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User Manual §xOoA Fabia R5

SXODA Motorsport
2017

03/2017

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1 Contents c
1
2
Contents
Prologue
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3 Maintenance à
3.1 List of the car f|uids..............
3.2 Torque * Recommended check before Ra1|y...............

4 q --l
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Electronics
4.1 Dash Display + Central Panel Buttons.......................

4.1.1

4.1.2 d
4.2 MPDU Display.......... €
4.2.1 Displaying modes ..........
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4.2.2 MPDU Display Menu.............
d
4.3

4.4
Atr
GDU Display
Steering Wheel Buttons
Co-driver's Buttons
..,....,...'.,...'..,....24

'..'.......,....., 25
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4.6 Stilo lntercom DG-10....... .................. 26

4.7 USB logger é

4.8 Device supply connectors.. ..................29
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i 4.9 Recommended Revisions 30
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5 Engine 31

5.'1 Operatlonal and Maximal Engine Values (pressure, temperature .) ............ . ............31 à
5.2 Engine fuel mapping
;
5.3 Engi ne start/stop..... ...........33

33 è
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5.4 Engine power test )A
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5.5

5.6
5.5.1
FIA Limiter...
Overrev Counting......
Road x Stage Mode
35
35
36
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5.7 Launch Start (L.S.) 36
5.8 38
5.8.1

5.8.2 Maximal Turbocharger RPM............ ..........38 4

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5.8.3
5.8.4
Waste gate Connection Diagram
Waste gate Preload Setting..........
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5.9 Calibration Pedal x Throttle........
5.10
5.1'l Alarms......

5.12 Errors - Error Manager, Backup Strategies.... 41

5'13 Adaptations .'....'..,^.,.......'......... 48

5.13.1 AdaptationsErase.........

5.14.2 Water circuit for heater and non-heater version .......49

5.15.1 Clutch operation - thrust bearing (axial bearing) ........50

5.15.2 Check of thrust washer status - axial clearance of crankshaft.,,.,..,........... '.....'.....51

5.15.3 Oil Level Check - Standard Engine Oìl Filling ..'.'..............53

5.15.4 Flywheeltightening procedure..., ..'..............,,''..,,..'.. 54

5.15.5 Spark plugs tightening procedure..., .......,...'...,...,..... 55

5.15.6 Change of Accessories 8e1t........... 56

5.15.7 Engine start-up after the car roll - over (procedure n the service zone) ..................................^..57

5.15.9 Fuel system bleeding after f uel/engine change. .....""..57

5.16,2 Sealing of the restrictor and turbocharger.....,..,......,......, .....................60

5.16.3 Sealing of the engine block

Enoine revision .....64

5-1&4 Over Rev...... ........................67

68
no.r' to Change Oil i n Transm ission..............

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61 Z Rear Differential ..................

6.2 Differential settin9...........

6.3 Clutch lnspection
6.4 Driveshaft nspection..
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6.5 Sealing _73

6.5.1 Gearbox Sxoon points
Fabia R5 sealing -: É

6.6
6.5.2 Rear differential §KODA Fabia R5 sealing points............

Operational and Maximal Gearbox Va1ues...,.,......

................., 7r

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....................75

7 Suspension 7A
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7.1

7.1.1
Brakes

Bleeding of brakes - pedal box.................

.........78

..................78 g
7.2

7.2.1
Dampers.......

Setting
'......,.'.............' -,79

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7.2.2 Damperrevision......... ......81

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7.3.2
82
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Ride Height. 83
84
86

4
88
90
7.5.1 Steering Circuit Bleeding Procedure.... ...........................9O

7.5.2 Steering Maintenance & New steering racks from §XOOA Motorsport ...........90

7.6

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8.1

8.2
9
:6661--srled Revisions . .. . 96
.97
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9.1.1 ..97

9.1.2

9.1.3

9.1.4
9.1.5
Peoa Bc:r
Gearshifc
Hand brake..,

Seats, Seat Belts & Brackets.......

.98
.99
100
102
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I 10.2

I 11

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I Engineering Revision Form " ' """'115
11.1.3 - Sportech
I 11.2
Steering rack

Manual """"" """""""116

11.2-1 Documents: Calliper Revision
= 11.2.2 R5 Centre pin operation instruction
"""""^"""""""""122

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2 Prologue
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Dear Customer,
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We appreciate very much your decision to buy a §XOOa Fabia R5 car. We tried to tm; :-.=-: . Éa-
best for its development and subsequent operation that the §XOOA Motorsport team is d s::=
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present. To make a start of your car as simple as possible, we have prepared a brief User Man-a '-' : -

On the following pages you will find all we consider as valuable for you to be permanently sat s':: :-

the car performance and reliability. We try to make our services better and better all the time sc "': '

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appreciate any response from you concerning both the car and this documentation.
J.tEr
Looking forward to our mutual cooperation, we wish you a lot of success and agreeable feelings witr'
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our car.

Be successfull
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Technical Chief of SKODA Motorsport L-l
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 3 Maintenance
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3.1 List of the car fluids

1
Where Oil/Fluid/Grease Quantity

Engine Castrol Edge 5w3O 4,751 (reach the mark on the

dipstick)

Engine Coolant G13 5,21

Gearbox Castrol Syntrax 2,51

Differential Castrol Syntrax 1,Ol

Power steering Castrol ATF TaD lll o,8l

Brakes Castrol SRF Racing Fluid 1,Ol

Drive shaft inner joint GKN XP 595 1659

Drive shaft outer joint Neo HPCC1 '1509

''Vheel bearing Maintenance free

I -'::. release bearing Maintenance free

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3,2 Torque - Recommended check before Rally
Area Connection PaÉ No. Tcqp lr.rbrication
Wshbone to strut ENT 402 OO1 DH \l3te
Re:arrinq nutM22 000 407 013
- e-.cc i-etarning ooo 407 026
nuts
ooo 407 020
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lt ENT 402 OO1 DA
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G-point ENT 402 OOl DB 70 N:: .--:
l' ENT 402 OO1 FG
o C-ossmember to bodyshell 100 Nr
o ENT 402 OO1 FH
Gearbox reaction
Front Top-mount uniball nut
Rear Top-mount uniball nut
ENT 402 OO1 EH
5JT 412325
sJT 412325
c60 Fo6 012
100 Nm
70 Nm
70 Nm
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Screws Top-mount to bodyshell 14 Nm
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Damper adaptor studs to upright
6W 407 504 A
6VT 407 503 B
70 Nm JrrEr
Wheel hub nut
Retaininq screws of hub nut
Damper adaptor nuts
Damper nut
6VT 407 631 C
c60 F03 008
ooo270307
6VT 411 059
50Ot10O Nm
2Nm
60 Nm
70t10 Nm
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Damper filter

Damper nut and bolt

6W 411679
ooo270307
ENT 402 001 FC
10 Nm

70 Nm
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Steering adaptor bolts
000 019 003
34 Nm
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Damper adapter strut dowels
6W 413143 100 Nm LUL--=- -
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6VT 407 059
F-ooint ENT 402 OO1 DK 70 Nm \ ^^^
Gravel kinqpin adaptor 6W 407265C 350 Nm Loc:,te 243 E
L-
Tarmac kinqpin adaptor bolts ooo o19 124 70 Nm None
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Klnqpin oravel 6VT 407 369 D BO Nm None
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Kinqoin tarmac 6W 407 171 80 Nm None
sJT 601 138 B '120 Nm None
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, - ::-:-: ^l: 6W 407 107 B 90 Nm Petec
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Screw of antiroll bar arm 000 730 056
000 730 056
37 Nm
37 Nm
None
None
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Loctite 243
C6O FOB OBO 20 Nm
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6W 4228248 BO Nm l'to-e

Rackto cross-a*:a- c60 Fo8 030 B 35 Nm è

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'i c60 Fo8 040 A
o Bearinq bracket rc :c:. s-. '!one
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^: \ - None
Steerinq wheel to adapior
Adaptor to flanqe
None
None
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Steerinq column bolts 35 Nryr None -
Calliper to upright 60 Nm None

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Retaininq rinq to hub
Brake bell bolt
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8Nm
5Nm
None
None
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Bleeding Screw 000 0r2 101

9 Nm Hot
'14 Nm Cold
None .J
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Steel Banio calliper Bolt 000 564 254 E 24 Nm None
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4 Electronics
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4.1 Dash Display + Central Panel Buttons
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I 4,1.1 Central Panel

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I Fire Extinguisher Switch

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I Start Button
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Switch Panel

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'.,: - S*'tch Turns on the main power in the car electric system'
I ;-::- S'*itch Activates ignition, injection and fuel pumps'
!::: 3 --cn Activates the starter motor.
I ',,:::*::^ Rotary switch for engine map selection (see chapter Engine start)'
:": i,: -:- S.er SWitCh Activates the extinguishing system, switches of the engine and
t disconnects the batterY.
Turns on/off the co-driver's map light.
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4.1.2 Switch Panel

Switchpanel isthemaincontrol interfacetooperatetheengineandcarelectrica

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It is membrane keyboard with illuminated buttons and LED indications of the buttors

Switch Panel Buttons Function

Button

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To change pages ofthe MPDU disP
'O 9P-,-w P e'c 0Ò ' e1
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To select Star-t Rplvl nìlter
L mltervaluew 1 be d splayed
(DOS t on I to 5l
on MPDU disllay g
ROAD mode (defèu lt)
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Lights 0FF
Side L qhts 0N
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Low bean't Side iqhts !\ I§I
Blower fan OFF

m # Blowerfan ON

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Screen heater OFF
Srreen heater
heater
500/o
'1000/o
0N (eng ne must run)
0N (enq ne rrust tun
4
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flash
Bumper I qhts 0FF
Bumper Lìqhts ON when H gh beam ON (pre att vated)
Bumoer lqhts ON when S de lqhts are ON
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lnner ghts

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0FF
nner I ghts ON when High beam ON (pre-actìvated)
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'€ flash

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nner rQhts 0N when
0uier ights 0Ft
Irter J
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nash !hts ON when High beam ON (pre-act vated)

I Outer llqhts ON when Side lights arelQ\

Rear foq light 0FF

0+ a I
l::-'oq light O\ (side lights mr-sr oe ON)

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No powerbox error
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flash
flash
Powerbox Open circuit (theck MPDU page), pres

No GDU a arm
Pres to
Short circuit (check MPDU

d sable a arm on GDU d soa

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4.2 MPDU Display
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- The information display for crew is used to display sensor and data values, diagnostic information and its
E buttons are used to operate the Display menu.
-< The display brightness can be changed through the Display menu, see section "MPDU Mènu",
independently for day and night conditions.
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4.21 Displaying modes
-=a
- a) Normal Mode
This mode is active after switch on.
= b) Service Mode
1 Thìs mode is activated by long pressing (2sec.) of MPDU PAGE button. The same way to deactivate.

Alarm Page
- - s oage is automatically displayed if serious problem appears.

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4
421.1 Normalmode
To change the page press the MPDU PAGE switch on the Switch panel. The pages will be smtcnec
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in a 1-2-3- 4-1 sequence.

Normal 1

Page displays general car parameters and sensor values

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Gear S peed
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Map 0 J
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Limiter fi12
01 Prail 0123 bar
23 ,.p* -JI
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#hffi"*oc Pf uel 0123 bar TI

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*-X 23 01 23 bar
01 23 oc V hatt 01 23 v
4
Description of 4 LED's (under enoine RPM):

ECU ignition switch signal - must be green to allow engine start.

a
4
IGN switch on central panel is ON, but the IGN LED is still red and engine do not staÉ, check
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external Emergency switch (below windscreen on right side), for possible problems which

5
could be caused for example by water.

SYi'lC CrankshafVca mshaft sensors synchronization

tf LED is red, at least one of the sensors is faulty (engine start still possible, but may take longer).
Error manager state
tf LED is red. some strategic sensor is faulty (check MPDU service page 3 - SENSOR ERROR)
=
USB disk sGte
If LED is red, USB is rrct present, or fuulty.

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Other importanl c:^s

I Handbrake icon - if pHandBrake > 5 bar.

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Do not drive the car with handbrake cortinuousty

Green background is lit when efraust temperature < 55O "C.

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Never switch off the engine if background is not green.

Twater Blue background indicates cold engine, below 5O"C.

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Heat the engine before drive.

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Normal 2
e','e + estimated value, brake pressures and steering position.

P BRAKE FROHT FUEL GUANTITY

0123har 0123 L
FUEL ESTIMATED
P BRAKE REAR
0123 L

0{ 23har SPEED
0123km/h
P HANDBRAKE
STEERING
0123bar 0123 0
Normal3
General car parameters and sensor values.

ur bo 0123 rpm
Engine 0123 rpm
Limiter ,,ft-
\fulr'
0123 rpm
TArìnB 0123oc P AMB 0123,nr,,,
r 22 S12§ oc P 21 0123 n,uu,
T EXH fl1 23 ocP 22 0123 n,ru,
T OIL 01 23 ocT GBX 0123 oc
T W ater 01 23 ocT DIFF 0123 oc

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Normal 4
l:-di-ver page with daytime and trip distance measuremenl:.

0{:01:01
SPEED 01 23 E
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trIST 01 23 km g
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#
L DIST 0123 km
IGN and ERR LED's are the same than on page Normal

4.2.1.2 Service Mode

1.
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To perform a quick check of the basic car data, the "service" mode of the display nn1
To change into service mode, press the MPDU PAGE switch on the Switch panel fu
To return to normal mode - use the long press of the MPDU PAGE switch once agir

Service 1
I mportant sensor values.

HGINE 0123 TU RBO 0123'p

'pm
EDAL 0123v' LAM o123
H ROT 0123 v. V Batt 0123 v
A RREL 0123 v FBRK F 0123 n"
H!FTER 01 23 v PBRK R 0123 n" fl
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UEL QT 01 23 L PHBRK 01 23 n, ÈT
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 Service 2
-erperature and pressure sensor values.
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T WAT 0123 oc P WAT 0123 bar

T otL 0123oc P OIL 0123 bar
T GEAR 0123 oc P FUEL0123bar
T RDIFF 0123 oc P RAIL 0123 bar
T AMB 0123 oc P AMB 01 23 hpa
T 22 Ù123 oc P 22 0123 mba
T EXH E P 21 0123 mba
Service3-SensorError
Strategic sensor error management.

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lry-cnsr cf displayed labels is in table below, also with definition of bit position in WinTAX channel
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=T gsiec error description and problem solving, check the section "Error Manager".

