Fuel Injection AUA, AUB, BBY, BBZ, BKY PDF

Service 5
Workshop Manual
FABIA 2000 ➤
1.4/55 ; 1.4/74 Engine - Fuel Injection
Edition 08.99
Engine code AUA AUB BBY BBZ BKY
Service Department. Technical Information Printed in Czech Republic

S00.5309.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5309.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
List of Supplements to Workshop Manual

FABIA 2000 ➤
1.4/55 ; 1.4/74 Engine - Fuel Injection
Edition 08.99
Supple-
Edition Subject Article Number
ment
08.99 Basic Edition S00.5309.00.20
1 07.00 Supplement to Basic Edition S00.5309.01.20
2 03.01 Modifications in Rep. Gr. 01 and 24 S00.5309.02.20
3 06.02 Additions to engines with the engine codes BBY, BBZ S00.5309.03.20
4 06.04 Supplement to engines with the engine codes BKY S00.5309.04.20
Edition 06.04 List of Supplements

S00.5309.04.20
List of Supplements Edition 06.04

S00.5309.04.20
Table of Contents
01 – Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 page 1
- Properties of the self-diagnosis ..................................................................... 01-1 page 1
- Technical data of self-diagnosis ..................................................................... 01-1 page 1
- Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the
dash panel insert ...................................................................................... 01-1 page 3
- Meaning of the exhaust gas warning light -K83- .................................................. 01-1 page 3
- Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for
engine electronics ..................................................................................... 01-1 page 4
- Interrogating and erasing fault memory of engine control unit ................................. 01-1 page 5
- Automatic test sequence ............................................................................. 01-1 page 6
- Performing actuator diagnosis ....................................................................... 01-1 page 7
Self-diagnosis II ......................................................................................... 01-2 page 1
- Readiness code ........................................................................................ 01-2 page 1
- Reading Readiness Code ............................................................................ 01-2 page 1
- Generating readiness code .......................................................................... 01-2 page 2
Self-diagnosis III ........................................................................................ 01-3 page 1
- Fault table, fault codes 16496...17566 ............................................................. 01-3 page 1
Self-diagnosis IV ....................................................................................... 01-4 page 1
- Fault table, fault codes 17573...18100 ............................................................. 01-4 page 1
Self-diagnosis V ........................................................................................ 01-5 page 1
- Measured value blocks ............................................................................... 01-5 page 1
- Safety measures ....................................................................................... 01-5 page 1
- Reading measured value block ..................................................................... 01-5 page 1
- Measured value blocks, display groups 001...006 - Basic functions .......................... 01-5 page 2
- Measured value blocks, display groups 010...029 - Ignition .................................... 01-5 page 8
Self-diagnosis VI ....................................................................................... 01-6 page 1
- Measured value blocks, display groups 030...049, 099 - Lambda control .................... 01-6 page 1
Self-diagnosis VII ....................................................................................... 01-7 page 1
- Measured value blocks, display groups 050...069 - Speed control ............................ 01-7 page 1
- Measured value blocks, display groups 070...075 - exhaust gas recirculation .............. 01-7 page 5
- Measured value blocks, display group 100 - readiness code .................................. 01-7 page 7
- Measured value blocks, display groups 120...129 - Communication .......................... 01-7 page 8
24 – Fuel Formation, Injection

Repairing the injection system ...................................................................... 24-1 page 1
- Installed location overview for engines with the engine codes AUA, AUB ................... 24-1 page 1
- Installed location overview for engines with the engine codes BBY, BBZ, BKY ............. 24-1 page 2
- General notes on the injection system ............................................................. 24-1 page 3
- Removing and installing parts of the injection system ........................................... 24-1 page 4
- Disassembling and assembling intake manifold .................................................. 24-1 page 6
- Disassembling and assembling fuel distributor with injectors .................................. 24-1 page 10
- Disassembling and assembling the air filter ....................................................... 24-1 page 11
Edition 06.04 Table of Contents I

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- Safety measures ...................................................................................... 24-1 page 12

- Rules of cleanliness ................................................................................... 24-1 page 13
Testing components ................................................................................... 24-2 page 1
- Testing throttle valve control unit ................................................................... 24-2 page 1
- Testing accelerator pedal position sender ......................................................... 24-2 page 2
- Testing the intake manifold pressure sender ..................................................... 24-2 page 4
- Testing intake manifold temperature sender ...................................................... 24-2 page 6
- Testing coolant temperature sender ................................................................ 24-2 page 8
Testing components I ................................................................................. 24-3 page 1
- Test engine speed sender ........................................................................... 24-3 page 1
- Testing injection valves ............................................................................... 24-3 page 2
- Testing the intake system for tightness (unmetered air) ........................................ 24-3 page 7
- Testing intake manifold preheating ................................................................. 24-3 page 8
- Idle testing .............................................................................................. 24-3 page 8
Testing components II ................................................................................ 24-4 page 1
- Test lambda probe heating before catalyst ........................................................ 24-4 page 1
- Testing lambda probe and lambda control upstream of catalytic converter .................. 24-4 page 3
- Test lambda probe heating after catalyst .......................................................... 24-4 page 5
- Testing lambda probe and lambda control after catalyst ........................................ 24-4 page 7
- Check lambda probe ageing before catalyst ...................................................... 24-4 page 10
- Testing the engine operating conditions ........................................................... 24-4 page 11
Engine control unit .................................................................................... 24-5 page 1
- Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-5 page 1
- Testing voltage supply for engine control unit .................................................... 24-5 page 1
- Procedure after voltage supply has been interrupted ............................................ 24-5 page 2
- Replacing engine control unit ........................................................................ 24-5 page 3
- Coding engine control unit ........................................................................... 24-5 page 5
- Adjusting the engine control unit to the throttle valve control unit ............................. 24-5 page 6
Testing auxiliary signals ............................................................................. 24-6 page 1
- Testing the speed signal ............................................................................. 24-6 page 1
- Testing signals from/to the air conditioning system .............................................. 24-6 page 2
- Test brake light switch -F- and brake pedal switch -F47- ....................................... 24-6 page 2
- Testing clutch pedal switch -F36- ................................................................... 24-6 page 4
- Activating and deactivating cruise control system (CCS) ....................................... 24-6 page 5
- Testing CCS ............................................................................................ 24-6 page 5
- Testing gear signal .................................................................................... 24-6 page 6
- Test data bus .......................................................................................... 24-6 page 7
28 – Ignition System
Repairing ignition system ............................................................................ 28-1 page 1
- General notes on the ignition system .............................................................. 28-1 page 1
- Removing and installing parts of the ignition system for engines with the engine codes AUA,
AUB ...................................................................................................... 28-1 page 2
- Removing and installing parts of the ignition system for engines with the engine codes BBZ,
BBY, BKY ............................................................................................... 28-1 page 3
- Safety measures ...................................................................................... 28-1 page 3
- Testing hall sender .................................................................................... 28-1 page 4
- Checking the ignition transformer (for engines with the engine codes AUA, AUB) ......... 28-1 page 6
Table of Contents Edition 06.04

II S00.5309.04.20
- Check ignition coils with power output stage (engines with engine codes BBY, BKY, BBZ) 28-1 page 8
- Testing knock sensor ................................................................................. 28-1 page 11
- Test combustion misfiring ............................................................................ 28-1 page 13
Edition 06.04 Table of Contents III

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Table of Contents Edition 06.04

IV S00.5309.04.20
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection 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, Fault
Finding and Fitting Locations“ binder should always be
used for fault finding.
The engine control unit -J537- is equipped with a fault
memory.
If malfunctions occur in the monitored sensors or compo-
nents, they are stored in the fault memory with indication
of the fault type.
The engine control unit analyses the information and dis-
tinguishes between the different fault codes ⇒ Fault Ta-
ble ⇒ Chapter 01-3 and ⇒ Chapter 01-4, and stores
these until the fault memory is erased.
Faults that only occur temporarily (sporadically) are out-
put with the suffix „sporadically occurred fault“. On the
display these faults are indicated by the suffix „SP“. Pos-
sible 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 50°C and switched off at more than 72
°C), the fault is then automatically erased fom the fault
memory.
The stored faults can be read out with the vehicle system
tester -V.A.G 1552- using programme card -6.0- and
higher version or fault reader -V.A.G 1551- using pro-
gramme card -9.0- and higher version or vehicle diagno-
sis, measurement and information system -VAS 5051-.
After the fault or faults have been rectified, it is necessary
to erase the fault memory ⇒ 01-1 page 5 and also to re-
generate the readiness code ⇒ Chapter 01-2.
Note
General information on self-diagnosis is provided in the
operating instructions for the diagnostic devices
-V.A.G 1551-, -V.A.G 1552- or -VAS 5051-.
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.
Edition 06.04 Self-diagnosis I 01-1 page 1

S00.5309.04.20
01 FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Equipment
Engine identification characters AUA, AUB BBY, BBZ BKY

System denomination MARELLI 4LV MARELLI 4MV MARELLI 4TV
Exhaust limits conforming to EU-4, EU-3DDK, EU- EU4, EU-3DDK, EU- EU4, EU-3DDK, EU-
2DDK 2DDK 2DDK
Electronic throttle system Yes Yes Yes
Self-diagnosis Yes Yes Yes
Actuator diagnosis Yes Yes Yes
Fault memory Permanent memory1) Permanent memory1) Permanent memory1)
Memory for initialisation values Volatile memory2) Volatile memory2) Volatile memory2)
Lambda control 2 probes 2 probes 2 probes
Knock control 1 Knock sensor 1 Knock sensor 1 Knock sensor
Intake manifold change-over No No No
Camshaft adjustment No No No
Boost-pressure control No No No
Secondary air system No No No
Exhaust gas recirculation Yes Yes Yes
1) Independent of voltage supply
2) The values are erased if the voltage supply is interrupted.
Functions available when using the vehicle sys-

tem tester -V.A.G 1552-
Note
The preconditions for selecting the desired functions are
given in the following table.
Operation Precondition
Function on the vehicle system tester Engine not run- Engine idling Normal driving
-V.A.G 1552 - ning, ignition
switched on
01 Interrogating control unit version yes yes yes
02 Interrogating fault memory yes1) yes yes
03 Actuator diagnosis yes no no
04 Basic setting2) yes yes yes
05 Erasing fault memory yes yes yes
06 Ending output yes yes yes
07 Coding control unit yes no no
08 Reading measured value block yes yes yes
15 Reading readiness code yes yes yes
1) Only to be carried out with the ignition switched on and if the engine does not start (activate starter for at least 6 seconds).
2) To be carried out after the following operations: replacing of engine control unit, throttle valve control unit, exhaust gas recirculation valve or
engine or disconnecting of battery. The air conditioning and the ACF system are automatically switched off in function 04.
01-1 page 2 Self-diagnosis I Edition 06.04

S00.5309.04.20
Meaning of the EPC warning lamp (fault
lamp for electric accelerator control
-K132-) in the dash panel insert
„EPC“ is the abbreviation of Electronic Power Control,
which in German is written Elektronische Motorleistungs-
Regelung (E-Gas).
Fitting location of the EPC warning lamp:
If faults are detected on the EPC system during operation
of the engine, the dashboard insert switches the EPC
warning light on. (These faults are identified in the fault
table). There is a simultaneous entry in the fault memory
of the engine control unit.
Functional test: CHECK
– Switch on ignition: the EPC warning lamp must light

up.
If the EPC warning lamp does not light up when the igni-
tion is switched on:
S01-0090
– Check the dash panel insert and the EPC warning
lamp ⇒ Electrical System; Rep. Gr. 90.
If the EPC warning lamp lights up when the ignition is
switched on:
– Start engine and run in idle. The EPC warning lamp

should go out after a few seconds.
If the EPC warning lamp does not go out:
– Interrogate fault memory, rectify any faults existing

and erase the fault memory ⇒ 01-1 page 5.
Meaning of the exhaust gas warning light

-K83-
Only for engines complying with exhaust emission
standard EU 4 and EU 3DDK
If the engine control unit detects a fault, this is indicated
by the lighting up of the exhaust warning lamp
Fitting location of exhaust warning light:
CHECK
Note
♦ The exhaust warning light may flash or come on 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 CHECK
condition. In this driving condition only low perform-

ance driving is allowed!
S01-0091

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

a fault which deteriorates the exhaust gas quality. In-
terrogate the engine control or the automatic gearbox
fault memory.
♦ If there is a driving behaviour problem or a customer
complaint and the exhaust gas warning light does not
light up, the fault memory should be interrogated since
it also possible that faults are stored there which do
not immediately switch on the exhaust gas warning
light.
Functional test:
– Switch on ignition: The exhaust warning light must
light up.
If the gas warning light does not come on when the igni-
tion is switched on:
– Check the dash panel insert and the exhaust gas

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

must go out after a few seconds.
If the gas warning light does not go out:
– Interrogate fault memory, rectify any faults existing

and erase the fault memory ⇒ 01-1 page 5.
Connecting up the vehicle system tester

-V.A.G 1552- and selecting the control
unit for engine electronics
Special 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 conditions
• Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
56 and 61 must be o.k. 11 17 23 31
1
• Battery voltage must be at least 11.5 volts.
6 12 18 24 32
2 7 13 19 25 33
3 8 14
• Earth connections between engine (at gearbox hous-
20 26 34
4 9 15 21 27 35
5 10
ing) and body (below battery) o.k. 16 22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
43 53 63
44 54 64
45 55 65
46 56 66
47 57 67
48 58 68
S01-0094

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Procedure
– Fold back trim panel -1-.
– Connect vehicle system tester -V.A.G 1552- with ap-
propriate cable.
– Select address word 01 „Engine electronics“.
1 2 3
4 5 6
7
C
8
O
9
Q HELP V.A.G. 1552
The control unit identification number and the coding are 036906034T MARELLI 4LV 2615 ->
shown on the vehicle system tester display, e.g.: Coding 00031 WSC XXXXX
♦ 036906034T = Part No. of the control unit (for current
control unit version see spare part cata-
logue)89MARELLI 4LV = description of system and
version
♦
♦ Coding 00031 = coding of control unit with code ver-
sions ⇒ Chapter 24-5
♦ WSC xxxxx = workshop code the -V.A.G 1552-, with
which the last coding was performed (WSC 00000 ap-
pears provided the factory-entered coding has not
been changed)
Note
♦ If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit
⇒ Chapter 24-5.
♦ 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
♦ Storage of non-existent faults in fault memory
♦ Impossibility of performing certain functions (lambda
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 6.

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

S00.5309.04.20
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select 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“.
X faults detected
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If no fault is stored:
– Press key.
If one or several faults are stored:

Vehicle system test HELP
– Select function 05 „Erase fault memory“. The fault memory is erased
Note
If the ignition was switched off between „Interrogate fault
memory“ and „Erase fault memory“, the fault memory is
not erased.
– Select function 06 „End output“ and switch ignition off.

– Rectify the faults displayed by referring to the fault ta-
ble ⇒ Chapter 01-3 and ⇒ Chapter 01-4.
– 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 inter-
rogate and erase the fault memory on all control units.
For this you must proceed as follows:
– Select 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 80°C.
♦ Once this temperature is reached, the following oper-
ating states must be reached several times: Idling,
part load, full load, overrun, enrichment.
♦ In case of full load the speed should be increased be-
yond 3500 rpm.

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– Once again interrogate the fault memories of all the
control units with the address word 00 „Automatic test
sequence“.
Note
If no fault has been recognized by the self-diagnostic sys-
tem proceed with fault finding as specified in the corre-
sponding fault table in the „Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations“ binder.
Performing actuator diagnosis

With the actuator diagnosis the following parts are acti-
vated in the sequence indicated:
1. Throttle valve positioner -V60-
2. Activated charcoal filter system solenoid valve 1 -N80-
3. Exhaust gas recirculation valve -N18-
4. Engine speed sender -G28- 1)

5. Fuel pump relay -J17-
6. Engine/air conditioning compressor electrical
connection1)

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
♦ Handheld multimeter, e.g. -V.A.G 1715-
♦ Diode test lamp e.g. -V.A.G 1527B-
♦ Measuring tool set e.g. -V.A.G 1594C-
♦ Current flow diagram
Test conditions
• Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
11 17 23 31
56 and 61 must be o.k. 1 6 12 18 24 32
2
• Battery voltage must be at least 11.5 volts.
7 13 19 25 33
3 8 14 20 26 34
4 9
• All electrical consumers, e.g. lights and rear window
15 21 27 35
5 10 16 22 28 36
heater, must be switched off. 39 49 59
29 37
30 38
• Throttle valve drive angle senders -G187- and -G188- 40
41
50
51
60
61
o.k 42 52 62
43 53 63
44 54 64
45 55 65
46 56 66
47 57 67
48 58 68
S01-0094
1) Ignore

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Note
♦ The actuator diagnosis can only be carried out when
the engine is not running and the ignition is switched
on.
♦ The final control diagnosis is aborted when the engine
is started or when a moment of momentum is detect-
ed.
♦ During the actuator diagnosis the individual actuators
remain activated until the next actuator is selected by
pressing key .
♦ 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 elec-
tronics“ ⇒ 01-1 page 4.
– Select function 03 „final control diagnosis“.
Vehicle system test Q
Readout on display: 03 - Actuator diagnosis
Activate throttle valve positioner -V60-:

– Confirm the entry with key Q.
Actuator diagnosis ->
Readout on display: Throttle valve positioner-V60
The throttle valve positioner should open and close the
throttle valve until the next actuator is activated by press-
ing key .
If the throttle valve does not move:
– Test throttle valve positioner ⇒ Chapter 24-2, test

throttle valve control unit.
Activate solenoid valve 1 for activated charcoal

filter system -N80-:
– Press key.
Readout on display:
Sol.valve 1 for act. char.filter -N80
The solenoid valve (on right, at suspension strut dome)
must continue clicking until the next control element is ac-
tuated 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 the auxiliary hose during the final control di-
agnosis (in the direction of the throttle valve control
unit). The valve must open and close.
If the solenoid valve does not click:
– Continue test ⇒ 01-1 page 10.

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Activate exhaust gas recirculation valve -N18-:
– Press key.
Readout on display: Exhaust gas recirculation valve -N18
The exhaust gas recirculation valve (left engine compart-
ment at cylinder head) must click until the next actuator is
activated by pressing key.
If the exhaust gas recirculation valve does not click:
– Continue test ⇒ 01-1 page 11.
Engine speed sender -G28-: (Ignore)

– Press key.
Readout on display: Engine speed sender -G28
Activate fuel pump relay -J17-:

– Press key.
Readout on display: Fuel pump relay-J17
The fuel pump relay (on the relay plate) must be activated
and deactivated until the next control element is actuated
by pressing the key.
Note
During activation of the fuel pump relay the fuel pump
should also be heard to run at intervals. The door contact
switch must not be actuated during the test.
If the relay does not click:

– Testing fuel pump relay ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
Engine/air conditioning compressor electrical

connection (ignore)
– Press key.
Readout on display:
Engine/air cond.compr.electr.connect.

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Continuing test if the activated charcoal filter

solenoid valve 1 does not click:
– Unplug 2-pin plug from solenoid valve 1 -N80- -arrow-.
S01-0092
– Connect diode testing lamp to the unplugged plug.

– LED must flash.
The LED flashes:
– Proceed with the final control diagnosis up to the end.

