SM 30

Service
Polo Estate 1998 ➤

Motronic inj. and ignition system (2-valve, roller ot g rocker
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Edition 12.1999
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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
Motronic inj. and ignition system (2-valve, roller rocker
finger)
Repair Group
01 - Self-diagnosis
24 - Mixture preparation, Injection
28 - Ignition system
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Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg 00056407920

Motronic inj. and ignition system (2-valve, roller rocker finger) - Edition 12.1999
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 General to self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 General to self-diagnosis V.o.lk.s.w.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.2 Features of self-diagnosis wage . . . . . . .A.G. d.o.es. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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1.4 Significance
tho of EPC warning lamp (fault lamp for electronic eo accelerator) in dash panel insert
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1.5 Significance of exhaust emissions warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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1.6 Connecting fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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2 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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2.1 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
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2.2 Interrogating and erasing fault memory of engine control unit . . . . . . . . . . . . . . . . . . . . . . . .7
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2.3 Automatic test sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
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3 Fault table: SAE P0 codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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3.1 Fault table: SAE P0 codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Fault table: SAE P1 codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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4.1 Fault table: SAE P1 codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
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5.1 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

5.2 Performing final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
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6 Readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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6.1 Readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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6.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
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6.3 Reading readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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6.4 Generating readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

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7 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

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7.1 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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7.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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7.3 Read measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
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8 Evaluating measured value blocks, display groups 0...9 -Basic functions- . . . . . . . . . . . . . .31
8.1 Evaluating measured value blocks, display groups 0...9 -Basic functions- . . . . . . . . . . . . . .31
9 Evaluating measured value blocks, display groups 10...29 -Ignition- . . . . . . . . . . . . . . . . . .34
9.1 Evaluating measured value blocks, display groups 10...29 -Ignition- . . . . . . . . . . . . . . . . . .34
10 Evaluating measured value blocks, display grps 30...49, 99 -Lambda regulation- . . . . . . . .38
10.1 Evaluating measured value blocks, display grps 30...49, 99 -Lambda regulation- . . . . . . . .38
11 Evaluating measured value blocks, display groups 50...69 -Speed regulation- . . . . . . . . . .43
11.1 Evaluating measured value blocks, display groups 50...69 -Speed regulation- . . . . . . . . . .43
12 Evaluating measured value blocks, display groups 70...79 -Reducing emissions- . . . . . . . .46
12.1 Evaluating measured value blocks, display groups 70...79 -Reducing emissions- . . . . . . . .46
13 Evaluating measured value blocks, display group 100 -Readiness code- . . . . . . . . . . . . . .47
13.1 Evaluating measured value blocks, display group 100 -Readiness code- . . . . . . . . . . . . . .47
24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
1.1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
1.2 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
1.3 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
1.4 Removing and installing parts of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
1.5 Dismantling and assembling intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
1.6 Dismantling and assembling fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
1.7 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Contents i
1.9 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

1.10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
2.1 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
2.2 Checking Lambda probe heating before catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
2.3 Checking Lambda probe heating after catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
2.4 Checking throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
2.5 Checking intake manifold pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
2.6 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
2.7 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
2.8 Checking engine speed sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
2.9 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
2.10 Checking fuel pressure regulator and holding pressure . . .A.G.. V. o.lk.sw . a. g.e.n. . . . . . . . . . . . . . . .102
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2.11 Checking intake air system for leaks (unmetered air) lks w. a.g.e . . . . . . . . . . . . . .do. e.s .n . . . . . . . . . .106
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2.12 Checking intake air preheating . . . . . . . . . . .se.d.by. . . . . . . . . . . . . . . . . . . . . . . . . . . u.a.ra.n . . . . .107
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2.13 Checking vacuum valve . . . . . . . . . . . . .ut.ho. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee. o. . .107
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3 Checking functions . . . . . . . . . . . . . . .ss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c .109
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3.1 Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

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3.2 Idling check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

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3.3 Checking Lambda probe and Lambda regulation before catalyst . . . . . . . . . . . . . . . . . . . .111
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3.4 Checking Lambda probe and Lambda regulation after catalyst . . . . . . . . . . . . . . . . . . . . . .116
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3.5 Checking ageing of Lambda probe before catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
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3.6 Checking engine operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
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4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
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4.1 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
4.2 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
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4.3 Procedure after voltage supply open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
4.4 Replacing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
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4.5 Coding engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

4.6 Adapting engine control unit to throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . .127
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4.7 Adapting engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

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5 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
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5.1 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
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5.2 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
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5.3 Checking signal from/to air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
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5.4 Checking signal from brake light switch and brake pedal switch . . . . . . . . . . . . . . . . . . . . . .133
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5.5 Checking rpm signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
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5.6 Checking matching resistor of data bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
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28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
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1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

1.1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
1.2 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
1.3 Removing and installing parts of the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
1.5 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
1.6 Checking Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
1.7 Checking ignition transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
1.8 Checking knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
1.9 Check misfiring recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
ii Contents
01 - Self-diagnosis
1 - General to self-diagnosis
1.1 - General to self-diagnosis
1.2 - Features of self-diagnosis
The engine control unit (Motronic control unit J220) 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.
After evaluating the information, the engine control unit decides among different faults => Fault table page
13 and stores these until the contents of the fault memory is erased.
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 40 warm-up phases (engine start below
50° C coolant temperature - switched off above 72° C), it will be erased from the fault memory.
The faults stored can be read-out with the fault reader V.A.G 1551, the vehicle system tester V.A.G 1552 or
the new tester VAS 5051 => Page 7 .
The fault memory must be erased after the faults have been rectified => Page 7 .
All values learnt by the engine control unit will be erased when the engine control unit connector is pulled off
or the battery is disconnected. However the contents of the fault memory are retained. When the engine is
subsequently started the idling could be rough for a brief period. In this case leave the engine running for a few
minutes at idling speed or perform a longer test drive, until the learninglksprocess
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Procedure after voltage supply open circuit =>Page 125 .swagen AG. Vo does
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General information for self-diagnosis can bessfound
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in the instruction manuals for the fault readeracV.A.G 1551,
vehicle system tester V.A.G 1552 or the new tester VAS 5051.
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1.3 - Technical data of self-diagnosis

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Control unit identification

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The faults stored can be read-out with the fault reader V.A.G 1551, the vehicle system tester V.A.G 1552 or
the new tester VAS 5051 => Page 7 .
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Engine code AKK ANW AUD

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System designation Motronic ME7.5.10 Motronic ME7.5.10 Motronic ME7.5.10

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Exhaust emissions fulfil MVEG II standard D4 standard EU4 standard

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EPC system yes yes yes

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Self-diagnosis yes yes yes

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Final control diagnosis yes yes yes
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Operating mode of data transfer to V.A.G Rapid data transfer Rapid data transfer Rapid data transfer
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Fault memory Non-volatile memo‐ Non-volatile memo‐ Non-volatile memo‐
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Memory for learnt values Volatile memory2) Volatile memory2) Volatile memory2)
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Knock control 1 knock sensor 1 knock sensor 1 knock sensor
1) Independent of voltage supply.
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2) Values are erased when voltage supply is interrupted.
Functions which can be selected when using the fault readers V.A.G 1551/1552 or VAS 5051
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The prerequisites to select the desired functions can be found in the following table.
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Function Prerequisite
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Functions on V.A.G 1551/1552 Engine stationary, ignition Engine running at idling Vehicle being driven
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01 Interrogate control unit ver‐ yes yes yes
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02 Interrogate fault memory yes1) yes yes
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03 Final control diagnosis yes no no
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04 Basic setting2) yes yes yes
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05 Erase fault memory yes yes yes

06 End output yes yes yes
07 Code control unit no no no
08 Read measured value yes yes yes
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10 Adaption no no no
15 Read readiness code3) yes yes yes
1) Only carry out with ignition switched on, when engine does not start (operate starter for at least 6 seconds
first).
2) Must be carried out after the following: Replacing engine control unit, throttle valve control part, engine
or disconnecting battery.
3) Only engine codes ANW, AUD
1.4 - Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel
insert
"EPC" is the abbreviation for Electronic Power Control.
2 01 - Self-diagnosis
-> Location of EPC warning lamp
If faults are recognised in electronic power control system when the engine is running, the combi-instrument
will switch on the EPC lamp. (These faults are identified in the fault table.) Simultaneously an entry is made in
the engine control unit fault memory.
Functional check:
- Switch on ignition:
the EPC warning lamp must light-up.
If the EPC warning lamp does not light-up with ignition switched on:
- Check combi-instrument and EPC warning lamp as follows:
=> Electrical system self-diagnosis; Repair group 01
If the EPC warning lamp lights up with ignition switched on:
- Start engine and run at idling speed:

The EPC warning lamp must go out after
a few seconds.
If the EPC warning lamp does not go out: n AG. Volkswagen AG do

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- Interrogate fault memory, if necessary, repair d any faults and then erase fault memory
b ua
ran => Page 7 , in‐
ir se
terrogating and erasing fault memory. tho tee
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1.5 - Significance of exhaust emissions warning lamp
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Engine code: AUD
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If the engine control unit detects a fault this is indicated by switching the exhaust emissions warning lamp on.
es, in part or in w
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tion in
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-> Location of exhaust emissions warning lamp
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The exhaust emissions warning lamp can switch on in the continuous or flashing mode. Always interrogate fault
memory => Page 7 .
◆ Flashing mode: There is a fault present which can damage the catalyst when continuing to drive at this
power output. If this occurs, continue driving only at reduced output.
1.4 - Significance of EPC warning lamp (fault lamp for electronic accelerator) in dash panel
insert 3
◆ Continuous mode: There is a fault present which causes the emissions to deteriorate. Interrogate engine or
gearbox control unit in this case.
◆ Interrogate the fault memory if the customer has a complaint or there is a driving characteristic problem and
the exhaust gas warning lamp does not light up, this is because faults can be stored which will not switch
the exhaust gas warning lamp on immediately.
Functional check:
- Switch on ignition:
the exhaust emissions warning lamp must light-up.
If the exhaust emissions warning lamp does not light-up with ignition switched on:
- Check combi-instrument and exhaust emissions warning lamp as follows:
=> Electrical system self-diagnosis; Repair group 01

If the exhaust emissions warning lamp lights-up with ignition switched on, continue check as follows:
- Start engine and run at idling speed:
The exhaust emissions warning lamp must go out after
a few seconds. AG. Volkswagen
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If the exhaust emissions warning lamp does db
y go out: ua
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- Interrogate fault memory, if necessary,
rise repair any faults and then erase faultntmemory
ee => Page 7 , in‐
tho
terrogating and erasing fault memory.
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1.6 - Connecting fault reader
erm
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All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the new
i
or
n thi
e
tester VAS 5051 in the operating mode vehicle self-diagnosis.

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=> Operating instructions for Vehicle Diagnosis, Testing and Information System VAS 5051.
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Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
fo
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◆ -> VAS 5051 Vehicle Diagnosis, Testing and Information System
yi Co
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◆ Diagnosis cable VAS 5051/1 or VAS 5051/3
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Test conditions:
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◆ -> Fuses No. 1, 3, 11, 15, 23, 30, 31, 32, 34, 36, 37, 39 and 40 must be OK.
◆ The battery voltage must be at least 11.5 V.
◆ Earth connection between engine (at bell housing) and body (under battery) OK.
◆ Earth connection in plenum chamber OK.
Connecting VAS 5051
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- -> Pull out ashtray -1-.
spec
- Fit connector from diagnosis cable VAS 5051/1 or VAS 5051/3 to diagnosis connection.
es, in part or in w
t to the co
- Depending upon desired function:
Switch ignition on
or
Start engine => Page 2 , Table "Selectable functions".
rrectness of i
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Selecting operating mode:
- Press button on display for "Vehicle self-diagnosis".

nform
mercia
Selecting vehicle system:

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tion in
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- Press button "01 - Engine electronics" on display.

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The control unit identification and coding are indicated on the display.
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If the coding differs from the vehicle version:
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- Check control unit coding and, if necessary, code engine control unit => Page 126
co lksw
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Prote AG.
Selecting diagnosis function:
All diagnostic functions available are indicated on the display.
- Press button on display for desired function.
Notes:
The display zones in functions 04 - Basic setting or 08 - Read measured value block are shown from top to
bottom.
The following test sequences are for fault reader V.A.G 1551.
Connecting V.A.G 1551
◆ V.A.G 1551 Fault reader

◆ V.A.G 1551/3 Cable
1.6 - Connecting fault reader 5

Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a print-out
is not possible.
Work sequence
- Connect fault reader V.A.G 1551 using cable V.A.G 1551/3.

- Depending upon desired function:
Switch ignition on
or
Start engine => Page 2 , Table "Selectable functions".
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Notes: by
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◆ If the display remains blank, acheck
ut
h
voltage supply for diagnostic connection according
ra
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to fault finding pro‐
gramme: ss
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=> Current flow diagrams, Electrical fault finding and Fitting locations
itte
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◆ If the display does not indicate as described in the work sequence:
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=> Fault reader operating instructions
hole
spec
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◆ If due to an input fault "Fault in the data transfer!" is displayed, pull wire off fault reader, reconnect and repeat
t to the co
work step.
-> Indicated on display:
rrectness of i
V.A.G - SELF DIAGNOSIS HELP
l purpos
1 - Rapid data transfer*

2 - Flash code output*
nform
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* Appears alternately
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- Operate fault reader taking into account the information on the display:
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- Press key 1 for "Rapid data transfer".

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- Press keys 0 and 1 for address word "Engine electronics" and confirm entry with Q key.
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-> The control unit identification and the coding will appear on the display, e.g.:
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6K0906032M Cop py
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◆ 6K0906032M = Part No. of control unit (for up-to-date control unit version see parts film)
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◆ ME 7.5.10 = System designation and version Prote AG.
◆ 2921 = Program level number
◆ Coding 00001 = Control unit coding
◆ WSC xxxxx = Workshop code from V.A.G 1551, of the workshop who carried out the last coding. (If the
factory coding has not been changed, WSC 00000 appears)
Note:
Replace control unit if the control version displayed does not correspond to the vehicle
=> Page 125 .
An incorrectly coded engine control unit leads to:
◆ Engine running faults (gear change jerks, load change jerks, etc.)
◆ Increased fuel consumption
◆ Increased exhaust gas emissions
◆ Faults stored in fault memory which are not actually present
◆ Functions will not be performed (Lambda regulation, activation of the activated charcoal filter system, etc.).
◆ Reduced gearbox life
If the coding differs from the vehicle version, then:
- Checking control unit coding => Page 126 ,

coding engine control unit
- Press ⇒key.

Rapid data transfer HELP
Select function XXX
- Further measures see repair procedures.
2 - Fault memory
2.1 - Fault memory
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=> Page 8 , Automatic test sequence horis
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2.2 - Interrogating and erasing fault memory of engine control unit
d
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◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
es, in part or in w
t to the co
Work sequence
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Note:
l purpos
All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the new
tester VAS 5051.
nform
ercia
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
m
a
unit. When doing this the engine must be running at idling speed.
com
tio
(Connecting fault reader and selecting engine control unit => Page 4 .)
n in
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Only when engine does not start:

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- Operate starter for approx. 6 seconds and then do not switch off the ignition.
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- Switch on fault reader printer with the print key. The warning lamp in key must light up. rig ht
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-> Indicated on display: Prote AG.
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 no fault is stored:
- Press ⇒key.
1.6 - Connecting fault reader 7

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If one or more faults are stored: by V gu
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The stored faults will be displayed and
au printed out one
t
after the other. ra
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-> After the stored faults have been printed out, the display will show:
un
pt
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Select function XX
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- Press keys 0 and 5 for the function "Erase fault memory" and confirm entry with Q key.
h re
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t to the co
Rapid data transfer
Fault memory is erased!
rrectne
Note:
s
If the ignition is switched off between "Interrogate fault memory" and "Erase fault memory" the fault memory
s o
will not be erased.
cial p
f inform
mer
- Press ⇒key.
atio
om
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Select function XX
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- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
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Rapid data transfer HELP cted agen
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Enter address word XX
- Switch off ignition.

- Rectify faults printed out using fault table:
SAE P0 codes=> Page 13
Only engine codes ANW, AUD
- Read readiness code=> Page 23 .
2.3 - Automatic test sequence
During test and assembly work faults can be recognised from other control units like e.g. plug disconnected.
Therefore, on completion, the fault memories of all control units must be interrogated and erased. To do this:
- Press key 0 twice for address word "Automatic test sequence" and confirm entry with Q key. The V.A.G
1551 transmits all known address words one after the other.
When a control unit answers with its identification the number of stored faults appears on the display or "No
fault recognised".
Any system faults that are stored will be displayed one after the other and printed out. The V.A.G 1551 will then
transmit the next address word.
-> The automatic test sequence has ended when following is indicated on display:
- Erase all fault memories and then carry out a road test.
Observe the valid safety measures during a test drive => Page 29 .
During the road test the following operating conditions must be fulfilled:
- The coolant temperature must exceed 80 °C .
- When the temperature is reached, the operating conditions
Idling
Part throttle
Full throttle
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must be attained several times. by
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- At full throttle the speed must
oris exceed 3500 rpm.
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- Again interrogate the fault
s memories
s of all control units using the "automatic test sequence".
c
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- Press the ⇒key.
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3 - Fault table: SAE P0 codes
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3.1 - Fault table: SAE P0 codes
l purpos
Notes:
nf
ercia
orm
m
◆ The fault code overview is listed according to SAE or V.A.G code.
atio
m
◆ Electronic accelerator "EPC" relevant faults are indicated additionally by the electronic accelerator warning
o
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lamp ("EPC warning lamp") in dash panel insert.

or
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◆ Explanation of the fault types (e.g. "open circuit/short circuit to earth"):

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=> Fault reader operating instructions
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◆ If components are indicated as faulty: t. C rig
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First check the wiring and connectors to these components as well as the system earth connections ac‐ yri
p by
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cording to current flow diagram. This is particularly relevant if faults are output as "occurring
lksw
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sporadically" (SP).
Prote AG.
◆ Erase fault memory after rectifying fault =>Page 7 .
V.A.G 1551 print out, e.g.:

16497 P0113 035
Intake air temperature sender -G42
Signal too large
Sporadic fault
Explanation:
◆ 16497 = Fault code
◆ P0113 = Additional fault code (only for USA at present and disregard)
◆ 035 = Fault type as a number
◆ Intake air temperature sender -G42 = Faulty current path or incorrect location
◆ Signal too large = Fault type as text
◆ Sporadic faults = Faults that are not always present e.g. loose contact
Fault code Fault text Fault elimination

SAE V.A.G
2.3 - Automatic test sequence 9


P0106 16490 Intake manifold pressure/air pressure => - - Check intake manifold pressure sender
G71/-F96implausible signal =>Page 84
P0107 16491 Intake manifold pressure/air pressure => -
G71/-F96signal too low
P0108 16492 Intake manifold pressure/air pressure => -
G71/-F96signal too high
P0112 16496 Intake air temperature sender -G42 signal too - Check intake air temperature sender => Page
high 86
P0113 16497 Intake air temperature sender -G42 signal too
high
P0116 16500 Coolant temperature sender -G62 implausible - Check coolant temperature sender => Page
signal 90
P0117 16501 Coolant temperature sender -G62 signal too - Checkn Athermostat:
G. Volkswagen AG d
low o
=>
lkswRepair group 19; Removing
age oes
not and installing
y V parts of cooling system; Parts of
gu cooling sys‐
d b ara
orise tem, engine-side Parts of cooling system,
nte
eo en‐
h
aut gine-side ra
c
ss
P0118 16502 Coolant temperature sender -G62 signal too
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high
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SAE V.A.G
h re
hole
spec
P0130 16514 Bank 1 probe 1 electrical fault in current circuit - Check Lambda probe and Lambda regulation
es, in part or in w
before catalyst
t to the co
=> Page 111
P0131 16515 Bank 1 probe 1 voltage too low - Check Lambda probe heating before catalyst
=> Page 74
rrectness of i
P0132 16516 Bank 1 probe 1 voltage too high
l purpos
P0133 16517 Bank 1 probe 1 signal too slow