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 SKOElA

Ambient ure sensor failure

Manifold sensor failure

Pressure before throttle sensor failure

Maximal detected (above 180.0OO RPM;

Exhaust te sensor failure

Knock sensor failure

WG valve'1 failure
sensor failure

- circuit
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Lambda too rich DL. = .I-I
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Lambda too lean Bit 10

Gearbox barrel failure Bit 11

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Lambda sensor failure Bit12
Rail pressure sensor failure Bit 13

Shifter load cell failure

4
Shifter load cell siqnificant drift
Constant charger speed over-rev (over 18O.O0O

Crank Snsr
Cam Snsr
ELB
Crank sensor failure
Cam sensor failure

ELB loqqer communication failure

Pedal track problem

4
Pedal '1
- track 1

Pedal 2 Pedal track problem - track2

Lambda SC -3- 3ca sensor failure - short circuit

tDiff
tGbx
LamMa sensor fuilure - open circuit
ature sensor failure 3:25 a
É-aÀ.e 3eca ?^c:--:- e

Car speed sensoT faiiure

WG valve 1 failure
Water temperature
- short circuit
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User Manual, §KODA Motorsport 27.3"2017
 Service 4 - Powerbox Open Circuit
'tre LED of "FUSE BACK" button on Switch panel is flashing yellow, this means Powerbox Oper C -:-:
: agnostics.

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For problem investigation, check MPDU page PBU OPEN CIRCUIT.
Ether the device or loom is broken, or connector disconnected.

PBU OPEN CIRCUIT

SCR HEAT L 5CR HEAT 8
E DAY LTGHT

REAR FOG
LTFT PUMP 2

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lf theLED
Service 5 - Powerbox Short Circuit
of "FUSE BACK" button on Switch panel is flashing red, check the PBU SHORT Cìtr--
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diagnostics - either the device is broken or there is a short circuit in the loom. E=J

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ENGINE TEST
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NGIN E fl{ IS ': 5500 r Prrr È
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EDAL {t{ ?3 {00 -
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H ROT {I{ T3 -a-)

URBO {}133 ;
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More info about engine test in chap:e' a.i

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1213 Alarm Page
Should ALARM appear, the MPDU display will automatically switch to the alarm page.
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I Source of the ALARM will be highlighted by red background.

-I Alarm page is displayed for 1O sec., after this time, it is possible to change the page to Normal or Service
pages. After another 1OO sec., if the alarm condition still exists, ALARM page will be automatically
il displayed again.

I Batte rv us lt. t] 1 23
I Oi I trressu re 01 23
7 Water temp 0123 Gear
I Oil temp 0123
I RearDiff temp 0123
I- Gearbox temp 0123 Speed
Water trressure 0123
=
-
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Fuel pressu re 01 23 012
J Exhaust temp 0123
t
= Alarms may be checked in WinTAX data in channel 'AlarmDisp", see c^apter "Alarms".

I In the same time, driver will be informed about ALARM by constant flash ng of GDU Alarm LED.

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422 MPDL Display Menu
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Buttorn on the MPDU display are used to operate the Display menu.

Function

tr Function UP in Display menu.

Function DO/I/N in Display menu.

Entering into Dìsplay menu and confirmation function in the menu.

ESCAPEfunction in Display menu

The display menu contains these main chapters:

1. Fuel Menu
2. Display Brightness
3. Calibration
4. Device Test
5. Trip master
1. Fuel menu
Fuel menu allows crew to:
Change the Estimated Fuel Consumption (FuelEst) by adding or removing the fuel quantity
Switching on the fuel pumps manually, e.g. in case of fuel sample is requested by FIA

2. Display brightness
l-,: :s :o change the brightness of MPDU and GDU displays in levels "O"-minimum to "7"-maximum
s.l:-e:e . 'c' ca',/ and night, based on Side Lights command.

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3. Calibration
Enables "zero" calibration of sensors:

A- Steering sensor
menu, but as soon as
Small adjustments of the steering sensor can be corrected through MPDU
the sensbr,or column was once disassembled from car, new calibration can only be done properly
through PC (SYSMA).
pressing it to front'
Unplug the sensor from its locked original position on steering column by
housing is still fixed against
noiatÀ by the sensor shaft over steering column, while sensor
in sYSMA project'
rotation in sensor bracket, while checking channel PBU-Ana3
Value must be between 4,900 V and 5,0OO V'

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Steeringlfifheel
F*U,Ana? v
Y
P§Ll-àna3
iteerlllheellearn No ru Horx

Set the new zero by confirming the SteerWheelLearn'

B. Brake pressure
small offset'
Front and Rear brake pressure sensors can be ad.iusted to zero' in case of

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

D. Barrel sensor
+-0,050 v. At least rough
For fine tuning, sensor output can be adjusted, but only in range
mechanical adjustment is required.

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Brrel sensor adjustment procedure:

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l, Ensure that neutral is engaged in the gearbox.
2. Reset the previous offset by confirming the "RESET OFFSET' in the barrel calbratim nrsrr
3, Go to service page 1, check the BARREL value. =
4, Rotate the sensor till the value on the display is in the range O,950 -'l,O5O V.
5, Tighten the sensor screws.
6 Go to the barrel calibration menu, confirm "SET NEUTRAL'.
4
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7, Check the barrel value again, it should be 1.OOO V.
4. Device test -
This section enables to manually test Cooler fan and Rear differential fan.

5. Tripmaster Jg
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Menu enables reset of both trip meters - Trip_Distance_1 and Trip_Distance_2.

Full Structure of the Display Menu

Of The Menu Describtion

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Refuel ing +-'1 Add / remove I L to Fue Est n-rat on withn/§buttons
Refuel ing +-13 Add / remove l0L to Fue Estimation w thE/Elbuttons È
'Éstlmate to 0 Not èctive

'Fuel Tank to 0

'Fuel Tank drain Fuel pumps ON

Reset Fuel Est mat on to 0

Activate alifue pumps manua y E

3a
Fuel pumps 0FF Stop a fuei pumps mènua y
-f
lq
N4PDUandGDU dspaybrghtnessva ue'0' m nimum -]
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MPDU and GDU display brightness va ue I

l:'--=: :r + : .. .
MPDU and GDU d sp ay br ghtness value '6'

MPDU and GDU dlsplay brghtnessva

Set zero ofSteerlng sensor

ue'7'- max muTr
a
+ I : s:.. tt-:- - -:.-
_. -
_ !:: z:-a ofBrake DTessure sei
+l-
+:: :
- , -

+
+:rl
l. - -' .-
aJ
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{,ita.lta§iéa: : ::+ Reset TRIP-I + Z Ressì Tr p_D stènre I and Trip_Distance_2
é

22/1,24 User Manual, §KODA Motorsport 27.3.2017

4
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 ÉroclA
4.3 GDU Display
Gear display is showing most important information for driver during race.
The display brightness can be changed through the Display menu, see section "MPDU Menu",
independently for day and night conditions.

High Beam LED (blue) Upshift LED'S (red) Alarm LED (orange)

To indicate high beam To indicate upshift request To indicate alarm.

Source of alarm to be checked on

MPDU display.

Left lndicator LED (green)

E
Right lndicator LED (green)

Flashes with left indicator lights. Flashes with right indicator Iights.

-I Displays engaged gear.

I When in ROAD mode - the digit is red, digit dot signals ON.

i 'rtilhen in STAGE mode - the digit is green, digit dot signals OFF.

upshift request in STAGE, the display changes from green to red together with upshift LEDs'
t il*1rexn

rrrher: -AUNCH START mode - the digit flashes'

t
*6ns "E" wtÉn the gearbox barrel sensor is disconnected or broken.
I
gro*s'P hfr€n sQnal is between the correct gears position - sensor is loose or not adjusted well'
I
Srffi.s 1tf m'-'wtten CAN communication is faul§.
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 J

4.4 Steering Wheel Buttons

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Washer
High Beam

To switch ON OFF high beam and extra lights (if

/
activated on the Switch Panel).
Activates washer and wiPer for
windscreen cleaning.
JJ
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J
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Wiper
lndicator

Press to left will activate left indicator 5x'

By first press the intermittent mode'

By second Press slow sPeed.

4
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Press to right will activate right indicator 5x'

À Lcng press (left or right) ensures it, remains By third Press fast sPeed.
a:: . e re,g, for standing at traff ic lights)' To off'
..... .::e t, push again to the same side' By fouÉh Press wiPer

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:-:- -::::
:'::-:e:
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27.3.2017
24/124 User Manual, SKoD,A Motorsport
 -::-il
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4.5 Co-driver's Buttons
Washer Reset

Activates washer and Resets the Trip distance

wiper for windscreen measured by the
cleaning. tripmaster.
Total distance must be
reseted in MDPU menu.

,y
 O a
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4,6 Stilo lntercom DG-1O
STA.IDAFIE' CcliilllANt,S
Lrn di$uhy fi{$it i.liri}!.n!
$ttEn sry bunon§ p.€6s lrylgl anybuttm bPr€§sd
ft6dsp§ysl§tfl§: tlbdsds/ stEus thÉ 88ttng
>à :. -r" rr T f,=€r Ef0W€mod6, of ÉlE€tdbn rìodé0,.§
:ri t[ ;-É:.t r* 'ahrRsd rncdè
.:!-- :È rE :r--as ;ìr€Es **-fr*a Volr*
R€6s tha nr§ Urìe:
ti§ctlsptsyilift§ rd
salowEthepl+sd\Dk rÉ,
tfÉ oth€r p,Bss clìarEE6

@w@ @
ihé vrluflié.

>::- i'en b.2 serÉs

r s, 3 ;r-s€ cal. Près§ thg
{ ry 2 sem.És to clc§,t.
-' ì j:l Ì.ì !.!:fll.ixì

3€ sfìcrt prBS§ the dott

rIl -:-
lsoiay btnks ald sf§rr§ thè
F*tldlrn€' PrassHi/er
- JÉ -to dusttlE
rc+lme also (l'dr€ a cal,
Tl'rs op€ratbn do€§1 €ff€cl
Pl§{ìe
§ @, §i-§iliìl èatls rili§{'
(àìfti:i{l*iirs l]liAl'l
Fressltteffi UIr§ tlE l€fi
-I
EZ
the inttrcom \dun€6. dsdaysfio\lt§ d,srd thè
nght disphy sfEws the Fr8€d

ffi___-
I A*rodge6s dutEEs bd$Een
rld$c$cstatlon radé.
0 = dlgltal ca§dètb{t crT.
1 : dlgita, cflc€lation n{rjrrum
r---"

g
2 = dlgilal carEdatbil rn€dum

Rt,{. ixll inae{} f* ;,*.;;l n$3{, {2i 3 = digrirl cJrcdstbn nÉxlTlun

Camsa cor}flg{tbn
ryTYTI lììi; li,f,r:
'r'iai..:,:À!rì:: : :r --
Actl\é
Acti\é
Actl\e
ActilrÈ
TlÉ s€cfid Ir6schatìgBs th6
IdsÉ carcalafion rnoè (0..3).
ilstli,: NO Acli\6
Fl"1iii.: NO Acthé

AD\,AìICED (}OMi'ANDS
Liltl $s{r.$} Fììnt d;tiar
'r' : Foadmoè's€bctbn YWgl }rll efibr h any
- irirÌ.:: F"3.1* rÈt ij.1i1: g' = Canìqa/ffdb oùÉì S§ng odfrqrrdixl tncde, I bar{§
Press 'i' tq Sout 3 s€conds h 't' = TdoptlorÉ\roLFie§€aÙ§ §ìo\r&R th€vaLE to sat
cr6r b etivéde "Cdna/Eado n' = Sfr€aoofi arrban setthg
o.1 gsn s€ftfE', tharì stÉrtt §à;:i,- riir &§li<i.{il
cr6s ùÀq '+" oa "-" ror aqust Èess'+' lcr &out 3
:'E QAn. so{tè hordeato
adi!6tè "Btj€boùÌ aLdb

@H@ 4@
otrt sdtird', ttst shstly
di\g r+r or !t-'!
Boss
tor &frg tle gEi!

:f,'$T@ BII 4
b - ixaern3Sàconds
r ,-g ts sr?ci inldwn h
si3rat\ rcdÉ
F,ts rY U"tEì Eòod
'ec.rÉ'..:mmt1e
\@ lsls'{,{.r* §l§
Pr§'JkabqrS
snds
htermm in st@
}"*i-}'

h o.dea to s',ì&n
rnodè.
*ry b{rtton sbod
PrÉ6s
nEra 16ècmdlo.tumon
tholn§am.
:: iJ il /..;, r1
. it*out2 s§ìdsh ùÉrtodvde"Fbfi,

J
Th€ i€lsn lrB dr s.IppòrrrE \dtalP to the R,shdorrrn l

poEcauea+ red. - dacj{FarEE1È&\Ct mods sebdba", tì€n shodly p.ess lt srrfich b€tx,€eo: lr ;

n s r€rffiidd tha i'oJ csrì€ct tlE ltrfcom . 'fim<l ltilode d6nt

lrilode 1 ' = §tvry rS
rs
tÉc€h€
L6rrE the ca, rÈ1 snllEh c. a dedcded s/ttctì. I . tÉptooecommlnbsdbr§,§o-dt\sdo€6it
rÉErtDnecommlnbsdbr§,§o-dhsdo€Git I

. 'tqoad t\ilodè ? = Both }lvsatd c+di!ryrècàtve ',

' rdD and plìorE conmw*:dofls

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26/724 User Manual, SKODA Mctorsport
273.2411

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> BLUETOOTH COMMAN:'S
=
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{Sl}àt*#Sl L§n i
./'-'---"'""'-'-"
§§u*§!+{! Tur"*t{
NsnBiylh6 Bue,both tse ì Prrcne mO U:ticn fìn abcut 5
I
§Òry HH< = BT b on and rcady f6r
arto tunls$n to geù|s r{lh kUhk=8T§ispalirumode I s*orrb{unff thebÀrLED isseagin I
thÒ kircom Oil=BTiscfi ! ordsrb trndf tlt Effreboth q,Sè.n.,1
t ll is possige tc swihh-on ths
Blu€'toofi by tr*dng the gr€È.t
Afion tor abc..{ 5 i€conls (i,

I th€ Blustcoth cÉr ptsri€rJsly

swii6hsdoO

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d 1. Prs lh6 gr€m Uitbr f.r sbout 5 §occ.td§ (rrll fhe bl.E LED B §€ryI
2. BhisLEDtrrls ott
I 3, Fls trì. grsn br Òclrt 7 seorÉs (unu tls bà.r6 LED drt! b Efrk @;
1 4" tÒok h. OG10 Blustoo& §ysErn *iih !q.r pàooc;
5. f rsquirrd, €.ts PIN csd. "!m".
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 SKODA
47 USB logger
ECU has an option to store the logger data to external USB flash.
SKODA is using USB disk OOO.9OO.OO7.A.