– Switch off ignition.
– Replace solenoid valve 1 -N80-.
The LED does not flash:

– Connect test box -V.A.G 1598/31- to wiring loom to
engine control unit ⇒ Chapter 24-5. Do not connect
up the engine control unit.
– Check wiring between the test box and the 2-pin plug
for interruption according to the Current Flow Dia-
gram:
Plug contact Test box bush

-V.A.G 1598/31-
2 64
– Line resistance: max. 1.5 Ω

– Additionally check the cable for a short circuit to bat-
tery positive and to earth.
Specified value: ∞ Ω.
– Check the cable between 2-pin plug contact 1 and the

fuel pump relay -J17- for interruption according to the
Current Flow Diagram.
If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.

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Continuing test if the exhaust gas recirculation
valve does not click:
– Unplug the 6-pin plug from the exhaust gas recircula-
tion valve -N18- -arrow- (on the front left cylinder
head).
– Connect up the diode test lamp using adapter cables
onto the contacts 1+ 5 of the removed plug connec-
tion.
– LED must flash.
The LED flashes:

– Replace the EGR valve -N18- ⇒ 1.4/55; 1.4/74 En-
gine - Mechanics; Rep. Gr. 26.
The LED does not flash:

– Connect test box -V.A.G 1598/31- to wiring loom to
engine control unit ⇒ Chapter 24-5. Do not connect
up the engine control unit.
gram:

-V.A.G 1598/31-
5 114

Specified value: ∞ Ω

S00.5309.04.20

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01-2 Self-diagnosis II
Readiness code
Reading Readiness Code

Operation
The readiness code is an 8-digit numerical code that pro-
vides information on the status of the emission-relevant
diagnosis.
If the diagnosis for a system (e.g. tank ventilation system)
was successfully performed, the relevant position of the
numerical code is set from 1 to 0.
This diagnosis is performed at regular intervals during
normal driving. If repairs have been done on a system rel-
evant 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 detect-
ed 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.

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

Readiness code
If the following readout appears in the display:
00101101 - Test not complete
One of the available diagnoses cannot be completed suc-
cessfully.
– Press key.
– Generate readiness code ⇒ 01-2 page 2.
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 Diagnosis function
0 Catalytic converter
0 Catalytic converter heater (no diagnosis at present/always „0“)
0 Activated charcoal filter system
0 Secondary air injection system (no diagnosis at present/always „0“)
Edition 06.04 Self-diagnosis II 01-2 page 1

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0 Air conditioning system (no diagnosis at present/always „0“)
0 Lambda probe
0 Lambda probe heater
0 Exhaust gas recirculation
Generating readiness code

-V.A.G 1551/3, 3A, 3B, oder 3C-.
Test conditions
• Vehicle stationary
• On vehicles with an automatic gearbox the selector le-
ver must be in position „P“ or „N“.
• All electrical consumers such as lights and rear win-
dow heater switched off
• Intake air temperature must be below 60 °C ⇒ display
group 004, display field 4
• Coolant temperature at least 80 °C ⇒ display group
004, display block 3
Procedure
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
Work step 1: Interrogating fault memory
– Select function 02 „Interrogate fault memory“.

X faults detected
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If a fault is stored in the memory:
– Rectify the faults displayed by referring to the fault ta-

ble:
Fault table ⇒ Chap. 01-3 and ⇒ Chap. 01-4.
– Press key.
Work step 2: Erasing fault memory

Vehicle system test ->
– Select function 05 „Erase fault memory“. The fault memory is erased
01-2 page 2 Self-diagnosis II Edition 06.04

S00.5309.04.20
Note
♦ The readiness code is reset or erased each time the
fault memory is erased.
♦ If the ignition was switched off between „Interrogate
fault memory“ and „Erase fault memory“, the fault
memory is not erased.
– Press key.
Note
The engine must not be readjusted during the work se-
quence.
Work step 3: Activated charcoal filter system diagno-
sis
– Select function 04 „Basic setting“ and display group

070.
– Depress neither brake nor clutch pedal.
If the diagnosis is initiated by the engine control unit the
display in display field 4 will switch from „Test OFF“ to
„Test ON“.
System in basic setting 70
– Leave engine running at idling speed until „TVV o.k.“ 29% 65% 342mbar TEV O.K.
is read out in display field 4.
If the display does not occur as described:
– Interrogating fault memory.

– Blip throttle about 3 times and repeat the process.
If the display occurs as described:
– Press C key.
Work step 4: Lambda probe-ageing diagnosis (inter-

val monitoring)

034.
– Depress accelerator pedal twice above 5000 rpm.
– Maintain speed between 1500...3900 rpm until display 1830/min 120 C 0.00s Test OFF
in display field 4 switches from „Test OFF“ to „Test
ON“.
– Leave engine running at idling speed until „B1-S1 o.k.“
is displayed in display field 4.
Read measured value block 30
– Select function 08 „Read measured value block“ and 111 110
display group number 030.
– Check operating state of lambda control upstream of
catalytic converter (display field 1):
Specified value: 111
– Check operating state of lambda control downstream

of catalytic converter (display field 2):

S00.5309.04.20
Note
The 3rd bit in display field 2 is only set to 1 under partial
load (2500...4000 rpm).
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 Lambda probe operational
1 Lambda probe heater switched on
If the specified values are not reached:
– Interrogate fault memory ⇒ Chapter 01-1.

If the specified values are reached:
Work step 5: Catalyst diagnosis
Note
This diagnosis is only successfully completed if no faults
relating to the lambda probes or the activated charcoal fil-
ter system exist.
– Select function 04 „initiating basic Setting“ and then

display group 046.
– Maintain speed between 2000…3000 rpm until dis- 2830/min 328,0 C 0.00s Test OFF
play in display field 4 switches from „Test OFF“ to
„Test ON“. Catalytic converter temperature in display
field 2 must be at least 300 °C.
– Further maintain speed between 2000...3000 rpm un-
til the nominal result of the test „CatB1 o.k“ is dis-
played in display field 4.
Note
It may also take a few minutes until the readout is
changed from „Test ON“ to „Cat B1 o.k.“

– Press C key.
Work step 6: Diagnosis of exhaust gas recirculation

system
– Select function 04 „initiating basic Setting“ and then

display group 075.
– Depress neither brake nor clutch pedal.
– Briefly blip throttle about 5 times up to max. speed.

S00.5309.04.20
If the diagnosis is initiated by the engine control unit the
display in display field 4 will switch from „Test OFF“ to 4830/min 371mbar 0mbar Test OFF
„Test ON“.
– Leave engine running at idling speed until „Syst. O.K.“

is displayed in display field 4.
If the display does not occur as described:

If the display occurs as described:

– Read out readiness code ⇒ 01-2 page 1.

S00.5309.04.20

S00.5309.04.20
01-3 Self-diagnosis III

Fault table, fault codes 16496...17566
Note
♦ Faults related to the electronic throttle are indicated
on the dash panel insert by the fault lamp for the elec-
tronic accelerator control „EPC warning lamp“).
♦ Faults related to the exhaust are indicated by the „ex-
haust gas warning lamp“ in the dash panel insert.
♦ Explanations regarding fault types (e.g. „open circuit
or short-circuit to earth“) ⇒ Operating instructions for
the vehicle system tester.
♦ If parts are output as faulty: First test all of the cables
and plug connections to these components as well as
the earth cables of the system according to the current
flow diagram. Only if no fault is detected here should
the part be replaced. This applies in particular if faults
are shown as „sporadic“ (SP).
♦ Once the fault has been corrected erase the fault
memory ⇒ Chapter 01-1 and re-generate the readi-
ness code ⇒ Chapter 01-2.
Printer edition e.g.:
16497 P0113 035
Intake manifold temperature sender -G72-
Signal too high
sporadically occurring fault
Explanations:
16497 = fault code
P0113 = Ignore the SAE code that may appear next to the
fault code.
035 = fault type as digit
Intake manifold temperature sender -G72- = faulty cur-
rent path or fault location
Signal too great = fault type as text
Sporadically occurring fault = fault not always present,
e.g. loose contact
Edition 06.04 Self-diagnosis III 01-3 page 1

S00.5309.04.20
Readout on -V.A.G 1552- Rectifying fault

16496 Signal too low – Read measured value block, display group 004, dis-
Intake manifold temperature play field 4 ⇒ Chapter 01-5
sender -G72-1)
– Inspecting intake manifold temperature sender
16497 Signal too high ⇒ Chap. 24-2
Intake manifold temperature
sender -G72-1) – Replace engine control unit ⇒ Chapter 24-5
16500 Implausible signal – Read measured value block, display group 001, dis-
Sender for the coolant temper- play field 2 ⇒ Chapter 01-5
ature -G62-1)
– Check the coolant temperature sender -G62-
⇒ Chapter 24-2
– Replace engine control unit ⇒ Chapter 24-5
16501 Signal too low – Read measured value block, display group 001, dis-
Sender for the coolant temper- play field 2 ⇒ Chapter 01-5
ature -G62-1)
– Check the coolant temperature sender -G62-
16502 Signal too high ⇒ Chapter 24-2
Sender for the coolant temper-
ature -G62-1) – Test coolant thermostat ⇒ 1.4/55; 1.4/74 Engine -
Mechanical Components; Rep. Gr. 19
16505 Implausible signal – Test throttle valve control unit ⇒ Chapter 24-2
Throttle valve potentiometer
-G69-1)
16506 Signal too low
-G69-1)
16507 Signal too high
-G69-1)
16514 Electrical fault in the cir- – Testing lambda probe and lambda control upstream
Bank 1 probe 11) cuit of catalytic converter ⇒ Chapter 24-4
– Remove short-circuit or line interruption ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting
Locations.
16517 Signal too low – Testing lambda probe and lambda control upstream
Bank 1 probe 1 elect.1) of catalytic converter ⇒ Chapter 24-4
16518 No activity – Reading measured value block, display group 030
Bank 1 probe 11) ⇒ Chap. 01-6
– Reading measured value block, display group 031
⇒ Chap. 01-6
16519 Heating circuit electrical – Testing lambda probe and lambda control upstream
Bank 1, probe 1 fault of catalytic converter ⇒ Chapter 24-4
16520 Electrical fault in the cir- – Test lambda probe heater downstream of catalytic
Bank 1 probe 21) cuit converter ⇒ Chapter 24-4
16521 Voltage too low – Test lambda control before catalytic converter
Bank 1 probe 21) ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic
converter ⇒ Chapter 24-4
01-3 page 2 Self-diagnosis III Edition 06.04

S00.5309.04.20

16522 Voltage too high – Test lambda probe heater downstream of catalytic
Bank 1 probe 21) converter ⇒ Chapter 24-4
16524 No activity – Test lambda probe after catalytic converter
Bank 1 probe 21) ⇒ Chapter 24-4
16525 Heating circuit electrical – Test lambda control before catalytic converter
Bank 1 probe 21) fault ⇒ Chapter 24-4
16554 Malfunction – Check fuel filter with regulating valve ⇒ 1.4/55, 1.4/
Bank 1, fuel metering system1) 74 Engine - Mechanics; Rep. Gr. 20
– Testing lambda control before catalyst ⇒ Chapter
24-4
⇒ Chap. 01-6
⇒ Chap. 01-6
16555 System too lean – Check fuel filter with regulating valve ⇒ 1.4/55, 1.4/
Bank 1, fuel metering system1) 74 Engine - Mechanics; Rep. Gr. 20
– Test injection valves ⇒ Chapter 24-3
– Testing lambda probe and lambda control upstream
of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control down-
stream of catalytic converter ⇒ Chapter 24-4
16556 System too rich – Test injection valves ⇒ Chapter 24-3
Bank 1, fuel metering system1)
– Testing lambda control before catalyst ⇒ Chapter
24-4
⇒ Chap. 01-6
– Test lambda control before catalytic converter
⇒ Chapter 24-4
16585 Electrical fault in the cir- – Test injection valves ⇒ Chapter 24-3
Injector cyl. 1 -N30-2) cuit
16586 Electrical fault in the cir-
16603 Maximum engine speed – Rectify any mechanical engine damage
exceeded
16605 Implausible signal – Read measured value block, display group 062
Angle sender 2 for TV drive ⇒ Chapter 01-7
-G188-1)2)
– Test throttle valve control unit ⇒ Chapter 24-2
Angle sender 2 for TV drive
-G188-1)2)
-G188-1)2)

S00.5309.04.20

16611 Signal too low – Read measured value block, display group 062
Sender for accelerator pedal ⇒ Chapter 01-7
position -G79-1)2)
– Test accelerator pedal position sender ⇒ Chapter
16612 Signal too high 24-2
Sender for accelerator pedal
position -G79-1)2)
16646 Short circuit to positive – Test injection valves ⇒ Chapter 24-3
Injector cyl. 1 -N30-1)
16649 Short circuit to positive
166841) Combustion misfiring – Test injection valves ⇒ Chapter 24-3
detected
– Test ignition leads and spark plugs ⇒ Chapter 28-1
– Testing ignition transformer with power amplifier
⇒ Chapter 28-1
– Inspecting misfiring detection ⇒ Chapter 28-1
16685 Combustion misfiring – Test injection valves ⇒ Chapter 24-3
Cylinder 11) detected
16686 Combustion misfiring
Cyl. 21) detected
Cyl. 31) detected
Cyl. 41) detected
16705 Implausible signal – Check engine speed sender -G28- ⇒ Chapter 24-3
Engine speed sender -G28-1)
16706 No signal – Remove line interruption or short-circuit ⇒ Current
Engine speed sender -G28-1) Flow Diagrams, Electrical Fault Finding and Fitting
Locations
– Check engine speed sender -G28- ⇒ Chapter 24-3
16708 Malfunction – Inspecting knock sensor ⇒ Chapter 28-1
Knock control
– Read measured value block 028 ⇒ Chapter 01-5
16709 Electrical fault in the cir- – Inspecting knock sensor ⇒ Chapter 28-1
Knock sensor 1 -G61- cuit
– Read measured value block 028 ⇒ Chapter 01-5
16710 Implausible signal
Knock sensor 1 -G61-

S00.5309.04.20

16725 Implausible signal – Inspecting hall sender ⇒ Chapter 28-1
Camshaft position sensor ⇒
sender -G40-1)
sender -G40-1)
sender -G40-1)
16735 Malfunction – Test combustion misfiring ⇒ Chapter 28-1
Ignition control cyl. 11)
16736 Malfunction
16737 Malfunction
16738 Malfunction
16785 Flow rate too low – Test exhaust gas recirculation valve -N18-
Exhaust gas recirculation ⇒ Chapter 01-1, final control diagnosis
system1)
– Perform basic setting (measured value block 074
16786 Flow rate too great and 075) ⇒ Chapter 01-7
Exhaust gas recirculation
system1)
16787 Malfunction
valve -N18-1)
16788 Control difference
system1)
Potentiometer for exhaust gas
recirculation -G212-1)
16804 Efficiency too low – Testing lambda probe and lambda control upstream
Bank 1, catalytic converter of catalytic converter ⇒ Chapter 24-4
system1)
– Testing intake system for tightness ⇒ Chapter 24-3
– Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
Engine - Mechanics; Rep. Gr. 26
– Check catalytic converter ⇒ 1.4/55; 1.4/74 Engine -
Mechanics; Rep. Gr. 26
16825 Flow rate incorrect – Testing solenoid valve 1 for activated charcoal filter
Tank ventilation system1) ⇒ Chapter 01-1, final control diagnosis
– Inspect hoses and connection pipes from fuel tank
up to injection rail ⇒ 1.4/55; 1.4/74 Engine - Me-
chanics; Rep. Gr. 20

S00.5309.04.20

16827 Electrical fault in the cir- – Testing solenoid valve 1 for activated charcoal filter
Tank ventilation valve -N80-1) cuit ⇒ Chapter 01-1, final control diagnosis
16828 Open circuit
Tank ventilation valve -N80-
16829 Short circuit
Tank ventilation valve -N80-
16845 Implausible signal – Testing signal of fuel gauge sender ⇒ Current Flow
Fuel level signal Diagrams, Electrical Fault Finding and Fitting Loca-
tions
16885 Implausible signal – Test speed signal ⇒ Chapter 24-6
Vehicle speed signal1)
– Read measured value block, display group 005, dis-
play field 3 ⇒ Chapter 01-5
– Remove open circuit in wiring or short circuit accord-
ing to current flow diagram ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
16897 Blocked – Adapt engine control unit to control unit for electronic
Engine control unit immobiliser ⇒ Electrical System; Rep. Gr. 96.
16916 Signal too low – Test G65 ⇒ Air conditioning system; Rep. Gr. 87
Pressure sensor for air condi-
tioning system
Pressure sensor for air condi-
tioning system
16946 Voltage too low – testing voltage supply ⇒ Chapter 24-5
Voltage supply
16947 Voltage too high – testing voltage supply ⇒ Chapter 24-5
Voltage supply
16955 Implausible signal – Test brake light switch and brake pedal switch
Brake light switch -F- ⇒ Chapter 24-6
16988 – Replace engine control unit -J537- ⇒ Chapter 24-5
Control unit defective1)
16989
16990
16991 Undervoltage on basic – Adapt engine control unit to throttle valve control unit
Throttle valve control unit settings ⇒ Chapter 24-5
-J338-2)
17022 Implausible signal – Check battery, if necessary charge ⇒ Electrical Sys-
Throttle valve control unit tem; Rep. Gr. 27
-J338-1)2)
17029 – Testing signals from and to the air conditioning sys-
Air conditioning system inlet/ tem ⇒ Electrical System; Rep. Gr. 90
outlet
17034 Electrical fault in the cir- – Testing signals from and to the warning light -K83-
Exhaust gas warning light cuit ⇒ Electrical System; Rep. Gr. 90
-K83-
17040 Electrical fault in the cir- – Check the fuel consumption signal ⇒ Electrical Sys-
Fuel consumption signal cuit tem; Rep. Gr. 90.
– Test CAN databus ⇒ Chap. 24-6.

