A- and bleed.
Push down brake pedal until the pressure gauge on

the tester indicates 5 MPa (50 bar).
Throughout the test which lasts 45 seconds the pressure loss must not exceed 0.4 MPa (4 bar).
If the pressure loss exceeds 0.4 MPa (4 bar) replace

the master brake cylinder. Tightening torque: Vent valve in brake caliper 10 Nm
V.A.G 1310
Removing and installing the master brake cylinder

Hose clamp -MP 7-602 Removal and installation pliers, e.g. -VAS 5024 Vehicle system tester -V.A.G 1552- or vehicle diagnoS47-0107
-VAS 5051/5A- or -VAS 5051/6A Brake filling and bleeding device, e.g. -ROMESS S15 Extraction bottle (commercially available) Repair kit SP.-No. 1H0 698 311 A Brake fluid Chapter 00-3
Note
The master brake cylinder must not be repaired. assignment Spare part catalogue
Removing
Remove engine cover Engine, Mechanics;

Rep. Gr. 10.
Remove air filter Engine, Fuel Injection;
Rep. Gr. 24 (fuel engines) or Rep. Gr. 23 (diesel engines). Note
Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
2
MAX MIN
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
3 4
Lay sufficient non-fluffing cloths around the engine

and gearbox.
Disconnect plug -1- from the brake fluid level warning

contact -F34-.
5
S47-0073
Unclip vacuum hose -6- from the brake fluid reservoir.

Edition 07.04 S00.5303.16.20 Brake Servo Unit, Master Brake Cylinder
47-2 page 3
47
After opening the breather screws on the front axle
brake calipers pump off brake fluid by repeatedly pressing the brake pedal.
FABIA 2000
Chassis
Clamp off the running-on line of the clutch master cylinder -2- with hose clamp -MP 7-602-.
Open spring strap clamps of the running-on line of the

clutch master cylinder using assembly pliers or -VAS 5024-.
Disconnect the running-on line of the clutch master

cylinder -2- from the brake fluid reservoir -3- and tie up.
Unclip the brake lines from the holder -7-. Unscrew the brake lines from the tandem master
brake cylinder -5- and shut off.
Shut-off the connections of the brake lines on the

master brake cylinder with screw plugs from the repair kit SP No. 1 H0 698 311 A.
Release the nuts of the master brake cylinder. Carefully pull off the master brake cylinder -5- from the
brake servo unit -4-. Installing Note
Install new gasket ring between the master brake cyl-
inder and the brake servo unit.

When installing the master brake cylinder with the
brake servo unit pay attention to the correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid.
Installation is carried out in the reverse order.
Fill up with new brake fluid. Install battery and battery tray Electrical System;
Rep. Gr. 27.

Vehicles without or with ABS BOSCH 5.7 or ABS, ABS/TCS BOSCH 8.0
Bleed brake system Chapter 47-4.

Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7
Perform basic setting:

45-13.
tion system -VAS 5051- Chapter 45-4.
47-2 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
45-14.
Bleed clutch gearbox; Rep. Gr. 30. Install air filter Engine, Fuel Injection; Rep. Gr. 24
(fuel engines) or Rep. Gr. 23 (diesel engines).

Rep. Gr. 10.
Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis system, measurement and information system -VAS 5051-. Tightening torques: Master brake cylinder to brake servo unit
Use new nuts!
20 Nm
Brake line to master brake cylinder
14 Nm
Removing and installing brake servo unit

Hose clamp -MP 7-602 Release tool -T30021- or -T10006 A Removal and installation pliers, e.g. -VAS 5024 Vehicle system tester -V.A.G 1552- or vehicle diagno-
-VAS 5051/5A- or -VAS 5051/6A Brake filling and bleeding device. -ROMESS S15 Extraction bottle (commercially available) Repair kit SP.-No. 1H0 698 311 A Brake fluid Chapter 00-3
Removing
Remove engine cover Engine, Mechanics;

Rep. Gr. 10.
Remove air filter Engine, Fuel Injection;
Rep. Gr. 24 (fuel engines) or Rep. Gr. 23 (diesel engines). Note
Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding.
Edition 07.04 S00.5303.16.20
47-2 page 5
47
Remove battery and battery tray Electrical System;
Rep. Gr. 27.
FABIA 2000
Chassis
Lay sufficient non-fluffing cloths around the engine

and gearbox.
Disconnect plug -1- from the brake fluid level warning

contact -F34-.
Unclip vacuum hose -6- from the brake fluid reservoir. After opening the breather screws on the front axle
Clamp off the running-on line of the clutch master cylinder -2- with hose clamp -MP 7-602-.
Open spring strap clamps of the running-on line of the

clutch master cylinder using assembly pliers or -VAS 5024-.
Disconnect the running-on line of the clutch master

cylinder -2- from the brake fluid reservoir -3- and tie up.
MAX MIN
2 3 4
Unclip the brake lines from the holder -7-. Unscrew the brake lines from the tandem master
brake cylinder -5- and shut off.

master brake cylinder with screw plugs from the repair kit SP No. 1 H0 698 311 A.
5
S47-0073
Vehicles without air conditioning

- J393- Body Work; Rep. Gr. 70. Continued for all vehicles
Removing brake light switch Chap. 45-16. Removing brake pedal from brake servo unit
Chapter 46-4.
Unscrew the nuts for brake servo unit -arrows-. Guide the brake servo unit with master brake cylinder
towards the front and remove. Installing Installation is carried out in the reverse order.
Clipping the brake pedal onto the brake servo unit

Chap. 46-4. 45-16.

S47-0074
47-2 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
Fill up with new brake fluid. Install battery and battery tray Electrical System;
Rep. Gr. 27.
Connect battery Electrical System; Rep. Gr. 27. Removing brake light switch Chap. 45-16. Removing brake pedal from brake servo unit
Chapter 46-4.
Unscrew the nuts for brake servo unit -arrows-. Guide the brake servo unit with master brake cylinder
towards the front and remove. Vehicles without or with ABS BOSCH 5.7 or ABS, ABS/TCS BOSCH 8.0

Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7

45-13.
S47-0074

45-14.
Bleed clutch gearbox; Rep. Gr. 30. Install air filter Engine, Fuel Injection; Rep. Gr. 24

Rep. Gr. 10.
Perform automatic test sequence Chapter 45-5 either using the vehicle system tester -V.A.G 1552- or the vehicle system test Chapter 45-4 using the vehicle diagnosis system, measurement and information system -VAS 5051-. Tightening torques: Brake servo unit to foot controls
Use new nuts!
20 Nm
Brake line to master brake cylinder
14 Nm
Removing and installing the vacuum pump for the brake servo unit
Vehicles with 1.9 ltr./47 kW SDI engine
Edition 07.04 S00.5303.16.20
47-2 page 7
47
The vacuum supply of the brake servo unit occurs via a vacuum pump on vehicles with a suction diesel engine 1.9/47 SDI Engine, Mechanics; Rep. Gr. 15.
FABIA 2000
Chassis
Removing and installing tandem pump for fuel and vacuum supply
For vehicles with TDI PD Turbocharger engines The vacuum supply of the brake servo unit occurs via a tandem pump on vehicles with a turbo-diesel engine TDI Engine, Mechanics; Rep. Gr. 20.
47-2 page 8
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
47-3
Brake-power regulator, brake-pressure reducer
Summary of Components of Brake-Power Regulator

Note
After removing the brake lines close connection bores on the brake-power regulator with screw plugs. Only remove the screw plugs from the connection bores when the brake lines are installed.
WARNING! Pay attention to the correct channel assignment of the brake lines. Interchanging the brake lines will result in dangerous brake control actions. 1 - Brake-power regulator load dependent assignment Spare part catalogue testing and adjusting 47-3 page 2 14 Adjusting values Chap. 00-3 2 - Bracket for brake-power regulator 3 - Hexagon screw, 20 Nm 4 - Brake line with pipe screw Brake-power regulator - rear right brake hose Tightening torque of the pipe screws: 14 Nm 5 - Brake line with pipe screw Brake-power regulator - rear left brake hose Tightening torque of the pipe screws: 14 Nm 6 - Brake line with pipe screw Master brake cylinder brake-power regulator Tightening torque of the pipe screws: 14 Nm 12 7 - Brake line with pipe screw Master brake cylinder brake-power regulator Tightening torque of the pipe screws: 14 Nm 8 - Bracket for rear axle 9 - Oval-head countersunk screw, 20 Nm 10 - Hexagonal screw 11 - Hexagonal nut, 20 Nm 12 - Tension spring 13 - Rear left brake hose 14 - Rear axle 15 - Hexagon screw, 16 Nm
1 15
13
7 6
11 10 9
S47-0075
Edition 07.04 S00.5303.16.20
47-3 page 1
47
Inspecting and adjusting the brake-power regulator
Brake-power regulator or brake system tester, e. g.
FABIA 2000
Chassis
-V.A.G 1310- or -V.A.G 1310 A Brake filling and bleeding device. -ROMESS S15-
Fitting location of the brake-power regulator The brake-power regulator is secured to a bracket assigned to the mount for rear axle and is controlled by the rear axle movement via a spring. Check for proper operation
Forcefully apply the brake pedal and release quickly

(vehicle is standing on its wheels). While doing so the lever of the brake-power regulator must move. Pressure test and adjustment Note
The brake-power regulator is adjusted on a vehicle
ready for driving.

Vehicle ready for driving: Weight of the vehicle with
full fuel tank and full water reservoir for windscreen wiper/washer and headlamp cleaning system, spare wheel, tool kit, jack and driver (75 kg). The spare wheel, tool kit, jack and driver must be located in the position prescribed by the vehicle manufacturer.
Raise vehicle and connect pressure gauge of the tester to the brake caliper (front left wheel) and connect to the wheel-brake cylinder (rear right wheel).
Bleed both pressure gauges. Lower vehicle and repeatedly depress vehicle and allow to settle on the rear axle.
Press brake pedal and measure pressures. Compare measured pressure values to the specified
adjusting values Chap. 00-3. page 2. Adjusting brake-power regulator Test pressure on rear axle too high:
V.A.G 1310
If necessary adjust brake-power regulator 47-3
Release tension spring on brake-power regulator.

Test pressure on rear axle too low:
Tighten tension spring on brake-power regulator.

Note Adjust without load on the brake pedal, observe the following sequence:
S47-0107
47-3 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
Read off values. Relieve brake pedal. Adjust tension spring on brake-power regulator. Again load brake pedal. Read-off values and if necessary correct adjustment. Remove pressure gauge. Bleed brake system Chapter 47-4.
Removing and installing brake-power regulator

-V.A.G 1310- or -V.A.G 1310 A Brake pedal arrester, e.g. -V.A.G 1238 B- or brake
pedal load device, e.g. -V.A.G 1869/2 Brake filling and bleeding device. -ROMESS S15 Oil catch pan Repair kit SP.-No. 1H0 698 311 A Brake fluid Chapter 00-3
Removing
Press brake pedal and arrest with brake pedal arrester.
Position the oil catch pan under the brake-power regulator to collect escaping brake fluid.
Mark brake lines. Unscrew brake lines -1-, -2-, -3- and -4- on the brakepower regulator.
1 7 2
Shut-off brake lines to prevent brake fluid from running out and soiling.

brake-power regulator with screw plugs from repair kit SP No. 1 H0 698 311 A.
Unscrew hexagon nut -5- and remove hexagon screw

-6-.
Release oval-head countersunk screw -7-. Remove brake-power regulator.

Installing
6 5
3
S47-0077
WARNING! Pay attention to the correct channel assignment of the brake lines. Interchanging the brake lines will result in dangerous brake control actions. Installation is carried out in the reverse order.
Bleed brake system Chapter 47-4. Adjusting brake-power regulator 47-3 page 2.
Edition 07.04 S00.5303.16.20 Brake-power regulator, brake-pressure reducer
47-3 page 3
47
Tightening torques: Brake-power regulator to bracket Brake line to brake-power regulator 20 Nm 14 Nm
FABIA 2000
Chassis
Brake-power regulator to tension spring 20 Nm
Inspecting the brake-pressure reducer

Brake-pressure reducers are fitted on vehicles without ABS and without load-dependent brake-power regulator, Assignment Spare part catalogue. Fitting location A brake-pressure reducer is fitted on each brake circuit. The brake-pressure reducer -3- is screwed directly into the master brake cylinder -1-, the other brake pressure reducer -4- is connected to the master brake cylinder by means of a short brake line. 25678Brake servo unit Front left disc brake Front right disc brake Rear right drum brake Rear left drum brake
3 4 5 8
S47-0079
Pressure test Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1310- or -V.A.G 1310 A Brake filling and bleeding device. -ROMESS S15-
Raise vehicle and connect pressure gauge of the tester to the front left brake caliper and connect to the rear right wheel-brake cylinder. Because of the diagonal brake circuits after the pressure test proceed in the same way for the 2nd brake circuit (front right brake caliper and rear left wheel brake cylinder).
Bleed both pressure gauges. Press brake pedal and measure pressures. Compare measured pressure values to the specified
values Chap. 00-3. At a given pressure of 10 MPa (100 bar) the pressure reducer must be closed. A drop in pressure of maximum 1MPa (10 bar) 3 minutes is allowed. If the test pressures are not reached, inspect the brake system for leaks. If the brake system is tight and the test pressures are exceeded, replace the brake pressure reducer. The brake pressure reducer must not be repaired.
V.A.G 1310
Remove pressure gauge.
S47-0107
47-3 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
Removing and installing the brake-pressure reducer

-V.A.G 1310- or -V.A.G 1310 A Brake pedal arrester, e.g. -V.A.G 1238 B- or brake
pedal load -V.A.G 1869/2 Brake filling and bleeding device, e. g.
-ROMESS S15 Bleeding bottle (commercially available) Brake fluid Chap. 00-3
Removing
Insert the bleeder hose of the bleeding bottle on the

vent valve of the left and right brake caliper.
After opening the breather screws on the front axle

Shut the vent valve once the brake fluid flowed out. Disconnect the bleeder hose from the vent valve. Removing the brake-pressure reducer.
1 - Brake-pressure reducer for front left wheel/rear right wheel brake circuit. 2 - Brake line from the brake-pressure reducer to the rear right wheel-brake cylinder 3 - Brake line from the brake-pressure reducer to the rear left wheel-brake cylinder 4 - Brake-pressure reducer for front right wheel/rear left wheel brake circuit. 5 - Brake line from the master brake cylinder to the front right brake caliper 6 - Brake line from the master brake cylinder to the front left brake caliper 7 - Brake line from the master brake cylinder to the brake pressure reducer Installing Installation is carried out in the reverse order.
5 4 3 2 1 6 7
S47-0080
Bleed brake system Chapter 47-4. Perform pressure test 47-3 page 4.
Tightening torques Brake-pressure reducer to master brake cylinder Brake line to brake-pressure reducer (tube or hose connection) Brake lines to master brake cylinder 14 Nm 14 Nm 14 Nm
Edition 07.04 S00.5303.16.20
47-3 page 5
47
FABIA 2000
Chassis
47-3 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
47-4
Bleeding Brake System
Bleeding Brake System - vehicles without and with ABS, ABS/EDL/TCS or ABS/ EDL/TCS/ESP BOSCH 5.7 or ABS, ABS/ TCS or ABS/ASR/ESP BOSCH 8.0
Note
On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/
ESP the EDL function is integrated in the TCS function.

The procedure for bleeding air from the brake system
is described with the brake filling and bleeding appliance -ROMESS S15-. Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0 If one chamber of the brake fluid reservoir has run completely dry, e.g. leakage in the brake system, the hydraulic unit must be bled via the function basic setting either using the vehicle system tester -V.A.G 1552- or using the vehicle diagnosis, measurement and information system -VAS 5051-. Continued for vehicles with ABS systems BOSCH 5.7 or BOSCH 8.0
WARNING! On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ ESP BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0 a filling pressure of at least 0.2 MPa (2 bar) must be maintained when filling with brake fluid using brake filling and bleeding device -ROMESS S15-. If the filling pressure of 0.2 MPa (2 bar) is not reached, proper bleeding of the hydraulic unit is no longer assured. Distinction between ABS, ABS/EDL/TCS and ABS/ EDL/TCS/ESP BOSCH 5.7 as well as ABS, ABS/TCS and ABS/TCS/ESP BOSCH 8.0 Chapter 45-2 Note
Perform basic setting on vehicles with ABS/EDL/TCS
or ABS/EDL/TCS/ESP BOSCH 5.7 either using the vehicle system tester -V.A.G 1552- Chapter 45-13 or using the vehicle diagnosis, measurement and information system -VAS 5051- Chapter 45-4.
Perform basic setting on vehicles with ABS/TCS/ESP
BOSCH 8.0 either using the vehicle system tester -V.A.G 1552- Chapter 45-14 or using the vehicle diagnosis, measurement and information system -VAS 5051- Chapter 45-4.
Bleeding brake system on vehicles with ABS BOSCH
5.7 or ABS, ABS/TCS BOSCH 8.0, as for vehicles without ABS.
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47-4 page 1
47
Bleeding brake system on vehicles without ABS
FABIA 2000
Chassis
BOSCH 5.7 or ABS, ABS/TCS BOSCH 8.0, as for vehicles without ABS. DUring bleeding move the rear wheel-brake lever of the brake-power regulator.
Only use new brake fluid Chap. 00-3.
WARNING!
Brake fluid is hygroscopic, i.e. it retains humidi-
ty from the ambient air, and must therefore always be stored in airtight containers.
Brake fluid must never come into contact with
fluids containing mineral oils (oil, petrol, cleaning agent). Mineral oils damage the plugs and boots of the brake system.
Drained (used) brake fluid must never be used
again.
Observe the disposal instructions! Brake fluid is toxic, avoid skin contact. Because of its caustic effect brake fluid must
not come into contact with paint.

Rinse any brake fluid spills with a lot of water. Dispose of brake fluid in compliance with the
applicable environmental regulations.
Bleeding the brake system of air using the brake filling and bleeding device, e. g. -ROMESS S15Special tools, test and measuring equipment and auxiliary items required
pedal load device, e.g. -V.A.G 1869/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3A-, -V.A.G 1551/3B-,
-V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A Brake filling and bleeding device. -ROMESS S15 Bleeding bottle (commercially available) Brake fluid Chapter 00-3
Note
Bleeding of the brake system on vehicles with ABS is
undertaken as for vehicles without ABS.

For vehicles without ABS and with brake-power regu-
lator move the rear wheel-brake lever of the regulator during bleeding.
Connect up the brake filling and bleeding device but

do not switch it on.
Press brake pedal and arrest with brake pedal arrester.

S45-0016
47-4 page 2
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
Remove dust caps from the vent valves of the brake

calipers/wheel-brake cylinder.
Open the bleed valves in the prescribed sequence

with the hose of the bleeding bottle fitted, switch on the brake filling and bleeding device and bleed both the wheel-brake cylinder and the brake calipers Bleeding sequence 1. Rear right wheel-brake cylinder/brake caliper 2. Rear left wheel-brake cylinder/brake caliper 3. Front right brake caliper 4. Front left brake caliper
After bleeding close the relevant vent valve and fit

dust cap.
Disconnect the brake filling and bleeding device. Separate connection from brake fluid reservoir and remove brake pedal arrester. Note
After bleeding perform a test drive. While doing so
perform at least one ABS adjustment!

After bleeding or replacing the ABS, EDL/TCS control
unit BOSCH 5.7 or the ABS, ABS/TCS control unit BOSCH 8.0 perform a final control diagnosis: either using vehicle system tester -V.A.G 1552 Chapter 45-12 using vehicle diagnosis, measurement and information system -VAS 5051- Chapter 45-4.
Perform test drive with ABS adjustment.

Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 Note The bleeding of the brake system on vehicles with ABS/ EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 occurs via the basic setting.