USB disc specif ication:

> USB 2.O
>
>
8GB capacity
compact package, not standard
3
Following formatting to be used:
> FAT32
> 32 kBlcluster
Note: =
4
Engine should not be started soon after Main Switch activation, to ensure the
correct data is recorded on the USB key - wait till MPDU display is fully active.
Note2: For the same purpose, turn off the Main Switch at least 3 seconds after engine off.
Note3: lt is recommended to download all data from internal logger in the ECU after each I hours of
recording, to have backup of all data from the car!

Location of USB disc connector under the dashboard: =

-

:l
ril# 4
=

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28/1-24 User Manual, sKOD,A N,,lotorsport 27.3.2017

4
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 Ér<oDA
4.8 Device supply connectors
There are several connectors to supply electrical devices in the car.

Name Location Max. Current Gonnector

457 - lntereom On tunnel, between seats 2A DTMO6.3S
Pin Function
+12V lntercom 1
2 +12V lntercom 2
3 GND

Name Location Max Qrrrent Connec{or

A54 - Soare 2 At oowerbox left side of tunnel 154 DTOS-2S
Pin Function
1 +12Y
2 GND

Name Location Mar Current Connector

459 - Maolioht2 Under dashboard. riqht side 1A AMP 2,8 F

,ltf
 ÉxoDA
4.9 Recommended Revisions
1

.-
:-r
:l
:entra panel oom ;vT97r r 59B 350km 55 2 000km SS 5 000km 55
ì{
*l
\4ain loom 5VT97t I 31 D l50km SS ) 000km SS 5 000km SS E
r loom 3VT97t 346C l50km SS i 000km SS 5 000km SS
qlternator cable 3V19722238 l50km 55 'l 000km SS I 000km SS
:ront left loom (FL) tvT97t 0l 7c l50km SS 5 000km 55 ;000km SS
:ront riqht ìoom fFRl lvT97 t0't BB l50km Ss 5 000km SS ;000km SS ---1
Rear loom
sth door loom
;vT97t t96A
)VT97ll47A
l50km SS
l50km SS
5 000km
5 000km SS
55 ;000km
i 000km 55
SS
E:=
]
Steerinq wheel switches loom avT97)477A 350km SS 2 000km SS 2 000km S5
Gearbox loom
Co-driver footrest loom
6VT0553078
6VT97t l674
350km 55
-ì50km SS
2 000km SS
5 000km SS
I 000km SS
5 000km SS
é
ndi.af^r l^^n 51T055348 5 000km 55 5 000km 55
-r50km SS
lYirror Ioom 5 T94-l
',t
8t l50km 55 5 000km 55 5 000km SS é

Car sDeed sensor 6VT90521 5A 350km SS l000km SS 2000km S5

4
J
f_l
Gearbox barrel Dosltion sensor 6V19064338 l50km Ss 2000km SS 200okm 5S

F)
3ear sh ft sensor 6VT907388 l50km SS :000km 55 2000km S5
Sìeer nq wheel anq e sensoT 5 T907469 350km SS 2000km SS 2000km SS
Brake pressure sensor 16t90605r c 350km 5S 5 000km 5S 5 000km SS
lccelerator peda pos tion sensor 6VT907475 l50km SS ?000km SS 2000km SS
l::rbor 0 TemDerdture Sefsor 6VT906088 l50km 5S 2000km 55 2000km 55 E
I -:-?nt a 0 I TemDerature Sensor 5VT906088A 350km SS
-l000km
55 2000km SS
-
F
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3a/724 User Manual, SKODA Motorsport 27.3.2017
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 Éxooa t

5 Engine

5.1 Operational and Maximal Engine Values (pressure, temperature...)

Pleasefindbelowthenormal operaic^ -a^qeo'crucial enginevaluesandsignals.

Normal Operational
Variable Signal Name Range Extreme Value
Ffaraet Valuel
Electric System | -r:-ev@ 2oA (engine on)
VBatt i -135 V @ 5OA (engine on)
voltage
i -122V@ OA(engineofF)
Oillevel -r -- - - S=: :-:::e' 'OÌl
:.: :a:: - :
Oil consumption .2: -:a-- l5 lOOkm

Engine water
8G11().C I '125'c-
temperature
I95
ocl i
tWater
Temperatures Engine oil temperature 9G135qC I 150 --
-- "c
toil 1125 0Cì i
Exhaust temperature
T4 7OO-9OOoC 93OoCforshorterthan 5 s
tExhaust
Water pressure <1.2bar t0.15 t,Rr
Pressure oWater
(R=relative) <1.5 bar (R) @ 3 500 RPM for
Oil pressure
(A=absolute) 3.O -5.5 bar (R) longer than 2 seconds when
pOil
7 7OO RPM - above this RPM
Engine RPM <7 soo RPM (FrA) the overrev sum is calculated
NEng
RPM to track the enqine lifetime
Turbocharger RPM '125k-170k RPM
190 000 RPM
NChrorl 125 OOO-170 OOO RPMI
lf ELB not connected then
i-3 ogger ELB_Status Link ON (=7) Link lost (+7)

Stage: 4O-7O l/'1OO km

:-: ::-;-rption Road:15-25 l/1OO km
Dependent on the track
 5.2 Engine fuel mapping
o
ÉxoDA
-

§XOOa provides fuel mappings for the following fuels:

> Carless Hiperflo WRC

> Carless Hiperflo Ultimate
> EIf ADVR
> oMV100
> P1 1O2Rx
> Panta 102 NS
> Panta 114 WRC
> Panta 102 Max
> ETSTBX5 EVO3
> ELF PerfolO5
> MOL
> ETS Extra Max
> Elf Turbo Ref
> ETSTBX6R5
> Carless Hiperflow Turbo Ultimate Dev2
> RTF Fuel

Each fuel has to be used only with the corresponding mapping otherwise the engine can be destroyed!!!

32/124 User Manual, SKODA Motorsport 273.2417

 ÉxoDA
5.3 Engine start/stop
5.3.1 Engine staÉ
When starting the engine follow the instructions bellow

1) Switch ON Main Switch,lgnition (Kill)Switch OFF

EÉÉ
trtrtr
trÉE
ÉÉÉ
EEts

2) Shift neutral
(t
3) Do not stand on any pedal
4l Press and hold (not more than losec continuously) the Start button to crank the engine. Repeat
until Poil > lbar (check the MPDU Display)

E tr fì,| Gea r 5p**d

0123
rt.il l? nr , I ir lllrr
**Se
t*ta
012
p 0
Lrrnrter 012
ur b0 §1 23 bar
exh
oil
mo'l ?3 ffi
Foil ùi23 uu,
ater fr1?3 oc

5 Wtren desired pressure is reached switch ON the lgnition switch and start the engine. Do not
cress dutch and throttle pedal during or after the start

a q?? F_ngirc stop

rhhs a-rmtrrrq dl'E engine, it is recommended to switch to road mode and wait until Text temPerature
= irrc.( J,.ml.55CIPC"

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 5.4 Engine power test
o
Éxoor
Engine test page is used for checking if the engine delivers the expected Power. Fo- :- : :::: : :

necessary to switch to STAGE mode - test does not depend on MAP (map 1 - 5 can ie *:-:
After switching to STAGE mode make acceleration in straight linewith full pedal on 4'- o- i :::
you reach the engine speed higher than 55OO the label for actual engine speed will be lit "' :- :-:
background colour

NGlltl E {t1r3
ENG!NE TEST
':r, 5500 r p*r flg
EDAL tI{ r3
H ROT IT{ T3
URBO tI1T§

22TGT
While driving check the following parameters:
a) Pedal - must have green background = fully pressed
b) Throttle - must have green background = fully opened
: Turbo - must have green background = value is higher than 135 000 RPM
: P22and P22TGT bar graph showing approximately same values or P22 is little higher than P22TGT
- =.:-.ihing from above is OK - engine power is in good condition - it is necessary to check
-::-3^ :a damage which could decrease the engine power.
i-g .. power test problem list
possible

4
=
:.:: 'ct reaching 1OO %
1) Check if something is not stuck under the pedal
2t Calibrate pedal and throttle (see chapter Calibration Pedal x Throftle)
Throtde not reaching lOOoÀ
4
1) ls the ERR dot red? Press RESET ERROR button on switch panel and if green test again

4
2l Calibrate pedal and throttle (see chapter Catibration Pedal xThrottle)
Turbo speed does not show green backEround
1) ls the ERR dot red? Press RESET ERROR button and if green test again
2l Continue to next point
5
4
d) P22is lawer than P22TGT EI
1) ls the ERR dot red? Press RESET ERROR button and if the dot is green test again
2) Check leak in the system - are all hoses mounted correctly? No hole in the intercooler?
-)

34/124 User Manuaì, §KODA Motorsport

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 ÉxoDA
5.5 FIA Limiter
,,/aximal engine RPM is given by FIA rules and is 7.500 RPM. After this level all the cylinders will ha'u'e c-:
-.lection and ignition^

5.5.1 Overrev Counting

To track the engine lifetime and prevent engine damage engine overrevs (time spent above 7 7OO RPM)
are counted by the channel overrevsum=integ (IFGT( '' '-: ,77OO\*( -77OO»-

> When the counter reaches 3 O0O units for the lifetime of the engine from the last revision, the engine
has to be sent for revision.
> lf RPM '1 time > I 3OO the engine has to be sent for revision.
> lf RPM 3 times > I OO0 the engine has to be sent for revision.

4.
 ÉxoDA
5.6 Road x Stage Mode
-^e engine is equipped with different mapping for stage operation and road operatio: "' :-:: - -:' :-:
siage oieration is to deliver the highest possible dynamics and power of
the engine whereas - -- - - ::
:re main focus is on minimal consumption .fhe road/stage is toggled by the "Stage" button o: :- : :--
'
panel and indicated by the green light above the button'

ffiB
ffiE
mffi g
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H@ 4
Road mode differences:

4
1. ALS NOT available.
2. Less aggressive pedal mapping to enable easier handling when taking off.
3. No injection for off-throttle operation to save fuel'
4. Different injected amount to save fuel.
5.
6.
Launch start is not allowed.
Lower RPM limiter.

5.7 Launch StaÉ (L.S.)

4
a
-)
The launch start procedure is intended for a quick standing start at the beginning of a rally stage'
The
.o'rect procedure is: -
' .'. z-- the engine and the car up to the operational temperatures'
- --= -: -^cr start RPM is displayed on the MPDU Display
=
-

urbo 0123
-j".'--
'p".
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0123 'p*
iT
ir zz
AnB 0123
0123
"c P
% ? 27
AUB 01Z3
q1?1
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r ExH I ". ? 22 0123 -0,
r wAr 0123 'c r GBx 0123 'c
r otL 0123'c r DIFF 0123 "c -r-;-

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36/724 User Manual, SKODA MotorsPort
27.3.2017
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3 rress the "Limiter" button on the switch panel several times to select the desired starting RPM. For
good grip select'7 OOO RPM (higher), slippery conditions'5 OOO RPM (lower).

4. Turn on STAGE mode and select the desired ALS level by "MAP SW".
5. Rev the engine a few times to increase the exhaust temperature above 7OO "C.
6. Shift first (or second) gear at least 3 seconds before activatlng the Launch start.
7. Press the "Launch start" button on the steering wheel.

--: 3ear display digit starts flashing indicating the launch start procedure.

: -:::^rottleinthedesired(pressed) positionatleast3secondsbeforethereal starttoprovide

: - -- -: - : ne f or the turbocharger to reach the optimal RPM.
' -:: --^-:----:rrwstAlt.
^ -^L !^ ^

- - :- . ..' :eaches lO km/h + l second the Launch start function start is automatically deactivated
- =

.-: -. -.--:- s:ar:'"viil notbeallowed ifthecarspeedsensorfails.

, :. - : :: : -: :-: -? -"ch start press and hold the "Launch start" button for 5 seconds.

Ir
 4
@
Éxosa
58 Turbocharger
581 Antilag System (ALS)
As the engine is turbocharged, it is fitted with an antilag function to improve the response of the
turbocharger when going from off and back on throttle. Select the level of the generated boost pressure
for off-throttle operation by selecting the position of the rotary switch (MAP SW) on the switch panel.

g
=

4
The ALS is activated in stage mode only. The ALS intensity selection is as follows (increasing intensity):
a
-
Positionl-noALS
Position
Position
Position
2
3
4
- minimal ALS (very slippery condition)
-:l
E
=
Position 5 - maximal ALS (perfect grip tarmac)

:s a safety function to prevent turbocharger damage when the engine is idling and the car is not moving
:-e : -S will be deactivated after 1O seconds. The ALS is then activated as soon as the pedal is pressed.

5 8.2 MaximalTurbocharger RPM a

-: '.'-;
a
? crv€d RPM of the turbocharger determined by the manufacturer is 180 OOO RPM. When
:^ : :- -:: - :
: s :::ceeded (turbocharger overrev) for a given time (wrong connection of the pipes, control
.: ,.. ': --= :- = s:retv function is triggered to prevent turbocharger damage:
E
) It first tries to srivitch the control of upper and lower chamber of the Waste gate (common situation
when lìoses were not connected properly, e.g. swapped).
-f
lf that does not help tre power of the engine is reduced to prevent turbocharger destruction which
-g
J
b)
would be inevitable.
.E
Both errors are clearty marked in tfre Error Manager
Strategies".
- see chapter "Errors - Error Manager, Backup
J
E
)
-a
38/124 User Manual, SKoDA Motorsport 27.3.2017

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J 5.8.3 Waste gate Connection Diagram
A connection diagram for hoses and waste gate valves is depicted below. Onlythis connection assures
= correct function of the turbocharger regulation"
3
3

5.8.4 Waste gate Preload Setting

he waste qate preload has to b set as follows:
Opening pressure 0.3-0.35 bar (Relative)
Travel at O.8 bar (Relative) 11-11.5 mm

Apply overpressure to the upper chamber with pistol pump

With 0.3-0.35 bar - the rod should start moving
With 0.8 bar - the rod should have moved 11-1L.5mm
-a

i o., 0",. = 11-11.5mm

T f
I
CIf rrr oreÉim srres eorrect function of the turbocharger regulation. lncorrect connectirxr
cr hgc yur trbocharg€r!
a To -ft- oÉn l performance of the engine and minimum regulation time of fte hrrboctrargiel
I t"d dÈÈ b buy togpttrer assembly of turbocharger and WG actuator frorn §XOOA" grclr an
ecÉ;- s.c-rrretely_set with SXOOA preload tools NeveÉheless, if you irave b e:rctrange the
! ffi ffi h th firad Sxool provirles bulletin describing ttre procedure.

I
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5-g Calibration Pedal x Throttle

Ércooa 4
mJ b udranged or flashed, when a pedal is exchanged, when a pedal sensor is exchanged
4
When an
when a tincÉde body is exchanged and before every race event calibration of the pedal and throttle has to
be perfwrned.