S00.5309.04.20

17510 Short circuit to positive – Testing lambda probe heater upstream of catalytic
Bank 1, probe 1 heating converter ⇒ Chapter 24-4
circuit1)
– Remove short-circuit according to Current Flow Dia-
gram ⇒ Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
17513 Short circuit to positive – Test lambda probe heater downstream of catalytic
circuit1)
17523 Short circuit to earth – Testing lambda probe heater upstream of catalytic
circuit1)
17524 Open circuit – Testing lambda probe heater upstream of catalytic
circuit1)
– Remove line interruption according to Current Flow
Diagram ⇒ Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
17525 Short circuit to earth – Test lambda probe heater downstream of catalytic
circuit1)
17526 Open circuit – Test injection valves ⇒ Chapter 24-3
Bank 1, probe 2 heating
circuit1)
17550 Below limit – Adapt engine control unit to throttle valve control unit
Load detection ⇒ Chapter 24-5
– Test accelerator pedal position sender ⇒ Chapter
24-2
– Test air filter ⇒ Chapter 24-1
– Check engine mechanics
17559 Below leanness limit – Test injection valves ⇒ Chapter 24-3
Bank 1, mixture adaptation
– Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechan-
range 11)
ics; Rep. Gr. 20
17560 Below leanness limit
Bank 2, mixture adaptation – Testing intake system for tightness ⇒ Chapter 24-3
range 21) – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
– Check exhaust gas recycling system ⇒ 1.4/55; 1.4/
74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for
leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20

S00.5309.04.20

17563 Short circuit to positive – Testing intake manifold pressure sender ⇒ Chap.
Intake manifold pressure 24-2
sender -G71-1)2)
– Testing intake system for tightness (unmetered air)
17564 Open circuit/Short-cir- ⇒ Chapter 24-3.
Intake manifold pressure cuit to earth
sender -G71-1)2)
17566 Implausible signal
Intake manifold pressure
sender -G71-1)2)
1) If this fault occurs the engine control unit switches on the exhaust gas warning lamp in the dash panel insert. Meaning of the exhaust gas warn-
ing lamp ⇒ Chapter 01-1
2) If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp
⇒ Chapter 01-1

S00.5309.04.20
01-4 Self-diagnosis IV
Fault table, fault codes 17573...18100

17573 Above richness limit – Test injection valves ⇒ Chapter 24-3
Bank 1, mixture adaptation
range 11)
– Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20
17574 Above richness limit
Bank 1, mixture adaptation – Testing intake system for tightness ⇒ Chapter 24-3
range 21) – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
– Check exhaust gas recirculation system ⇒ 1.4/55;
1.4/74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for leaks
⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
17579 Implausible signal – Test throttle valve control unit -J338- ⇒ Chapter 24-
Angle sender 2 for TV drive 2.
-G188-1)2)
17580 Signal too low – Test throttle valve control unit ⇒ Chapter 24-2
-G188-1)2)
– Adapt throttle valve control unit ⇒ Chapter 24-5.
-G188-1)2)
17582 Deviation of the injec- – Test injection valves ⇒ Chapter 24-3
Bank 1, fuel metering system1) tion periods
– Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20
– Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
– Inspect activated charcoal container system for leaks
⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
17584 Regulating limit – Testing intake system for tightness ⇒ Chapter 24-3
Bank1, lambda correction ac- reached
cording to catalytic converter1)
Edition 06.04 Self-diagnosis IV 01-4 page 1

S00.5309.04.20

17586 Open circuit – Testing lambda probe and lambda control upstream
Linear lambda probe/pump of catalytic converter ⇒ Chapter 24-4
current1)
– Testing lambda probe heater upstream of catalytic
17587 Short circuit to positive converter ⇒ Chapter 24-4
Linear lambda probe/pump
current1)
Linear lambda probe/pump
current1)
17589 Open circuit – Testing lambda probe and lambda control upstream
Linear lambda probe/refer- of catalytic converter ⇒ Chapter 24-4
ence voltage1)
– Testing lambda probe heater upstream of catalytic
17590 Short circuit to earth converter ⇒ Chapter 24-4
Linear lambda probe/refer-
ence voltage1) – Test ignition leads and spark plugs ⇒ Chapter 28-1
17591 Short circuit to positive – Test combustion misfiring ⇒ Chapter 28-1
ence voltage1)
17598 implausible
ence voltage1)
17604 Electrical fault – Testing lambda probe heater upstream of catalytic
Bank 1, probe 1, heating converter ⇒ Chapter 24-4
circuit1)
17606 Electrical fault – Test lambda probe heater downstream of catalytic
Bank 1, probe 2, heating converter ⇒ Chapter 24-4
circuit1)
17621 Short circuit to positive – Test injection valves ⇒ Chapter 24-3
17645 Open circuit – Test injection valves ⇒ Chapter 24-3
17646 Open circuit
17647 Open circuit
17648 Open circuit
17661 Short circuit to earth – Test dash panel insert ⇒ Electrical System;
Fuel consumption signal Rep. Gr. 90
Fuel consumption signal
17743 Regulating limit ex- – Testing intake system for tightness ⇒ Chap. 24-3.
Engine torque monitoring 21)2) ceeded
– Inspect accelerator pedal position sender -G79- and
-G185- ⇒ Chap. 24-2.
– Test throttle valve control unit -J338- ⇒ Chapter 24-
2.
01-4 page 2 Self-diagnosis IV Edition 06.04

S00.5309.04.20

17745 Short circuit to earth – Inspecting hall sender ⇒ Chapter 28-1
Bank 1, camshaft pos. sensor
-G40-
17746 Short circuit to positive – Check camshaft position sensor -G40- ⇒ Chap. 28-1
Bank 1, camshaft pos. sensor
-G40- – Remove open circuit in wiring or short circuit accord-
ing to current flow diagram ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations.
17749 Short circuit to earth – Inspect ignition transformer ⇒ Chapter 28-1
Ignition outlet 11)
17750 Short circuit to positive ing to current flow diagram ⇒ Current Flow Dia-
Ignition outlet 11) grams, Electrical Fault Finding and Fitting Locations.
17751 Short circuit to earth
Ignition outlet 21)
Ignition outlet 21)
17756 Open circuit
Ignition outlet 11)
17757 Open circuit
Ignition outlet 21)
17763 Open circuit3) – Inspect ignition transformer ⇒ Chapter 28-1
Ignition control cyl. 1
– Remove line interruption according to Current Flow
Diagram ⇒ Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
17764 Short circuit to positive3) – Check the ignition coils with power output stage
Ignition control cyl. 1 ⇒ Chapter 28-1.
17765 Short circuit to earth3) – Remove short-circuit according to Current Flow Dia-
Ignition control cyl. 1 gram ⇒ Current Flow Diagrams, Electrical Fault
17766 Open circuit3) Finding and Fitting Locations.
17767 Short circuit to positive3)
17768 Short circuit to earth3)
17769 Open circuit3)
17772 Open circuit3)
17793 – Replace engine control unit ⇒ Chapter 24-5
17796
Control unit defective1)2)

S00.5309.04.20

17806 Short circuit to earth – Test engine speed sender ⇒ Chapter 24-3
Engine speed signal, TD
17807 Short circuit to positive ing to current flow diagram ⇒ Current Flow Dia-
Engine speed signal, TD grams, Electrical Fault Finding and Fitting Locations
17809 Short circuit to earth – Test exhaust gas recirculation valve ⇒ Chapter 01-1,
Exhaust gas recirculation final control diagnosis.
valve -N18-1)
– Check the EGR valve ⇒ 1.4/55; 1.4/74 Engine - Me-
17810 Short circuit to positive chanics; Rep. Gr. 26.
valve -N18-1)
17811 Control difference
system1)
17812 Basic setting not per- – Conduct basic setting (measured value block 074)
Exhaust gas recirculation sys- formed ⇒ Chapter 01-7
tem
17818 Short circuit to positive – Test solenoid valve for activated charcoal filter
Tank ventilation valve -N80-1) ⇒ Chapter 01-1, final control diagnosis
17833 Short circuit to earth – Remove open circuit in wiring or short circuit accord-
Tank ventilation valve -N80-1) ing to current flow diagram ⇒ Current Flow Dia-
17834 Open circuit grams, Electrical Fault Finding and Fitting Locations
Tank ventilation valve -N80-1)
17847 Incorrect basic setting – Conduct basic setting (measured value block 074)
Potentiometer for exhaust gas ⇒ Chapter 01-7
17848 Open circuit – Check the EGR valve ⇒ 1.4/55; 1.4/74 Engine - Me-
Exhaust gas recirculation chanics; Rep. Gr. 26.
valve -N18-1)
– Test exhaust gas recirculation valve ⇒ Chapter 01-1,
17850 Signal too high final control diagnosis.
17909 Short circuit to earth – Test fuel pump relay -J17- ⇒ Chapter 01-1, final con-
Fuel pump relay -J17- trol diagnosis
17910 Short circuit to positive – Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
Fuel pump relay -J17- trical Fault Finding and Fitting Locations.
17912 Leak detected – Inspect intake air system for leaks (unmetered air)
Air intake system2) ⇒ Chapter 24-3
– Testing solenoid valve 1 for activated charcoal filter
⇒ Chapter 01-1, final control diagnosis
17949 Open circuit – Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
Fuel pump relay -J17- trical Fault Finding and Fitting Locations
17950 Implausible signal – Test throttle valve control unit ⇒ Chapter 24-2
Angle sender for TV drive
-G187-2)

S00.5309.04.20

17951 Signal too low – Test throttle valve control unit ⇒ Chapter 24-2
-G187-1)2)
-G187-1)2)
17953 Malfunction
Throttle valve control 1)2)
17961 implausible ratio – Testing intake manifold pressure sender ⇒ Chap. 24-
Level sender/intake manifold 2
pressure signal2)
– Testing intake system for tightness (unmetered air)
⇒ Chapter 24-3.
– Testing solenoid valve 1 for activated charcoal filter
⇒ Chapter 01-1, final control diagnosis
17962 Requirements for basic – Adapt engine control unit to throttle valve control unit
Throttle valve control unit setting not fulfilled ⇒ Chapter 24-5
-J338-2)
17967 Incorrect basic setting
Throttle valve control unit
-J338-1)2)
17968 – Repair mechanical damage
Maximum engine speed ex-
ceeded
17972 Undervoltage on basic – Test battery, charge if necessary ⇒ Electrical Sys-
Throttle valve control unit settings tem; Rep. Gr. 27
-J338-2)
– Adapt engine control unit to throttle valve control unit
⇒ Chapter 24-5
17973 Bottom limit not – Check throttle valve for damage or dirt
Throttle valve control unit reached
17977 Implausible signal – Inspecting cruise control system ⇒ Chap. 24-6
CCS switch -E45-
17978 – Test throttle valve control unit ⇒ Chapter 24-2
Engine control unit blocked1)2)
– Adapt engine control unit to electronic immobiliser
⇒ Electrical System; Rep. Gr. 96.
– Test electronic immobiliser ⇒ Electrical System;
Rep. Gr. 96
17989 Basic setting not per- – Adapt engine control unit to throttle valve control unit
Throttle valve control unit formed ⇒ Chapter 24-5
-J338-
18010 Voltage too low – Perform procedure for voltage interruption ⇒ Chap.
Voltage supply tml. 30 24-5
18019 Short circuit to earth – Inspect databus ⇒ Chapter 24-6
Fault lamp requirement on
– Test exhaust gas warning lamp ⇒ Current Flow Dia-
18020 Incorrectly coded – Code engine control unit ⇒ Chapter 24-5
Engine control unit

S00.5309.04.20

18021 Open circuit/Short cir- – Inspect databus ⇒ Chapter 24-6
Fault lamp requirement on cuit to positive
– Test exhaust gas warning lamp ⇒ Current Flow Dia-
18034 Missing message from – Inspect databus ⇒ Chapter 24-6
Data BUS drive gearbox CU
18038 Signal too low – Test accelerator pedal position sender ⇒ Chapter
Sender for accelerator pedal 24-2
position -G79-1)2)
Sender for accelerator pedal
position -G79-1)2)
Sender 2 for accelerator pedal
position -G185-1)2)
Sender 2 for accelerator pedal
position -G185-1)2)
Data BUS drive air conditioning system
CU – Testing air conditioning system CU ⇒ Heating and
Air conditioning; Rep. Gr. 87
Data BUS drive airbag CU
– Test airbag control unit ⇒ Body Fitting Work;
Rep. Gr. 01
18045 missing message form – Inspect databus ⇒ Chapter 24-6
Data BUS drive electron. CU
– Read out fault memory of electrical system control
unit ⇒ Electrical System; Rep. Gr. 90
18047 Implausible signal – Test accelerator pedal position sender ⇒ Chapter
Sender 1/2 for accelerator 24-2
pedal position -G79- +
-G185-2)
18048 – Inspect engine control unit power supply ⇒ Chapter
Control unit defective1) 24-5
– Replace engine control unit -J537- ⇒ Chapter 24-5
18049 – Read out air conditioning system control unit fault
Read out fault memory of air memory ⇒ Heating, Air conditioning; Rep. Gr. 01
conditioning CU
18056 defective – Inspect databus ⇒ Chapter 24-6
Data BUS drive
– Read out fault memories of all control units (automat-
ic test sequence) ⇒ Chapter 01-1
Data BUS drive ABS CU
– Read out fault memories of all control units (automat-
ic test sequence) ⇒ Chapter 01-1
Data BUS drive combiinstrument
– Test dash panel insert ⇒ Electrical System;
Rep. Gr. 90
18060 – Self-diagnosis of automatic gearbox CU
Read out fault memory of ⇒ Automatic Gearbox; Rep. Gr. 01
gearbox CU

S00.5309.04.20

18061 – Self-diagnosis of ABS control unit ⇒ Running Gear;
Read out fault memory of ABS Rep. Gr. 45
CU
18062 – Self-diagnosis of the dash panel insert control unit
Read out fault memory of the ⇒ Electrical System; Rep. Gr. 90
combi-instrument
18064 Short circuit to earth – Testing air conditioning system ⇒ Heating, Air con-
Air conditioning system inlet/ ditioning; Rep. Gr. 87
outlet
– Inspect databus ⇒ Chapter 24-6
Air conditioning system inlet/
outlet
18081 Error message from – Self-diagnosis of ABS control unit ⇒ Chassis;
Vehicle speed signal ABS CU Rep. Gr. 45
18085 Short circuit to positive – Inspect databus ⇒ Chapter 24-6
Fault lamp for electr. accelera-
tor control -K132-1)
– Test dash panel insert ⇒ Electrical System;
Rep. Gr. 90
18087 Open circuit
18097 Implausible message – Test CAN databus cables ⇒ Chap. 24-6
Databus drive from electron. CU
– Inspecting vehicle voltage control unit -J519-
⇒ Electrical System; Rep. Gr. 90.
18099 Open circuit – Inspect databus ⇒ Chapter 24-6
Exhaust gas warning light
-K83-
-K83-
-K83-
1) If this fault occurs the engine control unit switches on the exhaust gas warning lamp in the dash panel insert. Meaning of the exhaust gas warn-
ing lamp ⇒ Chapter 01-1.
2) If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp
⇒ Chapter 01-1.
3) The faults related to the "ignition control..." regarding the cables between the engine control unit and the power output stage in the ignition coil,
with which the power output stages are actuated by the engine control unit.

S00.5309.04.20

S00.5309.04.20
01-5 Self-diagnosis V
Measured value blocks
Safety measures
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 re-
lease of the passenger airbag in the event of an accident.
Reading measured value block

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The coolant temperature must be at least 80°C ⇒ dis-
play group 004, display field 3.
• All electrical consumers, e.g. lights and rear window
heater, must be switched off (radiator fan must not
run).
• If vehicle is equipped with air conditioning, this must
be switched off.
• No fault must be present in the fault memory ⇒ Chap.
01-1, interrogate fault memory and erase.
Procedure
Read measured value block HELP
– Select function 08 „Read measured value block“ and Enter display group number XXX
the desired display group number.
Note
Read measured value block 4
Display group number 004 is an example to represent the
850 rpm 13.9V 88 C 41 C
sequence.
Note
Proceed according to the following table to switch to an-
other display group:
Edition 06.04 Self-diagnosis V 01-5 page 1

S00.5309.04.20
Display -V.A.G 1551- -V.A.G 1552-

group
higher 3 Press key Press key
lower 1 Press key Press key
skip C Press key C Press key
– If the specifications are achieved in all the display

fields, press key .
Measured value blocks, display groups

001...006 - Basic functions
Display group 001 - Basic functions:

• Engine idling
Read measured value block 1→ ⇐ Read out on display:

xxxx rpm xx.x °C xx.x % xxxxxxxx
1 2 3 4 ⇐ Display field Specification Analysis:
Setting require- 10111111 ⇒ 01-5 page 2
ments
Lambda control value -15...15 % ⇒ 01-5 page 8
Coolant temperature 80...110 °C ⇒ 01-5 page 3
Engine speed (idling speed) ⇒ 01-5 page 3
Vehicles with engine code AUA 650...850 rpm1)
Vehicles with the engine codes BBY, BKY 660...860 rpm1)
Vehicles with automatic gearbox 580...780 rpm1)
(engine codes AUA, BBY, BKY)
Vehicles with engine code AUB 740...940 rpm1)
Vehicles with engine code BBZ 580...780 rpm1)
1) Current value ⇒ Inspection and Maintenance
Meaning of 8-digit numerical block
Meaning if display = 1
1 2 3 4 5 6 7 8 Meaning
1 Coolant temperature more than 80°C
1 Engine speed less than 2000 rpm
1 Throttle valve closed
1 Lambda control o.k.
1 Operating state - idling
01-5 page 2 Self-diagnosis V Edition 06.04

S00.5309.04.20
Meaning if display = 1
1 2 3 4 5 6 7 8 Meaning
1 AC compressor disconnected
1 Catalyst hot (over 300 °C)
1 No fault detected in self-diagnosis
Analysis of display group 001, engine speed (idling speed)
Dis- Readout Possible cause of fault Rectifying fault

play on dis-
field play:
1 less than ♦ Throttle valve control unit jams/defective – Test throttle valve control unit ⇒ Chapter
nominal 24-2
value
♦ Air filter element very dirty – Replace air filter element ⇒ Chap. 24-1
greater ♦ Throttle valve control unit jams/defective – Interrogate fault memory ⇒ Chapter 01-1
than
♦ Large unmetered air volume (cannot be – Testing intake system for tightness
nominal
value compensated by idle stabilizer) ⇒ Chapter 24-3
– Test throttle valve control unit ⇒ Chapter
24-2
– Performing idling test ⇒ Chap. 24-3
Analysis of display group 001, coolant temperature

play on dis-
field play:
2 less than ♦ Engine too cold – Conduct test drive if necessary
80 °C
♦ Sender for coolant temperature or wiring – Test coolant temperature sender
to engine control unit ⇒ Chapter 24-2
♦ Coolant regulator defective – Test coolant thermostat ⇒ 1.4/55, 1.4/74
Engine - Mechanical Components;
Rep. Gr. 19
greater ♦ Radiator dirty – Clean radiator
than 110
°C ♦ Radiator fan not operational – Inspect proper operation ⇒ Current Flow
Diagrams, Electrical Fault Finding and Fit-
ting Locations
♦ Coolant regulator defective – Test coolant thermostat ⇒ 1.4/55, 1.4/74
Rep. Gr. 19

• Engine idling

S00.5309.04.20

xxxx rpm xx % x.x ms xxx mbar
Intake manifold 240...420 mbar ⇒ 01-5 page 4
pressure
Injection period 2.0...4.0 ms ⇒ 01-5 page 4
Engine load 10...20 % ⇒ 01-5 page 8
Engine speed (idling speed) xxxx rpm1) ⇒ 01-5 page 3
1) Display group 001, display field 1 ⇒ 01-5 page 2.
Analysis of display group 002, injection period

play on dis-
field play:
3 less than ♦ High fuel volume from the activated char- – Testing solenoid valve 1 for activated
2.0 ms coal filter system charcoal filter ⇒ Chapter 01-1, final con-
trol diagnosis
♦ Incorrect injection valve with too great flow – Test injection valves ⇒ Chapter 24-3
rate fitted
– Check part No. of the injection valves
⇒ Spare parts catalogue
greater ♦ Increased engine load due to electric con- – Eliminate load (air conditioning, power
than 4.0 sumers, air conditioning system, engaged steering etc.)
ms driving position or power steering to the stop
♦ Incorrect injection valves with too small flow – Test injection valves ⇒ Chapter 24-3
rate fitted
– Check part No. of the injection valves
⇒ Spare parts catalogue
Analysis of display group 002 intake manifold pressure

play on dis-
field play:
4 less than ♦ Large volume of unmetered air between in- – Eliminate unmetered air
240 mbar take manifold and air filter
greater ♦ Driving position engaged (automatic gear- – Put selector lever in P or N
than 420 box)
mbar ♦ Engine loaded by auxiliary equipment – Eliminate load (air conditioning, power
steering etc.)

