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Service Workshop Manual FABIA 2000 Inspection and Maintenance Edition 08.99 Service Department. Technical Information Printed in Czech Republic S00.5301.00.20...
FABIA 2000 Inspection and Maintenance List of Supplements to Workshop Manual FABIA 2000 Inspection and Maintenance Edition 08.99 Supple- Edition Subject Article Number ment 08.99 Basic Edition S00.5301.00.20 12.99 Supplement to Basic Edition S00.5301.01.20 02.00 Vehicle identification number S00.5301.02.20 03.00 Inspection Service every 90.000 km;...
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FABIA 2000 Inspection and Maintenance List of Supplements Edition 09.04 S00.5301.14.20...
FABIA 2000 Inspection and Maintenance Table of Contents 02 – Inspection and Maintenance 02-1 General points ..................page 02-1 - Vehicle identification data ................page 02-1 - Storage of ŠKODA new vehicles ..............page 02-1 - Vehicle handover from stock ................
FABIA 2000 Inspection and Maintenance 02 – Inspection and Maintenance 02-1 General points Vehicle identification data Vehicle identification number The vehicle identification number (chassis number) is attached to the right suspension dome. The vehicle identification number (chassis number) can also be found bottom left of the front window cor- ner.
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FABIA 2000 Inspection and Maintenance U - 1.9 ltr. TDI PD/96 kW/diesel engine W - 1.2 ltr./40 kW/petrol engine Y - 1.2 ltr./47 kW/petrol engine Z - 1.4 ltr. TDI PD/55 kW/diesel engine 4 - Airbag System: 0 - no airbag...
FABIA 2000 Inspection and Maintenance Vehicle data sticker The vehicle data sticker is located at the rear left on the floor of the boot. Storage of ŠKODA new vehicles Notes on storage of new vehicles ⇒ Technical Service Handbook. Vehicle handover from stock –...
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FABIA 2000 Inspection and Maintenance General information: – Inform your customer about this so that he has each inspection carried out at the right time and none are forgetten. – Draw the attention of your customer to the sticker af- fixed to the side of the dash panel (driver's side) indi- cating when the next service event is due.
FABIA 2000 Inspection and Maintenance 02-2 Inspection Pre-Delivery Inspection -PDI- (Export) The operations marked with * apply to all countries; other operations are applicable to certain countries only! Compare as-delivered condition of vehicle with order form Chapter ♦ Engine fitted ♦...
FABIA 2000 Inspection and Maintenance Pre-sales Inspection - (the Czech Republic) Compare as-delivered condition of vehicle with order form Chapter ♦ Engine fitted ♦ Type plate in the engine compartment ♦ Vehicle data sticker (compare with stamped identification number) ♦...
FABIA 2000 Inspection and Maintenance – Proper operation of seat belts, seat belt height adjuster, power windows and sun roof – Inspect upholstery, interior trim, carpeting and footmats for cleanliness and damage – 02-6 Inspect all switches, all electrical components, gauges/indicators and controls –...
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FABIA 2000 Inspection and Maintenance – Fit roof aerial Engine compartment (from above) – 02-6 Check battery no-load voltage; recharge if necessary – Check tight connection of electric cables and plug connections (in particular battery ca- bles) – 02-5 Brake fluid level (at „MAX“ marking) –...
FABIA 2000 Inspection and Maintenance Oil Change Service every 15.000 km (QG0) An Oil Change Service need only be carried out if the vehicle has covered 15 000 km before one year has elapsed . If the Oil Change Service is due only a few months prior to the Annual Inspection, it is recommend- ed to carry out the Annual Inspection at the same time.
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FABIA 2000 Inspection and Maintenance – Track rod ends: Inspect play and correct attachment of boots – 02-5 Check the tyre inflation pressure (including spare wheel), correct if necessary – 02-5 Inspect tyre wear (including spare wheel) – 02-5 Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., RL..., SP...)
FABIA 2000 Inspection and Maintenance Every 60 000 km (QG0) Includes: Inspection every 30 000 km and additional operations stated in the table below Work involved Chapter – 02-3 Air filter: Clean housing, replace filter element – 02-3 Fuel filter: replace (vehicles with diesel engine) –...
FABIA 2000 Inspection and Maintenance Every 240 000 km (QG0) Includes: Inspection every 120 000 km and additional operations stated in the table below Work involved Chapter – 02-3 Replace tensioning pulley (PD diesel engine as of 08.03) Inspection Service (QG1, QG2) ♦...
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FABIA 2000 Inspection and Maintenance Work involved Chapter – 02-5 Check the tyre inflation pressure (including spare wheel), correct if necessary – 02-5 Inspect tyre wear (including spare wheel) – 02-5 Inspect tyre tread depth (including spare wheel) and record (FL..., FR..., RR..., RL..., SP...)
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FABIA 2000 Inspection and Maintenance Oil change (QG1, QG2) Work involved Chapter – 02-3 Change engine oil – Replace engine oil filter – 02-5 Disc brake pads: Inspect thickness – 02-6 Reset service interval display – Drain away water from the fuel filter (diesel engine with fuel operation, which does not...
FABIA 2000 Inspection and Maintenance 02-3 Engines Engine overview Engine identifica- tion charac- ters Emission EU4, EU4, standard EU2 DDK, EU2 DDK, EU3 DDK EU3 DDK Manufactur- 01.01 ... 07.02 02.02 ... 05.04 01.03 04.00 ... 03.03 (from...throu Displace- ment in litres...
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FABIA 2000 Inspection and Maintenance Regular grade unleaded petrol (min. 91 ROZ) can be used although engine power output is slightly reduced. Engine identifi- cation charac- ters Emission stand- EU4, EU3, EU4, EU3 DDK EU4, EU2 DDK, EU2 DDK, EU3 DDK...
FABIA 2000 Inspection and Maintenance Engine with identification characters AWY, AZQ, BMD. Engine with identification characters ASZ. Engine with identification characters AMF. Visual inspection: Engine for leaks and damage – Inspect engine for leaks and damage. – Inspect all lines, hoses and connections of the fuel system and of the cooling and heating system for leaks, chafing points, porous and brittle joints.
FABIA 2000 Inspection and Maintenance Replace engine oil filter Vehicles with petrol engine Special tools, test and measuring equipment and auxiliary items required ♦ Oil filter wrench – Release oil filter (e.g. Würth, Hazet) and remove. – Clean sealing surface at engine.
FABIA 2000 Inspection and Maintenance Note The timing belt must most definitely be replaced if any shortcomings are found. This will help prevent any fail- ures or operational problems. Replacing the timing belt is a repair measure. Replacing toothed belt and guide pulley for camshaft drive (1.9 SDI engines)
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FABIA 2000 Inspection and Maintenance ♦ 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.
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FABIA 2000 Inspection and Maintenance Only use engine oils: QGO, QG2 Specification VW 505 01 or VW 505 00 (oil according to VW 505 00 cannot be used for TDI PD - engines) Oils may be intermixed when topping up.
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FABIA 2000 Inspection and Maintenance – Extract a small quantity of coolant with the pipette and place on the measuring glass. Hold unit against a light source and read off the temperature down to which antifreeze protection exists on the scale for ethylene glycol.
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FABIA 2000 Inspection and Maintenance ♦ Coolant additives complying with standard TL VW 774C (G11) -bluish-green in colour-, must only be used for topping up on vehicles fitted with a cooling system which is already filled with this coolant. ♦...
FABIA 2000 Inspection and Maintenance Note The listed G12 PLUS coolant additives may be inter- mixed. Ribbed V-belt: Inspect condition Special tools, test and measuring equipment and auxiliary items required ♦ Wrench socket Perform the following procedure: – Raise vehicle.
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FABIA 2000 Inspection and Maintenance 1.0 litre/37 kW (ARV and AQV), 1.4 litre/44 kW (AZE and AZF), 1.4 litre/50 kW (AME, ATZ and AQW) with air-conditioning 1 - Crankshaft 2 - Tensioning pulley 3 - Coolant pump 4 - AC compressor...