Fofmr $r Procedure:

=
f
i ,". : : ^ off the "MAIN SW" L___r
:- liess throttle pedal, switch'MAIN SW" on =
-
=e: the throttle pedal fully pressed min 11s, max'l5s
l e ease the throttle pedal --> automatic calibration should start
g
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4,
e
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:f
-:f
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5 Optional: Check the progress of the automatic calibration in SYSMA in Iabel pedThrLearnState. The
state should change from lnit --> pedal Max -+ pedal Min -+ Throttle -+ Succeeded.
Successful automatic calibration is indicated by the state: Succeeded.
-

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40/724 User Manual, SKODA Motorsport
273.2417

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lZ 5.10 ELB Logger
The device is intended to track engine crucial parameters such as mileage, time in stage and road, extreme
a
temperatures and pressures, sensor failures etc. to assure that the history of the engine before revision is
I known. The ELB logger is a homologated component and has to be connected on every engine/car and
sealed to the engine loom and the ELB holder.

É#!.Brz

i;eG#§ar
-: q#?#r3,,
' -- - .*-*

w 3 --<§

6VT- I 99-357-c

of every team to check if their device is communicating with the ECU (please check
ElB-Sfafus=Link ON=7). ELB records have to match the WINTAX data as complete
resent before the engine revision.
e founrd in service menu of MPDU display, see chapter MPDU Display

!
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5.11 Alarms 4
)
:-. ..' :'. -: es ,,.vill be announced to the driver by constant blinking of the orange
a
-ì:- diode in the right
::-:-: :':-= llL - see chapter"GDU display" fordetailed GDU description.
: : :--: .,, oeshownon MPDU displayaswell,seechapter"MPDUdisplay". -
--= :-'^-el AlarmDisp consists of bit coded information where each bit has a given meaning, see chapter
-J
-J
: - - :-'Service 3 - Sensor Error". .--l
__l
5.12Errors - Error Manager, Backup Strategies
-he engine management system is equipped with advance error detection and with backup functions to
always deliver the highest possible performance and to prevent engine damage.
J
=
)
Signal MaskErr returns the bit coded information about the detected error. Below is a list explaining the
-2
meaning of each bit and the backup function used in case of error detection. );1
lf error is identified and resolved, please erase the error by pressing the "RESET Error" button on the
switch panel for 5s and reset the car (switch sf,f and on maln switch) the car - see ehapter "E!'ror
-J
erasett.
-l
4-
é
4
Bit # Description Detail, Backup Function Action to Be Taken ?4
--1
.1
Bit 0 Ambient Modelled value used to replace the Replace the sensor, check the
pressure failed sensor. Ioom.
sensor failure -4
-4
E=
Bit 1 Manifold Modelled value used to replace the Replace the sensor, check the
--
pressure failed sensor. loom.
sensor failure =
F1

-a L Pressure Modelled value used to replace the Replace the sensor, check the ?_/_
before throttle failed sensor. loom. >1
se.soT failure --à
=
^: - i ^:a -
Only warning. lf the charger speed Check the preload of the waste é
^: gate spring. Check the connection
I remains above the threshold actions
^ _

will be taken. See chapter "Maximal of the waste gate. Check the T=
-,J/

a- -, = turbocharger RPM". See also Bit16.É functionali§ of the waste gate

-2^ -- _ lli i
Bit3 artd'16 active the ECU remove the vatves.
power. -
Exhaust Replace the sensor, check the
É
Bit 4 I Modelled value used to replace the
temperaEure
|
fuiled sensor. loom.
E
È-
E=
é
É
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42/124 User Manual, SKODA Motorsport 27.3.2017
k--1
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-=
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Bit 5 Charger speed Sometimes can happen that sensor Cool down the transducer or
5.< sensor failure transducer on the air box can be change the sensor.
= overheated.

--t Modelled value used to replace the

failed sensor.
= Bit 6 Knock sensor Global ignition retard is used. Exact Replace the sensor, check the
- failure value dependent on RpM and load loom.

BitT WGl Open No WG control.

= circuit
Check air tightness of the system
(hoses, intercooler...). §XOOa can
= provide a tool for that.
:=
= Bit 8 Throttle pedal lf one track in a position sensor fails Replace the sensor, check the
:= problem the other track is used. loom.

= Bit 9 Lambda too Only warning. The lambda regulation Check the signal from the lambda
rich had to continuously enlean. regulation FacLamCtl. lf in partial
+ and full throttle operation still
constant enleanment (>1.25)
check the injectors, check the
lambda probe.
=
Bit 10 Lambda too Only warning. The lambda regulation
=
t Check the signal from the lambda
lean had to enrich constantly. regulation FacLamCtl. lf in partial
=
f and full throttle operation still
constant enrichment (>0.75)
-4 check the injectors, check the
lambda probe.
a
-
Bit'11 Gearbox barrel As barrel position is unknown constant
-a failure cut time during shifting will be used.
Replace the sensor, check the
loom.
a
! 1 Lambda sensor
=- Lambda regulation will be disabled. Replace the sensor, check the
a
I failure
loom.

I tsdt 13 | Rail pressure Open loop (no feedback) regulation for Replace the sensor, check the
I sensor failure fuel high pressure will be used. loom.
i
! No cut during shifting. Throtfle tift off, Replace the sensor, check the
or clutch has to be used for shifting. Ioom.
I

I
 À

- i ^^^r L
The sensor value drifted significantly Replace the sensor.
ÉrcoclA j
=
-= : -- -l so the validity of the signal is not
-

:'- ensured. Throttle lift off, or clutch has

=--! rgu to be used for shifting.
=
-- 5LdIL The ECU recognized long time charger Check the preload of the waste
crarger speed speed over-rev over the safety gate spring. Check the connection
overrev threshold defined by the manufacturer of the waste gate. Check the
recognized of the turbocharger. The power of the functionality of the waste gate
(over 18O.OOO engine was reduced to prevent valves. -
RPM) turbocharger destruction that would
be inevitable. When cause found ERASE
ERRORS (see chapter "Error
erase") and switch off and on
g
=
main switch.

Bit17 Charger speed Sometimes can happen that sensor Cool down the transducer or
-
sensor failure transducer on the air box can be change the sensor.
overheated.
When cause found ERASE
Modelled value used to replace the ERRORS (see chapter "Error
-
failed sensor. erase") and switch off and on
main switch. -
Bit 18 Crank sensor Only the Cam sensor is used for the Replace the sensor.

Bit 19
failure

Cam sensor
engine timing.

Only the Crank sensor is used for the Replace the sensor.
4
=
)
failure engine timing. Longer cranking time E
might be needed to start the engine.
:l
Bir 20 ELB logger no Only warning. Check the connection of the ELB
connection or change ELB logger.

l -- Throttle pedal Failure of sensor track 1, track 2 will be Replace the sensor, check the
problem - used. loom. )
track'1 E4
è
.. LL Failure of sensor track 2,
used.
track'l will be Replace the sensor, check the
loom.
J
=
)
Bit 23 WG vatvel =:a =-z:-: ." 3 .egr ation valve É1
fuilure - short sa: l^e:,: :tre',viring.
circuit è
é
Bit24 Lambda sensor Lambda regulat:or ;^,'i I be d sa: ed. Check the pins of the sensor
failure - open connector. Replace the sensor, é
circuit check the loom.
p:4
-_À
F=
44/724 User Manual, §KODA Motorspor'c
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 ÉxoclA
3t25 Rear Default value used instead (rear dif. fan Replace the sensor, check tne
differential willbe turned ON). loom.
temperature
sensor failure

Bìt 26 Gearbox Default value used instead. Replace the sensor, check the
temperature Ioom.
sensor failure

Bit27 Stuck throttle Safety: Engine injection switched off. ln normal engine operation the
pedal error should not occur.
The ECU detected a brake pedal
ln certain cases for example when
(pressure of the fluid) and throttle
bedding the brakes (brake and
pedal significantly pressed in the same throttle pedal pressed at the same
time for a long time), an error
time for an extended period of time.
could occur.

Check the pedal. Check the pedal

signal, Check the brake fluid
pressure signal.

When cause found ERASE

ERRORS (see chapter "Error
erase") and switclr off and on
main switch.

Bit 28 Throttle stuck Safe§: Engine injection switched off. Replace the throttle body.

The throttle body seems to be

damaged.

Bit 29 Car speed Default value used. Launch start will Replace the sensor, check the
sensor failure not be allowed. loom.

3:30 WGl Short no WG control Replace WG control valve.

circuit

T water sensor T water not corresponding with Toil Check T water sensor or replace.
c ia u sibility signal

tk
{l er*rys ntay be found on MPDU display on page service 3.

rtrrene.er Drcib{e check the state of the MaskErr to know the condition of your car control system.
--rs s * dìeckd also on the MPDU Display. On pages Normal 1 and 4 there has to be green LED above
:= =FIì re-
5.121 Error Erase
$
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Most of the detected errors have a self-healing capability. This means that the system recognizes uilen
the detected error was resolved (this functionality is active when engine is running). Sòme errorst
neverthqless, need to be erased for the system to recognize that the problem has bàen repaired. To
eliminate currently recognized errors, press the 'RESET ERROR' button on the switch panel for 5s and
switch off and on main switch.

5.12.2 Turbocharger speed sensor error

Because the sensor is coming from series production where temperatures under the hood are not
so high
the sensor in a race car can sometimes return very noisy signal.
The main reason is high temperature on the sensor amplifier - a part attached to the air box.

+!
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4
-

4
El
46/124 User Manual, §KODA Morcispo:
q
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lndication of error:

It is possible to see significant noise from the sensor in the logged data - probably for a short tirrp
after start of a stage - see picture bellowwith NChrgrl signal.

2l Due to the noise it may be possible that the ECU detects overspeed of the turbocharger. ln that
case MPDU Display will show red mark for Err indicator (small green/red dot) on the first page of
the display and engine will have limited power to prevent the turbocharger damage due to
overspeed.
Following actions should be done if such situation happens during rally

1) Check the service menu (service 3 - sensor error page) of the display to see what caused the
error - if it is ErrNChrgrMaxand/or ErrWg.

2) lf one of the errors is detected use a RESET ERROR button on the main panel to erase the
error(s). Hold the button for 5 seconds. Then'switch OFF and ON the Main switch of the car.

1'- er'*ar happens repeatedly check the logged data whether the power reduction is caused by
Bse or if tfrc charger really overrevs. lf necessary replace the sensor.
-
How to avoid the problem with the sensorl
0
Éxooa
1) Check if the sensor is mounted on airbox
2) Check if the fixation of the sensor is strong enough.
3) lf the car is to be stopped somewhere for a longer time (railroad crossing, Iong waiting beforeltE
start of the stage) stop the engine to cool down the engine bay.

5.13 Adaptations
The system has the ability to learn certain values such as:

> Continuousenrichment/enleanment
> Maximal intake manifold pressure to prevent pop-off opening
> Knocking Iimits

5.13.1 Adaptations Erase

To erase the learned, values press the 'RESET Errortr button for min 3 seconds

Note:
It is advised to erase errors and adaptation values before every event.

User Manual, §KODA l"/otorsport 27.3.2017

 il

ÉxoDA
; 5.14 Water circuit
5.14.1 Water circuit bleeding
I

circuit is going to bleed itself' lfs onty

special procedure to bleed water system is not necessary. water
the engine and fill up to level mark' if
I

required to check water level after filling the system and warming
I

I necessary. The possible trapped air should escape through the

bleeding hoses when the thermoregulator
I oC'
opens. Opening temperature is approximately 95
I

5.14,2 Water circuit for heater and non-heater version

I
Car can run with or without heater' The parts for
Heater connected
1 conversion are supplied with the car'

I To connect heater, drain the circuit and use suplied

6VT 121 155 B
tI tubes to connect heater with engine according to
picture. 6VT 121 ',154 A
t

l
a
É

a
B and 6VT'121 154 A
To remove heater, drain the circuit and remove two connecting tubes 6W 121155
-1 from engine bay. Replace them with bypass tube 6W 121155 C. The open
dashes to cockpit heater
the bleeding see paragraph
should be closed by the supplied caps. Fill the water circuit again, regarding
a
- 5.'14.1above.

=
a

=
1

=
-

-
=
- 6VT121155 C

--
-
4

=
-4
 5.15 Engine Maintenance
0
Èxooa
5.15.1 Clutch operation - thrust bearing (axial bearing)

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

For this reason, do not press and hold the clutch pedal for longer than 2O seconds! Pressing the pedal
ionger 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 pressed clutch {there is no reason for that),
'. Do not press and hold longer than 20 seconds,
: vlhen longer hold of the pedal is needed after 20 seconds 2x completely reJease and press the clutch
cedal. This assures lubrication of the axial bearing.
: "cir can then press and hold for another 20 seconds.
. r:leat point (c) for longer hold operation.

S' : : r provides Wintax mathematical channel (C/utchPressTooLong-Rlcust) that tries to calculate how
:-_::-e clutch was pressed for. As the clutch pressure/travel sensor is not allowed, this channel only
:: :- a:es the approximate time (idle + gear in = pressed clutched). Use this channel to check the
: r : -: : -.:e tlme of the pressed clutch.

-^. .^e--e s oniy informative.

5a'724 Jser MarLal. 5kODa lrcrc.:;:: 27.3.2017

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5.15.2 Check of thrust washer status - axial clearance of crankshaft
$
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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.

f 2) ln the space under the right side rail, install the timing gauge. The gauge has to be firmly attached to
stable and not moving part of the engine (best to engine block). The head of the timing gauge has to
-t be in contact with the bolt of the alternator pulley and has to be oriented in the crankshaft axis.

3
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=
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3, Push the flywheel inside the engine block. ln this end position,
set the timing gaùge . i -: :: ,:. :

4')Push back the flywheel from the engine block. At the opposite end position,
read the value of the
timing gauge.
5) lf the measured clearance is bigger than o.3 mm, please contact
§xooa customer service. Such an
engine should not be used and can be significantly damaged if not exchanged.

J
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52/124 User Manual, SKODA Mo!ors:c:

27 3.2A11

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5.15.3 Oil Level Check - Standard Engine Oil Filling

!=
!= Oil volume

settings
= To set right volume of oil in R5 engine is necessary to follow exactly
procedure written
below:
=
to the car' or
= This procedure is important to do just with new engine and first insertion
É after change of oil sumP diP stick'
-
--
let the
-t 1) When receive engine and install to the car, unscrew oil sump plug and
be final position with the
- engine completely drain (10 min, the engine must in

t gearbox).
- 2) Plug the oìl sumP.
- 3) lnsert oil to the engine 4,751.
=+ 4) check the oil sump dipstick and make mark wlth some sharp tooling in
position,

-
=4
=:i
E

:-
é
-
-
-
-
:- 5) Run in the engine and let the oil flow thru the engine'
6) lf necessary insert oil to be on the mark.
7) For next changes of oil use this mark as prescription'
-
: All Dip Sticks are after marking unique and matched with engine. After marking
is not
possible to change the oil dip stick to other engines'
I

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5.15.4 Flywheel tightening procedure

To fit the flywheel properly is necessary to follow exactly procedure written below:
1) Check the position of the clutch bearing- bearing has to be placed in the crankshaft
properly. Gap between the flywheel and the bearing has to be o.o5 - 0.35 mm (checked
during assembling state - see Step 1) - see Picture 1

Pic.ture 1
Flywheel
2) For each mounting of the flywheel use NEW ARp flywheel bolts - see picture 2
tightening
procedure

5t
37

84
26
+
4
=

Picture 2 Picture 3
-
-: :.:e :re bolt under the head with ARp lubricant - ARp Ultra-Torque
-
I : - : : ::- :^'ead on the bolt, keepthesurface in original condition
botts for 3ONm in order as on picture 3
ts 9odeg in the same order (turn of gOdeg has to be done in one stroke).

