Service Polo Estate 1998 > Edition 12.1999 Service Department. Technical InformationService List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Polo Estate 1998 > Repair Group 01 - Self-diagnosis 24 - Mixture preparation, Injection’ 8 - Ignition system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to enaure vehicle road-worthiness and sefety. 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 0005640832001 - Self-diagnosis . 24 - 44 42 5 5A 52 53 6 64 7 ma 8 a4 9 94 10 10.1 Mixture preparation, Injection .... See taweone PRPRNVHK Polo Estate 1998 ~ ‘Simos injection and ignition system - Edition 12.1999 Contents General to self-diagnosis. General to self-diagnosis, Features of self-diagnosis Technical data of self-diagnosis Connecting fault reader V.A.G 1551 and selecting engine control unit Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine. control unit Fault memory... . Fault memory ‘Automatic test sequence for interrogating all fault memories Interrogeting and erasing engine control unit fault memory . Fault table Fault table Final control diagnosis Final control diagnosis Performing final control diagnosis Measured value blocks Measured valuecbIocks 0°24 gan, Safety pretautions . Read measured value block Elaluating measured value blocks, display groups 0,,,5 -Basic functions- “Evaluating measured value blocks, display groups 0...5.-Basic functions Evaluating measured value blocks, display groups 6..9-Engine speed regulation- Evaluating measured value blocks, display groups 6...9 -Engine speed regulation- Evaluating measured value blocks, display groups 10...12 Lambda regulation- Evaluating measured value blocks, display groups 10. Evaluating measured value blocks, display groups 13. Evaluating measured value blocks, display groups 13, Evaluating measured value blocks, display groups 19, Evaluating measured value blocks, display groups 19. ‘Servicing injection system ‘Servicing injection system . Fitting locetions overview General notes on injection Removing and instaling parts ofthe injection system .. .__ Dismantling and assembling intake manifold - Upper part. » Dismantling and assembling fuel rail with injectors . ‘Dismantling and assembling air cleaner Safety precautions : e Rules for cleanliness ‘ Technical data... .. Checking componsits ‘Checking components . . Checking Lambda probe heating - Checking air mass meter Checking throttie valve control part Checking coolant temperature sender Checking intake air temperature sender Checking engine speed sender . 12 -Lemnbda regulation- 18 -Ignition- 48 -Ignition- {99 -Opefating condition- .99 -Opetating condition- @ contents I28 29 2.10 3 34 32 33 34 35 4 44 42 43 44 45 48 47 5 34 52 53 54 55 56 BT 28 - Ignition system 1 14 12 13 14 15 18 17 18 Polo Estate 1998 > ‘Simos injection and ignition system - Edition 12.1999 Checking injectors 83 Checking fuel pressure regulator and holding pressure...... a a 2 89 Checking intake air system for leeks (unmetered air). 92 Checking functions . ceseeeee bocce eee eeeeeeeeeeeeeeeeeeeee sees O83 Checking functions 93 Idling check . .. . 2 93 Checking Lambda probe and Lambda regulation 95 Checking engine operating mode. FPA ay -98 Checking intake manifold charige-over . 100 Engine control unit. = 402, Engine control uni’... .. eee eee e eee eeee Ri pees M02 Function ....<° 102 Checking control unit voltage supply ....... re 102 Replacing gngine control unit 104 Coding engine control unit... +... .seeseee a a Coding variations of engine control unit... —_ eee eee 106 Adapting engine control unit to throttle valve control part. $ 108 Checking additional signals... 108 Checking additional signals... 108 Testing speed signal 108 Checking engine speed signal 110 Checking signal fromito air conditioning system ......s...ceeseeesssee cee Att Checking driving range signal E 115 Checking signal from power steering pressure switch . w2 117 Checking signal from clutch pedal switch 119 ‘Servicing ignition system . ‘Servicing ignition system General notes°op ignition system . ’ Removing and installing parts of the ignition system oof 124 Safety precautions 2 127 Test data, spark plugs « “a. 128 Checking Hall sender... . 7 128 Checking ignition transformer 130 Checking knock sensor . cect b ee teeee eee fete ee teen eee ABM ii conanPolo Estate 1998 ~ ‘Simos injection and ignition system - Edition 12.1999 BRST e-llalei} 1 - General to self-diagnosis 1.1 - General to self-diagnosis 1.2 - Features of self-diagnosis The Simos control unit (J361) for the fuel injection and ignitiotSystem is equipped-with a fault memory. If faults occur in the sensors and components being’ monitored, they will be stored in the faultmemory together with an indication of the type of fault After evaluating the information, the engine'control unit decides among the different fault numbers fott=symbol charset-fontspeciic code=225 descr={iang]=> Fault fable beginning page 10) and stores tnese 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 of a brief open circuit. Ifa sporadic fault does not occur again within 40 engine starts, it wil be erased from the fault memory. “The faults stored can be read-oufswith the fault reader V.A.G 1551, the vehicle system tester V.A.G 1882 or the new tester VAS 5051 => Page 9 ‘The fault memory must be erased after the faults have been rectified => Page 9 Note: General information for self-diagnosis can be found in the instruction manuals for the fault reader V.A.G 1951, vehicle system tester V.A.G 1582 or the new tester VAS 5051. 