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FABIA 2000 Inspection and Maintenance 1.4 litre/55 kW (AUA, BKY) and 1.4 litre/74 kW (AUB, BBZ) without air-conditioning 1 - AC generator 2 - Crankshaft S02-0312 1.4 litre/55 kW (AUA, BKY) and 1.4 litre/74 kW (AUB, BBZ) with air-conditioning 1 - AC generator...
FABIA 2000 Inspection and Maintenance – 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.
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FABIA 2000 Inspection and Maintenance – Loosen the drain plug -arrow- and drain off approxi- mately 0.1 litres of fluid. – Tighten the drain plug. – Carry out the installation again in the reverse order. – Inspect the fuel system for tightness (visual inspec- tion).
FABIA 2000 Inspection and Maintenance 02-4 Gearbox Gearbox/Final drive: Check the oil level and top it if necessary 5 speed gearbox 002 Gearbox oil specification: G50 SAE 75W90 (synthetic oil) – Unscrew plug for inspecting gear oil -arrow-. The oil is at the correct level if the gear is filled up to the lower edge of the oil filler hole.
FABIA 2000 Inspection and Maintenance Gearbox oil specification: G50 SAE 75W90 (synthetic oil). – Unscrew plug for inspecting gear oil -arrow-. The oil is at the correct level if the gear is filled up to the lower edge of the oil filler hole.
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FABIA 2000 Inspection and Maintenance If ATF is added, use ATF with spare part number -G 052 990 A2-. – The gasket ring -arrow- for the ATF screw plug must always be replaced. Inspecting ATF level Test conditions • Gearbox not in emergency running mode, ATF tem- perature not above 30°C.
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FABIA 2000 Inspection and Maintenance – Bring ATF to test temperature. Test temperature: 35 C to 45 C – Remove screw plug for ATF inspection in the oil pan -arrow-. The ATF present in the overflow tube flows out. If ATF drips out of the hole: It is not necessary to top up with ATF.
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FABIA 2000 Inspection and Maintenance – Fit new gasket ring on screw plug -arrow 1- and tight- en to 15 Nm. – Insert screw plug of the filler tube and secure with new cap -arrow 2-. S37-0082 02-4 Edition 07.03...
FABIA 2000 Inspection and Maintenance 02-5 Chassis Inspecting thickness of front and rear brake pads/linings Front disc brake pads: Note For a better assessment of the residual pad thickness re- move wheels. Do not mix up wheels (mark). – Release the wheel bolts and remove wheel.
FABIA 2000 Inspection and Maintenance ways replace the brake linings on both sides (repair measure). Note 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.
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FABIA 2000 Inspection and Maintenance – Remove strainer and clean. – Use extraction device -1- to extract as much brake flu- id as possible from the brake fluid reservoir. WARNING! Drained (used) brake fluid must never be used again. –...
FABIA 2000 Inspection and Maintenance – Repeat the procedure for all wheels in the following sequence: rear left, front right and front left. – Insert strainer in the brake fluid reservoir and fill with brake fluid up to the specified level.
FABIA 2000 Inspection and Maintenance Track rod ends: Inspect play, correct at- tachment and joint boots – Raise vehicle (wheel clear of the ground) and inspect play by moving the track rods and wheels. Clearance: There must not be any play present.
FABIA 2000 Inspection and Maintenance Inspecting the tyre tread depth (includ- ing spare wheel) and entering This value may differ in individual countries as a result of differing statutory requirements. If the tyre tread depth is close to the legal minimum, in other words if no further tread exists at the points around the circumference of the tyre at which the 1.6 mm high...
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FABIA 2000 Inspection and Maintenance Tyre inflation pressure (kPa/bar) Engine Tyres Partial load Full load Front axle Rear axle Front axle Rear axle 165/70 R14 220/2,2 200/2,0 240/2,4 280/2,8 185/60 R14 210/2,1 190/1,9 230/2,3 270/2,7 1.9 ltr./47 kW SDI 1.4 ltr./55 kW TDI...