4
54/724 User Manual, SKODA I^rc::-:::: 27.3.2011

4
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=
5.15.5 Spark plugs tightening procedure
0
Éxooa

According to the supplier information the NGK spark ptug type R7438-9 should be
tightened to 2ONm if the cylinder head is aluminium and the diameter is M14. Please
follow the procedure bellow:

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

Spark
plugs
tightening
procedure

2) lnstall the spark plug and tighten to 2ONm.

3) Untighten the spark plug and tighten again to 2ONm.
 ,/{-l
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5.15.6 Change of Accessories Belt

Layout of accessory belt

Onginal functional Po§tion

§
4

4..
{

RÉEwith bolt on the tensioner (2), (blue arrow) into the mounting position'
(1)

lnsert stid( (3) into tfe mounting hole'

Rerrpve beft frst m the tensioner and then on the others'
(5) and alternator
ffi, put ùE lsv bclt srb the crankshaft pulley (4), then onto the guide pulley
pufe), (O, Hy pcÉtin the erxi'oner (2).
Rota6withtendrrs(yelorrrrov) and removethe stick (3)from the mounting hole'

stotryty rdce the E,rdrxrcr (a urdil it b in its original functional position.

4
Tools needed:
17 r* s .: .'. -:-:-

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56/124 User Manual, SKODA Mctcis:;a

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- 5.15.7 Engine start-up after the car roll - over (procedure in the service zone)

I Procedure for the service zone describing what to do with the engine when the car rolls
over the roof.

I 1) visually check the engine bay - Ieakage of coolant, oil and fuel, no parts damaged
2) check the air system - no dirt ahead and behind the airbox, air filter not damaged
{ 3) Take the spark plugs out from the engine
I 4) Check the top of the pistons through the spark plugs hole. lf you see small amount of oilfuel,
I
clean the combustion chamber using pressed air
t
I 5) Turn with the engine with ignitlon switch OFF (injection OFF) - Engine sounds normal? During
several first turns, the remaining oil can spray out from the combustion chamber.
a 6) Oil change - check the oil level and if necessary add oil to reach the mark on the dipstick
t 7) lnsert new spark plugs into the engine
I 8) Turn oN/oFF the ignition switch 3 times - check if fuel pressure is constant, higher than 4 bar
ì1 and there is no fuel leak in the engine bay - visually check
9) Start the engine
I
a
1O) Visually check the engine bay - no leak. Check the data

i
i 5.15.8 Driver Safety Function

i
For safety purposes (stuck throttle pedal) a throttle-pedal to brake-pressure overlay check is continuously
performed. lf the
ECU detected brake pedal (fluid pressure) and the accelerator pedal is significantly
i pressed at the same time for an extended period of time, the injection will be cut.
I
An error should not occur in normal engine operation. ln certain non-standard cases, for example when
I bedding the brake pads (brake and pedal pressed at the same time for a long time), the error can be
I
erased - see chapter Error Erase
i
I

I
I 5.15.9 Fuel system bleeding after fuel/engine change

' -!rn ON the Main Switch

- ^ )DU menu switch ON function ,,Fuel tank to drain,,
: ,'. : : 10 seconds and switch off function ,,Fuel tank to drain,,
- :... ::^ CFF the Main Switch
' I: :=:
:
:-: Ìuel system on connection on High pressure pump
- -- -^^ t ^t -
(Use papers around connection to
: ::: - : _:;o ng fuel, bleed only cold system _ cold exhaust etc.)

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SKODA

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-; =
§.: -*§
fEÉ
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=

6) lf the air coming from the hose repeat process from step 1.
4
=

7) Try to start car with normal procedure. -

8) lf the engine stalled repeat process from step 1.

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User Manual, SKODA Vc:c-s:.:

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5.16 Sealing
-
ì+
E= 5.16J Sealing of the PoP-off valve
> The diameter of all drilled holes is o1,5mm
--
....
-
Drilled mounting bolt
=
E Drilled mounting bolt
-
>

-
B

--
È=
Drilled rib on intake manifold
a: r
>-=_-

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Seal to be glued on Pop-Off tube

tr
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 ÉxoDA
5.16.2 Sealing of the restrictor and turbocharger

Wire pass through drilled

holes on the bearing
housing and air comPressor
housing

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1
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6a/724 User Manual, SKODA MotorspoL É
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Drilled mounting screw of the restrictor

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5.16.3 Sealing of the engine block

FI
ili' :*
iw§
É
ru#
È.'

&.é

=
=
Hole1,5 mm drilled
through the bolt boss.
Seal is glued on the
engine housing.

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:.]'t

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62/724 User Manual, §KODA Mc:o-strr:

 5.17 Durability of the PaÉs
0
Éxooa
1
Durability and exchange intervals of the main parts are listed below: d
,',;,;alll,.l:-
PaÉ No Recommended Replacement
=t Engine without turbocharger 6VT100028C After every rally 2 00Okm SS revision / 4 0O0km SS revision
= Turbocharger 6VT145689 After every rally 2 00Okm SS
!:! 6Vr200217D After every rally 5 000km SS
t Exhaust line
Water coolinq 6W'121089K After every rally 5 00okm SS
=t
t After every rally
whole assembly.
Check and
a eventually repair
Air intake 6W129519C 5.000km SS
, Camlocks for proper
mating rear and
front part of Air
-, intake
Breathing tank 6W1032358 Drain aiter every SS 5 OOOkm SS
z Air filter 6l'11129634 After every ra v 5C0k-r SS
- Engine oil N052'19500 After every raL v 5C3kr SS
f Oil filter 061115401 After every rally 5I3i:- SS

Spark plugs 000900064 Ailer even. ia, , 83C<.: SS

Alternator belt 000'100100 After e'"er,. -a 53Ckn SS
=
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5.18 Engine revision
5.18.1 General lnformation

This document will be subject to updates and/or additions. The provisirxrs h dEr .er,Érrrs d tfle rnangd
will be applicable from the date of their entry into force. They will replace md cencÈ the prwisions of the
former version as from the date of their implementation.

Non-observance of the recommendations of this manual may automati:ally

and maintenance of the engine on the appreciation
rn rr€i@fu let the repair
of §XOOA MotorsporL Al r=rrt rfl be paid by the
1
customer and may require §XOOA Motorsport to carry out work on the er{ire
In addition, non-observance will have the immediate and automatic conse$-rere:::a dl re annor.rnced
performance characteristics of the engine will be considered no longer valid r Sirelr, -=sc:re6.
=-
Any engine damage resulting from the team incorrect maintenance or any serd yatqE e tfre final
decision concerning the work on the engine on the appreciation of §XOOa llcrW"

ln case of crash or fire in the engine bay, §KoDA is not responsible for change of pnts

In case of trouble with the engine §KODA MotorspoÉ will be open to discuss a :c,- -"=-:;l :e.sr- .= -
the following is provided (more detail in next oages):

- Engine without damage

- All seals are present on the engine (3 seals).
-_r
- Full Wintax history of the engine is provided -
- ELB logger shows no issues
- No over Revs
- Strict respecting of Dashboard alarms
- Engine transpoÉ procedure respected
- Engine maintenance and service intervals respected

For any further information, contact both persons:

-f
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=
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Vàcdav Trkola
yadav.ffi ola@skoda -a uto.cz
SKODA Al-rTO a-s, ti. Véclava Klementa 869,
293 6(} Mbdà Boleslav,
4
CzecÌr Republb
T +42A 326814269
M+4m60429'2433

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5.18.2 Engine transPoÉ

When the customer delivers the engine to SKODA Motorsport it is necessary to respect all the following
points below (see pictures):

):.3.2C'7
 ÉxoDA
Send your engine with its ECU (if not possible, for example ryfienrriE Ft cilEin h lùe car,
SXOOI Motorsport has to be informed in advance) and ELB togger fud r ts rlerncamd fu-
case, with its top.

Send your engine without any liquids (oil, water, fuel).

Send the engine clean, in case of not will be required 5OO€ for deanig-
Do not send, clutch, air filter, exhaust line, alternator, alternatr br#. *criq prrp and

steering pump coupling.

Leave on your engine, engine loom, coil loom, flywheel, throttle bodf" C 585 Erbocftarge,
Waste gate actuator and Waste gate valves...
Put on the engine all caps delivered with the engine and the HP ryrpffierrry F*e
The customer is in charge of both shipments (delivery to §KODA ffffispd d.n&tirì dter
rebuild).

The customer has to inform §XOOI minimum 3 weeks before the ddiwrr'- ne$enCnS Gn Et Hufsf,rop
loaa §XOOR will provide the customer with estimated delivery date We xhre m. :D lrfurlr rE as sooll

as possible in order to plan your engine rebuild.

The engine will be authorized to leave §XOOA when the money is on the §<'m* ffir.nt Phssetake into
the account the time needed for the bank transfer.

If you plan to pick the engine up yourself please give §XOOa Mmorsprt h nilE cf dte person in
charge of the collection and the registration plate of the car, lf a bansprt cffrpq/ b to pick up the
engine please give the company the final address and the invoice nurrùer q dre efi1irc rrrnber. ln case of
missing information the engine will not be handed over.

For safety reasons, engine can be transported only in a flightd tt Ls porn*rte b buy the flight-case
directly trom §XOOA Motorsport. lt is necessary to let §XOOA lr{ottrspfft ltrtr t}le intention of buying
the flight-case at Ieast 3 weeks before the planned engine revisircn

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66/L24 User Manual, SKODA Mororspoa 27.3.2017

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5.183 Engine Sealing
prevent any engine opening. One is on the cylinder
The sKoDA Fabia R5 engine has three main seals to
head, second on the oil sump cover and the last on the
ELB logger' lt is completely FoRBIDDEN to
remove any of the seals'

lf the customer experiences an engine problem or failure he has

to inform §XOO4 Motorsport and send
the engine for analYsis.
on the en9ine
,, on" o. ,,,or" .""1" -ir"ino on the engine, the final decision concerning the work
"."
will be on the appreciation of §KODA MotorsPort'

5.18.4 Over Rev

engine overrevs (time spent above 7 7OO RPM)
To track the engine lifetime and prevent engine damage
(IFGT(N Eng'7700)-(NEng-77O0))'
are counted by the wintax channel overrevsurn=integ

the engine has

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

> lf RPM 1 time > 8 3OO the engine has to be sent for revision'
>lfRPM3times>SOOOtheenginehastobesentforrevision'

The maximum engine speed considered as "correct" ìs 7700

RPM

the current engine mileage is.

The ELB logger installed on the engine will record all overrevs
between two rebuilds of the engine' ln case
as described above full cost of the
of engine failure and if the ELB has recorded one or several overrevs
engine rebuild will be charged without any possibility to negotiate'

5.18.5 Data Acquisition

logged in the ECU since last rebuild'
The team is responsible for downloading and keeping all the data
in case of engine failure or complains'
sKoDA Motorsport reserves the right to demand any logged data

; :-e team is not able to provide all data history to §KODA Motorsoolt the final decision concerning

: ": : =-xchanged Parts

2,- .3.2017
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6 Tra,rrernission

6.1 How to Change Oil in Transmission

41.1 Gearbo'x
- L'nscrew the magnetic plug (1), bleed the oil, and clean the magnetic plug'
--::
-:.'. :re f ìlter plug (2) and replace the oil filter (5JT301519).
- ... -- 2,2 litres of oil Castrol Syntrax (OOOO13024) using the filling hole (3). ln case of changing the
: : : ^; system (heat exchanger and hoses) the total amount of oil is 2,5 liters'

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6.1.2 Rear Differential
1) Unscrew the magnetic plug (1), bleed the oil, and clean the magnetic plug.
2l Unscrew the filter plug (2) and replace the oil filter (5JT301519).
3) Fillwith 0.8 litres of oil Castrol Syntrax (OOOO13024) through the filling hole (3). ln case of changing
the cooling system (heat exchanger and hoses), the total amount of oil is'1 liter.

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Front diff erenth! ratios

-::' :-'- :: :- ta:es per side

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re 68 68 68 52 48 52 48

'. - -:er of f riction faces per side 4 6 I 4 4 6 6 el8

Differentia! locking ratios

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6.3 Clutch lnspection
Control at each insPection:
> Check clutch basket; hubs; sinter discs for cracks
> Check spring fingers for wear
> Check housing legs for indentions

Sinter paddle thickness must be > 4.6mm

 6.4 Driveshaft lnspection
0
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lnspect the d riveshafts after each event/test. lt is necessary to dry them after clea n - :

1) Check the rubber boot for any rupture, replace if necessary (6YT4}7377-outer, 6WaC-:-:-- - - - =
2) Take out the clamps and look at the rubber boot - to check the condition of grease, rep a.e : .' - : -
necessary.
3) Dismount the cap and release the spring (6!fI4O7287) measure the spring with a calliper. The r'= ".
spring is 125 mm long. lf it is shorter than'121 mm it needs to be replaced.

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6,5 Sealing
6.5.1 Gearbox §XOOa Fabia R5 sealing points
A) Maincase x Cluster housing
B) Maincase x Cluster plate x Bearing cover
C) Maincase x RH OutPut flange

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6.52 Rs dfferentid SKODA Fabia R5 sealing Points
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A) Rear dff cadng x Rear diff cover 4

B) Rs dff rcing x Rear drive clutch cover

C) Rear dff cover x LH Output flange
D) Rer dff casirg x RH Output flange :-
Rear diff casing x Oil pump
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6.6 Operational and Maximal Gearbox Vatues

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

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Normal Operational
_l Variable Signal Name Range Extreme Value
[TargetVatrel
=
É Gearbox oil level 2,51 in total
1 l2,2lin gearbox
O,3l in cooling s)rsteml
4
Rear differential oil
-= level

Gearbox oil
- temperature '-^::-' '120oC
Temperatures tGearbox
= Rear differential oil tf
iil
f temperatu re
tRearDrf-f

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27.3.2017
 6.7 Recommended Revisions
0
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lf you need to send your parts for revision, please fill in the "Transmission Revision Form' -::: --
Appendix. You can find it on page 114. Please fill in this form and send it via email to Vaclav.Trkola e s' : : =-

auto.cz. Parts should only be sent to Skoda Motorsport after agreed.

lnfo: There are two HB unit setups that should be used together with different handbrake springs and HB
diff opening pressures to increase driver comfort (by applying less force on handbrake lever). For more
information on this, please check chapter "9.1.4 Handbrake" on page 1OO and following.