45-13.
Perform test drive with at least one ABS adjustment.

Vehicles with ABS//TCS/ESP BOSCH 8.0 Note The bleeding of the brake system on vehicles with ABS/ TCS/ESP BOSCH 8.0 occurs via the basic setting.
Edition 07.04 S00.5303.16.20
47-4 page 3
47
FABIA 2000
Chassis
45-14.
Bleeding the brake system of air without using the brake filling and bleeding device
pedal load device, e.g. -V.A.G 1869/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3A-, -V.A.G 1551/3B-,
-V.A.G 1551/3C-, -VAS 5051/5A- or -VAS 5051/6A Bleeding bottle (commercially available) Brake fluid Chapter 00-3
Note
Bleeding of the brake system on vehicles with ABS is
undertaken as for vehicles without ABS.

For vehicles without ABS and with brake-power regu-
lator move the rear wheel-brake lever of the regulator during bleeding.
Always check the brake fluid level in the brake fluid
reservoir while bleeding the sustem of air and top up the brake fluid to the MAX marking if necessary.
Build up pressure in the brake system by pumping the

brake pedal.
Open the vent valve with the hose of the bleeding bottle fitted.
Close the vent valve while the pedal is pressed down. Repeat this procedure until no more air escapes.
Bleeding sequence 1. Rear right wheel-brake cylinder/brake caliper 2. Rear left wheel-brake cylinder/brake caliper 3. Front right brake caliper 4. Front left brake caliper
After bleeding close the relevant vent valve and fit

dust cap. Note After bleeding perform a test drive. While doing so perform at least one ABS adjustment!
Perform test drive with ABS adjustment.
47-4 page 4
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
47
Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 Note The bleeding of the brake system on vehicles with ABS/ EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 occurs via the basic setting.

45-13.

Vehicles with ABS//TCS/ESP BOSCH 8.0 Note The bleeding of the brake system on vehicles with ABS/ TCS/ESP BOSCH 8.0 occurs via the basic setting.

45-14.
Changing the brake fluid

Inspection and Maintenance
Edition 07.04 S00.5303.16.20
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47
FABIA 2000
Chassis
47-4 page 6
Edition 07.04 S00.5303.16.20
FABIA 2000
Chassis
48
48 Steering
48-1 Steering column
Summary of components
Note
Do not carry out repair work on the steering column. Replace the self-locking nuts and screws. Welding and straightening of the steering components is not allowed. Steering columns are supplied as a spare part with ignition lock housing but without lock cylinder and ignition starter
switch. The lock cylinder and ignition starter switch must be removed from the removed steering column or be obtained as a spare part.
After an accident and if the steering column is damaged replace steering components item 1 in 48-1 page 1 i.e.
2, 6 and 7. 1 - Steering column adjustable Assignment Spare part catalogue inspecting for damage Chap. 48-2 removing and installing Chap. 48-3 2 - Steering column rigid Assignment Spare part catalogue inspecting for damage Chap. 48-2 removing and installing Chap. 48-3 3 - Hexagon screw, 23 Nm 4 - Hexagon bolt, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 5 - Steering gear 6 - Bushing replace if damaged removing and installing Chap. 48-3 7 - Hexagon screw, 7 Nm 8 - Hexagon screw, 23 Nm Observe the mounting sequence Chap. 48-5 9 - Bracket removing and installing Chap. 48-5 10 - Hexagon screw, 19 Nm 11 - Hexagon screw, 23 Nm replace after each removal
15
14
12
11 10
13
9 7 8 1 2 6
4 5
3
S48-0213
Edition 08.01 S00.5303.09.20
Steering column
48-1 page 1
48
12 - Frequency link removing and installing Chap. 48-5 13 - Module carrier 14 - Front wall 15 - Combination screw, 25 Nm
FABIA 2000
Chassis
48-1 page 2
Steering column
Edition 08.01 S00.5303.09.20
FABIA 2000
Chassis
48
48-2
Inspecting steering column
Optical inspection
Inspecting parts of the steering column for damage. If any damage is visible, replace steering column completely.
Functional test
Inspection requirement:
Universal joint of steering column pulled off steering

gear.
Check whether the steering column turns freely without jerking.
Vehicles with an adjustable steering column
Check whether the length and height of the steering

column can be adjusted.

In the event of an accident so-called deformation elements may shift on the steering column. They are located on the two top bolted connections of the steering column. If there is any damage remove the steering column until dimension -a- can be checked.
S48-0206
Inspect dimension -a- with a sliding caliper.

Dimension -a-: minimum 37 mm If a fault is found during one of these inspections or if dimension -a- is not reached, the steering column must be replaced.
If this is the case replace the steering column completely.
Edition 08.01 S00.5303.09.20
48-2 page 1
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FABIA 2000
Chassis
48-2 page 2
Edition 08.01 S00.5303.09.20
FABIA 2000
Chassis
48
48-3
Removing and installing steering column
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3-, - V.A.G 1551/3A-,
-V.A.G 1551/3B- or - V.A.G 1551/3C Adhesive tape (commercially available)
Note
New steering columns supplied as spare parts are se-
cured for transport. This transport security must be removed once the steering column has been installed.
Steering columns are supplied as a spare part with ig-
nition lock housing but without lock cylinder and ignition starter switch. The lock cylinder and ignition starter switch must be removed from the removed steering column or be obtained and installed as a spare part.
Do not carry out repair work on the steering column. Always replace the self-locking nuts and screws. Welding and straightening on axle body and axle
studs not allowed.


Removing the steering column

Remove the storage area on the driver's side Body
Work; Rep. Gr. 70.
Removing steering-column control Electrical System; Rep. Gr. 94.
Unplug connector for the ignition starter switch -1- and

the connector for the immobilizer -2- reading coil.
S48-0159
Unbolt earth strap -arrow-. Unscrew plastic nuts -1-. Remove cover -2-.
S48-0106
Edition 07.03 S00.5303.14.20
48-3 page 1
48
Unscrew bolt -1-. Remove universal joint in the direction of the arrow
from the input shaft of the steering gear.
FABIA 2000
Chassis
1
S48-0107
Unclip cable guide -2- on the steering column and remove wiring loom -1-.
Remove cable strap -3- from the steering column in

the direction of the arrow.
2 1
Open the cover -2- of the cable guide -1- and remove
wiring loom -3-.
S48-0161
Remove cable strap -4- from the steering column in

the direction of the arrow. Note
For reasons of clarity the work steps in the following
figures are shown on a removed steering column, i.e. without background.

Before removing the steering column mark the posi-
3 2 1
S48-0162
tion of the top and bottom part relatively to each other and secure the steering column against separation.
On vehicles fitted with a rigid steering column there is
no colour coding and safe positioning of the top and bottom part of the steering column. If the top and bottom part of the steering column are separated the pairing of the clover-leaf profile is no longer guaranteed. Moreover, this could result in the greased area becoming soiled.
48-3 page 2
Edition 07.03 S00.5303.14.20
FABIA 2000
Chassis
48
Mark the top and bottom part of the steering column

relatively to each other on the bottom side with a colour marker. Arrow A - Marking on bottom part of the steering column Arrow B - Marking on top part of the steering column
B A
S48-0173
Secure the bottom part -1- and top part -2- of the
steering column against separation. To do so use the transport security -3- of a replacement steering column or attach the top and bottom part of the steering column with wire.
3
S48-0160
Unscrew bolt -4-.

1 - Steering column 2 - Bracket 3 - Frequency link
4 1 1
S48-0163
Edition 07.03 S00.5303.14.20
48-3 page 3
48
Unscrew bolts -2-. Remove steering column -1-.
3 - Bracket 4 - Module carrier
FABIA 2000
Chassis
4 3 2
Note
If the old steering column -3- is installed again do not
2
S48-0164
remove the bushing -1-.

Only remove the bushing -1- in the event of damage
or if a spare part steering column is used.
Unscrew bolt -2-. Remove the bushing -1- from the steering column fork
-3-. Note
Steering columns are supplied as a spare part with ig-
nition lock housing but without lock cylinder and ignition starter switch.
If the lock cylinder and ignition starter switch of the reS48-0165
moved steering column are O.K., they must be fitted in the new steering column.
Removing lock cylinder and ignition starter switch
Installing the steering column

Note
The installation of the steering column is described for
an adjustable steering column. When installing a rigid steering column one does not need to remove the securing mechanism of the top and bottom part of the steering column.
When installing the old steering column again do not
replace the bushing.

Only replace the bushing if damaged. If a spare part steering column is fitted, a new bushing
and a new screw must first be fitted in the steering column fork before installing the steering column.
Insert the new bushing -1- in the steering column fork

-3-.
Insert and tighten new new screw -2-.

S48-0165
48-3 page 4
Edition 07.03 S00.5303.14.20
FABIA 2000
Chassis
48
3
Installing the lock cylinder and ignition starter switch in

the ignition lock housing Electrical System; Rep. Gr. 94. bracket -2-.
Insert the steering column with bushing -1- in the Screw in screw -4- from the right and initially tighten to
5 Nm (do not fully tighten the screw yet). 3 - Frequency link
4 1 1
Swivel the steering column -1- on the bracket -3- and
align and match the fixing holes of the steering column and bracket. Note Carefully screw the screws in the bracket without tilting.
S48-0163
Insert and tighten screws -2-.

4 - Module carrier
4 3 2
Tighten the screw -4- to the specified tightening
torque. 1 - Steering column 2 - Bracket 3 - Frequency link
2
S48-0164
4 1 1
S48-0163
Edition 07.03 S00.5303.14.20
48-3 page 5
48
Remove transport security -3- or wire security.
1 - Bottom part of the steering column 2 - Top part of the steering column Further installation occurs in reverse order.
FABIA 2000
Chassis

If faults are stored in the fault memory:

Tightening torques:
Bushing on the steering column fork Bushing on bracket Steering column on bracket Universal joint on input shaft
Use new screw!
3
S48-0160
7 Nm 20 Nm 23 Nm 20 Nm + 90
48-3 page 6
Edition 07.03 S00.5303.14.20
FABIA 2000
Chassis
48
48-4
Removing and installing ignition lock housing
Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3-
Note

When the battery is reconnected perform the following
operations depending on the vehicle equipment: Encode the radio, re-set the clock, initialise the power windows Inspection and Maintenance.
Removing ignition lock housing

Removing trim panel Body Work; Rep. Gr. 70. Removing steering-column control Electrical System; Rep. Gr. 94.
Removing lock cylinder and ignition starter switch

S48-0176
Remove pull-off screws -arrows-. Remove the ignition lock housing.
Installing ignition lock housing

Insert the ignition lock housing and tighten new pull-off
screws.
Tighten pull-off screws until the head shears off. Installing lock cylinder and ignition starter switch
Electrical System; Rep. Gr. 94. Further installation occurs in reverse order.
Performing automatic test sequence Chap. 45-4.

If entries from the fault memory are shown:
Eliminating fault Chap. 48-25. Erasing fault memory Chap. 48-25.
Edition 07.00 S00.5303.03.20
48-4 page 1
48
FABIA 2000
Chassis
48-4 page 2
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
48-5
Frequency link, bracket
Removing and installing frequency link

Torque wrench (4...20 Nm), e.g. -V.A.G 1410 Torque wrench (5...50 Nm), e.g. -V.A.G 1331-
1 2
Removing
Removing scuttle Body Work; Rep. Gr. 66.

Note The wiper arms must be in end position.
Release hexagon screw -1-. Press wiper system towards the bulkhead. Unscrew combination screws -2-. Remove the cover with storage area Body Work; Rep. Gr. 70.
S48-0139
Unscrew hexagon screw -4-.

1 - Steering column 2 - Bracket 3 - Frequency link
Remove frequency link.

Installing
4 1
Tightening torques:
Frequency link on bulkhead Frequency link on bracket Wiper linkage on body 25 Nm 23 Nm 5 Nm
S48-0167
Removing and installing bracket

Torque wrench (5...50 Nm), e.g. -V.A.G 1331-
Removing
Removing the dash panel Body Work; Rep. Gr. 70. Removing steering column Chap. 48-3.
Edition 07.00 S00.5303.03.20
48-5 page 1
48
Note For reasons of clarity the surrounding components are not shown in the following figures.
FABIA 2000
Chassis
Remove frequency link -1- from the bracket -3-. Unscrew hexagon screw -2-.
3
Unscrew hexagon screw -3-. Unscrew hexagon screw -2- and remove bracket -1-.
4 - Module carrier
2
S48-0179
3 3 4
2
Installing
Note
Hexagon screws -2- and -3- are identical and are
1
S48-0178
tightened to the same torque.

When installing the bracket -1- observe the mounting
3 3 4
sequence of the hexagon screws -2- and -3-.
Position the bracket -1- on the module carrier -4-. Screw in hexagon screws -2- and initially tighten to 5
Nm (do not fully tighten the screws yet).
Insert and tighten hexagon screws -3-. Tighten the hexagon screws -2- to the specified tightening torque. Further installation occurs in reverse order.
2 2
1
S48-0178
Tightening torques:
Bracket on module carrier Frequency link on bracket 23 Nm 23 Nm
48-5 page 2
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
48-6
Steering without servo unit (mechanical steering)
Summary of components
Note
If the front axle is damaged as a result of an accident certain steering components must be replaced Chapter
48-9.
Repairs to the steering gear are not provided for, if there is a complaint about the steering gear it must be replaced. Replace the self-locking nuts and screws. Welding and straightening of the steering components is not allowed. Only use steering gear grease to grease the gear rack Chapter 00-2.
1 - Universal joint of steering column 2 - Tighten hexagon screw 20 Nm + 90 replace after each removal 3 - Tighten self-locking hexagon nut 20 Nm + 90 replace after each removal 4 - Steering-knuckle arm of the wheel-bearing housing 5 - Steering gear 6 - Assembly carrier with impression as shown in the figure, only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier without impression, not shown in the figure, only if the front exhaust pipe is fitted above the engine-gearbox assembly carrier 7 - Hinged bracket The shape of the hinged bracket depends on the gearbox 8 - Tighten hexagon screw 50 Nm + 90 replace after each removal
3 5 4
8 8
S48-0268
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48-6 page 1
48
FABIA 2000
Chassis
48-6 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-7
Removing and installing mechanical steering gear
Torque wrench (5...50 Nm), e.g. -V.A.G 1331 Torque wrench (40...200 Nm), e.g. -V.A.G 1332 Gearbox jack with adapter, e.g. -V.A.G 1383 A- with
-V.A.G 1359/2 Fixing device -T10096 Extractor -Matra V176 Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2Note Apart from replacing the bellows, track rod ends and track rods no other repairs may be carried out on the steering gear.
Removing steering gear

Caution! Bring the steering wheel in centre position (wheels straight ahead) and make sure they do not turn during repairs as this could damage the coil spring of the airbag unit.
Secure the steering wheel with the wheels in straight

ahead position with adhesive tape -arrow- against unintended turning.
S48-0196
Unscrew plastic nuts -1-. Remove cover -2-.
S48-0106
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48-7 page 1
48
Remove hexagon screw -1-. Remove universal joint in the direction of the arrow
from the input shaft of the steering gear.
FABIA 2000
Chassis
Raise vehicle.
1
S48-0107
Remove noise insulation panel -arrows-.

Note The figure shows the noise insulation panel on models with 1.4 ltr./74 kW engines. Other engine variants may have noise insulation panel versions that differ slightly from the figure.
Remove front wheels.

Vehicles with exhaust pipe under the assembly carrier
Removing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26.
S48-0111
Unscrew hexagon screw -1- and -2- from the pendulum support.
S48-0112
48-7 page 2
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
Matra V176 1
Screw up hexagon nut of the track rod end -1- sufficiently so that the extractor -Matra V176- is supported on the hexagon nut.
Use extractor -Matra V176- to press track rod/track

rod end -2- on both sides off the steering arm.
Unscrew hexagon nut on both sides from the track rod

end.
Pull track rod end on both sides out of steering arm.
S48-0114
Insert wooden insert (490 x 270 x 50 mm) -2- in the

adapter.
Position gearbox jack with adapter and support assembly carrier.
Release hexagon screws -1- for steering gear.
2 1
Note
Observe the recommended sequence for the follow-
ing steps.
V.A.G 1359/2 V.A.G 1383A
1
S48-0116
Unscrew left screw -4- for assembly carrier -3- and

screw in a fixing bolt of -T10096- to 20 Nm.

shown in figure) and screw in a fixing bolt of -T10096to 20 Nm.
5 4 2
Release hexagon screws -1- on both sides. Unscrew the left screw -2- and remove support -5-. Screw in fixing bolts of -T10096- to 20 Nm. Unscrew the right screw -2- and remove support -5-. Screw in fixing bolts of -T10096- to 20 Nm.
S48-0117
Edition 07.00 S00.5303.03.20
48-7 page 3
48
The fixing of the assembly carrier is completed once all 4 screws (Pos. -2- and -4-) are consecutively replaced with the fixing bolts. Note When pulling off the steering gear make sure the serration of the input shaft of the steering gear is not tilted or stuck relatively to the drive shaft of the steering column.
FABIA 2000
Chassis
5 4 2
Slowly lower assembly carrier with gearbox jack and

adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-.
Remove steering gear towards the rear.
Installing steering gear

Caution! After installing the steering gear check the position of the steering wheel after performing a test drive. If the steering wheel is not straight peform a chassis alignment. Note
Coat the seal on the steering gear with lubricant be-
S48-0117
fore installing the steering gear, e.g. lubricating soap.

Make sure all sealing surfaces are clean. After positioning the steering gear on the drive shaft of
the steering column make sure the seal on the steering gear is not bent on the assembly plate and correctly seals the footwell opening. Otherwise this could cause water penetration and/or noise.
Before fitting the steering gear check the centre posi-
tion of the gear rack Chap. 48-8.
Before positioning the universal joint of the steering
column on the input shaft of the steering gear, first make sure the vehicle is on the ground and all wheels are pointing straight ahead.
Check the centre position of the gear rack of the steering gear, if necessary adjust Chap. 48-8.
Place the steering gear from the rear onto the lowered
assembly carrier and tighten new hexagon screws -1by hand.
Check correct fit of the seal on the steering gear valve

housing.
2 1
Slowly raise the assembly carrier with gearbox jack

and adapter, and while doing so insert the input shaft of the steering gear in the opening in the vehicle floor. 2 - Wooden insert (490 x 270 x 50 mm)
V.A.G 1359/2 V.A.G 1383A
1
S48-0201
48-7 page 4
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
Note
ing steps.
Unscrew the fixing bolts of -T10096- one at a time.
Subsequently, replace it with a new bolt tightened to the recommended torque and further rotation.

screw in new bolt to the recommended tightening torque. 3 - Engine-gearbox assembly carrier

2 1 3
Unscrew fixing bolt -2- of -T10096- from the left. Install left support. Tighten new bolts for the rear left support by hand. Tighten new bolts for left console and support to the recommended tightening torque. ed tightening torque.
S48-0197
Tighten the rear left support bolts to the recommend Unscrew right fixing bolts -2- of -T10096- (shown in
figure).
Install right support. Tighten new bolts for the rear right support by hand. Tighten new bolts for right console and support to the
Tighten the rear right support bolts to the recommended tightening torque.
Remove gearbox jack with adapter. Tighten hexagon screws for fixing the steering gear to
the assembly carrier to the recommended tightening torque.
Insert track rod end/track rod into steering arm and

tighten new hexagon nut Chap. 48-16. If the joint stub rotates when tightening, counterhold with hexagon socket wrench (SW6).

new hexagon screws -1- and -2-.
Installing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26.
Fit front wheels. Install noise insulation panel.
S48-0112
Edition 07.00 S00.5303.03.20
48-7 page 5
48
Lower vehicle. Slide the universal joint of the steering column in the
direction of the arrow onto the input shaft of the steering and tighten with a new hexagon screw -1-.
FABIA 2000
Chassis
Fit cover for universal joint. Perform a test drive.

