ABS SKODA FABIA 2000 1.G / 6Y Workshop Manual

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
EnginesEdition 09.04
S00.5301.14.2002-3 page 9 02
♦It is absolutely necessary to observe the oil disposal
instructions!
♦It is not permitted to clean and re-use the oil filter!
–Remove oil filler cap.
–Remove the noise insulation.
–Screw out the oil drain plug and collect the oil in a suit-
able vessel.
–Clean the drain plug, screw in with a new seal and
tighten to the specified tightening torque:
Engine-oil pan: 30 Nm
–Pour in oil as stated in the specifications.
Engine oil capacities:
♦with oil filter change approx.:
2.4 litres (1.2 litre/40 kW - engine)
2.8 litres (1.2 litre/47 kW - engine)
3.2 litre (1.4 litre/55 kW (petrol) and 1.4 litre/74kW - en-
gine)
4.0 litre (1.0 litre/37 kW, 1.4 litre/44 kW, 1.4 litre/50 kW
and 2.0 litre/85 kW engine)
4.2 litre (1.4 litre/55 kW TDI PD - engine)
4.3 litre (1.9 litre/47 kW SDI, 1.9 litre/74 kW TDI PD and
1.9 litre/96 kW TDI PD - engine)
The engine is factory-filled with quality multigrade oil,
which can also be used as an all-season oil, except in ex-
tremely cold climatic zones.
Specification for petrol engines:
The given specifications must be indicated on the can in-
dividually or together with other specifications.
Only use engine oils:
QGO, QG2
Standard: VW 500 00, VW 501 01 or VW 502 00
Oils may be intermixed when topping up.
In exceptional cases:
Multigrade oils according to ACEA A2 or A3. Such oils
must only be used once for topping up within the speci-
fied oil change interval if, in exceptional cases, no ap-
proved engine oil is available.
QG1
Specification VW 503 00
Specification for diesel engines:
The given specifications must be indicated on the can in-
dividually or together with other specifications.

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EnginesEdition 09.04
S00.5301.14.2002-3 page 18 02
Replace air filter element
–Open the filter housing.
–Replace the filter element and clean the filter housing.
–Close filter housing and check correct fitting.
Replacing the fuel filter (diesel engine)
♦Make sure no diesel fuel comes into contact with the
coolant hoses. If necessary clean the hoses immedi-
ately!
♦It is absolutely necessary to observe the oil disposal
instructions!
♦Observe the disposal instructions!
Removing
–Remove retaining clips -3-.
–Remove regulating valve -4- with the connected fuel
hoses.
–Remove fuel hoses -1- and -2- on the filter.Engine fitted Spark plug manufac-
turer's designationParts No. Electrode spacing
1.0 litre/37 kW NGK BKR 6ETA-10 101 000 065
AA1.0 mm
1)
1) Distance between earth electrode and spark plug insulator.
1.2 ltr./40 kW AWY NGK PZFR5J-11 101 905 600
1.0 mm1)
NGK ZFR 5P-G 101 905 617
0.9 mm1)
BOSCH F7 HER2 101 905 601 B
0.9 mm1)
BMD NGK ZFR 5P-G 101 905 617
0.9 mm1)
BOSCH F7 HER2 101 905 601 B
0.9 mm1)
Brisk DOX 15 LE 101 905 618
0.9 mm1)
1.2 ltr./47 kW BOSCH F7 HER2 101 905 601 B
0.9 mm1)
NGK ZFR5P-G 101 905 617
0,8 mm1)
1.4 ltr./44 kW Brisk DR 15 TC 101 000 060
AA0,8 mm1)
1.4 ltr./50 kW Champion RC-89 PYC 101 000 049
AC0.8 mm1)
1.4 ltr./55 kW AUA, BBY NGK BKUR 6ET-10 101 000 033
AA1.0 mm1)
BKY BERU 14F-7 HUR 2 101 905 603 B
0.9 mm1)
1.4 ltr./74 kW NGK BKUR 6ET-10 101 000 033
AA1.0 mm1)
2.0 ltr./85 kW NGK BKUR 6ET-10 101 000 033
AA1.0 mm1)
Note
1
2
3
4
S02-0323

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EnginesEdition 09.04
S00.5301.14.2002-3 page 19 02
–Unlock hooks -arrows-.
–Loosen the fuel filter and remove.
Installing
–Install new fuel filter.
–Lock hooks -arrows-.
–Fit the new O-ring for the regulating valve.
–Install regulating valve -4- with the connected fuel
hoses.
–Attach retaining clips -3-.
–Install the fuel hoses -1- and -2- and secure with hose
clamps.
The direction of flow is indicated with arrows (do not
switch connections).
–Inspect the fuel system for tightness (visual inspec-
tion).
Draining the fuel filter (diesel engine)
♦Make sure no diesel fuel comes into contact with the
coolant hoses. If necessary clean the hoses immedi-
ately!
♦Collect fuel in a suitable vessel!
♦It is absolutely necessary to observe the oil disposal
instructions!
–Remove retaining clip -2- and remove regulating valve
-1- with the connected fuel hoses.
–Unlock hooks -arrows-.
–Loosen the fuel filter and remove.
Note
Note
S02-0324
1
2
1
2
3
4
S02-0323

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
ChassisEdition 02.04
S00.5301.13.2002-5 page 2 02
ways replace the brake linings on both sides (repair
measure).
Avoid soiling from brake fluid or grease flowing out.
Inspecting brake system for leaks and
damage
–Inspect master brake cylinder, brake servo unit (for
ABS: hydraulic unit), brake pressure regulator, brake
calipers for leaks and damage.
–Inspect brake hoses for twisting.
–Ensure that the brake hoses do not touch any parts of
the vehicle when the steering is turned to full left or full
right lock.
–Inspect the brake hoses for porous and brittle points.
Inspect the brake hoses and brake lines for chafing
points.
–Inspect the brake connections and attachments to en-
sure they are correctly fitted, free of leaks and corro-
sion.
Changing brake fluid (every 2 years)
Special tools, test and measuring equipment and
auxiliary items required
♦Extraction device
♦Brake pedal support, e.g. - V.A.G 1869/2-
Use only fresh genuine brake fluid FMVSS 571.116 DOT
4.
–Unscrew cap -1- from the brake fluid reservoir
Note
WARNING!
Any defects found must be rectified (repair meas-
ure).
WARNING!
Brake fluid must never come into contact with
fluids containing crude oils (oil, petrol, cleaning
agent). Crude oils damage the gaskets and
boots of the brake system.
Brake fluid is toxic. Because of its caustic effect
brake fluid must not come into contact with
paint.
Brake fluid is hygroscopic, i.e. it absorbs mois-
ture from the surrounding air . Therefore it
should always be stored in airtight containers.
Wash any parts stained with brake fluid with
large volumes of water.
Observe the disposal instructions!

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
ChassisEdition 02.04
S00.5301.13.2002-5 page 4 02
–Repeat the procedure for all wheels in the following
sequence: rear left, front right and front left.
1)
–Insert strainer in the brake fluid reservoir and fill with
brake fluid up to the specified level.
–Inspect pedal position and idle travel at brake pedal.
Idle travel: max. 1/3 of pedal travel.
Vehicles with ABS or ABS/EDL:
A road test on such models must be carried out after
bleeding the brake system. While doing so perform at
least one ABS adjustment!
Inspecting the brake fluid level
Use only fresh genuine brake fluid FMVSS 571.116 DOT
4.
The brake fluid must not be above the „MAX“ marking to
prevent fluid flowing out of the reservoir.
Delivery Inspection
The brake fluid level during the delivery inspection should
be at the „MAX“ marking.
Inspection Service:
–The brake fluid level (volume) must always be as-
sessed on the basis of the brake pad wear. When driv-
ing a slight drop in the brake fluid level occurs as a
result of wear-and-tear and the automatic slack ad-
justment of the brake pads.
–If the fluid brake level is on the „MIN“ marking or slight-
ly above, it is not necessary to top up the brake fluid if
the brake pads have practically reached their wear
limit.
–If the brake pads are new or far off the brake wear lim-
it, the brake fluid level must be between the „MIN“ and
„MAX“ markings.
–If the brake fluid level has dropped below the „MIN“
marking, it is necessary to inspect the brake system
before topping up the brake fluid ⇒02-5 page 2; car-
ry out repair measure if necessary.
1)for right-hand drive vehicles the following sequence applies: rear right, front left and front right
WARNING!
Brake fluid is toxic. Because of its caustic effect
brake fluid must not come into contact with
paint.
Brake fluid is hygroscopic, i.e. it absorbs mois-
ture from the surrounding air . Therefore it
should always be stored in airtight containers.
Note
S02-0305