1.3 - Technical data of self-diagnosis Control unit identification ‘The control unit version is displayed when the fault readéf'V.A.G 1551, the vehicle.system tester V.A.G 1552 or the new tester VAS 5051 is connected and engine electronics control unit'selected => Page 2 Equipment Engine code ‘AEH AKL [System designation SIMOS 2.1 SIMOS 2.4 Exhaust emissions futfil MVEG II Standard D3 standaré EPC system no no Selt-diagnosis yes yes Final control diagnosis yes yes lOperating mode of data transfer to V.AG 1551/1552 Rapid data transfer | Rapid data transfer Fault memory Nor-volatile Non-volatile memory‘) memory1) Leamt value memory Volatile memory2)_|_Volatile memory2) 1.1 = Ganaral to sett-diagnosis 1Polo Estate 1998 > ‘Simos injection and ignition system - Edition 12.1999 [Lambda regulation 1 probe 1 probe Knock control ‘’knock sensor 4 knock sensor Variable intake manifold , yes yes |Secondary air system, no no Exhaust gas reciretiation no no Variable valve timing no no 1) Independent of voltage supply. Note: Functions which can be selected when using the fault readers V.A.G 1551/1552 or VAS 5051 The prerequisites lo select the desired functions can be found in the folowing table. [Function Prerequisite Functions on fault reader V.A.G 1551 or | Engine stopped, igni-| Engine funning at _] Vehicle being driven ‘on system tester V.A.G 1852 tion switched on idling speed los interrogate control unt yes yes yes version oz Interrogate fault mem- yest) yes yes lory (03, Final control diagnosis| es. no no. jo4 [Basic setting2) yes no. no 05: [Erase fault memory est) es es 06 [End output yes yes yes o7. [Code control unit es 0 no oe Read measured value| yes yes yes block 10 [Adapting es no no. 1) Only carry out with ignition switched on, when engine does not start (operate starter for at least 5 seconds first. 2) Must be carried out after performing the following work: Replacing engine control unit, throttle valve control part or engine. 1.4 - Connecting fault reader V.A.G 1551 and selecting engine control unit FE 2 01-SaitatagnossPolo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 ‘Special tools, workshop equipment, testers, measuring instruments and auxiliary items required + V.AG 1551 Fault reader Notes: ‘+ 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 ‘* Allfunctions of V.A.G 1851/1552 can also be carried out with the new tester VAS 5051. Connecting VAS 5051 => Page 5. V.A.G 1551/3 * VAG 1551/3 Cable Test conditions QOROSESEREELEHCE 51 Earth connection in plenum chamber 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, On vehicles with an automatic gearbox the selector lever must be in P or N. Ifthe vehicle is equipped with an air conditioner, this rust be switched off. oe > The fuses 1, 3, 31, 34, 36 and 40 must be, OK. 1.4 Connaeting taut Bader V.A.G 1851 and selecting engine contol unt 3‘Simos injection and ignition system - Edition 12.1999 Work sequence + > Remove ash tray -1-. + Connect fault reader V.A.G 1551 with cable V.A.G 1551/3, After the fault reader has been connected: + Depending upon desired function: Switch igniion on Start engine => Page 2, Table “Selectable functions", Notes: + Ifthe display remains blank, check voltage supply for diagnostic connection: => Current flow diagrams, Electrical fault finding and Fitting locations + Ifthe display does not indicate as described in the work sequence: => Fault reader operating instructions + Ifdue to an input fault "Fault in the data transfer!” work step is displayed, pull wire off fault reader, reconnect and repeat = Operate fault reader taking into account thesinfétratiot’ én the-display: > Indicated on display: : napid ~ Appears alternately - Operate fault reader taking into account the information on the display: = Press key 1 for "Rapid data transfer". = Press keys 0 and 1 for address word "Engine electronics” and confirm entry with Q key. > The control unitidentification and coding are indicated on the display, e.g.: © 1c. g4/2V SINOS ATSO72 Base soc ‘6KO 906 019 = Part No. of the control unit (for current control unit versions, see parts catalogue) 1.6 Ir. = Engine displacement R4/2V = Engine configuration (4-Cyl. in-line engine, 2 valve) SIMOS = System designation HS = Manual gearbox (hand change) AT = Automatic gearbox ‘S073 = Programme version number Coding 10003 Control unit coding, coding variants of engine control unit => Page 406 + WSC xxx = Werkston code from V.A.G 1551, of the workshop which carried outthe last coding. (If the factory coding has not Been changed, WSC 00000 appears) Notes: * Replace contol unit if the control unit ejsion daplayed does not cetfespond tothe vehicle =>Page 1 * Check’to seg ithe correct coding has been Used if there are driving characteristic problems/malfunctions => Page + Press =key. > Indicated on display: 4 or - sartagnossPolo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 ~ Further measures see repair procedures. 