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Skoda Fabia 2000 Workshop Manual Chassis
Skoda Fabia 2000 Workshop Manual Chassis
Workshop Manual
FABIA 2000 ³
Chassis
Edition 08.99
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5303.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ Chassis
Suppleme
Edition Subject Article Number
nt
08.99 Basic Edition S00.5303.00.20
1 12.99 Supplement to Basic Edition S00.5303.01.20
2 05.00 Axles, brakes, electrical inspection ABS, ABS/EDL/TCS S00.5303.02.20
3 07.00 Steering S00.5303.03.20
4 08.00 ABS, Brake mechanics, Brake hydraulics S00.5303.04.20
5 11.00 Repairing the front axle, repairing the wheel bearing S00.5303.05.20
6 01.01 Repairing front suspension strut, repairing drive shafts S00.5303.06.20
7 02.01 Removing and installing rear axle and coil spring S00.5303.07.20
8 03.01 Chassis with Brakes FS-II and C54-II S00.5303.08.20
9 08.01 ESP and Rep.-Gr. 48, solid nut (twelve point nut), brake- S00.5303.09.20
pressure reducer
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, S00.5303.14.20
Supplement to the text
15 04.04 Steering KOYO, Correction of the text, Updating of the steering S00.5303.15.20
coding
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
Table of Contents
00 – Technical Data
Chassis ................................................................................................... 00-1 page 1
- Nominal values front axle ............................................................................ 00-1 page 1
- Nominal values rear axle ............................................................................. 00-1 page 2
- Vehicle data sticker and PR number ............................................................... 00-1 page 2
Steering ................................................................................................... 00-2 page 1
Brakes ..................................................................................................... 00-3 page 1
- Brake variants and their assignment ............................................................... 00-3 page 1
- Adjusting values for the load-dependent regulator ............................................... 00-3 page 5
- Pressure value of the distributor valve ............................................................. 00-3 page 5
- Brake fluid .............................................................................................. 00-3 page 5
Wheels, Tyres ........................................................................................... 00-4 page 1
- Possible wheel-tyre combinations .................................................................. 00-4 page 1
- Tyre legend ............................................................................................. 00-4 page 2
- 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 1
- Removing and installing a drive shaft .............................................................. 40-4 page 1
- Summary of components of drive shaft with CV joint ............................................ 40-4 page 2
- Repairing drive shaft with CV joint .................................................................. 40-4 page 5
- Inspecting a CV joint .................................................................................. 40-4 page 7
Drive shafts with tripod joint ........................................................................ 40-5 page 1
- Removing and installing a drive shaft .............................................................. 40-5 page 1
- V - Summary of components of drive shaft with AAR2000 tripod joint ........................ 40-5 page 1
- Inspecting outer CV joint ............................................................................. 40-5 page 3
- Repairing the drive shaft with AAR 2000 tripod joint ............................................. 40-5 page 3
- Removing and installing the outer CV joint ........................................................ 40-5 page 6
- Checking the camber on the front axle, if necessary take the mean .......................... 44-2 page 4
- Checking the camber on the rear axle ............................................................. 44-2 page 5
- Checking the track on the rear axle ................................................................ 44-2 page 5
- Checking the tracking on the front axle, adjusting if necessary ................................ 44-2 page 5
- Checking the left and right steering angle ......................................................... 44-2 page 6
- Calculation of the misalignment on the rear axle ................................................. 44-2 page 7
- 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/TCS/ESP BOSCH 5.7) ................ 45-13 page 3
- Null balance of the steering angle sender -G85- ................................................. 45-13 page 4
- Perform ESP road and system test (vehicles with ABS/EDL/TCS/ESP BOSCH 5.7) ...... 45-13 page 6
Basic setting - ABS systems BOSCH 8.0 ........................................................ 45-14 page 1
- 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 ESP road and system test (vehicles with ABS/TCS/ESP BOSCH 8.0) ............ 45-14 page 5
Electrical Test - ABS systems BOSCH 5.7 ....................................................... 45-15 page 1
- Test requirements ..................................................................................... 45-15 page 1
- Connecting test box -V.A.G 1598A- ................................................................ 45-15 page 1
- Multi-pin connector with contact assignment ...................................................... 45-15 page 1
- Overview of test steps ................................................................................ 45-15 page 3
- Test table ............................................................................................... 45-15 page 4
Electrical/electronic components and fitting locations - ABS/ESP systems BOSCH 5.7
and BOSCH 8.0 ......................................................................................... 45-16 page 1
- Summary of components - Electrical/electronic components and fitting locations - ABS/ESP
systems BOSCH 5.7 .................................................................................. 45-16 page 1
- Summary of components - Electrical/electronic components and fitting locations - ABS/ESP
systems BOSCH 8.0 .................................................................................. 45-16 page 3
- Indication of faults by means of warning lights ................................................... 45-16 page 6
- Setting, removing and installing the brake light switch -F- ...................................... 45-16 page 8
- 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 1
- Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake
Cylinder ................................................................................................. 45-17 page 1
- Removing and installing the hydraulic control unit ............................................... 45-17 page 2
- Repairing the hydraulic control unit ABS or ABS/EDL/TCS BOSCH 5.7 ..................... 45-17 page 6
- Removing and installing brake pressure sender 1 -G201- - vehicles with ABS/EDL/TCS/
ESP BOSCH 5.7 ...................................................................................... 45-17 page 10
Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo unit/Master brake
cylinder ................................................................................................... 45-18 page 1
- Summary of Components of Hydraulic Control Unit Brake Servo Unit/Master Brake
Cylinder ................................................................................................. 45-18 page 1
- Removing and installing the hydraulic control unit ............................................... 45-18 page 3
- Removing and installing bracket for the hydraulic control unit ................................. 45-18 page 6
- Connecting the brake lines .......................................................................... 45-18 page 7
Removing and Installing Parts of the ABS System on the Front and Rear Axle ........ 45-19 page 1
- Removing and installing wheel speed sensor on the front axle - Vehicles with ABS systems
BOSCH 5.7 or BOSCH 8.0 .......................................................................... 45-19 page 1
- Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH
5.7 ....................................................................................................... 45-19 page 1
- Removing and installing front wheel speed sensors - Vehicles with ABS systems BOSCH
8.0 ....................................................................................................... 45-19 page 4
- Sensor ring for ABS on the front and rear axle ................................................... 45-19 page 8
- Removing and installing wheel speed sensor on the rear axle ................................. 45-19 page 8
- Repairing rear wheel speed sensor cables - Vehicles with ABS systems BOSCH 5.7 and
BOSCH 8.0 ............................................................................................. 45-19 page 9
48 – Steering
Steering column ........................................................................................ 48-1 page 1
- Summary of components ............................................................................ 48-1 page 1
Inspecting steering column .......................................................................... 48-2 page 1
- Optical inspection ..................................................................................... 48-2 page 1
- Functional test ......................................................................................... 48-2 page 1
Removing and installing steering column ....................................................... 48-3 page 1
- Removing the steering column ...................................................................... 48-3 page 1
- Installing the steering column ....................................................................... 48-3 page 4
Removing and installing ignition lock housing ................................................. 48-4 page 1
- Removing ignition lock housing ..................................................................... 48-4 page 1
- Installing ignition lock housing ....................................................................... 48-4 page 1
Frequency link, bracket ............................................................................... 48-5 page 1
- Removing and installing frequency link ............................................................ 48-5 page 1
- Removing and installing bracket .................................................................... 48-5 page 1
Steering without servo unit (mechanical steering) ............................................. 48-6 page 1
- Summary of components ............................................................................ 48-6 page 1
Removing and installing mechanical steering gear ............................................ 48-7 page 1
- Removing steering gear .............................................................................. 48-7 page 1
- Installing steering gear ............................................................................... 48-7 page 4
Inspecting and adjusting mechanical steering gear ........................................... 48-8 page 1
- Check the centre position of the gear rack of the steering gear, if necessary adjust ....... 48-8 page 1
- Adjusting the steering gear (adjusting the pressure plate clearance) ......................... 48-8 page 1
Disassembling and assembling the steering gear ............................................. 48-9 page 1
Track rod ends, track rods ........................................................................... 48-10 page 1
- Play, correct attachment and joint boots ........................................................... 48-10 page 1
- Removing and installing track rod ends ............................................................ 48-10 page 1
- Removing and installing track rods ................................................................. 48-10 page 1
Power-assisted steering .............................................................................. 48-11 page 1
- Structure and function ................................................................................ 48-11 page 1
- Summary of components of power-assisted steering (TRW) .................................. 48-11 page 3
- Summary of components of power-assisted steering (KOYO) ................................. 48-11 page 5
- Summary of components of pressure line (hose) - power steering TRW or KOYO ........ 48-11 page 6
Removing and installing power-steering gear (TRW or KOYO) ............................. 48-12 page 1
- Connect vehicle diagnosis, measurement and information system -VAS 5051- and select
functions ................................................................................................ 48-25 page 11
Electrical Test of Power Steering ................................................................... 48-26 page 1
Checking the data BUS ............................................................................... 48-27 page 1
- Operation ............................................................................................... 48-27 page 1
- Test condition .......................................................................................... 48-27 page 1
- Test sequence ......................................................................................... 48-27 page 1
Electric/Electronic components and fitting locations ......................................... 48-28 page 1
00 – Technical Data
00-1 Chassis
S00-0151
00-2 Steering
Steering system: electro-hydraulic mechanical
(Electrically Powered Hydraulic
Steering - EPHS)
Steering gear: Rack pinion (input shaft) Zahnstange - Ritzel (Eingangswelle)
Rack pinion (input shaft)
Steering-wheel turns from turning an- 2,91 4,04
gle to the next:
Steering wheel diameter (mm): 370 370
Grease denomination for gear rack: TMS-L-10.482 1) SHELL STERAK
A0F 063 000 04 2)
Grease amount for gear rack in 11,0 +5,0 40,0
steering gear (g):
maximum clearance between pres- 0...0,08 0,04...0,09
sure plate and cover (mm):
authorised axial force for the dis- Displacement of the gear rack ---
placement of the gear rack (N):
♦ ± 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 1,0...3,5 3) 1,0...3,5 3)
from rest position (N):
Denomination of the hydraulic oil: PENTOSIN CHF 11S ---
N 052 146 00
TL 52 146
or
PENTOSIN CHF 202
N 052 146 01
TL 52 146
Hydraulic oil amount (l): 0,80 ---
1) applies for TRW steering
2) applies for KOYO steering
3) after 2 rotations
00-3 Brakes
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.
4,5
ible.
0 1 2 3 4 5 6 7 8 9 10 11
Pp(MPa)
Pressure values
S00-0183
Initial A B
setting
Pp (MPa) 2,5 4,5 5 6 7 8 9 10 11
Pz (MPa) 2,5 3,1 3,25 3,55 3,85 4,15 4,45 4,75 5,05
± 0,1 ± 0,2
Brake fluid
Engine Wheel size 1) Light-alloy rim 2) Steel rim 2) Offset (mm) Snow chains
permitted
155/80 R13 79T 3) - 5J x 13 H2 35 yes
165/70 R14 81T - 5J x 14 H2 35 yes
1.0 l/37 kW
1.2 l/40 kW 43 yes
185/60 R14 82T 6J x 14 H2 6J x 14 H2
1.2 l/47 kW 38 no
1.4 l/44 kW
195/50 R15 82T 6J x 15 H2 6J x 15 H2 43 no
1.4 l/50 kW
185/55 R15 81T 6J x 15 H2 6J x 15 H2 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
165/70 R14 81T - 5J x 14 H2 35 yes
43 yes
185/60 R14 82T 6J x 14 H2 6J x 14 H2
1.4 l/55 kW 38 no
1.4 l/55 kW TDI PD 185/55 R15 81T 6J x 15 H2 6J x 15 H2 43 yes
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
43 yes
185/60 R14 82H 6J x 14 H2 6J x 14 H2
38 no
1.4 l/74 kW
195/50 R15 82V, H 6J x 15 H2 6J x 15 H2 43 no
1.9 l/74 kW TDI PD
185/55 R15 81H 6J x 15 H2 6J x 15 H2 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
195/50 R15 82V, H 6J x 15 H2 - 43 no
2.0 l/85 kW 185/55 R15 81H 6J x 15 H2 - 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
165/70 R14 81T - 5J x 14 H2 35 yes
43 yes
185/60 R14 82T 6J x 14 H2 6J x 14 H2
38 no
1.9 l/47 kW SDI
195/50 R15 82T 6J x 15 H2 6J x 15 H2 43 no
185/55 R15 81T 6J x 15 H2 6J x 15 H2 43 yes
205/45 R16 83W, V 6.5J x 16 H2 - 42 no
205/45 R16 83W 6.5J x 16 H2 - 37 no
1.9 ltr./96 kW TDI
185/55 R15 84H 6J x 15 H2 - 43 yes
PD
205/45 R16 83W, V - 6,5J x 16 H2 4) 42 no
1) Tyre inflation pressure ⇒ Inspection and Maintenance as well as sticker on the fuel-tank cap
2) 5-hole fixing, diameter of the bolt circle 100 mm, diameter of the central hole 57 mm
3) without power steering
4) 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 dif-
fer per axle. It is exceptionally allowed to use a differ-
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, Meaning
e.g. 155/80 R13 79 T
155/80 Tyre width (mm) section ratio between height - width (%)
R Tyre type (radial)
13 Rim diameter (inch)
79 Load rating-index
T Speed symbol
79 = 437 kg
Load rating-indexes 81 = 462 kg
(Load index) 82 = 475 kg
83 = 500 kg
T = 190 km/h
H = 210 km/h
Speed symbols
V = 240 km/h
W = 270 km/h
IV III
S40-0153
I - Summary of components assembly carrier, console, axle link, anti-roll bar, cou-
pling 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
T removing and installing
26
⇒ 40-1 page 19
T assignment ⇒ Spare part 1 2 3 4 5
catalogue 27
2 - Nut, 40 Nm 6
T assignment ⇒ Spare part
catalogue
25 7
3 - Anti-roll bar 20
T to remove and install lower 8
assembly carrier 24
T removing and installing
⇒ 40-1 page 17 22
T assignment ⇒ Spare part
catalogue
4 - Rubber bearing
9
T assignment ⇒ Spare part 23 21 10 10
catalogue
5 - Clamp
11
T assignment ⇒ Spare part 19
catalogue 12
6 - Nut, 40 Nm 13
T assignment ⇒ Spare part
catalogue 14
7 - Coupling rod 18
T assignment ⇒ Spare part 15
catalogue
8 - Bracket
17
9 - Screw, 20 Nm + torque a fur-
ther 90° (1/4 turn) 16
T replace after each removal S40-0201
10 - Screw, 70 Nm + torque a fur-
ther 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
T replace after each removal
14 - Nut, self-locking, 20 Nm and torque a further 90° (1/4 turn)
T replace after each removal
– Pull the track control arm down with force and push up
again.
S40-0286
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.
S40-0287
Removing and installing the steering
joint
Special tools, test and measuring equipment and
auxiliary items required
♦ Engine/gearbox jack e.g. - V.A.G 1383- with
-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
Note
♦ Position gearbox jack with adapter, (e.g. -V.A.G 1383/
A- with -V.A.G 1359/2-, (risk of accident: due to falling
parts while the steering joint is being pressed out).
♦ To protect the thread, screw the nut a couple of thread
turns onto the steering joint.
S40-0161
Note
♦ Note the installed position of the steering joint. Matra V176
♦ 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
S40-0162
3 - means 13"
4 - means 14"
Right steering joint
R - means right
3 - means 13"
4 - means 14"
Arrow points in the driving direction on the 14" running
gear.
Note
2
Make sure the steering joint boot is neither damaged nor
twisted.
1 S40-0338
– Fit front wheel.
Tightening torques:
Note
When lowering the assembly carrier make sure that the
pressure line, return hose and the line of the power-as-
sisted steering sensor -G250- are not exposed to traction.
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 tight-
ened to the recommended torque.
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
Vehicles with exhaust pipe under the assembly carri-
er 1
– Install the front exhaust pipe with catalyst ⇒ Engine -
Mechanics; Rep. Gr. 26.
Tightening torques: 2 S10-0133
Removing
– Swivelling the track control arm -2- out of the assem- S40-0169
bly carrier.
– Pull out the track control arm -1- using the multi-pur-
pose tool -MP 3-419- from the console.
Note
When pulling out the track control arm ensure that the MP3-419
wheehouse trim panel and the noise insulation are not
damaged.
Installing
1
– Brush the track control arm studs with assembly slid-
ing 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.
Note
Use new screws and new lock washer to screw the steer- S40-0169
ing joint/track control arm.
– Position the track control arm -2- and steering joint -1-
relatively to each other in such a way that the holes
-arrows- of the track control arm and steering joint are
flush.
For better fixing use two drifts with 8.3 mm ∅ or as shown
in the figure, two drill bits with 8.3 mm ∅.
Continued for all vehicles
Further installation occurs in reverse order.
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
S48-0113
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 1
page 6.
1
– Take the console out of the assembly carrier.
Installing
Note
♦ Observe the jointing and screw sequence of the
screwed connections assembly carrier/track control 1
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 44-
2.
♦ Before inserting the screws for the assembly carrier,
position the steering gear on the assembly carrier and
insert the screws for the steering gear.
S40-0166
S40-0165
– Insert left and right coupling rod -3- into the stabilizer
-2-.
2
– Tighten the left and right nut -1-.
– Installing the track control arm ⇒ 40-1 page 8.
1
– Perform a test drive.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight, 3
perform a chassis alignment.
S40-0174
Note
When inserting the bonded rubber mounting counterhold
at spindle.
Note
♦ Never use grease!
♦ Use assembly sliding oil -G 294 421 A1- to insert. S40-0334
♦ This leaves a slightly sticky film, which ensures a tight
fit of the bearing.
S40-0339
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
1 2
The stud -1- of the bonded rubber bush must be flush with
marking -2- on the console.
S48-0112
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
S48-0113
– Screw out the screws -1- and tie up the steering gear
with wire.
– Release the assembly carrier and lower ⇒ 40-1 1
page 6.
1
– Remove the clamp from the anti-roll bar.
– Turn the anti-roll bar upwards and remove towards the
rear.
Installing
Note S40-0166
Note
Position the screws -1- in the elongated holes of the pen-
dulum support in such a way that there is maximum dis-
tance between the gearbox and the assembly carrier.
Tightening torques:
Removing
S40-0161
S48-0113
– Screw out the screws -1- and tie up the steering gear
with wire.
– Release the assembly carrier and lower ⇒ 40-1 1
page 6.
1
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.
1
♦ Always replace plate nuts of drive shaft on both sides
by twelve-point nuts.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment.
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
13
2 - Nut, 60 Nm + torque a further 12
90° (1/4 turn) 12
T replace after each removal
3- Screw 12
T replace after each removal
6
4- Shock absorber
T removing and installing
⇒ 40-2 page 2 11
T can be replaced individually 5
T must be replaced completely
T check ⇒ 40-2 page 7 10
T disposing of ⇒ 40-2 page 8
T assignment ⇒ Spare part 9
catalogue 4
5- Stop buffer
6- Boot
7- Helical spring
8
T check colour coding
T The surface of the spring coil 3
must not be damaged
T replace axle-wise 2
T per axle only use helical
springs of the same make
T removing and installing 7
⇒ 40-2 page 6
T assignment ⇒ Spare part
catalogue
8- Axial grooved ball bearing 1
9- Suspension strut bearing S40-0185
10 - Self-locking nut, 60 Nm
T replace after each removal
11 - Suspension strut dome
12 - Screw, 15 Nm + torque a further 90° (1/4 turn)
T replace after each removal
T when mounting the suspension strut, first mount the screws on the inside of the vehicle
13 - Cap
T clipped into suspension strut dome
Removing
S40-0342
S40-0288
Note
Never press on the steering joint with the gearbox jack.
Note
Remove possible corrosion, grease or adhesive sealing
material from the thread and from the serration of the out-
er joint as well as from the serration of the wheel hub.
Vehicles with 13" running gear
Note
♦ Always replace plate nuts of drive shaft on both sides
by twelve-point nuts.
♦ Replace nut on both sides. 2
– Screw the track control arm -1- with the steering joint
-2- with new screws -arrows- and new lock washer in 1 S40-0338
accordance with the former positions and markings.
– Tighten the new screws -arrows- in accordance with
the markings and the former positions to the specified
tightening torque.
– Perform a test drive.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment.
V.A.G
1752/4
V.A.G
1752/1
Tightening torque:
Note
A slight oil leak is beneficial as the gasket is lubricated
and this increases the life time. This applies for shock ab-
sorbers on the front as well as the rear axle.
Shock absorber noises
There is reason to believe that in the event of noise com-
plaints 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 driv-
ing because of the knocking noises caused by wheel hop-
ping, more specifically on poor road surfaces and they
must be replaced. The main cause of defect is oil leak-
age. The shock absorber then compresses and/or ex-
pands 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 no-
ticeable because of loud knocking noises caused by
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 oper-
ational yet pressureless shock absorber without prob-
lem.
♦ Adequate gas pressure in the shock absorber im-
proves the noise behaviour and function when driving
over poor road surfaces.
Note
There are two ways of disposing of shock absorbers.
Degassing the front and rear pressurized shock ab-
sorbers
Possibility A: Degassing by drilling open
I - Front pressurized shock absorber
II - Rear pressurized shock absorber
Caution!
Wear safety goggles during the drilling procedure.
Note
Gas will escape during drilling.
60
A
60
20
through (approx. 25 mm deep).
20
– Drill a second hole ∅ 6 mm -arrow B- through the out-
er and inner pipe of the shock absorber. B B
– 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 ab-
sorbers
Possibility B: Open with pipe cutter
I - Front pressurized shock absorber
II - Rear pressurized shock absorber
Caution!
Wear safety goggles during the drilling procedure.
Note
Gas will escape during drilling.
S40-0189
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.
♦ Always replace the self-locking nuts and screws.
♦ Always replace corroded self-locking nuts and screws.
1 - Suspension strut
T removing and installing 5
⇒ Chapter 40-2
1
T repair ⇒ Chapter 40-2
T assignment ⇒ Spare part 2
catalogue
28 6
2 - Drive shaft with CV joint 7
T removing and installing
⇒ Chapter 40-4
T inspect ⇒ Chapter 40-4
3
T repair ⇒ Chapter 40-4 27 4
T assignment ⇒ Spare part 26
catalogue 24 25
3 - Shim
T assignment ⇒ Spare part
catalogue 23
20
4 - Fillister head screw with inter-
nal serrations
19
T replace after each removal 22
T assignment ⇒ Spare part
8
catalogue 9
T M8 x 48
initially tighten all screws to
10 Nm, then tighten screws
crosswise 17
Tightening torque: 40 Nm 18
T M10 x 52 21 10
initially tighten all screws to 12
10 Nm, then tighten screws
16
crosswise 11
Tightening torque: 70 Nm 15 14 13 S40-0202
5 - Drive shaft with tripod joint
T removing and installing ⇒ Chapter 40-5
T repair ⇒ Chapter 40-5
T assignment ⇒ Spare part catalogue
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 replace after each removal
T assignment ⇒ Spare part catalogue
T M8 x 18
initially tighten all screws to 10 Nm, then tighten screws crosswise
Tightening torque: 40 Nm
T M8 x 28
III - Summary of components of the wheel bearing, suspension strut, drive shaft,
brake FS-II
Note
♦ Welding and straightening work is not allowed on the bearing and wheel control components of the front wheel
suspension.
♦ Always replace the self-locking nuts and screws.
♦ Always replace corroded self-locking nuts and screws.
1 - Suspension strut
T removing and installing
⇒ Chapter 40-2
T repair ⇒ Chapter 40-2 2
1
T assignment ⇒ Spare part
catalogue
27
2 - Drive shaft with CV joint
T removing and installing 3
⇒ Chapter 40-4
T inspect ⇒ Chapter 40-4
26 4
25
T repair ⇒ Chapter 40-4
T assignment ⇒ Spare part 23 24
catalogue
3 - Shim
T assignment ⇒ Spare part 22
19
catalogue
18
4 - Fillister head screw with inter-
nal serrations
T replace after each removal 17 5
T assignment ⇒ Spare part 21 16 6
catalogue
T M8 x 48
initially tighten all screws to 15
10 Nm, then tighten screws
crosswise
Tightening torque: 40 Nm 20 14 7
T M10 x 52 9
initially tighten all screws to
13
10 Nm, then tighten screws 8
crosswise
12 10
Tightening torque: 70 Nm
11 S40-0203
5 - Brake disc, internally ventilat-
ed
6 - Wheel bolt, 120 Nm
T assignment ⇒ Spare part catalogue
7 - Plate nut
T replace after each removal against twelve-point nut ⇒ item 8
8 - 50 Nm
T replace after each removal
T Do not grease thread of the outer joint of the drive shaft.
T assignment ⇒ Spare part catalogue
9 - Screw, 4 Nm
10 - Brake pad
T removing and installing ⇒ Chapter 46-1
11 - Brake caliper
T assignment ⇒ Spare part catalogue
T do not release brake hose when working on the front wheel suspension
T tie up with wire or anything similar
T repair ⇒ Chapter 47-1
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
T assignment ⇒ Spare part catalogue
15 - Screw, 10 Nm
T for air deflector
16 - 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 assignment ⇒ Spare part catalogue
17 - Screw, 10 Nm
18 - Cover plate
19 - Nut, 20 Nm + torque a further 90° (1/4 turn)
T replace after each removal
20 - Track rod and track-rod ends
T removing and installing ⇒ Chapter 48-16
21 - Wheel-bearing housing
T removing and installing ⇒ 40-3 page 7
T assignment ⇒ Spare part catalogue
22 - Nut, 60 Nm + torque a further 90° (1/4 turn)
T replace after each removal
23 - Screw
T replace after each removal
T the tip of bolt must point in the direction of travel
24 - Speed sensor ABS
T assignment ⇒ Spare part catalogue
25 - Allan screw, 8 Nm
T for speed sensor ABS
26 - Nut, 40 Nm
T assignment ⇒ Spare part catalogue
27 - Coupling rod
T assignment ⇒ Spare part catalogue
Note
♦ Welding and straightening work is not allowed on the bearing and wheel control components of the front wheel
suspension.
♦ Always replace the self-locking nuts and screws.
♦ Always replace corroded self-locking nuts and screws.
1 - Suspension strut
T removing and installing 5
⇒ Chapter 40-2 1
T repair ⇒ Chapter 40-2
T assignment ⇒ Spare part 2
catalogue 31 6
2 - Drive shaft with CV joint 7
T removing and installing
⇒ Chapter 40-4 3
T inspect ⇒ Chapter 40-4
T repair ⇒ Chapter 40-4 30 4
29
T assignment ⇒ Spare part
catalogue 27 28
3 - Shim
T assignment ⇒ Spare part 26
catalogue 23
4 - Fillister head screw with inter-
25 22
nal serrations 21
T replace after each removal 20
T assignment ⇒ Spare part 24 8
catalogue 9
T M8 x 48
initially tighten all screws to
17
10 Nm, then tighten screws 19
crosswise
Tightening torque: 40 Nm 15 14
T M10 x 52
12 10
initially tighten all screws to 13
10 Nm, then tighten screws
crosswise
18 13 11
17 14
Tightening torque: 70 Nm 16 S40-0204
5 - Drive shaft with tripod joint
T removing and installing ⇒ Chapter 40-5
T repair ⇒ Chapter 40-5
T assignment ⇒ Spare part catalogue
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 replace after each removal
T assignment ⇒ Spare part catalogue
T M8 x 18
initially tighten all screws to 10 Nm, then tighten screws crosswise
Tightening torque: 40 Nm
T M8 x 28
initially tighten all screws to 10 Nm, then tighten screws crosswise
Tightening torque: 40 Nm
T M10 x 23
initially tighten all screws to 10 Nm, then tighten screws crosswise
Tightening torque: 70 Nm
8- Brake disc, internally ventilated
9- Wheel bolt, 120 Nm
T assignment ⇒ Spare part catalogue
10 - Plate nut
T replace after each removal against twelve-point nut ⇒ item 11
11 - 50 Nm + 45°
T replace after each removal
T Do not grease thread of the outer joint of the drive shaft.
T assignment ⇒ Spare part catalogue
12 - Screw, 4 Nm
13 - Brake pad
T removing and installing ⇒ Chapter 46-1
14 - Pad retaining plate
T always replace when changing the brake pads
T brake pads contained in repair kit
15 - Brake carrier with guide bolts and protective caps
16 - Heat shield
T always replace when changing the brake pads
T brake pads contained in repair kit
17 - Brake caliper
T assignment ⇒ Spare part catalogue
T do not release brake hose when working on the front wheel suspension
T tie up with wire or anything similar
T repair ⇒ Chapter 47-1
18 - Screw, 30 Nm
T replace after each removal
19 - Track rod and track-rod ends
T removing and installing ⇒ Chapter 48-16
20 - 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
T assignment ⇒ Spare part catalogue
21 - Screw, 10 Nm
22 - Cover plate
23 - Nut, 20 Nm + torque a further 90° (1/4 turn)
T replace after each removal
24 - Screw, 125 Nm
T clean ribbing on underside each time removed
25 - Nut, 60 Nm + torque a further 90° (1/4 turn)
T replace after each removal
26 - Wheel-bearing housing
T removing and installing ⇒ 40-3 page 7
T assignment ⇒ Spare part catalogue
27 - Screw
T replace after each removal
T the tip of bolt must point in the direction of travel
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.
Removing
S48-0113
S40-0176
S40-0288
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.
– Perform a test drive.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment.
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-.
S40-0197
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
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.
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 insert-
ing.
– Pull the wheel hub with wheel bearing into the wheel-
bearing housing.
1- -MP 6-414/5-
3
2- -T10064/1-
3- -T10064/5-
4- -MP 6-414/10-
4 2
5- -T10064/4-
Chassis with an FS-III or C54-II brake
1
Note 5
♦ 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
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.
– Perform a test drive.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment.
Removing
Note
Remove possible corrosion, grease or adhesive sealing
material from the thread and from the serration of the out-
er joint as well as from the serration of the wheel hub.
Vehicles with 13" running gear
MP 6-425
– Smear the gearing of the outer joint of the drive shaft
lightly with adhesive sealing material -Loctite 601-.
S40-0178
Do not grease thread on the outer joint of the drive
shaft.
Vehicles with 14” and 15” running gear
Note
Always replace plate nuts of drive shaft on both sides by 2
twelve-point nuts. Replace nut on both sides.
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.
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.
6 - Disc spring
T Fitting position ⇒ 40-4 page 6
7 - Inner CV joint
T must be replaced completely
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
T assignment ⇒ Spare part catalogue
8 - Gasket
T The adherend must be free of grease and oil!
T replace
T Pull off protective foil and stick in housing
T assignment ⇒ Spare part catalogue
9 - Circlip
T replace
T use circlip pliers, e.g. -VW 161 A- for removing and installing
T assignment ⇒ Spare part catalogue
10 - Left drive shaft (solid shaft)
T assignment ⇒ Spare part catalogue
11 - Warm-type clamp
T replace
T tensioning ⇒ 40-4 page 5
12 - Joint boot
T Material: Hytrel (Polyelastomere)
T inspect for tears and chafing points
13 - Warm-type clamp
T replace
T tension with tensioning pliers, e.g. -V.A.G 1682 - ⇒ 40-4 page 5
14 - Disc spring
T Fitting position ⇒ 40-4 page 5
15 - Thrust ring
T Fitting position ⇒ 40-4 page 5
16 - Circlip
T replace
T insert in the shaft groove
17 - Outer CV joint
T must be replaced completely
T removing ⇒ 40-4 page 5
T before installing grease the serration with polycarbamide grease -G 052 142 A2-
T Installing: drive onto the shaft with a plastic hammer until the compressed circlip expands
T grease ⇒ 40-4 page 2
T check ⇒ 40-4 page 7
T assignment ⇒ Spare part catalogue
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°
T replace after each removal
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.
Note MP 6-428
Chamfer on inner diameter of the ball hub (serration)
MP 6-429
must point towards the bearing collar of the drive shaft.
– Fit new circlip on the drive shaft. For this use e.g. the
circlip pliers -VW 161 A-.
MP 3-407 MP 3-406
– Coat the edge of the inner joint boot cap with sealant
-D 454 300 A2-.
– Fit joint boot on the constant velocity joint.
Note S40-0099
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.
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 tor-
sional 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.
Note
The cage must be inserted in the correct position.
Note
The ball hub and joint piece are paired and must be
marked before disassembly. Do not interchange the
bearing track assignment.
– Tilt the ball hub out of the ball cage over the ball bear-
ing track -arrows-.
– Inspect the joint part, ball hub, ball cage and balls for
small broken out depressions (pitting = point corro-
sion) and seizing marks.
Note
Load alteration shocks indicate too much torsional clear-
ance in the joint. If this is the case, replace the joint.
Smoothing and bearing marks do not justify a joint re-
placement.
Assembling the inner CV joint
– Insert the ball hub in the ball cage over the two cham-
fers. The fitting location is random. Press the balls into
the cage.
– Insert the hub with cage upright into the joint part.
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-.
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 cata-
logue.
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.
S40-0145
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.
S40-0148
MP 3-407
MP 3-406 MP 6-429
S40-0143
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 B 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.
Note
♦ Welding and straightening on axle body and axle studs not allowed.
♦ Always replace the self-locking nuts and bolts.
♦ Always replace corroded self-locking nuts and screws.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
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
17 - Bonded rubber bush
T removing and installing ⇒ Chapter 42-2
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
T removing and installing ⇒ 42-1 page 3
19 - Axle stud
T Straightening work is not allowed!
T Re-cutting the thread is not allowed!
T removing and installing ⇒ Chapter 42-5
20 - Brake line
T Tightening torque of the pipe screws: 14 Nm
21 - 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
22 - Self-locking nut
T replace after each removal
23 - Screw, 40 Nm + torque a further 90° (1/4 turn)
T replace after each removal
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.
24 - Speed sensor ABS
T Allocation ⇒ Spare parts catalogue
25 - Plug
T for vehicles without ABS
T to plug the hole in the axle stud
26 - Allan screw, 8 Nm
T for speed sensor ABS
27 - Bottom spring base
T inspect for damage (visual inspection)
28 - Screw, 45 Nm + torque a further 90° (1/4 turn)
T replace after each removal
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
T replace after each removal
30 - Mount for rear axle
T attached to the vehicle body
Removing
– Remove wheels.
Caution!
♦ Before removing the rear suspension, the vehicle S46-0096
must be lashed securely on both sides at the sup-
porting 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 2
in the securing strap
1 - Supporting arm of lift platform
2 - Securing strap, e. g. -T10038-
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.
2
– Separate brake line.
Note
Seal brake lines with plugs.
1
Only on vehicles equipped with Xenon head-
lights
– Disconnect the tension rod for the sender at the rear
of the assembly carrier ⇒ Electrical System;
Rep. Gr. 94.
S42-0147
Note A
A second person is required for the further removal oper-
ations.
S42-0147
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 com-
partment, immediately behind the rear seat. S42-0150
Tightening torques:
Removing V.A.G
1752/1
Note
The rear silencer must be taken off in order to remove the
left coil spring.
Note
♦ Ensure that the spring holders are positioned as close V.A.G 1752/3 S42-0149
as possible to the spring coils -arrow-.
♦ During the tensioning operation, ensure that the
spring holder is correctly located at the spring coils.
♦ Do not use impact screw drivers. 2
– Insert spring tensioning device. 1
– Tension coil spring sufficiently until it can be removed. V.A.G 1752/3
– Remove coil spring.
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.
Edition 04.04 Servicing the rear axle with drum brakes 42-2 page 1
S00.5303.15.20
42 FABIA 2000 ³ Chassis
Removing
– Remove wheel.
– Place gearbox jack with attachment below and sup-
port rear suspension at shock absorber mounting.
42-2 page 2 Servicing the rear axle with drum brakes Edition 04.04
S00.5303.15.20
FABIA 2000 ³ Chassis 42
Disassembling and assembling shock absorber
Note
The shock absorbers must not be disassembled and repaired.
1 - Shock absorber
T can be replaced individually
T removing and installing 7
⇒ 42-2 page 2
T assignment ⇒ Spare part 6
catalogue
T disposal ⇒ Chapter 40-2
T inspect ⇒ Chapter 40-2
2 - Protective cap
3 - Protective tube 5
4 - Stop buffer
5 - Shock absorber bushing
6 - Self-locking nut, 25 Nm
T replace after each removal
T counterhold the piston rod of 4
the shock absorber at the tip
in order to slacken and tight-
en the nut
7 - Cover
3
1
S42-0152
Edition 04.04 Servicing the rear axle with drum brakes 42-2 page 3
S00.5303.15.20
42 FABIA 2000 ³ Chassis
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 sup-
porting 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-
S42-0147
42-2 page 4 Servicing the rear axle with drum brakes Edition 04.04
S00.5303.15.20
FABIA 2000 ³ Chassis 42
Only on vehicles fitted with load-sensitive brake
pressure regulator (without ABS)
– Release screw -1-. 1
– Slacken the front attachment of the wheelhouse liner
at the rear ⇒ Body Work; Rep. Gr. 66.
– Remove coil spring ⇒ 42-2 page 1.
Note
A second mechanic must counterhold at the rear axle
when pulling out the rubber-metal bearing.
MP 5-400/2
MP 3-419
S42-0143
Edition 04.04 Servicing the rear axle with drum brakes 42-2 page 5
S00.5303.15.20
42 FABIA 2000 ³ Chassis
Installing
Fabia RS
1
The axle -1- must be aligned with the edge -arrow- of the
trailing arm -2-.
2 S42-0160
1
2 S42-0151
Fabia RS
42-2 page 6 Servicing the rear axle with drum brakes Edition 04.04
S00.5303.15.20
FABIA 2000 ³ Chassis 42
Other vehicles (except Fabia RS)
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 rub-
ber-metal bearing must be replaced.
♦ To provide a clearer illustration, the rubber-metal
bearing is shown with the rear suspension removed.
Note
The axle beam should be moved into the horizontal posi- S42-0150
tion 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.
Edition 04.04 Servicing the rear axle with drum brakes 42-2 page 7
S00.5303.15.20
42 FABIA 2000 ³ Chassis
Tightening torques:
42-2 page 8 Servicing the rear axle with drum brakes Edition 04.04
S00.5303.15.20
FABIA 2000 ³ Chassis 42
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 27
T repairing ⇒ Chap. 47-1 28
2 - Wheel bolt, 120 Nm 26
T Assignment ⇒ Spare part
25 29
catalogue
3 - Cross-head screw, 4 Nm 23
4 - Brake disc
5 - Cap 24 18
T replace each time removed 22 19
17
T pressing off and inserting
⇒ Chap. 42-5 21 16
6 - Twelve-point nut, self-lock-
ing, 70 Nm + torque a further 20 15
30° (1/12 turn)
T replace each time removed
7 - Wheel hub with wheel bearing
T for vehicles with ABS the 14
sensor ring is built into the
wheel hub 12 13
T Wheel hub and wheel bear-
ing form one unit. The unit is
maintenance-free. Adjusting
and repairs are not possible.
1
T The sensor ring for ABS can-
not be replaced individually
T removing and installing
⇒ Chap. 42-5 2
T Assignment ⇒ Spare part
catalogue 3
8 - Hexagon bolt + washer, 11 10 9 8 7 6 5 4
30 Nm + torque a further 90° S42-0123
(1/4 turn)
T replace each time removed
9 - Cover plate
10 - Fixture for handbrake cable
T replace each time removed
T Fitting location ⇒ Chap. 46-3
11 - Handbrake cable
T removing and installing ⇒ Chap. 46-3
12 - Fixture for handbrake cable
13 - Bonded rubber bush
T removing and installing ⇒ Chap. 42-2
14 - Axle beam
T Assignment ⇒ Spare part catalogue
T The locating face and the threaded holes for axle stubs must be free from enamel and dirt
15 - Axle stub
T Straightening work is not allowed!
T Re-cutting the thread is not allowed!
T removing and installing ⇒ Chap. 42-5
16 - Hexagon bolt, 30 Nm + torque a further +30° (1/12 turn)
17 - Brake line with connection, banjo bolt and seals
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
T replace each time removed
19 - Hexagon bolt, 40 Nm + torque a further 90° (1/4 turn)
T replace each time removed
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.
20 - Speed sensor ABS
T Assignment ⇒ Spare part catalogue
21 - Hexagon socket bolt, 8 Nm
T for speed sensor ABS
22 - Bottom spring base
T inspect for damage (visual inspection)
23 - Hexagon bolt, 45 Nm + torque a further 90° (1/4 turn)
T replace each time removed
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
T replace each time removed
25 - Mount for rear suspension
T welded to body
26 - Coil spring
T removing and installing ⇒ Chap. 42-4
T check for paint damage, if necessary eliminate paint damage
T check colour coding
T Assignment ⇒ Spare part catalogue
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
28 - Hexagon bolt, 30 Nm + torque a further 90° (1/4 turn)
T replace each time removed
29 - Shock absorber
T removing and installing ⇒ Chap. 42-4
T inspecting ⇒ Chap. 40-2
T disposal ⇒ Chap. 40-2
T can be replaced individually
T Assignment ⇒ Spare part catalogue
T use only shock absorbers of the same make on an axle
Edition 02.01 Servicing rear suspension with disc brake 42-4 page 1
S00.5303.07.20
42 FABIA 2000 ³ Chassis
42-4 page 2 Servicing rear suspension with disc brake Edition 02.01
S00.5303.07.20
FABIA 2000 ³ Chassis 42
Removing
– Raise vehicle.
S42-0031
MP 5-404
S42-0125
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
Caution!
On vehicles with ABS make sure the sensor ring is
not damaged.
Note
♦ Do not tilt the wheel hub with wheel bearing on the
axle stud.
♦ Use new twelve-point nuts.
♦ Replace cap after each removal.
♦ Damaged caps allow moisture to penetrate.
Tightening torques:
MP 3-427
S42-0127
Removing
– Raise vehicle.
– Unscrew rear wheel.
MP 5-404
S42-0060
MP 5-404
S42-0061
Note
Do not unscrew the brake hose to remove the brake cal-
iper.
S42-0062
Caution!
On vehicles with ABS make sure the sensor ring is
not damaged.
Installing
– Carefully slide the wheel hub with wheel bearing onto
the axle stud up to the stop.
Caution!
On vehicles with ABS make sure the sensor ring is
not damaged.
Note
♦ Do not tilt the wheel hub with wheel bearing on the
axle stud.
♦ Use new twelve-point nuts.
♦ Replace cap after each removal.
♦ Damaged caps allow moisture to penetrate.
Tightening torques:
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-
Note
♦ Straightening work on axle studs is not allowed!
♦ Re-cutting the axle stud thread is not allowed!
Tightening torques:
S42-0131
Tightening torques:
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.
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
3 - Wheel bolt, 120 Nm
2
Note
3
When using anti-theft wheel
bolts for steel rims, the anti-theft 4
bolt must be mounted in direc- 5
tion of the valve.
4 - Remove wheel trim cap
T remove with pull-off hook
⇒ item 5.
Note
When using anti-theft wheel
bolts for steel rims, first assem-
ble the wheel trim cap onto the
anti-theft bolt (at valve).
5- Pull-off hook
T included in tool kit
6- Wheel bolt key
7 8 9 8 7 6
T included in tool kit
7- Balancing weights
T max. 60 g allowed per rim
flange
8- Retaining spring for balanc-
ing weights S44-0010
9- Valve
T only use valve in accordance with spare part catalogue
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
1
T for anti-theft wheel bolt
⇒ item 3
T Remove with pull-off hook 2
⇒ item 5.
3
4
5 - Pull-off shackle 5
T included in tool kit
6
6 - Wheel bolt key
7 - Adapter for anti-theft wheel
bolt
T included in tool kit
8 - Wheel trim cap
T can only be removed once 7
the wheel has been removed
T removing and installing
Note
Do not use a pull-off hook or oth-
er tools, e.g. screwdriver as this 8
could damage the wheel trim
cap.
Removing: 11 12 13 12 11 10 9
Push the wheel trim cap towards
the outside from the inside of the
rim.
Installing:
Push-in the wheel trim cap from S44-0011
the outside of the rim, it clicks
audibly.
9- Cap
T for wheel bolt ⇒ item 10
T Remove with pull-off hook ⇒ item 5.
10 - Wheel bolt, 120 Nm
11 - Balancing weights
T max. 60 g allowed per rim flange
12 - Retaining spring for balancing weights
13 - Valve
T only use valve in accordance with spare part catalogue
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
1
T included in tool kit
5 - Wheel bolt, 120 Nm
2
3
6 - Wheel trim cover 4
T remove with pull-off hook
⇒ item 7.
7 - Pull-off hook
T included in tool kit
5
8 - Wheel bolt key 6
9 - Balancing weights
T max. 60 g allowed per rim
flange
10 - Retaining spring for balanc-
ing weights
11 - Valve
T only use valve in accordance
with spare part catalogue
9 10 11 10 9 8 7
S44-0012
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 run-
ning 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 guaran-
teed!
♦ 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 bal-
ance 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).
Front axle part replaced Chassis alignment Rear axle part replaced Chassis alignment re-
required quired
yes no yes no
Axle link X Shock absorber X
Wheel-bearing housing X Helical spring X
Track rod/track-rod ends X Complete rear axle X
Steering gear X
Assembly carrier X
Suspension strut or shock ab- X
sorber or helical spring
Console for engine-gearbox X
assembly carrier
Anti-roll bar X
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 with-
out driver. The spare wheel, tool kit and jack must be
located in the position prescribed by the vehicle man-
ufacturer.
Measurement preliminaries
Special tools, test and measuring equipment and
auxiliary items required
♦ 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
Chassis terms
⇒ Chapter 00-1
Note
Only determine dimension -a- on the rear axle.
Determining dimension -a- for the left and right vehicle
side.
aleft - left vehicle side
α = 90°
– Release counternut -1 -.
– Adjust track by turning the left and/or right track rod.
Use an open-jawed spanner on the hexagon bolt -ar-
row- of the track rod.
Check that the bellows have not become twisted after S44-0015
turning the track rods!
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'
– 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'
♦ If the ABS warning light -K47- and the dual circuit and
hand brake system warning light -K7- do not light up 4
and if in spite of this the brake system is not fully op- S45-0187
erational, look for the fault in the conventional brake
1 2 3
system ⇒ Chap. 46-1 and ⇒ Chap. 47-1.
♦ Notes on rectifying sudden faults ⇒ Technical Service
Handbook.
b
S45-0068
a
b
S45-0181
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 adhe-
sion. This also applies when reversing.
♦ The traction control system (TCS) prevents the driving
wheels from slipping when accelerating while reduc-
ing the engine power output. This is possible over the
entire vehicle speed range. EDL and TCS are mutual-
ly 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 in-
dividual 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 ve-
hicle 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 ve-
hicle diagnosis, measurement and information system
- VAS 5051- ⇒ Chap. 45-4.
Distinguishing features
Note
Identification and assignment of the ABS systems
⇒ Spare parts catalogue.
ABS BOSCH 5.7
a
♦ Dimension -a-: 102 mm
♦ 8 valve domes: The protective sleeves for the valves
are visible if the control unit is separated from the hy-
draulic 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 S45-0108
with the vehicle diagnosis system, measurement and
information system -VAS 5051- ⇒ Chapter 45-4.
♦ List of available functions ⇒ Chap. 45-5.
Note
S45-0105
S45-0175
S45-0176
Fitting position of the ABS systems
BOSCH 5.7 and BOSCH 8.0
ABS, ABS/EDL/TCS or ABS/EDL/TCS/ESP BOSCH
5.7
In the engine compartment, to the right on the lateral part
of the engine compartment
Note
The Fig. shows the ABS or ABS/EDL/TCS BOSCH 5.7
hydraulic control unit.
S45-0104
Note
The Fig. shows the ABS or ABS/TCS BOSCH 8.0 hy-
draulic control unit.
3
S45-0183
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 con-
tents 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 „auto-
matic 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 locat-
ed 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 dis-
connected.
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 ex-
ception 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 warn-
ing 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 per-
formed 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
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.
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.
– Switch on ignition.
– On the screen, select the Geführte Fehlersuche .
– Select the following one after the other:
♦ Brand
♦ Type
♦ Model year
♦ Variant
♦ Engine identification characters
Edition 07.04 Vehicle diagnosis, measurement and information system 45-4 page 1
S00.5303.16.20 -VAS 5051-
45 FABIA 2000 ³ Chassis
Test requirements
• Approved tyre size fitted to all wheels; tyres inflated to
the specified pressure.
• Mechanical/hydraulic part of the brake system togeth-
er with the brake light switch and brake lights operat-
ing properly.
• No leaks in hydraulic connections and lines (visual in-
spection 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.
Note
♦ 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 com- V.A.G 1552
partment on the driver's side.
– Connect vehicle system tester -V.A.G 1552- with the V.A.G 1551/3
diagnostic cable -V.A.G 1551/3-.
– Switch on the ignition.
S01-0087
Edition 07.04 Performing Self-diagnosis - ABS systems BOSCH 5.7 and 45-5 page 1
S00.5303.16.20 BOSCH 8.0
45 FABIA 2000 ³ Chassis
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
– Press →.
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)
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
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
Note
Vehicle system test ->
♦ If the following message is displayed the test se-
Fault memory was not interrogated
quence is incorrect.
♦ 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 con-
firm with Q .
Vehicle system test HELP
Readout on display:
Enter address word XX
– 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.
Edition 07.04 Performing Self-diagnosis - ABS systems BOSCH 5.7 and 45-5 page 3
S00.5303.16.20 BOSCH 8.0
45 FABIA 2000 ³ Chassis
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 interro-
gating and erasing the fault memories of all control
units.
♦ With the automatic test sequence all fault memory
contents of the control units are interrogated.
Vehicle system test HELP
Readout on display: Enter address word XX
– Press 0 twice for address word „Automatic test se-
quence“ 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.
Vehicle system test HELP
The „automatic test sequence“ is completed when the fol- Enter address word XX
lowing read-out appears on the display:
Edition 07.04 Fault table - ABS systems BOSCH 5.7 45-6 page 1
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45 FABIA 2000 ³ Chassis
45-6 page 2 Fault table - ABS systems BOSCH 5.7 Edition 07.04
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Edition 07.04 Fault table - ABS systems BOSCH 5.7 45-6 page 3
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45 FABIA 2000 ³ Chassis
45-6 page 4 Fault table - ABS systems BOSCH 5.7 Edition 07.04
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FABIA 2000 ³ Chassis 45
Edition 07.04 Fault table - ABS systems BOSCH 5.7 45-6 page 5
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45 FABIA 2000 ³ Chassis
45-6 page 6 Fault table - ABS systems BOSCH 5.7 Edition 07.04
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FABIA 2000 ³ Chassis 45
Edition 07.04 Fault table - ABS systems BOSCH 5.7 45-6 page 7
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45 FABIA 2000 ³ Chassis
45-6 page 8 Fault table - ABS systems BOSCH 5.7 Edition 07.04
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FABIA 2000 ³ Chassis 45
Edition 07.04 Fault table - ABS systems BOSCH 5.7 45-6 page 9
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45 FABIA 2000 ³ Chassis
45-6 page 10 Fault table - ABS systems BOSCH 5.7 Edition 07.04
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Edition 07.04 Fault table - ABS systems BOSCH 8.0 45-7 page 1
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45 FABIA 2000 ³ Chassis
45-7 page 2 Fault table - ABS systems BOSCH 8.0 Edition 07.04
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Edition 07.04 Fault table - ABS systems BOSCH 8.0 45-7 page 3
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45 FABIA 2000 ³ Chassis
45-7 page 4 Fault table - ABS systems BOSCH 8.0 Edition 07.04
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Edition 07.04 Fault table - ABS systems BOSCH 8.0 45-7 page 5
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45 FABIA 2000 ³ Chassis
45-7 page 6 Fault table - ABS systems BOSCH 8.0 Edition 07.04
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Edition 07.04 Fault table - ABS systems BOSCH 8.0 45-7 page 7
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45 FABIA 2000 ³ Chassis
45-7 page 8 Fault table - ABS systems BOSCH 8.0 Edition 07.04
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FABIA 2000 ³ Chassis 45
Table of codes
Engine Engine identifi- ABS control unit iden- ABS version Code Gearbox
cation charac- tification number number
ters
6Q0614117 ABS 00036
1.0 litre/37 6Q0907379 ABS 00044
AQV, ARV Gearbox
kW 6Q0907379C ABS 00044
6Q0907379G ABS 00044
1.2 ltr./40 kW AWY 6Q0907379G ABS 00044 Gearbox
Edition 07.04 Code control unit - ABS systems BOSCH 5.7 45-8 page 1
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45 FABIA 2000 ³ Chassis
Engine Engine identifi- ABS control unit iden- ABS version Code Gearbox
cation charac- tification number number
ters
1.2 ltr./47 kW AZQ 6Q0907379G ABS 00044 Gearbox
6Q0907379 ABS 00044
1.4 ltr./44 kW AZF, AZE 6Q0907379C ABS 00044 Gearbox
6Q0907379G ABS 00044
6Q0614117 ABS 00036
6Q0614417 TCS 00052
6Q0907379 ABS 00044
6Q0907379A TCS 00060
1.4 ltr./50 kW AQW, AME, ATZ Gearbox
6Q0907379C ABS 00044
6Q0907379D TCS 00060
6Q0907379G ABS 00044
6Q0907379H TCS 00060
6Q0614117 ABS 00036
6Q0614417 TCS 00116
Gearbox
6Q0907379 ABS 00044
6Q0907379A TCS 00124
6Q0907379C ABS 00044 Gearbox
6Q0907379C ABS 00045 Automatic gearbox
6Q0907379D TCS 00124 Gearbox
1.4 ltr./55 kW AUA, BBY
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
1.4 ltr./74 kW AUB, BBZ 6Q0907379C ABS 00044 Gearbox
6Q0907379D TCS 00124
6Q0907379G ABS 00044
6Q0907379H TCS 00124
6Q0907379Q ESP 03386
45-8 page 2 Code control unit - ABS systems BOSCH 5.7 Edition 07.04
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FABIA 2000 ³ Chassis 45
Engine Engine identifi- ABS control unit iden- ABS version Code Gearbox
cation charac- tification number number
ters
6Q0907379 ABS 00044
6Q0907379A TCS 00188
6Q0907379C ABS 00044
6Q0907379D TCS 00188
6Q0907379G ABS 00044
2.0 ltr./85 kW AZL Gearbox
6Q0907379H TCS 00188
6Q0907379M ESP 033381)
6Q0907379M ESP 033412)
6Q0907379M ESP 033443)
6Q0907379Q ESP 03338
6Q0907379 ABS 00044
1.9 ltr./47 kW
ASY 6Q0907379C ABS 00044 Gearbox
SDI
6Q0907379G ABS 00044
6Q0614417 TCS 00180
6Q0907379 ABS 00044
6Q0907379A TCS 00188
1.9 ltr./74 kW 6Q0907379C ABS 00044
ATD Gearbox
TDI PD 6Q0907379D TCS 00188
6Q0907379G ABS 00044
6Q0907379H TCS 00188
6Q0907379Q ESP 03411
6Q0907379Q ESP 03479
1.4 ltr./55 kW
AMF 6Q0907379G ABS 00044 Gearbox
TDI PD
6Q0907379H TCS 00188
6Q0907379Q ESP 03357
1.9 ltr./96 kW
ASZ 6Q0907379G ABS 00044 Gearbox
TDI PD
6Q0907379H TCS 00188
1) Fabia
2) Fabia Sedan
3) Fabia estate car
The control unit coding is shown in the display, example 6Q0614117 TCS 5.7 Front X00 ->
00116: Coding 00116 WSC XXXXX
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
Only on vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
Note
The steering wheel must be in the straight ahead position
before executing the function „Coding 2“.
Edition 07.04 Code control unit - ABS systems BOSCH 5.7 45-8 page 3
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45 FABIA 2000 ³ Chassis
Note
The vehicle system tester -V.A.G 1552- must remain
connected up while the ignition is switched off.
Vehicle system test HELP
Readout on display: Select function XX
Continued for all vehicles
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 Code control unit - ABS systems BOSCH 5.7 Edition 07.04
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FABIA 2000 ³ Chassis 45
Edition 04.05 Code control unit - ABS BOSCH 8.0 45-9 page 1
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45 FABIA 2000 ³ Chassis
Table of codes
Engine Engine ABS control unit ABS Brakes at Brakes at Code Gearbox
identifica- identification ver- the front the rear number
tion char- number sion axle axle
acters
6Q0907379R ABS 13” FS-II Drum brake 0000005
6Q0907379R ABS 14” FS-III Drum brake 0000005
1.2 ltr./40 6Q0907379AA ABS 13” FS-II Drum brake 0000005
AWY, BMD Gearbox
kW 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
1.2 ltr./47 6Q0907379S TCS 14” FS-III Drum brake 0000005
AZQ, BME Gearbox
kW 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
Gearbox
6Q0907379AB TCS 14” FS-III Drum brake 0000005
6Q0907379AG TCS 14” FS-III Drum brake 0002106
6Q0907379T ESP 14” FS-III Drum brake 0000425
1.4 ltr./55 AUA, BBY, 6Q0907379AH ESP 14” FS-III Drum brake 0000425
kW BKY 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 Automatic gear-
6Q0907379AB TCS 14” FS-III Drum brake 0000011 box
6Q0907379AG TCS 14” FS-III Drum brake 0002127
6Q0907379T ESP 14” FS-III Drum brake 0000440
6Q0907379AH ESP 14” FS-III Drum brake 0000440
45-9 page 2 Code control unit - ABS BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
Engine Engine ABS control unit ABS Brakes at Brakes at Code Gearbox
identifica- identification ver- the front the rear number
tion char- number sion axle axle
acters
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
1.4 ltr./74 6Q0907379S TCS 14” FS-III Disc brake 0000005
AUB, BBZ Manual gearbox
kW 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
2.0 ltr./85
AZL 6Q0907379AG TCS 15” C54-II Disc brake 0002226 Gearbox
kW
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
1.4 ltr./55
AMF 6Q0907379AB TCS 14” FS-III Drum brake 0000008 Gearbox
kW TDI PD
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
1.9 ltr./47
ASY 6Q0907379AF ABS 14” FS-III Drum brake 0002142 Gearbox
kW SDI
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
1.9 ltr./74 6Q0907379S TCS 14” FS-III Disc brake 0000008
ATD Gearbox
kW TDI PD 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
Edition 04.05 Code control unit - ABS BOSCH 8.0 45-9 page 3
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45 FABIA 2000 ³ Chassis
Engine Engine ABS control unit ABS Brakes at Brakes at Code Gearbox
identifica- identification ver- the front the rear number
tion char- number sion axle axle
acters
6Q0907379AF ABS 15” C54-II Disc brake 0002229
6Q0907379AA ABS 15” C54-II Disc brake 0000008
6Q0907379R ABS 15” C54-II Disc brake 0000008
1.9 ltr./96 6Q0907379S TCS 15” C54-II Disc brake 0000008
ASZ Gearbox
kW TDI PD 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. 6Q0907379T ESP 8.0 front X00 -
0000365): Coding 0000365 WSC XXXXX
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
only on vehicles with ABS/TCS/ESP BOSCH 8.0
Note
The steering wheel must be in the straight ahead position
before executing the function „access authorisation“.
Note
The vehicle system tester -V.A.G 1552- must remain
connected up while the ignition is switched off.
45-9 page 4 Code control unit - ABS BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
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 Code control unit - ABS BOSCH 8.0 45-9 page 5
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45 FABIA 2000 ³ Chassis
45-9 page 6 Code control unit - ABS BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
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.
Note
To switch to another display group proceed as follows:
Edition 07.04 Reading measured value block - BOSCH 5.7 45-10 page 1
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45 FABIA 2000 ³ Chassis
45-10 page 2 Reading measured value block - BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
Note
Readout of the display group number must occur while the engine is running.
Edition 07.04 Reading measured value block - BOSCH 5.7 45-10 page 3
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45 FABIA 2000 ³ Chassis
45-10 page 4 Reading measured value block - BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
vehicles with ABS/EDL/TCS/ESP BOSCH 5.7
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 Reading measured value block - BOSCH 5.7 45-10 page 5
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45 FABIA 2000 ³ Chassis
1) The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine
control unit or gearbox control unit or dash panel insert defective.
2) Only on vehicles equipped with an automatic gearbox.
45-10 page 6 Reading measured value block - BOSCH 5.7 Edition 07.04
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FABIA 2000 ³ Chassis 45
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 ac-
cident which involves the front passenger airbag be-
ing deployed.
Edition 04.05 Reading measured value block - BOSCH 8.0 45-11 page 1
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45 FABIA 2000 ³ Chassis
Note
Proceed according to the following table to switch to an-
other display group:
45-11 page 2 Reading measured value block - BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
Display group number 002:
vehicles with ABS, ABS/TCS BOSCH 8.0
Edition 04.05 Reading measured value block - BOSCH 8.0 45-11 page 3
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45 FABIA 2000 ³ Chassis
Note
Readout of the display group number must occur while the engine is running.
45-11 page 4 Reading measured value block - BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
Display group number 004:
vehicles with ABS/TCS BOSCH 8.0
Edition 04.05 Reading measured value block - BOSCH 8.0 45-11 page 5
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45 FABIA 2000 ³ Chassis
45-11 page 6 Reading measured value block - BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
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.
Edition 04.05 Reading measured value block - BOSCH 8.0 45-11 page 7
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45 FABIA 2000 ³ Chassis
1) The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine
control unit or gearbox control unit or dash panel insert defective.
2) Only on vehicles fitted with automatic gearbox.
1) The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine
control unit or gearbox control unit or dash panel insert defective.
45-11 page 8 Reading measured value block - BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
Display group number 127 (for all vehicles):
1) The following fault causes may be present: Data BUS connection interrupted; data BUS wiring interchanged; steering angle sender or engine
control unit or gearbox control unit or dash panel insert defective.
Edition 04.05 Reading measured value block - BOSCH 8.0 45-11 page 9
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45 FABIA 2000 ³ Chassis
45-11 page 10 Reading measured value block - BOSCH 8.0 Edition 04.05
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FABIA 2000 ³ Chassis 45
Note
♦ The vehicle must be raised so that the wheels are
clear of the ground (2nd mechanic required for rotat-
ing 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 ef-
fort is then required to operate the brake pedal in order
to achieve the same fluid pressure in the brake sys-
tem 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 di-
agnosis.
Example (only for vehicle system tester
-V.A.G 1552-):
Final control diagnosis - ->
Read-out on display of V.A.G. 1552 during final control di- IFL: VBAT OFL: 0V Wheel FL locked
agnosis:
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
Final control diagnosis - ->
locked/free = Wheel status; must be checked by 2nd me-
EDL valves/Hydr.p:V BAT Wheel FL/FR lock
chanic
Hydr-P = Hydraulic pump (Return flow pump)
Edition 07.04 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 45-12 page 1
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45 FABIA 2000 ³ Chassis
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 .
Final control diagnosis - ->
Readout on display: Hydraulic pump ABS -V64
– Press → within the next 60 seconds.
Final control diagnosis - ->
Readout on display: Operate brake
– Operate brake pedal
– Press →.
Final control diagnosis - ->
Readout on display: IFL: OV OFL: 0V Wheel FL locked
– Instruct the 2nd mechanic to rotate the relevant wheel
by hand.
If the wheel does not lock, it is possible that there is a fault
in the mechanical/hydraulic part of the brake system.
– Press →.
Final control diagnosis - ->
Readout on display: IFL: VBAT OFL: 0V Wheel FL locked
– Press →.
45-12 page 2 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 Edition 07.04
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FABIA 2000 ³ Chassis 45
– Press →.
– Press →.
Final control diagnosis - ->
Readout on display: Release brake
– Take your foot off the brake pedal.
– Press →.
Final control diagnosis - ->
Readout on display: Operate brake
– Operate brake pedal
– Press →.
Final control diagnosis - ->
Readout on display: IFR: 0V OFR: 0V Wheel FR locked
– Instruct the 2nd mechanic to rotate the relevant wheel
by hand.
If the wheel does not lock, it is possible that there is a fault
in the mechanical/hydraulic part of the brake system.
– Press →.
Final control diagnosis - ->
Readout on display: IFR: VBAT OFR: 0V Wheel FR locked
– Press →.
– Press →.
Edition 07.04 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 45-12 page 3
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45 FABIA 2000 ³ Chassis
Readout on display:
Final control diagnosis - ->
IFR: VBAT OFR: 0V Wheel FR free
– Press →.
– Press →.
Final control diagnosis - ->
Readout on display: Release brake
– Take your foot off the brake pedal.
– Press →.
Final control diagnosis - ->
Readout on display: Operate brake
– Operate brake pedal
– Press →.
Final control diagnosis - ->
Readout on display: IRL: 0V ORL: 0V Wheel RL locked
– Instruct the 2nd mechanic to rotate the relevant wheel
by hand.
If the wheel does not lock, it is possible that there is a fault
in the mechanical/hydraulic part of the brake system.
– Press →.
Final control diagnosis - ->
Readout on display: IRL: VBAT ORL: 0V Wheel RL locked
– Press →.
– Press →.
45-12 page 4 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 Edition 07.04
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FABIA 2000 ³ Chassis 45
Brake pedal must be felt to yield.
If the brake pedal does not yield, there is a fault in the hy-
draulic unit. In that case replace the hydraulic unit
BOSCH 5.7 ⇒ Chap. 45-17, BOSCH 8.0 ⇒ Chap. 45-
18.
Final control diagnosis - ->
Readout on display: IRL: 0V ORL: 0V Wheel RL locked
– Instruct the 2nd mechanic to rotate the relevant wheel
by hand.
If the wheel does not lock, it is possible that there is a fault
in the mechanical/hydraulic part of the brake system.
– Press →.
Final control diagnosis - ->
Readout on display: Release brake
– Take your foot off the brake pedal.
– Press →.
Final control diagnosis - ->
Readout on display: Operate brake
– Operate brake pedal
– Press →.
Final control diagnosis - ->
Readout on display: IRR: 0V ORR: 0V Wheel RR locked
– Instruct the 2nd mechanic to rotate the relevant wheel
by hand.
If the wheel does not lock, it is possible that there is a fault
in the mechanical/hydraulic part of the brake system.
– Press →.
Final control diagnosis - ->
Readout on display: IRR: VBAT ORR: 0V Wheel RR locked
– Press →.
– Press →.
Edition 07.04 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 45-12 page 5
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45 FABIA 2000 ³ Chassis
– Press →.
Final control diagnosis - ->
Readout on display: Release brake
– Take your foot off the brake pedal.
– Press →.
Final control diagnosis - ->
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 hydrau-
lic part of the ABS system. In this case replace the hy-
draulic unit BOSCH 5.7 ⇒ Chap. 45-17, BOSCH 8.0
⇒ Chap. 45-18.
– Press →.
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
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.
45-12 page 6 Final control diagnosis - ABS system BOSCH 5.7 and BOSCH 8.0 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Note
Operate the vehicle system tester -V.A.G 1552- by refer-
ring 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 im-
portant to ensure a minimum filling pressure of 0.2
MPa (2 bar).
Edition 07.04 Basic setting - ABS systems BOSCH 5.7 45-13 page 1
S00.5303.16.20
45 FABIA 2000 ³ Chassis
Note
If you are using V.A.G. 1551 a <3> appears instead of
<↑>.
System in basic setting 10
Readout on display: Rel. pedal;FR+FL bleeder screws OPEN <↑>
– Press ↑.
System in basic setting 11
Readout on display: Actuate pedal 10x; wait
♦ Return flow pump for ABS -V39- runs.
System in basic setting 12
Readout on display: Actuate pedal 10x; wait
♦ Return flow pump for ABS -V39- runs.
System in basic setting 13
Readout on display: Bleeder screw CLOSED <↑>
– Press ↑.
System in basic setting 14
Readout on display: Rel. pedal;RR+RL bleeder screws OPEN <↑>
– Press ↑.
System in basic setting 15
Readout on display: Actuate pedal 10x; wait
♦ Return flow pump for ABS -V39- runs.
System in basic setting 16
Readout on display: Bleeder screw CLOSED <↑>
– Press ↑.
System in basic setting 17
Readout on display: Part bleeding ended...
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
– Press 0 and 6 for the function „End output“ and con-
firm the entry with Q .
Vehicle system test HELP
Readout on display:
Enter address word XX
– Switch off ignition.
45-13 page 2 Basic setting - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Separate plug connection to V.A.G. 1552.
– Bleed brake system ⇒ Chapter 47-4.
– Perform test drive with at least one ABS adjustment.
Note
Operate the vehicle system tester by referring to the
read-out on the display:
WARNING!
When replenishing brake fluid with a brake filling
and bleeding appliance, e.g. ROMESS S15, it is im-
portant to ensure a minimum filling pressure of 0.2
MPa (2 bar).
Edition 07.04 Basic setting - ABS systems BOSCH 5.7 45-13 page 3
S00.5303.16.20
45 FABIA 2000 ³ Chassis
45-13 page 4 Basic setting - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Special tools, test and measuring equipment and
auxiliary items required
♦ 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-
Note
For the null balance of the steering angle sender -G85-
first perform function 11 „coding 2“. To do so first enter
the workshop code in the vehicle system tester -V.A.G
1552-.
Edition 07.04 Basic setting - ABS systems BOSCH 5.7 45-13 page 5
S00.5303.16.20
45 FABIA 2000 ³ Chassis
Readout on display:
Basic setting 1 ON <8-OFF> -
1. Interrogate fault memory (Function 02) Bal. steer. angl. send. locked
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
– Press 0 6 for the function „End output“ and confirm
with Q .
Vehicle system test HELP
Readout on display: Enter address word XX
45-13 page 6 Basic setting - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– 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.
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.
Edition 07.04 Basic setting - ABS systems BOSCH 5.7 45-13 page 7
S00.5303.16.20
45 FABIA 2000 ³ Chassis
45-13 page 8 Basic setting - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Note
Operate the vehicle system tester by referring to the
read-out on the display:
Edition 07.04 Basic setting - ABS systems BOSCH 8.0 45-14 page 1
S00.5303.16.20
45 FABIA 2000 ³ Chassis
WARNING!
When replenishing brake fluid with a brake filling
and bleeding appliance, e.g. -ROMESS S15-, it is
important to ensure a minimum filling pressure of
0.2 MPa (2 bar).
45-14 page 2 Basic setting - ABS systems BOSCH 8.0 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Readout on display:
Vehicle system test HELP
– Switch off ignition. Enter address word XX
Note
For the null balance of the steering angle sender -G85-
first perform function 16 „access authorisation“. To do so
first enter the workshop code in the vehicle system tester
-V.A.G 1552-.
Edition 07.04 Basic setting - ABS systems BOSCH 8.0 45-14 page 3
S00.5303.16.20
45 FABIA 2000 ³ Chassis
45-14 page 4 Basic setting - ABS systems BOSCH 8.0 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Perform ESP road and system test (vehi-
cles 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 con-
trol unit).
The ESP road test should be performed after each re-
placement of the electrical components of the ESP sys-
tem.
If the ESP road test is initiated, it can no longer be inter-
rupted and must be performed.
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
– Press 0 6 for the function „End output“ and confirm
with Q .
Vehicle system test HELP
Readout on display: Enter address word XX
– 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 Basic setting - ABS systems BOSCH 8.0 45-14 page 5
S00.5303.16.20
45 FABIA 2000 ³ Chassis
WARNING!
♦ Observing the rules of the road traffic regula-
tions as well as paying attention to the traffic
conditions must be given top priority.
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.
45-14 page 6 Basic setting - ABS systems BOSCH 8.0 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Test requirements
2
• 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.). 1
Connecting test box -V.A.G 1598A-
– Unlatch the multi-pin connector -arrow 1- and discon- S45-0074
nect from the ABS with EDL control unit -J104- by pull-
ing 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 3
wiring loom -2-.
Use adapter -V.A.G 1598/34R- for RH drive vehicles. 1
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.
V.A.G 1598A
After the electrical test:
V.A.G 1598/34 2
– Insert the multi-plug connector on the ABS with EDL
control unit -J104- and lock.
S45-0034
– Performing automatic test sequence ⇒ Chapter 45-5.
Note
All unlisted contacts are not yet assigned and must under
no circumstances be connected to other components!
Edition 07.04 Electrical Test - ABS systems BOSCH 5.7 45-15 page 1
S00.5303.16.20
45 FABIA 2000 ³ Chassis
10 1 11
26 42 27 S45-0031
45-15 page 2 Electrical Test - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Edition 07.04 Electrical Test - ABS systems BOSCH 5.7 45-15 page 3
S00.5303.16.20
45 FABIA 2000 ³ 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 Di-
agrams, 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 com-
ponents test the cables and connectors; more specifically for nominal values below 10 Ω repeat the resistance
measurement on the component.
45-15 page 4 Electrical Test - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Edition 07.04 Electrical Test - ABS systems BOSCH 5.7 45-15 page 5
S00.5303.16.20
45 FABIA 2000 ³ Chassis
– Disconnect control
units on the data
BUS drive
⇒ Electrical Sys-
tem; Rep. Gr. 90
– Connect Test box
-V.A.G 1598A- with
adapter -V.A.G 1598/
34-
– Check the data BUS max. 1.5 Ω – Check data BUS
cable for open cir- ⇒ Chapter 48-27.
cuit.
– Check wiring accord-
• Ignition off ∞Ω ing to current flow di-
agram ⇒ Current
• Measuring range 20 Flow Diagrams, Elec-
MΩ set trical Fault Finding
– Check cables for and Fitting Locations.
short-circuit be-
tween the cables or
for short-circuit to
positive term. or
earth.
45-15 page 6 Electrical Test - ABS systems BOSCH 5.7 Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 1
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 3
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
⇒ 45-16 page 6
T the warning light flashes:
♦ during TCS/ESP control
4- ABS warning light -K47-
T Fitting location: in the dash panel insert ⇒ item 6
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
5- Dual circuit and hand brake system warning light -K7-
T Fitting location: in the dash panel insert ⇒ item 6
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
6- Dash panel insert
T fitted up to model year 2004
7- Traction control system warning light -K86- or ESP and TCS warning light -K155-
T Fitting location: in the dash panel insert ⇒ item 10
Operation:
T the warning light lights up:
♦ for about 2 seconds after ignition is switched on
♦ if fault is detected in TCS or ESP operation
♦ after switching the traction control system switch or TCS and ESP button to „OFF“
⇒ 45-16 page 6
T the warning light flashes:
♦ during TCS/ESP control
8- ABS warning light -K47-
T Fitting location: in the dash panel insert ⇒ item 10
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
9- Dual circuit and hand brake system warning light -K7-
T Fitting location: in the dash panel insert ⇒ item 10
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
10 - 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
T removing and installing ⇒ 45-16 page 10
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 5
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
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 in- 4
tegrated in the „Targeted fault finding“.
S45-0184
Dash panel insert up to model year 2004
1 2 3
Dash panel insert as of model year 2005
Warning lights
Pos. Denomination
1 Brake pad warning light -K32-
2 Traction control system warning light -K86-
ESP and TCS warning light -K155-
3 ABS warning light -K47-
4 Dual circuit and hand brake system warning
light -K7-
0
WARNING!
If an ABS fault -b- is present, the anti-lock brake
system remains switched off while the convention-
al brake system remains fully operational.
WARNING!
Once the ABS warning light -K47- and the dual cir-
cuit and hand brake system warning light -K7-
have lit up then one can expect the rear wheels to
lock quite early on when braking.
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 7
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
System condition Dual circuit and ABS warning light Traction control Traction control
hand brake sys- -K47- system warning system switch
tem warning light light -K86- or ESP -E132- or TCS and
-K7- and TCS warning ESP button -E256-
light -K155-
Ignition on lights up lights up lights up not actuated
test of the lights(-K7-
is only indicated for
the test in the dash
panel insert)
System o.k. does not light up does not light up does not light up not actuated
ESP/TCS or ABS/ does not light up does not light up flashes (3x/seconds) not actuated
TCS -in recess
ESP/TCS or ABS/ does not light up does not light up lights up activated
TCS are switched off
ESP/TCS or ABS/ does not light up does not light up does not light up activated
TCS are switched on
again via TCS and
ESP button -E256- or
traction control sys-
tem switch
-E132-(were
switched off)
Note
The brake light switch must be removed for setting.
– Turn brake light switch -1- 90° to the left and remove
from its bracket -2-.
Note 1
♦ 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 polycar-
bamide grease - G 052 142 A2- before installing the
2
brake light switch.
– Turn brake light switch -1- 45° to the left and remove
from its bracket -2-.
Note 1
♦ 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. 2
♦ The contact surface which the tappet is to touch on
the brake pedal should be greased using polycar-
bamide 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 adjust-
ed and set during assembly.
Brake pedal always remains in the off position in this case
(not actuated).
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 9
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
WARNING!
Disconnect earth strap from the battery before
commencing work on the electrical system.
If the battery earth strap is disconnected and con-
nected, carry out additional operations
⇒ Electrical System; Rep. Gr. 27.
2 1 S48-0188
S48-0189
2 3 S48-0190
2 S45-0199
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 11
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
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. 1 S48-0191
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 in-
tegrated 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.
WARNING!
♦ Disconnect earth strap from the battery before
commencing work on the electrical system.
♦ If the battery earth strap is disconnected and
connected, carry out additional operations
⇒ Electrical System; Rep. Gr. 27.
Note 3
2
♦ 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. 1
– Unplug plug -1- from the unit -3-.
– Unscrew hexagon nuts -2- and remove unit -3-.
Installing
Installation is performed in the reverse order. Pay atten-
tion to the following points:
Edition 11.04 Electrical/electronic components and fitting locations - ABS/ESP 45-16 page 13
S00.5303.17.20 systems BOSCH 5.7 and BOSCH 8.0
45 FABIA 2000 ³ Chassis
45-17 Hydraulic control unit (ABS systems BOSCH 5.7), Brake ser-
vo 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.
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 1
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
45-17 page 2 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
WARNING!
♦ Make absolutely sure that no brake fluid gets
into the plug connector housing of the hydrau-
lic 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.
Removing
Note
2
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding. 1
– Disconnect battery ⇒ Electrical System; Rep. Gr. 27.
– Remove engine cover ⇒ Engine, Mechanics;
Rep. Gr. 10.
Vehicles with TDI PD Turbocharger engines
S45-0193
– Remove top charge-air pipe -1- with connecting hose
-2- ⇒ TDI Engine, Mechanics; Rep. Gr. 21.
Continued for all vehicles
S45-0016
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 3
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
Note
To avoid overvoltage and static discharge do not touch
the plug contacts of the 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
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. 2
♦ 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
1
longer be guaranteed.
S45-0067
– Screw bracket -2- onto the hydraulic control unit.
45-17 page 4 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Tighten up the screws -arrows- fully to the specified
tightening torque.
– Insert bracket -1- onto the fixing bolt of the bracket -2-.
Note
Do not immediately tighten the nuts for securing the hy-
draulic control unit to the body. This facilitates the screw-
ing of the individual brake lines onto the hydraulic control
unit.
WARNING!
Pay attention to the correct channel assignment of
the brake lines. Interchanging the brake lines will
result in dangerous brake control actions.
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 5
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
Note
For vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP
BOSCH 5.7 perform a test drive after bleeding with at
least one ABS control!
Tightening torques:
Note
♦ Inspecting and repairs of the hydraulic control unit
must only be performed by skilled personnel in ap-
proved 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.
45-17 page 6 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Note
♦ The sealing surface on the hydraulic control unit must
be clean and undamaged. It must never be reworked,
e.g. with files, scrapers etc. If necessary replace the
hydraulic unit.
♦ The gasket on the control unit must not be removed, it
cannot be replaced.
♦ The screws (inner Torx T20) of the hydraulic unit/con-
trol unit must be replaced after each disassembling.
Use the screws included in the parts kit. Tightening
must occur in the prescribed sequence and in steps.
♦ If the control unit is being replaced tentatively tighten
the fixing screws only slightly Tighten the screws to
the specified torque once the control unit is correctly
positioned on the hydraulic control unit.
♦ Maximum 5 tightening procedures (hydraulic unit)
may be carried out throughout the entire life of the hy-
draulic control unit. Pay attention to the colour mark-
ings (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 dam-
aged (screws are hard to tighten by hand or they
cannot be tightened to the prescribed torque) replace
the hydraulic control unit.
♦ Blowing out of the control unit or the hydraulic unit with
compressed air to secure an oily or aqueous film on
and between the valve domes or the solenoid coils is S45-0111
not permissible. Only use moisture-free and oil-free
compressed air, e.g. from a spray. Cleaning with hy-
drocarbon solvents is not allowed.
♦ If the hydraulic control unit is open protect the valve
domes, solenoid coils, contact springs against dam-
age and soiling.
♦ If the hydraulic control unit is open it is not permissible
to apply a voltage to the contact springs of the hydrau-
lic 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 pro-
cedure for the ABS/EDL/TCS unit BOSCH 5.7 is iden-
tical. 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 -G201-
must be replaced ⇒ 45-17 page 10.
a
– 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 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 7
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
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 pres-
sure sender 1 -G201- must be replaced ⇒ 45-17
page 10.
S45-0071
45-17 page 8 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Inspect the sealing surface on the hydraulic unit for
soiling, if necessary clean with white spirits and a non-
fluffing 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-fluff-
ing paper or linen cloth.
– If there is a considerable oily and aqueous film be-
tween the valves use moisture-free and oil-free com-
pressed 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 con-
trol 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.
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. 5 2 4 1 6
♦ 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.
S45-0071
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 9
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
S45-0111
Removing and installing brake pressure
sender 1 -G201- - vehicles with ABS/EDL/
TCS/ESP BOSCH 5.7
A description of the structure and function of the brake
pressure sender 1 -G201- can be found in self-study pro-
gramme no. 42.
Note
♦ Repair of the brake pressure sender 1 -G201- is not
allowed. Only the brake pressure sender 1 -G201-
must 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 al-
lowed. 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 proce-
dures (torque connections). Pay attention to the col-
our 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
45-17 page 10 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Check the ball sealing surface of the hydraulic unit for
damage.
Teplace the hydraulic unit if they are damaged (e.g.
small surfaces, grooves). Reworking of the sealing
surface is not allowed.
Installing
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:
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo 45-17 page 11
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
45-17 page 12 Hydraulic control unit (ABS systems BOSCH 5.7), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
45-18 Hydraulic control unit (ABS systems BOSCH 8.0), Brake ser-
vo unit/Master brake cylinder
Note
♦ Removing and installing the hydraulic control unit completely ⇒ 45-18 page 3.
♦ Mount bracket before assembling the brake lines.
♦ Do not bend brake lines when assembling or when connecting.
♦ Install brake hoses without transposition.
♦ Brake hoses must not come into contact with other components during operating condition.
♦ Do not remove the plugs on the connection threads and the holes in the parts carrying brake fluid until just before
assembling.
♦ Tighten all the brake line pipe screws to a tightening torque of 14 Nm.
♦ The repair of the hydraulic control unit ABS/ASR/ESP BOSCH 8.0 is not permissible.
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo 45-18 page 1
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
45-18 page 2 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Removing and installing the hydraulic
control unit
WARNING!
♦ Make absolutely sure that no brake fluid gets
into the plug connector housing of the hydrau-
lic 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.
Removing
Note
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding.
2
1
S45-0193
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo 45-18 page 3
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
1 2 S45-0169
1
2 S45-0170
45-18 page 4 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
ABS, ABS/TCS BOSCH 8.0
2 3 4
– If necessary remove the brake lines from the line hold- 1
er.
– Mark brake lines -1…6-. 5
– Unscrew brake lines -1…6- from hydraulic control
unit.
– Close off immediately brake lines.
– Shut off immediately threaded bores (brake line con-
nections) on the hydraulic control unit with plugs from
repair kit SP No. 1 H0 698 311 A.
6
S45-0171
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo 45-18 page 5
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
WARNING!
Pay attention to the correct channel assignment of
the brake lines. Interchanging the brake lines will
result in dangerous brake control actions.
45-18 page 6 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Removing and installing bracket for ABS/TCS/ESP
BOSCH 8.0
1
Removing
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.
♦ Install brake hoses without transposition.
♦ Brake hoses must not come into contact with other
components during operating condition.
♦ Do not remove the plugs on the connection threads
and the holes in the parts carrying brake fluid until just
before assembling.
♦ Tightening torque of pipe screws for brake lines of 14
Nm.
WARNING!
Pay attention to the correct channel assignment of
the brake lines. Interchanging the brake lines will
result in dangerous brake control actions.
S45-0173
Edition 07.04 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo 45-18 page 7
S00.5303.16.20 unit/Master brake cylinder
45 FABIA 2000 ³ Chassis
45-18 page 8 Hydraulic control unit (ABS systems BOSCH 8.0), Brake servo
unit/Master brake cylinder
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Raise vehicle.
– Separate plug connection -1- wheel speed sensor ca-
ble/wheel speed sensor. 3
– Release Allan screw -3-. 1
– Remove wheel speed sensor -2- from the wheel-bear-
2
ing housing.
Installing
Note
♦ It is prohibited to repair shielded leads of the ABS sys-
tem.
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
Edition 07.04 Removing and Installing Parts of the ABS System on the Front 45-19 page 1
S00.5303.16.20 and Rear Axle
45 FABIA 2000 ³ Chassis
2
1
S45-0193
S45-0074
S45-0075
45-19 page 2 Removing and Installing Parts of the ABS System on the Front
and Rear Axle
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Release secondary lock (purple) with a small screw-
driver in the direction of the arrow.
S45-0076
– Remove wheel.
– Release plug connection on speed sensor and sepa-
rate plug connector.
– Remove defective speed sensor cable.
Installing
1
– 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 Removing and Installing Parts of the ABS System on the Front 45-19 page 3
S00.5303.16.20 and Rear Axle
45 FABIA 2000 ³ 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. L
VW AG 6Q0 973 042 R
1 928 403 931
– Insert the multi-plug connector on the control unit and B00 1928 404 293
lock.
S45-0079
Vehicles with TDI PD Turbocharger engines
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.
45-19 page 4 Removing and Installing Parts of the ABS System on the Front
and Rear Axle
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Disconnect battery ⇒ Electrical System; Rep. Gr. 27.
– Remove engine cover ⇒ Engine, Mechanics;
Rep. Gr. 10.
Vehicles with TDI PD Turbocharger engines
S45-0193
1 2 S45-0169
1
2 S45-0170
Edition 07.04 Removing and Installing Parts of the ABS System on the Front 45-19 page 5
S00.5303.16.20 and Rear Axle
45 FABIA 2000 ³ Chassis
I
D E L PH
S45-0194
S45-0195
– Remove wheel.
– Release plug connection on speed sensor and sepa-
rate plug connector.
– Remove defective speed sensor cable.
Installing
45-19 page 6 Removing and Installing Parts of the ABS System on the Front
and Rear Axle
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
– Clip on speed sensor cable -arrows- and mount in
bracket -1-.
– Actuate steering from left to right up to the stop and
check for free movement of the speed sensor cable.
1
Note
When assembling the speed sensor cable make sure it is
not twisted when installed in the wheelhouse.
DELPHI
S45-0197
S45-0198
2
Edition 07.04 Removing and Installing Parts of the ABS System on the Front 45-19 page 7
S00.5303.16.20 and Rear Axle
45 FABIA 2000 ³ Chassis
2
S45-0073
– Raise vehicle.
– Separate plug connection -1- wheel speed sensor ca-
ble - wheel speed sensor.
– Release Allan screw -2-.
– Pull the wheel speed sensor from the axle stud and 2 1
brake carrier.
Installing
45-19 page 8 Removing and Installing Parts of the ABS System on the Front
and Rear Axle
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 45
Removing and installing the wheel speed sensor occurs
in the same way as for the disc brake version ⇒ 45-19
page 8.
1 - Plug connection wheel speed sensor cable/wheel
speed sensor
2
2 - Allan screw for fixing the wheel speed sensor 1
Note
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding.
S45-0080
Edition 07.04 Removing and Installing Parts of the ABS System on the Front 45-19 page 9
S00.5303.16.20 and Rear Axle
45 FABIA 2000 ³ 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.
Note
♦ The crimp connector must be heated from the centre
towards the outside until it is fully sealed and the ad-
hesive 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.
45-19 page 10 Removing and Installing Parts of the ABS System on the Front
and Rear Axle
Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 46
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.
1 - Brake disc
T Thickness: 22 mm 14
T Wear limit: 19 mm
13
T always replace axle-wise
T Unscrew the brake caliper
before removing
T Do not use force to separate 12
the brake discs from the
wheel hub, if necessary use 11
rust solvent; as you could
otherwise damage the brake 10
discs.
2 - Screw, 4 Nm 1
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 9
T Thickness: 19.6 mm (includ- 6
ing the support plate) 5
T Wear limit: 2.0 mm without
supporting plate 8 2
T Check thickness
⇒ Inspection and Mainte- 7
nance
T always replace axle-wise 6
T do not unscrew the brake
hose when replacing the 5
brake pad
T removing and installing 4
⇒ 46-1 page 3 3 S46-0087
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
– 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
T repair ⇒ Chapter 47-1
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
T do not unscrew when replacing the brake pad
9 - Wheel hub with wheel bearing
T for vehicles with ABS the sensor ring is built into the wheel hub
Note
1
♦ 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.
S46-0089
Installing
Note
2
Drain brake fluid from the brake fluid reservoir using a
ventilation bottle before pushing the piston back in.
Caution!
Brake fluid is toxic and must never be sucked off by S46-0090
mouth.
Note MP 9-403
Use alcohol only to clean the brake caliper housing.
Note
Do not interchange the inside and outside brake pads.
Pay attention to identification.
S46-0074
Kolbenseite
M46-0001
FS -
S46-0101
Note
♦ After each brake pad replacement forcefully apply the
brake pedal repeatedly to ensure the brake pads go
into their normal operating position.
S46-0089
♦ Check brake fluid level after replacing the brake pads,
if necessary top up with brake fluid.
Note
⇒ 46-1 page 1
1 - Brake disc
T Thickness: 18 mm
T Wear limit: 15 mm
22
T always replace axle-wise
T Unscrew the brake caliper 21
before removing
T Do not use force to separate
the brake discs from the
wheel hub, if necessary use 20
rust solvent; as you could
otherwise damage the brake 19
discs.
2 - Screw, 4 Nm 18
3 - Brake pads 17 1
T with wear indicator
– with a corresponding wear
(limit:2 to 3 mm) the warning
lamp in the dash panel insert 16
lights up
T with riveted retaining spring 10 11 15
12
T Install brake pad with a 13 14
smaller pad surface on the 2
piston side
T Thickness: 17.6 mm (includ-
ing the support plate)
T Wear limit: 2.0 mm without 9 3
supporting plate
T Check thickness 8
⇒ Inspection and Mainte- 7 4
6 5
nance
T always replace axle-wise
T do not unscrew the brake S46-0091
hose when replacing the
brake pad
T removing and installing ⇒ 46-1 page 7
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
– Use brake pedal load
– Unscrew brake hose from brake caliper
T Installing:
– Installing brake pads ⇒ 46-1 page 7
– Screw the brake hose onto the brake caliper
– Remove brake pedal load
– Bleed the brake system ⇒ Chapter 47-4
T repair ⇒ Chapter 47-1
Removing
– Remove wheel.
Note 1
♦ 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.
Note
S46-0102
Figure shows floating caliper disc brake FS-II with re-
moved air deflector.
Installing
Note 2
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.
Note
Only use alcohol to clean the brake caliper housing.
S46-0074
S46-0103
Note
2
♦ After each brake pad replacement forcefully apply the
brake pedal repeatedly to ensure the brake pads go
into their normal operating position.
♦ Check brake fluid level after replacing the brake pads, S46-0102
if necessary top up with brake fluid.
Repairing the front brake - the floating caliper disc brake C54-II
Special tools, test and measuring equipment and aids required
♦ ⇒ 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 mark-
ing
T with a fixing hole for the
wheel hub
T Thickness: 25 mm
T Wear limit: 22 mm
T always replace axle-wise
T for removing, first of all un-
bolt 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.
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 always replace axle-wise
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 always replace when changing the brake pads
T brake pads contained in repair kit
T fit on before installing brake pads
5 - 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: 18.6 mm (including the support plate)
T Wear limit: 2.0 mm without supporting plate
T Check thickness ⇒ Inspection and Maintenance
T always replace axle-wise
Removing
– Remove wheel.
Note
♦ When removing mark the brake pads you intend to 2
keep using. Install in the same location, as otherwise 1
this may cause uneven braking!
♦ Do not unscrew the brake hose when replacing the
brake pad.
♦ If brake pads are changed, replace heat shield in the
caliper and pad retaining plates.
Installing
3
Installation is carried out in the reverse order. Pay atten-
tion to the following:
Note 1
Drain brake fluid from the brake fluid reservoir using a
ventilation bottle before pushing the piston back in. A
B
Caution!
Brake fluid is toxic and must never be sucked off by 4
mouth.
5 S46-0123
Note
Only use white spirits to clean the brake caliper housing
and brake carrier.
– Attach brake line to fixture and secure with new clip. S46-0124
Note
♦ After each brake pad replacement forcefully apply the
brake pedal repeatedly to ensure the brake pads go
into their normal operating position.
♦ Check brake fluid level after replacing the brake pads,
if necessary top up with brake fluid.
Tightening torques:
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.
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws: 120 Nm.
1 - 4 Nm
2 - Brake drum
T Brake drum diameter 200 15
mm
T Wear limit: 201 mm
T clean carefully, and check for 14 13
wear, damage, dimensional
accuracy and perfect brake 12 10
surface
3 - Cap
11 9
T replace after each removal
T pressing off and inserting
⇒ Chapter 42-5
4 - Self-locking twelve-point nut,
70 Nm and tighten a further
30° 8
T replace after each removal
5 - Wheel hub with wheel bearing
T for vehicles with ABS the 6
sensor ring is built into the
wheel hub
T must be replaced completely
T removing and installing
⇒ Chapter 42-5
T assignment ⇒ Spare part
7
catalogue
6 - turn 30 Nm and 90°
T replace after each removal 1
7 - Brake carrier with brake shoe 5 4 3 2
T removing:
– Reset brake ⇒ 46-2 page 3 S46-0092
– Remove the brake drum
– Use brake pedal load
– Unscrew the brake line
– Remove the brake carrier
– unhook the hand brake cable if necessary
T Installing:
– Install the brake carrier
– hook on the hand brake cable if necessary
– Screw on the brake line
– Remove brake pedal load
– Install the brake drum
– Bleed the brake system ⇒ Chapter 47-4
T repairing ⇒ 46-2 page 4
8- Hand-brake cable
T Setting the hand-brake ⇒ 46-2 page 8
9- Axle stud
T removing and installing ⇒ Chapter 42-5
10 - Brake line
T Tightening torque of the pipe screws: 14 Nm
11 - Speed sensor ABS
12 - Plug
T for vehicles without ABS
Resetting brake
– Use a screwdriver to push the wedge up through a
hole for the wheel screws in the brake drum.
S42-0031
Note
♦ Use brake pedal loader, e. g. -V.A.G 1869/2- before removing a brake cylinder, a brake carrier or before separating
a brake line from the brake cylinder.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
♦ After working on the rear axle brake: Release hand-brake; forcefully activate the brake pedal repeatedly.
1 - Spring cap
T to remove push against pres- 6 7 8
sure spring and turn 90°
2 - Pressure spring
3 - Locating spring
4 - Pressure rod
T Grease the contact points 3 4 5
with solid lubricant paste
-G 000 650- 9
5 - Wedge
T when removing and installing
8
the brake drum push up
through a hole for wheel 2
screws (reset brake) ⇒ 46-2
page 3
6 - Wheel-brake cylinder
T check the system for tight-
ness ⇒ 46-2 page 5 10
T Repairs not allowed
T removing:
– Remove the brake shoe 11
⇒ 46-2 page 6
– Use brake pedal load 12
– Unscrew the brake line
– Remove the wheel-brake 1 16 15 13
cylinder
T Installing:
– Install the wheel-brake cylin- 1 2 14
der
– Screw on the brake line
S46-0093
– Remove brake pedal load
– Install the brake shoe ⇒ 46-2 page 6
– Bleed the brake system ⇒ Chapter 47-4
7 - Allen screw, 8 Nm
8 - Tensioning pin
9 - Brake carrier
S46-0079
Note
The brake pads must not be soiled with brake fluid or
grease.
1 S46-0094
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.
2 3
– 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-. 1
– Unhook the retractor spring at the top -3- with hook A
-A-.
S46-0071
2
A
S46-0072
S46-0095
Note
Pay attention to the fitting position of the wedge. The
raised part of the wedge -arrow- must remain visible dur-
ing installation. 2
A
S46-0073
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.
Note
The adjusting nut must be screwed over the end of the
tension rod (self-locking effect).
Note
♦ After replacing the brake pads forcefully apply the brake pedal repeatedly to ensure the brake pads go into their
normal operating position.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
♦ Use the brake pedal load, e.g. -V.A.G 1869/2- before removing a brake caliper or separating a brake hose from the
brake caliper.
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws: 120 Nm.
1 - 4 Nm
2 - Brake disc
T Thickness: 9 mm 14
T Wear limit: 7 mm 13
15 16
T if worn replace axle-wise
3 - Cap
T replace after each removal
T pressing off and inserting
⇒ Chapter 42-5
4 - Self-locking twelve-point nut,
70 Nm and tighten a further 12
30°
T replace after each removal
11
5 - Wheel hub with wheel bearing
T must be replaced completely
T removing and installing 10 17
⇒ Chapter 42-5
9
T assignment ⇒ Spare part
catalogue
18
6 - turn 30 Nm and 90°
19
T replace after each removal
7 - Cover plate 8
8 - Axle stud
9 - ABS speed sensor
10 - Allen screw, 8 Nm
T for speed sensor ABS 1
11 - Axle body
12 - Hand-brake cable 7 6 5 4 3 2
T Setting the hand-brake
⇒ 46-2 page 13 S46-0097
13 - Allan screw, tighten to 30 Nm
and then turn by a further 30°
14 - Brake line with supports, hollow screw and seal
T must be replaced completely, do not dismantle
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 line on the brake caliper
when replacing the brake pad.
Removing
– Remove wheel.
S46-0098
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
Drain brake fluid from the brake fluid reservoir using a
ventilation bottle before pushing the piston back in.
Caution!
Brake fluid is toxic and must never be sucked off by
mouth.
Note B
♦ Only use the resetting and turning out tool to reset the
piston.
A
♦ When resetting the piston with a piston resetting de-
vice the automatic reset in the brake caliper is de-
stroyed.
Note
There are four self-locking hexagon screws in the repair
set, which must be fitted.
S46-0104
S46-0098
Note
♦ After each brake pad replacement forcefully apply the
brake pedal repeatedly to ensure the brake pads go
into their normal operating position.
♦ Check brake fluid level after replacing the brake pads,
if necessary top up with brake fluid.
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.
S46-0099
46-3 Handbrake
Removing
– Removing the centre console ⇒ Body Work;
Rep. Gr. 68.
– Raise vehicle.
– Remove wheel.
– Release the hand-brake.
– Release adjusting nut -arrow- and unhook hand-brake
cable from compensating clamp.
Note
The retaining clip for the hand-brake cable must be re-
placed each time it is removed.
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 re- 11 12 13
moved, as it is welded to
bracket
T removing and installing 14
⇒ 46-4 page 3
2 - Hexagonal screw
15
3 - Self-locking hexagon nut, 28
Nm
T replace after each removal
T 4 pieces for securing the
brake servo unit to the brack- 1
et
T 2 pieces for securing the 2
bracket to the assembly plate
4 - Brake light switch 3
T assignment ⇒ Spare part
catalogue
10
T before assembling the brake
light switch clip brake pedal
to the pressure rod of the
brake servo unit
9
T Setting, removing and install-
3
ing the brake light switch
⇒ Chap. 45-16 7 7
T Inspecting function of the
4
brake light ⇒ Chap. 45-16 6
5 - Accelerator pedal with sender 8 5
-G79- and -G185-
T removing and installing
⇒ Engine, Mechanics; S46-0113
Rep. Gr. 20
6 - Brake pedal
T removing and installing ⇒ 46-4 page 4
7 - Bushing
8 - Cap
9 - Bearing bolt
10 - Self-locking hexagon nut, 25 Nm
T replace after each removal
11 - Brake servo unit
T removing and installing ⇒ Chapter 47-2
T assignment ⇒ Spare part catalogue
12 - Front wall
13 - Module carrier
14 - Bracket
T for crash strut
15 - Self-locking hexagon screw, 10 Nm
T replace after each removal
Note
Fig. shows the separation of the brake pedal from the
brake servo unit with the foot controls removed for clarity.
– Press brake pedal -1- towards the brake servo unit T30021
and hold in position.
– Insert release tool -T30021- or -T10006 A- and pull to-
wards the driver's seat while counterholding the brake 2
pedal. (At this moment the pedal must not move back-
wards.)
This causes the retaining lugs -3- of the support to be
pressed off the spherical head of the push rod -2-.
– 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
Removing
Note
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding.
S48-0106
Removing
Note
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding.
Tightening torque:
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 4 5
-G 052 150 A2-
3 - Bushing 1 2
T insert in brake caliper hous-
ing 3
4 - Guide bolts, 28 Nm
5 - Caps
T insert in bushing
6 - Brake caliper housing
7 - Seal
T removing and installing 3
⇒ 47-1 page 2
8 - Piston
T removing and installing
⇒ 47-1 page 2
9 - Protective cap
T removing and installing
⇒ 47-1 page 2
T when inserting piston do not
damage
9 8 7 6 4 5
S47-0068
Removing
– Insert wooden plate in the channel to avoid damaging
the piston when it is ejected.
– Press out piston from the brake caliper housing with S47-0051
compressed air -arrow-.
Note
3409
When removing the gasket ring make sure the cylinder
surface is not damaged.
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-.
S47-0031
– Insert new gasket ring in the groove of the brake cali-
per housing.
– Position the new protective cap with the outer sealing
lip on the piston.
S47-0032
S47-0033
S47-0050
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-.
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 1 2 3
thread with lithium grease
-G 052 150 A2-
3 - Hexagon collar bolt, 30 Nm
T replace each time removed
4 - Guide bolts
5 - Protective cap
T insert into slot of the brake 4
carrier and of guide pin;
grease slot first of all, use 5
grease packing of repair kit
6 - Brake carrier with guide bolt
6
and protective cap
T is supplied as replacement
part assembled with guide
pin and protective caps as
well as adequate quantity of
grease on guide pins 3
T if there is any damage to the
protective caps or guide bolts
fit a repair set; use the en- 10
closed grease packing to lu-
bricate the guide bolts 9
7 - Protective cap 8
T removing and installing
⇒ 47-1 page 2
7
T when inserting piston do not
damage
8 - Piston
T removing and installing S47-0078
⇒ 47-1 page 2
9 - Seal
T removing and installing ⇒ 47-1 page 2
10 - Brake caliper housing
Note
♦ When repairing always install complete repair set.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ In the event of repair it is absolutely necessary to pre-bleed the brake calipers before installing them in the vehicle
(without brake pads) ⇒ 47-1 page 8.
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease -G 052 150 A2-.
Removing
– Insert resetting and turning out tool -MP 9-401 -.
Collar -arrow B- must be located before the piston.
B
Note MP 9-401
If there is a resistance in the piston position open-end
wrench waf 13 on the provided wrench surfaces -arrow
A-. S47-0035
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 S47-0036
-G 052 150 A2-.
– Insert new gasket ring in the brake caliper housing.
– Position the new protective cap with the outer sealing
lip on the piston.
S47-0037
S47-0038
Note
Set up brake caliper for pre-bleeding.
A
S47-0049
B
Note
The complete master brake cylinder and brake servo unit can be replaced independently of one another.
pressure supply
Functional test:
– With the engine off press 4
down brake pedal repeatedly
with force (this reduces the 5 5
pressure already present in 13 12
the device). 6
– Now hold the brake pedal in
brake position using a medi- 7
um foot pressure and start
the engine. If the brake servo
unit operates perfectly the
brake pedal must yield no-
ticeably under your foot (ser-
vo boost takes effect).
T if there are faults replace 10 9 6 8
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 -F34-
T 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:
Installation is carried out in the reverse order.
Edition 07.04 Brake Servo Unit, Master Brake Cylinder 47-2 page 1
S00.5303.16.20
47 FABIA 2000 ³ Chassis
Inspection requirement
47-2 page 2 Brake Servo Unit, Master Brake Cylinder Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 47
– Connect the pressure gauge of the tester -V.A.G
1310 - or -V.A.G 1310 A- and bleed.
– Push down brake pedal until the pressure gauge on
the tester indicates 5 MPa (50 bar).
– Throughout the test which lasts 45 seconds the pres-
sure loss must not exceed 0.4 MPa (4 bar).
– If the pressure loss exceeds 0.4 MPa (4 bar) replace
the master brake cylinder.
Tightening torque: V.A.G 1310
Vent valve in brake caliper 10 Nm
Note
♦ The master brake cylinder must not be repaired. 6 7
♦ assignment ⇒ Spare part catalogue 1
Removing
Note
2
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding. MAX
Edition 07.04 Brake Servo Unit, Master Brake Cylinder 47-2 page 3
S00.5303.16.20
47 FABIA 2000 ³ Chassis
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 position-
ing of the pressure rod in the master brake cylinder.
♦ Only fill up with new brake fluid.
47-2 page 4 Brake Servo Unit, Master Brake Cylinder Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 47
♦ using vehicle system tester -V.A.G 1552- ⇒ Chapter
45-14.
♦ using vehicle diagnosis, measurement and informa-
tion system -VAS 5051- ⇒ Chapter 45-4.
Continued for all vehicles
Removing
Note
Before disconnecting the battery determine the code of
radio sets fitted with anti-theft coding.
Edition 07.04 Brake Servo Unit, Master Brake Cylinder 47-2 page 5
S00.5303.16.20
47 FABIA 2000 ³ Chassis
47-2 page 6 Brake Servo Unit, Master Brake Cylinder Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 47
– Fill up with new brake fluid.
– Install battery and battery tray ⇒ Electrical System;
Rep. Gr. 27.
– Connect battery ⇒ Electrical System; Rep. Gr. 27.
– Removing brake light switch ⇒ Chap. 45-16.
– Removing brake pedal from brake servo unit
⇒ Chapter 46-4.
– Unscrew the nuts for brake servo unit -arrows-.
– Guide the brake servo unit with master brake cylinder
towards the front and remove.
Vehicles without or with ABS BOSCH 5.7 or ABS,
ABS/TCS BOSCH 8.0
Edition 07.04 Brake Servo Unit, Master Brake Cylinder 47-2 page 7
S00.5303.16.20
47 FABIA 2000 ³ Chassis
47-2 page 8 Brake Servo Unit, Master Brake Cylinder Edition 07.04
S00.5303.16.20
FABIA 2000 ³ Chassis 47
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
T assignment ⇒ Spare part
catalogue 1 2 3 4
T testing and adjusting
⇒ 47-3 page 2
T Adjusting values ⇒ Chap. 14 15
00-3 5
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
5 - Brake line with pipe screw
T Brake-power regulator - rear 13
left brake hose 7 6
T Tightening torque of the pipe
screws: 14 Nm
6 - Brake line with pipe screw
T Master brake cylinder -
brake-power regulator
T Tightening torque of the pipe
screws: 14 Nm 8
7 - Brake line with pipe screw
12 11
T Master brake cylinder -
brake-power regulator
T Tightening torque of the pipe 10 9
screws: 14 Nm S47-0075
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
15 - Hexagon screw, 16 Nm
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.
Note S47-0107
Removing
WARNING!
Pay attention to the correct channel assignment of
the brake lines. Interchanging the brake lines will
result in dangerous brake control actions.
Tightening torques:
Removing
Note
♦ On vehicles with ABS/EDL/TCS or ABS/EDL/TCS/
ESP the EDL function is integrated in the TCS func-
tion.
♦ The procedure for bleeding air from the brake system
is described with the brake filling and bleeding appli-
ance -ROMESS S15-.
Vehicles with ABS/EDL/TCS or ABS/EDL/TCS/ESP
BOSCH 5.7 or ABS/TCS/ESP BOSCH 8.0
If one chamber of the brake fluid reservoir has run com-
pletely dry, e.g. leakage in the brake system, the hydrau-
lic 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-.
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 in-
formation 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.
WARNING!
♦ Brake fluid is hygroscopic, i.e. it retains humidi-
ty from the ambient air, and must therefore al-
ways be stored in airtight containers.
♦ Brake fluid must never come into contact with
fluids containing mineral oils (oil, petrol, clean-
ing 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.
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.
Note
♦ After bleeding perform a test drive. While doing so
perform at least one ABS adjustment!
♦ After bleeding or replacing the ABS, EDL/TCS control
unit BOSCH 5.7 or the ABS, ABS/TCS control unit
BOSCH 8.0 perform a final control diagnosis:
either using vehicle system tester -V.A.G 1552-
⇒ Chapter 45-12
using vehicle diagnosis, measurement and informa-
tion system -VAS 5051- ⇒ Chapter 45-4.
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.
Note
The bleeding of the brake system on vehicles with ABS/
TCS/ESP BOSCH 8.0 occurs via the basic setting.
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.
Note
After bleeding perform a test drive. While doing so per-
form at least one ABS adjustment!
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.
Note
The bleeding of the brake system on vehicles with ABS/
TCS/ESP BOSCH 8.0 occurs via the basic setting.
48 – Steering
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 ob-
tained 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 15 14
T adjustable 12
T Assignment ⇒ Spare part 11
catalogue
T inspecting for damage
⇒ Chap. 48-2
10
T removing and installing
⇒ Chap. 48-3 13
2 - Steering column
T rigid
T Assignment ⇒ Spare part
catalogue
T inspecting for damage
⇒ Chap. 48-2 9
T removing and installing 8
⇒ Chap. 48-3
3 - Hexagon screw, 23 Nm 7
4 - Hexagon bolt, 20 Nm + torque
a further 90° (1/4 turn) 8 1
T replace after each removal
5 - Steering gear
6 - Bushing
2
T replace if damaged 6
T removing and installing
⇒ Chap. 48-3
7 - Hexagon screw, 7 Nm
8 - Hexagon screw, 23 Nm
T Observe the mounting se-
4 3
quence ⇒ Chap. 48-5
9 - Bracket
5
T removing and installing S48-0213
⇒ Chap. 48-5
10 - Hexagon screw, 19 Nm
11 - Hexagon screw, 23 Nm
T replace after each removal
12 - Frequency link
T removing and installing ⇒ Chap. 48-5
13 - Module carrier
14 - Front wall
15 - Combination screw, 25 Nm
Optical inspection
– Inspecting parts of the steering column for damage.
– If any damage is visible, replace steering column com-
pletely.
Functional test
Inspection requirement:
• Universal joint of steering column pulled off steering
gear.
Note
♦ New steering columns supplied as spare parts are se-
cured for transport. This transport security must be re-
moved 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 igni-
tion starter switch. The lock cylinder and ignition
starter switch must be removed from the removed
steering column or be obtained and installed as a
spare part.
♦ Do not carry out repair work on the steering column.
♦ Always replace the self-locking nuts and screws.
♦ Welding and straightening on axle body and axle
studs not allowed.
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
♦ Connect battery ⇒ Electrical System; Rep. Gr. 27.
S48-0106
S48-0107
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 4
the direction of the arrow.
Note
♦ For reasons of clarity the work steps in the following
figures are shown on a removed steering column, i.e.
without background. 3
♦ 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
2
no colour coding and safe positioning of the top and 1 S48-0162
bottom part of the steering column.
If the top and bottom part of the steering column are sep-
arated the pairing of the clover-leaf profile is no longer
guaranteed. Moreover, this could result in the greased
area becoming soiled.
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 replace- 1 2
ment steering column or attach the top and bottom
part of the steering column with wire.
3
S48-0160
4
1
1 S48-0163
4
3 2
2 S48-0164
Note
♦ If the old steering column -3- is installed again do not
remove the bushing -1-. 2
♦ Only remove the bushing -1- in the event of damage
3
or if a spare part steering column is used.
Note
♦ Steering columns are supplied as a spare part with ig-
nition lock housing but without lock cylinder and igni-
tion 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
⇒ Electrical System; Rep. Gr. 94.
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 se-
curing mechanism of the top and bottom part of the
2
steering column. 3
♦ 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 1
and a new screw must first be fitted in the steering col-
umn fork before installing the steering column.
S48-0165
4
1
1 S48-0163
4
3 2
2 S48-0164
4
1
1 S48-0163
Tightening torques: 3
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!
Note
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
♦ When the battery is reconnected perform the following
operations depending on the vehicle equipment: En-
code the radio, re-set the clock, initialise the power
windows ⇒ Inspection and Maintenance.
Edition 07.00 Removing and installing ignition lock housing 48-4 page 1
S00.5303.03.20
48 FABIA 2000 ³ Chassis
48-4 page 2 Removing and installing ignition lock housing Edition 07.00
S00.5303.03.20
FABIA 2000 ³ Chassis 48
2
Removing
– Removing scuttle ⇒ Body Work; Rep. Gr. 66.
Note
The wiper arms must be in end position.
Installing
4
The installation occurs in reverse order.
1
Tightening torques:
Removing
– Removing the dash panel ⇒ Body Work; Rep. Gr. 70.
– Removing steering column ⇒ Chap. 48-3.
Note
For reasons of clarity the surrounding components are 1
not shown in the following figures.
2
3
S48-0179
2 1
Installing 2
S48-0178
Note
♦ Hexagon screws -2- and -3- are identical and are
tightened to the same torque. 3
♦ When installing the bracket -1- observe the mounting
sequence of the hexagon screws -2- and -3-. 3
– Position the bracket -1- on the module carrier -4-. 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. 2 1
Further installation occurs in reverse order. 2
S48-0178
Tightening torques:
Summary of components
Note
♦ If the front axle is damaged as a result of an accident certain steering components must be replaced ⇒ Chapter
48-9.
♦ Repairs to the steering gear are not provided for, if there is a complaint about the steering gear it must be replaced.
♦ Replace the self-locking nuts and screws.
♦ Welding and straightening of the steering components is not allowed.
♦ Only use steering gear grease to grease the gear rack ⇒ Chapter 00-2.
1 - Universal joint
T of steering column 2
1
2 - Tighten hexagon screw
20 Nm + 90°
T replace after each removal
3 - Tighten self-locking hexagon
nut 20 Nm + 90°
T replace after each removal
4 - Steering-knuckle arm of the 3
wheel-bearing housing
5 - Steering gear
6 - Assembly carrier 5 4
T with impression as shown in
the figure, only if the front ex-
haust pipe is fitted below the
engine-gearbox assembly 6
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 7
bracket depends on the
gearbox
8 - Tighten hexagon screw
50 Nm + 90° 8
T replace after each removal
8 S48-0268
Edition 11.04 Steering without servo unit (mechanical steering) 48-6 page 1
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48 FABIA 2000 ³ Chassis
48-6 page 2 Steering without servo unit (mechanical steering) Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
Note
Apart from replacing the bellows, track rod ends and track
rods no other repairs may be carried out on the steering
gear.
Caution!
Bring the steering wheel in centre position (wheels
straight ahead) and make sure they do not turn dur-
ing repairs as this could damage the coil spring of
the airbag unit.
S48-0106
Edition 07.00 Removing and installing mechanical steering gear 48-7 page 1
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48 FABIA 2000 ³ Chassis
S48-0107
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.
2
1
S48-0112
48-7 page 2 Removing and installing mechanical steering gear Edition 07.00
S00.5303.03.20
FABIA 2000 ³ Chassis 48
– Screw up hexagon nut of the track rod end -1- suffi-
ciently so that the extractor -Matra V176- is supported Matra V176
on the hexagon nut.
1
– 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.
2
S48-0114
3
S48-0117
Edition 07.00 Removing and installing mechanical steering gear 48-7 page 3
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48 FABIA 2000 ³ Chassis
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 steer-
ing gear is not bent on the assembly plate and correct-
ly 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.
V.A.G 1359/2 1
48-7 page 4 Removing and installing mechanical steering gear Edition 07.00
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FABIA 2000 ³ Chassis 48
Note
♦ Observe the recommended sequence for the follow-
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.
Edition 07.00 Removing and installing mechanical steering gear 48-7 page 5
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48 FABIA 2000 ³ Chassis
– Lower vehicle.
– Slide the universal joint of the steering column in the
direction of the arrow onto the input shaft of the steer-
ing and tighten with a new hexagon screw -1-.
– Fit cover for universal joint.
– Perform a test drive.
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment. 1
– Carrying out chassis alignment ⇒ Chap. 44-2.
S48-0170
Tightening torques:
48-7 page 6 Removing and installing mechanical steering gear Edition 07.00
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FABIA 2000 ³ Chassis 48
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.
-a- = 68.5 mm
Note
2
2 mechanics are required for this adjustment.
Inspection requirement:
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.
Caution!
The steering must automatically return to straight
ahead position after a manoeuvre or cornering with- 1
out sticking, correct if necessary. S48-0183
Edition 07.00 Inspecting and adjusting mechanical steering gear 48-8 page 1
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48 FABIA 2000 ³ Chassis
S48-0184
48-8 page 2 Inspecting and adjusting mechanical steering gear Edition 07.00
S00.5303.03.20
FABIA 2000 ³ Chassis 48
Note
♦ Always replace all steering components (except pos. 6) after an accident or in the event of damage to the front axle.
♦ Do not carry out repair work on the steering gear ⇒ item 10 in 48-9 page 2. If there are any complaints about the
steering gear ⇒ item 10 in 48-9 page 2 replace it.
♦ Welding and straightening of the steering components is not allowed.