• Engine idling

S00.5309.04.20

xxxx rpm xxx mbar xx ° xx °
Ignition angle 0...10 ° BTDC —
Throttle valve angle (potenti- 0...11 ° ⇒ 01-5 page 8
ometer 1 -G187-)
Intake manifold pressure 240...420 mbar ⇒ 01-5 page 4

• Engine idling

xxxx rpm xx.x V xxx °C xxx °C
Intake manifold -40...120 °C ⇒ 01-5 page 6
temperature
Supply voltage of the engine control unit 12.5...14.5 V ⇒ 01-5 page 6
Note
♦ Re display field 3:
♦ As soon as a fault concerning the coolant temperature
sender -G62- is stored in the fault memory, the engine
control unit uses the intake manifold temperature as a
replacement value to start the engine (starting tem-
perature - replacement value) The temperature then
rises according to a model sequence stored in the
control unit. If the engine is warm after a certain period
a fixed replacement value is displayed. This fixed sub-
stitute value depends on the intake air temperature.
♦ The overall temperature range is indicated as nominal
value. The nominal value must be higher than the am-
bient temperature.

S00.5309.04.20
Analysis of display group 004, engine control unit voltage supply

play on dis-
field play:
2 less than ♦ Generator defective, battery heavily dis- – Inspect generator and battery voltage,
12.5 V charged charge battery ⇒ Electrical System;
Rep. Gr. 27
♦ Battery heavily loaded just after start by a – Increase engine speed slightly for a few
high charge current or by auxiliary equip- minutes and switch off additional con-
ment sumers
♦ Transition resistance in the power supply or – Inspect engine control unit power supply
earth connection for engine control unit ⇒ Chapter 24-5
♦ Current consumption with ignition off – Eliminate current consumption
greater ♦ Voltage regulator on generator defective – Check voltage regulator, if necessary re-
than 14.5 place ⇒ Electrical System; Rep. Gr. 27
V
♦ Overvoltage due to starting aid or quick – Interrogate fault memory ⇒ Chapter 01-
charger 1
Analysis of display group 004, coolant temperature
Dis- Read- Possible cause of fault Rectifying fault

play out on
field display:
3 less than ♦ Engine too cold – Conduct test drive if necessary
80 °C
♦ Coolant temperature sender or cable con- – Test coolant temperature sender
nection to engine control unit faulty ⇒ Chapter 24-2
♦ Coolant regulator defective – Test coolant thermostat ⇒ 1.4/55; 1.4/74
Rep. Gr. 19
greater ♦ Radiator dirty – Clean radiator
than 110
°C ♦ Radiator fan not operational – Inspect proper operation ⇒ Current Flow
Diagrams, Electrical Fault Finding and Fit-
ting Locations
♦ Coolant regulator defective – Test coolant thermostat ⇒ 1.4/55; 1.4/74
Rep. Gr. 19
constant ♦ Open circuit or short circuit to positive – Test coolant temperature sender
- 40 °C ⇒ Chapter 24-2
constant ♦ Short circuit to earth
120 °C

S00.5309.04.20
Analysis of display group 004, intake manifold temperature
Dis- Read- Possible cause of fault Rectifying fault

play out on
field display:
4 constant ♦ Open circuit or short circuit to positive – Inspecting intake manifold temperature
- 40 °C sender ⇒ Chap. 24-2
constant ♦ Short circuit to earth
120 °C

• Engine idling

xxxx rpm xx % xxx km/h Text
Operating condi- Idling
tion (idling, partial
—
load, enrichment,
trailing throttle)
Driving speed 0 km/h —

• Engine idling

xxxx rpm xx % xxx °C xx.x %
Level correction -30,0...5,0 %
—
factor
Intake manifold temperature -40...120 °C ⇒ 01-5 page 7
Note
♦ The overall temperature range is indicated as nominal
value. The display value must be higher than the am-
bient temperature.

S00.5309.04.20

010...029 - Ignition
Display group 010 ignition:

• Engine idling
Read measured value block 10 → ⇐Read out on display:

xxxx rpm xx % xx % xx.x °
Ignition angle 0...10.0 ° BTDC —
Throttle valve angle (potenti- 0...11 % ⇒ 01-5 page 8
ometer 1 -G187-)
Analysis of display group 010, engine load

play on dis-
field play:
2 less than ♦ Lower value can only occur during trailing
10 % throttle driving
greater ♦ Poor idling (engine not running on all cylin- – Test injection valves ⇒ Chapter 24-3
than 20 % ders)
– Test ignition leads and spark plugs
⇒ Chapter 28-1
♦ Electrical consumers on – Disconnect electric consumer
♦ Steering wheel at limit stop – Put steering wheel in centre position
♦ Driving position engaged (automatic gear- – Put selector lever in P or N
box)
Analysis of display group 010, throttle valve angle

play on dis-
field play:
3 greater ♦ Engine control unit not adapted to throttle – Adapt engine control unit to throttle valve
than 11 % valve control unit control unit ⇒ Chapter 24-5
♦ Throttle valve potentiometer in throttle valve – Test throttle valve control unit ⇒ Chapter
control unit defective 24-2
♦ Throttle valve blocked – Eliminate cause

S00.5309.04.20
Display group 014 - Ignition, sum of misfiring de-
tection:
• Driving
Read measured value block 14 → ⇐ Read out on display:

xxxx rpm xxx % xxx Text
Combustion mis- activated
firing detection
—
(activated, deacti-
vated)
Sum of ignition misfiring 0 ⇒ 01-5 page 9
Engine load 12…100 % —
Engine speed
Vehicles with engine code AUA 650…5700 rpm —
Vehicles with the engine codes BBY, BKY 660…5700 rpm —
Vehicles with automatic gearbox 580…5700 rpm
—
Vehicles with engine code AUB 740…6600 rpm —
Vehicles with engine code BBZ 580…6600 rpm —
Analysis of display group 014, sum of ignition misfiring

play on dis-
field play:
3 greater ♦ Spark plug defective – Test spark plugs and spark cables with
than 0 ♦ Spark plug connector defective spark plug connector ⇒ Chap. 28-1
♦ Ignition transformer defective – Inspect ignition transformer ⇒ Chapter
28-1
♦ Injection valve defective – Test injection valves ⇒ Chapter 24-3
♦ Exhaust gas recirculation valve jams/soiled – Test exhaust gas recirculation valve
⇒ Chapter 01-1, final control diagnosis.
Display group 015 - ignition, cylinder misfiring 1

to 3:
• Driving

S00.5309.04.20

xxx xxx xxx Text
Combustion mis- activated
firing detection
—
(activated, deacti-
vated)
Ignition misfiring cylinder 3 0 ⇒ 01-5 page 10
Display group 016 - ignition, cylinder misfiring 4:

• Driving

xxx — — Text
Combustion misfir- activated
ing detection
—
(activated, deacti-
vated)
— —
— —
Analysis of display groups 015 and 016, ignition misfiring cyl. 1 to cyl. 4

play on dis-
fields play:
Dis- greater ♦ Spark plug defective – Test spark plugs and spark cables with
play than 0 ♦ Spark plug connector defective spark plug connector ⇒ Chap. 28-1
group
15 ♦ Ignition transformer defective
display
field 1 – Inspect ignition transformer ⇒ Chapter
to 3 28-1
and ♦ Injection valve defective – Test injection valves ⇒ Chapter 24-3

display
♦ Exhaust gas recirculation valve jams/dirty – Test exhaust gas recirculation valve
group
16 ⇒ Chapter 01-1, final control diagno-
display sis.
field 1
Display group 022 ignition, knock control:

• Driving

S00.5309.04.20

xxxx rpm xxx % xx.x ° xx.x °
Ignition angle relief 0...14 ° ⇒ 01-5 page 12
cylinder 2 through
knock control
Ignition angle relief cylinder 1 0...14 ° ⇒ 01-5 page 12
through knock control
Engine load 15...100 % —
Engine speed
—
Note
♦ Notes on display groups 3 and 4:
♦ When idling the display value must be 0.0 .
♦ 14 is the largest ignition angle relief.
Display group 023 - ignition, knock control:

• Driving

xxxx rpm xxx % xx.x ° xx.x °
Ignition angle re- 0...14 ° ⇒ 01-5 page 12
lief cylinder 4
through knock
control
Ignition angle relief cylinder 3 0...14 ° ⇒ 01-5 page 12
through knock control
Engine Vehicles with engine code AUA 650…5700 rpm
—
speed
Vehicles with the engine codes BBY, 660…5700 rpm
—
BKY
—

S00.5309.04.20
Note
♦ Notes on display groups 3 and 4:
♦ When idling the display value must be 0.0 .
♦ 14 is the largest ignition angle relief.
Analysis of display groups 022/023, ignition angle relief

play on dis-
field play:
3 and All 14 ° ♦ Knock sensor defective – Inspecting knock sensor ⇒ Chapter 28-1
4 cylinder
♦ Plug connection corroded – Check knock sensor plug connection
⇒ Chap. 28-1
♦ Knock sensor incorrectly tightened – Release knock sensor and tighten (20 Nm)
♦ Component parts on engine loose – Attach component parts
♦ Poor fuel quality – Change fuel type
Once cyl- ♦ Plug connection corroded – Check knock sensor plug connection
inder ⇒ Chap. 28-1
clearly
deviates ♦ Engine damage – Test compression ⇒ 1.4/55; 1.4/74 Engine -
from the Mechanical Components; Rep. Gr. 15.
others ♦ Component parts on engine loose – Attach component parts
Display group 028 - ignition, knock control:

• Driving
• Diagnostic device in function 04 - basic setting
System in basic setting 28 → ⇐ Read out on display:

xxxx rpm xx % xxx.x °C Text
Result knock sen-
sor test (Test ON/
Syst. o.k. —
Test OFF/Syst.
o.k./Syst. n.o.k.)
Engine speed 2000...4000 rpm —

S00.5309.04.20
01-6 Self-diagnosis VI

030...049, 099 - Lambda control
Display group 030 - lambda control:

• Engine idling

xxx xxx — —
— —
— —
Status lambda control downstream of cat- 110 ⇒ 01-6 page 1
alytic converter
Status lambda control upstream of catalytic convert- 111 ⇒ 01-6 page 1
er
Note
♦ The 3rd display position is only set to 1 in the partial
load region.
Meaning of the 3-digit numerical block display field 1:
Meaning if display positions = 1

1 2 3
1 Lambda control active
1 Lambda probes operational
1 Lambda probe heating on
Display group 031 - lambda control, lambda val-

ues upstream of catalytic converter:
• Engine idling
• Coolant temperature ≥ 80 °C
Edition 06.04 Self-diagnosis VI 01-6 page 1

S00.5309.04.20
Read measured value block 31 → < Readout on display

x.xxxx x.xxxx
1 2 3 4 < Display field Specification Analysis:
No display --- ---
No display --- ---
Lambda nominal value - Bank 1 0,9900…1,0100 ---
Lambda actual value - Bank 1 0,9600…1,0400 ---
Display group 032 - Lambda control, Lambda in-

itialisation values:
• Engine idling

xx.x % xx.x % — —
— —
— —
Lambda learned value under partial load -10,0...10,0 % ⇒ 01-6 page 3
(multiplicative) upstream of catalytic con-
verter
Lambda learned value in idling (additive) upstream -10,0...10,0 % ⇒ 01-6 page 3
of catalytic converter
Note
♦ Re display fields 1 and 2:
♦ Low readouts indicate that the engine is running too
rich and the lambda control therefore produces a lean-
er mixture.
♦ High readouts mean that the engine is running too
lean and the lambda control therefore produces a rich-
er mixture.
♦ If the control unit is dead all initialisation values are re-
set.
♦ add = additive - The effect of the fault (e.g. unmetered
air) becomes increasingly less as engine speed rises.
In the case of an additive initialisation value the injec-
tion period is changed by a fixed rate. This rate is in-
dependent of the basic injection period.
♦ mul = multiplicative - The effect of the fault (e.g. faulty
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.
♦ Initialisation conditions for partial load. Coolant tem-
perature at least 75 C, intake air temperature max. 90
C, driving mode.
01-6 page 2 Self-diagnosis VI Edition 06.04

S00.5309.04.20
Analysis of display group 032, Lambda control, Lambda learned values

play on dis-
field play:
1 and low lamb- ♦ Low learned values in idling at normal – Disappears after motorway driving or oil
2 da learned values in partial load: Oil dilution change
learned (higher fuel content in the oil) possible
values ♦ Injection valve leaks – Test injection valves ⇒ Chapter 24-3
♦ Fuel pressure too high – Test fuel pressure regulator and holding
pressure ⇒ Engine 1.4/55; 1.4/74 Me-
chanics; Rep. Gr. 20.
♦ Solenoid valve 1 for activated charcoal filter – Testing solenoid valve 1 for activated
-N80- constantly open charcoal filter ⇒ Chapter 01-1, final con-
trol diagnosis
♦ Lambda probe heating defective or lambda – Testing lambda probe heater upstream
probe dirty of catalytic converter ⇒ Chapter 24-4

play on dis-
field play:
1 and high ♦ High learned values in idling at less high – Testing intake system for tightness
2 lambda learned values in partial load: Unmetered ⇒ Chapter 24-3
initialisa- air in intake manifold region possible
tion val- ♦ Unmetered air between air filter and throttle
ues
– Eliminate cause
valve
♦ Unmetered air at the exhaust manifold gas- – Eliminate cause
ket
♦ Injection valve blocked – Test injection valves ⇒ Chapter 24-3
♦ Fuel pressure too low – Test fuel pressure regulator and holding
pressure ⇒ 1.4/55; 1.4/74 Engine - Me-
chanics; Rep. Gr. 20.
♦ Lambda probe heating defective or lambda – Testing lambda probe heater upstream of
probe dirty catalytic converter ⇒ Chapter 24-4
Display group 033 - Lambda control, Lambda

control values:
• Engine idling

xx.x % x.xxx V — —
— —
— —
Lambda probe voltage before catalyst 0.4...0.5 V —
Lambda control before catalyst -15,0...15,0 % ⇒ 01-6 page 4

S00.5309.04.20
Note
♦ The display must oscillate around 0. If 0 is constantly
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.
Note
♦ Display 0.450 V equals approx. = 1.0.
♦ Voltage signal „Mixture rich“ (low level of residual ox-
ygen) is below 0.45...V.
♦ Voltage signal „Mixture lean“ (a lot of residual oxygen)
is above 0.45...V.
♦ Through its structure the wide-band lambda probe en-
ables a permanent lambda control due to the signal
routing for deviations as of = 1.
♦ The control is performed dynamic, as the deviation
from the specification is current and is known as the
concrete value.
Analysis of display group 033, lambda control upstream of catalytic converter

play on dis-
field play:
1 not within ♦ Minimum range: Engine too rich, lambda – wait 30 seconds until the display has
tolerance control leans off stabilised
♦ Plus range: Engine too lean, lambda control
enriches
♦ Unmetered air – Testing intake system for tightness
⇒ Chapter 24-3
♦ Injection valve defective – Test injection valve ⇒ Chap. 24-3
♦ Lambda learned values on limit – Test lambda initialisation values in dis-
play group 032 ⇒ 01-6 page 3
Display group 034 - Lambda control, diagnosis

of lambda probe upstream of catalytic converter
(ageing test over amplitude quality grade)
– Blip two short accelerations above 5000 rpm
• Vehicle standing, engine running at high speed

S00.5309.04.20

xxxx rpm xxx.x °C x.x s Text
Result of test of
lambda probe age-
ing upstream of
catalytic converter B1 S1 o.k. —
(Test OFF/Test
ON/B1 S1 o.k./B1
S1 n.o.k.)
Period of lambda probe up- max. 1.0 s
—
stream of catalytic converter
Catalytic converter temperature — —
Engine speed 1500…3900 rpm —
Note
♦ regarding display fields 3 and 4:
♦ The period duration indicates the time between two
voltage jumps (e.g. rich - lean - rich) of the lambda
probe and is thus an indication of the age condition of
the lambda probe. If the given time is exceeded, dis-
play field 4 = B1 S1 N.O.K.
Display group 036 - lambda control, operation

after catalyst
• Vehicle standing, brake pedal activated, engine run-
ning at raised idling (1500….4000 rpm)

x.xxx V Text — —
— —
— —
Test lambda probe downstream of catalyt- B1 S2 o.k.
ic converter —
(Test OFF/Test ON/B1 S2 n.o.k.)
Lambda probe voltage after catalytic converter 0.000...1.000 V ⇒ 01-6 page 6

S00.5309.04.20
Analysis of display group 036, lambda probe voltage, lambda probe downstream of catalytic con-
verter

play on dis-
field play:
1 constant ♦ Short-circuit to positive terminal in: Lambda – Test basic voltage of the lambda probe
1.100 V probe, lambda probe cable, earth lead, en- downstream of catalytic converter
gine control unit ⇒ Chap. 24-4
– Test lambda probe after catalytic con-
verter ⇒ Chapter 24-4
constant ♦ Line interruption in: Lambda probe, lambda
between probe cable, earth lead, engine control unit
0.400
...0.500 V
constant ♦ Short-circuit to earth in: Lambda probe,
0.000 V lambda probe cable, earth lead, engine con-
trol unit
Display group 037 - Lambda control, Lambda

probes downstream of catalytic converter:
• Driving

xx.x % x.xxx V x.x % Text
Test lambda
probes
(Test ON/Test Syst. o.k. —
OFF/Syst. o.k./
Syst. n.o.k.)
Ignore — —
Lambda probe voltage after catalytic 0.000...1.000 V ⇒ 01-6 page 6
converter
Engine load 12,0...40,0 % ⇒ Chapter 01-5
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).

S00.5309.04.20
♦ In view of the steep voltage jump the lambda control
is not able to maintain constant the ideal mixture com-
position which corresponds to = 1.0. The control
constantly fluctuates back and forward between the
„slightly too lean“ and „slightly too rich“ states.
♦ The readout must in some cases be less than 0.3 V
and in some cases more than 0.6 V. The readout be-
low 0.45 V indicates a lean mixture while above 0.45
V indicates a rich mixture.
♦ At idling speed, the voltage of the lambda probe up-
stream of the catalytic converter -G39- must fluctuate
between a rich and leaner mixture. The voltage of the
lambda probe downstream of the catalytic converter
-G130- should indicate a constant rich or lean mixture.
If the voltage also fluctuates downstream of the cata-
lytic converter, either the catalytic converter is faulty
(Read measured value block 046 ⇒ 01-6 page 8) or
the probes have been wrongly connected (irregular
engine running). Lambda control varies between -
15...15 %.
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 041 - lambda control, lambda

probe heating:
• Engine idling

— Text xxx ohms Text
Lambda probe Ht. after c. ON
heating down- Ht. after c. OFF
—
stream of catalytic
converter
Resistance lambda probe
heating downstream of cata- — —
lytic converter
Lambda probe heating upstream of cata- Ht. bf. c. ON
—
lytic converter Ht. bf. c. OFF
— —

S00.5309.04.20
Note
Depending on the operating state of the engine the lamb-
da 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 46 - Lambda control, Diagnosis of

catalyst (conversion test):
• Vehicle standing, engine running at high speed
• No fault in fault memory, coolant temperature 60...120
°C, lambda control active and stable

xxxx rpm xxx.x °C xx.x % Text
Result of the cata-
lyst conversion
test
Cat B1 o.k. —
(Test OFF/Test
ON/Cat B1 O.K./
Cat B1 N.O.K.)
Measured value catalytic con- at least 60 %
—
version
Catalytic converter temperature at least 300 °C —
Display group 099 - Lambda control, Operating

condition of lambda control:
• Engine idling

xxxx rpm xxx °C xx.x % Text
Operating condi- OFF
tion of lambda ON —
control
Lambda control before cata- -15,0...15,0 % ⇒ 01-6 page 4
lyst
Coolant temperature 80...110 °C ⇒ Chapter 01-5
Engine speed (idling speed) xxxx rpm1) ⇒ Chapter 01-5
1) Display group 001, display field 1 ⇒ Chap. 01-5.