1.5 - Connecting vehicle diagnosis, testing and information system VAS 5051 and selecting engine control unit All functions which could be done with V.A.G 1551/1852 can also be done with the new tester VAS 5051 in the operating mode: “vehicle self-diagnosis": => Operating instructions for Vehicle Diagnosis, Testing and Information System VAS 5051. ‘Special tools, workshop equipment, testers, measuring instruments and auxiliary items required VAS 5051 ‘+ VAS 5051 Vehicle Diagnosis, Testing and Information System Test conditions RCAGABEBOREABRR 51 > The fuses 1, 3, 31, 34, 36 and 40 must be OK. Earth connection in plenum chamber 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 On vehicles with an automatic gearbox the selector lever must be in P or N. If the vehicle is equipped with an air conditioner. this must be switched off, 1.4 Connecting taut Bader V.A.G 1851 and selecting engine contol unt 5‘Simos injection and ignition system - Edition 12.1999 \ vas 5051 Work sequence © = Connect the tester VAS 5054 using diagnostic cable VAS 5051/1 or VAS 5051/3 as follows’ 2 > Remove ash tray -1-. : 2 Fitdiagnosis cable connector onto diagnosis connector. a - Depending upan desired function: ‘Switch ignition‘on or Start engine => Page 2 , Table "Selectable functions”. [vas s051 5. $ Notes: + Inthe functions 04 - Basic setting/08 - Read data block, the display zones will be listed from top to bottom. + Ifthe display does not indicate as described in the work sequence => Operating instructions for Vehicle Diagnosis, Testing and Information System VAS 5051 > Indicated on display: Select operating mode: 6 01-saratagnosisPolo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 ~ Press the button on the display for "Vehicle self-diagnosis" -arrow-. > Indicated on display: sos" ro Select vehicle systent® "01 - Engine electronics” on the display -arrow-. > On the fisplay the control unit identification and coding are displayed, e.g If the coding differs from the vehicle version, then: = Checking contcol unit coding => Page 106, coding variations for engine control unit > Indicated on display: Select diagnostic function: At this point all diagnostic functions are available. - Press the desired function on the display. = Further meacures see repair procedures. 2 - Fault memory 2.4 - Fault memory Interrogate and erase engine control unit fault memory=> Page 9 1L5- Connecting vehicle agnosis, testing andinformation system VAS 5051 and selecting engine contol unt 7Polo Estate 1998 > ‘Simos injection and ignition system - Edition 12.1999 2.2 - Automatic test sequence for interrogating all fault memories ‘Special tools, workshop equipment, testers, measuring instruments and auxiliery items required + Fault reader V.A.G 1551 (or vehicle system tester V.AG 1552) with cable V.AG 1551/3 Work sequence Note: All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the new tester VAS 5051. The various control units/components are connected fodsthiar via acdate bus. This is why itis always sensible to interrogate the fault memory of all contral-Units first with the “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 addfess word "Automatic test sequence” and confirm entry with'@ key. The VAG 4551 transmits all known address words one after the other. When a control unit ansivers with its identification the number of stored faults appears on thé-display or "No fault recognised”. Any system faults haf are stored vil be displayed one after the other and printed out. The V.AG1554 wil then tranemit the next address word. -> The automatic test sequence has ended when the following appears on the display: Tesh - Erase all fault memories and then carry out a road test. Observe the valid safety, measures during a test drive => Page 21 During the road test thé following operating conditions must be futile: = The coolant temperature must exceed 80 °C. ~ When the temperature is ached, the operating concitions fing Part throttle Enrichment Full throttle Overrun must be attained several times. = Attull throttle the speed must exceed 3500 rpm, Again interrogate the fault memories of ail control units using the "automatic test sequence". If no fault is stored: + Press the =key, => Indicated on display: = Prees keys 0 and 6 for the function "End output" and confirm entry with the Q key. + Switch off ignition. 8 o1-saitatagnosisPolo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 3 - Interrogating and erasing engine control unit fault memory ‘Special tools, workshop equipment, testers, measuring instruments and auxiliary items required ‘¢ Fault reader V.A.G 1551 (or vehicle system tester V.A.G 1552) with cable V.A.G 1851/3 ‘Work sequence Note: All functions which could previously be performed with V.A.G 1551/1552 can also be performed with the new tester VAS 5051. ~ Connect faut reader V.AG 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control unit. When doing this the engine must be running at idling speed. (Connecting fault reader and selecting engine control unit => Page" 2j'0" ac Only when engine does not start = Operate the starter for at least 5 eecondia, Then do net auitch the ignition oft. - Switch on fault reader printer with the:print key. The warning lamp in key must light up. => Indicated on display = Operate fault reader taking into account the information on the display: = Press keys 0 and 2 for furiction "interrogate fault memory” and confirm entry with @ key. => The number of faults stored or"No fault recognised!” will be shown on the display. 5 sto fault is stored! : = Press =key If one or more fits are stored “The stored fauits willbe cisplayed and printed out one after the other é it, the display will show: - Press keys 0 and 5 for the function "Erase fault memory""atd,confirm entrywwith Q key. > Indicated on display: Note: If the ignition /s switched off between “interrogate fault memory" and "Erase fault memory" the fault memory will not be erased. = Press key. > Indicated on display: = Tae 2.3-Intarrogating and erasing engine contol unit faut memory Q~ Press keys 0 and 6 for the function "End output" and confirm entry with the Q key. = Switch off ignition. - Eliminate the faults printed out using the fault table: Fault table =>Page 10 3 - Fault table 3.1 - Fault table Notes: + The fault table is ordered actording to the 5-digit fault code. + Explanation of the fault types (e.g. “open circuit/short circuit to earth => Fault reader operating instructions * If. components are indicated as faulty First check the wiring and connectors to these components as well as the system earth connections ac- cording to current flow diagram. This is particularly relevant i faults are output es “occurring sporadically” (SP) + Erase fault memory after rectifying fault =>Page 9 V.AG 1551 print out, e.g. 00523 030 Intake air temperature sender -G42 Short to earth Sporadic fault Explanation: + 00523 = Fault code + 030 = Faulttype as number + Intake eir temperature sender -G42 = Faulty currSht path or incott8ét location + Open circuit/short to positive = Fault type as text * Sporadic faults = Faults thet are not always present e.g. loose contact Fault code Fault text Fault elimination 00282 | Throttie valve positioner -V601) __ |- Check throttle valve positioner [Short => Page 65 , Checking throtlle valve control part Throttle valve positioner -V601) Blocked or no voltage Throttle valve positioner -V601) |Connector Throttle valve positioner -V601) Upper stop value, Throttle valve positioner -V601) Signal outside tolerance Throttle valve positioner -V604) Implausible signal Throttle valve positioner -V601) Regulating difference 1) The throttle valve positioner (V60) is a component of the throttle valve control part (J338).Polo Estate 1998 ~ ‘Simos injection and ignition system - Edition 12.1999 Fauit code] Fault text Fauit elimination 00305. |Fuel consumption indicator signal] - Check fuel consumption indicator signal [Short to positive => Current flow diagram, Electrical fault finding and Fitting lo- cations (00513. [Engine speed sender -G26 | Check engine speed sender No signal Page 81 lEngine speed sender -G28 Implausible signel (00515 |Hell sender -G40, | Check Hail sender No signal Page 128 Hell sender -G40 - Check engine timing and adjust if necessary: Implausible signal Repair group 13: Dismantling and assembling engine; Re- moving, installing and tensioning toothed belt Removing, in- stalling and tensioning toothed belt Note on fault code 00513 ‘+ Metal particles can cause additional signals to be generated, ‘* Signals may not be generated or be too small and therefore not recognised if the sender gap to sender wheel is too large or the sender wheel is damaged, ‘* The signals can be irregular if the sender wheel is loose. Fauit code] Fault text Fault elimination 00516 [idling switch-F601) - Check idling switch lOpen circuit/short to positive Page 65, Checking throttle valve control part Idling switch-F601) Adjust accelerator cable: [Short to earth = Repair grou 20; Accelerator mechanism; Adjusting ac- [celerator cable Adjusting accelerator cable (00518 | Throttle valve potentiometer -G692)|- Check throttle valve potentiometer => Page 65, Checking JOpen circuit/short to positive throttie valve control part Throttle valve potentiometer -G692)| JOpen circuit/short to earth Throttle valve potentiometer -G692) implausible signal 1) The idling switch (F60) is a compénent of the throttle valve control part (J338). 