P0134 16518 Bank 1 probe 1 no activity
nform
ercia
P0135 16519 Bank 1 probe 1 heating current circuit electrical

m
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ion
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ate
Fault code Fault text Fault elimination do

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SAE V.A.G
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P0136 16520 Bank 1 probe 2 electrical fault in current circuit - Check Lambda probe and Lambda control af‐
Co
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ter catalyst
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=> Page 116 p by
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P0137 16521 Bank 1 probe 2 voltage too low - Check Lambda probe heating after catalyst => cted agen
Prote AG.
Page 78
P0138 16522 Bank 1 probe 2 voltage too high
P0139 16523 Bank 1 probe 2 signal too slow
P0140 16524 Bank 1 probe 2 no activity
P0141 16525 Bank 1 probe 2 heating current circuit electrical
fault

SAE V.A.G
P0170 16554 Bank 1, fuel measuring system faulty - Check fuel pressure regulator and holding pressure =>
Page 102
- Check injectors
=>Page 96
n AG. Volkswagen AG do Polo Estate 1998 ➤
wage es n
Motronic inj. y Vo and ignition system (2-valve,
lks ot g roller rocker finger) - Edition 12.1999
db ua
ran
ir se tee
ut
ho - Checkor fuel pump:
ss
a => Repair ac group 20; Removing and installing parts of fuel
system; Check fuel pump Check fuel pump
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nl
pt
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- Check intake system for leaks => Page 106
an
itte
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erm
- Check vacuum pipes for leaks
ab
ility
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es, in part or in w
SAE V.A.G
t to the co
P0171 16555 Bank 1, fuel measuring system, system too - Check fuel pressure regulator and holding
lean pressure =>Page 102
rrectness of i
- Check injectors
=>Page 96
l purpos
- Check fuel pump:

=> Repair group 20; Removing and installing
nf
ercia
parts of fuel system; Check fuel pump Check
or
fuel pump
m
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SAE V.A.G t. C rig
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P0172 16556 Bank 1, fuel measuring system, system too - Check fuel pressure regulator and holding
cop Vo
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rich cted pressure => Page 102
agen
Prote AG.
- Check injectors
=>Page 96
- Check tank venting valve
=> Page 19 , final control diagnosis
- Check Lambda probe and Lambda regulation
before catalyst
=> Page 111
after catalyst
=> Page 116

SAE V.A.G
P0300 16684 Misfiring recognised - Check injectors=>Page 96
P0301 16685 Cyl. 1 misfiring recognised - Removing and installing parts of the ignition system => Page
139
P0302 16686 Cyl. 2 misfiring recognised - Check ignition transformer => Page 144
P0303 16687 Cyl. 3 misfiring recognised - Check misfiring detection
=> Page 150
P0304 16688 Cyl. 4 misfiring recognised

SAE V.A.G
P0321 16705 Engine speed sender -G28 implausible signal - Check engine speed sender
=>Page 94
P0322 16706 Engine speed sender -G28 no signal
P0327 16711 Knock sensor 1 -G61 signal too low - Check knock sensor
=> Page 148
3.1 - Fault table: SAE P0 codes 11

P0328 16712 Knock sensor 1 -G61 signal too high

P0341 16725 Camshaft pos. sensor, =>sender -G40 implau‐ - Check Hall sender =>Page 143
sible signal
P0342 16726 Camshaft pos. sensor, =>sender -G40 signal
too low
P0343 16727 Camshaft pos. sensor, =>sender -G40 signal
too high
P0422 16806 Bank 1 main catalyst efficiency to low - Check catalyst:
AG . Volkswagen AG d
parts of exhaust system; Checking catalyst
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n Checking catalyst
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Fault code Fault text au acFault elimination
ss
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SAE V.A.G
nl
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P0440 16824 Tank venting system faulty - Check tank venting valve
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erm
=> Page 19 , Final control diagnosis
ab
ility
ot p
P0441 16825 Tank venting valve flow rate faulty - Check hoses and connecting pipes from fuel tank to throt‐
wit
, is n
tle valve control part:
h re
=> Repair group 20; Activated charcoal filter system;
hole
spec
Checking activated charcoal filter system for leaks Check‐
es, in part or in w
ing activated charcoal filter system for leaks
t to the co
rrectness of i
l purpos
SAE V.A.G
P0501 16885 Vehicle speed signal implausible - Check speed signal
=> Page 130
nf
ercia
or
P0506 16890 Idling speed control, Revs below specification - Check idling speed control => Page 109 ,
m
m
atio
Idling check
om
n in
c
P0507 16891 Idling speed control, Revs above specification

or
thi
te
sd
P0532 16916 A/C pressure sensor -G65 signal too low - Check high pressure sender -G65
iva
o
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=> Heating, air conditioning;

rp
cu
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=> Repair group 87

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ng
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P0533 16917 A/C pressure sensor -G65 signal too high ht. Cop py
rig
P0560 16944 Voltage supply signal implausible - Check voltage supply
rig ht
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=> Page 123
co lksw
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cted agen
Prote
P0562 16946 Voltage supply too low - Procedure after interrupting voltage supply =>
AG.
Page 125
P0563 16947 Voltage supply too high

SAE V.A.G
P0571 16955 Brake light switch -F,implausible signal1) - Check brake light switch and brake pedal switch
=> Page 133
P0600 16984 Drive train data bus message missing - Check matching resistor for data bus => Page
136
P0601 16985 Control unit defective - Replace engine control unit => Page 125
P0604 16988 Control unit defective
1) The system monitors both brake light switch -F and brake pedal switch -F47.
4 - Fault table: SAE P1 codes

4.1 - Fault table: SAE P1 codes
Notes:
◆ The fault code overview is listed according to SAE or V.A.G code.
◆ Erase fault memory after rectifying fault =>Page 7 .

SAE V.A.G
P1102 17510 Bank 1, probe 1 heating element circuit, short - Check Lambda probe heating before catalyst
to positive => Page 74
P1105 17513 Bank 1, probe 2 heating element circuit short to - Check Lambda probe heating after catalyst =>
positive Page 78
P1111 17519 Lambda control Bank 1 system too lean - Check Lambda probe and Lambda control
before catalyst
=> Page 111
P1112 17520 Lambda control Bank 1 system too rich
P1113 17521 Bank 1, probe 1 internal resistance too high - Check Lambda probe heating before catalyst
=> Page 74
P1114 17522 Bank 1, probe 2 internal resistance too high - Check Lambda probe heating after catalyst =>
G. Volk78
Page
gen A
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Fault code Fault text s au Fault elimination ra
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SAE V.A.G
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P1115 17523 Bank 1, probe 1 heating element circuit short - Check Lambda probe heating before catalyst
an
itte
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to earth => Page 74
erm
ab
ility
P1116 17524 Bank 1, probe 1 heating element circuit, open
ot p
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circuit
, is n
h re
P1117 17525 Bank 1, probe 2 heating element circuit short - Check Lambda probe heating after catalyst =>
hole
spec
to earth Page 78
es, in part or in w
t to the co
P1118 17526 Bank 1, probe 2 heating element circuit open
circuit
P1127 17535 Bank 1, mixture adaption (mult.) system too - Check fuel pressure regulator and holding
rich pressure => Page 102 rrectness of i
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- Check injectors
=>Page 96
- Check tank venting valve
nf
ercia
=> Page 19 , Final control diagnosis

rm
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atio
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SAE V.A.G
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P1128 17536 Bank 1 mixture adaption (mult.) system too - Check fuel pressure regulator and holding
t.
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lean pressure => Page 102
Cop py
ht. rig
- Check injectors
rig ht
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=>Page 96
by c lksw
cted agen
Prote AG.
- Check fuel pump:
parts of fuel system; Checking fuel pump
Checking fuel pump

- Check exhaust system for leaks:

parts of exhaust system

SAE V.A.G
P1136 17544 Bank 1, mixture adaption (add.) system too - Check fuel pressure regulator and holding
lean pressure => Page 102
- Check injectors
=>Page 96
- Check fuel pump:
parts of fuel system; Checking fuel pump Check‐
ing fuel pump
parts of exhaust system
Note:
add. = additive means, the fault only has an effect at idling speed.

SAE V.A.G
P1137 17545 Bank 1, mixture adaption (add.) system too rich - Check fuel pressure regulator and holding
pressure => Page V102
AG. olkswagen AG d
agen
- Checkolinjectors oes
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=>Page
ed by V 96 gu
ara
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th- Check tank venting valve
o eo
u
ss => Page 19 , Final control diagnosis
a ra
c
ce
P1142 17550 Load determination, level not reached - Check accelerator pedal position sender:
e
nl
pt
du
an
P1143 17551 Load determination, level exceeded => Repair group 20; Electronic power control
itte
y li
(EPC); Checking accelerator pedal position
erm
ab
ility
sender Checking accelerator pedal position
ot p
sender
wit
, is n
h re
hole
spec
Note:
es, in part or in w
t to the co
add. = additive means, the fault only has an effect at idling speed.
rrectness of i

l purpos
SAE V.A.G
P1155 17563 Intake manifold pressure sender -G71short to - Check intake manifold pressure sender
nform
ercia
positive1) =>Page 84
m
at
P1156 17564 Intake manifold pressure sender -G71 open cir‐

om
io
cuit/short to earth1)
n
c
in t
or
his
P1157 17565 Intake manifold pressure sender -G71 voltage

ate
do
riv
supply1)
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
P1158 17566 Intake manifold pressure sender-G71 implausi‐

ble signal1)
1) Engine control unit switches on the EPC warning lamp in dash panel insert with this fault. Significance of
EPC warning lamp => 2 .

SAE V.A.G
P1171 17579 Angle sender 2 for throttle valve drive -G188 - Check throttle valve control part => Page
implausible signal 1) 81
P1172 17580 Angle sender 2 for throttle valve drive -G188
signal too low 1)
P1173 17581 Angle sender 2 for throttle n AG. Volkswagen AG
swagevalve drive -G188does n
signal too high 1)by Volk ot g
u ara
ed nte
ris
ho e
1) If this fault occurs theu engine control
t unit switches on the EPC warning
or lamp in dash panel insert. Signif‐
a
sa
icance of EPC warning slamp => 2 . c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
SAE V.A.G
wit
is n
h re
P1176 17584 Bank 1 Lambda correction after cat. control limit - Check Lambda probe ageing before cata‐
ole,
reached lyst=> Page 120
spec
t to the co
after catalyst
=> Page 116
rrectne
- Check intake system for leaks => Page
106
P1196 17604 Bank 1, probe 1 heating current circuit electrical - Check Lambda probe heating before catalyst
ss o
fault => Page 74
cial p
f inform
P1198 17606 Bank 1, probe 2 heating current circuit electrical - Check Lambda probe heating after catalyst
mer
fault => Page 78

atio
om
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
SAE V.A.G
r
fo
en
ng
t.
yi
P1201 17609 Injector Cyl. 1 -N30 electrical fault in current circuit - Check injectors
Co
op py
=>Page 96
t. C rig
gh ht
yri by
P1202 17610 Injector Cyl. 2 -N31 electrical fault in current circuit
cop Vo
by lksw
cted agen
Prote AG.

P1213 17621 Injector Cyl. 1 -N30 short to positive
P1225 17633 Injector Cyl. 1 -N30 short to earth

SAE V.A.G


P1237 17645 Injector Cyl. 1 -N30 open circuit - Check injectors
=>Page 96
P1238 17646
Injector Cyl. 2 -N31 open circuit
P1239 17647
P1240 17648
P1250 17658
Fuel level too low - Fill fuel tank
P1325 17733
Cylinder 1 knock control, control limit reached - Fill fuel tank with at least 95 RON
P1326 Cylinder 2 knock control, control limit reached - Check knock sensor
17734
=> Page 148
P1327 17735 Cylinder 3 knock control, control limit reached - Eliminate cause for abnormal engine running
noises
P1328 17736 Cylinder 4 knock control, control limit reached - Loosen knock sensor and tighten again to 20
Nm

SAE V.A.G
P1335 17743 Engine torque monitoring system 2, control limit - Check intake air temperature sender => Page
AG. Volkswagen AG d
surpassed1) kswagen oes
not
86
Vol
P1336 17744 Engine torque d bymonitoring system, control limit g-uCheckara coolant temperature sender => Page
e
surpassed horis 84 ntee
t or
P1340 17748 Camshaftau position/crankshaft position sensor - Check aengine
c speed sender
ss
wrong allocation =>Page 143
ce
e
nl
pt
du
an
itte
y li
1) Engine control unit switches on the EPC warning lamp in dash panel insert with this fault. Significance of
erm
ab
EPC warning lamp => 2 .

ility
ot p
wit
, is n
h re
hole
spec

es, in part or in w
SAE V.A.G
t to the co
P1341 17749 Ignition output 1 short to earth - Check ignition transformer => Page 144
P1342 17750 Ignition output 1 short to positive - Check Hall sender => Page 143
rrectness of i
P1343 17751 Ignition output 2, short to earth

l purpos
P1344 17752 Ignition output 2, short to positive

P1348 17756 Ignition output 1, open circuit
nform
ercia
P1349 17757 Ignition output 2, open circuit

m
at
P1386 17794 Control unit defective - Renew engine control unit (J220) => Page
om
ion
125
c
in t
or
his
e
P1388 17796 Control unit defective 1)

at
do
riv
P1393 17801 Ignition output 1 electrical fault in current circuit - Check ignition transformer => Page 144
p
cum
for
en
g
P1394 17802 Ignition output 2 electrical fault in current circuit

n
t.
yi Co
Cop py
t. rig
gh
1) If this fault occurs the engine control unit switches on the EPC warning lamp in dash panel insert. Signif‐
ht
pyri by
Vo
o
icance of EPC warning lamp => 2 . by c lksw
cted agen
Prote AG.

SAE V.A.G
P1410 17818 Tank breathing valve -N80 short to positive - Check activated charcoal filter solenoid valve 1=>
Page 19 , Final control diagnosis
P1425 17833 Tank breathing valve -N80 short to earth
P1426 17834 Tank breathing valve -N80 open circuit
n AG. Volkswagen AG do Polo Estate 1998 ➤
wage es n
Motronic yV
oinj. and ignition system
lks o(2-valve,
t gu roller rocker finger) - Edition 12.1999
d b ara
ir se nte
ho eo
ut ra
a
Fault
ss code Fault text c Fault elimination
ce
e
SAE V.A.G
nl
pt
du
an
itte
P1501 17909 Fuel pump relay-J17, short to earth - Check fuel pump relay:
y li
erm
ab
=> Current flow diagrams, Electrical fault finding
ility
ot p
and Fitting locations binder
wit
, is n
P1502 17910 Fuel pump relay -J17, short to positive
h re
hole
P1523 17931 Crash signal from airbag control unit, Implau‐ => Body self-diagnosis; Repair group 01; Airbag
spec
es, in part or in w
sible signal system self-diagnosis Airbag system self-diag‐
t to the co
nosis
P1541 17949 Fuel pump relay -J17, open circuit - Check fuel pump relay:
rrectness of i
and Fitting locations binder
l purpos
P1542 17950 Angle sender for throttle valve drive -G187 im‐ - Check throttle valve control part => Page
plausible signal1) 81
nform
ercia
P1543 17951 Angle sender for throttle valve drive -G187

signal too low 1)
m
at
om
P1544 17952 Angle sender for throttle valve drive -G187
ion
c
signal too high 1)
in t
or
his
te
P1545 17953 Throttle valve control malfunction 1)

a
do
priv
P1558 17966 Throttle valve drive -G186 electrical fault in cum

for
en
g
current circuit 1)
n
t.
yi Co
Cop py
t. rig
gh
ht
pyri by
icance of EPC warning lamp => 2 .
co Vo
by lksw
cted agen
Prote AG.

SAE V.A.G
P1559 17967 Throttle valve control part -J338 - Adapt engine control unit to the throttle valve
fault in basic setting 1) control part => Page 127
P1560 17968 Maximum engine revs surpassed - Repair mechanical damage
P1564 17972 Throttle valve control part -J338 low voltage at - Check battery, charge if needed
basic setting 1) Adapt engine control unit to throttle valve con‐
trol part => Page 127
P1565 17973 Throttle valve control part -J338 lower limit not - Check throttle valve control part=> Page
reached 1) 81
P1568 17976 Throttle valve control part -J338 mechanical
fault 1)
P1570 17978 Engine control unit blocked - Adapt engine control unit (J220) to electronic
immobilizer => Page 129
P1579 17987 Throttle valve control part -J338 adaption not - Adapt engine control unit to throttle valve
started1) control part => Page 127

SAE V.A.G
P1600 18008 Voltage supply terminal 15 voltage too low - Check control unit voltage supply => Page
123
Check alternator:
and Fitting locations
P1602 18010 Voltage supply terminal 30 voltage too low

125
P1604 18012 Control unit defective 1)
P1612 18020 Engine control unit incorrectly coded - Code engine control unit
=> Page 126 . Volkswag
n AG en AG
P1626 18034 Drive train data bus no message from gear‐ - Check wage
olks matching resistor of datanotbus => Page
does
box CU ed 136
by V gu
ara
ris nte
tho eo
1) If this fault occurs the engine control unit switches
ss
a on the
u
EPC warning lamp in dash panel insert. Signif‐
ra
c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
SAE V.A.G
wit
is n
h re
ole,
P1630 18038 Accelerator pedal position sender -G79 signal - Check accelerator pedal position sender:
spec
too low 1) => Repair group 20; Electronic power control
(EPC); Check accelerator pedal position send‐
t to the co
er Check accelerator pedal position sender
P1631 18039 Accelerator pedal position sender -G79 signal
too high 1)
rrectne
P1633 18041 Accelerator pedal position sender 2 -G185 sig‐
nal too low 1)
ss o
cial p
f
P1634 18042 Accelerator pedal position sender 2 -G185 sig‐
in
nal too high 1)
form
mer
P1639 18047 Accelerator pedal position senders 1/2 -G79
atio
m
+G185 implausible signal 1)

o
n
c
i
or
n thi
te
sd
a
iv
o
pr
c
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
SAE V.A.G
by lksw
cted agen
Prote AG.
125
P1648 18056 Drive train data bus defective - Check matching resistor of data bus => Page
136
P1649 18057 Drive train data bus no messages from ABS
control unit
P1650 18058 Drive train data bus no message from combi-
instrument

SAE V.A.G
P1676 18084 Fault lamp for electric accelerator operation - - Check fault lamp:
K132 => Repair group 20; Electronic power control
electrical fault in current circuit (EPC); Checking fault lamp for electronic accel‐
erator operation Checking fault lamp for elec‐
tronic accelerator operation
P1677 18085 Fault lamp for electric accelerator operation -
K132
short to positive
K132
short to earth
AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Polo Estate 1998 ➤
ise nte
Motronic inj. and ignition
thor system (2-valve, roller rocker finger)
e or - Edition 12.1999
s au ac
s
ce
le
un
pt
an
d
itte
y li
K132
rm
ab
open circuit
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
SAE V.A.G
t to the co
P1690 18098 Self-diagnosis fault lamp -K83 - Check exhaust warning lamp
Current circuit electrical fault => Page 3
rrectness of i
P1691 18099 Self-diagnosis fault lamp -K83
Open circuit
l purpos

Short to earth
nform
ercia

current circuit electrical fault
m
a
com
tio
P1853 18261 Drive train data bus implausible message from - Check data bus matching resistor => Page
n in
r
ABS CU 136
te o
thi
s
iva
do
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fo
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5 - Final control diagnosis
Co
Cop py
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5.1 - Final control diagnosis
co Vo
by lksw
cted agen
Prote AG.
5.2 - Performing final control diagnosis
The final control diagnosis activates the following components in the stated sequence:
1. Tank venting valve (N80)
◆ Test box V.A.G 1598/22
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Diode test lamp V.A.G 1527
◆ Adapter set V.A.G 1594
◆ Current flow diagram
Check conditions
• -> The fuses 1, 11, 31 and 36 must be OK.

• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating must be switched off.

• If the vehicle is equipped with an air conditioning system, this must be switched off.
Notes:
◆ The final control diagnosis can only be carried out if the engine is stationary and ignition switched on.
◆ The final control diagnosis will be broken off if the engine is started or a rotational impulse is recognised.
◆ If the final control diagnosis is not terminated by pressing the ⇒key, the tank venting valve will be activated
for approx. 60 seconds during the final control diagnosis.
◆ The final control is checked acoustically or by touch.
◆ The electric fuel pump will run during the complete final control diagnosis.
◆ The final control diagnosis will be aborted after 10 minutes.

◆ If the final control diagnosis is to be repeated, the engine must be started briefly beforehand.
Work sequence
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switchagignition
n AG. Voon and
lkswagenselect
AG do engine control unit
with the "Address word" 01. lksw e es n
Vo ot g
(Connecting fault reader and selecting engine control sunit
ed => Page 4 .)
b y ua
ran
ri tee
tho or
-> Indicated on display: ss
au ac
ce
le

un
pt
Select function XX
an
d
itte
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rm
ab
- Press keys 0 and 3 for the function "Final control diagnosis".
pe
ility
ot
wit
, is n
h re
hole
spec
Rapid data transfer Q
es, in part or in w
03 Final control diagnosis
t to the co
Activate tank venting valve (N80) for activated charcoal filter:
- Confirm input with Q key.
rrectness of i
l purpos
Final control diagnosis

Tank venting valve-N80
The tank venting valve must click, until the final control diagnosis is terminated by pressing ⇒key.
nform
ercia
If valve clicks:
m
a
com
ti
- Press ⇒key.
on in
r
te o
thi
s
iva
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rp
cum
Final control diagnosis
fo
en
g
END
n
t.
yi Co
- Press ⇒key. t. Cop py
rig
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-> Indicated on display: cop Vo
by lksw
cted agen
Rapid data transfer HELP Prote AG.
Select function XX
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
If the valve does not click:
- -> Pull 2-pin connector off tank venting valve (N80) -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
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ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
- -> Connect diode test lamp V.A.G 1527 using adapter cables from V.A.G 1594 to detached connector.
t to the co
The LED must flash (bright/darker)
LED flashes:
rrectness of i
l purpos
- Proceed with final control diagnosis until completed.

- Renew tank venting valve (N80):
nform
ercia
=> Repair group 20; Activated charcoal filter system; Removing and installing parts of activated charcoal filter
m
a
com
ti
system Activated charcoal filter system Removing and installing parts of activated charcoal filter system
on in
r
te o
thi
- Interrogate fault memory, if necessary, repair any faults and then erase fault memory => Page 7 , inter‐
s
iva
do
rogating and erasing fault memory.
r
rp
cum
fo
en
ng
t.
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LED does not flash:
Co
Cop py
t. rig
gh ht
yri
- Proceed with final control diagnosis until completed. p by
co Vo
by lksw
- Switch off ignition. Prote
cted AG.
agen
- Remove left plenum chamber cover.

- -> Connect test box V.A.G 1598/22 to control unit wiring harness.
5.2 - Performing final control diagnosis 21

. Volkswagen AG
gen AG does
swa
- -> Check wire between testy Vbox socket 14+2-pin connector
olk not contact 2 for
gu open circuit using current flow
diagram. ised b ara
nte
Wire resistance:umax.
thor
1.5 ω eo
ra
- Additionally checkss wire for short to battery positive and earth.
a c
Specification: ∞ω
ce
e
nl
pt
- Check wire between 2 pin connector contact 1 and the fuel pump relay (J17) for open circuit using current
du
an
itte
flow diagram.
y li
erm
ab
Wire resistance: max. 1.5 ω
ility
ot p
wit
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If no wiring fault is detected:
h re
hole
spec
- Replace engine control unit
es, in part or in w
=> Page 125 .
t to the co
rrectness of i
6 - Readiness code
l purpos
6.1 - Readiness code

nform
mercia

at
om
ion
c
in t
or
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ate
do
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6.2 - Function
p
cum
for
en
ng
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op py
The readiness code is an 8-digit number code which displays the status of the emission relevant diagnosis.
. C rig
ht ht
rig by
opy Vo
When the diagnosis for a system (e.g. catalyst), has been successfully completed, the corresponding position
by c lksw
cted agen
in the number code will change from 1 to 0.
Prote AG.
The diagnosis is performed at regular intervals during normal driving. It is recommended that the readiness
code be generated after performing repairs on an emission relevant system, to guarantee that these systems
function correctly. If a fault is detected during the diagnosis it will be entered in the fault memory.
Each time the fault memory is erased or the voltage supply is interrupted the readiness code will be erased.
6.3 - Reading readiness code
Work sequence
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.

Select function XXX
- Press keys 1 and 5 for the "Readiness code" function and confirm entry with Q key.
Must appear on display when all diagnosis functions have been successfully completed:
Readiness code
00000000 - Test complete
- Press ⇒key.

Readiness code
00101101 - Test not complete
One of the diagnostic checks has not run through successfully:

- Press ⇒key.
- Generate readiness code => Page 23 .
Significance of figures in 8-digit number block for readiness code

The readiness code is generated only when all display zones show 0
1 2 3 4 5 6 7 8 Diagnostic function
0 Catalyst
0 Catalyst heating (currently no diagnosis/always "0")
0 Activated charcoal filter system (tank venting system)
0 Secondary air system (not fitted/always "0")
0 Air conditioner (currently no diagnosis/always "0")
0 Lambda probes
0 Lambda probe heating AG. Volkswagen AG d
agen oes
0 Exhaust gas recirculationy(not
Vol fitted/always
ksw "0") not
g b ua
ed ran
oris tee
th or
au ac
ss
6.4 - Generating readiness code
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
Test conditions
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
yri by
23
cop Vo
by lksw
Prote
cted AG. 6.3 - Reading readiness code
agen
• -> The fuses No. 1 and 11 must be OK.
• Vehicle stationary
• Exhaust system between catalyst and cylinder head must be free of leaks
• Coolant temperature must be at least 80 °C, =>display group 04, display zone 3.
• Intake air temperature less than 60°C
=>display group 04, display zone 4
Work sequence
Work step 1: Interrogate fault memory

Select function XXX
- Press keys 0 and 2 for function "InterrogateVfault memory" and confirm entry with Q key.
olkswa
AG. gen AG
agen does
lksw not
-> The number of faults stored orby"No
Vo fault recognised!" will be showngu on the
ara display.
ed
X Faults recognised! ris nte
ho eo
aut ra
ss c
If a fault is stored:
ce
e
nl
pt
du
an
itte
- Rectify faults printed out using fault table: y li

erm
SAE P0 codes=> Page 13 ab

ility
ot p
wit
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h re
hole
spec
- Press ⇒key.
es, in part or in w
t to the co
Work step 2: Erase fault memory

rrectness of i

l purpos

Select function XXX
nf
ercia
- Press keys 0 and 5 for the function "Erase fault memory" and confirm entry with Q key.
orm
m
atio
m
Note:
o
n in
or c
thi
e
The readiness code is reset or erased each time fault memory is erased.
t
sd
iva
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cu
o

f
en
ng
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Rapid data transfer Cop py
Fault memory is erased! t. rig
gh ht
pyri by
Vo
o
by c lksw
Note: cted agen
Prote AG.
If the ignition is switched off between "Interrogate fault memory" and "Erase fault memory" the fault memory
will not be erased.
- Press ⇒key.
Work step 3: Matching the throttle valve control part to the engine control unit

Select function XXX
- Press keys 0 and 4 for the function "Initiating basic settings" and confirm entry with Q key.

Basic setting
Input display group number XXX
- Press keys 0, 6 and 0 for the "Display group number 60" and confirm entry with Q key.

(1...4 = Display zones)
System in basic setting 60
xxx % xxx % x ADP. runs
- Check specifications in display zones 3 and 4:

Display zone 3: 0...9
Display zone 4: ADP. runs, ADP. OK

AG. Volkswagen AG d
System in basic setting 60 agen oes
xxx % xxx % 9 ADP. OK olksw not
y V gu
d b ara
rise nte
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- Terminate engine basic setting at aearliest
ut
h after 30 seconds by pressing the⇒ key. or a
ss c
ce
e
If the display does not indicate as described:

nl
pt
du
an
itte
y li
- Check throttle valve control part
erm
ab
ility
=> Page 81 .
ot p
wit
, is n
h re
If the display indicates as described:
hole
spec
es, in part or in w
- Start engine and run at idling speed.
t to the co
Work step 4: Activated charcoal filter system diagnosis (tank breathing system)
Note: rrectness of i
l purpos
◆ During the work sequence the engine must not be switched off.
nf
ercia

rm
m
atio
m

o
n in
Select function XXX

or c
thi
te
sd
a
- Press keys 0 and 4 for the "Introduce basic setting" function and confirm entry with Q key.
iv
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
op py
Basic setting t. C rig
Input display group number XXX gh ht
pyri by
Vo
co lksw
by
cted agen
- Press keys 0, 7 and 0 for "Display group number 70" and confirm entry with Q key.
Prote AG.

1 2 3 4
6.4 - Generating readiness code 25

Note:
The engine must not be loaded during this diagnosis because the diagnosis will be interrupted and will not be
started again until the engine is revved-up.
When the diagnosis is initiated by the engine control unit the display in display zone 4 jumps from "Test OFF"
to "Test ON"
- Run engine at idling speed until the

specification "TVV OK"
is displayed in display zone 4.
- Interrogate fault memory => Page 7 .
- Press C key.
Work step 5: Lambda regulation system diagnosis

Basic setting

Read measured value block 37 AG. Volkswagen AG d
1 2 3 4 agen oes
olksw not
y V gu
d b ara
ise nte
- Depress brake pedal. thor eo
au ra
ss c
The engine speed is increased by the control unit to
ce
le
un
approx. 1100...1300 rpm. pt

an
d
itte
y li
erm
ab
- Allow the engine to continue running at increased idling speed until the ility
ot p
specification "Syst. OK." wit

is n
is displayed in display zone 4.

h re
ole,
spec

t to the co

rrectne
- Press ⇒key.
ss o
cial p
f i
The engine speed decreases to idling speed.

nform
mer
atio
Work step 6: Lambda probe ageing diagnosis (cycle duration monitor)

om
n
c
i
or

thi
te
sd
iva

pr
cum
r
Select function XXX

fo
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
t. rig
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pyri by
co Vo
by lksw
cted agen
Prote AG.
Read measured value block

Read measured value block 30
1 2
- Check Lambda control status before catalyst (display zone 1):

Specification: 1 1 1
(Significance => Page 39 )
- Check Lambda control status after catalyst (display zone 2):
Notes: olkswage es n
ot g
byV ua
ed ran
◆ The first position of the 3hodigit
ris number block fluctuates between 0 and tee1 (Lambda probe heating on and off).
◆ Depending upon the sstatus
au
t
of the Lambda control the 3 digit number block or
ac can show 0 or 1.
◆ The bits in display zones 1 and 2 will not be set to 1 until the catalyst temperature has risen to above 400.0
s
ce
le
°C (=> display group 34, display zone 2).

un
pt
an
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If the specifications are not obtained:
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If the specifications are obtained:
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- Press ⇒key.
rrectne
Select function XXX
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- Press keys 0 and 4 for the "Introduce basic setting" function and confirm entry with Q key.
form
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System in basic setting 34 cted agen
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- Depress brake pedal.

approx. 1100...1300 rpm.
- Maintain the engine speed until the display

in display zone 4 jumps from "Test OFF" to "Test ON". The catalyst temperature in
display zone 2 must be min. 400 °C.
Note:
This process can take a few minutes.
- Check amplitude duration in display zone 3:

Specification: 0.7... 2.00
- Continue to maintain engine speed until the specification "B1-P1" appears in

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display zone 4. aut or
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- Press C key.
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Basic setting
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1 2 3 4
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The engine speed is increased by the control unit to rig ht
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Note:
- Continue to maintain engine speed until the specification "B1-P2 OK" appears in
display zone 4.


- Press C key.
Work step 7: Catalyst diagnosis

Note:
The diagnosis will only be terminated if the Lambda probe ageing diagnosis is first successfully completed.
Basic setting
1 2 3 4
The engine speed is increased by the engine control unit to

approx. 1100...1300 rpm.

- Check the amplitude ratio in display zone 3:

Specification: max. 0.50
- Continue to maintain the speed until the specification "Cat B1 OK" appears in
display zone 4.
- Press ⇒key.

AG. Volkswagen AG d
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- Read readiness code=> Page 22 olksw not
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7 - Measured value blocks
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7.1 - Measured value blocks
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7.2 - Safety precautions
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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 rrectness
location.
o
cial p
f inform
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
mer
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
atio
m
airbag is triggered.
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7.3 - Read measured value block

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The measured values in the functions read measured value block and basic setting are described during the p by
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individual component test. This table serves only as an overview.
by lksw
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Test conditions
• All electrical consumers, e.g. lights and rear window heating must be switched off
• No faults must be stored in fault memory
=> Page 7 , interrogating fault memory
Work sequence

Select function XXX
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

- Select required display group number.
Note:
The display group number 1 is an example, to illustrate the sequence.
kswage es n
-> Indicated on display: byV
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(1...4 = Display zones) ir se
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Read measured value block u 1 or
1 2 3 4 ss a ac
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Note:
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To change to another display group proceed as follows:

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Display group V.A.G 1551 V.A.G 1552

spec
Higher Press key 3 Press ↑key

t to the co
Lower Press key 1 Press ↓key

Skip Press key C Press key C
rrectne
- If the specifications in all display zones are obtained, press ⇒key.

ss

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form
mer
Select function XXX

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Note:
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Measured value blocks which are not described in this chapter are currently only intended for the research and
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development and production. The values displayed are not relevant for service department fault finding.
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8 - Evaluating measured value blocks, display groups 0...9 -Basic functions-

8.1 - Evaluating measured value blocks, display groups 0...9 -Basic functions-
Display group 1 -Basic functions-

▪ Engine running at idling speed
Read measured value block 1 ⇒ ◂ Indicated on display
xxxx rpm xx.x °C xx.x % xxxxxxxx
1 2 3 4 ◂ Display zones Specification Evaluation
Adjustment conditions for basic set‐ 1x111111 => Page 31
ting
Lambda regulator before catalyst -10.0...10.0 % => Page 41
Coolant temperature 80.0...110.0 °C => Page 33
Engine speed (idling speed) 810...900 rpm => Page 31
Evaluating display group 1, display zone 1 - Engine speed (idling speed)
Appears on display Possible fault cause Fault elimination

Less than - Throttle valve control part sticking or defective - Check throttle valve control part
specification => Page 81
- Perform idling check => Page 109
Greater than - Throttle valve control part sticking or defective - Interrogate fault memory, => Page 7
specification
=> Page 81
- Perform idling check => Page 109
Significance of figures in 8-digit number block, display zone 4 - adjustment conditions

AG. Volkswagen AG d
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Significance if display = 1 rise
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1 2 3 4 5 6 7s a 8
ut
Significance ra
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1 Coolant temperature exceeds 80.0 °C
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1 Speed below 2000 rpm

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1 Throttle valve closed

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1 Lambda regulation OK.

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1 Air conditioner compressor switched off

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x Not relevant
1 No faults recognised by self-diagnosis
rrectness of i

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xxxx rpm xxx.x % x.x ms xxx mbar
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Intake manifold pressure 250...500 mbar => Page 32

thi
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Injection period 2.0...7.0 ms => Page 32

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8.1 - Evaluating measured value blocks, display groups 0...9 -Basic functions-
AG.
Engine load 15.0...30.0 % => Page 35

Evaluating display group 2, display zone 3 - Injection period

Less than 2.0 ms - Large amount of fuel from the activated - Check tank venting valve
charcoal filter system => Page 19 , Final control diagnosis
. Volkswagen AG
Larger than 7.0 ms - Increased engine load due tokelectrical
swagen AG - Eliminate
doeincreased
s no load (air conditioner,
consumers, air conditioner,bygear
Vol selected or power assisted t gsteering
uara
etc.)
P.A.S. on full lock ris
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Evaluating display group 2, display zone
ss 4 - Intake manifold pressure c
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Less than 250 mbar - Large amount of unmetered air between - Check intake system for leaks
h re
intake manifold and air mass meter => Page 84
hole
spec
Larger than 500 mbar - Increased engine load due to electrical - Eliminate increased load (air conditioner,
es, in part or in w
t to the co
consumers, air conditioner, gear selected power assisted steering etc.)
or P.A.S. on full lock Check intake manifold pressure sender
=>Page 84
rrectness of i
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nform
ercia

m
a
xxxx rpm xxx mbar xxx.x % xx.x°BTDC
com
tion in
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Ignition angle -5.0...10.0 ° BTDC ---
s
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Throttle valve angle 0.2...5.0 % => Page 35
um
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(Potentiometer 1 -G187)
en
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Intake manifold pressure 250...500 mbar => Page 32
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Note on display zone 3:
AG.
With the accelerator pedal floored the display value is approx. 100.0 %.

xxxx rpm xx.xxx V xxx.x °C xxx.x °C
Intake air temperature -40.0...129.0 °C => Page 33
Engine control unit voltage supply 12.000...15.000 V => Page 33

The engine control unit will use the intake air temperature as a replacement value for an engine start (start
temperature - replacement value) as soon as there is a fault stored in the fault memory, which affects the coolant
temperature sender (G62). The temperature then rises according to a model stored in the control unit. When
the engine has reached normal working temperature a fixed replacement value will be displayed after a certain
period. This fixed value is also dependent upon the intake air temperature.
The total temperature range is given as the specification. The displayed value must be above ambient tem‐
perature.
Evaluating display group 4, display zone 2 - Control unit voltage supply
AG. Volkswagen AG d
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Appears on display Possible faulthor cause Fault elimination
eo
aut ra
Less than 12.000 V - Alternator defective,
s battery heavily dis‐
s - Check alternator and battery
voltage,
c
charged charge battery:
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e
nl
pt
du
=> Electrical system; Repair group 27
an
itte
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- Battery heavily charged shortly after start‐ - Increase revs slightly for a few minutes and
erm
ab
ing due to high charging current and current switch off current consumers
ility
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consumers
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- Transfer resistance in the current supply - Check engine control unit voltage supply
hole
spec
or the engine control unit earth connection => Page 123
es, in part or in w
- Current draw when ignition is off - Eliminate current draw
t to the co
More than 15.000 V - Voltage regulator on alternator defective - Check voltage, replace regulator if neces‐
sary:
rrectness of i
- Excess voltage due to jump starting or - Interrogate fault memory => Page 7
l purpos
quick charging unit
nform
ercia
Evaluating display group 4, display zone 3 - Coolant temperature

m
at
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ion
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in t
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at
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Less than 80.0 °C - Engine too cold - If necessary carry out test drive
p
cum
for
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- Coolant temperature sender or wiring to - Check coolant temperature sender

