Ev. č. / Ev.-Nr. xxxxxx ŠKODA AUTO a.s., tř.

ř. Václava Klementa 869, Mladá Boleslav II, 293 01 Mladá Boleslav, Czech Republic 1/181

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 1. Contents

1. Contents .......................................................................................................................................................................... 2
2. Introduction .................................................................................................................................................................... 7
3. Maintenance ................................................................................................................................................................... 8
3.1. List of car fluids ......................................................................................................................................................... 8
4. Electronics....................................................................................................................................................................... 9
4.1. Dash display + central panel buttons ............................................................................................................... 9
4.1.1. Central panel .......................................................................................................................................................... 9

4.1.2. Switch panel ........................................................................................................................................................ 10

4.2. Main Display ........................................................................................................................................................... 11

4.2.1. Display modes .................................................................................................................................................... 11

4.2.2. Main Display Menu............................................................................................................................................ 22

4.3. Driver Display.......................................................................................................................................................... 26

4.4. Steering Wheel Buttons – Mechanical Variant.......................................................................................... 31
4.5. Steering Wheel Buttons – Electronic Variant ............................................................................................ 32
4.6. Co-driver’s buttons .............................................................................................................................................. 34
4.7. Stilo Intercom DG-10 .......................................................................................................................................... 35
4.8. USB logger ............................................................................................................................................................... 37
4.9. Wipers ....................................................................................................................................................................... 38
4.10. Device supply connectors ................................................................................................................................. 38
4.11. Recommended revisions .................................................................................................................................... 39
4.12. Electronic device update .................................................................................................................................... 41
4.13. ADR (Accident Data Recorder) ....................................................................................................................... 41
4.13.1. Variant 1 - ADR .................................................................................................................................................. 42

4.13.2. Variant 2 – ADR4 ............................................................................................................................................... 43

5. Engine .............................................................................................................................................................................44
5.1. Operational and maximum engine values (pressure, temperature…) ............................................... 44
5.2. Summary of ‘ECU’ software & dataset available ...................................................................................... 45
5.3. Engine fuel mapping............................................................................................................................................. 46
5.4. Engine start/stop................................................................................................................................................... 47
5.4.1. Engine start.......................................................................................................................................................... 47

5.4.2. Engine stop .......................................................................................................................................................... 48

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 5.5. Engine power test ................................................................................................................................................. 48
5.6. FIA limiter ................................................................................................................................................................. 50
5.6.1. Overrev counting .............................................................................................................................................. 50

5.7. Road x stage mode ............................................................................................................................................... 50

5.8. Launch start (‘LS’) .................................................................................................................................................. 51
5.9. Turbocharger .......................................................................................................................................................... 53
5.9.1. Antilag system (‘ALS’) ...................................................................................................................................... 53

5.9.2. Summary of boost level settings depending on engine specification ......................................... 54

5.9.3. Engine boost setup ........................................................................................................................................... 54

5.9.4. Maximal turbocharger ‘RPM’ ........................................................................................................................ 57

5.9.5. Wastegate setting ............................................................................................................................................ 57

5.9.6. Turbo speed sensor setting (air gap) ......................................................................................................... 59

5.10. Calibration pedal x throttle ................................................................................................................................ 60

5.11. Calibration pedal x throttle troubleshooting .............................................................................................. 61
5.12. Wastegate calibration ......................................................................................................................................... 62
5.13. Shiftlights ................................................................................................................................................................. 63
5.14. Alarms ........................................................................................................................................................................ 68
5.15. Errors – Error manager, backup strategies ................................................................................................. 68
5.15.1. Clear errors .......................................................................................................................................................... 72

5.16. Adaptations ............................................................................................................................................................. 72

5.16.1. Clear adaptations .............................................................................................................................................. 72

5.17. Water circuit ........................................................................................................................................................... 73

5.17.1. Water circuit bleeding..................................................................................................................................... 73

5.17.2. Water circuit for versions with or without heater ............................................................................... 73

5.18. Engine maintenance ............................................................................................................................................. 75

5.18.1. Clutch operation – thrust bearing (axial bearing) ................................................................................. 75

5.18.2. Check of thrust washer status – axial clearance of crankshaft ...................................................... 76

5.18.3. Oil level check – Standard engine oil filling. This procedure applies for the oil dipstick
03F 115 611 E ....................................................................................................................................................................... 78

5.18.4. Oil level check – Standard engine oil filling. This procedure applies for the oil dipstick
6VT 115 611 E....................................................................................................................................................................... 79

5.18.5. Flywheel tightening procedure .................................................................................................................... 80

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 5.18.6. Spark plugs tightening procedure .............................................................................................................. 81

5.18.7. Change of accessories belt ........................................................................................................................... 82

5.18.8. Engine start-up after the car rolls over (procedure in the service zone) .................................... 83

5.18.9. Driver Safety Function .................................................................................................................................... 83

5.18.10. Fuel system bleeding after fuel/engine change .................................................................................... 84

5.18.11. Turbocharger speed sensor replacement/turbocharger replacement ........................................ 84

5.19. Sealing ....................................................................................................................................................................... 85

5.19.1. Sealing the pop-off valve ............................................................................................................................... 85

5.19.2. Sealing the restrictor and turbocharger .................................................................................................. 86

5.19.3. Sealing the engine block ................................................................................................................................. 88

5.20. Durability of Parts ................................................................................................................................................. 89

5.21. Engine revision ....................................................................................................................................................... 91
5.21.1. General information ......................................................................................................................................... 91

5.21.2. Engine transport to ŠKODA Motorsport................................................................................................. 93

5.21.3. Engine sealing ..................................................................................................................................................... 95

5.21.4. Over rev ................................................................................................................................................................ 95

5.21.5. Data acquisition ................................................................................................................................................. 95

6. Exhaust system ...........................................................................................................................................................96

6.1. Exhaust line maintenance and assembly ...................................................................................................... 96
7. Transmission ................................................................................................................................................................97
7.1. Type 1 gear ratios ................................................................................................................................................. 97
7.2 Type 2 gear ratios ............................................................................................................................................................. 97
7.3. How to change oil in transmission ................................................................................................................. 98
7.3.1. Gearbox ................................................................................................................................................................. 98

7.3.2. Rear Differential................................................................................................................................................. 99

7.4. Differential setting............................................................................................................................................. 100

7.5. Clutch inspection ............................................................................................................................................... 102
7.6. Driveshaft inspection ........................................................................................................................................ 103
7.7. Sealing .................................................................................................................................................................... 104
7.7.1. Gearbox ŠKODA FABIA Rally2 evo sealing points............................................................................ 104

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 7.7.2. Rear differential ŠKODA FABIA Rally2 evo sealing points ............................................................ 105

7.8. Operational and maximal transmission values ........................................................................................ 106

7.9. Recommended revisions ................................................................................................................................. 107
8. Suspension ................................................................................................................................................................. 110
8.1. Ride height and wheel alignment ................................................................................................................. 110
8.1.1. Wheel camber adjustment ......................................................................................................................... 110

8.1.2. Bumpsteer compensation – front axle .................................................................................................. 112

8.1.3. Bumpsteer compensation – rear axle..................................................................................................... 113

8.1.4. Ride height adjustment ................................................................................................................................ 114

8.2. Maintenance ......................................................................................................................................................... 119

8.2.1. Torque – Recommended check before rally ....................................................................................... 119

8.2.2. Revisions & lifetime ....................................................................................................................................... 121

8.3. Brakes ..................................................................................................................................................................... 122

8.3.1. Description........................................................................................................................................................ 122

8.3.2. Maintenance ..................................................................................................................................................... 122

8.3.3. Handbrake ......................................................................................................................................................... 125

8.3.4. Revisions ............................................................................................................................................................ 127

8.4. Dampers ................................................................................................................................................................. 129

8.4.1. Description........................................................................................................................................................ 129

8.4.2. Setting ................................................................................................................................................................ 129

8.4.3. Damper overview ........................................................................................................................................... 130

8.4.4. Assembly instructions .................................................................................................................................. 130

8.4.5. Damper lubrication oil change .................................................................................................................. 131

8.4.6. Dampers Storage ........................................................................................................................................... 134

8.4.7. Revisions ............................................................................................................................................................ 134

8.4.8. Springs ................................................................................................................................................................ 135

8.5. Anti-roll Bar .......................................................................................................................................................... 136

8.5.1. Description........................................................................................................................................................ 136

8.5.2. Stiffness ............................................................................................................................................................. 138

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 8.5.3. Anti-roll bar change ....................................................................................................................................... 138

8.6. Steering .................................................................................................................................................................. 140

8.6.1. Steering circuit bleeding ............................................................................................................................. 140

8.6.2. Steering maintenance & new steering racks from ŠKODA Motorsport ................................. 140

8.6.1. Revisions ............................................................................................................................................................ 140

8.6.2. Oil drain .............................................................................................................................................................. 141

8.6.3. Centre pin operation instructions ............................................................................................................ 142

9. Fuel system ................................................................................................................................................................ 143

9.1. Fuel level sensor ................................................................................................................................................ 143
9.2. Recommended Revisions ................................................................................................................................ 144
10. Cockpit ........................................................................................................................................................................ 145
10.1. Cockpit adjustments ......................................................................................................................................... 145
10.1.1. Steering wheel................................................................................................................................................. 145

10.1.2. Pedal box ........................................................................................................................................................... 146

10.1.3. Gearshift ............................................................................................................................................................ 148

10.1.4. Handbrake ......................................................................................................................................................... 149

10.1.5. Seats, seatbelts & brackets ........................................................................................................................ 151

10.1.6. Driver footrest ................................................................................................................................................. 163

10.1.7. Co-driver Footrest ......................................................................................................................................... 164

10.1.8. Automatic fire extinguisher system ‘FEV FX G-TEC 2900R3’ ..................................................... 166

10.1.9. Carjack, setup and use, instructions and servicing ........................................................................... 171

10.2. Rear Wing Adjustment .................................................................................................................................... 173

10.3. Side windows cleaning ..................................................................................................................................... 174
10.4. Body shell as a spare part ................................................................................................................................ 174
10.5. Recommended revisions ................................................................................................................................. 175
11. KIT ................................................................................................................................................................................. 176
11.1. Gravel to Tarmac KIT ........................................................................................................................................ 176
11.2. Tarmac to Gravel KIT ........................................................................................................................................ 179

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 2. Introduction

Dear Customer,

We would like to thank you for purchasing the new ŠKODA FABIA Rally2 evo. We hope you will be
delighted with this car and thoroughly enjoy using it.

In developing this model, we built on the knowledge and experience gained from its forerunner ŠKODA
FABIA Rally2 and incorporated this expertise into this updated version. Used correctly, this car will enable
you to be faster and more competitive than any of its predecessors. Even against much tougher
competition, we firmly believe that you will have the upper hand thanks to the consistent reliability and
superior performance of this racing car designed at the ŠKODA Motorsport workshop.

We have prepared this User Manual to help to ensure that your vehicle is handled and serviced
correctly. In doing so, we have included everything we consider essential for its optimal operation. In
addition to this User Manual, we will provide you with bulletins on technical changes and recommendations
as and when they are released.

In order to consistently improve, it is vital for us to understand your needs, to receive feedback and
comments on our services as well as our technology. We will be very happy to hear from you if – for any
reason – you decide to contact us. A dedicated team of dealers and technicians are ready to address all your
comments and questions.

We wish you a wealth of enjoyment with the new ŠKODA FABIA Rally2 evo.

Ing. Aleš Rada, PhD.

Technical Director of ŠKODA Motorsport

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 3. Maintenance
3.1. List of car fluids

Area Oil / Fluid / Grease Quantity

Approx. 4.8 l (reach the mark

on the dipstick, according to
Engine Castrol Edge 5w30
ref. oil change in the chapter
5.17.3)
Coolant G13
Note: Dilute coolant with water
according to specifications 50:50
Engine 4.5 l
Coolant G12 EVO
Note: Coolant is pre-mix
production, do not further dilute
with water

Gearbox Castrol Syntrax 2.5 l

Differential Castrol Syntrax 1.3 l

Castrol Transmax Dex III

Power steering 0.8 l
Multivehicle

Brakes Castrol SRF Racing Brake Fluid 1.0 l

Drive shaft inner joint MS9U025 165 g

Drive shaft outer joint MS9U024 150 g

Mobil Unirex N3
Wheel bearing 4g
Note: Maintenance free

Clutch release bearing Maintenance free

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 4. Electronics
4.1. Dash display + central panel buttons

4.1.1. Central panel

Blower Fan Speed Switch Map & Ambient Light

Switch

Fire Extinguisher Switch Menu

Main Switch
Ignition Switch

Start Button
Map Switch

Switch Panel

Main Switch Turns the main power ON/OFF in the car’s electrical system.
Ignition Switch Activates ignition, injection and fuel pumps.
Start Button Activates the starter motor.
Map Switch Rotary switch for engine map selection.
Menu Rotary encoder with push button to control the menu.
Blower Fan Speed Switch Rotary switch for blower fan speed selection.
Fire Extinguisher Switch Activates the extinguisher system, switches OFF the engine and
disconnects the battery.
Ambient Light Turns ambient light ON/OFF along with the co-driver’s map light.

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 4.1.2. Switch panel

The switch panel is the main control interface to operate the engine and electrical devices.
It is a membrane keyboard with illuminated buttons and LED indications.
Switch Panel Buttons Function Description

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 4.2. Main Display

The information screen for the crew is used to display sensor and data values, diagnostic information and
the display menu.
The screen brightness can be changed for day and night conditions through the display menu, see section
‘Display Menu’

4.2.1. Display modes

a) Normal Mode
This mode is active after switch on.
b) Service Mode
This mode is activated by pressing and holding (3 sec.) the ‘PAGE’ switch button. The same way to
deactivate.
c) Menu
This page is activated by a short press of the ‘MENU’ rotary encoder on the central panel.

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 Normal mode

To change page, press the ‘PAGE’ switch button on the Switch panel. The pages will be switched
in the sequence 1-2-3-4-1.
Mode Normal 1
Page displays general car parameters and sensor values

Description of 4 LEDs (under engine RPM):

.
ECU ignition switch signal – must be green to allow engine start.
If IGN switch on the central panel is ON, but the IGN LED is still red and the engine
does not start, check the external Emergency switch (below the windscreen on the
right side), for possible problems that could be caused, for example, by water.

Crankshaft/camshaft sensors synchronisation

If the LED is red, at least one of the sensors is faulty (It is possible to start the engine still,
but it may take longer)
Error manager state.
If the LED is red, a strategic sensor is faulty (check MPDU service page 3 – SENSOR
ERROR).

USB disk state

If the LED is red, USB is either not present or faulty.
Other important icons:
Handbrake icon – if handbrake > 5 bar.
Do not drive the car with the handbrake on.
t-exh Green background is lit when exhaust temperature < 550 °C.
Never switch off the engine if the background is not green.
t-water Blue background indicates cold engine, below 50°C.
Let the engine warm up before driving.

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 Mode Normal 2
Displays fuel level + estimated value, brake pressures and steering position.

Mode Normal 3
Displays general car parameters and sensor values.

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 Mode Normal 4
Contains co-driver page with daytime and trip distance measurement.
Average road consumption: ≤ 15 , > 15 ≤ 20 , > 20 l/100km
T-Amb blue background indicates low ambient temperature T-Amb ≤ 1 °C

‘IGN, ERR, SYNC, USB LEDs are the same as in the mode Normal 1.

After Stage page

This page is displayed once the car mode is changed (from Stage to Road)
All primary information about the car’s status after ‘stage’ are shown on this page.

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 Service Mode

To quickly check the basic car data, the ‘service’ mode may be used.
To switch into service mode, press and hold the ‘PAGE’ button on the Switch panel for more than 3 seconds.
To return to normal mode, press and hold the ‘PAGE’ button once again.

Mode Service 1
Displays important sensor values.

Mode Service 2
Displays temperature and pressure sensor and wastegate position values.

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 Mode Service 3 – Engine test

For more information about the engine test, check 5.5.

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 Mode Service 4 – Powerbox diagnostic

Powerbox Output Short Circuit

If the 'Fuse Back' LED on the panel switch flashes red, there is a short circuit in one or more Powerbox
outputs.

For troubleshooting, check the service page ‘Powerbox Diagnostic’ on the Main display.
Either the device is broken or there is a short circuit in the loom.
After the problem is solved, press the button to reset.

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 Powerbox Output Open Circuit
If the 'Fuse Back' LED on the switch panel flashes orange, there is an open circuit in one or more
Powerbox outputs.

For troubleshooting, check the service page ‘Powerbox Diagnostic’ on the Main display.
Either the device or loom is damaged, or the connector is disconnected.
After the problem is solved, press the button to reset.

Mode Service 5 – Power box current

Actual current consumption of each electrical device.

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 Mode Service 6 – Sensor Error
Strategic sensor error management.
@ - shows the current value of the corresponding channel

A description of displayed labels is in the table below with definitions of bit position in WinTAX channel
‘MaskErr’.
For detailed error description and troubleshooting, check section ‘5.15 Errors – Error manager, backup
strategies‘.

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 Label name Description Bit #

PAmbSnsr Ambient pressure sensor failure Bit 0

PMnfldSnsr Manifold pressure sensor failure Bit 1
PThrUsSnsr Pressure before throttle sensor failure Bit 2
NChrgrSnsr Turbo speed sensor failure (long time error) Bit 3
NChrgrSnsr Turbo speed sensor failure (short time error) Bit 4
NChrgrMax Charger speed over-rev detected Bit 5
Wg Wastegate actuator failure Bit 6
EWgPosnSnsr Wastegate position sensor failure (inside the actuator) Bit 7
EWgHB Wastegate actuator short circuit or open circuit Bit 8
EWgHB Wastegate actuator power failure Bit 9
LamSnsr Lambda sensor failure Bit 10
LamRich Lambda too rich Bit 11
LamLean Lambda too lean Bit 12
LamHeater Lambda heater failure (inside the sensor) Bit 13
TExhSnsr Exhaust temperature sensor failure Bit 14
GearSnsr Barrel position sensor failure Bit 15
GearLvrSnsr Shifter sensor failure Bit 16
GearLvrDrift Shifter sensor significant drift detected Bit 17
AcerPedl Pedal position sensor failure Bit 18
AccSnr1 Pedal position sensor track failure – track 1 Bit 19
AccSnr2 Pedal position sensor track failure – track 2 Bit 20
ThrActr Throttle body actuator failure Bit 21
PRailSnsr Rail pressure sensor failure Bit 22
KnkSnsr Knock sensor failure Bit 23
CrankSnsr Crank sensor failure Bit 24
CAMSnsr Cam sensor failure Bit 25
TDiffSnsr Rear differential temperature sensor failure Bit 26
OilTSnsrPlaus Oil temperature sensor failure or plausibility error Bit 27
TOilGbxSnsr Gearbox temperature sensor failure Bit 28
EngTSnsrPlaus Water temperature sensor failure or plausibility error Bit 29
VVehSnsr Car speed sensor failure Bit 30
AcerBrkPlaus Brake pressure and accelerator position sensor plausibility Bit 31

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 Alarm Page

Appears on each page on the bottom - in case of some alarm was triggered.
@ - shows the current value of the corresponding channel
If there are several alarms, they will appear on- by-one in a loop

Should ‘ALARM’ appear, the main display will automatically show it.
The source of the ‘ALARM’ will be highlighted by a red background.

The driver will simultaneously be informed about the ‘ALARM’ on the driver display

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 4.2.2. Main Display Menu

A short press of the ‘MENU’ rotary encoder on the central panel will switch it to the Main Display Menu.

Central panel contains rotary

encoder for controlling the main
display menu.

CCW rotation DOWN / -

CW rotation UP / +
Short press – OK / Menu
Long press (> 0.7 sec) - ESC

You can also see Fuel type at the bottom centre of this screen, which displays the name of the fuel map
(‘AVL’ map) currently loaded in your ‘ECU’.

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 The display menu contains these main chapters:
1. Boost Level Menu
2. Trip master
3. Fuel Menu
4. Display Brightness
5. Calibration
6. Device Test
7. Display page

1. Boost Level Menu

Boost level menu allows the crew to:
- Choose the boost level between 5 positions (5 being the highest). In the case of pop-off opening
problems or challenging road conditions, you may wish to reduce the boost level.

2. Trip master
Menu resets both trip meters – Trip_Distance_1 and Trip_Distance_2.

3. Fuel Menu
Fuel menu allows the crew to:
- Change the Estimated Fuel Consumption (FuelEst) by adding or removing a quantity of fuel
- Switch on the fuel pumps manually, e.g. if a fuel sample is requested by the ‘FIA’

4. Display brightness
Enables the brightness of the main and driver displays to be changed from ‘0’ - minimum to
‘7’ - maximum, separately for day and night, based on Side Lights command.

5. Calibration
Enables ‘zero’ calibration of sensors:

A. Steering sensor
Adjustments of the steering sensor can be corrected through the Main display menu. ECU will
store current position as “zero”. Sensor itself has a wide range ±780° so there is no special
calibration required like in previous Fabia Rally2 model.
You can also set the new zero in Sysma software:

B. Brake pressure
Front and Rear brake pressure sensors can be adjusted to zero, in the case of a small offset.

C. Handbrake pressure
Front and Rear brake pressure sensors can be adjusted to zero, in the case of a small offset.

D. Barrel sensor
For fine-tuning, the sensor output can be adjusted in the range of +-0.050 V. At least rough
mechanical adjustment is required.