1) The throttle valve potentiometer (G69) is a component of the throttle valve control part (338), Fault code| Fault text Fault elimination 00520 Air massifiow metér-G70/G19 _|- Check air mass meter JOpen circuit/shortto earth => Page 63 fair mass/fiow meter-G70/G18 [Short to positive: (00522 Coolant temperature sender -G62|- Check coolant temperature sender => Page 73 JOpen circuit/short to positive [Coolant temperature sender -G62|- Check thermostat [Short to earth Repair group 19; Removing and installing parts of cooling system; Parts of cooling system, engine side Parts of cooling Isystem, engine side [Coolant temperature sender -G&2| Implausible signal Fault code] Fault text Fault elimination (00523. Intake air temperature sepder-G42|- Check intake air temperature sender => Page’ 77 lOpen circuit/short to positive, Intake air temperature sender-G42 [Short to earth a1-Feuntane 11Polo Estate 1998 > ‘Simos injection and ignition system.,,Edition 12.1999 [Fauit code] Fault text aut elimination (00524 [Knock sensor 1 -G6t | Check knock sender implausible signal =>Page 134 IKnook sensor‘ -G61 Defective (00525. |Lambda probe -G39 | Check Lambda probe heating => Page 60 Short toxpositive Lambda probe -G39 |. Check Lambda probe and Lambda probe heating=>Page [Short to earth 95 Output open Lambda probe -G39 Laribda probe -639 implausible signal Signal to low Laribda probe -639 [Signal outsid: Lambda probe -G39 je tolerance Fault code| Fault text Fault elimination (00530 | Throttle valve positioner/potentiometer-G8B1) |- Adapt engine control unit to throttle valve control Open circuit/short to positive part => Page 106 [Throttie valve positioner/potentiometer -G881)|- Check throttle valve pesitioner/potentiometer |Open circuit/short to earth, [=>Page 65 , Checking throttle valve control part Throttle valve positioner/potentiometer -G881)| implausible signal 1) _ The throttle valve positioneripotentisineter (G88) is a compotént of the throttle valve control part (J338). It supplies information on the position of the throttle valve positioner to the control unit. Fault code Fault ittext Fault elimination 00533 [Idling speed regulation |- Check throitle valve positioner Lower stop value, Page 65, Checking throttle valve control part Idling speed regulation |- Check injectors Upper stop value =>Page 63 |- Check air intake system for leaks (unmetered air) => Page 92 Check signal from power-assisted steering pressure switch => Page 117 |- Check for blockage of air cleaner, replace if necessary Fault code] Fault text Fault elimination (00537 [Lambda regulation|- Check Lambda probe and Lambda regulation =>Page 95 Lower stop value - Check activated charcoal fiter system solenoid valve |=> Page 16, Final [control diagnosis - Check injectors Page 83 [ Check fuel pressure regulator and holding pressure => Page 68 mixture. Note on fault code 00513: Ifthe fault "Lambda regulation, Lower stop value" is recognised, the Lambda regulation has reached the reg- uleting limit in the direction of ‘making leaner”. Nevertheless, the Lambda probe is stil registering a ‘rich” [Fauit code] Fault text Fault elimination (00537 Lambda regulation|- Check Lembda probe and Lambda regulation=>Page 05 Upper stop value 120Polo Estate 1998 ~ ‘Simos injection and ignition system - Edition 12.1999 [Check injectors =>Page 83 - Check fuel pressiife regulator and holding pressure => Page 59 Check intake system for leaks (unmetered air) => Page 92. Check fuel pump: Repair group 20: Removing and installing parts of fuel supply &ystem: [Checking fuel pump Checking fuel pump Note on fault code 00537: If the fault "Lambda regulation, Upper stop value" is recognised, the Lambda regulation has reached thévreg- lating limit in the direction of ‘éeriching”. Nevertheless, the Lambda probe is stil registering a “lean” mixture. Fauit code] Fault text Fault elimination (00557 |Power assisted steering pressure switch -F88|- Check signal from power assisted steering pres- [Short to earth sure switch J=> Page 117 (00609 |Ignition output 1 | Check ignition coll => Page 130 hort to positive (00610 |ignition output 2 [Short to positive Note on fautt code 00557: If the fault is stored, itis possible that the subsequent fault "00533, ldling speed regulation, Lowes'stop value” has also been stored. Note on fault codes 00609 and 00610: {gnition outputs 1 and 2 are the outputs on the engine control unit via which the-enigine control unit activates the output stage (N122) of the ignition transformer (N152). Fault code] Fault text Fault elimination (00825 [Road speed signal | Check road speed signal => Page 108 Implausible signal (00635 Lambda probe heating before catalyat|- Check Lambda probe heating => Page 60 Defective (00850 Clutch pedal switch -F36 - Check clutch pedal switch signal => Page 119 [Short to positive (00668 System voltage terminal 30 - Check voltage supply to control unit => Page 102 JOpen circuit - Adapt engine control unit to throttle valve control part => Page 106 Note on fault code 00513: If the fault is recorded, the engine control unit assumes a fixed substitute value of 5 km/h. Note on fault code 00513: ‘+ The positive voltage supply to the Lambda probe heating comes via the fuel pump relay (J17), ‘+ The earth connection for the lambda probe heating is provided by the engine control unit, i. the entire current supply for the lambda probe heating comes via the engine controi unit Fault code] Fault text Fault elimination 01013. [Air conditioning compressor load signal|- Check signal to and from air conditioning => Page JOpen circuit/short to earth m1 [Air conditioning compressor load signal [Short to positive 3.1-Feutttabie 13,Polo