It is up to the customer to request the update HB diff setup when scheduling the rear differential
revision. From rear diff unit #81, all HB diff setup are the new setup. The rear diff unit number is located
on the rear diff HB unit casing, as in the picture (inside red box):

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ion revision Skoda Motorsport will recommend a list of parts that need to be
performance and durability of the transmission. Only after the customer's
be replaced.
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The tables below summarize the revision intervals for transmission related parts.

sEAEAOX

,art Name ,ért Ho leouired Check Recommended Replacement 6Jear Limit

I'/A NSHAFT I4 53 100301
'r 'll l50km SS
'1
800km S; 800km SS 200km RS

F NAt DR VE WHEEL -.14,53 100301 I l4 350km 55 800km 55 200km RS

1 202A LAYSHAFT 5ET 12/4A-)a131 100301IIB 350km 55 800km S5 200km RS

.12024 I B00km SS / 200km RS
GEAR SET 3rd.l6/29 10030t I r 9 350km SS
I2O2B GEAR SET 4th I6/2! 10030t r 20 350km SS 800km SS 200km RS

I 2028 GEAR SET 5th 22126 10030002 1 A l50km 5S B00km SS 200km RS

DOG RING (5mm - 5 DEG) 5lT3t I 294 l50km SS B00km 55 200km RS

:LUTCH SHAFT 100301 I 05 l50km SS B00km 55 200km R5

]IN ON DIFF 6YT409783 l50km 55 B00km 55 200km RS

;IDE GEAR 10030 3r5 l50km SS B00km SS 200km RS

:ROWNWHEEL & P NION SET I2 3I 10030 17 l50km 55 400km SS 600km RS

]EARINGS 00030 ol7 l50km SS B00km SS 200km RS

)EAL NGS 00030 a76 l50km 55 I B00km 5S / 200km R5

ìEVERSE IVA]N5HAFT GEAR 00030 ltI l50km 55 800km SS 200km RS

IEVERSE DLER GEAR 000t0 122 l50km SS B00km SS 200km RS

\P CLUTCH RETEASE CP6B59-1254 6VT3l 657 l50km SS S00km 55 200km RS

]IL FLLTER ,1T30 t9 l50km SS B00km SS 200km RS

]IL CASTROL SYNTRAX 3024 l50km 55

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P NION D]FF
> DE GEAR
]EAR NGS
JEAL NGS
]IL F IIER ;lT30t5t9
] L CASTROL SYNTRAX 13024

27.3.2017
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7 Suspension

7,1 Brakes
7'l '1 Bleeding of brakes - pedal box
-: : ::: t-i t-3re s tn a more efficient way start by opening the outer cap on the pedal box reservoir.
-:-
l:en the inner cap and pour brake fluid to the inside reservoir until it is almost full.
3 eed the brakes.
3rake pedal can do the full stroke 4 times.
At this moment the reservoir should be refill.
, Repeat the process until brakes are bled.
> Fill the reservoir with brake fluid to completely cover the 3 compartments inside the reservoir
Close the reservoir

vVhen bleeding the circuit, remove the stroke limiter that you could use a full stroke of the MC.

I
fravel limiter to be removed for bleeding.

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7,2 Dampers
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Description

> 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.

Compressed and retracted damper Iengths of gravel dampers are dif'ferent from tarmac dampers.

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 SKODA
721 Setti€
Con1pressm aq{§br is located at the bottom of the damper and it has possibility to adjust
corxìpresln n and ln high speed compression.

]fgh Speedse{Élg
> Oi:k O corresponds to the stiffest possible setting
> Gi(* 11 corresponds to the softest possible setting
Ltr SpE€d setting
> Click O corresponds to the stiffest possible setting

High speed Low:peed

compression compression
adjustment adjustrnent

Rebound adjustor is located at the top of the damper.

Rebound setting
>Click O corresponds to the stiffest possible setting
>Click 29 corresponds to the softest possible setting

Desired clicks have to be adiusted from the stiffest setting, all knobs have to be fully tightened
(clockwise).

8a/724 User Manual, SKODA Motorsport 273.24-tl

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722 Damper revision

It is advised to send the dampers for revision to the ZF service centre.

TipCode I Contact
Phone no. Website/Enrd
Service paÉnei Addre§s Country Fax-no.
Plaee Person

I 47-48 NN12 8GZ

Ben +441327855 +441327 www.bg motorsport.co
BG MotorspoÉ Ltd. Silverstone Silverstone GB
Fricker 200 855201 .uk
I Circuit Northants

08186 LLICA
NADAL C/. Estornell Marc +34938416 +3468O
D'AMUNT ES www.nadaltech.com
TECHNOLOGIES, no6 - baixos Nadal 098 445611
BARCELONA

41400 Eero +:1584()3011

PRINTSPORT OY Antintie 2 FI www.printsport.fi
Lievestuore Raikkonen &l

Avenue de
S.A.R.L. PKM 8303O Toulon -33294903 +33434 www.pkm-
Madrid, BP FR
À41 091045 consulting.com
Consult Cedex 9
765

S.A. MotorspoÉ 37023Grezzana Maurizir> +3933935O1 motorsport.skoda-

Via Roma 68 IT
Italia srl (VR) Medo 7t5 auto.it

Baumschlager Manf red +43758

+437582375
Rallye & Racing Schòn 48 4563 Micheldorf AT I nselsbac h 237508 www.brr.at
0816
GmbH er 90

15811 Northville,
f Race Benjamin +1 (734) benjamin-kuettner@zf .

Centennial Michigan, 48 USA

ErgishgNA Kùttner 582-1006 com
Drive 168

Bovenbergw Caminde +31 (0) s47

74755f Markelo NL
395 Smit 364423

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7.3 Springs
Description:
Fabia R5 is equipped with helical compression springs with linear characteristic. Springs are mace .' - :-
tensile spring steel; end coils are grinded for better load distribution on spring platforms.

The main spring is supported by a helper spring. Do omit to use main springs w/o helper spring to avoic
any damage on damper or spring platforms and to maintain proper spring function in every moment.

7.3.1 Range
Wire Approx. free
Rate lnner diameter
Part Nr. Ser. Nr. diameter length
lN/mnil mmI lmml
6VT 4111014E 1 5',13 000',l05 17.5 11.50 482

6W 4111014F 1 513 000 106 20.0 11.75 459

6Yr 411',101AG 1 513 000 107 22.5 12.OO 442

o 424
6VT 4111014H 1 513 000 108 25.O 95 12.25
G
o
6W 411 101 AJ 1 513 000 109 27.5 17.50 416

6W 41'l 101AK 1 513 000 110 30.0 12.75 407

6VT 411 101 AL 1 513 000 111 32.5 13.00 399

6W 411 101 Q 1 513 000 113 40.o 12.50 273

6W 41',1',101 R 1 513 0001'14 45.0 12.75 264

C'
o a,- 41'1 101 S 1 513 000 115 so.o 13.0O 257
E 95
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'101 T 1 513 000 116 s5.0 13.25 251
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1 513 000 117 60.o 13.50 247
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' 5.r3 000118 6s.0 13.75 243

Heher 2.O 77.5 5.OO 190

Spring rate is typicalty engraved also ol't one of the end coils.

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73.2 Ride Height

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

See the table below for spring platform heights for different spring rates and ride heights. It is not advised
to use a platform position outside of this range.

Spring Platform

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SKODA
7.3,3 Spring Platform Position

Ride Height Gravel Spring Rate [N/mm]

lmml 17.5 20.o 2.2.5 25.O 27.5 «).o 3a5
+25 199 238 237 234 231 231 229
lTrTiT:t
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Front reference +O 174 211 211 208 205 206 204 2C:_

EMI -5 169 206 206 203 200 201 199 197

;i'i§r-;"; +25 287 189 195 196 197 201 201 202
wffi:ji* +O 262 165 171 172 173 177 177 178
I t-l [l ;:- ! LÈr::

i:::in:: -5 257 N/A 166 167 168 172 172 173

Calculated for total weight 1 42O kg

and distribution 56 % to front.

Ride,Héight Tarmac SprinE Rate [N/mmI

[mml ' 40.o Its.o 50.o 55.O 60.o 65.O
G=:: +25 124 216 215 216 213 213 213
+O 99 '191 189 189 189
Front 191 191
mtn -15 84 176 175 176 174 174 174
+25 212 204 204 206 20s 207 207
: .j,::: i i reference +O 187 180 180 182 181 183 184
mtn -15 172 165 '166 168 167 168 169

Calculated for total weight 1 42O kg

and distribution 55 % to front.

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The spring platform height is measured from the bottom of the lower spring nut to the mounting p.-=
between strut body and damper reservoir bracket. Ride height measurement points are depicted in :^e
picture below.

5pring :eat
adjustment
Ride Height Front

Ride Height Rear

.=. :a<rng maximum care when installing springs on the damper un ts t'es:e'3 3 '"

-= -::essary to use a dedicated spring tool.

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7.3.4 Wheel camber adjustment

Éxooa 1
Description

The Fabia R5 uses a camber spacers system for precise adjusting of the cilrIF nEb- By c*ffgÉn'g glf
type the spacer or its orientation, it is possible to increase or decrease the anriber angb ef fu wireec-
Setting

ErT43I Oil h
.-.
8"rr 40I 0i1 15
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À

F\,'r407 0t1 D

E1rT40i BI C

§\rT40I oil 3

8,,/T401oli A
f,f 4ia nt a

6!T 4CI 0.I r:

61,rT4g1 0l: B

6\r'Trt07 0l'i E

F/T"+Oi OI F

§\,T43I 0i] G

§liT.lgi $: li +

Dot is on the
smaller side of
camber spacer.

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User Manual, SKODA l/c:c-s3::
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List of Available Camber Spacers

PaÉ Number Eccentricity Change on Damper Angte*

mm o

6W 407 071 o.ooo o.oo

6W 407 071 A o.234 o.20

6Vr 407 071 B o.469 0.40

6Yr 407 071C 0.703 o.59

6W 407 071D o.938 o.79

6W 407 071E 1.172 0.99

6W 407 071 F 1.406 1.19

6VT 407 071 G 1.641 1.38

6Vr 407 071H 1.875 1.58

* Change of damper angle does not equal to change of camber arg el

Damper angle is 13" when using camber spacer without eccertricirl.
Example:

lf we want to increase the camber (2"15' + 2"30') we have to decrease damper angle this means to use
camber spacer with bigger index towards ,,-" and vice versa.

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4

7.4 Anti-roll Bar 4

Description =
-
For Fabia R5 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 -é
two colour
stripes.
e
There are also 3 positions where the arb drop link can be attached to the suspension
arm to change
stiffness. They are called based on their position from the centre of the car: é
> lnner = soft a
> Middle = medium
1
> Outer = hard
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4
Setting
-
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Stiffness for ARB Setting 4
é

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For stiffness at the wheel for different aRB settings u.. g*p*, oe**

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Pay attention to the droplink position and screw orientation,

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7,5 Steering
7.5.1 Steering Circuit Bleeding Procedure
pump, for example) some air will go into the
lf the steering circuit on the car is opened (replace steering
steps must be done:
circuit. To bleed properly the steering circuit, the following

> Keep engine RPM >3300 on the following steps

> Rotate the steering wheel until lock position'
>onlockpositionforcethesteeringwheeltoforcetheoilcirculation.
>Forceandreleasethesteeringwheelinendpositionatleast6timesontherightsideandthen6times
on the left side.
no bubbles in the oil inside the tank' circuit is
> lf the feeling from steering wheel is ok and if there are
probably bled. Otherwise, keep repeating the previous steps
position and steer the steering wheel very
> lt is definitely not enough just to go from lock to lock
otherwise the air trapped in the
quickly. Steering has to be "forced" once lock position is reached,
cylinder will not come out!
Motorsport
7.5.2 Steering Maintenance & New steering racks from §XOOA
recommends to follow the
To have a more reliable steering system, §XOOA Motorsport strongly
recommended revisions.

steering filter should be cleaned every 75O km or every time

a new pump or rack is fitted to the car' To
flush it with petrol in the opposite direction' Please
1
clean the filter, remove the filter o-ring first, and then
oil'
make sure filter is properly dry before putting it back to steering

ln case there are chips in the filter, it is advised to replace

the filter for a new one and check for chips on
next kilometres (for example, 5O km after)'
Engineering' Each servicing includes a
All steering rack servicing are made by our supplier - spoÉech
ensure the steering rack is working within
series of low and nign preisure tests ,àa" Oy our supplier to
and serviced by SpoÉech
the performance tolerance. Steering ract<s should only be opened responsibility for any possible
take any
EnsiEerirrg. t teitner ixòòÀ uotor.part or sportech Enginàering
dt g" Lomplains due to steering rack disassembling by third parties'
".
for servicing. To do so, please fill in
o.r c,storners should send their steering racks directly to Sportech
it to the email to Nicolò Bertocco' You can find this form on in Appendix
the Revbion Form and attach
chapEr.steerirrgrack-SportechEngineeringRevisionForm''ofthisdocumentorin"sKoDAFabiaR5
Catabgrre' under-the tab "DOCUM ENTS" -> "Revision Forrns"'

Contact Person
Afress GountrY
(email)

+390''119673633

(FAO Nicolò
-encìneerjng.com
Bertocco)

LJser Manual, SKODA MotorsPort

27.3.2017
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AII steering racks (new or revised) irave been tested by our suppiier to ensure correct rack performance
i under certain conditions. The test is nace usìrg different oil from the one used on the car.

