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Service
Polo Estate 1998 ➤

Diesel direct injection and glow plug system
Engine ID AEY AHB AHU AKW ALE AFN
Edition 05.1998
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
01 - Self-diagnosis
23 - Mixture preparation, Injection
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their careful
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and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg 00056405620

Diesel direct injection and glow plug system - Edition 05.1998
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Features of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Connecting fault reader V.A.G 1551 and selecting engine electronics control unit . . . . . . . .2
2 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2 Interrogating fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.3 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Performing final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.1 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.3 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.4 Evaluating measured value block, engine code AEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.5 Evaluating measured value blocks, engine codes AHB, AKW . . . . . . . . . . . . . . . . . . . . . . . .26
4.6 Evaluating measured value blocks, engine codes AFN, AHU, ALE . . . . . . . . . . . . . . . . . . . .33
23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

1 Servicing Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.1 Servicing Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
1.2 Safety precautions . . A. G. ..V.ol.ks. w. a.g.en. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
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1.3 Rules for cleanliness wage . . . . . . . . . . . . .d.oe.s.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
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1.4 Fitting locations
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overview . . . . . . . . . . . . . . . .ua.ra.n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
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1.5 Servicing
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ho injection pump . . . . . . . . . . . . . . . . . . . te.e.o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
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1.6 Setting
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engine to number 1 cylinder with engine removed c . . . . . . . . . . . . . . . . . . . . . . . . . .58
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1.7 Checking throttle valve positioner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

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1.8 Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

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1.9 Dynamically checking and adjusting commencement of injection . . . . . . . . . . . . . . . . . . . .66

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1.10 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

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1.11 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

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1.12 Servicing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

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1.13 Renewing injection timing device cover O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

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2 Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

2.1 Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
2.2 Checking Diesel direct injection system voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
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2.3 Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

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2.4 Checking intake manifold pressure sender and altitude sender . . . . . . . . . . . . . . . . . . . . . .77
2.5 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
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2.6 Checking brake light switch and brake pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
2.7 Checking clutch pedal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
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2.8 Checking intake manifold sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

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2.9 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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2.10 Checking fuel temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

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2.11 Checking modulating piston movement sender and quantity adjuster . . . . . . . . . . . . . . . . . .95
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2.12 Checking needle lift sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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2.13 Checking injection timing control range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
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2.14 Checking throttle valve positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
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2.15 Checking exhaust gas recirculation and air mass meter function . . . . . . . . . . . . . . . . . . . .111
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2.16 Checking speedometer sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

3 Replacing, coding and matching engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
3.1 Replacing, coding and matching engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
3.2 Replacing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
3.3 Coding engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
3.4 Matching engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
1.2 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
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ii Contents
01 - Self-diagnosis
1 - Self-diagnosis
1.1 - Self-diagnosis
1.2 - Features of self-diagnosis
The control unit for the Diesel direct injection system is equipped with a fault memory.
If faults occur in the sensors and components being monitored, they will be stored in the fault memory together
with an indication of the type of fault.
Faults which only occur sporadically will have the addendum "sporadic fault" on the print out. These faults will
be indicated on the display by the addendum "/SP". The cause of sporadic faults can be e.g. a loose contact
or a brief open circuit. If a sporadic fault does not occur again within 50 engine starts, it will be erased from the
fault memory.
If faults are recognized, that affect the driving condition then the glow period warning lamp flashes.
The faults stored can be read-out with the fault reader V.A.G 1551 or the vehicle system tester V.A.G 1552 =>
Page 4 .
The fault memory must be erased after the faults has been eliminated => Page 12 .
Note:
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1.3 - Technical data of self-diagnosis

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◆ The data transfer between control unit and fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 is
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carried out in the operating mode "Rapid data transfer".

◆ Fault memory: Non-volatile memory and volatile memory1)

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1) Will be cancelled after 50th engine start if fault has not occurred again.
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Interrogating control unit versions

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The control unit version is displayed when the fault reader V.A.G 1551 or the vehicle system tester V.A.G 1552
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Selectable functions when using the fault reader V.A.G 1551 or V.A.G 1552
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The prerequisites for selecting the desired functions can be taken from the following table.
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1.1 - Self-diagnosis 1
Selectable functions under address word 01, engine electronics
Function Prerequisite
Functions on fault reader V.A.G 1551 or Engine stopped, igni‐ Engine running at Vehicle being driven
on system tester V.A.G 1552 tion switched on idling speed
01 Interrogate control yes yes yes
unit version
02 Interrogate fault mem‐ yes1) yes yes
ory
03 Final control diagno‐ yes yes no
sis
04 Basic setting no yes no
05 Erase fault memory yes yes yes
06 End output yes yes yes
07 Code control unit2) yes no no
08 Read measured value yes yes yes
block
1) Only carry out with ignition switched on, when engine does not start.
2) Function not for engine code AEY with MSA12 engine control unit
1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit
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Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
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◆ -> V.A.G 1551 Fault reader

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The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
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2 01 - Self-diagnosis
◆ -> V.A.G 1551/3A cable
Test conditions AG. Volkswagen AG d

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• Fuse 21 OK.
• Earth connections on engine and gearbox OK.
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Work sequence
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- -> Fold driver's side stowage compartment down.
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- Connect fault reader V.A.G 1551 with cable V.A.G 1551/3.
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After the fault reader has been connected:

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- Depending upon desired function:
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Switch ignition on
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Start engine => Page 1 , Table "Selectable functions".
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Notes:
◆ If the display does not indicate as described in the work sequence:
=> Fault reader operating instructions

◆ If due to an input fault "Fault in the data transfer!" is displayed, pull wire off fault reader, reconnect and repeat
work step.
-> Indicated on display:

V.A.G - Self-diagnosis HELP
1 - Rapid data transfer*
2 - Flash code output*
* Appears alternately
- Operate fault reader taking into account the information on the display:
- Press key 1 for "Rapid data transfer".
- Press keys 0 and 1 for address word "Engine electronics" and confirm entry with Q key.
-> The fault reader V.A.G 1551 display will show the control unit identification, e.g.:
028906021CQ 1.9 ltr. R4 EDC SG
D1V ⇒
Coding 0000 WSC0000
◆ 028906021CQ = Part No. of the control unit (for up-to-date control unit versions see parts catalogue)
◆ 1.9 ltr./1.7 ltr. = Engine capacity
◆ R4 = Type of engine (4 Cyl. in-line engine)
◆ EDC = Injection system (Electronic Diesel Control)
◆ SG = Gearbox type: manual gearbox
(AG = automatic gearbox)
1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit 3
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◆ D1V = Control unit software version ris tee
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◆ Coding 00002 coding variant ss
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Coding For vehicles with
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00001 Automatic gearbox
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◆ WSC xxxxx = Workshop code from V.A.G 1551, of the workshops who carried out the last coding. (If the
factory coding has not been changed, WSC 00000 appears)
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- Press the ⇒key.
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Rapid data transfer HELP
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Select function XX
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- Further measures see repair procedures.
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2 - Fault memory
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2.1 - Fault memory
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2.2 - Interrogating fault memory
◆ Fault reader V.A.G 1551 (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3
Work sequence
- Connect fault reader V.A.G 1551 (V.A.G 1552) and with the "Address word" 01 select the engine electronics
control unit. When doing this the engine should be idling.
(Connecting fault reader and selecting engine electronics control unit => Page 2 .)
Only when engine does not start:
- Switch ignition on.
- Switch on fault reader printer with the print key. The warning lamp in key must light up.

Select function XX
- Press keys 0 and 2 for function "Interrogate fault memory" and confirm entry with Q key.
-> The number of faults stored or "No fault recognised!" will be shown on the display.
X Faults recognised!
If one or more faults are stored:
The stored faults will be displayed and printed out one after the other.
-> After the stored faults have been printed out, the display will show:
Select function XX
The fault reader is required partially for further fault reading therefore leave the engine running and the fault
reader connected.
- Locate and eliminate faults printed out as per fault table => Page 5 .
- Afterwards erase fault memory => Page 12
If no fault is stored:
- Press the ⇒key.

Select function XX
- Press keys 0 and 6 for the "End data transfer" function and confirm input with the Q key.
2.3 - Fault table
Notes:
◆ The fault tables are listed according to the 5 digit fault code on the left.
◆ Explanation of the fault types (e.g. "open circuit/short circuit to earth"):
=> Fault reader operating instructions

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◆ Erase fault
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V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
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- Cold start problems - Check V60

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- Poor idling characteristics

Open circuit - Wiring open circuit
Open circuit/short to earth - Wiring open circuit or short to earth
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Engine speed sender -G28

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2.2 - Interrogating fault memory
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- Metal swarf on G28 or mount‐ - Poor starting
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- Reduced output
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No signal - G28 defective
hole
- Wiring open or short circuit
spec
es, in part or in w
t to the co
00519
rrectness of i
Intake manifold pressure sender -
G71
l purpos
implausible signal - Charge pressure control - Reduced output - Check N75

solenoid valve (N75) defec‐ - Increased emission fig‐ =>Page 77
nform
ercia
tive ures
- Hose connections inter‐
m
a
changed, not connected
com
tion in
- Intake manifold pressure
r
te o
sender (G71) defective
thi
s
iva
do
Short to positive
r
rp
cum
fo
Short to earth
en
ng
t.
yi Co
Voltage supply t. Cop py
rig
gh ht
yri by
cop Vo
by lksw
cted agen
00522
Prote AG.
Coolant temperature sender -

G62
Short to earth - G62 defective - Black exhaust when starting - Check G62
- Wiring short to earth - Engine pre-heating not oper‐ =>Page 78
ating
- Glow period always approx.
20 sec.
Open circuit/ short to positive - G62 defective
- Wiring open circuit or short
to positive
Implausible signal - G62 defective
00523
Intake air temperature sender -
G42
Short to earth - G42 defective - Engine pre-heating not op‐ - Check G42
- Wiring has short to earth erating =>Page 89
Open circuit/short to positive - G42 defective
- Open circuit or short to pos‐
itive
00527
Intake manifold temperature
sender -G721)
Short to earth - G72 defective - Engine pre-heating not - Check G72
- Wire has short to earth operating =>Page 89
Open circuit/short to - G72 defective
positive - Open circuit or short to
positive
00528
Altitude sender -F96

Open circuit/short to - F96 defective - Black exhaust at alti‐ - Check F96 => Page
earth - Wiring open circuit or tude 77
short to earth
AG. Volkswagen AG d
agen o
1) Designated olksas intake air temperatures nsender
w e
ot g (G42) with engine code AHB and AKW in the current flow
yV
diagram and
sed checked as such in the component
b ua test.
ran
ri tee
tho o
V.A.Gau 1551
print-out Possible causes of fault rPossible
ac effects Fault remedy
ss
00532
ce
e
nl
pt
du
Supply voltage
an
itte
y li
erm
implausible signal - Current supply relay ter‐ - Various running problems - Check current supply for
ab
ility
minal 30 (J317) defective including engine will not Diesel direct injection sys‐
ot p
wit
start tem control unit
, is n
h re
=>Page 73
hole
spec
00539
es, in part or in w
t to the co
Fuel temperature sender -
G81
Short to earth - G81 defective - Increased emission fig‐ - Check G81
rrectness of i
- Wiring short to earth ures => Page 92
Open circuit/short to pos‐ - G81 defective
l purpos
itive - Wiring open circuit or

short to positive
nform
ercia
m
at
om
io
00542
n
c
in t
or
Needle lift sender -G80

his
ate
do
riv
Input open - G80 defective - Glow period warning lamp - Check G80
p
cum
or
- Wiring open circuit or short lights up => Page 101

f
en
g
circuit - Engine runs rough

n
t.
yi Co
op
- Reduced output
C py
ht. rig
- Increased emission figures
rig ht
py by
co Vo
Open circuit/short to positive
by lksw
cted agen
Prote AG.
Short to earth
Implausible signal - G80 defective
- Injection system wiring to 3rd
cylinder not OK.
- Fuel shortage
- Air in fuel system
00550
Injection commencement regulation
Control difference - Commencement of injec‐ - Engine runs rough - Check N108
tion valve (N108) defective - Reduced output =>Page 66
- Needle lift sender (G80) - Poor cold start characteris‐
defective tics
- Fuel tank empty - Increased emission figures
- Fuel supply not OK., fuel
shortage
- Air in fuel system
- Start of delivery not OK
00553
Air mass meter -G70
Implausible signal - G70 defective - Reduced output - Check function of exhaust gas
- Black exhaust recirculation and air mass meter
=>Page 111
2.3 - Fault table 7

n AG. Volkswagen AG do
lkswage es n
Polo Estate 1998 ➤ byV
o ot g
ua
ed ran
horis - Edition 05.1998 tee
ut or
a ac
Open circuit/short to earth - G70 defective ss
ce
le
un
pt
an
d
to earth
itte
y li
erm
ab
Short to positive - G70 defective
ility
ot p
wit
is n
to positive
h re
ole,
Voltage supply - Wiring open or short circuit
spec
t to the co
00575
Intake manifold pressure
rrectne
Control difference - Charge pressure control - Reduced output - Check N75
solenoid valve (N75) defec‐ =>Page 13 , Final con‐
ss
tive trol diagnosis
o
cial p
f i
- Hose connections inter‐ Check charge pressure
nform
changed, not connected control
mer
- Leakage between turbo‐ => Repair group 21;
atio
m
charger and engine (charge Checking charge pressure

o
n
c
i
or
n
air circuit) system; Checking charge
thi
te
- Turbocharger defective pressure control Checking
sd
iva
o
r
charge pressure control

p
cum
r
fo
en
00625
ng
t.
yi Co
op
Speed signal C py
t. rig
gh ht
implausible signal - No signal from speedome‐ - Speedometer display not - Check signal from G21 or yri
p by
o Vo
ter (G21) or speedometer OK. G22
c by lksw
cted agen
sender (G22) - Cruise control system =>Page 115
Prote AG.
switched off
- Vehicle jerks when
changing gear
- Air conditioner is switch‐
ed off
Signal too large
00626
Glow period warning lamp -
K29
Open circuit/short to - Wiring open circuit - Glow period warning - Check glow period warning
earth - Bulb defective lamp not functioning lamp -K29
=> Current flow diagrams,
Electrical fault finding and
Fitting locations binder
- Short to earth - Glow period warning
lamp permanently on
Short to positive - Short to positive - Glow period warning
lamp not functioning
00668
Vehicle voltage
terminal 30
Signal too small - Current supply relay ter‐ - Engine will not start - Check Diesel direct injec‐
minal 30 (J317) defective - Various running prob‐ tion system control unit cur‐
lems including engine will rent supply
not start =>Page 73
Implausible signal
00671
CCS Switch -E45
Undefined switch position - E45 defective - Cruise control system - Check cruise control sys‐
- Wiring open/short circuit switched off tem
=> Current flow diagrams,
Electrical fault finding and
Fitting locations binder
00741
Brake pedal monitoring
Implausible signal - Brake light switch (F) - Glow period warning - Check F and F47
defective lamp flashes =>Page 81
- Brake pedal switch - Brake light defective
(F47) defective
00765
Modulating piston movement sender
-G149
- Injection pump defec‐ - Glow period warning - Check G149
tive lamp flashes => Page 95
- Wiring open/short circuit - Various running prob‐
lems
- Engine will not start
V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

fault
00777
Accelerator position sender -
G79
Implausible signal - G79 defective - Glow period warning - Check and adjust G79
- G79 incorrectly adjus‐ lamp flashes => Repair group 20; Re‐
ted - Increased idling speed moving and installing
parts of fuel supply sys‐
tem; Servicing accelera‐
tor mechanism Servicing
accelerator mechanism
Short to positive - G79 defective
- Wiring short to posi‐
agen tive
AG. Volksw agen AG
does
lksw n
Voltage y V supply
o - Wiring openotor
gu short
db ara
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th eo
01044 au ra
c
ss
Control unit incorrectly coded
ce
e
nl
pt
du
- Invalid control unit - Code control unit

an
itte
y li
coding =>Page 118

erm
ab
ility
ot p

wit
, is n
fault
h re
hole
spec
01117
es, in part or in w
Load signal for alternator terminal DF

t to the co
Implausible signal - Alternator defective - Engine pre-heating - Check alternator

- Voltage regulator not operating => Current flow dia‐
rrectness of i
defective gram, Electrical fault