1
S48-0170
Carrying out chassis alignment Chap. 44-2.

Tightening torques:
Steering gear to assembly carrier
Use new screws!
50 Nm + 90
Assembly carrier to body

Use new screws!
70 Nm + 90
Support to body
Use new screws!
20 Nm + 90

Use new screws!
30 Nm + 90

Use new nuts!
20 Nm + 90
Universal joint to steering gear

Use new screw!
20 Nm + 90
Wheel bolts
120 Nm
48-7 page 6
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
48-8
Inspecting and adjusting mechanical steering gear
Check the centre position of the gear rack of the steering gear, if necessary adjust
Note
Before installing the steering gear place the gear rack
in centre position.
The gear rack of spare part steering gears is already
in centre position.
Dimension -a- must be equal on both the right and left
side if the steering gear. If the dimension on the two sides is not the same, distance -a- must be corrected.
Check dimension -a-, if necessary adjust.

-a- = 68.5 mm
S48-0181
Adjusting dimension -a- by turning the input shaft -1of the steering gear. 2 - Gear rack
Adjusting the steering gear (adjusting the pressure plate clearance)

Note 2 mechanics are required for this adjustment.
Inspection requirement:
Put the wheels in straight ahead position. Raise vehicle. Move the steering wheel alternately approx. 30. on
the centre axle. If the steering clearance is too great rattling noises will be audible inside the vehicle.
S48-0182
While moving the steering wheel have the 2nd mechanic carefully screw in the ajusting screw -1- until no more rattling noises can be heard inside the vehicle.

Caution! The steering must automatically return to straight ahead position after a manoeuvre or cornering without sticking, correct if necessary.
1
S48-0183
Edition 07.00 S00.5303.03.20
48-8 page 1
48
Secure adjusting screw -1- against turning.
To this end apply 3 centre punch marks -arrows- uniformly distributed on the collar of the steering gear housing.
FABIA 2000
Chassis
S48-0184
48-8 page 2
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
48-9
Disassembling and assembling the steering gear
Hose strap pliers, e.g. -V.A.G 1275 Removal and installation pliers, e.g. -VAS 5024 Steering gear grease Chapter 00-2
Note
Always replace all steering components (except pos. 6) after an accident or in the event of damage to the front axle. Do not carry out repair work on the steering gear item 10 in 48-9 page 2. If there are any complaints about the
steering gear item 10 in 48-9 page 2 replace it.
Welding and straightening of the steering components is not allowed. Always use original clamping collars and circlips. Only use steering gear grease to grease the gear rack Chapter 00-2.
1 - Right track rod end inspect Chapter 48-10 removing and installing Chapter 48-10 before installing, remove grease on tapered stud 2 - Lock nut, 50 Nm 3 - Spring strap clip use assembly pliers, e.g. -VAS 5024- for removing and installing 4 - Boot can only be replaced with the steering gear removed before removing boot detach the track-rod end Chapter 8 48-10 must not be twisted after setting the wheel toe inspect for wear and damage (cuts, splits) 5 - Warm-type clamp replace after each removal removing: open with cutting pliers tensioning Chapter 48-10 12 6 - Gasket pay attention to installation instructions for installing Chapter 48-7 7 - Clamp replace if thread of stamp nut damaged 8 - Right track rod tightening torque on steering rack: 80 Nm removing and installing Chapter 48-10
1 2
4 5
6 7 9 10
4 3
11
S48-0269
Edition 11.04 S00.5303.17.20
48-9 page 1
48
FABIA 2000
Chassis
9-
10 -
11 -
12 -
track rod and track rod end are supplied as replacement part pre-set lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing replacement track rod/track rod end tighten lock nut fully to 50 Nm Setting wheel toe Chap. 44-2. Rubber insert Fitting position: larger bore must point outwards replace if damaged or worn Steering gear do not repair removing and installing Chapter 48-7 setting Chapter 48-8 inspecting centre position Chapter 48-8 Left track rod end inspect Chapter 48-10 removing and installing Chapter 48-10 before installing, remove grease on tapered stud Left track rod tightening torque on steering rack: 80 Nm removing and installing Chapter 48-10 track rod and track rod end are supplied as replacement part pre-set lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing replacement track rod/track rod end tighten lock nut fully to 50 Nm Setting wheel toe Chap. 44-2.
48-9 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-10 Track rod ends, track rods

Play, correct attachment and joint boots
Chap. 48-16
Removing and installing track rod ends

Chap. 48-16
Removing and installing track rods

Chap. 48-16
Edition 07.00 S00.5303.03.20
Track rod ends, track rods
48-10 page 1
48
FABIA 2000
Chassis
48-10 page 2
Track rod ends, track rods
Edition 07.00 S00.5303.03.20
FABIA 2000
Chassis
48
48-11 Power-assisted steering

Structure and function
The EPHS (Electrically Powered Hydraulic Steering) is a power-assisted steering system which uses its own electric motor to drive the pump. 12345678910 11 12 13 14 15 16 17 18 19 20 abcdefPower-steering gear Sensor for power steering -G250Steering column Control unit in dash panel insert -J285Sender for speedometer -G22Engine control unit Servotronic warning light -K92- in dash panel insert Signal for servotronic warning light -K92- through databus Signal for engine speed via data BUS Signal for driving speed via data BUS Hollow screw with non-return valve Pressure line Signal for steering angle speed Return-flow line Airbag control unit -J234Crash signal over the databus Terminal +30 Terminal + 15 Earth Engine pump aggregate - consisting of: Screwed lid Reservoir for hydraulic oil Pressure limiting valve Gear pump Electric motor Power-assisted steering control unit -J500-
5 4 3 1 2
6 7
8 9
10 11 12 13
19 18 17
a b c
M
20 d
14
e 16 15
S48-0200
The steering hydraulics pump -V119- includes the gear pump -d- and the electric motor -e-. This steering uses a gear pump integrated in the engine pump aggregate instead of the servo pump (vane pump) traditionally used in power-assisted steering systems. This gear pump -d- is not driven directly via the vehicle's combustion engine but by an electric motor -e- integrated in the engine pump aggregate. Signals for steering angle speed -13-, for vehicle speed -10- and engine speed -9- are sent to the control unit -f-. This control unit controls the speed of the electric motor -e- on the gear pump and thus also the supplied quantity or volume of hydraulic oil. Re-engaging protection The electrohydraulic power-assisted steering has a reengaging protection after faults, failure or crash.
Edition 11.04 S00.5303.17.20
Power-assisted steering
48-11 page 1
48
After a crash or after the display of the crash signal on the vehicle system tester -V.A.G 1552- or at the vehicle diagnostic, measuring and information system -VAS 5051the vehicle memory must be erased to de-activate the reengaging protection. The re-engaging protection can be neutralised by switching off the ignition and switching it on again. If necessary wait 15 minutes to allow the engine pump aggregate to cool down after overheating. If after this waiting period the re-engaging protection cannot be neutralised by switching the engine on again, the fault must be found in the vehicle electric system or e.g. in the engine pump aggregate. In these instances perform the self-diagnosis and if necessary replace the engine pump aggregate.
FABIA 2000
Chassis
48-11 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Summary of components of power-assisted steering (TRW)

Note
If the front axle is damaged as a result of an accident certain steering components must be replaced Chapter
48-15.
Repairs on the power-steering gear are not foreseen. In the event of failure determine the cause with the pressure
and tightness test as well as by performing self-diagnosis.

If there is a fault on the power-steering gear, replace the steering gear, unless the fault is in the power-steering
sensor.
Replace the self-locking nuts and screws. Welding and straightening of the steering components is not allowed. Only use steering gear grease to grease the gear rack Chapter 00-2. Oil types: Hydraulic oil Chapter 00-2. Oil volume in the system Chapter 00-2
1 - Self-tapping screw, 6 Nm 1 2 1 3 2 - Heat shield assignment Spare part catalogue 3 - Steering column universal joint 4 - Screw, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 5 - Gasket for power-assisted steering sensor -G250- with adapter 19 cable item 6 replace after each removal 17 assignment Spare part catalogue 20 6 - Sensor for power steering -G250with adapter cable item 8 removing and installing Chapter 48-13 assignment Spare part catalogue 22 7 - Screw, 6 Nm for power-assisted steering sensor -G250- with adapter cable item 6 21 assignment Spare part catalogue 8 - Adapter cable assignment Spare part 21 catalogue 9 - Gasket for power-assisted steering sensor -G250- with fixed connecting line item 10 replace after each removal assignment Spare part catalogue 10 - Sensor for power steering -G250with fixed connecting line removing and installing Chapter 48-13 assignment Spare part catalogue
Edition 11.04 S00.5303.17.20 Power-assisted steering
4 9
7 8
10 11 7
11
12 13
15 17 18 16
14
S48-0266
48-11 page 3
48
11 - Screw, 6 Nm for power-assisted steering sensor -G250- with fixed connecting line item 10 assignment Spare part catalogue
FABIA 2000
Chassis
12 - Nut, self-locking, 20 Nm and torque a further 90 (1/4 turn) replace after each removal 13 - Steering-knuckle arm (of the wheel-bearing housing) 14 - Return-flow line Pipe screw M16x1.5 power-assisted steering gear - engine pump aggregate Torque for pipe screw on the power-assisted steering gear: 30 Nm 15 - O-ring replace after each removal 16 - Hollow screw, 35 Nm replace after each removal with non-return valve M14x1.5 17 - Gasket ring replace after each removal 18 - Pressure line power-assisted steering gear - engine pump aggregate Pay attention to installation position relative to subframe 48-11 page 6 Torque for pipe screw on the engine pump aggregate: 30 Nm 19 - Power-steering gear removing and installing Chapter 48-12 20 - Assembly carrier with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier 21 - Screw, 50 Nm + torque a further 90 (1/4 turn) replace after each removal 22 - Hinged bracket The shape of the hinged bracket depends on the gearbox
48-11 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Summary of components of power-assisted steering (KOYO)

1 - Self-tapping screw, 6 Nm 1 2 1 4 2 - Heat shield 3 assignment Spare part catalogue 3 - Steering column universal 5 6 7 joint 4 - Screw, 20 Nm + torque a further 90 (1/4 turn) replace after each removal 8 5 - Gasket for power-steering sensor -G250- item 6 15 9 replace after each removal assignment Spare part catalogue 13 6 - Sensor for power steering 16 13 11 -G250removing and installing 14 12 10 Chapter 48-13 assignment Spare part catalogue 7 - Screw, 7,5 Nm for power-steering sensor -G250 item 6 18 assignment Spare part catalogue 17 8 - Nut, self-locking, 20 Nm and 1/ turn) torque a further 90 ( 4 replace after each removal S48-0267 17 9 - Steering-knuckle arm (of the wheel-bearing housing) 10 - Return-flow line Pipe screw M16x1.5 power-assisted steering gear - engine pump aggregate Torque for pipe screw on the power-assisted steering gear: 30 Nm 11 - O-ring replace after each removal 12 - Hollow screw, 40 Nm with non-return valve M14x1.5 13 - Gasket ring replace after each removal 14 - Pressure line power-assisted steering gear - engine pump aggregate Pay attention to installation position relative to subframe 48-11 page 6 Torque for pipe screw on the engine pump aggregate: 30 Nm 15 - Power-steering gear removing and installing Chapter 48-12 16 - Assembly carrier with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
Edition 11.04 S00.5303.17.20
48-11 page 5
48
17 - Screw, 50 Nm + torque a further 90 (1/4 turn) replace after each removal 18 - Hinged bracket The shape of the hinged bracket depends on the gearbox
FABIA 2000
Chassis
Summary of components of pressure line (hose) - power steering TRW or KOYO

In the figure, the hose is illustrated at an engine pump aggregate of the TRW. The hose is analogous for the engine pump aggregate of KOYO 1 - Engine pump aggregate with encapsulation, assignment Spare part catalogue with half encapsulation, assignment Spare part catalogue without encapsulation, assignment Spare part catalogue 2 - Return line (return hose) 3 assignment Spare part catalogue 2 must not be pinched off during disassembling work No less than minimum bend1 ing radius of 100 mm removing and installing Chapter 48-13 3 - Line holder 4 - Power-steering gear 5 - Pressure line (expansion hose) assignment Spare part catalogue must not be pinched off during disassembling work No less than minimum bending radius of 100 mm Pay attention to installation position relative to subframe 48-11 page 6 removing and installing Chapter 48-13 6 - Spacer holder clipped onto body 7 - Cable of power-assisted steering sensor -G250power-assisted steering gear - engine pump aggregate
5 6
S48-0198
Fitting location of pressure line (flexible hose) Maintain a clearance of about 10 mm between pressure line (flexible hose) and subframe.
48-11 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Insert a suitable spacer between subframe and pressure line. Use new hollow screw for power-assisted steering gear of TRW.
Tighten banjo bolt of pressure line by hand with new

seals at the power-assisted steering gear.
Remove spacer. Inspect clearance between subframe and pressure

line, adjust if necessary.
Tighten banjo bolt fully to the specified tightening

torque. Tightening torque: Pressure line to the power-assisted steering gear (TRW)
Use new hollow screw!
35 Nm
Pressure line to the power-assisted steering gear (KOYO)
40 Nm
Edition 11.04 S00.5303.17.20
48-11 page 7
48
FABIA 2000
Chassis
48-11 page 8
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-12 Removing and installing power-steering gear (TRW or KOYO)

Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
-V.A.G 1359/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3A -, - V.A.G 1551/3B-,
- V.A.G 1551/3C- or -VAS 5051/6A Fixing device -T10096 Extractor -Matra V176 Jumper cable (commercially available) Extraction bottle (commercially available) Oil catch pan (commercially available) Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2 Plastic screw plugs for line connections on the power-
assisted steering gear (commercially available)

Hydraulic oil Chap. 00-2
Note
Apart from replacing the bellows, track rod ends and
track rods no other repairs may be carried out on the power-steering gear.
Absolute cleanliness is required when working on the
power steering.
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover if
the repair cannot be carried out immediately.

before fitting.
Use only genuine - wrapped parts. Do not use drained hydraulic oil again. Replace gaskets on hydraulic lines after each disas-
sembly.
For vehicles with KOYO steering manufactured as of
43/04 a component modification was performed as an enhancement for which the steering gear pinion has been offset by 1 tooth. For these reasons the steering gear is modified as of this date. For vehicles manufactured before this date the steering wheel is turned by approx. 1/8 turn when replacing the steering gear. Do not set the steering wheel with track rods, rather offset the steering wheel in the grooves of the steering column Body Work; Rep. Gr. 69.
Disposing of the power-steering gear Chap. 48-17.
Edition 04.05 S00.5303.18.20
Removing and installing power-steering gear (TRW or KOYO)
48-12 page 1
48
Removing the power-assisted steering drive
Caution! Bring the steering wheel in its central position (with the wheels straight ahead) and make sure that it does not turn during repairs as this could damage the coil spring of the airbag unit.
FABIA 2000
Chassis
Secure the steering wheel with the wheels in straight

ahead position with adhesive tape -arrow- against unintended turning.
S48-0196
Unscrew plastic nuts -1-. Remove cover -2-.
S48-0106
Release screw -1-. Remove universal joint in the direction of the arrow
from the input shaft of the power-steering gear.

of radio sets fitted with anti-theft coding. Note Because of the different dimensions of the battery the screw cap of the hydraulic oil reservoir on certain vehicle versions is concealed by the battery tray and battery. If this is the case remove the battery tray and battery.
1
S48-0107
48-12 page 2
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
48
Disconnect battery Electrical System; Rep. Gr. 27. Remove air filter, if necessary Engine, Fuel Injection System; Rep. Gr. 24 (petrol engines) or Rep. Gr. 23 (diesel engines).
If necessary remove the battery and battery tray

Electrical System; Rep. Gr. 27. line holder -arrows-.
Unhook cable of power-steering sensor -G250- from Raise vehicle.
S48-0109
Remove noise insulation panel -arrows-.

Remove front wheels.

Removing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26. Continued for all vehicles
S48-0111
S48-0112
Edition 04.05 S00.5303.18.20
48-12 page 3
48
-2-.
FABIA 2000
Chassis
2 1
S48-0113
Screw up nut of the track rod end -1- sufficiently so

that the extractor -Matra V176- is supported on the nut.
Matra V176 1
Use puller - Matra V176- to press track rod/track rod

Screw off the nut on both sides from the track rod end. Pull track rod end on both sides out of steering arm.
S48-0114
Unscrew the screwed lid -1- of the hydraulic oil reservoir -2- of the engine pump aggregate.
2 1
Extract the hydraulic oil with an extraction bottle via

the filler neck. Note
After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the return hose and expansion hose.
Do not use drained hydraulic oil again. Do not pinch off the expansion hose and the return
hose with hose clamps -MP 7-602- or any other tools. Pinching off may result in damage to the expansion hose and return hose.
To avoid damage make sure the bending radius of at
S48-0147
least 100 mm is respected when bending or tying up the expansion hose or return hose.
48-12 page 4
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
48
Place the oil catch pan to catch drained off hydraulic

oil under the steering gear.
Insert wooden insert (490 x 270 x 50 mm) -2- in the

adapter, e.g. -V.A.G 1359/2-.
Position gearbox jack with adapter and support assembly carrier.
2 1
Release screws -1- for power-steering gear.

Note
ing steps.
V.A.G 1359/2 V.A.G 1383A
1
S48-0116
Unscrew left screw -4- for assembly carrier -3- and

screw in a fixing bolt of -T10096- to 20 Nm.

shown in figure) and screw in a fixing bolt of - T10096to 20 Nm.
5 4 2
Release screws -1- on both sides. Unscrew the left screw -2- and remove support -5-. Screw in fixing bolts of -T10096- to 20 Nm. Unscrew the right screw -2- and remove support -5-. Screw in fixing bolts of -T10096- to 20 Nm.
The fixing of the assembly carrier is completed once all 4 screws (Pos. -2- and -4-) are consecutively replaced with the fixing bolts. Caution! When lowering the assembly carrier make sure the pressure line (expansion hose), return hose and the line of the power-steering sensor -G250- are not exposed to traction.
S48-0117
Lower subframe -4- about 4 cm.

5 - Fixing bolt of -T10096-
Unscrew pressure line (expansion hose) -1- and return line (return hose) -2- on the power-steering gear.
Shut off the pressure line and return line with a plastic
bag and adhesive tape.
4 1 5
Tie up the pressure line and return line. Shut off the threaded bores (connections for pressure
and return lines) on the power-steering gear with plastig screw plugs.
S48-0115
Edition 04.05 S00.5303.18.20
48-12 page 5
48
Vehicles with power steering (TRW)
FABIA 2000
Chassis
Release Allen screws -1-. Remove the power-assisted steering sensor -G250(-2-) with seal -3- out of the power-steering gear valve housing. The new removal of the power-assisted steering sensor -G250- with adapter cable is illustrated in the figure. The removal of the power-assisted steering sensor -G250with fixed connection line occurs in the same way.
4 1
S48-0259
Vehicles with power steering (KOYO)
Release Allen screw -1-. Remove the power-assisted steering sensor -G250(-2-) with seal -3- out of the power-steering gear valve housing. Continued for all vehicles Note When lowering the assembly carrier make sure there is sufficient clearance between the drive shafts and the stabilizer.
3 2
1
S48-0260
Slowly lower assembly carrier with gearbox jack and

adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-.
Remove power-steering gear towards the rear.
Installing the power-assisted steering drive

Pay attention to fitting position when attaching pres-
sure line (flexible hose) to the power steering gear Chap. 48-11.
When tensioning and while driving the pressure line
(expansion hose) and the return line (return hose) must not touch or chafe.
To connect the pressure line use new gasket rings. Use new hollow screw for the connection of the pres-
sure line to the power steering gear (TRW).