♦ Always use original clamping collars and circlips.
♦ Only use steering gear grease to grease the gear rack ⇒ Chapter 00-2.
Edition 11.04 Disassembling and assembling the steering gear 48-9 page 1
S00.5303.17.20
48 FABIA 2000 ³ 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 re-
placement track rod/track rod end tighten lock nut fully to 50 Nm
T Setting wheel toe ⇒ Chap. 44-2.
9- Rubber insert
Fitting position:
♦ larger bore must point outwards
♦ replace if damaged or worn
10 - Steering gear
T do not repair
T removing and installing ⇒ Chapter 48-7
T setting ⇒ Chapter 48-8
T inspecting centre position ⇒ Chapter 48-8
11 - Left track rod end
T inspect ⇒ Chapter 48-10
T removing and installing ⇒ Chapter 48-10
T before installing, remove grease on tapered stud
12 - Left track rod
T tightening torque on steering rack: 80 Nm
T removing and installing ⇒ Chapter 48-10
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 re-
placement track rod/track rod end tighten lock nut fully to 50 Nm
T Setting wheel toe ⇒ Chap. 44-2.
48-9 page 2 Disassembling and assembling the steering gear Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
18 - Terminal + 15
19 - Earth
20 - Engine pump aggregate - consisting of:
a- Screwed lid
b- Reservoir for hydraulic oil
c- Pressure limiting valve
d- Gear pump
e- Electric motor
f- 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 re-
engaging protection after faults, failure or crash.
Note
♦ If the front axle is damaged as a result of an accident certain steering components must be replaced ⇒ Chapter
48-15.
♦ Repairs on the power-steering gear are not foreseen. In the event of failure determine the cause with the pressure
and tightness test as well as by performing self-diagnosis.
♦ If there is a fault on the power-steering gear, replace the steering gear, unless the fault is in the power-steering
sensor.
♦ Replace the self-locking nuts and screws.
♦ Welding and straightening of the steering components is not allowed.
♦ Only use steering gear grease to grease the gear rack ⇒ Chapter 00-2.
♦ Oil types: Hydraulic oil ⇒ Chapter 00-2.
♦ Oil volume in the system ⇒ Chapter 00-2
1 - Self-tapping screw, 6 Nm 1 2 1 3 4 5
2 - Heat shield 6
T assignment ⇒ Spare part 7
catalogue 9
3 - Steering column universal 10 8
joint
7
4 - Screw, 20 Nm + torque a fur- 11
ther 90° (1/4 turn) 11
T replace after each removal
12
5 - Gasket
T for power-assisted steering
sensor -G250- with adapter
cable ⇒ item 6 19 13
T replace after each removal
T assignment ⇒ Spare part
17
catalogue
20 17 15
6 - Sensor for power steering
-G250- 18 16
T with adapter cable ⇒ item 8 14
T removing and installing
⇒ Chapter 48-13
T assignment ⇒ Spare part
catalogue
7 - Screw, 6 Nm 22
T for power-assisted steering
sensor -G250- with adapter
cable ⇒ item 6
T assignment ⇒ Spare part 21
catalogue
8 - Adapter cable
T assignment ⇒ Spare part 21 S48-0266
catalogue
9 - Gasket
T for power-assisted steering sensor -G250- with fixed connecting line ⇒ item 10
T replace after each removal
T assignment ⇒ Spare part catalogue
10 - Sensor for power steering -G250-
T with fixed connecting line
T removing and installing ⇒ Chapter 48-13
T assignment ⇒ Spare part catalogue
11 - Screw, 6 Nm
T for power-assisted steering sensor -G250- with fixed connecting line ⇒ item 10
T assignment ⇒ Spare part catalogue
12 - Nut, self-locking, 20 Nm and torque a further 90° (1/4 turn)
T replace after each removal
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
T replace after each removal
16 - Hollow screw, 35 Nm
T replace after each removal
T with non-return valve
T M14x1.5
17 - Gasket ring
T replace after each removal
18 - Pressure line
T power-assisted steering gear - engine pump aggregate
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 removing and installing ⇒ Chapter 48-12
20 - Assembly carrier
T with impression (as shown in Figure), only if the front exhaust pipe is fitted below the engine-gearbox assem-
bly carrier
T with impression (not shown), only if the front exhaust pipe is fitted below the engine-gearbox assembly carrier
21 - Screw, 50 Nm + torque a further 90° (1/4 turn)
T replace after each removal
22 - Hinged bracket
T The shape of the hinged bracket depends on the gearbox
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.
♦ Do not use fluffy clothes.
♦ Remove spare parts from their wrapping 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 manufac-
tured 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 col-
umn ⇒ Body Work; Rep. Gr. 69.
♦ Disposing of the power-steering gear ⇒ Chap. 48-17.
Edition 04.05 Removing and installing power-steering gear (TRW or KOYO) 48-12 page 1
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48 FABIA 2000 ³ Chassis
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.
S48-0196
S48-0106
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 Removing and installing power-steering gear (TRW or KOYO) Edition 04.05
S00.5303.18.20
FABIA 2000 ³ Chassis 48
– Disconnect battery ⇒ Electrical System; Rep. Gr. 27.
– Remove air filter, if necessary ⇒ Engine, Fuel Injec-
tion System; Rep. Gr. 24 (petrol engines) or
⇒ Rep. Gr. 23 (diesel engines).
– If necessary remove the battery and battery tray
⇒ Electrical System; Rep. Gr. 27.
– Unhook cable of power-steering sensor -G250- from
line holder -arrows-.
– Raise vehicle.
S48-0109
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.
2
1
S48-0112
Edition 04.05 Removing and installing power-steering gear (TRW or KOYO) 48-12 page 3
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48 FABIA 2000 ³ Chassis
S48-0113
S48-0114
Note
♦ After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the return
hose and expansion hose.
♦ Do not use drained hydraulic oil again.
♦ Do not pinch off the expansion hose and the return
hose with hose clamps -MP 7-602- or any other tools.
Pinching off may result in damage to the expansion
hose and return hose. 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 Removing and installing power-steering gear (TRW or KOYO) Edition 04.05
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FABIA 2000 ³ Chassis 48
– Place the oil catch pan to catch drained off hydraulic
oil under the steering gear.
– Insert wooden insert (490 x 270 x 50 mm) -2- in the
adapter, e.g. -V.A.G 1359/2-.
2
– Position gearbox jack with adapter and support as- 1
sembly carrier.
1
– Release screws -1- for power-steering gear.
Note
♦ Observe the recommended sequence for the follow-
ing steps. V.A.G 1359/2 1
♦ The fixing bolts for -T10096- must only be tightened to
maximum 20 Nm as otherwise the fixing bolt thread V.A.G 1383A S48-0116
becomes damaged.
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 ex-
posed to traction.
5 S48-0115
Edition 04.05 Removing and installing power-steering gear (TRW or KOYO) 48-12 page 5
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48 FABIA 2000 ³ Chassis
S48-0259
Note
When lowering the assembly carrier make sure there is
sufficient clearance between the drive shafts and the sta-
bilizer.
1
– Slowly lower assembly carrier with gearbox jack and S48-0260
adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-.
– Remove power-steering gear towards the rear.
48-12 page 6 Removing and installing power-steering gear (TRW or KOYO) Edition 04.05
S00.5303.18.20
FABIA 2000 ³ Chassis 48
♦ Before fitting the power-steering gear check the cen-
tre position of the gear rack ⇒ Chap. 48-14.
♦ Before positioning the universal joint of the steering
column on the input shaft of the steering gear, first
make sure the vehicle is on the ground and all wheels
are pointing straight ahead.
♦ For vehicles with KOYO steering manufactured as of
43/04 a component modification was performed as an
enhancement for which the steering gear pinion has
been offset by 1 tooth. For these reasons the steering
gear is modified as of this date. For vehicles manufac-
tured 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 col-
umn ⇒ Body Work; Rep. Gr. 69.
2
1
– Check the centre position of the gear rack of the pow- 1
er-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 -1-
by hand.
– Check correct fit of the seal on the power-steering V.A.G 1359/2 1
gear valve housing.
– Align the assembly carrier with the fixing bolts of V.A.G 1383A S48-0201
-T10096- screwed into the body.
Note
Raise the assembly carrier until a distance of approx. 4
cm is between the console and body.
S48-0260
Edition 04.05 Removing and installing power-steering gear (TRW or KOYO) 48-12 page 7
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48 FABIA 2000 ³ Chassis
Note
♦ Observe the recommended sequence for the follow-
ing steps.
♦ Unscrew the fixing bolts of -T10096- one at a time. It
should be subsequently replaced by a new bolt tight-
ened to the recommended torque.
48-12 page 8 Removing and installing power-steering gear (TRW or KOYO) Edition 04.05
S00.5303.18.20
FABIA 2000 ³ Chassis 48
If the joint stub rotates when tightening, counterhold
with hexagon socket wrench (SW 6).
S48-0109
Caution!
Observe the applicable safety instructions for dis-
connecting the battery with the jumper cable!
Edition 04.05 Removing and installing power-steering gear (TRW or KOYO) 48-12 page 9
S00.5303.18.20
48 FABIA 2000 ³ Chassis
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment.
Note
For vehicles with KOYO steering manufactured as of 43/
04 a component modification was performed as an en-
hancement 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 be-
fore 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:
48-12 page 10 Removing and installing power-steering gear (TRW or KOYO) Edition 04.05
S00.5303.18.20
FABIA 2000 ³ Chassis 48
Removing
– Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
– Disconnect battery ⇒ Electrical System; Rep. Gr. 27.
– Remove air filter, if necessary ⇒ Engine - Fuel Injec-
tion System; Rep. Gr. 24 (petrol engines) or
⇒ Rep. Gr. 23 (diesel engines).
– Raise vehicle.
– Remove front left wheel.
– Remove soundproofing panel.
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66.
Note
The followings steps for removing the line do not need to
be carried out on vehicles with a power steering of TRW
and a power-assisted steering sensor -G250- (-2-) with 2 3
an adapter cable -4-.
4
1
S48-0259
Edition 11.04 Power-assisted steering sensor -G250- and the hydraulic line for 48-13 page 1
S00.5303.17.20 power steering
48 FABIA 2000 ³ Chassis
S48-0109
S48-0125
2
S48-0126
48-13 page 2 Power-assisted steering sensor -G250- and the hydraulic line for
power steering
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
Inspecting the power-assisted steering sensor
-G250- (TRW)
for power-assisted steering sensor -G250- with fixed con-
necting line (TRW):
4
1
S48-0270
4
1
S48-0259
Edition 11.04 Power-assisted steering sensor -G250- and the hydraulic line for 48-13 page 3
S00.5303.17.20 power steering
48 FABIA 2000 ³ Chassis
Removing
– Use catch pan to collect the drained off hydraulic oil.
– Unscrew the screwed lid -1- of the hydraulic oil reser-
voir -2- of the engine pump aggregate.
– Extract the hydraulic oil with an extraction bottle via S48-0147
the filler neck.
48-13 page 4 Power-assisted steering sensor -G250- and the hydraulic line for
power steering
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
– Remove front wheels.
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66.
– Unclip return line -4- from the line holders -5-.
5
– Open spacer holder -7-. 2
4
– Take return-flow line -4- or pressure line -6- out of the 6
spacer -7-.
– Open spring strap clamp -2- with assembly pliers and 7
carefully pull off return line from the support of the en-
gine pump aggregate -1-.
– Unscrew pipe screw -3- from the engine pump aggra- 3
gate and pull out the pressure line.
1
8 - Lines of power-assisted steering sensor -G250-
8
– Close the threaded bores and supports on the engine
pump aggregate. S48-0199
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.
Installing
5 S48-0115
– When installing the pressure line it is essential to pay
attention to the fitting location ⇒ Chapter 48-11.
– Mount return line with new O-ring on the power steer-
ing 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.
Further installation occurs in reverse order, while paying
attention to the following:
Edition 11.04 Power-assisted steering sensor -G250- and the hydraulic line for 48-13 page 5
S00.5303.17.20 power steering
48 FABIA 2000 ³ Chassis
Caution!
If after the test drive and with the front wheels point-
ing straight ahead the steering wheel is off straight,
perform a chassis alignment.
48-13 page 6 Power-assisted steering sensor -G250- and the hydraulic line for
power steering
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
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.
-a- = 72.5 mm
Note
2 mechanics are required for this adjustment.
2
Inspection requirement:
– 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 Inspecting and adjusting the power-steering gear 48-14 page 1
S00.5303.17.20
48 FABIA 2000 ³ Chassis
Caution!
The steering must automatically return to straight
ahead position after a manoeuvre or cornering with-
out sticking, correct if necessary.
1
S48-0183
S48-0184
48-14 page 2 Inspecting and adjusting the power-steering gear Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
Note
♦ If the front axle is damaged as a result of an accident
these steering components must be replaced: Posi-
tion 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 fail-
ure determine the cause with the pressure and tight-
ness 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.
♦ Always use original clamping collars and circlips.
♦ Only use steering gear grease to grease the gear rack
⇒ Chapter 00-2.
♦ A mixed lining of TRW and KOYO components is not
permissible, assignment ⇒ Spare part catalogue.
Edition 11.04 Disassembling and assembling the power-assisted steering gear 48-15 page 1
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48 FABIA 2000 ³ Chassis
48-15 page 2 Disassembling and assembling the power-assisted steering gear Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
12 - Power-steering gear
T assignment ⇒ Spare part catalogue
T no provision made for repairs
T removing and installing ⇒ Chapter 48-12
T setting ⇒ Chapter 48-14
T inspecting centre position ⇒ Chapter 48-14
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
T replace after each removal
14 - Gasket
T replace after each removal
15 - for power-assisted steering sensor -G250- with adapter cable
T removing and installing ⇒ Chapter 48-13
16 - Screw, 6 Nm
17 - Adapter cable
18 - for power-assisted steering sensor -G250- with fixed connecting line
T removing and installing ⇒ Chapter 48-13
19 - Left track rod end
T inspect ⇒ Chapter 48-16
T removing and installing ⇒ Chapter 48-16
T before installing, remove grease on tapered stud
20 - Left track rod
T tightening torque on steering rack: 80 Nm
T removing and installing ⇒ Chapter 48-16
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 the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm.
T Setting wheel toe ⇒ Chap. 44-2.
Edition 11.04 Disassembling and assembling the power-assisted steering gear 48-15 page 3
S00.5303.17.20
48 FABIA 2000 ³ 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.
♦ Welding and straightening of the steering components is not allowed.
♦ Always use original clamping collars and circlips.
♦ Only use steering gear grease to grease the gear rack ⇒ Chapter 00-2.
♦ A mixed lining of TRW and KOYO components is not permissible, assignment ⇒ Spare part catalogue.
7 - Self-tapping screw, 6 Nm
T for attaching heat shield
8 - Heat shield
T Allocation ⇒ Spare parts catalogue
9 - Clamp
Fitting position:
♦ inscription must point in direction of travel
♦ Replace the clamp if the thread of the nut is damaged
10 - Right track rod
T tightening torque on steering rack: 80 Nm
T removing and installing ⇒ Chapter 48-16
48-15 page 4 Disassembling and assembling the power-assisted steering gear Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
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 the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm.
T setting the wheel toe ⇒ Chapter 44-2.
11 - Rubber bearing
Fitting position:
♦ the larger internal diameter points towards the outer side of the vehicle
♦ replace if damaged or worn
12 - Power-steering gear
T assignment ⇒ Spare part catalogue
T no provision made for repairs
T removing and installing ⇒ Chapter 48-12
T setting ⇒ Chapter 48-14
T inspecting centre position ⇒ Chapter 48-14
13 - Gasket
T replace after each removal
14 - Sensor for power steering -G250-
T removing and installing ⇒ Chapter 48-13
15 - Screw, 6 Nm
16 - Left track rod end
T inspect ⇒ Chapter 48-16
T removing and installing ⇒ Chapter 48-16
T before installing, remove grease on tapered stud
17 - Left track rod
T tightening torque on steering rack: 80 Nm
T removing and installing ⇒ Chapter 48-16
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 the replacement track rod/track rod end and track adjuster, tighten lock nut fully to 50 Nm.
T Setting wheel toe ⇒ Chap. 44-2.
Edition 11.04 Disassembling and assembling the power-assisted steering gear 48-15 page 5
S00.5303.17.20
48 FABIA 2000 ³ Chassis
48-15 page 6 Disassembling and assembling the power-assisted steering gear Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
– Inspect attachment.
– Check boots for damaged (e.g. tears) and for correct
position.
– If necessary replace track rod ends.
– Raise vehicle.
– Remove front wheel.
– Screw up hexagon nut -1- sufficiently so that the puller 2
-Matra V176- is supported on the hexagon nut.
– Use puller -Matra V176- to press track rod/track rod
end -2- off the steering arm.
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-.
1 3
S48-0120
Edition 11.04 Track rod ends, track rods for power steering and mechanical 48-16 page 1
S00.5303.17.20 steering
48 FABIA 2000 ³ Chassis
Installing
Note
When installing pay attention to marking on the shank of I
the track rod end -arrow-.
I - Left track rod end - marking „D“
II - Right track rod end - marking „C“
Note
The track rods can only be removed and installed if the
mechanical steering gear or power-steering gear is re-
moved.
48-16 page 2 Track rod ends, track rods for power steering and mechanical
steering
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
Removing
– Removing mechanical steering gear ⇒ Chap. 48-7, or
power-steering gear ⇒ Chap. 48-12.
– Clean outside of steering gear in the area of the boot.
– Open warm-type clamp as well as spring strap clip
and push back boot.
Mechanical steering gear
– 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
V.A.G 1332
steering rack.
3
Installing
Mechanical 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.
Continued for all vehicles
Edition 11.04 Track rod ends, track rods for power steering and mechanical 48-16 page 3
S00.5303.17.20 steering
48 FABIA 2000 ³ Chassis
Note
Always use original clamping collars and circlips.
– Tighten the warm-type clamp using the hose binding V.A.G 1275
claw, e.g. -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:
48-16 page 4 Track rod ends, track rods for power steering and mechanical
steering
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
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 dis-
posed 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.
1 1
♦ After »draining« the used parts must be allowed to 2
drip.
♦ When disposing of used parts comply with the appli-
cable regulations as there are minor residual amounts
of hydraulic oil in the power-steering gear.
1
♦ The ambient temperature must be of at least 20°C to 3
drain the steering gear.
S48-0128
– Unscrew pipe screws -1-.
– Pull off coolant hoses -2- and -3-.
Note
Do not shut off the threaded bores -arrows-.
Note
♦ No provision is made for repairing the engine pump aggregate.
♦ The cause of any problems which may be arising is determined by the pressure and tightness test.
♦ If there is insufficient hydraulic oil in the reservoir always check the steering system for leaks.
♦ If there is a leak in the area of the line connections first check the lines/line connections for tightness, if necessary
tighten and wipe dry.
♦ Do not use drained hydraulic oil again.
♦ Always replace gasket rings.
♦ Oil types: Hydraulic oil ⇒ Chapter 00-2.