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engine control unit =>Page 90 t. Cop py
rig
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More than 110.0 °C - Radiator soiled - Clean radiator
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- Radiator fan not functioning - Check radiator fan:
lksw
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AG.
parts of cooling system; Checking radiator

fan Checking radiator fan
- Thermostat defective (Thermostat) - Check thermostat:
parts of cooling system; Parts of cooling sys‐
tem - engine side Parts of cooling system -
engine side
- Coolant temperature sender or wiring to - Check coolant temperature sender
engine control unit =>Page 90
Constant -40.0 °C - Wiring open circuit or short to positive - Check coolant temperature sender
=>Page 90
Constant 129.0 °C - Short to earth
Evaluating display group 4, display zone 4 - Intake air temperature

Constant -40.0 °C - Wiring open circuit or short to positive - Check intake air temperature sender
=>Page 86
8.1 - Evaluating measured value blocks, display groups 0...9 -Basic functions- 33
. Volkswagen AG
gen AG d
Polo Estate 1998 ➤ olks
wa oes
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ised b (2-valve, roller rocker finger)
ara - Edition 12.1999
n r tee
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Constant 129.0 °C - Short to earth
ss
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xxxx rpm xxx.x % xxx km/h Text
es, in part or in w
t to the co
Operating mode: Idling ---
Idling, part throttle, enrichment, overrun,
rrectness of i
full throttle
Road speed 0 km/h ---
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Engine load 15.0...30.0 % => Page 35

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xxxx rpm xxx.x % xxx.x °C xx.x %

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Altitude correction factor -50.0...20.0 % ---
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Intake air temperature Prote
-40.0...129.0 °C => Page 33
AG.
Engine load 15.0...30.0 % => Page 35

The total temperature range is given as the specification. The displayed value must be above ambient tem‐
perature.
9 - Evaluating measured value blocks, display groups 10...29 -Ignition-

9.1 - Evaluating measured value blocks, display groups 10...29 -Ignition-
Display group 10 -Ignition-

xxxx rpm xxx.x % xxx.x % xx.x°BTDC
Ignition angle -5.0...10.0 ° BTDC ---
Throttle valve angle 0.2...5.0 % => Page 35
Engine load 15.0...30.0 % => Page 35
With the accelerator pedal floored the display value must be approx. 100.0 %.
Evaluating display group 10, display zone 2 - Engine load

Less than 15.0 % - Lesser values can only occur when driving in ---
overrun
Larger than 30.0 % - Rough idling (not running on all cylinders) - Check injectors => Page 139
- Throttle valve control part defective - Check throttle valve control part
=> Page 81
- Electric consumers switched on - Switch off electric consumers
- Steering wheel at full lock - Set steering wheel to centre position
Evaluating display group 10, display zone 3 - Throttle valve angle potentiometer 1

More than 5 % - Engine control unit not adapted to throttle - Adapt engine control unit to throttle valve
valve control part control part => Page 127
- Throttle valve potentiometer in throttle - Check throttle valve control part
valve control part defective => Page 81
- Throttle valve sticking - Eliminate cause
Only engine codes ANW, AUD AG. Volkswagen AG d

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Display group14 -Ignition- Misfire recognition
thor total eo
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▪ Whilst driving ss c
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xxxx rpm xx.x % xxxText

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Misfire recognition activated ---
wit
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(activated, blocked)
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spec
Misfire total 0 => Page 35
es, in part or in w
t to the co
Engine load 15.0...100.0 % ---
Engine speed 810...5700 rpm ---
rrectness of i
Evaluating display group 14, display zone 3 - Total number of misfires

l purpos
nform
ercia

m
More than 0 - Spark plug defective - Removing and installing parts of the ignition system
com
tion in
- Spark plug connector defective => Page 144

r
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- Ignition coil defective

thi
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- Ignition coil output stage defective

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- Injector defective - Check injectors

fo
en
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=> Page 96
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t.
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Cop py
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gh ht
Only engine codes ANW, AUD yri
p by
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by lksw
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Prote AG.
Display group 15 -Ignition- Misfire recognition Cyl. 1 to Cyl. 3

▪ Whilst driving
9.1 - Evaluating measured value blocks, display groups 10...29 -Ignition- 35

xxx xxx Text xxx

1 2 4 ◂ Display zones Specification
3 Evaluation
Misfire Cyl. n3AG. Volkswagen AG do 0 => Page 36
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Misfire Cyl. 2 by Vol ot g
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ed ran
Misfire Cyl. 1 ho
ris tee 0 => Page 36
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Display group 16 -Ignition- misfire recognition Cyl. 4
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▪ Whilst driving
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xxx --- --- Text
es, in part or in w
t to the co
rrectness of i
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Misfire Cyl. 4 0 => Page 36
nform
mercia
at
Evaluating display group 15 display zones 1 to 3 or display group 16 display zone 1 - Misfire recognition Cyl.
om
io
1 to Cyl. 4
n
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More than 0 - Spark plug defective - Removing and installing parts of the ignition system
t. C rig
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- Spark plug connector defective => Page 144 p by
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- Ignition coil defective
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- Ignition coil output stage defective
AG.
- Injector defective - Check injectors

=> Page 96
Display group 20 -Ignition- Knock control Cyl. 1 to Cyl. 4

▪ Whilst driving
xx.x °CA xx.x °CA xx.x °CA xx.x °CA
Cyl. No. 4 retardation of ignition by 0.0...12.0 °CA => Page 37
knock control
Cyl. No. 3 retardation of ignition by knock con‐ 0.0...12.0 °CA => Page 37
trol
Cyl. No. 2 retardation of ignition by knock control 0.0...12.0 °CA => Page 37
Cyl. No. 1 retardation of ignition by knock control 0.0...12.0 °CA => Page 37
Note on display zones 1 to 4:
Display value should be 0.0 °CA at idling speed.
Evaluating display group 20, display zones 1 to 4 - Cyl. 1 to Cyl. 4 ignition retardation

All cylinders greater than 12.0 °CA - Knock sensor defective - Check knock sensor => Page 148
- Connector corroded
- Knock sensor incorrectly tight‐ - Loosen knock sensor and tighten to
ened 20 Nm
- Ancillary components on engine - Tighten ancillary components
loose
- Poor fuel quality - Change type of fuel
One cylinder deviates greatly from - Connector corroded - Check knock sensor => Page 148
the others
- Engine damaged - Check compression pressures:
=> Repair group 15; Removing and
installing cylinder head; Checking
compression pressure Checking
compression pressure
- Ancillaryecomponents
n AG. Volkswageon engine
n AG - Tighten ancillary components
loose
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Display group 22 -Ignition- 2 knock control Cyl.
ss 1 and Cyl. c
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▪ Whilst driving
un
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xxxx rpm x.xx % xx.x °CA xx.x °CA
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Cyl. No. 2 retardation of ignition tim‐ 0.0...12.0 °CA => Page 38
hole
spec
ing by knock control
es, in part or in w
t to the co
Cyl. No. 1 retardation of ignition timing by 0.0...12.0 °CA => Page 38
knock control
Engine load 15.0...100.0 % rrectness of i
---
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Note on display zones 3 and 4:

nform
ercia
The display value should be 0.0 °CA at idling speed.

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Display group 23 -Ignition- Cyl. 3 and Cyl. 4 knock control

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▪ Whilst driving
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xxxx rpm x.xx % xx.x °CA xx.x °CA C py
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◂ Display zones Specification Evaluation
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Cyl. No. 4 retardation of ignition by Prote
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0.0...12.0 °CA => Page 38
knock control
Cyl. No. 3 retardation of ignition by knock con‐ 0.0...12.0 °CA => Page 38
trol
Engine load 15.0...100.0 % ---
9.1 - Evaluating measured value blocks, display groups 10...29 -Ignition- 37

Note on display zones 3 and 4:
The display value should be 0.0 °CA at idling speed.
Evaluating display groups 22/23, display zones 3 and 4 - Retardation of ignition

All cylinders greater than 12.0 °CA - Knock sensor defective - Check knock sensor => Page 148
- Connector corroded
- Knock sensor incorrectly tight‐ - Loosen knock sensor and tighten to
ened 20 Nm
loose
- Poor fuel quality - Change type of fuel
One cylinder deviates greatly from - Connector corroded - Check knock sensor => Page 148
the others
- Engine damaged - Check compression pressures:
=> Repair group 15; Removing and
installing cylinder head; Checking
compression pressure Checking
compression pressure
loose
Display group 28 -Ignition- knock agencontrol

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▪ Control unit in mode
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04-Basic settings eo
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Read measured ss a value block 28 ⇒ ◂ Indicated on display c
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xxxx rpm xx.x % xxx.x °C Text

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Knock sensor test result Sys. OK. ---

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es, in part or in w
Engine load 15.0...100.0 % ---

t to the co

rrectness of i
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10 - Evaluating measured value blocks, display grps 30...49, 99 -Lambda

regulation-
nf
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10.1 - Evaluating measured value blocks, display grps 30...49, 99 -Lambda regulation-
m
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Display group 30 -Lambda regulation-

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xxx xxx --- ---
p by
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1 2 3 4
agen
Prote AG.
AG. Volkswagen AG d
agen oes Polo Estate 1998 ➤
olksw not
V
Motronic d by inj. and ignition system (2-valve,
gu
ara roller rocker finger) - Edition 12.1999
rise nte
tho e o
au Status of Lambda regulation rafter ac catalyst1) 111 => Page 39
ss
▪ Catalyst temperature at least 400.0 °C
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nl
▪ (=>display group 34, display zone 2)
pt
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Status of Lambda regulation before catalyst 111 => Page 39
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ility
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1) Only engines conforming to D4 standard (engine code ANW)
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Notes on display zones 1 and 2:
spec
es, in part or in w
t to the co
◆ The first position in 3-digit number block fluctuates between 0 and 1 (Lambda probe heating off and on).
◆ Depending on status of Lambda regulation 0 or 1 is displayed alternately in 3-digit number block.
◆ The bits in display zones 1 and 2 are set to 1, when the catalyst temperature has exceeded 400.0 °C (=>
rrectness of i
display group 34, display zone 2).
l purpos
Significance of figures in 3-digit number block, display zones 1 and 2 - status of Lambda regulation before and
after catalyst
nform
mercia
at
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Significance if display = 1
o
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ate
1 2 3 Significance
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1 Lambda regulation active

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1 Lambda probe operationally ready
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Display group 32 -Lambda regulation- Lambda learnt values before catalyst

Read measured value block 32 ⇒ ◂ Indicated on dis‐
play
xx.x % xx.x % --- ---
Lambda learnt value at part load (multiplicative) -10.0...10.0 % => Page 40

before catalyst
Lambda learnt value at idling speed (additive) before catalyst -10.0...10.0 % => Page 40
Notes on display zones 1 and 2:
Low values indicate that the engine is running too rich and therefore the Lambda regulation is leaning the
mixture.
◆ High values indicate that the engine is running too lean and therefore the Lambda regulation enriches the
mixture.
◆ If there is no voltage supply to the control unit all the values learnt will be cancelled.
◆ add = additive - The effects of the fault (e.g. unmetered air) will reduce as the engine speed increases. The
injection period will be modified by a fixed amount for additive learnt values. This amount is not dependent
upon the basic injection period.
◆ mul = multiplicative - The effects of the fault (e.g. faulty injector) will increase as the engine speed increases.
A multiplicative learnt value is a proportional change to the injection period. This change is dependent on
the basic injection period.
Initiating learning process: Control unit in mode 04, Basic settings
◆ Learning conditions for idling: Idling, coolant temperature min. 75 °C, intake air temperature max. 90 °C
◆ Learning conditions for part load: coolant temperature min. 75 °C, intake air temperature max. 90 °C
39
Evaluating display group 32, display zones 1 and 2 - Lambda learnt values before catalyst

Low Lambda learnt values - Low learnt values at idling but with nor‐ - Disappears after motorway drive or oil
mal learnt values at part throttle: possi‐ change
ble oil dilution (high level of fuel in oil)
- Injector leaking - Check injector =>Page 96
- Fuel pressure too high - Check fuel pressure regulator and hold‐
ing pressure => Page 102
- Tank venting valve for activated char‐ - Check tank venting valve
coal filter permanently open => Page 19 , final control diagnosis
- Lambda probe heating defective or - Check Lambda probe heating before
Lambda probe soiled catalyst =>Page 74
Appears on dis‐ Possible fault Fault elimination

play cause
High Lambda - High learnt val‐ - Check intake air
learnt values ues at idling system for leaks
speed, not so =>Page 106
high learnt values agen
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at part throttle: Volksw not
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possible unme‐ sed by ara
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tered air in area of hori
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intake manifold aut ra
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- Injector blocked - Check injectors
ce
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un
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=>Page 96
an
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- Fuel pressure - Check fuel pres‐
erm
ab
too low sure regulator
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and holding pres‐

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sure => Page

h re
ole,
102 spec
- Unmetered air at t to the co

exhaust manifold
gasket
- Lambda probe - Check Lambda
rrectne
heating defective probe heating be‐

or Lambda probe fore catalyst
s
soiled =>Page 74
s o
cial p
f inform
mer
Display group 33 -Lambda regulation- Lambda regulation values before catalyst

atio
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xx.x % x.xxx V --- ---

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4 ◂ Display zones Specification Evaluation

en
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Lambda probe voltage before catalyst 1.000...2.000 V ---
cted agen
Prote AG.
Lambda regulator before catalyst -10.0...10.0 % => Page 41
Notes on display zone 1:
◆ The display must fluctuate around 0.0 %. If constant 0.0 % is displayed, the Lambda regulation has switched
from regulation to control, because there is a fault in the Lambda regulation. Interrogate fault memory =>
Page 7 .
Evaluating display group 33, display zone 1 - Lambda regulator before catalyst
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Appears on display Fault elimination
utho Possible fault cause eo
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a
Outside tolerance range - Minus range: Mixture too rich, Lambda - Wait 30 seconds until the display has sta‐
ss c
ce
control weakens mixture bilised e
nl
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- Positive range: Mixture too lean, Lamb‐
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da control enriches mixture
erm
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- Unmetered air - Check intake system for leaks
ot p
=> Page 106
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- Injector defective - Check injectors =>Page 96
hole
spec
- Lambda learnt value on limit - Check Lambda learnt value in display
es, in part or in w
group 32
t to the co
rrectness of i
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Display group 34 -Lambda regulation- Lambda probe diagnosis before catalyst (checking ageing via amplitude
duration monitoring)
nf
ercia
o
▪ Control unit in mode 04-Basic setting
rm
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atio
- Depress brake pedal
om
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c
▪ Vehicle stationary, engine runs at increased idling speed

or
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xxxx rpm xxx.x °C x.xx Text

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Result of Lambda probe before B1-P1 OK ---
C py
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catalyst ageing check
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(Test OFF / test ON / B1-P1 OK /
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B1-P1 n.OK) Prote AG.
Amplitude duration Lambda probe before 0.7... 2.00 ---

catalyst
Catalyst temperature min. 400.0 °C ---
Value calculated from engine speed and engine load.
Display group 36 -Lambda regulation- Operational readiness of probe after catalyst

x.xxx V xxx.x °C x.xx Text
Check Lambda probe after catalyst B1-P2 OK ---
(Test ON / test OFF / B1-P2 OK. / B1-P2
n.OK)
Specification Lambda probe after catalyst --- ---
Lambda probe voltage after catalyst 0.000...1.000 V => Page 42
41
Evaluating display group 36, display zone 1 - Lambda probe voltage, Lambda probe after catalyst

Constant 1.085 V - Short to positive via: - Check Lambda probe 2 basic voltage
- Lambda probe, probe wiring, earth wiring, en‐ => Page 119
gine control unit
Constant between - Open circuit via:
0.400...0.500 V - Lambda probe, probe wiring, earth wiring, en‐
gine control unit
Constant 0.000 V - Short to earth via:
- Lambda probe, probe wiring, earth wiring, en‐
gine control unit
Display group 37 -Lambda regulation- Lambda probes

▪ Vehicle stationary, engine running at increased idling speed
▪ Control unit in mode 04-Basic settings
xxx % x.xxx V xxx.xxx Text
Test of Lambda probes Syst. OK
(Test ON / OFF / Syst. OK / n.OK)
Not for ServiceAG. Volkswagen AG d
--- ---
agen oes
Lambda probe voltageolksw not 0.000...1.000 V => Page 42
yV gu
Lambda probe ed b after catalyst ara
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ris
Engine load ut
ho e o 15.0...30.0 %
r => Page 35
a ac
ss
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Display group 41 -Lambda regulation- Lambda probe heating

itte
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--- Text --- Text

ole,
spec

t to the co
Lambda probe heating after catalyst1) Htg.aC.ON ---

Htg.aC.OFF
rrectne
Lambda probe heating before catalyst Htg.bC.ON ---

Htg.bC.OFF
ss o
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f inform
mer
1) Only engines conforming to D4 standard (engine code ANW)

atio
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Note:
c
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The Lambda probe heating may be switched ON or OFF depending on the operating conditions of the engine,
iv
o
pr
therefore the display in display zone 2 or 4 may show "Htg.b(a)C.ON" or alternating from "Htg.b(a)C.ON" to
um
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Htg.b(a)C.OFF".
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Only engine codes ANW, AUD gh ht
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Prote AG.
Display group 46 -Lambda regulation- Catalyst diagnosis (conversion test)


xxxx rpm xxx.x °C x.xx Text
Result of catalyst conversion test Cat B1 OK ---
(Test OFF / test ON / Cat B1 OK/Cat B1
n.OK)
Amplitude ratio 0.00...0.50 ---
Display group 99 -Lambda regulation- Lambda regulation operating condition

▪ Control unit in mode 04-Basic setting, Lambda regulation off
▪ Control unit in mode 08-Read measured value block, Lambda regulation on
xxxx rpm xxx.x °C xx.x % Text
Lambda regulation operating mode λ-Reg. OFF or ---
λ-Reg. ON
Lambda regulator beforeagcatalyst
n AG. Volkswagen AG do-10.0...10.0 % => Page 41
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Coolant temperature byV
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80.0...110.0
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ed ran
Engine speed (idling speed) ho
ris 810...900 rpm tee => Page 31
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◆ For a defined fault finding the Lambda regulation is switched off when selecting display group 99 under
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"Basic setting" or switched on under "Read measured value block".
ility
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When the function 04 "Basic setting" is exited the Lambda regulation is automatically active again.
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◆ It is possible to switch between the function 04 "Basic setting" and the function 08 "Read measured value
h re
block" by pressing the keys 4 and 8 on V.A.G 1551/1552.
hole
spec
es, in part or in w
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11 - Evaluating measured value blocks, display groups 50...69 -Speed
regulation-
rrectness of i
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11.1 - Evaluating measured value blocks, display groups 50...69 -Speed regulation-
nf
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Display group 50 -Speed regulation- Operating condition

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xxxx rpm xxxx rpm Text Text

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Air conditioner compressor operating mode Compr. ON or ---
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ON/OFF Compr. OFF
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Prote AG.
Air conditioner operating mode A/C-High or ---
A/C-Low
Engine speed (idling speed specification) 700 rpm ---
43
The value displayed is the specified figure calculated by the control unit.
◆ A/C-High = Air conditioner demands too high a heating or cooling output

A/C-Low = Air conditioner not switched on.
◆ "Compr. OFF" is always displayed on vehicles without air conditioner.