To connect the return line use new O-rings. Coat the seal on the power-steering gear with lubri-
cant before installing the power-steering gear, e.g. lubricating soap.

Make sure all sealing surfaces are clean. After positioning the power-steering gear on the drive
shaft of the steering column make sure the seal on the power-steering gear is not bent on the assembly plate and correctly seals the footwell opening. Otherwise this could cause water penetration and/or noise.
48-12 page 6
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
48
Before fitting the power-steering gear check the cen-
tre position of the gear rack Chap. 48-14.
Before positioning the universal joint of the steering
column on the input shaft of the steering gear, first make sure the vehicle is on the ground and all wheels are pointing straight ahead.
For vehicles with KOYO steering manufactured as of
43/04 a component modification was performed as an enhancement for which the steering gear pinion has been offset by 1 tooth. For these reasons the steering gear is modified as of this date. For vehicles manufactured before this date the steering wheel is turned by approx. 1/8 turn when replacing the steering gear. Do not set the steering wheel with track rods, rather offset the steering wheel in the grooves of the steering column Body Work; Rep. Gr. 69.
2 1
Check the centre position of the gear rack of the power-steering gear, if necessary adjust Chap. 48-14.
Place the power-steering gear from the rear onto the

lowered assembly carrier and tighten new screws -1by hand.
Check correct fit of the seal on the power-steering

gear valve housing.
V.A.G 1359/2 V.A.G 1383A
1
S48-0201
Align the assembly carrier with the fixing bolts of

-T10096- screwed into the body. Note Raise the assembly carrier until a distance of approx. 4 cm is between the console and body.
Slowly raise the assembly carrier with gearbox jack

and adapter, and while doing so insert the input shaft of the power-steering gear in the opening in the vehicle floor. 2 - Wooden insert (490 x 270 x 50 mm) Vehicles with power steering (TRW)
4 1
S48-0259
Insert the power-assisted steering sensor -G250- (-2-)

with new seal -3- into the power-steering gear valve housing.
Insert and tighten screws -1-.

The installation of the power-assisted steering sensor -G250- with adapter cable is illustrated in the ilustration. The installation of the power-assisted steering sensor -G250- with fixed connection line occurs in the same way. Vehicles with power steering (KOYO)
3 2
Insert the power-assisted steering sensor -G250- (-2-)

with new seal -3- into the power-steering gear valve housing.
Insert and tighten screw -1-.

1
S48-0260
Edition 04.05 S00.5303.18.20
48-12 page 7
48
Mount the pressure line (expansion hose) -1- and return line (return hose) -2- on the power-steering gear with new gasket rings.
FABIA 2000
Chassis
A new hollow screw must be used to connect the pressure line (expansion hose) -1- to the power-steering gear (TRW). 3 - for power-assisted steering sensor -G250- with fixed connecting line 4 - Assembly carrier 5 - Fixing bolt of -T10096Pay attention to fitting location of pressure line Chap. 48-11.
4 1 5
Raise assembly carrier until the console touches the

body. Note
S48-0115
ing steps.
Unscrew the fixing bolts of -T10096- one at a time. It
should be subsequently replaced by a new bolt tightened to the recommended torque.

screw in new bolt to the recommended tightening torque. 3 - Assembly carrier

2 1 3
Unscrew fixing bolt -2- of -T10096- from the left. Install left support. Tighten new bolts for the rear left support by hand. Tighten new bolts for left console and support to the recommended tightening torque. ed tightening torque.
S48-0197
Tighten the rear left support bolts to the recommend Unscrew right fixing bolts -2- of -T10096- (shown in
figure).
Install right support. Tighten new bolts for the rear right support by hand. Tighten new bolts for left console and support to the
Tighten up the rear right support bolts to the recommended tightening torque.
Remove gearbox jack with adapter. Tighten screws for fixing the steering gear to the assembly carrier to the recommended tightening torque.

tighten new nut Chap. 48-16.
48-12 page 8
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
48
If the joint stub rotates when tightening, counterhold with hexagon socket wrench (SW 6).
Hook the coupling rod joint stub in the stabilizer and

tighten nut.

new screws -1- and -2-. Vehicles with exhaust pipe under the assembly carrier
Installing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26. Continued for all vehicles
Fit front wheels. Install noise insulation panel. Attach line of power-steering sensor -G250- with the
line holders -arrows-.
S48-0112
S48-0109
Slide the universal joint of the steering column in the

-direction of the arrow- onto the input shaft of the power steering and tighten with a new screw -1-.
Fit cover for universal joint.

Caution! Observe the applicable safety instructions for disconnecting the battery with the jumper cable!
Connect the removed battery with jumper cable. Filling and bleeding the power-steering system
Chap. 48-23.
1
S48-0170
Disconnect the Jumper cable. If necessary install the battery and battery tray
Connect battery Electrical System; Rep. Gr. 27. Install air filter, if removed Engine, Fuel Injection
System; Rep. Gr. 24 (petrol engines) or Rep. Gr. 23 (diesel engines).
Perform self-diagnosis Chap. 48-25.

If faults are displayed in the fault memory:
Edition 04.05 S00.5303.18.20
48-12 page 9
48
Eliminating fault Chapter 48-25. Erasing fault memory Chapter 48-25. Perform a test drive.
FABIA 2000
Chassis

Note For vehicles with KOYO steering manufactured as of 43/ 04 a component modification was performed as an enhancement for which the steering gear pinion has been offset by 1 tooth. For these reasons the steering gear is modified as of this date. For vehicles manufactured before this date the steering wheel is turned by approx. 1/8 turn when replacing the steering gear. Do not set the steering wheel with track rods, rather offset the steering wheel in the grooves of the steering column Body Work; Rep. Gr. 69. Tightening torques: Power-steering gear to assembly carrier 50 Nm + 90
Use new screws!
Assembly carrier to body

Use new screws!
70 Nm + 90
Support to body
Use new screws!
20 Nm + 90

Use new screws!
30 Nm + 90

Use new nuts!
20 Nm + 90
power-assisted steering sensor -G250to power-assisted steering gear (TRW) power-assisted steering sensor -G250to power-assisted steering gear (KOYO) Hollow screw for pressure line to power steering gear (M14x1.5) - TRW
6 Nm 7.5 Nm 35 Nm
Hollow screw for pressure line to power steering gear (M14x1.5) - KOYO Pipe screw for return line to power steering gear (M16x1.5) Coupling rod to anti-roll bar Universal joint to power-steering gear
Use new screw!
40 Nm 30 Nm 40 Nm 20 Nm + 90
Wheel bolts
120 Nm
48-12 page 10
Edition 04.05 S00.5303.18.20
FABIA 2000
Chassis
48
48-13 Power-assisted steering sensor -G250- and the hydraulic line for power steering
Check power-assisted steering sensor -G250- (TRW or KOYO)
Check power-assisted steering sensor -G250- (TRW) Chapter 48-25 Check power-assisted steering sensor -G250- (KOYO) Chapter 48-25
Remving and installing power-assisted steering sensor -G250- (TRW or KOYO)

sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3A-, - V.A.G 1551/3B-
or -V.A.G 1551/3C- Diagnostic cable -VAS 5051/5Aor -VAS 5051/6A-
Removing

Disconnect battery Electrical System; Rep. Gr. 27. Remove air filter, if necessary Engine - Fuel Injection System; Rep. Gr. 24 (petrol engines) or Rep. Gr. 23 (diesel engines).
Raise vehicle. Remove front left wheel. Remove soundproofing panel. Remove the front left wheelhouse liner Body Work; Rep. Gr. 66. Note
The followings steps for removing the line do not need to be carried out on vehicles with a power steering of TRW and a power-assisted steering sensor -G250- (-2-) with an adapter cable -4-.
4 1
S48-0259
Edition 11.04 S00.5303.17.20
Power-assisted steering sensor -G250- and the hydraulic line for power steering
48-13 page 1
48
Unhook line of the power-assisted steering sensor
-G250- from the line holders -arrows-. The line of the power-assisted steering sensor -G250- is attached with 3 line holders and a spacer holder.
FABIA 2000
Chassis
S48-0109
Open spacer holder -arrow-. Remove line -1- power-assisted steering sensor/engine pump aggregate.
S48-0125
Disconnect plug -1- from the engine pump aggregate

with noise encapsulation -2-. The engine pump aggregate of TRW is illustrated in the figure. The plug assignment for the engine pump aggregate of KOYO is analogous to the version of TRW.
2
S48-0126
48-13 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Inspecting the power-assisted steering sensor -G250- (TRW) for power-assisted steering sensor -G250- with fixed connecting line (TRW):
Unscrew bolts -1- completely. Pull the power-assisted steering sensor -G250- (-2-)
with the seal -3- out of the power-steering gear.
4 1
S48-0270
for power-assisted steering sensor -G250- with adapter cable (TRW):
Detach the adapter cable -4-from the power-assisted

steering sensor -G250- (-2-).
Unscrew bolts -1- completely. Pull the power-assisted steering sensor -G250- (-2-)
4 1
S48-0259
The power-steering sensor -G250- (KOYO)
Unscrew bolt -1-. Pull the power-assisted steering sensor -G250- (-2-)
3 2
Installing
Installation is performed in a similar way in the reverse order. Pay attention to the following points:
Use new seal for power-assisted steering sensor

-G250-!
1
S48-0260
Install air filter, if removed Engine, Fuel Injection

Connect battery Electrical System; Rep. Gr. 27. Perform automatic test sequence Chapter 48-25
either using the vehicle system tester -V.A.G 1552- or using the vehicle system test Chapter 48-25 using the vehicle diagnosis, measurement and information system -VAS 5051-. If a fault is stored in the fault memory:
Eliminating fault Chapter 48-25.

Edition 11.04 S00.5303.17.20 Power-assisted steering sensor -G250- and the hydraulic line for power steering
48-13 page 3
48
Erasing fault memory Chapter 48-25.
Tightening torques: power-assisted steering sensor -G250 - to power-assisted steering gear (TRW) power-assisted steering sensor -G250 - to power-assisted steering gear (KOYO) Wheel bolts 6 Nm 7.5 Nm 120 Nm
FABIA 2000
Chassis
Removing and installing hydraulic lines (TRW or KOYO)

Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
-V.A.G 1359/2 Fixing device -T10096 Extractor -Matra V176 Extraction bottle (commercially available) Catch pan (commercially available) Wooden insert 490 x 270 x 50 mm for adapter
-V.A.G 1359/2 Plastic screw plugs for line connections on the power-
assisted steering gear (commercially available)

Notes for working on hydraulic lines

After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the return line and pressure line (expansion hose).
Do not use drained hydraulic oil again. Do not pinch off the pressure line (expansion hose)
and the return line with hose clamps -MP 7-602- or with any other tools. Pinching off may cause damage to the hydraulic lines.
Use new hollow screw for the connection of the pres-
sure line to the power steering gear (TRW).

Pay attention to fitting location of pressure line (flexi-
ble hose) Chapter 48-11.
2 1
least 100 mm is respected when bending the pressure line (expansion hose) or return line.
Replace O-rings as well as gasket rings on the hy-
draulic lines after each disassembly.
Removing
Use catch pan to collect the drained off hydraulic oil. Unscrew the screwed lid -1- of the hydraulic oil reservoir -2- of the engine pump aggregate.

the filler neck.
S48-0147
48-13 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Remove front wheels. Remove the front left wheelhouse liner Body Work;
Rep. Gr. 66.
Unclip return line -4- from the line holders -5-. Open spacer holder -7-. Take return-flow line -4- or pressure line -6- out of the
spacer -7-.
5 4
6 7
Open spring strap clamp -2- with assembly pliers and

carefully pull off return line from the support of the engine pump aggregate -1-.
Unscrew pipe screw -3- from the engine pump aggragate and pull out the pressure line. 8 - Lines of power-assisted steering sensor -G250-
3 1
S48-0199
Close the threaded bores and supports on the engine

pump aggregate.
Remove the screws attaching the assembly carrier to

the body in the prescribed sequence and replace them with the fixing bolts from -T10096- Chapter 48-12. Caution! When lowering the assembly carrier make sure the line of the power-assisted steering sensor -G250- is not exposed to traction, if necessary pull out the plug on the engine pump aggregate.
Lowering assembly carrier with power-assisted steering gear.
Disconnect pressure line -1- or return-flow line -2from steering gear. 3 - for power-assisted steering sensor -G250- with fixed connecting line (TRW): 4 - Assembly carrier 5 - Fixing bolt from -T10096-
Seal threaded holes on the steering gear (e.g. with

plastic screw plugs).
4 1 5
Remove pressure or return line.

Installing
When installing the pressure line it is essential to pay

attention to the fitting location Chapter 48-11. ing gear.
S48-0115
Mount return line with new O-ring on the power steer Attach a pressure line tightly with new seals to the
power steering gear Chapter 48-11. pump aggregate. Further installation occurs in reverse order, while paying attention to the following:
Screw return line with new O-ring onto the engine
Edition 11.04 S00.5303.17.20
48-13 page 5
48
Installing assembly carrier Chapter 48-12. Filling with hydraulic oil and bleeding the steering system Chapter 48-23.
FABIA 2000
Chassis


Tightening torques: Hollow screw for pressure line to powerassisted steering gear (M14 x 1.5), TRW
35 Nm
Hollow screw for pressure line to powerassisted steering gear (M14 x 1.5), KOYO Pipe screw for return line to power-assisted steering gear (M16 x 1.5) Pipe screw for pressure line to engine pump aggregate (TRW) Pipe screw for pressure line to engine pump aggregate (KOYO) Wheel bolts
40 Nm
30 Nm 30 Nm 29 Nm 120 Nm
48-13 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-14 Inspecting and adjusting the power-steering gear

The checking and adjusting is illustrated on a powersteering gear of TRW. For the power-steering gear of KOYO the checking and adjusting is performed analogously to the power-steering gear of TRW.
Check the centre position of the gear rack of the power-steering gear, if necessary adjust
Before installing the power-steering gear place the

gear rack in centre position. Note
The gear rack of spare part steering gears is already
in centre position.
Dimension -a- must be equal on both the right and left
side if the steering gear. If the dimension on the two sides is not the same, distance -a- must be corrected.
Check dimension -a-, if necessary adjust.

-a- = 72.5 mm
S48-0131
Adjusting dimension -a- by turning the input shaft -1of the power-steering gear. 2 - Gear rack
Adjusting the power-steering gear (adjusting the pressure plate clearance)

Note 2 mechanics are required for this adjustment. Inspection requirement:
Put the wheels in straight-ahead position. Raise vehicle. Move the steering wheel alternately approx. 30. on
the centre axle. If the steering clearance is too great rattling noises will be audible inside the vehicle.
S48-0132
Edition 11.04 S00.5303.17.20
Inspecting and adjusting the power-steering gear
48-14 page 1
48
While moving the steering wheel have the 2nd mechanic carefully screw in the ajusting screw -1- until no more rattling noises can be heard inside the vehicle.
FABIA 2000
Chassis

Caution! The steering must automatically return to straight ahead position after a manoeuvre or cornering without sticking, correct if necessary.
1
S48-0183
Secure adjusting screw -1- against turning. Apply 3 centre punch marks -arrows- uniformly distributed on the collar of the power-steering gear housing.
S48-0184
48-14 page 2
Inspecting and adjusting the power-steering gear
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-15 Disassembling and assembling the power-assisted steering gear

Disassembling and assembling the power-assisted steering gear (TRW)
Note
If the front axle is damaged as a result of an accident
these steering components must be replaced: Position 1 to 5 and position 9 to 20.

No provision is made for repairing the power-steering
gear item 12 in 48-15 page 3. In the event of failure determine the cause with the pressure and tightness test as well as by performing self-diagnosis or vehicle system test. If there is a complaint about the power -assisted steering gear item 12 in 48-15 page 3 then it must be replaced. is not allowed.
Welding and straightening of the steering components Always use original clamping collars and circlips. Only use steering gear grease to grease the gear rack
Chapter 00-2.
A mixed lining of TRW and KOYO components is not
permissible, assignment Spare part catalogue.
Edition 11.04 S00.5303.17.20
Disassembling and assembling the power-assisted steering gear
48-15 page 1
48
FABIA 2000
Chassis
1 - Right track rod end 1 2 inspect Chapter 48-16 3 removing and installing 4 Chapter 48-16 before installing, remove 5 grease on tapered stud 2 - Lock nut, 50 Nm 3 - Spring strap clip use assembly pliers, e.g. 7 8 -VAS 5024- for removing 7 and installing 4 - Boot 6 14 can only be replaced with the 15 power steering gear re9 moved 16 before removing boot detach the track-rod end Chapter 17 10 11 48-16 must not be twisted 12 16 inspect for wear and damage 18 (cuts, splits) 5 - Warm-type clamp 13 replace after each removal 16 removing: open with cutting 16 pliers tensioning Chapter 48-16 6 - Gasket 20 pay attention to installation 5 instructions for installing 2 19 4 Chapter 48-12 with and without recess for 3 S48-0264 anti-twist lock assignment Spare part catalogue Change to the steering gear housing in the area of the sealing surface With series start the steering gear housing is fitted with an anti-twist lock -arrow- for the seal. In the course of the series production the anti-twist lock is no longer applicable. 7 - Self-tapping screw, 6 Nm for attaching heat shield 8 - Heat shield Allocation Spare parts catalogue 9 - Clamp Fitting position: inscription must point in direction of travel Replace the clamp if the thread of the nut is damaged 10 - Right track rod tightening torque on steering rack: 80 Nm removing and installing Chapter 48-16 track rod and track rod end are supplied as replacement part pre-set lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm. Setting wheel toe Chap. 44-2. 11 - Rubber bearing Fitting position: the larger internal diameter points towards the outer side of the vehicle replace if damaged or worn
48-15 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
12 - Power-steering gear assignment Spare part catalogue no provision made for repairs removing and installing Chapter 48-12 setting Chapter 48-14 inspecting centre position Chapter 48-14 Change to the steering gear housing in the area of the sealing surface With series start the steering gear housing is fitted with an anti-twist lock -arrow- for the seal. In the course of the series production the anti-twist lock is no longer applicable. 13 - Gasket replace after each removal 14 - Gasket replace after each removal 15 - for power-assisted steering sensor -G250- with adapter cable removing and installing Chapter 48-13 16 - Screw, 6 Nm 17 - Adapter cable 18 - for power-assisted steering sensor -G250- with fixed connecting line removing and installing Chapter 48-13 19 - Left track rod end inspect Chapter 48-16 removing and installing Chapter 48-16 before installing, remove grease on tapered stud 20 - Left track rod tightening torque on steering rack: 80 Nm removing and installing Chapter 48-16 track rod and track rod end are supplied as replacement part pre-set lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm. Setting wheel toe Chap. 44-2.
Disassembling and assembling the power-assisted steering gear (KOYO)

Edition 11.04 S00.5303.17.20
48-15 page 3
48
Note
FABIA 2000
Chassis
If the front axle is damaged as a result of an accident these steering components must be replaced: Position 1 to
5 and position 9 to 17.