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 Barrel sensor adjustment procedure:
1. Make sure that neutral is engaged in the gearbox.
2. Reset the previous offset by confirming the ‘RESET OFFSET’ in the barrel calibration menu.
3. Go to service page 1, check the BARREL value.
4. Rotate the sensor until the value on the display is in the range 0.950 – 1.050 V. Use centring
tool 6VT01248 as in the picture if needed.
5. Tighten the sensor screws.
6. Go to the barrel calibration menu, confirm ‘SET NEUTRAL’.
7. Check the barrel value again, it should be 1.000 V.

6. Device test
This section enables the testing of the Cooler fan, Rear differential fan and Water pump manually.

7. Display page
Option to select the desired ‘ROAD’ and ‘STAGE’ pages on the driver’s display.

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 Full Structure of the Display Menu

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 4.3. Driver Display

The Driver display shows all essential information to the driver during the race.
The display brightness and layout can be changed through the Display menu, see section ‘Main display
Menu’, independently for day and night conditions.

Road Mode Page1

Driver can see basic information and actual average fuel consumption.
This value is only informative in nature and it could be helpful for the driver to improve their road
section consumption. Do not use this value for fuel calculation and refuelling!
Reset of the trip on driver display is activated by launch start button

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 Road Mode Page2
On the second page is ‘ROAD’ mode ‘Brake Bedding’ screen
When the desired pressure is reached, the background of value Front Brake is green

‘STAGE’ mode Page1

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 ‘STAGE’ mode Page1 ‘UP SHIFT’

‘STAGE’ mode Page2

On the second page is added trip in meter. Trip is reset at each launch start button push.

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 ‘STAGE’ mode Page2 ‘UP SHIFT’

Display Digit

When in ‘ROAD’ mode, the gear is red

When in ‘STAGE’ mode, the gear is green

When upshift request appears in ‘STAGE’, the gear changes from green to red together with upshift
indications.

When in ‘LAUNCH START’ mode, the gear flashes.

Shows ‘E’ when the gearbox barrel sensor is disconnected or broken.

Shows ‘F’ when signal is between the correct gears, sensor is loose or not properly adjusted.

Shows ‘H’ or ‘–’ when ‘CAN’ communication is faulty.

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 ‘STAGE’ mode Page3

When the desired pressure is reached, the background of value Front Brake is green.

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 4.4. Steering Wheel Buttons – Mechanical Variant

High Beam or Main Beam

Washer
To switch high beam and extra lights ‘ON / OFF’ (if activated
on the Switch Panel). Activates washer and wiper for
windscreen.
Press and hold (> 3 sec.) switches between ‘ROAD’ and
‘STAGE’ mode.

Indicator Wiper
Press to the left will activate left indicator 5x. First press activates intermittent mode.
Press to the right will activate right indicator 5x. Second press activates slow speed.
Press and hold (left or right) ensures it remains Third press activates fast speed.
active (e.g. for standing at traffic lights). To
Fourth press switches wiper off.
deactivate it, push to the same side again.
Press and hold switch off wiper

Start Lim
Activates launch start mode when pressed.
Press and hold (2 sec.) deactivates this mode.
Also resets the trip on driver’s display.

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 4.5. Steering Wheel Buttons – Electronic Variant

High Beam or Main Beam Wiper

To switch high beam and extra First press activates intermittent
lights ‘ON / OFF’ (if activated on the mode.
Switch Panel).
Second press activates slow
Press and hold (> 3 sec.) switches speed.
between ‘ROAD’ and ‘STAGE’ Washer
Third press activates fast speed.
mode.
Fourth press switches wiper off. Activates washer
and wiper for
Press and hold switch off wiper windscreen.

Not used

Start Lim Fast defrost

Activates Activate windshield Trip Reset
launch start heater and internal Reset the trip on
mode when blower fan. driver’s display on
pressed. Work only when STAGE mode page 2
engine is running. or Road Mode Page1
Press and hold
(2 sec.)
deactivates Indicator
this mode.
Press to the left will activate left indicator 5x.
Also resets
Press to the right will activate right indicator 5x.
the trip on
driver’s display Press and hold (left or right) ensures it remains active (e.g. for standing
in STAGE at traffic lights). To deactivate it, push to the same side again.

Installation notes

Connect steering wheel buttons loom into connector A20 SW_BUTT (4 positions DTM connector)
instead of A16 S-LOOM (8 positions DTM connector).

To allow working TRIP RESET button you should have uploaded layout version 21cw01 or higher in your
Driver Display.

When you are using electronic steering wheel buttons for the first time you have to upload configuration
into your ECU. New configuration change buttons setting which may result that some devices may be
activated during the upload. Follow instruction on next page.

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 1. Switch off the Main switch.
2. Disconnect A6 (yellow) connector on power box unit, disconnect wiper motor under the hood.
3. Switch on the Main switch.
4. Connect your laptop with the ECU via diagnostic cable.
5. Open SYSMA software.
6. Copy new configuration *XXcwYY_Electronic_SWButtons_Diff*.CLX file into the correct SYSMA
CLX folder based on your ECU software version, typically: C:\SYSMAPRO\Projects\
MM14000_AVL200_EVO\CLX or C:\SYSMA PRO\Projects\MM14350_AVL250_EVO\CLX or use
you specific directory.
Please use correct version (XXcwYY) of the configuration file:
a. 21cw01 – ECU software MM14000_AVL200
b. 21cw23 – ECU software MM14350_AVL250 – engine spec. 2019
c. 21cw24 – ECU software MM14350_AVL250 – engine spec. 2021
7. Establish communication with the ECU in SYSMA software.
8. Open CLX Management by shortcut shift+F1
9. Use right mouse button on new buttons configuration * XXcwYY_Electronic_SWButtons_Diff*. and
select Write Calibrations.

10. Upload correct acquisition table (TPX) version based on your ECU software specification.
Please use correct version (XXcwYY) of the acquisition table:
a. SKR5_EVO_200_C_21cw01 – ECU software MM14000_AVL200
b. SKR5_EVO_250_C_21cw23 – ECU software MM14350_AVL250 – engine spec. 2019
c. SKR5_EVO_250_C_21cw24 – ECU software MM14350_AVL250 – engine spec. 2021
11. When it is ready, terminate communication in SYSMA.
12. Switch off the Main switch.
13. Connect back A6 (yellow) connector on power box unit. Make sure that the connector is properly
locked. Connect back wiper motor connector.
14. Switch on the Main switch and verify functions of the steering wheel buttons.

Only one configuration of steering wheel buttons can be active in the ECU at the time. If you want to put
back standard mechanical steering wheel buttons, please follow again instruction 1. – 12. but use
configuration file (*.CLX) for mechanical steering wheel buttons instead.

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 4.6. Co-driver’s buttons

Reset
Washer
Horn Resets the Trip distance
Activates washer and measured by the tripmaster.
Activates the horn. wiper for windscreen.
Total distance must be
reset in MDPU menu.

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 4.7. Stilo Intercom DG-10

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 4.8. USB logger

‘ECU’ has the option to save logger data on an external USB flash.
ŠKODA uses USB disc 000.900.007.F.
It is highly recommended to use USB provided by SKODA Motorsport. Otherwise SKODA Motorsport
cannot guarantee functioning of the system.

USB disc specification:

 USB 2.0
 8GB capacity
 compact package, not standard
Formatting to be used:
 FAT32
 64 kB/cluster

Note: Engine should not be started soon after Main Switch activation to ensure the correct data is
recorded on the ‘USB’ key – wait until Main display is fully active.
Note 2: For the same purpose, turn off the Main Switch at least 3 seconds after engine off.
Note 3: It is recommended to download all data from the internal logger in the ‘ECU’ after every 8 hours
of recording, to have a backup of all data from the car!

Location of USB disc connector under the dashboard:

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 4.9. Wipers

Warning: Use wipers only when washing the windscreen or it is raining. If wipers are used on
a dry windscreen, they may malfunction due to high current consumption!

4.10. Device supply connectors

There are several connectors that supply energy to the electrical devices in the car.

Name Location Max. Current Connector

A57 - Intercom On tunnel, between seats 2A DTM06-3S
Pin Function
1 +12V Intercom 1
2 +12V Intercom 2
3 GND

Name Location Max. Current Connector

A44 - Spare 1 Under dashboard, right side 7,5 A AMP - 6.4F
Pin Function
1 +12V
2 GND

Name Location Max. Current Connector

A54 - Spare 2 On right side of tunnel, between seats 15 A DT06-2S
Pin Function
1 +12V
2 GND

Name Location Max. Current Connector

A58 – Maplight 1 Under dashboard, right side 1A DTM06-3S
Pin Function
1 +12V Map light1
2 +12V Map light2
3 GND

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 4.11. Recommended revisions

Units

Required Recommended
Part Name Part No Wear limit
check replacement
Engine control unit ‘SRG-341’ evo 6VT 906 030 C 350 km SS 5 000 km SS 5 000 km SS
Power box ‘FOX’ - 442 6VT 906056 A 350 km SS 5 000 km SS 5 000 km SS
Dashboard display CD32 6VT 906 242 B 350 km SS 5 000 km SS 5 000 km SS
Gear display ‘SDU’ 6VT 906 302 B 350 km SS 5 000 km SS 5 000 km SS
Central panel 6VT 971 159 E 350 km SS 2 000 km SS 5 000 km SS
Switch panel ‘GEMS’ 6VT 907 043 D 350 km SS 5 000 km SS 5 000 km SS
Intercom Stilo DG-10 6VT 907 060 350 km SS 2 000 km SS 2 000 km SS
Micro ‘ADR’ - unit 6VT 907 166 350 km SS 5 000 km SS 5 000 km SS

Warning: If you will send units for software/configuration update or repair to ŠKODA
Motorsport, seals must not be damaged!

Looms

Required Recommended
Part Name Part No Wear limit
check replacement
Main loom 6VT 971 131 K 350 km SS 5 000 km SS 5 000 km SS
Power loom 6VT 971 346 D 350 km SS 5 000 km SS 5 000 km SS
Alternator cable 6VT 9712 223 B 350 km SS 1 000 km SS 1 000 km SS
Engine ground cable 6VT 955 183 350 km SS 1 000 km SS 1 000 km SS
Front loom left 6VT 971 017 E 350 km SS 5 000 km SS 5 000 km SS
Front loom right 6VT 971 018 D 350 km SS 5 000 km SS 5 000 km SS
Rear loom 6VT 971 196 A 350 km SS 5 000 km SS 5 000 km SS
5 door loom
th
6VT 971 147 A 350 km SS 5 000 km SS 5 000 km SS
Steering wheel switches loom 6VT 971 477 C 350 km SS 2 000 km SS 2 000 km SS
Gearbox loom 6VT 055 307 B 350 km SS 3 000 km SS 3 000 km SS
Co – driver footrest loom 6VT 971 367 A 350 km SS 5 000 km SS 5 000 km SS
Indicator loom - door 5JT 055 348 350 km SS 5 000 km SS 5 000 km SS
Mirror loom 5JT 941 181 350 km SS 5 000 km SS 5 000 km SS
Micro ADR - loom 6VT 900 327 350 km SS 5 000 km SS 5 000 km SS

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 Sensors

Required Recommended
Part Name Part No Wear limit
check replacement
Car speed sensor 6VT 905 215 A 350 km SS 1 000 km SS 2 000 km SS
Gearbox barrel position sensor 6VT 906 433 C 350 km SS 3 000 km SS 4 000 km SS
Gear shift sensor 6VT 907 388 A 350 km SS 2 000 km SS 3 000 km SS
Steering wheel angle sensor 6VT 919 681 350 km SS 2 500 km SS 4 000 km SS
Brake pressure sensor 06J 906 051 C 350 km SS 5 000 km SS 5 000 km SS
Accelerator pedal position sensor 6VT 907 475 A 350 km SS 2 000 km SS 3 000 km SS
Gearbox oil temperature sensor 6VT 906 088 350 km SS 2 000 km SS 2 000 km SS
Differential oil temperature sensor 6VT 906 088 350 km SS 1 000 km SS 2 000 km SS

Devices

Required Recommended
Part Name Part No Wear limit
check replacement
Alternator Denso 6VT 903 026 350 km SS 800 km SS 1500 km SS
Starter 6VT 911 023 350 km SS 2 000 km SS 2 000 km SS
Wiper motor 6VT 955 023 350 km SS 5 000 km SS 5 000 km SS
Wiper arm L 6V1 955 409 A 350 km SS 2 000 km SS 2 000 km SS
Wiper arm R 6V1 955 410 A 350 km SS 2 000 km SS 2 000 km SS
Wiper blade L + R 6V1 998 001 350 km SS 800 km SS 1500 km SS
Battery Red Top 000 492 400 350 km SS 2 000 km SS 2 000 km SS
Battery 9V 000 900 022 350 km SS 350 km SS 350 km SS
Emergency switch 6VT 911 011 A 350 km SS 2 000 km SS 2 000 km SS
Master relay SSR - 300 6VT 911 262 350 km SS 5 000 km SS 5 000 km SS
Horn 5JF 951 101 A 350 km SS 2 000 km SS 5 000 km SS
Fire extinguisher unit 6VT 911 265 B 350 km SS 2 000 km SS 2 000 km SS
Rear differential fan 6VT 959175 A 350 km SS 2 000 km SS 2 000 km SS
Blower fan 6VT 819 015 350 km SS 1500 km SS 2 000 km SS
LED Map light 6VT 947 109 B 350 km SS 5 000 km SS 5 000 km SS
Head light left 6VT 941 015 D 350 km SS 5 000 km SS 5 000 km SS
Head light right 6VT 941 016 D 350 km SS 5 000 km SS 5 000 km SS
Blower fan regulator - unit 6VT 819 022 350 km SS 2 000 km SS 4 000 km SS
Blower fan regulator - switch 6VT 819 024 350 km SS 2 000 km SS 2 000 km SS
Rear light left 6V6 945 095 350 km SS 5 000 km SS 5 000 km SS
Rear light right 6V6 945 096 350 km SS 5 000 km SS 5 000 km SS
Rear number plate light - LED 5NA 943 021 350 km SS 5 000 km SS 5 000 km SS
Additional brake light 3CN 945 087 350 km SS 5 000 km SS 5 000 km SS

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 4.12. Electronic device update

In case there is a software release for any electronic device used in Fabia Rally2 evo car, you will be
informed by technical bulletin.

It is necessary to send some devices back to SKODA Motorsport for an update, where technical engineers
have license for the devices update.

Devices which you have to send to SKODA Motorsport for update:

Power Box FOX - 6VT906056A

Engine Control Unit - 6VT906030C 1GU (or 6VT906030C 128)

Main Display - 6VT906167C – basic specification display (one page only)

Driver Display - 6VT906100B – basic specification display (one page only)

Note: SKODA Motorsport will not update any device with damaged or removed security seals.

Devices which you are able to update yourself:

Main display - 6VT906167B – full specification display

Driver display - 6VT906100A – full specification display

You can update your displays by following steps in document “Main display layout update manual.” In case
you did not receive this document, please contact SKODA Motorsport customer support.

4.13. ADR (Accident Data Recorder)

ADR is FIA homologated device. Must be placed in all SKODA FABIA Rally2 evo cars. In the event
of an accident the data of the ADR unit may be taken only by an authorised FIA representative. Position and
orientation of the device must retain regarding to homologation and it is prohibited to change it.

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 4.13.1. Variant 1 - ADR

SKODA FABIA Rally2 evo ADR unit

LED status explanation table

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 4.13.2. Variant 2 – ADR4

SKODA FABIA Rally2 evo ADR4 unit

LED status explanation table

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 5. Engine
5.1. Operational and maximum engine values (pressure, temperature…)

Please find below the normal operating range of crucial engine values and signals.

Normal Operational Range

Variable Signal Name Extreme Value
[Target Value]

Electric System ~13.8 V @ 25A (engine on)

VBatt ~13.5 V @ 50A (engine on) -
voltage ~12.2 V @ 0A (engine off)
[approx. 4.8 L] – reach the
Oil level mark on the dipstick, -
-
according to ref. oil change
in the chapter 5.17.3
Oil consumption 0.5 l/100 km
- < 0.4 l/100 km

Engine water
70 - 110 °C 125 °C
temperature
[95 °C]
tWater
Temperatures Engine oil temperature 90 - 135 °C
150 °C
tOil [125 °C]
Exhaust temperature 930 °C for shorter than
T4 700 - 900 °C 5 sec
tExhaust
Water pressure 1.5 bar (R)
< 1.2 bar ± 0.15 (R)
pWater
Pressure < 1.5 bar (R) @
(R = relative) 3 500 RPM for longer
Oil pressure
(A = absolute) 3.0 - 5.5 bar (R) than 2 seconds when
pOil
engine in load
7 700 RPM - above this
Engine RPM RPM, the overrev sum is
< 7 500 RPM (FIA) calculated to track the
NEng
RPM engine lifetime

Turbocharger RPM 125k – 170k RPM

190 000 RPM
NChrgr1 [125 000 - 170 000 RPM]
Stage: 40 - 70 l/100 km
Road: 15 - 25 l/100 km
Fuel consumption - Dependent on the track -
type and driving style.

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 5.2. Summary of ‘ECU’ software & dataset available

Below is a summary of ‘ECU’ software versions and datasets available depending on your engine
specification.
Recommended datasets (depending on your engine specification) are in grey. Those datasets are the only
ones supported by SKODA Motorsport.
Latest
Engine ‘ECU’ Software Name in available
Software release
Specification version homologation form dataset on
09/05/22
Spec 2019 AVL200 SRG_SKODA_14.0.0.0 MM14000_AVL200 19CW29
Spec 2019 AVL200 SRG_SKODA_14.0.0.0 MM14000_AVL200 19CW44
Spec 2019 AVL200 SRG_SKODA_14.0.0.0 MM14000_AVL200 20CW35
Spec 2019 AVL200 SRG_SKODA_14.0.0.0 MM14000_AVL200 20CW38
Spec 2021 AVL200 SRG_SKODA_14.0.0.0 MM14000_AVL200 21CW01
Spec 2019 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 21CW23
Spec 2021 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 21CW24
Spec 2019 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 21CW33
Spec 2021 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 21CW34
Spec 2019 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 22CW01
Spec 2021 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 22CW02
Spec 2019 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 22CW16
Spec 2021 AVL250 SRG_SKODA_14.3.5.0 MM14350_AVL250 22CW17

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 5.3. Engine fuel mapping

ŠKODA provides fuel mappings for the following fuels:

SKODA FABIA Rally2 evo Engine specification

Spec 2019 Spec 2021
0 OMV Maxx Motion 100 X X
1 Panta Max (102) X
2 Panta MAX WRC X
3 ELF Turbo Ref X X
4 ETS TBX6 R5 X X
5 Carless Hiperflo Turbo Ultimate Dev 2 X X
6 VP R5 X
7 Verva 100 X X
8 MOL Hi5 X X
9 Total Excellium Rally X X
10 P1 XR5 X X
11 RR2 R TF-R5 X X
12 Warter Racing 102 X
13 Panta HP2 X X
14 VP R5.1 X X
15 Gulf Rally X X
16 Panta MAX X
17 P1 WRC X X
18 ETS TBX7 X
19 P1 XR5 Evo2 X

When using P1 WRC fuel, please carefully follow all the recommendations from ŠKODA Motorsport
Technical bulletin 2022-00240 and following updates.
For Total Excellium Rally fuel, customers should take care to use only batch PCF030317G and newer (usage
of Total Excellium Rally fuel from a batch older than PCF030317G can lead to engine damages).
For ETS TBX6 R5 fuel, customers should take care to use only fuel version Spec 1 (batches BI-17-
MM/XXXX, BI-18-MM/XXXX & BI-20-MM/XXXX). Usage of ETS TBX6 R5 fuel version Spec 2 (batch BI-19-
MM/XXXX) can lead to engine damages.
Each fuel must only be used with the corresponding mapping, otherwise the engine can be destroyed!
ŠKODA Motorsport accepts no responsibility if customer uses a fuel that is contrary to the desired
specification of the ‘FIA’ or ‘ASN’ in the country the competition is taking place.
Be aware that it can take up to 24 hours to unlock the fuel mapping for you. Please contact us in good time
beforehand.

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 5.4. Engine start/stop

5.4.1. Engine start

When starting the engine, follow the instructions bellow.

1) Switch Main Switch ‘ON’. Ignition Switch ‘OFF’

Main Switch
Ignition Switch

Start Button

2) Shift into neutral

3) Do not step on the clutch or accelerator
4) Press and hold (not more than 10 sec) the Start button to crank the engine. Repeat until P Oil >
1 bar (check the Main display)

5) Once the desired pressure is reached, switch the Ignition Switch ‘ON’ and start the engine. Do not
press clutch or accelerator during or after the start.

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 5.4.2. Engine stop

When switching off the engine, it is recommended to switch to the ‘ROAD’ mode and wait until Text
temperature drops under 550°C.