◆ Checking signal from and to air conditioner compressor =>Page 132
Display group 54 -Speed regulation-

▪ Whilst driving AG. Volkswagen AG d
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Read measured value block 54 o
⇒ d by V ◂ Indicated on display gu
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xxxx rpm Text xxx.x % xxx.x
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% eo
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1 2 3 ss a
4 ◂ Display zones Specification
c Evaluation
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Throttle valve angle 0.0...100.0% ---

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Accelerator pedal position sender 1 -G79 0.0...100.0% ---
ab
ility
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Operating mode: --- ---
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Idling, part throttle, enrichment, overrun, full throttle
h re
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spec
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Display group 55 -Speed regulation- Idling stabilisation
rrectne
ss
xxxx rpm xx.x % xx.x % xxxxx
o
cial p
f i
nform
mer
Operating mode xxxxx => Page 44 atio

m
Idling speed regulation learnt value: -8.0...8.0 % ---

o
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c
Air conditioner on (A/C-High) -5.0...5.0 %

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Air conditioner off (A/C-Low)

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Idling speed regulator -4.3...12.2 % ---

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Displayed is the amount that the idling speed stabilisation has moved away from the prescribed average. For
Prote AG.
a new engine the values lie in the positive range, because of the higher friction and in the negative range with
an engine that has run-in.
Significance of figures in 5-digit number block, display zone 4 - operating modes
Significance if display = 1
1 2 3 4 5 Significance
1 Air conditioner compressor switched on
x Not relevant
1 Air conditioning system switched on
x Not relevant
AG. Volkswagen AG d
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Significance if display = 1 olksw not
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Display group 56 -Speed regulation- Idling speed stabilisation
pt
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xxxx rpm xxxx rpm xx.x % xxxxx
, is n
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1 2 3 4
spec
Operating mode xxxxx => Page 44
es, in part or in w
t to the co
Idling speed regulator -4.3...12.2 % ---
Engine speed (idling speed specification) 700 rpm ---
rrectness of i
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nform
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The value displayed is the specified figure calculated by the control unit.
m
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com
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Display group 60 -Speed regulation- Adaption EPC system 1)
thi
s
iva
do
▪ Ignition on, engine not running
r
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▪ Control unit in mode 04 basic setting
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Cop py
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xx % xx % x Text
ht ht
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4 ◂ Display zones Specification Evaluation
o
1 2 3 by c lksw
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Prote AG.
Adaption condition ADP OK ---
(ADP runs / ADP OK / ADP ERROR)
Learning step counter 0...9 ---
Throttle valve angle (Potentiometer 2 -G188) 90...10 % ---
Throttle valve angle (Potentiometer 1 -G187) 10...90 % ---
1) Adapting engine control unit to throttle valve control part => Page 127 .
Note on display group 60:
◆ Matching the throttle valve control part is performed with ignition switched on.
◆ Engine control unit is adapted to throttle valve control unit when selecting display group 60 under function
04 "Basic setting". This adaption must always be carried out when another throttle valve control part (or
another complete engine) or another engine control unit is fitted.
◆ If the voltage supply is interrupted (battery disconnected) the adaption (matching) must be carried out again
=> Page 125 Procedure after voltage supply open circuit.
◆ During adaption the counter counts upwards from 0 to 9 in display zone 3.
Display group 61 -Speed regulation- Electronic accelerator system

▪ Whilst driving
xxxx rpm --- xxx.x % xxxxx
Operating mode xxxxx => Page 44
Throttle valve angle 0.0...100.0% ---
11.1 - Evaluating measured value blocks, display groups 50...69 -Speed regulation-
45
Display group 62 -Speed regulation- Electronic accelerator system

▪ Ignition on, engine not running
xx % xx % xx % xx %
Accelerator pedal position sender 2 -G185 4...49 % ---
Accelerator pedal position sender 1 -G79 12...97 % ---
Throttle valve angle (potentiometer 2 -G188) 90...10 % ---
Throttle valve angle (potentiometer
wage
n1AG
-G187)
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doe 10...90 % ---
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12 - Evaluating measured
ss value blocks, display groups 70...79 -Reducing c
ce
emissions-
le
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12.1 - Evaluating measured value blocks, display groups 70...79 -Reducing emissions-
ility
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spec
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Display group 70 -Reducing emissions- Activated charcoal filter system diagnosis (tank breathing system)
rrectne
▪ Coolant temperature at least 80.0 °C
s
▪ Control unit in mode 04-Basic settings
s o
cial p
Read measured value block 70 ⇒ ◂ Indicated on display f inform

xx.x % xx.x % --- Text
mer
atio

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n
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Result of activated charcoal filter diag‐ TVV OK ---

or
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nosis
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(Test OFF / test ON / TVV OK / TVV

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n.OK)
fo
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Lambda regulator deviation during TVV diagnosis gh
-10.0...10.0 % ---
ht
pyri by
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Tank venting valve -N80 for activated charcoal filter system duty by c
0.0...99.0 % ---
lksw
cted agen
cycle
Prote AG.
Note:
TVV means tank venting valve. The diagnosis can only be initiated once per engine start.
◆ Lambda regulator deviation in negative range: Activated charcoal filter full

◆ Lambda regulator deviation in positive range: Activated charcoal filter empty
13 - Evaluating measured value blocks, display group 100 -Readiness code-

13.1 - Evaluating measured value blocks, display group 100 -Readiness code-
Display group 100 -Readiness code-

xxxxxxxx xxx.x °C xxx.x s xxxxxxxx
Diagnosis status --- ---
Period since last engine start --- ---
Readiness code 00000000 => Page 47
Significance of figures in 8-digit number block, display zone 1 - Readiness code
The readiness code is generated only when all display agen

Azones
G. Volksshow 0G do
wagen A
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1 2 3 4 5 6 7 8 by Vol
Diagnostic function
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0 Catalyst horis tee
ut or
0 Catalystsheating
s a (currently no diagnosis/always "0") ac
ce
le
0 Activated charcoal filter system (tank venting system)

un
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0 Secondary air system (not fitted/always "0")

itte
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0 Air conditioner (currently no diagnosis/always "0")
ility
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0 Lambda probes
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0 Lambda probe heating
ole,
spec
0 Exhaust gas recirculation (not fitted/always "0")

t to the co
rrectness o
cial p
f inform
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n
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13.1 - Evaluating measured value blocks, display group 100 -Readiness code- 47
24 - Mixture preparation, Injection
1 - Servicing injection system

1.1 - Servicing injection system
AG. Volkswagen AG d
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Prote AG.
1.2 - Fitting locations overview
Component A is not shown on the illustration.
A - Accelerator pedal position sender (G79)

◆ In footwell on accelerator pedal:
48 24 - 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
1 Tank venting valve (N80)*/**
=> Repair group 20; Activated charcoal filter system Activated charcoal filter system
2 Connector
◆ Engines fulfilling D4 standard only
◆ For Lambda probe 2 after catalyst (G130) and Lambda probe heating (Z29)
◆ Black, 4-pin
◆ Contacts 3 and 4 gold plated
AG. Volkswagen AG d
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3 Intake manifold pressure sender (G71)* with intake air temperature sender (G42)*
cial p
f inform
4 Knock sensor 1 (G61)*

mer
atio
5 Lambda probe 2 after catalyst (G130)*, 50 Nm

om

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or
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6 Throttle valve control part (J338)*

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7 Fuel pressure regulator

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8 Intake manifold
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9 Engine speed sender (G28)* C py
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10 Motronic control unit (J220)* op Vo
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Prote AG.
1.2 - Fitting locations overview 49

11 Brake pedal switch (F47)

◆ In footwell on brake pedal
◆ Checking => Page 133
AG. Volkswagen AG d
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ate
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12 Brake light switch (F)
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Prote AG.
◆ In footwell on brake pedal
13 Ignition transformer (N152)*
◆ With ignition cable identification, do not interchange
◆ => Page 139 , item 2
14 3 pin connector
◆ Black
◆ For engine speed sender (G28)
15 Coolant temperature sender (G62)*
◆ With coolant temperature gauge sender (G2)

AG. Volkswagen AG d
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Prote AG.
16 Connector
◆ For Lambda probe 1 before catalyst (G39) and Lambda probe heating (Z19)
Engine code AKK
◆ Black, 4-pin
◆ Connector contacts 3 and 4 are gold-plated
Engine codes ANW, AUD
◆ Black, 6-pin
◆ Contacts gold plated
17 Hall sender (G40)*
◆ => Page 141 , item 8
18 Lambda probe 1 before catalyst (G39)*, 50Nm
19 Injectors (N30...N33)*
20 Fuel rail
21 Activated charcoal filter
1.2 - Fitting locations overview 51

1.3 - General notes on injection
Servicing ignition part:
=> Repair group 28
◆ The engine control unit is equipped with self-diagnosis. Before carrying out repairs and fault finding the fault
memory must be interrogated. Also the vacuum hoses and connections must be checked (unmetered air).
◆ Fuel hoses in engine compartment must only be secured with spring type clips. The use of clamp or screw
type clips is not permissible.
◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
engine control unit could be damaged.
◆ Components marked with * are checked n Avia
G. Vthe
olkswself
agendiagnosis
AG do
=> Page 7 , interrogating and Verasing wagefault memory. es n
olks ot g
◆ Components marked with **can ed by be checked with the final control ua diagnosis => Page 19 .
ran
◆ For trouble-free operation thorisof the electrical components, a voltage of teat
e o least 11.5 V is necessary.
◆ Do not use sealants containing
s au silicone. Particles of silicone drawn into r athe engine, will not be burnt in the
c
engine and damage sthe Lambda probe.
ce
le
◆ If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests,
un
pt
an
d
then the fault may lie with the immobilizer which is blocking the engine control unit. The fault memory must
itte
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be interrogated and if necessary the control unit matched => Page 129 .
erm
ab
ility
◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after com‐
ot p
pleting all checks and repairs the fault memory must be interrogated and if necessary erased.
wit
is n
h re
=> Page 7 , interrogating and erasing fault memory
ole,
◆ Vehicles with an airbag are fitted with a crash/fuel shut-off. It reduces the risk of a vehicle burning in the
spec
event of a crash in that the fuel pump is switched off by the fuel pump relay. At the same time this device
t to the co
improves the starting of the engine because as soon as the door is opened the fuel pump is activated to
build-up pressure in the fuel system.
rrectne
Safety precautions =>Page 72
s
Rules for cleanliness => Page 73 s o
cial p
f in
Technical data => Page 73

form
mer
atio
m
Checking intake system for leaks (unmetered air) => Page 106 .
o
n
c
i
or
n thi
e
Checking engine operating mode => Page 121

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Prote AG.

1.4 - Removing and installing parts of the injection system
AG. Volkswagen AG d
agen oes
olksw not
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ility
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spec
es, in part or in w
1 Motronic control unit (J220)*

t to the co
◆ Fitting location => Page 48 , engine compartment overview

◆ For injection system, Lambda regulation, activated charcoal filter tank venting valve, knock control, speed
governing, ignition and self-diagnosis
rrectness of i
◆ Checking voltage supply => Page 123

◆ Procedure after voltage supply open circuit => Page 125
l purpos
◆ Renew => Page 125

◆ If replaced carry out basic setting => Page 127
nf
ercia
◆ On replacement, the control unit must be matched to the electronic immobilizer => Page 129
orm
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n in
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Prote AG.
1.4 - Removing and installing parts of the injection system 53

AG. Volkswagen AG d
agen oes
ksw not
Polo Estate 1998 ➤ by Vol
gu
ara
d
Motronic inj. and ignition systemorise (2-valve, roller rocker finger) -nteEdition
eo
12.1999
th
au ra
ss c
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e
nl
pt
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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ate
do
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Cop py
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co lksw
by
cted agen
Prote AG.
2 Retaining frame
3 Supply hose
◆ Black with white marks
◆ Secure with spring-type clips
◆ Check securely seated
◆ From fuel filter:
=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing fuel tank
with attachments and fuel filter Removing and installing parts of fuel supply system Removing and installing
fuel tank with attachments and fuel filter
4 Return hose
◆ Blue or with blue marking
◆ To the fuel delivery unit in fuel tank

AG. Volkswagen AG d
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h eo
Motronic inj. andaut ignition system (2-valve, roller rocker finger) ra
c
- Edition 12.1999
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5 10 Nm
6 Cable/line guide
◆ Clipped onto fuel rail
7 Securing clip
◆ Note version
8 Connector
◆ Black, 2-pin
◆ For injector (N30...N33)
9 Connector
◆ Black, 6-pin
◆ For throttle valve control part (J338)
◆ Connector contacts are gold-plated
10 Connector
◆ Black, 4-pin
◆ For intake manifold pressure sender and sender for intake air temperature in intake manifold

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11 Fuel manifold with injectors

rrectness of i
◆ Dismantling and assembling => Page 65

l purpos
12 Vacuum hose
13 20 Nm
nf
ercia
14 Intake manifold
orm
◆ Dismantling and assembling => Page 65

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15 From brake servo

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16 5 Nm
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17 Engine speed sender (G28)*

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◆ Fitting location => Page 48 , fitting location overview

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◆ To remove, remove intake manifold item 14

t.
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◆ Checking => Page 94 C py
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18 Connector
cted agen
Prote AG.
◆ For Lambda probe 2 after catalyst (G130) and Lambda probe heating (Z29)
◆ Black, 4-pin
◆ Contacts 3 and 4 gold plated
19 Lambda probe 2 after catalyst (G130)*, 50Nm
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
◆ Probe heating voltage supply via fuel pump relay (J17)
◆ Check Lambda probe heating for Lambda probe after catalyst => Page 78
◆ Check Lambda probe and Lambda regulation after catalyst => Page 116

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20 Lambda probe 1 before catalyst (G39)*, 50Nm
ss
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
o
cial p
body
inform
◆ Probe heating voltage supply via fuel pump relay (J17)

mer
◆ Checking Lambda probe heating before catalyst => Page 74

atio
m
◆ Checking Lambda probe and Lambda regulation before catalyst

o
n
c
=> Page 111

i
or
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◆ Checking Lambda probe ageing Lambda probe 1 => Page 120

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AG. Volkswagen AG d
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21 Connector aut ra
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◆ For Lambda probe 1 before catalyst (G39) and Lambda probe heating (Z19)
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Engine code AKK

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◆ Black, 4-pin
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◆ Connector contacts 3 and 4 are gold-plated

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◆ Black, 6-pin
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◆ Contacts gold plated

hole
spec
22 Seal
es, in part or in w
t to the co
◆ Renew
23 Thermostat housing
24 Retaining clip
rrectness of i
◆ Check seated securely

l purpos
25 O-ring
◆ Renew if damaged
nf
ercia
26 Plug
orm
◆ If necessary release pressure in cooling system before removing

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59
AG.
1.4 - Removing and installing parts of the injection system
AG. Volkswagen AG d
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27 Connector
◆ Black, 4-pin
◆ For coolant temperature sender (G62) and coolant temperature gauge sender (G2)
28 Coolant temperature sender (G62)*
◆ Green
◆ For engine control unit
◆ With coolant temperature gauge sender (G2)
◆ If necessary release pressure in cooling system before removing
◆ Resistance values between contacts 3 and 4
=>Page 71 , Fig. 1
◆ Checking =>Page 90
29 Guide tube
◆ For dipstick
30 6 Nm
◆ Notes on installing => Page 72

AG. Volkswagen AG d
agen oes
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nte
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1998 ➤
h
aut
(2-valve, roller rocker finger) - Edition r a 12.1999
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31 Vent pipe
◆ From tank venting valve in activated charcoal filter:
32 Connector
◆ Only disconnect or connect with ignition switched off

1.5 - Dismantling and assembling intake manifold

AG. Volkswagen AG d
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1 Vent pipe
◆ From tank venting valve in activated charcoal filter:
2 Bracket
3 Vacuum valve
4 Breather hose
◆ To throttle valve control part
5 10 Nm
6 Breather hose
◆ From crankshaft breather housing connection
7 Throttle valve control part (J338)*
◆ If replaced match engine control unit => Page 127

AG. Volkswagen AG d
agen oes
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V gu
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8 Seal
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9 Vacuum hose
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◆ From fuel pressure regulator
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=> Page 66 , item 6
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10 20 Nm
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Prote AG.
11 Intake manifold
◆ Removing and installing
=>Page 53 , removing and installing parts of the injection system
12 From brake servo
13 Seal
◆ Renew
1.5 - Dismantling and assembling intake manifold 63

Polo Estate 1998 ➤ gen AG. Volkswagen AG d
wa oes
Motronic inj. andy Vignition
olks system (2-valve, noroller
tg rocker finger) - Edition 12.1999
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nl
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14 O-ring
15 Intake manifold pressure sender (G71)* with intake air temperature sender (G42)*
◆ Checking intake manifold pressure sender
=>Page 84
◆ Checking intake air temperature sender =>Page 86
◆ Intake air temperature sender resistance values between contacts 1 and 2=>Page 71 , Fig. 2
16 3 Nm
17 Connection

1.6 - Dismantling and assembling fuel rail with injectors
AG. Volkswagen AG d
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1 Fuel manifold pyri
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◆ Removing and installing

co Vo
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=>Page 99 , checking spray pattern and injectors for leaks Prote AG.
2 10 Nm
3 Retaining clip
◆ Check seated securely
4 O-ring
◆ Before installing moisten with clean engine oil
5 Fuel pressure regulator
◆ Checking => Page 102 , checking fuel pressure regulator and holding pressure
1.6 - Dismantling and assembling fuel rail with injectors 65

AG. Volkswagen AG d
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pt
6 Vacuum hose
an
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◆ To intake manifold => Page 63 , item 9
erm
ab
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7 Retaining clip
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◆ Ensure seated correctly at injector and fuel rail

h re
ole,
8 O-ring spec
◆ Renew
t to the co
◆ Before installing moisten with clean engine oil

9 Injectors (N30...N33)*
rrectne
◆ Resistance 12...17 ω
ss o
cial p
f inform
mer
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10 Return hose gh ht
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◆ Blue or with blue marking
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◆ Secure with spring-type clips Prote AG.
◆ To the fuel delivery unit in fuel tank
11 Supply hose
◆ Black with white marks
◆ From fuel filter:
1.6 - Dismantling and assembling fuel rail with injectors 67

1.7 - Dismantling and assembling air cleaner
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Removing and installing air cleaner => Page 71 , Fig. 3
1 Plug
2 Hexagon bolt, 10 Nm
◆ With guide for spacer
3 Spacer sleeve
4 Air cleaner upper part
5 Filter element
6 Gasket
◆ Note installation position

AG. Volkswagen AG d
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7 Seal
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8 Stop
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◆ Check securely seated yri
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9 3 Nm
agen
Prote AG.