S00.5309.04.20
01-7 Self-diagnosis VII


050...069 - Speed control
Display group 050 - Speed control, Operating

conditions:
• Engine idling

xxxx rpm xxxx rpm Text Text
Operating state of ON
—
AC compressor OFF
Operating condition of air ON
—
conditioning system OFF
Engine speed (idling speed - specified
value)
Vehicles with engine code 750 rpm
AUA (830 rpm)1)
AUB (870 rpm)1)
Vehicles with the engine 760 rpm
codes BBY and BKY
BBZ
Vehicles with automatic gear- 680 rpm
box (800 rpm)1)
Engine speed (idling speed - actual value) xxxx rpm2) ⇒ Chapter 01-5
1) Air conditioning switched on
2) Display group 001, display field 1 ⇒ Chap. 01-5
Note
♦ The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is
displayed.
♦ The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely over-
heated.
Note
♦ regarding display fields 3 and 4:
♦ „OFF“ is always displayed on vehicles without air con-
ditioning system.
Edition 06.04 Self-diagnosis VII 01-7 page 1

S00.5309.04.20
Display group 054 - Lambda control:

• Driving

xxxx rpm Text xxx % xxx %
Throttle valve an- 3...97 %
gle (potentiome- —
ter 1 -G187-)
Sender 1 for accelerator pedal 3...97 %
—
position -G79-
Operating position: Idling, part load, en-
— —
richment, overrun, full load
Engine speed
Vehicles with engine code AUA 650 ... 5700 rpm —
Vehicles with the engine codes BBY, BKY 660 ... 5700 rpm —
Vehicles with automatic gearbox 580 ... 5700 rpm —
Vehicles with engine code AUB 740 ... 6600 rpm —
Vehicles with engine code BBZ 580 ... 6600 rpm —
Note
♦ The operating condition is displayed according to the
speed or load. As of increased speed „trailing throttle“
with closed throttle valve is only displayed up to 1450
rpm, after that it returns to idling.
Display group 055 - Speed control, idle stabiliz-

er:
• Engine idling

xxxx rpm xx Nm xx.x % xxxxx
Operating condi- xxxxx ⇒ 01-7 page 3
tions
Initialisation value idling con-
trol
Air conditioning on -6,0...8,0 % —
Air conditioning off -3,0...8,0 %
Idling control -10…0 Nm —
Engine speed (idling speed) xxxx rpm1) ⇒ Chapter 01-5
01-7 page 2 Self-diagnosis VII Edition 06.04

S00.5309.04.20
Note
♦ The display shows to what extent the idling stabilizer
has „disinitialised“ from the constructively given mean
value. On a new engine the value is in the positive re-
gion because of the higher friction, on a run-in engine
it is in the negative region.
Display field 4 - Operating conditions, meaning of the digits in the 5-digit number block
Meaning if display positions = 1

1 2 3 4 5 Meaning
1 Air conditioning compressor on
1 Driving position engaged
1 Air conditioning switched on
x No meaning
x No meaning
Display group 056 - engine speed control, idling

speed stabilisation:
• Engine idling

xxxx rpm xxxx rpm xx Nm xxxxx
tions
Idling control -10...0 Nm —
Engine speed (idling speed - specified
value)
AUA (830 rpm)1)
AUB (870 rpm)1)
Vehicles with the engine 760 rpm
codes BBY and BKY
BBZ
Vehicles with automatic gear- 680 rpm
box: (800 rpm)1)
Engine speed (idling speed - actual value) xxxx rpm2) ⇒ Chapter 01-5
1) Air conditioning switched on

S00.5309.04.20
Note
♦ The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is
displayed.
♦ The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely over-
heated.
Display group 60 - Speed control, Electronic

Throttle Adaptation:
• Ignition on, engine stopped
• Diagnostic device in function 04 „basic setting“

xxx % xxx % xx Text
Adaption state
(ADP runs, ADP ADP o.k. —
o.k. or ADP n.o.k.)
Initialisation step counter 0...12 —
Throttle valve angle (potentiometer 2 3...97%
—
-G188-)
Throttle valve angle 3...97% —
Potentiometer 1 -G187-
Note
♦ To display group 60:
♦ The adaptation of the throttle valve control unit occurs
with the ignition switched on and accelerator pedal not
depressed.
♦ The engine control unit is adjusted to the throttle valve
control unit by selecting display group under function
04 „Basic setting“. This adjustment must always be
performed if a different throttle valve (or completely
different engine) or a different engine control unit has
been fitted.
♦ If the power supply was interrupted (battery discon-
nected) an adaptation must also be carried out
⇒ Chap. 24-5. Work sequence after a power supply
interruption.
♦ During adaptation the counter in display field 3 counts
up to 12.
♦ The basic setting may only be ended once the counter
in display field 3 has reached step 12.
Display group 61 - engine speed control, EPC:

• Driving

S00.5309.04.20

xxxx rpm — xxx.x % xxxxx
tions
Throttle valve angle (potenti- 0...100 %
—
ometer 1 -G187-)
— —
Engine speed
—
Display group 062 - engine speed control, EPC:


xx % xx % xx % xx %
Sender 2 for accel- 0...100 %
erator pedal posi- —
tion -G185-
Sender 1 for accelerator ped- 0...100 %
—
al position -G79-
Throttle valve angle (potentiometer 2 3...97 %
—
-G188-)
Throttle valve angle (potentiometer 1 -G187-) 3...97 % —

070...075 - exhaust gas recirculation
Display group 070 - Exhaust gas reduction, Acti-

vated charcoal filter system diagnosis (tank ven-
tilation system):
• Engine idling
• Coolant temperature minimum 80 °C

S00.5309.04.20

xx % xx % xxx mbar Text
Result of the acti- TVV o.k.
vated charcoal fil-
ter system
diagnosis —
(Test OFF/Test
ON/TVV O.K./
TVV N.O.K.)
Intake manifold pressure 240…420 mbar —
Result of current diagnosis > 25 % —
Opening level 13…25 % —
Note
TVV means Tank Vent Valve (activated charcoal filter so-
lenoid valve 1).
Note
♦ During diagnosis the display fluctuates in the region
from 13...25 % to approx. 6 %.
Display group 074 - Exhaust gas reduction, Ex-

haust gas recirculation valve adaptation:

x.x V x.x V x.xxx V Text
Adaption state ADP o.k.
(ADP runs, ADP —
o.k. or ADP n.o.k.)
Current pot voltage value 0,300…4.600 V —
100 %- Position 2,9…4.6 V —
0 - Position (basic setting) 0,3…1.3 V —
Note
♦ The adaptation of the exhaust gas recirculation valve
occurs with the ignition on.
♦ The engine control unit is adapted to the exhaust gas
recirculation valve by selecting display group 074 un-
der function 04 „Basic position“. This adaption must

S00.5309.04.20
always be performed if another EGR valve (or com-
pletely different engine) or another engine control unit
has been installed.
Display group 075 - Exhaust gas recirculation:

• Engine idling
– Briefly blip throttle 5 times up to max. speed.

xxxx rpm xxx mbar xxx mbar Text
Result: Test ON/ Syst. o.k.
Test OFF, Syst. —
o.k./Syst. n.o.k.
Intake manifold pressure dif- min. 50 mbar
—
ference
Intake manifold pressure 240…420 mbar —
Note
♦ An error can already occur under 140 mbar.
Measured value blocks, display group

100 - readiness code
Display group 100 - readiness code:

• Engine idling

xxxxxxxx xxx.x °C xxx s xxxxxxxx
Diagnosis status — —
Time since engine start — —
Coolant temperature 80.0...110.0 °C ⇒ Chapter 01-5
Readiness code 00000000 ⇒ 01-7 page 7
Display field 1 - Readiness code - Meaning of the digits in the 8-digit numerical block
1 2 3 4 5 6 7 8 Diagnosis function
0 Catalytic converter
0 Catalytic converter heating (no diagnosis at present/always „0“)

S00.5309.04.20
0 Activated charcoal filter system (tank ventilation system)
0 Secondary air injection system (not fitted/always „0“)
0 Air conditioning system (currently no diagnosis/always „0“)
0 Lambda probes
0 Lambda probe heater
0 Exhaust gas recirculation

120...129 - Communication
Display group 120 - traction control system

(TCS):
• Driving

xxxx rpm xxx Nm xxx Nm Text
Status active/inactive —
Actual engine load — —
Nominal engine load — —
Engine speed xxxx rpm1) ⇒ Chapter 01-5
Display group 122 - Gearbox (only automatic):

• Driving

xxxx rpm xxx Nm xxx Nm Text
Status Engine ctl./ no ctl. —
Actual engine load — —
Nominal engine load — —
Engine speed xxxx rpm1) ⇒ Chapter 01-5
Display group 125 - communication, databus

messages
• Engine idling

S00.5309.04.20

Text Text Text Text
Status airbag Airbag 1 —
Status of combiinstrument Combi 1 —
Status gearbox Gearbox 1 —
Status ABS ABS 1 —
Note
♦ Nominal value = 1; the control units with active data
bus are displayed.

S00.5309.04.20

S00.5309.04.20
24 – Fuel Formation, Injection
24-1 Repairing the injection system
Installed location overview for engines with the engine codes AUA, AUB
1 - Activated charcoal filter sys-
tem solenoid valve 1 -N80- */** 3
❑ inspecting ⇒ Chap. 01-1
1 6
2 - 3-pin connector 9
❑ for engine speed sender
-G28- 2
3 - Intake manifold pressure 4 5 7 8
sender -G71- * with intake
manifold temperature sender
-G72- **
4 - Intake manifold
5 - Injector - (N30…N33)- *
6 - Knock sensor -G61- *
❑ Fitting location: Cylinder-
block intake side
❑ inspect ⇒ Chapter 28-1
7 - Engine control unit *
8 - Throttle valve control unit
-J338- *
9 - Engine speed sender -G28- *
❑ inductive pickup
block intake side 14
10 - Ignition transformer -N152- * 11
16 13
❑ with identification for ignition
D
leads, do not switch
❑ inspect ⇒ Chapter 28-1 12 10
B
11 - 6-pin connector 15
❑ for wide band lambda probe
with lambda probe heating S24-0333
before catalyst
12 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- * 1.4/55;
13 - Sender for coolant temperature -G62- *
14 - Hall sender - G40- *
15 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm
❑ Fitting location: in the exhaust manifold
❑ 6-pin connector
16 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm
❑ Fitting location: downstream of catalytic converter
❑ 4-pin connector
Edition 06.04 Repairing the injection system 24-1 page 1

S00.5309.04.20
Installed location overview for engines with the engine codes BBY, BBZ, BKY
1 - Activated charcoal filter sys-
tem solenoid valve 1 -N80- */**
❑ inspecting ⇒ Chap. 01-1
2 - 3-pin connector
❑ for engine speed sender
-G28-
3 - The vacuum regulating valve
(PCV valve)
❑ for crankcase ventilation
4 - Heating resistor of crankcase
ventilation -N79-
5 - Intake manifold pressure
-G72- **
6 - Intake manifold
7 - Injectors -(N30…N33)- *
8 - Knock sensor -G61- *
block intake side
9 - Engine control unit *
-J338- *
❑ inductive pickup
block intake side
12 - 6-pin connector
❑ Observe current flow dia-
gram
❑ for wide band lambda probe
with lambda probe heating before catalyst
13 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- * 1.4/55;
15 - Hall sender -G40- *
16 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm
❑ pay attention to the spare part number
❑ in exhaust manifold - engines BBY, BBZ
❑ exhaust tube front - engine BKY
❑ 6-pin connector - pay attention to different connections for engines with the engine codes BKY EU-4 and EU-
2DDK 05.04 ➤
❑ Fitting location: downstream of catalytic converter
❑ 4-pin connector
18 - Ignition coils with a power output stage -N70, N127, N291 und N292-
❑ remove with extractor -T 10094-
24-1 page 2 Repairing the injection system Edition 06.04

S00.5309.04.20
General notes on the injection system
Repairing the ignition ⇒ Rep. Gr. 28.
♦ The engine control unit is equipped with a self-diagno-
sis system. 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).
♦ Fuel hoses in the engine compartment must be se-
cured with spring band clamps. The use of clamp-type
or screw-type clips is not allowed.
♦ Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV con-
trol unit.
♦ Components marked with an * are checked by self-di-
agnosis ⇒ Chapter 01-1.
♦ Components marked with ** can be tested with the fi-
nal control diagnosis ⇒ Chap. 01-1.

♦ A minimum voltage of 11.5 V is required for perfect
functioning of the electrical 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 probes.
♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is pos-
sible that the immobiliser blocks the 4AV control unit.
The fault memory must then be interrogated and if
necessary adapted to the control unit ⇒ Chapter 24-
5.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to inter-
rogate the fault memory after having completed all
inspections and repairs, and if necessary erase
⇒ Chapter 01-1.
♦ Vehicles fitted with airbags are equipped with a crash
fuel shut-off. It is intended to reduce the risk of a vehi-
cle 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 or-
der to build up the pressure in the fuel system.
Safety measures ⇒ 24-1 page 12.
Cleanliless rules ⇒ 24-1 page 13.
Inspect intake air system for leaks (unmetered air)
⇒ Chap. 24-3.
Inspecting engine operating conditions ⇒ Chapter 24-4.

S00.5309.04.20
Removing and installing parts of the injection system

1 - Plug
❑ pay attention to correct in- 33
stallation position
32
2 - Air filter
❑ disassembling and assem- 31
bling ⇒ 24-1 page 11 1
3 - Cable guide 30
❑ clipped on to fuel rail
29 2
4 - 10 Nm
5 - Vent valve 28 3
6 - Fuel rail with injection valves 26 27
❑ disassembling and assem- 4
bling ⇒ 24-1 page 10 22
7 - 20 Nm 5
8 - from brake servo unit
6
9 - Connector 25
❑ 6-pin 26 7
❑ for throttle valve control unit 24
-J338-
8
23
❑ Contacts of connector gold- 22 9
plated
10 - Activated charcoal filter sys- 21
tem solenoid valve 1 -N80- */** 20 10
❑ ⇒ 1.4/55; 1.4/74 Engine -
Mechanical Components; 11
Rep. Gr. 20 19
11 - Intake manifold 12
❑ disassembling and assem-
bling ⇒ 24-1 page 6 13
12 - Gasket
❑ replace
18 17 16 15 14 S24-0338
13 - 10 Nm
14 - Connecting tube
❑ to exhaust gas recirculation valve
❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
❑ with 4-pin connector
❑ Contacts 3 and 4 gilded
❑ Power supply for lamda probe heating supplied via fuel pump relay -J17-
❑ Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
❑ Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
❑ Fitting location: downstream of main catalytic converter
16 - Connector for lambda probe downstream of catalytic converter
❑ 4-pin
17 - Lambda probe 1 upstream of catalytic converter -G39-*, 50 Nm
❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
❑ with 6-pin connector
❑ contacts gold-plated
❑ Power supply for lamda probe heating supplied via fuel pump relay -J17-
❑ Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
❑ Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
❑ Fitting location: Engines BBY, BBZ in the exhaust manifold, engine BKY in the front exhaust pipe

S00.5309.04.20
18 - Connector for lambda probe upstream of catalytic converter
❑ 6-pin - pay attention to different connections for engines with the engine codes BKY EU-4 and EU-2DDK
05.04 ➤
20 - 5 Nm
21 - Gasket
❑ replace
22 - Retaining clip
❑ check tightness
23 - Connector
❑ black, 2 pin
❑ for sender for coolant temperature -G62-
❑ before removing, reduce pressure in cooling system
25 - Plug
❑ before removing, reduce pressure in cooling system
26 - O-ring
❑ replace if damaged
27 - 10 Nm
28 - Coolant regulator housing
29 - Fuel-intake hose
❑ secure with spring strap clamps
❑ check for firm seating
❑ from fuel filter ⇒ 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
30 - Connector
❑ for engine control unit
❑ insert or remove only when the ignition is switched off
31 - Engine control unit*
❑ testing voltage supply ⇒ Chapter 24-5
❑ Procedure to follow after power supply interruption has occurred ⇒ Chapter 24-5
❑ replacing ⇒ Chapter 24-5
❑ coding ⇒ Chapter 24-5
❑ Fitting location ⇒ 24-1 page 1, overview of the engine compartment
32 - Retaining frame
33 - 2 Nm

S00.5309.04.20
Disassembling and assembling intake manifold

Engines with engine codes AUA and BBY; vehicles mit engines BBY and manual gearbox ➤ 08.03

-J338- *
❑ if replaced adapt engine con-
trol unit ⇒ Chapter 24-5
❑ if replaced adapt automatic
gearbox control unit ⇒ chap.
24-5
2 - 10 Nm
3 - Gasket
❑ Check fitting position
❑ replace
4 - Induction pipe
5 - Gasket ring
6 - 20 Nm
7 - Gasket ring
❑ replace
8 - Guide plate
❑ pay attention to correct in-
stallation position
9 - O-ring
10 - 3 Nm
-G72- **
❑ Testing intake manifold pres-
sure sender ⇒ Chap. 24-2
❑ Inspecting intake manifold
temperature sender ⇒ Chap. 24-2
12 - Intake manifold
❑ out of plastic
❑ removing and installing ⇒ 24-1 page 4

S00.5309.04.20
Engines with engine code AUB

-J338- *
2 - Gasket ring
3 - 10 Nm
4 - 20 Nm
5 - Intake manifold
❑ Aluminium casting
❑ pay attention to the spare
part number
❑ removing and installing
⇒ 24-1 page 4
6 - Gasket ring
❑ replace
7 - Guide plate
stallation position
8 - O-ring
-G72- **
temperature sender
⇒ Chap. 24-2
10 - 3 Nm

S00.5309.04.20
Engines with engine codes BBZ; vehicles mit engines BBY and manual gearbox 09.03 ➤
1 - Intake manifold
❑ out of plastic
part number
⇒ 24-1 page 4
-J338- *
3 - 10 Nm
4 - Gasket ring
5 - 20 Nm
6 - Gasket ring
❑ replace
7 - Guide plate
stallation position
8 - O-ring
9 - 3 Nm
-G72- **
temperature sender
⇒ Chap. 24-2

S00.5309.04.20
Engines with engine identification letters BKY
1 - Intake manifold
❑ out of plastic
part number
⇒ 24-1 page 4
-J338- *
❑ if replaced adapt automatic
gearbox control unit ⇒ chap.
24-5
3 - 7 Nm
4 - Gasket
5 - 20 Nm
6 - Gasket ring
❑ replace
7 - O-ring
-G72- **
temperature sender
⇒ Chap. 24-2

S00.5309.04.20
Disassembling and assembling fuel distributor with injectors

1 - Fuel-intake hose
❑ secure with spring strap
clamps
1 2 3 2
2 - 10 Nm
3 - Fuel distributor 4
4 - Vent valve
5 - Retaining clip 5
❑ check tightness on the injec-
tion valve and fuel distributor 6
6 - O-ring
❑ replace
❑ before fitting moisten lightly
with clean engine oil 7
7 - Injector -N30-…-N33- *
❑ inspect ⇒ Chapter 24-3 6

❑ Resistor 14...17 Ω at 20 °C
5
7
S24-0339
Removing
– Unplug connector -arrows- of the injectors.