5.5. Engine power test

The engine test page is used to check if the engine is delivering the expected power. For this test, it is
necessary to:
- switch to ‘STAGE mode’ – test is not dependent on used MAP (map 1 – 5 can be used)
- accelerate in a straight line at full acceleration in 4th or 5th gear
- reach an engine speed higher than 5500 rpm – the indicator for actual engine speed will be lit with
the green background colour

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 Check the following parameters while driving:
a) Pedal – must have green background = fully pressed
b) Throttle – must have green background = fully opened
c) Turbo – must have green background = value is higher than 135 000 RPM
d) P22 and P22TGT bar graph showing approximately the same values or P22 is slightly higher than
P22TGT
e) EWgPosn and EWgPosnTGT bar graphs showing approximately the same value

If everything above is OK, the engine power is correct. Otherwise, it will be necessary to check for possible
damage that could decrease the engine power.

Engine power test problem list

a) Pedal not reaching 100 %
1) Check if something is stuck under the pedal
2) Calibrate pedal and throttle (see chapter Calibration Pedal x Throttle)
b) Throttle not reaching 100%
1) Is the ‘ERR’ dot red? Press ‘RESET ERROR’ button on switch panel and, when green, test
again
2) Calibrate pedal and throttle (see chapter Calibration Pedal x Throttle)
c) Turbo speed does not show green background
1) Is the ‘ERR’ dot red? Press ‘RESET ERROR’ button and, when green, test again
2) Continue to next point
d) P22 is lower than ‘P22TGT’
1) Is the ‘ERR’ dot red? Press ‘RESET ERROR’ button and when the dot is green, test again
2) Check for leak in the system – are all hoses mounted correctly? No hole in the intercooler?
e) EWgPosn is different from EWgPosnTGT
1) Is the ERR dot red? Press RESET ERROR button on switch panel and, when green, test
again
2) Calibrate Wastegate (see chapter ‘Wastegate Calibration’)

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 5.6. FIA limiter

Maximal engine ‘RPM’ is stated in the FIA rules and it is ‘7 500 RPM’. Once this limit is reached, all the
cylinders and ignition will be cut.

5.6.1. Overrev counting

To track the engine lifetime and prevent engine damage due to engine overrevs (time spent above ‘7
700 RPM’) are counted by the channel overrevsum=integ (IFGT(NEng,7700)*(NEng-7700)).
 When the counter reaches 3 000 units for the lifetime of the engine from the last revision, the engine
must be sent for revision.
 If ‘RPM’ 1 time > 8 300, the engine must be sent for revision.
 If ‘RPM’ 3 times > 8 000, the engine must be sent for revision.

5.7. Road x stage mode

The engine is equipped with different mapping for stage operation and road operation. The aim of the stage
operation is to deliver the highest possible engine dynamics and power, whereas in road mode the main
focus is on minimum consumption. The road/stage is toggled by the ‘Stage’ button on the switch panel and
indicated by the green light above the button.

Road mode differences:

1. ‘ALS’ is NOT triggered.
2. Less aggressive pedal mapping to enable easier handling when pulling away.
3. No injection for off-throttle operation to save fuel.
4. Different injection strategy to save fuel.
5. Launch start is not allowed.
6. Lower ‘RPM’ limiter.
7. Lower boost level.

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 5.8. Launch start (‘LS’)

The launch start procedure is intended for a quick standing start at the beginning of a rally stage. The
correct procedure is:

1. Warm the engine and the car up to the operational temperatures.

2. The Launch start ‘RPM’ is displayed on the Main Display.

3. Press the ‘Limiter’ button on the switch panel several times to select the desired starting ‘RPM’. For
good grip select ‘7 400 RPM’ (higher), slippery conditions’ 5 500 RPM’ (lower).

4. Select the desired ‘ALS’ level by choosing the desired position of ‘MAP SW’ on the central panel and
then turn on ‘STAGE’ mode.
5. Rev the engine a few times to increase the exhaust temperature to above 700 °C.
6. Shift into first (or second) gear at least 3 seconds before activating the Launch start.

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 7. Press the ‘Launch start’ button on the steering wheel.

The Driver display digit starts flashing, indicating the launch start procedure.

8. Hold throttle in the desired (pressed) position for at least 3 seconds before the real start to provide
enough time for the turbocharger to reach the optimal ‘RPM’.
9. Use the clutch to start.
10. When the car reaches 10 km/h + 1 second the Launch start function start is automatically deactivated
(FIA rule).

Note: The Launch start will not be engaged if the car speed sensor fails.
Note 2: To abort the Launch start, press and hold the ‘Launch start’ button for 2 seconds.

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 5.9. Turbocharger

5.9.1. Antilag system (‘ALS’)

Because the engine is turbocharged, it is equipped with an antilag function to improve the response of the
turbocharger when going from off the throttle to back on the throttle. Select the level of boost pressure
for the off-throttle operation by selecting the position of the rotary switch (‘MAP SW’) on the switch panel.

The ‘ALS’ is activated in stage mode only. The ‘ALS’ intensity selection is as follows (increasing intensity):

Position 1 – no ‘ALS’
Position 2 – minimal ALS (very slippery conditions)
Position 3
Position 4
Position 5 – maximum ‘ALS’ (perfect grip tarmac)

As a safety function to prevent turbocharger damage when the engine is idling and the car is not moving,
the ‘ALS’ will be deactivated after 10 seconds. The ‘ALS’ is re-activated as soon as the pedal is pressed.

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 5.9.2. Summary of boost level settings depending on engine specification

Below is a summary of the boost level settings (which you can adjust through the Main Display, see below),
depending on your engine specification and ECU software version (only for datasets supported by SKODA
Motorsport).
Boost levels
Spec 2019/ Spec 2021 Boost value
AVL200 / AVL250
5 1500mBars
4 1450mBars
3 1400mBars
2 1350mBars
1 1300mBars
The values are valid if adaptation is reset –see page 72.

5.9.3. Engine boost setup

You can choose a boost level between 5 positions (5 being the highest). In the case of pop-off opening
problems or challenging road conditions, you may wish to reduce the boost level. To do so, please follow
the steps below:

1) Switch Main Switch ‘ON’, Ignition (kill) Switch ‘OFF’.

2) Make a short press on the rotary encoder (‘MENU’) on the central panel to access the main display
menu, and then rotate the encoder to reach the Boost level menu.

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 3) Press the encoder to enter the Boost level menu, and the current boost level is displayed.

4) Rotate the encoder to choose a new boost level.

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 5) Press the encoder to confirm the new boost level, which will be marked by two stars.

6) Press and hold the encoder to return to the Boost level menu page.

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 5.9.4. Maximal turbocharger ‘RPM’

The Maximum allowed ‘RPM’ of the turbocharger is 190 000 RPM. If the threshold is exceeded, we
recommended checking that the Wastegate actuator is still working properly. When this threshold is
exceeded (turbocharger overrev) for any given time, the safety function is triggered to prevent damage to
the turbocharger.

Faults are clearly marked in the Error Manager – see chapter: ’Errors – Error manager, backup strategies‘

5.9.5. Wastegate setting

- (ONLY for software version MM14000_AVL200) -

Correct setting of Wastegate actuator - see picture below.

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 This measurement has to be conducted on a dismounted wastegate actuator.

Wastegate replacement – Steps to follow:

- Disconnect the wastegate loom connector from the engine loom.

- Disassemble the complete wastegate (including the U-shape fork) from the turbocharger.
- Unscrew the U-shape fork at the end of the wastegate rod, and mount this U-shape fork on the
new wastegate.
- Adjust the rod length (by screwing or unscrewing the U-shape fork) according to the drawing
above.
- Once you reach the correct wastegate rod length, tighten the counter nut.
- Re-assemble the complete wastegate on your turbocharger. You don’t have to untighten the U-
shape fork, you can rotate the complete assembly (rod + U-shape fork) to reach the correct angle
allowing you to put the pin and the safety clip between the U-shape fork and the waste gate lever
from the turbocharger.
- Once the wastegate is re-assembled on the turbocharger, connect the wastegate loom connector
to the engine loom.
- Proceed to wastegate calibration according to the procedure described in chapter 5.12. Wastegate
calibration.

- (ONLY for software version MM14350_AVL250 and newer) -

Before the first usage of your Fabia Rally2 evo with software MM14350_AVL250 or newer, it is mandatory
to proceed to the adjustment of the EWG rod length and to a new EWG calibration.

Please carefully follow all the steps detailed in the dedicated manual “Fabia Rally2 evo - EWG calibration
procedure - Software MM14350_AVL250_v2”.

In case of questions, please contact our customer support.

Wastegate replacement – Steps to follow:

- Follow all the steps detailed in the dedicated manual “Fabia Rally2 evo - EWG calibration procedure
- Software MM14350_AVL250_v2”.

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 5.9.6. Turbo speed sensor setting (air gap)

Make sure that the air gap of the turbo speed sensor is within 0.9mm ±0,1 mm (try to set the air gap as
small as possible within this range).

You can find more information about the different washers available (to adjust this air gap) in the catalogue.

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 5.10. Calibration pedal x throttle

Calibration must be carried out in the following cases:

- ECU is exchanged or flashed
- pedal is exchanged
- pedal sensor is exchanged
- throttle body is exchanged

It is essential to perform the calibration before every race/event.

Follow the Procedure:

1. Switch ‘OFF’ the ‘MAIN SW’.

2. Fully press the accelerator, switch ‘MAIN SW ON’.

3. The calibration screen will automatically appear on the main display.
4. Follow the instructions on the main display, and when releasing the accelerator, automatic calibration
will start.
5. During the calibration process the Throttle value goes to 0% -> 100% and then it settles at around 25%
(idle value, can vary depending on the conditions).

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 5.11. Calibration pedal x throttle troubleshooting

A) Wrong positioning of pedal sensor

1) Go to service mode on main display - page 1 (see chapter Display modes)

2) Target is to reach value 3.700 V (+/- 120 mV) on channel Pedal1 and 1.000 V (+/- 120 mV) on
channel Pedal2.

o Make sure magnet inside of pedal assembly is with black part pointing up. Magnet should
be in the centre and aligned with side of the pedal assembly as much as possible.
o Put the sensor on place on pedal box and push the sensor against the aluminium edge on
pedal assembly, cable must point to the floor. Rotate the sensor clockwise until you touch
the aluminium edge with left side of the sensor, then check values on the display (put out
all iron tools >10 cm to not affect magnetic field) and rotate slowly counter-clockwise,
keep pushing the sensor against the edge, until you reach specified values, tight and check
values again, if OK follow calibration procedure in chapter Calibration pedal x throttle.
Standard position of the sensor after correct values are reached is shown in picture below.

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 o If not possible to reach specified values:

 Replace sensor (order number 6VT907475A)

 OK  follow procedure in chapter Calibration pedal x throttle
 NOK  continue with point b.
 Replace magnet in pedal box (order number 000723001)
 OK  follow procedure in chapter Calibration pedal x throttle
 NOK  continue with point c.
 Test different ECU and contact SKODA Customer support

5.12. Wastegate calibration

Follow the procedure:

Wastegate calibration automatically follows the ‘Calibration Pedal x Throttle’ procedure, as mentioned
above.

1. The calibration screen will automatically appear on the main display, where you can check the calibration
progress
2. During the calibration process, the EWgPosn value goes to 0% -> 100% and then it settles around
starting value (can vary depending on the conditions).
3. Otherwise, wastegate calibration proceeds automatically each time the ‘IGN SW’ is switched ON.

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 5.13. Shiftlights

Please find below recommendations from SKODA Motorsport regarding shiftlights for ŠKODA FABIA
Rally2 evo.

Following values are provided as recommendation only, depending on the engine specification, the surface
and the fuel.
Depending on the road type and driving style, shiftlights can be adjusted by the customer to suit his
requirements (see Sysma manual or Technical information “Shiftlights (single & double)”).

As a reminder, you can find below the shiftlights group the fuel (+ fuel map) you are using is corresponding
to. You can also find this information in the in Technical information “Fuel Maps Available”.

SKODA FABIA Rally2 evo (as of 09/05/22)

Spec Spec Shiftlights
2019 2021 group
0 OMV Maxx Motion 100 X X 3
1 Panta Max (102) X 1
2 Panta MAX WRC X 1
3 ELF Turbo Ref X X 2
4 ETS TBX6 R5 X X 2
5 Carless Hiperflo Turbo Ultimate Dev 2 X X 2
6 VP R5 X 2
7 Verva 100 X X 3
8 MOL Hi5 X X 2
9 Total Excellium Rally X X 1
10 P1 XR5 X X 2
11 RR2 R TF-R5 X X 1
12 Warter Racing 102 X 3
13 Panta HP2 X X 2
14 VP R5.1 X X 2
15 Gulf Rally X X 1
16 Panta MAX X 1
17 P1 WRC X X 1
18 ETS TBX7 X X 2
19 P1 XR5 Evo2 X 2

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 ENGINE SPEC 2019

TYPE 1 GEAR RATIOS

Single shiflights
Surface Fuel 1 to 2
st nd
2nd to 3rd 3rd to 4th 4th to 5th Default
Group 1 5873 5998 6192 6163 6192

Tarmac Group 2 5776 5906 5995 5980 5995

Group 3 6083 6394 6562 6495 6562

Group 1 6244 6206 6283 6186 6283

Gravel Group 2 6143 6111 6083 6002 6143

Group 3 6464 6614 6658 6519 6658

Double shiflights
Surface Fuel 1st to 2nd 2nd to 3rd 3rd to 4th 4th to 5th Default
5807 5903 5978 5740 5978
Group 1
5938 6093 6405 6585 6585

5728 5834 5916 5684 5916

Tarmac Group 2
5824 5978 6073 6275 6275

6005 6082 6153 5942 6153

Group 3
6160 6706 6970 7046 7046

6175 6108 6066 5762 6175

Group 1
6312 6304 6499 6609 6609

6092 6037 6003 5705 6092

Gravel Group 2
6193 6185 6162 6298 6298

6382 6291 6243 5964 6382

Group 3
6545 6934 7071 7072 7072

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 ENGINE SPEC 2019

TYPE 2 GEAR RATIOS

Single shiflights
Surface Fuel 1 to 2
st nd
2nd to 3rd 3rd to 4th 4th to 5th Default
Group 1 5889 6074 6112 6159 6159

Tarmac Group 2 5889 6059 5933 6007 6059

Group 3 6201 6477 6464 6486 6486

Group 1 6250 6280 6201 6181 6280

Gravel Group 2 6249 6265 6019 6029 6265

Group 3 6577 6695 6558 6509 6695

Double shiflights
Surface Fuel 1st to 2nd 2nd to 3rd 3rd to 4th 4th to 5th Default
5818 5979 5770 5707 5979
Group 1
5961 6168 6453 6610 6610

5748 5913 5711 5655 5913

Tarmac Group 2
6028 6205 6154 6358 6358

5998 6150 5955 5904 6150

Group 3
6403 6803 6972 7066 7066

6175 6182 5854 5728 6182

Group 1
6325 6377 6547 6634 6634

6102 6115 5794 5676 6115

Gravel Group 2
6396 6415 6243 6382 6415

6364 6358 6042 5926 6364

Group 3
6790 7031 7072 7092 7092

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 ENGINE SPEC 2021

TYPE 1 GEAR RATIOS

Single shiflights
Surface Fuel 1 to 2
st nd
2nd to 3rd 3rd to 4th 4th to 5th Default
Group 1 6059 6166 6275 6181 6275

Tarmac Group 2 5962 6047 6128 5976 6128

Group 3 6293 6509 6678 6602 6678

Group 1 6439 6378 6367 6203 6439

Gravel Group 2 6337 6256 6218 5999 6337

Group 3 6684 6731 6775 6627 6775

Double shiflights
Surface Fuel 1st to 2nd 2nd to 3rd 3rd to 4th 4th to 5th Default
6036 6117 6184 5955 6184
Group 1
6082 6215 6367 6406 6406

5936 6026 6093 5873 6093

Tarmac Group 2
5989 6069 6163 6080 6163

6217 6283 6325 6059 6325

Group 3
6369 6735 7032 7146 7146

6415 6328 6274 5977 6415

Group 1
6463 6429 6460 6430 6463

6310 6234 6182 5894 6310

Gravel Group 2
6365 6278 6253 6103 6365

6605 6498 6417 6081 6605

Group 3
6764 6964 7133 7172 7172

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 ENGINE SPEC 2021

TYPE 2 GEAR RATIOS

Single shiflights
Surface Fuel 1 to 2
st nd
2nd to 3rd 3rd to 4th 4th to 5th Default
Group 1 6058 6240 6126 6183 6240

Tarmac Group 2 5971 6120 5973 5958 6120

Group 3 6283 6591 6570 6590 6591

Group 1 6427 6451 6215 6206 6451

Gravel Group 2 6335 6327 6060 5980 6335

Group 3 6663 6812 6664 6614 6812

Double shiflights
Surface Fuel 1st to 2nd 2nd to 3rd 3rd to 4th 4th to 5th Default
6038 6188 5982 5925 6188
Group 1
6078 6292 6270 6442 6442

5947 6099 5897 5845 6099

Tarmac Group 2
5994 6141 6050 6072 6141

6196 6343 6093 6023 6343

Group 3
6370 6838 7046 7157 7157

6405 6398 6069 5946 6405

Group 1
6448 6505 6361 6465 6505

6310 6306 5983 5866 6310

Gravel Group 2
6360 6349 6138 6094 6360

6571 6557 6182 6045 6571

Group 3
6754 7067 7147 7183 7183

For further information about shiftlights, we recommend you to check the Technical information
“Shiftlights (single & double)” available in the catalogue.
ŠKODA Motorsport cannot be held responsible for any possible failure that could occur when using these
settings.

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 5.14. Alarms

Serious faults will be announced to the driver by a message (with red background) on the driver display –
see chapter ‘Driver display’ for detailed driver display description.

All alarms will also be shown on the Main display, see ‘Main display’ chapter. For more information on alarms
on both Driver and Main display, see chapter ‘4.2.1.3 Alarm Page‘.

Descriptions of the displayed labels are listed below (5.15 Errors – Error manager, backup strategies), also
with bit position in WinTAX channel ‘MaskErr’.

5.15. Errors – Error manager, backup strategies

The engine management system is equipped with advanced error detection and backup functions to always
ensure the highest possible performance and prevent the engine from being damaged.

Signal MaskErr returns the bit coded information about the detected error. Below is a list explaining the
meaning of each bit and the backup function used should an error be detected.

If an error is identified and resolved, please clear the error by pressing the ‘RESET Error’ button on the
switch panel for 5 sec and reset the car (switch OFF and ON main switch) - see chapter ‘5.13.1 Error Erase‘.

If an error is permanently detected (caused by any sensor fault), it is recommended to disconnect the
malfunctioning sensor until it is possible to replace it with a new one. In this case, the engine management
will be working with the default value, or the missing signal will be calculated automatically.

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 Bit # Description Detail, Backup Function Action to Be Taken

Ambient
Modelled value used to replace the failed Replace the sensor, check the
Bit 0 pressure
sensor. loom.
sensor failure
Manifold
Modelled value used to replace the failed Replace the sensor, check the
Bit 1 pressure
sensor. loom.
sensor failure
Pressure
Modelled value used to replace the failed Replace the sensor, check the
Bit 2 before throttle
sensor. loom.
sensor failure
Turbo speed
sensor failure Modelled value used to replace the failed Replace the sensor, check the
Bit 3
(long time sensor. loom.
error)
Turbo speed
sensor failure Modelled value used to replace the failed Replace the sensor, check the
Bit 4
(short time sensor. loom.
error)

The ECU detected charger speed over Check the functionality of the
the safety threshold defined by the wastegate and the
Charger speed
manufacturer of the turbocharger. If the turbocharger.
over-rev
charger speed over-rev continues for an When the cause is found,
Bit 5 detected
extended period, or comes back several ‘ERASE ERRORS’ ” (see
(above
times, the power of the engine is chapter ‘Error erase‘) and
190 000 RPM)
reduced to prevent turbocharger switch ‘OFF’ and ‘ON’ the
destruction that would be inevitable. main switch.

Wastegate Replace the actuator, check

Bit 6 No ‘WG’ control.
actuator failure the loom and the turbocharger.

Wastegate
position sensor Modelled value used to replace the failed Replace the actuator, check
Bit 7
failure (inside sensor. the loom.
the actuator)

Wastegate
actuator short Replace the actuator, check
Bit 8 No ‘WG’ control.
circuit or open the loom.
circuit

Wastegate
Replace the actuator, check
Bit 9 actuator power No ‘WG’ control.
the loom.
failure
Lambda sensor Replace the sensor, check the
Bit 10 Lambda regulation will be disabled.
failure loom.

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 Check the signal from the
lambda regulation FacLamCtl.
If in partial and full throttle
Lambda too Only warning. The lambda regulation had
Bit 11 operation still constant
rich to continuously enlean.
enleanment (<0.75) check the
injectors, the lambda probe
and the loom.
Check the signal from the
lambda regulation FacLamCtl.
Lambda too Only warning. The lambda regulation had If in partial and full throttle
Bit 12 operation still constant
lean to constantly enrich.
enrichment (>1.25) check the
injectors, the lambda probe
and the loom.
Lambda heater
Replace the sensor, check the
Bit 13 failure (inside Lambda regulation will be disabled.
loom.
the sensor)

Exhaust
Modelled value used to replace the failed Replace the sensor, check the
Bit 14 temperature
sensor. loom.
sensor failure

Barrel position As gear position is unknown, constant Replace the sensor, check the
Bit 15
sensor failure cut time during shifting will be used. loom.