- Wiring open circuit finding and Fitting loca‐
l purpos
tions binder
01180
nform
ercia
Engine/air conditioner cut-off electri‐

cal connection
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
9
op Vo
by c lksw
Prote
cted AG.
agen 2.3 - Fault table
Short to positive - Short in the wiring - Vehicle acceleration - Check air conditioner
reduced, when air con‐ compressor cut-in
ditioner is switched on =>Page 13 , final con‐
trol diagnosis
01193
Low heat output relay -J359
Open circuit/short to earth - Wiring open circuit swag-enEngine AG. Volkpre-heating
swagen AG
doenot - Check J359 or J360
s no
- Low heat outputbrelay yV
olk
- functioning t gu=>Page 13 , final control
J359 or high output
ris
ed relay diagnosis
ara
nte
-J360 defective
ut
ho eo
ra
a c
- Short tos earth
s
- Engine preheating per‐
ce
le
manently on
un
pt
an
d
Short to positive - Short to positive - Engine preheating not

itte
y li
rm
ab
functioning
pe
ility
01193
ot
wit
, is n
High heat output relay -
h re
hole
J360
spec
es, in part or in w
Short to positive - Wiring open circuit - Engine preheating not - Check J360
t to the co
- Short to positive functioning =>Page 13 , Final control
- High heat output relay - diagnosis
J360 defective
rrectness of i
l purpos
01208
nform
Data
ercia
changed - Fault in data - Vehicle looses registra‐ - Renew J248

m
a
com
- Data manipulated tion (Germany) => Page 117
tion in
01237
r
te o
thi
s
Fuel cut-off valve -N109
iva
do
r
rp
Mechanical fault - N109 defective, leaking - Reduced output - Check N109 cum
fo
en
g
or sticking - Engine will not start =>Page 13 , Final control

n
t.
yi Co
t. Cop
diagnosis py
rig
gh
Open/short circuit to earth - N109 defective
ht
pyri by
- Wiring open circuit/short
o Vo
by c lksw
cted agen
to earth Prote AG.
01242
Control unit output stages
Open/short to positive - All components activa‐ - Various running problems - Carry out final control di‐
ted by final control diag‐ - Engine stops agnosis =>Page 13
nosis Check wiring connections
to control elements
Control unit defective if con‐
trol elements OK.
Implausible signal - Exhaust gas recircula‐ - Increased emissions
tion valve N18 defective

fault
01262
Charge pressure control solenoid
valve -N75
Open circuit/short to - Wiring open circuit - Reduced output - Check N75
earth - Solenoid valve defec‐ - Charge pressure too =>Page 13 , Final con‐
tive low trol diagnosis
- Short to earth - Reduced output

- Charge pressure too
high
Short to positive - Short to positive - Reduced output
- Charge pressure too
low
01265
Exhaust gas recirculation
valve -N18
Open circuit/short to - Wiring open circuit - No exhaust gas recircu‐ - Check N18
earth - Exhaust gas recircula‐ lation =>Page 13 , Final con‐
tion valve defective trol diagnosis
- Short to earth - Too much exhaust gas
recirculation
- Reduced output, black
n AG. Volksmoke
swagen AG
swage does
Short to positive - Short btoy Vpositive
olk
- No exhaust ngas
ot g recircu‐
ua
ir se
d lation ran
te
ho eo
01266 aut ra
c
ss
Glow plug relay -J52
ce
le
un
pt
Open circuit/short to - Wiring open circuit - Glow plug system not - Check J52
an
d
itte
earth - Glow plug relay defec‐ working =>Page 13 , Final con‐
y li
erm
ab
tive trol diagnosis
ility
ot p
- Short to earth - Glow plug system per‐
wit
is n
manently on
h re
ole,
spec
Short to positive - Short to positive - Glow plug system not
working
t to the co
rrectne
01268
Metering device -N146
s
Control difference - Injection pump defective - Glow period warning lamp flashes - Check N146 s o
- Wiring open/short circuit - Various running problems =>Page 95
cial p
f in

form
mer
Lower limit value - Metering device incorrectly set - Black smoke

atio
m
- Metering device blocked by dirt - Rough idling

o
n
c
i
or
Upper limit value - Metering device incorrectly set - Jerking, poor performance
thi
te
sd
a
- Metering device blocked by dirt

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
op
01269
C py
t. rig
gh ht
yri
Commencement of injection p by
co Vo
valve -N108
by lksw
cted agen
Prote AG.
Open circuit/short to - Wiring open circuit - Engine knocks at idling, - Check N108
earth - Commencement of in‐ because commencement =>Page 13 , Final con‐
jection valve defective of injection is constantly trol diagnosis
"advanced"
- Short to earth - Poor performance, be‐
cause commencement of
injection is constantly "re‐
tarded"
Short to positive - Short to positive - Engine knocks at idling,
because commencement
of injection is constantly
"advanced"
2.3 - Fault table 11

17978
Engine control unit blocked - Attempted manipulation - Engine starts briefly and - Match engine control unit
- Short in communication then stops again to electronic immobilizer
wire - Glow period warning => Page 120
- Fault in immobilizer sys‐ lamp lights up Check electronic immobil‐
tem izer:
- Immobilizer control unit => Repair group 96; Serv‐
defective/missing icing electronic immobiliz‐
- Engine control unit has er
been replaced and not
adapted (matched) to the
immobilizer
65535
Control unit -J248 defective - Control unit internals de‐ - Various running prob‐ - Replace J248
fective lems => Page 117
- Glow period warning
lamp flashes
2.4 - Erasing fault memory
Special tools, workshop equipment, testers, measuring

agen
AG. Volkinstruments
swagen AG and auxiliary items required
do w es n
olks ot g
yV
◆ Fault reader V.A.G 1551 or vehicle ed system
b tester V.A.G 1552 with cableua
raV.A.G
nte 1551/3
ris
tho eo
Test conditions au ra
c
ss
ce
le
un
• Fault eliminated pt
an
d
itte
y li
erm
ab
Note: ility
ot p
wit
is n
After eliminating faults the fault memory must be interrogated again as follows and then erased.
h re
ole,
spec
Work sequence
t to the co
- Connect fault reader V.A.G 1551 (V.A.G 1552) and select engine electronics control unit with the "Address
word" 01. When doing this the engine must be running at idling speed.
rrectne

ss o
cial p

in
Select function XX
form
mer
atio
m
- Press keys 0 and 2 for function "Interrogate fault memory" and confirm entry with Q key.
o
n
c
-
i
or

thi
e
Select function XX
t
sd
iva
o
r
-> Press ⇒key until all faults still stored have appeared and the display reads:
p
cum
r
fo
- Press keys 0 and 5 for the function "Erase fault memory" and confirm entry with Q key.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
Rapid data transfer c by lksw
Fault memory is erased! cted agen
Prote AG.
- If the fault memory will not erase there is a fault still in the system and this must be rectified.
- Press the ⇒key.

Select function XX
- Carry out a road test and interrogate fault memory again. No faults should be shown.
3 - Final control diagnosis

en AG. V
olkswagen AG
wag does
olks not
3.1 - Final control ed diagnosis
byV gu
ara
nte
ris
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
3.2 - Performing final control diagnosis
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3
es, in part or in w
t to the co
Test requirements for vehicles with air conditioning system
rrectness of i
• Vehicle at room temperature (warmer than + 15 °C)
• Air conditioning system switched on
l purpos
• Select lowest temperature and highest blower speed
The final control diagnosis activates the following components in the stated sequence:
nf
ercia
orm
m
atio
1. Commencement of injection valve (N108)
om
n in
or c
2. Exhaust gas recirculation valve (N18)

thi
te
sd
iva
o
r
rp
cu
3. Conditioner compressor interruption

o
m
f
en
ng
t.
yi Co
4. Engine codes AEY1), AFN, AHU, ALE: . Cop py
Fuel cut-off valve (N109)
ht rig
rig ht
by
Engine codes AEY2), AHB, AKW: copy Vo
by lksw
Throttle valve positioner (V60) cted agen
Prote AG.
5. Engine code AEY1):

Throttle valve positioner (V60)
Engine codes AEY2), AHB, AKW:
Fuel cut-off valve (N109)
Engine codes AFN, AHU, ALE:
Charge pressure limitation solenoid valve (N75)
6. Glow plug relay (J52)
7. Glow period warning lamp (K29)
8. Low heater output relay (J359)
9. High heater output relay (J360)
10. Blower relay (J323)

(engine code AFN only)
1) with MSA 12 engine control unit
2) with MSA 15 engine control unit
Notes:
◆ Activation of individual control elements is limited to 30 secs. but can be stopped at any time by pressing
the ⇒button.
2.4 - Erasing fault memory 13

◆ The ignition must be switched off before repeating the final control diagnosis.
Work sequence

Select function XX
- Press keys 0 and 3 for the function "Final control diagnosis".
-> Indicated on display: n AG. Volkswagen AG do

Rapid data transfer Q lkswage es n
o ot g
03 Final control diagnosis byV ua
d ran
ir se tee
tho
or
- Confirm input with Qskey.
au ac
s
ce
e
nl
pt
du
an
itte
y li
Final control diagnosis
erm
ab
Commencement of injection valve -N108
ility
ot p
wit
, is n
Activating the valve, influences the noise of combustion considerably (pre-ignition).
h re
hole
spec
If no changes in the combustion noises are heard:
es, in part or in w
t to the co
- Check injection adjuster control range
=> Page 103
- Press the ⇒key.
rrectness of i
l purpos

nform
ercia
Exhaust gas recirculation valve -N18

m
at
The valve must click.

om
ion
c
in t
or
Notes:
his
ate
do
priv
◆ Because of engine noises the clicking of the valve cannot be heard and therefore must be felt to detect its
um
for
en
operation.
ng
t.
yi Co
◆ The piston movement of the mechanical exhaust gas recirculation valve is visible in the side slot.
t. Cop py
rig
gh ht
yri by
Valve does not click: cop Vo
by lksw
cted agen
Prote AG.
- Check exhaust gas recirculation system
Engine codes AEY, AHB, AKW:

=> Repair group 26; Exhaust gas recirculation system, engine codes 1Y, AEY, AHB, AKW; Checking exhaust
gas recirculation Exhaust gas recirculation system, engine codes 1Y, AEY, AHB, AKW Checking exhaust gas
recirculation
Engine codes AFN, AHU, ALE:
=> Repair group 26; Exhaust gas recirculation system, engine codes AFN, AHU, ALE; Checking exhaust gas
recirculation Exhaust gas recirculation system, engine codes AFN, AHU, ALE Checking exhaust gas recircu‐
lation
- Press the ⇒key.

Conditioner compressor interruption
Air conditioner compressor switch-off is checked.
The test step is also recalled on vehicles without air conditioner system.
The conditioner compressor must stop within 5 secs. (visual check) then start approx. every 5 secs. and
then stop.
If the conditioner compressor is not switched off:
- Check conditioner compressor cut-off:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
n AG. Volkswagen AG
age does
ksw not
Vol
- Press the ⇒key. ed
by gu
ara
ris nte
tho eo
-> Indicated on display aufor engine codes AEY (engine control unit MSAr a12),
c AFN, AHU, ALE:
ss
ce
e

nl
pt
du
Fuel cut-off valve -N109
an
itte
y li
erm
ab
The engine must stop.
ility
ot p
wit
, is n
If the engine does not stop:
h re
hole
spec
- Switch off ignition.
es, in part or in w
t to the co
- Unscrew fuel cut-off valve and remove any metal particles or dirt.
- Repeat final control diagnosis and if the engine will not stop replace fuel cut-off valve => Fitting locations
overview, Page 46 .
- Continue final control diagnosis with engine stopped and ignition switched on.
rrectness of i
- Press the ⇒key.
l purpos
-> Indicated on display for engine codes AEY (MSA 15 engine control unit), AHB, AKW:
nform
ercia

Throttle valve positioner-V60
m
at
om
ion
The solenoid valve must click.

c
in t
or
his
ate
Note:
do
priv
cum
for
en
g
The clicking of the valve is difficult to hear and is therefore best checked by touch.
n
t.
yi Co
Cop py
t. rig
If the valve does not click: gh ht
pyri by
Vo
co lksw
by
cted
- Check throttle valve positioner (V60) => Page 108 .
agen
Prote AG.
- Press the ⇒key.
-> Indicated on display for engine code AEY (MSA 12 engine control unit):
Throttle valve positioner-V60
Note:
If the solenoid valve does not click:
- Check throttle valve positioner (V60) => Page 108 .

- Press the ⇒key.
-> Indicated on display for engine codes AEY (MSA 15 engine control unit), AHB, AKW:
3.2 - Performing final control diagnosis 15


Fuel cut-off valve-N109
The engine must stop.
If the engine does not stop:

- Unscrew fuel cut-off valve and remove any metal particles or dirt.
- Repeat final control diagnosis and if the engine will not stop replace fuel cut-off valve => Fitting locations
overview, Page 46 .
- Continue final control diagnosis with engine stopped and ignition switched on.
- Press the ⇒key.
-> Indicated on display for engine codes AFN, AHU, ALE:

Charge pressure control solen. valve -
N75
Note:
If the solenoid valve does not click:
- Check charge pressure control solenoid valve (N75)
=> Repair group 21; Checking charge air system; Checking charge pressure control Checking charge air system
Checking charge pressure control
- Press the ⇒key. AG. Volkswagen AG d

agen oes
olksw not
V gu
Continued for all engine codes ed by ara
nte
ris
ho eo
ut
-> Indicated on display: ss a ra
c ce
le

un
pt
Glow plug relay -J52
an
d
itte
y li
rm
ab
The relay must click.

pe
ility
ot
Switching on and off the relay can also be observed as the interior light becomes brighter and darker as a
wit
, is n
result of the glow plug high power consumption.

h re
hole
spec
If the relay does not click:

es, in part or in w
t to the co
- Check glow plug relay:

rrectness of i
l purpos
- Press the ⇒key.

nform
ercia

m

com
tio
Glow period warning lamp -K29

n in
r
te o
thi
The control lamp must blink.

s
iva
do
r
rp
cum
fo
Control lamp does not blink:

en
ng
t.
yi Co
Cop py
- Check glow period warning lamp:
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nt
ut
ho Polo Estate 1998 ➤ee or
a ac
Diesel direct injectionssand glow plug system - Edition 05.1998
ce
e
nl
pt
du
an
itte
y li
erm
ab
- Press the ⇒key.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Low heater output relay -J359
t to the co
rrectness of i
l purpos
- Check low heater output relay:
nf
ercia
orm
m
atio
m
- Press the ⇒key.
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
Final control diagnosis o
m
f
en
High heater output relay -J360 ng t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
by lksw
cted
agen
Prote AG.
- Check high heat output relay:
- Press the ⇒key.
-> Indicated on display for engine code AFN:

Fan relay -J323
The fan must run every 5 seconds and then stop again.
If the fan does not run:
- Check the fan relay:
- Press the ⇒key.

Select function XX
3.2 - Performing final control diagnosis 17

4 - Measured value blocks

4.1 - Measured value blocks
4.2 - Safety precautions
Observe following if test and measuring instruments are required during a test drive:
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
4.3 - Reading measured value block d b ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Test conditions
wit
, is n
h re
hole
• Coolant temperature must be at least 80 °C.
spec
es, in part or in w
• All electrical consumers like e.g. rear window heating must be switched off.
t to the co
• If the vehicle is equipped with an air conditioner, this must be switched off.
• On vehicles with an automatic gearbox the selector lever must be in P or N.
• No faults must be stored in fault memory
rrectness of i
=> Page 4 , interrogating fault memory
l purpos
Work sequence
nf
ercia
or
m
m
atio
om
n in
or c
-> Indicated on display: thi

te
sd
iva
o
r

rp
cu
o
Select function XX
m
f
en
ng
t.
yi Co
op
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key. C py
ht. rig
rig ht
py by
o Vo
-> Indicated on display: by c lksw
cted agen
Prote AG.
Read measured value block HELP
Input display group number XXX
Note:
The display group number 001 is an example, to illustrate the sequence.
- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

(1...4 = Display zones)
Read measured value block 1
1 2 3 4
- Press ⇒key.

Select function XX
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
Note:
To change to another display group proceed as follows:
Display group V.A.G 1551 V.A.G 1552

Higher Press key 3 Press ↑key
Lower Press key 1 Press ↓key agen
AG. Volkswagen AG d
oes
ksw not
Skip Press key C Press key C by
Vol
gu
ara
ed
ris nte
ho eo
aut ra
ss c
4.4 - Evaluating measured value block, engine code AEY
ce
e
nl
pt
du
an
itte
y li
erm
ab
Display group 000 at idling speed (engine warm, coolant temperature not below 80 °C)
ility
ot p
wit
, is n
h re
Display group 000 (decimal displayed value)
hole
spec
▪ Engine running at idling speed
es, in part or in w
t to the co
Read measured value block 0 [ltrif ] Indicated on display
x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 [ltrif ] Display zones Specification
rrectness of i
Displayed value not relevant not relevant
l purpos
Fuel temperature 91...201

Intake air temperature 182...50
nform
ercia
Coolant temperature 80...35

m
at
om
Atmospheric pressure not relevant
ion
c
in t
r

o
his
ate
Injected quantity 11...45
do
priv
cum
or
Accelerator pedal position 0

f
en
ng
t.
yi
Commencement of injection 0...88
Co
Cop py
t. rig
Engine speed gh
41...45
ht
pyri by
Vo
o
by c lksw
cted
agen
Prote AG.
Display group 001 -Injected quantity-

Read measured value block 1 ⇒ [ltrif ] Indicated on display
xxxx rpm xx.x mg/H x.xx V xxx.x °C
1 2 3 4 [ltrif ] Display zones Specification Evaluation
Coolant temperature 80...110 °C ---
Modulating piston movement sender voltage 1.40...1.80 V => Page 20
Injected quantity 2.2...9 mg/H => Page 19
Engine speed 861...945 rpm ---
Evaluation: Injected quantity display
V.A.G 1551 display Possible fault cause Fault elimination

Below 2.2 mg/H - Injection pump too rich - Renew injection pump => Page 61
4.3 - Reading measured value block 19

Polo Estate 1998 ➤ n AG. Volkswagen AG do
Diesel direct injection and glow plug system - Editionl wage
ks05.1998 es n
Vo ot gu
y
db ara
ise nte
V.A.G 1551 display Possible fault cause Fault elimination tho
r eo
au ra
Above 9 mg/H - Engine too cold - Run engines at increased speed to warm up and
s repeat check c
ce
e
- Injection pump too lean - Renew injection pump => Page 61
nl
pt
du
an
itte
y li
erm
Evaluation: Modulating piston movement sender voltage display
ab
ility
ot p
wit
, is n
h re
hole
Below 1.40 V - Injection pump too rich - Renew injection pump => Page 61
spec
es, in part or in w
Above 1.80 V - Engine too cold - Run engine at increased speed to warm up and repeat test
t to the co
rrectness of i
l purpos
Display group 002 -idling speed-
nform
ercia
xxxx rpm xxx.x % xxx xxx.x °C

m
at
om
ion
c
in t
or
his
te
Operating condition 010 => Page 20

a
do
priv
c
Accelerator pedal position 0% => Page 20
um
for
en
ng
t.
Engine speed C
861...945 rpm
op
yi
--- Co
py
t. rig
gh ht
yri
Evaluation: Accelerator pedal position display p by
o Vo
by c lksw
cted agen
Prote AG.
1...100 % - Accelerator pedal position sender -G79 in‐ - Check G-79 and if necessary adjust
correctly adjusted or defective => Repair group 20; removing and installing
parts of fuel system; servicing accelerator
mechanism servicing accelerator mecha‐
nism
- Wiring open circuit to G79
Evaluation: Operating condition display
Significance of figures in 3-digit number block for engine operating condition:
Significance when display = 1

x x x Engine operating condition
1 Air conditioner compressor switched on
1 Idling speed switch closed (accelerator pedal position below 17 %)
1 Increased idling speed because air conditioner is switched on
Display group 003 -Exhaust gas recirculation-

xxxx rpm xxx mg/H xxx mg/H xxx %
Exhaust gas recirculation valve duty cycle 90...98 % ---
MSA 12 engine contr. unit 4...6 %
MSA 15 engine contr. unit
Not relevant 0 mg/H ---
Air mass drawn in (specified) 146 mg/H ---
Display group 004 -Commencement of injection-n AG. Volkswagen AG

Read measured value block 4 ⇒ [ltrif wage does
Vol]ksIndicated on display not
gu
by ara
xxxx rpm xx.x ° xx.x ° xxx ri%
sed
nte
BTDC BTDC uth o eo
ra
a c
3 s 4 [ltrif ] Display zones Specification Evaluation
s
1 2
ce
le
un
Commencement of injection valve duty 10...60 % => Page 21
pt
an
d
cycle 3...60 %
itte
y li
erm
ab
ility
ot p
wit
is n
Commencement of injection (actual) 0...5°BTDC => Page 21
h re
ole,
Commencement of injection (specified) 0...5°BTDC => Page 21
spec
t to the co
Evaluation: Commencement of injection display (specified)
rrectne
s
Earlier than 5°BTDC - Engine too cold - Run engine at increased speed to warm up and repeat check.
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
Earlier than 5°BTDC - Engine too cold - Run engine at increased speed to warm
te
sd
va
up and repeat check.

i
o
pr
cum
r
fo
- Injection pump set too "advanced" - Check and adjust commencement of in‐
en
ng
t.
jection dynamically => Page 66
yi Co
Cop py
- Commencement of injection valve -N108 - Check -N108 => Page 13 , final control
ht. rig
rig ht
by
defective diagnosis copy Vo
by lksw
cted agen
Later than 0°ATDC - Injection pump set extremely "retarded" - Check and adjust commencement of in‐
Prote AG.
- Injection adjustment blocked - Check -N108 => Page 13 , final control
diagnosis
- Commencement of injection valve -N108
defective
Evaluation: Commencement of injection valve duty cycle display

Above 60 % - Injection pump set "retarded" - Check and adjust commencement of injection dynami‐
cally => Page 66
Display group 006 with ignition switched on
Display group 006 -Switch positions-

xxx km/h xxx xxxxxx xxx
Cruise control system1) --- ---
Cruise control system => Page 22
Brake pedal monitor => Page 22
4.4 - Evaluating measured value block, engine code AEY 21

Speed --- ---
1) 0 = Vehicles with cruise control system
255 = Vehicles without cruise control system
Evaluation: Brake pedal monitor display
Relevance of figures in 3-digit number block for brake pedal monitor:

x x x Brake pedal monitor
1 Brake light switch -F- closed
1 Brake pedal switch -F-47- open
1 Clutch pedal switch -F36- open
Evaluation: Cruise control system display
Relevance of figures in 6-digit number block for cruise control system:
"1" signifies:
n AG. Volkswagen AG
x x x x x x olks
wage Cruise control
does system
not
y V gu
1 Cruise control
ised b system switched on ara
nte
or
1 Cruise
aut control and memory switched off
h eo
ra
s c
1 Set
s speed (SET/FIX button)
ce
e
nl
1 Resume/acceleration pt
du
an
itte
1 Brake pedal operated y li

erm
ab
ility
ot p
1 Clutch pedal operated wit

, is n
h re
Display group 007 with ignition switched on (engine cold and not running)
hole
spec
es, in part or in w
t to the co
Display group 007 -Temperatures-

xxx.x °C xxx.x °C xxx.x °C
rrectness of i

l purpos
Coolant temperature Approx. ambient tempera‐ => Page 23

ture1)
nf
ercia
Intake air temperature Approx. ambient tempera‐ => Page 23

orm
ture1)
m
atio
om
No display
n in
or c
thi
Fuel temperature Approx. ambient tempera‐ => Page 22

te
sd
a
ture1)
iv
o
r
rp
cu
o
m
f
en
ng
t.
1) Details of temperature specifications are not possible. When the engine is cold the fuel, intake air and op
yi Co
coolant temperatures must equate approximately to ambient temperature. If a temperature deviates noticeably
C py
ht. rig
then the relevant sender must be checked. rig ht
py by
co Vo
by lksw
cted agen
Evaluation: Fuel temperature display
Prote AG.

- 5.6 °C - Short circuit or fuel temperature sender - - Check G81 => Page 92
G81 defective If a fault is present the measured value block
indicates a fuel temperature of -5.6 °C
. Volkswagen AG
gen AG d
Evaluation: Intake
Vol
kair
swatemperature display oes no
t
y gu
db ara
ise n
V.A.G 1551
tho display
r Possible fault cause tee o Fault elimination
au ra
Approx.19
ss °C - Intake air temperature sender -G42c de‐ - Check G42 => Page 89
fective If a fault is present the measured value block
ce
le
un
pt
indicates a constant intake air temperature of
an
d
itte
y li
approx.19 °C
rm
ab
pe
ility
ot
Evaluation: Coolant temperature display
wit
, is n
h re
hole
spec
es, in part or in w
Large deviation from ambient tem‐ - Short circuit or coolant tempera‐ - Check G62 => Page 78
t to the co
perature ture sender -G62 defective If a fault is present the fuel tempera‐
ture is displayed alternatively
rrectness of i
l purpos
Display group 013 -Idling speed smooth running control-

nform
ercia
x.xx mg/H x.xx mg/H x.xx mg/H

m
a
com
ti
on in
r
No display ---
te o
thi
s
iva
Different quantity injected Cyl.1 and Cyl. - 2.0...+ 2.0 mg/H => Page 23
do
r
rp
c
3
um
fo
en
ng
t.
Different quantity injected Cyl. 2 and Cyl. 3 - 2.0...+ 2.0 mg/H => Page 23
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
Evaluation: Idling speed smooth running control display
cted agen
Prote AG.
The injection system is equipped with an idling speed smooth running control. There may be power differ‐
ences between the individual cylinders (component tolerances, jet drillings, compressions etc.) which are
recognised and equalized via selective injected quantities.
Recognition at idling speed is via the signal from the engine speed sender which delivers four signals per
crankshaft revolution to the control unit. If the signals are delivered at the same rhythm then all cylinders
work the same. If one cylinder is weaker then the crankshaft takes longer for the next half revolution. Con‐
versely a more powerful cylinder accelerates the crankshaft so less time is taken.
If the control unit recognises a difference, then the relevant cylinder is given more or less fuel, until the
engine runs evenly again.
The measured value block displays the injected quantity differences of the individual cylinders compared
with No. 3 cylinder that is required to ensure an even engine idling speed.
+... mg/H: The relevant cylinder is less powerful than No. 3 cylinder and is therefore supplied with more fuel.
-... mg/H: The relevant cylinder is more powerful than No. 3 cylinder and is therefore supplied with less fuel.
Display group 000 at full throttle (test drive in 3rd gear, coolant temperature not below 80 °C)
Notes:
◆ When testing, accelerate vehicle at full throttle.
◆ The measured values must be printed out or read (2nd person required) when the revolutions reach 3,000
rpm.

▪ Engine speed 2850...3150 rpm
x x x x x x x x x x


Injected quantity 100...1301)
Commencement of injection n AG. Volkswagen AG do
120...160
wage
Engine speed yV
olks es n
ot g 136...150
d b ua
ran
ir se tee
1) If the control unit recognises a fault, the emergency
utho
mode injected quantity of 90 is displayed. or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Notes:
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
rpm.
t to the co
Display group 004 -Commencement of injection-
rrectness of i
xxxx rpm xx.x ° xx.x ° xxx %
l purpos
BTDC BTDC
nf
ercia
o
Duty cycle from com‐ 60...90 % => Page 24
rm
m
mencement of injection
atio
m
valve
o
n in
or c
Commencement of injection (ac‐ Approx. Commencement of => Page 24
thi
te
sd
a
tual) inj. (specified)

iv
o
r
rp
cu
Commencement of injection (specified) 6...10°CA BTDC ---
o
m
f
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
yri by
Evaluation: Commencement of injection display (specified) cop Vo
by lksw
cted agen
Prote AG.
For large deviation from specified - Commencement of injection valve - Check -N108 => Page 13 , final
value (approx. 5°CA) -N108 defective control diagnosis
- Injection pump timing way off - Check commencement of injection
dynamically and adjust => Page
66
- Air in fuel system - Check fuel supply system
Evaluation: Duty cycle from commencement of injection valve display

Below 60 or - Commencement of injection valve -N108 - Check -N108 => Page 13 , final control
above 90 % defective diagnosis
- Check commencement of injection dynam‐
ically and adjust => Page 66
- Check fuel supply system
Notes:

rpm.
Display group 008 -Injected quantity limitation-

xxxx rpm xx.x mg/H xx.x mg/H xx.x mg/H
Injected quantity limitation (opaci‐ 20...26 mg/H => Page 25
ty map)
Injected quantity limitation (torque map) 24...25 mg/H => Page 25
Injected quantity (driver's requirement) . Volks w30...34
agen AG mg/H => Page 25
gen AG doe
swa
Engine speed yV
olk 2850...3150srpm
not
gu ---
b ara
ed nte
oris
Evaluation: Injected quantity (driver's requirement) au
th e or
ac
ss
ce
e

nl
pt
du
an
itte
Below 30 mg/H - No full throttle - Repeat check at full throttle.
y li
erm
ab
- Accelerator pedal position sender -G79 in‐ - Check G-79 and if necessary adjust
ility
ot p
wit
, is n
h re
hole
spec
nism
es, in part or in w
t to the co
Evaluation: Injected quantity limitation display (torque map)
rrectness of i
l purpos
Below 24 mg/H - Speed too high or too low - Read off specified value at 3000 rpm.
nform
ercia
Evaluation: Injected quantity limitation display (opacity map)

m
at
om
ion
c
in t
r
Below 20 mg/H - Air mass drawn in insufficient - Check exhaust gas recirculation:
o
his
e
=> Repair group 26; Exhaust gas recirculation

at
do
riv
system, engine codes 1Y, AEY, AHB, AKW;

p
cum
or
Checking exhaust gas recirculation Checking

f
en
ng
t.
exhaust gas recirculation
yi Co
Cop py
- Exhaust recirculation quantity too high ht. rig
rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.
Notes:
◆ When testing, accelerate the vehicle at full throttle.

rpm.
Display group 011 -Charge pressure control-

xxxx rpm xxxx mbr xxxx mbr xxx %

Throttle valve positioner duty cycle 94...96 % ---

MSA 12 engine contr. unit 4...6 %
No display n AG. Volkswagen A
age G do
No display y Vol
ksw es n
ot g
b ua
Engine speed oris
ed ran2850...3150
tee rpm ---
th or
au ac
ss
ce
e
nl
pt
du
4.5 - Evaluating measured value blocks, engine codes AHB, AKW
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
x x x x x x x x x x
rrectness of i
l purpos
Displayed value not relevant 255

nform
ercia

Engine code AHB 138...190
m
at
om
Engine code AKW
ion
c
in t
r

o
his
ate
do
priv
cum
or

f
en
ng
t.
yi
Co
op py
t. C rig
gh ht
Engine code AKW pyri by
Vo
o
by c lksw
Accelerator pedal position cted
0
agen
Prote AG.
Engine code AKW
Engine speed 41...45

Voltage from modulating piston movement 1.50...2.00 V => Page 27
sender
Injected quantity 2.2...9 mg/H => Page 26
Engine code AHB 2.2...7 mg/H
Engine code AKW

Above 7 mg/H - Engine too cold - Run engine at increased speed to warm up and repeat check
or 9 mg/H
Evaluation: Voltage from modulating piston movement sender display

Display group 002 at idling speed (engine warm,

wage
n AG. Vocoolant temperature
lkswagen AG
doe not below 80 °C)
ks s no
Vol t gu
d by ara
Display group 002 -idling speed-ris
e nte
tho eo
Read measured value block au 2 ⇒ [ltrif ] Indicated on display ra
c
ss
xxxx rpm xxx.x %
xxx.x °C xxx
ce
le
un
pt
1 2 4 [ltrif ] Display zones
3 Specification Evaluation
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Evaluation: Accelerator pedal display
rrectness of i
l purpos
nform
ercia

nism
m
a
com
ti
on in
r
te o
thi

s
iva
do
r
rp
cum
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
pyri by
o Vo
by c lksw
cted agen
Prote
AG.

1 Idling speed switch closed (accelerator pedal position below 17 %)

Exhaust gas recirculation valve duty cycle 4...6 % ---
Engine code AHB 94...96 %
Engine code AKW
No display
No display
4.5 - Evaluating measured value blocks, engine codes AHB, AKW 27


BTDC BTDC
Commencement of injection valve duty 20...80 % => Page 28
cycle
Commencement of injection (actual) 0...6°BTDC => Page 28
Engine code AHB 0...3°BTDC
Engine code AKW
Commencement of injection (specified) 0...6°BTDC => Page 28
Engine code AHB 0...3°BTDC
Engine code AKW

Earlier than 3°BTDC - Engine too cold - Run engine atwincreased
agen
AG. V speed to warm
olkswagen AG
does up and repeat check.
or 6°BTDC yV
olks not
gu b ara
ed nte
oris e
Evaluation: Commencement of injection displayau (actual)
th or
ac
ss
ce
le

un
pt
an
d
itte
y li
rm
ab
or 6°BTDC up and repeat check.
pe
ility
ot
- Injection pump set too "advanced" - Check and adjust commencement of in‐
wit
, is n
h re
hole
spec
- Commencement of injection valve -N108 - Check -N108 => Page 13 , final control
es, in part or in w
defective diagnosis
t to the co
rrectness of i
diagnosis
l purpos

defective
nform
ercia
Evaluation: Commencement of injection valve duty cycle display

m
a
com
tion in
r

te o
thi
s
iva
Above 80 % - Injection pump set "retarded" - Check and adjust commencement of injection dynami‐
do
r
rp
cally => Page 66

um
fo
en
ng
t.
yi Co
op
Display group 006 with ignition switched on C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
Cruise control system1) --- ---
Cruise control system => Page 29
Brake pedal monitor => Page 29
Speed --- ---
Relevance of figures in 3-digit number block for brake pedal monitor:

Relevance of figures in 6-digit number block for cruise control system:
"1" signifies:
x x x x x x Cruise
. Vocontrol
lkswagensystem
gen AG AG do
1 Cruise control systemVoswitched
lkswa
on es n
ot g
by ua
1 Cruise control andris
ed memory switched off ran
tee
o
1 Set speed (SET/FIX
auth
button) or
ac
ss
1 Resume/acceleration
ce
e
nl
pt
du
1 Brake pedal operated
an
itte
y li
1 Clutch pedal operated
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Coolant temperature Approx. ambient tempera‐ => Page 30

l purpos
ture1)
Intake air temperature Approx. ambient tempera‐ => Page 30
nf
ercia
ture1)
orm
m
No display
atio
om
n in

or c
ture1)
thi
te
sd
iva
o
r
rp
cu
1) Details of temperature specifications are not possible. When the engine is cold the fuel, intake air and
o
m
f
en
ng
t.
yi Co
op
then the relevant sender must be checked. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Evaluation: Intake manifold temperature display

Approx.136.8 °C - Intake manifold temperature sender -G42 - Check G42 => Page 89
or approx. 19 °C defective If a fault is present the measured value block
indicates a constant intake manifold temper‐
ature of approx.136.8 °C or approx. 19 °C

Engine code AHB

x.xx mg/H x.xx mg/H x.xx mg/H
ge n AG. VolksNo
wagen AG
display
d ---
a oes
ksw not
Vol
ed
by Different quantity injected Cyl. gua
ran 1 and Cyl. - 2.0...+ 2.0 mg/H => Page 30
horis 3 tee
ut o
ss
a Different quantity injected Cyl. 2 and Cyl. 3 r ac - 2.0...+ 2.0 mg/H => Page 30
ce
le
un
pt
an
d
itte
y li

erm
ab
ility
ot p
wit
is n
h re
ole,
spec

t to the co
rrectne
ss
o
cial p
f i
nform
mer
atio
om
Engine code AKW

c
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo

en
ng
t.
yi Co
x.xx mg/H x.xx mg/H x.xx mg/H x.xx mg/H t. Cop py
rig
gh ht
pyri by
Vo
o
by c
Smooth running control quantity - 2.0...+ 2.0 mg/H => Page 31
lksw
cted agen
Prote
injected Cyl. 4
AG.
Smooth running control quantity injected - 2.0...+ 2.0 mg/H => Page 31
Cyl. 3
Smooth running control quantity injected Cyl. 2 - 2.0...+ 2.0 mg/H => Page 31
Smooth running control quantity injected Cyl.1 - 2.0...+ 2.0 mg/H => Page 31
+... mg/H: The respective cylinder is less powerful and is therefore supplied with more fuel.
-... mg/H: The respective cylinder is more powerful and is therefore supplied with less fuel.
Notes:

rpm.
. Volkswagen AG
gen AG does
Display group 000 (decimal displayed value) olks
wa not
byV gu
▪ Engine speed 2800...3200 rpm ris
ed
ara
nte
ho eo
Read measured value block 0 au
t [ltrif ] Indicated on display ra
c
ss
x x x x x x x x x x
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Engine code AKW
es, in part or in w
t to the co
rrectness of i
l purpos

Engine code AKW
nform
ercia

m

at
om
Engine code AHB 119...150 ion

c
in t
r
Engine code AKW

o
his
ate
Engine speed 133...153

do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
Notes:
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.
rpm.

BTDC BTDC


AG. Volkvalve
swagen AG
agen does
olksw Commencement of injection not (ac‐ Approx. Commencement of => Page 32
yV gu
ised b
tual) ara
nte inj. (specified
r
tho Commencement of injection (specified) r a
eo
6...12°CA BTDC ---
au
ss Engine code AHB c 6...9°CA BTDC
ce
Engine code AKW
le
un
pt
an
d

itte
y li
rm
ab
pe
ility
Evaluation: Commencement of injection display (actual)
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
value (approx. 5°CA) -N108 defective control diagnosis
rrectness of i
66
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do

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fo

en
ng
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. Cop py
rig
ht ht
rig by
py
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cted agen
Prote AG.
Notes:
rpm.

Injected quantity limitation (opaci‐ 21...25 mg/H => Page 33
ty map) 22...25 mg/H
Engine code AHB
Engine code AKW
Injected quantity limitation (torque map) 22...24 mg/H => Page 33
Engine code AHB 24...25 mg/H
Engine code AKW
Injected quantity (driver's requirement) 38...44 mg/H => Page 32
Engine code AHB 40...43 mg/H
Engine code AKW
Evaluation: Injected quantity display (driver's requirement)

Below 38 mg/H - No full throttle - Repeat check at full throttle.
or 40 mg/H
nism
Evaluation: Injected quantity limitation display (torque map)

Below 22 mg/H - Speed too high or too low - Read off specified value at 3000 rpm.
or 24 mg/H
Evaluation: Injected quantity limitation display (opacity map)

Below 21 mg/H - Atmospheric pressure en AG. sensor
Volkswagin
e control
n AG d - Renew Diesel direct injection system con‐
or 22 mg/H unit defectiveolkswag oes
not trol unit (J248) => Page 117
yV g
d b temperature sender -G42 defec‐ u-aCheck
- Intakeiseair ran G42 => Page 89
tiveuthor tee
o
a ra
ss c
ce
e
nl
pt
du
an
itte
Notes:
y li
erm
ab
ility
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wit
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rpm.
hole
spec
es, in part or in w
t to the co
rrectness of i
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Duty cycle from throttle valve positioner 4...6 % ---

No display
nf
ercia
No display
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
o
r
rp
cu
4.6 - Evaluating measured value blocks, engine codes AFN, AHU, ALE
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 [ltrif ] Display zones Specification Corresponds to
Air mass1) 69...128 230...420 mg/H
Fuel temperature 91...201 20...80°C
Intake manifold temperature 182...51 10...100°C
Coolant temperature 80...35 80...110°C
Atmospheric pressure Not relevant ---
Intake manifold pressure Not relevant ---
Injected quantity 11...45 2.2...9 mg/H


Accelerator pedal position 0 0%
Commencement of injection 50... 100 1°...5°BTDC
Engine code AFN 0... 88 3°after...4°BTDC
Engine code AHU 25...100 1°after...5°BTDC
Engine code ALE
Engine speed 41...45 861...945 rpm
1) The measured values are only valid when the exhaust gas recirculation (EGR) is switched on. The EGR
is switched off after approx. 3 minutes at idling speed, therefore give burst on throttle or restart engine.

Modulating piston movement sender voltage 1.30...1.90 V => Page 34
Engine code AFN, ALE 1.25...1.70 V
Engine code AHU
Injected quantity n AG. Volkswagen AG do 2.2...9 mg/H => Page 34
lkswage es n
Engine speed by
Vo ot g
ua 861...945 rpm ---
ed ran
ris tee
tho
au
or
ac
ss
ce
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nl
pt
du
an
itte
y li
erm
ab
Above 9 mg/H - Engine too cold - Run engine at increased speed to warm up and repeat check ility
ot p
wit
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- Injection pump too lean - Renew injection pump => Page 61 h re

hole
spec
Evaluation: Modulating piston movement sender voltage display

es, in part or in w
t to the co

rrectness of i
or 1.30 V
l purpos
nform
ercia
m
at
om
ion
c
in t
r
Display group 002 -idling speed-

o
his
ate

do
priv
cum
xxxx rpm xxx.x % xxx xxx.x °C

for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote
AG.
Evaluation: Accelerator pedal position display
nism

1 Idling switch closed

Duty cycle from exhaust gas recircula‐ 30...80 % ---
tion valve 40...60 %
Engine code AFN 30...80 %
Engine code AHU
Engine code ALE
Air mass drawn in (actual) 230...420 mg/H => Page 35
Air mass drawn in (specified) 230...370 mg/H => Page 35
Evaluation: Air mass drawn in (specified) display lkswage es n
o ot g
byV ua
d ran
ir se tee
V.A.G 1551 display Possible fault cause utho Fault elimination or
a ac
Above 370 mg/H - Engine too cold - Run
ss engine at increased speed to warm up and repeat check.
ce
le
un
pt
an
d
Evaluation: Air mass drawn in (actual) display

itte
y li
erm
ab
ility
ot p

wit
is n
Below 230 mg/H - Excessive exhaust gas recirculation - Check exhaust gas recirculation:
h re
ole,
=> Repair group 26; exhaust gas recirculation sys‐

spec
tem engine codes AFN, AHU, ALE; Checking ex‐

t to the co
haust gas recirculation Checking exhaust gas

recirculation
- Unmetered air - Check intake air system for leaks.
rrectne
Above 420 mg/H - Engine too cold - Run engine at increased speed to warm up and
repeat check.
ss
- Insufficient exhaust gas recirculation - Engine running at idling speed for 3 mins., give
o
cial p
f i
burst on throttle.
nform
mer
- Air mass meter -G70 defective - Check exhaust gas recirculation and air mass
atio
meter function => Page 111

om
If a fault is present the measured value block in‐

c
i
or
n thi
dicates a constant air mass value of approx. 550

te
sd
a
mg/H over the complete rpm and load range.

iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
35
cted agen
Prote AG.
4.6 - Evaluating measured value blocks, engine codes AFN, AHU, ALE

B/ATDC B/ATDC
Commencement of injection valve 2...80 % ---
duty cycle 2...95 %
Engine code AFN 2...80 %
Engine code AHU
Engine code ALE
Commencement of injection (actual) 1°...5°BTDC => Page 36
Engine code AFN 3°ATDC...4°BTDC
Engine code AHU 1°ATDC...5°BTDC
Engine code ALE
Commencement of injection (specified) 1°...5°BTDC => Page 36
Engine code AFN 3°ATDC...4°BTDC
Engine code AHU 1°ATDC...5°BTDC
Engine code ALE
Evaluation: Commencement of injection (specified) display

Earlier than 4°BTDC - Engine too cold - Run engine at increased speed to warm up and repeat check.
or 5°BTDC
Evaluation: Commencement of injection display (actual)

or 5°BTDC n AG. Volkswagen AG do up and repeat check.
swage es n
- Injection pump by V set too "advanced"
olk
- oCheck
t gu and adjust commencement of in‐
ir se
d jectionara
ndynamically
tee => Page 66
utho
- Commencement of injection valve -N108 - Check -N108
or => Page 13 , final control
a ac
defective
ss diagnosis
ce
le
un
pt
an
d
itte
or 1°ATDC jection dynamically => Page 66

y li
rm
ab
or 1°BTDC
pe
ility

ot
wit
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diagnosis
h re
hole

spec
defective
es, in part or in w
t to the co
Display group 005

rrectness of i
The values displayed are not relevant for fault finding within the service department.
l purpos
Display group 005 -Starting conditions-

nform
ercia
xxxx rpm xx.x mg/H xx.x ° xxx.x °C

m
B/ATDC
com
tion in

r
te o
thi
Coolant temperature --- ---

s
iva
do
r
rp
Commencement of injection (actual) --- ---

um
fo
en
ng
Starting quantity --- ---

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Engine speed --- ---
Display group 006 with ignition switched on

1 2 3 AG. Volk s4wag[ltrif
en AG] Display zones Specification Evaluation
agen does
ksw Cruise controlgu system1) --- ---
ol not
byV ara
oris
ed
Cruise control system nte => Page 37
h eo
aut Brake pedal monitor ra => Page 37
ss c
Speed --- ---
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Significance of figures in 3-digit number block for brake pedal monitor:
rrectness of i
l purpos

nform
ercia

m
at

om
ion
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
Significance of figures in 6-digit number block for cruise control system:
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted
x x x x x x Cruise control system
agen
Prote AG.
1 Cruise control system switched on

1 Cruise control and memory switched off
1 Set speed (SET/FIX button)
1 Resume/acceleration
1 Brake pedal operated
1 Clutch pedal operated

Coolant temperature Approx. ambient tempera‐ ---
ture1)
Intake manifold temperature Approx. ambient tempera‐ => Page 38
ture1)
No display
4.6 - Evaluating measured value blocks, engine codes AFN, AHU, ALE 37

ture1)
1) Details of temperature specifications are not possible. When the engine is cold the fuel, intake air and
then the relevant sender must be checked.

Evaluation: Intake manifold temperature display

Approx.136.8 °C - Intake manifold temperature sender -G72 - Check G72 => Page 86
defective If a fault is present the measured value block
indicates a constant intake manifold temper‐
ature of approx.136.8 °C

Display group 009
n AG. Volkswagen AG
Display group 009 -Injected quantity limitation- olks
wage does
not
V gu
Read measured value block 9 ⇒ [ltrife
y
d] Indicated on display
b ara
nte
ris
xxxx rpm xx.x mg/H xx.x mg/H x.xx V ut
h o eo
ra
a c
1 2 3 4 s [ltrif ] Display zones
s
Specification Evaluation
ce
le
un
Modulating piston movement send‐ --- ---

pt
an
d
er voltage
itte
y li
erm
ab
Injected quantity limitation from automatic gearbox --- ---

ility
ot p
during gear change

wit
is n
h re
Injected quantity (cruise control system active) --- ---

ole,
spec

t to the co
Display group 012

rrectne
s
Display group 012 -Glow plug system-

s o
cial p

inform
xxxx xx.xx sec. xx.x V xxx.x °C

mer
atio

om
n
c
Coolant temperature --- ---

i
or
n thi
te
Supply voltage from control unit --- ---

sd
iva
o
pr
Pre-glow period --- ---

um
r
fo
en
ng
t.
Not relevant Cop
yi Co
py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen o
Display group 013 -Idling speed olks smooth running control-s not g
w e
byV ua
Read measured value rblock ise
d 13 ⇒ [ltrif ] Indicated on display
ran
tee
o
x.xx mg/H x.xx mg/H au x.xx mg/H
th or
ac
ss
ce
e
nl
pt
du
No display ---
an
itte
y li
Different quantity injected Cyl. 1 and Cyl. - 2.0...+ 2.0 mg/H => Page 39
erm
ab
3
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
o
rm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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f
en
ng
t.
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Cop py
Display group 015
t. rig
gh ht
pyri by
Vo
co lksw
by
The values displayed are not relevant for fault finding within the service department. cted agen
Prote AG.
Display group 015 -Fuel consumption-

xxxx rpm xx.x mg/H xx.xx l/h xx.x mg/H
Injection quantity requirement (driver's --- ---
requirement via accelerator pedal)
Fuel consumption --- ---
Injection quantity (actual) --- ---
Display group 016 at idling
Display group 016 -Additional heater-

xxx % xxxxxxxx xx xx.x V
Voltage supply from control unit --- ---
Activation of heater elements => Page 40
Additional heater => Page 40
Alternator loading --- ---
Evaluation: Additional heater display
Significance of figures in 8-digit number block for additional heater:

x x x x x x x x Additional heater switched off, because:
1 Coolant temperature more than 70 °C...80 °C or intake air temperature
more than + 5 °C
1 Alternator defective
ag en A1
G . VolksBattery voltage
wagen AG
does below 9 V
olksw not
by
V 1 Engine speed below gua 760 rpm
ed ran
oris 1 Engine start within last
tee 10 secs.
th or
au ac
ss 1 Coolant temperature sender -G62 or
intake manifold temperature sender -G72 defective
ce
le
un
pt
an
d
1 Not relevant
itte
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erm
ab
1 Not relevant
ility
ot p
wit
is n
Evaluation: Heater element activation display
h re
ole,
spec
t to the co
Significance of figures in 2-digit number block for heater element activation:
Significance when display = 1 rrectne
x x Heater element activation

1 Low heat output relay -J359 on
ss o
cial p
1 High heat output relay -J360 on

f inform
mer
atio
om
n
c
i
or
Notes:
thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi
rpm.
Co
Cop py
ht. rig
rig ht
py by
Display group 000 (decimal displayed value) co Vo
by lksw
cted agen
▪ Engine speed 2800...3200 rpm Prote AG.

x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 [ltrif ] Display zones Specification Corresponds to
Air mass 225...255 750...890 mg/H
Fuel temperature 91...201 20...80°C
Intake manifold temperature 51...182 10...100°C
Engine code AFN 80...180 10...80°C
Engine code AHU 51...190 5...100°C
Engine code ALE
Coolant temperature 80...35 80...110°C
Atmospheric pressure Not relevant ---
Intake manifold pressure 158...194 1650...2000 mbar
Injected quantity 180...210 36...42 mg/H
Engine code AFN 160...190 32...38 mg/H
Engine code AHU, ALE
Accelerator pedal position 255 100 %
n AG. Volkswagen AG do Polo Estate 1998 ➤
lkswage es n
Diesel direct byinjection
Vo and glow plug system
ot g
uara - Edition 05.1998
ed nte
oris eo
Display group 000 (decimal displayed
auth value) ra
ss c
Commencement of injection 137...213 8...14°BTDC
ce
e
nl
Engine codes AFN, ALE 135...165 7.8...10.2°BTDC
pt
du
an
Engine code AHU
itte
y li
erm
ab
Engine speed 130...155 2800..3200 rpm
ility
ot p
wit
, is n
h re
hole
spec
Notes:
es, in part or in w
t to the co
rrectness of i
rpm.
l purpos

nf
ercia
o
rm
m
B/ATDC B/ATDC
atio
om
4 [ltrif ] Display zones Specification Evaluation
n in
1 2 3
or c
thi
e

t
sd
iva
o
r
rp
cu
valve
o
m
f
en
ng
t.
yi
Commencement of injection (ac‐ Approx. Commencement of => Page 41
Co
op py
tual) inj. (specified t. C rig
gh ht
yri by
Commencement of injection (specified) 8...14°BTDC ---
cop Vo
by lksw
Engine codes AFN, ALE 6...12°BTDC cted agen
Prote AG.
Engine code AHU
Evaluation: Commencement of injection (actual) display

value (approx. 5°) -N108 defective control diagnosis
66

Notes:
rpm.