1 - Encapsulation
T bottom open version
T not fitted to all vehicles
3
T assignment ⇒ Spare part
catalogue
2 - Encapsulation
4
T bottom closed version
6 1
T not fitted to all vehicles
5 2
T Disassembling is only possi- 7
ble after removing the engine
pump aggregate and the 8 9
holder 10
T assignment ⇒ Spare part
catalogue
3 - Screwed lid
T with oil dipstick
9
4 - Gasket ring
5 - Reservoir
T replacing ⇒ Chapter 48-21
9 8
6 - Clamp 8 11
T replace after each removal
T different versions 12
T assignment ⇒ Spare part
catalogue
T Tightening torque: 3 Nm 14 13
7 - Gasket ring
T different versions
11
T assignment ⇒ Spare part
catalogue
8 - Hexagonal nut, 7 Nm 16 15 11 S48-0261
T when tightening counterhold
on rubber bearing ⇒ item 9
9 - Rubber bearing
T Tightening torque: 7 Nm
T check for damage (tears in rubber, rubber torn away from metal plate), if necessary replace
10 - Engine pump aggregate
T with power-assisted steering control unit -J500-
T No provision is made for repair
T Replacing reservoir ⇒ Chap. 48-21
T inspect ⇒ Chapter 48-19
T Self-diagnosis ⇒ Chap. 48-25
T Electrical test ⇒ Chap. 48-26
T removing and installing ⇒ Chapter 48-20
11 - Tighten hexagon screw 20 Nm + 90°
T replace after each removal
12 - Bracket
T for engine pump aggregate
13 - Spring strap clip
T install with assembly pliers, e. g. -VAS 5024-
14 - Return line (return hose)
T power-assisted steering gear - engine pump aggregate
15 - O-ring
T replace after disassembling the pressure line
16 - Pressure line (expansion hose)
T Tightening torque of the pipe screws: 30 Nm
T Engine pump aggregate - Power-steering gear
Note
♦ No provision is made for repairing the engine pump aggregate.
♦ The cause of any problems which may be arising is determined by the pressure and tightness test.
♦ If there is insufficient hydraulic oil in the reservoir always check the steering system for leaks.
♦ If there is a leak in the area of the line connection first check the lines/line connections for tightness, if necessary
tighten and wipe dry.
♦ Do not use drained hydraulic oil again.
♦ Always replace gasket rings.
♦ Oil types: Hydraulic oil ⇒ Chapter 00-2.
1 - Rear bracket
T for engine pump aggregate 4 6
T the bearings in the bracket
are not used as replacement
part, in case of bearing dam- 1 7
age replace bracket
2 - Tighten hexagon screw
20 Nm + 90°
2
8
T replace after each removal 2 5
3 - Fillister head screw, 7 Nm
4 - Screwed lid 9
3 9
T with flat gasket ring
T as replacement part only 14
screwed lid with oil dipstick is 19 10 14
available together
T assignment ⇒ Spare part
20
catalogue 10
5 - Flat gasket ring 9 9 11
11
6 - Screwed lid
T with O-ring 18 17 12
T assignment ⇒ Spare part
catalogue 13
7 - O-ring
8 - Encapsulation 16
T bottom open version
T not fitted to all vehicles 2
T assignment ⇒ Spare part 3
catalogue
9 - Self-locking fillister head 15
screw, 7 Nm
T replace after each removal S48-0262
T assignment ⇒ Spare part
catalogue
10 - Cap nuts, 7 Nm
T assignment ⇒ Spare part catalogue
11 - Reservoir
T replacing ⇒ Chapter 48-21
– Raise vehicle.
– Remove front left wheel.
– Remove the front left wheelhouse liner ⇒ Body Work;
Rep. Gr. 66.
– Switch on ignition.
– Start engine.
– If necessary turn steering up to stop.
– Listen to and/or touch the engine pump aggregate to
check whether it is running.
If the engine pump aggregate is not working:
Note
♦ If there is insufficient hydraulic oil in the reservoir of
the engine pump aggregate always check the power-
steering system for leaks ⇒ Chap. 48-23.
♦ If there is a leak on the power-steering gear first check
the lines/line connections for tightness, if necessary
tighten and wipe dry.
♦ Inspecting the gasket ring on the input shaft of the
power-steering gear and on the gear rack seal
⇒ Chap. 48-23. If there are leaks on the gasket ring
or on the gear rack seal replace the power-steering
gear.
♦ Disposing of the power-steering gear ⇒ Chap. 48-17.
♦ After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the pressure
line (expansion hose).
♦ Do not use drained hydraulic oil again.
♦ After the feed pressure test replace the O-ring on the
pipe screw of the pressure line.
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 bat- 2
tery tray and battery.
♦ Before disconnecting the battery determine the code 1
of radio sets fitted with anti-theft coding.
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.
S48-0111
Note
After removing the pressure line from the engine pump
aggregate hydraulic oil will escape from the connection
opening.
1
2
– Place the catch pan under the engine pump aggre- S48-0135
gate to collect escaping hydraulic oil.
– Release pipe screws -3- from the engine pump aggre-
gate -1-.
– Pull out the pressure line (expansion hose) -2- from 2
the engine pump aggregate.
3
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.
S48-0136
Connect tester
C
– Connect Power-steering tester -1-, e. g. -V.A.G 1402-.
– Suspend the power-steering tester on front axle. Hos-
es must not be exposed to tension. B 5
2- Adapter, e.g. -V.A.G 1402/3-
3- Hose from adapter set, e. g. -V.A.G 1402/6-
4- Adapter, e.g. -V.A.G 1402/2-
5- Adapter, e.g. -V.A.G 1402/1A-
A- Pressure line (expansion hose) 4
B- Engine pump aggregate with encapsulation
C- Return line (return hose)
A 1
2
S48-0138
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. 5…10 sec-
onds.
♦ 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 aggre-
gate responds.
– Start engine.
– Given a maximum left and right steering angle hold
the steering wheel in position with a force of approx.
10…20 Nm during approx. 5…10 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 ac-
cording to the following table.
Note
If the nominal value is exceeded or if it is not reached re-
place the engine pump aggregate.
Note
♦ Do not use drained hydraulic oil again.
♦ After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the hydraulic
lines.
♦ Do not pinch off the hydraulic lines with hose clamps
-MP 7-602- or any other tools. Pinching off may result
in damage to the pressure and return line.
♦ To avoid damage make sure the bending radius of at
least 100 mm is respected when bending or tying up
the pressure line.
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 2
battery. If this is the case remove the air filter, the bat-
tery tray and battery. 1
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
Edition 11.04 Removing and installing as well as disposing of engine pump 48-20 page 1
S00.5303.17.20 aggregate
48 FABIA 2000 ³ Chassis
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.
– Disconnect plugs -1- and -2- from the radiator fan con-
trol unit -J293- -4-.
3
– Unscrew nuts -3-.
– Remove radiator fan control unit -4-.
Continued for all vehicles 3
2
1
S48-0140
S48-0141
Note
♦ Residual hydraulic oil remains in the engine pump ag-
gregate. When removing the pressure line some of
this residual amount will flow out.
♦ When tying up the hydraulic line make sure the bend-
ing radius of 100 mm is reached. 4
S48-0143
4
S48-0142
1
S48-0144
Edition 11.04 Removing and installing as well as disposing of engine pump 48-20 page 3
S00.5303.17.20 aggregate
48 FABIA 2000 ³ Chassis
Note
To replace the rubber bearing do not remove the encap-
sulation.
S48-0145
Note
♦ Only use original spring band clamps.
♦ Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
♦ Do not use drained hydraulic oil again.
♦ After installing the engine pump aggregate fill with hy-
draulic oil ⇒ 48-23.
♦ When installing the pressure line on the engine pump
aggregate use new O-ring. S48-0146
Caution!
Observe the applicable safety instructions for dis-
connecting the battery with the jumper cable!
Note
♦ Do not use drained hydraulic oil again.
♦ After extraction there will be residual hydraulic oil in
the engine pump aggregate as well as in the hydraulic
lines.
♦ Do not pinch off the hydraulic lines with hose clamps
-MP 7-602- or any other tools. Pinching off may result
in damage to the pressure and return line.
♦ To avoid damage make sure the bending radius of at
least 100 mm is respected when bending or tying up
the pressure line.
Edition 11.04 Removing and installing as well as disposing of engine pump 48-20 page 5
S00.5303.17.20 aggregate
48 FABIA 2000 ³ Chassis
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 bat- 2
tery tray and battery.
♦ Before disconnecting the battery determine the code 1
of radio sets fitted with anti-theft coding.
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.
S48-0111
– Disconnect plugs -1- and -2- from the radiator fan con-
trol unit -J293- -4-.
3
– Unscrew nuts -3-.
– Remove radiator fan control unit -4-.
Continued for all vehicles 3
2
1
S48-0140
S48-0141
Note 3
♦ Residual hydraulic oil remains in the engine pump ag-
gregate. When removing the pressure line some of
this residual amount will flow out.
2
♦ When tying up the hydraulic line make sure the bend- 1
ing radius of 100 mm is reached.
S48-0271
Edition 11.04 Removing and installing as well as disposing of engine pump 48-20 page 7
S00.5303.17.20 aggregate
48 FABIA 2000 ³ Chassis
3
4
S48-0272
S48-0273
2
S48-0274
6
Caution! 5
The power steering control unit -J500- (-A-) and the
electric motor -B- must not be separated.
A
5
5 B S48-0275
Installing engine pump aggregate
Note
♦ Only use original spring band clamps.
♦ Install spring strap clamp with assembly pliers, e.g.
-VAS 5024-.
♦ Do not use drained hydraulic oil again.
♦ After installing the engine pump aggregate fill with hy-
draulic oil ⇒ 48-23.
♦ When installing the pressure line on the engine pump
aggregate use new O-ring.
Installation is carried out in the reverse order. Pay atten-
tion to the following:
Caution!
Observe the applicable safety instructions for dis-
connecting the battery with the jumper cable!
Edition 11.04 Removing and installing as well as disposing of engine pump 48-20 page 9
S00.5303.17.20 aggregate
48 FABIA 2000 ³ Chassis
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.
Note
♦ When replacing the reservoir make sure that the
housing -1- of the engine pump aggregate is not ex-
posed to traction, pressure or knock.
♦ A damage of the housing can lead to damage at the
pump or at the seal power-assisted steering control
unit -J500-/housing.
Disassemble reservoir
– Removing the engine pump aggregate ⇒ Chap. 48-
20.
After extraction of the hydraulic oil there will be residues 1
in the engine pump aggregate.
S48-0290
– Close screw connection for the pressure line at the
engine pump aggregate.
S48-0276
Note
♦ The engine pump aggregate must only be clamped at
the power steering control unit -J500- (-1-), on no ac-
count at the housing -2-.
♦ The housing -2- must not rest against the vice or
against the work bench. 1
♦ A non-observance of the mentioned safety measures
leads to a non-repairable damage at the engine pump 2
aggregate.
S48-0289
WARNING!
Wear gloves when heating and pulling off the res-
2
ervoir.
1
– Heat the reservoir -2- in the lower area evenly all
around with a hot-air blower e.g. -V.A.G 1416-
Caution!
The reservoir must be heated up to maximum 80 °C. 3
– Detach reservoir -2- from engine pump aggregate -3-. S48-0277
Note
♦ Ensure a clean, grease- and oil-free contact surface
for gasket ring and reservoir at the engine pump ag-
gregate.
♦ 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.
Note
♦ The engine pump aggregate must only be clamped at
the power steering control unit -J500- (-1-), on no ac-
count at the housing -2-.
♦ The housing -2- must not rest against the vice or 1
against the work bench.
♦ A non-observance of the mentioned safety measures 2
leads to a non-repairable damage at the engine pump
aggregate.
WARNING!
Wear gloves when heating and positioning the res-
ervoir.
Caution!
The reservoir must be heated up to maximum 80 °C.
S48-0280
B A
S48-0280
Note
When detaching the reservoir -1-, one must absolutely
counterhold at pump aggregate -2-
Caution!
The pump aggregate -2- must on no account be 1
pulled out from the housing with power-assisted
steering control unit -J500- -3-. A separation leads to
damage at the engine pump aggregate, which can- 2
not be eliminated with workshop possibilities.
S48-0281
Assembling reservoir
Note
♦ Ensure a clean, grease- and oil-free contact surface
for gasket ring and reservoir at the engine pump ag-
gregate.
♦ 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 counter-
hold at the pump aggregate -2-.
Caution! 1
The pump aggregate -2- must on no account be
pulled out from the housing with power-assisted 2
steering control unit -J500- -3-. A separation leads to
damage at the engine pump aggregate, which can-
not be eliminated with workshop possibilities. 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. A B
Note
Begin with the tightening of the screws with fillister head
screws -arrows B-. B A
– 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. 3
– Empty the reservoir. 1
For reasons of guarantee, mark the replacement of
the reservoir. 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-.
S48-0280
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
2
of the engine compartment.
1
♦ On certain models the screwed lid -1- of the reservoir
is covered by the battery tray because of the different
battery dimensions. If this is the case remove the bat-
tery tray and battery.
♦ Check the hydraulic oil level with the dipstick of the
screwed lid -1-.
♦ Do not refer to the „MAX“ and „MIN“ markings on the
reservoir to check the hydraulic oil level.
♦ Do not use drained hydraulic oil again.
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding. S48-0147
Note
The correct oil level can only be determined for a fully
screwed in screwed lid.
Note
♦ Hydraulic oil amount in the system: approx. 0.80 ltr.
♦ The screwed lid for filling the power steering system
with hydraulic oil is located in a recess on the frame
side rail in the front left section of the engine compart-
ment.
♦ Because of the different battery dimensions, on cer-
tain models the screwed lid covered by the battery
tray and battery. If this is the case remove the air filter,
the battery tray and battery.
♦ Only fill an empty hydraulic system when the engine is
cold.
♦ Hydraulic oil ⇒ Chap. 00-2
♦ Hydraulic oil amount in the system: approx. 0.80 ltr.
♦ Use new hydraulic oil only.
♦ Topping up hydraulic oil ⇒ Chap. 48-22
♦ Check the hydraulic oil level with the dipstick of the
screwed lid of the engine pump aggregate reservoir.
♦ Do not refer to the „MAX“ and „MIN“ markings on the 2
reservoir to check the hydraulic oil level.
♦ Before disconnecting the battery determine the code 1
of radio sets fitted with anti-theft coding.
Edition 11.04 Filling and bleeding the power steering system, and checking 48-23 page 1
S00.5303.17.20 tightness
48 FABIA 2000 ³ 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.
Caution!
Observe the applicable safety instructions for dis-
connecting the battery with the jumper cable!
48-23 page 2 Filling and bleeding the power steering system, and checking
tightness
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
Note
Possible residual air in the steering system will automati-
cally escape during driving after approx. 10…20 km.
Note
♦ Because of the different battery dimensions, on cer-
tain models the screwed lid with oil dipstick for check-
ing 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.
♦ Before disconnecting the battery determine the code
of radio sets fitted with anti-theft coding.
Edition 11.04 Filling and bleeding the power steering system, and checking 48-23 page 3
S00.5303.17.20 tightness
48 FABIA 2000 ³ Chassis
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.
Caution! S48-0111
Note
A 2nd mechanic is required to check the tightness of the
pressure line, return line and the connections.
48-23 page 4 Filling and bleeding the power steering system, and checking
tightness
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
Note
♦ If there is a repeated loss of hydraulic oil from the en-
gine pump aggregate reservoir, and if the line or hose 2 1
and its connections as well as the engine pump aggre-
gate and its reservoir have been repeatedly thorough-
ly inspected, remove and inspect the power steering
gear.
♦ The checking of the power-steering gear is identical to 2
the steering gears of TRW and KOYO. The figure
shows the power-steering gear of TRW.
S48-0152
Note 2
If there is no more hydraulic oil in the engine pump aggre-
gate reservoir the engine pump aggregate may have »run
dry« and may have been damaged.
3
– Replace engine pump aggregate ⇒ Chap. 48-20.
– If necessary disconnect the jumper cable. 3 S48-0285
Edition 11.04 Filling and bleeding the power steering system, and checking 48-23 page 5
S00.5303.17.20 tightness
48 FABIA 2000 ³ Chassis
48-23 page 6 Filling and bleeding the power steering system, and checking
tightness
Edition 11.04
S00.5303.17.20
FABIA 2000 ³ Chassis 48
1
S48-0205
Note
To test the rubber bearing for damage remove the engine
pump aggregate with encapsulation and disassemble the
holder.
S48-0146
S48-0273
2
S48-0274
5 S48-0286
Note
To test the rubber bearing for damage remove the engine
pump aggregate -2- and disassemble the holder -1-. 1 2 3
– Removing the engine pump aggregate ⇒ Chap. 48-
20.
– Remove holder -1- from the engine pump aggregate
-2-.
4
The rubber bearing -3- can be checked on an installed
holder -4-.
6
– Check rubber bearing -3- and -6- for damage (e.g.
tears).
– In case of rubber bearing, replace holder -1- or holder
-4- ⇒ Chapter 48-20.
5 S48-0287
5 - Fillister head screws
Tightening torques:
S48-0288
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
Note
If there is no readout on the display: ⇒ Operating instruc-
tions of the vehicle system tester
– Press →.
Vehicle system test HELP
If one of the following messages appears in the display, The control unit does not respond
carry out fault finding as stated in the fault finding pro-
gramme in the diagnostic cable ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations. Vehicle system test HELP
Fault in communication build-up
or
or Vehicle system test HELP
K cable does not connect to earth
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
– Press →.
Vehicle system test HELP
Readout on display:
Select function XX
– Select function 0 6 „End output“ and confirm with
Q.
– 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 →.
Vehicle system test HELP
Readout on display:
Select function XX
– Select function 0 6 „End output“ and confirm with
Q.
– Switch off ignition.
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.
Caution!
Recoding of the control unit for the power-assisted
steering at the customer's request can only be un-
dertaken in compliance with the table of codes. Oth-
er 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)
Code Meaning
number:
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«
(has not been used before)
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«
(has not been used before)
101501) Convenience - greater power steering at low driving speeds (e.g. when parking) for »light vehicles«
(has not been used before)
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. 6Q0423156 Power steering 0001 ->
00110) Coding 00110 WSC XXXXX
– Press →.
Vehicle system test HELP
Readout on display:
Select function XX
– Select function 0 6 „End output“ and confirm with
Q.
Readout on display:
Vehicle system test HELP
Select function XX
– Enter function 0 8 „Read measured value block“
and confirm the entry with key Q .
Read measured value block HELP
Readout on display:
Enter display group number XXX
– Enter display group ⇒ 48-25 page 10.
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.
– Switch on ignition.
– On the screen, select the Geführte Fehlersuche .
– Select the following one after the other:
♦ Brand
♦ Type
♦ Model year
♦ Variant
♦ Engine identification characters
Test conditions
2
1
S48-0271
Connector -2-:
1 - Terminal 30
2 - Earth
Connector -1-
between contact: Specified value:
4 and earth approx. battery voltage
Connector -2-
between contact: Specified value:
1 and 2 approx. battery voltage
1 and earth approx. battery voltage
Connector -1-
between contact: Specified value:
4 and earth ∞Ω
Connector -2-
between contact: Specified value:
1 and earth ∞Ω
2 and earth approx. 0 Ω
1 and 2 approx. 60 Ω
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 -J500-
and 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.
Test condition
• A data BUS fault was detected by the power steering
control unit -J500-.
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 con-
nected.
– Connect the earth clip of the test box -arrow- to the
negative battery terminal.
– Test the central terminating resistor in the engine con-
trol unit.
– To this end perform a resistance measurement be-
tween the test box bushes ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
V.A.G 1598/31
Nominal value: 60…72 Ω
If the resistance is not within the nominal value
S24-0380
range:
– Test the data BUS cables for a short-circuit to the pos- S24-0380
itive battery terminal or earth or for interruption
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
♦ 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-
T Perform self-diagnosis ⇒ Chap. 48-25
T removing and installing ⇒ Chapter 48-13
T assignment ⇒ Spare part catalogue
8- Adapter cable
T for power-steering sensor -G250- ⇒ item 7
9- Power-assisted steering control unit -J500-
T 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 Perform self-diagnosis ⇒ Chap. 48-25
T Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate
⇒ Chap. 48-20
10 - Engine pump aggregate (TRW)
T removing and installing ⇒ Chapter 48-20
11 - Power-assisted steering control unit -J500-
T 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 Perform self-diagnosis ⇒ Chap. 48-25
T Power steering control unit -J500- cannot be replaced individually; replace the engine pump aggregate
⇒ Chap. 48-20
12 - Engine pump aggregate (KOYO)
T removing and installing ⇒ Chapter 48-20