Barrel position sensor value used to

Shifter sensor Replace the sensor, check the
Bit 16 replace the failed sensor. No change in
failure loom.
shifting strategy.

The sensor value drifted significantly, so

Replace the sensor and check
Shifter sensor the validity of the signal is not ensured.
the mounting of the sensor
Bit 17 significant drift Barrel position sensor value used to
(sensor is not preloaded: 2.5 V
detected replace the failed sensor. No change in
at idle position)
shifting strategy.
Pedal position If one track in a position sensor fails, the Replace the sensor, check the
Bit 18
sensor failure other track is used. loom.

Pedal position
Failure of sensor track 1, track 2 will be Replace the sensor, check the
Bit 19 sensor track
used. loom.
failure - track 1
Pedal position
Failure of sensor track 2, track 1 will be Replace the sensor, check the
Bit 20 sensor track
used. loom.
failure - track 2

Throttle body Safety: Engine injection switched off.

Bit 21 Replace the throttle body.
actuator failure The throttle body seems to be damaged.

Rail pressure Open loop regulation (no feedback) for Replace the sensor, check the
Bit 22
sensor failure fuel high pressure will be used. loom.

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 Knock sensor Replace the sensor, check the
Bit 23 Safe ignition map is used.
failure loom.

Bit 24 Crank sensor Only the Cam sensor is used for the
Replace the sensor.
failure engine timing.
Only the Crank sensor is used for the
Bit 25 Cam sensor
engine timing. Longer cranking time Replace the sensor.
failure
might be needed to start the engine.
Rear
Bit 26 differential Default value used instead (rear dif. fan Replace the sensor, check the
temperature will be turned ‘ON’). loom.
sensor failure
Oil
Bit 27 temperature Replace the sensor, check the
Default value used instead.
sensor failure loom.
or plausibility
error
Gearbox
Bit 28 Replace the sensor, check the
temperature Default value used instead.
loom.
sensor failure
Water
temperature Default value used instead (water cooler Replace the sensor, check the
Bit 29
sensor failure fan will be turned ‘ON’). loom.
or plausibility
error
Bit 30 Car speed Default value used. Launch start will not Replace the sensor, check the
sensor failure be allowed. loom.

In normal engine operation, the

error should not occur.
In certain cases, for example,
when bedding the brakes
Safety: Engine injection switched off. (brake and accelerator pressed
Brake pressure
at the same time for a long
and accelerator
Bit 31 The ‘ECU’ detected the brake pedal time), an error could occur.
position sensor
(brake fluid pressure) and accelerator Check the accelerator and
plausibility
were pressed at the same time for an sensor signal. Check the brake
error
extended period. pressure signal.
When the cause is found,
‘ERASE ERRORS’ (see chapter
‘Error erase‘) and switch ‘OFF’
and ‘ON’ the main switch.

Note:
All errors can be found on the Main display on ‘Mode Service 6’.
Whenever possible, check the state of the MaskErr to know the condition of your car control system.
This can also be checked on the Main display. On pages Normal 1 and 4, there must be a green LED above
the ‘ERR’ label.

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 5.15.1. Clear errors

Most of the detected errors can be resolved automatically. This means that the system recognises when
the detected error has been corrected (this function is active when the engine is running). Nevertheless,
some errors need to be cleared so that the system can recognise that the problem has been fixed. To clear
currently displayed errors, press the ‘RESET ERROR’ button on the switch panel for 5s and switch ‘OFF’ and
‘ON’ the main switch.

5.16. Adaptations

The system has the ability to learn certain values such as:
 Continuous enrichment/enleanment
 Maximal intake manifold pressure to prevent pop-off opening
 Knocking limits

5.16.1. Clear adaptations

To clear the learned values, press the ‘RESET Error’ button for min 10 seconds
Note:
It is advised to clear errors and adaptation values before every event.

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 5.17. Water circuit

5.17.1. Water circuit bleeding

The capacity of the cooling circuit is 4.5 L without heater.

It is required to change a coolant liquid for the new one every time when is drained out from the engine.

Skoda motorsport strictly recommend to bleed water system per steps described below.

Detailed steps as follows:

1) Add cooling liquid (G13 + H2O, mixing ratio 50:50 or G12 EVO pre-mix with no further water mixing)
in the expansion tank, until the level is at MAX and remains stable. Do not use pure water.
2) Switch on the water pump for about 2 minutes (through the device test menu, please see chapter
4.2.2.). Trapped air will go out from the engine head.
3) Add missing cooling liquid until the level is at MAX.
4) Close the expansion tank.
5) Start the car and let it warm up. The level in the expansion tank will decrease gradually as the system
bleeds itself.
6) At water ≈ 80-85°C, the thermostat will open, and cooling liquid with air will start to flow through the
thick hose from the radiator to the expansion tank. If the temperature is above 100°C and there is still
no flow through the breather hose, check the water pump function and water level.

5.17.2. Water circuit for versions with or without heater

The car can run with or without a heater. The parts for conversion are supplied with the car.

To connect a heater, drain the circuit and use the supplied tubes to connect the heater to the engine
according to the picture.

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 To remove the heater, drain the circuit and remove the two connecting tubes 6VT 121 155 B and
6VT 121 154 A from the engine bay. Replace them with bypass tube 6VT 121 155 C. The opened dashes
to cockpit heater should be closed by the supplied caps. Fill the water circuit again, regarding the bleeding
see paragraph 5.15.1.

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 5.18. Engine maintenance

5.18.1. Clutch operation – thrust bearing (axial bearing)

As the forces coming from the racing clutch are approx. 2 times higher than in serial production cars, the
lifetime of the axial bearing is limited. When the clutch is pressed, the axial bearing is not sufficiently
lubricated, which leads to wear of the bearing. As a result, the crankshaft clearance increases to the point
where it jams and destroys the engine.

For this reason, do not press and hold the clutch pedal for longer than 20 seconds! Pressing the pedal
for longer period of time increases the risk of damaged axial bearing, which can lead to engine
damage. When operating the clutch pedal:

a) Do not start the car with the clutch down. Make sure the transmission is in neutral.
b) Do not press and hold it longer than 20 seconds.
c) If the clutch needs to be held down longer, after 20 seconds release it and press the clutch pedal down
twice completely. This lubricates the axial bearing
d) You can then press and hold for another 20 seconds.
e) Repeat point (c) for a longer hold.

ŠKODA provides Wintax mathematical channel (ClutchPressTooLong_R5Cust) that calculates how long the
clutch was down. As the clutch pressure/travel sensor is not allowed, this channel only calculates the
approximate time (idle + gear in = pressed clutched). Use this channel to check the approximate time the
clutch has been down.

The channel is only for information purposes.

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 5.18.2. Check of thrust washer status – axial clearance of crankshaft

Before/after every event (rally, test), measure the axial bearing clearance:
1) Remove the wheels, sump guard, cross member and the gearbox. Remove the alternator belt.
2) In the space under the right side rail, install the timing gauge. The gauge has to be firmly attached to a
stable and non-moving part of the engine (best to the engine block). The head of the timing gauge has
to be in contact with the bolt of the alternator pulley and has to be oriented in the crankshaft axis.

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 3) Push the flywheel inside the engine block. In this end position, set the timing gauge value to zero.
4) Push back the flywheel from the engine block. At the opposite end position, read the value of the
timing gauge.

5) If the measured clearance is greater than 0.3 mm, please contact ŠKODA customer service. An engine
in this condition should not be used and can be significantly damaged if not replaced.

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 5.18.3. Oil level check – Standard engine oil filling.
This procedure applies for the oil dipstick 03F 115 611 E

Ref: Description:

1. ‘OIL CHANGE’:
When changing oil, the correct oil level is determined by the mark on the dipstick. The
Oil Change
typical amount of oil, when changing, is approximately 4,8L. Always measure the oil
level with the turned off engine at least 3 minutes after switching it off.
To set the correct oil volume after oil dip stick / oil sump change in the Rally2 evo
engine, the procedure below must be followed exactly:
The procedure determines the correct calibration methodology for the oil dipstick. New
cars are already calibrated. When the original dipstick is damaged or after a change of
oil sump, calibration must be performed.

2. ‘CALIBRATION PROCEDURE’:
 Fill up 4l of flush oil, according to the engine specification.
 Start the engine and wait for the first coolant fan switch on, or minimum
oil temperature of 95 °C and minimum coolant temperature of 100 °C.
 Drain the oil. Open time – minimum 15 min.
 Amount of oil is specified in section 3 of this procedure
 Measure the amount of oil on calibrated weight scale.
 30 min after filling, make a mark on the oil dipstick. The lower edge of
the mark corresponds to the oil level.
 Roll out the car (run the car for a short while)
 After roll-out, park the car in the workshop. Put the car on the assembly
Oil volume stands. The relaxing time of the oil should be 30 minutes.
 Add oil to the previously made mark on the oil dipstick.
settings

3. ‘OIL TOLERANCE’
 4000-4080 g - ‘CASTROL EDGE 5W30’

WHERE TO MARK AND

MEASURE OIL LEVEL

All dipsticks are unique and matched to a specific engine. After marking them it is not
possible to use the same oil dip stick on other engines or on the same engine with a
different oil sump.

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 5.18.4. Oil level check – Standard engine oil filling.
This procedure applies for the oil dipstick 6VT 115 611 E

Ref: Description:

1. ‘OIL CHANGE’:
When changing oil, the correct oil level is determined by the mark on the dipstick. The
Oil Change
correct oil level crosses the mark on the dipstick. Always measure the oil level with the
turned off engine at least 3 minutes after switching it off.
To set the correct oil volume:

2. ‘CALIBRATION PROCEDURE’:

 There is no need to calibrate the dipstick, it is already calibrated.

3. ‘OIL VOLUME’
 The figure below shows the correct amount of oil in engine.*
 The typical amount of oil in the engine is approximately 4.8L.

*The oil quantity marks are oriented obliquely on the oil dipstick because the dipstick is immersed in the oil at
an angle.

Oil volume
settings

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 5.18.5. Flywheel tightening procedure

Ref: Description:

To fit the flywheel properly, the following procedure must be followed exactly:
1) Check the position of the clutch bearing – the bearing must be placed in the
crankshaft properly. The gap between the flywheel and the bearing must be 0.05 – 0.35
mm (checked during assembly – see Picture 1)

Picture 1
Flywheel
2) For each mounting of the flywheel, use ‘NEW ARP’ flywheel bolts – see Picture 2
tightening
procedure

Picture 2 Picture 3
3) Lubricate the bolt under the head with ARP lubricant - ARP Ultra-Torque
4) Don’t clean the thread on the bolt, keep the surface in original condition
5) Tighten all bolts at 30 Nm following the order shown in Picture 3
6) Turn all bolts 90° in the same order (90° must be turned in one stroke).

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 5.18.6. Spark plugs tightening procedure

Ref: Description:

According to the supplier information, the NGK spark plug type R7438-9 should be
tightened to 20 Nm if the cylinder head is aluminium and the diameter is M14. Please
follow the procedure below:

1) Unpack the spark plugs and grease the thread as shown in the picture
with copper paste Cu-7439 plus paste.

Spark
plugs
tightening
procedure

2) Install the spark plug and tighten to 20 Nm.

3) Untighten the spark plug and tighten again to 20 Nm.

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 5.18.7. Change of accessories belt

 Rotate with bolt (1) on the tensioner (2), (blue arrow) into the mounting position.
 Insert stick (3) into the mounting hole.
 First, remove the belt from the tensioner and then from the other pulleys.
 First, put the new belt onto the crankshaft pulley (4), then onto the guide pulley (5) and alternator
pulley (6) and finally onto the tensioner (2).
 Rotate with tensioner (yellow arrow) and remove the stick (3) from the mounting hole.
 Slowly release the tensioner (2) until it is in its original functional position.

Tools needed:
17 mm side wrench

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 5.18.8. Engine start-up after the car rolls over (procedure in the service zone)

The procedure for the service zone describing what to do with the engine when the car rolls over.

1) Visually check the engine bay for leakages of coolant, oil and fuel. Check that no parts are damaged
2) Check the air system – no dirt in front of or behind the airbox, air filter not damaged
3) Take out the spark plugs from the engine
4) Check the top of the pistons through the spark plug holes. If you see a small amount of oil/fuel,
clean the combustion chamber using compressed air
5) Turn on the engine with ignition switch ‘OFF’ (injection ‘OFF’) – Does the engine sound normal?
During several first turns, residual oil can spill out from the combustion chamber.
6) Oil change – check the oil level and if necessary, add oil to reach the mark on the dipstick
7) Insert new spark plugs into the engine
8) Turn ‘ON/OFF’ the ignition switch 3 times – check if fuel pressure is constant(higher than 4 bar)
and make sure there is no fuel leak in the engine bay – check visually
9) Start the engine
10) Check the engine bay visually for possible liquid leakages.
11) Check the data

5.18.9. Driver Safety Function

For safety purposes (stuck accelerator) an accelerator-pedal to brake-pressure overlay check is

continuously performed. If the ‘ECU’ detects that the brake pedal (fluid pressure) and the accelerator pedal
are pressed simultaneously for an extended period, the injection will be cut.

An error should not occur in normal engine operation. In certain non-standard cases, for example, when
bedding the brake pads (brake and accelerator pressed at the same time for a long period), the error can be
cleared - see chapter Error Clearing.

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 5.18.10. Fuel system bleeding after fuel/engine change

1) Turn the Main Switch ‘ON’

2) In the ‘DDU’ menu switch ‘Fuel tank to drain function’ ‘ON’
3) Wait 10 seconds and switch ‘Fuel tank to drain’ function ‘OFF’
4) Switch ‘OFF’ the Main Switch
5) Bleed the fuel system by loosening the fitting connected to the high-pressure pump. Use papers
around the connection to catch leaking fuel. Bleed the fuel only when the system is cold (cold
exhaust, etc.).

6) If air is coming from the hose, repeat the process from step 1
7) Try to start the car with the standard procedure
8) If the engine stalls, repeat process from step 1

5.18.11. Turbocharger speed sensor replacement/turbocharger

replacement

When mounted in its position inside the turbocharger, the turbo speed sensor also secures a plastic ring
located inside the compressor housing in the correct position.

As a result, you should not move the turbocharger when the turbo speed sensor is not mounted in
the correct position because there is the risk that the ring will rotate, which would then make it impossible
to put the turbo speed sensor back in its place inside the compressor housing.

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 5.19. Sealing

5.19.1. Sealing the pop-off valve

 The diameter of all drilled holes is 1.5mm

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 5.19.2. Sealing the restrictor and turbocharger

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 87/181 User Manual, ŠKODA Motorsport 29.7.2022

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 5.19.3. Sealing the engine block

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 5.20. Durability of Parts

ŠKODA Motorsport provides you with recommended check mileage and recommended replacement
mileage for selected engine parts. Mileages are given as information. Depending on conditions during rallies
and events, recommended values can differ. It is responsibility of the customer to carefully check parts and
assemblies and to decide if the replacement of them is necessary.

Engine

Recommended
Part Name Part No Recommended Check
Replacement
Engine without 6VT 100 028 E 3 000 km SS small revision
After every rally
turbocharger 6VT 100 028 F 6 000 km SS big revision
6VT 145 689 B
Turbocharger * After every rally 2 000 km SS
6VT 145 689 E
Exhaust line 6VT 200 217 E After every rally 5 000 km SS
Exhaust middle part
6VT 253 209 E After every rally 2 000 km SS
(silencer)
6VT 129 803 E
Exhaust manifold After every rally 2 000 km SS
6VT 129 803 B
6VT 145 120
Heat isolation After every rally 2 000 km SS
6VT 145 120 A
Turbocharger gasket 6VT 253 039 A After every rally 500 km SS
Overflow pipe 000 103 010 After every rally 500 km SS
Water cooling circuit 6VT 121 089 N After every rally 5 000 km SS
After every rally whole assembly.
6VT 129 607 D Check and eventually repair
Air intake camlocks for proper mating rear
5 000 km SS
6VT 129 607 C
and front part of Air intake
Breathing tank 6VT 103 130 D Drain after every SS 5 000 km SS
Air filter 6VT 129 634 After every rally 500 km SS
Engine oil N 052 195 00 After every rally 500 km SS
Oil filter 06L 115 401 J After every rally 500 km SS
Spark plugs 000 900 064 After every rally 800 km SS
Alternator belt 000 100 100 A After every rally 500 km SS
Exchanger modified 6VT 122 252 A After every rally 2 000 km SS
Engine silent-block
6VT 199 187 After every rally 3 000 km SS
assembly
Belt tensioner 06L 903 133 D After every rally 3 000 km SS
Flywheel 6VT 105 270 E After every rally 6 000 km SS
Regulation valve WG 6VT 145 829 1 000 km SS 2 000 km SS
Turbo speed sensor 6VT 927 321 A 1 000 km SS 2 000 km SS
Turbocharger bracket 6VT 145 493 D 1 000 km SS 3 000 km SS
Throttle body 6VT 133 062 After every rally 1 500 km SS
Engine loom assembly 6VT 971 012 D 1 000 km SS 6 000 km SS

(*) Note: It is important to check the turbocharger gasket (6VT253039A) after every rally. It is important
to change the turbocharger gasket (6VT253039A), the nuts (N91130801) and the bolts (000100066)
when the turbocharger is replaced.

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 Engine compartment
Recommended
Part Name Part No Required Check
Replacement
Ambient air pressure and
000 R50 023 A 3 000 km SS 3 000 km SS
temperature sensor
Lambda sensor 6VT 906 203 B 1 000 km SS 3 000 km SS
Exhaust gas temperature 6VT 907 542 1 000 km SS 3 000 km SS
Cooling fan 6VT 121 301 E 3 000 km SS 6 000 km SS
Fuel low pressure sensor 000 R50 024 3 000 km SS 6 000 km SS
Water pressure sensor 000 R50 024 3 000 km SS 6 000 km SS
Watercooler 6VT 122 209 M After every rally 2 000 km SS
6VT 145 785 G
Intercooler After every rally 2 000 km SS
6VT 145 785 J

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 5.21. Engine revision

5.21.1. General information

This document is subject to updates and/or additions. The provisions in later versions of this manual will be
applicable from the date they enter into force. They will replace the provisions of previous versions from
their implementation date.

Failing to observe the recommendations in this manual may require the car to be immediately returned to
ŠKODA Motorsport for repair and maintenance of the engine. All costs ŠKODA Motorsport incurs carrying
out work on the engine will be covered by the customer.

In addition, failing to observe the recommendations will have the immediate and automatic consequence of
the stated engine performance characteristics no longer being valid or achievable.

The work on any engine damage resulting from the team’s incorrect maintenance including seal failure will
be carried out at ŠKODA Motorsport’s discretion.

ŠKODA is not responsible for exchanging parts resulting from a crash or fire in the engine bay.

Should engine problems arise, ŠKODA Motorsport is open to discussing a commercial gesture,
provided (additional details in the subsequent pages):

 the engine is without damage

 both seals are present on the engine
 full Wintax history of the engine is provided
 no over revs are recorded
 dashboard alarms are strictly respected
 engine transport procedure is respected
 engine maintenance and service intervals are respected

For further information, please do not hesitate to contact our Customer Technical Support. To proceed
with the engine revision or repair, please complete the form you can find in the ‘ŠKODA FABIA Rally2 evo
Catalogue’ under the tab ‘FORMS’ -> ‘Revision Forms’ -> ‘Engine Repair or Revision Order Form’ and send
the form via e-mail to:

Václav Trkola Mgr. David Kučera

[email protected] [email protected]
ŠKODA AUTO a.s. - ŠKODA ŠKODA AUTO a.s. – ŠKODA
MOTORSPORT MOTORSPORT
Plazy 129 Plazy 129
293 01 Mladá Boleslav, 293 01 Mladá Boleslav,
Czech Republic Czech Republic
T +420 326 8 14269 M +420 725 506 079
M +420 604 292 433

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 Service Zip Code
Address Country Contact Person Phone no. Website / Email
partner / Place

Original ŠKODA Motorsport service centre

www.skoda-auto.com
To the attention of: vaclav.trkola@skoda-
ŠKODA 293 01 auto.com
Plazy 129 CZ Václav Trkola or +420 604 292 433
Motorsport Plazy or
David Kučera +420 725 506 079 ext.david.kucera@skoda-
auto.cz

Official ŠKODA Motorsport service partners

+33 (0)6.88.68.50.90
58470 To the attention of: l.combemale@oreca-
ORECA Technopole +33 (0)6.75.00.94.55 magnycours.fr
Magny- FR Loïc Combemale
Magny-Cours du Circuit or or
Cours or Kévin Roy [email protected]
+33 (0)3.86.21.08.00

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 5.21.2. Engine transport to ŠKODA Motorsport

If the customer would like to ship an engine to ŠKODA Motorsport, all the following points must be
observed (see illustrative pictures):

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  Send your engine in the correct Fly box. It is possible to buy these directly from ŠKODA Motorsport
under part number 000 012 003 A in the catalogue.
 Send your engine with its ‘ECU’ (if not possible, for example, when using a spare engine in the
car, ŠKODA Motorsport should be informed in advance).
 Send your engine without any liquids (oil, water, fuel).
 Send a sample of 1 litre of engine oil that was last used in the engine before the inspection. Use a
container that does not contaminate the oil sample with particles.
 Send the engine clean. Otherwise, there is a €500 fee for cleaning.
 Do not send the clutch, air filter, exhaust line, alternator, alternator bracket, steering pump or
steering pump coupling (Oldham joint).
 Leave on your engine the engine loom, coil loom, flywheel, throttle body, all sensors, turbocharger,
wastegate actuator and water pump.
 Put on the engine all caps delivered with the engine and the HP pump bracket closing plate.
 The customer is responsible for both shipments (delivery to ŠKODA Motorsport and collection
after rebuild).
The customer must inform ŠKODA at least 3 weeks before the delivery. Depending on the work capacity
at the workshop, ŠKODA will provide the customer with an estimated delivery date. We advise customers
to inform us as soon as possible so that we can plan the engine rebuild. Engine revisions that are ordered
further in advance will be completed with higher priority.