Estate988 > ‘Simos injection and ignition system - Editior42.1999 (01087 Basic setting not carried out - Adapt engine eontrol unit to throttle valve control part =>) implausible signal Page 106) [Check voltage supply for control unit => Page 102 [Check throttle vaive-control part (J338)=>Page 65 Fault code Fault text Fault elimination 01126 [Engine speed signal _|- Check engine speed signal Defective [=> Page 110 01163 |Backtire | Check ignition transformer=> Page 130 Check intake system for leaks (unmetefed air) => Page 02 01177 [Engine controlunit _|- Check voltage supply for control unit => Page 102 Defective | Renew engine control unit J=>Page 108 Note on fault code 01126: The “engine speed signal" Is not the signal from "engine speed sender (G28)" on the crankshaft, but rather an engine speed s)gne! put out by the engine contol unit This signal's nzeded. emang other things. by the automatic gearbox control unit for calculating the shift points and for the rev counter in the dash panel insert. Note on fault cote 01163: The engine cannot bé Stated until the fault entered in the fault memory has been erased =>Page 9, inter- rogating and erasing fauit memory Fault code Fault text Fault elimination (01242 [Output state in control unit | Renew engine control unit Defective Page 104 (01243 _|intake manifold press.change valve-N156 |- Check N156 => Page 16 , Final control diagnosis [Short to positive Intake manifold press change valve-N156 [Short to earth Intake manifold press change valve-N156 Output open (01247 [ACF solenoid 1-NE0 [Short to positive [ACF solenoid 1-N8O Page 16 , Final control diagnosis, [Short to earth [ACF solenoid 1-N8O [Output open Fault code Fault text Fault elimination (01249 Injector, cylinder 1 -N3O (Check injector [Short to positive =>Page 83 Injector, cylinder 1 N30 [Short to earth Injector, cylinder 1 -N3O JOutput open, (01250 Injector, cylinder 2 -N31 - Cheek injector [Short to positive Page 83 Injector, cylinder 2 -N31 [Short to earth Injector, eylineler 2 -N34 JQutput open 071251 Injector, cylinder 3 -N32 - Check injector [Short to positive Page 83‘Simos injection and ignition system - Edition 12.1999 Polo Estate 1998 ~ [Short to earth Injector, cylinder 3 -N32 [Output open, Injector, cylinder 3 -N32 Fault code| Fault text Fault elimination 01252 Injection, cylinder 4 -N33, [Short to positive Check injector Page 63 Injection, cylinder 4 -N33, [Short to earth Injection, cylinder 4 -N33 JOutput open 01259 Fuel pump relay -J17 Defective - Check J17 => Page 16 , Final control diagnosis (01312 [Drive train data bys defective|- Check data bus Wiring for open circuit to engine control unit (pins 28 and 31) using currentiflow diagram: => Current flow diagrams, Electrical faut finding and Fitting loca- lions. Note on fault code 01259: If the fault is $tored, the faults "00520, 00635, 01247 and 01249...01252 could also be stored as these com- ponents ara supplied with voltage via the fuel pump relay (J17). Fault code] Fault text Fault elimination (01315; [Gearbox control unit, No communication|- Check data bus wiring for open circuit to engine control lunit (pins 29 and 31) using current flow diagram: Current flow diagrams, Electrical fault finding and Fit. ting locations. (01316) [Brake control unit, No communication _|- Check data bus wiring for open circuit to engine control] unit (pins 29 and 31) using curfent low diagram: => Current flow diagrams, Electrical fault finding and Fit. ting tocations (01321 Airbag control unit, No communication |- Check data bus wiring for open circuit to engine control] it (pins 29 and 31) using eurrent flow diagram: => Current flow diagrams, Electrical fault finding and Fit. ting locations Fault code] Fault text Fault elitination 17978 [Engine control unit blocked| ‘Adapt engine control unit to electronic immobilizer }=> Electrical system self-diagnosis; Repair group 01; Immobilizer selt- IGiagnosis; Adapting aftertenewing engine control unit Immobilizer self-diagnosis; Adapting after renewing engine control unit, Note to fault code 17978: Uf starting is attempted with an unauthorised key @ permanent fault will be stored. After a subsequent start with an authorised key the fault will be converted to a sporadic fault. 3.1-Feuittabie 15,Polo Estate 1998 > ‘Simos injection and ignition system - Edition 12.1999 4 - Final control diagnosis 4.1 - Final control diagnosis 4.2 - Performing final control diagnosis” . : ‘The final control diagnosis activates the following components in the stated sequence: 4, Fuel pump relay ~J17 2. Solenoid valve 1 for activated charcoal iter -NBO 3. Intake manifold change-over valve -N156 ‘Special tools, workstiop equipment, testers, measuring instruments and auxiliary items required + Diode test lamp V.A.G 1527 Fault reader V.AG 1551 (or vehicle system tester V.A.G 1552) with cable V.AG 1551/3, + Adapter set V.A‘G 1594 + Test box V.AG 1598/22 * Current flow diagram 2 Check conditions = +> The fuses 1, 31, 36 and 40 must be OK. ‘The battery voitage must be at least 11.5 V. Earth connection in plenum chamber OX. + Allelectrical consumers, e.g. lights and rear window heating must be switched off + Ifthe Vehicle is equipped with an air conditioner, this must be switched off. Notes: * Allfuncions of VAG 1551/1552 can also be carried out withthe new tester VAS 5051, Connecting VAS age + 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 ifthe engine is started or a rotational impulse is recognised. During the final control diagnosis the individual final controls are activated 50 times unless the = key is Bressed to switch manually to the next final control + The final controls are checked acoustically or by touching. * Ifitis necessary to repeat the final control diagnosis, without frst running the engine briefly, switch the ignition off for approx. 