Fuel Injection AZL

Service
Workshop Manual
FABIA 2000
Edition 03.01
Engine code
2.0/85 Engine, Fuel Injection

AZL
Service Department. Technical Information
Printed in Czech Republic S00.5310.00.20
Service
The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.
Printed in Czech Republic S00.5310.00.20
FABIA 2000 2.0/85 Engine, Fuel Injection
List of Supplements to Workshop Manual
FABIA 2000
2.0/85 Engine, Fuel Injection
Edition 03.01
Supplement 1
Edition 03.01 11.04
Subject Basic Edition
Article Number S00.5310.00.20 S00.5310.01.20
Edition 11.04 S00.5310.01.20
List of Supplements
List of Supplements
Edition 11.04 S00.5310.01.20
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Meaning of the exhaust gas warning light -K83- .................................................. 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting engine electronics control unit ....................................................................................................... 01-1 - Interrogating and erasing fault memory of engine control unit ................................. 01-1 - Automatic test sequence ............................................................................. 01-1 - Performing actuator diagnosis ....................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Readiness code ........................................................................................ 01-2 - Reading Readiness Code ............................................................................ 01-2 - Generating readiness code .......................................................................... 01-2 Self-diagnosis III ........................................................................................ 01-3 - Fault table, fault codes 16485...17606 ............................................................. 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Fault table, fault codes 17621...18104 ............................................................. 01-4 Self-diagnosis V ........................................................................................ 01-5 - Reading measured value block ..................................................................... 01-5 - Reading measured value blocks, display groups 001 to 029 ................................... 01-5 Self-diagnosis VII ....................................................................................... 01-6 - Reading measured value block, display groups 030 to 062 .................................... 01-6 Self-diagnosis VIII ...................................................................................... 01-7 - Reading measured value blocks, display groups 66 to 126 .................................... 01-7 page page page page page page page page page page page page page page page page page page page page page page page 1 1 1 3 4 5 5 6 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1
24 Fuel Formation, Injection

Repairing the injection system ...................................................................... 24-1 - General notes on the injection system ............................................................. 24-1 - Overview of fitting location ........................................................................... 24-1 - Removing and installing parts of the injection system ........................................... 24-1 - Disassembling and assembling bottom part of intake manifold ................................ 24-1 - Disassembling and assembling the air filter ....................................................... 24-1 - Safety measures ....................................................................................... 24-1 - Rules of cleanliness ................................................................................... 24-1 Testing components ................................................................................... 24-2 - Testing throttle valve control unit -J338- ........................................................... 24-2 - Testing accelerator pedal position sender ......................................................... 24-2 - Testing injection valves ............................................................................... 24-2 - Test fuel pressure regulator and holding pressure ............................................... 24-2 Testing functions II .................................................................................... 24-3 - Testing lambda probe -G39- and lambda control upstream of catalytic converter .......... 24-3 - Testing lambda probe ageing upstream of catalytic converter -G39- ......................... 24-3 - Testing lambda probe -G130- and lambda control downstream of catalytic converter ..... 24-3 Engine control unit ..................................................................................... 24-4
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page page page page page page page page page page page page page page page page page page
1 1 2 3 5 6 7 7 1 1 2 3 4 1 1 2 3 1
FABIA 2000 2.0/85 Engine, Fuel Injection - Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-4 - Testing voltage supply for engine control unit .................................................... 24-4 - Procedure after voltage supply has been interrupted ............................................ 24-4 - Replacing engine control unit .. ...................................................................... 24-4 - Coding engine control unit ........................................................................... 24-4 - Adjusting the engine control unit to the throttle valve control unit ............................. 24-4 Testing auxiliary signals ............................................................................. 24-5 - Testing the speed signal ............................................................................. 24-5 - Test data bus .......................................................................................... 24-5 - Activating and deactivating cruise control system (CCS) ....................................... 24-5 page page page page page page page page page page 1 1 2 3 4 5 1 1 1 2
28 Ignition System
Repairing ignition system ............................................................................ 28-1 - General notes on the ignition system .............................................................. 28-1 - Safety measures ...................................................................................... 28-1 - Removing and installing parts of the ignition system ............................................ 28-1 - Testing camshaft position sensor -G163- ......................................................... 28-1 page page page page page 1 1 1 2 3
II
Table of Contents
Edition 11.04 S00.5310.01.20
01
01 Self-diagnosis
01-1 Self-diagnosis I
Properties of the self-diagnosis

Note The self-diagnosis monitors only a part of the injection and ignition system. The Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder should always be used for fault finding. The MOTRONIC engine control unit -J220- is equipped with a fault memory. If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication of the fault type. The engine control unit analyses the information and distinguishes different fault codes Chap. 01-3 or 01-4 and stores these until the contents of the fault memory are erased. Faults that only occur temporarily (sporadically) are output with the suffix sporadically occurred fault. On the display these faults are indicated by the suffix SP. Possible causes of sporadic faults are e.g. a loose contact or a momentary line interruption. If a sporadic fault no longer occurs within 40 warming-up phases (engine started at a temperature of 50C and switched off at more than 72 C), the fault is then automatically erased fom the fault memory. After the fault or faults have been rectified, it is necessary to erase the fault memory 01-1 page 5 and also to regenerate the readiness code Chapter 01-2. Note
The following description only relates to vehicle sys-
tem tester -V.A.G 1552- using the program card -5.0-, or higher. card -8.0- or higher and integrated printer, or if vehicle system tester -V.A.S 5051- is used, slight variations in the readouts in the display are possible.
If fault read-out scan tool -V.A.G 1551- with program
Technical data of self-diagnosis

Control unit identification:
The control unit version is displayed when the vehicle system tester -V.A.G 1552- is connected and address word 01 Engine electronics is selected 01-1 page 4.
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Self-diagnosis I
01-1 page 1
01
Equipment
Engine identification characters System denomination Exhaust limits conforming to Electronic throttle system Self-diagnosis Actuator diagnosis Fault memory Memory for initialisation values Lambda control Knock control Intake manifold change-over Camshaft adjustment Boost-pressure control Secondary air system Exhaust gas recirculation
1) 2)
AZL Motronic 7.5 ME EU4, EU3 DDK, EU2 DDK Yes Yes Yes Permanent memory1) Volatile memory2) 2 probes 2 knock sensors No No No Yes No
Independent of the voltage supply. The values are erased if the voltage supply is interrupted.
Functions available when using the vehicle system tester -V.A.G 1552Note The preconditions for selecting the desired functions are given in the following table.
Operation Function on the vehicle system tester -V.A.G 155201 02 03 04 05 06 07 08 15

1) 2)
Precondition Engine not running, ignition switched on yes yes1) yes yes yes yes yes yes yes Engine idling Normal driving
Interrogating control unit version Interrogating fault memory Actuator diagnosis Basic setting2) Erasing fault memory Ending output Coding control unit Reading measured value block Reading Readiness Code
yes yes no yes yes yes no yes yes
yes yes no yes yes yes no yes yes
Only to be carried out with the ignition switched on and if the engine does not start (activate starter for at least 6 seconds). To be carried out after the following operations: replacing engine control unit, throttle valve control unit, or after disconnecting battery. The air conditioning and the ACF system are automatically switched off in function 04.
01-1 page 2
Self-diagnosis I
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01
Meaning of the exhaust gas warning light -K83For engines complying with exhaust emission standard EU-4, EU-3 DDK If the engine control unit detects faults, which impair the exhaust gases, this is indicated by the lighting up of the exhaust warning lamp -K83-. Fitting location of exhaust warning light: Note
The exhaust warning light -K83- may flash or come on
CHECK
as a steady light. The fault memory must be interrogated whatever happens 01-1 page 5.
The warning light flashes: There is a fault, which is
likely to damage the catalytic converter in this driving condition. In this driving condition only low performance driving is allowed! a fault which deteriorates the exhaust gas quality. Read fault memory of engine control unit.
CHECK
The warning light comes on as a steady light: There is

S01-0091
There is a vehicle performance fault or the customer
is making a complaint and the exhaust warning light -K83- does not light up so the fault memory should be interrogated since there may be faults stored there which do not immediately switch on the exhaust warning light -K83-.
Check for proper operation
Switch on ignition.
The exhaust warning light -K83- must light up. If the exhaust gas warning light -K83- does not come on when the ignition is switched on:
Check dash panel insert and exhaust gas warning

light -K83- Electrical equipment; Rep. Gr. 90. If the exhaust gas warning light -K83- comes on when the ignition is switched on:
Start engine and run in idle.

The exhaust gas warning light -K83- must go out after a few seconds. If the exhaust gas warning light -K83- does not go out:
Interrogate the fault memory of the engine control unit,

remove any faults which exist and delete the fault memory 01-1 page 5.
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Self-diagnosis I
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01
Connecting vehicle system tester -V.A.G 1552- and selecting engine electronics control unit
Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
1 2 3 4 5 39 40 41 42 43 44 45 46 47 48
6 7 8 9 10 49 50 51 52 53 54 55 56 57 58
11 12 13 14 15 16
17 18 19 20 21 22 59 60 61 62 63 64 65 66 67 68
-V.A.G 1551/3, 3A, 3B oder 3C-
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
Test conditions
The fuses must be in proper order. Battery voltage must be at least 11.5 volts. Assembly earth connections o.k.
Procedure
S01-0094
Fold back trim panel -1-. Connect vehicle system tester -V.A.G 1552-. Enter address word 01 Engine electronics. Switch on ignition.
1 4 7 C 2 5 8 O 3 6 9 Q HELP
V.A.G. 1552
The control unit identification number and the coding are shown on the vehicle system tester display, e.g.:
06A906032CC = Part No. of the control unit (for cur-
06A906032CC 2.0l R4/2V G Coding 00071
3658 -> WSC XXXXX
rent version see spare part catalogue) 2 valves per cylinder CCS is not active)
2.0 l R4/2V = Displacement 2.0 l, 4-cyl. inline engine, G = CCS activated (if nothing is displayed at this point, 3658 = programme number Coding 00001 = Coding of control unit Chap. 24-4 WSC xxxxx = Workshop code of the -V.A.G 1552-
with which the last coding was performed Note
If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit Chapter 24-4.
Incorrect coding of the engine control unit results in: Handling problems (jerky gear change, load change
jolts etc.)
Increase in fuel consumption Increase in pollution
01-1 page 4
Self-diagnosis I
Edition 11.04 S00.5310.01.20

Storage of non-existent faults in fault memory Impossibility of performing certain functions (lambda
01
control, actuation of activated charcoal filter system, etc.)
Interrogating and erasing fault memory of engine control unit

Interrogate and erase the fault memories of al control units 01-1 page 5. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and enter address word 01 Engine electronics 01-1 page 4. Only if the engine does not start:
Operate starter for about 6 seconds. after this do not

switch off ignition.
Select function 02 Interrogate fault memory.

The number of stored faults or No fault recognised appears in the display. If no fault is stored:
X faults detected
Press
key.
If one or several faults are stored:
Rectify the faults displayed by referring to the fault table Chap. 01-3 or 01-4.
Select function 05 Erase fault memory.

Note The fault memory is not erased if the ignition was switched off during the functions of Interrogating fault memory and Erasing fault memory.
Vehicle system test The fault memory is erased
HELP
Select function 06 End output and switch ignition off. Read out readiness code Chap. 01-2. If the fault
memory has been erased or if the continuous voltage supply from the engine control unit was interrupted, it is then necessary to re-generate the readiness code.
Automatic test sequence

During testing and installation other control units may also detect faults, e.g. pulled-out connectors. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:
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Self-diagnosis I
01-1 page 5
01
Enter address word 00 Automatic Test Sequence.
The tester -V.A.G 1552- sends all known address words in sequence. If a control unit responds with its identification, the display will indicate the number of faults in the memory or No fault detected.
Erase the fault memory and then carry out a test drive.
During the test drive the following operating conditions must be fulfilled:
The coolant temperature should rise beyond 80C. Once this temperature is reached, the following oper-
ating states must be reached several times: Idling, part load, full load, overrun, enrichment. yond 3500 rpm.
In case of full load the speed should be increased be-
Once again interrogate the fault memories of all the

control units with the address word 00 Automatic test sequence. If no fault is stored:
Select function 06 End output and switch ignition off.

Note If no fault has been recognized by the self-diagnosis, proceed with fault finding as specified in the Current Flow Diagrams, Electrical Fault Finding and Fitting Locations binder.
Performing actuator diagnosis

With the actuator diagnosis the following parts are activated in the sequence indicated: 1. Activated charcoal filter system solenoid valve 1 -N802. Secondary air pump relay -J2993. Injector cyl. 1 -N304. Injector cyl. 3 -N325. Injector cyl. 4 -N336. Injector cyl. 2 -N31Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set e.g. -V.A.G 1594 A, B oder C Current flow diagram
01-1 page 6
Self-diagnosis I
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01
Test conditions
The fuses must be in proper order. Battery voltage must be at least 11.5 volts. All electrical consumers, e.g. lights and rear window
heater, must be switched off. Note
The actuator diagnosis can only be carried out when
1 2 3 4 5 39 40 41 42 43 44 45 46 47 48
6 7 8 9 10 49 50 51 52 53 54 55 56 57 58
11 12 13 14 15 16
17 18 19 20 21 22 59 60 61 62 63 64 65 66 67 68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
the engine is not running and the ignition is switched on. is started or when a moment of momentum is detected. remain activated until the next actuator is selected by pressing key . nal control diagnosis.
The final control diagnosis is aborted when the engine
During the actuator diagnosis the individual actuators
S01-0094
The electric fuel delivery unit runs during the entire fi The actuators are tested acoustically or by touch.
Procedure
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics 01-1 page 4.
Select function 03 final control diagnosis.

Activate solenoid valve 1 for activated charcoal filter system -N80-:
Vehicle system test 03 - Actuator diagnosis
Press
key. Actuator diagnosis Tank vent valve -N80 ->
Readout on display: The solenoid valve (on right, at suspension strut dome) must continue clicking until the next control element is actuated by pressing the key.
Detach hose from the activated charcoal filter at the

solenoid valve.
Fit auxiliary hose onto the free connection of the

valve.
Blow into this hose during final control diagnosis. The

valve must open and close. If the solenoid valve does not click:
Test resistance at solenoid valve -N80- Chap. 241.
Test cables for open circuit, short circuit to earth and
to positive Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Actuate secondary air pump relay -J299-:
Press
key.
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Self-diagnosis I
01-1 page 7
01
Readout on display: The secondary air pump relay must continue clicking until the next control element is actuated by pressing the key. If the relay does not click:
Actuator diagnosis Secondary air pump relay -J299
->
Test secondary air pump relay -J299- and cables for

open circuit, short circuit to earth and to positive Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Actuate injectors -N30- to -N33-:
Press
key. Actuator diagnosis Injector cylinder 1 -N30 ->
Readout on display: The injector closes 5x.
The next injector is operated by pressing the

ton.
but-
Test all the injectors one after the other in this way.
If one of the injectors is not actuated:
Test resistance of injector Chap. 24-1. Test cables for open circuit, short circuit to earth and

Note The ignition must be switched off after final control diagnosis is ended. If the ignition is not switched off before the engine is started, the engine will not start as the injectors and the ignition transformer are not operated.
01-1 page 8
Self-diagnosis I
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01
01-2
Self-diagnosis II
Readiness code Reading Readiness Code

Operation The readiness code is an 8-digit numerical code that provides information on the status of the emission-relevant diagnosis. If the diagnosis is performed for a system, the corresponding digit of the numerical code switches from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that the systems operate according to the specifications. If a fault is detected during the diagnosis it is entered in the fault memory. The readiness code is erased if the fault memory is erased or if there is an interruption to the voltage supply. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-.
Procedure
Connect vehicle system tester -V.A.G 1552- and enter

address word 01 Engine electronics Chap. 01-1.
Select function 15 Readiness code.

If all diagnoses were performed successfully, the display must indicate the following:
Readiness code 00000000 - Test complete 01101101

If the following readout appears in the display:
Readiness code 01101101 - Test not complete 01101101
Press key. Generate readiness code 01-2 page 2.
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Self-diagnosis II
01-2 page 1
01
Meaning of the 8-digit numerical block of the readiness code

The readiness code is only generated if all the display positions show 0 1 2 3 4 5 6 7 8 0 0 0 0 0 0 0 0 Catalytic converter Catalytic converter heater (no diagnosis at present/always 0) Activated charcoal filter system Secondary air system Air conditioning system (no diagnosis at present/always 0) Lambda probes Lambda probe heater Exhaust gas recirculation (no diagnosis at present/always 0) Diagnosis function
Generating readiness code

-V.A.G 1551/3, 3A, 3B oder 3C-.
Test conditions
Vehicle stationary. All electrical consumers, e.g. lights and rear window
heater switched off.
Air conditioning switched off. Intake air temperature less than 60 C display
group 004, display block 4.
Coolant temperature at least 80 C display group

004, display block 3.
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1. Work step 1: Interrogating fault memory
Select function 02 Interrogate fault memory.

The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
X faults detected
Rectify the faults displayed by referring to the fault table: Fault table Chap. 01-3 or 01-4. If no fault is stored:
Press
key.
01-2 page 2
Self-diagnosis II
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FABIA 2000 2.0/85 Engine, Fuel Injection Work step 2: Erasing fault memory
01
Vehicle system test The fault memory is erased ->
Select function 05 Erase fault memory.

Note
The readiness code is reset or erased each time the
fault memory is erased.
The fault memory is not erased if the ignition was
switched off during the functions of Interrogating fault memory and Erasing fault memory.
key.
Press
Work step 3: Adjusting the engine control unit to the throttle valve control unit
Select function 04 Initiate basic setting and display

group 060.
System in basic setting 60 xx % xx % 8
-> ADP runs
Display field 4:
Specified value: ADP runs, ADP o.k.
End adjustment only after 30 seconds have passed by

pressing the key. If the specified values are not reached:
Test throttle valve control unit Chapter 24-2.

Work step 4: Diagnosis of secondary air injection system
Start engine and run in idle.

Note The engine must not be switched off during the entire period.
Select function 04 Initiate basic setting and display

group 077. After initiating diagnosis the message in display field 4 changes from Test OFF to Test ON.
System in basic setting 77 xxx/min xx.x g/s xx.x % -> Test ON
Leave engine idling until the following readout appears in display field 4: Syst. o.k.. If the specified values are not reached:
Interrogate fault memory Chapter 01-1.

If the specified values are reached:
Press
C key.
Work step 5: Diagnosis of activated charcoal filter system (tank vent system)
Enter display group 070.

After initiating diagnosis the message in display field 4 changes from Test OFF to Test ON.
System in basic setting 70 29% 65% 342% Test ON
Leave engine running at idling speed until TVV o.k.

is displayed in display field 4.
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01-2 page 3
01
If the specified values are not reached:
Blip throttle about 3 times and repeat the process. Interrogate fault memory Chapter 01-1.
Press
key.
Work step 6: Testing operating state of lambda control The lambda control can only be tested at a catalytic converter temperature of more than 352 C. To achieve this, engine speed must be increased for several minutes to 2800...3200 rpm. Read off the catalytic converter temperature in measured value block 034.
Select function 08 Read measured value block and

display group 034.
Set engine speed to 2800...3200 rpm: Maintain engine speed at 2800...3200 rpm until the
catalytic converter temperature in display field 2 is more than 352 C. Note This may take a few mlnutes.
Reading measured value block 3000 rpm 352 C xx.xx
34
-> Text
Press C key. Enter display group 030. Check operating state of lambda control upstream of
catalytic converter (display field 1): Specified value: 111
Reading measured value block 111 110
30
->
Check operating state of lambda control downstream

of catalytic converter (display field 2): Specified value: 110 Note Bits in display field 2 are only set to value 1 once the lambda probe downstream of the catalytic converter is active. The catalytic converter temperature must be more than 352 C.
Meaning of 3-digit numerical block in the display fields 1 and 2:

Meaning, if display positions = 1 1 2 3 1 Lambda control active (partial load) 1 1 Lambda probe operational Lambda probe heater switched on
01-2 page 4
Self-diagnosis II
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01

Press
key.
Work step 7: Diagnosis of lambda probe ageing (monitoring period)
Select function 04 Basic setting and display group

034.
Depress brake pedal and accelerator simultaneously. Engine speed is increased and the readout in display
field 4 switches from Test OFF to Test ON. Catalytic converter temperature in display field 2 must be at least 352 C.
System in basic setting 34 1600 rpm 352 C 1.99
-> Test OFF
Check period in display field 3.

Specified value: maximum 2.2 s Specification in display field 4: B1 S1 o.k. If the specified values are not reached:

Press
C key.
Work step 8: Catalyst diagnosis Note This diagnosis is only successfully completed if no faults relating to the lambda probe or the activated charcoal filter system exist.
Enter display group 046. Depress brake pedal and accelerator simultaneously. Engine speed is increased and the readout in display
field 4 switches from Test OFF to Test ON. Catalytic converter temperature in display field 2 must be at least 352 C.
System in basic setting 46 2300 rpm 328.0C 0.00 Test OFF
Continue running engine until Cat B1 o.k. is displayed. Note It may also take a few minutes until the readout is changed from Test ON to Cat B1 o.k. If the specified values are not reached:

Press
key.
Work step 9: Reading Readiness Code
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Self-diagnosis II
01-2 page 5
01
Read out readiness code 01-2 page 1.
01-2 page 6
Self-diagnosis II
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01
01-3
Self-diagnosis III
Fault table, fault codes 16485...17606

Note
The fault table is arranged according to the 5-digit
fault code on the left.
Faults related to the electronic throttle are indicated
on the dash panel insert by the fault lamp for the electronic accelerator control EPC warning lamp). the fault code (e.g. P0107) can be ignored (at present only valid for USA). or short-circuit to earth) Operating instructions for the vehicle system tester. bles and plug connections to these components as well as the earth cables of the system according to the current flow diagram. Replace the component only if this test does not reveal any fault. This applies in particular if the fault is shown as sporadic (SP). fuel injection system and when testing electric cables, proceed according to appropriate current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. Note
The SAE code which is displayed on the right next to
Explanations regarding fault types (e.g. open circuit
If parts are output as faulty: First of all, test all the ca-
When testing senders and other components of the
16486 = Fault denomination P0113 = next fault code (at present only applicable for
USA)
035 = fault type as number air mass meter -G70- = current path or fault point de-
fective
Signal too small = designate fault type with text SP sporadically occurring fault = fault which does not
occur often, e.g. a loose contact
Readout on -V.A.G 155216485 Air mass meter -G7016486 Air mass meter -G7016487 Air mass meter -G70Implausible signal Signal too low Signal too high
Rectifying fault
Read measured value block, display group 005 Chapter 01-5 Check wiring to meter -G70- Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
Read measured value block, display group 005 Chapter 01-5 Testing the intake system for tightness (unmetered air) Replace air filter element Check wiring to meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
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Self-diagnosis III
01-3 page 1
01
Readout on -V.A.G 155216496 Intake air temperature sender -G4216497 Intake air temperature sender -G4216500 Sender for the coolant temperature -G6216501 Sender for the coolant temperature -G6216502 Sender for the coolant temperature -G6216505 Throttle valve potentiometer -G6916506 Throttle valve potentiometer -G6916507 Throttle valve potentiometer -G6916514 Bank 1 - probe 1 16516 Bank 1 - probe 1 16517 Bank 1 - probe 1 16518 Bank 1 - probe 1 16519 Bank 1 - probe 1, heating circuit 16520 Bank 1 - probe 2 16521 Bank 1 - probe 2 16522 Bank 1 - probe 2 16523 Bank 1 - probe 2 16524 Bank 1 - probe 2 16525 Bank 1 - probe 2, heating circuit Signal too low Rectifying fault
Read measured value block, display group 004 Chap. 01-5 Test resistance of intake air temperature sender -G42 - Chap. 24-1
Signal too high
Read measured value block, display group 004 Chap. 01-5 Test resistance of coolant temperature sender -G42 - Chap. 24-1 Signal too low Test coolant thermostat 2.0/85 Engine, Mechanical Components;
Implausible signal Rep. Gr. 19 Signal too high Implausible signal Signal too low
Test throttle valve control unit Chapter 24-2
Signal too high Electrical fault in the circuit Voltage too high Signal too slow No activity Electrical fault
Test lambda probe -G39- and lambda control upstream of catalytic

converter Chapter 24-3
Electrical fault in the circuit Voltage too low Voltage too high Signal too slow No activity Electrical fault
Test lambda probe -G130- and lambda control downstream of catalytic converter Chapter 24-3
01-3 page 2
Self-diagnosis III
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FABIA 2000 2.0/85 Engine, Fuel Injection Readout on -V.A.G 155216554 Bank 1, fuel metering system 16555 Bank 1, fuel metering system Malfunction Rectifying fault
01
System too lean
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injection valves Chapter 24-2 Test fuel delivery unit 2.0/85 Engine, Mechanical Components;
Rep. Gr. 20
Inspect exhaust system for leaks 2,0/85 kW Engine, Mechanical

Components; Rep. Gr. 26
Inspect secondary air system for leaks 2.0/85 kW Engine, Mechanical Components; Rep. Gr. 26
16556 Bank 1, fuel metering system
System too rich
Inspect vacuum lines for leaks Inspect intake system for leaks Test fuel pressure regulator and holding pressure Chap. 24-2 Test injection valves Chapter 24-2 Test solenoid valve for activated charcoal filter Chapter 01-1, final control diagnosis
16585 Injector cyl. 1 -N3016586 Injector cyl. 2 -N3116587 Injector cyl. 3 -N3216588 Injector cyl. 4 -N3316603
Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit Maximum engine speed exceeded Implausible signal Signal too low
Test injectors Chapter 01-1, Final control diagnosis
Rectify any mechanical damage Read measured value block, display group 062 Chapter 01-6 Test throttle valve control unit Chapter 24-2
16605 Angle sender 2 for TV drive -G18816606 Angle sender 2 for TV drive -G18816607 Angle sender 2 for TV drive -G18816610 Angle sender for 1/2 accelerator pedal position -G79- + -G18516611 Sender for accelerator pedal position -G7916612 Sender for accelerator pedal position -G7916614 Fuel pump relay -J17-
Signal too high Implausible signal
Read measured value block, display group 062 Chapter 01-6 Test accelerator pedal position sender Chapter 24-2
Signal too low
Signal too high Electrical fault in the circuit
Test fuel pump relay -J17- Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
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Readout on -V.A.G 155216645 Injector cyl. 1 -N3016646 Injector cyl. 1 -N3016648 Injector cyl. 2 -N3116649 Injector cyl. 2 -N3116651 Injector cyl. 3 -N3216652 Injector cyl. 3 -N3216654 Injector cyl. 4 -N3316655 Injector cyl. 4 -N3316684 Short circuit to earth Short circuit to positive Short circuit to earth Short circuit to positive Short circuit to earth Short circuit to positive Short circuit to earth Short circuit to positive Combustion misfiring detected Rectifying fault
16685 Cyl. 1 16686 Cyl. 2 16687 Cyl. 3 16688 Cyl. 4
Combustion misfiring detected Combustion misfiring detected Combustion misfiring detected Combustion misfiring detected
Test combustion misfiring, display group 014, 015, 016 Chap. 01-5 Test injectors Chapter 01-1, Final control diagnosis Test ignition leads and spark plugs Chapter 28-1 Inspect ignition transformer Chapter 28-1 Test combustion misfiring, display group 015 Chap. 01-5 Test injectors Chapter 01-1, Final control diagnosis Test ignition leads and spark plugs Chapter 28-1 Inspect ignition transformer Chapter 28-1
16705 Engine speed sender -G2816706 Engine speed sender -G2816708 Knock control 16711 Knock sensor 1 -G6116712 Knock sensor 1 -G6116716 Knock sensor 2 -G6616717 Knock sensor 2 -G66-
Implausible signal No signal
Test combustion misfiring, display group 016 Chap. 01-5 Test injectors Chapter 01-1, Final control diagnosis Test ignition leads and spark plugs Chapter 28-1 Inspect ignition transformer Chapter 28-1 Test resistance of engine speed sender -G28- Chap. 24-1
Malfunction Signal too low Signal too high Signal too low Signal too high
Read measured value block, display group 026 Chap. 01-5
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FABIA 2000 2.0/85 Engine, Fuel Injection Readout on -V.A.G 155216724 Incorrect asCamshaft position/ signment crankshaft position sensor 16725 Camshaft position sensor sender -G40 16726 Camshaft position sensor sender -G40 16727 Camshaft position sensor sender -G40 16735 Ignition control cyl. 1 16736 Ignition control cyl. 2 16737 Ignition control cyl. 3 16738 Ignition control cyl. 4 16795 Secondary air system Implausible signal Signal too low Rectifying fault
01
Test camshaft position sensor -G163- Chapter 28-1
Signal too high Malfunction Malfunction Malfunction Malfunction Flow rate incorrect
Test ignition leads and spark plugs Chapter 28-1 Inspect ignition transformer Chapter 28-1 Read measured value block, display group 014 Chapter 01-5
Read measured value block, display group 077 Chap. 01-7 Test secondary air injection pump 2.0/85 Engine, Mechanical Components; Rep. Gr. 26
Test combination valve 2.0/85 Engine, Mechanical Components;

Rep. Gr. 26
Inspect hoses and connection pipes to individual components, and

also between components 2.0/85 Engine, Mechanical Components; Rep. Gr. 26 diagnosis 16802 Malfunction Secondary air pump relay -J29916804 Bank 1, catalytic converter system 16806 Bank 1, main catalytic converter Efficiency too low Efficiency too low
Test the relay or the secondary air pump Chapter 01-1, final control Generate readiness code Chapter 01-2 Check emission levels if the same faults are displayed Inspection
and Maintenance; Rep. Gr. 02
16824 Malfunction Tank ventilation system 16825 Flow rate inTank ventilation system correct 16885 Vehicle speed signal 16890 Idling control 16891 Idling control 16894 Idling speed switch -F60Implausible signal Speed under nominal value
Test solenoid valve for activated charcoal filter Chapter 01-1, final
control diagnosis
Inspect hoses and connection pipes from fuel tank up to injection rail
2.0/85 Engine, Mechanical Components; Rep. Gr. 20
Test vehicle speed signal Chapter 24-5
Test throttle valve control unit Chapter 24-2 Adapt engine control unit to throttle valve control unit Chapter 24-4 Speed above nominal value Inspect intake system for leaks Malfunction Test throttle valve control unit Chapter 24-2
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Readout on -V.A.G 155216897 Immobilizer 16944 Voltage supply 16946 Voltage supply 16947 Voltage supply 16952 CCS switch -E4516955 Brake light switch -F16984 Databus drive incorrect code number Implausible signal Voltage too low Voltage too high Implausible signal Implausible signal missing message Rectifying fault
Adapt engine control unit to electronic immobiliser Electrical System; Rep. Gr. 96.
Inspect engine control unit power supply Chapter 24-4 Test battery and alternator Electrical System; Rep. Gr. 27 procedure if voltage interrupted Chapter 24-4
Test cruise control system (CCS), display group 066 Chap. 01-7 Read measured value block, display group 066 Chapter 01-7
Read measured value block, display group 125 Chap. 01-7 Inspect databus Chapter 24-5 Perform automatic test sequence Chapter 01-1 Replace engine control unit -J220- Chapter 24-4
16985 Control unit defective 16986 Control unit programming 16988 Control unit defective 16989 Control unit defective 16990 Control unit defective 17022 Throttle valve control unit -J33817026 Knock control 17069 Main relay -J27117070 Main relay -J27117071 Main relay -J27117510 Bank 1 - probe 1, heating circuit 17511 Bank 1 - probe 1, heating circuit 17513 Bank 1 - probe 2, heating circuit Implausible signal Control unit defective Open circuit Short circuit to earth Short circuit to positive Short circuit to positive Output too small Short circuit to positive Malfunction
Check parts of the engine control unit and the gearbox control unit
and replace the control unit if necessary
Replace engine control unit -J220- Chapter 24-4
Test throttle valve control unit Chapter 24-2 Replace engine control unit Chapter 24-4 Test the power supply relay -J271- for the engine control unit
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

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FABIA 2000 2.0/85 Engine, Fuel Injection Readout on -V.A.G 155217519 Lambda control (bank 1) 17520 Lambda control (bank 1) 17523 Bank 1 - probe 1, heating circuit 17524 Bank 1 - probe 1, heating circuit 17525 Bank 1 - probe 2, heating circuit 17526 Bank 1 - probe 2, heating circuit 17535 Bank 1, mixture adaptation (mult.) System too lean System too rich Short circuit to earth Open circuit Rectifying fault
01

Short circuit to earth Open circuit
System too rich
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injection valves Chapter 24-2 Test activated charcoal filter solenoid valve 1 -N80- Chap. 01-1, Final control diagnosis
17536 Bank 1, mixture adaptation (mult.)
System too lean
Rep. Gr. 20
Inspect intake system for leaks Inspect exhaust system for leaks 2.0/85 kW Engine, Mechanical
Components; Rep. Gr. 26
Inspect secondary air injection system for leaks 2.0/85 kW Engine,

Mechanical Components; Rep. Gr. 26 17549 Load detection 17550 Load detection 17551 Load detection 17553 Air mass meter -G7017557 Lambda control (bank 1) 17559 Bank 1, mixture adaptation range 1 implausible value Below limit Above limit Short circuit to positive implausible control value Below leanness limit
Inspect vacuum lines for leaks Test throttle valve control unit Chapter 24-2 Test accelerator pedal position sender Chapter 24-2 Test injection valves Chapter 24-2 Inspect intake system for leaks Read measured value block, display group 005 Chapter 01-5 Read measured value block, display group 005 Chapter 01-5

Testing the intake system for tightness (unmetered air)
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Readout on -V.A.G 155217560 Bank 1, mixture adaptation range 2 Below leanness limit Rectifying fault
Inspect secondary air injection system for leaks 2.0/85 kW Engine,

Mechanical Components; Rep. Gr. 26
Rep. Gr. 20 Above richness limit Above richness limit Implausible signal Signal too low
17573 Bank 1, mixture adaptation range 1 17574 Bank 1, mixture adaptation range 2 17579 Angle sender 2 for TV drive -G18817580 Angle sender 2 for TV drive -G18817581 Angle sender 2 for TV drive -G18817584 Bank1, lambda correction according to catalytic converter
Test fuel pressure regulator and holding pressure Chap. 24-2 Test injection valves Chapter 24-2 Test activated charcoal filter solenoid valve 1 -N80- Chap. 01-1, Final control diagnosis
Check angle sender in measured value block, display group 060

Chapter 01-6
Test throttle valve control unit Chapter 24-2
Signal too high Regulating limit reached
Test lambda probe ageing upstream of catalytic converter Chapter

24-3
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Self-diagnosis III
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FABIA 2000 2.0/85 Engine, Fuel Injection Readout on -V.A.G 155217586 Linear lambda probe/ pump current 17587 Linear lambda probe/ pump current 17588 Linear lambda probe/ pump current 17589 Linear lambda probe/ reference voltage 17590 Linear lambda probe/ reference voltage 17591 Linear lambda probe/ reference voltage 17592 Linear lambda probe/ combined earth cable 17593 Linear lambda probe/ combined earth cable 17594 Linear lambda probe/ combined earth cable 17606 Bank 1 - probe 2, heating circuit Open circuit Rectifying fault
01

Short circuit to earth Short circuit to positive Open circuit
Short circuit to earth Short circuit to positive Open circuit
Short circuit to earth Short circuit to positive Electrical fault
Note
re fault codes 16505 and 16506: As soon as one of these faults is detected, the engine
control unit uses a substitute value which is generated from the engine speed and the inducted air mass.
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Self-diagnosis III
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01-4
Self-diagnosis IV
Fault table, fault codes 17621...18104

Readout on - V.A.G 155217621 Injector cyl. 1 -N3017622 Injector cyl. 2 -N3117623 Injector cyl. 3 -N3217624 Injector cyl. 4 -N3317633 Injector cyl. 1 -N3017634 Injector cyl. 2 -N3117635 Injector cyl. 3 -N3217636 Injector cyl. 4 -N3317645 Injector cyl. 1 -N3017646 Injector cyl. 2 -N3117647 Injector cyl. 3 -N3217648 Injector cyl. 4 -N3317704 Cooling system 17708 Combustion misfiring detected 17733 Knock control Cyl. 1 17734 Knock control Cyl. 2 17735 Knock control Cyl. 3 17736 Knock control Cyl. 4 Short circuit to positive Short circuit to positive Short circuit to positive Short circuit to positive Short circuit to earth Short circuit to earth Short circuit to earth Short circuit to earth Open circuit Open circuit Open circuit Open circuit Fault Rectifying fault
Test coolant temperature sender Chapter 24-1 Test coolant thermostat 2.0/85 Engine, Mechanical Components;
Rep. Gr. 19
Reason: Fuel shortage Regulating limit reached Regulating limit reached Regulating limit reached Regulating limit reached
Refuel Test signal from fuel gauge sender Read measured value block, display group 026 Chap. 01-5 Eliminate abnormal engine running noises (loose ancillaries, bracket or
bolt bent)
Check wiring and plug connections according to the current flow diagram Slacken knock sensors and then tighten again to 20 Nm Change type of fuel Read measured value block, display group 005 Chapter 01-5 Inspect vacuum lines for leaks Inspect intake system for leaks Test resistance of coolant temperature sender -G42 - Chap. 24-1 Test resistance of intake air temperature sender -G42 - Chap. 24-1
17743 Regulating Engine torque monitor- limit exceed ing 2 ed 17744 Regulating Engine torque monitor- limit exceed- ing ed
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Readout on - V.A.G 155217745 Bank 1, camshaft position sensor -G163 17746 Bank 1, camshaft position sensor -G163 17747 Crankshaft position.- / engine speed sensor 17748 Camshaft position/ crankshaft position sensor 17763 Ignition control cyl. 1 17764 Ignition control cyl. 1 17765 Ignition control cyl. 1 17766 Ignition control cyl. 2 17767 Ignition control cyl. 2 17768 Ignition control cyl. 2 17769 Ignition control cyl. 3 17770 Ignition control cyl. 3 17771 Ignition control cyl. 3 17772 Ignition control cyl. 4 17773 Ignition control cyl. 4 17774 Ignition control cyl. 4 17794 Control unit defective 17795 Control unit defective 17796 Control unit defective 17818 Tank ventilation valve -N8017832 Bank 1, secondary air system Short circuit to positive Leak detected Short circuit to earth Open circuit/ Short circuit to positive Wrongly connected Incorrect assignment Rectifying fault
Test camshaft position sensor -G163- Chapter 28-1
Test camshaft position sensor -G163- Chapter 28-1 Test resistance of engine speed sender -G28- Chap. 24-1 Inspect camshaft position sensor -G163- for tight installation
Open circuit Short circuit to positive Short circuit to earth Open circuit Short circuit to positive Short circuit to earth Open circuit Short circuit to positive Short circuit to earth Open circuit Short circuit to positive Short circuit to earth
Inspect ignition transformer Chapter 28-1
Replace engine control unit -J220- Chapter 24-4 Test earth cables according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test activated charcoal filter solenoid valve 1 -N80- Chap. 01-1, Final control diagnosis
Read measured value block, display group 077 Chap. 01-7 Test secondary air system for leaks
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FABIA 2000 2.0/85 Engine, Fuel Injection Readout on - V.A.G 155217833 Tank ventilation valve -N8017834 Tank ventilation valve -N80Short circuit to earth Open circuit Rectifying fault
01
Test activated charcoal filter solenoid valve 1 -N80- Chap. 01-1, Final control diagnosis
17841 Open circuit Secondary air pump relay -J29917842 Short circuit Secondary air pump re- to positive lay -J29917843 Short circuit Secondary air pump re- to earth lay -J29917860 Secondary air system 17908 Fuel pump relay -J1717909 Fuel pump relay -J1717910 Fuel pump relay -J1717921 2nd valve for variable intake manifold changeover -N26117922 2nd valve for variable intake manifold changeover -N261Open circuit Electrical fault in the circuit Short circuit to earth Short circuit to positive Short circuit to positive
Test the relay or the secondary air pump -J299- Chapter 01-1, final
control diagnosis
Test fuel pump relay -J17- Current Flow Diagrams, Electrical Fault
Test fuel delivery unit 2.0/85 Engine, Mechanical Components;

Rep. Gr. 20
Check wiring and plug connections according to the current flow dia-
gram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Short circuit to earth
17923 Short circuit Valve for variable into earth take manifold changeover -N15617925 Main relay -J27117926 Main relay -J27117931 Crash signal from airbag CU 17947 Clutch pedal switch -F3617949 Fuel pump relay -J17Electrical fault in the circuit Short circuit to positive Implausible signal Implausible signal Open circuit
Test the power supply relay for Motronic -J271- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Read measured value block, display group 004 Chap. 01-5 Test airbag Body Work; Rep. Gr. 01 Read measured value block, display group 066 Chapter 01-7 Test fuel pump relay -J17- Current Flow Diagrams, Electrical Fault
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Readout on - V.A.G 155217950 Angle sender for TV drive -G187-1) 17951 Angle sender for TV drive -G187-2) 17952 Angle sender for TV drive -G187-2) 17953 Throttle valve control 17966 Throttle valve drive -G186-1) 17967 Throttle valve control unit -J33817968 Maximum engine speed exceeded 17972 Throttle valve control unit -J33817973 Throttle valve control unit -J33817976 Throttle valve control unit -J33817977 CCS switch -E4517978 Engine control unit inhibited 17987 Throttle valve control unit -J33818010 Voltage supply tml. 30 18011 Control unit defective 18014 Poor road info/engine spec. torque from ABS CU 18017 Electrical fault in the circuit Deactivation actuated in case of an accident Adaptation was not initiated Voltage too low Undervoltage on basic setting Bottom limit not reached Mechanical fault Implausible signal Implausible signal Signal too low Signal too high Malfunction Electrical fault in the circuit Incorrect basic setting Rectifying fault
Read measured value block, display group 062 Chapter 01-6 Test throttle valve control unit -J338- Chap. 24-2
Adapt engine control unit to throttle valve control unit Chapter 24-4 Inspect engine for mechanical damage and erase fault memory
Chapter 01-1
Test alternator and battery Electrical System; Rep. Gr. 27 Adapt engine control unit to throttle valve control unit Chapter 24-4 Read measured value block, display group 062 Chapter 01-6 Inspect throttle valve for damage and dirt Test throttle valve control unit -J338- Chap. 24-2 Read measured value block, display group 066 Chapter 01-7 Adapt engine control unit to electronic immobiliser Electrical System; Rep. Gr. 90.
Adapt engine control unit to throttle valve control unit Chapter 24-4 Test throttle valve control unit -J338- Chap. 24-2 Inspect engine control unit power supply Chapter 24-4 Test alternator and battery Electrical System; Rep. Gr. 27 Replace engine control unit Chapter 24-4 Read out fault memory of ABS control unit Chassis; Rep. Gr. 45 Inspect databus Chapter 24-5 Interrogate fault memory of airbag control unit and erase Body
Work; Rep. Gr. 01
18018 Control unit defective 18020 Engine control unit Incorrectly coded
Replace engine control unit Chapter 24-4 Code engine control unit Chapter 24-4
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Self-diagnosis IV
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FABIA 2000 2.0/85 Engine, Fuel Injection Readout on - V.A.G 155218034 Databus drive 18038 Sender for accelerator pedal position -G7918039 Sender for accelerator pedal position -G7918041 Sender 2 for accelerator pedal position -G18518042 Sender 2 for accelerator pedal position -G18518044 Databus drive 18047 Sender 1/2 for accelerator pedal position -G79- + -G18518048 Control unit defective 18056 Databus drive 18057 Databus drive 18058 Databus drive defective Missing message from ABS CU Missing message from combiinstrument implausible message from ABS CU implausible message from airbagSG implausible message from steering column Missing message from gearbox CU Signal too low Signal too high Signal too low Rectifying fault
01
Inspect databus Chapter 24-5 Test accelerator pedal position sender Chapter 24-2
Read measured value block, display group 062 Chapter 01-6 Test accelerator pedal position sender Chapter 24-2
Signal too high
Missing message from airbag CU Implausible signal
Inspect databus Chapter 24-5 Test accelerator pedal position sender Chapter 24-2
Replace engine control unit Chapter 24-4 Inspect databus Chapter 24-5 Read out fault memories of all control units (automatic test sequence)
Chapter 01-1
18090 Databus drive
18091 Databus drive
18104 Databus drive
1) 2)
Throttle valve drive (electronic power control) -G186- is also known as throttle valve positioner (for intake manifold) -V60-. Angle sensor for throttle valve drive (electronic power control) -G187- is also known as throttle valve position sender -G127-.
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Note
regarding fault code 17978: The immobilizer control unit is located in the dash
panel insert and cannot be replaced individually.
When attempting to start with a non-adapted key a
static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key the fault is changed to a sporadic fault.
01-4 page 6
Self-diagnosis IV
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01-5
Self-diagnosis V
Reading measured value block

-V.A.G 1551/3, 3A, 3B oder 3C-.
Test conditions
The coolant temperature must be at least 80C display group 004, display field 3. heater, must be switched off. be switched off.
All electrical consumers, e.g. lights and rear window If vehicle is equipped with air conditioning, this must There must not be any faults present in the fault memory Chapter 01-1.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.

the desired display group number. Note Display group number 004 is an example to represent the sequence. Note Proceed according to the following table to switch to another display group: Display group higher lower skip -V.A.G 15513 Press key 1 Press key C Press key
Read measured value block Enter display group number
HELP XXX
Read measured value block
-V.A.G 1552 Press key Press key C Press key
If the specifications are achieved in all the display

fields, press key .
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Reading measured value blocks, display groups 001 to 029

Display group 001 - Basic functions
Engine idling
Read measured value block 1 xxxx rpm 1 xx.x C 2 xx.x % 3 xxxxxx 4 Display fields Operating conditions Lambda regulator upstream of catalytic converter Coolant temperature Engine speed (idling speed) Specification 11111111 -10,0...10,0 % 80.0...110.0 C 680...880 rpm Analysis 01-5 page 3 01-5 page 3 01-5 page 2 01-5 page 2 Readout on display
Note
Re display field 3: Readout must fluctuate around zero. If zero is always
displayed, the lambda control has switched from closed-loop to open-loop control because of a fault in the lambda control. Interrogate fault memory Chapter 01-1.
Analysis of display group 001, display field 1 - engine speed (idling speed)
Readout on -V.A.G 1552less than 680 rpm greater than 880 rpm Rectifying fault
Test throttle valve control unit Chapter 24-2 Inspect intake system for leaks Interrogate fault memory Chapter 01-1 Inspect intake system for leaks Test throttle valve control unit Chapter 24-2
Analysis of display group 001, display field 2 - coolant temperature

Readout on -V.A.G 1552less than 80 C greater than 110 C Rectifying fault
Conduct test drive if necessary Test resistance of coolant temperature sender Chap. 24-1 Clean radiator Test function of the radiator fan Test coolant thermostat, replace if necessary 2.0/85 kW Engine, Mechanical Components; Rep. Gr. 19
Test resistance of coolant temperature sender Chap. 24-1
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Self-diagnosis V
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Analysis of display group 001, display field 3 - lambda controller upstream of catalytic converter
Readout on -V.A.G 1552Signal outside tolerance Rectifying fault
Wait 30 seconds until readout has stabilised Inspect intake system for leaks Test injectors Chapter 01-1, Final control diagnosis Check lambda learned values in display group 032 Chapter 01-6
Analysis of display group 001, display field 4 - operating states

1 2 3 4 5 6 7 1 1 1 1 1 1 1 8 1 Meaning, if display positions = 1 Coolant temperature more than 80C Speed below 2000 rpm Throttle valve closed Lambda control o.k. Operating state - idling AC compressor disconnected No meaning No fault detected in self-diagnosis
Display group 002 - basic functions - air mass meter
Engine idling
Read measured value block 2 xxxx rpm 1 xxx % 2 x.xx ms 3 x.x g/s 4 Display fields Drawn in air mass Injection period Engine load Engine speed (idling speed) Specification 2.0...5.0 g/s 2.00...5.50 ms 15...35 % 680...880 rpm Analysis 01-5 page 4 01-5 page 4 01-5 page 4 01-5 page 2 Readout on display
Note
Re display field 4: What is displayed is the inducted air mass which is de-
termined by the air mass meter.
If a fault is detected at the air mass meter by the en-
gine control unit, the substitute value of the throttle valve potentiometer in g/s is displayed. throttle valve control unit, the engine runs without idling speed stabilisation at a higher idling speed
In the emergency mode resulting from a fault at the
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which is dependent on the throttle valve position in an emergency mode position (approx. 1100...1500 rpm). Drawn in air mass approx. 4.5...5.5 g/s.
Analysis of display group 002, display field 2 - engine load

Readout on -V.A.G 1552less than 15 % greater than 35 % Rectifying fault
Test throttle valve control unit Chapter 24-2 Test injectors Chapter 01-1, Final control diagnosis If necessary, replace spark plugs Disconnect electric consumer Test throttle valve control unit Chapter 24-2
Note
The maximum engine load decreases approximately
10 % for each 1000 m above mean sea level. at high temperatures.
The maximum engine load decreases by up to 10 % The following readouts must be reached when driving
at full throttle: at 4000 rpm approx. 78 %, at 6000 rpm approx. 75 %.
Analysis of display group 002, display field 3 - injection time

Readout on -V.A.G 1552less than 2.00 ms Rectifying fault
Test drive without full load for at least 10 minutes Test solenoid valve for activated charcoal filter Chapter 01-1, final control diagnosis
greater than 5.50 ms
Test injection valves Chapter 24-2 inspect fuel pressure regulator Chapter 24-2 Eliminate increased load (air conditioning, power steering etc.)
Analysis of display group 002, display field 4 - inducted air mass

Readout on -V.A.G 1552less than 2.0 g/s greater than 5.0 g/s Rectifying fault
Inspect intake system for leaks Eliminate load (AC, el. components switched on, etc.)
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Self-diagnosis V
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Display group 003 - basic functions - air mass meter
Engine idling
Read measured value block 3 xxxx rpm 1 x.x g/s 2 x.x % 3 xx.x BTDC 4 Display fields Ignition angle Throttle valve angle Drawn in air mass Engine speed (idling speed) Specification 0...12.0 BTDC 0,2...5,0 % 2.0...5.0 g/s 680...880 rpm Analysis 01-5 page 5 01-5 page 4 01-5 page 2 Readout on display
Analysis of display group 003, display field 3 - throttle valve angle

Readout on -V.A.G 1552greater than 5.0 % 24-4 Rectifying fault
Adapt engine control unit to throttle valve control unit Chapter Interrogate fault memory Chapter 01-1 Test throttle valve control unit Chapter 24-2
Note Readout when accelerator pedal fully depressed is (90...100 %).
Engine idling
Read measured value block 4 xxxx rpm 1 xx.xxx V 2 xxx.x C 3 xxx.x C 4 Display fields Intake manifold temperature Coolant temperature Supply voltage of the engine control unit Engine speed (idling speed) Specification -45.0...140.0 C 85.0...110.0 C 12.500...14.500 V 680...880 rpm Analysis 01-5 page 6 01-5 page 2 01-5 page 6 01-5 page 2 Readout on display
Note If a fault relating to the coolant temperature sender -G62is stored in the fault memory, the engine control unit uses the intake air temperature as a substitute value (start temperature - substitute value) when the engine is start-
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ed. The temperature then rises according to a model sequence stored in the control unit. Once the engine has reached normal operating temperature a fixed substitute value is displayed after a certain time. This fixed substitute value depends on the intake air temperature. The readout must be higher than the temperature of the ambient air.
Analysis of display group 004, display field 2 - supply voltage to the engine control unit
Readout on -V.A.G 1552less than 12.500 V tem; Rep. Gr. 27 Rectifying fault
Test generator and battery voltage, charge battery Electrical Sys Increase engine speed slightly for a few minutes and switch off additional consumers
greater than 14.500 V
Inspect engine control unit power supply Chapter 24-4 Eliminate current consumption Test voltage, replace voltage regulator if necessary Interrogate fault memory Chapter 01-1
Analysis of display group 004, display field 4 - intake air temperature

Readout on -V.A.G 1552approx. 140.0 C approx. -46.5 C approx. 140 C (readout appears only for a short time and then jumps to 19.5 C) 24-1 Rectifying fault
Test resistance of intake air temperature sender -G42 - Chap. Test cables to intake air temperature sender -G42- Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
Display group 005 - basic functions
Engine idling
Read measured value block 5 xxxx rpm 1 xxx % 2 xxx km/h 3 Text 4 Display fields Operating state (idling, part load, full load, enrichment, overrun) Vehicle speed Engine load Engine speed (idling speed) Specification Idling Analysis Readout on display
0 km/h 10...35 % 680...880 rpm
01-5 page 4 01-5 page 2
Note Testing speed signal Chap. 24-5.
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Self-diagnosis V
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Engine idling
Read measured value block 6 xxxx rpm 1 xx.x % 2 xxx.x C 3 x.x % 4 Display fields Level correction factor Intake manifold temperature Engine load Engine speed (idling speed) Specification -45.0...140.0 C 15,0...35,0 % 680...880 rpm Analysis 01-5 page 4 01-5 page 2 Readout on display
Note
Re display field 2: The maximum engine load decreases approximately
10 % for each 1000 m above mean sea level. at high temperatures.
The maximum engine load decreases by up to 10 % The following readouts must be reached when driving
at full throttle: at 4000 rpm approx. 78 %, at 6000 rpm approx. 75 %.
Display group 010 ignition
Engine idling
Read measured value block 10 xxxx rpm 1 xx.x % 2 x.x % 3 xx.x BTDC 4 Display fields Ignition angle Throttle valve angle Engine load Engine speed (idling speed) Specification 0...12 BTDC 0,2...5,0 % 15,0...35,0 % 680...880 rpm Analysis 01-5 page 5 01-5 page 4 01-5 page 2 Readout on display
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01
Display group 014 - ignition misfiring detection
Engine idling
Read measured value block 14 xxxx rpm 1 xx.x % 2 xxx 3 Text 4 Display fields Status of misfiring detection (activated, deactivated) Total of ignition misfirings Engine load Engine speed (idling speed) Specification activated Analysis Readout on display
0...5 15,0...35,0 % 680...880 rpm
01-5 page 9 01-5 page 4 01-5 page 2
Display group 015 - ignition misfiring detection cylinders 1 to 3
Engine idling
Read measured value block 15 xxx 1 xxx 2 xxx 3 Text 4 Display fields Status of misfiring detection (activated, deactivated) Total of ignition misfirings cyl. 3 Total of ignition misfirings cyl. 2 Total of ignition misfirings cyl. 1 Specification activated Analysis Readout on display
0 0 0
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Display group 016 - ignition misfiring detection cyl. 4
Engine idling
Read measured value block 16 xxx 1 2 3 4 Text Display fields Status of misfiring detection (activated, deactivated) Specification activated Analysis Readout on display
Total of ignition misfirings cyl. 4 0
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Analysis of display groups 014, 015, 016 - total of ignition misfiring cyl. 1 to 4
Readout on -V.A.G 1552greater than 5 Rectifying fault
Inspect ignition transformer Chapter 28-1 Test spark plugs and spark cables with spark plug connector Test injectors Chapter 01-1 Check fuel level in tank
Display group 022, ignition - knock control
Normal driving
Read measured value block 22 xxxx rpm 1 xxx.x % 2 xx.x CA 3 xx.x CA 4 Display fields Ignition angle retarded in cylinder 2 by knock control Ignition angle retarded in cylinder 1 by knock control Engine load Engine speed Specification 0...15.0 CA Analysis 01-5 page 10 Readout on display
0...15.0 CA 0,0...100,0 % 680...6500 rpm
01-5 page 10
Display group 023, ignition - knock control
Normal driving
Read measured value block 23 xxxx rpm 1 xxx.x % 2 xx.x CA 3 xx.x CA 4 Display fields Ignition angle retarded in cylinder 4 by knock control Ignition angle retarded in cylinder 3 by knock control Engine load Engine speed Specification 0...15.0 CA Analysis 01-5 page 10 Readout on display
0...15.0 CA 0,0...100,0 % 680...6500 rpm
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Note
Knock control active from an engine load of more than
40 %.
If an engine load of 40 % is exceeded, the current re-
tardation of the ignition angles are displayed. If the engine load was not reached, the values last used are displayed. ignition angle detectable, increase engine speed for 5 seconds to more than 3500 rpm in order to activate the knock sensor fault detection (for self-diagnosis).
If knocking can be heard without any retardation of the
Analysis of display groups 022/023, display fields 3 and 4 - ignition angle retardation
Readout on -V.A.G 1552Rectifying fault Test knock sensors -G61- and -G66Slacken knock sensor and tighten again to 20 Nm Tighten up loose parts Change type of fuel Test knock sensors -G61- and -G66Testing compression: 2.0/85 TDI Engine, Mechanical Components; Rep. Gr. 15
one cylinder clearly deviates from the oth- ers
all cylinders greater than 15 CA
Tighten up loose parts
Display group 026, ignition - knock sensor
Normal driving
Read measured value block 26 x.xxx V 1 x.xxx V 2 x.xxx V 3 x.xxx V 4 Display fields Knock sensor voltage signal cyl. 4 Knock sensor voltage signal cyl. 3 Knock sensor voltage signal cyl. 2 Knock sensor voltage signal cyl. 1 Specification 0.400...2.000 V 0.400...2.000 V 0.400...2.000 V 0.400...2.000 V Analysis Readout on display
Note
If no fault is found when testing the knock sensor, the
wiring and the plug connections, inspect the ancillaries or the engine for damage. sor voltage signal may be as much as 5.1 V.
At higher engine speeds the readout of the knock sen If a difference of more than 50 % exists between the
smallest and largest knock sensor signal, the cause may be corrosion at the plug connection.
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Display group 028, ignition - testing knock sensor
Normal driving
Read measured value block 28 xxxx rpm 1 xxx.x % 2 xxx.x C 3 Text 4 Display fields Test Knock sensor (Test OFF, Test ON, Syst. o.k., Syst. n.o.k.) Coolant temperature Engine load Engine speed Specification Syst. o.k. Analysis Readout on display
80.0...100.0 C 20,0...100,0 % 2500...6500 rpm
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01-6
Self-diagnosis VII
Reading measured value block, display groups 030 to 062

Display group 030 - lambda control
Engine idling Catalytic converter temperature at least 352 C (display group 34, display field 2)
Read measured value block 30 xxx 1 xxx 2 3 4 Display fields Specification Analysis Readout on display
Status lambda control downstream of catalytic converter Status lambda control upstream of catalytic converter
110 111
01-6 page 1 01-6 page 1
Meaning of 3-digit numerical block in display fields 1 and 2:

1 1 1 Meaning, if display positions = 1 Lambda control active Lambda probe operational Lambda probe heater switched on
Display group 031, lambda control - lambda values upstream of catalytic converter
Engine idling
Read measured value block 31 x.xx 1 x.xx 2 3 4 Display fields Specification Lambda nominal value - Bank 1 Lambda actual value - Bank 1 0,99...1,01 0,96...1,04 Analysis Readout on display
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Display group 032, lambda control - lambda learned values
Engine idling
Read measured value block 32 xx.x % 1 xx.x % 2 3 4 Display fields Specification Lambda learned value at part load upstream of catalytic converter (multiplicative) Lambda learned value at idling speed upstream of catalytic converter (additive) -10,0...10,0 % -10,0...10,0 % Analysis 01-6 page 3 01-6 page 3 Readout on display
Note
to the display fields 1 and 2: Low readouts indicate that the engine is running too
rich and the lambda control therefore produces a leaner mixture. lean and the lambda control therefore produces a richer mixture. set.
High readouts mean that the engine is running too
If the control unit is dead all initialisation values are re Condition for part load learning: Coolant temperature
at least 75 C, intake air temperature max. 90 C, driving mode. air) becomes increasingly less as engine speed rises. In the case of an additive initialisation value the injection period is changed by a fixed rate. This rate is independent of the basic injection period. injector) becomes greater as engine speed rises. The multiplicative learned value is a percentage change in the injection period. This change is dependent on the basic injection period.
add = additive - The effect of the fault (e.g. unmetered
mul = multiplicative - The effect of the fault (e.g. faulty
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Analysis of display group 032, display fields 1 and 2 - lambda learned values
Readout on -V.A.G 1552 low learned values Rectifying fault
Disappears after driving on motorway or changing oil Test injectors Chapter 01-1 Test fuel pressure regulator and holding pressure Chap. 24-2 Test activated charcoal filter solenoid valve Chapter 01-1 Test air mass meter Testing lambda probe heater upstream of catalytic converter Chapter 24-3 Inspect intake system for leaks Test injected quantity Chapter 24-2 Test air mass meter Test fuel pressure regulator and holding pressure Chap. 24-2 Inspect intake system for leaks Test exhaust manifold 2.0/85 Engine, Mechanical Components; Rep. Gr. 26 Chapter 24-3
high learned values
Testing lambda probe heater upstream of catalytic converter
Display group 033, lambda control upstream of catalytic converter - lambda control values
Engine idling
Read measured value block 33 xx.x % 1 x.xxx V 2 3 4 Display fields Specification Lambda probe voltage upstream of catalytic converter Lambda control before catalyst 1.400 V...1.600 V -10,0...10,0 % Analysis 01-6 page 4 Chap. 01-5, display group 001, display field 3 Readout on display
Note
Re display field 1: Readout must fluctuate around zero. If zero is always
displayed, the lambda control has switched from closed-loop to open-loop control because of a fault in the lambda control. Interrogate fault memory Chapter 01-1.
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Note
Re display field 2: Voltage signal Mixture rich (low level of residual ox-
ygen) is between 0.130...1.500 V.
Voltage signal Mixture rich (high level of residual ox-
ygen) is at approx. 1.500...4.800 V.
Analysis of display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
Display field: 1 constant 0.000...1.400 V or constant 1.600...3.000 V constant 3.600 V constant 0.000 V verter Chapter 24-3 Rectifying fault
Testing lambda probe and lambda control upstream of catalytic con-
Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter
Brake pedal and accelerator depressed Vehicle stationary, engine running at fast idling Control unit in function 04 - initiate basic setting
System in basic setting 34 xxxx rpm 1 xxx.x C 2 3 Text 4 Display fields Result of test of lambda probe ageing upstream of catalytic converter (Test OFF /Test ON/B1 S1 o.k./ B1 S1 n.o.k.) Period of lambda probe upstream of catalytic converter Catalytic converter temperature Engine speed Specification B1 S1 o.k. Analysis -- Readout on display x.x s
max. 2.2 min. 352 C 1400...2800 rpm
-------
Note
Re display field 3: The period indicates the time between two jumps (e.g.
rich - lean - rich mixture) and is thus a measure of the status of the lambda probe ageing. If the specified time is exceeded, the following appears in display field 4: B1 S1 n.o.k.
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Display group 036, lambda control - operation downstream of catalytic converter
Engine idling
Read measured value block 36 x.xxx V 1 Text 2 3 4 Display fields Specification Test lambda probe downstream of catalytic converter (B1 S2 o.k./B1 S2 n.o.k.) Lambda probe voltage after catalytic converter B1 S2 o.k. 0.000...1.000 V Analysis 01-6 page 5 Readout on display
Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter
Display field: 1 constant 0.000...0.300 V or constant 0.700...1.000 V constant 1.000 V constant 0.400 ...0.500 V constant 0.000 V Rectifying fault
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-3
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-3
Note
Voltage signal Mixture rich (low level of residual oxy-
gen) is at approx. 0.7...1.0 V.
Voltage signal Mixture lean (high level of residual ox-
ygen) is at approx. 0.0...0.3 V.
A voltage jump from 0.7...1.0 V to 0.0...0.3 V or vice
versa takes place at the transition from rich to lean and vice versa ( = 1.0). is not able to maintain constant the ideal mixture composition which corresponds to = 1.0. The control constantly fluctuates back and forward between the slightly too lean and slightly too rich states. and in some cases more than 0.6 V. The readout below 0.45 V indicates a lean mixture while above 0.45 V indicates a rich mixture. the catalytic converter must fluctuate between a rich and leaner mixture. The lambda probe voltage downstream of the catalytic converter should indicate a constant rich or lean mixture. If the voltage also fluctu-
In view of the steep voltage jump the lambda control
The readout must in some cases be less than 0.3 V
At idling speed, the lambda probe voltage upstream of
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ates downstream of the catalytic converter, either the catalytic converter is faulty ( Read measured value block 046 01-6 page 7) or the probes have been wrongly connected (irregular engine running). Lambda control varies between -10...10 %. Voltage of the 4-pin lambda probe in U in mV A: Lambda probe voltage high rich mixture (fuel surplus or air shortage) high CO value B: Lambda probe voltage low lean mixture (fuel shortage or air surplus) low CO value
Display group 037, lambda control - operation downstream of catalytic converter
Engine idling Control unit in function 04 - initiate basic setting

System in basic setting 37 xx.x % 1 x.xxx V 2 3 Text 4 Display fields Test lambda probe downstream of catalytic converter (Test ON / Test OFF, Syst. o.k. / Syst. n.o.k.) Waiting time of lambda control upstream of catalytic converter Lambda probe voltage after catalytic converter Engine load Specification Syst. o.k. Analysis Readout on display x.xxx
0.000...1.000 V 15,0...35,0 %
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Display group 041, lambda control - lambda probe heating
Engine idling
Read measured value block 41 1 Text 2 3 4 Text Display fields Heater of lambda probe downstream of catalytic converter (Heating.aC.OFF, heating.aC.ON) Heater of lambda probe upstream of catalytic converter (Heating.bC.OFF/heating.bC.ON) Specification Htg dC.OFF Htg dC.ON Analysis Readout on display
Htg.uC.OFF Htg.uC.ON
Note Depending on the operating state of the engine the lambda probe heaters are switched on or off, i.e. the readouts in display field 2 and 4 may show either Htg.u(d)C.ON or Htg.u(d)C.OFF.
Display group 046, lambda control - diagnosis of catalytic converter
Brake pedal and accelerator depressed Vehicle stationary, engine running at fast idling Control unit in function 04 - initiate basic setting
System in basic setting 46 xxxx rpm 1 xxx.x C 2 3 x.xx Text 4 Display fields Result of test of catalytic conversion (Test OFF / Test ON / Cat B1 o.k. / Cat B1 n.o.k.) Amplitude ratio Catalytic converter temperature Engine speed Specification Cat B1 o.k. Analysis Readout on display
0,00...0,55 min. 352.0 C 2000...3200 rpm
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Display group 050, engine speed control - operating states
Engine idling
Read measured value block 50 xxxx rpm 1 xxxx rpm 2 Text 3 Text 4 Display fields Operating condition air conditioning compressor ON/OFF Operating condition of air conditioning system Engine speed (idling speed - specified value) Engine speed (idling speed) Specification Compr. ON or Compr. OFF A/C High or A/C Low 780 rpm 680...880 rpm Analysis Readout on display
Chapter 01-5 display group 001, display field 1
Note
Re display field 2: What is displayed is the specification for the engine
speed which is fixed by the engine control unit (internal computed value in control unit). Note
Re display field 3: A/C High = air conditioning switched on to high heat-
ing or cooling capacity
A/C Low = air conditioning not switched on
Note
Re display field 4: Compr. OFF is always displayed on vehicles without
air conditioning system.
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Display group 054, engine speed control - operating states
Engine idling
Read measured value block 54 xxxx rpm 1 Text 2 xxx.x % 3 4 xxx.x % Display fields Throttle valve positioner angle Sender for accelerator pedal position Specification 0...100 % 3...97 % Analysis Chapter 01-5, display group 003, display field 3 Chap. 01-5, display group 001, display field 1 Readout on display
Operating state (idling, part load, full load, enrichment, overrun) Engine speed (idling speed)
Idling 680...880 rpm
Display group 055, engine speed control - idling speed stabilisation
Engine idling
Read measured value block 55 xxxx rpm 1 x.xx % 2 x.xx % 3 4 xxxxx Display fields Operating conditions Initialisation value idling regulator Idling regulator Engine speed (idling speed) Specification xxxxx -1,50...1,50 % -2,00...2,00 %1) 680...880 rpm Analysis 01-6 page 9 Chap. 01-5, display group 001, display field 1 Readout on display
1)
On a new engine the value is in the positive region because of the higher friction, on a run-in engine it is in the negative region.
Meaning of the 4-digit numerical block display field 4

1 2 3 4 1 1 1 1 5 1 No meaning Air conditioning switched on No meaning No meaning Meaning if display position Air conditioning compressor on
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Display group 056, engine speed control - idling speed stabilisation
Engine idling
Read measured value block 56 xxxx rpm 1 xxxx rpm 2 x.xx % 3 4 xxxxx Display fields Operating conditions Idling regulator Engine speed (idling speed - specified value) Engine speed (idling speed) Specification xxxxx -2,00...2,00 % 780 rpm 680...880 rpm Analysis 01-6 page 9 Chap. 01-5, display group 001, display field 1 Readout on display
Display group 060, engine speed control - adapting throttle valve control unit
Ignition switched on, engine switched off Control unit in function 04 - initiate basic setting
System in basic setting 60 xx % 1 xx % 2 x 3 Text 4 Display fields Adaption state (ADP runs, ADP o.k. or ADP ERROR) Operating state of engine Counter of learning steps Throttle valve angle potentiometer -G188Throttle valve angle potentiometer -G187Specification ADP o.k. 0...8 97...3 % 3...97 % Analysis Chapter 01-5, display group 003, display field 3 Readout on display
Note
When display group 060 is selected in function 04 In-
itiate basic setting, the engine control unit is adapted to the throttle valve control unit. This adjustment must always be performed if a different throttle valve control unit (or completely different engine) or a different engine control unit has been fitted. out the adaptation of the throttle valve control unit.
The ignition should be switched on in order to carry If the voltage supply has been interrupted (battery dis-
connected), it is also necessary to carry out adaption Chap. 24-4.
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Display group 061 - engine speed control, EPC
Engine idling or vehicle driven

Read measured value block 61 xxxx rpm 1 xx.xxx V 2 xxx.x % 3 4 Readout on display xxxxx Display fields Operating conditions Activate throttle valve positioner Supply voltage of the engine control unit Engine speed Specification xxxxx 0,0...100,0 % 12,500...14,500 V 680...6500 rpm Analysis 01-6 page 9
Display group 062 - engine speed control, EPC
Ignition on or engine running

Read measured value block 62 xx % 1 xx % 2 xx % 3 xx % 4 Display fields Sender for accelerator pedal position -G185Sender for accelerator pedal position -G79Throttle valve angle potentiometer -G188Throttle valve angle potentiometer -G187Specification 3...50 % 6...97 % 97...3 % 3...97 % Analysis Readout on display
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01-7
Self-diagnosis VIII
Reading measured value blocks, display groups 66 to 126

Display group 066 - cruise control system (only models with CCS)
Engine idling
Read measured value block 66 x km/h 1 xxxxxxxx 2 x km/h 3 xxxxxxxx 4 Display fields CCS switch position Specified vehicle speed (value last stored by CCS) Brake pedal, clutch pedal and CCS position Vehicle speed Specification 0000xxxx x km/h 0000xxxx x km/h Analysis 01-7 page 1 01-7 page 1 Readout on display
Meaning of digits in 4-digit numerical block, display field 2, brake and clutch pedal switch, CCS switch
1 2 3 1 1 1 4 1 Meaning if display position Brake pedal depressed (brake light switch) Brake pedal depressed (brake pedal switch) Clutch depressed CCS actuated
Meaning of digits in 4-digit numerical block, display field 4, CCS switch
4 1
Meaning if display position CCS sliding switch in OFF position (only if closed)
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1 2 1 1 3 1 4 CCS pushbutton SET operated CCS sliding switch -B- in RES position
FABIA 2000 2.0/85 Engine, Fuel Injection Meaning if display position CCS sliding switch in OFF position (closes or closed)
Display group 070 - exhaust gas reduction - diagnosis of activated charcoal filter system
Engine idling Coolant temperature at least 40 C (display group 001, display field 2) Control unit in function 04 - initiate basic setting
System in basic setting 70 xxx.x % 1 xx.x % 2 3 Text 4 Display fields Result of diagnosis (Test ON / Test OFF or TVV O.K. / TVV N.O.K) Idling speed controller variation during TVV diagnosis Lambda controller variation during TVV diagnosis On/off ratio of activated charcoal filter solenoid valve Specification TVV o.k. Analysis Readout on display xxx.x %
0...150,0 % -7,8...7,8 % 0,0...100,0 %
Note TVV means Tank Vent Valve (activated charcoal filter solenoid valve). Diagnosis can only be initiated once each time the engine is started. Note
Lambda regulator variation in negative range: activat-
ed charcoal filter full.
Lambda regulator variation in positive range: activat-
ed charcoal filter empty.
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Display group 077 - exhaust gas reduction - diagnosis of secondary air injection system
Engine idling Control unit in function 04 - initiate basic setting

System in basic setting 77 xxxx rpm 1 xx.x g/s 2 3 Text 4 Display fields Result of diagnosis (Test ON / Test OFF, Syst. o.k. / Syst. n.o.k.) Air mass ratio, secondary air injection system Air mass Engine speed (idling speed) Specification Syst. o.k. Analysis Readout on display xx.x %
-7,0...7,0 % 1.0...10.0 g/s 680...880 rpm
Chap. 01-5, display group 001, display field 1
Display group 100 - readiness code
Engine idling
Read measured value block 100 xxxxxxxx 1 xxx.x C 2 xxxx s 3 xxxxxxxx 4 Display fields Diagnosis status Time since engine start Coolant temperature Specification 80.0...110.0 C Analysis Chap. 01-6, display group 001, display field 2 01-7 page 3 Readout on display
Readiness code
00000000
Meaning of 8-digit numerical block for readiness code, display field 1

1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Catalytic converter Catalytic converter heater (no diagnosis at present/always 0) Activated charcoal filter (tank vent system) Secondary air system Air conditioning system (no diagnosis at present/always 0) Lambda probes Lambda probe heater Exhaust gas recirculation (not fitted/always 0) Diagnosis function
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Note The Readiness code is only generated when all display positions are 0.
Display group 120 - traction control system -TCS-
Driving
Read measured value block 120 xxxx rpm 1 xxx Nm 2 xxx Nm 3 Text 4 Display fields Status Actual engine load Nominal engine load Engine speed Specification TCS active / TCS n. active 0...260 Nm 0...399 Nm 680...6500 rpm Analysis Readout on display
Display group 125 - communication, databus messages
Engine idling
Read measured value block 125 1 Text 2 Text 3 Text 4 Display fields Status of the air-conditioning system Status of combiinstrument Status ABS Specification Clima 1 Combi 1 ABS 1 Analysis 01-7 page 5 01-7 page 5 01-7 page 5 Readout on display
Display group 126 - communication, databus messages
Engine idling
Read measured value block 126 1 2 Text 3 Text 4 Display fields Status of the electrical system control unit Status airbag Specification El. CU 1 Airbag 1 Note on display fields 125 and 126: Nominal value = 1; the control units with active data bus are displayed. Analysis 01-7 page 5 01-7 page 5 Readout on display
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Analysis: Display groups 125 and 126

Readout on -V.A.G 1552if 0 displayed instead of 1 Possible cause of fault
CAN databus connection defective no CAN databus cables used - control
Rectifying fault
Perform the automatic test sequence for

interrogation of all fault memories.
unit unit
CAN databus cables defective - control
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24 Fuel Formation, Injection

24-1 Repairing the injection system
General notes on the injection system

Repairing the ignition: Rep. Gr. 28.
The engine control unit is equipped with a self-diagno-
sis. The first step, before commencing repairs or fault finding, is to interrogate the fault memories of all the control units using the automatic test sequence. This is necessary because different control units are interconnected via data bus. Also check the vacuum hoses and connections (unmetered air). cured with spring band clamps. The use of clamp-type or screw-type clips is not allowed. connecting and re-connecting the battery otherwise the engine control unit may be damaged.
Fuel hoses in the engine compartment must be se-
The ignition must always be switched off before dis-
Components marked with an * are checked by self-di-
agnosis Chap. 01-1.
Components marked with
can be tested with the final control diagnosis Chap. 01-1.
**
A minimum voltage of 11.5 V is required for the perfect
functioning of the electric components.
Do not use sealants containing silicone. Traces of sil-
icone elements drawn in by the engine are not burnt in the engine and damage the lambda probe.
Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary erase Chap. 01-1. fuel shut-off. It is intended to reduce the risk of a vehicle fire after a crash as the fuel pump is disconnected by the fuel pump relay. This installation also enhances the starting behaviour of the engine. When opening the door the fuel pump is activated for 2 seconds in order to build up the pressure in the fuel system.
Vehicles fitted with airbags are equipped with a crash
Safety measures 24-1 page 7. Cleanliless rules 24-1 page 7.
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Overview of fitting location
1 - Solenoid valve 1 for activated charcoal filter -N80-*/** Resistance 22...30 Test 2.0/85 Engine, Mechanical Components; Rep. Gr. 20 2 - 4-pin plug connector for lambda probe and lambda probe heater downstream of catalytic converter 3 - 6-pin plug and socket connector for lambda probe and lambda probe heater upstream of catalytic converter 4 - Throttle valve control unit -J338- * 5 - Sender for coolant temperature -G62- * resistances Fig. 1 in 24-1 page 6 6 - Air mass meter -G70- * with intake air temperature sender -G42-** Resistances for intake air temperature sender -G42 Fig. 1 in 24-1 page 6 7 - Engine control unit * Control unit for Motronic fuel injection system - J220 testing voltage supply Chap. 24-4 procedure if voltage interrupted Chap. 24-4 replacing Chap. 24-4. coding Chap. 24-4 8 - Engine speed sender -G28-* item 15 in 24-1 page 3 9 - Ignition transformer * with power output stage - N112 with ignition coils -N-, -N128 inspecting Chap. 28-1
16
15
14 13
12
11
10
S24-0487
10 - Injectors -N30-...-N33-* item 8 in 24-1 page 5 11 - Secondary air pump -V101 secondary air injection system 2.0/85 Engine, Mechanical Components; Rep. Gr. 26 12 - Knock sensor 2 -G66- * 13 - Connecting plug 3-pin, grey for engine speed sender -G28 14 - Knock sensor 1 -G61- * 15 - Fuel pressure regulator 16 - Camshaft position sensor -G163 - *
24-1 page 2
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Removing and installing parts of the injection system

1 - Top part of intake manifold 2 - Connecting plug 81-pin insert or remove plug when the ignition is switched off unlock for removing
1 26
3 4
3 - Engine control unit -J220-* fitting location 24-1 page 2 testing voltage supply Chap. 24-4 procedure if voltage interrupted Chap. 24-4 replacing Chap. 24-4 coding Chap. 24-4 23 4 - Connecting plug 40-pin insert or remove plug when the ignition is switched off unlock for removing 22 5 - Air filter disassembling and assembling 24-1 page 6 6 - 10 Nm 19 7 - to air guide pipe item 7 in 24-1 page 5 8 - Air intake hose to secondary air pump -V101 9 - 10 Nm 10 - Connecting plug 2-pin to coolant temperature sender - G62-
25 6 24 8 6 21 17 12 16 18 14 15 6 13 10 11
S24-0486
5 7 9
20
11 - Sender for coolant temperature -G62-* resistances Fig. 1 in 24-1 page 6 before removing, reduce pressure in cooling system if necessary 12 - Retaining clip check tightness 13 - Connecting plug 3-pin, grey for engine speed sender -G28 14 - O-ring replace if damaged 15 - Engine speed sender -G28-* specified resistance between contacts 2 + 3: 730...990 (at 20 C) resistance higher when engine at normal operating temperature 16 - Lambda probe downstream of catalytic converter -G130 - *, 50 Nm coat only thread with G 052 112 A3; paste must not get into the slots of the probe body with 4-pin connector
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FABIA 2000 2.0/85 Engine, Fuel Injection contacts 3 and 4 gold-plated Voltage of lambda probe heater supplied through fuel pump relay -J17 test lambda probe -G130- and lambda control downstream of catalytic converter Chap. 24-3 Plug connection for lambda probe downstream of catalytic converter Lambda probe upstream of catalytic converter -G39-*, 50 Nm coat only thread with G 052 112 A3; paste must not get into the slots of the probe body with 6-pin connector contacts gold-plated Voltage of lambda probe heater supplied through fuel pump relay -J17 Test lambda probe -G39- and lambda control upstream of catalytic converter Chap. 24-3 Fitting location: in the exhaust manifold Plug connection for lambda probe upstream of catalytic converter Bottom part of intake manifold disassembling and assembling 24-1 page 5 Fuel rail with injection valves disassemble and assemble bottom part of intake manifold 24-1 page 5 Fuel return-flow line blue secure with spring band clams check fitting position to fuel pump in fuel tank 2.0 l/85 Engine, Mechanical Components; Rep. Gr. 20 Fuel feed line black secure with spring band clams check fitting position from fuel filter 2.0/85 Engine, Mechanical Components; Rep. Gr. 20 Gasket replace if damaged check fitting position To crankcase vent valve Air intake hose
17 18 -
19 20 21 22 -
23 -
24 -
25 26 -
24-1 page 4
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Disassembling and assembling bottom part of intake manifold

1 - Fuel pressure regulator testing fuel pressure regulator and pressure in system Chap. 24-2 2 - Vacuum hose 3 - Cable rail for connectors of injectors - N30-...-N334 - Bottom part of intake manifold 5 - 10 Nm 6 - O-ring replace if damaged 7 - To intake hose item 7 in 24-1 page 3 8 - Injectors resistance: 14,0...17,0 (at 20 C), resistance is about 4 to 6 higher when engine is at normal operating temperature 9 - Retaining clip check tightness 10 - Fuel distributor 11 - Fuel return-flow line 12 - Fuel feed line 13 - Air guide pipe to injectors -N30-...-N33-*/**
11 12 13 9 6
7 6 4
8 10
5
S24-0308
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24-1 page 5
24
Disassembling and assembling the air filter
1 - 6 Nm 2 - Air mass meter -G70-* with intake air temperature sender - G42-* Resistances for intake air temperature sender -G42 Fig. 1 in 24-1 page 6 3 - Gasket replace if damaged 4 - Air filter top part 5 - Air deflector in air filter top part 6 - Filter insert 7 - Air filter bottom part 8 - 10 Nm 9 - Air deflector
3 4
1 6 7 8
S24-0484
Fig. 1:
Resistances for coolant temperature sender -G62- and intake air temperature sender -G627000 6000 5000 4000 3000 2000 1000 0 10
B
900 800 700 600 500 400 300 200 100
Coolant temperature sender - G62- at contacts 1 + 2. Intake air temperature sender -G42- at contacts 1 + 3.
The diagram is divided into two temperature ranges: A - from 0 to 50 C B - from 50 to 105 C Read out examples:
For a temperature of 30 C the specification is
1500...2000 275...375
20 30
40
50
60 70
80
90 100C
For a temperature of 80 C the specification is
N24-0157
24-1 page 6
Edition 03.01 S00.5310.00.20
FABIA 2000 2.0/85 Engine, Fuel Injection Fig. 2: Removing and installing engine trim panel
24
Removing
Withdraw dipstick. Remove engine trim panel in direction of -arrows-.
Safety measures
WARNING! The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point. Observe the following points to prevent injury to persons and/or damage to the injection and ignition system:
For reasons of safety fuse No. 61 must be removed
S24-0485
from the fuse holder before opening the fuel system, as the door contact switch could activate the fuel pump. running or at start speed.
Do not touch or remove ignition leads with the engine Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there.
If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.
If the engine must be operated at start speed without
the engine starting: -arrow-.
Unplug the 4-pin connector from ignition transformer Remove fuse 35 for injectors and fuse 61 for fuel
pump.
Rules of cleanliness
When working on the fuel supply/fuel injection system, pay careful attention to the following 5 rules for cleanliness.
Thoroughly clean the connection points and their sur-
1 2 3 4 5 39 40 41 42 43 44 45 46 47 48
6 7 8 9 10 49 50 51 52 53 54 55 56 57 58
11 12 13 14 15 16
17 18 19 20 21 22 59 60 61 62 63 64 65 66 67 68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
roundings before releasing. not use fuzzy cloths!
Place removed parts on a clean surface and cover. Do Carefully cover or close opened components if the re-
pair is not completed immediately.
S01-0094
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24-1 page 7
24
Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped, e.g. on a shelf or in a tool box. pressed air. Avoid moving the vehicle.
When the system is open: avoid working with com-
24-1 page 8
Edition 03.01 S00.5310.00.20
24
24-2
Testing components
Testing throttle valve control unit -J338Components for throttle valve control unit -J338-: Throttle valve drive -V60-, throttle valve drive angle sender 1 -G187- and throttle valve drive angle sender 2 -G188-. Note If the throttle valve control unit is replaced, then adapt this throttle valve control unit to the engine control unit Chapter 24-4. Special tools, test and measuring equipment and auxiliary items required
Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set e.g. -V.A.G 1594 A, B oder C Current flow diagram
Test condition
Throttle valve is not damaged or dirty.

Test sequence
Unplug the 6-pin connector at the throttle valve control

unit.
Measure resistance of throttle valve drive between

contacts 3 + 5. Specified value: 1...5 If the specified value is not reached:
Replace throttle valve control unit -J338-.

If the specified value is reached:
Test voltage supply of throttle valve control unit and

cables to engine control unit 24-2 page 1.
Checking voltage supply
S24-0346
Unplug the 6-pin connector at the throttle valve control

unit.
Connect the multimeter for voltage measurement to

contacts 2 + 6 of the connector.
Switch on ignition.
Specified value: min. 4,5 V
Switch off ignition. Connect the multimeter for voltage measurement to

contact 2 of the connector and to earth.
Switch on ignition.
Specified value: min. 4,5 V
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Testing components
24-2 page 1
24
Switch off ignition.
If wiring is o.k.:
Replace engine control unit Chapter 24-4.
Testing accelerator pedal position sender

Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set e.g. -V.A.G 1594 A, B oder C Test box -V.A.G 1598/31 Current flow diagram
Operation The two accelerator pedal position senders -G79- and -G185- are located at the accelerator pedal and pass on the driver input to the engine control unit completely independently of each other (when accelerator is depressed). Both senders are located in a housing.
Test condition
Battery voltage at least 11.5 V.

Test sequence
Remove storage compartment on driver side Body

Work; Rep. Gr. 68.
Separate the 6-pin plug connection of the accelerator

pedal position sender.
Switch on ignition. Connect the multimeter for voltage measurement to

the following contacts of the connector: Contact 1 + earth Contact 1 + 5 Contact 2 + earth Contact 2 + 3 Specified value: min. 4,5 V

24-2 page 2
Testing components
Edition 11.04 S00.5310.01.20
FABIA 2000 2.0/85 Engine, Fuel Injection If the lines are not found to be faulty:
24
Replace engine control unit Chapter 24-4.
Testing injection valves

Inspecting the injection rate, tightness and jet formation of the injectors
Remote control -V.A.G 1348/3A Adapter -V.A.G 1348/3-2 Measuring glasses, e.g. -V.A.G 1602 Measuring tool set, e.g. -V.A.G 1594 A, B oder C-
Test condition
Fuel pump relay -J17- O.K. Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
The fuel pressure must be OK, test 24-2 page 4 Fuel temperature 15...20 C, fuel must according to
the valid standards
Test sequence
Unplug connectors at all the injectors. Remove fuel rail together with injectors. Detach vacuum hose from fuel pressure regulator. Lift fuel rail together with injectors off intake manifold and support.
Check tightness
Initiate final control diagnosis and actuate injector of
cylinder 1 -N30- Chapter 01-1; the fuel delivery unit must run. With the fuel delivery unit running, only 1 to 2 drops a minute should drip out at each valve.
Test the tightness of the injectors (visual inspection).
If the fuel loss is greater than this:
End final control diagnosis and replace the leaking injector. Note Replace seals at the same time.
Test injected quantity and spray pattern

Note When testing the injection rate also check the jet formation. The jet must be the same for all valves.
Edition 11.04 S00.5310.01.20 Testing components
24-2 page 3
24
Insert injector to be tested in a measuring glass. Connect one contact of injector to engine earth. Connect the second contact of the injector to the remote control.
Connect terminal to battery positive (+).
Connect battery positive (+) and fuse socket No. 61

with adapter cable and adapter -V.A.G 1348/3-2-. The fuel delivery unit must start running.
1 2 3 4 5 39 40 41 42 43 44 45 46 47 48 6 7 8 9 10 49 50 51 52 53 54 55 56 57 58 11 12 13 14 15 16 17 18 19 20 21 22 59 60 61 62 63 64 65 66 67 68 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Operate remote control for 30 seconds. Repeat test at the other injectors. Always use a new
measuring glass.
Once all the injectors have been driven, position the

graduated measuring glasses on an even base.
Switch off voltage supply of fuel delivery unit. Compare the individual quantities of fuel injected.
Specified value: 88...98 ml per valve If the measurement obtained for one or several injectors is below or above the specification:
S01-0094
Replace the defective injection valve Chapter 24-1.

The injectors are installed in the reverse order. Pay attention to the following:
Replace the O-rings and all the injectors and moisten
lightly with clean engine oil.
Insert injectors vertically and into the correct position
in the fuel rail and secure with retaining clips. and press down evenly.
Fit fuel rail with secured injectors onto intake manifold
Test fuel pressure regulator and holding pressure

The fuel pressure regulator regulates the fuel pressure in line with the intake manifold pressure. Special tools, test and measuring equipment and auxiliary items required
Pressure measuring device -V.A.G 1318 Adapter -V.A.G 1318/10 Adapter -V.A.G 1318/11 Adapter -V.A.G 1318/16-
24-2 page 4
Testing components
Edition 11.04 S00.5310.01.20
24
Test condition
Delivery rate of fuel delivery unit o.k., testing 2.0/85

Engine, Mechanical Components; Rep. Gr. 20
Test sequence
WARNING! The fuel system is under pressure! Place a cloth around the connecting point before releasing hose connections or when opening the system. Then release pressure by carefully detaching.
Pull off the fuel feed line -1- and gather residual fuel in
a cloth.
Connect up the pressure measuring device. Open shut-off cock of the pressure measuring device.
Lever points in direction of flow.
Start engine and run in idle. Measure fuel pressure.

Specified value: approx. 0.25 MPa (2.5 bar). If the specified value is reached:
Detach vacuum hose -1- from connection -2-.

The fuel pressure must rise to approx. 0.3 MPa (3.0 bar).

If the pressure does not rise:
Test for leaks and holding pressure. Observe pressure drop at gauge. A pressure of at least 0.2 MPa (2.0 bar) must be indicated on the gauge after 10 minutes. If the holding pressure drops below 0.2 MPa (2 bar):
Edition 11.04 S00.5310.01.20
Testing components
24-2 page 5
24
Start engine and run in idle. After the pressure has been built up, switch ignition
off. At the same time close the shut-off cock of the pressure measuring device (lever at right angles to direction of flow of fuel -arrow-).
Observe pressure drop at gauge.

If the pressure again drops:
Test non-return valve of fuel delivery unit 2.0/85

kW Engine, Mechanical Components; Rep. Gr. 20. If the pressure does not drop:
Open shut-off cock of pressure measuring device

-V.A.G 1318- (lever in direction of flow of fuel).
Start engine and run in idle. After the pressure has been built up, switch ignition
off. Press together the return-flow hose at the same time. If the pressure does not drop:
Replace the fuel pressure regulator.

If the pressure again drops:
Inspect connections, O-rings and fuel distributor for

leaks.
Inspect pressure measuring device for leaks.

Note Before taking off the pressure measuring device, place cleaning cloths around the loose hoses of the feed line.
24-2 page 6
Testing components
Edition 11.04 S00.5310.01.20
24
24-3
Testing functions II
Testing lambda probe -G39- and lambda control upstream of catalytic converter
Handheld multimeter, e.g. -V.A.G 1526 A Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
Fuse 43 must be o.k. Battery voltage at least 11.5 V. The fuel pump relay must be o.k.
Test sequence
8 5 1 2 24 25 26 27 28 29 30 3 4 31 32 33 34 35 36 37 6 7 9 10 11 38 39 40 41 42 43 44
12 13 14 15
16 17 18 19
20 21 22 23
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chap. 01-1.
Check display groups 030, 031, 032, 033, 034 and

036 Chap. 01-6. If the specified values are not reached:
S97-0319
Test resistance of heating element between contacts

3 + 4, voltage supply for heater and cables to -Z19 Current Flow Diagrams, Electrical Fault Finding and Fitting Locations, as necessary. Note At ambient temperature the resistance of the heating element should be approx. 1...5 . The resistance increases considerably even if the temperature rises only slightly.
Test voltage supply of heater and cables to -Z19-.

If the specified resistance and voltage supply for heater and cables to -Z19- are o.k.
Use handheld multimeter to measure voltage between

the contacts 1 and 5 of connector -2- at the wiring loom.
Start engine.
Specified value: 0.40...0.50 V

Replace lambda probe -G39-.

Test cables between engine control unit and connector of lambda probe Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
M24-0056
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24-3 page 1
24
If the cable is not found to be faulty:
Replace engine control unit Chap. 24-4.
Testing lambda probe ageing upstream of catalytic converter -G39Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
Coolant temperature at least 80 C Read measured

value block 004, display field 3 Chap. 01-5
Inspect proper operation
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chap. 01-1.
Select function 04 for Initiate basic setting and display group 034.
Depress brake pedal and accelerator simultaneously. Engine speed is raised to 1400...2800 rpm.
Note This may take a few minutes.
System in basic setting 34 -> 1600 rpm 355 C 2.20 s B1 S1 o.k.
Maintain engine speed at 1400...2800 rpm until the readout in display field 4 switches from Test off. to Test runs. Catalytic converter temperature in display field 2 must be at least 352 C.
Check period in display field 3:

Specified value: max. 2.20 sec.
Maintain engine speed at 1400...2800 rpm until the readout in display field 4 shows B1 S1 o.k.. If the specified values are not reached:
Conduct a test drive in order to eliminate any residues

on the lambda probe and repeat the test. Pay attention to safety measures during the road test Chap. 24-1. If the specified value is again not reached:
Replace lambda probe upstream of catalytic converter

-G39-.
24-3 page 2
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24
Testing lambda probe -G130- and lambda control downstream of catalytic converter
Test conditions
Fuse 43 must be o.k. Battery voltage at least 11.5 V. The fuel pump relay must be o.k. Coolant temperature at least 80 C Read measured value block 004, display field 3 Chap. 01-5
5 1 2 24 25 3 4 31 32 33 34 35 36 37 6 7 8 9 10 11 38 39 40 41 42 43 44 12 13 14 15 16 17 18 19 20 21 22 23
Test sequence
26 27 28 29 30
Check display groups 030, 031, 036 and 037 Chap.

01-6. If the specified values are not reached:
Test resistance of heating element between contacts

1 + 2, voltage supply for heater and cables to -Z29-, as necessary. Note At ambient temperature the resistance of the heating element should be approx. 1...5 . The resistance increases considerably even if the temperature rises only slightly. If the specified resistance and voltage supply and cables to -Z29- are o.k.
S97-0319
Use handheld multimeter to measure voltage between

the contacts 3 and 4 of connector at the wiring loom.
Start engine.
Specified value: 0.40...0.50 V

If the specified value is reached:
Replace lambda probe downstream of catalytic converter -G130 -. If the specified value is not reached:
Test cables to lambda probe -G130- Current Flow

Diagrams, Electrical Fault Finding and Fitting Locations. If the cable is not found to be faulty:
4
A24-0094
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24-3 page 3
24
24-3 page 4
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24
24-4
Engine control unit
Wiring and Component Test with Test Box V.A.G. 1598/31

Test box -V.A.G 1598/31-
Note
The test box -V.A.G 1598/31- is designed in such a
way that it can be simultaneously connected to the wiring loom of the engine control unit and to the actual engine control unit. trol remains fully operational with the test box connected (e.g. measuring signals while the engine is running).
The advantage being that the electronic engine con-
Refer to the relevant test procedures to determine
whether the control unit is connected to the test box or not. unit and the socket numbers of the test box are identical.
The contact numbers of the connector of the control
Switch off ignition. Release the connector catches and unplug the control
unit connectors.
Connect test box -V.A.G 1598/31- to connector of wiring loom. The earth clip of the test box must be connected to the negative battery terminal.
Perform test as described in the relevant repair sequences. DANGER! To avoid damaging the electronic components, switch on the relevant measuring range before connecting the measuring equipment and comply with the test conditions.
V.A.G. 1598/31
S01-0089
Testing voltage supply for engine control unit

-V.A.G 1551/3, 3A, 3B oder 3C-
Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set e.g. -V.A.G 1594 A, B oder C Current flow diagram
Edition 11.04 S00.5310.01.20
Engine control unit
24-4 page 1
24
Test conditions
Battery voltage at least 11.5 V. Fuses no. 3, 14, 17, 48, 52 and 56 must be in proper
order.
Generator o.k., test Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
1 2 3 4 5 39 40 41 42 43 44 45 46 47 48
6 7 8 9 10 49 50 51 52 53 54 55 56 57 58
11 12 13 14 15 16
17 18 19 20 21 22 59 60 61 62 63 64 65 66 67 68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.

display group 004.
S01-0094
Read off readout in display field 2.

Specified value: min. 11.5 V
Reading measured value block 840 rpm 13.6V 95.0C
4 -> 62.0C

If the specified value is not reached:
Connect test box -V.A.G 1598/31- to connector of wiring loom 24-4 page 1. The engine control unit is not connected here.
Testing voltage of terminal 30
Measure supply voltage between sockets 1 + 62 of the

test box: Specified value: min. 11.5 V If the specified value is not reached:
Test cable connections to relay plate according to the
current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Testing voltage of terminal 15
Use multimeter to measure voltage between sockets

1 + 121 at the test box.
Switch on ignition.
Specified value: min. 11.5 V If the specified value is not reached:
Test cable connections to relay plate according to current flow diagram: Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Procedure after voltage supply has been interrupted

If the power supply is interrupted the engine control unit forgets all initialisation or basic setting values and the Readiness Code is erased. Depnding on the mileage
24-4 page 2
Engine control unit
Edition 11.04 S00.5310.01.20
FABIA 2000 2.0/85 Engine, Fuel Injection which the vehicle has driven, this may result in considerable driveability problems. Special tools, test and measuring equipment and auxiliary items required
24
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
After the voltage supply has been interrupted, it is necessary to carry out the following steps:
Switch ignition on for at least 10 seconds. Switch ignition off for at least 30 seconds. Adapt engine control unit to throttle valve control unit
24-4 page 5.
Perform idling speed test Chap. 01-5, display

group 001, display field 1.
Conduct a lengthy test drive until the problems have

been rectified. During the test drive the following operating conditions must be fulfilled:
The coolant temperature should rise beyond 80C Once this temperature is reached, the operating
states of idling speed, part load, fuel shut-off on overrun, must be reached several times. yond 3500 rpm.
in case of full load the speed should be increased be-
Read out readiness code Chap. 01-2.
Replacing engine control unit

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Enter the control unit identification and thus also the

coding of the previous control unit as follows:

ignition on and select address word 01 Engine electronics Chap. 01-1. The control unit identification number and the coding are shown on the display, e.g.:
06A906032CC 2.0l R4/2V Coding 00001 3658 -> WSCXXXXX

Remove air filter Chap. 24-1.
Edition 11.04 S00.5310.01.20
Engine control unit
24-4 page 3
24
Release the plug locks and unplug control unit connectors -arrow-.
S10-0111
Press open the latches of the fixture -arrows A- and

pull the engine control unit forward -arrow B-.
Release the second plug lock and unplug the control

unit connector.
A B A
Installation is carried out in the reverse order.

Note
Check current coding and code new control unit
24-4 page 4.
Adapt new control unit to the electronic immobiliser
Electrical System; Rep. Gr. 90. 24-4 page 5.
Adapt engine control unit to throttle valve control unit Activate CCS Chapter 24-5. Test idling speed Chap. 01-5, display group 001,
S24-0337
display field 1.
Interrogate fault memory, rectify any faults and erase
fault memory Chap. 01-1.
Generate readiness code Chapter 01-2.
Coding engine control unit

Note
A 5-digit code must always be displayed during the
time the control unit identification is shown.
If the code displayed does not match the vehicle, or if
the control unit has been replaced, it is then necessary to code the control unit as follows.
-V.A.G 1551/3, 3A, 3B oder 3C-
24-4 page 4
Engine control unit
Edition 11.04 S00.5310.01.20
24
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1.
Select function 07 coding control unit. Enter the relevant code number of the vehicle and
confirm with button Q . for vehicles with Air Conditioning without air conditioning Code number 00001 00021
Code control unit Enter code number XXXXX
Q (0-00127)
The control unit identification number and the coding are shown on the display, e.g.: If this display appears, an incorrect code number has been entered.
06A906032CC 2.0l R4/2V Coding 00001 Function unknown or cannot be carried out at the moment
3658 -> WSCXXXXX ->

Note
The engine control unit does not use the code entered
and shown in the display until after the ignition has been switched off. Incorrect coding results in: jolts etc.)
Handling problems (jerky gear change, load change Increase in fuel consumption Increase in pollution Storage of non-existent faults in fault memory non-execution of functions (lambda control, activated
charcoal filter system actuation, etc.)
On front-wheel-drive vehicles the Traction Control
System does not operate (TCS warning light on)
Adjusting the engine control unit to the throttle valve control unit
This adaptation teaches the engine control unit the various positions of the throttle valve with the ignition on and the engine stopped. These positions are stored in the engine control unit. The feedback of the throttle valve position is provided by the two angle sensors for the throttle valve drive. Adaptation must be performed if:
the power supply was interrupted the throttle valve control unit was removed and in-
stalled
the throttle valve control unit was replaced if another engine or another throttle valve control unit
was installed
Edition 11.04 S00.5310.01.20
Engine control unit
24-4 page 5
24
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
There must not be any fault present in the fault memory Chap. 01-1, Interrogating fault memory.
Battery voltage at least 11.5 V. The throttle valve must be in idling speed position. Coolant temperature must be 5...95 C Chap. 01-5
display group 004, display field 3.
If a cruise control system is fitted, its setting must be

O.K.
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1.
Select function 04 Basic setting and display group

060. In this state, the throttle valve is moved by a mechanical spring integrated in the throttle valve control unit, into an emergency running position. The values generated by the two angle senders in this emergency position are stored by the engine control unit. Subsequently the throttle valve is opened at a given value. If this value is reached, the throttle valve positioner is again switched dead. Now the mechanical spring must close the throttle valve within a given period in the previously initialised emergency position (spring test). The throttle valve is subsequently closed by the throttle valve positioner: the values sent by the angle sender to the throttle valve control unit are stored in the engine control unit. If during driving the engine control unit switches the throttle valve positioner dead, this is indicated by a fluctuating increased idling speed. The engine then has a very poor throttle response.
System in basic setting 60 8% 60% 0 ADP runs
->
Check specifications in display fields 3 and 4.

Specification in display field 3: 8 Specification in display field 4: ADP runs ADP o.k. If the specified values are reached: The adaptation was successfully performed. To store the values:
System in basic setting 60 60% 94% 8 ADP o.k.
->
Switch ignition off for at least 30 seconds.
24-4 page 6
Engine control unit
Edition 11.04 S00.5310.01.20
24
Note
If the basic setting is aborted by the control unit, this
may be due to the following reasons:
The throttle valve does not reach the mechanical
idling limit due to dirt, e.g. carbon deposits or another mechanical fault.
The battery voltage is too low. The throttle valve control unit or the cable connection
is faulty, test Chapter 24-2.
If the basic setting is aborted, the fault is still in the
fault memory. When the ignition is switched on again the basic setting is automatically performed again.
Edition 11.04 S00.5310.01.20
Engine control unit
24-4 page 7
24
24-4 page 8
Engine control unit
Edition 11.04 S00.5310.01.20
24
24-5
Testing auxiliary signals
Testing the speed signal

Test box -V.A.G 1598/31 Diode test lamp, e.g. -V.A.G 1527 B Adapter cable set, e.g. -V.A.G 1594 A Current flow diagram
Test conditions
Battery voltage at least 11.5 V. Speedometer o.k., testing Electrical System;

Rep. Gr. 90.
Test sequence
Connect test box -V.A.G 1598/31 - to wiring loom to
engine control unit Chap. 24-4. The engine control unit is not connected.
Raise vehicle at front left. Connect diode test lamp to sockets 4 (terminal 15) +
54 (cruise control signal) of the test box.
Switch on ignition. Rotate front left wheel and observe diode test lamp.
Specified value: the LED must flicker If the LED does not flicker:
Test the cables to the speedometer and to the vehicle

speed sender Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Test data bus

Operation The engine control unit communicates over a CAN databus with all the control units with databus capability. The control units that are compatible with the data bus are connected via two twisted data bus cables (CAN_High and CAN_Low) and exchange information (messages). Both the engine control unit and the other CAN data bus control units detect missing information on the data bus as faults.
Test condition
A fault has been detected by the CAN data bus selfdiagnosis.
Edition 03.01 S00.5310.00.20
24-5 page 1
24
Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 A Adapter cable set, e.g. -V.A.G 1594 A Current flow diagram
Test sequence
Switch off ignition. Unlock connector at control unit and unplug. Connect the -V.A.G 1598/31- to the engine control
unit. The wiring loom of the control unit is not connected for this test.
Test the central terminating resistor in the engine control unit:
Carry out a resistance measurement for this purpose

between sockets 58 and 60 of the test box. Specified value: 60...72 If the resistance value is not within the nominal value range:

If the resistance value is within the nominal value range:
Test CAN databus Electrical System; Rep. Gr. 90
Activating and deactivating cruise control system (CCS)

Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
There must not be any faults present in the fault memory Chap. 01-1.
Test sequence

ignition on and select address word 01 Engine electronics Chap. 01-1. Readout on display, e.g.: If 2.0 l R4/2V G is displayed, CCS is activated. Readout on display, e.g.: If 2.0 l R4/2V G is displayed, CCS is not activated.
06A906032BL 2.0 l R4/2V Coding 00071 3530 -> WSC XXXXX 06A906032CC 2.0 l R4/2V G Coding 00071 3658 -> WSC XXXXX
Press
dure.
key and select function 11 Login proce-
Login procedure Enter code number
XXXXX
24-5 page 2
Edition 03.01 S00.5310.00.20
FABIA 2000 2.0/85 Engine, Fuel Injection Enter code number by referring to the table below and confirm entry with Q key. Code number 11463 16167 Cruise control system (CCS) Cruise control system (CCS) is activated Cruise control system (CCS) is deactivated
24

After the CCS is activated, conduct a test drive as an operational check.
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28
28 Ignition System
28-1 Repairing ignition system
General notes on the ignition system

This section deals specifically with the components
relating to the ignition system. The other components of the fuel injection and ignition system Chap. 24-1 and following. necting the battery, as this may damage the 4AV control unit. sis.
Switch off the ignition before disconnecting and con-
The engine control unit is equipped with a self-diagno Components marked with an * are checked by self-di-
agnosis Chap. 01-1.
A minimum voltage of 11.5 V is required for the perfect
functioning of the electric components.
Certain inspections may cause the control unit to de-
tect and store a fault. That is why it is necessary to interrogate and erase the fault memory after completing all test and repair work Chap. 01-1.
Safety measures 28-1 page 1.
Safety measures
Observe the following points to prevent injury to persons and/or damage to the injection and ignition system:
Do not disconnect or connect ignition cables when the
engine is running or operating at starting speed.
Do not disconnect or connect cables of the fuel injec-
tion and ignition system, also not cables of test equipment, unless the ignition is switched off. gine actually starting: -2-.
To operate the engine at starter speed without the en-
Unplug 4-pin connector -1- from ignition transformer Remove fuse 28 for the fuel pump.
If test and measuring devices are required during test drives observe the following:
Attach test and measuring equipment always on the
1 2 24 25 26 27 28 29 30 3 4 31 32 33 34 35 36 37 8 5 6 7 9 10 11 38 39 40 41 42 43 44 12 13 14 15 16 17 18 19 20 21 22 23
rear seat and have them operated from there by a second person. the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.
If the test and measuring devices are operated from
S97-0319
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Repairing ignition system
28-1 page 1
28
Removing and installing parts of the ignition system

1 - Ignition lead with shielded plug and sparkplug 2 - Spark plug, 20-30 Nm use special spark plug wrench (e.g. -3122 B-) for removing and installing type and electrode gap Inspection and Maintenance; Rep. Gr. 02 3 - 20 Nm The torque influences the knock sensor function 4 - Knock sensor 2 -G66-* Sensor and connecting plug contacts are gold-plated 5 - Triple-pin plug and socket connector contacts gold-plated black for knock sensor 1 -G61 brown for knock sensor 2 -G66-
10
C B
A D
11
6 - Knock sensor 1 -G61-* Sensor and connecting plug contacts are gold-plated 7 - Camshaft position sensor -G163-* check 28-1 page 3 8 - Connecting plug 5 black, 3 pins for camshaft position sensor -G1639 - Connecting plug for ignition transformer black, 4 pins 10 - Ignition transformer (N, N128) with identification for ignition leads: A = Cylinder 1 B = Cylinder 2 C = Cylinder 3 D = Cylinder 4 with power output stage - N122 resistances Fig. 1 in 28-1 page 3 11 - 10 Nm
S28-0126
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FABIA 2000 2.0/85 Engine, Fuel Injection Fig. 1: Resistances of ignition coils
28
Specified value: 4...6 k.
Testing camshaft position sensor -G163Special tools, test and measuring equipment and auxiliary items required
Test conditions
Battery voltage 11.5 V

Test sequence
S28-0099
Unplug 3-pin connector -1- from camshaft position

sensor -2-.
Connect handheld multimeter for voltage measurement to contacts 1 + 3 of connector -1-.
Switch on ignition.
Specified value: at least 4.5 V
2
3 2 1
Switch off ignition. Test cables for open circuit, short circuit to earth and
If the wiring is in proper order and the desired voltage was measured at contacts 1 + 3
N28-0146
Replace camshaft position sensor -G163-.

If the wiring is in proper order and the desired voltage was not measured at contacts 1 + 3
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Service

2.0/85 Engine, Fuel Injection

Service Department. Technical Information

Printed in Czech Republic S00.5310.00.20

Printed in Czech Republic S00.5310.00.20

FABIA 2000 2.0/85 Engine, Fuel Injection

List of Supplements to Workshop Manual

Edition 03.01 11.04

Subject Basic Edition

Article Number S00.5310.00.20 S00.5310.01.20

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

24 Fuel Formation, Injection

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

Properties of the self-diagnosis

If fault read-out scan tool -V.A.G 1551- with program

Technical data of self-diagnosis

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

Operation Function on the vehicle system tester -V.A.G 155201 02 03 04 05 06 07 08 15

yes yes no yes yes yes no yes yes

yes yes no yes yes yes no yes yes

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

The warning light flashes: There is a fault, which is

The warning light comes on as a steady light: There is

There is a vehicle performance fault or the customer

Check for proper operation

Check dash panel insert and exhaust gas warning

Start engine and run in idle.

Interrogate the fault memory of the engine control unit,

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

-V.A.G 1551/3, 3A, 3B oder 3C-

06A906032CC 2.0l R4/2V G Coding 00071

3658 -> WSC XXXXX

with which the last coding was performed Note

If the control unit version displayed does not corre-

spond to the vehicle, replace the control unit Chapter 24-4.

Increase in fuel consumption Increase in pollution

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

control, actuation of activated charcoal filter system, etc.)

Interrogating and erasing fault memory of engine control unit

-V.A.G 1551/3, 3A, 3B oder 3C-

Operate starter for about 6 seconds. after this do not

Select function 02 Interrogate fault memory.

If one or several faults are stored:

Select function 05 Erase fault memory.

Vehicle system test The fault memory is erased

Automatic test sequence

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

In case of full load the speed should be increased be-

Once again interrogate the fault memories of all the

Select function 06 End output and switch ignition off.

Performing actuator diagnosis

-V.A.G 1551/3, 3A, 3B oder 3C-

Edition 11.04 S00.5310.01.20

FABIA 2000 2.0/85 Engine, Fuel Injection

The final control diagnosis is aborted when the engine