The engine will be authorised to leave ŠKODA Motorsport once the funds have cleared in ŠKODA’s account.
Please, bear in mind the time needed for the bank transfer.

If a transport company is to pick up the engine, the customer is requested to give the company the final
address and the invoice number or the engine number. The engine will not be handed over if shipping
information is missing.

Deliveries carried out by external companies are the responsibility of the team. If the engine is damaged
upon delivery, the responsibility lies with the transport company – not ŠKODA Motorsport.

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 5.21.3. Engine sealing

The ŠKODA FABIA Rally2 evo engine has two seals to prevent the engine from opening. One is on the timing
case cover; the second one is on the oil sump cover. Removing either of the seals is PROHIBITED. Should
an exceptional and urgent situation arise, ŠKODA Motorsport must be informed as to why the seals were
dismounted.

If the customer experiences an engine problem or failure, ŠKODA Motorsport should be informed and the
engine sent for analysis.

If the engine seals are missing or damaged, any work carried out on the engine will be at the discretion
of ŠKODA Motorsport.

5.21.4. Over rev

To track the engine lifetime and prevent engine damage, overrevs (time spent above 7 700 RPM) are
counted by the Wintax channel overrevsum=integ (IFGT(NEng,7700)*(NEng-7700)).

When the counter reaches 3 000 units for the lifetime of the engine from the last revision, the engine must
be sent for revision.

 If RPM 1 time > 8 300 the engine has to be sent for revision.
 If RPM 3 times > 8 000 the engine has to be sent for revision.
The maximum engine speed considered to be ‘correct’ is 7700 RPM

If those parameters are reached, send the engine to ŠKODA Motorsport for rebuild regardless of the
current engine mileage.

5.21.5. Data acquisition

The team is responsible for downloading and keeping all the data logged in the ‘ECU’ since the last rebuild.
ŠKODA Motorsport reserves the right to demand any logged data in the case of engine failure or
complaints.

Unless the team is able to provide ŠKODA Motorsport with all data history, any work carried out on
the engine will be at the discretion of ŠKODA Motorsport.

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 6. Exhaust system
6.1. Exhaust line maintenance and assembly

Use ‘LOCTITE ANTI-SEIZE 8009’ Graphite lubricant to lubricate both ball joints of front exhaust line and
the sliding connection of the front and middle parts before assembly (see picture below for more details).

During the assembly of the exhaust line, make sure that all components of the front part of the exhaust
line are aligned.

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 7. Transmission
7.1. Type 1 gear ratios

Gear Number of teeth Gear ratio

1 12:43 3.583

2 13:33 2.538

3 15:28 1.867

4 17:24 1.412

5 22:25 1.136

R 12:19:35 2.917

Final ratio 13:55 4.231

Type 1 gear ratios are recommended for tarmac, twisty (slow corners), “up-hill” and high altitude stages
with speeds not above 170 kph. Maximum speed of the car with Type 1 gear ratios is 187 kph.

7.2 Type 2 gear ratios

Gear Number of teeth Gear ratio

1 12:36 3.000

2 15:33 2.200

3 19:31 1.632

4 17:22 1.294

5 19:20 1.053

R 12:19:35 2.917

Final ratio 13:55 4.231

Type 2 gear ratios are recommended for gravel and fast stages (stages without slow corners where is
chance to reach more than 170 kph). Maximum speed of the car is 202 kph. Type 2 ratios are
homologated in 10/04 ER from 1st August 2020. Part numbers for Type 2 ratios are added into the table
with recommended revisions in chapter 7.9.

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 7.3. How to change oil in transmission

7.3.1. Gearbox

1) Unscrew the magnetic plug (1), drain the oil, and clean the magnetic plug.
2) Unscrew the filter plug (2) and replace the oil filter (5JT 301 519).
3) Fill with 2.2 litres of Castrol Syntrax Limited Slip 75W-140 oil (000 013 024) using the filling hole (3).
When changing the cooling system (heat exchanger and hoses), the total amount of oil is 2.5 L.

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 7.3.2. Rear Differential

1) Unscrew the magnetic plug (1), drain the oil, and clean the magnetic plug.
2) Unscrew the filter plug (2) and replace the oil filter (5JT 301 519).
3) Fill with 1.1 L of Castrol Syntrax Limited Slip 75W-140 oil (000 013 024) through the filling hole (3).
When changing the cooling system (heat exchanger and hoses), the total amount of oil is 1.3 L.

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 7.4. Differential setting

Front differential

Ramps ° 48 42 48 42 48 42

Number of friction faces per side - 4 4 6 6 8 8

Rear differential

Ramps ° 60 55 60 55 60 55

Number of friction faces per side - 4 4 6 6 8 8

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 In 10/04 ER from 1st August 2020 new optional ramp 48/70 is homologated (customer needs to order
000301540 and 000301541) for usage in gearbox differential only. This option has main benefit when
braking on slippery conditions (improving stability of the car).

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 7.5. Clutch inspection

Control at each inspection:

 Check clutch basket, hubs, and sinter discs for cracks
 Check spring fingers for wear
 Sinter paddle thickness must be > 4.6mm
 It is recommended to change all plates together and do not combine plates from different used
clutches

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 7.6. Driveshaft inspection

Check the driveshaft after each event/test. It is necessary to dry them after cleaning. Do not spray water
directly into the plunger (2). To increase durability of driveshafts on your car, it is recommended to keep
their orientation on the right-hand side and left-hand side. After servicing the driveshafts, do not mix the
sides!

1) Check the rubber boot for rupture, replace if necessary (6VT 407 377 A - outer,
6VT 407 347 A - inner).
2) Take out the clamps and look at the rubber boot to check the condition of the grease. Replace if
necessary.
3) Handle the driveshaft carefully – avoid pulling out the tripod rollers from the tulip (use groove (1) to pull
the inner joint from the gearbox or rear differential), and do not knock the plunger (2) into the tulip
(inner joint).

Service recommendation:

1) Remove transport lube used during car build before the first start
2) After each ride (especially in wet conditions) disassemble driveshafts from the car, clean, dry up
and lube splines and location surfaces
3) In dusty conditions is recommended to not lube at all the splines and location surfaces but rather
carefully clean them
4) It is recommended to lube splines and location surfaces of driveshaft before long shutdown or
transport

For splines and location surfaces use WEICON Anti-Seize High-Tech or Castrol LMX Li-Komplexfett

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 7.7. Sealing

7.7.1. Gearbox ŠKODA FABIA Rally2 evo sealing points

A) Maincase x Cluster housing – FIA sealing tag with 2 aluminium seals

B) Cluster housing x Cluster plate x Bearing cover - FIA sealing tag with 2 aluminium seals
C) Maincase x RH Output flange – 2 aluminium seals

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 7.7.2. Rear differential ŠKODA FABIA Rally2 evo sealing points

A) Rear diff casing x Rear diff cover – FIA sealing tag with 2 aluminium seals
B) Rear diff casing x Rear drive clutch cover – FIA sealing tag with 2 aluminium seals
C) Rear diff casing x LH Output flange x Oil pump – 2 aluminium seals

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 7.8. Operational and maximal transmission values

Please find below the normal operating range of crucial gearbox and rear differential values and signals.

Normal Operational Range

Variable Signal Name Extreme Value
[Target Value]

2.5 L in total
Gearbox oil level - [2.2 L in gearbox; -
0.3 L in cooling system]

1.3 L in total
Rear differential
- [1.1 L in rear differential; -
oil level
0.2 L in cooling system]

Gearbox oil
90 - 110 °C
temperature 135 °C
[105 °C]
tGearbox
Temperatures
Rear differential oil
110 - 125 °C
temperature MIN. 60 °C / MAX. 135 °C
[120 °C]
tRearDiff

Transmission breathing

It is possible to use a set of breathing into the bottles (like on previous SKODA FABIA Rally2 car) to
prevent oil leakage.

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 7.9. Recommended revisions

If you need to send parts for revision, please fill in the ‘Transmission Revision Form’. You can find this form
in ‘ŠKODA FABIA Rally2 evo Catalogue’ under the tab ‘FORMS’ -> ‘Revision Forms’. Please complete this
form and send it via email to [email protected] and [email protected]. Parts
should only be sent to ŠKODA Motorsport after agreement.

To revise the entire transmission, ŠKODA Motorsport will recommend a list of parts that need to be
replaced for the best performance and durability of the transmission. Only with the customer’s agreement
will the parts be replaced. The tables below summarise the revision intervals for transmission related parts.

Gearbox
Required Recommended
Description Part No Wear Limit
Check Replacement
1 800 km SS /
Mainshaft 13:55 000 418 019 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Final drive wheel - 13:55 000 730 528 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292a layshaft set 12/43-13/33 000 418 014 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292b gear set 3rd 15/28 000 418 013 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292b gear set 4th 17/24 000 418 012 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292b gear set 5th 22/25 000 418 015 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292a layshaft set 12/36-15/33 000 418 027 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292b gear set 3rd 19/31 000 418 028 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292b gear set 4th 17/22 000 418 029 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
1292b gear set 5th 19/20 000 418 030 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Dog ring (5mm - 5 deg) 5JT 311 294 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Clutch shaft 000 301 105 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Pinion diff 000 301 318 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Side gear 000 301 315 350 km SS 1 800 km SS
200 km RS
5 400 km SS /
Crownwheel & pinion set 12:31 000 730 527 350 km SS 1 800 km SS
600 km RS
1 800 km SS /
Reverse mainshaft gear 000 301 111 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Reverse idler gear 000 301 122 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Ap clutch release cp6859-1254 6VT 311 657 350 km SS 1 200 km SS
200 km RS

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 Gearbox
Required Recommended
Description Part No Wear Limit
Check Replacement
1 800 km SS /
Bearings 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Sealings 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Oil filter 5JT 301 519 350 km SS 1 200 km SS
200 km RS
Oil Syntrax Limited Slip 75W-140 000 013 024 350 km SS 350 km SS

Rear Differential
Required Recommended
Description Part No Wear Limit
Control Replacement
5 400 km SS /
Crown wheel & pinion set 12:31 000 301 525 350 km SS 1 800 km SS
600 km RS
1 800 km SS /
Pinion diff 000 301 318 350 km SS 1 200 km SS
200 km RS
1 800 km SS /
Side gear 000 301 315 350 km SS 1 200 km SS
200 km RS
1 800 km SS /
Bearings 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Sealings 350 km SS 1 800 km SS
200 km RS
1 800 km SS /
Oil filter 5JT 301 519 350 km SS 1 200 km SS
200 km RS
Oil Syntrax Limited Slip 75W-140 000 013 024 350 km SS 350 km SS

Clutch
Required Recommended
Description Part No Wear Limit
Control Replacement
Check after 1 800 km SS /
Clutch complete 6VT 141 015 B 1 200 km SS
each race 200 km RS
after every
Bolt 000 019 136
check
Driveshaft
Required Recommended
Description Part No Wear Limit
Check Replacement
1 800 km SS /
Inner joint spring 6VT 407 227 350 km SS 1 800 km SS
200 km RS*
1 800 km SS /
Inner joint 6VT 407 185 B 350 km SS 1 800 km SS
200 km RS**
1 800 km SS /
Outer joint 6VT 407 223 C 350 km SS 1 800 km SS
200 km RS***
* Check length after each action Lmin=110mm
** Preservation splinning Weicon AT44 after each action, check joint grease 000407011 (165g +/-5g)
after each action

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 Propshaft
Required Recommended
Description Part No Wear Limit
Check Replacement
1 800 km SS /
Universal joint 350 km SS 1 800 km SS 200 km RS*

* Check after each action

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 8. Suspension
8.1. Ride height and wheel alignment

8.1.1. Wheel camber adjustment

Description

The ŠKODA FABIA Rally2 evo uses a camber spacer system for precise adjustments to the camber angle.
By changing the spacer type or orientation, it is possible to increase or decrease the camber angle of the
wheel.

Setting

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 Part Number Dot position Camber

6VT 407 070 F -

6VT 407 070 E -
6VT 407 070 D -
6VT 407 070 C -
6VT 407 070 B -
6VT 407 070 A -
6VT 407 070 +/-
6VT 407 070 A +
6VT 407 070 B +
6VT 407 070 C +
6VT 407 070 D +
6VT 407 070 E +
6VT 407 070 F +

List of available Camber Spacers

Part Number Eccentricity Change of camber

6VT 407 070 0.0 mm 0° 00’

6VT 407 070 A 0.3 mm 0° 11’
6VT 407 070 B 0.6 mm 0° 22’
6VT 407 070 C 0.9 mm 0° 33’
6VT 407 070 D 1.2 mm 0° 45’
6VT 407 070 E 1.5 mm 0° 56’
6VT 407 070 F 1.8 mm 1° 07’

Example

If we want to increase the camber (2° 15‘→ 2° 26‘), we have to use camber spacer with a bigger index
towards „-’ and vice versa.

Each time the camber angle is changed, the toe of the wheels must be readjusted to the initial/required
value!

Disclaimer!

When tightening M10 nuts securing the damper adaptor connection, always start with full tightening the
nut over the camber spacer (in the centre).

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 8.1.2. Bumpsteer compensation – front axle

Dependent on camber, different bumpsteer spacers on the upright are recommended for use on tarmac.
The values are identical for both the front and rear axle. On gravel, no such compensation is necessary.

Tarmac Gravel

Std. spacers, camber abs < 1.6° 1.6° < < 2.4° > 2.4° ALL
Spacer - upright on top 4.1 mm (index L) 5.1 mm (index J) 6.1 mm (index K) 5.1 mm (index J)
Spacer - upright on bottom 6.1 mm (index K) 5.1 mm (index J) 4.1 mm (index L) 5.1 mm (index J)
Upgr. spacers, camber abs < 1.6° 1.6° < < 2.4° > 2.4° ALL
Spacer - upright on top 4.1 mm (index M) 5.1 mm (index N) 6.1 mm (index P) 5.1 mm (index N)
Spacer - upright on bottom 6.1 mm (index P) 5.1 mm (index N) 4.1 mm (index M) 5.1 mm (index N)

There is a choice of 2 viable spacer versions. Both have the exact same geometry, upgraded spacers are
made from stronger material, which exhibits reduced chance of problems during exploitation.

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 8.1.3. Bumpsteer compensation – rear axle

Tarmac Gravel

Spacer - crossmember on top 11,5 mm (index E) 13,5 mm (index B)

Spacer - crossmember on bottom 13,5 mm (index B) 11,5 mm (index E)

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 8.1.4. Ride height adjustment

Pay attention when changing the springs for different rates; the ride height may vary slightly. You can set
the car to the required ride height by adjusting the lower spring platform.

See the table below for spring platform heights for various spring rates and ride heights. It is not advised to
use a platform position beyond this range. The spring seat positions defined on the table below are linked
to the old spring platform type for gravel/tarmac. Skoda Motorsport recommends the use of „HAT“ spring
seats as described on the following bulletins: „ZMS 1375“ and „ZMS 1354“.

Spring platform position – Dampers 2019 specification

Ride Height “GRAVEL” Spring Rate [N/mm]

[mm] 15,0* 17,5* 20,0 22,5 25,0 27,5 30,0 32,5 35,0 37,5
N/A
RH +15
max +25 N/A maximum:
238 236 232 232 230 231 227 229
Front 251
reference 0 229 235 212 210 207 207 205 206 203 205
min -5 223 230 207 205 202 202 200 201 198 200
max +25 193 208 191 193 195 199 199 203 202 205
Rear reference 0 167 183 166 169 171 175 175 179 178 182
min -5 N/A 178 N/A 165 166 170 170 175 173 177
Calculated for total weight 1 420 kg
and distribution 56 % to front.

“TARMAC” Spring Rate [N/mm]

Ride Height
[mm] 30,0* 35,0* 40,0* 45,0* 50,0 55,0 60,0

max +20 227 228 226 224 235 234 233

Front reference 0 206 208 206 204 216 214 214

min -15 191 193 191 189 201 199 199

max +20 204 210 209 210 222 222 222

Rear reference +0 184 190 190 190 203 203 203

min -15 169 175 175 176 188 188 189

Calculated for total weight 1 420 kg

and distribution 55 % to front.

* In this spring rate, it is mandatory to use springs which have green colour. Do not use black colour spring
in this spring rate. For more information please check chapter “Springs” 8.4.7

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 Spring platform position – Dampers 2021 specification

Ride Height “GRAVEL” Spring Rate [N/mm]

[mm] 15,0* 17,5* 20,0 22,5 25,0 27,5 30,0 32,5 35,0 37,5
max +25 N/A N/A 244 241 237 236 233 234 230 232
Front reference 0 236 241 218 215 211 211 209 209 206 208
min -5 230 236 213 210 206 206 204 204 201 203
max +25 200 214 196 198 200 203 203 206 205 208
Rear reference 0 174 189 172 174 175 179 178 183 181 184
min -5 169 184 167 169 170 174 174 178 176 180
Calculated for total weight 1 420 kg
and distribution 56 % to front.

“TARMAC” Spring Rate [N/mm]

Ride Height
[mm] 30,0* 35,0* 40,0* 45,0* 50,0 55,0 60,0
N/A N/A N/A
RH +17 RH +19 RH +19
max +20 232 233 230 228 maximum: maximum: maximum:
236 236 235
Front
reference 0 212 213 210 208 219 217 216

min -15 196 197 195 193 204 202 201

max +20 209 214 213 213 225 225 225

Rear reference +0 190 194 194 194 206 206 206

min -15 174 179 179 179 192 191 191

Calculated for total weight 1 420 kg

and distribution 55 % to front.

* In this spring rate, it is mandatory to use springs which have green colour. Do not use black colour spring
in this spring rate. For more information please check chapter “Springs” 8.4.7

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 Measurement

The spring platform height is measured from the bottom of the lower spring nut to the mounting plane
between the strut body and damper reservoir bracket. The ride height measurement points are shown in
the diagram below.