! It is recommended to drain the remaining oil from the steering rack before putting it to the car. To
drain the oil from the rack, please follo',^,, s:e:s:
I 1. Fittheball jointstotherackandtigrt:'?-ccmpete\ as'nthepicture. lf thisstepisskipped,

*T
3 you will crush the seals and rack,,^,,r i s::-: :: ea,,

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;*"*"r.,,."rrrȧ

2. With rack input/output ports pointing to the E-c_ _ -::::: :-: : - l- ._ ,,,to one side until you
reach end stop. Use a 16mm spanner.
3. Drain the oil with the rack on that position.
4. Repeat the procedure for the opposite side.
5. Drain the oil with the rack on that position.
6. Rotate the pinion to bring the rack bar to middle posrt c -

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7.6 Revisions
7.6.1 Recommended Revisions
SUSPENSION
Recommended
PaÉ Name PaÉ No Required fevision
renlacement
Cross-Member Front 6VT'199 287 C Visual check after every rally 3OOO km

Cross-Member Rear 6W 500 029 B Visual check after every rallY 3OOO km

Wishbone Arm 6W 407 157 A Visual check after every rallY 3OOO km

Wishbone Strut 6W 407 431 A Visual check after every rally 3OOO km

Tie-Rod Front 6W 422 808 C Visual check after every rally 3OOO km

Tie-Rod Rear 6VT 501 531 A Visual check after every rallY 3OOO km

Topmount 6VT 413 351 A Visual check after every rally 3OOO km
4OO km - wheel bearing change
Upright 6VT 407 58',1 24OO km
6Vr 4O7 087 F)*
Damper Adapter 6W 407 247 D Visual check after every rallY 3OOO km

Steering Adapter 6W 407 05s C Visual check after everY rallY 3OOO km

Kingpin Adapter Tarmac 6W 407 203 Visual check after every rally 3OOO km

Anti-Roll Bar Arm Front 6Vr 411317 C Visual check after every rallY 3OOO km

Anti-Roll Bar Arm Rear 6Yr 411317 D Visual check after every rallY 3OOO km
*Temporary recommendation based on Technical lnformation 16/3/2016, valid until recall

BRAKES
Recommended
PaÉ Name PaÉ No Required revision reDIacèment
3'a<e Calliper Left 6VT 615 125 D 1OOO km or > 230 "C 2OOO km or >260 oC

3- a. e Calliper Right 6VT 6',15126 D 10OO km or > 23O "C 2OOO km or >26O "C
6W 611 019 L 15OO km 45OO km

3':". *"':.::- CVlinder 6W 6'1',1 019 M 1500 km 45OO km

6VT 611 019 N 15OO km 45OO km

Ha-,::-:.i '.J:-=-3' rder 6W611 O19M 1500 km 45OO km

Cftrteh hilmr qfrlder 6W 721263C 1500 km 45OO km

92/724 User Manual, §KoDA Mmorspot 27.3.2017

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3OO0 km
3 Damper Tarmac FL 6VT 412 031 K
3OOO km
6W 412032 K
t Damper Tarmac FR
3OO0 km
Damper Tarmac RL 6W 412 031 P
I Damper Tarmac RR 6Vr 412032P
3OOO km

3OOO km
) Damper Gravel FL 6VT 412 031 L

Damper Gravel FR 6W 412032L

3
Damper Gravel RL 6VT 412 031 R
a
u Damper Gravel RR 6YT 412032 R
* Revision at ZF service centre
7
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STEERING
I :

PaÉ No Required revision

:{
6VT 419 861 A
6W 422405F Visual check after everY rallY
3
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I Fuel system 1
8.1 Fuel Level Sensor
Fuel Ievel sensor - 6VT 2O1 489 B

The fuel level sensor installed in the car is calibrated (Empty/Full) for fuel Panta MAX 114WRC
Gasoline.
It is necessary to recalibrate the fuel level sensor for the Wpe/brand of used fuel. Each type/brand
(manufacturer) of fuel has different electrical capacity. The sensor can display the wrong values
without calibrationl!!

Calibration of fuel level sensor from the carlspare fuel level sensor
>
>
Switch off the Main switch (electriciti,tn ti..e car s c-
Disconnect the cables of the loom from ti'e sersci-
1
> Remove the sensor from the fuel tank,
> It is necessaryto perform the calibration with tne À :oc: .- :-. s.^sc-.
>
>
Get ready an external power supply (12V).
Get ready a container with required fuel. 4
"Empty" state adjustment:
to be out of the container with tested f uei,
Fuel level sensor has
Connect the sensor NEG to the external power supply - pole,
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=
Connect temporarily SEND and NEG terminals.
Connect the sensor POS to the external power supply + pole.
Remove the temporary connection SEND - NEG exactly after'10 seconcs - -. -; s . e-. mportantlll
POS and the external power supply + pole leave connected for another 20 se:c^:s:c complete the
car bration.
I sconnect the sensor POS from external power supply.
-=r
' Full ' state adjustment: _l
llhe sensor is dipped in the container with required fuel (right up to the black plastic). -_l
Connect the sensor NEG to the external power supply - pole.
Terrporary connect the SEND and NEG terminals. --)
Conrcct the sensor POS to the external power supply + pole. =
Rernove the tef,nporary connection SEND - NEG exactly after 20 seconds. Timing is very importantlll .
POS artd the external power supply + pole leave connected for another 2O seconds to complete the
calibrati:n-
Disconnect the sensor POS from external power supply.

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r Check of the calibration:

- > The sensor SEND should have voltage O,5V when is the sensor fully out of the fuel.
> The sensor SEND should have voltage 4,5V when is the sensor fully in the fuel (up to the black plastic).
; > The sensor SEND should have voltage 2,5V when is the sensor halfway in the fuel.

3 > lf not the calibration have to be repeated.

t The fuel level sensor can be reeonnected on the car only when the Main switch is off!!!

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- Temporary connection of SEND and
a NEG terminals

I Adjustment of the spare fuel level sensor 6W 2O1 489 B

I > The Length of a new fuel level sensor shou ld be a dju sted bef o re rnsta llation to properly f it in the f uel
tank.
I > It is necessary to ensure minimal safety space between the end of the sensor (Al boot) and bottom of
-a the fuel tank = MIN. 2 mm.
> The sensor has an inner and outer tube separated by plastic insulates.
T
a > lt is recommended to cut the outer tube using a tube cutter. lt is recommended to cut the inner tube
using pliers. It is necessary to clean the ends of tubes from metal chips and dirt. The inner tube must
I
! not be longer than the outer tube.
-! :. After shortening, it is necessary to perform the calibration with the type of fuel used!

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FUEL SYSTEM

Part Name
5 years
*
6VT 201 055 C after every rallY
Fuel tank
after every rallY 5OO km
Fuel filter inseÉ ooo 210 346
after every rallY 5OO km
O-ring 57x2.5 ooo 210 342 A
after every rallY 3OOO km
Fuel pressure regulator 5 bar 5JT906 051 B

after every rallY 3OOO km

Fuel level sensor 6VT 201 489 B
sJT 919 050 A after every rallY 2OOO km
Low pressure PumP 6Vr 701 050
after every rallY 2OOO km
Fuel pump (high Pressure) 5JT 919 051 A
after every rallY 5OOO km
Valve vent FIA ooo 564 501 B

after every rallY 3OOO km/1year

Fuel cell cover 6VT 201 164
*No bladder maY b e used more than 5 years after the date ot manuta tcture,
unless insPected and recert ified by the manufacturer
for a period of up to ano,ther two Years.

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9 Cockpit
9.1 CockpitAdiustments
ln order to suit each driver it is possible to adjust positions of the car equipment'

9.1.1 Steering wheel

It is possible to adjust the steering wheel position in two directions: _.
> Closer or further tofrom the driver by using different spacers. The spacers are available from 3Omm
to gomm in stePs of 'lOmm.
> Up and down by moving a bearing bracket in the roll cage holder

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9.1.2 Pedal Box =
The pedal box can be adjusted closer or further tolfrom the driver. This can be -:
-:--: done b.
pedalboxinthreedifferentpositionsinstepsof 25mm.Whenmovingthepedal boxmainr-=.-u-.
bracket has to be moved accordingly, too.
Be aware that there are more mounting holes. Those should not be
used for the pedal box but fo. a : -
foot-rest plate.

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*25mm

r -: :-^ ^g of pedal pad position

is possible by moving the pad on the pedal lever in range of 2Omm.

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9.1.3 Gearshift
There are also three possible positions in steps of 25mm to adjust the gearshift. Gearshìft sho-: ::
perpendicular to the bodyshell. ln side view from this position it is possible to move the centre of :-:
gearshift head by 12mm forward or rearward.

Adjustment of the gearshift bar length can be done by moving a circlip in grooves of the adjusting cylinder
and then tightening its retaining nut above it. Finer tuning is possible by adjusting the rod ends on both
ends of the gearshift bar.

The gearshift has to be adjusted together with the handbrake. To avoid any collision between the
gearshift and the handbrake during shifting, a minimum dimension between the gearshift and the
handbrake lever in idle position must be respected. This dimension should be bigger than 2mm and
measured in side view as shown in the picture below (real distance is bigger).

A
 9.1t Handbrake
SKODA
The lHdbr*e b acljusted together with the gearshift in 25mm steps because they
of the fìanÉrake it is also possible to do final tuning of the lever position
share one air 6- r-,ce
between indivirttral *p§ r:
uoa'rsur Design position corresponds to the picture below. To adjust position
of the lever you o'.
cf[ar4e the 24mm dimension but be aware to keep a sufficient
thread overlay of the rod end and ma$er
q{rhnder' Do not change the lomm dimension
because there could be contact between the MC and the
iever or insufficient thread overlay.

10 rB

Handbrake Hydraulic Setup

The handbrake has to be set also from the hydraulic point of view.
The rear difFerential can be
disconnected by means of a hydraulically operated piston in
the rear differential unit. This system can be
tuned on the handbrake tandem master cylinder.
A preloaded spring is located on the brake side which ensures
that the pressure on the brake side will not
rise until the rear clutch is disconnected. This spring has
to be mornted in accordance with the assembly
manual (spring cap in contactwith MC piston rod) to
ensure its p.oper f unction,
There is a stroke limiter which limits the stroke of the rear
disconnect ng c utch not to be unnecessarily
long.
There are 5 options, which are differentiated
by the length of the limiter and for easrer identification, by
3c our as well. See the table below.

PaÉ No. Lenqth of the limiter Stroke limitation Colour

6VT 711 393 K 24,7 mm 4mm
I
j 6\tl-Z13s3 c 25,2 mm 3,5 mm
T
25,7 mm 3mm
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6VT 711 393 H | 26,2 mm 2,5 mm
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6VT 711 393 J 26,7 rnm 2mm
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The longer the spacer used, the shorter the travel on the clutch side and the smaller the pressure rdue
reached on the line.

There are two HB unit setups that should be used together with different handbrake springs and HB diff
opening pressures to increase driver comfort (by applying less force on handbrake lever):
o Old HB diff setup: handbrake spring to use should be 6W 711 329 H and the recommended
opening pressure is 23 to 25bar.
r New HB diff setup: handbrake spring to use should be 6W 711 329 F and the recommended
opening pressure is 17 to 19 bar.

The above "opening pressures" are the recommended pressures when reaching the travel limiter.
lf the opening pressure does not reach the lower recommended value we recommend checking bleeding
of the system, especially, on the HB diff unit. ln case 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.

With new HB diff setup, we recommend to use green limiter (6VT 711 3g3 L), which means 3 mm travel
on the clutch side of the master cylinder. This should ensure correct disconnecting on all rear diff units of
the same setup in case they are correctly bled.

Note: It is up to the customer to request the update HB diff setup when scheduling the rear differential
revision. From rear diff unit #81, all HB diff setup are the new setup. See "6.7 Recommended Revisions,,
inside the Gearbox chapter for more info on page 76 and following.
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9.1.5 Seats, Seat Belts & Brackets
The position of the seats can be adjusted by moving forward, backwa'c -: :l '- -- :' reclining' The
rangeof motiondependsontheselectedseatbracket.seatbeltscanse::.-!:.:: :-:lsrgtheproper
position of the anchor points. Which position to choose depends on the s. ::::: :::: _ -=:''i

Driver

Seat bracket driver R

CIL- tu_

N -Se:t
bracket driver L

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The overview of the seat bracket variations is shown on tl'e'c 3

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27.3.2017
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For driver:
!

I 6W 8BI 035 AL {r Z r0 to +40mm, 3 X, 0 to -30(60)mm tuffi

I 6VT BB'1 035 AA {r z *:O to +70mm <- x: 0 to -30(60)mm
I 6VT B8I 035 AB {r Z .:: to +73mm <- X: -43 to -73(103)mm

I
I 6W B8I 035 AC fr,ZrOto*20mm, + X:0to-30(60)mm $re
I 3VT 8Bl 035 Al.4 rfrZ : +35to+55mm, 3 Xr 0to-30(60)mm }Iq
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3 6W 881.035,4D 4z ------- <-x :-.---'

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I 6VT BBt 035 Al {r Z

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O to +60mm, {- X: 3 to -30(60)rnm Èa
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3 6VT 88r 035 AK {rZ, Oto+40mm, 3 X: 0to-30(60)mm LÌq

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For co-dr,,e, )=
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Bracket no. )
Z r 0 to +20mm,
3 X, 0 to -30(60)mm
+ I
:-

Z r 0 to +ZOmm,
3 X, 0 to -30(60)mm
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6W 8BI O37AB Z :Ato+40mm, 3 X' 0to-25(50)mm )=
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6W8Bt A37 Ar Z :0 to +40mm, 1i X r 0 ro -30(60)mm
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9.1.6 Driver Footrest
Driver footrest can be adjusted by moving forward or backward depending on the position of the pedal
box (see the picture at7.1.2 Pedal Box).

: .- _'

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9.1.7 Go-eiver ffiest é
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Co-driìrerfooEest can be adjusted by moving forward or backward.
-:
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ts-
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P
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É

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6VT 867 O9o
Settlng bolt
A
95mm
6\.I. 867 o9O
Sett:no oolt 75mm
6VT 867 090 B --
2Pc Sèttin9 boit 25mm
2pG- 2 Pcs
Ii*P"§il"
'-l- _-
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H

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9,2 Rear Wing Adiustment
1) Front view coverage (horizontal line in the scheme) is prior to dimension including tolerances.
2l Both mounting dimensions as well as front view coverage must be met.

Scheme of the adjustment from the homologation form:

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

Horizonta! roof line

)
t1% unless otherwise stated

Zero gradient of the car is defined with the upper surface of the inner sill - for the calibration of the
:rorizontal line.