2 seconds. 1@ electric fuel pump will run during the complete final control diagnosis. Work sequence - Connect the fault reader V.AG 1551 (V.A.G 1552). Then switch ignition on and select engine contro! unit with the "Address word” 01 160Polo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 Page, RaW ckiswagen ag (Connecting fault reader and selecting engine control unit > Indicated on displa oh i fer «HELP data crane: - Operate fault reader taking into account thecinformation on the display: ~ Press keys 0 and 3 for the function "Final control diagnosis”. > Indicated on display: Repia dete © Activating fuel pump relay (J17): = Confirm input with Q key. > Indicated on display: Fuel pump relay (relay position 6 on refay plate) must click (maximum 50 times) until you activate the next © final control by pressing the key. § Note: During the activation of the fuel pump relay the fi] pump must be heard fo run at intervals, Ifthe relay does not click: a = Check fuel pump relay: nN => Current flow diagrams, Electrical fault finding and Fitting locations Activating activated charcoal filter solenoid valve 1 (N80): Press >key. > Indicated on displ The activated charcoal fiter solenoid valve 1 must click (maximum 50 times) until you activate the next final control by pressing the >key. Ifthe solenoid valve does not click: = > Pullthe 2 pin connector off solenoid valve 1 (N80) -arrow- 4.2-Pestorming nal conta! diagnosis 17Polo Estate 1998 > ‘Simos injection and ignition system - Edition 12.1999 - > Connect disde test lamp V.AG 1527 using adapter cabiés,from VAG 1594 to detached connector. The LED must flash LED flashes: = Progéed with final control diagnosis until completed. + Sutch off ignition. + Replace solenoid valve 4 (N80): Repair group 20; Activated charcoal filter system; Servicing parts of activated charcoal filter system Activated charcoal filter system Servicing parts of activated charcoal fiter system == + _nterrogate fault memory, if necessary, repair any faults and then erase fault memory => Page 9, inter- Erogatng and erasing fault memory. LED does net flash: + Proceed with final control diagnosis until completed. = Switch off ignition. - > Connect test box V.A.G 1598/22 to control unit wiring harness. I~ 1 2 = > Check wiring for open circuit between test box and 2-pin connector using current flow diagram: Contact 2 and test box socket 15, Wire resistance: max. 1.5 w 180Polo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 = Check wiring additionally for short to vehicle earth or battery positive. Specification: Page 1 ke manifold change-over valve (N156): = Preis >key. > Indicated on displ ‘The intake manifold change-over valve must click (maximum 50 times) until you the final control diagnosis “by pressing the =key. Checking intake manifold change-over => Page 100 If the solenoid vaive does not click: = > Pull 2-pin connector off intake manifold change-over valve (N156) -arrow-. = > Connect diode test lamp V.A.G 1527 using adapter cables from V.A.G 1594 to detached connector. The LED must flash 4.2-Pestorming thal contra! diagnosis 1Polo Estate 1998 > ‘Simos injection and ignition system - Edition 12.1999 LED flashes = Proceed with final control diagnosis until completed. + Switch off ignition = Renew intake manifold change-over valve (N156) Page 53, item 12 -_ Interrogate fault memory, if necessary, repair eny faults and then erase fault memory => Page 9, inter- rogating and erasing fault memory. LED does net flash: = Proceed with final control diagnosis untit completed. = Switch off ignition. - > Connect test box V.A.G 1598/22 to cantrol unit wiring harness. + > Check wiring for open circuit between test box and 2-pin connector using current flow diagram: Contact 2 and test box socket 64 Wire resistance: max 1.5 w = Check wiring additionally for short to vehicle earth or battery positive. Specification: =w = Check wire between 2 pin connector contact 1 and fuel pump relay (J17) for open circuit using current flow diagram ire resistance: max. 1.5 w If no wiring fault is detected: + Replace engine control unit => Page 104 - Press key. => Indicated on display: exol diagnosis => Indicated on display: 200)Polo Estate 1998 > @ Simos injection and ignition system - Edition 12.1999 - Press =key. = Press keys 0 and 6 for the "End output" function and confirm input with the Q key. + Switch off ignition 5 - Measured value blocks 