S00.5309.04.20
– Pull out the fuel feed hose -arrow- and catch the fuel
which flows out with a cleaning cloth.
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
– Remove the fuel distributor with injectors from the inlet

manifold.
Installing
S10-0099
– Installation is carried out in the reverse order.
Note
♦ Replace O-rings.
♦ before fitting moisten O-rings lightly with clean engine
oil
Disassembling and assembling the air filter

1 - Air filter top part
2 - Gasket
❑ replace if damaged 4 5 6 7
3 - Filter insert
4 - Air filter bottom part
5
5 - Rubber holder
6 - 3 Nm 6
7 - Gasket ring
8 - Inlet connection with control
flap
❑ Inspecting intake manifold 8
preheating ⇒ Chapter 24-3
3
1
2
S24-0331

S00.5309.04.20
Fig. 1: Resistance values for the coolant tempera-

ture sender -G62-
The diagram is divided into two temperature ranges:
A - from 0...50 °C
B - from 50...105 °C
Read out examples:
♦ 30 °C is in range A and corresponds to a resistance of
1.5...2.0 kΩ
♦ 80 °C is in range B and corresponds to a resistance of
275...375 Ω
Fig. 2: Resistances for intake manifold pressure

sender -G72-
The diagram is divided into two temperature ranges:
A - from 0...50 °C
B - from 50...105 °C
Read out examples:
♦ 20 °C is in range A and corresponds to a resistance of
2.3...2.6 kΩ
♦ 80 °C is in range B and corresponds to a resistance of
290...330 Ω
Fig. 3: Removing and installing an engine cover

with air filter
Removing
– Pull off hose -1- (engines 04.02 ➤) and remove en-
gine cover -2- with air filter upwards -arrows-.
Installing
– Installation of the engine cover with air filter occurs in
reverse order.
Safety measures
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion 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:

S00.5309.04.20
♦ For reasons of safety fuse no. 40 must be removed
from the fuse holder before opening the fuel system,
as the door contact switch could activate the fuel
pump.
♦ Do not touch or remove ignition leads with the engine
running or at start speed.
♦ Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and igni-
tion system as well as of test equipment.
rear seat and also have a second person operate
them there.
♦ If the engine must be operated at start speed without
the engine starting:
For engines with the engine codes AUA, AUB
– Unplug the 4-pin connector -arrow- from the ignition

transformer.
For engines with the engine codes BBY, BKY, BBZ
– Pull out all ignition coils using the extractor -T 10094-.

For all vehicles
Rules of cleanliness
When working on the fuel supply/fuel injection system,
pay careful attention to the following „5 rules“ for cleanli-
ness.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ 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.
♦ When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.

S00.5309.04.20

S00.5309.04.20
24-2 Testing components

Testing throttle valve control unit
Components for throttle valve control unit -J338-: Throttle
valve drive -G186-, throttle valve drive angle sender 1
-G187- and throttle valve drive angle sender 2 -G188-.
Note
♦ If the throttle valve control unit is replaced, it is then
essential to adapt this new throttle valve control unit to
the engine control unit ⇒ Chap. 24-5.
♦ On vehicles with an automatic gearbox the gearbox
control unit must also be replaced ⇒ Chap. 24-5.

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
♦ Handheld multimeter, e.g. -V.A.G 1526 B-
♦ Measuring tool set e.g. -V.A.G 1594 C-
Test condition
• Throttle valve is not damaged or dirty.
Test sequence
– Unplug the 6-pin connector from the throttle valve
control unit.
– Measure resistance of throttle valve drive between
contacts 3 + 5.
Specified value: 3...200 Ω
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.
If the power supply and wiring is O.K.:
Testing voltage supply and wiring to the control

unit
– Unplug the 6-pin connector from the throttle valve
control unit.
– Connect the multimeter for voltage measurement to
contacts 2 + 6 of the connector.
– Switch on ignition.
Edition 06.04 Testing components 24-2 page 1

S00.5309.04.20
Specified value: min. 4,5 V

contact 2 of the connector and to earth.

– Connect test box -V.A.G 1598/31- to wiring loom of

control unit ⇒ Chapter 24-5. The engine control unit is
not connected here.
for interruption:

-V.A.G. 1598/31-
1 92
2 83
3 117
4 84
5 118
6 91
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other.

– Inspect engine control unit power supply ⇒ Chapter

24-5.
Testing accelerator pedal position send-

er
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
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 inde-
pendently of each other (when accelerator is depressed).
Both senders are located in a housing.
24-2 page 2 Testing components Edition 06.04

S00.5309.04.20
Test condition
• Battery voltage at least 11.5 V.
Test sequence
tronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and
display group 062.
Reading measured value block 62 ->
– Test the nominal value of sender 1 -G79- at idle stop 2% 2% 14% 14%
in display field 3:
Specified value: 3...100 %
– Test the nominal value of sender 2 -G185- at idle stop

in display field 4:
Specified value: 3...100 %
Note
The engine control unit converts the voltage values of the
throttle valve drive angle sender in percentage (in relation
to 5 Volts) (5 Volts power supply correspond to 100%).
– Slowly press the accelerator pedal while observing

the values in the display fields 3 and 4.
Sollwert: 3…100 %
– Test the voltage supply and the wiring of the acceler-

ator pedal position sender ⇒ 24-2 page 3.
Testing voltage supply and wiring to the control

unit
– Remove storage compartment on driver side ⇒ Body
Fitting Work; Rep. Gr. 68.
– Disconnect the 6 pin plug connection from the accel-
erator pedal position sender.
the following contacts of the connector:
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3


S00.5309.04.20

not connected here.
– Check wiring between the test box and the plug for in-
terruption according to the Current Flow Diagram:

-V.A.G. 1598/31-
1 72
2 73
3 36
4 35
5 33
6 34

– Replace accelerator pedal position sender.
Testing the intake manifold pressure

sender
Note
Only use gilded contacts to repair contacts in the plug
connection of the sender.

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
Test sequence
– Read off intake manifold pressure values indicated in 840/min 365mbar 2
display field 2.
Specified value: 240…420 mbar
– Briefly open throttle valve. The intake manifold pres-

sure value in display field 2 must increase briefly.

S00.5309.04.20
If 91 mbar or 1254 mbar is always indicated:
Display Cause Continue test

91 mbar Line interruption ⇒ 24-2 page 5
or short-circuit to
earth
1254 mbar Short circuit to ⇒ 24-2 page 6
positive
Continuation of the test if the display reads 91

mbar:
– Disconnect the 4-pin plug connection from the intake
manifold pressure sender - G71- with intake manifold
temperature sender -G72- -arrow- (engine may stall).
– Bridge contacts 3 + 4 of the plug connection and ob-

serve the read-out on the display.
If the display jumps to 1254 mbar:

– Replace the intake manifold pressure sender -G71-
with intake manifold temperature sender -G72-
⇒ Chap. 24-1.
If the display remains at 91 mbar:

not connected here.
gram.

-V.A.G. 1598/31-
3 98
4 109
– Also test wire contact 4 for short-circuit to earth and to

contact 1.

S00.5309.04.20
Continuation of the test if the display reads 1254

mbar:
manifold pressure sender - G71- with intake manifold
temperature sender -G72- -arrow- (engine may stall).
If the display jumps to 91 mbar:

⇒ Chap. 24-1.
If the display remains at 1254 mbar:

– Unlock connector at control unit and unplug.
– Check the wires for plug of control unit at 4-pin plug
contact 4 for short-circuit to wire contact 3 as well as
after positive battery.
Testing intake manifold temperature

sender
Note
Only use gilded contacts to repair contacts in the plug

♦ Vehicle system tester e.g. -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, 3C-
♦ Test box -V.A.G 1598/31-
Test sequence
display group 004.
– Read off intake manifold temperature value in display 840 rpm 13.6V 91 C 62 C
field 4.
Specified value: Ambient temperature 1)
1) If a temperature is displayed that is below the ambient temperature of the sender, check the sender wires for transition impedances. Make sure
that the sender heats up or is heated by radiant heat.

S00.5309.04.20
If implausible value appears in the display:

manifold temperature sender -G72- with intake mani-
fold pressure sender -G71- -arrow-.
– Connect the multimeter for resistance measurement
to contacts 1 and 2 of the intake manifold temperature
sender.
Specified value:
The nominal value in field A applies for temperature

range 0...50 °C, nominal value in field B applies for tem-
perature range 50...105 °C.
Example:
♦ For a temperature of 20 °C the specification is
2.3...2.6 kΩ
290...330 Ω

⇒ Chap. 24-1.

not connected here.
gram.

-V.A.G. 1598/31-
1 108
2 85

tery positive.

S00.5309.04.20
Testing coolant temperature sender
Special tools, test and measuring equipment

and aids required
-V.A.G 1551/3, 3A, 3B, 3C-
♦ Test box -V.A.G 1598/31-
Test sequence
display group 001. Reading measured value block 1 ->
840/min 88 C 4.0% 00111111
– Read off coolant temperatur value indicated in display
field 2.
Specified value: Coolant temperature
If implausible value appears in the display:

– Unplug the 2-pin plug for the coolant temperature sen-
sor -G62- -arrow-.
to contacts 1 and 2 of the coolant temperature sender.
Specified value:
S24-0349
The nominal value in field A applies for temperature

range 0...100 °C, nominal value in field B applies for tem-
perature range 50...105 °C.
Example:
1500...2000 Ω
275...375 Ω
– Replace the coolant temperature sender -G62-

⇒ Chapter 24-1

not connected here.

S00.5309.04.20
gram.

-V.A.G. 1598/31-
1 93
2 108

tery positive. 1 2
Specified value: ∞ Ω S24-0341

S00.5309.04.20

S00.5309.04.20
24-3 Testing components I

Test engine speed sender
The engine speed sender -G28- is a speed and reference
marking sender. If the speed signal fails with the engine
running this could result in an engine stoppage.

♦ Test box -V.A.G 1598/31-
Test condition
Test sequence
– Disconnect the 3-pin plug connection from the engine V
speed sender -G28- ⇒ Chap. 24-1.
contact 1 (positive) and 3 (earth) of the plug for engine
speed sender.
Specified value: min. 4.5 V

If no voltage is present:

not connected here.
gram.

-V.A.G 1598/31-
1 87
2 82
3 108

If no fault was detected in the wiring and if there was no
voltage between contact 1 + 3:
– Replace engine speed sender -G28- ⇒ Chapter 24-1.
Edition 06.04 Testing components I 24-3 page 1

S00.5309.04.20

Testing injection valves
Test control
11 17 23
Special tools, test and measuring equipment and 1 6 12 18
31
24 32
auxiliary items required 2 7 13 19 25 33
3 8 14 20 26 34
♦ Test box -V.A.G 1598/31- 4
5
9 15 21 27 35
10 16 22 28 36
♦ Handheld multimeter, e.g. -V.A.G 1715- 39 49 59
29 37
30 38
♦ Diode test lamp e.g. -V.A.G 1527- 40 50 60
41 51 61
♦ Measuring tool set e.g. -V.A.G 1594 C- 42 52 62
43
♦ Current flow diagram 53 63
44 54 64
♦ Extractor -T 10094- 45 55 65
46 56 66
47 57 67
Test conditions 48 58 68
S01-0094
• Fuse 35 must be OK
• Earth connections between the engine (on gearbox
housing) and body (under battery) are o.k.
• Engine speed sender o.k.; check ⇒ 24-3 page 1.
• Check that the Hall sender is o.k. ⇒ Chapter 28-1.
• Fuel pump relay OK
Test sequence
Engines with the engine codes AUA, AUB

transformer.
Engines with the engine codes BBY, BBZ, BKY
– Pull out all ignition coils using the extractor -T 10094-.

For all vehicles
24-3 page 2 Testing components I Edition 06.04

S00.5309.04.20
– Connect up the diode test lamp to the contacts of the

plug for cylinder 1.
– Actuate the starter and check the power supply to the
injection valve of cylinder 1.
LED must flash.
1
– Repeat test on the plug connections for the injection
valves on cylinder 2 to 4.
If the LED does not light up on any cylinder:
2 S24-0344
– Connect the diode test lamp to the plug connection on

cylinder 1, contact 1 and earth.
– Actuate the starter and check the power supply to the
injection valve of cylinder 1.
LED must flash.
– Repeat test on the plug connections for the injection

valves on cylinder 2 to 4.
If the LED does not flash:

fuel pump relay -J17- for interruption according to the 1
Current Flow Diagram. S24-0345

If the LED does not light up on one or more cylinders:

S00.5309.04.20

not connected here.
– Check wiring between the test box and the 2-pin plugs 1 2
on the injection valves for interruption according to the
Injector Plug contact Test box bush

-V.A.G 1598/31-
1 2 96
2 2 97
3 2 88
4 2 89

S24-0343
– Check wiring between contacts 1 of the plug connec-

tion on the injection valves for interruption of each oth-
er.
Testing resistances of the injection valves
Test sequence
– Check resistance of the individual injection valves.
Specification at 20 °C: 14,0...17,0 Ω
If the engine is warm the resistance increases by approx-
imately 4 to 6 Ω.
– Replace the defective injection valve ⇒ Chapter 24-1.
Test spray pattern, leak tightness and injected

quantity

♦ Torque wrench
♦ Measuring tool set, e.g. -V.A.G 1594 C-
♦ Remote control, e.g. -V.A.G 1348/3 A-
♦ Adapter, e.g. -V.A.G 1348/3-2-
♦ Digital potentiometer, e.g. -V.A.G 1630-
♦ Measuring vessel, for example -V.A.G 1602-

S00.5309.04.20
Test conditions
• The fuel pressure must be OK, test it ⇒ 1.4/55; 1.4/74
Engine - Mechanics; Rep. Gr. 20.
• Fuel pump relay o.k., testing ⇒ Chap. 01-1, final con-
trol diagnosis.
• Fuel temperature 15... 20 °C, the fuel must conform to
the valid standards.
Test sequence
– Completely remove the fuel rail with all injection
valves from the intake manifold (the fuel hose remains
connected) ⇒ Chapter 24-1.
Testing jet formation and tightness

– Unplug the 2-pin plug for the coolant temperature sen-
sor -G62- -arrow-.
S24-0349
– Connect up digital potentiometer V.A.G -1630- to con-

tacts 1 + 2 of the plug connection and set the connect-
ed side to 15 kΩ.
V.A.G 1630
1
S24-0342

S00.5309.04.20
– Hold measuring vessel under the injection valve to be

tested and disconnect the plug on the other injection
valves.
– Have a 2nd mechanic actuate the starter. The injec-
tion valve must emit a pulsed jet of fuel.
– Repeat test at the other injectors. Make sure that only
the valve to be tested is connected.
The jet must be the same for all valves.
– Then check the injection valve for leaks. No more than

2 drops/min may trickle out.
If the fuel loss is greater than this:
– Switch off ignition. S24-0340

Testing fuel injected quantity
Note
When testing the injection rate also check the jet forma-
tion. The jet must be the same for all injection valves.
– Insert injector to be tested in a measuring glass, e.g.

-V.A.G 1602-.
– Connect a contact of the injector to be tested with
adapter cables to the battery earth.
– Connect the second contact of the injector to be test-
ed with remote control and adapter cable to positive
battery.
– 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.
– Activate remote control for 30 seconds.

– Repeat the measurement on all injectors. Always use S24-0340
a new measuring glass.
– After the measurement of all valves, deactivate the
voltage supply of the fuel delivery unit.
– Place the measuring glasses on a flat surface and
compare the quantities of fuel injected.
Nominal value per injection valve:
1.4/55 kW Engine: 57 ... 65 ml
1.4/74 kW Engine: 88 ... 98 ml
If the measurement obtained for one injector is not within
the specification:

The injectors are installed in the reverse order for remov-
al. Pay attention to the following:

S00.5309.04.20
♦ Replace the O-rings on all the injectors and moisten
lightly with clean engine oil.
♦ Fit the fuel rail with the installed injection valves to the
intake manifold and tighten screws uniformly to 10
Nm.
Testing the intake system for tightness

(unmetered air)
Testing with engine leak search spray

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Engine leak search spray (e.g. G 001 800 A1)
Test condition
• Coolant temperature must be at least 80 °C
⇒ Chapter 01-5 display group 001, display field 2.
Test sequence
Note
♦ Because of the vacuum in the intake system the leak
search spray is sucked in with the unmetered air. The
leak search spray reduces the ignition performance of
the mixture. This results in a drop in engine speed and
a change in the lambda probe voltage.
♦ You must comply with the safety instructions on the
box.

display group 033.
– Observe the control value in display field 1. 2.0% 0.462V
– Systematically spray parts of the intake system with
engine leak search spray.
If the engine speed drops or if the control values chang-
es:
– Check the sprayed location of the intake system for

leaks and if necessary eliminate the fault.
If the engine speed or control value does not change:

S00.5309.04.20
Testing intake manifold preheating

♦ Cooling spray
Testing control flap

– Remove air filter ⇒ Chap. 24-1.
– Check position of the regulating flap -1-.
♦ Above +23 °C the flap must close the hot air connec-
tion
♦ Below +10 °C the flap opens the hot air connection.
Note
Operation of the thermo-element -2- can easily be tested
by spraying on a cooling spray.
1
Idle testing
Note 2 S24-0332
♦ The idling speed, ignition point and CO content are

only measured as they cannot be adjusted.
♦ The idling speed is set to nominal value by the throttle
valve positioner together with the DLS function.
♦ The CO content is set to nominal value by the lambda
control. Faults in the lambda control are detected by
the self-diagnostic system and stored in the fault
memory.

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The exhaust system between the cylinder head and
the catalyst must be tight.
• Coolant temperature at least 80 °C ⇒ Chapter 01-5
display group 004, display field 3.
• All electrical components such as lights and rear win-
dow heater must be switched off.
• If vehicle is equipped with air conditioning, this must
be switched off.
Test sequence

S00.5309.04.20
– Interrogate fault memory, rectify any faults and then
erase the fault memory ⇒ Chapter 01-1.
Testing idling speed

display group 056.
– Check the operating condition in indicator field 4. 750/min 750/min 5Nm 00000
Specified value: 00000 (meaning ⇒ Chapter 01-7).
– Check nominal idling speed in display field 2.

Specified value:
Vehicles with engine code AUA: 750 rpm
Vehicles with the engine codes BBY, BKY: 760 rpm
Vehicles with automatic gearbox (engine codes AUA,
BBY, BKY): 680 rpm
Vehicles with engine code AUB: 840 rpm
Vehicles with engine code BBZ: 680 rpm
Note
The idling speed of the engine is increased if the battery
is heavily discharged or the engine is extremely overheat-
ed.
– Check idling speed in display field 1.

Specified value:
Vehicles with engine code AUA: 650 ... 850 rpm 1)

Vehicles with the engine codes BBY, BKY: 660 ... 860
rpm1)
Vehicles with automatic gearbox 580... 780 rpm1)
Vehicles with engine code AUB: 740 ... 940 rpm1)
Vehicles with engine code BBZ: 580 ... 780 rpm1)

If the idling speed is not reached:

⇒ Chapter 24-5.
– Perform a test drive.
– Interrogate the fault memory on the control unit again.
– Repeat idling speed test.
If the nominal values are again not reached:
– Test throttle valve control unit ⇒ Chapter 24-2.

– Inspecting engine operating conditions ⇒ Chapter
24-4.
– Testing intake system for tightness ⇒ Chap. 24-3.
1) Current value ⇒ Inspection and Maintenance.

S00.5309.04.20

S00.5309.04.20
24-4 Testing components II

Test lambda probe heating before cata-
lyst
-V.A.G 1551/3, 3A, 3B, 3C-
♦ Test box -V.A.G 1598/31-
Test conditions
11 17 23 31
1
• Fuses No. 3 and 9 must be O.K.
6 12 18 24 32
2 7 13 19 25 33
3 8
14 20 26 34
4 9 15 21 27 35
5 10 16
• The fuel pump relay must be OK.
22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
Test sequence 42 52 62
43 53 63
– Connect vehicle system tester -V.A.G 1552-. Start en- 44 54 64
gine and select the address word 01 „Engine electron- 45 55 65
ics“ ⇒ Chapter 01-1. 46 56 66
47 57 67
Engine idling. 48 58 68
S01-0094
display group 041.
– Check status of the lambda probe heater in display Ht. before c. ON 15 Ohm Ht. after c. ON
field 2.
Specified value: „Ht. before c. ON“.
Note
in display field 2 may show either „Htg. before C.ON“ or
„Htg. before C.OFF“.
– Remove the 6-pin plug -arrow- to the lambda probe

before the catalyst -G39-.
Note
Depending on the lambda probe version, the heater can
be connected to contacts 1 + 2 or 3 + 5 of the 6-pin plug
(only on engines with code letters BKY EU-4 and EU-
2DDK 05.04 ➤; the instructions for these engines are list-
ed below in the brackets).
S24-0347
Edition 06.04 Testing components II 24-4 page 1

S00.5309.04.20
– Check probe heater at connector for lambda probe,

contact 1 + 2 (3 + 5) for continuity. 1 3 5
Note
At ambient temperature the resistance of the heating ele-
ment should be approx. 1...5 . The resistance increases
considerably even if the temperature rises only slightly.
If there is an interruption in the lambda probe heating:
– Replace lambda probe upstream of the catalyst

-G39-.
If the probe heating has continuity:
S24-0346
2 4 6
– Switch the multimeter to voltage measurement and

connect it to contacts 1 + 2 (3 + 5) of the connector to
the engine control unit.
– Start engine and run in idle.
– Measure the voltage supply and at the same time ob-
serve display group 041, display field 2.
Display: „Ht. before c. ON.“
Specified value: 11.0...14.5 V
or
Display: „Ht. bf. c. ON“/„Ht. bf. c. OFF“ (alternately)
Specified value: fluctuating between 0...14.5 V


not connected here.
for interruption:

-V.A.G. 1598/31-
1 (3) 5
Specified value - line resistance: max. 1.5 Ω

– Check wiring from contact 2 (5) to fuel pump relay

-J17- according to the Current Flow Diagram
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
If wiring is o.k.:
24-4 page 2 Testing components II Edition 06.04

S00.5309.04.20
Testing lambda probe and lambda con-
trol upstream of catalytic converter
-V.A.G 1551/3, 3A, 3B, 3C-
♦ Test box -V.A.G 1598/31-
Test conditions
• Coolant temperature at least 80 °C ⇒ display group
004, display block 3.
• The exhaust system must be tight between the cata-
lyst and the cylinder head.
Check for proper operation

– Check status of the lambda control before catalyst
(display field 1):
Specified value: 111 111 110
Meaning of the 3-digit numerical block display

field 1:

1 2 3
1 Lambda control active
Note
The first digit of the 3-digit numerical block (heating) fluc-
tuates between 0 and 1.
– Test lambda probe heating before catalyst ⇒ 24-4

page 1.
System in basic setting 34 ->
– Select function 04 „Basic setting“ and display group 2350/min 244.0 C 0.25s Test ON
034.
– Blip 2 accelerations above 5000 rpm.

S00.5309.04.20
– Set engine speed to 1500...3900 rpm.

– Maintain speed until „Test ON“ is displayed in display
field 4.
– Run engine at this speed until display field indicates
specified value „B1-S1 O.K.“.
If „B1-S1 nok“ is shown in display field 4:
– Press key.
display group 033.
– Observe lambda control in display field 1. The readout 2.0% 0.462 V
must fluctuate in the region from -10.0...10.0 %.
– Read off voltage in display block 2. The voltage must
oscillate at least 20 times per minute in the region be-
tween 0 to 1.0 V.
If the display in display field 2 remains constantly on one
value:
– Continue test according to the following table:

between Open circuit Check voltage
0.400 .... ⇒ 24-4 page 4
0.500 V
1.105 V Short circuit to posi- Check lambda
tive probe wiring
0.000 V Short circuit to earth ⇒ 24-4 page 4
If the lambda control in display field 1 does not oscillate

in the given region:

– Conduct test drive and repeat test.
Comply with the applicable safety instructions for a test
drive ⇒ Chap. 24-1.
If the nominal value in display field 1 is still not reached
after a test drive or if the value does not fluctuate by at
least 2 %:
– Test basic voltage.
Test basic voltage

– Remove the 6-pin plug to the lambda probe before the
catalyst -G39-.
Note
Depending on the wide-band lambda probe version, it
can be connected to contacts 3+ 4 +5 + 6 or 2 + 1 + 4 +
6 of the 6-pin plug (only on engines with code letters BKY
EU-4 and EU-2DDK 05.04 ➤; the instructions for these
engines are listed below in the brackets).
S24-0347

S00.5309.04.20
contacts 3 + 4 (2 + 1) of the connector at the engine
wiring harness.
– Switch on ignition and measure voltage.


-G39-.
– Check lambda probe wiring.
Check lambda probe wire upstream of catalytic

converter
not connected here.
gram.

-V.A.G. 1598/31-
3 (2) 52
4 (1) 71
5 (4) 70
6 (6) 51
– Check wiring at plug contact 3 + 4 (2 + 1) for short-cir-

cuit to contact 1 + 2 (3 + 5).
Test lambda probe heating after catalyst

-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-

S00.5309.04.20
Test conditions
• Fuses No. 3 and 9 must be O.K. 11 17 23 31
• Battery voltage at least 11.5 V. 1
2
6
7
12
13
18
19
24 32
25 33
• The fuel pump relay must be OK.
3 8 14 20 26 34
4 9 15 21 27 35
5 10 16 22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
44 54 64
46
gine and select the address word 01 „Engine electron- 56 66
ics“ ⇒ Chapter 01-1. 47 57 67

48 58 68
– Select function 08 „Read measured value block“ and S01-0094
display group 041.
– Check status of the lambda probe heater in display Reading measured value block 41 ->
field 4. Ht. before c. ON 15 Ohm Ht. after c. ON
Specified value: „Ht. after c. ON“.
Note
in display field 4 may show either „Htg. after C.ON“ or
„Htg. after C.OFF“.
– Remove the 4-pin plug to the lambda probe -G130-

-arrow-.
S24-0348
– Check probe heater at connector for lambda probe,

contact 1 + 2 for continuity.
Note
At ambient temperature the resistance of the heating ele-
ment should be approx. 1...5 . The resistance increases
considerably even if the temperature rises only slightly.
If there is an interruption in the probe heating:
– Replace lambda probe after catalyst -G130-.

If the probe heating has continuity:

S00.5309.04.20
– Connect multimeter for voltage measurement to con-
tacts 1 + 2 (plug at engine wiring harness).
– Start engine and run in idle. V
– Measure the voltage supply and at the same time ob-
serve display group 041, display field 4.
Display: „Ht. after c. ON“
or
Display: „Ht. after c. ON“ / „Ht. after c. OFF“ (alternately)
Specified value: fluctuating between 0.0....14.5 V


not connected here.
for interruption:

-V.A.G. 1598/31-
2 63


If wiring is o.k.:
Testing lambda probe and lambda con-

trol after catalyst
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
Test conditions
• The coolant temperature must be at least 80°C, ⇒

S00.5309.04.20

– Check status of the lambda control after catalyst (dis- 111 110
play field 2):
Note
The 3rd bit in display field 2 is only set to 1 under partial
load (2500...4000 rpm).
Meaning of the 3-digit numerical block display

field 2:

1 2 3
x Lambda control active; specified value: 1/0
Note
♦ The lambda control of the lambda probe after catalyst
(B1-S2) is inactive without load.
♦ The first digit of the 3-digit numerical block (heating)
fluctuates between 0 and 1.
– Test lambda probe heating after catalyst ⇒ 24-4

page 5.

036.
– Depress brake pedal and hold pressed. The speed
automatically increases.
„ B1-S2 O.K.“ appears in display field 2.
0.856 V Test ON
If „B1-S2 n.o.k“ is shown in display field 2:
– Test lambda probe voltage 2 at idle in display field 1.

Specified value: 0,000…1.000 V
– Continue test according to the following table:

S00.5309.04.20

between Open circuit Check voltage
0.400.... ⇒ 24-4 page 9
0.500 V
1.105 V Short circuit to positive Check lambda
0.000 V Short circuit to earth probe wiring
⇒ 24-4 page 9
If the lambda control in display field 1 does not oscillate

in the given region:

– Conduct test drive and repeat test.
If the nominal value in display field 1 is still not reached
after a test drive or if the value does not fluctuate by at
least 2 %:
– Test basic voltage.
Test basic voltage

S24-0348
– Remove the 4-pin plug to the lambda probe -G130-
-arrow-.
– Connect multimeter for voltage measurement to con-
tacts 3 + 4 (plug at engine wiring harness).
– Switch on ignition and measure voltage.
Specified value: 0,40…0.50 V

– Replace lambda probe after catalyst -G130-.

– Check lambda probe wire downstream of catalytic

converter.
Check lambda probe wire downstream of cata-

lytic converter
not connected here.
gram.

-V.A.G. 1598/31-
3 68
4 69

S00.5309.04.20
– Check wiring of contact 3 + 4 of the plug for short-cir-

cuit to contact 1 + 2.
Check lambda probe ageing before cata-

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

– Select function 04 „Basic setting“ and display group 2300/min 244.0 C 0.25s Test ON
034.
– Blip 2 accelerations above 5000 rpm.
– Set engine speed to 1500...3900 rpm.
– Maintain this speed until the value in display field 4
jumps from „Test ON“ to „B1-S1 o.k.“.
Note
This may take a few mlnutes.
– Check period in display field 3:

Specified value: maximum 1.0 s
– Maintain the speed at 1500...3900 rpm until display

field 4 indicates nominal value „B1 S1 O.K.“.
– Conduct a test drive in order to eliminate any residues

on the lambda probe and repeat the test.
If the specified value is again not reached:

-G39-.

S00.5309.04.20
Testing the engine operating conditions
Note
Test whether the engine control unit detects the operating
conditions idling, trailing throttle, partial load, enrichment
and full load of the engine.

-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
Test sequence
– Test whether the control unit recognizes the operating 840/min 20% 0km/h Idling
conditions (display field 4):
♦ Idling
As long as the engine is idling, the following must be dis-

played: Idling.
♦ Trailing throttle
– Engine speed must increase to more than 3000 rpm.

– Suddenly close the throttle valve.
As long as the speed is above 1400 rpm the following
must be displayed. Trailing throttle.
Note
Once engine speed is below 1400 rpm idling is again dis-
played.
♦ Partial load
– Accelerate constantly.
As long as the acceleration is constant the following must
be displayed: Partial load.
♦ Enrichment
– Push the accelerator pedal down sharply to the stop.

When accelerating the following must be briefly dis-
played: Enrichment.

S00.5309.04.20

– Interrogate fault memory, rectify any faults and erase

fault memory ⇒ Chap. 01-1.
– Test throttle valve control unit ⇒ Chapter 24-1.

S00.5309.04.20
24-5 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.
♦ The advantage being that the electronic engine con-
trol remains fully operational with the test box con-
nected (e.g. measuring signals while the engine is
running).
♦ Whether the control unit remains connected to the test
box or not, is described in the relevant test proce-
dures.
♦ The contact numbers of the connector of the control
unit and the socket numbers of the test box are iden-
tical.

– Release the connector catches and unplug the control
unit connectors.
– Connect test box -V.A.G 1598/31- to connector of wir-
ing loom. The earth clip of the test box must be con-
nected to the negative battery terminal.
– Perform test as described in the relevant repair se-
quences.
DANGER!
To avoid damaging the electronic components,
switch on the relevant measuring range before
connecting the measuring cables and comply with
the test conditions.
V.A.G. 1598/31
S01-0089
Testing voltage supply for engine con-
trol unit
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
Edition 06.04 Engine control unit 24-5 page 1

S00.5309.04.20
Test conditions
• Battery voltage at least 11.5 V. 11 17 23 31
• Fuses No. 3, 14, 17, 48, and 56 must be OK. 1
2
6
7
12
13
18
19
24 32
25 33
• AC generator o.k., test: ⇒ Electrical system;
3 8 14 20 26 34
4 9 15 21 27 35
Rep. Gr. 27. 5 10 16 22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
44 54 64
46
gine and select the address word 01 „Engine electron- 56 66
ics“ ⇒ Chapter 01-1. 47 57 67

48 58 68
– Select function 08 „Read measured value block“ and S01-0094
display group 004.
– Read off readout in display field 2. Reading measured value block 4 ->
840 rpm 13.6V 91 C 62 C

– Connect test box -V.A.G 1598/31- to connector of wir-

ing loom ⇒ 24-5 page 1. The engine control unit is
not connected here.
Testing voltage of terminal 30

– Measure supply voltage between sockets 1 + 3 of the
test box:
– Test cable connections to relay plate according to the

current flow diagram ⇒ Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations.
Testing voltage of terminal 15

– Use multimeter to measure voltage between sockets
2 + 4 at the test box.
– Test cable connections to relay plate according to the

current flow diagram ⇒ Current Flow Diagrams, Elec-
trical 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
24-5 page 2 Engine control unit Edition 06.04

S00.5309.04.20
which the vehicle has driven, this may result in consider-
able driveability problems.

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
After the voltage supply has been interrupted, it is neces-
sary to carry out the following steps:
– Switch ignition on for at least 10 seconds.

– Switch ignition off for at least 30 seconds.
⇒ 24-5 page 6.
– Performing idling test ⇒ Chap. 24-4.
On vehicles with an automatic gearbox the gearbox con-
trol unit must also be adapted.
– Conduct a lengthy test drive until the problems have

been rectified.
must be fulfilled:
♦ After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a
number of times: Idling, part load, full load, overrun.
yond 3500 rpm.
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:
036906034T MARELLI 4LV 2615 ->
The control unit identification number and the coding are
Coding 00031 WSCXXXXX
shown on the display, e.g.:

S00.5309.04.20

– Release the connector catches and unplug the con-
nector -arrow- from the control unit.
S10-0111
– Press open the latches of the fixture -arrows A- and

pull the engine control unit forward -arrow B-.
– Release the catch of the second connector and un- A
plug the connector from the control unit.
Installation is carried out in the reverse order.
B
– Check current coding and code new control unit
⇒ 24-5 page 5. A
– Adapt engine control unit to control unit for electronic
immobiliser ⇒ Electrical System; Rep. Gr. 96.
– Activate cruise control system function in engine con-
trol unit (on vehicles with CCS the lever for the CCS is
located on the left below the steering wheel) ⇒ Chap.
24-6. S24-0337
– Adapt the new control unit to the throttle valve control
unit ⇒ 24-5 page 6.
– Adapt potentiometer for exhaust gas recirculation.
– Select function 04 „Basic setting“ and display group 0.9V 3.8V 0.968V ADP. O.K.
070 when ignition is switched on.
Specification in display field 4:
ADP runs
ADP O.K.
– Deactivate adaptation by pressing the button .
Note
– Finally interrogate the fault memory of the new engine

control unit and if necessary erase.
– Performing idling test ⇒ Chap. 24-4.
– Generate readiness code ⇒ Chapter 01-2.

S00.5309.04.20
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 neces-
sary to code the control unit as follows.

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Code control unit Q
– Select function 07 „coding control unit“. Enter code number XXXXX (0-00127)
– Enter the relevant code number of the vehicle and
confirm with button Q .
Code for vehicles with

number
00001 Gearbox
00011 Gearbox and ABS
00021 Gearbox and airbag
00031 Gearbox, ABS and airbag
00041 Gearbox and air conditioning system
00051 Gearbox, air conditioning system and ABS
00061 Gearbox, air conditioning system and air-
bag
00071 Gearbox, air conditioning system, ABS and
airbag
00003 Automatic gearbox
00013 Automatic gearbox and ABS
00023 Automatic gearbox and airbag
00033 Automatic gearbox, ABS and airbag
00043 Automatic gearbox and air conditioning
system
00053 Automatic gearbox, air conditioning system
and ABS
00063 Automatic gearbox, air conditioning system
and airbag
00073 Automatic gearbox, air conditioning sys-
tem, ABS and airbag
036906034T MARELLI 4LV 2615 ->
The control unit identification number and the coding are Coding 00031 WSCXXXXX
shown on the display, e.g.:
Function unknown or cannot ->
If this display appears, an incorrect code number has
be carried out at the moment
been entered.

S00.5309.04.20
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:
♦ Handling problems (jerky gear change, load change
jolts etc.)
♦ 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)
♦ Reduction of the gearbox life
Adjusting the engine control unit to the

throttle valve control unit
This adaptation teaches the engine control unit the vari-
ous positions of the throttle valve with the ignition on and
the engine stopped. These positions are stored in the en-
gine control unit. The feedback of the throttle valve posi-
tion 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
Note

-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• There must not be any fault present in the fault mem-
ory ⇒ Chap. 01-1, Interrogating fault memory.
• Engine not running, ignition switched on.
• Accelerator pedal fully released.
• The throttle valve must be in idling speed position.

S00.5309.04.20
• The coolant temperature must be 5...95 °C ⇒ display
group 004, display field 3.
• When using the cruise control system, it must be cor-
rectly set.
Procedure
– Select function 04 „Basic setting“ and display group 2% 95% 5 ADP. running
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 val-
ue. 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 previ-
ously 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 con-
trol unit.
If during driving the engine control unit switches the throt-
tle valve positioner dead, this is indicated by a fluctuating
increased idling speed. The engine then has a very poor
throttle response.
– Check the specified values for the throttle valve posi- 2% 95% 12 ADP o.k.
tioner control unit in display fields 3 and 4.
Specification in display field 3: 12
Specification in display field 4:
ADP runs
ADP O.K.
The adaptation was successfully performed.
To store the values:
– Switch ignition off for at least 30 seconds.
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.

S00.5309.04.20
♦ 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.

S00.5309.04.20
24-6 Testing auxiliary signals

Testing the speed signal
♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ 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-
Test conditions
• Battery voltage must be at least 11.5 V.
• Speedometer o.k., testing ⇒ Electrical System;
Rep. Gr. 90.
• Fuse 56 o.k.
Test sequence
Note
♦ The vehicle must be driven in order to test the vehicle
speed signal. The assistance of a second person is
required.
♦ Pay attention to safety precautions for test drives
⇒ Chap. 24-1.
– Connect vehicle system tester -V.A.G 1552 -. Leave

the engine on and select address word 01 „Engine
electronics“ ⇒ Chap. 01-1.
– Select function 08 „Reading measured value block“
and display group number 005.
– Determine by means of a test drive whether the driv- 1380 rpm 20 % 15 km/h Enrich-
ing speed is displayed in display field 3.
– Select function 06 „End output“ and switch off ignition.
– Connect the test box-V.A.G 1598/31- to the wiring

loom on the engine control unit ⇒ Chap. 24-5. The
engine control unit is not connected.
– Connect the multimeter for voltage measurement be-
tween the bushes 4 (Term. 15) + 54 (speed signal) of
the test box.
– Switch on the ignition.
– Raise the front left side of the vehicle.
– Turn the front left wheel by hand.
Diode test lamp must flash (very short signal).
If the diode test lamp does not flash:
Edition 03.01 Testing auxiliary signals 24-6 page 1

S00.5309.02.20
– Test the wiring to the speedometer and to the speed-

ometer sender ⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
Testing signals from/to the air condition-

ing system
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The air conditioning system must be switched off.
• There must not be any fault in the fault memory, inter-
rogate fault memory ⇒ Chap. 01-1.
Test sequence
– Readout on display: 830/min 840/min off off
– Observe display field 2.
Specified value: 840/min
Specifications in display fields 3 and 4: „off“
– Switch on the air conditioning system.