No provision is made for repairing the power-steering gear item 12 in 48-15 page 5. In the event of failure de-
termine the cause with the pressure and tightness test as well as by performing self-diagnosis or vehicle system test. If there is a complaint about the power -assisted steering gear item 12 in 48-15 page 5 then it must be replaced.
Welding and straightening of the steering components is not allowed. Always use original clamping collars and circlips. Only use steering gear grease to grease the gear rack Chapter 00-2. A mixed lining of TRW and KOYO components is not permissible, assignment Spare part catalogue.
1 - Right track rod end 1 2 inspect Chapter 48-16 removing and installing Chapter 48-16 before installing, remove grease on tapered stud 2 - Lock nut, 50 Nm 3 - Spring strap clip use assembly pliers, e.g. -VAS 5024- for removing and installing 4 - Boot can only be replaced with the power steering gear re9 moved before removing boot detach the track-rod end Chapter 10 11 48-16 must not be twisted inspect for wear and damage (cuts, splits) 5 - Warm-type clamp replace after each removal removing: open with cutting pliers tensioning Chapter 48-16 6 - Gasket 17 pay attention to installation 5 instructions for installing Chapter 48-12 4 assignment Spare part catalogue 7 - Self-tapping screw, 6 Nm for attaching heat shield 8 - Heat shield Allocation Spare parts catalogue 9 - Clamp Fitting position: inscription must point in direction of travel Replace the clamp if the thread of the nut is damaged 10 - Right track rod tightening torque on steering rack: 80 Nm removing and installing Chapter 48-16
4 5
7 6
12
13 14 15
2 3
16
S48-0265
48-15 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
11 -
12 -
13 14 15 16 -
17 -
track rod and track rod end are supplied as replacement part pre-set lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm. setting the wheel toe Chapter 44-2. Rubber bearing Fitting position: the larger internal diameter points towards the outer side of the vehicle replace if damaged or worn Power-steering gear assignment Spare part catalogue no provision made for repairs removing and installing Chapter 48-12 setting Chapter 48-14 inspecting centre position Chapter 48-14 Gasket replace after each removal Sensor for power steering -G250removing and installing Chapter 48-13 Screw, 6 Nm Left track rod end inspect Chapter 48-16 removing and installing Chapter 48-16 before installing, remove grease on tapered stud Left track rod tightening torque on steering rack: 80 Nm removing and installing Chapter 48-16 track rod and track rod end are supplied as replacement part pre-set lock nut for track rod/track rod end on replacement parts tightened initially only to 10 Nm. After installing the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm. Setting wheel toe Chap. 44-2.
Edition 11.04 S00.5303.17.20
48-15 page 5
48
FABIA 2000
Chassis
48-15 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-16 Track rod ends, track rods for power steering and mechanical steering
The checking as well as removing and installing the track rod ends are identical on the power steering of TRW or KOYO of the mechanical steering.
Inspecting play, correct attachment and boots of track rod ends

Raise vehicle (wheel clear of the ground) and inspect
play by moving the track rods and wheels. Nominal value play: no play
Inspect attachment. Check boots for damaged (e.g. tears) and for correct
position.
If necessary replace track rod ends.
Removing and installing track rod ends

Extractor -Matra V176-
Removing
The track rod ends can be replaced with the track rods and the power steering gear installed.
Matra V176 1
Raise vehicle. Remove front wheel. Screw up hexagon nut -1- sufficiently so that the puller
-Matra V176- is supported on the hexagon nut.
Use puller -Matra V176- to press track rod/track rod

Unscrew hexagon nut from the track rod end. Pull track rod end out of steering arm. Release hexagon nut (lock nut) -2-. Unscrew track rod end -3- from track rod -1-.
S48-0114
The surrounding components are not shown to simplify the illustration.
3
S48-0120
Edition 11.04 S00.5303.17.20
Track rod ends, track rods for power steering and mechanical steering
48-16 page 1
48
Installing
Note When installing pay attention to marking on the shank of the track rod end -arrow-. I - Left track rod end - marking D II - Right track rod end - marking C
FABIA 2000
Chassis
Remove grease on tapered shank of track rod end. Screw track rod end fully onto the track rod. Tighten hexagon nut (lock nut). Align track rod in such a way that the stud of the track rod end is in the installation position. tighten hexagon nut. If the joint stub rotates when tightening, counterhold with hexagon socket wrench (SW6).
II
Fit front wheel. Lower the vehicle. Carry out check of chassis alignment Chapter 44-2
Tightening torques: Lock nut of track rod/track-rod end Hexagon nut of track rod end/track rod to steering arm
Use new nut!
50 Nm 20 Nm + 90
S48-0121
Wheel bolts
120 Nm
Removing and installing track rods

Hose strap pliers, e.g. -V.A.G 1275 Torque wrench, e. g. -V.A.G 1332 Open-jawed wrench insert waf 32, e.g. -V.A.G 1332/
6 Open-jawed wrench insert waf 36, e.g. -V.A.G 1332/
8 Removal and installation pliers, e.g. -VAS 5024 Grease EN-0042, Material No. N 052 721 00 con-
forming to TL 721 Note The track rods can only be removed and installed if the mechanical steering gear or power-steering gear is removed.
48-16 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Removing
Removing mechanical steering gear Chap. 48-7, or

power-steering gear Chap. 48-12.
Clean outside of steering gear in the area of the boot. Open warm-type clamp as well as spring strap clip
and push back boot. Mechanical steering gear
Grip the steering gear in a vice with protective jaws on

the gear rack. Make sure the gear rack serration is not gripped.
When removing counterhold the track rods on the

gear rack of the steering gear.
Unscrew track rod -1- from the gear rack -2-.

Power-steering gear Note When removing and installing the right-hand track rod, open the warm-type clamp and wring strap clip of the lefthand boot additionally and push back the boot. The reason for this is that it is always necessary to counterhold at the left-hand side of the steering rack when slackening and tightening the track rods.
V.A.G 1332 2 1 V.A.G 1332/8

S48-0185
Unscrew the front track rod -1- of the steering rack -2-.
To do so use torque wrench with open-jawed wrench insert SW 32, e. g. -V.A.G 1332/6-. Counterhold open-end wrench SW 19 -3- on the left side of the steering rack.
V.A.G 1332 3
Installing
Mechanical steering gear
Grip the steering gear in a vice on the gear rack. Use

protective jaws.
1 2 V.A.G 1332/6
S48-0122
Screw track rod into the gear rack of the steering gear. When installing counterhold the track rods on the gear
rack of the steering gear.
Tighten track rod.

Power-steering gear
Screw track rod into the gear rack of the steering gear. Counterhold on flattened part of left gear rack with
open-end wrench.
Tighten track rod.

Unscrew track rod end from the track rod 48-16

page 1.
Inspect boot for wear (cuts, splits) and inspect sealing

surfaces for boot cleanliness. If there is any damage, replace boot.
Edition 11.04 S00.5303.17.20
48-16 page 3
48
Note Always use original clamping collars and circlips.
FABIA 2000
Chassis
Push boot, warm-type clamp and spring strap clips

onto track rod.
Screw track rod end onto the track rod 48-16

page 1.
Turn track rod in such a way that the stud of the track
rod end is in the installation position.
Grease contact surface of boot on track rod (recess)

with grease EN-0042, Material No. N 052 721 00 conforming to TL 721 (grease quantity: 0.8g).
Fit on boot.
The boot must on no account be installed twisted (distorted).
Tighten the warm-type clamp using the hose binding

claw, e.g. -V.A.G 1275-.
V.A.G 1275
Install spring strap clamp with assembly pliers, e.g.

-VAS 5024-.
Installing mechanical steering gear Chap. 48-7, or

installing power-steering gear Chap. 48-12. alignment Chapter 44-2.
Check overall track and adjust if necessary, vehicle

Tightening torques: Track rod in gear rack of the mechanical steering gear Track rod in steering rack of power steering gear 80 Nm 80 Nm
S48-0059
48-16 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-17 Disposing of the powersteering gear

Catch pan for hydraulic oil (commercially available)
Note
The disposal of the power-steering gear of TRW or
KOYO is identical.
The oils used in the power-steering gears do not con-
tain any harmful substances. These oils may be disposed of together with the drained engine and gearbox oil.
Dispose of used oils in compliance with the applicable
environmental regulations.
Used oils (this concept refers to used engine and gear
oils including ATF as well as mineral hydraulic oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or thinners, chemicals etc.
After draining the used parts must be allowed to
1 2
drip.
When disposing of used parts comply with the appli-
cable regulations as there are minor residual amounts of hydraulic oil in the power-steering gear.
The ambient temperature must be of at least 20C to
1
S48-0128
drain the steering gear.
Unscrew pipe screws -1-. Pull off coolant hoses -2- and -3-.
Note Do not shut off the threaded bores -arrows-.
Hold the power-steering gear over a catch pan and repeatedly turn the steering pinion from stop to stop until no more hydraulic oil runs out of the threaded bores.
Disposing of the power-steering gear.
Edition 11.04 S00.5303.17.20
Disposing of the power-steering gear
48-17 page 1
48
FABIA 2000
Chassis
48-17 page 2
Disposing of the power-steering gear
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-18 Engine pump aggregate

Summary of components of engine pump aggregate (TRW)
The engine pump aggregate
is a complete component consisting of steering hydraulics pump -V119- (electric motor and gear rack pump), the
power-steering control unit -J500- and the hydraulic oil reservoir.

has a re-engaging protection after faults, failure or crash Chap. 48-11.
Note
No provision is made for repairing the engine pump aggregate. The cause of any problems which may be arising is determined by the pressure and tightness test. If there is insufficient hydraulic oil in the reservoir always check the steering system for leaks. If there is a leak in the area of the line connections first check the lines/line connections for tightness, if necessary
tighten and wipe dry.

Do not use drained hydraulic oil again. Always replace gasket rings. Oil types: Hydraulic oil Chapter 00-2.
1 - Encapsulation bottom open version not fitted to all vehicles assignment Spare part catalogue 2 - Encapsulation bottom closed version not fitted to all vehicles Disassembling is only possible after removing the engine pump aggregate and the holder assignment Spare part catalogue 3 - Screwed lid with oil dipstick 4 - Gasket ring 5 - Reservoir replacing Chapter 48-21 6 - Clamp replace after each removal different versions assignment Spare part catalogue Tightening torque: 3 Nm 7 - Gasket ring different versions assignment Spare part catalogue 8 - Hexagonal nut, 7 Nm when tightening counterhold on rubber bearing item 9 9 - Rubber bearing Tightening torque: 7 Nm
3 6 7 8 9 10 4 5 2 1
9 9 8 8 11 12 14 13 11
16
15
11
S48-0261
Edition 11.04 S00.5303.17.20
Engine pump aggregate
48-18 page 1
48
10 -
FABIA 2000 check for damage (tears in rubber, rubber torn away from metal plate), if necessary replace Engine pump aggregate with power-assisted steering control unit -J500No provision is made for repair Replacing reservoir Chap. 48-21 inspect Chapter 48-19 Self-diagnosis Chap. 48-25 Electrical test Chap. 48-26 removing and installing Chapter 48-20 Tighten hexagon screw 20 Nm + 90 replace after each removal Bracket for engine pump aggregate Spring strap clip install with assembly pliers, e. g. -VAS 5024Return line (return hose) power-assisted steering gear - engine pump aggregate O-ring replace after disassembling the pressure line Pressure line (expansion hose) Tightening torque of the pipe screws: 30 Nm Engine pump aggregate - Power-steering gear
Chassis
11 12 13 14 15 16 -
48-18 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Summary of components of engine pump aggregate (KOYO)

The engine pump aggregate
is a complete component consisting of steering hydraulics pump -V119- (electric motor and gear rack pump), the
power-steering control unit -J500- and the hydraulic oil reservoir.

has a re-engaging protection after faults, failure or crash Chap. 48-11.
Note
No provision is made for repairing the engine pump aggregate. The cause of any problems which may be arising is determined by the pressure and tightness test. If there is insufficient hydraulic oil in the reservoir always check the steering system for leaks. If there is a leak in the area of the line connection first check the lines/line connections for tightness, if necessary
tighten and wipe dry.

Do not use drained hydraulic oil again. Always replace gasket rings. Oil types: Hydraulic oil Chapter 00-2.
1 - Rear bracket for engine pump aggregate the bearings in the bracket are not used as replacement part, in case of bearing dam1 age replace bracket 2 - Tighten hexagon screw 2 20 Nm + 90 replace after each removal 3 - Fillister head screw, 7 Nm 4 - Screwed lid 3 with flat gasket ring as replacement part only screwed lid with oil dipstick is 19 available together assignment Spare part catalogue 5 - Flat gasket ring 6 - Screwed lid with O-ring 18 17 assignment Spare part catalogue 7 - O-ring 8 - Encapsulation bottom open version not fitted to all vehicles 2 assignment Spare part catalogue 9 - Self-locking fillister head screw, 7 Nm replace after each removal assignment Spare part catalogue 10 - Cap nuts, 7 Nm assignment Spare part catalogue 11 - Reservoir replacing Chapter 48-21
6 7 8 9 14 14 9 10 11 12 13 9
5 9 10
20
11
16 3 15
S48-0262
Edition 11.04 S00.5303.17.20
48-18 page 3
48
12 13 -
FABIA 2000
Chassis
14 15 -
16 -
17 18 -
19 20 -
assignment Spare part catalogue Gasket ring replace after each removal Engine pump aggregate with screwed in threaded bores with power-assisted steering control unit -J500power-assisted steering control unit -J500- and electric motor must not be separated No provision is made for repair Replacing reservoir Chap. 48-21 inspect Chapter 48-19 Self-diagnosis Chap. 48-25 Electrical test Chap. 48-26 removing and installing Chapter 48-20 assignment Spare part catalogue Fillister head screw, 7 Nm assignment Spare part catalogue Engine pump aggregate without threaded bores Screw insert -arrow- only with fillister head screws item 9 with power-assisted steering control unit -J500power-assisted steering control unit -J500- and electric motor must not be separated No provision is made for repair Replacing reservoir Chap. 48-21 inspect Chapter 48-19 Self-diagnosis Chap. 48-25 Electrical test Chap. 48-26 removing and installing Chapter 48-20 assignment Spare part catalogue Front bracket for engine pump aggregate the bearings in the bracket are not used as replacement part, in case of bearing damage replace bracket O-ring replace after disassembling the pressure line Pressure line (expansion hose) Tightening torque of the pipe screws: 29 Nm Engine pump aggregate - Power-steering gear Return line (return hose) power-assisted steering gear - engine pump aggregate Spring strap clip install with assembly pliers, e. g. -VAS 5024-
48-18 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-19 Inspecting engine pump aggregate

The engine pump aggregates TRW or KOYO can also be checked apart from the inspections described in this chapter in the framework of the self-diagnosis of the power-steering Chapter 48-25, of the electrical test Chapter 48-26 or the self-diagnosis with the vehicle diagnosis, measurement and information system -VAS 5051- Chapter 48-25.
Testing function of the engine pump aggregate

sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3- or -VAS 5051/6A-
The checking of the function is identical for the engine pump aggregates of TRW or KOYO. Check for proper operation
Raise vehicle. Remove front left wheel. Remove the front left wheelhouse liner Body Work;
Rep. Gr. 66.
Switch on ignition. Start engine. If necessary turn steering up to stop. Listen to and/or touch the engine pump aggregate to check whether it is running.
If the engine pump aggregate is not working:
Perform self-diagnosis Chap. 48-25. Switch off ignition. Carry out electrical test Chap. 48-26. Remove fault. Install the front left wheelhouse liner Body Work; Rep. Gr. 66.
Install left front wheel. Lower the vehicle.

If the engine pump aggregate is working and if there are other faults:

If entries from the fault memory are displayed:
Edition 11.04 S00.5303.17.20
Inspecting engine pump aggregate
48-19 page 1
48
If no faults are displayed in the fault memory:
FABIA 2000
Chassis
Check the feed pressure of the engine pump aggregate 48-19 page 2. Tightening torque: Wheel bolts 120 Nm
Check the feed pressure of the engine pump aggregate

The checking of the feed pressure is identical for the engine pump aggregates of TRW or KOYO. The description of the test is performed on an engine pump aggregate of TRW. Special tools, test and measuring equipment and auxiliary items required
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3- or -VAS 5051/6A Power-assisted steering testing device, e. g.
-V.A.G 1402 Adapter, e.g. -V.A.G 1402/1A Adapter, e.g. -V.A.G 1402/2 Adapter, e.g. -V.A.G 1402/3 Hose from adapter set, e. g. -V.A.G 1402/6 Extraction bottle (commercially available) Jumper cable (commercially available) Oil catch pan (commercially available) Hydraulic oil Chap. 00-2
Note
If there is insufficient hydraulic oil in the reservoir of
the engine pump aggregate always check the powersteering system for leaks Chap. 48-23.
If there is a leak on the power-steering gear first check
the lines/line connections for tightness, if necessary tighten and wipe dry.
Inspecting the gasket ring on the input shaft of the
power-steering gear and on the gear rack seal Chap. 48-23. If there are leaks on the gasket ring or on the gear rack seal replace the power-steering gear.
Disposing of the power-steering gear Chap. 48-17. After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the pressure line (expansion hose).
Do not use drained hydraulic oil again. After the feed pressure test replace the O-ring on the
pipe screw of the pressure line.
48-19 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Do not pinch off the pressure hose and the return
hose with hose clamps -MP 7-602- or any other tools. Pinching off may result in damage to the pressure and return line.
least 100 mm is respected when bending or tying up the pressure line. Test requirements
Tightness of the system Pressure and return line not buckled or tied up.
Note
Because of the different battery dimensions, on cer-
tain models the screwed lid of the hydraulic oil filler and inspection hole is covered by the battery tray and battery. If this is the case remove the air filter, the battery tray and battery.
2 1
Remove air filter, if necessary Engine, Fuel Injection System; Rep. Gr. 24 (petrol engines) or Rep. Gr. 23 (diesel engines).

Unscrew the screwed lid -1- of the hydraulic oil reservoir of the engine pump aggregate -2-.

the filler neck.
S48-0147
Raise vehicle. Remove noise insulation panel -arrows-.

S48-0111
Edition 11.04 S00.5303.17.20
48-19 page 3
48
Remove front left wheel. Remove the front left wheelhouse liner Body Work;
Rep. Gr. 66
FABIA 2000
Chassis
Open spacer holder -1- and remove pressure line (expansion hose) -2-. Note After removing the pressure line from the engine pump aggregate hydraulic oil will escape from the connection opening.
2
Place the catch pan under the engine pump aggregate to collect escaping hydraulic oil.
1
S48-0135
Release pipe screws -3- from the engine pump aggregate -1-.
Pull out the pressure line (expansion hose) -2- from

the engine pump aggregate. Note
The pressure line must not be exposed to traction. Make sure the bending radius of the pressure line is
2 3
no less than 100 mm.
Tie up the pressure line on the stabilizer.

S48-0136
Connect tester
Connect Power-steering tester -1-, e. g. -V.A.G 1402-. Suspend the power-steering tester on front axle. Hoses must not be exposed to tension. 2345ABCAdapter, e.g. -V.A.G 1402/3Hose from adapter set, e. g. -V.A.G 1402/6Adapter, e.g. -V.A.G 1402/2Adapter, e.g. -V.A.G 1402/1APressure line (expansion hose) Engine pump aggregate with encapsulation Return line (return hose)
C B 5
4 A 2 3 1
S48-0138
48-19 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Test preparations
Open the shut-off valve on the power-steering tester

pressure gauge -1-. Lever -2- points perpendicularly down.
Lower the vehicle.

Caution! Observe the applicable safety instructions for disconnecting the battery with the jumper cable!
If necessary connect battery to jumper cable. Filling with hydraulic oil and bleeding the steering system Chapter 48-23. Test Note
A 2nd mechanic is required to check the feed pres-
2
S48-0195
sure of the engine pump aggregate or the system pressure.