10 Air cleaner lower part
11 Air intake housing with regulating flap
◆ Check intake air preheating => Page 107
12 Connecting piece for cold air intake
◆ Note installation position
1.7 - Dismantling and assembling air cleaner 69

AG. Volkswagen AG d
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13 Crankcase breather hose

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◆ From oil separator:

wit
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hole
=> Repair group 17; Removing and installing parts of lubrication system Removing and installing parts of lu‐
spec
brication system
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t to the co
rrectness of i
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-> Fig. 1 Resistance values for coolant temperature sender (G62)
The diagram is divided into two temperature ranges:

A- From 0...50 °C
B- From 50...105 °C
Examples:
◆ 30 °C is in range A and corresponds to a resistance of 1.5...2.0 kω
◆ 80 °C is in range B and corresponds to a resistance of 275...375 ω
-> Fig.2 Resistance values for intake air temperature sender (G42)
The diagram is divided into two temperature ranges:

agen
AG. Volkswagen AG d
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A- From 0...50 °C ed by ua
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B- From 50...105 °C tho
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Examples:
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◆ 20 °C is in range A and corresponds to a resistance of 2.3...2.6 kω

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◆ 80 °C is in range B and corresponds to a resistance of 290...330 ω

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-> Fig. 3 Removing and installing air cleaner

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Removing
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- Remove plugs -1-. yri
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- Remove securing screws -2-. cop Vo
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- Pull crankcase breather hose -4- off air cleaner housing.
cted agen
Prote AG.
- Pull cylinder head cover breather hose off air cleaner housing.
- Unclip ignition cables -5- out of air cleaner upper part.
1.7 - Dismantling and assembling air cleaner 71

- Remove air cleaner.
Installing
- Installing the air cleaner is carried out in the reverse order.
- -> Tighten securing screws -2- to

10 Nm.
(Ensure that the spacer sleeves -3- are first fitted into the air cleaner upper part.)
G. Volkswagen AG d
- Ensure that the ignition cables -5- are laid so that the loops of the cables
ksw
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en A touch the air cleaner
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housing.
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Notes: rise ran
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When installing, ensure that the connecting pipe over thesswarm air intake is not touching body work.
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nl
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To secure the air cleaner lower part to the air cleaner upper part self tapping screws are used. If these screws
itte
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are loosened or tightened with a power tool the thread in the air cleaner upper or lower parts can be damaged.
erm
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For this reason the use of a power tool can only be used when:
, is n
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hole
spec
◆ The maximum speed of the power tool is 300 rpm.
es, in part or in w
◆ The tightening torque is set to a maximum of 6 Nm.
t to the co
rrectness of i
l purpos
nform
ercia
Warning!
The fuel system is pressurized! Before loosening hose connections or opening the test connection, wrap a cloth
m
at
around the connection. Then release pressure by carefully pulling off the hose or carefully unscrewing sealing
om
io
plug.
n
c
in t
or
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ate
do
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To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
p
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or
noted:
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◆ For safety reasons the fuse No. 40 must be removed from the fuse holder before opening the fuel system, t. C rig
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otherwise the fuel pump can be activated by the door contact switch. pyri by
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◆ Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
by lksw
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◆ The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or
AG.
tester cables.
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.

◆ If the engine is to be turned at starter speed, without starting:
- -> Pull 4 pin connector off ignition transformer -arrow-.
AG. Volkswagen AG d
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- -> Pull plug -arrows- off all injectors. horis
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1.9 - Rules for cleanliness
d
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ility
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When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
wit
is n
h re
ole,
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
spec
◆ 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.
◆ Only install clean components: t to the co
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
rrectne
◆ When the system is open:

Do not work with compressed air if this can be avoided.
s
Do not move vehicle unless absolutely necessary.

s o
cial p
f inform
mer
atio
1.10 - Technical data

om
n
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Engine code AKK ANW, AUD

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Idling speed check

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Idling speed2) rpm 810...9001) 810...9001)
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1.8 - Safety precautions 73


System Motronic ME7.5.10 Motronic ME7.5.10
Part number =>Parts film =>Parts film
Governed speed rpm from approx. 5700 from approx. 5700
1) Up-to-date specifications:
=> Exhaust emissions test binder
2) Not adjustable
3) Replacing engine control unit => Page 125
2 - Checking components
2.1 - Checking components
2.2 - Checking Lambda probe heating before catalyst
AG. Volkswagen AG d
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Check conditions
rrectness of i
• -> Fuse No. 1 must be OK.

l purpos

• Fuel pump relay must be OK
nform
ercia
Test sequence
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Select function XXX


1 2 3 4
- Check status of Lambda probe heating before catalyst in display zone 2:

AG. Volkswagen AG d
Display: Htg.bC.ON lksw
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Note: oris tee
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The Lambda probe heating may be switchedss on or off depending on the operating mode of the engine,
a ac therefore
the display in display zone 2 may show "Htg.bC.ON or alternating from Htg.bC.ON to Htg.bC.OFF.
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If the specification is obtained:

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- Press ⇒key.
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If the specification is not obtained:
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t to the co
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nform
mercia
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Engine code AKK => Page 77
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- -> Separate 6-pin connector (black) to Lambda probe before catalyst (G39) -arrow-. Prote
cted AG.
agen
Checking voltage supply
2.2 - Checking Lambda probe heating before catalyst 75

- -> Connect the Multimeter with aux. cables from V.A.G 1594 to measure voltage on contacts 3 + 4 (connector
to engine control unit).
- Measure the voltage supply:
When display group 41, display zone 2 displays
Display, Htg.bC.ON:
Specification: 11.0...14.5 V
Display, Htg. bC.ON/Htg.bC.OFF (alternating) agen
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- Press keys 0 and 6 for the function "End output" thorand confirm entry with the Q key. eo
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- -> Check wire between test box and 6-pin connector (connector to control unit) for open circuit using current
flow diagram.
Contact 4+socket 1
- Check wire between 6-pin connector contact 3 and fuel pump relay (J17) for open circuit using current flow
diagram.

Only engine code AKK
- -> Separate 4-pin connector (black) to Lambda probe before catalyst (G39) -arrow-.
- -> Check probe heating for continuity at Lambda probe connector contacts 1 and 2.
Note:
The heater element resistance is approx. 1...5 ω at room temperature. Even slight increases in room temper‐
ature increase the resistance greatly. olkswage es n
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2.2 - Checking Lambda probe heating before catalyst
- -> Connect multimeter using aux. cables from V.A.G 1594 to measure voltage at contacts 1+2 (connector
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2.3 - Checking Lambda probe heating after catalyst

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Check conditions


Test sequence

Select function XXX


1 2 3 4
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2.3 - Checking Lambda probe heating after catalyst 79

- -> Connect multimeter using aux. cables from V.A.G 1594 to measure voltage at contacts 1+2 (connector
- Measure the voltage supply:
When display group 41, display zone 4 displays
Display, Htg.aC.ON:
Display, Htg. aC.ON/Htg.aC.OFF (alternating)
Specification: Between 0.0...12.0 V fluctuating n AG. Volkswagen AG do
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- Press keys 0 and 6 for the functionir se
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- Switch off ignition. tho
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- -> Check wires between test box and 4-pin connector (connector to control unit) for open circuit using current
flow diagram.
Contact 2+socket 13


- Check wire between 4 pin connector contact 1 and fuel pump relay (J17) for open circuit using current flow
diagram.
If no voltage is present and the wiring is OK:

- Renew the Lambda probe 2 after catalyst (G130) =>Page 57 , item 19 .
2.4 - Checking throttle valve control part
Components of throttle valve control part (J338):

Throttle valve drive (G186), angle sender 1 for throttle valve drive (G187) and angle sender 2 for throttle valve
drive (G188).
Note:
If the throttle valve control part is replaced, the new control part must without fail be adapted to the engine
control unit => Page 127 .
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◆ Fault reader V.A.G Vol 1551 or vehicle system tester
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◆ Test box V.A.G ed by 1598/22 ara
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◆ Hand multimeter
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◆ Adaptera set V.A.G 1594
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Read measured value block 62 cted agen
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1 2 3 4
- Check throttle valve angle at idling stop from sender 1 (G187) in display zone 1
Specification: 10...90 %
- Check throttle valve at idling stop from sender 2 (G188) in display zone 2.
Specification: 90...10 %
2.3 - Checking Lambda probe heating after catalyst 81

- Depress accelerator slowly to full throttle position and observe angles displayed in display zones 1 and 2:
The percentage figure in display zone 1 must increase evenly. Although the tolerance range 10...90 % will
not be fully exploited.
The percentage figure in display zone 2 must decrease evenly. Although the tolerance range 90...10 % will
not be fully exploited.
Notes:
◆ The reason why the display in display zone 1 increases and the display in display zone 2 decreases is
because the potentiometers (angle senders) in the throttle valve control part run in opposite directions.
◆ This means that the voltage of one angle sender moves towards 5 volts. (The more the throttle valve is
opened the higher the voltage; percentage figure increases).
◆ Whilst the voltage of angle sender 2 decreases from 5 volts towards 0 volts. (The more the throttle valve is
opened the lower the voltage; percentage figure decreases).
- Press ⇒key.
If the displays do not indicate as described:
- Remove air cleaner => Page 71 , Fig. 3 .
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- -> Pull 6-pin connector off throttle valve control part -arrow-.
es, in part or in w
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- Replace throttle valve control part

=> Page 62 , item 7 .

- Adapt engine control unit to throttle valve control part => Page 127 .
- Check voltage supply of throttle valve control part and wiring to control unit => Page 83 .
- Check the accelerator pedal position sender.
=> Repair group 20; Electronic engine output regulation (electronic accelerator (EPC)); Checking accelerator
pedal position sender Electronic engine output regulation (electronic accelerator (EPC)) Checking accelerator
pedal position sender
If the voltage supply and wiring is OK:

=> Page 125 .
Checking voltage supply and wiring to control unit
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Test sequence rrectness of i
- -> Connect Multimeter to measure voltage at connector contacts 2 + 6.

- Switch on ignition.
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Specification: min. 4.5 V

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- -> Connect Multimeter to measure voltage at connector contact 2 and earth.

If the specifications are not attained:
2.4 - Checking throttle valve control part 83

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- Remove left plenum chamber cover. Vol
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- -> Connect test box V.A.G 1598/22 to control unit wiring
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flow diagram.
Contact 1+socket 68
nform
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Contact 2+socket 55
Contact 3+socket 80
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Contact 4+socket 75
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Contact 5+socket 66
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Contact 6+socket 61
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- Check engine control unit voltage supply => Page 123 . Prote AG.
2.5 - Checking intake manifold pressure sender
Note:
Only gold-plated contacts may be used when servicing the sender connector contacts



Test sequence
- -> Pull 4-pin connector off intake manifold pressure sender (G71) and intake air temperature sender (G42)
-arrow-.
- Remove left plenum chamber

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Contact 3+socket 62
Contact 4+socket 70
nform
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- Additionally check wires for short to one another, to vehicle earth and to battery positive.
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2.5 - Checking intake manifold pressure sender 85

=> Page 64 , item 15 .
2.6 - Checking intake air temperature sender
Note:
Only gold-plated contacts may be used when servicing the sender connector contacts
◆ Chilling spray (commercially available)
Test sequence

Select function XXX

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- Press keys 0, 0 and 4 for "Display group
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Display Cause Continuation of

t to the co
check
Approx. ambient --- => Page 87
temperature1)
rrectness of i
-40 °C Open circuit or => Page 87

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short to positive
129 °C Short to earth => Page 89
nf
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1) If a temperature is displayed which is below the ambient air temperature of the sender, check sender
atio
m
wiring for transfer resistances. Note when doing this that sender is heated from external sources, e.g. radiated
o
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c
heat when engine is not running.

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Continuation of check when display = ambient temperature:
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Functional check of sender
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- Spray sender with commercial chilling agent whilst observing the temperature value. The temperature value
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- Press ⇒key.
t to the co
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=> Page 64 , item 15 .
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Continuation of check when display -40 °C:

- -> Pull 4 pin connector off intake air temperature sender (G42) with intake manifold pressure sender (G71)
-arrow-.
2.6 - Checking intake air temperature sender 87

- -> Bridge connector contacts 1+2 using aux. cables from V.A.G 1594 and observe display.
Display jumps to 129 °C:

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- Press keys 0 andrise6 for the function "End output" and confirm
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- Renew the sintake
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=> Page 64 , item 15 .
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If the display remains at -40 °C:
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flow diagram.
Contact 1+socket 54
Contact 2+socket 56
- Check wiring additionally for short circuit to battery positive.
=> Page 64 , item 15 .

AG. Volkswagen AG d
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Motronic inj. and ignition systemhoris
(2-valve, roller rocker finger) - teEdition
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Continuation of check when display
s shows 129 °C:
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nform
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- -> Pull 4 pin connector off intake air temperature sender (G42) with intake manifold pressure sender (G71)
-arrow-.
m
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If the display jumps to -40 °C:
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- Press ⇒key.
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=> Page 64 , item 15 .
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If display remains at 129 °C:
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- Press ⇒key.

2.6 - Checking intake air temperature sender 89

flow diagram.
Contact 1+socket 54
Contact 2+socket 56

=> Page 64 , item 15 .
2.7 - Checking coolant temperature sender
Test conditions
• Engine must be cold.
Test sequence

Rapid data transfer HELP AG. Volkswagen AG d
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- Press keys 0 andth8o for the function "Read measured value block"
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- Read off coolant temperature value in display zone 3.

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Approx. coolant --- Only if spora-

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=> Page 91
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check
-40 °C Open circuit or => Page 92
short to positive
129 °C Short to earth => Page 93
1) If a temperature is displayed which deviates greatly from the ambient temperature of the sender, check
sender wiring for transfer resistances.
2) Check is only possible when the engine is cold.
Continuation of check when display = coolant temperature:
Functional check of sender
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- Observe coolant temperature value in display zone 3 with engine running. The temperature value must
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increase evenly without interruption.
Notes:
nform
ercia
◆ Temperature increases in steps of 1.0 °C.

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◆ If irregular engine running occurs in certain temperature ranges and the temperature figure does not increase
om
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without interruption, the temperature signal is temporarily interrupted and the sender must be renewed.
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- Replace coolant temperature sender (G62) with coolant temperature gauge sender (G2) =>Page 60 , item Prote AG.
28 .
2.7 - Checking coolant temperature sender 91

Continuation of check when display shows -40 °C:
- -> Pull the 4 pin connector off coolant temperature sender (G62) with coolant temperature gauge sender
(G2) -arrow-.
- -> Bridge connector contacts 3+4 using aux. cables from V.A.G 1594 and observe display.
Display jumps to 129 °C: AG. Volkswagen AG d

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a(G2)
c =>Page 60 , item
28 . s
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If the display remains at -40 °C:
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- Press ⇒key.
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- -> Check wires for open circuit between test box and 4-pin connector (connector to control unit) using current
flow diagram.
Contact 3+socket 74
Contact 4+socket 54
- Replace coolant temperature sender (G62) with coolant temperature gauge sender (G2) =>Page 60 , item
28 .
Continuation of check when display shows

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129
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- -> Pull the 4 pin connector off coolant temperature sender (G62) with coolant temperature gauge sender
(G2) -arrow-.
nform
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If the display jumps to -40 °C:

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2.7 - Checking coolant temperature sender 93

- -> Check wires for open circuit between test box and 4-pin connector (connector to control unit) using current
flow diagram.
Contact 3+socket 74
Contact 4+socket 54

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2.8 - Checkings aengine
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The engine speed sender (G28) is a speed and reference mark sender. The engine will not start if there is no
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Test conditions
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Test sequence

- -> Detach black 3-pin connector to engine speed sender -arrow- (on thermostat housing).
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- -> Connect multimeter to measure voltage using aux. cables from V.A.G 1594 to contacts 1 (positive) and
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3 (earth) on engine speed sender connector.
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- Remove left plenum chamber cover. cted agen
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flow diagram.
Contact 1+socket 62
Contact 2+socket 53
Contact 3+socket 67
- Additionally check wires for short to one another.

2.8 - Checking engine speed sender 95

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Motronic inj. and ignition system (2-valve,s aroller rocker finger) - Edition 12.1999 or ac
ut
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If no wiring fault is detected and voltage was present between contacts 1+3:
un
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- Replace engine speed sender (G28)
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=>Page 56 , item 17 .
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If no wiring fault is detected and no voltage was present between contacts 1+3:
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=> Page 125 .
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2.9 - Checking injectors
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Checking activation
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Check conditions
• Earth connection between engine (on gearbox bell housing) and body (below battery) OK.
• Earth connection in plenum chamber OK.
• Engine speed sender must be OK, checking Page 94 .
• Hall sender must be OK, checking

=>Page 143 .

Test sequence
- -> Pull plug -arrows- off all injectors.
- -> Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 to connector contacts of Cyl. 1.
- Operate the starter and check the voltage supply for No. 1 cylinder injector.
The LED must light up n AG. Volkswagen AG do
- Repeat check at the injector connectors
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- Switch off ignition. d byV t gu
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- -> Connect diode test lamp to Cyl. 1 connector, contact 1 and earth.
The LED must light up
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- Repeat check at the injector connectors for Cyls. 2...4.

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If the LED does not light up:

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- Check wire between 2 pin connector contact 1 and fuel pump relay (J17) for open circuit according to current
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2.9 - Checking injectors 97
If the LED does not light up on one or several cylinders:

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- -> Check wires between test box and 2-pin connectors for injectors (connector to control unit) for open circuit ility
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using current flow diagram.
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Injector 1: contact 2+socket 79
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Injector: max. 1.5 ω
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- Check wiring between connector contacts 1 of injectors for open circuit to one another.
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Wire resistance: Max. 1.5 ω

nform
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Checking resistance of injectors

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Test sequence
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- -> Check resistance of injectors between contacts.
Specification: 12...17 ω
Note:
The resistance figures are valid for approx. 20 °C. At higher temperatures the resistance figures will increase.
If the specification is not attained:
- Renew defective injector

Page 66 , item 9 .
Perform installation of injectors in reverse order. When doing this note the following:
◆ Renew O-rings on all injectors and lightly moisten with clean engine oil.
◆ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
◆ With injectors secured to fuel rail, fit fuel rail on cylinder head and press in evenly.
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Checking spray pattern and for leaks

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Special tools, workshop equipment, test and measuring appliances and auxiliary items required
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◆ V.A.G 1331 Torque wrench (5...50 Nm)
◆ V.A.G 1594 A Adapter set
◆ V.A.G 1630 Digital potentiometer
◆ Measuring container
Test conditions
• The fuel pressure must be in order, checking

=> Page 102 , checking fuel pressure regulator and holding pressure.
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Test sequence
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- -> Pull the 4 pin connector off coolant temperature sender (G62) with coolant temperature gauge sender Prote AG.
(G2) -arrow-.
- -> Connect digital potentiometer V.A.G 1630 using adapter cables from V.A.G 1594 to contacts 3+4 of
connector and set connected side to 15 kω.

- -> Pull the vacuum hose off fuel pressure regulator -arrow-.
- Unclip injector wiring harness on fuel rail.
- Remove fuel rail complete with injectors from cylinder head (fuel hoses remain connected)
=> Page 56 , item 11 .
- -> Hold a small container under the injector to be checked and pull connectors off all other injectors.
- Have 2nd person operate starter. Injector must spray in pulses.
- Repeat check with other injectors ensuring that injector to be checked is only connected.
- Switch off ignitionwaand
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- Renew defective injector

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Page 66 , item 9 .
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Perform installation of injectors in reverse order. When doing this note the following:
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◆ Renew O-rings on all injectors and lightly moisten with clean engine oil.
es, in part or in w
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◆ Insert injectors vertically and in the correct position into the fuel rail and secure with retaining clips.
◆ With injectors secured to fuel rail, fit fuel rail on cylinder head and press in evenly.
rrectness of i
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2.10 - Checking fuel pressure regulator and holding pressure
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The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure. t. C rig
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The specification for the check is dependent upon the working pressure of the fuel pump. This is
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approx. 3.0 bar
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
◆ V.A.G 1318 Pressure gauge

◆ V.A.G 1318/10 Adapter
◆ V.A.G 1318/11 Adapter
◆ V.A.G 1318/16 Hose adapter
◆ V.A.G 1921 Spring-type clip pliers

Test sequence
- Pull fuel pump fuse No. 40 out of fuse holder.

- -> Pull off supply pipe/hose -1- (with white marking) and collect fuel that leaks out with a cloth.
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Warning!
or
Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connec‐
m
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- -> Connect pressure gauge V.A.G 1318 with adapter V.A.G 1318/10 to supply hose -1- and with adapter
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V.A.G 1318/11 and hose adapter V.A.G 1318/16 to supply pipe.

