Mecanica PDF

5
Service
Workshop Manual
FABIA 2000
Chassis
Edition 08.99
Service Department. Technical Information
Printed in Czech Republic

S00.5303.00.20
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.
Service
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
Subject
Article Number
08.99
Basic Edition
S00.5303.00.20
12.99
Supplement to Basic Edition
S00.5303.01.20
05.00
Axles, brakes, electrical inspection ABS, ABS/EDL/TCS
S00.5303.02.20
07.00
Steering
S00.5303.03.20
08.00
ABS, Brake mechanics, Brake hydraulics
S00.5303.04.20
11.00
Repairing the front axle, repairing the wheel bearing
S00.5303.05.20
01.01
Repairing front suspension strut, repairing drive shafts
S00.5303.06.20
02.01
Removing and installing rear axle and coil spring
S00.5303.07.20
03.01
Chassis with Brakes FS-II and C54-II
S00.5303.08.20
08.01
ESP and Rep.-Gr. 48, solid nut (twelve point nut), brakepressure reducer
S00.5303.09.20
10
11.01
Geometrical change
S00.5303.10.20
11
03.02
Changes to the text in Rep. Gr. 00, 40, 42, 46 and 48
S00.5303.11.20
12
10.02
Brake pedal switch, control unit for the ABS (fault table, coding)
S00.5303.12.20
13
02.03
1.2 ltr./47 kW Engine, Supplement to the text
S00.5303.13.20
14
07.03
1.9 ltr./96 kW TDI PD Motor, 1.4 ltr./55 kW TDI PD Engine,

Supplement to the text
S00.5303.14.20
15
04.04
Steering KOYO, Correction of the text, Updating of the steering

coding
S00.5303.15.20
16
07.04
Supplement to Rep. Gr. 40, 44, 45, 46 and 47, ABS BOSCH 8.0
S00.5303.16.20
17
11.04
Supplement to Rep. - Gr. 45 and 48 TRW/KOYO steering
S00.5303.17.20
18
04.05
Text adaptation, Supplement to the coding of ABS, TCS, ESP
S00.5303.18.20
Edition 04.05
S00.5303.18.20
Edition
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
page
- Nominal values front axle ............................................................................ 00-1
page
- Nominal values rear axle ............................................................................. 00-1
page
- Vehicle data sticker and PR number ............................................................... 00-1
page
Steering ................................................................................................... 00-2
page
Brakes ..................................................................................................... 00-3
page
- Brake variants and their assignment ............................................................... 00-3
page
- Adjusting values for the load-dependent regulator ............................................... 00-3
page
- Pressure value of the distributor valve ............................................................. 00-3
page
- Brake fluid .............................................................................................. 00-3
page
Wheels, Tyres ........................................................................................... 00-4
page
- Possible wheel-tyre combinations .................................................................. 00-4
page
- Tyre legend ............................................................................................. 00-4
page
Repairing front axle .................................................................................... 40-1
page
- An overview of the front axle ........................................................................ 40-1
page
- I - Summary of components assembly carrier, console, axle link, anti-roll bar, coupling rod,
bracket, pendulum support ........................................................................... 40-1
page
- Inspecting the steering joint .......................................................................... 40-1
page
- Removing and installing the steering joint ......................................................... 40-1
page
- Release the assembly carrier and tighten (fix) .................................................... 40-1
page
- Removing and installing the track control arm .................................................... 40-1
page
- Removing and installing the console ............................................................... 40-1
page 10
- Disconnecting and assembling the track control arm and console ............................ 40-1
page 13
- Replacing the bonded rubber bush for track control arm ........................................ 40-1
page 13
- Replacing the bonded rubber bush for console - removal version 1 .......................... 40-1
page 13
- Replacing the bonded rubber bush for console - removal version 2 .......................... 40-1
page 15
- Removing and installing the anti-roll bar ........................................................... 40-1
page 17
- Removing and installing assembly carrier ......................................................... 40-1
page 19
Repairing front suspension strut ................................................................... 40-2
page
- II - Summary of components of suspension strut ................................................. 40-2
page
- Removing and installing the suspension strut .................................................... 40-2
page
- Repairing the suspension strut ...................................................................... 40-2
page
- Inspecting the shock absorber ...................................................................... 40-2
page
- Disposing of the shock absorber .................................................................... 40-2
page
Repairing the wheel bearing ......................................................................... 40-3
page
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FSIII ......................................................................................................... 40-3
page
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake FSII .......................................................................................................... 40-3
page
- III - Summary of components of the wheel bearing, suspension strut, drive shaft, brake C54II .......................................................................................................... 40-3
page
- Removing and installing wheel bearing housing .................................................. 40-3
page
40 Front wheel suspension
Edition 04.05
S00.5303.18.20
Table of Contents
FABIA 2000 Chassis

- Removing and installing the wheel hub with wheel bearing with the wheel-bearing housing
fitted ..................................................................................................... 40-3
page 10
Drive shafts with CV joints ........................................................................... 40-4
page
- Removing and installing a drive shaft .............................................................. 40-4
page
- Summary of components of drive shaft with CV joint ............................................ 40-4
page
- Repairing drive shaft with CV joint .................................................................. 40-4
page
- Inspecting a CV joint .................................................................................. 40-4
page
Drive shafts with tripod joint ........................................................................ 40-5
page
- Removing and installing a drive shaft .............................................................. 40-5
page
- V - Summary of components of drive shaft with AAR2000 tripod joint ........................ 40-5
page
- Inspecting outer CV joint ............................................................................. 40-5
page
- Repairing the drive shaft with AAR 2000 tripod joint ............................................. 40-5
page
- Removing and installing the outer CV joint ........................................................ 40-5
page
Rear axle with drum brake ........................................................................... 42-1
page
- Summary of components of rear axle .............................................................. 42-1
page
- Removing and installing rear suspension ......................................................... 42-1
page
Servicing the rear axle with drum brakes ........................................................ 42-2
page
- Removing and installing coil spring ................................................................. 42-2
page
- Removing and installing shock absorber .......................................................... 42-2
page
- Disassembling and assembling shock absorber ................................................. 42-2
page
- Inspecting the shock absorber ...................................................................... 42-2
page
- Disposing of the shock absorber .................................................................... 42-2
page
- removing and installing rubber-metal bearing .................................................... 42-2
page
Rear suspension with disc brake ................................................................... 42-3
page
- Summary of components of rear suspension ..................................................... 42-3
page
- Removing and installing rear suspension ......................................................... 42-3
page
Servicing rear suspension with disc brake ...................................................... 42-4
page
Repairing the wheel bearing ......................................................................... 42-5
page
- Summary of components of wheel bearing - drum brake ....................................... 42-5
page
- Removing and installing the wheel hub with wheel bearing - drum brake .................... 42-5
page
- Summary of components of wheel bearing - disc brake ........................................ 42-5
page
- Removing and installing the wheel hub with wheel bearing - disc brake .................... 42-5
page
- Removing and installing axle studs ................................................................. 42-5
page
Wheels, Tyres ........................................................................................... 44-1
page
- General points ......................................................................................... 44-1
page
- Disc wheel .............................................................................................. 44-1
page
- Light-alloy wheel ....................................................................................... 44-1
page
Vehicle alignment ...................................................................................... 44-2
page
- General points ......................................................................................... 44-2
page
- Test requirements ..................................................................................... 44-2
page
- Measurement preliminaries .......................................................................... 44-2
page
- Chassis terms .......................................................................................... 44-2
page
- Nominal values for vehicle alignment .............................................................. 44-2
page
- Checking the transversal inclination of the vehicle ............................................... 44-2
page
42 Rear wheel suspension
44 Wheels, Tyres, Chassis Alignment
II
Table of Contents
Edition 04.05
S00.5303.18.20
FABIA 2000 Chassis

- Checking the camber on the front axle, if necessary take the mean .......................... 44-2
- Checking the camber on the rear axle ............................................................. 44-2
page
page
4
5
- Checking the track on the rear axle ................................................................ 44-2
page
- Checking the tracking on the front axle, adjusting if necessary ................................ 44-2
page
- Checking the left and right steering angle ......................................................... 44-2
page
- Calculation of the misalignment on the rear axle ................................................. 44-2
page
Antilock braking system (ABS) ..................................................................... 45-1
page
- Safety precautions, basic information on fault finding and on repairing ...................... 45-1
page
........................................ 45-1
page
- Required technical information ...................................................................... 45-1
page
Distinguishing features of the ABS system ...................................................... 45-2
page
- General Instructions ................................................................................... 45-2
page
- Distinguishing features ............................................................................... 45-2
page
- Fitting position of the ABS systems BOSCH 5.7 and BOSCH 8.0 ............................. 45-2
page
Function of Self-diagnosis ........................................................................... 45-3
page
- General Instructions ................................................................................... 45-3
page
- Vehicle fitted with ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 does not have an EDL
function .................................................................................................. 45-3
page
Vehicle diagnosis, measurement and information system -VAS 5051- .................... 45-4
page
- Connect vehicle diagnosis, measurement and information system -VAS 5051- and select
functions (ABS systems BOSCH 5.7 and BOSCH 8.0) ......................................... 45-4
page
45 Anti-Lock Brake System
- Instructions for repair work on Antilock braking system
Performing Self-diagnosis - ABS systems BOSCH 5.7 and BOSCH 8.0 ................... 45-5
page
- Test requirements ..................................................................................... 45-5
page
- Connecting vehicle system tester -V.A.G 1552- and selecting function ...................... 45-5
page
- Interrogating control unit version .................................................................... 45-5
page
- Overview of selectable functions .................................................................... 45-5
page
- Interrogating fault memory ........................................................................... 45-5
page
- Erasing fault memory ................................................................................. 45-5
page
- Ending output .......................................................................................... 45-5
page
- Automatic test sequence ............................................................................. 45-5
page
Fault table - ABS systems BOSCH 5.7 ............................................................ 45-6
page
Fault table - ABS systems BOSCH 8.0 ............................................................ 45-7
page
Code control unit - ABS systems BOSCH 5.7 ................................................... 45-8
page
- Table of codes ......................................................................................... 45-8
page
Code control unit - ABS BOSCH 8.0 .............................................................. 45-9
page
- Table of codes ......................................................................................... 45-9
page
................................................... 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
Reading measured value block - BOSCH 5.7
Edition 04.05
S00.5303.18.20
Table of Contents
III
FABIA 2000 Chassis

- 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
1
3
- 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
- Removing and installing brake pressure sender 1 -G201- - vehicles with ABS/EDL/TCS/
ESP BOSCH 5.7 ...................................................................................... 45-17 page 10
IV
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
Table of Contents
Edition 04.05
S00.5303.18.20
FABIA 2000 Chassis

- 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
8
9
46 Brakes, Brake mechanics

Repairing the front wheel brake .................................................................... 46-1
page
- Repairing front brake, the floating caliper disc brake FS-III ..................................... 46-1
page
- Removing and installing brake pads - Floating caliper disc brake FS-III ..................... 46-1
page
- Repairing front brake, the floating caliper disc brake FS-III ..................................... 46-1
page
- Removing and installing brake pads - Floating caliper disc brake FS-II ...................... 46-1
page
- Repairing the front brake - the floating caliper disc brake C54-II .............................. 46-1
page 10
- Removing and installing brake pads - the floating caliper disc brake C54-II ................. 46-1
page 12
Repairing a rear brake ................................................................................. 46-2
page
- Removing and installing rear brake - Drum brake ................................................ 46-2
page
- Resetting brake ........................................................................................ 46-2
page
- Repairing rear brake - drum brake .................................................................. 46-2
page
- Removing and installing brake shoe - Drum brake ............................................... 46-2
page
- Setting the hand-brake - drum brake ............................................................... 46-2
page
- Removing and installing rear brake - Disc brake ................................................. 46-2
page
- Removing and installing brake pads - Disc brake ................................................ 46-2
page 10
- Setting the hand-brake - disc brake ................................................................ 46-2
page 13
Handbrake ............................................................................................... 46-3
page
- Summary of components of hand brake ........................................................... 46-3
page
- Removing and installing the hand-brake cable ................................................... 46-3
page
Foot Controls, Brake Pedal .......................................................................... 46-4
page
- Summary of Components of Foot Controls, Brake Pedal ....................................... 46-4
page
- Separating the brake pedal from the brake servo unit and clipping onto brake servo unit . 46-4
page
- Removing and installing the foot controls .......................................................... 46-4
page
- Removing and installing brake pedal ............................................................... 46-4
page
Repairing the brake caliper .......................................................................... 47-1
page
- Summary of Components of Brake Caliper FS-III ................................................ 47-1
page
- Removing and installing piston of brake caliper FS-III ........................................... 47-1
page
- Summary of Components of Brake Caliper FS-II ................................................. 47-1
page
- Removing and installing piston of brake caliper FS-II ........................................... 47-1
page
- Summary of components of brake caliper C54-II ................................................. 47-1
page
- Removing and installing piston of brake caliper C54-II .......................................... 47-1
page
- Summary of components of rear brake caliper ................................................... 47-1
page
- Removing and installing the rear brake caliper piston ........................................... 47-1
page
Brake Servo Unit, Master Brake Cylinder ......................................................... 47-2
page
- Summary of Components of Brake Servo Unit, Master Brake Cylinder ...................... 47-2
page
- Checking the master brake cylinder for tightness ................................................ 47-2
page
- Removing and installing the master brake cylinder .............................................. 47-2
page
- Removing and installing brake servo unit .......................................................... 47-2
page
- Removing and installing the vacuum pump for the brake servo unit .......................... 47-2
page
- Removing and installing tandem pump for fuel and vacuum supply .......................... 47-2
page
Brake-power regulator, brake-pressure reducer ................................................ 47-3
page
47 Brake, Brake Hydraulics
Edition 04.05
S00.5303.18.20
Table of Contents
FABIA 2000 Chassis

- Summary of Components of Brake-Power Regulator ........................................... 47-3
- Inspecting and adjusting the brake-power regulator ............................................. 47-3
page
page
1
2
- Removing and installing brake-power regulator .................................................. 47-3
page
- Inspecting the brake-pressure reducer ............................................................ 47-3
page
- Removing and installing the brake-pressure reducer ............................................ 47-3
page
Bleeding Brake System ............................................................................... 47-4
page
- 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
page
- Bleeding the brake system of air using the brake filling and bleeding device, e. g.
-ROMESS S15- ........................................................................................ 47-4
page
- Bleeding the brake system of air without using the brake filling and bleeding device ...... 47-4
page
- Changing the brake fluid ............................................................................. 47-4
page
Steering column ........................................................................................ 48-1
page
- Summary of components ............................................................................ 48-1
page
Inspecting steering column .......................................................................... 48-2
page
- Optical inspection ..................................................................................... 48-2
page
- Functional test ......................................................................................... 48-2
page
Removing and installing steering column ....................................................... 48-3
page
- Removing the steering column ...................................................................... 48-3
page
- Installing the steering column ....................................................................... 48-3
page
Removing and installing ignition lock housing ................................................. 48-4
page
- Removing ignition lock housing ..................................................................... 48-4
page
- Installing ignition lock housing ....................................................................... 48-4
page
Frequency link, bracket ............................................................................... 48-5
page
- Removing and installing frequency link ............................................................ 48-5
page
- Removing and installing bracket .................................................................... 48-5
page
Steering without servo unit (mechanical steering) ............................................. 48-6
page
- Summary of components ............................................................................ 48-6
page
Removing and installing mechanical steering gear ............................................ 48-7
page
- Removing steering gear .............................................................................. 48-7
page
- Installing steering gear ............................................................................... 48-7
page
Inspecting and adjusting mechanical steering gear ........................................... 48-8
page
- Check the centre position of the gear rack of the steering gear, if necessary adjust ....... 48-8
page
- Adjusting the steering gear (adjusting the pressure plate clearance) ......................... 48-8
page
Disassembling and assembling the steering gear ............................................. 48-9
page
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
48 Steering
VI
Table of Contents
Edition 04.05
S00.5303.18.20
FABIA 2000 Chassis

- Removing the power-assisted steering drive ...................................................... 48-12 page
- Installing the power-assisted steering drive ....................................................... 48-12 page
2
6
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
- Disposing of the engine pump aggregate .......................................................... 48-20 page 10

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
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
VIII
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
Table of Contents
Edition 04.05
S00.5303.18.20
00
FABIA 2000 Chassis
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
Running gear/PR No.
Standard suspension
Sport chassis
Rough road suspension
1GA, 1GG
G01, G02, G05
G04
1GB
G03, G06
Explanations concerning this PR No. 00-1 page 2

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)
4)
5)
010' 10'
010' 10'
010' 10'
- 1 32' 20'
- 1 28' 20' 1)
- 55' 20' 2)
---
- 53' 20' 2)
6 50' 1)
6 45'
6 50' 1)
4 5' 2)
---
6 50' 2)
39 14' 1)
38 37'
39 34' 1)
36 59' 2)
---
39 34' 2)
-30' 30'4)
-39' 30'
-15' 30'
30'
30'
30'
4 28' 30' 1)
4 42' 30'
4 14' 30' 1)
2 55' 30' 2)
---
2 42' 30' 2)
30'
30'
30'
- 1 30' 20'
1)
-28' 30' 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
FABIA 2000 Chassis
Nominal values rear 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).
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.
20' 10' 1)
26' 10'
15' 10' 1)
21' 10' 2)
---
16' 10' 2)
-1 25' 10' 3)
-1 33' 10' 4)
-1 25' 10' 3)
-1 33' 10'5) 4)
-1 30' 10' 6)
-1 33' 10'5) 4)
Overall track -not adjustableCamber -not adjustable-
-1 30' 10' 6)
Max. difference between left and
right side
Max. misalignment of the rear axle
1)
2)
3)
4)
5)
6)
-1 30' 10' 6)
30'
30'
30'
20'
20'
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
00
FABIA 2000 Chassis
00-2
Steering
Steering system:
electro-hydraulic
(Electrically Powered Hydraulic
Steering - EPHS)
mechanical
Steering gear:
Rack pinion (input shaft)
Zahnstange - Ritzel (Eingangswelle)

Rack pinion (input shaft)
Steering-wheel turns from turning angle to the next:
2,91
Steering wheel diameter (mm):
370
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):
4,04
370
TMS-L-10.482
A0F 063 000 04 2)
SHELL STERAK
11,0 +5,0
40,0
0...0,08
0,04...0,09
1)
Displacement of the gear rack
---
40 mm: Axial force 200 N

over 40 mm up to the stop: Axial
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:
Hydraulic oil amount (l):

1)
2)
3)
1,0...3,5 3)
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
---
applies for TRW steering

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

Engine
litre/
kW
1,0/37
1,2/40
1,2/47
Engine code letters:
ARV, AQV
AWY, BMD
AZQ,BME
S = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
mm
Brake booster -
Inch
20,64
Left-hand drive with and without ABS:
Right-hand drive with and without ABS:
8,5
8,5
Front disc brake:
Front brake caliper (type denomination)
FS-II
FS-III
FS-II
FS-III
Front brake caliper, piston -
mm
48,0
54,0
48,0
54,0
Front brake disc -
mm
239,0
256,0
239,0
256,0
Brake disc - average effective di- mm

ameter
193,8
208,0
193,8
208,0
Brake disc, thickness
mm
18,0
22,0
18,0
22,0
Brake disc, minimum thickness
mm
15,0
19,0
15,0
19,0
Pad thickness with supporting

plate
mm
17,6
19,6
17,6
19,6
Minimum thickness without supporting plate
mm
2,0
2,0
2,0
2,0
Rear disc brake:
Rear brake caliper, piston -
mm
Rear brake disc -
mm
Rear brake disc - average effective diameter
mm
mm
mm

plate
mm
mm
Rear drum brake:
Brake drum -
mm
200,0
200,0
200,0
200,0
Brake drum - maximum diameter
mm
201,0
201,0
201,0
201,0
Wheel-brake cylinder -
mm
19,05
19,05
19,05
19,05
Brake pad, width
mm
40,0
40,0
40,0
40,0
Pad thickness without supporting shoe
mm
5,4
5,4
5,4
5,4
Minimum thickness without supporting shoe
mm
1,5
1,5
1,5
1,5
Edition 04.05
S00.5303.18.20
Brakes
00-3 page 1
00
Engine
FABIA 2000 Chassis
litre/
kW
1,2/47
1,4/44
1,4/50
AZQ,BME
AZE, AZF
AME, ATZ,
AQW
S = Manual gearbox
mm
Brake booster -
Inch
20,64
8,5
8,5
Front disc brake:
FS-II
FS-II
FS-III
FS-III
mm
48,0
48,0
54,0
54,0
Front brake disc -
mm
239,0
239,0
256,0
256,0
Brake disc - average effective di- mm

ameter
193,8
193,8
208,0
208,0
mm
18,0
18,0
22,0
22,0
mm
15,0
15,0
19,0
19,0

plate
mm
17,6
17,6
19,6
19,6
mm
2,0
2,0
2,0
2,0
Rear disc brake:
mm
Rear brake disc -
mm
mm
mm
mm

plate
mm
mm
Rear drum brake:
Brake drum -
mm
200,0
200,0
200,0
200,0
mm
201,0
201,0
201,0
201,0
mm
19,05
19,05
19,05
19,05
Brake pad, width
mm
40,0
40,0
40,0
40,0
Pad thickness without supporting shoe
mm
5,4
5,4
5,4
5,4
mm
1,5
1,5
1,5
1,5
00-3 page 2
Brakes
Edition 04.05
S00.5303.18.20
00
FABIA 2000 Chassis
Engine
litre/
kW

S = Manual gearbox
mm
Brake booster -
Inch
1,4/55
1,4/74
2,0/85
1.9/47 SDI
AUA, BBY,
BKY
AUB, BBZ
AZL
ASY
20,64
8,5
8,5
Front disc brake:
FS-III
FS-III
C54-II
FS-III
mm
54,0
54,0
54,0
54,0
54,0
Front brake disc -
mm
256,0
256,0
256,0
288,0
256,0
Brake disc - average effective diameter
mm
208,0
208,0
208,0
244,0
208,0
mm
22,0
22,0
22,0
25,0
22,0
mm
19,0
19,0
19,0
22,0
19,0

plate
mm
19,6
19,6
19,6
18,6
19,6
mm
2,0
2,0
2,0
2,0
2,0
Rear disc brake:
mm
38,0
38,0
Rear brake disc -
mm
232,0
232,0
mm
196,0
196,0
mm
9,0
9,0
mm
7,0
7,0

plate
mm
16,9
16,9
mm
2,0
2,0
Rear drum brake:
Brake drum -
mm
200,0
200,0
200,0
200,0
mm
201,0
201,0
201,0
201,0
mm
19,05
19,05
19,05
19,05
Brake pad, width
mm
40,0
40,0
40,0
40,0
Pad thickness without supporting

shoe
mm
5,4
5,4
5,4
5,4
mm
1,5
1,5
1,5
1,5
Edition 04.05
S00.5303.18.20
Brakes
00-3 page 3
00
Engine
FABIA 2000 Chassis
litre/
kW
1.9/74 TDI PD
1.9/96 TDI PD
1.4/55 TDI PD
ATD
ASZ
AMF

S = Manual gearbox
mm
Brake booster -
Inch
20,64
8,5
8,5
Front disc brake:
FS-III
C54-II
FS-III
mm
54,0
54,0
54,0
Front brake disc -
mm
256,0
288,0
256,0
Brake disc - average effective diameter
mm
208,0
244,0
208,0
mm
22,0
25,0
22,0
mm
19,0
22,0
19,0

plate
mm
19,6
18,6
19,6
mm
2,0
2,0
2,0
mm
38,0
38,0
Rear brake disc -
mm
232,0
232,0
mm
196,0
196,0
mm
9,0
9,0
mm
7,0
7,0

plate
mm
16,9
16,9
mm
2,0
2,0
Brake drum -
mm
200,0
200,0
mm
201,0
201,0
mm
19,05
19,05
Brake pad, width
mm
40,0
40,0
Pad thickness without supporting

shoe
mm
5,4
5,4
mm
1,5
1,5
Rear disc brake:
Rear drum brake:
00-3 page 4
Brakes
Edition 04.05
S00.5303.18.20
00
FABIA 2000 Chassis
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
bar
MPa
bar
MPa
Vehicles without electro-hydraulic

steering - drum brakes on rear axle
Front axle
70
7,0
Front axle
100
10,0
Rear axle
38 3
3,8 0,3
Rear axle
47 3
4,7 0,3
Vehicles with electro-hydraulic

steering - drum brakes on rear axle
Front axle
70
7,0
Front axle
100
10,0
Rear axle
43 3
4,3 0,3
Rear axle
56 3
5,6 0,3
Pressure value of the distributor valve

Pz(MPa)
1 MPa = 10 bar
B
4,75
4
3,1
2,5
Part no.of the distributor valve: 6Y0612151
The colour marking on the main brake cylinder is not visible.
1
2,5
Pp = input pressure at the distributor valve and left or right

front wheel
4,5
Pz = output pressure at the distributor valve and left or

right rear wheel
Pressure values
10 11
Pp(MPa)
S00-0183
Initial
setting
Pp (MPa)
2,5
4,5
10
11
Pz (MPa)
2,5
3,1
0,1
3,25
3,55
3,85
4,15
4,45
4,75
0,2
5,05
Brake fluid
Classification
N 052 766 X0 (USA standard FMVSS 571.116 DOT4)

TL 766 X0
Capacity
0.500 l
Vehicles with rear disc brakes, with ABS
0.470 l
Vehicles with rear drum brakes, with ABS
0.430 l
Vehicles with rear drum brakes, without ABS
Replace
Edition 04.05
S00.5303.18.20
every 2 years
Brakes
00-3 page 5
00
00-3 page 6
FABIA 2000 Chassis
Brakes
Edition 04.05
S00.5303.18.20
00
FABIA 2000 Chassis
00-4
Wheels, Tyres
Possible wheel-tyre combinations

Engine
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
Light-alloy rim 2)
Steel rim 2)
Offset (mm)
155/80 R13 79T 3)
5J x 13 H2
35
yes
165/70 R14 81T
5J x 14 H2
35
yes
185/60 R14 82T
6J x 14 H2
6J x 14 H2
43
yes
195/50 R15 82T
6J x 15 H2
185/55 R15 81T
Wheel size 1)
38
no
6J x 15 H2
43
no
6J x 15 H2
6J x 15 H2
43
6.5J x 16 H2
42
165/70 R14 81T
5J x 14 H2
35
yes
185/60 R14 82T
6J x 14 H2
6J x 14 H2
43
yes
185/55 R15 81T
6J x 15 H2
6J x 15 H2
43
195/50 R15 82V, T
6J x 15 H2
6J x 15 H2
43
no
205/45 R16 83W, V
6.5J x 16 H2
42
no
185/60 R14 82H
6J x 14 H2
6J x 14 H2
195/50 R15 82V, H
6J x 15 H2
185/55 R15 81H
205/45 R16 83W, V
1.4 l/55 kW
1.4 l/55 kW TDI PD
1.4 l/74 kW
1.9 l/74 kW TDI PD
2.0 l/85 kW
1.9 ltr./96 kW TDI

PD
2)
3)
4)
no
38
43
no
yes
yes
no
6J x 15 H2
43
no
6J x 15 H2
6J x 15 H2
43
205/45 R16 83W, V
6.5J x 16 H2
42
no
195/50 R15 82V, H
6J x 15 H2
43
no
185/55 R15 81H
6J x 15 H2
43
6.5J x 16 H2
42
165/70 R14 81T
5J x 14 H2
35
yes
185/60 R14 82T
6J x 14 H2
6J x 14 H2
43
yes
195/50 R15 82T
6J x 15 H2
185/55 R15 81T
yes
yes
no
38
no
6J x 15 H2
43
no
6J x 15 H2
6J x 15 H2
43
205/45 R16 83W, V
6.5J x 16 H2
42
no
205/45 R16 83W
6.5J x 16 H2
37
no
185/55 R15 84H
6J x 15 H2
205/45 R16 83W, V

1)
yes
38
205/45 R16 83W, V
1.9 l/47 kW SDI
Snow chains
permitted
6,5J x 16 H2
43
4)
42
yes
yes
no
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
FABIA 2000 Chassis
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
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
Meaning
Tyre width (mm) section ratio between height - width (%)
Tyre type (radial)
13
Rim diameter (inch)
79
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
40
FABIA 2000 Chassis
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
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
T removing and installing
40-1 page 19
1
2
3
4
T assignment Spare part
27
catalogue
2 - Nut, 40 Nm
catalogue
25
3 - Anti-roll bar
20
T to remove and install lower
assembly carrier
24
40-1 page 17
22
catalogue
4 - Rubber bearing
21
23
catalogue
5 - Clamp
19
catalogue
6 - Nut, 40 Nm
catalogue
7 - Coupling rod
18
catalogue
8 - Bracket
17
9 - Screw, 20 Nm + torque a further 90 (1/4 turn)
T replace after each removal
11 - Bonded rubber bush
T removing and installing - removal version 1 40-1 page 13
T removing and installing - removal version 2 40-1 page 15
12 - Axle link
T removing and installing 40-1 page 8
T removing and assembling the track control arm and console 40-1 page 13
T Bonded rubber bush -arrow- is a component part of the track control arm
13 - Lock washer
5
6
7
8
9
10
10
11
12
13
14
15
16
S40-0201
14 - Nut, self-locking, 20 Nm and torque a further 90 (1/4 turn)

40-1 page 2
Edition 04.05
S00.5303.18.20
40
FABIA 2000 Chassis

15 - Steering joint
T check 40-1 page 4
17 - Air deflector
T assignment Spare part catalogue
18 - Clip
20 - Console
T Can only be removed and fitted together with the track control arm
T Disconnecting and assembling the track control arm and console 40-1 page 13
T 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
T 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

T 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)
25 - Hinged bracket
T do not disassemble
T 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
26 - Shield
T for drive shaft
27 - Screw, 35 Nm
Edition 04.05
S00.5303.18.20
40-1 page 3
40
FABIA 2000 Chassis
Inspecting the steering joint

Inspecting axial play
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
S40-0287
Special tools, test and measuring equipment and

auxiliary items required
Engine/gearbox jack e.g. - V.A.G 1383- with
-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.
40-1 page 4
S40-0161
Edition 04.05
S00.5303.18.20
40
FABIA 2000 Chassis
Push out the steering joint with the ball joint extractor.
Installing
Note
Matra V176
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
by twelve-point nuts.
Fitting position
Left steering joint
L - means left
3 - means 13"
4 - means 14"
S40-0162
Right steering joint

R - means right
3 - means 13"
4 - means 14"
Arrow points in the driving direction on the 14" running
gear.
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.
Fit front wheel.