To avoid damaging the engine pump aggregate or the
power-steering system, the test of the feed or system pressure must not last longer that approx. 510 seconds.
Do not close the shut-off valve of the tester pressure
gauge during this test. If the shut-off valve is closed the indicated nominal pressure will drop to 0 MPa (bar) once a pressure valve in the engine pump aggregate responds.
Start engine. Given a maximum left and right steering angle hold
the steering wheel in position with a force of approx. 1020 Nm during approx. 510 seconds.
Read off pressure at maximum steering angle (left/

.right) and with the engine at idling speed.
Compare the measured value to the nominal value according to the following table. Engine Fuel engines Diesel engines
1)
Nominal value overpressure1) MPa 9,610,4 9,610,4 bar 96104 96104
2 1
maximum system pressure or feed pressure of the engine pump aggregate
Note If the nominal value is exceeded or if it is not reached replace the engine pump aggregate.
Switch off engine. Unscrew the screwed lid -1- of the hydraulic oil reservoir of the engine pump aggregate -2-.
S48-0147
Edition 11.04 S00.5303.17.20
48-19 page 5
48
the filler neck.
FABIA 2000
Chassis
Removing Power-steering tester, e. g. -V.A.G 1402-. If necessary replace defective engine pump aggregate Chap. 48-20. Disposing of the engine pump aggregate Chap. 4820
Position pressure line (expansion hose) -2- in spacer

holder -1- and close spacer holder.
Mount pressure line on the engine pump aggregate. Filling with hydraulic oil and bleeding the steering system Chapter 48-23.
Disconnect the jumper cable. Install the front left wheelhouse liner Body Work;
Rep. Gr. 66.
Install noise insulation panel. Fit front wheel. If necessary install the battery and battery tray
1
S48-0135
If necessary connect battery Electrical System;

Rep. Gr. 27.

Perform self-diagnosis Chap. 48-25


Tightening torques: Pressure line to engine pump aggregate TRW Pressure line to engine pump aggregate KOYO Wheel bolts 30 Nm 29 Nm 120 Nm
48-19 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-20 Removing and installing as well as disposing of engine pump aggregate

Removing and installing engine pump aggregate (TRW)
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3- or -VAS 5051/6A Removal and installation pliers, e.g. -VAS 5024 Jumper cable (commercially available) Oil catch pan (commercially available) Extraction bottle (commercially available) Hydraulic oil Chap. 00-2
In the event of failure determine the cause with the functional, pressure and tightness test as well as by performing self-diagnosis. Note
Do not use drained hydraulic oil again. After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the hydraulic lines.

Do not pinch off the hydraulic lines with hose clamps
-MP 7-602- or any other tools. Pinching off may result in damage to the pressure and return line.
least 100 mm is respected when bending or tying up the pressure line.
Removing engine pump aggregate

Note
2 1

S48-0147
Edition 11.04 S00.5303.17.20
Removing and installing as well as disposing of engine pump aggregate
48-20 page 1
48
the filler neck.
FABIA 2000
Chassis

Rep. Gr. 66 Vehicles with radiator fan control unit -J293-
S48-0111
Disconnect plugs -1- and -2- from the radiator fan control unit -J293- -4-.
Unscrew nuts -3-. Remove radiator fan control unit -4-.

3 3 4
S48-0140
Open spacer holder -1- and remove pressure line (expansion hose) -3-, return line -2- and the line of the power-steering sensor -G250-.
Position the oil catch pan under the engine pump aggregate.
S48-0141
48-20 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
1 2 3
Disconnect plugs -1-, -2- and -3- from the engine

pump aggregate with encapsulation -4-. 1 - Data BUS plug and terminal 15 2 - Earth plug and terminal 30 3 - Power-steering sensor -G250- plug Note
Residual hydraulic oil remains in the engine pump ag-
gregate. When removing the pressure line some of this residual amount will flow out.
When tying up the hydraulic line make sure the bend-
ing radius of 100 mm is reached.
4
S48-0143
Unscrew the pressure line (expansion hose) -1- from

the engine pump aggregate and tie up.
Shut off the pressure line with a plastic bag and adhesive tape to protect it against dirt.
Open the spring strap clamp -3- on the return line (return hose) -2-.
2 1
Carefully pull off the return line -2- from the reservoir
support of the engine pump aggregate -4- and shut off with a plastic bag and adhesive tape to protect it against dirt.
4
S48-0142
Release hexagon screws -arrows-. Remove engine pump aggregate with encapsulation
-1- and with holder -2- downwards.
1
S48-0144
Edition 11.04 S00.5303.17.20
48-20 page 3
48
Removing the holder and rubber bearing.
FABIA 2000
Chassis
Unscrew the hexagon nuts -arrows-. Remove holder -2-. Open encapsulation -3-. Remove engine pump aggregate -1-. Note
2 1
To replace the rubber bearing do not remove the encapsulation.
S48-0145
Unscrew rubber bearing -arrow-.

Installing engine pump aggregate
Note
Only use original spring band clamps. Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
Do not use drained hydraulic oil again. After installing the engine pump aggregate fill with hy-
draulic oil 48-23.
When installing the pressure line on the engine pump
aggregate use new O-ring. Installation is carried out in the reverse order. Pay attention to the following:
S48-0146
It is absolutely necessary to counterhold the rubber

bearing when tightening the hexagon nuts to secure the holder on the engine pump aggregate. Caution! Observe the applicable safety instructions for disconnecting the battery with the jumper cable!
If necessary connect removed battery to jumper cable.
If necessary install air filter. Filling with hydraulic oil and bleeding the steering system Chapter 48-23.
If necessary disconnect the jumper cable. If necessary re-install the air filter. If necessary install the battery and battery tray
48-20 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48


Tightening torques: Rubber bearing to engine pump aggregate TRW Holder to engine pump aggregate TRW Holder with engine pump aggregate TRW to body
Use new screws!
7 Nm 7 Nm 20 Nm + 90
Pressure line to engine pump aggregate TRW Radiator fan control unit -J293- to body Wheel bolts
30 Nm 6 Nm 120 Nm
Removing and installing engine pump aggregate (KOYO)

sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3- or -VAS 5051/6A Removal and installation pliers, e.g. -VAS 5024 Jumper cable (commercially available) Oil catch pan (commercially available) Extraction bottle (commercially available) Hydraulic oil Chap. 00-2
In the event of failure determine the cause with the functional, pressure and tightness test as well as by performing self-diagnosis. Note
Do not use drained hydraulic oil again. After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the hydraulic lines.

Do not pinch off the hydraulic lines with hose clamps
-MP 7-602- or any other tools. Pinching off may result in damage to the pressure and return line.
least 100 mm is respected when bending or tying up the pressure line.
Edition 11.04 S00.5303.17.20
48-20 page 5
48
Removing engine pump aggregate
Note
FABIA 2000
Chassis
2 1


the filler neck.
S48-0147

Rep. Gr. 66
S48-0111
48-20 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Vehicles with radiator fan control unit -J293-
Disconnect plugs -1- and -2- from the radiator fan control unit -J293- -4-.
Unscrew nuts -3-. Remove radiator fan control unit -4-.

3 3 4
S48-0140
Open spacer holder -1- and remove pressure line (expansion hose) -3-, return line -2- and the line of the power-steering sensor -G250-.
Position the oil catch pan under the engine pump aggregate.
S48-0141
Disconnect plugs -1-, -2- and -3- from the engine

pump aggregate. 1 - Data BUS plug and terminal 15 2 - Earth plug and terminal 30 3 - Power-steering sensor -G250- plug Note
Residual hydraulic oil remains in the engine pump ag-
3 2
S48-0271
gregate. When removing the pressure line some of this residual amount will flow out.
When tying up the hydraulic line make sure the bend-
ing radius of 100 mm is reached.
Edition 11.04 S00.5303.17.20
48-20 page 7
48
Unscrew the pressure line (expansion hose) -3- at the
engine pump aggregate -4- and tie up.
FABIA 2000
Chassis
Shut off the pressure line with a plastic bag and adhesive tape to protect it against dirt.
Open the spring strap clamp -1- on the return line (return hose) -2-.
Carefully pull off the return line -2- from the reservoir
support of the engine pump aggregate -4- and shut off with a plastic bag and adhesive tape to protect it against dirt.
3 4
Unscrew hexagon screw -arrow-.
1 - Front bracket
S48-0272
S48-0273
Release hexagon screws -arrows-. Remove engine pump aggregate -2- with the brackets
-1- and -3- downwards.
S48-0274
48-20 page 8
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
1 2 3
Remove bracket
Unscrew fillister head screws -5-. Remove bracket -1- and -3- from the engine pump aggregate -2-. The bearings -4- and -6- are not used as replacement part. In case of bearing damage the corresponding bracket must be replaced. Caution! The power steering control unit -J500- (-A-) and the electric motor -B- must not be separated.
4 6 5 A B
S48-0275
5
Installing engine pump aggregate
Note
Only use original spring band clamps. Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
Do not use drained hydraulic oil again. After installing the engine pump aggregate fill with hy-
draulic oil 48-23.
When installing the pressure line on the engine pump
aggregate use new O-ring. Installation is carried out in the reverse order. Pay attention to the following: Caution! Observe the applicable safety instructions for disconnecting the battery with the jumper cable!
If necessary connect removed battery to jumper cable.
If necessary install air filter. Filling with hydraulic oil and bleeding the steering system Chapter 48-23.
If necessary disconnect the jumper cable. If necessary re-install the air filter. If necessary install the battery and battery tray


Tightening torques:
Edition 11.04 S00.5303.17.20
48-20 page 9
48
Front bracket on engine pump aggregate KOYO Rear bracket on engine pump aggregate KOYO Holder with engine pump aggregate KOYO to body
Use new screws!
FABIA 2000
Chassis
7 Nm 7 Nm 20 Nm + 90
Pressure line to engine pump aggregate KOYO Radiator fan control unit -J293- to body Wheel bolts
29 Nm 6 Nm 120 Nm
Disposing of the engine pump aggregate

Catch pan for hydraulic oil (commercially available)
Note
The oils used in the engine pump aggregate do not
contain any harmful substances. These oils can be disposed of together with drained engine and gearbox oil.
Dispose of used oils in compliance with the applicable
environmental regulations.
Used oils (this concept refers to used engine and gear
oils including ATF as well as mineral hydraulic oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or thinners, chemicals etc.
After draining the used parts must be allowed to
drip.
When disposing of used parts comply with the appli-
cable regulations as there are minor residual amounts of hydraulic oil in the engine pump aggregate.
To drain the engine pump aggregate the ambient tem-
perature must be of at least 20 C. 20.
Removing the engine pump aggregate Chap. 48 Removing the holder, encapsulation and rubber bearing. Do not shut off the line connections -arrows A and B- or the filling opening of the reservoir -arrow C-.
Unscrew the screwed lid of the engine pump aggregate reservoir.
Hold the engine pump aggregate over a catch pan

and fully drain the hydraulic oil by turning it repeatedly.
A B
S48-0154
Dispose of the engine pump aggregate in compliance

with the applicable regulations.
48-20 page 10
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-21 Replace reservoir of engine pump aggregate

Note
Absolute cleanliness is required when replacing the
reservoir.
Clean thoroughly the area between the connection fit-
ting for return flow at the reservoir and connection for pressure line at the engine pump aggregate before separating via the entire circumference, but do not use any aggressive cleaning agents, such as brake cleaner, petroleum, thinner or similar.
Place removed parts on a clean surface and cover. Carefully cover opened components if the repair is not
completed immediately.
before fitting.
Use only genuine wrapped parts. The contact surface of the reservoir/engine pump ag-
gregate must not come in contact with sealants.

Noise insulation not fitted on all vehicles, assignment
Spare part catalogue.
Replace reservoir of engine pump aggregate (TRW)

Hot-air blower e.g. -V.A.G 1416 Hydraulic oil Chap. 00-2 Protective gloves (commercially available) Rubber hammer (commercially available)
Note
When replacing the reservoir make sure that the
housing -1- of the engine pump aggregate is not exposed to traction, pressure or knock.
A damage of the housing can lead to damage at the
pump or at the seal power-assisted steering control unit -J500-/housing.
Disassemble reservoir
Removing the engine pump aggregate Chap. 4820. After extraction of the hydraulic oil there will be residues in the engine pump aggregate.
1
S48-0290
Close screw connection for the pressure line at the

engine pump aggregate.
Edition 11.04 S00.5303.17.20
Replace reservoir of engine pump aggregate
48-21 page 1
48
Remove holder -1- from the engine pump aggregate
-3-.
FABIA 2000
Chassis
If fitted, remove encapsulation -2- from engine pump

aggregate.
1 3
S48-0276
Clamp the engine pump aggregate in a vice with protective jaws. Note
The engine pump aggregate must only be clamped at
the power steering control unit -J500- (-1-), on no account at the housing -2-.
The housing -2- must not rest against the vice or
against the work bench.

A non-observance of the mentioned safety measures
1 2
S48-0289
leads to a non-repairable damage at the engine pump aggregate.
Open clamp -1- and remove upwards.

WARNING! Wear gloves when heating and pulling off the reservoir.
2 1
Heat the reservoir -2- in the lower area evenly all

around with a hot-air blower e.g. -V.A.G 1416Caution! The reservoir must be heated up to maximum 80 C.
3
S48-0277
Detach reservoir -2- from engine pump aggregate -3-.
48-21 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Assembling reservoir
Note
Ensure a clean, grease- and oil-free contact surface
for gasket ring and reservoir at the engine pump aggregate.

No lubricant must be used for assembling the reser-
voir on the engine pump aggregate.

The contact surface of the reservoir/engine pump ag-
gregate must not come in contact with sealants.
Clamp the engine pump aggregate in a vice with protective jaws. Note
The engine pump aggregate must only be clamped at
the power steering control unit -J500- (-1-), on no account at the housing -2-.
The housing -2- must not rest against the vice or
against the work bench.

A non-observance of the mentioned safety measures
1 2
S48-0289
leads to a non-repairable damage at the engine pump aggregate.
Insert a new gasket ring Spare part catalogue in

the sealing surface of the engine pump aggregate.
Ensure that the gasket ring is sitting correctly.

WARNING! Wear gloves when heating and positioning the reservoir.
Heat the new reservoir in the lower area evenly all

around with a hot-air blower e.g. -V.A.G 1416Caution! The reservoir must be heated up to maximum 80 C.
Position the reservoir -1- on the engine pump aggregate -2-.
Position the reservoir in such a way that the connection fitting for the return-flow line -arrow A- is located vertically above the screw connection for the pressure line -arrow B-.
Pull the reservoir -1- up to the stop onto the engine

pump aggregate -2-.
For this step knock with a rubber hammer evenly all

around on the reservoir -1-, but on no account on the filler tube.
Make sure that the reservoir does not tilt. Attach reservoir with new clamp at engine pump aggregate.
B
S48-0278
Tighten the screw of the clamp to the specified tightening torque.

Edition 11.04 S00.5303.17.20 Replace reservoir of engine pump aggregate
48-21 page 3
48
Close connection fitting for the return-flow line at reservoir.
FABIA 2000
Chassis
Fill reservoir up to approx. 1/4 with hydraulic oil and

check for tightness at joint of reservoir/engine pump aggregate.
2 3
In case of leakage eliminate the fault. Empty the reservoir.

For reasons of guarantee, mark the replacement of the reservoir.
Make an approx. 15x30 mm large permanent colour

marking -2- e.g with seal paint on the location marked in the figure. The marking must cover the reservoir -1-, the clamp -3and the engine pump aggregate -4-.
4
S48-0279
If fitted, mount encapsulation -2- at engine pump aggregate -3-, assignment of encapsulation Spare part catalogue.
Install holder -1- at the engine pump aggregate -3-. Open connection fitting for the return-flow line at the
reservoir and screw connection for the pressure line at the engine pump aggregate.
1 3
Installing the engine pump aggregate Chap. 48-20.

Tightening torque: Clamp at reservoir of engine pump aggregate
Use new clamp!
3 Nm
S48-0276
Replace reservoir of engine pump aggregate (KOYO)

There are two versions for attaching the reservoir -1- at the engine pump aggregate -6-:
Attachment with fillister head screws -2-, as well as
1 3
with cap nuts -3- and threaded bores -5 Attachment with fillister head screws -2- and -4-
Disassemble reservoir
Removing the engine pump aggregate Chap. 4820. After extraction of the hydraulic oil there will be residues in the engine pump aggregate.
5 5 6
S48-0284
Close screw connection for the pressure line at the

engine pump aggregate.
48-21 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
If fitted, remove encapsulation from engine pump aggregate. Reservoir attached with cap nuts and fillister head screws
Unscrew cap nuts -arrows A-. Unscrew fillister head screws -arrows B-.
When detaching the reservoir, the engine pump aggregate must not be counterheld.
Detach reservoir from the engine pump aggregate.
S48-0280
Reservoir attached with fillister head screws
Unscrew fillister head screws -arrows A-. Unscrew fillister head screws -arrows B-.
S48-0280
Note When detaching the reservoir -1-, one must absolutely counterhold at pump aggregate -2Caution! The pump aggregate -2- must on no account be pulled out from the housing with power-assisted steering control unit -J500- -3-. A separation leads to damage at the engine pump aggregate, which cannot be eliminated with workshop possibilities.
1 2 3
Carefully detach reservoir -1- from pump aggregate

-2-.
S48-0281
Edition 11.04 S00.5303.17.20
48-21 page 5
48
Assembling reservoir
Note
Ensure a clean, grease- and oil-free contact surface
FABIA 2000
Chassis
for gasket ring and reservoir at the engine pump aggregate.

Do not use any sealant for sealing the contact surfac-
es of the reservoir/engine pump aggregate.

When inserting a new gasket ring -1- and when as-
sembling the reservoir, one must absolutely counterhold at the pump aggregate -2-. Caution! The pump aggregate -2- must on no account be pulled out from the housing with power-assisted steering control unit -J500- -3-. A separation leads to damage at the engine pump aggregate, which cannot be eliminated with workshop possibilities.
1 2 3
S48-0282
Insert a new gasket ring -1- Spare part catalogue in

the sealing surface of the pump aggregate -2-. At the same time absolutely counterhold at pump aggregate.
Ensure that the gasket ring is sitting correctly. Position new reservoir on the engine pump aggregate. Screw in new fillister head screws -arrows B- and
pretighten hand-tight.
Screw on or in cap nuts or fillister head screws -arrows

A- and pretighten hand-tight. Note Begin with the tightening of the screws with fillister head screws -arrows B-.
Tighten up fillister head screws -arrows B- and cap

nuts or fillister head screws -arrows A- crosswise to the specified tightening torque.
Close connection fitting for the return-flow line at reservoir.
S48-0280
Fill reservoir up to approx. 1/4 with hydraulic oil and

check for tightness at joint of reservoir/engine pump aggregate.
In case of leakage eliminate the fault. Empty the reservoir.

For reasons of guarantee, mark the replacement of the reservoir.
1 2
Make a large permanent colour marking -2- e.g with

seal paint on the location marked in the figure. The marking must cover the reservoir -3- and the fillister head screw -1-.
If fitted, mount encapsulation at engine pump aggre-
gate, assignment of encapsulation Spare part catalogue.
S48-0283
48-21 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Open connection fitting for the return-flow line and

screw connection for the pressure line.
Installing the engine pump aggregate Chap. 48-20.

Tightening torques: Reservoir to engine pump aggregate - fillister head screws -arrows B Use new fillister head screws!
7 Nm
Reservoir to engine pump aggregate cap nuts -arrows AReservoir to engine pump aggregate - fillister head screws -arrows A-
7 Nm 7 Nm
S48-0280
Edition 11.04 S00.5303.17.20
48-21 page 7
48
FABIA 2000
Chassis
48-21 page 8
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-22 Checking hydraulic oil level

Inspecting hydraulic oil level, if necessary topping up
sis, measurement and information system -VAS 5051 Diagnostic cable -V.A.G 1551/3A-, -V.A.G 1551/3B-
or -V.A.G 1551/3C- Diagnostic cable -VAS 5051/5Aor -VAS 5051/6A Extraction bottle (commercially available) Hydraulic oil Chap. 00-2
Note
Preferably check the hydraulic oil level in cold condi-
tion.
Hydraulic oil amount in the system: approx. 0.80 ltr. The screwed lid -1- for the reservoir -2- is located in an
opening on the frame side rail in the front left section of the engine compartment.
On certain models the screwed lid -1- of the reservoir
2 1
is covered by the battery tray because of the different battery dimensions. If this is the case remove the battery tray and battery.
Check the hydraulic oil level with the dipstick of the
screwed lid -1-.