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- Open shut-off tap on pressure gauge. The handle points in direction of flow.
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- Insert fuel pump fuse No. 40 into fuse holder.
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Specification: Approx. 2.5 bar
2.10 - Checking fuel pressure regulator and holding pressure 103

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- -> Pull vacuum hose off fuel pressure regulator -arrow-. The fuel pressure must increase to
spec
approx. 3.0 bar.
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- Check quantity supplied by fuel pump.
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=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump
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- Check for leaks and holding pressure by observing pressure drop on gauge. After 10 minutes there must
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a residual pressure of
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If the holding pressure drops below 2 bar:

- -> Switch ignition off after the pressure has built-up. At the same time close pressure measured device cut-
off tap (handle cross through-flow direction -arrow-).
- Observe pressure drop on gauge.
If the pressure does not drop:

- Check fuel pump non-return valve.
=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump
If the pressure drops again:
- -> Open pressure gauge V.A.G 1318 shut-off tap (handle in direction of flow).
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- -> Switch ignition off after the pressure has build-up. At the same time clamp-off the return hose (with blue
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If the pressure does not drop:

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- Renew fuel pressure regulator

=>Page 65 , item 5 .
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If the pressure drops again:

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- Check pipe connections, O-rings on fuel manifold and injectors for leaks.
nform
ercia
- Check pressure gauge for leaks.

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Note:
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Before removing pressure gauge place a cloth around the connections to be loosened.
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2.10 - Checking fuel pressure regulator and holding pressure 105

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2.11 - Checking intake air system for leaks (unmetered
olks air)
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Checking with engine leak detector spray G 001 800 au ra
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◆ The vacuum in the intake system will cause the leak detector spray to be drawn in with the unmetered air.
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The leak detector spray reduces the ignitability of the mixture. This leads to a drop in engine speed and to
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a change of Lambda probe reading.
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◆ The safety precautions listed on the container must be adhered to.
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◆ Engine leak detector spray G 001 800 A1
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Test conditions
nform
mercia
Test sequence
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-> Indicated on display: t. C rig
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1 2 3 4
Only continue with the test when
• The coolant temperature exceeds 80 °C

-display zone 2-
- Observe the engine speed in display zone 1 and the Lambda regulation in display zone 3.
- Systematically spray parts of the intake system with engine leak detector spray.
If the engine speed drops or the Lambda regulator changes:
- Press ⇒key.
- Check sprayed areas of intake system for leaks and rectify if necessary.
If the engine speed or Lambda regulator does not change:
- Press ⇒key.

AG. Volkswagen AG d
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2.12 - Checking intake air preheating
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◆ Chilling spray (commercially available)
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Checking regulating flap
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- -> Check control flap position -1-.
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- Above +23 °C flap must close warm air connection
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- Below +10 °C flap opens warm air connection
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Note:
Prote AG.
The function of the thermo-element can be checked easily by spraying it with a commercial chilling agent, to
do this the air intake housing must be removed => Page 68 , Dismantling and assembling air cleaner.
2.13 - Checking vacuum valve
◆ -> V.A.G 1368 Vacuum tester
2.11 - Checking intake air system for leaks (unmetered air) 107
◆ -> V.A.G 1390 Hand vacuum pump
Test conditions
• Ignition must be switched off
Test sequence
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- -> Remove vacuum valve -1- => Page 62 , item 3.
rrectness of i
- Then connect hand vacuum pump V.A.G 1390 and vacuum tester V.A.G 1368 as shown (arrow on vacuum
valve -1- points to V.A.G 1368).
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- Set vacuum tester to -A/B- position.

- Operate hand vacuum pump V.A.G 1390 several times.
Vacuum must not
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build up.
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Note:
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The vacuum valve is open in the rest position.

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- Renew vacuum valve. gh ht
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If vacuum does not build up:
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- -> Close connection -2- on vacuum valve.

- Hold vacuum valve in the hand.
nform
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- Operate V.A.G 1390 several times, until the valve closes

with a noticeable click.
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Note:
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The vacuum valve closes at a vacuum between 250...350 mbar.
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- Renew vacuum valve.
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Prote AG.
3 - Checking functions
3.1 - Checking functions
3.2 - Idling check
Notes:
◆ Idling speed, ignition timing and CO content not adjustable.

◆ The idling speed is regulated to specification by the throttle valve positioner in conjunction with the DIS
function.
◆ CO content regulated by Lambda regulation. Faults in Lambda control are detected in self-diagnosis and
stored in fault memory.
Check conditions
• Exhaust system between cylinder head and catalyst free of leaks

• All electrical consumers, e.g. lights and rear window heating must be switched off
2.13 - Checking vacuum valve 109

AG. Volkswagen AG d
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Polo Estateaut 1998 ➤ ra
c
s
Motronics inj. and ignition system (2-valve, roller rocker finger) - Edition 12.1999
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Test sequence
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spec
es, in part or in w
t to the co
- Interrogate fault memory, if necessary, repair fault and then erase fault memory.
rrectness of i
- Then:
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- Leave fault reader V.A.G 1551 connected.

- Continue running engine at idling speed.
nform
ercia

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Select function XXX

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1 2 3 4
Note:
In the "System in basic setting" function the tank venting valve (N80) is closed and the air conditioner com‐
pressor switched off.
- Check the adjustment conditions for basic setting in display zone 4:

Specification: 1x111111
Significance of the numbers => Page 31
- Briefly increase engine speed (rev- up) and then allow engine to run at idling speed for 2 minutes.
Checking idling speed
- Change to display group 56 as follows:

- Press C key.

1 2 3 4
- Check operating modes in display zone 4

Specification: x x 0 x 0
- Check specified idling speed in display zone 2.
Specification: 850 rpm
- Check idling speed in display zone 1.
Specification: 810...900 rpm1)
1) Up-to-date specifications:

AG. Volkswagen AG d
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thor eo Polo Estate 1998 ➤
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Motronic
ss a inj. and ignition system (2-valve, roller
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Note:
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During the idling check the tank venting valve (N80) and the air conditioner are switched off and the Lambda
h re
regulation learning process is initiated.
hole
spec
es, in part or in w
t to the co
- Press ⇒key.
rrectness of i
If the idling speed is not obtained:
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- Adapt the engine control unit to the throttle valve control part => Page 127
- Carry out test drive.
nform
ercia
Observe the valid safety precautions when carrying out a road test => Page 72 .
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tion in
- Again interrogate the control unit fault memory.
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- Repeat the idling check.
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If the specifications are not obtained again:
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=> Page 81 . gh ht
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- Check the operating condition of engine
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=> Page 121 .
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- Check intake air system for unmetered air
=> Page 106
- Check the signals from/to air conditioner
=> Page 132 .
3.3 - Checking Lambda probe and Lambda regulation before catalyst
Check conditions

3.2 - Idling check 111

Functional check

Select function XXX
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- Press keys 0 and 8 for the function "Read measured value isedblock" and confirm entry with Q key.uara
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-> Indicated on display: ss a c
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1 2
- Check Lambda control status before catalyst (display zone 1):
rrectness of i
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Notes:
nform
ercia
◆ The first position of the 3 digit number block fluctuates between 0 and 1 (Lambda probe heating on and off).
m
a
◆ Depending upon the status of the Lambda control the 3 digit number block can show 0 or 1.
com
tion in
◆ The bits in display zone 1 will not be set to 1 until the catalyst temperature has exceeded 400.0 °C (=>
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- Check the Lambda probe heating before catalyst . Cop py
=> Page 74 .
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- Press C key.

1 2
- Check Lambda learnt values at idling speed (additive) in display zone 1.

Specification: -10.0...10.0 %
- Check Lambda learnt values at part load (multiplicative) in display zone 2.
Specification: -10.0...10.0 %
If the specifications are not obtained:

- =>Page 40 , Evaluating display group 32

V.A.G 1551: Press key 3

V.A.G 1552: Press key ↑

1 2
- Observe Lambda regulation in display zone 1. The display must fluctuate at least 2 % in the range
-10.0...10.0 %
- Press ⇒key.
If the Lambda regulation does not fluctuate in display zone 1:

- Check Lambda probe wiring for Lambda probe 1 => Page 113 .
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Engine codes ANW, ksw AUD => Page 113 . es not
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Engine codes Vol => Page 114 .
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If the Lambda
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in display zone 1 does not as stated: fluctuate
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- Carry out road test and burn Lambda probes clean and repeat check.
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If the the specifications in display zone 1 are not obtained even after a test drive, or the value does not fluctuate
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- Check ageing of the Lambda probe before catalyst =>Page 120 .

spec
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Check Lambda probe wiring Lambda probe 1
Engine codes AKK => Page 114 .
rrectness of i
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- Remove left plenum chamber cover. Prote AG.
3.3 - Checking Lambda probe and Lambda regulation before catalyst 113
- -> Separate 6-pin connector (black) to Lambda probe before catalyst (G39) -arrow-.
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flow diagram.
Contact 1+socket 46
rrectness of i
Contact 2+socket 34
Contact 5+socket 20
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Contact 6+socket 35
- Additionally check wires all for short to one another.
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- Renew Lambda probe before catalyst (G39)
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=>Page 58 , item 20 .
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Check Lambda probe wiring Lambda probe 1
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Only engine code AKK

- -> Separate the 4-pin connector (black) to Lambda probe before catalyst (G39) -arrow-.

- -> Connect multimeter with aux. cables from V.A.G 1594 to measure voltage at contacts 3+4 (connector to
engine control unit).
- Switch on ignition and measure basic voltage.

=>Page 58 , item 20 .
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- -> Check wiring between test box and 4 pin connector (to control unit) for open circuit according to current
a
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flow diagram.
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Contact 3+socket 21
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Contact 4+socket 47
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- Check wiring at connector contacts 3+4 for short circuit to contacts 1+2 according to current flow diagram.
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=>Page 58 , item 20 .
3.3 - Checking Lambda probe and Lambda regulation before catalyst 115
3.4 - Checking Lambda probe and Lambda regulation after catalyst
Note:
Only gold-plated contacts may be used when servicing Lambda probe connector contacts 3 and 4.
Check conditions

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Functional check Volksw not
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- Connect fault reader V.A.G 1551 (V.A.G 1552). Start enginethoand select "Address word" 01 of engine control
r eo
unit. When doing this the engine must be running at idling
ss a speed.
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(Connecting fault reader and selecting engine control unit => Page 4 .) ce
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Select function XXX

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- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.
spec
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Basic setting
rrectne
ss o
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inform

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1 2 3 4
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approx. 1100...1300 rpm.
- Run engine at increased speed until the catalyst temperature in

display zone 2 increases to min. 400 °C.
Note:
- Press C key.

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Input display group
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- Press ut
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or e o 30" and confirm entry with Q key.
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- Check Lambda control status after catalyst (display zone 2): h re

hole
Specification: 1 1 1 spec
es, in part or in w
t to the co
Notes:
rrectness of i
◆ The first position of the 3 digit number block fluctuates between 0 and 1 (Lambda probe heating on and off).
◆ Depending upon the status of the Lambda control the 3 digit number block can show 0 or 1.
l purpos
◆ The bits in display zone 1 will not be set to 1 until the catalyst temperature has exceeded 400.0 °C (=>
nform
ercia

m
at
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ion
- Check Lambda probe heating after catalyst=> Page 78 .

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Basic setting Prote AG.

1 2 3 4

approx. 1100...1300 rpm.
- Check the Lambda probe voltage after catalyst in display zone 1:

3.4 - Checking Lambda probe and Lambda regulation after catalyst 117
(can fluctuate slightly)
If the display in display zone 1 remains constant:

- Press ⇒key.
- Continue check according to following table.
Appears on display Possible fault Fault elimination

cause
Constant 1.085 V - Short to posi‐ - Check Lambda
tive via: probe 2 basic
- Lambda probe, voltage
probe wiring, => Page 119
earth wiring, en‐
gine control unit
Constant between - Open circuit
0.400...0.500 V via:
- Lambda probe,
probe wiring,
earth wiring, en‐
gine control unit
Constant 0.000 V - Short to earth
via:
- Lambda probe,
probe wiring,
earth wiring, en‐
gine control unit
- Run the engine at increased speed until the display

in display zone 4 jumps from "Test OFF" to"Test ON. The catalyst temperature
in display zone 2 must be min. 400 °C.
- Maintain the increased engine speed until the display
in display zone 4 shows the specification
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If display zone 4 showsris"B1-P2
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- Press ⇒key. tho eo
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=> Repair group 26; Removing and installing parts of exhaust system Removing and installing parts of exhaust
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system
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- Carry out a test drive to remove possible residue on Lambda probe and repeat check.
hole
spec
es, in part or in w
t to the co
If the specifications are again not attained:

- Replace the Lambda probe after catalyst (G130) => Page 57 , item 19 .
rrectness of i
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Checking Lambda probe 2 basic voltage
- -> Separate 4-pin connector (black) to Lambda probe after catalyst (G130) -arrow-.
- -> Connect multimeter with aux. cables from V.A.G 1594 Ato
G.measure
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- Start engine and measure the basic voltage. ed by
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Specification: 0.400...0.500 V horis tee
- Switch off ignition. s aut or
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- Check Lambda probe wiring for Lambda probe 2 => Page 119 .
erm
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Checking Lambda probe wiring Lambda probe 2

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3.4 - Checking Lambda probe and Lambda regulation after catalyst 119
flow diagram.
Contact 3+socket 21
Contact 4+socket 47
- Check wiring at connector contacts 3+4 for short circuit to contacts 1+2 using current flow diagram.
3.5 - Checking ageing of Lambda probe before catalyst

AG. Volkswagen AG d
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Only engine codes oris ANW, AUD
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Special tools,s workshop equipment, testers, measuring instruments
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and auxiliary items required
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Test conditions
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Functional check C py
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Select function XXX
- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.

Basic setting



1 2 3 4

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- Continue to maintain engine speed until the specification "B1-P1" appears in
display zone 4.
rrectness of i
- Press ⇒key.
l purpos
nform
ercia
- Carry out a road test to free Lambda probe of possible residues and repeat the test.
m
at
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If the specifications are again not attained:

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=>Page 58 , item 20 . C py
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3.6 - Checking engine operating mode
Note:
Checks whether engine control unit recognises the engine operating modes idling, overrun, part throttle, en‐
richment, full throttle.
Test conditions
Test sequence

Select function XXX
3.5 - Checking ageing of Lambda probe before catalyst 121

-> Indicated on display: agen

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◆ Idling:
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As long as the engine is running at idling speed idling must be displayed
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Display: Idling
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spec
◆ Overrun mode:
es, in part or in w
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- Increase engine speed to above 3000 rpm.
- Close throttle abruptly.
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As long as the engine speed is above 1400 rpm overrun must be displayed
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Display: Overrun
Note:
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Below 1400 rpm idling speed will be recognised.

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◆ Part throttle:
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As long as the engine is being revved up evenly, part throttle must be displayed
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- Floor accelerator pedal (onto throttle valve stop).
Acceleration enrichment must be displayed briefly

Display: Enrichment
◆ Full throttle:
- Floor accelerator pedal (onto throttle valve stop).
Full throttle must be displayed briefly

Display: Full throttle
Note:
A test drive may have to be performed to show "Full throttle" in display.
- Press ⇒key.


=> Page 81 .
- Check parts of the electronic throttle control (EPC) for ease of movement:
=> Repair group 20; Electronic throttle control (EPC); Servicing parts of the electronic throttle control (EPC)
Electronic throttle control (EPC) Servicing parts of the electronic throttle control (EPC)
4 - Engine control unit

4.1 - Engine control unit
4.2 - Checking control unit voltage supply
Check conditions
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• -> Fuses No. 31 and 36 must be OK.

t to the co
• Earth connection between engine (on gearbox bell housing) and body (below battery) OK.
• Earth connection in plenum chamber OK.
rrectness of i
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• Alternator OK, checking:
nform
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Test sequence
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Rapid data transfer HELP cted agen
Select function XXX Prote AG.
3.6 - Checking engine operating mode 123

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Polo Estate 1998 ➤ aut
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Motronic inj. and ignition system (2-valve, roller rocker finger) - Edition 12.1999 s
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1 2 3 4
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- Read off figure displayed in display zone 2.
Specification: At least 11.5 V
- Press the ⇒key.
nform
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Checking voltage supply terminal 30
- Measure voltage supply with multimeter and aux. cables from V.A.G 1594 between test box sockets 2+15
and 15+28:
- Check wiring connections to relay plate according to current flow diagram.
Checking voltage supply terminal 15
- Measure voltage supply with multimeter and aux. cables from V.A.G 1594 between test box sockets 2+27
and 27+28:
- Check wiring connections to relay plate according to current flow diagram.

4.3 - Procedure after voltage supply open circuit
All values learnt by the engine control unit and the basic setting values as well as the readiness code will be
erased if the voltage supply is interrupted. Therefore, depending upon the vehicle mileage it can lead to serious
engine running problems.
Work sequence
G. Volkswagen
Perform the following operations after voltage
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- Switch ignition on for at least o10 ris seconds.
e ran
tee
- Switch off ignition. aut
h or
a
- Adapt the engine control sunit
s to the throttle valve control part => Page 127 c
- Perform idling check
ce
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un
pt
=> Page 109
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Note:
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During the idling check the tank venting valve (N80) and the air conditioner are switched off and the Lambda
h re
hole
regulation learning process is initiated.
spec
es, in part or in w
t to the co
- Perform a longer test drive until the poor driving characteristics are eliminated.
rrectness of i
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Idling
Part throttle
Full throttle
nform
ercia
Overrun
m
must be attained several times.

a
com
tio
- At full throttle the speed must exceed 3500 rpm. n in
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4.4 - Replacing engine control unit

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◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3A
AG.
Removing
- First print out the control unit identification and thereby the previous control unit coding as follows:
-> On the display the control unit identification and coding are displayed, e.g.:
6K0906032M ME 7. 5. 10 2921
⇒
Coding 00001 WSC 00000
- Print out the control unit identification by pressing the fault reader print button.
- Press the ⇒key.

4.3 - Procedure after voltage supply open circuit 125

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➤ eo
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Motronic inj. sand
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- Unlock engine control unit connector and pull it off.
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
- -> Carefully lever off securing clip, using a screwdriver -right arrow-.
m
at
om
i
- Pull control unit forwards out of retaining frame -arrows-.
on
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in t
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Installing
at
do
priv
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or
- Slide the new control unit into the retaining frame.

f
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ng
t.
- Engage the retaining clip.
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- Install control unit connector and lock.
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- Adapt new control unit to throttle valve control part => Page 127
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pyri by
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- Adapt new control unit to the electronic immobilizer => Page 129 by c lksw
cted agen
Prote AG.
Engine code AUD
=> Electrical system; Repair group 01; Immobilizer self-diagnosis; Adaption following renewal of engine control
unit Immobilizer self-diagnosis Adaption following renewal of engine control unit
4.5 - Coding engine control unit
Notes:
◆ A 5-character code must always be displayed during the control unit identification.
◆ The control unit must be recoded if the vehicle relevant coding is not displayed or the control unit has been
renewed.
◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3
Work sequence

Select function XXX
- Press keys 0 and 7 for the function "Code control unit" and confirm entry with Q key.

Coding control unit Q
Enter code number XXXXX (0-32000)
- Enter the relevant code number for this vehicle and confirm with Q key.