Edition 04.05
S00.5303.18.20
S40-0338
40-1 page 5
40
FABIA 2000 Chassis
Tightening torques:
20 Nm + 90
Steering joint to wheel-bearing housing

Use new nut!
50 Nm
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.
Twelve-point nut of drive shaft to wheel hub 14" and 15" running gear
50 Nm + 45
Use new nut!

Steering joint to track control arm
20 Nm + 90
Use new screws!

Use new lock washer!
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.
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
40-1 page 6
S40-0168
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40
FABIA 2000 Chassis
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.
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-.

The fixing of the assembly carrier is completed once all 4

screws (Pos. -2- and -4-) are consecutively replaced with
the fixing bolts.
S48-0117
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.
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.
Unscrew fixing bolt -1- of -T10096- from the right
(shown in figure) and screw in new bolt to the recommended tightening torque.
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
S48-0197
recommended tightening torque.
Tighten the rear left support bolts to the recommended tightening torque.
Unscrew right fixing bolts -2- of -T10096- (shown in

figure).
Install right support.
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40
FABIA 2000 Chassis
Screw in new bolts for the right support and tighten at

the rear by hand.
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.
Install the front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26.
Tightening torques:
Console to body
S10-0133
70 Nm + 90
Use new screws!
Support to body
20 Nm + 90
Use new screws!
Pendulum support to gearbox
30 Nm + 90
Use new screws!
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-.
Turn steering to right lock (removal on the left side) or

to left lock (removal on the right side).
40-1 page 8
S40-0338
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FABIA 2000 Chassis
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.
S40-0169
Swivelling the track control arm -2- out of the assembly carrier.
Pull out the track control arm -1- using the multi-purpose tool -MP 3-419- from the console.
Note
MP3-419
When pulling out the track control arm ensure that the
wheehouse trim panel and the noise insulation are not
damaged.
Installing
Brush the track control arm studs with assembly sliding oil -G 294 421 A1-.
Caution!
S40-0333
When sliding in observe that the track control
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.
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S40-0169
40-1 page 9
40
FABIA 2000 Chassis
Vehicles on which the track control arm was replaced
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 .
Further installation occurs in reverse order.
Install and tighten the wheel Chapter 44-1.
Tightening torques:
S40-0337
70 Nm + 90
Track control arm to assembly carrier

Use new screw!
20 Nm + 90
Use new screws!

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
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FABIA 2000 Chassis
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.
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
S40-0166
control arm in unladen weight position Chapter 442.
Before inserting the screws for the assembly carrier,
position the steering gear on the assembly carrier and

insert the screws for the steering gear.
Insert console into the assembly carrier.

Insert and tighten screws -1-.
Tighten assembly carrier 40-1 page 6.
1
1
1
S40-0166
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40
FABIA 2000 Chassis
Screw the anti-roll bar to the console -arrows-.
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.
2
1
Caution!
If after the test drive and with the front wheels pointing straight ahead the steering wheel is off straight,
perform a chassis alignment.
Carry out check of chassis alignment Chapter 44-2

S48-0113
Tightening torques:
70 Nm + 90
Track control arm to assembly carrier

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

Use new screws!
Coupling rod to anti-roll bar
40 Nm
Clamp for anti-roll bar to console
20 Nm + 90
Use new screws!
40-1 page 12
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FABIA 2000 Chassis
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
S40-0343
2
1
A
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.
B
S40-0171
In the event of damage to the bearing, the track control

arm must be completely replaced together with the bearing Spare Part Catalogue.

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-
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40
FABIA 2000 Chassis
Pulling out the bonded rubber bush

Screw in the screw -T10030/3- (-1-) into the console.
234567-
3
1 2
Nut of -T10030/3Washer of -T10030/3Axial bearing of -MP 5-402Pressure plate -MP 3-459Console

Pressure plate -T30035-
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
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.
S40-0173
At the console on the right the marking points towards
the body.
Arrangement of the special tools for installation without console.

1234567-
Nut 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
S40-0174
40-1 page 14
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FABIA 2000 Chassis
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.
Position the bonded rubber mounting -5- parallel to

the console -4-.
Note
When inserting the bonded rubber mounting counterhold
at spindle.
Do not twist the bonded rubber mounting and insert up
S40-0175
to the stop.
Remove the special tools.


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

S40-0341
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.
1
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.
MP5-401/2

Note
Never use grease!
Use assembly sliding oil -G 294 421 A1- to insert.
S40-0334
fit of the bearing.

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FABIA 2000 Chassis


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-.

Attach the underfloor trim panel.
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.
S40-0339
40-1 page 16
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FABIA 2000 Chassis
Note
Never use grease!
Use assembly sliding oil -G 294 421 A1- to insert.
fit of the bearing.



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-.

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
FABIA 2000 Chassis
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.

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-.

-2-.
S48-0113
with wire.

page 6.
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.
1
S40-0166
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.
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
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FABIA 2000 Chassis

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
70 Nm + 90
Use new screws!
Support to body
20 Nm + 90
Use new screws!
S10-0133
50 Nm + 90
Use new screws!

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

Clamp for anti-roll bar to console
40 Nm
20 Nm + 90
Use new screws!
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.
S40-0161
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40
FABIA 2000 Chassis

-2-.
Swivel the anti-roll bar upwards.
S48-0113
with wire.

page 6.
Installing
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.
Raise the assembly carrier and fix 40-1 page 6.
S40-0166


shaft.

Screw the steering joint and the track control arm with
new screws.
40-1 page 20
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FABIA 2000 Chassis
Caution!

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

50 Nm
Use new nut!

50 Nm + 45
Use new nut!

40 Nm
20 Nm + 90
Use new screws!

Wheel bolts
Edition 04.05
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120 Nm
40-1 page 21
40
40-1 page 22
FABIA 2000 Chassis
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FABIA 2000 Chassis
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)
34-
567-
8910 11 -

Screw
Shock absorber
40-2 page 2
T can be replaced individually
T must be replaced completely
T check 40-2 page 7
T disposing of 40-2 page 8
catalogue
Stop buffer
Boot
Helical spring
T check colour coding
T The surface of the spring coil
must not be damaged
T replace axle-wise
T per axle only use helical
springs of the same make
40-2 page 6
catalogue
Axial grooved ball bearing
Suspension strut bearing
Self-locking nut, 60 Nm
Suspension strut dome
12
13
12
12
11
10
9
8
3
2
7
1
S40-0185

T when mounting the suspension strut, first mount the screws on the inside of the vehicle
13 - Cap
T clipped into suspension strut dome
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FABIA 2000 Chassis
Removing and installing the suspension

strut
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

Unscrew plate nut (or the twelve-point nut) from the
drive shaft using a 19 mm Allen key.
Remove wheel.
S40-0338

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
1
-Matra V176- is supported on the nut.
Use puller -Matra V176- to press track rod/track rod

end -2- off the steering arm.
Screw off the nut from the track rod end.

Pull track rod end out of steering arm.
Tie up track rod.
Chapter 40-4 and tie up.
Screw steering joint to the track control arm. To do so

use the removed screws and the removed lock washer.
Position the gearbox jack with adapter (e.g. - V.A.G
S40-0177
1383/A- with -V.A.G 1359/2-) under the wheel-bearing housing.
40-2 page 2
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FABIA 2000 Chassis
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.
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FABIA 2000 Chassis
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.
Remove spreader -3424-.

Screw on the new nuts and tighten up fully -arrow-.
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.

S40-0288

shaft.
shaft.
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
Replace nut on both sides.
Screw the track control arm -1- with the steering joint
S40-0338
Tighten the new screws -arrows- in accordance with

the markings and the former positions to the specified
tightening torque.
40-2 page 4
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FABIA 2000 Chassis
Caution!

Tightening torques:
15 Nm + 90
Suspension strut to suspension strut dome

Use new screws!
Wheel-bearing housing to suspension strut
60 Nm + 90
Use new screws and nuts!
Track rod end/track rod to steering arm
20 Nm + 90
Use new nuts!
The anti-roll bar on the suspension strut
40 Nm
50 Nm
Use new nuts!

50 Nm + 45
Use new nuts!

20 Nm + 90
Use new screws!

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-
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40
FABIA 2000 Chassis
Removing the helical spring
V.A.G 1752/1
Removing the suspension strut 40-2 page 2

Preload the helical spring with the spring tensioner un-
1
MP 6-427
til the suspension strut bearing -3- is relieved.
Unscrew the nut from the piston rod using socket
2
3
wrench insert OK 21 -MP 6-427- and counterhold with

an hexagonal wrench -2-.
1 - Ratchet or torque wrench
V.A.G
1752/4
S40-0187
Remove component parts of the suspension strut and

preloaded helical spring with the clamping fixture.
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
V.A.G 1752/4
Installing the helical spring
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-.
Tightening torque:
Nut for suspension strut bearing on the
piston rod
60 Nm
Assembling the shock absorber 40-2 page 1
40-2 page 6
S40-0259
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FABIA 2000 Chassis
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
S40-0071
Defective wheel bearing

Cracked welding points on body
Loose parts or parts fitted under stress (exhaust sys-
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
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40
FABIA 2000 Chassis
wheel hopping and externally usually exhibit considerable oil leakage.

Check by hand whether or not the shock absorber is
defective as follows:
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
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FABIA 2000 Chassis
Drill a hole 3 mm -arrow A- through the outer pipe

of the shock absorber.
II
Note
Drill a second hole 6 mm -arrow B- through the out-
er and inner pipe of the shock absorber.
A
20
20
through (approx. 25 mm deep).
60
Drill further until the inner pipe has been drilled
60
Gas will escape during drilling.
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.
S40-0188
Caution!
Wear safety goggles during the drilling procedure.
Drill a hole 3 mm -arrow A- through the outer pipe

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
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
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40
40-2 page 10
FABIA 2000 Chassis
Edition 04.05
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FABIA 2000 Chassis
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
5
Chapter 40-2
1
T repair Chapter 40-2
2
catalogue
6
28
2 - Drive shaft with CV joint
7
Chapter 40-4
3
T inspect Chapter 40-4
4
27
26
catalogue
25
24
3 - Shim
23
catalogue
20
4 - Fillister head screw with inter19
nal serrations
22
8
catalogue
9
T M8 x 48
initially tighten all screws to
10 Nm, then tighten screws
crosswise
17
18
Tightening torque: 40 Nm
21
T M10 x 52
10
12
16
crosswise
11
14
15
13 S40-0202
5 - Drive shaft with tripod joint
T removing and installing Chapter 40-5
6 - Shim
T only replace along with a cylindrical screw with internal serrations M8 x 28 head, item 7
7 - Fillister head screw with internal serrations
T M8 x 18
initially tighten all screws to 10 Nm, then tighten screws crosswise
T M8 x 28
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40-3 page 1
40
8910 11 -
12 13 14 -
15 16 17 18 -
19 -
FABIA 2000 Chassis

T M10 x 23
Brake disc, internally ventilated
Wheel bolt, 120 Nm
Plate nut
T replace after each removal against twelve-point nut item 11
50 Nm + 45
T Do not grease thread of the outer joint of the drive shaft.
Screw, 4 Nm
Brake pad
Brake caliper
T do not release brake hose when working on the front wheel suspension
T tie up with wire or anything similar
Guide bolts, 28 Nm
Cap
T removing
Screw, 10 Nm
Wheel hub with wheel bearing
T for vehicles with ABS the sensor ring is built into the wheel hub
T 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.
T The sensor ring for ABS cannot be replaced individually
T replace after each removal, is destroyed during removal
T Removing and installing the wheel hub with wheel bearing 40-3 page 10
Cover plate
20 - Nut, 20 Nm + torque a further 90 (1/4 turn)

21 - Track rod and track-rod ends
24 - Screw
T the tip of bolt must point in the direction of travel
25 - Speed sensor ABS
26 - Allan screw, 8 Nm
T for speed sensor ABS
27 - Nut, 40 Nm
40-3 page 2
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FABIA 2000 Chassis

28 - Coupling rod
brake FS-II
Note
suspension.
Chapter 40-2
2
1
catalogue
27
3
Chapter 40-4
26
25
24
23
catalogue
3 - Shim
22
19
catalogue
21
catalogue
T M8 x 48
15
crosswise
20
14
T M10 x 52
13
crosswise
12
5 - Brake disc, internally ventilated
6 - Wheel bolt, 120 Nm
7 - Plate nut
8 - 50 Nm
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18
17
16
11
10
7
8
S40-0203
40-3 page 3
40
FABIA 2000 Chassis
9 - Screw, 4 Nm
10 - Brake pad
11 - Brake caliper
12 - Fillister head screw with internal serrations, 25 Nm
T M8 x 49
13 - Fillister head screw with internal serrations, 25 Nm
T M8 x 59
14 - Air deflector
15 - Screw, 10 Nm
T for air deflector
16 - Wheel hub with wheel bearing
17 - Screw, 10 Nm
18 - Cover plate
20 - Track rod and track-rod ends
23 - Screw
26 - Nut, 40 Nm
27 - Coupling rod
40-3 page 4
Edition 04.05
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40
FABIA 2000 Chassis
brake C54-II
Note
suspension.
5
Chapter 40-2
1
2
31
catalogue
6
7
Chapter 40-4
3
4
30
29
catalogue
28
27
3 - Shim
26
catalogue
23
4 - Fillister head screw with inter22
25
nal serrations
21
20
24
catalogue
T M8 x 48
17
19
crosswise
15 14
T M10 x 52
12
13
18
crosswise
17
14
16
5 - Drive shaft with tripod joint
6 - Shim
T only replace along with a cylindrical screw with internal serrations M8 x 28 head, item 7
T M8 x 18
T M8 x 28
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10
13
11
S40-0204
40-3 page 5
40
8910 11 -
12 13 14 -
15 16 -
17 -
18 19 20 -
21 22 -
FABIA 2000 Chassis

T M10 x 23
Brake disc, internally ventilated
Wheel bolt, 120 Nm
Plate nut
50 Nm + 45
Screw, 4 Nm
Brake pad
Pad retaining plate
T always replace when changing the brake pads
T brake pads contained in repair kit
Brake carrier with guide bolts and protective caps
Heat shield
Brake caliper
Screw, 30 Nm
Track rod and track-rod ends
T Removing and installing the wheel hub with wheel bearing 40-3 page 10
Screw, 10 Nm
Cover plate

24 - Screw, 125 Nm
T clean ribbing on underside each time removed
27 - Screw
40-3 page 6
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FABIA 2000 Chassis

30 - Nut, 40 Nm
31 - Coupling rod
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.
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

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
FABIA 2000 Chassis
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
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-.
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.

Remove the track rod end from the steering-knuckle

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

1
S40-0197
Separate the screwed connection wheel-bearing

housing/suspension strut -arrow-.
S40-0288
40-3 page 8
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FABIA 2000 Chassis
Insert the spreader -3424- in the slot on the wheelbearing housing.
Turn ratchet 90 and remove from spreader -3424-.

strut.
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
S40-0179
screw.

strut.
Remove spreader -3424-.


shaft.
shaft.

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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40
FABIA 2000 Chassis
Caution!

Tightening torques:
60 Nm + 90
Wheel-bearing housing to suspension strut

50 Nm
Use new nuts!

50 Nm + 45
Use new nuts!

Track-rod end to steering lever
20 Nm + 90
Use new nuts!
20 Nm + 90
Use new screws!

FS-III brake caliper to wheel bearing housing
28 Nm
FS-II brake caliper to wheel bearing housing
25 Nm
Brake carrier with C54-II brake caliper to wheel bearing housing

125 Nm
40 Nm
Speed sensor to wheel-bearing housing
8 Nm
Wheel bolts
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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FABIA 2000 Chassis

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-
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).
S40-0176
Vehicles fitted with C54-II floating caliper brake
Release screws -1-.
1
S40-0197
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40
FABIA 2000 Chassis
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.

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-.
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 6-414/6-
Note
S40-0181
Instead of the side door removal tool -MP 8-605/1-
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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FABIA 2000 Chassis

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.
2
4
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-
S40-0180
over the entire surface.

Screw the grippers -1- to the wheel hub with wheel
bearing -2-.
Grippers -1Chassis with an FS-II brake
-T10064/5-
Chassis with an FS-III or

C54-II brake
-T10064/6-
Note
The wheel bolts -3- must not protrude from the rear of the
grippers -1-.
Chassis with an FS-II brake
2
S40-0194
Note
Do not tilt the wheel hub with wheel bearing while inserting.
Edition 04.05
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40-3 page 13
40
FABIA 2000 Chassis
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-
3
4
Chassis with an FS-III or C54-II brake
1
5
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.
S40-0195
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.
Pull the wheel hub with wheel bearing into the wheel-
bearing housing.
12345-
-MP 6-414/5-T10064/1-T10064/6-MP 6-414/10-T10064/4-
2
1
5
S40-0183
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


2
1

shaft.
S40-0196
Grease the serration on the propeller shaft with polycarbamide grease -GG 052 142 A2-.
shaft.
40-3 page 14
Edition 04.05
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FABIA 2000 Chassis


Note
twelve-point nuts.
Screw the steering joint and track control arm with the
new screws in the former positions.

Caution!

Tightening torques:
Cover plate to wheel-bearing housing
10 Nm
Phillips head screw of brake disc to wheel hub with wheel bearing
4 Nm
50 Nm
Use new nuts!

50 Nm + 45
Use new nuts!

Track rod/track rod end to steering lever
20 Nm + 90
Use new nuts!
20 Nm + 90
Use new screws!

FS-III brake caliper to wheel bearing housing
28 Nm
FS-II brake caliper to wheel bearing housing
25 Nm
Brake carrier with C54-II brake caliper to wheel bearing housing

40 Nm
Wheel bolts
Edition 04.05
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125 Nm
120 Nm
40-3 page 15
40
40-3 page 16
FABIA 2000 Chassis
Edition 04.05
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FABIA 2000 Chassis
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.


2
1
S40-0338
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.
Smear the gearing of the outer joint of the drive shaft

lightly with adhesive sealing material -Loctite 601-.
MP 6-425
S40-0178

shaft.
shaft.
Edition 04.05
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40-4 page 1
40
FABIA 2000 Chassis
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
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

twelve-point nuts. Replace nut on both sides.
Tighten the drive shaft on the flange shaft - gearbox to

the prescribed torque.
S40-0338
Screw the track control arm -1- with the steering joint
Tighten the new screws -arrows- in accordance with

the markings and the former positions to the specified
tightening torque.
Tightening torques:
M 8 = 40 Nm
M 10 = 70 Nm
Drive shaft to flange shaft/gearbox

Use new screws!
50 Nm
Use new nut!

50 Nm + 45
Use new nut!

20 Nm + 90
Use new screws!

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
FABIA 2000 Chassis
Grease
of which in:
Total
amount
Joint
Joint boot
Outer joint
mm
[g]
[g]
[g]
90
80 +10
80 +10
---
100
100 +10
100 +10
---
90
80 +10
40 +5
40 +5
100
110 +10
55 +5
55 +5
Inner joint
mm
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)

catalogue
2 - Screw
T 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
catalogue
3 - Shim
catalogue
4 - Warm-type clamp
T replace
T tensioning 40-4 page 5
5 - Joint boot for inner CV joint
T Material: Hytrel (Polyelastomere)
T inspect for tears and chafing
points
T remove from CV joint with
drift
T before installation coat the inside of the cap with sealant -D 454 300 A2T assignment Spare part catalogue
Edition 04.05
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40-4 page 3
40
FABIA 2000 Chassis
6 - Disc spring
T Fitting position 40-4 page 6
7 - Inner CV joint
T pressing off 40-4 page 6
T pressing on 40-4 page 6
T grease 40-4 page 2
T check 40-4 page 8
8 - Gasket
T The adherend must be free of grease and oil!
T replace
T Pull off protective foil and stick in housing
9 - Circlip
T replace
T use circlip pliers, e.g. -VW 161 A- for removing and installing
10 - Left drive shaft (solid shaft)
11 - Warm-type clamp
T replace
12 - Joint boot
T Material: Hytrel (Polyelastomere)
T inspect for tears and chafing points
T replace
T tension with tensioning pliers, e.g. -V.A.G 1682 - 40-4 page 5
14 - Disc spring
15 - Thrust ring
16 - Circlip
T replace
T insert in the shaft groove
17 - Outer CV joint
T removing 40-4 page 5
T before installing grease the serration with polycarbamide grease -G 052 142 A2T Installing: drive onto the shaft with a plastic hammer until the compressed circlip expands
T check 40-4 page 7
18 - Thrower ring
T 13" chassis - black
T 14" and 15" chassis - white
19 - Twelve-point nut
T 13" chassis - black, 50 Nm
T 14" and 15" chassis - silvery, 50 Nm + 45
40-4 page 4
Edition 04.05
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FABIA 2000 Chassis
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
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40-4 page 5
40
FABIA 2000 Chassis
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.
V.A.G 1682
A
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
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
S40-0078
MP 3-448
Removing inner CV joint
Removing drive shaft 40-4 page 1.
MP 3-407
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.
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
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40
FABIA 2000 Chassis
Push the new joint boot onto the drive shaft.

Press CV joint onto the drive shaft up to the stop.
MP 6-428
Note
Chamfer on inner diameter of the ball hub (serration)
must point towards the bearing collar of the drive shaft.
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
MP 3-407
MP 3-406
-D 454 300 A2-.
Fit joint boot on the constant velocity joint.

S40-0099
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.
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.
Edition 04.05
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40-4 page 7
40
FABIA 2000 Chassis
Turn the cage until two rectangular cage windows -arrow- rest on the joint part.
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

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
Edition 04.05
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40
FABIA 2000 Chassis
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
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40-4 page 9
40
FABIA 2000 Chassis
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-.
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.

Press the required grease mass into the joint part
40-4 page 2
Spread any residual grease in the joint boot 40-4

page 2.
Installing the joint boot 40-4 page 5.
40-4 page 10
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40
FABIA 2000 Chassis
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:
Total
amount
Joint
Joint boot
Outer joint
mm
[g]
[g]
[g]
100
100
+10
100
+10
---
Tripod joint
mm
108
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
Drive shafts with tripod joint
40-5 page 1
40
FABIA 2000 Chassis
1 - Joint boot for the joint

T inspect for tears and chafing
points
catalogue
2 - Warm-type clamp
T replace
T tensioning Chapter 40-4
3 - Screw
T 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
catalogue
4 - Shim
catalogue
5 - Joint part
catalogue
6 - Tripod spider with rollers
T Chamfer -arrow- points towards the drive shaft serration
7 - Circlip
T replace
8 - O-ring seal
T replace
9 - Cover
T replace
10 - Hose clamp
T for tripod joint
T replace
11 - Joint boot for tripod joint
T inspect for tears and chafing points
12 - Drive shaft
T replace
40-5 page 2
Edition 04.05
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40
FABIA 2000 Chassis

14 - Disc spring
T Fitting location Chapter 40-4
15 - Thrust ring
16 - Circlip
T replace
17 - Outer CV joint
T removing Chapter 40-4
T Installing: carefully drive onto the shaft with a plastic hammer until the compressed circlip expands
T greasing Chapter 40-4
18 - Thrower ring
T 13" chassis - black
T 14" and 15" chassis - white
19 - Twelve-point nut
T 13" chassis - black, 50 Nm
T 14" and 15" chassis - silvery, 50 Nm + 45
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.
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40-5 page 3
40
FABIA 2000 Chassis
Straighten the metal tabs -arrows- with a screwdriver

and lever off cover.
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
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40
FABIA 2000 Chassis
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
MP 6-405
drive shaft.
Remove the tripod spider with rollers and lay aside on

a clean surface.
MP 3-406
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
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
MP 3-408
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
MP 3-458/2
clamp in the vice.
MP 3-407
MP 3-406
MP 6-429
S40-0143
Edition 04.05
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40-5 page 5
40
FABIA 2000 Chassis
Press 60 grams of -Hochtemperaturfett- from the re-
pair kit into the tripod joint (on the tripod spider side)
-arrow A-.
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
S40-0106
part.
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
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42
FABIA 2000 Chassis
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.
Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.

T Allocation Spare parts
catalogue
30
2 - Screw, 4 Nm
3 - Brake drum
T reset brake before removing
the brake drum Chapter
46-2
29
4 - Cap
T pressing off and inserting
Chapter 42-5
5 - Twelve-point nut, self-locking, 70 Nm and turn a further
30 (1/12 turn)
15
T for vehicles with ABS the
14
sensor ring is built into the
wheel hub
13
T wheel hub and wheel bearing
form one unit; it does not
need servicing.
T the sensor ring for ABS cannot be replaced individually
Chapter 42-5
T Allocation Spare parts
catalogue
7 - Screw, 30 Nm + torque a fur10
ther 90 (1/4 turn)
8 - Brake carrier with brake shoe
T repairing Chapter 46-2
9 - Holder for hand-brake cable
10 - Hand-brake cable
Edition 03.02
S00.5303.11.20
32
33
31
34
28
23
27
22
26
25
24
12
16
12
20
21
19
18
17
8
11
1
9
6 5 4 3
S42-0122
42-1 page 1
42
FABIA 2000 Chassis
11 - Bracket
T for brake-power regulator
T attached to the vehicle body
12 - Screw, 20 Nm
13 - Brake-power regulator
T load dependent
T for vehicles without ABS
T inspecting and setting Chapter 47-3.
14 - Screw, 16 Nm
15 - Screw, 16 Nm
16 - Holder for hand-brake cable
18 - Axle body
T Allocation Spare parts catalogue
T The locating face and the threaded holes for axle studs must be free from enamel and dirt
19 - Axle stud
T Straightening work is not allowed!
T Re-cutting the thread is not allowed!
20 - Brake line
T Tightening torque of the pipe screws: 14 Nm
21 - Axle body
T The locating face and the threaded holes for axle studs must be free from enamel and dirt
22 - Self-locking nut
T insert from the inside of the vehicle
T 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.
25 - Plug
T to plug the hole in the axle stud
27 - Bottom spring base
T inspect for damage (visual inspection)
T insert from the outside of the vehicle
T 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
30 - Mount for rear axle
T attached to the vehicle body
42-1 page 2
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42
FABIA 2000 Chassis

31 - Helical spring
T check for paint damage, if necessary eliminate paint damage
T replace axle-wise
T per rear axle only use helical springs of the same make
32 - Top spring base
T installing Chapter 42-2
34 - Shock absorber
T inspecting Chapter 40-2
T disposal Chapter 40-2
T 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/
3 Securing strap, e. g. -T10038-
S42-0145
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
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42-1 page 3
42
FABIA 2000 Chassis
Removing the centre console Body Work;

Rep. Gr. 68.
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
S46-0096
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-
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.
42-1 page 4
S42-0147
Edition 03.02
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42
FABIA 2000 Chassis
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
S42-0148
at the rear Body Work; Rep. Gr. 66.
Insert wooden block -A- into attachment, e. g.

- V.A.G 1359/2-.
V.A.G 1359/2
Support rear axle with gearbox jack and attachment.
Note
A second person is required for the further removal operations.
Unbolt rear suspension from shock absorbers -arrows-.
Secure rear suspension at attachment, e. g. with strap
V.A.G 1383 A
N42-0130
of attachment V.A.G 1359/2.
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
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42-1 page 5
42
FABIA 2000 Chassis
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 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.
If fitted, adjust the upper position of the tension rod in

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.
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
16 Nm
The sender at the rear on the rear axle
16 Nm
Wheel bolts
42-1 page 6
120 Nm
Edition 03.02
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42
FABIA 2000 Chassis
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-
V.A.G
1752/1
Removing
Note
The rear silencer must be taken off in order to remove the
left coil spring.
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-.
V.A.G 1752/3
S42-0149
During the tensioning operation, ensure that the
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.
2
1
V.A.G 1752/3
1 - top base
2 - Mount for top base
Installing
Check to ensure that the zinc base (bottom base) is

not damaged.
V.A.G 1752/1
S42-0146
Replace if necessary.
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
Servicing the rear axle with drum brakes
42-2 page 1
42
FABIA 2000 Chassis
Removing and installing shock absorber

Torque wrench
Gearbox jack with adapter, e.g. - V.A.G 1383 A- with
-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
Install a bolt on the shock absorber for the rear axle

and tighten by hand.

such away before tightening up so that the sender lever points towards the rear when whipping the rear
Place vehicle onto its wheels and ensure it is at its un-
laden 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
S42-0040
Tightening torques:
Shock absorber to body
V.A.G 1359/2
30 Nm + 90
Use new screws!
Shock absorber to rear suspension
40 Nm + 90
Wheel bolts
42-2 page 2
120 Nm
Edition 04.04
S00.5303.15.20
42
FABIA 2000 Chassis
Disassembling and assembling shock absorber

Note
The shock absorbers must not be disassembled and repaired.
1 - Shock absorber
42-2 page 2
catalogue
T disposal Chapter 40-2
2 - Protective cap
3 - Protective tube
4 - Stop buffer
5 - Shock absorber bushing
6 - Self-locking nut, 25 Nm
T 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
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42-2 page 3
42
FABIA 2000 Chassis
Assembly device, e. g. -MP 5-400 Assembly device, e. g. -MP 5-401 Assembly device, e. g. -MP 6-430 Torque wrench
-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 sepa-
rate.
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
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42
FABIA 2000 Chassis
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
MP 5-400/2
A second mechanic must counterhold at the rear axle

when pulling out the rubber-metal bearing.
MP 3-419
Edition 04.04
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S42-0143
42-2 page 5
42
FABIA 2000 Chassis
Installing
Fabia RS
The axle -1- must be aligned with the edge -arrow- of the
trailing arm -2-.
S42-0160
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-.
Mark the position of the marking -1- on the rubbermetal bearing.
1
S42-0151
Fabia RS
Insert special tools together with rubber-metal bearing

as shown.
42-2 page 6
Edition 04.04
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42
FABIA 2000 Chassis

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.

such away before tightening up so that the sender lever points towards the rear when whipping the rear
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.
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42
FABIA 2000 Chassis
Tightening torques:
Rear suspension to bearing bracket
45 Nm + 90
Brake pressure regulator to rear suspension
16 Nm
The sender at the rear on the rear axle
16 Nm
Wheel bolts
42-2 page 8
120 Nm
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FABIA 2000 Chassis
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
T repairing Chap. 47-1
25
T Assignment Spare part
catalogue
3 - Cross-head screw, 4 Nm
4 - Brake disc
24
5 - Cap
T replace each time removed
Chap. 42-5
6 - Twelve-point nut, self-locking, 70 Nm + torque a further
30 (1/12 turn)
wheel hub
T Wheel hub and wheel bearing form one unit. The unit is
maintenance-free. Adjusting
and repairs are not possible.
Chap. 42-5
catalogue
8 - Hexagon bolt + washer,
30 Nm + torque a further 90
(1/4 turn)
9 - Cover plate
10 - Fixture for handbrake cable
T Fitting location Chap. 46-3
11 - Handbrake cable
T removing and installing Chap. 46-3
12 - Fixture for handbrake cable
14 - Axle beam
T Assignment Spare part catalogue
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27
28
26
29
23
18
17
19
22
16
21
15
20
14
12
13
1
2
11
10
8 7 6 5 4
3
S42-0123
42-3 page 1
42
FABIA 2000 Chassis
T The locating face and the threaded holes for axle stubs must be free from enamel and dirt
15 - Axle stub
T Re-cutting the thread is not allowed!
16 - Hexagon bolt, 30 Nm + torque a further +30 (1/12 turn)
17 - Brake line with connection, banjo bolt and seals
T must not be disassembled, must be replaced completely
T Tightening torque of banjo bolt: 35 Nm
T do not unscrew when replacing the brake pad
18 - Self-locking hexagon nut
19 - Hexagon bolt, 40 Nm + torque a further 90 (1/4 turn)
T insert from the inside of the vehicle
T 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.
21 - Hexagon socket bolt, 8 Nm
22 - Bottom spring base
T inspect for damage (visual inspection)
T insert from the outside of the vehicle
T 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
25 - Mount for rear suspension
T welded to body
26 - Coil spring
T check for paint damage, if necessary eliminate paint damage
T always replace on both sides of axle
T use only coil springs of the same make on an axle
27 - Top spring base
T installing Chap. 42-4
29 - Shock absorber
T inspecting Chap. 40-2
T disposal Chap. 40-2
T use only shock absorbers of the same make on an axle
42-3 page 2
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FABIA 2000 Chassis
Fitting location of shock absorber of rear suspension

Chap. 42-1
Removing and installing rear suspension

Chap. 42-1
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42
42-3 page 4
FABIA 2000 Chassis
Edition 02.01
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42
FABIA 2000 Chassis
42-4
Servicing rear suspension

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

1 - Phillips screw, 4 Nm
2 - Brake drum
3 - Cap
T extracting and inserting
42-5 page 1
4 - Self-locking twelve-point nut,
70 Nm and tighten a further
30
T Wheel hub with wheel bearing form one unit. The unit is
42-5 page 1
T Assignment Spare Part
Catalogue
6 - Axle body
Chap. 46-2
8 - Tighten combination hexagon
screw 30 Nm and 90
9 - Axle stud
T Re-cutting the thread is not
allowed!
42-5 page 6
8
9
2
1
S42-0124

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.
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42-5 page 1
42
FABIA 2000 Chassis
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.
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
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FABIA 2000 Chassis
Caution!
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.
Drive in new cap.

Tightening torques:
Twelve-point nut to axle stud
70 Nm + 30
Use new nut!
Drum brake to wheel hub

Wheel bolts
4 Nm
120 Nm
MP 3-427
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S42-0127
42-5 page 3
42
FABIA 2000 Chassis
Summary of components of wheel bearing - disc brake

1 - Phillips screw, 4 Nm
2 - Brake disc
3 - Cap
T extracting and inserting
42-5 page 4
30
T Wheel hub with wheel bearing form one unit. The unit is
42-5 page 4
T 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
T Re-cutting the thread is not
allowed!
42-5 page 6
11 - Tighten combination hexagon
screw 30 Nm and 90
10
11
2
1
S42-0128

with wheel bearing - disc brake
Removing
Raise vehicle.
Unscrew rear wheel.
42-5 page 4
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42
FABIA 2000 Chassis
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
FABIA 2000 Chassis
Caution!
not damaged.
Installing
Carefully slide the wheel hub with wheel bearing onto

the axle stud up to the stop.
Caution!
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.
Drive in new cap.

Tightening torques:
Brake carrier with brake caliper to axle
body
30 Nm +30
70 Nm +30
Use new nut!
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
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FABIA 2000 Chassis

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
30 Nm + 90
Use new screws!
S42-0130
70 Nm + 30
Use new nut!
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.

Remove cover plate and axle stud.
S42-0131
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42
FABIA 2000 Chassis
Tightening torques:
Axle stud to axle body
30 Nm + 90
Use new screws!
70 Nm + 30
Use new nut!
Brake disc to wheel hub

Brake carrier with brake caliper to axle
body
Wheel bolts
42-5 page 8
4 Nm
30 Nm +30
120 Nm
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FABIA 2000 Chassis
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.
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Wheels, Tyres
44-1 page 1
44
FABIA 2000 Chassis
Disc wheel
Note
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
T 5J x 13, ET 35
T 5J x 14, ET 35
T 6J x 14, ET 43
T 6J x 15, ET 43
1
2
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
T remove with pull-off hook
item 5.
Note
567-
89-
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
T included in tool kit
Wheel bolt key
7
8
Balancing weights
T max. 60 g allowed per rim
flange
Retaining spring for balancing weights
Valve
T only use valve in accordance with spare part catalogue
44-1 page 2
Wheels, Tyres
S44-0010
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FABIA 2000 Chassis
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
T 6J x 14, ET 43
3 - Anti-theft wheel bolt, 120 Nm
4 - Cap
T for anti-theft wheel bolt
item 3
T Remove with pull-off hook
item 5.
5 - Pull-off shackle
6 - Wheel bolt key
7 - Adapter for anti-theft wheel
bolt
8 - Wheel trim cap
T can only be removed once
the wheel has been removed
1
2
Note
9-
10 11 12 13 -
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
T for wheel bolt item 10
T Remove with pull-off hook item 5.
Wheel bolt, 120 Nm
Balancing weights
T max. 60 g allowed per rim flange
Retaining spring for balancing weights
Valve
T only use valve in accordance with spare part catalogue
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Wheels, Tyres
8
13
12
11
10
S44-0011
44-1 page 3
44
FABIA 2000 Chassis
Light-alloy rim 6J x 15, 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
T 6J x 15, ET 43
3 - Anti-theft wheel bolt, 120 Nm
4 - Adapter for anti-theft wheel
bolt
6 - Wheel trim cover
T remove with pull-off hook
item 7.
7 - Pull-off hook
8 - Wheel bolt key
9 - Balancing weights
T max. 60 g allowed per rim
flange
10 - Retaining spring for balancing weights
11 - Valve
T only use valve in accordance
with spare part catalogue
1
2
10
11
10
S44-0012
44-1 page 4
Wheels, Tyres
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FABIA 2000 Chassis
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
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Vehicle alignment
44-2 page 1
44
FABIA 2000 Chassis
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
Front axle part replaced
Chassis alignment
required
yes
Rear axle part replaced
no
Chassis alignment required

yes
no
Axle link
Shock absorber
Wheel-bearing housing
Helical spring
Track rod/track-rod ends
Complete rear axle
Steering gear
Assembly carrier
Suspension strut or shock absorber or helical spring
Console for engine-gearbox

assembly carrier
Anti-roll bar
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.
Check the tyre tread depth. The difference between

the left and right tyres on an axle must not exceed 2
mm.
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
FABIA 2000 Chassis

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
S45-0016
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.
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Vehicle alignment
44-2 page 3
44
FABIA 2000 Chassis
Chassis terms
Chapter 00-1
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.
S44-0013
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
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
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44
FABIA 2000 Chassis

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.
Tighten 70 Nm
+ 90
1
S44-0014
Use new screws!
Checking the camber on the rear axle

The camber cannot be 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.
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
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!
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Vehicle alignment
S44-0015
44-2 page 5
44
FABIA 2000 Chassis
Twisted bellows wear fast.
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
S44-0016
(screw into track-rod end).
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
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44
FABIA 2000 Chassis
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
Track value on the rear right wheel
+15'
+5'
15' - 5' = 10'
10' : 2 = 5'
Deviation from the running direction = 5'
Value with a different preceding sign (+/-) are added up and the sum is divided by 2.
Track value on the rear left wheel
Track value on the rear right wheel
+15'
-5'
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.
Edition 07.04
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Vehicle alignment
44-2 page 7
44
44-2 page 8
FABIA 2000 Chassis
Vehicle alignment
Edition 07.04
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45
FABIA 2000 Chassis
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
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).
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.
The brake pad warning light -K32- (-1-) indicates the
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.
4
1
S45-0187
Notes on rectifying sudden faults Technical Service
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
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Antilock braking system (ABS)
45-1 page 1
45
FABIA 2000 Chassis
The separation of the hydraulic unit for ABS -N55- and
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
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45
FABIA 2000 Chassis

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.
Do not drive the vehicle if the connector is unplugged
from the control unit.

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).
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45
FABIA 2000 Chassis
Required technical information

Binder Current Flow Diagrams, Electrical Fault Find-
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
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FABIA 2000 Chassis
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.
Code ABS systems BOSCH 8.0 with the vehicle sys-
tem tester -V.A.G 1552- Chap. 45-9 or with the vehicle diagnosis, measurement and information system
- VAS 5051- Chap. 45-4.
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Distinguishing features of the ABS system
45-2 page 1
45
FABIA 2000 Chassis
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
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.
S45-0108
List of available functions Chap. 45-5.
ABS/EDL/TCS BOSCH 5.7

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

12 valve domes
Brake pressure sender 1 -G201- (-1-)

Note
S45-0105
45-2 page 2
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45
FABIA 2000 Chassis

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

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.
Inscription ESP on the hydraulic unit for ABS -N55 12 valve domes

Fitting position of the ABS systems

BOSCH 5.7 and BOSCH 8.0
S45-0176
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.
S45-0104
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45-2 page 3
45
FABIA 2000 Chassis
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.
S45-0183
45-2 page 4
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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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45
FABIA 2000 Chassis
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-
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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FABIA 2000 Chassis
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-.
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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Vehicle diagnosis, measurement and information system

-VAS 5051-
45-4 page 1
45
FABIA 2000 Chassis
Select on the display chassis

Select on the display brake system
Select on the display the indicated 01-self-diagnosable system.
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
Vehicle diagnosis, measurement and information system

-VAS 5051-
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FABIA 2000 Chassis
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.
Connect vehicle system tester -V.A.G 1552- with the
V.A.G 1552
V.A.G 1551/3
diagnostic cable -V.A.G 1551/3-.
Switch on the ignition.

S01-0087
Interrogating control unit version

Vehicle system test
Enter address word XX
Readout on display:
Press
HELP
0 and 3 for the address word brake electron-
ics and confirm the entry with Q .

After approx. 5 seconds the display will show:
Edition 07.04
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6Q0614117
ABS 5.7
Coding 00036
Performing Self-diagnosis - ABS systems BOSCH 5.7 and

BOSCH 8.0
FRONT
X00
->
WSC xxxxx
45-5 page 1
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FABIA 2000 Chassis
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
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
Readout on display:
Vehicle system test

Select function XX
HELP
Vehicle system test

Select function XX
HELP
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:
Press
0 and 2 for the function Interrogate fault
memory and confirm with Q .
X faults detected!
The number of faults stored appears on the display

or
No fault detected!
->
Vehicle system test

Select function XX
HELP
Eventuell gespeicherte Fehler eines Systems werden

nacheinander angezeigt.
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

BOSCH 8.0
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FABIA 2000 Chassis
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:
Vehicle system test
Select function XX
Readout on display:
HELP
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
.
Vehicle system test
Select function XX
Readout on display:
HELP
Note
If the following message is displayed the test se-
quence is incorrect.
Vehicle system test

Fault memory was not interrogated
->
Carefully follow the test sequence step by step: first
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
Readout on display:
HELP
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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BOSCH 8.0
45-5 page 3
45
FABIA 2000 Chassis
Automatic test sequence

Note
During testing and installation other control units may
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:
Vehicle system test

HELP
Vehicle system test

HELP
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

BOSCH 8.0
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FABIA 2000 Chassis
45-6
Fault table - ABS systems BOSCH 5.7
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.
All the possible faults which can be detected by the ABS control unit -J104- and which can be displayed on vehicle
system tester -V.A.G 1552- during interrogation of the fault memory content, are listed below.
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 1552-
Rectifying fault
no fault detected
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
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.
ABS RR -N135 outlet

valve
00276
ABS RL -N136 outlet valve
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45-6 page 1
45
FABIA 2000 Chassis
Rectifying fault
00283
Open circuit/Short circuit to positive
Read the measured value block Chapter 45-10, dis-
Implausible signal
Check wiring and plug connections according to the cur-
Speed sensor vl-G47
play group 001.

rent flow diagram Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
Check the front left speed sensor -G47- and sensor ring
for damage.
Replace the speed sensor -G47- or the sensor ring as required Chapter 45-19.
If the fault occurs again:
00285
Speed sensor vr-G45
Implausible signal
play group 001.

Check the front right speed sensor -G45- for damage.

00287
Speed sensor hr-G44
Implausible signal
play group 001.

Check the rear right speed sensor -G44- for damage.

00290
Speed sensor hl-G46
Implausible signal
play group 001.

Check the rear left speed sensor -G46- for damage.

45-6 page 2
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FABIA 2000 Chassis

Rectifying fault
00301
Open circuit
play group 002 or 006 .
Return flow pump for ABS

- V39
Erasing fault memory (05) Chapter 45-5.

Ending output (06) Chapter 45-5.
Switch on ignition.
00302
Open circuit
Replace hydraulic control unit Chapter 45-17.

Read the measured value block Chapter 45-10, display group 006.
ABS solenoid valve relay J106

Fitting Locations.
fault:
00526
Open circuit
Brake light switch -F
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
00532
Supply voltage
Signal outside tolerance
Note:
Signal too low
This fault is related to
the voltage supply of

the control unit.
This fault is only stored
if it occurs at a vehicle
speed above 6 km/h.
Replacing brake light switch Chapter 45-16.

45-15.
Determine and eliminate open circuit in voltage supply

Fitting Locations.
Test battery, AC generator and voltage regulator

Fitting Locations.
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
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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.
45-6 page 3
45
FABIA 2000 Chassis
Rectifying fault
00753
Electrical fault in the circuit
defective
Electr. connections wheel

speed pulses
00778

Fitting Locations.
play groups 005 and 125.
Steering angle sender G85
Perform null balance of the steering angle sender -G85 Chapter 45-13.
If necessary replace steering angle sender -G85 Chap. 45-16.
Balance not performed
Implausible signal
Read the measured value block Chapter 45-10, display groups 005 and 125.
Check fitting position of the steering angle sender -G85 Chapter 45-16.

01044
Control unit wrongly coded
01119
Coding ABS with EDL control unit -J104- Chapter 458.
Performing automatic test sequence Chapter 45-5.
Signal for gear recognition

01197
Data bus drive: wrong

software version
01200
Power supply for ABS
valves
Note:
the voltage supply to

the hydraulic unit -N55and the return flow
pump motor -V39-.

45-15.

Fitting Locations.

Fitting Locations.
Test relay for solenoid valves, read measured value block

Chapter 45-10, display groups 002 or 006.

Chapter 45-12.
45-6 page 4
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45
FABIA 2000 Chassis

Read-out on display -V.A.G 155201312
defective
Rectifying fault
Coding ABS with EDL control unit -J104- Chapter 45-
1)
8.
Drive databus
Test the control unit coding Engine - Fuel Injection;

Rep. Gr. 01.
Testing data BUS Electrical system; Rep. Gr. 90

45-15.
Erasing fault memory Chapter 45-5.

No further measures required.
Inform customer.
defect
sporadic 1)
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.
Rectifying fault
01314
No communication
play group 125.
Engine control unit

45-15.

Perform self-diagnosis of the engine control unit
Engine - Fuel Injection; Rep. Gr. 01.
01315
please read out fault

memory
Read out fault memory of the engine control unit
No communication

play group 125.
Gearbox control unit

45-15.

Perform self-diagnosis of the gearbox control unit
automatic gearbox 001; Rep. Gr. 01.
01316

memory
Read out the fault memory of the automatic gearbox con-
No communication
No communication
trol unit Automatic Gearbox; Rep. Gr. 01.
Brake control unit

01317
play group 125.
Control unit with display in

dash panel insert -J285

45-15.

Perform self-diagnosis of the dash panel insert
Electrical System; Rep. Gr. 90.
01321
Airbag control unit -J234
No communication

Read out fault memory of the airbag control unit Body
Work; Rep. Gr. 01
Edition 07.04
S00.5303.16.20
45-6 page 5
45
FABIA 2000 Chassis

Rectifying fault
01418
Vehicle stability program
switch valve -1- N225
01419
01420
high pressure valve -1N227

Fitting Locations.
01421
45-6 page 6
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Rectifying fault
01423
Check fitting position of the lateral acceleration sender

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

group 005; replace lateral acceleration sender -G200- if
necessary Chapter 45-16.
fault:

group 005; replace lateral acceleration sender -G200- if
fault:
Implausible signal
Check attachment of the lateral acceleration sender

-G200- Chapter 45-16.
Erase fault memory Chapter 45-5, perform test drive

and again interrogate fault memory Chapter 45-5.
Replacing lateral acceleration sender -G200 Chap. 45-16.

fault:
01424
Yaw rate sender -G202,
signal line
01425
Yaw rate sender -G202,
reference line

group 005; replace yaw rate sender -G202- if necessary

Chapter 45-16.
fault:
Edition 07.04
S00.5303.16.20
45-6 page 7
45
FABIA 2000 Chassis
Rectifying fault
01435
Read the measured value block Chapter 45-10, display groups 002 and 005.
Brake pressure sender 1 G201
Replacing brake pressure sender 1 -G201- Chap. 4517.

fault:
Replacing brake pressure sender 1 -G201- Chap. 4517.

fault:
Implausible signal

group 005; replace brake pressure sender 1 -G201- if
fault:
45-6 page 8
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Rectifying fault
01542
defective

Yaw rate sender -G202

group 005; replace yaw rate sender -G202- if necessary
Chapter 45-16.
If the fault has still not been corrected:
Implausible signal
Check attachment of the yaw rate sender -G202 Chapter 45-16.
Erase fault memory Chapter 45-5, perform test drive

and again interrogate fault memory.
Replacing yaw rate sender -G202- Chap. 45-16.

fault:
Test fuse 1.
Test wiring and plug connections to the steering angle
01826
(Information in the literature)
Note:
sender -G85- according to the current flow diagram

Fitting Locations.
This fault concerns the
Test battery, charge if necessary Electrical System;
voltage supply of the

steering angle sender
-G85-.
Rep. Gr. 27.
18055
8.
Inspect coding/variants of
the control units in the
drive train

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

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.
Edition 07.04
S00.5303.16.20
45-6 page 9
45
FABIA 2000 Chassis
Rectifying fault
18265
Load signal
65535
Control unit defective
45-6 page 10
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.
All the possible faults which can be detected by the ABS control unit -J104- and which can be displayed on vehicle
system tester -V.A.G 1552- during interrogation of the fault memory content, are listed below.
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
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.
Rectifying fault
no fault detected
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
Replacing hydraulic control unit Chap. 45-18.
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

Chapter 45-12.

Fitting Locations.
00274

fault:
ABS RL -N134 inlet valve
00275
ABS RR -N135 outlet
valve
00276
ABS RL -N136 outlet valve
Edition 07.04
S00.5303.16.20
45-7 page 1
45
FABIA 2000 Chassis
Rectifying fault
00283
Mechanical fault
play group 001.
Speed sensor vl-G47

Implausible signal
Check the front left speed sensor -G47- and sensor ring

for damage.
00285
Mechanical fault

Speed sensor vr-G45

Implausible signal
Check the front right speed sensor -G45- and sensor ring

for damage.
00287
Mechanical fault

Speed sensor hr-G44

Implausible signal
Check the rear right speed sensor -G44- and sensor ring

for damage.
00290
Mechanical fault

Speed sensor hl-G46

Implausible signal
Check the rear left speed sensor -G46- and sensor ring

for damage.
45-7 page 2
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Rectifying fault
00301
Implausible signal
play group 006.
Return flow pump for ABS

- V39
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
no signal/communication
ESP sensor unit -G419

Read the measured value block Chapter 45-11, display groups 005 or 126.

Implausible signal

Fitting Locations.
fault:
Replacing ESP sensor unit -G419- Chapter 45-16.

00526
Implausible signal
00532
Brake light switch -F

Open circuit
Signal too low
Replacing brake light switch -F- Chap. 45-16.


play group 006.
Supply voltage
Note:

Fitting Locations.
the voltage supply of

the control unit.

Fitting Locations.
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
Mechanical fault
Different wheel speed

pulses

00753
Short circuit to positive
Electr. connections wheel

speed pulses
Edition 07.04
S00.5303.16.20

Fitting Locations.
45-7 page 3
45
FABIA 2000 Chassis
Rectifying fault
00778
defective
play groups 005 and 125.
Steering angle sender G85
If necessary replace steering angle sender -G85 Chap. 45-16.
No or incorrect basic
setting/adaption
Perform null balance of the steering angle sender -G85-
Chapter 45-14.
play group 125.
Implausible signal
Check fitting position of the steering angle sender -G85 Chapter 45-16.

01044
Control unit wrongly coded

01119
Signal for gear recognition

01130
ABS operation

Switch on ignition.
Interrogating fault memory (02) Chap. 45-5.
01200
valves
Note:

valves of the hydraulic
unit -N55-.