Do not refer to the MAX and MIN markings on the
reservoir to check the hydraulic oil level.

Do not use drained hydraulic oil again. Before disconnecting the battery determine the code
S48-0147

Electrical System; Rep. Gr. 27. gate reservoir.
Unscrew the screwed lid from the engine pump aggre Wipe the oil dipstick with a clean non-fluffing cloth. Screw the lid by hand onto the engine pump aggregate reservoir and unscrew again. Note The correct oil level can only be determined for a fully screwed in screwed lid.
Checking the oil level.
Edition 11.04 S00.5303.17.20
Checking hydraulic oil level
48-22 page 1
48
Hydraulic oil in a cold condition (for an engine temperature up to approx. 50 C)
The oil level must be located: between the bottom marking -arrow A- and the top marking -arrow B- of the oil dipstick TRW. In the area between the markings Min and Max on the oil dipstick KOYO.
If the oil level is above the upper marking -arrow B- or
FABIA 2000
Chassis
Max, drain off some oil.

If the oil level is below the lower marking -arrow A- or
Min, first check the hydraulic system for leaks (Inspecting power-assisted steering system for tightness Chapter 48-23), and then one can begin to top up the system with hydraulic oil. It is not enough to simply top up the oil.
Do not use drained hydraulic oil again.
Screw the lid by hand onto the engine pump aggregate reservoir.
Hydraulic oil at a normal operating temperature (for an engine temperature above 50 C)

The oil level must be located: between the bottom marking -arrow A- and the top marking -arrow B- of the oil dipstick TRW. In the area between the markings Min and Max on the oil dipstick KOYO.
An oil level above the upper marking -arrow B- or
Max is permissible in warm condition, no oil is drained off.

If the oil level is above the upper marking -arrow B- or
Max, no oil is drained off.

If the oil level is below the lower marking -arrow A- or
Min, first check the hydraulic system for leaks (Inspecting power-assisted steering system for tightness Chapter 48-23), and then one can begin to top up the system with hydraulic oil. It is not enough to simply top up the oil.
Screw the lid by hand onto the engine pump aggregate reservoir.
If necessary install the battery and battery tray


System; Rep. Gr. 24 (petrol engines) or Rep. Gr. 23 (diesel engines). If the battery was removed:

48-22 page 2
Checking hydraulic oil level
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-23 Filling and bleeding the power steering system, and checking tightness
Filling and bleeding the power steering system
or -V.A.G 1551/3C- Diagnostic cable -VAS 5051/5Aor -VAS 5051/6A Removal and installation pliers, e.g. -VAS 5024 Oil catch pan (commercially available) Extraction bottle (commercially available) Jumper cable (commercially available) Hydraulic oil Chap. 00-2
Note
Hydraulic oil amount in the system: approx. 0.80 ltr. The screwed lid for filling the power steering system
with hydraulic oil is located in a recess on the frame side rail in the front left section of the engine compartment.
tain models the screwed lid covered by the battery tray and battery. If this is the case remove the air filter, the battery tray and battery.
Only fill an empty hydraulic system when the engine is
cold.
Hydraulic oil Chap. 00-2 Hydraulic oil amount in the system: approx. 0.80 ltr. Use new hydraulic oil only. Topping up hydraulic oil Chap. 48-22 Check the hydraulic oil level with the dipstick of the
screwed lid of the engine pump aggregate reservoir.

Do not refer to the MAX and MIN markings on the
reservoir to check the hydraulic oil level.

2 1

Fill the engine pump aggregate reservoir -2- with hydraulic oil and check the hydraulic oil level with the screwed lid dipstick -1-.
S48-0147
Edition 11.04 S00.5303.17.20
Filling and bleeding the power steering system, and checking tightness
48-23 page 1
48
For checking the hydraulic oil level, screw the screwed lid hand-tight to the reservoir. Note
Only the oil level of the fully screwed in lid applies. Pay attention to the different appearances of Min
FABIA 2000
Chassis
and Max markings at oil dipstick of the screwed lid for the reservoir of TRW or KOYO.
For an empty power steering system fill with enough

hydraulic oil to reach the top marking -arrow B- or Max on the oil dipstick. Arrow A - bottom marking on screwed lid of TRW MIN - bottom marking on screwed lid of KOYO Caution! Observe the applicable safety instructions for disconnecting the battery with the jumper cable!
If necessary connect the battery with jumper cable. Install air filter, if removed Engine, Fuel Injection
Raise the vehicle until the front wheels are fully off the
ground.
Put the front wheels in straight ahead position. Open the screwed lid of the hydraulic oil reservoir. With the engine off turn the steering wheel 10 x from
stop to stop.
Inspecting the hydraulic oil level and if necessary top

up Chap. 48-22.
Loosely screw on the screwed lid of the hydraulic oil

reservoir, do not tighten.
Start engine and run for approx. 10 seconds. Switch off engine. Inspecting the hydraulic oil level and if necessary top
up Chap. 48-22.
Loosely screw on the screwed lid of the hydraulic oil

reservoir, do not tighten.
Repeat the following steps until the hydraulic oil level

no longer drops. The hydraulic oil level must reach the top marking.
Start the engine. Turn steering wheel 10 x from stop to stop. Switch off engine. Inspecting the hydraulic oil level and if necessary top
up Chap. 48-22. gate reservoir.
Screw the lid by hand onto the engine pump aggre-
48-23 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Note Possible residual air in the steering system will automatically escape during driving after approx. 1020 km.
Disconnect the jumper cable. If necessary re-install the air filter.

Only run through the following steps if the battery has been disconnected and the battery, battery tray and air filter have been removed.
Install the battery and battery tray Electrical System; Rep. Gr. 27.
Install air filter Engine, Fuel Injection; Rep. Gr. 24



Tightening torques: Pressure line to engine pump aggregate TRW Pressure line to engine pump aggregate KOYO Screwed lid on hydraulic oil reservoir Wheel bolts 30 Nm 29 Nm tightened by hand 120 Nm
Checking the power steering system for leaks

Check the power steering system for tightness after assembly work and in the event of hydraulic oil loss in the reservoir. Special tools, test and measuring equipment and auxiliary items required
or -V.A.G 1551/3C- Diagnostic cable -VAS 5051/5Aor -VAS 5051/6ANote

tain models the screwed lid with oil dipstick for checking and topping up the hydraulic oil is covered by the battery tray and battery. If this is the case remove the air filter, the battery tray and battery.
Edition 11.04 S00.5303.17.20
48-23 page 3
48
FABIA 2000
Chassis


Rep. Gr. 66. Caution! Observe the applicable safety instructions for disconnecting the battery with the jumper cable!
S48-0111
If necessary connect battery to jumper cable. Start engine, idling speed.

Note A 2nd mechanic is required to check the tightness of the pressure line, return line and the connections.
Turn the steering wheel in both directions up to the

stop and hold for maximum 510 seconds. This will build up the highest possible pressure.
Check the pressure line (expansion hose) and return

line (return hose) for tightness. If there are leaks replace the relevant line or hose.
Check all line and hose connections for correct position and tightness. In the event of leaks tighten the line or hose connections to the allowed tightening torques or replace the seal or line.
Checking the engine pump aggregate for tightness.

If there are leaks replace the engine pump aggregate.
Check the hydraulic oil reservoir for tightness.

If there are leaks replace the engine pump aggregate.
Inspecting the hydraulic oil level and if necessary top

up Chap. 48-22.
48-23 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Note
If there is a repeated loss of hydraulic oil from the en-
gine pump aggregate reservoir, and if the line or hose and its connections as well as the engine pump aggregate and its reservoir have been repeatedly thoroughly inspected, remove and inspect the power steering gear.
The checking of the power-steering gear is identical to
the steering gears of TRW and KOYO. The figure shows the power-steering gear of TRW.
2 3 3
S48-0285
Removing power steering gear Chap. 48-12. Remove gasket -1-. Open warm-type clamps -3-. Push back boots -2-. Check the input shaft gasket ring on the valve housing of the power steering gear -arrow A- for tightness.
Check gear rack gasket rings -arrow B- for leaks.

If hydraulic oil is visible in the steering gear housing and/ or in the boot, replace the power steering gear.
A B
S48-0152
If there is no hydraulic oil in the steering gear housing

and/or in the boot, secure the boot -2- with new warmtype clamp -3- Chap. 48-16.
Mount gasket -1- on the valve housing of the power

steering gear Chapter 48-12.
Installing power steering gear Chap. 48-12.

Note If there is no more hydraulic oil in the engine pump aggregate reservoir the engine pump aggregate may have run dry and may have been damaged.
2 3 3
S48-0285
Replace engine pump aggregate Chap. 48-20. If necessary disconnect the jumper cable. Install the front left wheelhouse liner Body Work;
Rep. Gr. 66.
Install noise insulation panel. Fit front wheel. If necessary install the battery and battery tray
Edition 11.04 S00.5303.17.20
48-23 page 5
48
System; Rep. Gr. 24 (petrol engines) or Rep. Gr. 23 (diesel engines). If the battery was removed:
FABIA 2000
Chassis

48-23 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-24 Power steering noises

Notes for eliminating the noises
A closed hydraulic system will always produce running noise. Noise is always produced when the steering is turned up to the end stops (this must only occur briefly). The increased pumping noise in the steering end stops (during parking manoeuvers) is system related and technically unavoidable. For noises that differ from the usual technically unavoidable operating noises take the following measures:
Checking the hydraulic oil level in the reservoir of the

engine pump aggregate Chap. 48-22. gregate Chap. 48-19.
Checking the feed pressure of the engine pump ag Check the connections of the pressure line (expansion hose) and return line (return hose) on the power steering gear as well as the engine pump aggregate (air in steering system).
Check routing of the pressure line (expansion hose)

and return line (return hose) (lines pinched or in contact with other vehicle parts)
Check attachment of the power steering gear to the

assembly carrier -arrows-.
If necessary tighten hexagon screws.

Check attachment of engine pump aggregate (TRW)
S48-0153
Check attachment of holder -2- with engine pump aggregate -1- to body -arrows-.
If necessary tighten hexagon screws.

For reasons of clarity the surrounding components are not shown in the following figures.
1
S48-0205
Edition 11.04 S00.5303.17.20
Power steering noises
48-24 page 1
48
Check attachment of holder -2- to engine pump aggregate -1- -arrows-. 3 - Encapsulation
FABIA 2000
Chassis
2 1
If necessary tighten hexagon nuts to the specified

tightening torques, while doing so counterhold rubber bearings. Note To test the rubber bearing for damage remove the engine pump aggregate with encapsulation and disassemble the holder.
Removing the engine pump aggregate Chap. 4820.
S48-0145
Check rubber bearing (3) -arrow- for damage (e.g.

tears, separation of the metal plates with threaded bores from the rubber bearing).
In case of damage replace rubber bearing Chap.

48-20.
Check attachment of engine pump aggregate (KOYO)

For reasons of clarity the surrounding components are not shown in the following figures.
S48-0146
Check attachment of front holder -1- with engine

pump aggregate to body.
If necessary tighten the hexagon screw -arrow- to the

specified tightening torque.
S48-0273
48-24 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
1
Check attachment of rear holder -1- with engine pump

aggregate -2- to body.
If necessary tighten the hexagon screws -arrows- to

the specified tightening torque. 3 - Front bracket
2
Check attachment of bracket -1- and -3- at the engine
pump aggregate -2-.
S48-0274
If necessary tighten the fillister head screws -4- and

-5- to the specified tightening torque.
5
Note To test the rubber bearing for damage remove the engine pump aggregate -2- and disassemble the holder -1-.
S48-0286
Removing the engine pump aggregate Chap. 4820.
Remove holder -1- from the engine pump aggregate

-2-. The rubber bearing -3- can be checked on an installed holder -4-.
4 6
Check rubber bearing -3- and -6- for damage (e.g.

tears).
In case of rubber bearing, replace holder -1- or holder

-4- Chapter 48-20.
S48-0287
5 - Fillister head screws
Edition 11.04 S00.5303.17.20
48-24 page 3
48
Tightening torques:
Pipe screw for return-flow line to powersteering gear (TRW/KOYO) Hollow screw for pressure line to power steering gear (TRW)
FABIA 2000
Chassis
30 Nm 35 Nm
Hollow screw for pressure line to power steering gear (KOYO) Pipe screw for pressure line to engine pump aggregate (TRW) Pipe screw for pressure line to engine pump aggregate (KOYO) Holder with engine pump aggregate to body (TRW/KOYO)
Use new screws!
40 Nm 30 Nm 29 Nm 20 Nm + 90
Holder to engine pump aggregate (TRW/KOYO) Rubber bearing to engine pump aggregate (TRW) Power-steering gear to assembly carrier (TRW/KOYO)
Use new screws!
7 Nm 7 Nm 50 Nm + 90
48-24 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-25 Self-diagnosis on the power-assisted steering system

The power steering of TRW or KOYO can be checked with the self-diagnosis. Performing the self-diagnosis is identical on both steering systems. The self-diagnosis can be carried out:
using the vehicle system tester -V.A.G 1552-, or the
fault read-out scan tool -V.A.G 1551- 48-25 page 1 tion system -VAS 5051- 48-25 page 11.
or the vehicle diagnosis, measurement and informa-
The control unit and the hydraulic unit (eletric motor and gear pump) as well as the hydraulic oil reservoir form a single unit, the so-called engine pump aggregate, which cannot be disassembled. Only the reservoir for hydraulic oil is replaceable. The engine pump aggregate is located in the front left of the engine compartment between the bumper and the wheelhouse. Self-diagnosis is related to the electrical and electronic parts of the power-assisted steering. The control unit detects faults during the operation of the vehicle and stores them in a permanent memory, whose information is retained even if the battery voltage is disconnected. After the ignition is switched on servotronic warning light -K92- lights up. As soon as this starts an internal check cycle is completed 48-25 page 1. Before starting fault finding, always initiate self-diagnosis. If faults are stored, these can be displayed or be printed out with vehicle system tester -V.A.G 1552- or fault readout scan tool -V.A.G 1551- or the vehicle diagnosis, measurement and information system -VAS 5051-.
Indication of faults by means of warning light for Servotronic -K92If the servotronic warning light -K92- -arrow- does not go out after the ignition is switched on faults may be stored. I - Dash panel insert up to model year 2004 II - Dash panel insert as of model year 2005
Connect vehicle system tester -V.A.G 1552- or fault read-out scan tool -V.A.G 1551- and select functions.
vehicle system tester -V.A.G 1552- or fault read-out
II
scan tool -V.A.G 1551 Diagnostic cable -V.A.G 1551/3A, 3B oder 3C-
S48-0288
Edition 11.04 S00.5303.17.20
Self-diagnosis on the power-assisted steering system
48-25 page 1
48
Note
The description of the self-diagnosis only relates to
FABIA 2000
Chassis
vehicle system tester -V.A.G 1552- using the current program card.
The use of fault reader -V.A.G 1551- with integrated
printer is similar. A minor deviation on the display read-out is possible. Test conditions
Fuses must be OK in compliance with the current flow

diagram.
Battery voltage at least 11.5 volts All electrical components must be switched off
The diagnostic connection is located on the left next to the storage compartment on the driver's side.
V.A.G 1552 V.A.G 1551/3

S01-0087
Unclip cover and remove downward. Connect vehicle system tester -V.A.G 1552- or fault
read-out scan tool -V.A.G 1551- with appropriate cable.
Switch on ignition.
Readout on display: Note If there is no readout on the display: Operating instructions of the vehicle system tester
Enter address word

Readout on display:
4 4 for power-assisted steering and confirm the entry with Q . 6Q0423156 Power steering Coding 00110 0001 -> WSC XXXXX
6Q0423156 : Version number of the control unit Power-assisted steering: System denomination 0001: Software version number Coding 00110: Coding of the control unit WSC XXXXX : Workshop code
Press
. Vehicle system test The control unit does not respond HELP
If one of the following messages appears in the display, carry out fault finding as stated in the fault finding programme in the diagnostic cable Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. or or
Vehicle system test Fault in communication build-up Vehicle system test K cable does not connect to earth
HELP
HELP
or
Vehicle system test HELP K cable does not connect to pos. term.
Overview of the selectable functions on the Vehicle system tester -V.A.G 155201 - Interrogating control unit version 48-25 page 1
48-25 page 2
Edition 11.04 S00.5303.17.20
FABIA 2000 02 05 06 07 08 -
Chassis
48
Interrogating fault memory 48-25 page 3 Erasing fault memory 48-25 page 3 Ending output Coding control unit 48-25 page 8 Reading measured value block 48-25 page 9
Interrogating and erasing fault memory

Interrogating fault memory
Readout on display:
Enter function
0 2 Interrogate fault memory and X faults detected!
confirm entry with Q . The number of faults stored appears on the display. The stored faults are displayed in sequence.
Find the fault displayed in the fault table 48-25

page 5 and rectify fault. If No fault detected is shown in the display and if the key is pressed, the programme returns to the initial position. Readout on display:
No fault detected ->
Vehicle system test Select function XX
HELP

Note The contents of the fault memory are output automatically after the fault memory is erased. If it is not possible to erase the fault memory, interrogate the fault memory once again and rectify any faults. Requirements
Fault memory was interrogated 48-25 page 3. All faults were rectified. Select function
firm with Q . Readout on display: The fault memory is now erased.
Vehicle system test Fault memory erased! -> 0 5 Erase fault memory and con-
Press
Readout on display:
Select function
Q.
0 6 End output and confirm with
Automatic test sequence

During testing and installation other control units may also detect faults, e.g. pulled-out connectors or CAN databus faults. This is why, when the work is concluded,
Edition 11.04 S00.5303.17.20
48-25 page 3
48
that it is necessary to interrogate and erase the fault memory on all control units.
FABIA 2000
Chassis
Select function
0 0 Automatic test sequence and
confirm with Q . The vehicle system tester -V.A.G 1552- sends all known address words in sequence. When a control unit answers with its identification, the fault memory of the relevant system is also read out. Any faults stored for one of the systems are displayed in sequence. The -V.A.G 1552- then transmits the next address word. The automatic test sequence has ended when the following read-out appears on the display:
Erase the fault memory and then carry out a test drive. Once again interrogate the fault memory of all the
control units using the automatic test sequence. If no fault is stored:
Press
Readout on display:
Select function
Q.
Switch off ignition.
48-25 page 4
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Fault table
Note
All the possible faults which can be detected by the dash panel insert and can be displayed by -V.A.G 1552- are
listed below according to the 5-digit fault code.

Do not take any notice of the SAE code to the right of the fault code or the fault index (e.g. 136). Before replacing components found to be defective first check the wiring and plug connections to these compo-
nents as well as the earth cables according to the current flow diagram.
After repair always interrogate the fault memory using vehicle system tester -V.A.G 1552- and erase the memory. All static and sporadic faults are stored in the fault memory. A fault is detected as static if it exists for at least 2
seconds. If the fault is then no longer present, it is stored as a sporadic (temporary) fault. /SP appears on the right of the display.
After switching on the ignition, all the faults which exist are set to sporadic and are not stored as static faults unless
they continue to exist after completing the check.

If a sporadic fault no longer occurs during 50 driving cycles (ignition on for at least 5 minutes, road speed > 30 km/
h), it is erased. Readout on -V.A.G 155200566 Power steering operation Implausible signal Possible cause of fault
The motor pump
Possible effects
Power steering discon-
Rectifying fault
Analyse measured
value block 001 display field 1 48-25 page 9
assembly is defect
Fault terminal 30
nects
Replace the motor

pump assembly
Electrical test
00816 Power steering sensor -G250 Short circuit to earth
Short circuit to The power-assisted
Chapter 48-26. value block 002 48-25 page 9
Analysing measured Test wiring Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations
earth in the line connection from the power steering sensor to the control unit
Sensor for power
steering is operating in emergency mode

Steering requires
greater effort
The control lamp on
steering defective 00816 Power steering sensor -G250 Open circuit/ Short circuit to positive
Short circuit to
the servotronic -K92- is lit up

The power-assisted
Replace sensor Analysing measured

value block 002 48-25 page 9
pos. in the line connection from the power steering sensor to the control unit
Line interruption Sensor for power

Steering requires
greater effort
The control lamp on
Test wiring Current


The power-assisted
steering defective 00816 Power steering sensor -G250 defective

Sensor for power

steering defective

Steering requires
greater effort
The control lamp on
Replace sensor
Edition 11.04 S00.5303.17.20
48-25 page 5
48
Readout on -V.A.G 155200817 Power steering temperature protection 01288 Terminal 30 power steering Signal too high Signal too low Possible cause of fault draulic system too high Possible effects
FABIA 2000 Rectifying fault
Chassis
Temperature in hy- Steering requires
Allow temperature to
drop
greater effort
nects
Alternator not reg Steering requires
Analysing measured
Analysing measured
ulating voltage
Battery dis-
greater effort
charged/excessively charged
nects
The control lamp on
Check battery
Electrical System; Rep. Gr. 27. Electrical System; Rep. Gr. 27. connections according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test alternator
Check wiring and plug
01289 Terminal 15 power steering Signal too low
Loose contact
Steering requires
Analysing measured
greater effort
nects
Test wiring Current

01290 Power steering reference voltage Short circuit to positive
Short circuit to
The power-assisted
Analysing measured
pos. in the line connection from the power steering sensor to the control unit
Sensor defective

Steering requires
greater effort
Test wiring Current

01290 Power steering reference voltage Short circuit to earth
Short circuit to
The power-assisted

earth in the line connection from the power steering sensor to the control unit
Sensor defective

Steering requires
greater effort
Test wiring Current

01309 Power steering control unit J500 defective
Power steering
Steering requires
Replace sensor Replace the motor

pump assembly
control unit defective
greater effort
nects
48-25 page 6
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis Possible cause of fault

Data bus cables
48
Possible effects
Readout on -V.A.G 155201312 Data bus drive defective
Rectifying fault
Check data bus
defect
a connected con-
nects
Steering requires
Chapter 48-27
trol unit is faulty 01314 Engine control unit No communication

Data bus cables
greater effort
The power-assisted
Check data bus
defect
Engine control unit
defective
steering is operating in emergency mode or does not operate at all

Steering requires
Chapter 48-27 ory of engine control unit Engine, Fuel Injection; Rep. Gr. 01.
Interrogate fault mem-
greater effort 01314 Engine control unit please read out fault memory
Data bus cables The power-assisted
Check data bus
defect
Engine control unit
defective
steering is operating in emergency mode or does not operate at all

Steering requires
Chapter 48-27 ory of engine control unit Engine, Fuel Injection; Rep. Gr. 01.
greater effort 01317 Control unit with display in dash panel insert J285 No communication
Check data bus
defect
Dash panel insert

Steering requires
Chapter 48-27 ory of dash panel insert Electrical System; Rep. Gr. 90
defective
greater effort
The control lamp on
the servotronic -K92- is lit up 01317 Control unit with display in dash panel insert J285 01321 Airbag control unit -J234 No communication please read out fault memory
Check data bus
defect
Dash panel insert

Steering requires
Chapter 48-27 ory of dash panel insert Electrical System; Rep. Gr. 90
defective
greater effort
Data bus cables
Check data bus
defect
Airbag control unit
Chapter 48-27 memory of the airbag control unit Body Work; Rep. Gr. 01
defective
Interrogate the fault
01321 Airbag control unit -J234 please read out fault memory
Data bus cables
Check data bus
defect
Airbag control unit
Chapter 48-27 memory of the airbag control unit Body Work; Rep. Gr. 01
defective
Interrogate the fault
01656 Crash signal
Airbag control unit

48-25 page 3
-J234- has triggered airbags

Final control diag-
nects
nosis Airbag control unit -J234completed
Edition 11.04 S00.5303.17.20
48-25 page 7
48
Readout on -V.A.G 155201656 Crash signal Implausible signal Possible cause of fault
Crash signal of
FABIA 2000 Possible effects

Chassis
Rectifying fault

48-25 page 3
airbag control unit -J234- N.O.K.

Data bus cables
nects
Check data bus
defect
Control units on
Chapter 48-27 Body Work; Rep. Gr. 01; Self-diagnosis airbag system
Test crash signal
the data bus are incorrectly coded
Coding control unit

Connect up the vehicle system tester -V.A.G 1552and select power-assisted steering (address word 44) 48-25 page 1. Readout on display:
Enter function
firm with Q .
0 7 code the control unit and conCode control unit Enter code number XXXXX HELP (0-32000)
Readout on display:

confirm with
Q.
Table of codes 48-25 page 8
Table of codes Power steering control unit -J500Caution! Recoding of the control unit for the power-assisted steering at the customer's request can only be undertaken in compliance with the table of codes. Other assignments are not allowed. Note The weight PR numbers for the front axle/engine can be found on the vehicle data sticker. The vehicle data sticker is located on the luggage compartment floor and in the Service Schedule. Table of codes (up to 04/2001) Shock absorber PR number J06, J07, J08, J13, J14, J15, J20, J21, J22 Selectable coding1) 00110 00130 00160 00140 00150 00160
J01, J02, J03, J04, J05, J09, J10, J11, J12, J16, J17, J18, J19, J23, J24, J25, J26
1)
Coding at customer's request
48-25 page 8
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Table of codes (up to 05/2001) Shock absorber + power steering + airbags PR. number L05 (L06, L07, L08, L19, L20, L21, L32, L33) + 1N2 + 4UC (4UE, 4UF) L09 (L11, L12, L13, L14, L26, L35) + 1N2 + 4UC (4UE, 4UF) L01 (L02, L03, L04, L15, L16, L17, L18) + 1N2 + 4UC (4UE, 4UF) 1N5 + 4UC (4UE, 4UF) L05 (L06, L07, L08, L19, L20, L21, L32, L33) + 1N2 + 4UA L09 (L11, L12, L13, L14, L26, L35) + 1N2 + 4UA L01 (L02, L03, L04, L15, L16, L17, L18) + 1N2 + 4UA 1N5 + 4UA 00110 00120 00140 00160 Selectable coding without airbag with airbag 10110 10120 10140 10160
The meaning of the code numbers

Code number: 00110 101101) 00120 101201) 00130 101301) 00140 101401) 00150 101501) 00160 101601)
1)
Meaning Normal power steering for heavy vehicles Normal power steering for heavy vehicles Sport steering RS Sport steering RS Convenience - greater power steering at low driving speeds (e.g. when parking) for heavy vehicles (has not been used before) Convenience - greater power steering at low driving speeds (e.g. when parking) for heavy vehicles (has not been used before) Normal power steering for light vehicles Normal power steering for light vehicles Convenience - greater power steering at low driving speeds (e.g. when parking) for light vehicles (has not been used before) Convenience - greater power steering at low driving speeds (e.g. when parking) for light vehicles (has not been used before) Handicap - greater power steering for vehicles for the handicapped Handicap - greater power steering for vehicles for the handicapped
These code numbers cannot be entered in old software versions of the control unit.
The control unit coding appears in the display, (e.g. 00110)
6Q0423156 Power steering Coding 00110
0001 -> WSC XXXXX
Press
Readout on display:
Select function
Q.
Reading measured value block

Connect up the vehicle system tester-V.A.G 1552and select power-assisted steering (address word 44) 48-25 page 1.
Edition 11.04 S00.5303.17.20
48-25 page 9
48
Readout on display:
Vehicle system test Select function XX
FABIA 2000
Chassis
HELP
Enter function
0 8 Read measured value block
and confirm the entry with key Q . Readout on display:

Read measured value block Enter display group number HELP XXX
Enter display group 48-25 page 10.

List of display groups
Measured value block 001
Reading measured value block 1 12.3 V 0.0 A 27 C
off
Readout on display: Pump motor

off on
Temperature on the control unit for the power-assisted steering Pump motor current Voltage terminal 30
Reading measured value block 2 0.0 /s 0 rpm 0 rpm
0.0 A
Readout on display: Pump motor current
Actual speed pump motor Nominal speed pump motor Angular speed on power steering sensor
48-25 page 10
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
Reading measured value block 3 0 km/h 0 rpm off
yes
Readout on display: Power steering sensor G250

yes no
Pump motor
off on
Vehicle engine speed Vehicle speed
Reading measured value block 4 0h 2 correct
12.1 V
Readout on display: Voltage terminal 15
Sensor for power steering reference voltage

too small correct too great
Engaging counter of power steering Engaging duration of the power steering in hours
Connect vehicle diagnosis, measurement and information system -VAS 5051and select functions
Vehicle diagnosis, measurement and information sys-
tem -VAS 5051 Diagnostic cable -VAS 5051/5A- or Diagnostic cable
-VAS 5051/6A-
WARNING!
For test drives, test and measuring equipment
must always be fastened to the rear seat.

The equipment must be operated by an assist-
ant during test drives.
Mount the plug of the diagnostic cable - VAS 5051/

5A- or the diagnostic cable -VAS 5051/6A - on the di-
Edition 11.04 S00.5303.17.20
48-25 page 11
48
agnostic connection in the storage compartment on the driver's side.
FABIA 2000
Chassis
Switch on the vehicle diagnosis, measurement and information system -VAS 5051-. The vehicle diagnosis, measurement and information system -VAS 5051- is operational, if it shows the keyboards of its operating modes.
Switch on ignition. On the screen, select the Gefhrte Fehlersuche . Select the following one after the other:
Brand Type Model year Variant Engine identification characters
Confirm the data entered.

Wait until the vehicle diagnosis, measurement and information system -VAS 5051- has communicated with all the control units in the vehicle (vehicle system test).
Press the
Sprung and choose the Selected Functions/Components option.
Select on the display chassis. Select on the display steering. Select on the display the indicated 01-self-diagnosable system.
Select on the display the indicated electrical power

steering. Now all possible components and functions of the steering system in the vehicle are indicated.
Select on the display the desired component or the

desired function.
48-25 page 12
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-26 Electrical Test of Power Steering

Hand multimeter, e.g. -V.A.G 1526B Measuring tool set, e.g. -V.A.G 1594C-
2 1
Test conditions
Fuses according to current flow diagram O.K. Battery voltage at least 11.5 volts
Procedure
Remove the front left wheelhouse liner Body Work;

Rep. Gr. 66 Engine pump aggregate TRW
S48-0291
Unplug connectors -1- and -2-.

Engine pump aggregate KOYO
Unplug connectors -1- and -2-.

3 - Plug of power-assisted steering sensor -G250-, remains in position
3 2
S48-0271
Contact assignment (TRW or KOYO) Connector -1-: 1234Data BUS Low Data BUS High not yet assigned Terminal 15
1
1 2
Connector -2-: 1 - Terminal 30 2 - Earth
Switch on the ignition. Test with a hand-held multimeter and suitable test
prods from the measuring tool set: Contact assignment (TRW or KOYO) Connector -1between contact: 4 and earth Specified value: approx. battery voltage
S48-0151
Edition 11.04 S00.5303.17.20
Electrical Test of Power Steering
48-26 page 1
48
Connector -2between contact: 1 and 2 1 and earth Specified value: approx. battery voltage approx. battery voltage
FABIA 2000
Chassis
Switch off the ignition.
Resistance measurement (TRW or KOYO) Connector -1between contact: 4 and earth Specified value:
Connector -2between contact: 1 and earth 2 and earth 1 and 2 Specified value: approx. 0 approx. 60
If the specified values are not reached:
Test the wiring according to the current flow diagram

Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
48-26 page 2
Electrical Test of Power Steering
Edition 11.04 S00.5303.17.20
FABIA 2000
Chassis
48
48-27 Checking the data BUS

Operation
The control units that are compatible with the data bus are connected via two twisted data BUS cables (CAN_High and CAN_Low) and exchange information (messages). Both the power steering control unit -J500and the other data bus compatible control units detect missing information on the data BUS as faults. Other information: Self-study Programme No. 24; The CAN data bus Note The central terminating resistor of the data BUS cables is located in the engine control unit. The test will thus focus on the engine control unit. Special tools, test and measuring equipment and auxiliary items required
Hand multimeter, e.g. -V.A.G 1526 A Measuring tool set, e.g. -V.A.G 1594 A Test box -V.A.G 1598/31 Current flow diagram
Test condition
A data BUS fault was detected by the power steering
Test sequence
Switch off the ignition. Unlock the connector from the engine control unit and
unplug.
Connect the test box -V.A.G 1598/31- to the engine

control unit.The control unit wiring loom is not connected.
Connect the earth clip of the test box -arrow- to the

negative battery terminal.
Test the central terminating resistor in the engine control unit.
To this end perform a resistance measurement be-
tween the test box bushes Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Nominal value: 6072
V.A.G 1598/31
S24-0380
If the resistance is not within the nominal value range:
Replace the engine control unit Chap. 24-8.

If the resistance is within the nominal value range:
Unplug the test box -V.A.G 1598/31- from the engine

control unit.
Edition 12.99 S00.5303.01.20 Checking the data BUS
48-27 page 1
48
Connect the test box -V.A.G 1598/31- to the wiring
loom control unit. Connect the earth clip of the test box -arrow- to the negative battery terminal.
FABIA 2000
Chassis
Test the data BUS cables for short-circuits. To this end perform a resistance measurement be-
tween the test box bushes Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Nominal value:
If the nominal value is reached (there is no short-circuit between the cables):
V.A.G 1598/31
S24-0380
Test the data BUS cables for a short-circuit to the positive battery terminal or earth or for interruption Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
48-27 page 2
Checking the data BUS
Edition 12.99 S00.5303.01.20
FABIA 2000
Chassis
48
48-28 Electric/Electronic components and fitting locations

1 - Servotronic warning light -K92Fitting location: in the dash 3 4 panel insert Operation: 1 The servotronic warning light lights up until the engine starts if it does not go out, faults 2 may have been stored 1 Perform self-diagnosis Chap. 48-25 2 - Dash panel insert up to model year 2004 3 - Dash panel insert as of model 12 year 2005 4 - Diagnostic connection Fitting location: in the storage area on the driver's side 5 5 - The power-steering sensor -G250- (KOYO) Fitting location: in the valve 11 dome of the power-steering 10 gear Operation: Determining the steeringwheel angle and calculating 6 the steering angle speed if the sensor fails the power 7 steering switches to pro9 grammed emergency opera8 tion, the steering function is S48-0263 guaranteed, but the steering effort becomes greater Malfunctions of the sensor are stored in the power steering control unit -J500Perform self-diagnosis Chap. 48-25 removing and installing Chapter 48-13 assignment Spare part catalogue 6 - Inspecting the power-assisted steering sensor -G250- (TRW) with fixed connecting line Fitting location: in the valve dome of the power-steering gear Operation: Determining the steering-wheel angle and calculating the steering angle speed if the sensor fails the power steering switches to programmed emergency operation, the steering function is guaranteed, but the steering effort becomes greater Malfunctions of the sensor are stored in the power steering control unit -J500Perform self-diagnosis Chap. 48-25 removing and installing Chapter 48-13 assignment Spare part catalogue 7 - Inspecting the power-assisted steering sensor -G250- (TRW) with adapter cable Fitting location: in the valve dome of the power-steering gear Operation:
0
Edition 11.04 S00.5303.17.20
Electric/Electronic components and fitting locations
48-28 page 1
48
FABIA 2000
Chassis
Determining the steering-wheel angle and calculating the steering angle speed if the sensor fails the power steering switches to programmed emergency operation, the steering function is
guaranteed, but the steering effort becomes greater

Malfunctions of the sensor are stored in the power steering control unit -J500-
89-
10 11 -
12 -
Perform self-diagnosis Chap. 48-25 removing and installing Chapter 48-13 assignment Spare part catalogue Adapter cable for power-steering sensor -G250- item 7 Power-assisted steering control unit -J500Fitting location: integrated in the engine pump aggregate item 10 Operation: To convert the signals for driving the gear pump in function of the steering angle speed and the vehicle speed. Re-engaging protection after faults Temperature protection for power steering detects faults during operation and stores them in a permanent memory Perform self-diagnosis Chap. 48-25 Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate Chap. 48-20 Engine pump aggregate (TRW) removing and installing Chapter 48-20 Power-assisted steering control unit -J500Fitting location: integrated in the engine pump aggregate item 12 Operation: To convert the signals for driving the gear pump in function of the steering angle speed and the vehicle speed. Re-engaging protection after faults Temperature protection for power steering detects faults during operation and stores them in a permanent memory Perform self-diagnosis Chap. 48-25 Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate Chap. 48-20 Engine pump aggregate (KOYO) removing and installing Chapter 48-20
48-28 page 2
Electric/Electronic components and fitting locations
Edition 11.04 S00.5303.17.20

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Service

Service Department. Technical Information

Printed in Czech Republic S00.5303.00.20

Printed in Czech Republic S00.5303.00.20

List of Supplements to Workshop Manual

Edition 04.05 S00.5303.18.20

Edition 04.05 S00.5303.18.20

40 Front wheel suspension

Edition 04.05 S00.5303.18.20

42 Rear wheel suspension

44 Wheels, Tyres, Chassis Alignment

Edition 04.05 S00.5303.18.20

Chassis page page page page page page 4 5 5 5 6 7

45 Anti-Lock Brake System

................................................... 45-10 page

Edition 04.05 S00.5303.18.20

Edition 04.05 S00.5303.18.20

46 Brakes, Brake mechanics

page 10 page 12 page page page page page page page 1 1 3 4 6 8 9

47 Brake, Brake Hydraulics

Edition 04.05 S00.5303.18.20

Edition 04.05 S00.5303.18.20

- Disposing of the engine pump aggregate .......................................................... 48-20 page 10

Edition 04.05 S00.5303.18.20

Edition 04.05 S00.5303.18.20

Nominal values front axle

Sport chassis G04

Edition 04.05 S00.5303.18.20

26' 10' ---1 33' 10' 4) -1 30' 10' 6) 30' 20'

up to 05.01 from 06.01 up to 12.02 up to 08.03 as of 01.03 from 09.03

Vehicle data sticker and PR number

Edition 04.05 S00.5303.18.20

ion torque = 0.8...1.3 Nm

Hydraulic oil amount (l):

Edition 04.04 S00.5303.15.20

Edition 04.04 S00.5303.15.20

Brake variants and their assignment

1,0/37 ARV, AQV S S

1,2/40 AWY, BMD 20,64 S -

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

Edition 04.05 S00.5303.18.20

1,4/44 AZE, AZF 20,64 S -

1,4/50 AME, ATZ, AQW S -

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

Edition 04.05 S00.5303.18.20

38,0 232,0 196,0 9,0 7,0 16,9 2,0

38,0 232,0 196,0 9,0 7,0 16,9 2,0

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

200,0 201,0 19,05 40,0 5,4 1,5

Edition 04.05 S00.5303.18.20

1.9/74 TDI PD ATD S -

1.9/96 TDI PD ASZ S -

1.4/55 TDI PD AMF S -

38,0 232,0 196,0 9,0 7,0 16,9 2,0

38,0 232,0 196,0 9,0 7,0 16,9 2,0