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9,3 Reconrrnended Revisions

6W 711 303 D

6W 711 053 H

6W 721 021 B 45OO kr'

S:a:- -3 C.c ur-'nn 4500 km
---:--::.--.ottlespring(6W721143),Throttlepedalspringho

User Manual, SKoDA Motorsport

21.3.2017
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10 KIT

1O.1 Gravel to Tarmac KIT

T Table below contains all the parts necessary for conversion from Gravel car specification to Tarmac car
,, specification.
t
il GRAVEL TO TARMAC KIT
I Part Name
Kingpin adaptor tarmac
EEEIIIIIIIIIEII
6VT 407203
Quantity
4

I Camber spacer
KircD n bolt tarmac
l: : '.'- ];r20 socket
6V1 407 071 D
6Y1 407 171
4
4
head 000 019 124 10
I 000 407 025
6VT407 090 A
tb
4
t- a
6VT412031 K
6VI 412032K
1

I rl
6VT412031 P
5\,n 412A32P 1
1

§ 5\",T /-.T .0. T 2

:' - , 5 2
o
1

n HraLo -:_
Brake c s:3ll-ll :-
a Brakecsc3ll-:-
tsrake É -::: . -::- 2
Brake caliper hose Tarrnac 2 -^'----= 2
Master brake cylinderiT.qz22.ffi er,T 6-- or9 L 1
Catiper space. ovtbt5 ì B 4
Do*.| 14f15 6r/T 40' R1 4
eot Mìoxgs;aGtt'ead- ooo 615 oo8 4
I
anti-Rott Uar tront meaium-
! Rim Bx18 ET23 Al Speedline
6VT 411 053 D 1

6\n- 601 025 B 5

I Sumpquara assy Fe 31k;- 6VT 825 248 H 1
! Tunel stonequard Fe r, ce assi, 2Okq 6VT 82s 841 1
Bolt MlOxl,25x25 ir:bus ENT 402 OO1 CA 4
I
I Washer 10 ooo 800 088 4
I Diff stoneguard Fe rvice assy 35kq 6VT 825 236 M 1
t
I L:! Bott M12x1,5x25 5JT 825 296 10
1I__ Washersumpguard 6Vr 825 445 10
Doorstep cover L front 6VT 871217 1
I ìr Doorstep cover R front 6VT 871218 1
T Doorstep cover L center 6VI 87129 1

I Doorstep cover R center 6Vr 871220 1

a Doorstep cover L rear 6W 871221 1
Doorstep cover R rear 6VT 871 222 1
I ,A
Rivet 4x8 ooo o18 069 32
a
a Rivet 4x12 o00 018 047 16
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Rivet 4x16 Allsteel 000 018 046 14
Washer M4 o00 731 061 2
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For the successful conversion from Gravel to Tarmac car, it is necessary tc :a-a'- -: : --: : -,
Car Setup Sheet (available online in Catalogue\Documents\Setup Sheets). Furtre- : :::: -:.: . . : '- :-
position of Steering adaptors was changed on all four uprights (detailed illustration ... .=: - -:-: . - .:
Chapter 20.1).

When using §t<OOa Hydraulic Jack (5JT O11O21C), do not forget to setup the position of the -: : -:=

Parts listed in previous table enable the change to default Gravel setup. SKODA offers to cus::-.-.
variant parts, to adjust the car to specific conditions. Complete ranges of Camber spacers and An: -::
bars are possible to use for both car specifications (Gravel and Tarmac). Table below contains:

Complete range of Camber spacers (can be used for both car specifications - Gravel &
Tarmac)
Complete range of Anti-Roll bars (can be used for both car specifications - Gravel & Tarmac)
Complete range of Tarmac Damper springs
Magnesium Tarmac OZ rim
Wheel cover for Tarmac OZ rim
Wheel scraper for tarmac rims (for complete info see Catalogue 20.1.1b)

PaÉ Name PaÉ Number

Camber spacer 6V1 407 071
Camber spacer 6VT 407 071 A
Camber spacer 6VT 407 071 B
Camber spacer 6VT 407 071 C
Camber spacer 6Vr 407 071 D
Camber spacer 6Vr 407 071 E
Camber spacer 6Vr 407 071 F
Camber sDacer 6VT 407 071G
Camber spacer 6VT 407 071 H
Anti-Roll bar front scft 6VT 411 053 C
Anti-Roll bar f ront reci..:r 6VT 411 053 D
Anti-Roll bar f ront i'ai-c 6VT 411 053 E
Anti-Roll bar rear so't 6VT 511 409 C
il Anti-Roll bar rear rec -- 6VT 511 409 D
Anti-Roll bar rear l'arc 6VT 511 409 E
Main sprinc 40-273 6VT411 101 Q
Main sprìnq 45-25r 6VT 4'11 101 R
Main spring 5O-257 6VT 41'l '101 S
il Main spring 55-25'1
Main sprinq 60-247
6VT 411 10'l T
6VT411 101 AA
Main sprinq 65-2a3 6VT 4'1'f iO1 AB
Rim 8x18 ET23 Mq OZ 6VT 601 025 C
Wheel cover Tarmac OZ 6VT 601 131 E
,181
Wheel scraper tarmac Sp€ecll.e 6VT 601 A
Wheel scraper tarmac OZ 6VT 601 181 B
Sumpquard assy AL 20 kc 6VT 825249 L
Tunel stonequard Fe wrde assi, '15 kq 6VT 82s 841 A
Tunel stoneguard Fe wide assi,-O kq 6VT 82s 841 B
Tunel stonequard Fe wide assi, 5 kq 6VT 825 841 C

Tarmac KIT and \,,'ar-a.: parts can be ordered vla SXOOA Fabia R5 catalogue (Chapter 20.1), where the
parts are illustrated,

1La/724 User Manual, SKODA Mororsport 27.3.2017

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3 1O.2 Tarmac to Gravel KIT
Table betow contains all the parts necessary for conversion from Tarmac car specification to Gravel car
3 specification.

t
TARMAC TO GRAVEL KIT
I
I 6VT 407 0718

I 6VT 505 415

6VT 505 416
N
N

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Bolt M5x12 low head
6VT 50s 119

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6
6W 412032L
6VT412 031 R
3
I o 6VT 412 032 R
6VT 411 101 AJ
6VT 4.11 101 AG
I Brake disc 300-32 left
6VT 413 143
6VT 615 301 J
I Brake disc 3OO-32 r
6VT 615 151 G
,I
6VT 611 019 M
f
! Bolt M10x55 socket head
6VT 411 053 C
f Rim 7x'15 ET2B Al
! 6VT 825 248 G
t Diff stoneguard AL wide assy 15
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Rivet 4x16 Allsteel

t Foam EVR 452 llm

I 6VT 8218228

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 Éxooa
Fotrthe srccesf'nd coolrersion from Tarmac to Gravel car, it is necessary to carefulty folorr the Gravel Car
Setu,p Stet iavaffi online in Catalogue\Documents\Setup Sheets). Further please rnake sure that
ec*!tr' cf fuertng adaptors was changed on all four uprights (detailed illustration availabb in catalogue -
A.+rarres'm2i.

\Arhe{ì LEftg §KODA Hydraulic Jack (5JT O11O21C), do not forget to setup the position of the Iift tube

.Eàr§ Isted in previous table, enable the change to default Gravel setup. §XOO,A, offers to customers
r?{^i?rlt partq to adjust the car to specific conditions. Complete ranges of Camber spacers and Anti-Roll
krs re possibte to use for both car specifications (Gravel and Tarmac). Table below contains:

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

PaÉ Name PaÉ Number

Camber spacer 6Vr 407 071
Camber spacer 6VT 407 071 A
Camber spacer 6Vr 407 071 B
Camber spacer 6Vr 407 071 C
Camber spacer 6VT 407 071D
Camber spacer 6Vr 407 071 E
Camber spacer 6VT 407 071 F
Camber spacer 6Vr 407 071 G
1,, Camber spacer 6VT 407 071H
ti Anti-Roll bar front so't 6VT4'l'l O53 C
2
tI Anti-Roll bar f ront mec --
Anti-Roll bar f rcnt l-ai:
6VT 411 053 D
6VT 411 053 E
2 Anti-Roll bar rear sct 6VT 511 409 C
É
7/ Anti-Roll bar rear mecl-- 6VT 511 409 D
a Anti-Roll bar rear i'arc 6VT 511 409 E
I
il Main spring 17.5-4e2 6VT 411 101 AE
a Main spring 20-459 6W 4'11 101 AF
Main spring 22.5-112 6VT411 '101 AG

Main spring 25-428 6VT 411 '101 AH

Maìn spring 27,5-416 6VT 411 101 AJ
Main spring 3O-4O7 6VT 411 101 AK
Main spring 32,5-399 6VT411 101 AL
Rim 7x15 ET28 Mg OZ 6VT 601 026 D
Wheel cover Gravel Speedline 6VT 601 131 B
Wheel cover Gravel OZ 6VT 601 131 D

Gravel KIT and Variant parts can be ordered via §XOol Fabia R5 catalogue (Chapter 20.2), where the
parts are illustrated,

!12/1-24 User Manual, SKODA Motorsport 27.3.2017

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I 11 Appendix
a
I
11.1 Revision Forms
I 11,1.1 Engine
!
Engi ne revisiott, Transfer protscol
I Teanì *ante
lontact
I comunication partn€r:

I ingi*e infornrations:

I Engine nunrber: {§o

ryI*.h*§xD*;ffii
Total engine nrileage
I
I Used engine oil

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i Reason oftransport to òxooa:

Y N

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I Engine cond,tion,
description of problenr
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I Engine delivery:

I Date of shipnrent to SKODA

Xeeded collection date

I \otesr
,:'::iim'ill b€trcrfil[edbe6*reshipmesttoSKODA,enginewill benote.cePtedloourworkshop
I : : -,; -i - j§ .€ cì:an and in the speciel engine bor: {in case of not,
:: ::::-- :: f: rcrkslop or not)
ÈKOOI will decide if the engine uill

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t trensier is d*taihd ìn Enqint policy

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€lrstdnÈrnanr€ alrd dÈlirElytsddr€§5,

TEÀI§f,'l}§${ilÈ1i BATA 6earbor Rear Differential

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S€ruidt€re6c6 rÉquest:

MEèrid plÈcEqf rhepFs&tero [Ff asf]

Full revision
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Czech Republic
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rt4/124 User Manual, §KoDA Motorsport 27.3.2017

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11.1.3 Steering rack - Sportech Engineering Revision Form

Steering Rarft Revision Form

CU5TOMETT,§ EATA

CustomÈt name:

Customer refu rence pe rson:

CustBmE r refu rence mail :

Custemer reference
teleFhBne number:
Addreslvrhere t§ Eend back
the rtsEk:

UAT numher:

VAT name and address (if

difhere nt frem Eustome r nsne
and delivery addressJ

§.ACK'§ AATA

# Serial l,éumber:

[''lileage from last servicing:

L'lileage fiom heginning:

Servicing reasen requ.e5t:

Date and place afthe proHem

iif any)

3erC thi=formby mail to

: ' : , f=r tr Nicolò Bertocco +3§0{ {9 873633

: :i:+::^l the racktcl

E-Bl gi Belluzzo §.r-l-
ViaAo*ta, {l
t0tI44- Pianezza [TOf

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11.2 Manua 7l nstruction
'11.21 Documents: Calliper Revision Manual

Prior to any calliper action, brake calliper seals should be immersed in SCF seal conditioning fluid (5-rT en 4
Z'll for 24 hours. Skoda Motorsport recommends using the following tools:
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38mm piston tool )'4
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The following instructions should be taken to revise brake callipers

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1. Clean the calliper to remove any dirt/dust
2. Put the blocking tool inside the calliper as in the picture

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Put air pressure to push the pistons against the blocking tool. lf there is an quick coupling connect
the male version first

4. Pull the blocking tool out of the calliper

5. Use the 32mm piston tool to pull the 32mm pistons out. Careful must be taken not to scratch the
piston face by hitting against anything else

6 Use the 38mm piston tool to pull the 38mm pistons out. Careful must be taken not to scratch the
piston face by hitting against anything else

2i 3.2417

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rc the se* from inside the calliper body. Careful must be -.-4
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44
9. Calliper body and pistons should be clean - brake fluid cleaner or similar is recommended. Any é
cloth that does not scratch calliper body or piston surface can be used.
#
10. Make sure the piston surface is not scratched or damaged. lf it is, a new piston should be used
-
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lf any is, the

-
1'1. Make sure the piston bores on the calliper body are not scratched or damaged.
calliper should be replaced 4

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!78/t24 User Manual, §KoDA Molorsport 27.3.2017

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12. Remove the seals from the fluid and fit them inside the groove on the calliper body. Place them
completely inside the groove. Make sure they are not twisted
13. Fit the piston springs on the calliper pistons. The complete flat face of the spring should touch the
calliper piston
*;"'r"

14. Push the pistons inside the calliper body. Make sure the pìston spring is centred when pushing the
piston

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15. Place the calliper in a vertical position similar as it is on the car. Bleeding nipple pointing up.

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16. Put the blocking tool inside the calliper and bleed the calliper
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17. After bled, increase the pressure until 6O bar and maintain it during lminute. lf pressure is not
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decreasing, you can proceed with next steps. If not, something was made wrong so far 14
18. Pull the blocking tool out and push the pistons completely in.

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Other impoÉant notes:

, o The procedure described above is based on the steps done by Skoda Motorsport. Skoda
Motorsport does not take responsibility if costumers are revising the callipers.
lf procedure is not done accordingly or if there is no experience, Skoda Motorsport does not
recommend to do the calliper revision yourself.
Brake callipers should only be revised in case they are in good condition. Callipers in the following
conditions should be replaced or sent to Brembo for inspection and must not be used due to
safety reasons:
o Calliper body too damaged due to stones or others
o Bridge of the calliper body too damaged due to stones or others
o Calliper bore scratched, damaged or with marks on the surface protection
o High damage around the bleeding nipple area
o Callipers exposed to high temperatures (>23O "C) for a long time (normally calliper body
change colour to brown and Brembo logo turn to black colour)
o Any sign or damage that might compromise the safety of the car passengers, people
outside the car, calliper or car.

To revise one car set of callipers you will need:

Skoda Name Skoda p/n Quantity

SCF seal conditioninq fluid 5JT 698 2'11 1

Calliper Piston Sprinqoo0 012 089 16

Sealkit 38mm oo0 615 011 1

Sealkit 32mm oo0 615 012 1

Please check with Skoda Costumer Suppor7Sales support the updated calliper seals and springs you
should use on calliper revision.

Recommended tool kit for ealliper revision:

Skoda Name Skoda p/n Quanti§

Calliper piston tools 6VT 012 011 1

Other parts available:

Skoda Name Skoda p/n Quantity

Calliper Piston 32mm ooo o'12 090 I
Calliper Piston 38mm ooo o12 091 B
Steel Piston lnsert 32mm ooo 012 092 I
Steel Piston lnsert 38mm ooo 012 093 I
S:eel Piston rinq 38mm ooo 012 099 I
S:ee f, ston rinq 32mm ooo o'12'100 I
ooo 012 101 4

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11.2.2 R5 Centre pin operation instruction

Please follow the instructions below to find t@

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Be sure the knob is unscrewed and is to see the 3 threads -

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2. Turn the to the left a
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27.3.2017 _f
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3. Screw the centre pin to the steerinq rack

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4. Turn the steering wheel slowly to the right to feel the click of the centre groove (steering middle

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t the knob of the centre

6. Do the wheel alignment

7. Remove the centre pin from the rack without turning tfre rack to rffi r left not to damage the

'jLti.:i:,3t::iJi§:

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121/!24 User Manual, §KODA N.,lotorsport