The reference ride height for the FABIA Rally2 evo is different from the SKODA FABIA Rally2. These
differences are listed in the table below:

Ride height
ŠKODA FABIA ŠKODA FABIA
Packet 2021
Rally2 Rally2 evo
Zero
TARMAC GRAVEL TARMAC GRAVEL TARMAC GRAVEL
reference
Front 104 mm 184 mm
99 mm 174 mm 104 mm 184 mm
axle
Rear axle 187 mm 262 mm 134 mm 214 mm 176 mm 256 mm

Front axle

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 Rear axle

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 Rear axle (Packet 2021 cross-member)

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 8.2. Maintenance

8.2.1. Torque – Recommended check before rally

Area Connection Part No. Torque Lubrication

Wishbone to strut ENT 402 001 HK 100 Nm None

000 407 013 100 Nm
Retaining nut M22 None
ENT 402 001 GF 140 Nm
Front tie-rod retaining nut ENT 402 001 GR 60 Nm None
Crossmember

ENT 402 001 HF

Rear tie-rod retaining nuts 60 Nm None
ENT 402 001 GH
A-point ENT 402 001 HJ 120 Nm None
B-point ENT 402 001 HJ 120 Nm None
G-point ENT 402 001 HL 70 Nm None
ENT 402 001 FG
Crossmember to bodyshell 100 Nm None
ENT 402 001 FH
Gearbox reaction ENT 402 001 EH 100 Nm None
Damper adaptor studs to upright 6VT 407 503 C 70 Nm Loctite 270
Strut dowel lower to damper adaptor 6VT 407 059 100 Nm Loctite 270
Camber spacer stud to upright 6VT 407 504 C 70 Nm Loctite 270
Camber spacer dowel 6VT 407 130 E 250 Nm Loctite 270
Grease on seal
Wheel hub nut 6VT 407 631 G 370 Nm
diameter
Retaining screws of hub nut C60 F03 008 2 Nm Loctite 243
Damper adaptor nuts 000 270 311 60 Nm None
000 019 003
Steering adaptor bolts 34 Nm None
Uprights

C60 F08 030

F-point ENT 402 001 HM 70 Nm None
Kingpin adaptor 6VT 407 265 F 500 Nm Loctite 270
Tarmac kingpin adaptor bolts 000 019 124 70 Nm None
Kingpin bolt gravel 6VT 407 369 G 100 Nm None
Kingpin bolt tarmac 6VT 407 171 C 80 Nm None
Wheel nuts 6VT 601 138 120 Nm None
Driveshaft bolt 6VT 401 135 A 80 Nm None
Scraper to upright bolt C60 F08 016 A 20 Nm None
000 019 124 30 Nm
Protective plate to upright bolts None
C60 F05 012 A 10 Nm
Scraper assy bolt 000 407 016 10 Nm None
Front Top-mount uniball 6VT 412 327 C 70 Nm Loctite 270
Rear Top-mount uniball 6VT 412 327 C 70 Nm Loctite 270
Bolts Top-mount to bodyshell 000 129 021 14 Nm Loctite 243
Dampers

Damper adapter strut dowels 6VT 413 143 100 Nm Loctite 270
Damper bolts on adaptor ENT 402 001 GS 70 Nm None
Damper nuts on adaptor 000 270 311 70 Nm None
Damper nut 6VT 411 059 Torque by nutgun None
Damper filter 6VT 411 679 10 Nm None

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 Area Connection Part No. Torque Lubrication

Steering pump to engine 000 103 012 20 Nm Loctite 243

Ball joint to rack 6VT 422 824 G 110 Nm None
C60 F08 025
Rack to crossmember 45 Nm None
Steering

000 019 040

Bearing bracket to bodyshell 000 019 012 25 Nm None
Steering rack adaptor bolt 4D0 419 699 25 Nm None
Steering wheel to adaptor C60 F05 012 8 Nm None
Adaptor to quick release 000 419 003 8 Nm None
Steering column bolts 000 733 077 35 Nm None
Screw of antiroll bar arm 000 411 013 37 Nm None
ARB

Droplink pin 6VT 411 055 D 37 Nm None

ARB arm bolt 6VT 411 352 6 Nm None
000 615 003
Calliper to upright 60 Nm None
000 615 007
Fixing ring to hub C60 F05 010 8 Nm None
Brakes

Brake bell bolt 6VT 615 187 8 - 9 Nm None

Hot: max 14 Nm
Bleeding Screw 6VT 609 289 None
Cold: max 18 Nm
Steel Banjo calliper Bolt 000 564 254 E 24 Nm None

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 8.2.2. Revisions & lifetime

Recommended
Area Part Name Part No Required revision
replacement
Cross-Member Front 6VT 199 287 G Visual check after every rally 3 000 km SS
Cross-Member Rear 6VT 505 317 E Visual check after every rally 3 000 km SS
Cross-Member Rear*** 6VT 505 317 F Visual check after every rally 3 000 km SS
Wishbone Arm 6VT 407 157 D Visual check after every rally 3 000 km SS
Wishbone Strut 6VT 407 431 C Visual check after every rally 3 000 km SS
Tie-Rod Front 6VT 422 808 K Visual check after every rally 3 000 km SS
Tie-Rod Rear 6VT 501 531 C Visual check after every rally 3 000 km SS
Top-mount 6VT 413 351 E Visual check after every rally 3 000 km SS
Suspension

1 000 km – wheel bearing +

Upright left 6VT 407 251 G seal change (6VT 407 087 H 3 000 km SS
+ 000 407 028)
1 000 km – wheel bearing +
Upright right 6VT 407 252 G seal change (6VT 407 087 H 3 000 km SS
+ 000 407 028)
Damper Adapter 6VT 407 247 G Visual check after every rally 3 000 km SS
Steering Adapter 6VT 407 055 F Visual check after every rally 3 000 km SS
Kingpin Adapter Tarmac 6VT 407 203 C Visual check after every rally 3 000 km SS
Anti-Roll Bar Arm Front 6VT 411 317 C Visual check after every rally 3 000 km SS
Anti-Roll Bar Arm Rear 6VT 411 317 D Visual check after every rally 3 000 km SS
6VT 615 125 K 2 000 km or
Brake Calliper Left/Right 1 000 km or temp. > 230 °C
6VT 615 126 K temp. >260 °C
Accelerator axis 6VT 721 145 E 2 000 km SS
Brakes

6VT 611 019

Brake Master Cylinder 1 500 km 4 500 km SS
P/S/AT
Handbrake Master
6VT 611 019 AM 1 500 km 4 500 km SS
Cylinder
Clutch Master Cylinder 6VT 721 263 B 1 500 km 4 500 km SS
6VT 412 031
Damper Tarmac Left F/R 750 km* 3 000 km SS
BK/BM
Dampers

6VT 412 032

Damper Tarmac Right F/R 750 km* 3 000 km SS
BK/BM
Damper Gravel Left F/R 6VT 412 031 BN/BP 500 km* 3 000 km SS
Damper Gravel Right F/R 6VT 412 032 BN/BP 500 km* 3 000 km SS
ZF Steering Pump 6VT 419 861 A 1 500 km SS
Steering

Steering Tank 6VT 422 405 F Visual check after every rally 1 500 km SS
Steering Filter 000 419 030 Clean after 750 km 1 500 km SS
Steering Rack 6VT 422 189 D 2 000 km** 4 000 km SS
* Revision at ŠKODA Motorsport, for more info see damper revision chapter 8.4.7
** Revision at Sportech Engineering, for more info see steering revision chapter 8.6.1
*** New Packet 2021 Cross-Member Rear

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 8.3. Brakes

8.3.1. Description

Brake components used in ŠKODA FABIA Rally2 evo are parts produced by Alcon Company. Therefore,
maintenance of the brake components should be done properly to reach the best possible braking
performance.

8.3.2. Maintenance

Bleeding

Begin the bleeding procedure by opening the cap on the pedal box to bleed the brakes more efficiently.

Then:

 Pour brake fluid to the inside reservoir until it is almost full.

 Pressurise the system by pushing the brake pedal a few times.
 Press the pedal and hold it down. At this moment, the mechanics will open the bleeding screws of
the callipers (you can bleed one side of the car at the same time or each calliper singe.
 When the mechanics inform you that the bleeding screws are closed, you can release the brake.
 Repeat this procedure until the pedal stiffness informs you that the circuit is bled.
 Press the brake pedal fully 4 times.
 The reservoir should then be refilled.
 Repeat the process until the brakes are bled.
 Fill the reservoir with brake fluid to completely fill the 3 compartments inside the reservoir.
 Close the reservoir.

Warm-up procedure

If you purchased bedded brake discs, make sure they are warmed up before use so that the best possible
brake performance is achieved from the beginning of the rally. The best way is to pair the discs and pads
together, prepare them and switch both of them during the rally at the same time.

USE TAPE TO LOCK THE INLETS OF THE BRAKES’ COOLING DUCTS BEFORE WARM UP
PROCEDURE

Warm-up procedure

Starting Ending Time Check list

Pressure Brake
Step speed speed between
[bar] applications
[km/h] [km/h] braking [s] Set 1 Set 2 Set 3 Set 4
1 8 80 30 2 5
2 16 80 30 2 5
3 23 80 30 2 5
Return to service without using the brakes

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 Bedding procedure

If the brake components (either discs or pads) are purchased as unbedded, for the first usage of such a
brake set, the warm-up procedure needs to be extended into bedding procedure. It is necessary to increase
the temperature of the brake disc to above 500 ⁰C in controllable manner. After performing the bedding
procedure the set can be treated like a bedded one and it is only necessary to make sure to warm it up
before next use so that the best possible brake performance is achieved from the beginning of the rally.

 Brakes bedding procedure for pads compounds: Endless N105SP and Endless N35S:

USE TAPE TO LOCK THE INLETS OF THE BRAKES’ COOLING DUCTS BEFORE BEDDING
PROCEDURE

Bedding procedure

Starting Ending Time Check list

Pressure Brake
Step speed speed between
[bar] applications
[km/h] [km/h] braking [s] Set 1 Set 2 Set 3 Set 4
1 8 80 30 2 5
2 16 80 30 2 5
3 23 80 30 2 5
4 8 170 90 1 -
5 8 170 90 1 -
6 23 160 50 1 -
7 31 160 50 1 -
Return to service without using the brakes
Cooling for 30 seconds at 110 km/h
Stop in service using the handbrake only

Maximal temperature of the calliper

Before each rally or test it is advised to use new temperature stickers

(6VT 609 451) to monitor the temperature of brake callipers.

Three temperature ranges predict the future performance of the brake

callipers:
> below 200 ⁰C – ideal working conditions for callipers
> 200 ⁰C – 240 ⁰C – brake drag may increase, and resistance to knock-
back may be reduced
> above 240 ⁰C – seal failure and fluid leakage possible.

After reaching high temperature it is advised to revise the calipers

using the kit 6VT 609 225 (contains seals and grease for one axle)

In case of prolonged working conditions above 240-250 °C calipers

should be sent for an inspection to check the hardness of material as
the mechanical properties of the part could be influenced.

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 Minimal thickness of discs and pads

 The recommended thickness of the brake disc is 31 – 32 mm.

 The minimum thickness of the pads including the backplate is 5 mm.

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 8.3.3. Handbrake

Handbrake reservoir pressure

It is possible that with increased oil temperature, the pressure inside the handbrake reservoir may rise.
You can monitor the value of the hand brake pressure on the ‘MPDU’.

If the pressure is higher than 0.5 bar (even though the handbrake is not activated), you should unscrew the
reservoir at the handbrake master cylinder to release the pressure and screw it back on afterwards.

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 Bleeding

To bleed the rear diff circuit, the car should be on a non-sloping, even surface. To bleed the circuit, remove
the tank cap on the handbrake ‘MC’ and also the travel limiter so you can use the full stroke of the ‘MC’.

Once the circuit is bled, fill the tank to the fluid top-level mark and close the cap. On the ‘MPDU’, confirm
the target hand brake pressure is reached when pulling the HB during the run and that there is no pressure
increase when the HB is not activated.

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 8.3.4. Revisions

Calliper revisions

If the callipers reach high temperatures, or for every 1 000 km covered, revising the callipers is
recommended.

In the revision kit, you can find new seals and special grease for assembling the callipers. The revision
procedure is as follows:

1. Press out the pistons from the calliper, optimally by using compressed air through the calliper
hydraulic inlet port. It is necessary to use tool ‘6VT 012 207 A’ to limit the movement of the piston
to press out all the pistons from the calliper.
2. Remove the seals from the grooves, taking care not to scratch the calliper bore or seal groove itself.
3. Clean the calliper bores and pistons with warm water.
4. Everything needs to be clean and dry before reassembly.
5. Inspect the calliper bores and pistons for scratches. The part should be replaced if it is scratched.

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 6. Apply a small amount of grease (6VT 609 207) to the seal and place it inside the groove in the
calliper.

7. Apply a small amount of grease (6VT 609 207) to the piston surface.
8. Check the piston springs are properly mounted on the pistons (if the contact between the parts is
correct and not at an angle).

9. Press the piston inside the calliper bore, as much in the axis of the bore as possible.
10. The piston should not be pushed with high force. If high force is applied, check everything was done
correctly, including grease applied to the parts as described in previous steps.
11. Bleed the callipers when cold until brake pedal has its normal stiffness.
12. Bleed a second time after rollout where the brake fluid is warmed. Without performing a second
bleeding procedure, the car cannot be guaranteed to be competition ready.

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 8.4. Dampers

8.4.1. Description

 Manufacturer: ZF Race Engineering

 3-way adjustable (bump/rebound independently) with external reservoir.
 Low- and high-speed bump adjustment at remote reservoir.
 Rebound adjustment through piston rod.
 Non-adjustable hydraulic bump stop.
 Non-adjustable hydraulic rebound stop.
 Gas charged monotube design.

The compressed and extended damper lengths of gravel dampers are different from tarmac dampers.

8.4.2. Setting

Compression adjuster

The compression adjuster is located at the bottom of the damper. It allows damping in compression to be
adjusted for low speed and high speed separately.

High-Speed setting

 Click 0 (fully closed adjuster) corresponds

to the stiffest setting
 For Basic setting click 8 corresponds to
the softest setting

Low-Speed setting

 Click 0 (fully closed adjuster) corresponds

to the stiffest setting
 For Basic setting click 8 corresponds to
the softest setting

Notes:

1. For the setting name of each damper, please refer to the sticker on the damper reservoir.
2. Full soft position is defined by number of clicks, not
by mechanical stop of adjuster. It is strongly
recommended to set within the click range as
specified above.

Rebound adjuster

The rebound adjuster is located at the top of the damper.

 Click 0 (fully closed adjuster) corresponds to the

stiffest possible setting
 Click 24 corresponds to the softest possible
setting

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 For both compression and rebound, the desired clicks must be adjusted from the stiffest setting. All knobs
must be fully tightened (clockwise) and set from that position to the target click value.

Rebound adjustment note:

In case the damper rebound adjustment doesn’t work properly (clicks are not felt) and it is not possible to
adjust the rebound, it signals that the oil level in the damper needs to be inspected in one of revision centres.
Such a situation might also happen when the car is on stands while the adjustment feeling works well when
the car is standing on the wheels.

In this situation the damper should be sent to revision centres for check of the sealing and oil level in the
damper.

8.4.3. Damper overview

Position Part name Setting name Click Range

(HS–LS–RB)

Tarmac
FL Damper tarmac left assy P12549B 8 – 8 - 24
FR Damper tarmac right assy P12549B 8 – 8 - 24
RL Damper tarmac left assy P12753B 8 – 8 - 24
Spec 2019

RR Damper tarmac right assy P12753B 8 – 8 - 24

Gravel
FL Damper gravel left assy P12957A 8 – 8 - 24
FR Damper gravel right assy P12957A 8 – 8 - 24
RL Damper gravel left assy P13159A 8 – 8 - 24
RR Damper gravel right assy P13159A 8 – 8 - 24
Tarmac
FL Damper tarmac left assy P14185B 24 – 20 - 24
FR Damper tarmac right assy P14185B 24 – 20 - 24
(with upgrade)

RL Damper tarmac left assy P14387B 24 – 20 - 24

Spec 2021

RR Damper tarmac right assy P14387B 24 – 20 - 24

Gravel
FL Damper gravel left assy P13781A 24 – 20 - 24
FR Damper gravel right assy P13781A 24 – 20 - 24
RL Damper gravel left assy P13883A 24 – 20 - 24
RR Damper gravel right assy P13883A 24 – 20 - 24

8.4.4. Assembly instructions

When installing the rebound adjuster assembly on the damper shaft, the red ring must be close to the upper
stop position. If this procedure is not followed, the rebound adjuster ring will remain stuck when tightened
and damage to the internal damper parts occurs. This will affect the damping characteristics!

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 8.4.5. Damper lubrication oil change

This maintenance procedure is not obligatory, and there is no prescribed interval for change.
Changing the lubrication oil is performed as part of a standard damper revision.

Tools required:
 Nut socket 6 mm ¼’
 Ratchet ¼’
 Circlip pliers for external rings
 Torque wrench ¼’

New parts required:

Item Qty per damper ŠKODA P/N
K-nut M5 10 000 730 053
Strut circlip 1 6VT 411 091 C
Lubrication oil 20 ml 000 744 794

1. Damper strut disassembly

a. Prior to any action, make sure the damper is clean and dry.
b. Remove the cap and click pin from the damper.
c. Clamp the strut gently into a vice in a horizontal position.
d. Use circlip pliers to remove the strut circlip from the top of the damper.
e. Mark the position of the damper against the damper strut.

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 f. Loosen and remove all 10 K-nuts from the bottom of the damper.
g. Take the complete damper off the vice. Keeping it horizontal and holding the damper
reservoir, place it above an oil pan, tilt it vertically and carefully slide the strut together with
the chrome tube few centimetres up from damper.

h. Wait until most of the used lubrication oil flows out. Slide off the strut together with the
chrome tube from the damper completely and extend it fully.

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 2. Maintenance
a. Use a degreaser to clean the damper and the inner side of the strut and chrome tube.
b. Dry and wipe all parts with compressed air and a cloth.

3. Assembly
a. Clamp the strut into the vice horizontally.
b. Put c damper into the strut so that the piston rod goes through the top of the chrome tube
and place a new strut circlip onto the piston rod. Screw the damper cap on.
c. Clamp the assembly upside down into the vice tilted slightly off vertical.
d. Prepare 20 ml of new lubrication oil into a measuring jug.
e. Push the chrome tube a few centimetres into the strut and pour the oil in between the
damper tube and the strut.

f. Push the damper down to the strut with the studs going through the holes in the damper.
Take care positioning the strut and damper; make sure that the marks line up.
g. Screw the K-nuts on the studs with 6Nm of torque.

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 8.4.6. Dampers Storage

When your car is stationary for a longer period of time we highly recommend to dismount the dampers
from the car and store them at your workshop at a dry, temperature constant place. Do not keep the car
on the stands with wheels and dampers hanging for a long period of time as internal parts of dampers can
suffer a damage.

8.4.7. Revisions

It is advised to send the dampers for revision at the ŠKODA Motorsport service centre.

For damper revision or upgrade requests at ŠKODA Motorsport, please, contact Vaclav.Trkola@skoda-
auto.cz or [email protected] for further information. Please, complete the form you can find
in the ‘ŠKODA FABIA Rally2 evo Catalogue’ under the tab ‘FORMS  Damper revision form’

Zip Code / Contact

Service partner Address Country Phone no. Website / Email
Place Person

Original ŠKODA Motorsport service centre

www.skoda-auto.com
vaclav.trkola@skoda-
ŠKODA +420 326 814
Plazy 129 293 01 Plazy CZ Václav Trkola auto.com
Motorsport 269 ext.david.kucera@skoda-
auto.cz

Other service partners

Baumschlager
4563 Manfred +43 www.brr.at
Rallye & Racing Schön 48 AT
Micheldorf Inselsbacher 75823750816 [email protected]
GmbH

47-48 NN12 8GZ www.bgmotorsport.co.uk

BG Motorsport +44
Silverstone Silverstone GB Ben Fricker [email protected]
Ltd. 1327855200 k
Circuit Northants

Dullinger
A-4091 Günther +43-676- www.dullinger.co.at
Fahrwerkstechnik Kasten 3 AT
Vichtenstein Dullinger 6850371 [email protected]
GmbH

KRESTA RACING Družstevní 763 26 Roman +420 774 407 www.krestaracing.com

CZ
s.r.o. 1047 Luhačovice Kresta 044 [email protected]

08186 LLICÀ
NADAL C/. Estornell www.nadaltech.com
D'AMUNT ES Marc Nadal +34 938416098
TECHNOLOGIES, n°6 - baixos [email protected]
BARCELONA

41400 Eero +35 www.printsport.fi

PRINTSPORT OY Antintie 2 FI
Lievestuore Raikkonen 8403011401 [email protected]

Rue de 6220 Fabio www.rtec.ws

R.Tec BE +3271377707
Capilone 1 Heppignies Lazzerni [email protected]

38380 ST
4 ZA Grange Daniel +33047606283 www.rtec.ws
R.Tec LAURENT DU FR
Venin Giround 7 r.tecamadoo.fr
PONT

Sergeja Girtz +37191202508 www.srt.lv

SIA Bairons (STR) 1079 Riga LV
Eisensteina 2 Krutzmanis 88 [email protected]

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 tripleeight.com.au
Triple Eight Race Depot Street Banyo QLD Andrew
AU +61736357008 CustomerSupport@tripleeight
Engineering 40 4014 Simpson .com.au

WEVERS Sport Bovenbergweg 7475ST www.weverssport.com

NL Eric Wevers +31 654968388
B.V. 5 Markelo [email protected]

15811 Northville,
ZF Race +1 (734) 582- www.zf.com
Centennial Michigan, USA Mark Rotary
Engineering NA 1628 [email protected]
Drive 48168

8.4.8. Springs

Description

The SKODA FABIA Rally evo is equipped with helical compression springs with a linear characteristic. The
springs are made of high tensile spring steel; the end coils are ground for better load distribution on the
spring platforms.

The main spring is supported by an auxiliary spring. We strongly recommend always using the main springs
with auxiliary springs to avoid any damage to the damper or spring platforms and to consistently maintain
proper spring function.

Range

Part No. Rate [N/mm] Approx. free [mm] Colour

6VT 411 102 H 15.0 498 Green*

6VT 411 102 J 17.5 460 Green*
6VT 411 101 AF 20.0 459 Black
6VT 411 101 AG 22.5 442 Black
Gravel

6VT 411 101 AH 25.0 428 Black

6VT 411 101 AJ 27.5 416 Black
6VT 411 101 AK 30.0 407 Black
6VT 411 101 AL 32.5 399 Black
6VT 411 101 AM 35.0 392 Black
6VT 411 101 AN 37.5 386 Black
6VT 411 102 30.0 308 Green*
6VT 411 102 A 35.0 292 Green*
6VT 411 102 B 40.0 283 Green*
Tarmac

6VT 411 102 C 45.0 274 Green*

6VT 411 101 S 50.0 257 Black
6VT 411 101 T 55.0 251 Black
6VT 411 101 AA 60.0 247 Black
Helper 6VT 411 104 2.0 190 Black

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 * For the spring rates (Gravel 15.0; 17.5 N/mm and Tarmac 30; 35; 40; 45 N/mm) it
is mandatory to use the green coloured springs. Usage of black springs in this specific
rates can result in damage of spring seats at specific RH and real weight balance of
the car.

Installation

ŠKODA Motorsport strongly recommends taking maximum care when installing springs on the damper
units (especially gravel springs). It may be necessary to use a dedicated spring tool.

8.5. Anti-roll Bar

8.5.1. Description

For the SKODA FABIA Rally2 evo there are 3 diameters of front and 3 diameters of rear anti-roll bars; they
are coloured as follows for easier orientation:

 Green = soft
 Yellow = medium
 Red = hard

Front anti-roll bars are marked with one colour stripe, rear anti-roll bars are marked with two colour stripes.

There are also 3 positions the ‘ARB’ drop link can be attached to the suspension arm to change stiffness.
Their names relate to their position from the centre of the car:

 Inner = soft
 Middle = medium
 Outer = hard

Take care with the drop link position and screw orientation.

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 8.5.2. Stiffness

For stiffness at the wheel for different ‘ARB’ settings, see the graph below.

Stiffness for ARB Setting

Stiffness of ARB at

Front
Rear
wheel

Green InnerGreen MiddleGreen OuterYellow Inner

Yellow Middle
Yellow Outer Red Inner Red Middle Red Outer

8.5.3. Anti-roll bar change

It is possible to change the antiroll bar on both axles without disconnecting the damper or arm from the
upright.

On the front axle, it is necessary to use the detachable bushing:

1) Remove the ‘ARB’ drop link bolt on the wishbone arm on both sides
2) Remove the ‘ARB’ arm on both sides

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 3) Pull the ARB detachable bushing (left side) out of the bodyshell
a) It should be possible to remove the bushing by hand (or a flat screwdriver with little force)
b) When reassembling, apply anti-seize to the outer diameter of the bush

4) Pull out the ‘ARB’ bar close to the damper

5) Realign the ‘ARB’ bar to avoid collision with the damper and pull the ARB bar out

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 8.6. Steering

8.6.1. Steering circuit bleeding

If the steering circuit on the car is opened (when replacing the steering pump, for example), some air will
enter the circuit. To bleed the steering circuit properly, the following steps must be performed:

 Keep engine ‘RPM’ >3300 during the following steps

 Rotate the steering wheel to the lock position.
 Turn the steering wheel from lock to lock position to get the oil into the circuit.
 Force and release the steering wheel in the end position at least 6 times to the right and then 6 times
to the left.
 When the steering feels ok and there are no bubbles in the oil inside the tank, the circuit will have been
bled successfully. Otherwise, keep repeating the previous steps.
 Simply steering from lock to lock position and manipulating the steering wheel very quickly is not
adequate. The steering has to be ‘forced’ once the lock position is reached. Otherwise the air trapped
in the cylinder will not come out!

8.6.2. Steering maintenance & new steering racks from ŠKODA Motorsport

To maintain the performance of the steering system, ŠKODA Motorsport strongly recommends complying
with the following revisions:

The steering filter should be cleaned every 750 km or every time a new pump or rack is fitted to the car. To
clean the filter, remove the filter O-ring first, and then flush it with petrol in the opposite direction. Please
make sure the filter is properly dry before putting it back into the steering oil.

If there are metallic particles in the filter, the filter should be replaced. Check for metallic particles after a
few kilometres (for example, after 50 km).

Ensure that the steering circuit is connected before starting the engine to avoid running the steering pump
without oil flowing. If the steering circuit is disconnected when the engine is running, the steering pump
may fail.

8.6.1. Revisions

Our supplier Sportech Engineering provides steering rack services. Each service includes a series of low and
high-pressure tests to ensure the steering rack performs within tolerance. Steering racks should only be
opened and serviced by Sportech Engineering. Neither ŠKODA Motorsport nor Sportech Engineering take
any responsibility for damage or destruction due to the steering rack being disassembled by a third party.

Our customers should send their steering racks directly to Sportech for servicing. To do so, please complete
the Revision Form and attach it in an email to Nicolò Bertocco. You can find this form in the ‘ŠKODA FABIA
Rally2 evo Catalogue’ under the tab ‘FORMS’ -> ‘Revision Forms’. The form is in MS Word format.

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 Service Contact Person
Address Country Phone no. Fax-no.
partner (email)
Sportech Engineering
s.r.l. +390119673633
Sportech Francesca.cravetto@spo
Via Nino Bixio 83 Italy +390119673633 (FAO Nicolò
Engineering rtech-engineering.com
10042 Nichelino (TO) Bertocco)
Italy

8.6.2. Oil drain

All steering racks (new or revised) have been bench tested by our supplier. The test is done using different
oil.

It is highly recommended to drain the remaining oil from the steering rack before putting it to the car.
To drain the oil from the rack, please follow these steps:
1. Fit the ball joints to the rack and tighten them completely (by hand is sufficient) as in the picture.
If this step is skipped, you will crush the seals and the rack will start to leak.

2. With rack input/output ports pointing to the ground, rotate the pinion fully to one side until you
reach the end stop. Use a 16mm spanner.
3. Drain the oil with the rack in that position.
4. Repeat the procedure for the opposite side.
5. Drain the oil with the rack in that position.
6. Rotate the pinion to bring the rack bar to the middle position.

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 8.6.3. Centre pin operation instructions

There is a special tool (6VT 012 113) for centring the steering rack to the initial position. The procedure is
as below:

1. Check the knob on the centring tool is unscrewed and there are at least 3 threads visible.

2. Turn the steering rack slightly to the left (remember never to rotate the steering rack extensively
without assembled ball-joints).

3. Turn the steering wheel slowly to the right until you feel the click of the centre groove (steering
middle position).
4. Tighten the knob of the centring tool completely.
5. You can proceed with wheel alignment.
6. Remove the centring tool from the steering rack without turning the rack to the right or left, so as
not to damage the pin.

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 9. Fuel system
The SKODA FABIA Rally2 evo is designed to be driven only with fuels according to the FIA regulation
Appendix J Article 252 Art. 9.1 Petrol

9.1. Fuel level sensor

Fuel level sensor – 6VT 201 489 D

 The fuel level sensor installed in the car is calibrated (Empty/Full) for fuel approved by FIA for WRC2 in
the year your car was produced.
 It is necessary to recalibrate the fuel level sensor for the type/brand of fuel used. Each type/brand
(manufacturer) of fuel has a different electrical capacity. The sensor can display the wrong values
without calibration!

Calibration of fuel level sensor from the car/spare fuel level sensor
 Switch off the Main switch (electricity in the car is off).
 Disconnect the cables of the loom from the sensor.
 Remove the sensor from the fuel tank.
 It is necessary to perform the calibration with the Al boot on the sensor.
 Prepare an external power supply (12V).
 Prepare a container with the required fuel.
 Prepare a ‘DTM’ connector 6VT 201 045.
 Red wire - positive (+12V)
 Black wire - negative (-12V)
 White wire - signal (for check output voltage)

‘Full’ state adjustment:

 Install the sensor in the tank and turn the power ‘ON’.
 Fill the tank or any container to the required full level.
 Remove the calibration bung from the sensor and use a suitable tool to press the ‘PCB’ mounted
calibration button. Hold for 5 seconds to set full point — release button.

 Check full point (~4.8V).

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 ‘Empty’ state adjustment:
 Empty the tank, remove the sensor from the tank and shake to remove excess liquid.
 Disconnect the power supply.
 Use a suitable tool to press the ‘PCB’ mounted calibration button. Hold for 5 seconds to set the empty
point — release button.
 Check empty (~0.25V) point and refit the bung.

Calibration check:
 Connect the sensor ‘NEG’ to the power supply negative (‘-’) pole and the sensor ‘POS’ to the power
supply positive (‘+’) pole.
 The sensor ‘SEND’ should have voltage ~ 0.25 V when the sensor is fully out of the fuel.
 The sensor ‘SEND’ should have voltage ~ 4.8 V when the sensor is fully in the fuel (up to the black plastic).
 The sensor ‘SEND’ should have voltage ~ 2.5 V when is the sensor halfway in the fuel.
 If the voltages mentioned above are out of the range, repeat the ‘full’ and ‘empty’ calibration steps.

9.2. Recommended Revisions

FUEL SYSTEM
Recommended
Part Name Part No Required revision
replacement
Fuel tank 6VT 201 055 F after every rally 5 years *
Fuel filter insert 000 210 346 after every rally 500 km SS
O-ring 57x2.5 000 210 342 A after every rally 500 km SS
Fuel pressure regulator 5 bar 5JT 906 051 B after every rally 3 000 km SS
Fuel level sensor 6VT 201 489 D after every rally 3 000 km SS
Low-pressure pump 6VT 201 050 A after every rally 2 000 km SS
Fuel pump (high pressure) 6VT 201 150 after every rally 2 000 km SS
Valve vent FIA 6VT 201 136 after every rally 5 000 km SS
Fuel cell cover 6VT 201 164 B after every rally 3 000 km SS / 1 year
*No bladder can be used more than 5 years after the date of manufacture unless inspected and recertified by the
bladder manufacturer for a period of up to another two years.
However, we recommend inspecting the fuel tank bladder every other year or every 3000 km SS or following
any concerns voiced by the bladder manufacturer.
If the car is standing at your workshop for more than 2 weeks, we highly recommend to drain the racing fuel,
which can be aggressive for the fuel tank bladder and fill it in with usual, non-racing fuel (for example Verva 100).

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 10. Cockpit
10.1. Cockpit adjustments

The car equipment can be repositioned to suit the requirements of the driver and crew.

10.1.1. Steering wheel

It is possible to adjust the steering wheel position in two directions:

 Closer to or further from the driver by using various spacers. The spacers are available from 20mm to
100mm in steps of 10mm, and a 120mm option is also available.

Part Name Part number

Steering wheel adapter 20mm 6VT 419 087 N

Steering wheel adapter 30mm 6VT 419 087 P
Steering wheel adapter 40mm 6VT 419 087 Q
Steering wheel adapter 50mm 6VT 419 087 R
Steering wheel adapter 60mm 6VT 419 087 S
Steering wheel adapter 70mm 6VT 419 087 T
Steering wheel adapter 80mm 6VT 419 087 AA
Steering wheel adapter 90mm 6VT 419 087 AB
Steering wheel adapter 120mm 6VT 419 087 AC
Steering wheel adapter 100mm 6VT 419 087 AN

 Up and down by moving the bearing bracket in the roll cage holder.

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 10.1.2. Pedal box

The pedal box can be adjusted closer to or further from the driver. This can be done by mounting the pedal
box in four different positions in steps of 25mm. When moving the pedal box main bracket, the MC brackets
must also be moved accordingly.

Fine tuning the pedal pad position is possible by moving the pad on the pedal lever in range of 20 mm for
the brake pedal and 25 mm for accelerator and clutch pedal.

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 Note: As during the usage of the car the bodyshell floor is exposed to possible hits (from the
curbs, protruding rocks etc.) it is suggested to regularly inspect the pedal box attachment elements
(highlighted on the picture) to check their condition.

Special attention should be put to the flatness of the bodyshell (highlighted green) surfaces which
master cylinders brackets (highlighted red) are tightened against. Any clearly noticeable curvature or
deflection of those surfaces can cause excessive stress in the brackets during tightening the bolts, which
can lead to a damage of master cylinders brackets.

If noticed the deflection of those elements, it is necessary to grind/flatten the interface

surfaces.

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 10.1.3. Gearshift

The gearshift should be perpendicular to the bodyshell. Looking at this position from the side, it is possible
to move the centre of the gearshift head forward or backward by 40 mm.

The length of the gearshift bar can be adjusted by moving the circlip along the grooves of the adjusting
cylinder and then tightening the retaining nut. Finer tuning is possible by adjusting the rod ends on both
ends of the gearshift bar.

There are also 3 positions for the shift rod available on the shift lever. By changing this position, it is possible
to find the best combination of force required by the driver and distance travelled by the lever.

Shift rod position Shifting force required from driver Lever travel

TOP High Short

MIDDLE Middle Middle
BOTTOM Low Long

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 10.1.4. Handbrake

To adjust the position of the handbrake lever, the length of 278 mm can be modified. Take are to leave a
sufficient thread overlay of the rod end and master cylinder.

There are also 2 positions for the master cylinder available on the handbrake lever. By changing this position,
it is possible to find the best combination of force required by the driver and distance travelled by the lever
in the same fashion as for shifting.

Shift rod position Shifting force required from driver Lever travel

TOP High Short

BOTTOM Low Long

Handbrakes spacers

The handbrake must also be set from a hydraulic point of view. The rear differential can be disconnected
using a hydraulically operated slave cylinder in the rear differential unit. This system can be tuned on the
handbrake tandem master cylinder.

A preloaded spring, located on the brake side, ensures that the pressure on the brake side will not rise until
the rear clutch is disconnected. This spring must be mounted in accordance with the assembly manual to
ensure correct functioning.

There is a stroke limiter that limits the stroke of the rear disconnecting clutch, so that it is not unnecessarily
long. There are 3 options differentiated by the length of the limiter. These are coloured to facilitate
identification. See the table below.

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 Part No. Limiter length Stroke limitation Colour

6VT 711 309 A 18.35 mm 2.5 mm Blue

6VT 711 309 G 18.10 mm 2.75 mm Purple

6VT 711 309 B 17.85 mm 3 mm Green

The longer the spacer used, the shorter the travelling distance on the clutch side and the smaller the
pressure value reached in the line.

The opening pressure is 10 bar. If it is not possible to reach this, use a spacer that can enable a longer stroke.

If the opening pressure does not reach the lower recommended value, we recommend bleeding the system
on the HB diff unit. If the pressure is much higher than the upper recommended value, it is possible to use
a longer spacer to limit the stroke of the rear disconnecting clutch.

We recommend using the purple limiter (6VT 711 309 G), which means 2.75 mm travelling distance on the
clutch side of the master cylinder. This should ensure all rear diff units are correctly disconnected, providing
they are correctly bled.

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 10.1.5. Seats, seatbelts & brackets

Seats and seat brackets

The position of the seats can be adjusted by moving forward, backward, up, down or by reclining. The range
of motion depends on the selected seat bracket.

Seat belts can be adjusted by choosing the proper position of the anchor points. The position to choose
depends on the selected seat bracket.

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 For driver:

Sparco ADV SCX Bracket no. Positions Picture

6VT.881.035.AR Z : 0 to +20mm, X: 0 to -30(60)mm

6VT.881.035.BS Z +0 to +40mm X: 0 to -30(60)mm

6VT.881.035.BL Z +30 to +70mm X: 0 to -30(60)mm

6VT.881.035.AQ Z +33 to +72mm X : -43 to -73(103)mm

Recaro 1400 R Bracket no. Positions Picture

6VT.881.035.BM Z : 0 to +20mm, X : 0 to -30(60)mm

6VT.881.035.BT Z : +35 to +55mm, X : 0 to -30(60)mm

OMP HTE ONE Bracket no. Positions Picture

6VT.881.035.AS Z : 0 to +60mm, X : 0 to -30(60)mm

Sabelt GT620 Bracket no. Positions Picture

6VT.881.035.BQ Z : 0 to +60mm, X : 0 to -30(60)mm

Atech Carbon RS Bracket no. Positions Picture

6VT.881.035.BR Z : 0 to +40mm, X : 0 to -30(60)mm

OMP HTE ONE XL Bracket no. Positions Picture

6VT.881.035.AT Z : 0 to +20mm, X 0 to -30(60)mm

6VT.881.035.BA Z : 0 to +40mm, X : 30 to -60(90)mm

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 For co-driver:
Sparco ADV SCX Bracket no. Positions Picture

6VT.881.037.BD Z : 0 to +20mm, X : 0 to -30(60)mm

Recaro 1400 R Bracket no. Positions Picture

6VT.881.037.AR Z : 0 to +20mm, X : 0 to -30(60)mm

OMP HTE + XL Bracket no. Positions Picture

6VT.881.037.AN Z : 0 to +20mm, X : 0 to -30mm

6VT.881.037.AP Z : 10 to +30mm, X : 0 to -30mm

6VT.881.037.AQ Z : 50 to +70mm, X : 0 to -30mm

Sabelt GT620 Bracket no. Positions Picture

6VT.881.037.BB Z : 0 to +60mm, X : 0 to -30(60)mm

Atech Carbon RS Bracket no. Positions Picture

6VT.881.037.BC Z : 0 to +40mm, X : 0 to -30(60)mm

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 Racing seats FIA 8862-2009:
Type Picture Dimensions (mm) Homologated seatbrackets

6VT.881.035.AQ - driver
6VT.881.035.AR - driver
6VT.881.035.BL - driver
6VT.881.035.BS - driver
6VT.881.037.BD - co-driver
Sparco ADV-SCX H
5JT.881.021.F
(available to buy)

6VT.881.035.AQ - driver
6VT.881.035.AR - driver
6VT.881.035.BL - driver
6VT.881.035.BS - driver
6VT.881.037.BD - co-driver
Sparco ADV-SCX
5JT.881.021.A
(available to buy)

6VT.881.035.BM - driver
6VT.881.035.BT - driver
6VT.881.037.AR - co-driver

Recaro Ultima 1.0

5JT.881.021.C
(not available to buy)

6VT.881.035.AS - driver
6VT.881.037.AN - co-driver
6VT.881.037.AP - co-driver
6VT.881.037.AQ - co-driver
OMP HTE ONE
6VT.881.021.D
(available to buy)

6VT.881.035.BR - driver
6VT.881.037.BC - co-driver

Atech Carbon RS
6VT.881.021.H
(available to buy)

6VT.881.035.BQ - driver
6VT.881.037.BB - co-driver

Sabelt GT-620
(not available to buy)

6VT.881.035.AT - driver
6VT.881.037.BA - driver

OMP HTE ONE XL

6VT.881.021.G
(available to buy)

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 Safety belts – Installation guide

To meet the recommended geometrical locations of anchorage point is necessary to respect correct
installation of all straps.
DO NOT install Profi racing harness belts into vehicles to be driven on public roads. They DO NOT meet
regional or national vehicle safety regulations and are designed and tested to be used exclusively in race
cars and only at track events.
There are 3 options for mounting each crotch belt based on the type of seat and safety belt:
 Option I – eye bolts
 Option II – mounting on the front tube
 Option III – mounting on the rear tube

The diagram below illustrates the recommended geometrical locations of the anchorage points, from FIA
253 Appendix J dated from 5/02/2019. Please, always check the current valid version of this document.

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 Option I

Available for Schroth, OMP, Sparco

5JT 857 115

Eye bolt
8pcs

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 Option II

 Available for Schroth and Sparco

 Mounting on the front tube (covering sharp edges using protection profile 5JT 103 543 –
80mm)

5JT 857 115

Eye bolt
4pcs

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 Option III

 Available for Schroth and Sparco

 Mounting on the rear tube (covering sharp edges using protection profile 5JT 103 543 –
80mm)

5JT 857 115

Eye bolt
4pcs

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 10.1.5.2.1. Driver side

Seatbelt
Schroth Schroth Schroth Sparco Sparco Sparco OMP OMP OMP
Option I Option II Option III Option I Option II Option III Option I Option II Option III
Sparco + 6VT881035AQ front X X X X X X X
Sparco + 6VT881035AQ rear X X X X X
Sparco + 6VT881035AR front X X X
Sparco + 6VT881035AR rear X X X
Sparco + 6VT881035BS front X X X
Sparco + 6VT881035BS rear X X X
Seat + seat bracket + position

Sparco + 6VT881035BL front X X X

Sparco + 6VT881035BL rear X X X
OMP + 6VT881035AS front X X X X X
OMP + 6VT881035AS rear X X X
OMP + 6VT881035AT front X X X
OMP + 6VT881035AT rear X X X
OMP + 6VT881035BA front X X X
OMP + 6VT881035BA rear X X X
Recaro + 6VT881035BM front X X X X X X X
Recaro + 6VT881035BM rear X X X X X
Recaro + 6VT881035BT front X X X X X X X
Recaro + 6VT881035BT rear X X X X X X X
Sabelt + 6VT881035BQ front X X X
Sabelt + 6VT881035BQ rear X X X
Atech + 6VT881035BR front X X X
Atech + 6VT881035BR rear X X X

10.1.5.2.2. Co-driver side

Seatbelt

Schroth Schroth Schroth Sparco Sparco Sparco OMP OMP OMP

Option I Option II Option III Option I Option II Option III Option I Option II Option III
Atech + 6VT881037BC front X X X X X X X
Atech + 6VT881037BC rear X X X
Seat + seat bracket + position

Sabelt + 6VT881037BB front X X X X X X X

Sabelt + 6VT881037BB rear X X X
Sparco + 6VT881037BD front X X X
Sparco + 6VT881037BD rear X X X X X
Recaro + 6VT881037AR front X X X X
Recaro + 6VT881037AR rear X X X X X X X
OMP + 6VT881037AQ front X X X X
OMP + 6VT881037AQ rear X X X X X X X
OMP + 6VT881037AP front X X
OMP + 6VT881037AP rear X X X X
OMP + 6VT881037AN front X X
OMP + 6VT881037AN rear X X

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 10.1.5.2.3. Schroth safety belts

 ‘SCHROTH’ seat belts: 6VT 857 677 J

 Homologation: SH.014.17-T-6

Allowed attachment methods – Applicable for all straps (shoulder, pelvic, crotch):

2-bar slide 3-bar slide 2-bar slide

3-bar slide 2-bar slide 3-bar slide

10.1.5.2.4. Sparco safety belts

 Sparco seat belts: 6VT 857 677 R

 Homologation: SH.005.16-T-6

Allowed attachment methods:

2-bar slide

2-bar slide 3-bar slide

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 10.1.5.2.5. OMP safety belts

 OMP seat belts: 6VT 857 677 L

 Homologation: SH.005.16-T-6

Allowed attachment methods:

2-bar slide

3-bar slide 3-bar slide

10.1.5.2.6. Shoulder belt mounting

For instructions on how to correctly install the Hybrid Head Restraints, please refer to Simpson's website,
Instructions & Installations chapter, USER AND INSTALLATION MANUAL by Simpson®.