Injected quantity limitation due to 36...44 mg/H => Page 42
air mass drawn in (smoke preven‐ 34...40 mg/H
tion) 34...38 mg/H
Engine code AFN
Engine code AHU
Engine code ALE
Injected quantity limitation via revs. (torque 41...42 mg/H => Page 42
limitation) 34...40 mg/H
Engine code AHU 37...38 mg/H
Engine code AHU
Engine code ALE
Injected quantity (driver's requirement) 42...44 mg/H => Page 42
Engine code AFN 38...42 mg/H
Engine code AHU, ALE
AG. Volkswagen AG d
Evaluation: Injected quantity (driver's requirement) display agen oes
olksw not
byV gu
ara
ed
is n
V.A.G 1551 display Possible fault causethor Fault elimination tee o
u ra
Below 38 mg/H - No full throttle ss
a
- Repeat check at full throttle. c
or 42 mg/H
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
nism
h re
hole
spec
es, in part or in w
Evaluation: Injected quantity limitation via revs. (torque limitation) display
t to the co
Below min. value - Revs. too high or too low - Read off specified value at 3000 rpm.
rrectness of i
l purpos
Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
nf
ercia
orm
Below min. value - Air mass drawn in insufficient - Check exhaust gas recirculation and air mass
m
atio
m
meter function => Page 111

o
n in
or c
- Exhaust recirculation quantity too high - Check exhaust gas recirculation

thi
te
=> Repair group 26; exhaust gas recirculation

sd
iva
system engine codes AFN, AHU, ALE; Checking

r
rp
cu
o
exhaust gas recirculation Checking exhaust gas

f
en
ng
t.
recirculation
yi Co
Cop py
ht. rig
rig ht
Display group 010 at full throttle (test drive in 3rd gear, coolant temperature not below 80 °C) py by
co Vo
by lksw
cted agen
Prote AG.
Notes:
rpm.
Display group 010 -Air quantities-

xxx mg/H xxxx mbr xxxx mbr xxx.x %
Accelerator pedal position 100 % => Page 43
Intake manifold pressure (charge pressure) 1650...2000 mbar => Page 43

Atmospheric pressure (ambient pressure) No specification ---
Air mass drawn in 750...890 mg/H => Page 43
Engine codes AFN, ALE 800...898 mg/H
Engine code AHU
Evaluation: Air mass drawn in display

n AG. Volkswagen AG
Below 800 mg/H - Revs. too low
ksw
ageor too high - Read dooff
es n specified value at 3000 rpm.
or 750 mg/H y Vol ot g
u
b ara
ed
-hoCharge
ris pressure too low - Check charge pressure nte
eo control
aut
=> Repair group 21; r acheck charge air system; checking ex‐
c
ss haust gas turbocharger checking exhaust gas turbocharger
ce
le
un
pt
- Air mass meter defective - Check exhaust gas recirculation and air mass meter function
an
d
itte
=> Page 111
y li
erm
ab
If a fault is present the measured value block indicates a con‐
ility
ot p
stant air mass value of approx. 550 mg/H over total speed and
wit
is n
load range
h re
ole,
spec
Evaluation: Intake manifold pressure (charge pressure) display
t to the co
Below 1650 mbar - Charge pressure control defective - Check charge pressure control
rrectne
=> Repair group 21; check charge air system; check‐
ing exhaust gas turbocharger checking exhaust gas
s
turbocharger
s o
cial p
f
Above 2000 mbar - Turbocharger defective
inform
mer
atio
Evaluation: Accelerator pedal position display
om
n
c
i
or
n thi

te
sd
va
Below 100 % - No full throttle - Repeat test at full throttle.

i
o
pr
cum
r
fo
en
ng
t.
yi
Co
Cop py
parts of fuel supply system; servicing accel‐
t. rig
gh ht
yri
erator mechanism servicing accelerator
p by
co Vo
by lksw
mechanism Prote
cted AG.
agen
Notes:

rpm.

Duty cycle from charge pressure 20...70 % ---
control valve
Charge pressure (actual) 1650...2000 mbar => Page 44
Charge pressure (specified) 1650...1950 mbar ---
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Polo Estate 1998 oris ➤
e nte
h e
Diesel direct ainjection
ut and glow plug system - Edition o05.1998 ra
c
ss
ce
e
Evaluation: Charge pressure display (actual)
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
Below 1650 mbar - Charge pressure control defective - Check charge pressure control
wit
, is n
=> Repair group 21; check charge air sys‐
h re
tem; checking exhaust gas turbocharger
hole
spec
checking exhaust gas turbocharger
es, in part or in w
t to the co
- Turbocharger defective
- Charge pressure hose not connected to - Connect charge pressure hose
control unit
rrectness of i
Above 2000 mbar - Turbocharger defective - Check charge pressure control
l purpos
=> Repair group 21; check charge air sys‐

tem; checking turbocharger checking turbo‐
charger
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
23 - Mixture preparation, Injection

swa
gen AG
. Volkswagen AG
does
k not
Vol gu
d by ara
e nte
ris
utho eo
ra
a c
ss
1 - Servicing Diesel direct injection system
ce
e
nl
pt
du
an
itte
y li
1.1 - Servicing Diesel direct injection system
erm
ab
ility
ot p
wit
, is n
h re
Diesel is drawn from the fuel tank by the distributor injection pump, pressurised, and then sprayed into the
hole
spec
combustion chamber onto the crown of the piston by the injector.
es, in part or in w
t to the co
The quantity injected is regulated electronically by the Diesel direct injection system control unit. The electronic
regulation allows the quantity injected and the injection characteristics, commencement of injection and exhaust
gas recirculation, to be regulated flexibly to meet requirements.
rrectness of i
The Diesel direct injection system control unit is equipped with a fault memory. Before starting repairs, adjust‐
l purpos
ments and fault finding, the fault memory must be interrogated and final control diagnosis completed =>Page
4.
nform
ercia
Note:
m
at
om
ion
When performing check and adjustment operations the control unit may recognized and store faults.
c
in t
or
his
ate
For this reason after completing all check and adjustment operations it is necessary to erase fault memory
do
priv
cum
for
=>Page 12 .
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
1.2 - Safety precautions
by lksw
cted agen
Prote AG.
To prevent injuries to persons and/or damage to the injection and glow plug system, the following must be
noted:
◆ The ignition must be switched off before connecting or disconnecting injection or glow plug system wiring
or tester cables.
◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull con‐
nector off fuel cut-off valve (N109) on injection pump.
◆ Before disconnecting battery, obtain radio code for radios fitted with anti-theft coding.
◆ Disconnecting and connecting the battery must only be undertaken when the ignition switched off otherwise
the Diesel direct injection system control unit may be damaged.
Observe following if test and measuring instruments are required during a test drive:
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
1.3 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
1.1 - Servicing Diesel direct injection system 45

◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
◆ Also ensure that no Diesel fuel runs onto the coolant hoses. If necessary hoses must be cleaned immedi‐
ately. Affected hoses must be replaced.
1.4 - Fitting locations overview
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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Components A to D are not shown on the illustration.
A - Brake pedal switch (F)

◆ In footwell => Page 58 , Fig. 1
B - Brake light switch (F47)
C - Accelerator pedal position sender (G79)
◆ In footwell on accelerator
46 23 - Mixture preparation, Injection

=> Repair group 20; removing and installing parts of fuel supply system; servicing accelerator mechanism
removing and installing parts of fuel supply system servicing accelerator mechanism
D - Clutch pedal switch (F36)

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Engine codes AEY, AHB, AKW
agen
Prote AG.
1 Throttle valve housing

◆ Removing, installing and checking =>Page 59
2 Injector with needle lift sender (G80)
3 Exhaust gas recirculation valve (N18)
4 Throttle valve positioner (V60)
5 Diesel direct injection system control unit (J248)
◆ Only engine code AEY with altitude sender (F96)
6 Supplementary heater element relay (J325)
◆ With low heater output relay (J359)
◆ With high heater output relay (J360)
1.4 - Fitting locations overview 47

AG. Volkswagen AG d
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7 Connector s
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◆ For needle lift sender (G80)

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8 Connector
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◆ For engine speed sender (G28)

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9 Coolant temperature sender (G62)

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10 Connector
hole
spec
◆ For fuel temperature sender (G81)

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◆ For quantity adjuster (N146)

t to the co
◆ For modulating piston movement sender (G149)

◆ For fuel cut-off valve (N109) (only with 10 pin connector)
◆ For commencement of injection valve (N108) (only with 10 pin connector)
rrectness of i
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ion
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11 Connector
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◆ Only with 7 pin connector for injection pump
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◆ For fuel shut-off valve (N109) t. C rig
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12 Fuel cut-off valve (N109) cted agen
Prote AG.
13 Injection pump quantity adjuster

◆ With fuel temperature sender
◆ With quantity adjuster (N146)
◆ With modulating piston movement sender (G149)
14 Intake air temperature sender (G42)
◆ Is displayed as intake manifold temperature sender (G72) for engine codes AHB and AKW, if there is a
fault

Diesel direct injection and glow plug
en AG. V
olkswsystem
agen AG - Edition 05.1998
ag does
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Prote AG.
Engine codes AFN, AHU, ALE
1 Air mass meter (G70)

2 Injector with needle lift sender (G80)
3 Exhaust gas recirculation valve (N18)
4 Charge pressure limiting solenoid valve (N75)
5 Intake manifold temperature sender (G72)
6 Diesel direct injection system control unit (J248)
◆ With sender for intake manifold pressure (G71)
◆ With altitude sender (F96)
◆ Renew => Page 117

AG. Volkswagen AG d
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7 Central connector co Vo
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8 2 pin connector Prote AG.
◆ For needle lift sender (G80)

9 3 pin connector
◆ For engine speed sender (G28)
10 Coolant temperature sender (G62)
11 Connector
◆ For fuel temperature sender (G81)
◆ For quantity adjuster (N146)
◆ For modulating piston movement sender (G149)
12 3 pin connector
◆ For fuel shut-off valve (N109)
◆ For commencement of injection valve (N108)

AG. Volkswagen AG d
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nform
mercia
at
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ion
c
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do
priv
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Cop py
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Prote AG.
13 Fuel cut-off valve (N109)
14 Injection pump quantity adjuster

1.5 - Servicing injection pump
AG. Volkswagen AG d
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◆ Observe rules for cleanliness

ab
pe
ility
=>Page 45
ot
wit
◆ Removing and installing injection pump

, is n
h re
=>Page 61
hole
spec
◆ Dynamically checking and adjusting injection pump =>Page 66

es, in part or in w
◆ Always renew seals and O-rings

t to the co
1 55 Nm
2 Injection pump sprocket
rrectness of i
◆ Removing => Removing injection pump Page 61

l purpos
3 Woodruff key
◆ Check seated securely
nform
ercia
4 Supply pipe, 25 Nm
m
◆ From fuel filter

a
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1.5 - Servicing injection pump 53

AG. Volkswagen AG d
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5 Seal cted agen
Prote AG.
◆ Renew
6 Banjo bolt, 25 Nm
7 Supply pipe
◆ From fuel filter
8 Injection pump
◆ With quantity adjuster (metering)
9 O-Ring
◆ Renew if damaged
10 Fuel shut off valve, 40 Nm
11 Pipe union
◆ For return pipe
◆ To control valve/fuel filter

AG. Volkswagen AG d
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c
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Prote AG.
12 25 Nm
13 Return pipe
◆ To control valve/fuel filter
14 Injector pipes
◆ Tighten to 25 Nm
◆ Remove with 3035
◆ Always remove pipework complete
◆ Do not alter shape
15 Injector
◆ For 3rd cylinder with needle lift sender
◆ Removing and installing
=> Page 71
◆ Servicing => Page 72
16 20 Nm
17 Dished washer
18 Retainer
19 Mounting

AG. Volkswagen AG d
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20 Connector
t to the co
◆ For fuel cut-off and commencement of injection valves
◆ (3 pin) with 7 pin injection pump connector
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21 Pipe union, 45 Nm
◆ With pressure valve
l purpos
22 Timing control cover

◆ If leaking, replace O-ring =>Page 73
nf
ercia
23 Heat insulation seal

rm
m
atio
◆ Renew
om
n in
c
24 10 Nm
or
thi
e
25 Commencement of injection valve (N108)

t
sd
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◆ Checking =>Page 13 , final control diagnosis

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26 Strainer
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27 Retainer C py
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Prote AG.

AG. Volkswagen AG d
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28 Sleeve
hole
spec
◆ Tapered
es, in part or in w
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29 25 Nm
◆ Nut with taper
30 Console
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Prote AG.

-> Fig. 1 Switches in footwell
1 - Clutch pedal switch
2 - Brake pedal switch
3 - Brake light switch
1.6 - Setting engine to number 1 cylinder with engine removed
◆ -> 2068 A Setting device
Work sequence
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Engine codes AEY, AHB, AKW

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ab
ility
- -> Attach adjusting tool as shown.

ot p
- Set adjusting tool to 5.0 mm. The reference point is the graduation mark on the left of the vernier scale -
wit
, is n
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arrow A-.
hole
- Turn crankshaft until TDC mark on the flywheel is aligned with the tip of the adjusting tool -arrow B-.
spec
es, in part or in w
t to the co
rrectness of i
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Prote AG.
- -> Attach adjusting tool as shown.
- Set adjusting tool to 96.0 mm. The reference point is the graduation mark on the left of the vernier scale -
arrow A-.
- Turn crankshaft until TDC mark on the flywheel is aligned with the tip of the adjusting tool -arrow B-.
AG. Volkswagen AG d
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1.7 - Checking throttle valve positioner housing
Vo gu
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At low engine speeds the vacuum in the intake manifold is not sufficient to ensure correct functioning of the
l purpos
exhaust gas recirculation system. Therefore to increase vacuum the throttle valve remains closed up to 2200
rpm after starting the engine.
nform
ercia
◆ -> Hand vacuum pump V.A.G 1390
m
at
om
◆ Torque wrench V.A.G 1331 (5...50 Nm)
ion
c
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Prote AG.
- -> Remove intake hose -1-.

- Pull vacuum hose -6- off vacuum unit -5-.
- Unscrew securing bolts -2- and remove throttle valve housing -3- with O ring -4-.
Installing
1.6 - Setting engine to number 1 cylinder with engine removed 59

- Attach throttle valve housing with O ring to intake manifold and tighten securing bolts to
10 Nm.
Note:
Renew O ring if damaged.
- -> Attach vacuum hose -6- and install intake hose -1-.
Functional check of vacuum unit
- -> Connect vacuum pump V.A.G 1390 to vacuum unit -1- and create a vacuum.
Specification:
The throttle valve must close up to stop and remain closed.
If the specification is not attained:
- Renew vacuum unit.
AG. Volkswagen AG d
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c by lksw
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AG. Volkswagen AG d
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Diesel direct injection and glow r a plug
c system - Edition 05.1998
s
ce
e
1.8 - Removing and installing injection pump
nl
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Cop py
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Prote AG.
Special tools, workshop equipment, test and measuring appliances and aux. items required
◆ 2064 Locking pin

◆ 2065 A Setting bar
◆ 2068 A TDC setting device
◆ 3032 Puller
◆ 3035 Ring spanner
◆ 3036 Retainer
1.8 - Removing and installing injection pump 61

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◆ V159 Pin wrench

es, in part or in w
◆ V.A.G 1318/10 Adapter hose

t to the co
◆ V.A.G 1331 Torque wrench (5...50 Nm)

◆ V.A.G 1332 (40...200 Nm) Torque wrench
◆ V.A.G 1390 Hand vacuum pump
rrectness of i
Removing
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Prote AG.
- Remove air cleaner.

- Remove upper toothed belt guard.
- Remove cylinder head cover.

AG. Volkswagen AG d
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Diesel direct injection and glow ra
c plug system - Edition 05.1998
s
ce
e
- -> Turn crankshaft to TDC No. 1 cylinder -arrow-.
nl
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ility
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nf
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or
- -> Lock camshaft with setting bar.
m
m
atio
- Centralize setting bar as follows:
om
n in
Turn arrested camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge es‐
or c
thi
tablish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between
te
sd
a
setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd
iv
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feeler gauge, of same thickness, at the other end between setting bar and cylinder head.
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- Remove idler roller.
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- Remove tensioning roller nut. t. Cop py
- Relieve tooth belt tension and take off camshaft and injection pump sprockets.
rig
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- Lock injection pump sprocket with pin 2064. cop Vo
by lksw
- Remove injection pump sprocket securing nut. cted agen
Prote AG.
- -> Loosen puller arms and offer up.

- Locate puller arms through holes in injection pump sprocket and tighten.
- Place injection pump sprocket under tension with puller.
- Release injection pump sprocket from injection pump taper by tapping lightly on puller spindle -arrow- (when
doing this hold sprocket so that it does not fall off).
- Unbolt all fuel lines at fuel pump.
- Cover openings with a clean cloth.
Note:
Use slotted ring spanner 3035 to remove high pressure fuel pipes.

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- Disconnect fuel cut-off valve/commencement of injection valve connector.
t to the co
- Disconnect quantity adjuster connector and unclip connector from retainer.
- -> Remove securing bolts from console -arrows-.
rrectness of i
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mercia
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Cop py
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- -> Then remove bolt from rear support -arrow-.
co lksw
by
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- Take off injection pump. Prote AG.
Installing
- Insert injection pump into console and then tighten securing bolt on rear support with conical nut first.
- Align injection pump to central position in console elongated holes and secure hand tight.
Note:
The commencement of injection is set dynamically with V.A.G 1551.
- -> Install injection pump sprocket and lock in position with pin 2064. When installing observe spring washer
seating.
- Tighten securing nut to 55 Nm.

Note:
Never use setting bar as a counter hold when loosening and tightening the camshaft sprocket, use retainer
3036.
- Loosen camshaft sprocket securing bolt a half turn.

- Place a drift through hole in the rear of the toothed belt guard and release the camshaft sprocket from
camshaft taper with a blow from a hammer.
- Take camshaft sprocket off.
- Check whether TDC mark on flywheel and reference mark are aligned.
- Place tooth belt on injection pump sprocket and tensioning roller.
- Fit camshaft sprocket into toothed belt and secure sprocket so that the camshaft can still turn.
- Install idler roller.
- Remove locking pin from injection pump sprocket.
- -> Tension toothed belt. Using pin wrench (e.g. Matra V159) on eccentric turn clockwise until the notch and
the raised mark -arrows- align.
AG. Volkswagen AG d
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Note: byV
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If the eccentric has been turned too far the tensioning
aut
h roller must be relieved completely and retensioned.
eo
ra The
eccentric must never be turned back when it has
ss been turned too far. c
ce
e
nl
pt
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- Tighten securing nut to 20 Nm.
an
itte
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- Check TDC mark on flywheel again.
erm
ab
- Tighten camshaft sprocket securing bolt to
ility
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45 Nm.
wit
, is n
- Remove setting bar 2065A from camshaft.
h re
hole
- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
spec
- Check if
es, in part or in w
t to the co
the TDC mark on flywheel
the setting bar on camshaft
the pin 2064 in injection pump sprocket
the tensioning roller setting (notch/raised mark)
rrectness of i
align/are fitted correctly.

l purpos
- If notch and raised mark do not align, tension the tensioning roller. To do this, hold tensioning roller with pin
wrench Matra V159, loosen securing nut, turn eccentric clockwise further until notch and raised mark align
opposite one another and tighten securing nut to 20 Nm.
nf
ercia
orm
m
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Cop py
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Prote AG.

- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
- Repeat check.
- Reconnect injection pipes, fuel pipes and electrical wiring.
-> Fill injection pump with Diesel as follows.
- Screw adapter 1318/10 into injection pump return supply opening.

- Connect hand vacuum pump 1390 with approx. 1 m transparent
A G. Volkswagenplastic
AG do hose to adapter.
- Operate vacuum pump until fuel flows out oforeturn agensupply opening. Doesnot
lksw not draw fuel into vacuum pump.
- Remove adapter and connect return supply d by pipe.
V gu
ara
- Install toothed belt guard, cylinder head
horise cover and air cleaner. nte
eo
- Dynamically check commencement a of injection and adjust if necessary =>Page 66r a.c
ut
ss ce
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pt
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1.9 - Dynamically checking and adjusting commencement of injection

erm
ab
ility
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Notes:
hole
spec
es, in part or in w
◆ Dynamically checking and correcting commencement of injection is only possible in function 04 "Engine
t to the co
basic setting".
◆ The commencement of injection must always be checked after renewing the toothed belt or loosening the
injection pump bolts or toothed belt sprockets and if necessary adjusted.
rrectness of i
l purpos
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
nform
mercia
at
om
ion
c
in t
or
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ate
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◆ -> V.A.G 1331 Torque wrench (5...50 Nm)
Checking and adjustment conditions

• Mechanical engine basic setting OK.
• Toothed belt tension OK.
Work sequence

Select function XX
- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.

Basic setting HELP
- Press key 0 three times for "Display group number 0" and confirm entry with Q key.

(1...10 = Display zones)
System in basic setting 0
1 2 3 4 5 6
7 8 9 10
The commencement of injection in display zone 2 is dependent on the fuel temperature in display zone 9.
Engine code AEY swa
gen AG
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-> A - Display zone 2 commencement of injection

rrectness of i
B - Display zone 9 fuel temperature

C - Specified range for commencement of injection
l purpos
Example:
The numerical value 90 in display zone 9 (B) corresponds to a numerical value range of 42...69 in display zone
nform
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2 (A).
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Engine codes AHB, AKW

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1.9 - Dynamically checking and adjusting commencement of injection 67

-> A - Display zone 2 commencement of injection
C - Specified range for commencement of injection
Example:
2 (A).
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-> A - Display zone 2 commencement of injection s
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C - Specified range for commencement of injection an

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Example:
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2 (A).
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Continued for all engine codes
Notes:
rrectness of i
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◆ If the commencement of injection is advanced turn injection pump in engine direction of rotation, if the
commencement of injection is retarded turn against direction of rotation.
◆ If when checking the commencement of injection the specifications are within zone -C- then no adjustment
nform
ercia
is required. After repairs e.g. removing and installing injection pump, adjusting timing then the commence‐
ment of injection is to be set to the mean valve (dashed line) of specification zone -C-.
m
at
om
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- Loosen injection pump securing bolts approx. one turn, leaving the easiest bolt to reach till last.
or
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- Hold injection pump by hand under tension in direction to be adjusted.

at
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- Carefully loosen last securing bolt until the pump can be turned slightly and then retighten securing bolt.
p
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- Observe figures in zone 2 and if necessary adjust again until the mean value for specification zone -C- is
f
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displayed.
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- Tighten injection pump securing bolts to 25 Nm. C py
ht. rig
- Check commencement of injection again. rig ht
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- Press the ⇒key.
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Note:
Loosen and re-tighten (25 Nm) the injection pipes on the injection pump after dynamically adjusting the injection
pump. This relieves the strain on pipes and prevents vibration breakages.

AG. Volkswagen AG d
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ised Diesel direct injection and ara glow
nte plug system - Edition 05.1998
or eo
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1.10 - Checking
ss a valve timing ra
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nform
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Special tools, workshop equipment, test and measuring appliances and aux. items required
◆ 2064 Locking pin
◆ 2065 A Setting bar
◆ 3036 Retainer
◆ V.A.G 1331 Torque wrench (5...50 Nm)
1.10 - Checking valve timing 69

Work sequence
- Remove upper toothed belt guard and cylinder head cover.

- Check tension of toothed belt.
- -> Turn crankshaft to TDC No. 1 cylinder -arrow-.
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- -> Setting bar must fit into the slot in the camshaft.horiIf
s it is not possible to insert the bar, adjust ntevalve
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as follows. s aut ra
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- Rotate camshaft so that setting bar can be inserted.
s
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- Centralize setting bar as follows:

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Turn arrested camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge es‐
itte
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tablish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between
erm
ab
setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd
ility
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feeler gauge, of same thickness, at the other end between setting bar and cylinder head.
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Note:
spec
es, in part or in w
t to the co
Never use setting bar as a counter hold when loosening and tightening the camshaft sprocket, use retainer
3036.
rrectness of i
- Loosen camshaft sprocket securing bolt a half turn.
- Place a drift through hole in the rear of the toothed belt guard and release the camshaft sprocket from
l purpos
camshaft taper with a blow from a hammer.
nform
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- -> Lock injection pump sprocket with pin 2064.

- Check crankshaft TDC setting. The TDC marking on the flywheel and the casting on the clutch bell housing
must align.
- Remove locking pin.
- Tighten camshaft sprocket securing bolt to
45 Nm.
- Remove setting bar.
- Install toothed belt guard and cylinder head cover.
- Dynamically check commencement of injection=>Page 66 .

AG. Volkswagen AG d
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ara system - Edition 05.1998
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1.11 - Removing and installing injectors
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◆ -> V.A.G 1331 Torque wrench (5...50 Nm)

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◆ -> 3035 Ring spanner
Note:
Defective injectors cause the following faults:
◆ Misfiring
◆ Knocking in one or more cylinders
◆ Engine over-heating
◆ Loss of power
◆ Excessive black exhaust smoke
◆ Higher fuel consumption
◆ Excessive blue smoke when starting from cold
Defective injectors can be located by loosening the high pressure pipe union on each injector in turn with the
engine running at a fast idling speed. If engine speed remains constant after loosening a pipe union, this indi‐
cates a defective injector.
Removing
- Remove injection pipes with an slotted ring spanner 3035.
Note:
Always remove pipe set complete. Do not alter pipe shape.
- Remove securing nut, take off retainer and take out injector.
1.11 - Removing and installing injectors 71

Installing
Note:
Always renew heat insulating seal betweenGcylinder head and injectors.
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- Insert injector. yV
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- Check mounting is seated rise correctly in cylinder head. nte
- Fit retainer. tho eo
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Tightening torques:
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Injection pipes = 25 Nm
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Retainer nut = 20 Nm
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1.12 - Servicing injectors
hole
spec
es, in part or in w
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This engine is equipped with dual spring injectors. The fuel injected therefore occurs in 2 stages.
If faults occur with these injectors then they are to be exchanged as neither servicing nor pressure setting is
rrectness of i
possible.
l purpos
◆ Injector test unit V.A.G 1322 with pressure pipe V.A.G 1322/2
nform
mercia
at
Test conditions
om
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or
• Pressure gauge on
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Checking injection pressure

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When testing injectors ensure that the jet of fuel does not contact the hands as the high pressure will cause
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- -> Connect injector to injector test unit.

- Press pump lever down slowly. When spray begins, read off opening pressure. For deviations from speci‐
fication renew injector.
Engine codes AEY, AFN, AHB, AHU, AKW
Specification:
New injectors: 190 ... 200 bar
Wear limit: 170 bar
Engine code ALE
Specification:

New injectors: 220 ... 230 bar
Wear limit: 200 bar
Checking for leaks
- Move pump lever down slowly and maintain a pressure of approx. 150 bar for 10 seconds. No fuel should
leak from the nozzle tip.
- If injector leaks, replace.
1.13 - Renewing injection timing device cover O-ring
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- Place a clean cloth under the injection pump.
wit
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- -> Remove cover screws -1- with commercially available key for Torx socket head screws, e.g. Hazet 2115-
h re
ole,
T30.
spec
- Remove cover -2- and clean it.
t to the co
- Renew O-ring -3- and install cover with existing shims -4-.
rrectne
2 - Checking components and functions
ss o
2.1 - Checking components and functions
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mer
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2.2 - Checking Diesel direct injection system voltage supply
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◆ Test box V.A.G 1598/18 or V.A.G 1598/22 p by
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◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
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◆ Adapter set V.A.G 1594
AG.
◆ Current flow diagram
Test prerequisites:
• Battery voltage OK.
1.12 - Servicing injectors 73

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Test sequence
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Vehicles with 68-pin control unit
t to the co
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Bridge sockets 42+46 with auxiliary cables from V.A.G 1594.
rrectness of i
l purpos
- Measure voltage between following sockets:

45+1, 68+1, 23+1 and 23+24
Specification: approx. battery voltage
nform
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- Measure voltage between following sockets:
2+1, 28+1, 27+2 and 28+27
Continued for all vehicles
If the specification is not obtained:
- Check voltage supply relay terminal 30 (J317).

- Check wiring connections for open circuit, short circuit and transfer resistance at contacts according to
current flow diagram.
If no fault is found in wiring and relay:
- Renew Diesel direct injection system control unit (J248) => Page 117 .

2.3 - Checking engine speed sender
The engine speed sender is speed and reference mark sender. During failure the engine continues running in
an emergency programme. Replacement sender is needle lift sender -G80.
olksw
◆ Test box V.A.G 1598/18 or V.A.G ag1598/22
en AG. V agen AG
does
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◆ Adapter set V.A.G 1594 ris
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Test sequence
nform
mercia
at
om
ion
- Disconnect connector for engine speed sender.
c
in t
or
=>Fitting location overview, Page 46 .

his
ate
- -> Measure resistance between connector contacts 1+2.

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Specification: 1.0 ... 1.5 kω

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If the specification is not obtained: t. Cop py
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=> Repair group 13; Dismantling and assembling engine Dismantling and assembling engine
If the specification is obtained:
2.3 - Checking engine speed sender 75

- -> Check wiring between test box and 3 pin connector for open circuit according to current flow diagram.
Contact 1+ socket 33
Contact 2+ socket 8
Contact 3+ socket 1
Wire resistance: max. 1.5 ω
- Check wiring at 3 pin connector for short circuit to one another according to current flow diagram.
Specification: ∞ω
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- -> Connect test box V.A.G 1598/22 to control unit wiring harness.
t to the co
rrectness o
cial p
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mer
atio
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Contact 1+ socket 69 C py
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- Check wiring at 3 pin connector for short circuit to one another according to current flow diagram.

If no wiring fault is detected:
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2.4 - Checking intake manifold
Vol
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pressure sender
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Both pressure senders are located in the Diesel direct injection system control unit.
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nform
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a
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tion in
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◆ -> V.A.G 1397 A Turbocharger tester

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Test sequence
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Cop py
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- Connect the fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics
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control unit with the "Address word" 01. cop Vo
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(Connecting fault reader and selecting engine electronics control unit => Page 2 .)cted agen
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Select function XX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.


0 mg/H 1027 mbar 1013 mbar 0
%
- Compare display in display zone 2 (altitude sender -F96) and display zone 3 (intake manifold pressure
sender -G71).
Specification: Pressures the same

(Tolerance ±30 mbar)
2.3 - Checking engine speed sender 77

- Compare pressure display with a barometer (e.g. turbocharger test unit V.A.G 1397/A).
Tolerance ±30 mbar
Value in display zone 3 deviates:
- Pull pressure hose off control unit.
Value in display zone 3 still deviates: n AG. Volkswagen AG do

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- Press the ⇒key. d b ua
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- Press keys 0 and 6 for the "End
tho data transfer" function and confirm inputteewith
or the Q key.
- Switch off ignition. au ac
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2.5 - Checking coolant temperature sender
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◆ Test box V.A.G 1598/18 or V.A.G 1598/22
rrectness of i
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Test sequence
nform
mercia
a
com
tio
word" 01. When doing this the engine must be running at idling speed. n in
r
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Select function XX Cop py
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- ->
15.4 5C 15.9 5C 16.7 5C
Indicated on display:
- Observe coolant temperature figure in display zone 4. The temperature figure must
Increase uniformly and without interruption.
- In case of faults the fuel temperature is displayed as a substitute.
- If no realistic display appears in display zone 4 or the fuel temperature is displayed as a substitute. Check
coolant temperature sender and wiring connections to sender as follows:
- Press the ⇒key.

- -> Pull connector off coolant temperature sender -1-.

- Measure resistance between sender contacts 1+3.
-> Specification see diagram
Scale A shows resistance values for temperature range 0...50 °C and scale B the values for temperature range
50...100 °C.
Examples:
◆ 30 °C corresponds to a resistance from 1500...2000 ω wage

es n
◆ 80 °C corresponds to a resistance from 275...375 ω y Volks ot g
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If the specification is not obtained: tho e or
au ac
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- Replace coolant temperature sender (G62).
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rm
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es, in part or in w
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nform
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a
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tion in
r

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t.
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2.5 - Checking coolant temperature sender
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
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- -> Connect test box V.A.G 1598/22 to control unit wiring harness. ility
ot
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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tion in
r
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iva
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t.
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Specification: ∞ω p by
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2.6 - Checking brake light switch and brake pedal switch
Because the injection system operates with an accelerator pedal sender (potentiometer) which may be defec‐
tive, the engine is regulated for reasons of safety when the brakes are operated. To do this the control unit
requires signals from the brake light switch and also the brake pedal switch. This means that if the brakes are
operated when the accelerator pedal is held at a constant position the engine is immediately reduced to idling
speed. Incorrectly adjusted switches may lead to unrequired regulating action
Test sequence
- Connect the fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine electronics
control unit with the "Address word" 01.

Select function XX
- Press keys 0 and 8 for the function "Read measured

olksw
value block" and confirm entry with Q key.
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-> Indicated on display: yV
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Read measured value block orise HELP nte
Input display group number th XXX eo
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- Observe display in display zone 2.

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-> Specification: 0 0 0
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0 km/h 0 0 0 000000 255

spec
es, in part or in w
t to the co
- Operate brake pedal slowly.
rrectness of i
Both displays must change from 0 to 1 at same time.

l purpos
0 km/h 0 1 1 000000 255

nform
ercia
- Centre display = Brake pedal switch

- Right-hand display = Brake light switch
m
at
If no change takes place: adjust brake pedal switch switch point by turning the switch or adjust brake light
om
ion
switch point by moving the plunger.

c
in t
or
his
ate
- If one or both of the displays do not change from 0 to 1. Check switches or wiring connections to switches
do
priv
as described in the following.

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Checking brake pedal switch (F47) C py
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- Press the ⇒key.
co Vo
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Prote AG.
2.5 - Checking coolant temperature sender 81

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- -> Pull connector off brake pedal switch -1-.
- Measure resistance between switch contacts.
rrectne
Specification:
Brake pedal not depressed: under 10 ω
Brake pedal depressed:∞ω
ss o
cial p
f i
nform
mer
atio
- Replace brake pedal switch (F47).
om
n
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i
or
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- -> Check wiring between test box and connector for open circuit according to current flow diagram.

- -> Check wiring between AG. Vtest box

olkswagenand
AG dconnector for open circuit using current flow diagram.
Contact 1+socket agen28 oes
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Wire orisresistance: max. 1.5 ω nte
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- Additionally
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check wires for short to one another, toovehicle ra earth and to battery positive.
s Specification: ∞ω
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Checking brake light switch (F)

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ab
ility
- Press the ⇒key.

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ole,
- Set multimeter scale to measure voltage and connect between test box sockets.
spec
t to the co
Vehicles with 68-pin control unit:

Socket 1+44
rrectne
Vehicles with 80-pin control unit:

Socket 1+20
ss o
cial p
- Observe voltage display.

f in
Specification:
form
mer
Brake pedal not depressed: 0 Volt

atio
m
Brake pedal depressed: approx. battery voltage

o
n
c
i
or
n thi
e
No voltage is displayed:
t
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- Check whether brake light functions.

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t.
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2.6 - Checking brake light switch and brake pedal switch 83

Brake light OK:
- Check wiring to brake light switch for open/short circuit according to current flow diagram.
Brake light not OK:
- Replace brake light switch (F).
2.7 - Checking clutch pedal switch
The clutch pedal switch (F36) informs the control unit when the clutch is being engaged or disengaged. This
prevents the engine from jolting when disengaging and engaging and also prevents the engine from racing
during disengaging operations when the cruise control system is switched on.
◆ Current flow diagram Volkswa n AG. gen AG
wage does
Test sequence Volks not
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- Connect the fault reader V.A.G 1551 (V.A.G 1552) aand
ut
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with ignition switched on select engine electronics
ra
control unit with the "Address word" 01. ss c
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Select function XX
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spec
t to the co
rrectne
- Press keys 0, 0 and 6 for "Display group number 6" and confirm entry with Q key. ss
o
cial p
f inform
mer
atio
m

o
n
c
0 km/h 0 0 0 000000
i
or
n thi
255
te
sd
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- Operate clutch pedal. The left-hand position must change to 1.

um
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-> Specification: 1 0 0 C py
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Read measured value block 6 pyri by
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0 km/h 1 0 0 000000 by lksw
255 cted agen
Prote AG.
If the specifications are not obtained:
- Press the ⇒key.


- -> Pull connector off clutch pedal switch -1- .

- Measure resistance at switch contacts.
Specification
Clutch not depressed: max. 10 ω
Clutch depressed: ∞ω
If the specifications are not obtained: agen

AG. Volkswagen AG d
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- Replace clutch pedal switch (F36). ise
d b ara
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If the specifications are obtained: ss a c
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2.7 - Checking clutch pedal switch 85

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Contact 1+ socket 2
l purpos
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2.8 - Checking intake manifold sender
Prote AG.
(Only engine codes AFN, AHU, ALE)

◆ Test box V.A.G 1598/18
Test sequence


Select function XX


15.4 5C 15.9 5C 16.7 5C
- If no realistic display appears in display zone 3 or a substitute temperature of 136.8 °C is displayed, check
intake manifold temperature sender and the wiring to the sender as follows:
- Press the ⇒key.
AG. Volkswagen AG d
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- -> Pull connector -1- off intake manifold temperature sender -2-.
rm
ab
pe
ility
- Measure resistance between sender contacts.
ot
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
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50...100 °C.
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Examples:
ht
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◆ 30 °C corresponds to a resistance from 1500...2000 ω
Prote AG.
2.8 - Checking intake manifold sender 87


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- Replace intake manifold temperature sender (G72).
rrectness of i
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2.9 - Checking intake air temperature sender
(Only engine codes AEY, AHB, AKW)

AG. Volkswagen AG d
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In case of fault the fault readeraV.A.G
ut
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(G72) for engine codes AHB and AKW. ss
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Test sequence
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Select function XX
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Read measured value block HELP Cop py
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15.4 5C 15.9 5C 16.7 5C
- If no realistic display appears in display zone 3 or a substitute temperature of 18.9 °C or 136.8 °C is displayed,
check intake air temperature sender and the wiring connections to sender as follows:
- Press the ⇒key.

- -> Pull connector -1- off intake manifold temperature sender -2-.
2.9 - Checking intake air temperature sender 89

- Measure resistance between sender contacts.
AG. Volkswagen AG d
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-> Specification seed diagram
by Vo gu
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Scale A shows resistance
auth
values for temperature range 0...50 °C and
r a scale B the values for temperature range
50...100 °C. s s c
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Examples:
itte
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ility
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spec
- Replace intake manifold temperature sender (G42). t to the co

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mer
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nform
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tion in
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2.9 - Checking intake air temperature sender
Prote AG.
AG. Volkswagen AG d
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Polo Estate 1998 ➤ orise nte
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Diesel direct injections a and glow plug system - Edition 05.1998 or ac
ut
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du
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2.10 - Checking fuel temperature sender
Test sequence

Select function XX


15.4 5C 15.9 5C 16.7 5C
AG. Volks wagen AG
agen does
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- If no realistic by Vodisplay
l appears in display zone
not 1 or a substitute temperature of -5.6 °C or -5.4 °C is displayed,
gu
check rfuel
ise temperature sender and wiring connections
d ara
nte to sender as follows:
- Press uthothe ⇒key. eo
r
- Press
ss
a keys 0 and 6 for the "End data transfer" function ac and confirm input with the Q key.
ce
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rm
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nform
mercia

com
tion in
r
te o
- -> Disconnect connector for fuel temperature sender (connection to injection pump metering control).
thi
s
iva
- Measure sender resistance at contacts 4+7.

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- -> Disconnect 10 pin connector for fuel temperature sender (connection to injection pump metering control).
- Measure sender resistance at contacts 4+7.
2.10 - Checking fuel temperature sender 93

AG. Volkswagen AG d
agen oes
olksw not
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aut ra
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nl
pt
du
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ab
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50...100 °C.
hole
spec
Examples:
es, in part or in w
t to the co
rrectness of i
l purpos
- Replace injection pump => Page 61 .

nf
ercia
orm
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- -> Check wiring between test box and connector for open circuit aaccording
gen AG
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gen AG flow diagram.
does
Contact 7+ socket 63 olksw not
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Contact 4+ socket 33 ed b ara
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Wire resistance: max. 1.5 ω thor eo
- Additionally check wires for short to one another, sto vehicle earth and to battery positive.
au ra
c
Specification: ∞ω s
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rm
ab
pe
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
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on in
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Prote AG.
2.11 - Checking modulating piston movement sender and quantity adjuster
The metering unit is an electro-magnetic swivelling positioner which is controlled by the control unit via a directed
duty cycle (on-off ratio). The eccentric shaft on the metering unit moves the modulating piston on the high
pressure piston and thereby regulates the quantity of fuel injected.
The modulating piston movement sender informs the control unit of the position of quantity adjuster -N146 and
therefore stipulates the amount injected.
2.10 - Checking fuel temperature sender 95

. Volkswagen AG
gen AG d
Special tools, workshop equipment, testers, measuring instruments and olksauxiliary items required s not g
wa oe
yV ua
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552isewith cable V.A.G 1551/3
d b ran
◆ Test box V.A.G 1598/18 or V.A.G 1598/22 uthor tee
or
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715ss a ac
ce
e
nl
pt
du
an
itte
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erm
ab
Test sequence
ility
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Select function XX
rrectness of i
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nf
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840 rpm 6.5 mg/H 1.480 V 87.3
o
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5C yi
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- Check coolant temperature in display zone 4. C py
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Specification: at least 85 °C
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Continue with check only when coolant temperature is attained. Prote AG.
- measured value block 1

Read
840 rpm 6.5 mg/H 1.480 V 87.3 5C
-> Check voltage supply from modulating piston movement sender in display zone 3.
Specification:
Engine code AEY: 1.400...1.800 V
Engine code AFN: 1.300... 1.900 V
Engine code AHB: 1.500... 2.000 V
Engine code AHU: 1.250... 1.700 V
Engine code AKW: 1.500... 2.000 V
Engine code ALE: 1.300... 1.900 V
- If specification is not obtained, check modulating piston movement sender and quantity adjuster as descri‐
bed in following:
Checking modulating piston movement sender (G149).

- Press the ⇒key.

wage
Vehicles with 68-pinycontrol
Volks unit es n
ot g
b ua
ed ra
- -> Disconnecthor connection for fuel temperature sender n(connection
is tee to fuel pump quantity adjuster).
- Measures aresistance
ut
between connector contacts 1 + 2 and or 2 + 3.
ac
s Specification: 5 ... 7 ω
ce
le
un
pt
an
d

itte
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erm
ab
ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
- -> Disconnect 10 pin connector for fuel temperature sender (connection to injection pump metering control).
om
- Measure resistance between connector contacts 1 + 2 and 2 + 3.
n
c
i
or
n
Specification: 5 ... 7 ω
thi
te
sd
iva
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pr
c
um
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fo
en
ng
t.
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Co
Cop py
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If the specification is obtained: Prote AG.

2.11 - Checking modulating piston movement sender and quantity adjuster 97

Contact 2+ socket 7
AG. Volkswagen AG d
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Vehicles with 80-pin control unit ised ara
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- -> Connect test box V.A.G 1598/22 to control unit
ss a
wiring harness. c
ce
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nl
pt
du
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ab
ility
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Contact 2+ socket 57 atio

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Prote AG.

Checking quantity adjuster (N146)
- Press the ⇒key.


- -> Disconnect connector for quantity adjuster(connector to injection pump quantity adjuster).
AG. Volkswagen AG d
agen oes
olksw not
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un
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spec
es, in part or in w
t to the co
- Measure resistance between connector contacts 5+6.
Specification: 0.5...2.5 ω
rrectness of i

l purpos
- -> Disconnect 10 pin connector for quantity adjuster(connection to injection pump quantity adjuster).
- Measure resistance between connector contacts 5+6.
nform
ercia
Specification: 0.5...2.5 ω
m
a
com

ion in
r
te o

thi
s
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do

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cum
fo
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t.
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rig ht
py by
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by lksw
cted agen
Prote AG.

Vehicles with 68-pin control
olks unit
wage es n
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V
by ua
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- -> Connect test
ho
r box V.A.G
is 1598/18 to control unit wiringnloom.tee
aut or
ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
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t to the co
rrectness of i
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Contact 5+ sockets 23, 45 and 68
nf
ercia
or
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Contact 5+ sockets 2 and 28

2.12 - Checking needle lift sender
The needle lift sender signal is used to determine the commencement of injection. If it fails the commencement
of injection switches to open-loop control (according to engine speed and engine load). During normal operation
the commencement of injection is controlled by a closed-loop function (according to engine speed, engine load
and temperature).
◆ Test box V.A.G 1598/18 or V.A.G 1598/22 gen AG. Volkswagen AG d

◆ Hand multimeter V.A.G 1526 or multimeter olks V.A.G 1715
wa oes
not
◆ Adapter set V.A.G 1594 byV gu
ara
ed
◆ Current flow diagram thoris nte
eo
au ra
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ss
Test sequence
ce
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un
pt
an
d
itte
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erm
ab
ility
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ole,
spec
t to the co
rrectness o
cial p
f inform

mer
- Disconnect connector for needle lift sender => Fitting location overview, Page 46 .
atio
m
- -> Measure resistance between connector contacts.

o
n
c
Specification: 80...120 ω
i
or
n thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
- Replace No. 3 cylinder injector with needle lift sender (G80) => Page 55 , item 15 .
yi Co
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AG. Volkswagen AG d
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nl
pt
du
an
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erm
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ility
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es, in part or in w
t to the co
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l purpos
nform
mercia
at
om
ion
c
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at
do
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p
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or

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at
om
ion
c
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or
2.13 - Checking injection timing control range

his
ate
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for
en
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◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3 pyri by
Vo
co
by lksw
cted agen
Prote AG.

Engine codes AEY, AHB, AHU
Engine codes AFN, AKW, ALE =>Page 105
The control range of the injection adjuster can be checked with help of final control element test and at the
same time calling-up measured value block 04. To do this it is required to activate the control element Com‐
mencement of injection valve -N108 and then exiting the final control element test with key -C-. Using this
sequence the commencement of injection valve continues to be pulsed so that with help of measured value
block 04 (display zone 3) the injection adjuster control range can be read.
2.12 - Checking needle lift sender 103

Test sequence

Select function XX

Rapid data transfer Q
03 Final control diagnosis
Note:
The individual control elements are only activated for 30 seconds. Within this period various work sequences
must be carried out with the fault reader unit as well as reading the measured values. Therefore read the
following work sequence first to become conversant with the procedure.
- Confirm input with Q key. agen AG. Volkswagen AG do
lksw es n
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- Press C key.
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ility
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es, in part or in w
t to the co

rrectness of i

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840 rpm 0.95 BTDC 0.95 BTDC 3

%
nf
ercia
The displays in display zones 3 and 4 must fluctuate within following control range:
orm
m
atio
m
Engine codes AEY, AHB

o
n in
or c
thi
e
- Specification display zone 3

t
sd
iva
lower range 1°ATDC...5.0°BTDC

o
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rp
cu
upper range 14.0...17.4°BTDC

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en
ng

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lower range 2...5% C py
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upper range 90...95%
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pyri by
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Because the fault reader display is slow the displayed figures vary greatly. Therefore ensure that in
Prote AG.
display zone 3 the lowest figure lies between 1.0 and 5.0 and the highest figure lies between 14.0 and 17.4
and in display zone 4 the lowest figure lies between 2 and 5, and the highest figure lies between 90 and 95.
Engine code AHU

lower range 1°ATDC...4.0°BTDC
upper range 14.0...17.4°BTDC
lower range 2...5%

upper range 90...95%
Because the fault reader display is slow the displayed figures vary greatly. Therefore ensure that only in
display zone 3 the lowest figure lies between 1.0 and 4.0 and the highest figure lies between 14.0 and 17.4
and in display zone 4 the lowest figure lies between 2 and 5, and the highest figure lies between 90 and 95.
Continued for all engine codes
- Check commencement of injection valve => Page 106 .
Engine codes AFN, AKW, ALE
Checking the function of the exhaust gas recirculation is undertaken in function 04 (Basic settings). Using this
procedure the exhaust gas recirculation valve is pulsed so that the extremity values for advanced (early) and
retarded (late) positions for the timing
wage
ndevice
AG. Volkcan be read
swagen AG
doein measured value block 004, display zone 3.
ks s no
Vol t gu
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Test sequence ris
ed
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a
- Connect fault (V.A.G 1552) and reader
ss V.A.G 1551
control unit with the "Address select engine electronics
c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Select function XX
hole
spec
es, in part or in w
- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.
t to the co
rrectness of i
Basic setting HELP
l purpos
nform
ercia

m
at
om

on
c
820 rpm advanced 7.95 BTDC

in t
or
47%
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ate
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Specification display zone 3:

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Engine codes AFN, ALE 6.5...9.5° BTDC

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820 rpm retarded 4.45 BTDC
32%
Specification display zone 3:

Engine codes AFN, ALE 2.5...5.5° BTDC
Engine code AKW 3...5° BTDC
- Press the ⇒key.

2.13 - Checking injection timing control range 105

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- -> Measure resistance between connector contacts 2 + 3.

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- Disconnect 10 pin connector =>Installation position overview, Page 46 .

- -> Measure resistance between connector contacts 9+10.

- Replace commencement of injection valve (N108)
=>Page 56 .


- -> Check wiring between test box and 3Apin connector for open circuit according to current flow diagram.
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Contact 3+ socket 68 d by V ua
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Specification: ∞ωss
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Contact 10+ socket 2+28
2.13 - Checking injection timing control range 107


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2.14 - Checking throttle valve positioner
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- Pull connector off throttle valve positioner =>Fitting locations overview, Page 46 .
- -> Measure resistance between throttle valve positioner contacts.
Specification: 25...45 ω
- Renew throttle valve positioner (V60)

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- Check wiring between test box and connector for open circuit according to current flow diagram.
2.14 - Checking throttle valve positioner 109

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Contact 1+ socket 2+28
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2.15 - Checking exhaust gas recirculation and air mass meter function
◆ Test box V.A.G 1598/18
Engine code AHU
Engine codes AFN, ALE =>Page 113
The exhaust gas recirculation and air mass meter function can be checked with the help of final control element
test and at the same time calling-up measured value block 003. To do this the control element Exhaust gas
recirculation (EGR) valve -N18 must be activated and then exit the final control element test with -C- key. Using
this sequence the EGR valve continues to be pulsed so that with the help of the measured value block 003
(display zone 3) the extreme values for the EGR (air mass meter) can be read.
Test sequence

Select function XX

Rapid data transfer Q
03 Final control diagnosis
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The individual control elements are onlys auactivated for 30 seconds. Within this period various
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must be carried out with the fault reader unit as well as reading the measured values. Therefore read the
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following work sequence first to become conversant with the procedure.

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- Confirm input with Q key.

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- Press the ⇒key.

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Exhaust gas recirculation valve -N18
nform
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- Press C key.
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2.15 - Checking exhaust gas recirculation and air mass meter function 111
Read "
840 rpm 272 mg/H 268 mg/H 54 %
The displays in display zones 3 and 4 must fluctuate within following control range:

Lower range 230...310 mg/stroke
Upper range 360...480 mg/stroke
Lower range 2...5%
Upper range 90...95%
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and lower range figures in edisplay
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- Check air mass meter as follows:
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- -> Pull connector -1- off air mass meter -2-.

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- -> Measure air mass meter voltage supply between following connector contacts:
Connector on -G70 contact Specification

3 + Earth App. battery voltage
3+5 App. battery voltage
1 + earth Approx. 5 V


1+5 Approx. 5 V
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- Check wiring between test box and connections for open circuit according to current flow diagram.
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Contact 5+ socket 1
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If the specifications are obtained:

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- Check exhaust gas recirculation:

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If no fault is detected on the air mass meter and the exhaust gas recirculation system:
AG.
Engine codes AFN, ALE
Checking air mass meter
The air mass meter signal is used by the control unit to calculate the quantity injected and to control the required
exhaust gas recirculation. The smaller the signal from air mass meter the smaller the quantity of fuel injected.
Test sequence
Warning!
Secure fault reader to rear seat and operate from this position.
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Rapid data transfer r
HELP
Select function XX tho eo
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Read
309 mg/H 1027 mbar 1011 mbar 0.0 %
-> Specification: 230...420 mg/H
rrectness of i
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- Check exhaust gas recirculation:
nform
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- Accelerate vehicle in 2nd gear from about 1500 rpm using full throttle.
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- Press PRINT key on V.A.G 1551 at approx. 3000 rpm. The accelerator pedal must be fully depressed at
en
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t.
this moment in time.
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-> Specification in display zone 4: 100 % (accelerator pedal position)
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- Repeat test and accelerate vehicle at full throttle.
- ->
830 mg/H 1027 mbar 1850 mbar 100 %
Specification in display zone 1: above 750 mg/H (mass of air drawn in).

- Renew air mass meter.
If a constant 550 mg/H (predetermined replacement value) is displayed in display zone 1.

- Press the ⇒key.
- Disconnect connector for air mass meter
=>Fitting locations overview, Page 46 .

- -> Measure air mass meter voltage supply between following connector contacts:

3 + Earth App. battery voltage
3+5 App. battery voltage
1 + earth Approx. 5 V
1+5 Approx. 5 V
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- -> Check wiring between test box and connections for open circuit using current flow diagram.
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Contact 5+ socket 1
AG.

- Renew Diesel direct injection system control unit (J248) => Page 117
2.16 - Checking speedometer sender
◆ Diode test lamp V.A.G 1527
Note:
To check the speed signal the vehicle must be driven. To do this a second person is necessary.
Warning!
Secure fault reader to rear seat and operate from this position.
Test sequence
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- Carry out a test drive and compare display with speedometer (2nd person required).
-> Specification display zone 1: Approx. road speed.
rrectness of i
55 km/h 0 0 0 000000
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255
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or
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If no speed is indicated:
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- Set multimeter scale to measure voltage and connect between test box sockets 43 + 33.
- Rotate front wheel and observe voltage display.
Specification: between 0 and at least 5 Volt fluctuating

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Note:
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If necessary, hold the front right wheel to prevent it from turning.
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If the display does not fluctuate:
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- Check wiring to speedometer or to speedometer sender.
t to the co
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- Connect diode test lamp between socket 1 (earth) and socket 51 (speed signal).
- Switch on the ignition and turn the front left wheel by hand.
Note:
If necessary, hold the front right wheel to prevent it from turning.
- The diode test lamp must flash (approx. four times per wheel rotation).
- If the diode test lamp does not flash, check wiring from engine control unit connector contact 51 to dash
panel insert for open/short circuit.
3 - Replacing, coding and matching engine control unit

3.1 - Replacing, coding and matching engine control unit
3.2 - Replacing engine control unit
Work sequence
- First print out the control unit identification and thereby the previous control unit coding as follows:
- Connect fault reader V.A.G 1551 (V.A.G 1552) and select the engine electronics control unit with the "ad‐
dress word" 01
=> Page 2 ; Connecting fault reader and selecting engine electronics control unit.
-
028906021DL 1.9l R4 EDC G00SG 0828
Coding 00002 WSC XXXXX
2.16 - Checking speedometer sender 117

-> Press Print key of fault reader for control unit identification print-out (example).
- Press ⇒key.

AG. Volkswagen AG d
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Select function XX y V gu
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- Switch off ignition.s au ra
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- Remove plenum chamber cover. s
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=> General body repairs; Repair group 66; Trim; Removing and installing plenum chamber cover Trim Re‐
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moving and installing plenum chamber cover
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- Pull vacuum hose off control unit.
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- Release and pull off control unit connector.
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- -> Remove control unit bracket and take out old control unit with bracket.
f
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- Before installing exchange engine control unit, note part number.
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- Install new control unit with bracket. t. C rig
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- Check the previous coding and Part No. of the old control unit and code the exchange control unit according
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to table => Page 118 .
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- If the vehicle is equipped with a cruise control system (CCS) (recognised by a G before gearbox version,
e.g. G00SG) then this must be activated on exchange engine control unit.
- Match engine control unit to the electronic immobilizer => Page 120
3.3 - Coding engine control unit
There are control units which must not be coded (engine control unit MSA12) and control units which must be
coded (engine control unit MSA15).
If the appropriate code for the vehicle is not displayed or if the control unit has been renewed, the control unit
must be coded as follows.
Warning!
Always display the the control unit identification first and print out if necessary.
emissions.

Work sequence
word" 01. When doing this the ignition must be switched on.
Control unit identification of MSA12
-> If the fault reader V.A.G 1551 displays this control unit identification, then the control unit must not be coded
(example):
028906021C 1.9 ltr. R4 EDC
SG D..
Coding 0000 WSC0000
◆ There are no zeros in front of the type of gearbox (MG or AG).

◆ The software version begins with a letter.
Externally the MSA12 can be recognised by the plastic housing.

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Control unit identification of MSA15 by Vo gu
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-> If the fault reader V.A.G uth
1551 displays this control unit identification, then
ra the control unit must be coded
sa
(example). s c
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028906021DF 1.9l R4 EDC G00SG 0602
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◆ There are two zeros in front of gearbox version (SG or AG) or G if the vehicle is equipped with a cruise
wit
control system (CCS).
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◆ The software version is made up of a 4 digit number, e.g. 0602 or a capital letter-number combination, e.g.
ole,
spec
KD02.
◆ The display KDxx means that the engine control unit is an exchange engine control unit. See engine control
t to the co
unit print-out for coding to be entered.
Externally the MSA15 is recognised by the aluminium housing.

rrectne
- Press ⇒key.
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Select function XX
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- Press keys 0 and 7 for the function "Code control unit" and confirm entry with Q key.
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Code control unit Q yi Co
Input code number xxxxx (0-32000) Cop py
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Coding when replacing a MSA 12 engine control unit with a MSA 15 engine control unit
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- Code the exchange engine control unit MSA15 according to table.
Example:
Part number of old control unit MSA12:

- 028 906 021 CJ
Part number of exchange control unit MSA15:

- 028 906 021 HA
Coding of exchange engine control unit MSA15:

- 00002
3.3 - Coding engine control unit 119

Control unit Exchange control Coding for ex‐

MSA12 unit MSA15 change control
unit MSA 15
028 906 021 CJ 028 906 021 HA 00002
028 906 021 CQ 028 906 021 HA 00005
Coding engine control unit MSA 15 (without display "KDxx" in control unit identification)
- Enter the appropriate code number for this vehicle and confirm with Q key.
Coding For vehicles with

00001 Automatic gearbox (not relevant)
engine code in Caddy
-> Fault reader V.A.G 1551 displays control unit coding, e.g.:
028906021HA 1.9l R4 EDC G00SG 1439
- Press ⇒key.
- Switch ignition off and then on again.
Note:
The coding entered will be activated by switching the ignition off and then on again. If after entering the valid
code the ignition is not switched off and on again,
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- Erasing fault memory => Page ris 12
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Activating cruise control system
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3.4 - Matching engine control unit to electronic immobilizer

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Test conditions
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• Authorized vehicle key required
Work sequence
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- -> Fold driver's side stowage compartment down.
- Connect fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3.
- Connect fault reader or system tester using cable V.A.G 1551/3 to diagnosis connection.
- Operate fault reader or vehicle system tester taking into account the information on the display:
- Press key 1 for "Rapid data transfer".
- Press keys 2 and 5 for address word "Immobilizer" and confirm entry with Q key.
- Press the ⇒key.

Select function XX
- Press keys 1 and 0 for function "Adaption" and confirm entry with Q key.

Adaption
Feed in channel number XX
- Press key 0 twice for "Channel number 0" and confirm entry with Q key.

Adaption Q
Erase learnt values?
- Confirm input with Q key.

Adaption
Learnt values have been erased
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- Press keys 0 and 6 for theris"End
ed data transfer" function and confirm ninput
tee with the Q key.
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- Switch off ignition. ss
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Note:
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The identity of the engine control unit is read into the immobilizer control unit when next switching the ignition
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3.4 - Matching engine control unit to electronic immobilizer 121

28 - Glow plug system
1 - Checking glow plug system

1.1 - Checking glow plug system
◆ Hand multimeter V.A.G 1526

Test conditions
• Battery voltage at least 11.5 V

• Ignition switched off
• Diesel direct injection system control unit (J248) OK.
• Glow plug strip fuse (S 39) OK.
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Test sequence ut
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- -> Pull connector off coolant temperature sender -1-.
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Note:
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Pulling the connector off sender, simulates engine condition "cold" and when switching the ignition on the
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relevant glow period is carried out.

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spec
- Pull glow plug connector off glow plug.

t to the co
- Connect multimeter to measure voltage between a glow plug connector and vehicle earth.
- Switch on ignition for approx. 20 seconds
approx. battery voltage
must be displayed.
rrectne
- If no voltage is present:
ss
o
cial p
f inform
mer
atio
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1.2 - Checking glow plugs

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◆ Diode test lamp V.A.G 1527
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122 28 - Glow plug system

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◆ -> 3220 Jointed socket
◆ Torque wrench V.A.G 1331 (5...50 Nm)
rrectness of i
Test conditions
l purpos
• Battery voltage at least 11.5 V
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- Pull glow plug connector off glow plug.

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- -> Connect diode test lamp wire using auxiliary clips from auxiliary cable set to battery positive (+).
- Place diode test lamp probe on each glow plug one after the other.
Diode lights up: glow plug OK.
Diode does not light up: replace glow plug.
- Remove and install glow plugs with jointed spanner 3220
Tightening torque: 15 Nm.
1.2 - Checking glow plugs 123

SM 8

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SM 8

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Service

Polo Estate 1998 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056405620

23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

1.7 Checking throttle valve positioner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

1.8 Removing and installing injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

1.9 Dynamically checking and adjusting commencement of injection . . . . . . . . . . . . . . . . . . . .66

1.10 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

1.11 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

1.12 Servicing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

1.13 Renewing injection timing device cover O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

2 Checking components and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

2.3 Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

2.8 Checking intake manifold sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

2.9 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

2.10 Checking fuel temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

2.12 Checking needle lift sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

2.16 Checking speedometer sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

1.2 - Features of self-diagnosis

1.3 - Technical data of self-diagnosis

carried out in the operating mode "Rapid data transfer".

◆ Fault memory: Non-volatile memory and volatile memory1)

Interrogating control unit versions

is connected and engine electronics control unit selected => Page 2 .

◆ -> V.A.G 1551 Fault reader

Test conditions AG. Volkswagen AG d

After the fault reader has been connected:

=> Fault reader operating instructions

-> Indicated on display:

2.2 - Interrogating fault memory

Only when engine does not start:

- Switch ignition on.

-> Indicated on display:

- Press the ⇒key.

-> Indicated on display:

2.3 - Fault table

=> Fault reader operating instructions

Throttle valve positioner -V60

- Cold start problems - Check V60

Short to positive - Short to positive

- V60 defective/sticking in direction - Cold running problems =>Page 108

open - Hard load changes

- Poor idling characteristics

Engine speed sender -G28

- Wiring open or short circuit

implausible signal - Charge pressure control - Reduced output - Check N75

sender (G71) defective

Coolant temperature sender -

Altitude sender -F96

itive - Wiring open circuit or

Needle lift sender -G80

- Wiring open circuit or short lights up => Page 101

circuit - Engine runs rough

2.3 - Fault table 7

- Leakage between turbo‐ => Repair group 21;

charger and engine (charge Checking charge pressure

- Turbocharger defective pressure control Checking

charge pressure control

V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

- Invalid control unit - Code control unit