– Observe display field 2.
Specified value: 870/min
Specifications in display fields 3 and 4: „on“

– Test the air conditioning system ⇒ Heating, Air Con-

ditioning; Rep. Gr. 01.
– Check the CAN databus ⇒ 24-6 page 7.
Test brake light switch -F- and brake

pedal switch -F47-
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
24-6 page 2 Testing auxiliary signals Edition 03.01

S00.5309.02.20
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
Test conditions
• Fuses Nos. 2 and 28 O.K.
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Switch
the ignition on and select address word 01 „Engine
Electronics“ ⇒ Chap. 01-1.
– Check the display value in display field 2. 0 km/h 0000 0 km/h 0000
Specified value: „x x 0 0“
– Operate brake pedal

Specified value: „x x 1 1“

– Remove the bottom part of the dash panel on driver

side ⇒ Body Fitting Work; Rep. Gr. 70.
– Unplug the connector from the brake light/brake pedal
switch.
between contact 1 and 4.

Specified value: max. 1.5 Ω 4 1
Specified value: max. 1.5 Ω

Specified value: ∞ Ω S24-0458
– Replace the brake light/brake pedal switch.

– Test the cable to the sender for open circuit and for
short circuit to battery positive or earth ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.

S00.5309.02.20
Testing clutch pedal switch -F36-

Signal from clutch pedal switch -F36- is used for avoiding
engine overrevving and load change jolts when the clutch
is released.

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
11 17 23
♦ Handheld multimeter, e.g. -V.A.G 1526 A- 1 6 12 18 24
31
32
2 7 13
♦ Adapter cable set, e.g. -V.A.G 1594 A- 3 8 14
19
20
25 33
26 34
4 9 15 21 27 35
5 10 16 22 28 36
Test condition 39 49 59
29 37
30 38
40 50 60
• Fuse 28 must be o.k. 41 51 61
42 52 62
43 53 63
45 55 65
– Connect vehicle system tester -V.A.G 1551 -. Switch 46 56 66
47
the ignition on and select address word 01 „Engine 57 67

48 58 68
S01-0094
– Check the display value in display field 2. 0 km/h 0000 0 km/h 0000
Specified value: x0xx
– Operate clutch pedal.

Specified value: x1xx

– Remove the bottom part of the dash panel on driver

side ⇒ Body Fitting Work; Rep. Gr. 70.
– Unplug the connector at the clutch pedal switch.
Specified value: max. 1.5 Ω
– Operate clutch pedal. 4 1

– Replace the clutch pedal switch -F36-.

S24-0458
– Test the cable to the sender for open circuit and for
short circuit to battery positive or earth ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.

S00.5309.02.20
Activating and deactivating cruise con-
trol system (CCS)
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• There must not be any fault in the fault memory
⇒ Chap. 01-1, Interrogating fault memory.
Test sequence
036906034F MARELLI 4LV G 2615 ->
Readout on display, e.g.: Coding 00031 WSC XXXXX
If „MARELLI 4LV G“ is displayed, CCS is activated.
036906034F MARELLI 4LV 2615 ->
Readout on display, e.g.: Coding 00031 WSC XXXXX
If „MARELLI 4LV“ is displayed, CCS is not activated.
Login procedure
– Press and select function 11 „Login procedure“. Enter code number XXXXX
Enter the code number by referring to table below and
confirm entry with Q .
Code number Cruise control system (CCS)

11463 Cruise control system (CCS) is acti-
vated
16167 Cruise control system (CCS) is deac-
tivated

Conduct a test drive after activating the CCS.
Testing CCS
With the exception of an operating switch the CCS does
not have any components of its own. All functions are
performed by the engine control unit. The minimum vehi-
cle speed for the CCS function is 30 km/h.

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• Activate CCS ⇒ 24-6 page 5.

S00.5309.02.20
Test sequence
– Read off the values in display fields 2 and 4. 0 km/h 0000 0 km/h 0000
Display field 2
Specified value:
1xxx - CCS activated
0xxx - CCS deactivated
Display field 4
Test condition Display field

4
Switch -B- locked to „OFF“ 0000
Switch -B- to „OFF“ before operating 00011)
point
Switch -B- to „ON“ 0011
Switch -B- to „RES“ 1011
Switch -A- pressed (switch -B- to „ON“) 0111
1) Not active at present.
A B N23-0199

– Test wiring to CCS switch for open circuit as well as
short circuit to earth and to positive ⇒ Current Flow
Diagrams, Electrical Fault Finding and Fitting Loca-
tions.
Testing gear signal

Only for vehicles with autom. gearbox
The engine control unit receives from the gearbox control
unit the information: Gear engaged (selector lever in 1/2/
3/R/D) or no gear engaged (selector lever in P or N)

-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• The selector lever of the automatic gearbox must be
in position „P“ or „N“.
• Air conditioning switched off.

S00.5309.02.20
Test sequence
– Test the value in display field 4. 840 rpm 840 rpm 5 Nm 00000
Specified value:
00000 (selector lever in P or N)
00010 (selector lever in 1/2/3/R/D)

– Check the data bus ⇒ 24-6 page 7.
Test data bus

Operation
The engine control unit communicates over a CAN data-
bus with all the control units with databus capability.
The control units with databus capability are linked by two
twisted databus cables (CAN_High and CAN_Low) and
exchange information (messages). Both the engine con-
trol unit and the other CAN data bus control units detect
missing information on the data bus as faults.
Test condition
• A fault is detected by the CAN databus by self-diagno-
sis.

♦ Test box -V.A.G 1598/31-
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
Test sequence
– Switch off the ignition.
– Release the connector of the engine control unit and
unplug it.
– Connect test box -V.A.G 1598/31 - to engine control
unit ⇒ Chap. 24-5. Wiring loom to control unit is not
connected.
– Test the central terminating resistor in the engine con-
trol unit.
– To to this, conduct a resistance measurement be-
tween test box sockets 58 and 60.
Specified value: 60...72 Ω

S00.5309.02.20
If the resistance value is not within the nominal value

range:
– Replace the motronic control unit ⇒ Chap. 24-5.

If the resistance value is within the nominal value range:
– Test the CAN databus ⇒ Electrical System;

Rep. Gr. 90.

S00.5309.02.20
28 – Ignition System
28-1 Repairing ignition system
General notes on the ignition system

♦ This section specially deals with the components in
the ignition system. For other components of the injec-
tion and ignition system ⇒ Rep. Gr.24.
♦ Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV con-
trol unit.
♦ The engine control unit is equipped with a self-diagno-
sis system.
♦ Components marked with an * are checked by self-di-
agnosis ⇒ Chapter 01-1.
♦ A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components.
♦ Before repairs and for fault finding interrogate the fault
memory ⇒ Chap. 01-1.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to inter-
rogate the fault memory after having completed all
inspections and repairs, and if necessary erase
⇒ Chapter 01-1.
♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is pos-
sible that the immobiliser blocks the 4AV control unit.
The fault memory must then be interrogated and if
necessary adapted to the engine control unit
⇒ Chapter 24-5.
Safety measures ⇒ 28-1 page 3.
Setting data, spark plugs ⇒ Inspection and Maintenance.
Edition 06.04 Repairing ignition system 28-1 page 1

S00.5309.04.20
Removing and installing parts of the ignition system for engines with the engine
codes AUA, AUB
1 - Ignition lead
❑ with shielded plug and spark-
plug
❑ Resistor 4.8...7.2 kΩ
2 - Ignition transformer -N152-
❑ with identification for ignition
leads:
A = Cylinder 1
B = Cylinder 2
C = Cylinder 3
D = Cylinder 4
❑ check ⇒ 28-1 page 6
❑ Fitting location ⇒ Chapter
24-1
3 - Connector
❑ 4-pin
❑ for ignition transformer
-N152-
4 - 10 Nm
5 - Connector
❑ 2-pin
❑ for knock sensor 1 -G61-
❑ Contacts of connector gold-
plated
6 - Knock sensor 1 -G61- *
24-1
7 - 20 Nm
❑ The tightening torque influ-
ences the knock sensor func-
tion
8 - Connector
❑ 3-pin
❑ for hall sender -G40-
❑ Fitting location ⇒ Chapter 24-1
10 - O-ring
11 - Ignition lead guide
12 - Spark-plug, 30 Nm
❑ use of the spark plug wrench e.g. -3122 B- for removing and installing
❑ type and electrode gap ⇒ Inspection and Maintenance
28-1 page 2 Repairing ignition system Edition 06.04

S00.5309.04.20
Removing and installing parts of the ignition system for engines with the engine
codes BBZ, BBY, BKY
1 - Connector
❑ 4-pin
2 - Ignition coils with a power
output stage
-N70, N127, N291, N292-
❑ remove with extractor
-T 10094-
3 - Connector
❑ 2-pin
❑ for knock sensor 1 -G61-
4 - Knock sensor 1 -G61- *
24-1
5 - 20 Nm
❑ The tightening torque influ-
ences the knock sensor func-
tion
6 - Connector
❑ 3-pin
❑ for hall sender -G40-
24-1
8 - O-ring
9 - 10 Nm
10 - Spark-plug, 30 Nm
❑ use of the spark plug wrench
e.g. -3122 B- for removing and installing
❑ type and electrode gap ⇒ Inspection and Maintenance
11 - Bracket
❑ Tighten at cylinder head cover to 5 Nm
Safety measures
Observe the following points to prevent injury to persons
and/or damage to the injection and ignition system:
♦ Do not touch or remove ignition leads with the engine
running or at start speed.
♦ Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and igni-
tion system as well as of test equipment.

S00.5309.04.20

rear seat and also have a second person operate
them there.
♦ If the engine must be operated at start speed without
the engine starting:
Engines with the engine codes AUA, AUB

transformer.
Engines with the engine codes BBY, BBZ, BKY
– Remove the connector and pull out all ignition coils

with extractor -T 10094-.
For all vehicles
Testing hall sender

♦ Test box -V.A.G 1598/31-
Test condition
Test sequence

S00.5309.04.20
– Disconnect the 3-pin plug connection from Hall sender
-arrow-.

contact 1 (positive) and 3 (earth) of the plug for the
Hall sender. V


control unit ⇒ Chapter 24-5.
gram.

-V.A.G 1598/31-
1 98
2 86
3 108

If no fault was found in the cables and the specified volt-
age measured between contacts 1 + 3:
– Replace hall sender -G40-.


S00.5309.04.20
Checking the ignition transformer (for

engines with the engine codes AUA,
AUB)
♦ Test box -V.A.G 1598/31-
♦ Diode test lamp e.g. -V.A.G 1527-
Test conditions
• The hall sender must be OK, test it ⇒ 28-1 page 4.
• The engine speed sender must be O.K., test it
⇒ Chapter 24-3.
Test sequence
transformer.
Checking voltage supply 11 17 23 31

1 6 12 18 24 32
2 7 13 19 25 33
3 8 14
Test condition 4 9 15
20
21
26 34
27 35
5 10 16 22
• Fuse 52 must be o.k.
28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
43 53 63
44 54 64
45 55 65
46 56 66
47 57 67
48 58 68
S01-0094
– Measure power supply between contacts 2 + 4 of the

removed plug using the multimeter.
– Switch on ignition. V


S00.5309.04.20
relay plate for interruption according to the Current
Flow Diagram.

earth for interruption according to the Current Flow Di-
agram.
Test control
WARNING!
During the following test do not touch neither the
connecting parts of the ignition transformer nor
the auxiliary cables.
– Connect the diode test lamp to contacts 1 + 4 (ignition

outlet 1) and contacts 3 + 4 (ignition outlet 2) of the re-
moved plug.
– Actuate the starter and check the ignition signal on the
engine control unit. The LED must flash.
If the LED flashes and there is a voltage existing between
contact 2 and 4:
– Replace ignition transformer -N152- ⇒ item 2 in 28-1

page 2.
If the LED does not flash:
– Test wiring ⇒ 28-1 page 8.

S00.5309.04.20
Checking wires
not connected here.
gram.

-V.A.G 1598/31-
1 102
3 103

If no fault was detected in the wiring and if there is a volt-
age detected between contact 2 and 4:
Testing secondary resistances

– Test secondary resistances on terminal 4 between
cylinder 1 + cylinder 4 and cylinder 2 + cylinder 3.
Specified value: 4,0 ... 6.0 kΩ (at 20 °C)
– Replace ignition transformer -N152- ⇒ item 2 in 28-1

page 2.
Check ignition coils with power output

stage (engines with engine codes BBY,
BKY, BBZ)
♦ Test box -V.A.G 1598/31-
♦ Diode test lamp e.g. -V.A.G 1527 B-
Test sequence
Note
Ignition coil and power output stage form a building unit.
Cylinder, which does not operate or misfire, determine as
follows:
– Test combustion misfiring ⇒ 28-1 page 13.

S00.5309.04.20
If a combustion misfiring was detected:
– Proceed with test on cylinder determined as defective.

If no combustion misfiring was detected:
– Successively remove contacts of the injectors while

engine is running and monitor engine run,
or
– Compare spark plugs of all cylinders and pay attention

to contaminated (covered with soot) electrodes.
If a defective cylinder was determined:
– Replace the spark plug of the defective cylinder with

the one of another cylinder.
If the fault on this spark plug still exists:
– Replace spark plug.

If the given cylinder is still defective:
– Replace the ignition coil of the defective cylinder with

the one of another cylinder.
If the fault on this ignition coil still exists:
– Replace ignition coil.

If the given cylinder is still defective:
– Remove the 4-pin plug -1...4- from the ignition coils

and check wiring ⇒ Current Flow Diagrams, Fault
Finding and Fitting Locations.
Checking voltage supply

– Unplug the 4 pin plug connections from all ignition
coils.
Test condition
• The fuses of the ignition system must be in proper or-
der ⇒ Current Flow Diagrams, Fault Finding and Fit-
ting Locations.
– Measure the voltage supply beween contacts 2 + 4

and 3 + 1 of the removed plug using the multimeter
and the adapter cables from the measuring tool set.


S00.5309.04.20

relay plate for interruption according to the Current
Flow Diagram.
– Check the cable between 4-pin plug contact 2 + earth

and contact 1 + earth for interruption according to the
Test control
WARNING!
Caution! During the following test do not touch
neither the connecting parts of the ignition coils
nor the auxiliary cables.
– Connect the diode test lamp V.A.G 1527 with adapter

cables from V.A.G 1594 to contacts 1 + 4 of the re-
moved plug.
– Actuate the starter and check the ignition signal on the
engine control unit.
The LED must light up.

If the diode lights up and there is a voltage existing be-
tween contacts 1 + 4:
– Replace ignition coil.

If the LED does not light up:
– Check wires.

S00.5309.04.20
Checking wires
– Connect test Box V.A.G. 1598/31 to wiring loom of the
control unit. The engine control unit is not connected.
gram:
Plug contact 4 Test box bush

cylinder: -V.A.G 1598/31-
1 102
2 103
3 94
4 95

If no fault has been determined on the wiring and there is
a voltage between contacts 2 + 3:
Testing knock sensor
Note
♦ The perfect functioning of the knock sensor requires
an exact tightening torque of 20 Nm.
♦ Only use gilded contacts to repair contacts in the plug

♦ Test box -V.A.G 1598/31-

S00.5309.04.20
Test condition
• Faults on the knock sensor detected by self-diagnosis
⇒ Chapter 01-1, interrogate fault memory and erase.
Test sequence
– Disconnect the 2-pin plug from the knock sender -ar-
row-.
not connected here.
gram.

-V.A.G 1598/31-
1 106
2 99

– Slacken knock sensor and then tighten again to 20

Nm.
– Perform a test drive.
Comply with the safety instructions for a test drive
⇒ 28-1 page 3.
must be fulfilled:
♦ After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a
number of times: Idling, part load, full load, overrun.
yond 3500 rpm.
– Interrogate the fault memory on the control unit again.

If the fault still exists:
– Replace knock sensor -G61-.

S00.5309.04.20
Test combustion misfiring
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• Driving
Test sequence
display group 014.
– Read off value in display block 4. 840/min 17% 0 activated
Specified value: „activated“.
– Check the number of combustion misfirings in indica-

tor field 3.
Specified value: 0.

– Changeover in indicator group 015.

– Read off value in display block 4. 0 0 0 activated
Specified value: „activated“.
– Check misfiring combustion in the indicator fields 1 to

3, cyl. 1...3.
Nominal values: 0.
– Changeover in indicator group 016.

– Read off value in display block 4.
Specified value: „activated“ 0 activated
– Check the number of combustion misfirings in indica-
tor field 1, cyl. 4.
Specified value: 0.
If the nominal values in the display groups 015 and 016
are achieved:

– Eliminate fault ⇒ Chapter 01-3, Analysing display

group 015 and 016.

S00.5309.04.20

S00.5309.04.20

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 06.04 List of Supplements

List of Supplements Edition 06.04

24 – Fuel Formation, Injection

Edition 06.04 Table of Contents I

- Safety measures ...................................................................................... 24-1 page 12

Table of Contents Edition 06.04

Edition 06.04 Table of Contents III

Table of Contents Edition 06.04

Properties of the self-diagnosis

Technical data of self-diagnosis

Control unit identification:

Edition 06.04 Self-diagnosis I 01-1 page 1

Engine identification characters AUA, AUB BBY, BBZ BKY

Functions available when using the vehicle sys-

01-1 page 2 Self-diagnosis I Edition 06.04

Functional test: CHECK

– Switch on ignition: the EPC warning lamp must light

– Start engine and run in idle. The EPC warning lamp

– Interrogate fault memory, rectify any faults existing

Meaning of the exhaust gas warning light

condition. In this driving condition only low perform-

Edition 06.04 Self-diagnosis I 01-1 page 3

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

– Check the dash panel insert and the exhaust gas

– Start engine and run in idle. The gas warning light

– Interrogate fault memory, rectify any faults existing

Connecting up the vehicle system tester

01-1 page 4 Self-diagnosis I Edition 06.04

Interrogating and erasing fault memory

Special tools, test and measuring equipment and

Edition 06.04 Self-diagnosis I 01-1 page 5

– Operate starter for about 6 seconds. after this do not

If one or several faults are stored:

– Select function 06 „End output“ and switch ignition off.

Automatic test sequence

– Select address word 00 „Automatic Test Sequence“.

01-1 page 6 Self-diagnosis I Edition 06.04

– Select function 06 „End output“ and switch ignition off.

Performing actuator diagnosis

4. Engine speed sender -G28- 1)

Special tools, test and measuring equipment and

Edition 06.04 Self-diagnosis I 01-1 page 7

Activate throttle valve positioner -V60-:

– Test throttle valve positioner ⇒ Chapter 24-2, test

Activate solenoid valve 1 for activated charcoal

– Detach hose from the activated charcoal filter at the

– Continue test ⇒ 01-1 page 10.

01-1 page 8 Self-diagnosis I Edition 06.04

– Continue test ⇒ 01-1 page 11.

Engine speed sender -G28-: (Ignore)

Activate fuel pump relay -J17-:

– Select function 06 „End output“ and switch ignition off.

Engine/air conditioning compressor electrical

Edition 06.04 Self-diagnosis I 01-1 page 9

Continuing test if the activated charcoal filter

– Connect diode testing lamp to the unplugged plug.

– Proceed with the final control diagnosis up to the end.

– Proceed with the final control diagnosis up to the end.

Plug contact Test box bush

– Line resistance: max. 1.5 Ω