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 10.1.5.2.7. Wrapping instructions

3-Bar slide wrapping instructions:

2-Bar slide wrapping instructions:

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 10.1.6. Driver footrest

The driver footrest can be adjusted forward or backwards depending on the position of the pedal box (see
the picture at ‘10.1.2 Pedal box‘).

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 10.1.7. Co-driver Footrest

The co-driver’s footrest can be adjusted forward or backwards.

The position of the footrest.

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 The position of the footrest can be adjusted, as seen in the picture.

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 10.1.8. Automatic fire extinguisher system ‘FEV FX G-TEC 2900R3’

EV Control box V1 FIA 8865

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 FEV Control box V2 FIA 8865

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 Note: We recommend checking the expiry date of ‘FEV FX G-TEC 2900R3’ automatic fire extinguishers.
After two years, return the current fire bottle to F.E.V. Co. Ltd and they will exchange it.

Delivery address: Fire Extinguisher Valve Co Ltd

Unit 10, Ford Lane Business Park
Ford, Nr Arundel
West Sussex BN18 0UZ
Tel: 0044 (0)1243 555566
Fax: 0044 (0)1243 555660
Email: [email protected]

List of official service agents for the FEV fire extinguisher systems:

FINLAND

Printsport OY
Eero Raikkonen
[email protected]
Hohontie 10
41400 Lievestuore, FINLAND
Tel: +358 403011401
www.printsport.fi

ITALY
DF Antincendio
[email protected]
Via E. de Amicis 51
46024 Moglia, ITALY
Tel: +39 3494577984
www.dfantincendio.com

FRANCE
Danielson Equipement
David Vallet
[email protected]
5 Rue De Champ Magny
58470 Magny-Cours, FRANCE
Tel: +33 (0) 386212255
www.danielson-equipement.com

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 USA

Race Parts Xpress, LLC

Lendle McElwain
[email protected]
4486 Providence Mill Road
NC 28650, Maiden, USA
Tel: (828) 428-0820
www.rpxpress.com

CANADA

Braidan Motorsport
Brad Shimbashi
[email protected]
9399 Markham Road
ON L3P 3J3 Markham, Canada
Tel: +1 416 460 5252
www.braidanmotorsport.com

AUSTRALIA

Garage 1 PTY LTD

John Evans
[email protected]
Unit 2/42 Kitchen Road
VIC 3175 Dandenong South, Australia
Tel: (04) 5252 6562
www.garage1.com.au

Racer Industries
Ryan Mcleod
[email protected]
75 Norwell Road
4208 Norwell, Queensland, Australia
Tel: (07) 5546 2040
www.raceindustries.com.au

JAPAN

IRS Corporation
Takeshi Iwashita
[email protected]
2-1-15 Higashi Shinkoiwa, Katsushika- KU
124-0023, Tokyo, Japan
Tel: +81 (0)3 3696 7960
www.irs.co.jp

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 SOUTH AFRICA

Automotive Technology Specialist PTY Ltd

Kobus Roos
[email protected]
30 Schoongezight Road
1709 Bergbron, Johannesburg, RSA
Tel: +27 (0) 11 6708400
www.ats-motorsport.co.za

EAST AFRICA

BHP Performance/ BC Racing

Baldev Chager
[email protected]
No 75 Lower Kabete Road
Westlands, Nairobi
Tel: +254 722 722761

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 10.1.9. Carjack, setup and use, instructions and servicing

1. Mechanics – setup the jack:

- Setup the minimum height for the punctured wheel work on an appropriate surface
- Adjust the angle between the jack main body and sill pin to under 45°
- Visually check for oil leaks
- Make sure the screw thread on the main body of the jack is covered.
- Do not modify the jack on your own
2. Drivers
- Ensure the car does not roll forward or backwards by applying the handbrake or skid-pan. If
you use a skid-pan, secure the car in the direction of the slope of the road
- When placing the jack into the body sill, the jacking pin must be in max position inside. If not,
there is danger of breaking the sill pin from the jack body
- Jack angle from the car camber – hold the jack by the oil reservoir, maintaining a clearance of
approximately 50 mm between the car and jack oil reservoir
- Lock the hydraulics using the release pressure lever on the jack head to the up position
DOWN

UP

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 Instructions on how to change the hydraulic oil

1. We recommend warming up the oil in the jack a little by lifting the car a few times before the
bleeding.
2. Pump the jack to the highest position.
3. Wedge the jack against a solid object (for example a wall or the edge of a workbench) in the
horizontal position, so that the bleed screws are in the highest spot of the oil reservoir.
4. Open the valve and the bleed screws.
5. Push the jack very slowly and continuously, so the air comes out.
6. Once pushed to the lowest position, immediately close the bleed screws.
7. Check the functionality, and if the jack still needs bleeding, repeat the process.

1. Pump the jack to the highest position.

2. Unscrew the cap, open the valve and drain the oil.
3. Fill with the new oil (the oil we use is Castrol Transmax Dex III Multivehicle), pump the handle to
draw the oil in (be careful not to draw in air). Repeat until the jack is full.
4. Bleed the jack by pumping the handle, pushing the jack down and pump up again. Repeat until all
the air comes out.
5. When the jack is pumped to the highest position, the oil surface should level the thread (orange line
on the picture).
6. Screw in the cap.
7. Perform the bleeding according to the previous page to remove the air from under the cap and
excess oil. (We recommend changing the oil at least once per season.)

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 10.2. Rear Wing Adjustment

1) All dimensions and wing position tolerances are derived from the frontal projection of the top point
of the body (indicated by the horizontal line in the diagram)
2) Both mounting dimensions must be within the tolerances

The wing attachment diagram is based on the homologation form.

The rear edge of the roof sheet metal, the edge of the rear door sheet metal.

Zero gradient of the car is defined with the upper surface of the inner sill – for the calibration of the
horizontal line.

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 10.3. Side windows cleaning

Don’t use any cleaners with high percentage of alcohol for side windows cleaning. Alcohol degrades the
material structure and reduces strength of the polycarbonate. We recommend to use low percentage
alcohol cleaners for example Sonax 338 241.

10.4. Body shell as a spare part

A rule is in place for exchanging the body shell to prevent unauthorised repair of roll cages and to ensure
the maximum possible safety of the crew. To purchase a new body shell with the indexed safety cage serial
number and identical ‘VIN’ number, it is necessary to return the part of the body shell and roll cage. Below,
you can find the terms and conditions on how to return the original body shell ‘VIN’ number and roll cage
number.

Terms of purchase: The body shell as a spare part:

It is only possible to buy a spare body shell as a replacement for the damaged body shell. The original body
shell ‘VIN’ number will be retained but the safety cage number will be issued with an index. To purchase the
new spare bodywork with a new safety cage index, the VIN number must be cut out from the original
bodywork and returned along with the safety cage label and a part of the main roll-bar tube as shown below
in Picture 3. To register the spare body shell with the ‘FIA’ to request an ‘FIA’ passport, first return the ‘FIA’
passport of the previous body shell to the ‘FIA’.

The serial chassis number is stamped on the left lower corner of the fuel tank cover plate, and it is necessary
to cut out and return the ‘VIN’ number.

Stamped serial
chassis number

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 10.5. Recommended revisions

Cockpit

Recommended
Part Name Part No.
replacement
Hand Brake Lever 6VT 711 303 J 4 500 km SS
Gearshift lever 6VT 711 053 N 4 500 km SS
Pedal Box 6VT 721 021 D 4 500 km SS
Accelerator axis 6VT 723 145 E 2 000 km SS
Steering Column 6VT 419 501 F 4 500 km SS

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 11. KIT
11.1. Gravel to Tarmac KIT

The table below contains all the parts necessary for switching from Gravel car specification to Tarmac car
specification.

GRAVEL TO TARMAC KIT

Part Name Part Number Quantity
Kingpin adaptor tarmac 6VT 407 203 C 4
Kingpin bolt tarmac 6VT 407 171 C 4
Bolt M10x20 socket head 000 019 124 10
M10 Washer locking VS 000 407 025 16
Damper adaptor washer 6VT 407 090 A 4
Damper tarmac left assy 6VT 412 031 BK 1
Damper tarmac right assy 6VT 412 032 BK 1
Damper tarmac left assy 6VT 412 031 BM 1
Damper tarmac right assy 6VT 412 032 BM 1
Main spring 45-274 6VT 411 102 C 2
Main spring 40-283 6VT 411 102 B 2
SUSPENSION PARTS

Strut dowel upper 6VT 413 143 8

Brake disc assy left 6VT 615 105 G/K 1
Brake disc assy right 6VT 615 106 G/K 1
Brake disc 300-32 left 6VT 615 301 AJ/AK 1
Brake disc 300-32 right 6VT 615 302 AJ/AK 1
Brake pads Endless N105SP unb./
Endless N105SP bedded/Carbone 6VT 615 151 AE/AF/C 2
Lorraine RC8R
Brake calliper hose Tarmac 6VT 611 711 J 2
Master brake cylinder 19,05/25,4
6VT 611 019 P 1
vertical
Calliper spacer 6VT 615 111 C 4
Dowel 14x15 6VT 407 131 D 4
Bolt M10x80 socket head 000 615 003 4
Anti-Roll bar front medium 6VT 411 053 D 1
Anti-Roll bar rear hard 6VT 511 409 E 1
Rim 8x18 ET23 Al Speedline 6VT 601 025 B 5
Sumpguard assy Al 30kg 6VT 825 249 T 1
Tunel stoneguard Fe wide assy
6VT 825 841 E 1
20kg
BODYWORK PROTECTIONS

Bolt M10x1,25x25 imbus ENT 402 001 CA 4

Washer 10 000 800 088 4
Diff stoneguard - brake cooling
6VT 825 236 AF 1
Fe 35kg*
Rear axle housing front cover L*;
6VT 871 109 B 1
**
Rear axle housing front cover R*;
6VT 871 110 B 1
**
Brakes cooling tunnel L*; ** 6VT 871 049 A 1
Brakes cooling tunnel R*; ** 6VT 871 050 A 1
Rivet 4x8 000 018 069 12

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 Washer M4 000 731 061 18
Cam lock 5JT 825 274 6
Rivet 3x8 000 018 035 12
Rivet 4x16 000 018 058 6
Bolt M12x1,5x25 5JT 825 296 10
Washer sumpguard 6VT 825 445 10
Doorstep cover L front 6VT 871 217 B 1
Doorstep cover R front 6VT 871 218 B 1
Doorstep cover L centre 6VT 871 219 B 1
Doorstep cover R centre 6VT 871 220 B 1
Doorstep cover L rear 6VT 871 221 B 1
Doorstep cover R rear 6VT 871 222 B 1
Rivet 4x8 000 018 069 32
Rivet 4x12 000 018 047 16
Rivet 4x16 Al/steel 000 018 046 14
Washer M4 000 731 061 2
Washer M4 000 731 061 2
*Diff stoneguard (6VT 825 236 AF) for Packet 2021 Cross-Member Rear
(6VT505317F) with brake cooling

To switch from Gravel to Tarmac, it is necessary to follow the Tarmac Car Setup Sheet (available online in
Catalogue\Documents\evo Setup Sheets) carefully. Also, please ensure that position of Steering adaptors
are changed on all four uprights (detailed illustration available in catalogue, Chapter 20.1).

When using ŠKODA Hydraulic Jack (5JT 011 021 C), do not forget to setup the position of the lift tube.

The parts listed in the previous table enable the change to default Gravel setup. ŠKODA offers variant parts
to adjust the car to specific conditions. It is possible to use the entire range of Camber spacers and Anti-
Roll bars for both car specifications (Gravel and Tarmac). The table below contains:

 The complete range of Camber spacers (can be used for both car specifications - Gravel &
Tarmac)
 The complete range of Anti-Roll bars (can be used for both car specifications - Gravel &
Tarmac)
 The complete range of Tarmac Damper springs
 A magnesium Tarmac OZ rim
 A wheel cover for Tarmac OZ rim

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 Part Name Part Number
Camber spacer 6VT 407 070
Camber spacer 6VT 407 070 A
Camber spacer 6VT 407 070 B
Camber spacer 6VT 407 070 C
Camber spacer 6VT 407 070 D
Camber spacer 6VT 407 070 E
Camber spacer 6VT 407 070 F
Anti-Roll bar front soft 6VT 411 053 C
Anti-Roll bar front medium 6VT 411 053 D
Anti-Roll bar front hard 6VT 411 053 E
Anti-Roll bar rear soft 6VT 511 409 C
Anti-Roll bar rear medium 6VT 511 409 D
‘OPTIONAL PARTS’

Anti-Roll bar rear hard 6VT 511 409 E

Main spring 30-308 6VT 411 102
Main spring 35-292 6VT 411 102 A
Main spring 40-283 6VT 411 102 B
Main spring 45-274 6VT 411 102 C
Main spring 50-257 6VT 411 101 S
Main spring 55-251 6VT 411 101 T
Main spring 60-247 6VT 411 101 AA
Rim 8x18 ET23 Mg OZ 6VT 601 025 C
Wheel cover Tarmac OZ 6VT 601 131 E
Wheel scraper tarmac Speedline/OZ 6VT601178A/ 6VT601179A
Sumpguard assy AL 20 kg 6VT 825 249 S
Tunel stoneguard Fe wide assy 15 kg 6VT 825 841 F
Tunel stoneguard Fe wide assy 10 kg 6VT 825 841 G
Tunel stoneguard Fe wide assy 5 kg 6VT 825 841 H
Diff stoneguard - brake cooling Fe 36,5kg** 6VT 825 236 AP
Diff stoneguard Fe wide assy 35kg*** 6VT 825 236 T
Rear axle housing front cover L*** 6VT 871 109 A
Rear axle housing front cover R*** 6VT 871 110 A
*Diff stoneguard (6VT 825 236 AF) for Packet 2021 Cross-Member Rear
(6VT505317F) with brake cooling
** Diff stoneguard (6VT 825 236 AP) for Cross-Member Rear (6VT505317E)
with brake cooling
***Diff stoneguard (6VT 825 236 T) for Packet 2021 Cross-Member Rear
(6VT505317F) without brake cooling

The tarmac KIT and variant parts can be ordered from the ŠKODA FABIA Rally2 evo catalogue (Chapter
20.1), where the parts are illustrated.

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 11.2. Tarmac to Gravel KIT

The table below contains all the parts necessary for switching from Tarmac car specification to Gravel car
specification.

TARMAC TO GRAVEL KIT

Part Name Part Number Quantity
Kingpin bolt gravel 6VT 407 369 G 4
Protective plate left 6VT 505 415 AB 1
Protective plate right 6VT 505 416 AB 1
Protective side plate left 6VT 505 105 F 1
Protective side plate right 6VT 505 106 F 1
Protective lower plate left 6VT 505 085 D 1
Protective lower plate right 6VT 505 086 D 1
Scraper body left 6VT 505 143 G 1
Scraper body right 6VT 505 144 G 1
Scraper plate 6VT 505 146 B 2
Scraper rubber 6VT 505 149 D 2
Scraper plate spacer 6VT 505 119 6
Bolt M5x12 low head 000 407 016 6
Nut M5 RIPP 000 730 095 6
Bolt M8x16 C60 F08 016 A 4
SUSPENSION PARTS

Bolt M5x12 C60 F05 012 A 2

Washer M5 000 407 017 2
Damper gravel left assy 6VT 412 031 BN 1
Damper gravel right assy 6VT 412 032 BN 1
Damper gravel left assy 6VT 412 031 BP 1
Damper gravel right assy 6VT 412 032 BP 1
Main spring 25-428 6VT 411 101 AH 2
Main spring 20-459 6VT 411 101 AF 2
Strut dowel upper 6VT 413 143 8
Brake disc 300-32 left 6VT 615 301 AK/AF 2
Brake disc 300-32 right 6VT 615 302 AK/AF 2
Brake pads Endless N35S unb./Endless 6VT 615 151
2
N35S bedded/ Carbone Lorraine RC8R AG/AH/C
Brake calliper hose 6VT 611 711 K 2
Brake calliper hose 6VT 611 711 L 2
TY-Rap TY25M 000 200 129 2
Master brake cylinder 17,8/25,4
6VT 611 019 S 1
vertical
Bolt M10x50 socket head 000 615 007 4
Anti-Roll bar front soft 6VT 411 053 C 1
Anti-Roll bar rear medium 6VT 511 409 D 1
Rim 7x15 ET28 Al Speedline 6VT 601 026 C 5
Sumpguard assy Hardox 36 kg 6VT 825 248 N 1
PROTECTIONS

Diff stoneguard AL 17kg* 6VT 825 236 AR 1

BODYWORK

PA-Brake caliper duct L* 6VT825163 1

PA-Brake caliper duct R* 6VT825164 1
Flexible hose 0,8m* 000800121 0,8 m
Hose clamp* 000800122 4
Bolt M5x12 socket head* C60F05012A 2

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 TARMAC TO GRAVEL KIT
Part Name Part Number Quantity
Bolt M10x20 socket head* 000019124 2
Cam lock 5JT 825 274 6
Rivet 3x8 000 018 035 12
Rivet 4x16 000 018 058 6
Rear axle housing front cover L* 6VT 871 109 C 1
Rear axle housing front cover R* 6VT 871 110 C 1
Bolt M12x1,5x25 5JT 825 296 8
Washer sumpguard 6VT 825 445 8
Doorstep cover 6VT 871 397 D 1
Doorstep cover 6VT 871 398 D 1
Rivet 4x16 Al/steel 000 018 046 54
Foam EVR 452 000 011 736 11 m
Mudguard front 6VT 821 819 C 2
Mudguard rear 6VT 821 822 B 2
Rivet 4x12 000 018 047 24
Rivet 5x30 000 800 099 2
Washer M4 000 731 023 14
*Diff stoneguard (6VT 825 236 AR) for Packet 2021 Cross-Member Rear
(6VT505317F) with brake cooling

To switch from Tarmac to Gravel car, it is necessary to follow the Gravel Car Setup Sheet (available online
in Catalogue\Documents\Setup Sheets) carefully. Also, please ensure that position of steering adaptors are
changed on all four uprights (detailed illustration available in catalogue – Chapter 20.2).

When using ŠKODA Hydraulic Jack (5JT 011 021 C), do not forget to setup the position of the lift tube.

The parts listed in the previous table enable the change to default Gravel setup. ŠKODA offers variant parts
to adjust the car to specific conditions. It is possible to use the entire range of Camber spacers and Anti-
Roll bars for both car specifications (Gravel and Tarmac). The table below contains:

 The complete range of Camber spacers (can be used for both car specifications - Gravel and
Tarmac)
 The complete range of Anti-Roll bars (can be used for both car specifications - Gravel and Tarmac)
 The complete range of Gravel Damper springs
 A magnesium Gravel OZ rim
 Wheel covers for Gravel rims.

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 Part Name Part Number

Camber spacer 6VT 407 070

Camber spacer 6VT 407 070 A
Camber spacer 6VT 407 070 B
Camber spacer 6VT 407 070 C
Camber spacer 6VT 407 070 D
Camber spacer 6VT 407 070 E
Camber spacer 6VT 407 070 F
Anti-Roll bar front soft 6VT 411 053 C
Anti-Roll bar front medium 6VT 411 053 D
Anti-Roll bar front hard 6VT 411 053 E
Anti-Roll bar rear soft 6VT 511 409 C
Anti-Roll bar rear medium 6VT 511 409 D
‘OPTIONAL PARTS’

Anti-Roll bar rear hard 6VT 511 409 E

Main spring 15-498 6VT 411 102 H
Main spring 17,5-460 6VT 411 102 J
Main spring 20-459 6VT 411 101 AF
Main spring 22,5-442 6VT 411 101 AG
Main spring 25-428 6VT 411 101 AH
Main spring 27,5-416 6VT 411 101 AJ
Main spring 30-407 6VT 411 101 AK
Main spring 32,5-399 6VT 411 101 AL
Main spring 35-392 6VT 411 101 AM
Main spring 37,5-386 6VT 411 101 AN
Rim 7x15 ET28 Mg OZ 6VT 601 026 D
Wheel scraper tarmac Speedline 6VT 601 178 A
Wheel scraper tarmac OZ 6VT 601 179 A
Wheel cover Gravel Speedline 6VT 601 131 B
Wheel cover Gravel OZ 6VT 601 131 D
Diff stoneguard AL wide assy 15,5 kg** 6VT 825 236 AC
Diff stoneguard AL 17,4 kg*** 6VT 825 236 AQ
*Diff stoneguard (6VT 825 236 AR) for Packet 2021 Cross-
Member Rear (6VT505317F) with brake cooling
**Diff stoneguard 6VT 825 236 AC) for Packet 2021 Cross-
Member Rear (6VT505317F) without brake cooling
***Diff stoneguard (6VT 825 236 AQ) for Cross-Member Rear
(6VT505317E) without brake cooling

The Gravel KIT and variant parts can be ordered from the ŠKODA FABIA Rally2 evo catalogue (Chapter
20.2), where the parts are illustrated.

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