5.1 - Measured value blocks vem 5.2 - Safety precautions Observe following if test and measuring.instruments are required during a test drive: ‘+ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this location. If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in = an accident, there is @ possibility that the person sitting in this seat may receive serious injuries when the aitbag Is triggered, 5.3 - Read measured value block 2 The measured values in the functions read measured value block and basic setting are described during the individual component test. This table serves only as an overview. § Special tools, workshop equipment, testérs, measuring instruments and auxiliary items required ‘+ Fault reader V.AG 1851 (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3 Test conditions ~The fuses 1, 3, 31, 34, 36 and 40 must be OK Earth connection in plenum chamber OK. All electrical consumers, e.g, lights and rear window heating must be switched off. On vehicles with an automatic gearbox the selector lever must be in P or N. Ifthe vehicle is equipped with an air conditioner, this must be switched off. No faults must be stored in fault memory => Page 9 , interrogating and erasing fault memory. 4.2-Pestorming tinal contro! dagnosis 21+ Coolant temperature must be at least 80 °C, =>Display group 01, display zone 2. Work sequence AG + Connect faultéader V.AG 1551 (V-A.G 1552). Start engine and select "Address word” 01 of engine control Unit. When'doing this the engine must be running at idling Speed (Conneeting fault reader and selecting engine control unit => Page 2.) => Indigéted on display: % ee - Press keys 0 and 8 for the function "Read measured value block” and gonfirm entry with Q key. Bobut display ai Select required display group number. 3 Note: The display group number 1 is an example, to illustrate the sequence. + Press keys 0, 0 and 1 for “Display group number 1” and confirm entry with Q key. +> Indicated on display: (i..4 = Display zones) Note: c 0 To change to another alsplay group proceed as follows: [Display group VAG 1551 | VAG 1552 Higher Presskey3 | Press 1ke} Lower Presskey1 | Press ikey [Skip PresskeyC | Press key C - If the specifications in all display zones are obtained, press =key. -> Indicated on display Rapid 4 + Press keys 0 and 6 for the “End output" function and confirm input with the Q key. + Switch off ignition. Note: Measured value blocks which are not described in this chapter are currently only intended for the research and development and production. The values displayed are not relevant for service department fault finding.Polo Estate 1998 ~ \Simosvinjection and ignition system - Edition 12.1999 6 - Evaluating measured value blocks, display groups 0...5 -Basic functions- 6.1 - Evaluating measured value blocks, display groups 0:,,5 -Basic functions- Note: If display group 001 of function 04 “Basie functions” is selected while ignition is switehed on (engine off, the ‘engine contro! unit will be adapted to the throttle valve control part => Page 106 (display group 98) Display group 1 -Basic functions- * Efigine running at idling speed Read measured value biock 1 => [lif] Indicated on display 2o0ge pM 200°C _x%V_woo.G00 4 27 3 4 rit] Display zones Specification | Evaluation ‘Adjustment conditions fer adapting | 00000010 | => Page 24 8 throttie valve i ‘ Lambda probe voltage 0.00..4.00V | => Page 29 Coolant temperature 20..110°C | => Page 23 Engine speed (Idling speed) [620.040 rpmt)| => Page 23 1) Up-to“dste specifications => Exhaust emissions test binder - Evaluating display group 1,"Gisplay zone 1 - Engine speei! (icing speed) [Appears on display] Possible fault cause Fault elmination Less than _|- Throttle valve control part sticking or defec-|- Check throttle valve control part specication [tive Page 85 - Large amount of unmetered air (cannot be |- Check intake air system for leaks |compensated for by the idling stabilisation) |=> Page 92 = Perform idling check => Page 93 More than —_|- Idling switch not closedidefective - interrogate fault memory, => Page 9, In-| specification terrogating and erasing fault memory ~Large amount of unmetered air (cannot be |- Check intake air system for leaks compensated for by the idling stabilisation) |=> Page 92 - Throttle valve control part sticking/defective|- Check thratile valve control part Page 65 - Perform idling check => Page 93 Evaluating display group 1, display zone 2 - Coolant temperature [Appears on display Possible fault cause [Less than specification|- Engine too cold sf necessary carry out test drive - Coolant temperature sender (G62) or |- Check coolant temperature sender wiring to engine control unit =>Page 73 - Thermostat sticking/defective - Check thermostat: Repair group 18; Removing and instal- ling parts of cooling system: Parts of cooling jsystem, engine side - Clean radiator - Radiator fan not functioning - Check function Current flow diagrams, Electrical fault linding and Fiting locations Fault elimination More than specification|- Radiator soiled 6.1 - Evaluating measured valve biock, cisplay coups 0..8 Beste tunctons- 23