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
Electrical SystemEdition 09.04
S00.5301.14.2002-6 page 1 02
02-6 Electrical System
Power windows: Inspecting positioning
If the battery is diconnected the power windows forget
their current position.
Test conditions:
•All car doors closed
The inspection procedure is carried out from the outside
Close window with the car key using the convenience
closing system.
–Turn car key into close position and hold until all the
windows are closed.
–After closing the windows hold the key in the close po-
sition for approximately another 3 seconds.
Electrical components: Check for proper
operation
–Inspect lighting, main headlights, headlight beam con-
trol, fog lights, turn signal lights, hazard warning light
system, tail lights, rear fog lights, reversing lights,
brake lights, parking light control for brightness and
proper operation.
–Inspect interior lights, illuminated storage compart-
ment, illuminated ashtray for proper operation.
–Airbag warning lamps: Check operation ⇒Chapter
02-7.
–Inspect warning buzzer, onboard computer, all switch-
es in centre console as well as on the dash panel and
horn for proper operation.
–Inspect power windows, exterior mirrors (heated and
electrically adjustable), central locking system, infra-
red remote control and convenience closing system
for proper operation
–Inspect heating of front seats for proper operation.
–Inspect radio for proper reception and absence of in-
terference, also inspect speakers ⇒02-6 page 2.
Battery: Testing no-load voltage
Special tools, test and measuring equipment and
auxiliary items required
♦Multimeter (e.g. -V.A.G 1526 A-)
Prior to the measurement the vehicle must have been in
the no-load state for at least two hours (no engine starts,
no charging or discharging of battery).
The following procedure applies to measuring the battery
voltage in the no-load state (after at least two hours):
–With the battery installed measure the voltage be-
tween the terminals (ignition switched off).

Downloaded from www.Manualslib.com manuals search engine FABIA 2000➤Inspection and Maintenance
MiscellaneousEdition 06.01
S00.5301.06.2002-9 page 2 02
–As soon as the engine starts, press clutch and remove
gear to avoid driving into the towing vehicle.
Do not start the engine of vehicles fitted with an exhaust
catalyst by towing over a long distance as unburnt fuel
may get into the catalyst and burn there. This may result
in overheating and hence in the destruction of the cata-
lyst.
Perform a test drive
The following must be assessed within the scope of a test
drive according to the vehicle equipment and the availa-
ble possibilities (city/country, weather)
–Inspect engine for performance, misfiring, idling be-
haviour and acceleration.
–Foot and handbrake: Functional test (jerking, squeak-
ing, pulling to one side) ABS operation. Brake pedal-
idle travel: max.
1/3 of the idle travel.
–Inspect the lever position and smooth operation of the
gearshifts.
–Inspect the driving behaviour of the clutch as well as
the pedal force and smell.
–Inspect automatic gearbox: Selector lever position,
selector lever lock, shifting behaviour, display indica-
tion in dash panel insert.
–Inspect steering clearance of the vehicle standing on
its wheels, with engine running by turning the steering
wheel one way and then the other (wheels straight
ahead). There must be no play on the steering.
–Inspecting the sun roof operation.
–Pay attention to pulling and to the straigt ahead posi-
tion of the steering wheel during driving.
–Inspect the imbalance of the wheels, drive shafts and
propshafts.
–Inspecting functions: Heating, air conditioning, venti-
lation, instruments and warning lights, mirror adjust-
ment.
–Inspect engine, gearbox, axles, steering, brakes,
clutch, bodywork for abnormal noises
Raising the vehicle
Using a lift platform and a workshop jack
The vehicle must only be raised with a workshop jack in
the indicated jacking points -arrows-.
To avoid damage use a suitable rubber or wood insert.
Note
S02-0316