Test relay for solenoid valves, read measured value block
Chapter 45-11, display group 006.

Fitting Locations.

Fitting Locations.

Chapter 45-12.
45-7 page 4
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Rectifying fault
01201
Test relay for return flow pump for ABS -V39-, read
measured value block Chapter 45-11, display group

006.

pump
Note:

Fitting Locations.

return flow pump for
ABS -V39-.

Fitting Locations.

Chapter 45-12.
01312
defective 1)
9.
Drive databus

Rep. Gr. 01.
defect
sporadic 1)
1)

No further measures required.
Inform customer.
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.
Rectifying fault
01314
Engine control unit
play group 125.

01315
Gearbox control unit

memory

play group 125.

Perform self-diagnosis of the gearbox control unit
automatic gearbox 001; Rep. Gr. 01.
01317
dash panel insert -J285

memory
Read out the fault memory of the automatic gearbox con-
trol unit Automatic Gearbox; Rep. Gr. 01.

play group 125.

Edition 07.04
S00.5303.16.20
45-7 page 5
45
FABIA 2000 Chassis
Rectifying fault
01321
Airbag control unit -J234
play group 127.

Perform self-diagnosis for airbag system Body Work;
Rep. Gr. 01
01418
01419


Fitting Locations.
01420

Chapter 45-12.
01421
01435
Brake pressure sender 1 G201
Implausible signal

Switch on ignition.
01486
System function test activated
01683
Wheel speed signals/
speed

Perform or end ESP road and system test Chap. 4514

Check wiring and plug connections for the speed sensor
01765
Engine control unit control
difference
45-7 page 6

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Rectifying fault
01766
Brake control unit control

difference
Implausible signal
Perform ESP road and system test Chap. 45-14

Switch on ignition.

01826
Test wiring and plug connections to the steering angle

sender -G85- according to the current flow diagram
Fitting Locations.
Steering angle sender G85, voltage supply KL30

Note:
This fault is stored, if
the steering angle

sender -G85- is separated from the voltage
supply or the onboard
voltage is NOK.

Fitting Locations.
Perform test drive or null balance of the steering angle

sender -G85- Chapter 45-14.

Switch on ignition.
01827
dash panel insert -J285,
wheel circumference implausible
16347
Replace steering angle sender -G85- Chap. 45-16.


18055
Inspect coding/variants of
the control units in the
drive train

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

gearbox 001; Rep. Gr. 01.
18265
Load signal
Edition 07.04
S00.5303.16.20

45-7 page 7
45
45-7 page 8
FABIA 2000 Chassis
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.
Vehicle system test
Select function XX
Readout on display:
Select function
HELP
0 7 code the control unit and con-
firm with Q .
Coding 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
1.0 litre/37
kW
1.2 ltr./40 kW
Edition 07.04
S00.5303.16.20
AQV, ARV
AWY
ABS control unit iden- ABS version

tification number
Code
number
6Q0614117
ABS
00036
6Q0907379
ABS
00044
6Q0907379C
ABS
00044
6Q0907379G
ABS
00044
6Q0907379G
ABS
00044
Code control unit - ABS systems BOSCH 5.7
Gearbox
Gearbox
Gearbox
45-8 page 1
45
Engine
1.2 ltr./47 kW
1.4 ltr./44 kW
1.4 ltr./50 kW
1.4 ltr./55 kW
1.4 ltr./74 kW
45-8 page 2
FABIA 2000 Chassis

AZQ
AZF, AZE
AQW, AME, ATZ
AUA, BBY
AUB, BBZ

tification number
Code
number
Gearbox
6Q0907379G
ABS
00044
6Q0907379
ABS
00044
6Q0907379C
ABS
00044
6Q0907379G
ABS
00044
6Q0614117
ABS
00036
6Q0614417
TCS
00052
6Q0907379
ABS
00044
6Q0907379A
TCS
00060
6Q0907379C
ABS
00044
6Q0907379D
TCS
00060
6Q0907379G
ABS
00044
6Q0907379H
TCS
00060
6Q0614117
ABS
00036
6Q0614417
TCS
00116
6Q0907379
ABS
00044
6Q0907379A
TCS
00124
6Q0907379C
ABS
00044
Gearbox
6Q0907379C
ABS
00045
Automatic gearbox
6Q0907379D
TCS
00124
Gearbox
6Q0907379D
TCS
00125
Automatic gearbox
6Q0907379G
ABS
00044
Gearbox
6Q0907379G
ABS
00045
Automatic gearbox
6Q0907379H
TCS
00124
Gearbox
6Q0907379H
TCS
00125
Automatic gearbox
6Q0907379Q
ESP
03453
Gearbox
6Q0907379Q
ESP
03485
Automatic gearbox
6Q0614117
ABS
00036
6Q0614417
TCS
00116
6Q0907379
ABS
00044
6Q0907379A
TCS
00124
6Q0907379C
ABS
00044
6Q0907379D
TCS
00124
6Q0907379G
ABS
00044
6Q0907379H
TCS
00124
6Q0907379Q
ESP
03386
Gearbox
Gearbox
Gearbox
Gearbox
Gearbox
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Engine
2.0 ltr./85 kW
AZL
1.9 ltr./47 kW
SDI
ASY
1.9 ltr./74 kW
TDI PD
ATD
1.4 ltr./55 kW
TDI PD
AMF
1.9 ltr./96 kW
TDI PD
1)
2)
3)
ASZ

tification number
Code
number
Gearbox
6Q0907379
ABS
00044
6Q0907379A
TCS
00188
6Q0907379C
ABS
00044
6Q0907379D
TCS
00188
6Q0907379G
ABS
00044
6Q0907379H
TCS
00188
6Q0907379M
ESP
033381)
6Q0907379M
ESP
033412)
6Q0907379M
ESP
033443)
6Q0907379Q
ESP
03338
6Q0907379
ABS
00044
6Q0907379C
ABS
00044
6Q0907379G
ABS
00044
6Q0614417
TCS
00180
6Q0907379
ABS
00044
6Q0907379A
TCS
00188
6Q0907379C
ABS
00044
6Q0907379D
TCS
00188
6Q0907379G
ABS
00044
6Q0907379H
TCS
00188
6Q0907379Q
ESP
03411
6Q0907379Q
ESP
03479
6Q0907379G
ABS
00044
6Q0907379H
TCS
00188
6Q0907379Q
ESP
03357
6Q0907379G
ABS
00044
6Q0907379H
TCS
00188
Gearbox
Gearbox
Gearbox
Gearbox
Gearbox
Fabia
Fabia Sedan
Fabia estate car
The control unit coding is shown in the display, example

00116:
Press
6Q0614117
TCS 5.7
Coding 00116
Front
X00
->
WSC XXXXX
.
Vehicle system test
Select function XX
Readout on display:
HELP
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
Readout on display:
XXXXX
Note
The steering wheel must be in the straight ahead position
before executing the function Coding 2.
Edition 07.04
S00.5303.16.20
45-8 page 3
45
FABIA 2000 Chassis
Enter code number 40168 and confirm with
Q.
Vehicle system test
Select function XX
Readout on display:
Select function
HELP
0 4 initiate basic setting and con-
firm entry with Q .

Initiating basic setting
Enter display group number XXX
Readout on display:
Select display group 0 0 1 and confirm with

Switch off the ignition for about 2 seconds.
Switch on ignition.
Q.
Note
The vehicle system tester -V.A.G 1552- must remain
connected up while the ignition is switched off.
Readout on display:
Vehicle system test

Select function XX
HELP
Vehicle system test

HELP
Press
0 6 for the function End output and confirm
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
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.

Vehicle system test
Select function XX
Readout on display:
Select function
HELP
firm with Q .
Coding control unit
Enter code number XXXXXXX
Readout on display:

confirm with Q .
Edition 04.05
S00.5303.18.20
Code control unit - ABS BOSCH 8.0
45-9 page 1
45
FABIA 2000 Chassis
Table of codes
Engine
1.2 ltr./40
kW
1.2 ltr./47
kW
1.4 ltr./55
kW
45-9 page 2
Engine
identification characters
AWY, BMD
AZQ, BME
AUA, BBY,
BKY
ABS control unit

identification
number
ABS
version
Brakes at
the front
axle
Brakes at
the rear
axle
6Q0907379R
ABS
13 FS-II
Drum brake 0000005
6Q0907379R
ABS
14 FS-III
Drum brake 0000005
6Q0907379AA
ABS
13 FS-II
Drum brake 0000005
6Q0907379AA
ABS
14 FS-III
Drum brake 0000005
6Q0907379AF
ABS
13 FS-II
Drum brake 0002058
6Q0907379AF
ABS
14 FS-III
Drum brake 0002100
6Q0907379R
ABS
14 FS-III
Drum brake 0000005
6Q0907379AA
ABS
14 FS-III
Drum brake 0000005
6Q0907379AF
ABS
13 FS-II
Drum brake 0002061
6Q0907379AF
ABS
14 FS-III
Drum brake 0002103
6Q0907379S
TCS
14 FS-III
Drum brake 0000005
6Q0907379AB
TCS
14 FS-III
Drum brake 0000005
6Q0907379AG
TCS
13 FS-II
Drum brake 0002061
6Q0907379AG
TCS
14 FS-III
Drum brake 0002103
6Q0907379AH
ESP
14 FS-III
Drum brake 0000428
6Q0907379T
ESP
14 FS-III
Drum brake 0000428
6Q0907379R
ABS
14 FS-III
Drum brake 0000005
6Q0907379AA
ABS
14 FS-III
Drum brake 0000005
6Q0907379AF
ABS
14 FS-III
Drum brake 0002106
6Q0907379S
TCS
14 FS-III
Drum brake 0000005
6Q0907379AB
TCS
14 FS-III
Drum brake 0000005
6Q0907379AG
TCS
14 FS-III
Drum brake 0002106
6Q0907379T
ESP
14 FS-III
Drum brake 0000425
6Q0907379AH
ESP
14 FS-III
Drum brake 0000425
6Q0907379R
ABS
14 FS-III
Drum brake 0000011
6Q0907379AA
ABS
14 FS-III
Drum brake 0000011
6Q0907379AF
ABS
14 FS-III
Drum brake 0002127
6Q0907379S
TCS
14 FS-III
Drum brake 0000011
6Q0907379AB
TCS
14 FS-III
Drum brake 0000011
6Q0907379AG
TCS
14 FS-III
Drum brake 0002127
6Q0907379T
ESP
14 FS-III
Drum brake 0000440
6Q0907379AH
ESP
14 FS-III
Drum brake 0000440
Code
number
Gearbox
Gearbox
Gearbox
Gearbox
Automatic gearbox
Edition 04.05
S00.5303.18.20
45
FABIA 2000 Chassis

Engine
1.4 ltr./74
kW
2.0 ltr./85
kW
1.4 ltr./55
kW TDI PD
1.9 ltr./47
kW SDI
1.9 ltr./74
kW TDI PD
Edition 04.05
S00.5303.18.20
Engine
AUB, BBZ
AZL
AMF
ASY
ATD
ABS control unit

identification
number
ABS
version
Brakes at
the front
axle
Brakes at
the rear
axle
Code
number
6Q0907379R
ABS
14 FS-III
Disc brake
0000005
6Q0907379AA
ABS
14 FS-III
Disc brake
0000005
6Q0907379AF
ABS
14 FS-III
Drum brake 0002109
6Q0907379AF
ABS
14 FS-III
Disc brake
0002178
6Q0907379S
TCS
14 FS-III
Disc brake
0000005
6Q0907379AB
TCS
14 FS-III
Disc brake
0000005
6Q0907379AG
TCS
14 FS-III
Drum brake 0002109
6Q0907379AG
TCS
14 FS-III
Disc brake
0002178
6Q0907379AH
ESP
14 FS-III
Disc brake
0000329
6Q0907379T
ESP
14 FS-III
Disc brake
0000329
6Q0907379AA
ABS
15 C54-II
Disc brake
0000008
6Q0907379R
ABS
15 C54-II
Disc brake
0000008
6Q0907379AB
TCS
15 C54-II
Disc brake
0000008
6Q0907379AG
TCS
15 C54-II
Disc brake
0002226
6Q0907379S
TCS
15 C54-II
Disc brake
0000008
6Q0907379T
ESP
15 C54-II
Disc brake
0000275
6Q0907379AH
ESP
15 C54-II
Disc brake
0000275
6Q0907379R
ABS
14 FS-III
Drum brake 0000008
6Q0907379AA
ABS
14 FS-III
Drum brake 0000008
6Q0907379AF
ABS
14 FS-III
Drum brake 0002148
6Q0907379AF
ABS
14 FS-III
Drum brake 0002151
6Q0907379S
TCS
14 FS-III
Drum brake 0000008
6Q0907379AB
TCS
14 FS-III
Drum brake 0000008
6Q0907379AG
TCS
14 FS-III
Drum brake 0002148
6Q0907379AG
TCS
14 FS-III
Drum brake 0002151
6Q0907379T
ESP
14 FS-III
Drum brake 0000431
6Q0907379AH
ESP
14 FS-III
Drum brake 0000431
6Q0907379AH
ESP
14 FS-III
Drum brake 0000437
6Q0907379R
ABS
14 FS-III
Drum brake 0000008
6Q0907379AF
ABS
14 FS-III
Drum brake 0002142
6Q0907379AA
ABS
14 FS-III
Drum brake 0000008
6Q0907379R
ABS
14 FS-III
Disc brake
0000008
6Q0907379AA
ABS
14 FS-III
Disc brake
0000008
6Q0907379AF
ABS
14 FS-III
Disc brake
0002196
6Q0907379AF
ABS
14 FS-III
Drum brake 0002154
6Q0907379S
TCS
14 FS-III
Disc brake
0000008
6Q0907379AB
TCS
14 FS-III
Disc brake
0000008
6Q0907379AG
TCS
14 FS-III
Disc brake
0002196
6Q0907379AG
TCS
14 FS-III
Drum brake 0002154
6Q0907379T
ESP
14 FS-III
Disc brake
0000365
6Q0907379AH
ESP
14 FS-III
Disc brake
0000365
Gearbox
Manual gearbox
Gearbox
Gearbox
Gearbox
Gearbox
45-9 page 3
45
FABIA 2000 Chassis
Engine
Engine
1.9 ltr./96
kW TDI PD
ASZ
ABS control unit

identification
number
ABS
version
Brakes at
the front
axle
Brakes at
the rear
axle
Code
number
6Q0907379AF
ABS
15 C54-II
Disc brake
0002229
6Q0907379AA
ABS
15 C54-II
Disc brake
0000008
6Q0907379R
ABS
15 C54-II
Disc brake
0000008
6Q0907379S
TCS
15 C54-II
Disc brake
0000008
6Q0907379AB
TCS
15 C54-II
Disc brake
0000008
6Q0907379AG
TCS
15 C54-II
Disc brake
0002229
6Q0907379AH
ESP
15 C54-II
Disc brake
0000296
6Q0907379T
ESP
15 C54-II
Disc brake
0000296
The read-out on display is the control unit coding, e.g.

0000365):
Press
6Q0907379T
ESP 8.0
Coding 0000365
front
Gearbox
Gearbox
X00
WSC XXXXX
.
Vehicle system test
Select function XX
Readout on display:
HELP
only on vehicles with ABS/TCS/ESP BOSCH 8.0
Function
1 6 select access authorisation and con-
firm with Q .
Access authorisation
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
Q.
Vehicle system test
Select function XX
Readout on display:
Select function
HELP
0 4 initiate basic setting and con-
firm entry with Q . Readout on display:

Initiating basic setting
Enter display group number
Readout on display:
Select display group
XXX
0 0 1 and confirm with Q .

Basic setting
1
EIN <8-OFF>
Bal. steer. angl. send. O.K.
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
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45
FABIA 2000 Chassis
Press
with Q .
Vehicle system test
Readout on display:
HELP
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.
Edition 04.05
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45-9 page 5
45
45-9 page 6
FABIA 2000 Chassis
Edition 04.05
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45
FABIA 2000 Chassis
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
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.
Vehicle system test
Select function XX
Readout on display:
HELP
Press
0 and 8 for the function Read measured value block and confirm with Q .
Reading measured value block
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
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45-10 page 1
45
FABIA 2000 Chassis
Display group
number
-V.A.G 1551-
-V.A.G 1552-
higher
Press 3
Press
lower
Press 1
Press
skip
Press C
Press C
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
Readout on display
0 km/h
Rear right wheel speed (km/h)
Rear left wheel speed (km/h)
Front right wheel speed (km/h)

Front left wheel speed (km/h)

vehicles with ABS, ABS/EDL/TCS BOSCH 5.7

0
Readout on display
1
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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45
FABIA 2000 Chassis

vehicles with ABS/EDL/TCS/ESP BOSCH 5.7

0
activated
Readout on display
0
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

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

vehicles with ABS/EDL/TCS BOSCH 5.7
Note
Readout of the display group number must occur while the engine is running.

800 rpm
10 %
Readout on display
1
not assigned
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

770 rpm
33 Nm
33 Nm
Readout on display
0%
Throttle valve angle
Engine loss torque

Display range 0630 Nm

Engine speed


2:50 h
Readout on display
0
not assigned
Disregard display
EDL disconnected because of increased brake temperature
0 - none
1 - yes
Stationary time information

too great
ERROR
invalid
45-10 page 4
Edition 07.04
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45
FABIA 2000 Chassis


2:50 h
Readout on display
on/off
not assigned
not assigned
Stationary time information
too great
ERROR
invalid


0,00
0.00/s
1.3 bar
0.00
Readout on display
m/s2
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-.
Edition 07.04
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45-10 page 5
45
FABIA 2000 Chassis


12.7 V
on
off
Readout on display
WSC XXXXX
Workshop code operating instructions vehicle system
tester -V.A.G 1552Return 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


Steering
angle 1
Engine 1
Gearbox 1
Readout on display
Combi 1
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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45
FABIA 2000 Chassis
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
Chapter 45-4
Perform with the vehicle system tester -V.A.G 1552-

Vehicle system test
Select function XX
Readout on display:
Select function
HELP
0 8 Read measured value block
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
FABIA 2000 Chassis
Note
Proceed according to the following table to switch to another display group:
Display group
number
-V.A.G 1551-
-V.A.G 1552-
higher
Press 3
Press
lower
Press 1
Press
skip
Press C
Press C
If the nominal values are reached in all display fields,

press the key .
Press
with Q .
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).

0 km/h
0 km/h
0 km/h
Readout on display
0 km/h
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
Edition 04.05
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45
FABIA 2000 Chassis

vehicles with ABS, ABS/TCS BOSCH 8.0

0
Readout on display
1
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.

1 - Brake pedal actuated
Vehicles with ABS//TCS/ESP BOSCH 8.0

0
activated
Readout on display
0
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

operated - brake pedal operated

Edition 04.05
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45-11 page 3
45
FABIA 2000 Chassis

vehicles with ABS/TCS BOSCH 8.0
Note
Readout of the display group number must occur while the engine is running.

800 rpm
10 %
Readout on display
1
not assigned
TCS switch -E132 0 - Switch not actuated
1 - Switch actuated

Engine speed

770 rpm
33 Nm
33 Nm
Readout on display
0%
Throttle valve angle
Engine loss torque


Engine speed
45-11 page 4
Edition 04.05
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45
FABIA 2000 Chassis

vehicles with ABS/TCS BOSCH 8.0

2:50 h
on/off
Readout on display
0
not assigned
Disregard display
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

2:50 h
Readout on display
on/off
not assigned
not assigned
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
Edition 04.05
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45-11 page 5
45
FABIA 2000 Chassis


0,00
0.00/s
1.3 bar
Readout on display
0.00 m/s2
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-.


12.7 V
on
off
Readout on display
WSC XXXXX
Workshop code operating instructions vehicle system
tester -V.A.G 1552Return 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
Edition 04.05
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45
FABIA 2000 Chassis

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.

o.k.
o.k.
o.k.
Readout on display
o.k.
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



0
Readout on display
1.3 bar
not assigned
Brake pressure sender 1 -G201-1)
Specified value for not-operated brake: -7,07.0 bar


1)
The sender is located in the hydraulic control unit.
Edition 04.05
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45-11 page 7
45
FABIA 2000 Chassis
Display group number 125 (for all vehicles):

Steering
angle 1 1
Engine 1
Gearbox 1
Readout on display
Combi 1
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)
Only on vehicles fitted with automatic gearbox.

Readout on display
ESP
sensors 1
Data BUS ESP sensor unit -G419 1 - Data BUS connection is present
not assigned
not assigned
not assigned
1)
45-11 page 8
Edition 04.05
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45
FABIA 2000 Chassis

Display group number 127 (for all vehicles):
Readout on display
Airbag 1
not assigned
not assigned
Data BUS for airbag control unit
not assigned
1)
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45-11 page 9
45
45-11 page 10
FABIA 2000 Chassis
Edition 04.05
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45
FABIA 2000 Chassis
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.
Operate vehicle system tester following the indica-
tions on the display, i.e. carry out all self-diagnosis

working steps in the prescribed sequence.
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:
Final control diagnosis

IFL: VBAT
OFL: 0V
- ->
Wheel FL locked
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

- ->
EDL valves/Hydr.p:V BAT Wheel FL/FR lock
Hydr-P = Hydraulic pump (Return flow pump)
Edition 07.04
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Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0
45-12 page 1
45
FABIA 2000 Chassis
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-
Vehicle system test
Select function XX
Readout on display:
Press
HELP
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:
Press

Hydraulic pump ABS -V64
->

Operate brake
->
within the next 60 seconds.
Readout on display:
Operate brake pedal

Press
.
- ->
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
Readout on display:
Press

IFL: VBAT
OFL: 0V
- ->
Wheel FL locked

IFL: VBAT
OFL: VBAT
- ->
Wheel FL free

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:

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
Edition 07.04
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45
FABIA 2000 Chassis
Press
Return flow pump for ABS -V39- no longer runs.

IFL: VBAT
OFL: 0V
Readout on display:
Press
- ->
Wheel FL free
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.
- ->
IFL: OV
OFL: 0V
Wheel FL locked
Readout on display:

by hand.
Press
Readout on display:

Release brake
->

Operate brake
->
Take your foot off the brake pedal.

Press
Readout on display:
Operate brake pedal

Press
.
- ->
IFR: 0V
OFR: 0V
Wheel FR locked
Readout on display:

by hand.
Press
Readout on display:
Press

IFR: VBAT
OFR: 0V
- ->
Wheel FR locked

IFR: VBAT
OFR: VBAT
- ->
Wheel FR free

Chap. 45-17, BOSCH 8.0 Chap. 45-18.
Readout on display:

by hand.
Press
Edition 07.04
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45-12 page 3
45
FABIA 2000 Chassis
Readout on display:
Press

IFR: VBAT
OFR: 0V
- ->
Wheel FR free

- ->
IFR: 0V
OFR: 0V
Wheel FR locked
Readout on display:

by hand.
Press
Readout on display:

Release brake
->

Operate brake
->

Press
Readout on display:
Operate brake pedal

Press
.
- ->
IRL: 0V
ORL: 0V
Wheel RL locked
Readout on display:

by hand.
Press
Readout on display:
Press

IRL: VBAT
ORL: 0V
- ->
Wheel RL locked

IRL: VBAT
ORL: VBAT
- ->
Wheel RL free

IRL: VBAT
ORL: 0V
- ->
Wheel RL free

Chap. 45-17, BOSCH 8.0 Chap. 45-18.
Readout on display:

by hand.
Press

Readout on display:
Press
45-12 page 4
Edition 07.04
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45
FABIA 2000 Chassis

- ->
IRL: 0V
ORL: 0V
Wheel RL locked
Readout on display:

by hand.
Press
Readout on display:

Release brake
->

Operate brake
->

Press
Readout on display:
Operate brake pedal

Press
.
- ->
IRR: 0V
ORR: 0V
Wheel RR locked
Readout on display:

by hand.
Press
Readout on display:
Press

IRR: VBAT
ORR: 0V
- ->
Wheel RR locked

IRR: VBAT
ORR: VBAT
- ->
Wheel RR free

IRR: VBAT
ORR: 0V
- ->
Wheel RR free

Chap. 45-17, BOSCH 8.0 Chap. 45-18.
Readout on display:

by hand.
Press

Readout on display:
Press

Edition 07.04
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45-12 page 5
45
FABIA 2000 Chassis

- ->
IRR: 0V
ORR: 0V
Wheel RR locked
Readout on display:

by hand.
Press
.
Release brake
Readout on display:
->

Press
Read-out on display (for vehicles with EDL):

- ->
EDL valves/Hydr. p: VBAT Wheel FL/FR lock
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):
Function unknown or cannot

be executed at this moment
->
The final control diagnosis is ended.
Press
.
Vehicle system test
Select function XX
Readout on display:
HELP
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
FABIA 2000 Chassis
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.
Bleeding the hydraulic unit (vehicles with ABS/EDL/

Null balance of the steering angle sender -G85 45-13 page 4.
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
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Basic setting - ABS systems BOSCH 5.7
45-13 page 1
45
FABIA 2000 Chassis
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.

Vehicle system test
Select function XX
Readout on display:
HELP
Press
0 and 4 for the function basic setting and

confirm with Q .
Basic setting
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
<>.
System in basic setting
10
Rel. pedal;FR+FL bleeder screws OPEN <>
Readout on display:
Press
Readout on display:

Actuate pedal 10x; wait
11

12
Return flow pump for ABS -V39- runs.
Readout on display:

Bleeder screw CLOSED
Readout on display:
Press
.
14
Rel. pedal;RR+RL bleeder screws OPEN <>
Readout on display:
Press
13
<>
.
Readout on display:
15

Readout on display:
Press
.
Part bleeding ended...
Readout on display:
Press
17
Readout on display:
Press
16
<>
Vehicle system test

Select function XX
HELP
Vehicle system test

HELP
firm the entry with Q .

Readout on display:
45-13 page 2
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45
FABIA 2000 Chassis
Separate plug connection to V.A.G. 1552.

Perform test drive with at least one ABS adjustment.

with ABS/EDL/TCS/ESP BOSCH 5.7)


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!
and bleeding appliance, e.g. ROMESS S15, it is important to ensure a minimum filling pressure of 0.2
MPa (2 bar).
Connect brake filling and bleeding appliance, e. g.

ROMESS S15.

Vehicle system test
Select function XX
Readout on display:
Press
HELP
confirm with Q .
Readout on display:
Edition 07.04
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Basic setting
45-13 page 3
45
FABIA 2000 Chassis

down.
Press

Basic setting
10
EIN <8-OFF>
Rel. pedal;FR+FL bleeder screws OPEN <8>
Readout on display:
Press
8.
Readout on display:
Basic setting
10
<8-OFF>
Basic setting
10
<8-OFF>
Basic setting
10
<8-OFF>
<8>
Readout on display:
Readout on display:
Press
8.
Basic setting
10
<8-OFF>
Rel. pedal;RR+RL bleeder screws OPEN <8>
Readout on display:
Press
8.
Readout on display:
Basic setting
10
<8-OFF>
Basic setting
10
<8-OFF>
<8>
Basic setting
10
<8-OFF>
Readout on display:
Press
8.
Readout on display:
Press
Readout on display:
Press
Vehicle system test

Select function XX
HELP
Vehicle system test

HELP

Readout on display:
Steering angle sender

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
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45
FABIA 2000 Chassis

-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!
Vehicle system test
Select function XX
Readout on display:
Press
HELP
1 and 1 for the function Coding 2 and con-
firm with Q .
Coding 2
Enter code number
Readout on display:
Enter code number 40168 and confirm entry with
XXXXX
Q.
Vehicle system test
Select function XX
Readout on display:
HELP
Press

confirm with Q .
Readout on display:
Press
If this appears on the display, function 11 coding 2 was

not successfully performed.
Readout on display:
Basic setting
be carried out at the moment
->
Basic setting
1
ON <8-OFF>
Basic setting
1
ON <8-OFF>
Bal. steer. angl. send. N.O.K.

number 005.
or:
Readout on display:
or:
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45-13 page 5
45
FABIA 2000 Chassis
Readout on display:
1. Interrogate fault memory (Function 02)
Basic setting
1
ON <8-OFF>
Bal. steer. angl. send. locked
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.
Press
.
Vehicle system test
Readout on display:
Press
HELP
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.
-V.A.G 1551/3B- or -V.A.G 1551/3C-
Vehicle system test
Select function XX
Readout on display:
Press
HELP
confirm with Q .
Basic setting
Readout on display:
Press

System in basic setting 3
System test activated O.K.
Readout on display:
->
The ESP road and system test is activated, ESP and TCS
warning light -K155- lights up.
Press
Readout on display:
Press
Vehicle system test

Select function XX
HELP
Vehicle system test

HELP
with Q .
Readout on display:
45-13 page 6
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45
FABIA 2000 Chassis
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
45-13 page 8
FABIA 2000 Chassis
Edition 07.04
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45
FABIA 2000 Chassis
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.
Perform road and system test (vehicles with ABS/


with ABS/TCS/ESP BOSCH 8.0)


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
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45-14 page 1
45
FABIA 2000 Chassis
WARNING!
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,
Connect brake filling and bleeding device, e.g.

-ROMESS S15-.

Vehicle system test
Select function XX
Readout on display:
Press
HELP
confirm with Q .
Basic setting
Readout on display:

down.
Press

Basic setting
10
EIN <8-OFF>
Rel. pedal;FR+FL bleeder screws OPEN <8>
Readout on display:
Press
8.
Readout on display:
Basic setting
10
<8-OFF>
Basic setting
10
<8-OFF>
Readout on display:
Basic setting
10
Readout on display:
Press
8.
Basic setting
10
<8-OFF>
Rel. pedal;RR+RL bleeder screws OPEN <8>
Readout on display:
Press
<8-OFF>
<8>
8.
Basic setting
10
Readout on display:
<8-OFF>

Basic setting
Readout on display:
Press
Basic setting
10
<8-OFF>
.
Vehicle system test
Select function XX
Readout on display:
Press
<8-OFF>
<8>
8.
Readout on display:
Press
10
HELP
45-14 page 2
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FABIA 2000 Chassis

Readout on display:
Vehicle system test

HELP

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.

-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
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45-14 page 3
45
FABIA 2000 Chassis
Make sure the steering wheel is not moved. Do not

switch off the ignition!
Vehicle system test
Select function XX
Readout on display:
Press
HELP
1 and 6 for the function access authorisa-
tion and confirm with Q .

Access authorisation
Readout on display:
Enter code number 40168 and confirm entry with
Q.
Vehicle system test
Select function XX
Readout on display:
Press
confirm with Q .
Basic setting
Readout on display:
Press
HELP
If this appears on the display, function 16 access authorisation was not successfully performed.
Readout on display:

be carried out at the moment
->
Basic setting
1
ON <8-OFF>
->
Basic setting
1
ON <8-OFF>
Bal. steer. angl. send. N.O.K.
->
Basic setting
1
ON <8-OFF>
Bal. steer. angl. send. locked
Null balance steering angle sender -G85- is performed

successfully.

number 005.
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).
Switch off ignition then switch on again after 10 seconds.
Repeat the null balance of the steering angle sender

-G85-.
Press
.
Vehicle system test
Readout on display:
Press
HELP
firm with Q .
45-14 page 4
Edition 07.04
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45
FABIA 2000 Chassis
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.

-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-
Vehicle system test
Select function XX
Readout on display:
Press
HELP
confirm with Q .
Basic setting
Readout on display:
Press

System in basic setting 3
System test activated O.K.
Readout on display:
->
The ESP road and system test is activated, ESP and TCS
warning light -K155- lights up.
Press
.
Vehicle system test
Select function XX
Readout on display:
Press
HELP
with Q .
Vehicle system test
Readout on display:
HELP
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
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45
FABIA 2000 Chassis
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 45-14

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
45-15 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.
Before starting the test switch off the ignition and elec-
trical consumers (headlights, lighting, blowers etc.).
Connecting test box -V.A.G 1598AS45-0074
Unlatch the multi-pin connector -arrow 1- and disconnect from the ABS with EDL control unit -J104- by pulling upwards -arrow 2-.
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-.
3
1
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:
Insert the multi-plug connector on the ABS with EDL

control unit -J104- and lock.
V.A.G 1598A
V.A.G 1598/34
2
S45-0034
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
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Electrical Test - ABS systems BOSCH 5.7
45-15 page 1
45
FABIA 2000 Chassis
Contact assignment of 42-pin plug connection -T42wiring loom/ABS control unit -J104-
26
Contact
10
42
27
11
S45-0031
Wiring to component
Earth terminal 31
Voltage supply of battery + (terminal 30)
Earth terminal 31
Voltage supply of battery + (terminal 30)
81)
Lateral acceleration sender -G200- (signal line)
91)
Lateral acceleration sender -G200- and yaw rate sender -G202-
101)
Lateral acceleration sender -G200- and yaw rate sender -G202-
12
Speed sensor front left -G47-
13
Speed sensor rear left -G46-
14
15
Speed sensor front right -G45-
16
192)
Rear right speed sensor output
211)
Lateral acceleration sender -G200- and yaw rate sender -G202- (earth cable)
23
Voltage supply (terminal 15)
24
Data BUS cable (CAN-R) Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
251)
Brake pressure sender 1 -G201- (earth cable)
261)
Brake pressure sender 1 -G201- (signal line)
27
Traction control system switch -E132- or TCS and ESP button -E256-
28
30
Speed sensor rear right -G44-
31
32
Brake light switch -F-
342)
Rear left speed sensor output
371)
Brake pedal switch -F47-
381)
Handbrake warning switch -F9-
391)
Voltage supply for:

Steering angle sender -G85 Lateral acceleration sender -G200 Yaw rate sender -G202-
45-15 page 2
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45
FABIA 2000 Chassis

Contact
40
1)
2)
Wiring to component
Data BUS cable (CAN-L) Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
411)
Yaw rate sender -G202- (signal line)
421)
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
Test steps in test table

45-15 page 4
Voltage supply for the ABS return flow pump -V39- to the ABS control unit -J104-
Perform test step 1

Perform test step 2
Voltage 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
-E256-
Perform test step 6

Perform test step 7
Test of the data BUS cables

Handbrake warning switch -F91)
Perform test step 3

Perform test step 4
Perform test step 5
1)
Test can only be performed on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7.
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FABIA 2000 Chassis
Test table
Note
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.
If the measured values deviate from the nominal values perform the fault eliminating measures listed in the right
part of the table.

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 1598/34-
Test covers
Test conditions
Specification
Measures for deviations from nominal

value
approx. battery voltage
Test cable from con-
additional
works
1
1+2
5+2
1+6
5+6
23 + 1
23 + 5
Voltage supply for the

ABS return flow pump
-V39- to the ABS control unit -J104-
Ignition off
Voltage supply for the

valves in the ABS return flow pump -V39to the ABS control unit
-J104-
Ignition off
Voltage supply (terminal 15) to the ABS

control unit -J104-
Ignition on
tact 1 or 5 to earth.
Test cable from contact 2 via fuse to battery + Current

Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
Test cable from contact 1 or 5 to earth.
Test cable from contact 6 via fuse to battery + Current

Flow Diagrams,
Test cable from contact 1 or 5 to earth.
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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FABIA 2000 Chassis

Test
step
Test box
-V.A.G 1598/34-
Test covers
Test conditions
Specification
Measures for deviations from nominal

value
< 1.0 V
Test brake light
additional
works
4
5 + 32
Function of the brake

light switch -F-
Ignition off
Brake pedal
switch -F- and read

measured value
block Chap. 4510, display group
number 003.
not actuated
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
switch -F- Chap.

45-16.
Test fuse.
5
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.
tery voltage
Traction control < 1.0 V

system switch
or TCS and
ESP button not
pressed.
Edition 07.04
S00.5303.16.20
Test cable from contact 5 to earth.
Test cable fom

contact 27 to traction
control system
switch -E132- or
TCS and ESP button
-E256-.
Check traction control system switch

-E132- or TCS and
ESP button -E256-
45-15 page 5
45
FABIA 2000 Chassis
Switch on measuring range: Resistance measurement (200 /20 M)

Test
step
Test box
-V.A.G 1598/3424 + 40
Test covers
Test conditions
additional works
Data BUS cables
Specification
Measures for deviations from nominal value
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/
34max. 1.5
Check the data BUS
Check data BUS
Chapter 48-27.
cable for open circuit.
Ignition off
Measuring range 20
M set
Check cables for
Check wiring according to current flow diagram Current

Flow Diagrams, Electrical Fault Finding
short-circuit between the cables or

for short-circuit to
positive term. or
earth.

Test
step
71)
Test box
-V.A.G 1598/3438 + 2
Test covers
Test conditions
additional works
Switch for handbrake control -F9-
Specification
Ignition off
Handbrake not ap-
< 1.0 V
Reading measured
value block Chap.

45-10, display group
number 002.
plied
Apply handbrake.
Measures for deviations from nominal value
Test cable from contact 2 via fuse to battery +.
Test cable from

contact 38 to the
handbrake warning
switch -F9 Current Flow Diagrams, Electrical
1)
This test sequence can only be performed on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7.
45-15 page 6
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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
T fitted until CW 21/2004
T 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
T Fitting location: in right of engine compartment
Chapter 45-17
T 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)
T only on vehicles with ABS/
12
EDL/TCS/ESP BOSCH 5.7
T Fitting location: screwed into
13
the hydraulic control unit
Chapter 45-17
15
14
T 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 -E256T Fitting location: Centre part of dash panel above radio
T Operation: Switching off the TCS or ESP function
T can be inspected in the measured value block Chapter 45-10 and during the Electrical Test Chapter
45-15
T 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 -K155T Fitting location: in the dash panel insert
Operation:
T 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
FABIA 2000 Chassis

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
T the warning light flashes:
during TCS/ESP control
6 - ABS warning light -K47T Fitting location: in the dash panel insert
Operation:
T 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 -K7T Fitting location: in the dash panel insert
Operation:
T 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
T fitted up to model year 2004
9 - Steering angle sender -G85-1)
T only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
T Fitting location: on steering column between the steering wheel and the steering column switch
T can be tested in the measured value block Chapter 45-10
10 - Diagnostic connection
T Fitting location: in the storage area on the driver's side
T 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)
T removing and installing (disc brake or drum brake) Chapter 45-19
T Rear wheel speed sensor cables
removing and installing (disc brake or drum brake) Chapter 45-19
13 - Switch for hand-brake control -F9T Fitting location: on handbrake lever
T can be inspected in the measured value block Chapter 45-10 and during the Electrical Test Chapter
45-15.
14 - Lateral acceleration sender -G200- and yaw rate sender -G202-1)
T only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
T Fitting location: under left front seat
T both senders are integrated in one housing
T can be tested in the measured value block Chapter 45-10
15 - Brake light switch -F-1)
T 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
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45
FABIA 2000 Chassis
replace after each removal

T can be inspected in the measured value block Chapter 45-10 and during the Electrical Test Chapter 4515
17 - Front right and front left wheel speed sensors -G45/G47-1)

T 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)
T fitted as of CW 22/2004
T different versions:
ABS
ABS/TCS
assignment Spare part
catalogue
Distinguishing features
Chapter 45-2
Chapter 45-18
2 - Traction control system
21
switch -E132- or TCS and ESP
button -E256-1)
T Fitting location: Centre part
of dash panel above radio
T Operation: Switching off the
TCS or ESP function
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
T Fitting location: in the dash
panel insert item 6
Operation:
Edition 11.04
S00.5303.17.20

9 10
11
12
13
14
16
15
S45-0185
45-16 page 3
45
4-
5-
67-
8-
9-
10 -
FABIA 2000 Chassis

45-16 page 6
ABS warning light -K47T Fitting location: in the dash panel insert item 6
Operation:
45-16 page 6
Dual circuit and hand brake system warning light -K7T Fitting location: in the dash panel insert item 6
Operation:
45-16 page 6
Dash panel insert
T fitted up to model year 2004
Traction control system warning light -K86- or ESP and TCS warning light -K155T Fitting location: in the dash panel insert item 10
Operation:
45-16 page 6
ABS warning light -K47T Fitting location: in the dash panel insert item 10
Operation:
45-16 page 6
Dual circuit and hand brake system warning light -K7T Fitting location: in the dash panel insert item 10
Operation:
45-16 page 6
Dash panel insert
T fitted as of model year 2005
11 - Steering angle sender -G85-1)

T only on vehicles with ABS/TCS/ESP BOSCH 8.0
T Fitting location: on steering column between the steering wheel and the steering column switch
45-16 page 4

Edition 11.04
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45
FABIA 2000 Chassis

13 - Rear right and rear left wheel speed sensors -G44/G46-1)

T removing and installing (disc brake or drum brake) Chapter 45-19
T Rear wheel speed sensor cables
removing and installing (disc brake or drum brake) Chapter 45-19
15 - Handbrake warning switch -F9-1)
T Fitting location: on handbrake lever
16 - ESP sensor unit -G419-1)
T only on vehicles with ABS/TCS/ESP BOSCH 8.0
T Fitting location: under left front seat
T 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)
T is open in the off position
adjust 45-16 page 8
removing and installing 45-16 page 8
replace after each removal
19 - Brake servo unit with master brake cylinder and brake fluid reservoir
20 - Front right and front left wheel speed sensors -G45/G47-1)
T Front wheel speed sensor cables
removing and installing Chapter 45-19
21 - Hydraulic control unit BOSCH 8.01)
T ABS/TCS/ESP
T Distinguishing features Chapter 45-2
T ABS/TCS/ESP BOSCH 8.0 must not be disassembled and repaired
Edition 11.04
S00.5303.17.20

45-16 page 5
45
FABIA 2000 Chassis
Indication of faults by means of warning

lights
Vehicle system tester -V.A.G 1552- or fault read-out
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
S45-0184
Dash panel insert as of model year 2005

Warning lights
Denomination
Brake pad warning light -K32-
Traction control system warning light -K86ESP and TCS warning light -K155-
ABS warning light -K47-
Dual circuit and hand brake system warning

light -K7-
Pos.
Brake pad warning light -K32- (-1-)

If the brake pad warning light -K32- (-1-) does not go
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
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45
FABIA 2000 Chassis
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
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
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
FABIA 2000 Chassis
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).
1
Display overview of the warning lights -K7-,
-K47-, -K86- or -K 155-
Warning 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 -K155-
3
S45-0203
For 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
-K7-
ABS warning light

-K47-
Traction control
system warning
light -K86- or ESP
and TCS warning
light -K155-
Traction control
system switch
-E132- or TCS and
ESP button -E256-
lights up
lights up
lights up
not actuated
System o.k.
does not light up
does not light up
does not light up
not actuated
ESP/TCS or ABS/
TCS -in recess
does not light up
does not light up
flashes (3x/seconds)
not actuated
ESP/TCS or ABS/
TCS are switched off
does not light up
does not light up
lights up
activated
ESP/TCS or ABS/
TCS are switched on
again via TCS and
ESP button -E256- or
traction control system switch
-E132-(were
switched off)
does not light up
does not light up
does not light up
activated
Ignition on
test of the lights(-K7is only indicated for
the test in the dash
panel insert)
Setting, removing and installing the

brake light switch -FSpecial tools, test and measuring equipment and
Polycarbamide grease -G 052 142 A2-
45-16 page 8

Edition 11.04
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45
FABIA 2000 Chassis
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).
Insert plug into brake light switch.

Edition 11.04
S00.5303.17.20

45-16 page 9
45
FABIA 2000 Chassis
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.
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.

-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
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:
45-16 page 10

S48-0188
Edition 11.04
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45
FABIA 2000 Chassis

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-
S48-0190
Disconnect plugs -1- and -2-.
Edition 11.04
S00.5303.17.20

S45-0199
45-16 page 11
45
FABIA 2000 Chassis
Carefully release catch hooks -arrows-, remove housing -1- with steering angle sender -G85- and coil
spring.
Installing
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.
Removing transport protection or adhesive tape.

Position the steering angle sender in the centre position:
S48-0191
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-.
S48-0189

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 45-13.

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

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.

45-16 page 12

Edition 11.04
S00.5303.17.20
45
FABIA 2000 Chassis
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.


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

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


Remove the driver's seat Body Work; Rep. Gr. 72.
Note
The unit is located under the base of the left front seat
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:
Edition 11.04
S00.5303.17.20

S45-0113
45-16 page 13
45
FABIA 2000 Chassis
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 torques:
Sender -G200/G202 - on body (ABS/EDL/
TCS/ESP BOSCH 5.7)
6 Nm
ESP sensor unit -G419- on body (ABS/TCS/

ESP BOSCH 8.0)
6 Nm
45-16 page 14

Edition 11.04
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45
FABIA 2000 Chassis
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

T ABS BOSCH 5.7
T ABS/EDL/TCS BOSCH 5.7
2
catalogue
T fitted until CW 21/2004
2 - Brake line
1
T identification marking of the
hydraulic unit VL
T to front left brake caliper
3 - Brake line
hydraulic unit VR
T to front right brake caliper
4 - Brake line
21
hydraulic unit HZ2
T Master brake cylinder/floating piston circuit to hydraulic
control unit
5 - Brake line
19
hydraulic unit HZ1
18
T Master brake cylinder/pressure rod piston circuit to hy17
draulic control unit
6 - Brake line
hydraulic unit HL
T to wheel brake cylinder/rear
left brake caliper
16
7 - Brake line
T identification marking of the hydraulic unit HR
T to wheel brake cylinder/rear right brake caliper
8 - Brake pressure sender 1 -G201T removing and installing 45-17 page 10
Edition 07.04
S00.5303.16.20
5
8
11
10
12
20
19
13
13
12
15
Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo

unit/Master brake cylinder
14
S45-0107
45-17 page 1
45
9-
10 -
11 -
12 -
13 -
14 -
15 -
16 17 18 19 20 21 -
FABIA 2000 Chassis

T must only be replaced, but not repaired
Line
T ABS/EDL/TCS/ESP BOSCH 5.7
T to ABS control unit
Hydraulic control unit
T ABS/EDL/TCS/ESP BOSCH 5.7
T must not be repaired, replace completely in the event of faults
T Brake pressure sender 1 -G201- must be replaced, but not repaired
T fitted until KW 21/2004
Line holder
T for brake line
Bracket
T for brake line
T 2 units
Bracket
T for brake line
T 3 units
Brake servo unit
Master brake cylinder
T cannot be repaired, replace completely in the event of faults
T Tightness test Chapter 47-2
Brake fluid reservoir
Self-locking nuts, 20 Nm
Bracket
T for ABS, ABS/ABS/EDL or ABS/EDL/TCS/ESP BOSCH 5.7
Screw, 8 Nm
Bracket
T for ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7
Hexagon collar nut, self-locking, 20 Nm
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
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45
FABIA 2000 Chassis
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.

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

Remove engine cover Engine, Mechanics;
Rep. Gr. 10.
Vehicles with TDI PD Turbocharger engines
Remove top charge-air pipe -1- with connecting hose
S45-0193
-2- TDI Engine, Mechanics; Rep. Gr. 21.
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
S45-0016
Edition 07.04
S00.5303.16.20

45-17 page 3
45
FABIA 2000 Chassis
Unlatch the multi-pin connector -arrow 1- and pull off

upwards from the control unit -arrow 2-.
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.
S45-0065

Note
To avoid overvoltage and static discharge do not touch
the plug contacts of the brake pressure sender 1 -G201-.
Unplug connector from brake pressure sender 1

-G201-.
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.
Remove the hydraulic control unit downwards from
the vehicle.
S45-0067
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
unit before the brake line is installed, then brake fluid

may escape and adequate filling and bleeding can no
longer be guaranteed.
2
1
S45-0067
Screw bracket -2- onto the hydraulic control unit.
45-17 page 4

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.
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.
Insert the multi-plug connector on the control unit and

lock.
Install top charge-air pipe -1- with connecting hose -2 TDI Engine, Mechanics; Rep. Gr. 21.
Installing engine cover Engine, Mechanics;
Rep. Gr. 10.

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.
Edition 07.04
S00.5303.16.20

S45-0193
45-17 page 5
45
FABIA 2000 Chassis
-VAS 5051-.

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
8 Nm
Bracket to hydraulic control unit and

to body
20 Nm
Use new nuts and new hexagon
collar nut!
Brake line to hydraulic control unit
14 Nm
Drive shaft to flange shaft - gearbox
M8 = 40 Nm
M10 = 70 Nm
Use new screws!
Shield to assembly carrier
35 Nm
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.

Caliper gauge (commercially available)
45-17 page 6

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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
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.
S45-0111
If the hydraulic control unit is open protect the valve
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
FABIA 2000 Chassis
Hydraulic unit: The valve block includes the control
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
1
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-.
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.
1
S45-0110
45-17 page 8

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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
FABIA 2000 Chassis
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.
Install hydraulic control unit with bracket 45-17

page 2.
Tightening torque:
Control unit to hydraulic unit
3 Nm
Use new screws!
Removing and installing brake pressure

sender 1 -G201- - vehicles with ABS/EDL/
TCS/ESP BOSCH 5.7
S45-0111
A description of the structure and function of the brake

pressure sender 1 -G201- can be found in self-study programme no. 42.

-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-
45-17 page 10

S45-0112
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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:
Replace the brake pressure sender 1 -G201- or hy-
S45-0112
draulic unit and check tightness.

-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
Edition 07.04
S00.5303.16.20
20 Nm

45-17 page 11
45
45-17 page 12
FABIA 2000 Chassis

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.
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.

T ABS BOSCH 8.0
45-18 page 3
5
T ABS/TCS BOSCH 8.0
4
3
catalogue
2
hydraulic unit ABS
1
2 - Brake line
hydraulic unit VR
T to front right brake caliper
T Connect 45-18 page 7
20
3 - Brake line
hydraulic unit HL
left brake caliper
4 - Brake line
19
18
hydraulic unit HR
17
right brake caliper
5 - Brake line
hydraulic unit VL
T to front left brake caliper
16
T ABS/TCS/ESP BOSCH 8.0
Edition 07.04
S00.5303.16.20
2
7
11
12
21
9
10
10
12
13
13
12
15

14
S45-0168
45-18 page 1
45
7-
8-
9-
10 11 -
12 -
13 -
14 -
15 -
16 17 -
18 -
19 -
20 -
21 -
FABIA 2000 Chassis

T identification marking of the hydraulic unit ESP
Brake line
T identification marking of the hydraulic unit HZ2
T Master brake cylinder/floating piston circuit to hydraulic control unit
Brake line
T identification marking of the hydraulic unit HZ1
T Master brake cylinder/pressure rod piston circuit to hydraulic control unit
Bracket
T for hydraulic control unit ABS/TCS/ESP BOSCH 8.0
Screws, 8 Nm
T for holder to hydraulic control unit
Line holder
T for brake line
Bracket
T for brake line
T 2 units
Bracket
T for brake line
T 3 units
Brake servo unit
T Tightness test Chapter 47-2
Brake fluid reservoir
Self-locking nuts, 20 Nm
T for bracket to body
Bracket
T for ABS, ABS/TCS, ABS/TCS/ESP BOSCH 8.0
Hexagon collar nut, 20 Nm
T for bracket to body
Bracket
T for hydraulic control unit ABS, ABS/TCS BOSCH 8.0
Bracket
T for brake line
T 2 units
45-18 page 2

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.

pedal load -V.A.G 1869/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-

-VAS 5051 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-,

Repair kit SP-No. 1H0 698 311 A
Removing
Note

Rep. Gr. 10.

2
1
S45-0193
Edition 07.04
S00.5303.16.20

45-18 page 3
45
FABIA 2000 Chassis
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.
Place sufficient non-fluffing cloths under and around
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-.
S45-0169
Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
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.
45-18 page 4

S45-0170
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

er.
If necessary remove the brake lines from the line hold-
4
5
Mark brake lines -16-.

Unscrew brake lines -16- from hydraulic control
unit.

6
S45-0171

er.
If necessary remove the brake lines from the line hold-
4
5
Mark brake lines -16-.

Unscrew brake lines -16- from hydraulic control
unit.

Remove the hydraulic control unit
S45-0172
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.
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.
1
7
5 - Threaded bores welded to the body

7 - Threaded bores welded to the body
Installing
3
6
Note
New hydraulic control units are filled with hydraulic oil
and bleed.
Only then remove plugs from the hydraulic unit when
5
4
S45-0178
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!
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-

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.
Perform test drive after the bleeding of air with at least

one ABS adjustment.
Tightening torques:
Brake line to hydraulic control unit
14 Nm
Bracket with hexagon collar nut to

body
20 Nm
Use new nut!
Bracket with nuts to body
20 Nm
Use new nuts!
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-.
Release screws -3- (2x).

Remove bracket -2- from hydraulic control unit -1-.
Installing
3
3
Installation is carried out in the reverse order.

Tightening torque:
Bracket to hydraulic control unit
8 Nm
4
S45-0179
45-18 page 6

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

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-.
Release screws -3- (3x).

Remove bracket -2- from hydraulic control unit -1-.
Installing
Tightening torque:
Bracket to hydraulic control unit
8 Nm
3
4
Connecting the brake lines

Note
S45-0180
Mount braket before assembling the brake lines.

Do not bend brake lines when assembling or when
connecting.
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!
vehicles with ABS or ABS/TCS BOSCH 8.0
Connecting the brake lines to the master brake cylinder
Pos.
Denomination
Connecting points
HZ1
Master brake cylinder/push rod

piston circuit
HZ2
Master brake cylinder/floating

piston circuit
1
2
S45-0173
Edition 07.04
S00.5303.16.20

45-18 page 7
45
FABIA 2000 Chassis
Connecting the brake lines to the hydraulic control

unit
Pos.
Denomination
FR
Front right brake caliper
RL
Wheel brake cylinder/rear left

brake caliper
RR
Wheel brake cylinder/rear right

brake caliper
FL
Front left brake caliper
HZ2

piston circuit
HZ1

piston circuit
Connecting points
6
S45-0171

Connecting the brake lines to the master brake cylinder
Pos.
Denomination
HZ1

piston circuit
HZ2

piston circuit
Connecting points
1
2
Note
When tightening the pipe screw to the brake line in the
S45-0174
area of the crimping -arrow A- counterhold by hand.

When tightening the pipe screw to the brake line in the
area of the crimp -arrow B- counterhold by hand.

Connecting the brake lines to the hydraulic control
unit
Pos.
Denomination
FR
Front right brake caliper
RL
Wheel brake cylinder/rear left

brake caliper
RR
Wheel brake cylinder/rear right

brake caliper
FL
Front left brake caliper
HZ2
HZ1
45-18 page 8
Connecting points

piston circuit
6
S45-0172

piston circuit

Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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.
Release Allan screw -3-.

Remove wheel speed sensor -2- from the wheel-bear-
1
2
ing 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

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.

Rep. Gr. 10.
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

and Rear Axle
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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
Wiring to component
15 + 16
12 + 28
30 + 31
13 + 14
10
42
27
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 sepa-
26
S45-0031
rate plug connector.
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

and Rear Axle
45-19 page 3
45
FABIA 2000 Chassis
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.
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
VW AG 6Q0 973 042

B00 1928 404 293
R
1 928 403 931
lock.
S45-0079

Rep. Gr. 10.

Perform automatic test sequence Chapter 45-5 ei-
2
1
ther using the vehicle system tester -V.A.G 1552- or

-VAS 5051-.

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

Note
It is prohibited to repair shielded leads of the ABS sys-
tem.
45-19 page 4

and Rear Axle
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

Rep. Gr. 10.

S45-0193
Release multi-pin connector -1-.

Insert red fuse -2- up to the stop in -direction of the arrow-.
S45-0169
Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
Pull out multi-pin connector -2- from hydraulic control

unit.
Edition 07.04
S00.5303.16.20

and Rear Axle
S45-0170
45-19 page 5
45
FABIA 2000 Chassis
Open cable straps -2-.

Lever off the cap -1- of the multi-pin connector on both
sides from the catches -arrowwith a screwdriver.
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
Wiring to component
6 + 18
22 +34
19 + 31
20 + 33
Open wiring loom.

Using a suitable ejection tool from the wiring loom repair kit press out the relevant contacts.
13
38
12
37
24
Raise vehicle.
Remove wheel.
Release plug connection on speed sensor and sepa-
14
26
25
S45-0196
rate 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

and Rear Axle
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis
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
S45-0078
cable seal with a suitable plug-in tool from the wiring

loom repair kit up to the stop.
Secure contacts by sliding the secondary lock (purple).
DELPHI
Insert catch -arrow A- of the cap -1- into the recess

-arrow B- of the bottom part -2- of the multi-pin connector.
S45-0197
1
B
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.

DELPHI
Edition 07.04
S00.5303.16.20

and Rear Axle
S45-0198
45-19 page 7
45
FABIA 2000 Chassis

Rep. Gr. 10.

Perform automatic test sequence Chapter 45-5 ei-
ther using the vehicle system tester -V.A.G 1552- or

-VAS 5051-.
S45-0193

Sensor ring for ABS on the front and rear

axle
I
1
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
Removing and installing wheel speed

sensor on the rear axle
II
1
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

and Rear Axle
Edition 07.04
S00.5303.16.20
45
FABIA 2000 Chassis

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 5051/6AS45-0201
Removing
Note

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
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

and Rear Axle
45-19 page 9
45
FABIA 2000 Chassis
Note
The insulation of the cable extremities must not be
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.
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.

-VAS 5051-.
ABS systems BOSCH 5.7

ABS systems BOSCH 8.0

Erase fault memory.
45-19 page 10

and Rear Axle
Edition 07.04
S00.5303.16.20
46
FABIA 2000 Chassis
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

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
FABIA 2000 Chassis
1 - Brake disc
T Thickness: 22 mm
T Wear limit: 19 mm
T always replace axle-wise
T Unscrew the brake caliper
before removing
T 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
T with wear indicator
with a corresponding wear
(limit 2 to 3 mm) the warning
lamp in the dash panel insert
lights up
T Thickness: 19.6 mm (including the support plate)
T Wear limit: 2.0 mm without
supporting plate
8
T Check thickness
Inspection and Mainte7
nance
T do not unscrew the brake
hose when replacing the
brake pad
46-1 page 3
T do not interchange the inside
and outside brake pads 46-1 page 3
4 - Brake caliper
T removing:
Remove the brake pads 46-1 page 3
14
13
12
11
10
1
6
5
6
5
4
S46-0087
Use brake pedal load

Unscrew brake hose from brake caliper
T Installing:
Installing brake pads 46-1 page 3
Screw the brake hose onto the brake caliper

Remove brake pedal load
Bleed the brake system Chapter 47-4
5 - Guide bolts, 28 Nm
6 - Cap
T removing
7 - Tensioning sleeve
8 - Brake hose with supports, hollow screw and gasket rings
T must be replaced completely, do not dismantle
T Tightening torque: 35 Nm
46-1 page 2
Edition 02.03
S00.5303.13.20
46
FABIA 2000 Chassis
10 11 12 13 14 -

Screw, 10 Nm
Cover plate
Speed sensor ABS
Allan screw, 8 Nm
Removing and installing brake pads Floating caliper disc brake FS-III
Piston jig -MP 9-403 Torque wrench

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
FABIA 2000 Chassis
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.
Remove brake pads -2- and -3- from the brake caliper.
1
3
Installing
Note
Drain brake fluid from the brake fluid reservoir using a

ventilation bottle before pushing the piston back in.
Caution!
S46-0090
Brake fluid is toxic and must never be sucked off by

mouth.
MP 9-403
Note
Use alcohol only to clean the brake caliper housing.
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
46
FABIA 2000 Chassis
First position the brake caliper at the bottom.

Mount the brake caliper with brake pads onto the
wheel bearing housing.
FS -
The brake caliper pin -arrow- must be located behind the

guide of the wheel bearing housing!
S46-0101
Screw the brake caliper with both guide bolts -arrowsonto the wheel bearing housing.
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
FABIA 2000 Chassis
Repairing front brake, the floating caliper disc brake FS-III

Special tools, test and measuring equipment and aids required
46-1 page 1
Note
46-1 page 1
1 - Brake disc
T Thickness: 18 mm
T Wear limit: 15 mm
22
21
T Unscrew the brake caliper
before removing
20
rust solvent; as you could
discs.
2 - Screw, 4 Nm
3 - Brake pads
with a corresponding wear
(limit:2 to 3 mm) the warning
lamp in the dash panel insert
16
lights up
15
10
T with riveted retaining spring
11
12
T Install brake pad with a
13 14
smaller pad surface on the
piston side
T Wear limit: 2.0 mm without
9
supporting plate
T Check thickness
8
7
Inspection and Mainte6 5
nance
T do not unscrew the brake
hose when replacing the
brake pad
T do not interchange the inside and outside brake pads 46-1 page 7
4 - Brake caliper
T removing:
Remove the brake pads 46-1 page 7
19
18
17
3
4
S46-0091

T Installing:
Installing brake pads 46-1 page 7

46-1 page 6
Edition 02.03
S00.5303.13.20
46
FABIA 2000 Chassis

5 - The rubber bush below
T before screwing in coat thread with lithium grease -G 052 150 A26 - Bottom bushing
T with slits on one side
T before screwing in coat thread with lithium grease -G 052 150 A27 - Bottom distance sleeve
T before screwing in coat thread with lithium grease -G 052 150 A28 - Fillister head screw with internal serrations bottom, 25 Nm
T M8 x 48
9 - Air deflector
10 - Screw, 10 Nm
T for air deflector
11 - Fillister head screw with internal serrations top, 25 Nm
T M8 x 59
12 - Top distance sleeve
T before screwing in coat thread with lithium grease -G 052 150 A213 - Top bushing
T with slits on one side
T before screwing in coat thread with lithium grease -G 052 150 A214 - The rubber bush above
T before screwing in coat thread with lithium grease -G 052 150 A215 - Tensioning sleeve
16 - Brake hose with supports, hollow screw and gasket rings
18 - Screw, 10 Nm
19 - Cover plate
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
FABIA 2000 Chassis
Note

brake pad.

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

Remove brake pads -2- and -3- from the brake caliper.
1
3
Installing
Note
Caution!
S46-0090

mouth.
Note
Only use alcohol to clean the brake caliper housing.

Push piston back with piston jig -MP 9-403-.
Install brake pad with a smaller pad surface on the pis-
MP 9-403
ton side.
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
46
FABIA 2000 Chassis
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 -2-

Attach the wheel.

Note

S46-0102
Edition 02.03
S00.5303.13.20
46-1 page 9
46
FABIA 2000 Chassis
Repairing the front brake - the floating caliper disc brake C54-II
46-1 page 1
Note
46-1 page 1
1 - Brake disc
T the max. wheel run-out is not
marked
T released combination of a
brake disc without marking
and a wheel hub with marking
T with a fixing hole for the
wheel hub
T Thickness: 25 mm
T Wear limit: 22 mm
T for removing, first of all unbolt brake caliper complete
from wheel bearing housing
rust solvent, as you could
discs.
2 - Screw, 4 Nm
3 - Brake disc
T with a roughly 5 mm marking
for marking the maximum
wheel run-out
T released combination of a
brake disc with marking and
a wheel hub without marking
T with 5 fixing holes for the
wheel hub
T Thickness: 25 mm
T Wear limit: 22 mm
T for removing, first of all unbolt brake caliper complete from wheel bearing housing
T 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
T fit on before installing brake pads
5 - Brake pads
with a corresponding wear (limit 2 to 3 mm) the warning lamp in the dash panel insert lights up
T Wear limit: 2.0 mm without supporting plate
T Check thickness Inspection and Maintenance
46-1 page 10
Edition 02.03
S00.5303.13.20
46
FABIA 2000 Chassis
6-
7-
89-
10 -
T do not unscrew the brake hose when replacing the brake pad
Brake carrier
T is supplied as replacement part assembled with guide pin and protective caps as well as adequate quantity
of grease on guide pins
T 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)
T also use grease packing for greasing the slot on the guide pin and brake caliper for attaching the protective
cap
Protective cap
T contained in repair kit
T 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
Heat shield
T insert into piston
Fitting position: insert plate at heat shield into opening (slot) of the brake caliper
Brake caliper
T removing:

Unbolt brake caliper from brake carrier
T Installing:
Bolt brake caliper onto brake carrier

11 12 13 -
14 15 16 17 18 19 20 -

Screw, 30 Nm
Tensioning sleeve
Brake hose with supports, hollow screw and gasket rings
Screw, 125 Nm
T clean ribbing on underside each time removed
Allan screw, 8 Nm
Speed sensor ABS
Cover plate
Screw, 10 Nm
T with and without marking of the maximum wheel run-out
T 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
Edition 02.03
S00.5303.13.20
46-1 page 11
46
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.
Screw out bolt -1-.

Remove brake caliper -2- and secure with wire in such
S46-0122
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
Note
A
B
Caution!
mouth.
46-1 page 12
4
5
S46-0123
Edition 02.03
S00.5303.13.20
46
FABIA 2000 Chassis
Note
Only use white spirits to clean the brake caliper housing
and brake carrier.

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 -.
MP 9-403
Install the heat shield.

Fitting position: insert plate at heat shield into opening
(slot) of the brake caliper.
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.

S46-0124
Attach the wheel.

Note

Tightening torques:
Brake caliper to brake carrier
30 Nm
Use new screws!
Wheel bolts
Edition 02.03
S00.5303.13.20
120 Nm
46-1 page 13
46
46-1 page 14
FABIA 2000 Chassis
Edition 02.03
S00.5303.13.20
46
FABIA 2000 Chassis
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
FABIA 2000 Chassis
1 - 4 Nm
2 - Brake drum
T Brake drum diameter 200
mm
T Wear limit: 201 mm
T clean carefully, and check for
wear, damage, dimensional
accuracy and perfect brake
surface
3 - Cap
Chapter 42-5
30
wheel hub
Chapter 42-5
catalogue
6 - turn 30 Nm and 90
T removing:
Reset brake 46-2 page 3
15
13
14
12
10
11
8
6
1
S46-0092
Remove the brake drum
hook on the hand brake cable if necessary

Unscrew the brake line
Remove the brake carrier
unhook the hand brake cable if necessary

T Installing:
Install the brake carrier
8910 11 12 -
Screw on the brake line

Install the brake drum

T repairing 46-2 page 4
Hand-brake cable
T Setting the hand-brake 46-2 page 8
Axle stud
Brake line
Speed sensor ABS
Plug
46-2 page 2
Edition 04.05
S00.5303.18.20
46
FABIA 2000 Chassis

T to plug the hole for the speed sensor in the axle stud
14 - Axle body
15 - Axle body
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
FABIA 2000 Chassis
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)
Solid lubricant paste -G 000 650-
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.

After working on the rear axle brake: Release hand-brake; forcefully activate the brake pedal repeatedly.
1 - Spring cap
T to remove push against pressure spring and turn 90
2 - Pressure spring
3 - Locating spring
4 - Pressure rod
T Grease the contact points
with solid lubricant paste
-G 000 6505 - Wedge
T 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
T check the system for tightness 46-2 page 5
T Repairs not allowed
T removing:
Remove the brake shoe
46-2 page 6
Unscrew the brake line

Remove the wheel-brake
5
9
8
10
11
12
1
16
13
15
cylinder
T Installing:
Install the wheel-brake cylinder
Screw on the brake line

Install the brake shoe 46-2 page 6
14
S46-0093
7 - Allen screw, 8 Nm
8 - Tensioning pin
9 - Brake carrier
46-2 page 4
Edition 04.05
S00.5303.18.20
46
FABIA 2000 Chassis
10 - Cap
T remove to check brake pad thickness
11 - Sliding block
T Cover the whole contact surface of the brake shoe with solid lubricant paste -G 000 65012 - Brake shoe
T Minimum pad thickness without supporting shoe: 1.5 mm
T Check the brake pad thickness Inspection and Maintenance
T Visual checking of the brake pad thickness through the inspection hole in the brake carrier 46-2 page 5.
T always use equivalent pad quality per axle
T Brake pads can also be supplied without supporting shoe
13 - Tension spring
14 - Bottom retractor spring
T Grease the contact points with solid lubricant paste -G 000 65015 - Top retractor spring
16 - Brake shoe with lever for hand-brake
T 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.
Edition 04.05
S00.5303.18.20
S46-0094
46-2 page 5
46
FABIA 2000 Chassis
Removing and installing brake shoe Drum brake

Torque wrench
Hook (commercially available)
Solid lubricant paste -G 000 650-
Removing
Remove wheel.
Remove the brake drum.
Remove spring cap with pressure springs.
S46-0070
Use a screwdriver to lever off the brake shoes from

the bottom support in the direction of the arrow.
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
46
FABIA 2000 Chassis
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.

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46-2 page 7
46
FABIA 2000 Chassis
Attach the wheel.
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
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46
FABIA 2000 Chassis
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)
Note
After replacing the brake pads forcefully apply the brake pedal repeatedly to ensure the brake pads go into their
normal operating position.

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
T Thickness: 9 mm
13
T Wear limit: 7 mm
T if worn replace axle-wise
3 - Cap
Chapter 42-5
12
30
11
10
Chapter 42-5
9
catalogue
6 - turn 30 Nm and 90
7 - Cover plate
8
8 - Axle stud
9 - ABS speed sensor
10 - Allen screw, 8 Nm
11 - Axle body
12 - Hand-brake cable
T 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
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14
16
15
17
18
19
1
7
6 5 4 3 2
S46-0097
46-2 page 9
46
FABIA 2000 Chassis
T Tightening torque of the hollow screws: 35 Nm

15 - Self-locking hexagon screw, 35 Nm
16 - Brake caliper
T removing:
Unscrew brake line from brake caliper

T Installing:
Screw the brake line onto the brake caliper

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
T Wear limit: 2.0 mm without supporting plate
T Check thickness Inspection and Maintenance
18 - Pad retaining spring
T always replace when changing the pads
19 - Brake carrier with guide bolts and protective caps
T must be assembled with sufficient grease on the guide bolt, supplied as a spare part
T 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)
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
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46
FABIA 2000 Chassis

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.

Installing
Note
S46-0104
Caution!
mouth.
Edition 04.05
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46-2 page 11
46
FABIA 2000 Chassis
Note
Only use the resetting and turning out tool to reset the
piston.
B
A
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.
Screw in the piston by turning the knurled wheel clock-
MP 9-401
S47-0039
wise 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.
S46-0098
46-2 page 12
Edition 04.05
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46
FABIA 2000 Chassis

and hook on the hand-brake cable -3-.
Fit clip -1-.

Setting the hand-brake 46-2 page 13
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.

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
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46-2 page 13
46
FABIA 2000 Chassis
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.
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
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46
FABIA 2000 Chassis
46-3
Handbrake
Summary of components of hand brake

1 - Hand-brake lever
T removing and installing:
Rep. Gr. 68
catalogue
2 - Cover
T 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.
T Installing:
Slide the trim panel until the
catch peg catches onto the
hand-brake lever. Check
trim panel catch.
catalogue
3 - Compensating clamp
4 - Adjusting nut
T Setting the hand-brake
Chap. 46-2
5 - Grommet
T removing:
Pull hand-brake cable from
guide tube.
Release grommet.
3
2
11
1
11
78-
910 -
11 -
10
6
7
8
9
5
S46-0106
Pull grommet from guide
6-
tube.
T Installing:
The installation occurs in reverse order. After installing make sure the grommet fits correctly in the body recess.
Right guide tube
T for hand-brake cable
Left guide tube
T for hand-brake cable
Hand-brake cable
T 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
T welded to the body tunnel
Switch for hand-brake control -F9T clipped onto hand-brake lever
T replace if defective
Tighten self-locking hexagon nut 20 Nm and 90
Edition 08.00
S00.5303.04.20
Handbrake
46-3 page 1
46
FABIA 2000 Chassis
Removing and installing the hand-brake

cable
Torque wrench (40...200 Nm), e.g. -V.A.G 1332-
Removing

Rep. Gr. 68.
Raise vehicle.
Remove wheel.
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.
S46-0096
Vehicles with disc brakes
Lift off the clip -1- with a screwdriver and pull down to
remove.

and unhook the hand-brake cable -3-.
Pull hand-brake cable out of guide tube.
2
Installing
Insert new retaining clip on the hand-brake cable.
N46-0176
The positioning ring must be located in the recess of

the retaining clip.
Setting the hand-brake:

Vehicles with drum brakes Chap. 46-2
Vehicles with disc brakes Chap. 46-2
46-3 page 2
Handbrake
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46
FABIA 2000 Chassis
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
T for foot controls
T Crash strut cannot be removed, as it is welded to
bracket
46-4 page 3
2 - Hexagonal screw
3 - Self-locking hexagon nut, 28
Nm
T 4 pieces for securing the
brake servo unit to the bracket
T 2 pieces for securing the
bracket to the assembly plate
4 - Brake light switch
catalogue
T before assembling the brake
light switch clip brake pedal
to the pressure rod of the
brake servo unit
T Setting, removing and installing the brake light switch
Chap. 45-16
T Inspecting function of the
brake light Chap. 45-16
5 - Accelerator pedal with sender
-G79- and -G185T removing and installing
Engine, Mechanics;
Rep. Gr. 20
6 - Brake pedal
7 - Bushing
8 - Cap
9 - Bearing bolt
10 - Self-locking hexagon nut, 25 Nm
11 - Brake servo unit
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11
12
13
14
15
1
2
3
10
9
7
8
3
7
6
4
5
S46-0113
46-4 page 1
46
FABIA 2000 Chassis
12 - Front wall
13 - Module carrier
14 - Bracket
T for crash strut
15 - Self-locking hexagon screw, 10 Nm
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.
T30021
Press brake pedal -1- towards the brake servo unit

and hold in position.
Insert release tool -T30021- or -T10006 A- and pull to-
wards 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).
S46-0114
Clipping the brake pedal onto the brake servo unit
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
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46
FABIA 2000 Chassis
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-
Removing
Note

Rep. Gr. 70.
Vehicles without air conditioning
Removing the left footwell vent Heating, Air Conditioning; Rep. Gr. 80.
Vehicles with air conditioning
Vehicles with Convenience system central control
unit -J393-
Remove the convenience system central control unit

-J393- Body Work; Rep. Gr. 70.
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
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46-4 page 3
46
FABIA 2000 Chassis
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.
Remove foot controls.

Installing

45-16.

-VAS 5051-.
Tightening torque:
Foot controls on brake servo unit and on assembly plate
28 Nm
S46-0116
Use new nuts!
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-
Removing
Note

Rep. Gr. 70.
46-4 page 4
Edition 07.04
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46
FABIA 2000 Chassis
unit -J393-

-J393- Body Work; Rep. Gr. 70.

Pull out plug of accelerator pedal position sender
-G79-.
46-4 page 2.
Unscrew hexagon nut -1-.
Note
In the Fig. hexagon screw for bearing bolt is covered by
the bracket.
S46-0117
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.
1
2
Note
Replace all removed bushings.
Insert and tension interior extractor -Kukko 21/2- on
KUKKO 21/02
the bushing -2-.
Pull out bushing by hand from the casing tube.

Installing
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.

-VAS 5051-.
Edition 07.04
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46-4 page 5
46
FABIA 2000 Chassis
Tightening torque:
Brake pedal to bracket
25 Nm
Use new nut!
46-4 page 6
Edition 07.04
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47
FABIA 2000 Chassis
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
T before screwing in thinly coat
thread with lithium grease
-G 052 150 A23 - Bushing
T insert in brake caliper housing
4 - Guide bolts, 28 Nm
5 - Caps
T insert in bushing
6 - Brake caliper housing
7 - Seal
47-1 page 2
8 - Piston
47-1 page 2
9 - Protective cap
47-1 page 2
T when inserting piston do not
damage
S47-0068
Edition 03.01
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47-1 page 1
47
FABIA 2000 Chassis
Removing and installing piston of brake

caliper FS-III
Piston jig -MP 9-403 Disassembly wedge -3409 Lithium grease -G 052 150 A2-
Removing
Insert wooden plate in the channel to avoid damaging

the piston when it is ejected.
S47-0051
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.
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 cali-
S47-0031
per housing.
Position the new protective cap with the outer sealing

lip on the piston.
S47-0032
47-1 page 2
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47
FABIA 2000 Chassis
Insert inner sealing lip of the protective cap with disas-
3409
sembly 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-.
MP 9-403
Note
The outer sealing lip of the protective cap will fall in the
piston groove.
S47-0050
Edition 03.01
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47-1 page 3
47
FABIA 2000 Chassis
Summary of Components of Brake Caliper FS-II

Note

2 - Dust cap
-G 052 150 A24 - Top distance sleeve
T insert with Lithium grease
-G 052 150 A25 - Top bushing
T slotted
-G 052 150 A26 - Top bush
-G 052 150 A27 - Bottom bush
-G 052 150 A28 - Bottom bushing
T slotted
-G 052 150 A29 - Bottom distance sleeve
-G 052 150 A210 - Seal
12
47-1 page 2
11 - Piston
47-1 page 2
12 - Protective cap
T when inserting piston do not damage
2
1
6
7
11
10
8
S47-0069

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
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47
FABIA 2000 Chassis
Summary of components of brake caliper C54-II

Note
1 - Dust cap
1
2
-G 052 150 A23 - Hexagon collar bolt, 30 Nm
4 - Guide bolts
5 - Protective cap
T 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
T is supplied as replacement
part assembled with guide
pin and protective caps as
well as adequate quantity of
3
grease on guide pins
T 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
47-1 page 2
damage
8 - Piston
47-1 page 2
9 - Seal
4
5
6
10
9
8
7
S47-0078

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
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47-1 page 5
47
FABIA 2000 Chassis
Summary of components of rear brake caliper

Note
When repairing always install complete repair set.
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.
1 - Self-locking hexagon screw,

35 Nm
T counterhold at guide bolt
2
1
when releasing and tigtening
2 - Dust cap
3
-G 052 150 A24 - Guide bolts
T grease before fitting protective cap item 5
T to grease use the grease
supplied with the repair set
5 - Protective cap
T pull onto brake carrier and
guide bolt
1
6 - Brake carrier with guide bolt
and protective cap
T must be assembled with sufficient grease on the guide
bolts, supplied as a spare
part
T 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
47-1 page 7
damage
8 - Piston with automatic adjusting device
9 - Seal
10 - Brake caliper housing with lever for hand-brake cable
T replace brake caliper housing if the lever for the hand-brake cable is not tight
T after repair pre-bleed brake caliper housing 47-1 page 8
47-1 page 6
4
5
6
S47-0070
Edition 03.01
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47
FABIA 2000 Chassis
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-
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.
3409
Note
When removing the gasket ring make sure the cylinder
surface is not damaged.
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
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47-1 page 7
47
FABIA 2000 Chassis
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.
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
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.
MP 9-401
Screw in piston by turning the knurled wheel to the

right.
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
47-1 page 8
S47-0049
Edition 03.01
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47
FABIA 2000 Chassis
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
47-2 page 5
3
catalogue
T on petrol engines the re1
2
quired negative pressure is
drawn from the induction
pipe
14
T 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
T if there are faults replace
completely
T disconnect from brake pedal
11
or clip onto brake pedal
Chap. 46-4
T Non-return valve in vacuum
S47-0071
hose of the vacuum pump
47-2 page 7
T 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 -F34T cannot be removed or repaired
3 - Cap
4 - Brake fluid reservoir
T 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.
T Installing:
Edition 07.04
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47-2 page 1
47
FABIA 2000 Chassis
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
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.
Sealing plugs
T moisten with brake fluid and press in brake fluid reservoir
T replace after each installation
T Tightness test 47-2 page 2
Retaining pin
T to secure brake fluid reservoir at brake master cylinder
Gasket ring
T replace after disassembling the master brake cylinder
Sealing plugs
Vacuum hose
T insert with brake servo unit
Cap
T check for firm seating
Gasket
T for brake servo unit
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
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FABIA 2000 Chassis
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.
V.A.G 1310
Tightening torque:
Vent valve in brake caliper
10 Nm
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 diagno-
S47-0107

-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
Note
The master brake cylinder must not be repaired.
assignment Spare part catalogue
Removing

Rep. Gr. 10.
Remove air filter Engine, Fuel Injection;
Rep. Gr. 24 (fuel engines) or Rep. Gr. 23 (diesel

engines).
Note

MAX
Remove battery and battery tray Electrical System;
MIN
Rep. Gr. 27.
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.

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S47-0073
47-2 page 3
47
FABIA 2000 Chassis
After opening the breather screws on the front axle

brake calipers pump off brake fluid by repeatedly
pressing the brake pedal.
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.

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

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

45-13.
47-2 page 4
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FABIA 2000 Chassis

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.
the vehicle system test Chapter 45-4 using the vehicle diagnosis system, measurement and information
system -VAS 5051-.
Tightening torques:
20 Nm
Master brake cylinder to brake servo

unit
Use new nuts!
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)
Removing

Rep. Gr. 10.
Remove air filter Engine, Fuel Injection;
Rep. Gr. 24 (fuel engines) or Rep. Gr. 23 (diesel

engines).
Note

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47-2 page 5
47
FABIA 2000 Chassis
Remove battery and battery tray Electrical System;

Rep. Gr. 27.
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.

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
MAX
MIN
brake cylinder -5- and shut off.
master brake cylinder with screw plugs from the repair

kit SP No. 1 H0 698 311 A.
S47-0073
unit -J393-

- J393- Body Work; Rep. Gr. 70.

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
Clipping the brake pedal onto the brake servo unit

Chap. 46-4.

45-16.
47-2 page 6
S47-0074
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FABIA 2000 Chassis

Install battery and battery tray Electrical System;
Rep. Gr. 27.

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

BOSCH 5.7

S47-0074
45-13.

45-14.
Bleed clutch gearbox; Rep. Gr. 30.


Rep. Gr. 10.
the vehicle system test Chapter 45-4 using the vehicle diagnosis system, measurement and information
system -VAS 5051-.
Tightening torques:
20 Nm
Brake servo unit to foot controls

Use new nuts!
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
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47-2 page 7
47
FABIA 2000 Chassis
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.
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
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FABIA 2000 Chassis
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
T load dependent
catalogue
T testing and adjusting
47-3 page 2
14
T Adjusting values Chap.
00-3
2 - Bracket
T for brake-power regulator
3 - Hexagon screw, 20 Nm
4 - Brake line with pipe screw
T Brake-power regulator - rear
right brake hose
T Tightening torque of the pipe
screws: 14 Nm
T Brake-power regulator - rear
left brake hose
screws: 14 Nm
T Master brake cylinder brake-power regulator
screws: 14 Nm
12
T Master brake cylinder brake-power regulator
screws: 14 Nm
8 - Bracket
T 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
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5
13
7 6
11
10
S47-0075
47-3 page 1
47
FABIA 2000 Chassis
Inspecting and adjusting the brake-power regulator

Brake-power regulator or brake system tester, e. g.
-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.
V.A.G 1310
If necessary adjust brake-power regulator 47-3

page 2.
Adjusting brake-power regulator
Test pressure on rear axle too high:
Release tension spring on brake-power regulator.

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

Note
S47-0107
Adjust without load on the brake pedal, observe the following sequence:
47-3 page 2
Edition 07.04
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FABIA 2000 Chassis
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.
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
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 brake-
power regulator.
Shut-off brake lines to prevent brake fluid from run-
ning 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!

Adjusting brake-power regulator 47-3 page 2.
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47
FABIA 2000 Chassis
Tightening torques:
Brake-power regulator to bracket
20 Nm
Brake-power regulator to tension spring 20 Nm

Brake line to brake-power regulator
14 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.
25678-
Brake servo unit

Front left disc brake
Front right disc brake
Rear right drum brake
Rear left drum brake
3
4
Pressure test
8
S47-0079
-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
V.A.G 1310
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.
Remove pressure gauge.
47-3 page 4
S47-0107
Edition 07.04
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FABIA 2000 Chassis
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.

Removing
Insert the bleeder hose of the bleeding bottle on the

vent valve of the left and right brake caliper.

Shut the vent valve once the brake fluid flowed out.
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
5
6
4
3
2
7
S47-0080
Installing

Perform pressure test 47-3 page 4.
Tightening torques
Brake-pressure reducer to master brake
cylinder
14 Nm
Brake line to brake-pressure reducer

(tube or hose connection)
14 Nm
Brake lines to master brake cylinder
14 Nm
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47
47-3 page 6
FABIA 2000 Chassis
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FABIA 2000 Chassis
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-.
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-.
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
FABIA 2000 Chassis
Bleeding brake system on vehicles without ABS
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
pedal load device, e.g. -V.A.G 1869/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-

-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)
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
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47
FABIA 2000 Chassis
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
Perform test drive with ABS adjustment.

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.

Note
TCS/ESP BOSCH 8.0 occurs via the basic setting.
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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-

-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)
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
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47
FABIA 2000 Chassis

BOSCH 5.7
Note
EDL/TCS or ABS/EDL/TCS/ESP BOSCH 5.7 occurs via
the basic setting.

45-13.

Note
TCS/ESP BOSCH 8.0 occurs via the basic setting.

45-14.
Changing the brake fluid

Inspection and Maintenance
Edition 07.04
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47
47-4 page 6
FABIA 2000 Chassis
Edition 07.04
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FABIA 2000 Chassis
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
T adjustable
catalogue
T inspecting for damage
Chap. 48-2
Chap. 48-3
2 - Steering column
T rigid
catalogue
T inspecting for damage
Chap. 48-2
Chap. 48-3
4 - Hexagon bolt, 20 Nm + torque
a further 90 (1/4 turn)
5 - Steering gear
6 - Bushing
T replace if damaged
Chap. 48-3
T Observe the mounting sequence Chap. 48-5
9 - Bracket
Chap. 48-5
Edition 08.01
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14
12
11
10
13
7
8
1
2
5
S48-0213
Steering column
48-1 page 1
48
FABIA 2000 Chassis
12 - Frequency link
13 - Module carrier
14 - Front wall
15 - Combination screw, 25 Nm
48-1 page 2
Steering column
Edition 08.01
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48
FABIA 2000 Chassis
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
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48-2 page 1
48
48-2 page 2
FABIA 2000 Chassis
Edition 08.01
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48
FABIA 2000 Chassis
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.
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 Sys-
tem; Rep. Gr. 94.
Unplug connector for the ignition starter switch -1- and

the connector for the immobilizer -2- reading coil.
Unbolt earth strap -arrow-.

Remove cover -2-.
S48-0159
S48-0106
Edition 07.03
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Removing and installing steering column
48-3 page 1
48
FABIA 2000 Chassis
Unscrew bolt -1-.

Remove universal joint in the direction of the arrow
from the input shaft of the steering gear.
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

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

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-
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.
2
1
S48-0162
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
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48
FABIA 2000 Chassis
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
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
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S48-0163
48-3 page 3
48
FABIA 2000 Chassis
Unscrew bolts -2-.

Remove steering column -1-.
3 - Bracket
4 - Module carrier
4
2
3
2
S48-0164
Note
If the old steering column -3- is installed again do not
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 re-
S48-0165
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
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48
FABIA 2000 Chassis
Installing the lock cylinder and ignition starter switch in

the ignition lock housing Electrical System;
Rep. Gr. 94.
Insert the steering column with bushing -1- in the

bracket -2-.
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
S48-0163
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.

4 - Module carrier
4
2
3
2
S48-0164
Tighten the screw -4- to the specified tightening

torque.
1 - Steering column
2 - Bracket
3 - Frequency link
4
1
1
Edition 07.03
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S48-0163
48-3 page 5
48
FABIA 2000 Chassis
Remove transport security -3- or wire security.

1 - Bottom part of the steering column
2 - Top part of the steering column


Tightening torques:
S48-0160
Bushing on the steering column fork
7 Nm
Bushing on bracket
20 Nm
Steering column on bracket
23 Nm
Universal joint on input shaft
20 Nm + 90
Use new screw!
48-3 page 6
Edition 07.03
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48
FABIA 2000 Chassis
48-4

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
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
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Removing and installing ignition lock housing
48-4 page 1
48
48-4 page 2
FABIA 2000 Chassis
Removing and installing ignition lock housing
Edition 07.00
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48
FABIA 2000 Chassis
48-5
Frequency link, bracket
Removing and installing frequency link

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-.
S48-0139

Rep. Gr. 70.
Unscrew hexagon screw -4-.
1 - Steering column
2 - Bracket
3 - Frequency link
Remove frequency link.

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

Removing
Removing the dash panel Body Work; Rep. Gr. 70.

Removing steering column Chap. 48-3.
Edition 07.00
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48-5 page 1
48
FABIA 2000 Chassis
Note
For reasons of clarity the surrounding components are

not shown in the following figures.
Remove frequency link -1- from the bracket -3-.

S48-0179

Unscrew hexagon screw -2- and remove bracket -1-.
3
3
4 - Module carrier
2
2
Installing
S48-0178
Note
Hexagon screws -2- and -3- are identical and are
tightened to the same torque.

When installing the bracket -1- observe the mounting
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 tight-
ening torque.
S48-0178
Tightening torques:
Bracket on module carrier
23 Nm
Frequency link on bracket
23 Nm
48-5 page 2
Edition 07.00
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48
FABIA 2000 Chassis
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.
Only use steering gear grease to grease the gear rack Chapter 00-2.
1 - Universal joint
T of steering column
2 - Tighten hexagon screw
20 Nm + 90
3 - Tighten self-locking hexagon
nut 20 Nm + 90
4 - Steering-knuckle arm of the
wheel-bearing housing
5 - Steering gear
T with impression as shown in
the figure, only if the front exhaust pipe is fitted below the
engine-gearbox assembly
carrier
T without impression, not
shown in the figure, only if
the front exhaust pipe is fitted
above the engine-gearbox
assembly carrier
7 - Hinged bracket
T The shape of the hinged
bracket depends on the
gearbox
50 Nm + 90
3
5
8
8
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48-6 page 1
48
48-6 page 2
FABIA 2000 Chassis
Edition 11.04
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48
FABIA 2000 Chassis
48-7

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.
S48-0196
Secure the steering wheel with the wheels in straight

ahead position with adhesive tape -arrow- against unintended turning.

Remove cover -2-.
S48-0106
Edition 07.00
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Removing and installing mechanical steering gear
48-7 page 1
48
FABIA 2000 Chassis
Remove hexagon screw -1-.

from the input shaft of the steering gear.
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 -
S48-0111
Mechanics; Rep. Gr. 26.
Unscrew hexagon screw -1- and -2- from the pendulum support.
S48-0112
48-7 page 2
Edition 07.00
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48
FABIA 2000 Chassis
Screw up hexagon nut of the track rod end -1- suffi-
Matra V176
1
ciently 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.
1
Note
Observe the recommended sequence for the follow-
ing steps.

becomes damaged.
V.A.G 1359/2
V.A.G 1383A
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.
Release hexagon screws -1- on both sides.


Edition 07.00
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S48-0117
48-7 page 3
48
FABIA 2000 Chassis

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.
1
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
S48-0117
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-
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.
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
48-7 page 4
1
S48-0201
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48
FABIA 2000 Chassis
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.

torque.
3 - Engine-gearbox assembly carrier

Tighten new bolts for the rear left support by hand.

S48-0197

figure).

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.

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-.
Vehicles with exhaust pipe under the assembly

carrier
Installing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26.
Fit front wheels.

Install noise insulation panel.
Edition 07.00
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S48-0112
48-7 page 5
48
FABIA 2000 Chassis
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-.
Fit cover for universal joint.

Caution!
Carrying out chassis alignment Chap. 44-2.

S48-0170
Tightening torques:
50 Nm + 90
Steering gear to assembly carrier

Use new screws!
Assembly carrier to body
70 Nm + 90
Use new screws!
Support to body
20 Nm + 90
Use new screws!
30 Nm + 90
Use new screws!
20 Nm + 90
Use new nuts!
Universal joint to steering gear
20 Nm + 90
Use new screw!
Wheel bolts
48-7 page 6
120 Nm
Edition 07.00
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48
FABIA 2000 Chassis
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.
S48-0181
-a- = 68.5 mm
Adjusting dimension -a- by turning the input shaft -1-
of the steering gear.

2 - Gear rack
Adjusting the steering gear (adjusting

the pressure plate clearance)
Note
2 mechanics are required for this adjustment.
S48-0182
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.
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.
Edition 07.00
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Inspecting and adjusting mechanical steering gear
S48-0183
48-8 page 1
48
FABIA 2000 Chassis
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.
S48-0184
48-8 page 2
Inspecting and adjusting mechanical steering gear
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48
FABIA 2000 Chassis
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.

Always use original clamping collars and circlips.
1 - Right track rod end

Chapter 48-10
T before installing, remove
grease on tapered stud
2 - Lock nut, 50 Nm
3 - Spring strap clip
T use assembly pliers, e.g.
-VAS 5024- for removing
and installing
4 - Boot
T can only be replaced with the
steering gear removed
T before removing boot detach
the track-rod end Chapter
8
48-10
T must not be twisted after setting the wheel toe
T inspect for wear and damage
(cuts, splits)
5 - Warm-type clamp
T removing: open with cutting
pliers
12
6 - Gasket
T pay attention to installation
instructions for installing
Chapter 48-7
7 - Clamp
T replace if thread of stamp nut
damaged
8 - Right track rod
T tightening torque on steering rack: 80 Nm
Edition 11.04
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1 2
4
5
6
7
9
10
Disassembling and assembling the steering gear
11
S48-0269
48-9 page 1
48
9-
10 -
11 -
12 -
FABIA 2000 Chassis

T track rod and track rod end are supplied as replacement part pre-set
T 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
T Setting wheel toe Chap. 44-2.
Rubber insert
Fitting position:
larger bore must point outwards
replace if damaged or worn
Steering gear
T do not repair
T setting Chapter 48-8
T inspecting centre position Chapter 48-8
Left track rod end
T before installing, remove grease on tapered stud
Left track rod
T 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
48-9 page 2
Disassembling and assembling the steering gear
Edition 11.04
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48
FABIA 2000 Chassis
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
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Track rod ends, track rods
48-10 page 1
48
48-10 page 2
FABIA 2000 Chassis
Track rod ends, track rods
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48
FABIA 2000 Chassis
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 abcdef-
Power-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:
6 7
5
4
9
10
11 12 13
3
1
19
18
17
20
a
b
c
14
d
M
e 16 15
S48-0200
Screwed lid
Reservoir for hydraulic oil
Pressure limiting valve
Gear pump
Electric motor
Power-assisted steering control unit -J500-
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
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Power-assisted steering
48-11 page 1
48
FABIA 2000 Chassis
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.
48-11 page 2
Edition 11.04
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48
FABIA 2000 Chassis
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.
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
catalogue
3 - Steering column universal
joint
5 - Gasket
T for power-assisted steering
sensor -G250- with adapter
19
cable item 6
17
catalogue
20
6 - Sensor for power steering
-G250T with adapter cable item 8
Chapter 48-13
catalogue
22
7 - Screw, 6 Nm
T for power-assisted steering
sensor -G250- with adapter
cable item 6
21
catalogue
8 - Adapter cable
21
catalogue
9 - Gasket
T for power-assisted steering sensor -G250- with fixed connecting line item 10
10 - Sensor for power steering -G250T with fixed connecting line
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4
9
10
8
11
11
7
12
13
15
17
18 16
14
S48-0266
48-11 page 3
48
FABIA 2000 Chassis
11 - Screw, 6 Nm
T for power-assisted steering sensor -G250- with fixed connecting line item 10
12 - Nut, self-locking, 20 Nm and torque a further 90 (1/4 turn)
13 - Steering-knuckle arm (of the wheel-bearing housing)
14 - Return-flow line
T Pipe screw M16x1.5
T power-assisted steering gear - engine pump aggregate
T Torque for pipe screw on the power-assisted steering gear: 30 Nm
15 - O-ring
16 - Hollow screw, 35 Nm
T with non-return valve
T M14x1.5
17 - Gasket ring
18 - Pressure line
T Pay attention to installation position relative to subframe 48-11 page 6
T Torque for pipe screw on the engine pump aggregate: 30 Nm
19 - Power-steering gear
T with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
T with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
22 - Hinged bracket
T The shape of the hinged bracket depends on the gearbox
48-11 page 4
Edition 11.04
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48
FABIA 2000 Chassis
Summary of components of power-assisted steering (KOYO)

1 2 1
4
2 - Heat shield
3
catalogue
3 - Steering column universal
5 6 7
joint
8
5 - Gasket
T for power-steering sensor
-G250- item 6
15
9
catalogue
13
6 - Sensor for power steering
16
13 11
-G250T removing and installing
14 12
10
Chapter 48-13
catalogue
7 - Screw, 7,5 Nm
T for power-steering sensor
-G250 item 6
18
catalogue
17
8 - Nut, self-locking, 20 Nm and
1
torque a further 90 ( /4 turn)
S48-0267
17
9 - Steering-knuckle arm (of the
wheel-bearing housing)
10 - Return-flow line
T Pipe screw M16x1.5
T Torque for pipe screw on the power-assisted steering gear: 30 Nm
11 - O-ring
12 - Hollow screw, 40 Nm
T with non-return valve
T M14x1.5
13 - Gasket ring
14 - Pressure line
T Pay attention to installation position relative to subframe 48-11 page 6
T Torque for pipe screw on the engine pump aggregate: 30 Nm
T with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
T with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
Edition 11.04
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48-11 page 5
48
FABIA 2000 Chassis

18 - Hinged bracket
T The shape of the hinged bracket depends on the gearbox
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
T with encapsulation, assignment Spare part catalogue
T with half encapsulation, assignment Spare part catalogue
T without encapsulation, assignment Spare part catalogue
2 - Return line (return hose)
3
catalogue
2
T must not be pinched off during disassembling work
T No less than minimum bend1
ing radius of 100 mm
Chapter 48-13
3 - Line holder
5 - Pressure line (expansion
hose)
catalogue
T must not be pinched off during disassembling work
T No less than minimum bending radius of 100 mm
T Pay attention to installation
position relative to subframe
48-11 page 6
Chapter 48-13
6 - Spacer holder
T clipped onto body
7 - Cable of power-assisted steering sensor -G250T power-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
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48
FABIA 2000 Chassis
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)
35 Nm
Use new hollow screw!
Pressure line to the power-assisted steering gear (KOYO)
Edition 11.04
S00.5303.17.20
40 Nm
48-11 page 7
48
48-11 page 8
FABIA 2000 Chassis
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
48-12 Removing and installing

power-steering gear (TRW
or KOYO)
-V.A.G 1359/2 Vehicle system tester -V.A.G 1552- or vehicle diagno-

-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
FABIA 2000 Chassis
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.
Secure the steering wheel with the wheels in straight

ahead position with adhesive tape -arrow- against unintended turning.
S48-0196

Remove cover -2-.
S48-0106
Release screw -1-.

from the input shaft of the power-steering gear.

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
48
FABIA 2000 Chassis

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

Unhook cable of power-steering sensor -G250- from

line holder -arrows-.
Raise vehicle.
S48-0109

Note
from the figure.

Removing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26.
S48-0111
S48-0112
Edition 04.05
S00.5303.18.20
48-12 page 3
48
FABIA 2000 Chassis

-2-.
S48-0113
Screw up nut of the track rod end -1- sufficiently so
Matra V176
1
that the extractor -Matra V176- is supported on the

nut.
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.
Extract the hydraulic oil with an extraction bottle via

the filler neck.
2
1
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 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.
S48-0147
To avoid damage make sure the bending radius of at
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
48
FABIA 2000 Chassis
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.
Release screws -1- for power-steering gear.

Note
ing steps.
V.A.G 1359/2
V.A.G 1383A

becomes damaged.
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.
Release screws -1- on both sides.



the fixing bolts.
S48-0117
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.
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.
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.
Edition 04.05
S00.5303.18.20
S48-0115
48-12 page 5
48
FABIA 2000 Chassis
Vehicles with power steering (TRW)
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.

Note
When lowering the assembly carrier make sure there is
sufficient clearance between the drive shafts and the stabilizer.
Slowly lower assembly carrier with gearbox jack and

adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-.
S48-0260
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
48
FABIA 2000 Chassis

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.
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.
Align the assembly carrier with the fixing bolts of

-T10096- screwed into the body.
V.A.G 1359/2
V.A.G 1383A
S48-0201
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)
Insert the power-assisted steering sensor -G250- (-2-)
with new seal -3- into the power-steering gear valve

housing.
S48-0259

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)
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
FABIA 2000 Chassis
Mount the pressure line (expansion hose) -1- and return line (return hose) -2- on the power-steering gear
with new gasket rings.
A new hollow screw must be used to connect the pres-
sure line (expansion hose) -1- to the power-steering

gear (TRW).
3 - for power-assisted steering sensor -G250- with
fixed connecting line
5 - Fixing bolt of -T10096-
4
1
Pay attention to fitting location of pressure line

Chap. 48-11.
Raise assembly carrier until the console touches the
S48-0115
body.
Note
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.

torque.

Tighten new bolts for the rear left support by hand.
S48-0197

figure).

Tighten new bolts for the rear right support by hand.
Tighten up the rear right support bolts to the recommended tightening torque.

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
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48
FABIA 2000 Chassis

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-.
Installing front exhaust pipe with catalyst Engine Mechanics; Rep. Gr. 26.
Fit front wheels.

Attach line of power-steering sensor -G250- with the
S48-0112
line holders -arrows-.
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.
Disconnect the Jumper cable.

If necessary install the battery and battery tray
S48-0170

Install air filter, if removed Engine, Fuel Injection
System; Rep. Gr. 24 (petrol engines) or
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
FABIA 2000 Chassis

Caution!

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
70 Nm + 90
Use new screws!
Support to body
20 Nm + 90
Use new screws!
30 Nm + 90
Use new screws!
20 Nm + 90
Use new nuts!
power-assisted steering sensor -G250to power-assisted steering gear (TRW)
6 Nm
power-assisted steering sensor -G250to power-assisted steering gear (KOYO)
7.5 Nm
Hollow screw for pressure line to power

steering gear (M14x1.5) - TRW
35 Nm

steering gear (M14x1.5) - KOYO
40 Nm
Pipe screw for return line to power

steering gear (M16x1.5)
30 Nm
40 Nm
Universal joint to power-steering gear
20 Nm + 90
Use new screw!
Wheel bolts
48-12 page 10
120 Nm
Edition 04.05
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48
FABIA 2000 Chassis
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)

-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


Remove air filter, if necessary Engine - Fuel Injection System; Rep. Gr. 24 (petrol engines) or
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
FABIA 2000 Chassis
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.
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

power steering
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis

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.

4
1
S48-0259
The power-steering sensor -G250- (KOYO)
Unscrew bolt -1-.

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-!

S48-0260

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-.

Edition 11.04
S00.5303.17.20

power steering
48-13 page 3
48
FABIA 2000 Chassis

Tightening torques:
power-assisted steering sensor -G250 - to
power-assisted steering gear (TRW)
6 Nm
power-assisted steering sensor -G250 - to

power-assisted steering gear (KOYO)
7.5 Nm
Wheel bolts
120 Nm
Removing and installing hydraulic lines

(TRW or KOYO)
-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

the engine pump aggregate as well as in the return

line and pressure line (expansion hose).
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.
least 100 mm is respected when bending the pressure

line (expansion hose) or return line.
2
1
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.
48-13 page 4

power steering
S48-0147
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis

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
5
4
spacer -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-
Close the threaded bores and supports on the engine
S48-0199
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):
5 - Fixing bolt from -T10096-
Seal threaded holes on the steering gear (e.g. with

plastic screw plugs).
Remove pressure or return line.

Installing
When installing the pressure line it is essential to pay
1
5
S48-0115
attention to the fitting location Chapter 48-11.
Mount return line with new O-ring on the power steering gear.
Attach a pressure line tightly with new seals to the

power steering gear Chapter 48-11.
Screw return line with new O-ring onto the engine

pump aggregate.
Edition 11.04
S00.5303.17.20

power steering
48-13 page 5
48
FABIA 2000 Chassis
Installing assembly carrier Chapter 48-12.

Filling with hydraulic oil and bleeding the steering system Chapter 48-23.

Caution!

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
40 Nm
Pipe screw for return line to power-assisted steering gear (M16 x 1.5)
30 Nm
Pipe screw for pressure line to engine

pump aggregate (TRW)
30 Nm

pump aggregate (KOYO)
29 Nm
Wheel bolts
48-13 page 6
120 Nm

power steering
Edition 11.04
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48
FABIA 2000 Chassis
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.
S48-0131
-a- = 72.5 mm
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.
Put the wheels in straight-ahead position.
S48-0132
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.
Edition 11.04
S00.5303.17.20
Inspecting and adjusting the power-steering gear
48-14 page 1
48
FABIA 2000 Chassis
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
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
48
FABIA 2000 Chassis
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.
Welding and straightening of the steering components
is not allowed.
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 2
3
4
Chapter 48-16
5
2 - Lock nut, 50 Nm
7
8
7
and installing
4 - Boot
6
14
15
power steering gear re9
moved
16
17
10
11
48-16
T must not be twisted
12
16
18
(cuts, splits)
5 - Warm-type clamp
13
16
16
pliers
6 - Gasket
20
5
2
19
4
Chapter 48-12
T with and without recess for
3
S48-0264
anti-twist lock
catalogue
T 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.
T for attaching heat shield
8 - Heat shield
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
T 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.
11 - Rubber bearing
Fitting position:
the larger internal diameter points towards the outer side of the vehicle
48-15 page 2
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
T no provision made for repairs
T 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
14 - Gasket
15 - for power-assisted steering sensor -G250- with adapter cable
16 - Screw, 6 Nm
17 - Adapter cable
18 - for power-assisted steering sensor -G250- with fixed connecting line
19 - Left track rod end
20 - Left track rod
Disassembling and assembling the power-assisted steering gear (KOYO)

Edition 11.04
S00.5303.17.20
48-15 page 3
48
FABIA 2000 Chassis
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 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.
A mixed lining of TRW and KOYO components is not permissible, assignment Spare part catalogue.

1 2
Chapter 48-16
2 - Lock nut, 50 Nm
and installing
4 - Boot
power steering gear re9
moved
10
11
48-16
T must not be twisted
(cuts, splits)
5 - Warm-type clamp
pliers
6 - Gasket
17
5
Chapter 48-12
4
catalogue
T for attaching heat shield
8 - Heat shield
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
48-15 page 4
4
5
7
6
12
13
14
15
2
3
16
S48-0265
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
11 -
12 -
13 14 15 16 -
17 -
T setting the wheel toe Chapter 44-2.
Rubber bearing
Fitting position:
the larger internal diameter points towards the outer side of the vehicle
Power-steering gear
T no provision made for repairs
Gasket
Sensor for power steering -G250T removing and installing Chapter 48-13
Screw, 6 Nm
Left track rod end
Left track rod
Edition 11.04
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48-15 page 5
48
48-15 page 6
FABIA 2000 Chassis
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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

Matra V176
1
Extractor -Matra V176-
Removing
The track rod ends can be replaced with the track rods
and the power steering gear installed.
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

S48-0114
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-.
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
FABIA 2000 Chassis
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
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.
Tightening torques:
Lock nut of track rod/track-rod end
Hexagon nut of track rod end/track rod
to steering arm
50 Nm
S48-0121
20 Nm + 90
Use new nut!
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
steering
Edition 11.04
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48
FABIA 2000 Chassis
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.
V.A.G 1332
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.
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.
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.
2
V.A.G 1332/6
S48-0122
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
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steering
48-16 page 3
48
FABIA 2000 Chassis
Note
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.
Check overall track and adjust if necessary, vehicle

alignment Chapter 44-2.
Tightening torques:
Track rod in gear rack of the mechanical steering gear
80 Nm
Track rod in steering rack of power

steering gear
80 Nm
48-16 page 4
steering
S48-0059
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48
FABIA 2000 Chassis
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
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
drain the steering gear.
1
S48-0128
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
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Disposing of the power-steering gear
48-17 page 1
48
48-17 page 2
FABIA 2000 Chassis
Disposing of the power-steering gear
Edition 11.04
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48
FABIA 2000 Chassis
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.

Always replace gasket rings.
1 - Encapsulation
T bottom open version
T not fitted to all vehicles
catalogue
2 - Encapsulation
T bottom closed version
T Disassembling is only possible after removing the engine
pump aggregate and the
holder
catalogue
3 - Screwed lid
T with oil dipstick
4 - Gasket ring
5 - Reservoir
T replacing Chapter 48-21
6 - Clamp
T different versions
catalogue
7 - Gasket ring
T different versions
catalogue
8 - Hexagonal nut, 7 Nm
T when tightening counterhold
on rubber bearing item 9
9 - Rubber bearing
Edition 11.04
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3
4
7
8 9
10
9
9 8
8
11
12
14
13
11
16
15
Engine pump aggregate
11
S48-0261
48-18 page 1
48
10 -
11 12 13 14 15 16 -
FABIA 2000 Chassis

T check for damage (tears in rubber, rubber torn away from metal plate), if necessary replace
T with power-assisted steering control unit -J500T No provision is made for repair
T Replacing reservoir Chap. 48-21
T Self-diagnosis Chap. 48-25
T Electrical test Chap. 48-26
Tighten hexagon screw 20 Nm + 90
Bracket
T for engine pump aggregate
Spring strap clip
T install with assembly pliers, e. g. -VAS 5024Return line (return hose)
O-ring
T replace after disassembling the pressure line
Pressure line (expansion hose)
T Engine pump aggregate - Power-steering gear
48-18 page 2
Edition 11.04
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48
FABIA 2000 Chassis
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

Always replace gasket rings.
1 - Rear bracket
T the bearings in the bracket
are not used as replacement
part, in case of bearing dam1
age replace bracket
2
20 Nm + 90
3 - Fillister head screw, 7 Nm
4 - Screwed lid
3
T with flat gasket ring
T as replacement part only
screwed lid with oil dipstick is
19
available together
catalogue
5 - Flat gasket ring
6 - Screwed lid
T with O-ring
18 17
catalogue
7 - O-ring
8 - Encapsulation
T bottom open version
2
catalogue
9 - Self-locking fillister head
screw, 7 Nm
catalogue
10 - Cap nuts, 7 Nm
11 - Reservoir
T replacing Chapter 48-21
Edition 11.04
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6
7
8
14
14
10
20
10
11
12
11
13
16
3
15
S48-0262
48-18 page 3
48
12 13 -
14 15 -
16 -
17 18 -
19 20 -
FABIA 2000 Chassis

Gasket ring
T with screwed in threaded bores
T with power-assisted steering control unit -J500T power-assisted steering control unit -J500- and electric motor must not be separated
T No provision is made for repair
Fillister head screw, 7 Nm
T without threaded bores
T Screw insert -arrow- only with fillister head screws item 9
T with power-assisted steering control unit -J500T power-assisted steering control unit -J500- and electric motor must not be separated
T No provision is made for repair
Front bracket
T the bearings in the bracket are not used as replacement part, in case of bearing damage replace bracket
O-ring
T replace after disassembling the pressure line
Pressure line (expansion hose)
T Engine pump aggregate - Power-steering gear
Return line (return hose)
Spring strap clip
T install with assembly pliers, e. g. -VAS 5024-
48-18 page 4
Edition 11.04
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48
FABIA 2000 Chassis
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


-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.
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:

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
FABIA 2000 Chassis
If no faults are displayed in the fault memory:
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.

-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)
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

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.
the engine pump aggregate as well as in the pressure

line (expansion hose).
After the feed pressure test replace the O-ring on the
pipe screw of the pressure line.
48-19 page 2
Edition 11.04
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48
FABIA 2000 Chassis

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.

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

Unscrew the screwed lid -1- of the hydraulic oil reservoir of the engine pump aggregate -2-.

the filler neck.
S48-0147
Raise vehicle.
Note
from the figure.
S48-0111
Edition 11.04
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48-19 page 3
48
FABIA 2000 Chassis

Rep. Gr. 66
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.
1
S48-0135
Place the catch pan under the engine pump aggregate to collect escaping hydraulic oil.
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
no less than 100 mm.
Tie up the pressure line on the stabilizer.
1
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.
2345ABC-
C
B
Adapter, 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)
4
A
1
2
S48-0138
48-19 page 4
Edition 11.04
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48
FABIA 2000 Chassis

Test preparations
Open the shut-off valve on the power-steering tester

pressure gauge -1-. Lever -2- points perpendicularly
down.
Lower the vehicle.
Caution!
If necessary connect battery to jumper cable.

2
S48-0195
Test
Note
A 2nd mechanic is required to check the feed pres-
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
Nominal value overpressure1)

MPa
bar
Fuel engines
9,610,4
96104
Diesel engines
9,610,4
96104
1)
maximum system pressure or feed pressure of the engine pump

aggregate
2
1
Note
If the nominal value is exceeded or if it is not reached replace the engine pump aggregate.
Switch off engine.

Edition 11.04
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S48-0147
48-19 page 5
48
FABIA 2000 Chassis

the filler neck.
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.

Disconnect the jumper cable.

Rep. Gr. 66.

Fit front wheel.
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
30 Nm

KOYO
29 Nm
Wheel bolts
48-19 page 6
120 Nm
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
48-20 Removing and installing

as well as disposing of engine pump aggregate
Removing and installing engine pump
aggregate (TRW)

-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)
In the event of failure determine the cause with the functional, pressure and tightness test as well as by performing self-diagnosis.
Note
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.

the pressure line.
Removing engine pump aggregate

Note

2
1

Edition 11.04
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Removing and installing as well as disposing of engine pump

aggregate
S48-0147
48-20 page 1
48
FABIA 2000 Chassis

the filler neck.
Raise vehicle.
Note
from the figure.

S48-0111
Rep. Gr. 66
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-.
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

aggregate
Edition 11.04
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48
FABIA 2000 Chassis
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.
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 (re-
turn 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.
4
S48-0142

Remove engine pump aggregate with encapsulation
-1- and with holder -2- downwards.
1
S48-0144
Edition 11.04
S00.5303.17.20

aggregate
48-20 page 3
48
FABIA 2000 Chassis
Removing the holder and rubber bearing.
Unscrew the hexagon nuts -arrows-.
Remove holder -2-.
Open encapsulation -3-.

Remove engine pump aggregate -1-.
Note
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.
-VAS 5024-.
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.
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!
If necessary connect removed battery to jumper cable.
If necessary install air filter.

If necessary disconnect the jumper cable.

If necessary re-install the air filter.

48-20 page 4

aggregate
Edition 11.04
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48
FABIA 2000 Chassis


Tightening torques:
Rubber bearing to engine pump aggregate TRW
7 Nm
Holder to engine pump aggregate TRW
7 Nm
Holder with engine pump aggregate

TRW to body
20 Nm +
90
Use new screws!

TRW
30 Nm
Radiator fan control unit -J293- to body
6 Nm
Wheel bolts
120 Nm
Removing and installing engine pump

aggregate (KOYO)

-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)
In the event of failure determine the cause with the functional, pressure and tightness test as well as by performing self-diagnosis.
Note
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.

the pressure line.
Edition 11.04
S00.5303.17.20

aggregate
48-20 page 5
48
FABIA 2000 Chassis
Removing engine pump aggregate

Note

2
1


the filler neck.
S48-0147
Raise vehicle.
Note
from the figure.

Rep. Gr. 66
S48-0111
48-20 page 6

aggregate
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis

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-.
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-
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.
2
S48-0271
Edition 11.04
S00.5303.17.20

aggregate
48-20 page 7
48
FABIA 2000 Chassis
Unscrew the pressure line (expansion hose) -3- at the

engine pump aggregate -4- and tie up.
Shut off the pressure line with a plastic bag and adhe-
sive 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
S48-0272
Unscrew hexagon screw -arrow-.

1 - Front bracket
S48-0273

Remove engine pump aggregate -2- with the brackets
-1- and -3- downwards.
48-20 page 8

aggregate
S48-0274
Edition 11.04
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48
FABIA 2000 Chassis

Remove bracket
Unscrew fillister head screws -5-.

Remove bracket -1- and -3- from the engine pump ag-
gregate -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.
5
5
Installing engine pump aggregate
A
B
S48-0275
Note
Only use original spring band clamps.
-VAS 5024-.
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.

Caution!
If necessary connect removed battery to jumper cable.
If necessary install air filter.





Tightening torques:
Edition 11.04
S00.5303.17.20

aggregate
48-20 page 9
48
FABIA 2000 Chassis
Front bracket on engine pump aggregate

KOYO
7 Nm
Rear bracket on engine pump aggregate

KOYO
7 Nm
Holder with engine pump aggregate

KOYO to body
20 Nm +
90
Use new screws!

KOYO
29 Nm
Radiator fan control unit -J293- to body
6 Nm
Wheel bolts
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.
Removing the engine pump aggregate Chap. 4820.
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.
Dispose of the engine pump aggregate in compliance

with the applicable regulations.
B
S48-0154
48-20 page 10

aggregate
Edition 11.04
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48
FABIA 2000 Chassis
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

After extraction of the hydraulic oil there will be residues
Close screw connection for the pressure line at the
S48-0290
engine pump aggregate.
Edition 11.04
S00.5303.17.20
Replace reservoir of engine pump aggregate
48-21 page 1
48
FABIA 2000 Chassis
Remove holder -1- from the engine pump aggregate

-3-.
If fitted, remove encapsulation -2- from engine pump
aggregate.
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
leads to a non-repairable damage at the engine pump

aggregate.
S48-0289
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.
Detach reservoir -2- from engine pump aggregate -3-.
48-21 page 2
S48-0277
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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
leads to a non-repairable damage at the engine pump

aggregate.
Insert a new gasket ring Spare part catalogue in
S48-0289
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 ag-
B
S48-0278
gregate.
Tighten the screw of the clamp to the specified tightening torque.

Edition 11.04
S00.5303.17.20
48-21 page 3
48
FABIA 2000 Chassis
Close connection fitting for the return-flow line at reservoir.
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.
Make an approx. 15x30 mm large permanent colour

marking -2- e.g with seal paint on the location marked
in the figure.
4
S48-0279
The marking must cover the reservoir -1-, the clamp -3and the engine pump aggregate -4-.
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.
Installing the engine pump aggregate Chap. 48-20.

Tightening torque:
Clamp at reservoir of engine pump aggregate
3 Nm
S48-0276
Use new clamp!
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
with cap nuts -3- and threaded bores -5 Attachment with fillister head screws -2- and -4-
Disassemble reservoir
After extraction of the hydraulic oil there will be residues

Close screw connection for the pressure line at the
S48-0284
engine pump aggregate.
48-21 page 4
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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.
Carefully detach reservoir -1- from pump aggregate
1
2
3
-2-.
S48-0281
Edition 11.04
S00.5303.17.20
48-21 page 5
48
FABIA 2000 Chassis
Assembling reservoir
Note
Ensure a clean, grease- and oil-free contact surface
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.
2
3
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.
S48-0282
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 res-
S48-0280
ervoir.
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.
48-21 page 6
S48-0283
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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-
7 Nm
Use new fillister head screws!
Reservoir to engine pump aggregate cap nuts -arrows A-
7 Nm
Reservoir to engine pump aggregate - fillister head screws -arrows A-
7 Nm
S48-0280
Edition 11.04
S00.5303.17.20
48-21 page 7
48
48-21 page 8
FABIA 2000 Chassis
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
48-22 Checking hydraulic oil

level
Inspecting hydraulic oil level, if necessary topping up

-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)
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.

S48-0147

Unscrew the screwed lid from the engine pump aggregate reservoir.
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
FABIA 2000 Chassis
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
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.
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.


If the battery was removed:


48-22 page 2
Checking hydraulic oil level
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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)
Jumper cable (commercially available)
Note
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.
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
FABIA 2000 Chassis
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
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!
If necessary connect the battery with jumper cable.

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.
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.
up Chap. 48-22.
48-23 page 2

tightness
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
Note
Possible residual air in the steering system will automatically escape during driving after approx. 1020 km.
Disconnect the jumper cable.

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.



Tightening torques:
TRW
30 Nm

KOYO
29 Nm
Screwed lid on hydraulic oil reservoir

Wheel bolts
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.

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

tightness
48-23 page 3
48
FABIA 2000 Chassis

Raise vehicle.
Note
from the figure.

Rep. Gr. 66.
Caution!
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.

up Chap. 48-22.
48-23 page 4

tightness
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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.
Removing power steering gear Chap. 48-12.
Remove gasket -1-.
Open warm-type clamps -3-.
S48-0285
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.
A
B
If hydraulic oil is visible in the steering gear housing and/

or in the boot, replace the power steering gear.
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.
Replace engine pump aggregate Chap. 48-20.

S48-0285
Rep. Gr. 66.

Fit front wheel.
Edition 11.04
S00.5303.17.20

tightness
48-23 page 5
48
FABIA 2000 Chassis

If the battery was removed:


48-23 page 6

tightness
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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.
Checking the feed pressure of the engine pump aggregate Chap. 48-19.
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.

S48-0153
Check attachment of engine pump aggregate

(TRW)
Check attachment of holder -2- with engine pump aggregate -1- to body -arrows-.
If necessary tighten hexagon screws.

1
S48-0205
Edition 11.04
S00.5303.17.20
Power steering noises
48-24 page 1
48
FABIA 2000 Chassis
Check attachment of holder -2- to engine pump aggregate -1- -arrows-.

3 - Encapsulation
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. 48-
S48-0145
20.
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)
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
48
FABIA 2000 Chassis
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.
S48-0286
Note
To test the rubber bearing for damage remove the engine
pump aggregate -2- and disassemble the holder -1-.
Remove holder -1- from the engine pump aggregate

-2-.
The rubber bearing -3- can be checked on an installed

holder -4-.
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
FABIA 2000 Chassis
Tightening torques:
Pipe screw for return-flow line to powersteering gear (TRW/KOYO)
30 Nm

steering gear (TRW)
35 Nm

steering gear (KOYO)
40 Nm

pump aggregate (TRW)
30 Nm

pump aggregate (KOYO)
29 Nm
Holder with engine pump aggregate to

body (TRW/KOYO)
20 Nm + 90
Use new screws!
Holder to engine pump aggregate

(TRW/KOYO)
7 Nm
Rubber bearing to engine pump aggregate (TRW)
7 Nm
Power-steering gear to assembly carrier

(TRW/KOYO)
50 Nm + 90
Use new screws!
48-24 page 4
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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
or the vehicle diagnosis, measurement and informa-
tion system -VAS 5051- 48-25 page 11.
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.
II

vehicle system tester -V.A.G 1552- or fault read-out
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
FABIA 2000 Chassis
Note
The description of the self-diagnosis only relates to
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.
Unclip cover and remove downward.

Connect vehicle system tester -V.A.G 1552- or fault
V.A.G 1552
V.A.G 1551/3
read-out scan tool -V.A.G 1551- with appropriate cable.
S01-0087
Switch on ignition.
Vehicle system test
Readout on display:
HELP
Note
If there is no readout on the display: Operating instructions of the vehicle system tester
Enter address word
4 4 for power-assisted steering and confirm the entry with Q .

6Q0423156
Power steering
Coding 00110
Readout on display:
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
Vehicle system test

Fault in communication build-up
HELP
or
Vehicle system test

K cable does not connect to earth
HELP
or
Vehicle system test

HELP
K cable does not connect to pos. term.
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
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
48
FABIA 2000 Chassis

02 05 06 07 08 -
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
Vehicle system test
Select function XX
Readout on display:
Enter function
HELP
0 2 Interrogate fault memory and
confirm entry with Q .

The number of faults stored appears on the display.
X faults detected!
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.
No fault detected
Vehicle system test

Select function XX
Readout on display:
->
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
0 5 Erase fault memory and con-
firm with Q .
Vehicle system test
Fault memory erased!
Readout on display:
->
The fault memory is now erased.
Press
.
Vehicle system test
Select function XX
Readout on display:
Select function
HELP
0 6 End output and confirm with
Q.
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
FABIA 2000 Chassis
that it is necessary to interrogate and erase the fault

memory on all control units.
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:
Vehicle system test

HELP
Vehicle system test

Select function XX
HELP
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.
48-25 page 4
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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 1552-
Possible cause of
fault
Possible effects
Rectifying fault
00566
The motor pump
Power steering discon-
Analyse measured
Power steering
operation
Implausible signal
assembly is defect
nects
Fault terminal 30
value block 001 display field 1 48-25

page 9
Replace the motor

pump assembly
Electrical test
Chapter 48-26.
Short circuit to
00816
Power steering
sensor -G250
Short circuit to
earth
earth in the line

connection from
the power steering sensor to the
control unit
Sensor for power
steering defective
Short circuit to
00816
Power steering
sensor -G250
Open circuit/
Short circuit to
positive
pos. in the line

connection from
control unit
Line interruption
Sensor for power
The power-assisted
steering is operating in
emergency mode
Steering requires
greater effort
The control lamp on
the servotronic -K92- is

lit up
The power-assisted
emergency mode
Steering requires
greater effort
The control lamp on

lit up
steering defective
Sensor for power
00816
Power steering
sensor -G250
defective
steering defective
The power-assisted
emergency mode
Steering requires
greater effort
Analysing measured
value block 002
48-25 page 9
Test wiring Current

and Fitting Locations
Replace sensor
Analysing measured
value block 002
48-25 page 9
Test wiring Current

Replace sensor
Analysing measured
value block 002
48-25 page 9
Replace sensor
The control lamp on

lit up
Edition 11.04
S00.5303.17.20
48-25 page 5
48
FABIA 2000 Chassis
Possible cause of
fault
00817
Temperature in hy- Steering requires
draulic system too

high
Power steering
temperature
protection
greater effort
nects
01288
Terminal 30
power steering
Possible effects
Signal too high

Signal too low
Rectifying fault
Allow temperature to
drop
Analysing measured
value block 001
48-25 page 9
Alternator not reg-
Steering requires
Analysing measured
ulating voltage
greater effort
value block 001

48-25 page 9
Battery dis-
charged/excessively charged
nects
The control lamp on

lit up
Check battery
Electrical System;
Rep. Gr. 27.
Test alternator
Electrical System;
Rep. Gr. 27.
Check wiring and plug

connections according to the current flow
diagram Current
Loose contact
01289
Terminal 15
power steering
Signal too low
Steering requires
Analysing measured
greater effort
value block 004

48-25 page 9
nects
Test wiring Current

Short circuit to
01290
Power steering
reference voltage
Short circuit to
positive
pos. in the line

connection from
control unit
The power-assisted
emergency mode
Steering requires
greater effort
Sensor defective
Short circuit to
01290
Power steering
reference voltage
Short circuit to
earth
earth in the line

connection from
control unit
The power-assisted
emergency mode
Steering requires
greater effort
Sensor defective
Power steering
01309
Power steering
control unit J500
48-25 page 6
defective
control unit defective
Analysing measured
value block 004
48-25 page 9
Test wiring Current

Replace sensor
Analysing measured
value block 004
48-25 page 9
Test wiring Current

Steering requires
Replace sensor
Replace the motor
greater effort
pump assembly
nects
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis

Possible cause of
fault
Possible effects
Rectifying fault
01312
Data bus cables
Check data bus
Data bus drive
defect
defective
a connected con-
trol unit is faulty

Data bus cables
01314
Engine control
unit
No communication
defect
Engine control unit
defective
nects
greater effort
The power-assisted
emergency mode or
does not operate at all
Steering requires
greater effort
Data bus cables
01314
Engine control
unit
please read out

fault memory
defect
Engine control unit
defective
The power-assisted
emergency mode or
does not operate at all
Steering requires
greater effort
Data bus cables
01317
Control unit with
display in dash
panel insert J285
No communication
defect
Dash panel insert
defective
Chapter 48-27
Steering requires
The power-assisted
emergency mode
Steering requires
greater effort
The control lamp on
Check data bus
Chapter 48-27
Interrogate fault memory of engine control

unit Engine, Fuel
Injection; Rep. Gr. 01.
Check data bus
Chapter 48-27
Interrogate fault memory of engine control

unit Engine, Fuel
Injection; Rep. Gr. 01.
Check data bus
Chapter 48-27
Interrogate fault memory of dash panel insert Electrical

System; Rep. Gr. 90

lit up
Data bus cables
01317
Control unit with
display in dash
panel insert J285
please read out

fault memory
Dash panel insert
defective
The power-assisted
emergency mode
Steering requires
greater effort
Data bus cables
01321
Airbag control
unit -J234
defect
No communication
Airbag control
unit -J234
memory of the airbag

control unit Body
Work; Rep. Gr. 01
Check data bus
Chapter 48-27
defect
Airbag control unit
Crash signal
Airbag control unit
-J234- has triggered airbags
ory of dash panel insert Electrical

System; Rep. Gr. 90
Interrogate the fault
Interrogate the fault
defective
01656
Interrogate fault mem-
Chapter 48-27
Airbag control unit
Data bus cables
please read out

fault memory
Chapter 48-27
Check data bus
defect
defective
01321
Check data bus
memory of the airbag

control unit Body
Work; Rep. Gr. 01
nects

48-25 page 3
Final control diag-
nosis Airbag control unit -J234completed
Edition 11.04
S00.5303.17.20
48-25 page 7
48
FABIA 2000 Chassis
Possible cause of
fault
Possible effects
Rectifying fault
01656
Crash signal of
Crash signal
Implausible signal
airbag control unit

-J234- N.O.K.
nects
48-25 page 3
Check data bus
Data bus cables
Chapter 48-27
defect
Test crash signal
Control units on
Body Work;
Rep. Gr. 01; Self-diagnosis airbag system
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.
Vehicle system test
Select function XX
Readout on display:
Enter function
HELP
firm with Q .
Code control unit
Readout on display:
HELP
(0-32000)

confirm with
Q.
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
Selectable coding1)
J06, J07, J08, J13, J14, J15, J20, J21, J22
00110
00130
00160
J01, J02, J03, J04, J05, J09, J10, J11, J12, J16, J17, J18, J19, J23, J24, J25, J26
00140
00150
00160
1)
Coding at customer's request
48-25 page 8
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis

Table of codes (up to 05/2001)
Shock absorber + power steering + airbags PR. number
Selectable coding
without airbag
with airbag
L05 (L06, L07, L08, L19, L20, L21, L32, L33) + 1N2 + 4UC (4UE, 4UF)
10110
L09 (L11, L12, L13, L14, L26, L35) + 1N2 + 4UC (4UE, 4UF)
10120
L01 (L02, L03, L04, L15, L16, L17, L18) + 1N2 + 4UC (4UE, 4UF)
10140
1N5 + 4UC (4UE, 4UF)
10160
L05 (L06, L07, L08, L19, L20, L21, L32, L33) + 1N2 + 4UA
00110
L09 (L11, L12, L13, L14, L26, L35) + 1N2 + 4UA
00120
L01 (L02, L03, L04, L15, L16, L17, L18) + 1N2 + 4UA
00140
1N5 + 4UA
00160
The meaning of the code numbers

Code
number:
Meaning
00110
Normal power steering for heavy vehicles
101101)
Normal power steering for heavy vehicles
00120
Sport steering RS
101201)
Sport steering RS
00130
Convenience - greater power steering at low driving speeds (e.g. when parking) for heavy vehicles
(has not been used before)
101301)
Convenience - greater power steering at low driving speeds (e.g. when parking) for heavy vehicles
00140
Normal power steering for light vehicles
101401)
Normal power steering for light vehicles
00150
Convenience - greater power steering at low driving speeds (e.g. when parking) for light vehicles
101501)
Convenience - greater power steering at low driving speeds (e.g. when parking) for light vehicles
00160
Handicap - greater power steering for vehicles for the handicapped
101601)
Handicap - greater power steering for vehicles for the handicapped
1)
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)
Press
6Q0423156
Power steering
Coding 00110
0001 ->
WSC XXXXX
.
Vehicle system test
Select function XX
Readout on display:
Select function
HELP
Q.

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
FABIA 2000 Chassis
Readout on display:
Enter function
Vehicle system test

Select function XX
0 8 Read measured value block
HELP
and confirm the entry with key Q .

Read measured value block
Readout on display:
HELP
XXX
Enter display group 48-25 page 10.

List of display groups
Measured value block 001

12.3 V
27 C
0.0 A
Readout on display:
off
Pump motor
off
on
Temperature on the control unit for the power-assisted steering

Pump motor current
Voltage terminal 30

0.0 /s
0 rpm
0 rpm
Readout on display:
0.0 A
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
48
FABIA 2000 Chassis


0 km/h
0 rpm
off
Readout on display:
yes
Power steering sensor G250
yes
no
Pump motor
off
on
Vehicle engine speed

Vehicle speed

0h
correct
Readout on display:
12.1 V
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
FABIA 2000 Chassis
agnostic connection in the storage compartment on

the driver's side.
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
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
48
FABIA 2000 Chassis
48-26 Electrical Test of Power

Steering
2

Hand multimeter, e.g. -V.A.G 1526B Measuring tool set, e.g. -V.A.G 1594C-
Test conditions
Fuses according to current flow diagram O.K.

Battery voltage at least 11.5 volts
Procedure

Rep. Gr. 66
S48-0291
Engine pump aggregate TRW
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-:
1234-
Data BUS Low

Data BUS High
not yet assigned
Terminal 15
1
1
Connector -2-:
1 - Terminal 30
2 - Earth
Switch on the ignition.

Test with a hand-held multimeter and suitable test
S48-0151
prods from the measuring tool set:

Contact assignment (TRW or KOYO)
Connector -1between contact:
Specified value:
4 and earth
Edition 11.04
S00.5303.17.20
Electrical Test of Power Steering
48-26 page 1
48
FABIA 2000 Chassis
Specified value:
1 and 2
1 and earth
Switch off the ignition.
Resistance measurement (TRW or KOYO)

Specified value:
4 and earth
Specified value:
1 and earth
2 and earth
approx. 0
1 and 2
approx. 60
If the specified values are not reached:
Test the wiring according to the current flow diagram

48-26 page 2
Electrical Test of Power Steering
Edition 11.04
S00.5303.17.20
48
FABIA 2000 Chassis
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.
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,

Nominal value: 6072
If the resistance is not within the nominal value

range:
V.A.G 1598/31
S24-0380
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
FABIA 2000 Chassis
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.
Test the data BUS cables for short-circuits.

To this end perform a resistance measurement be-
tween the test box bushes Current Flow Diagrams,

Nominal value:
If the nominal value is reached (there is no short-circuit

between the cables):
Test the data BUS cables for a short-circuit to the pos-
V.A.G 1598/31
S24-0380
itive battery terminal or earth or for interruption

48-27 page 2
Checking the data BUS
Edition 12.99
S00.5303.01.20
48
FABIA 2000 Chassis
48-28 Electric/Electronic components and fitting locations
1 - Servotronic warning light

-K92T Fitting location: in the dash
3
4
panel insert
T 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
T 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
5
5 - The power-steering sensor
-G250- (KOYO)
T Fitting location: in the valve
11
dome of the power-steering
10
gear
T 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 -J500T Perform self-diagnosis Chap. 48-25
6 - Inspecting the power-assisted steering sensor -G250- (TRW)
T with fixed connecting line
T Fitting location: in the valve dome of the power-steering gear
T 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 -J500T Perform self-diagnosis Chap. 48-25
7 - Inspecting the power-assisted steering sensor -G250- (TRW)
T with adapter cable
T Fitting location: in the valve dome of the power-steering gear
T Operation:
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 -
T Perform self-diagnosis Chap. 48-25

Adapter cable
T for power-steering sensor -G250- item 7
Power-assisted steering control unit -J500T Fitting location: integrated in the engine pump aggregate item 10
T 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
T Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate
Chap. 48-20
Engine pump aggregate (TRW)
Power-assisted steering control unit -J500T Fitting location: integrated in the engine pump aggregate item 12
T 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
T Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate
Chap. 48-20
Engine pump aggregate (KOYO)
48-28 page 2
Electric/Electronic components and fitting locations
Edition 11.04
S00.5303.17.20

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5

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2000 Chassis

List of Supplements to Workshop Manual

Supplement to Basic Edition

Axles, brakes, electrical inspection ABS, ABS/EDL/TCS

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

Changes to the text in Rep. Gr. 00, 40, 42, 46 and 48

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,

Steering KOYO, Correction of the text, Updating of the steering

Supplement to Rep. - Gr. 45 and 48 TRW/KOYO steering

Text adaptation, Supplement to the coding of ABS, TCS, ESP

FABIA 2000 Chassis

FABIA 2000 Chassis

- 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

Repairing front axle .................................................................................... 40-1

- An overview of the front axle ........................................................................ 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

- 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

- Removing and installing wheel bearing housing .................................................. 40-3

40 Front wheel suspension

FABIA 2000 Chassis

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

- Inspecting outer CV joint ............................................................................. 40-5

- Removing and installing the outer CV joint ........................................................ 40-5

Rear axle with drum brake ........................................................................... 42-1

- Summary of components of rear axle .............................................................. 42-1