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FABIA 2000 Inspection and Maintenance Tyre inflation pressure (kPa/bar) Engine Tyres Partial load Full load Front axle Rear axle Front axle Rear axle 185/60 R14 220/2,2 220/2,2 230/2,3 290/2,9 185/55 R15 220/2,2 210/2,1 230/2,3 280/2,8 1.9 ltr./74 kW TDI 195/50 R15...
FABIA 2000 Inspection and Maintenance 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.
FABIA 2000 Inspection and Maintenance If the tester indicates a voltage of 12.5 Volts or more, the battery is O.K. If the voltage is less than 12.5 Volts determine the cause (repair measure). Battery: Inspecting electrolyte level, top- ping up with distilled water if necessary...
FABIA 2000 Inspection and Maintenance holding the knob in the left or right position respective- Connect vehicle system tester and inter- rogate fault memory The stored faults can be read out with vehicle system tester -V.A.G 1552-, -V.A.G 1551-, or -V.A.S. 5051-.
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FABIA 2000 Inspection and Maintenance Vehicle system test HELP K cable does not connect to earth Vehicle system test HELP K cable does not connect to pos. term. Operate the vehicle system tester by referring to the read-out on the display:...
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FABIA 2000 Inspection and Maintenance Resetting service interval display (SID) with -V.A.G 1552- (QG0) – Connect -V.A.G 1552-. – Switch on ignition. 6Y1919870B COMBIINSTRUMENT VDO X09 -> – Enter address word 17 „Dash Panel Insert“ and con- Coding 20141 WSC 12345 firm with –...
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FABIA 2000 Inspection and Maintenance Note „in 100 km“ = adaptation value x100 The current read-out of the short journey counter for the OIL service is displayed (is still 100 km in our example until the next OIL service). –...
FABIA 2000 Inspection and Maintenance Note ♦ For vehicles with the dash panel insert 6Y0 920 xxx x, the SID with the set button -1- cannot be reset before a service is required. ♦ Always only reset the desired service interval („OIL service“...
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FABIA 2000 Inspection and Maintenance Resetting service interval display (SID) with -V.A.G 1552- (QG1, QG2) – Connect -V.A.G 1552-. – Switch on ignition. – Enter address word 17 „Dash Panel Insert“ and con- firm with 6Y1919870B COMBIINSTRUMENT VDO X09 ->...
FABIA 2000 Inspection and Maintenance – Press set button -1- and hold and simultaneously switch on ignition. – Release set button -1- and turn to the right. All counters are reset. – Switch off ignition. Note ♦ For vehicles with the dash panel insert 6Y0 920 xxx x, the SID with the set button -1- cannot be reset before a service is required.
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FABIA 2000 Inspection and Maintenance – Connect -V.A.G 1552-. – Switch on ignition. – Enter address word 17 „Dash Panel Insert“ and con- firm with 6Y1919870B COMBIINSTRUMENT VDO X09 -> Readout on display (e.g.): Coding 03111 WSC 12345 – Note the dash panel insert coding.
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FABIA 2000 Inspection and Maintenance Test and setting conditions • Tyre inflation pressure O.K. • Lenses must neither be damaged nor soiled. • Reflectors and bulbs O.K. • Vehicle load must be achieved. Load: With an individual or 75 kg on the driver's seat in an otherwise unladen vehicle (dead weight).
FABIA 2000 Inspection and Maintenance Note ♦ To easily determine the kink -2-, alternately cover and uncover the left half of the headlight (in the driving di- rection) a few times. After this, check the low beam once again. ♦...
FABIA 2000 Inspection and Maintenance Vehicles as MY 2005 Left fog light (right fog light in mirror image) – Unclip the cap -1- on the bumper. – Use a screwdriver to turn screw -2- and to align the fog light beam.
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FABIA 2000 Inspection and Maintenance 02-6 Electrical System Edition 09.04 page S00.5301.14.20...
FABIA 2000 Inspection and Maintenance 02-7 Body Airbag units: Visual inspection Inspecting operation of airbag unit When the ignition is switched on the airbag warning lamp K75 lights up for approximately 4 seconds. Should the warning lamp flash again for a further 12 seconds this is...
FABIA 2000 Inspection and Maintenance Note Do not affix any stickers or cover over the padded boss of the steering wheel -1- and the foam-lined surface of the airbag unit on the front passenger side -2- or do not carry out any modifications to these parts.
FABIA 2000 Inspection and Maintenance The materials and the corresponding work instructions are listed in the ⇒ Technical Service Handbook, Part 6 - Technology of paint repairs, chemical materials. Inspecting plenum chamber and water drain openings for dirt, cleaning if neces-...
FABIA 2000 Inspection and Maintenance The specified tightening torque for the windscreen wiper arms is 20 Nm. Wiper arms of rear window: Inspecting park po- sition, adjusting if necessary, spray nozzle of rear window: Inspect setting and adjust if neces-...
FABIA 2000 Inspection and Maintenance Child safety locks (rear doors): The rear doors are additionally equipped with a child safety lock. – Insert car key in the lock. – The child safety lock is activated when the key is turned to the left in the direction of the arrow. The in- ner door opening lever is blocked.
FABIA 2000 Inspection and Maintenance – Separate filter element from the frame. Installing: Installation is carried out in the reverse order. S02-0310 Sticking the vehicle data sticker – Stick the vehicle data sticker to the floor of the luggage compartment inside the vehicle next to the spare wheel -arrow-.
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FABIA 2000 Inspection and Maintenance Note When applying G 052 778 A2 make sure that the product does not penetrate into the gap between the lock bolt, control lever, eccentric and trailer arm housing. Trailer coupling: Check for proper operation –...
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FABIA 2000 Inspection and Maintenance 02-7 Body Edition 09.04 page S00.5301.14.20...
FABIA 2000 Inspection and Maintenance 02-8 Exhaust-emission Analy- Note The exhaust-emission analysis must be carried out ac- cording to the relevant national legislation of the particu- lar country. Exhaust-Emission Analysis on Models with Fuel Engines Note Perform the following visual inspections and comply with...
FABIA 2000 Inspection and Maintenance ♦ Disconnect and connect wires of the ignition system (including high-voltage wires) when the ignition is switched off. – Connect the tester in compliance with the operating instructions. Note The exhaust gas probe must be fully inserted into the ex- haust tailpipe (do not insert into the suction tube)! –...
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FABIA 2000 Inspection and Maintenance Engine identification AZE, AZF and characters Model year MY03 MY00 MY03 MY00 MY01 MY03 min. 80 °C min. 80 °C min. 80 °C min. 80 °C Oil temperature 2 min. 2 min. 2 min. 2 min.
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FABIA 2000 Inspection and Maintenance Engine identification with automatic characters gearbox Model year MY02 MY00 MY02 MY02 MY01 min. 80 °C min. 80 °C min. 80 °C min. 80 °C Oil temperature 2 min. 2 min. 2 min. 2 min.
FABIA 2000 Inspection and Maintenance Note All tubes and plug connections, which had been removed or disconnected for the test and adjustment, must be re- inserted or connected. Technical data of the spark plugs Chapter 02-3. Exhaust-Emission Analysis on Models...
FABIA 2000 Inspection and Maintenance Test Values for Exhaust-Emission Analysis on Diesel Engines Engine identification characters Model year MY03 MY00 MY02 MY03 MY03 min. 80 °C min. 80 °C min. 80 °C min. 80 °C Oil temperature Idling speed 850 … 1050 825 …...
FABIA 2000 Inspection and Maintenance 02-9 Miscellaneous Tow starting/Towing Note ♦ A towing rope or towing bar must only be fitted to the above towing lugs. ♦ The towing rope must be elastic to protect the vehicle. Therefore only use synthetic ropes or ropes manufac- tured in an equally elastic material.
FABIA 2000 Inspection and Maintenance – As soon as the engine starts, press clutch and remove gear to avoid driving into the towing vehicle. Note 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.
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FABIA 2000 Inspection and Maintenance The rear support points are located in the make axle em- bossed in the sill -arrow-. WARNING! Under no circumstances may the arms of the lift platform or jack be positioned under the engine, the gearbox, the front or rear axles.
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