-> On the display the control unit identification and coding are displayed, e.g.:
6K0906032M ME 7. 5. 10 2921
⇒
Coding 00001 WSC 00000
-> Indicated on display when a non-authorised code number has been entered.
Function is not recognised or cannot
⇒
be performed at the moment.
- Press the ⇒key.

Note:
The code unit entered and shown on the display will not be used by the Motronic control unit until the ignition
has been switched off once.
An incorrect coding leads to:
◆ Engine running faults (gear change jerks, load change jerks, etc.)
◆ Increased fuel consumption
◆ Increased exhaust gas emissions n AG. Volkswagen A G do
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◆ Faults stored in fault memory which are ed
bynot actually present
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ran
◆ Functions will not be performed (Lambda
horis regulation, activation of the activated techarcoal
eo filter system, etc.).
◆ On front wheel drive vehicles the autraction control will not function (TC warning lamp
t r a comes on)
c
◆ Reduced gearbox life ss
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Code table:
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Code number Vehicles with
ot
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00001 Manual gearbox
h re
hole
spec
00011 Manual gearbox with ABS
es, in part or in w
00021 Manual gearbox with airbag
t to the co
00031 Manual gearbox with ABS and airbag
00003 Automatic gearbox rrectness of i
00013 Automatic gearbox with ABS
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00023 Automatic gearbox with airbag

00033 Automatic gearbox with ABS
nform
ercia
and airbag
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4.6 - Adapting engine control unit to throttle valve control part

s
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The adaption teaches the engine control unit the various positions of the throttle unit when the ignition is
Co
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switched on and the engine is not running. These positions are stored in the control unit. The feedback of the
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Adapting sequence must be performed if:
◆ The voltage supply is interrupted

◆ The throttle valve control unit is removed and installed
◆ The throttle valve control unit is renewed
◆ If when installing another engine another throttle valve control unit is installed
◆ The engine control unit is renewed.
4.5 - Coding engine control unit 127

Check conditions
• Ignition on, engine not running

• No faults must be stored in fault memory => Page 7 , interrogating and erasing fault memory.
• The throttle valve must be at idling speed position (The accelerator must not be operated during the test).
• Coolant temperature must be 5...105 °C =>display group 04, display zone 3.
Work sequence
(Connecting fault reader and selecting engine control unit => Page 4 .)G. Volkswagen
nA AG do
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-> Indicated on display: by
V ua
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Rapid data transfer HELP oris tee
Select function XXX th or
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Basic setting
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(1...4 = display zones)
rrectne
Basic setting 60
xxx % xxx % x ADP. runs
ss o
cial p
f
After pressing the Q key the throttle valve positioner is switched so that it is not supplied with voltage at start
in
of test.
form
mer
atio
m
◆ Learning step 1: The engine control unit checks if all test conditions are fulfilled.
o
n
c
i
or
n thi
e
◆ Learning step 2: The throttle valve part is switched to no voltage (emergency operation position). The angle
t
sd
va
sender values of the emergency operation position are stored in engine control unit.
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◆ Learning step 3: The throttle valve is set to a value above the emergency operation point.
en
ng
t.
◆ Learning step 4: The final stage of the throttle valve positioner is switched off. Now the mechanical spring op
yi Co
must set the throttle valve to the previously learnt emergency operation position within a certain time (spring
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◆ Learning step 5: The throttle valve is closed by the throttle valve positioner (lower mechanical stop).
co lksw
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◆ Learning step 6: The throttle valve angle value on lower mechanical stop will be stored in control unit. Then Prote AG.
the lower electrical stop will be defined (calculated) and stored in the control unit.
◆ Learning step 7: The final stage is switched off at the lower mechanical stop. Now the mechanical spring
must set the throttle valve in the emergency operation position (spring opening test).
◆ Learning step 8: The sender angle values are checked.

◆ Learning step 9: Adaption ends.

(1...4 = display zones)
Basic setting 60
xxx % xxx % 9 ADP. OK.
Adapting has been performed successfully.

en AG. Vsystem
olkswagen (2-valve,
AG roller rocker finger) - Edition 12.1999
ag does
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- Terminate engine d b basic setting at earliest after 30 seconds
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- ise 6 for the function "End output" and confirm
Press keys 0horand nte entry with the Q key.
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To store thes values:
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Note:
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If the basic setting of the control unit is interrupted, the cause could be one of the following:
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◆ The test conditions were not fulfilled.
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◆ Throttle valve control unit or wiring is defective. Check => Page 81 .
After an interruption a fault is stored in fault memory. When next switching on ignition the basic setting is
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automatically performed again.
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4.7 - Adapting engine control unit to electronic immobilizer
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=> Electrical system; Repair group 01; Immobilizer self-diagnosis; Adaption following renewal of engine control
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unit Immobilizer self-diagnosis Adaption following renewal of engine control unit

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◆ VAS 5051 Vehicle Diagnosis, Testing and Information System
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◆ Diagnosis cable VAS 5051/1 or VAS 5051/3
Conditions
• Authorized vehicle key required.
Work sequence
- -> Pull out ashtray -1-.

- Fit connector from diagnosis cable VAS 5051/1 or VAS 5051/3 to diagnosis connection.
- Operate fault reader or vehicle system tester taking into account the information on the display:
- Press button on display for "Vehicle self-diagnosis".
- Press keys 2 and 5 for address word "Immobilizer" and confirm entry with Q key.

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Coding 00000 WSC XXXXX
4.6 - Adapting engine control unit to throttle valve control part 129
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- Press the ⇒key. tho
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Select function XXX
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- Press keys 1 and 0 for function "Adaption" and confirm entry with Q key.
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Adaption
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Feed in channel number XX
- Press key 0 twice for "Channel number 0" and confirm entry with Q key.
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Adaption Q
Erase learnt values?
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- Confirm input with Q key.
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Adaption
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Note:
The identity of the engine control unit is read into the immobilizer control unit when next switching the ignition
on.
5 - Checking additional signals

5.1 - Checking additional signals
5.2 - Checking speed signal
Check conditions

• Speedometer must be OK., checking speedometer:

Test sequence
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.

Select function XXX


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- Carry out test drive with a 2nd person to riseobserve
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If no speed is indicated or the display values reduce when driving slowly:

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5.2 - Checking speed signal 131

- Connect multimeter to measure voltage between test box sockets 27 (terminal 15) + 5 (speed signal).
- Lift vehicle at front left.
- Rotate front wheel and observe voltage display.
Specification: between 0 and at least 4 Volt fluctuating
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- Check wiring to speedometer/speedometer sender:

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=> Current flow diagrams, Electrical fault finding and Fitting locations binder
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5.3 - Checking signal from/to air conditioning system
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Test conditions
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• Vehicle at room temperature (warmer than + 15 °C).

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Select function XXX


1 2 3 4
- Observe display in display zone 3. It must show

A/C-Low.
- Observe display in display zone 4. It must show

Compr. OFF.
- Switch on air conditioning system.

- Select lowest temperature and highest blower speed.
The display in display zone 3 must change to

A/C-High.
The display in display zone 4 must change to
Compr. ON.
- Floor acceleratorwapedal
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for a few seconds (compressor switch-off when vehicle is accelerating).
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- Check wiring for open circuit between test box sockets 17 + 42 and air conditioner using current flow diagram.
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If no fault can be found in the wiring:
- Check function of air conditioner control unit.
5.4 - Checking signal from brake light switch and brake pedal switch

5.3 - Checking signal from/to air conditioning system 133

Check conditions
• -> Fuses No. 15 and 24 must be OK.

Test sequence
Note: agen
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- -> Pull the connector off brake light switch (item 2) and brake pedal switch (item 1).
- Connect the multimeter to measure resistance between contacts 1 and 2 of brake light switch (item 2).
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Specification: ∞ ω (no continuity)

nform
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Specification: approx. 0 ω
- Connect the multimeter to measure resistance between contacts 1 and 2 of brake pedal switch (item 1).
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Specification: approx. 0 ω
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- Depress the brake pedal.

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- Replace the brake light switch or brake pedal switch.

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- -> Connect multimeter to measure voltage between contact 1 of brake light switch -2- and earth.
Specification: at least 11.5 V
- Switch ignition on.
- Connect multimeter to measure voltage between contact 1 of brake pedal switch -1- and earth.
Specification: at least 11.5 V
AG. Volkswagen AG d
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If the specifications are by not obtained:
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- Check wiring
aut between connector contact 1 and fuse box using
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ra current flow diagram.
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- Remove left plenum chamber cover. i

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- Check wiring for open circuit between test box and connectors using current flow diagram.
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Contact 2+socket 51 brake pedal switch

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Contact 2+socket 23 brake light switch

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- Additionally check wires for short to one another. yri
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- Additionally check the wiring for short to battery positive or earth.
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5.5 - Checking rpm signal
Note:
The engine rpm signal output is on contact 41 of engine control unit. Amongst other things the signal is nec‐
essary for the rev. counter in dash panel insert.

Test conditions
Test sequence
5.4 - Checking signal from brake light switch and brake pedal switch 135
- Check wiring from test box contact 41 to dash panel insert for open circuit using current flow diagram:
5.6 - Checking matching resistor of data bus

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The engine control unit communicatesuwith
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Test conditions
• A data bus fault has been recognised by the self-diagnosis. t to the co

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Test sequence
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- Connect test box V.A.G 1598/22 to engine control unit.

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If the resistance measurement is outside the specified range:
- Renew engine control unit => Page 125 .
If the resistance value is within the specified range:
- Repair the fault:

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tho roller rocker finger) - Edition 12.1999 eo
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5.6 - Checking matching resistor of data bus 137

AG. Volkswagen AG d
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Motronic inj. rand
ised ignition system (2-valve, rollerran rocker finger) - Edition 12.1999
t ee
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28 - Ignition system s au ac
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1 - Servicing ignition system
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1.1 - Servicing ignition system
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1.2 - General notes on ignition system
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◆ Only the components which specifically relate to the ignition system are dealt with here. For the other com‐
nform
ercia
ponents of the injection and ignition system => Repair group 24.
◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
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com
t
engine control unit could be damaged.
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◆ The engine control unit is equipped with self diagnosis.
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◆ Components marked with * are checked via the self diagnosis
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=> Page 7 , interrogating and erasing fault memory.
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◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
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◆ Before carrying out repairs and for fault finding, interrogate fault memory => Page 7 , interrogating and
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erasing fault memory C py
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◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after com‐
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pleting all checks and repairs the fault memory must be interrogated and if necessary erased.
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◆ If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests,
then the fault may lie with the immobilizer which is blocking the engine control unit. The fault memory must
be interrogated and if necessary the control unit matched => Page 129 .
Safety precautions => Page 142
Test data, spark plugs => Page 142
138 28 - Ignition system

1.3 - Removing and installing parts of the ignition system
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Note:
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Motronic control unit (J220)* with connectors
=> Page 49 , item 10 .
1 Connector
◆ Black, 4 pin
◆ For ignition transformer (N152)
2 Ignition transformer (N152)*
◆ With marking for ignition cables:
A = Cylinder 1
B = Cylinder 3
C = Cylinder 2
D = Cylinder 4
3 10 Nm
1.3 - Removing and installing parts of the ignition system 139

AG. Volkswagen AG d
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Polo Estate 1998 d by ➤
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Motronic inj. horand
is
ignition system (2-valve, roller rocker
eo finger) - Edition 12.1999
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4 Connector
◆ Black, 2-pin
◆ For knock sensor 1 (G61)
◆ Sensor and connector contacts are gold-plated
5 Knock sensor 1 (G61)*
◆ Sensor and connector contacts are gold-plated
6 20 Nm
◆ Tightening torque influences the function of the knock sensor
7 Connector
◆ Black, 3-pin
◆ Hall sender (G40)

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8 Hall sender (G40)*
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10 Spark plug, 30 Nm Prote AG.
◆ Remove and install with spark plug spanner 3122B

◆ Type and electrode gap
=> Page 142 , test data, spark plugs
11 Bracket
◆ For ignition transformer (N152)
12 H.T. cable
◆ With suppression connector and spark plug connector
◆ Resistance 4.8...7.2 kω
1.3 - Removing and installing parts of the ignition system 141

en AG. V
olksystem
swagen AG (2-valve, roller rocker finger) - Edition 12.1999
ag does
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To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
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noted:
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◆ Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
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◆ The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or
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tester cables.
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◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
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◆ If the engine is to be turned at starter speed, without starting:
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- -> Pull plug -arrows- off all injectors.
1.5 - Test data, spark plugs

Firing order 1-3-4-2 1-3-4-2
Spark plugs1), 2)

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Motronics inj. and ignition system (2-valve, roller rocker
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s
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VW/Audi rm 101 000 062 AB 101 000 062 AB
ab
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Manufacturer's designation NGK PZFR 5 D-11 NGK PZFR 5 D-11
ot
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Electrode gap max. 1.0... 1.1 mm max. 1.0... 1.1 mm
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Tightening torque 30 Nm 30 Nm
spec
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t to the co
1) The up-to-date figures and the spark plug change intervals:
rrectness of i
2) Remove and install spark plugs with 3122B
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nform
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1.6 - Checking Hall sender

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Check conditions
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• Hall sender screwed on tight
Test sequence
- -> Pull 3-pin connector off Hall sender -arrow-.
1.5 - Test data, spark plugs 143

- -> Connect multimeter to measure voltage with adapter cables from V.A.G 1594 to contacts 1 (positive) and
3 (earth) on the Hall sender connector.
- Remove left plenum chamber cover. n AG. Volkswagen AG do

- -> Connect test box V.A.G 1598/22 to control unit wiring
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- -> Check wiring between test box and 3-pin connector (connector to control unit) for open circuit using current
flow diagram.
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Contact 1+socket 62
Contact 2+socket 60
nform
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Contact 3+socket 54
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- Renew Hall sender (G40)

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=> Page 141 , item 8 .
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If no wiring fault is detected and no voltage was present between contacts 1+3:
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- Replace engine control unit Prote AG.
=> Page 125 .
1.7 - Checking ignition transformer

Check conditions

• Hall sender must be OK, checking
=>Page 143 .
• Engine speed sender must be OK, checking Page 94 .
AG. Volkswagen AG d
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Test sequence
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- -> Using multimeter and adapter cables from V.A.G 1594 measure the supply voltage between contacts 2
thi
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+4 of disconnected connector.
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1.7 - Checking ignition transformer
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- -> Check wire
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ed
ntrelay
ee plate for open circuit according to current flow
diagram.auth or
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Wire
s resistance: max. 1.5 ω
s
- Check wire between 4 pin connector contact 4 and earth for open circuit according to current flow diagram.
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Wire resistance: max. 1.5 ω pt

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During the following test do not touch the terminals of the ignition transformer or test cables.
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- -> Pull plug -arrows- off all injectors. Cop py
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- -> Connect diode test lamp V.A.G 1527 with adapter cables from V.A.G 1594 to
contacts 1 + 4 (ignition output 1),
contacts 3 + 4 (ignition output 2)

of disconnected connector.
- Operate starter and check the ignition signal from engine control unit.
The LED must flicker
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- Switch off ignition. lksw
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If the LED flickers and there is voltage
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between contacts 2 + 4: tee
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- Renew ignition transformers (N152)
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=> Page 139 , item 2 .
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The LED does not flicker:
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- Check wiring => Page 147
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flow diagram..
Contact 1+socket 57
Contact 3+socket 71

=> Page 125 .
1.7 - Checking ignition transformer 147

Checking secondary resistance
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- -> Check the secondary winding on terminal 4 between rised ara
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Cyl. 1+Cyl. 4, ut
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Cyl. 2+Cyl. 3. ss a c
Specification: 4.0... 6.0 kω (at 20 °C)
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=> Page 139 , item 2 .
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1.8 - Checking knock sensor
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Notes:
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◆ It is extremely important to keep to the tightening torque of 20 Nm to ensure the knock sensors perform
perfectly.
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◆ Only gold-plated contacts may be used when servicing the knock sensor connector contacts.
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Test conditions
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• Knock sensor fault recognised by self-diagnosis =>Page 7 , interrogating and erasing fault memory.

Test sequence
- -> Pull 2 pin connector off knock sensor -arrow-.

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flow diagram.
Contact 1+socket 77
Contact 2+socket 63
- Loosen knock sensor and tighten again to 20 Nm.

- Carry out test drive.
Observe the valid safety precautions when carrying out a test drive => Page 142 .

Idling
Part throttle
Full throttle
Overrun
must be attained several times.
- At full throttle the speed must exceed 3500 rpm.
Again interrogate the control unit fault memory.
If the fault is still present:
- Replace knock sensor (G61) =>Page 140 , item 5 .
1.8 - Checking knock sensor 149

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Test sequence
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Select function XXX
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Input display group number XXX t.

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1 2 3 4
- Check the misfire recognition status in display zone 4.

Specification: "activated"
- Check total misfires in display zone 3.
Specification: 0

- Press ⇒key.


1 2 3 4
- Check the misfire recognition status in display zone 4.

- Check misfiring of Cyl. 1...Cyl. 3 in display zones 1...3.

Specification: 0

- Press ⇒key.

- =>Page 36 , Evaluating display group 15 and display group 16.


(1 and 4 = Display zones)
1 4
- Check misfire recognition status in display zone 4.

- Check misfiring of Cyl. 4 in display zone 1

Specification: 0
- Press ⇒key.
- =>Page 36 , Evaluating display group 15 and display group 16.

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1.9 - Check misfiring recognition 151

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Service

Polo Estate 1998 ➤

Service Department. Technical Information

All rights reserved.

Copyright © 2011 Volkswagen AG, Wolfsburg 00056407920

1.6 Connecting fault reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.2 Interrogating and erasing fault memory of engine control unit . . . . . . . . . . . . . . . . . . . . . . . .7

3 Fault table: SAE P0 codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5.1 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

6 Readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

6.1 Readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

6.3 Reading readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

6.4 Generating readiness code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

7 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

1.9 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

3.1 Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

3.2 Idling check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

3.5 Checking ageing of Lambda probe before catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

3.6 Checking engine operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

4.5 Coding engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

4.7 Adapting engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

1.2 - Features of self-diagnosis

1.3 - Technical data of self-diagnosis

Control unit identification

Engine code AKK ANW AUD

System designation Motronic ME7.5.10 Motronic ME7.5.10 Motronic ME7.5.10

Exhaust emissions fulfil MVEG II standard D4 standard EU4 standard

EPC system yes yes yes

Self-diagnosis yes yes yes

01 Interrogate control unit ver‐ yes yes yes

05 Erase fault memory yes yes yes

"EPC" is the abbreviation for Electronic Power Control.

- Check combi-instrument and EPC warning lamp as follows:

=> Electrical system self-diagnosis; Repair group 01

If the EPC warning lamp lights up with ignition switched on:

- Start engine and run at idling speed:

If the EPC warning lamp does not go out: n AG. Volkswagen AG do

Engine code: AUD

=> Electrical system self-diagnosis; Repair group 01

tester VAS 5051 in the operating mode vehicle self-diagnosis.

Connecting VAS 5051

- -> Pull out ashtray -1-.

Selecting operating mode:

- Press button on display for "Vehicle self-diagnosis".

Selecting vehicle system:

- Press button "01 - Engine electronics" on display.

Selecting diagnosis function:

All diagnostic functions available are indicated on the display.

- Press button on display for desired function.

Connecting V.A.G 1551

◆ V.A.G 1551 Fault reader

1.6 - Connecting fault reader 5

- Connect fault reader V.A.G 1551 using cable V.A.G 1551/3.

-> Indicated on display:

1 - Rapid data transfer*

- Press key 1 for "Rapid data transfer".

=> Page 125 .

An incorrectly coded engine control unit leads to:

- Checking control unit coding => Page 126 ,

-> Indicated on display: