Skoda Fabia 2000 Workshop Manual Engine Fuel Injection

Service 5
Workshop Manual
FABIA 2000 ³
1.2/40; 1.2/47 Engine, Fuel Injection
Edition 04.02
Engine code AWY AZQ BMD BME
Service Department. Technical Information Printed in Czech Republic

S00.5323.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5323.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ³ 1.2/40; 1.2/47 Engine, Fuel Injection
List of Supplements to Workshop Manual

FABIA 2000 ³
1.2/40; 1.2/47 Engine, Fuel Injection
Edition 04.02
Supple-
Edition Subject Article Number
ment
04.02 Basic Edition S00.5323.00.20
1 04.03 Supplement to Basic Edition regarding engine with engine identifi- S00.5323.01.20
cation characters AZQ
2 06.04 Changes for engine with engine identification characters BMD S00.5323.02.20
3 01.05 Changes for engine with engine identification characters BME S00.5323.03.20
Edition 01.05 List of Supplements

S00.5323.03.20
List of Supplements Edition 01.05

S00.5323.03.20
Table of Contents
01 – Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 page 1
- Operation ............................................................................................... 01-1 page 1
- Technical data of self-diagnosis ..................................................................... 01-1 page 2
- Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the
dash panel insert ...................................................................................... 01-1 page 3
- Meaning of the exhaust gas warning light -K83- .................................................. 01-1 page 3
- Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for
engine electronics ..................................................................................... 01-1 page 4
- Interrogating and erasing fault memory ............................................................ 01-1 page 5
- Performing actuator diagnosis ....................................................................... 01-1 page 6
Self-diagnosis II ......................................................................................... 01-2 page 1
- Fault codes 16496 … 16990 ......................................................................... 01-2 page 1
Self-diagnosis III ........................................................................................ 01-3 page 1
- Fault codes 17040 … 18088 ......................................................................... 01-3 page 1
Self-diagnosis IV ....................................................................................... 01-4 page 1
- Readiness code ........................................................................................ 01-4 page 1
- Reading readiness code .............................................................................. 01-4 page 1
- Generating readiness code .......................................................................... 01-4 page 2
Self-diagnosis V ........................................................................................ 01-5 page 1
- Reading measured value block ..................................................................... 01-5 page 1
- Display groups 000 to 028 ........................................................................... 01-5 page 2
Self-diagnosis VI ....................................................................................... 01-6 page 1
- Reading measured value block - display groups 030 to 126 ................................... 01-6 page 1
24 – Fuel Formation, Injection

Fuel Injection System ................................................................................. 24-1 page 1
- Safety measures ....................................................................................... 24-1 page 1
- Rules of cleanliness ................................................................................... 24-1 page 1
- Overview of fitting locations .......................................................................... 24-1 page 2
- General notes on the injection system ............................................................. 24-1 page 6
- Removing and installing parts of the injection system ........................................... 24-1 page 7
- Disassembling and assembling fuel distributor with injectors .................................. 24-1 page 13
- Disassembling and assembling intake manifold .................................................. 24-1 page 16
- Removing and installing an engine cover with air filter .......................................... 24-1 page 19
- Disassembling and assembling the air filter ....................................................... 24-1 page 21
- Resistances for intake air temperature sender -G42- ............................................ 24-1 page 23
- Resistances for the coolant temperature sender -G62- ......................................... 24-1 page 24
Testing components ................................................................................... 24-2 page 1
- Testing lines and components with test box -V.A.G 1598/31- .................................. 24-2 page 1
- Inspecting the injection rate, tightness and jet formation of the injectors ..................... 24-2 page 1
- Testing fuel pressure regulator and holding pressure ........................................... 24-2 page 3
- Testing intake manifold preheating ................................................................. 24-2 page 4
- Inspect intake system for leaks (unmetered air) .................................................. 24-2 page 5
- Testing idling speed ................................................................................... 24-2 page 5
Edition 01.05 Table of Contents I

S00.5323.03.20
Lambda control ......................................................................................... 24-3 page 1

- Testing lambda probe -G39- and lambda control upstream of catalytic converter .......... 24-3 page 1
- Testing lambda probe -G130- and lambda control downstream of catalytic converter ..... 24-3 page 3
- Test of ageing of lambda probe upstream of catalytic converter -G39- ....................... 24-3 page 4
Electronic Power Control (electronic throttle) ................................................... 24-4 page 1
- Function of the Electronic Throttle System ........................................................ 24-4 page 1
- Testing throttle valve control unit -J338- ........................................................... 24-4 page 1
- Testing Accelerator pedal position sender ........................................................ 24-4 page 2
Engine control unit .................................................................................... 24-5 page 1
- Operation ............................................................................................... 24-5 page 1
- Replacing engine control unit ........................................................................ 24-5 page 1
- Coding engine control unit ........................................................................... 24-5 page 2
- Adjusting the engine control unit to the throttle valve control unit -J338- ..................... 24-5 page 3
- Adapting EGR valve .................................................................................. 24-5 page 3
- Activating and deactivating cruise control system (CCS) ....................................... 24-5 page 4
Testing auxiliary signals ............................................................................. 24-6 page 1
- Testing the speed signal ............................................................................. 24-6 page 1
- Checking the data BUS .............................................................................. 24-6 page 1
28 – Ignition System
Ignition System ......................................................................................... 28-1 page 1
- General notes on the ignition system .............................................................. 28-1 page 1
- Work safety rules ...................................................................................... 28-1 page 1
- Removing and installing ignition system ........................................................... 28-1 page 1
- Resistance values for ignition coils with power output stages -N70-, -N127-, -N291- ...... 28-1 page 3
- Inspecting the camshaft position sensor -G163- ................................................. 28-1 page 3
- Testing Engine speed sender -G28- ............................................................... 28-1 page 4
Table of Contents Edition 01.05

II S00.5323.03.20
FABIA 2000 ³ 1.2/40; 1.2/47 Engine, Fuel Injection 01
01 – Self-diagnosis
01-1 Self-diagnosis I
Note
The self-diagnosis monitors only a part of the injection
and ignition system.
Operation
The engine control unit is equipped with a fault memory.
The fault memory is designed as a permanent memory.
If malfunctions occur in the monitored sensors or compo-
nents, they are stored in the fault memory with indication
of the fault type.
Faults which occur only temporarily (sporadically) are
displayed with the suffix „/SP“. Possible causes of spo-
radic faults are e.g. a loose contact or a temporary line in-
terruption. If a sporadic fault no longer occurs after 40
engine starts, it is automatically erased.
The stored faults can be read out with vehicle system
tester -V.A.G 1552-, fault read-out scan tool
-V.A.G 1551- or with vehicle diagnosis, measurement
and informations system -VAS 5051- ⇒ 01-1 page 4.
After the fault(s) has(have) been removed the fault mem-
ory must be erased ⇒ 01-1 page 5.
Note
Following description only relates to vehicle system test-
er -V.A.G 1552- with the current program card 5.0. When
not using the current program card or when using the
fault read-out scan tool -V.A.G 1551- with integrated
printer or using the vehicle diagnosis, measurement and
information system -VAS 5051- a minor deviation in the
display is possible.
Edition 01.05 Self-diagnosis I 01-1 page 1

S00.5323.03.20
01 FABIA 2000 ³ 1.2/40; 1.2/47 Engine, Fuel Injection
Technical data of self-diagnosis

Equipment
Engine identification char- AWY BMD AZQ BME

acters
System denomination SIMOS 3PD SIMOS 3PG SIMOS 3PE SIMOS 3PG
Exhaust limits conforming to EU-4, EU-3 DDK, EU-4, EU-2 DDK EU-4, EU-3 DDK, EU-4, EU-2 DDK
EU-2 DDK EU-2 DDK
Electronic throttle system yes yes yes yes
Lambda control 2 lambda probes 1) 2 lambda probes 1) 2 lambda probes 2 lambda probes
Knock control yes yes yes yes
Exhaust gas recirculation no no yes yes
Secondary air system no no no no
Camshaft adjustment no no no no
Boost-pressure control no no no no
Electronically controlled no no no no
cooling system
1) Engine version complying with exhaust emission standard EU-2 DDK only with one lambda probe before catalyst.
Interrogating control unit version

The control unit version is displayed once the vehicle sys-
tem tester -V.A.G 1552- is connected and the engine
electronics control unit is selected ⇒ 01-1 page 4.
Overview of the selectable functions on the Ve-

hicle system tester -V.A.G 1552-
The conditions under which the desired functions can be
selected are given in the following table.
Operation Precondition
Engine not running, Engine idling Normal driving
ignition switched on
01 Interrogating control unit version yes yes yes
02 Interrogating fault memory yes1) yes yes
03 Actuator diagnosis yes no no
04 Basic setting2) yes yes yes
05 Erasing fault memory yes yes no
06 Ending output yes yes yes
07 Coding control unit yes no no
08 Reading measured value block yes yes yes
11 Login procedure yes no no
15 Reading Readiness Code yes yes yes
1) When the ignition is switched on only if the engine does not start (starter must be operated first of all for at least 6 seconds).
2) To be carried out after the following operations: replacing engine control unit, throttle valve control unit or engine or disconnecting battery.
01-1 page 2 Self-diagnosis I Edition 01.05

S00.5323.03.20
Meaning of the EPC warning lamp (fault
lamp for electric accelerator control
-K132-) in the dash panel insert
„EPC“ is an English abbreviation for Electronic Power
Control which in German is written Elektronische Motor-
leistungs-Regelung (E-Gas).
Fitting location of the EPC warning lamp:
If an error is found in the EPC when running the engine
then the safety aspects of its running will be negatively in-
fluenced and the EPC warning lamp will light up on the
dash panel insert. There is a simultaneous entry in the
fault memory of the engine control unit.
Check for proper operation CHECK
– Switch on ignition.
The electronic power control fault lamp -K132- must light
up.
If the electronic power control fault lamp -K132- does not S01-0090
light up with the ignition switched on.
– Inspect the dash panel insert and the electronic power

control fault lamp -K132- ⇒ Electrical System;
Rep. Gr. 90.
If the electronic power control fault lamp -K132- lights up
when the ignition is switched on:
– Start engine and run in idle.

The electronic power control fault lamp -K132- must go
out after a few seconds.
If the electronic power control fault lamp -K132- does not
go out.
– Interrogate the fault memory of the engine control unit,

remove any faults which exist and then delete the fault
memory ⇒ 01-1 page 5.
Meaning of the exhaust gas warning light

-K83-
for engine complying with EU-4, EU-3 DDK exhaust
emission standard
If the engine control unit detects a fault which could have CHECK
a negative effect on the exhaust gases then the exhaust
gas warning light - K83- will light up on the dash panel in-
sert.
Fitting location of exhaust warning light:
CHECK
S01-0091

S00.5323.03.20
Note
♦ The exhaust warning light -K83- may flash or come on
as a steady light. The fault memory must be interro-
gated whatever happens ⇒ 01-1 page 5.
♦ Warning light flashes: There is a fault which is likely to
damage the catalytic converter in this driving condi-
tion. Only low performance driving is allowed in this
driving condition!
♦ Warning comes on as a steady light: There is a fault
which deteriorates the exhaust gas quality. Interro-
gate the fault memory of the engine control unit.
♦ There is a vehicle performance fault or the customer
is making a complaint and the exhaust warning light
-K83- does not light up so the fault memory should be
interrogated since there may be faults stored there
which do not immediately switch on the exhaust warn-
ing light -K83-.
Check for proper operation

The exhaust warning light -K83- must light up.
If the exhaust gas warning light - K83- does not come on
when the ignition is switched on:
– Check the dash panel insert and the exhaust gas

warning light -K83- ⇒ Electrical equipment; Rep. Gr.
90.
If the exhaust gas warning light - K83- comes on when
the ignition is switched on:

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

remove any faults which exist and then delete the fault
memory ⇒ 01-1 page 5.
Connecting up the vehicle system tester

-V.A.G 1552- and selecting the control
unit for engine electronics
Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• Battery voltage at least 11.5 volts
• Earth connection to engine and gearbox O.K.
• Fuses according to current flow diagram O.K.

S00.5323.03.20
Procedure
– Connect up the vehicle system tester -V.A.G 1552-
using the appropriate diagnostic cables.
– Switch on ignition or start ⇒ 01-1 page 2 engine de-
pending on the function desired.
Note 1
4
2
5
3
6
7
C
8
O
9
Q HELP V.A.G. 1552
♦ If the readout which appears in display does not

match the procedure ⇒ Operating instructions for ve-
hicle system tester.
♦ If because of an input error „data transfer fault“ is dis-
played, remove the cables from the vehicle system
tester, re-connect and repeat all the steps.
– Select the address word 0 1 „Engine electronics“

and confirm with Q .
03D906032A 1.2l/2V SIMOS 3 00HS 1501 ->
The vehicle system tester -V.A.G 1552- displays the con- Coding 00031 WSC XXXXX
trol unit identification, e.g.:
♦ 03D906032A = part no. of the control unit (for current
control unit version see spare parts catalogue)
♦ 1.2l /2V= displacement of engine and number of
valves per cylinder
♦ SIMOS 3 = system designation
♦ 00 = number of set adaptation channels
♦ HS = manual gearbox
♦ 1501 = software number
♦ Coding 00031 = coding of the control unit
♦ WSC XXXXX = workshop code from -V.A.G 1552 -
with which the last coding was performed (WSC
00000 appears provided the factory-entered coding
has not been changed)
– Press → twice.
Vehicle system test HELP
Readout on display: Select function XX
– Further procedure, see repair sequences.
Interrogating and erasing fault memory

– Select function 0 2 „Interrogate fault memory“ and
confirm with Q .
X faults detected!
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If one or several faults are stored:

Press key → to display the stored faults consecutively.
Readout on display:
Select function XX
– Select function 0 5 „Erase fault memory“ and con-
firm with Q .

S00.5323.03.20
Note
If the ignition is switched off during „Interrogating fault
memory“ and „Erasing fault memory“, the fault memory is
not erased.
Vehicle system test ->
Readout on display:
Fault memory erased!
– Select function 0 6 „End output“ and confirm with
Q.
– Rectify the faults displayed by referring to the fault ta-
ble ⇒ Chapter 01-2 and 01-3.
– Read readiness code ⇒ Chapter 01-4. If the fault
memory has been erased or if the continuous voltage
supply from the engine control unit was interrupted, it
is then necessary to re-generate the readiness code.
– Once the fault has been removed, perform a test
drive.
Note
Pay attention to safety precautions for test drives
⇒ Chapter 24-1.
During the test drive the following operating conditions
must be fulfilled:
♦ The coolant temperature should rise beyond 80°C.
♦ Once the desired temperature has been reached the
following operating conditions must be reached a
number of times:
Idling speed
partial load
enrichment
full load
overrun
♦ In case of full load the speed should be increased be-
yond 3500 rpm.
– Interrogate the fault memory on the engine control unit

again.
If no fault is stored:
– Select function 0 6 „End output“ and confirm with
Q.
Performing actuator diagnosis

With the actuator diagnosis the following parts are acti-
vated in the sequence indicated:
1. Fuel pump relay -J17-

2. Solenoid valve 1 for activated charcoal filter -N80-
For engine with engine identification characters

AZQ, BME

S00.5323.03.20
3. Exhaust gas recirculation valve -N18-
Note
♦ The actuator diagnosis can only be carried out when
the engine is not running and the ignition is switched
on.
♦ The actuator diagnosis is aborted when the engine is
started or when a signal from the rotary speed sender
is detected.
♦ The actuators are tested acoustically or by touch.
♦ If the actuator diagnosis must be repeated without the
engine being started in the meantime, switch off igni-
tion for about 40 seconds.
♦ The ignition must be switched off before starting up
the engine after the actuator diagnosis.
Test conditions
• The fuses must be OK according to the current current 1 6
11
12
17
18
23 31
24 32
flow diagram 2 7 13 19 25 33
3 8 14 20 26 34
4 9 15 21 27 35
Special tools, test and measuring equipment and 5 10 16 22 28 36
auxiliary items required 39 49 59
29 37
30 38
40 50 60
♦ Vehicle system tester -V.A.G 1552- with cable 41 51 61
-V.A.G 1551/3, 3A, 3B oder 3C- 42 52 62
43 53 63
44 54 64
Procedure 45 55 65
46 56 66
– Connect vehicle system tester -V.A.G 1552-. Switch 47 57 67
ignition on and select address word 01 „Engine elec- 48 58 68
tronics“ ⇒ Chap. 01-1. S01-0094
– Select function 0 3 „actuator diagnosis“.

Actuator diagnosis ->
Readout on display: Fuel pump relay-J17
The fuel pump relay - J17- (relay holder, relay position 4)
must continue clicking until the next control element is ac-
tuated by pressing the → .
Note
During the activation of the fuel pump relay, the fuel pump
-J17- must also be heard to run at intervals.
If the relay does not click:
– Test wiring and plug connections to the fuel pump re-

lay -J17- according to the current flow diagram.
– Press →.
Readout on display:
Solenoid valve 1 for activated charcoal fil-
The solenoid valve must continue clicking until the next
control element is actuated by pressing the → .
If the solenoid valve does not click:
– Read measured value block, display group 070

⇒ Chapter 01-6, if necessary test wiring and plug

S00.5323.03.20
connections to solenoid valve 1 for activated charcoal

filter -N80- according to wiring diagram.
– Press →.

AZQ, BME
Actuator diagnosis
Readout on display: Exhaust gas recirculation valve -N18
Valve must click until → is pressed.
If the valve does not click:
– Test wiring and plug connections to the exhaust gas

recirculation valve -N18- according to the current flow
diagram.
– Press →.
Continued for all engines

Readout on display: END
– Select function 0 6 „End output“ and switch ignition
off.

S00.5323.03.20
01-2 Self-diagnosis II
Fault codes 16496 … 16990
Note
♦ The fault table is ordered according to the fault code on the left.
♦ The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only
valid for USA).
♦ Explanations regarding fault types (e.g. „open circuit or short-circuit to earth“) ⇒ Operating instructions for the ve-
hicle system tester.
♦ If parts are output as faulty: First check all cables and connectors to these components as well as the earth con-
nections according to the Current Flow Diagram. Replace component only if these tests do not reveal any fault.
This applies in particular if a fault is shown as „sporadic“ (SP).
♦ If the vehicle system tester -V.A.G 1552 - displays „Information in the documentation“; look up the relevant text in
the fault table according to the fault code indicated.
Readout on -V.A.G 1552- Rectifying fault

16496 Signal too low – Read measured value block, display group 004, display
Intake manifold temperature field 4 ⇒ Chap. 01-5.
sender -G42
– Test resistances ⇒ Chapter 24-1.
16497 Signal too high
Intake manifold temperature – Test wiring and plug connections according to current
sender -G42 flow diagram.
16500 Implausible signal
Coolant temperature sender -
G62 – Read measured value block, display group 004, display
16501 Signal too low field 3 ⇒ Chap. 01-5.
Coolant temperature sender - – Test resistances ⇒ Chapter 24-1.
G62
– Test wiring and plug connections according to current
16502 Signal too high flow diagram.
Coolant temperature sender -
G62
16514 Electrical fault in the
Bank 1, probe 1 circuit
16515 Voltage too low
Bank 1, probe 1
16516 Voltage too large – Test lambda probe upstream of catalytic converter
Bank 1, probe 1 -G39- and lambda control ⇒ Chapter 24-3.
16517 Signal too slow
Bank 1, probe 1
16518 No activity
Bank 1, probe 1
Bank 1, probe 2 circuit
16521 Voltage too low
Bank 1, probe 2 – Test lambda probe downstream of catalytic converter
16522 Voltage too large -G130- and lambda control ⇒ Chapter 24-3.
Bank 1, probe 2
16524 No activity
Bank 1, probe 2
Edition 04.03 Self-diagnosis II 01-2 page 1

S00.5323.01.20

16555 System too lean – Test lambda probe upstream of catalytic converter
Bank 1, fuel metering system -G39- and lambda control ⇒ Chapter 24-3.
16556 System too rich – Check fuel pressure regulator and system pressure
Bank 1, fuel metering system ⇒ Chapter 24-2.
– Check the exhaust gas system for leaks (particularly
when using lambda probes).
16585 Open circuit
Injector cyl. 1 -N30
16586 Open circuit
16587 Open circuit
16645 Short circuit to earth
Injector cyl. 1 -N30 – Check the resistance values of the injectors (12...17 Ω
16646 Short circuit to posi- at approx. 20 °C).
Injector cyl. 1 -N30 tive – Test wiring and plug connections according to current
16648 Short circuit to earth flow diagram.
16649 Short circuit to posi-
Injector cyl. 2 -N31 tive
Injector cyl. 3 -N32 tive
16684
Combustion misfiring detected
– Check the resistance values of the injectors (12...17 Ω
16685
at approx. 20 °C).
Cyl. 1 combustion misfirings
detected – Test spark plugs ⇒ Chapter 28-1.
16686 – Test ignition coils with power output stage -N70-,
Cyl. 2 combustion misfirings - N127-, -N291- ⇒ Chapter 28-1.
detected
– Read measured value block, display groups 014 and
16687 015 ⇒ Chap. 01-5.
Cyl. 3 combustion misfirings
detected
– Inspecting Engine speed sender -G28- ⇒ Chap. 28-1.
Engine speed sender -G28
16706 No signal – Test wiring and plug connections according to current
Engine speed sender -G28 flow diagram.
16712 Signal too high – Read measured value block, display groups 020, 026
Knock sensor 1 -G61 and 028 ⇒ Chap. 01-5.
16719 Malfunction – Inspecting Engine speed sender -G28- ⇒ Chap. 28-1.
Engine speed sender -G28
flow diagram.
16725 Implausible signal – Read measured value block; display group 012; check
Camshaft pos. sensor => values in display fields 3 and 4 ⇒ Chapter 01-5.
Sender -G40 1)
– Inspecting camshaft position sensor -G163- ⇒ Chapter
16726 Signal too low 28-1.
Camshaft pos. sensor =>
Sender -G40 1) – Test wiring and plug connections according to current
flow diagram.
01-2 page 2 Self-diagnosis II Edition 04.03

S00.5323.01.20

16785 Flow rate too low
Exhaust gas recirculation sys-
tem – Test exhaust gas recirculation valve -N18- ⇒ Chapter
16786 Flow rate too great 01-1, final control diagnosis
Exhaust gas recirculation sys- – Adapt EGR valve -N18- ⇒ Chap. 24-5.
tem
– Test exhaust gas recirculation system ⇒ 1.2l/40; 1.2/
16788 Control difference 47 Engine, Mechanical Components; Rep. Gr. 26.
tem
16804 Efficiency too low – Read measured value block, display group 046, check
Bank 1, catalyst system values in display field 3 ⇒ Chapter 01-6.
– Inspect exhaust system for leaks or inspect for damage
if necessary between both lambda probes ⇒ 1.2/40;
1.2/47 Engine, Mechanical Components; Rep. Gr. 26.
– Perform emission test ⇒ Inspection and Maintenance.
16825 Flow rate incorrect – Test solenoid valve 1 for activated charcoal filter sys-
Tank ventilation system tem -N80- in final control diagnosis ⇒ Chapter 01-1.
– Inspect hoses and connection pipes from fuel tank up
to the throttle valve control unit ⇒ 1.2/40; 1.2/47 En-
gine, Mechanical Components; Rep. Gr. 20.
flow diagram.
16845 Implausible signal – Test fuel gauge sender -G- ⇒ Electrical System;
Fuel gauge signal Rep. Gr. 90.
– Check data BUS ⇒ Chapter 24-6.
– Test dash panel insert ⇒ Electrical System;
Rep. Gr. 90.
16885 Implausible signal – Reading measured value block, display group 005,
Vehicle speed signal checking values in display field 3 ⇒ Chap. 01-5.
– Test vehicle speed signal ⇒ Chapter 24-6.
– Test dash panel insert ⇒ Electrical System;
Rep. Gr. 90.
16890 Speed under nomi- – Test throttle valve control unit -J338- ⇒ Chapter 24-4.
Idling control nal value
– Inspect intake air system for leaks (unmetered air)
16891 Speed above nomi- ⇒ Chapter 24-2.
Idling control nal value
– Adjust the throttle valve control unit ⇒ Chapter 24-5.
16955 Implausible signal – Read measured value block, display group 066
Brake light switch -F ⇒ Chapter 01-6.
flow diagram.
16984 missing message – Check data BUS ⇒ Chapter 24-6.
Databus drive
– Read out fault memory of all control units.
Edition 04.03 Self-diagnosis II 01-2 page 3

S00.5323.01.20

16985
Control unit defective
– Replace engine control unit ⇒ Chapter 24-5.
16988
16990 – Test battery, charge if necessary ⇒ Electrical System;
Control unit defective Rep. Gr. 27.
– Delete the fault memory, undertake a test drive and re
read the fault memory ⇒ Chap. 01-1.
If the fault occurs again:

1) The camshaft position sensor - G163- is identical to the Hall sender -G40-.
01-2 page 4 Self-diagnosis II Edition 04.03

S00.5323.01.20
01-3 Self-diagnosis III
Fault codes 17040 … 18088

17040 Electrical fault in the – Check the fuel consumption signal ⇒ Electrical Sys-
Fuel consumption signal circuit tem; Rep. Gr. 90.
– Check data BUS ⇒ Chapter 24-6.
Bank 1 - probe 1, heating cir- tive – Test lambda probe upstream of catalytic converter
cuit -G39- and lambda control ⇒ Chapter 24-3.
17511 Output too low – Test wiring and plug connections according to current
Bank 1 - probe 1, heating cir- flow diagram.
cuit
17513 Short circuit to posi- – Test lambda probe downstream of catalytic converter
Bank 1 - probe 2, heating cir- tive -G130- and lambda control ⇒ Chapter 24-3.
cuit
flow diagram.
Bank 1 - probe 1, heating cir- – Test lambda probe upstream of catalytic converter
17524 Open circuit – Test wiring and plug connections according to current
cuit
Bank 1 - probe 2, heating cir- – Test lambda probe downstream of catalytic converter
17526 Open circuit – Test wiring and plug connections according to current
cuit
17549 implausible value – Inspecting air intake system for tightness (unmetered
Load detection air) ⇒ Chapter 24-2.
– Erase the fault memory and carry out test drive.
17559 Below leanness limit – Testing injection valves ⇒ Chap. 24-2.
Bank 1, mixture adaptation
range 11)
– Test fuel pump ⇒ 1.2/40, 1.2/47 Engine, Mechanics;
Rep. Gr. 20.
– Testing intake system for leaks ⇒ Chap. 24-2.
– Inspect exhaust system for leaks ⇒ 1.2/40, 1.2/47 En-
gine, Mechanics; Rep. Gr. 26.
– Test exhaust gas recirculation system ⇒ 1.2/40, 1.2/47
Engine, Mechanics; Rep. Gr. 26.
– Inspect activated charcoal filter system for leaks ⇒ 1.2/
40, 1.2/47 Engine, Mechanics; Rep. Gr. 20.
– Test lambda probe and lambda control upstream of cat-
alytic converter ⇒ Chapter 24-3.
– Test lambda probe and lambda control downstream of
catalytic converter ⇒ Chapter 24-3.
Edition 06.04 Self-diagnosis III 01-3 page 1

S00.5323.02.20

Intake manifold pressure send- tive – Read measured value block, display group 003, display
er -G71 field 2 ⇒ Chapter 01-5.
17564 Open circuit/Short- – Test wiring and plug connections according to current
Intake manifold pressure send- circuit to earth flow diagram.
er -G71
17573 Above richness limit – Testing injection valves ⇒ Chap. 24-2.
Bank 1, mixture adaptation
range 11)
Rep. Gr. 20.
– Testing intake system for leaks ⇒ Chap. 24-2.
TV drive angle sender 2 -G188
17580 Signal too low – Test throttle valve control unit -J338- ⇒ Chapter 24-4.
TV drive angle sender 2 -G188 – Adjust the throttle valve control unit ⇒ Chapter 24-5.
TV drive angle sender 2 -G188
17582 Deviation of the in- – Testing injection valves ⇒ Chap. 24-2.
Bank 1, fuel metering system1) jection periods
Rep. Gr. 20.
– Inspect air intake system for leaks ⇒ Chapter 24-2.
17584 Regulating limit – Test lambda probe upstream of catalytic converter
Bank 1, lambda correction reached -G39- and lambda control ⇒ Chapter 24-3.
downstream of cat.
– Test lambda probe downstream of catalytic converter
-G130- and lambda control ⇒ Chapter 24-3.
– Check the exhaust gas system for leaks (particularly
when using lambda probes) ⇒ 1.2/40, 1.2/47 Engine,
Mechanics; Rep. Gr. 26.
– Inspect intake air system for leaks (unmetered air)
⇒ Chapter 24-2.
01-3 page 2 Self-diagnosis III Edition 06.04

S00.5323.02.20

17586 Open circuit – Test lambda probe and lambda control upstream of cat-
Linear lambda probe/pump alytic converter ⇒ Chapter 24-3.
current1)
– Testing lambda probe heating before catalyst ⇒ Chap.
17587 Short circuit to posi- 24-3.
Linear lambda probe/pump tive
current1)
Linear lambda probe/pump tive
current1)
17589 Open circuit – Test lambda probe and lambda control upstream of cat-
Linear lambda probe/reference alytic converter ⇒ Chapter 24-3.
current1)
– Testing lambda probe heating before catalyst ⇒ Chap.
17590 Short circuit to earth 24-3.
Linear lambda probe/reference
current1) – Test ignition cables and spark plugs ⇒ Chap. 28-1.
17591 Short circuit to posi- – Test combustion misfiring, display groups 014 and 015
Linear lambda probe/reference tive ⇒ Chap. 01-5.
current1)
17598 implausible
Linear lambda probe/reference
current1)
17604 Electrical fault – Testing lambda probe heating before catalyst ⇒ Chap.
Bank 1 - probe 1, heating 24-3.
circuit1)
17658 too low – Top up the fuel tank.
Fuel level
– Delete the fault memory, undertake a test drive and re
read the fault memory ⇒ Chap. 01-1.
17743 Regulating limit ex-
– Inspecting air intake system for tightness (unmetered
Engine torque monitoring 2 ceeded
air) ⇒ Chapter 24-2.
17744 Regulating limit ex-
Engine torque monitoring ceeded – Test throttle valve control unit -J338- ⇒ Chapter 24-4.
17746 Open circuit/Short – Inspecting camshaft position sensor -G163- ⇒ Chapter
Bank1, camshaft position sen- circuit to positive 28-1.
sor => sender -G163
flow diagram.
17748 Incorrect assignment – Inspecting Engine speed sender -G28- ⇒ Chap. 28-1.
Camshaft position/crankshaft
position sensor – Inspecting camshaft position sensor -G163- ⇒ Chapter
28-1.

S00.5323.02.20

17763 Open circuit
Ignition control cyl. 1
Ignition control cyl. 1 tive
17766 Open circuit
Ignition control cyl. 2 – Test ignition coils with power output stage -N70-,
17767 Short circuit to posi- -N127-, -N291- ⇒ Chapter 28-1.
Ignition control cyl. 2 tive – Test wiring and plug connections according to current
17768 Short circuit to earth flow diagram.
17769 Open circuit
Ignition control cyl. 3 tive
17794
17795
17796
17805 Adaption limit – Inspecting Engine speed sender -G28- ⇒ Chap. 28-1.
Rotor for engine speed reached
– Check flywheel ⇒ 1.2/40, 1.2/47 Engine, Mechanics;
Rep. Gr. 13.
Exhaust gas recirculation valve
-N18
Exhaust gas recirculation valve tive
– Test EGR valve -N18- in final control diagnosis
-N18 ⇒ Chapter 01-1.
17811 Control difference

tem
17812 Basic setting not
Exhaust gas recirculation sys- performed – Adapt EGR valve -N18- ⇒ Chap. 24-5.
tem
17818 Short circuit to posi- – Test solenoid valve 1 for activated charcoal filter sys-
Tank vent valve -N80 tive tem -N80- in final control diagnosis ⇒ Chapter 01-1.
Tank vent valve -N80
– Perform actuator diagnosis ⇒ Chapter 01-1.
17834 Open circuit
Tank vent valve -N80
17847 Incorrect basic set-
Potentiometer for exhaust gas ting – Adapt EGR valve -N18- ⇒ Chap. 24-5.
recirculation -G212-
17848 Open circuit – Perform actuator diagnosis ⇒ Chapter 01-1.
Exhaust gas recirculation valve
-N18

S00.5323.02.20

17850 Signal too high – Inspect wiring and plug connections ⇒ Current Flow
EGR potentiometer -G212 Diagrams, Electrical Fault Finding and Fitting Loca-
17851 Signal too low tions.
EGR potentiometer -G212 – Test exhaust gas recirculation valve ⇒ Chapter 01-1,
final control diagnosis.
Fuel pump relay -J17
– Perform actuator diagnosis ⇒ Chapter 01-1.
Fuel pump relay -J17 tive
17925 Electrical fault in the – Check power supply relay for Simos control unit -J363-
Main relay -J217 circuit ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
– Read measured value block, display group 004, display
field 2 ⇒ Chap. 01-5.
17931 Implausible signal – Interrogate fault memory of airbag control unit and
Crash signal from airbag CU erase ⇒ Body Work; Rep. Gr. 01.
– Test airbag system ⇒ Body Work; Rep. Gr. 01.
TV drive angle sender -G187
– Test throttle valve control unit -J338- ⇒ Chapter 24-4.
17951 Signal too low
TV drive angle sender -G187 – Adjust the throttle valve control unit -J338- ⇒ Chapter
24-5.
TV drive angle sender -G187
17953 Malfunction
Throttle valve control
Throttle valve drive -G186 circuit – Adjust the throttle valve control unit -J338- ⇒ Chapter
24-5.
17967 Incorrect basic set-
Throttle valve control unit -J338 ting
17972 Undervoltage on ba- – Test battery, charge if necessary ⇒ Electrical System;
Throttle valve control unit -J338 sic setting Rep. Gr. 27.
– Adjust the throttle valve control unit -J338- ⇒ Chapter
24-5.
17973 Bottom limit not – Check throttle valve for damage or dirt.
Throttle valve control unit -J338 reached
17976 Mechanical fault
Throttle valve control unit -J338
17977 Implausible signal – Read measured value block, display group 066
Cruise control system switch - ⇒ Chapter 01-6.
E45
17978 – Adjust the engine control unit to the electronic immobi-
Engine control unit blocked 2) liser ⇒ Electrical System; Rep. Gr. 96.
– Test immobiliser ⇒ Electrical System; Rep. Gr. 96.

S00.5323.02.20

17987 Adaption not started – Read out the fault memory, and possibly Remove faults
Throttle valve control unit -J338 as necessary and erase the fault memory ⇒ Chap. 01-
1.
– One should check whether the air and coolant temper-
ature are greater than 6 °C and the coolant tempera-
ture is less than 120 °C; display group 004 ⇒ Chapter
01-5, or that the coolant can be warmed up or cooled
down.
– Adjust the throttle valve control unit ⇒ Chapter 24-5.
18010 Voltage too low – Check the battery voltage ⇒ Electrical System;
Voltage supply tml. 30 Rep. Gr. 27.
– Inspect AC generator ⇒ Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations.
– Remove line interruption according to Current Flow Di-
agram ⇒ Current Flow Diagrams, Electrical Fault Find-
ing and Fitting Locations.
18011 – Replace engine control unit ⇒ Chapter 24-5.
18017 – Interrogate fault memory of engine control unit and
Crash disconnect activated erase ⇒ Chap. 01-1.
– Test airbag system ⇒ Body Work; Rep. Gr. 01.
18020 – Code engine control unit ⇒ Chapter 24-5.
Engine control unit incorrectly
coded
18038 Signal too low
Accelerator pedal position
sender -G79
sender -G79 – Inspect accelerator pedal position sender ⇒ Chapter
18041 Signal too low 24-4.
sender -2 -G185
sender -2 -G185
18044 Missing message – Check data BUS ⇒ Chapter 24-6.
Databus drive from airbag CU
– Test airbag control unit ⇒ Body work; Rep. Gr. 01.
18047 Implausible signal – Inspect accelerator pedal position sender ⇒ Chapter
1/2 for accelerator pedal posi- 24-4.
tion sender -G79+G185
18056 defective – Check data BUS ⇒ Chapter 24-6.
Databus drive

S00.5323.02.20

Databus drive from ABS CU
– Inspecting ABS control unit - J104- ⇒ Running Gear;
Rep. Gr. 45.
Databus drive from combiinstru-
ment – Test dash panel insert ⇒ Electrical System;
Rep. Gr. 90.
18088 – Test throttle valve control unit -J338- ⇒ Chapter 24-4.
Resetting continuous emergen-
cy operation – Inspect accelerator pedal position sender ⇒ Chapter
24-4.
1) If this fault occurs the engine control unit switches on the exhaust gas warning lamp in the dash panel insert. Meaning of the exhaust gas warn-
ing lamp ⇒ Chapter 01-1
2) When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key
the fault is changed to a sporadic fault.

S00.5323.02.20

S00.5323.02.20
01-4 Self-diagnosis IV
Readiness code
Operation
The readiness code is an 8-digit numerical code which in-

dicates the status of the emission-relevant diagnoses.
If a system diagnosis (e.g. catalytic converter diagnosis)
has been performed with success, the relevant position in
the readiness code switches from 1 to 0.
This diagnosis is also undertaken during normal opera-
tion of the vehicle when the conditions for initiating a spe-
cific diagnostic function (engine speed, loading, etc.) are
fulfilled. If repairs have been completed on a system
which effect the exhaust system then it is recommended
to activate the diagnostic function (to generate the readi-
ness code) in order to check whether the system is work-
ing perfectly. If a fault is detected during diagnosis, it is
then stored in the fault memory.
The readiness code will be deleted through deletion of
the fault memory or though interruption of the power sup-
ply, that is all relevant points will be set to 1.
Generation of the readiness code means to activate the
diagnostic functions such as knocking sensor diagnosis,
diagnosis of the lamda probe before the catalytic convert-
er, etc.
Reading readiness code

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
– Select function 1 5 „Readiness code“ and confirm
with Q .
Readiness code ->
The following readout must appear in the display after 00000000 - Test complete
successfully completing all the tests:
– Press →.
– Enter function 0 6 „End output“ and confirm with Q .

Readiness code ->
Read-out on display:
00101101 - Test not complete
Not all of the tests were successful.
– Press → .
– Generate readiness code ⇒ 01-4 page 2.
Edition 01.05 Self-diagnosis IV 01-4 page 1

S00.5323.03.20
Meaning of the 8-digit numerical block of the readiness code
X X X X X X X X The tested part of the system

0 Exhaust gas recirculation (for engine with identification char-
acters AWY and BMD always 0)
0 Lambda probe heater
0 Lambda probes
0 Air conditioning system (no diagnosis at present/always 0)
0 Secondary air injection system (not available/always 0)
0 Tank ventilation system
0 Catalytic converter heater (no diagnosis at present/always 0)
0 Catalytic converter
Generating readiness code

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• Vehicle stopped.
• All electrical consumers such as e.g. lights and rear
window heater must be switched off.
• The coolant temperature must be at least 80°C
⇒ display group 004, display field 3.
• Intake air temperature less than 60°C ⇒ display
group 004, display block 4.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Pull on
the handbrake, start the engine and select address
word 01 „Engine electronics“ ⇒ Chapter 01-1.
Work step 1: Interrogating fault memory

– Enter function 0 2 „Interrogate fault memory“ and
confirm with Q .
X faults detected →
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If a fault is stored in the memory:
– Rectify the faults by referring to the fault table

⇒ Chapter 01-2 and 01-3.
If no fault is stored:
– Press →.
01-4 page 2 Self-diagnosis IV Edition 01.05

S00.5323.03.20
Work step 2: Erasing fault memory
– Enter function 0 5 „Erase fault memory“ and confirm
with Q .
Note
The readiness code is erased each time the fault memory
is erased.
Vehicle system test ->
Readout on display: The fault memory is erased
Note
If the ignition is switched off during „Interrogating fault
memory“ and „Erasing fault memory“, the fault memory is
not erased.
– Press →.
Work step only for engine with engine identifica-

tion characters AZQ, BME: Diagnosis of exhaust
gas recirculation system
– Select function 0 4 „Initiate basic setting“ and also
the display group 073.
System in basic setting 73
Readout on display: 700 rpm 18.0 % 0.0 % Test OFF
– Actuate the brake pedal and then the accelerator ped-
al. The engine control unit will begin to regulate the ex-
cessively high engine speed down to the prescribed
value. Maintain both pedals depressed until the mes-
sage shown in indicator field 4 springs from „Test
OFF“ to „Test ON“and then to „System OK“ (in the
case of a fault „System not OK“).
If the test was not successful:
– Interrogate fault memory ⇒ Chapter 01-1.

If the test was successful:
– Press C.
Work step 3: Knocking sensor diagnosis

System in basic setting 28
Readout on display:
700 rpm 19.2 % 85°C Test OFF
– Push down on the accelerator pedal a number of
times strongly but for a short time so that the engine
speed exceeds 2500 rpm, the indicator springs from
„Test OFF“ to „Test ON“ and then to „System OK“ (in
the case of a fault „System not OK“).

– Press C.

S00.5323.03.20
Work step 4: Diagnosis of ageing of lambda

probe upstream of catalytic converter
– 0 3 4 for the indicator group 034 and confirm entry
with Q.
System in basic setting 34 ->
Readout on display: 700 rpm 384.0 °C 0.00 Test OFF
value. Maintain both pedals depressed until the cata-
lytic converter temperature shown in indicator field 2
is 400 °C and the message shown in indicator field 4
springs from „Test OFF“ to „Test ON“.
Note
The test only begins when the engine has been running
for at least 2 minutes.
– Maintain both pedals depressed until the message

shown in indicator field 4 springs from „Test ON“ to
„B1-S1 OK“ (and in the case of a fault „B1-S1 not
OK“).

– Press C.
Work step 5: Catalyst diagnosis

with Q.
Readout on display:
700 rpm 500°C 0.96 Test OFF
– Maintain both pedals depressed until the prescribed
value in the in indicator field 4 indicates „Cat B1 OK“
(in the case of a fault „Cat B1 not OK“).

No fault in the fault memory:
– Conduct a test drive at a constant speed.

– Pay attention to safety precautions for test drives
⇒ Chapter 24-1.
– Conduct another catalytic converter diagnosis (check
the conversion).

S00.5323.03.20
If the same result is achieved:
– Replace the catalytic converter ⇒ 1.2 l/40; 1.2/47 En-

– Press C.
Work step 6: Diagnosis of ageing of lambda

probe downstream of catalytic converter
with Q.
Readout on display: 700/min 650.0 °C 0.85 V Test OFF
OK“).

– Press C.
Work step 7: Diagnosis tank venting valve (tank

vent system)
with Q.
Readout on display: 4.3 % 10.9 % -1.1 % Test OFF
If the diagnosis is initiated by the engine control unit the
display in display field 4 will switch from „Test OFF“ to
„Test ON“.
– Run engine at idling speed until display field 4 indi-

cates the nominal value „TVV OK“ (and in the case of
a fault „TVV not OK“).

– Press → .
– Read out readiness code ⇒ 01-4 page 1.

S00.5323.03.20

S00.5323.03.20
01-5 Self-diagnosis V
Reading measured value block

-V.A.G 1551/3, 3A, 3B oder 3C-
Safety measures
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
If the test and measuring equipment is operated from the
front passenger seat, this can result in injuries to the per-
sons sitting on that seat in the event of an accident which
involves the front passenger airbag being deployed.
Test conditions
• Coolant temperature must be at least 80 °C.
• All electrical consumers such as e.g. rear window
heater must be switched off.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
– Enter function 0 8 „Read measured value block“
and confirm the entry with Q key.
Read measured value block HELP
Readout on display:
Enter display group number XXX
– Select desired display group:
♦ Display groups 000...028 ⇒ 01-5 page 2.
♦ Display groups 030...126 ⇒ Chapter 01-6.
Note
Proceed according to the following table to switch to an-
other display group:
Display group -V.A.G 1551- -V.A.G 1552-

number
higher Press 3 Press ↑
lower Press 1 Press ↓
skip Press C Press C
Edition 01.05 Self-diagnosis V 01-5 page 1

S00.5323.03.20
– If the specifications are achieved in all the display

fields, press key → .
– 0 Press 0 6 for the function „End output“ and con-
firm with Q .
Display groups 000 to 028
Display group 000, basic function

Engine idling
Coolant temperature ≥ 80 °C
For engine with engine identification characters AWY, BMD
Read measured value block 0 → < Readout on display

x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 < Display field Specification corresponds to
Initialisation value 102...153 -10...10 %
of the fuel prepara-
tion - under partial
load
Initialisation value of 125…131 -2,25…3 ms
the fuel preparation -
when idling
Control value of the fuel 102…153 -10…10 %
preparation
Initialisation value idle stabilizer 77...179 -10...10 %
Idling regulator 51…205 -30...30 %
Throttle valve angle 2…12 1…6°
Supply voltage 125…145 12,5…14.5 V
Engine speed (idling speed) 19…26 610…830 rpm
Engine load 31...94 12...37 %
Coolant temperature 171…217 80… 115 °C
01-5 page 2 Self-diagnosis V Edition 01.05

S00.5323.03.20
For engine with engine identification characters AZQ, BME

x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 < Display field Specification corresponds to
Initialisation value 102...153 -10...10 %
of the fuel prepara-
tion - under partial
load
Initialisation value of 125…131 -2,25…3 ms
the fuel preparation -
when idling
Control value of the fuel 102…153 -10…10 %
preparation
Initialisation value idle stabilizer 77...179 -10...10 %
Idling regulator 51…205 -30...30 %
Throttle valve angle 2…12 1…6°
Supply voltage 125…145 12,5…14.5 V
Engine speed (idling speed) 18…25 580…800 rpm
Engine load 31...94 12...37 %
Coolant temperature 171…217 80… 115 °C
Analysis: Display group 000, display field 1 - coolant temperature
Display Possible cause of fault Rectifying fault

-V.A.G 1552 -
less than 171 ♦ Engine too cold – Conduct road test if necessary.
(80°C) ♦ Coolant temperature sender -G62- or ca- – Test resistances ⇒ Chapter 24-1.
ble connection to engine control unit faulty
– Test wiring and plug connections accord-
♦ Coolant regulator (thermostat) leaking
ing to current flow diagram.
– Inspect coolant regulator (thermostat) for
leaks.
greater than 217 ♦ Radiator dirty – Clean radiator.
(115°C) ♦ Radiator fan not operational – Test function of the radiator fan.
♦ Coolant regulator (thermostat) defective
– Inspect coolant regulator (thermostat).
♦ Coolant temperature sender -G62- or ca-
ble connection to engine control unit faulty – Test resistances ⇒ Chapter 24-1.
– inspecting idling speed ⇒ Chapter 24-2.

S00.5323.03.20
Analysis: Display group 000, display field 2 - engine load

-V.A.G 1552 -
less than 31 ♦ smaller values can only be shown in over-
(12 %) run conditions
♦ Unmetered air – Inspect air intake system for leaks
⇒ Chapter 24-2.
greater than 94 ♦ Poor idling (engine not running on all cyl- – Injector or spark plugs faulty.
(37 %) inders)
♦ Electrical consumers on – Switch off electrical consumers.
Analysis: Display group 000, display field 3 - engine speed (idling speed)

-V.A.G 1552-
less than 19 ♦ Throttle valve control unit -J338- defect or – Test throttle valve control unit -J338-
(610 rpm) 1) clamps up ⇒ Chapter 24-4.
less than 18
(580 rpm) 2)
less than 26 ♦ Idling not detected – Interrogate fault memory ⇒ Chapter 01-1.
(830 rpm) 1) ♦ Throttle valve control unit -J338- defect or
less than 25
– Test throttle valve control unit -J338-
clamps up ⇒ Chapter 24-4.
(800 rpm) 2)
♦ large unmetered air volume (can no long-
– Inspect air intake system for leaks
er be compensated by idle stabilizer)
⇒ Chapter 24-2.
1) for engines with engine identification characters AWY, BMD
2) For engines with engine identification characters AZQ, BME
Analysis: Display group 000, display field 4 - supply voltage

-V.A.G 1552 -
below 125 V (12.5 ♦ AC generator defective, battery heavily – Check voltage, charge battery
V) discharged ⇒ Electrical System; Rep. Gr. 27.
♦ Battery heavily loaded just after start by a – Increase engine speed slightly for a few
high charge current or by auxiliary equip- minutes and switch off additional consum-
ment ers.
♦ Transition resistance in the power supply
– Check the supply voltage of the engine
or earth connection for the engine control
control unit ⇒ Current Flow Diagrams,
unit
Electrical Fault Finding and Fitting Loca-
♦ Current consumption with ignition off tions.
– Rectify any current drain.
above 145 V (14.5 ♦ Voltage regulator on AC generator defec- – Check the AC generator ⇒ Electrical sys-
V) tive tem; Rep. Gr. 27.
♦ Overvoltage due to starting aid or quick – Interrogate fault memory ⇒ Chapter 01-1.
charger

S00.5323.03.20
Analysis: Display group 000, display field 5 - Throttle valve angle

-V.A.G 1552 -
less than 2 (1°) ♦ Potentiometer or throttle valve control unit – Test throttle valve control unit -J338-
-J338- defective or incorrectly set ⇒ Chapter 24-4.
♦ Unmetered air between the intake mani- – Inspect air intake system for leaks
fold and the air mass meter (results in a ⇒ Chapter 24-2.
higher idling speed as the throttle valve
control unit attempts to reduce the in-
creased idling speed to the nominal idling
speed)
greater than 12 (6°) ♦ Adjustment of the throttle valve control – Adjust the throttle valve control unit -J338-
unit -J338 - was not undertaken ⇒ Chapter 24-5.
♦ Potentiometer or throttle valve control unit – Test throttle valve control unit -J338-
-J338- defective or incorrectly set ⇒ Chapter 24-4.
♦ The throttle valve gets stuck
– Eliminate cause.
Analysis: Display group 000, display field 6 - idling regulator

-V.A.G 1552 -
below 51 (-30 %) ♦ Potentiometer or throttle valve control unit – Test throttle valve control unit -J338-
above 205 (30 %) -J338- defective or incorrectly set ⇒ Chapter 24-4.
– Adjust the throttle valve control unit -J338-
⇒ Chapter 24-5.
Display group 001 - setting conditions for the basic function

Engine idling

xxx xxx.x xx.x xxxxxxxx
rpm °C %
1 2 3 4 < Display field Specification Analysis
Conditions for the ba- 1x111111 ⇒ 01-5 page 6
sic setting
Lambda regulation for the cata- -15,0…15,0 % ⇒ 01-5 page 6
lytic converter
Coolant temperature 80,0…115.0°C ⇒ 01-5 page 3
Engine speed (idling speed) 610…830 1 rpm 1)580 ⇒ 01-5 page 4
…800 rpm 2)

S00.5323.03.20
Analysis: Display group 001, display field 3 - lambda control before the catalytic converter

-V.A.G 1552 -
not within tolerance ♦ Minus value: Mixture too rich, lambda – Wait 30 seconds until readout has stabi-
control leans it off lised.
♦ Plus value: Mixture too lean, lambda con-
trol enriches it
⇒ Chapter 24-2.
♦ Injection valve defective – Check the resistance values of the injec-
tors (12…17 Ω at approx. 20°C).
Analysis: Display group 001, display field 4 - conditions for the basic setting
X X X X X X X X Meaning
1 No fault detected by the self-diagnostic function
1 The catalytic converter temperature of 649 °C was reached
1 AC compressor disconnected
1 Idling detected
1 Lambda control: o.k.
1 Throttle valve closed
1 Engine speed less than 2000 rpm
1 Coolant temperature more than 80°C
Display group 002 - basic function of the injection time, inlet manifold pressure
Engine idling

xxx xxx.x x.x xxxx
rpm % ms mbar
Intake manifold pres- 270...550 mbar ---
sure
Injection period 2,0…4.0 ms ⇒ 01-5 page 7
Engine load 12,0…37,0 % ⇒ 01-5 page 4
Engine speed (idling speed) — ⇒ 01-5 page 5

S00.5323.03.20
Analysis: Display group 002, display field 3 - injection time

-V.A.G 1552 -
less than 2.0 ms ♦ high fuel volume from the activated char- – Test solenoid valve 1 for activated char-
coal filter system coal filter system -N80- in final control di-
♦ incorrect injection valve with too great agnosis ⇒ Chapter 01-1.
flow rate fitted – Test for absence of leaks and spray pat-
tern of injectors ⇒ Chapter 24-2.
above 4.0 ms ♦ Increased engine load caused by electri- – Eliminate increased engine load (AC, fog
cal consumers (air conditioning system, lights etc.)
fog lights etc.)
Display group 003 - basic function of the inlet manifold pressure, throttle valve angle
Engine idling

xxx xxxx x.x xx.x
rpm mbar % ° b. TDC
Ignition angle 0,0…15.0° b. TDC ---
Throttle valve angle 1,0…6,0 % ⇒ 01-5 page 5
Intake manifold pressure 270...550 mbar ---
Display group 004 - basic functions concerning temperature

Engine idling

xxx xx.x xxx.x xxx.x
rpm V °C °C
Intake manifold tem- -39,8…105,0 °C ⇒ 01-5 page 8
perature
Supply voltage of the engine control unit 12,5…14.5 V ⇒ 01-5 page 4

S00.5323.03.20
Analysis: Display group 004, display field 4 - intake air temperature

-V.A.G 1552 -
constant 0.0 or ♦ Open circuit in the wiring or a short circuit – Test resistances ⇒ Chapter 24-1.
39.8 °C to positive or a short circuit to earth
– Test wiring and plug connections to intake
manifold temperature sender -G42- ac-
cording to current flow diagram.
Display group 005 - engine operating condition

Press down on the accelerator pedal a number of times and let it go

xxxx xx.x xxx Text
rpm % km/h
Operating state Idling 1)
(idling, part load, en-
richment, overrun, full
throttle)
Driving speed 0 km/h ---
Engine load xx.x % ⇒ 01-5 page 4
1) Display field 4 shows the operating conditions of the engine one after the other „idling“, „partial load“, „enrichment“, „full load“ and „overrun“.
Display group 005 - checking the speed signal

Drive at a constant steady speed in 4th gear

xxxx xx.x xxx Text
rpm % km/h
Operating state Partial load ---
(idling, part load, en-
richment, overrun, full
throttle)
Driving speed > 90 km/h ---
Engine load xx.x % ---
Engine speed (idling speed) > 4000 rpm ---

S00.5323.03.20
Display group 012 - position of camshaft relative to crankshaft
Engine idling

xxx xxx.x xx xx
rpm %
No. of the crankshaft 25…31 ---
gear for camshaft
pressure change high
- low 1)
No. of the crankshaft gear for 85…91 ---
camshaft pressure change low -
high 1)
Engine load 12,0…37,0 % ⇒ 01-5 page 4
1) If the value is outside the tolerance and if fault 16725 or 17748 has been stored in the fault memory, the voltage of the timing chain must be
checked (on engines with high mileage).
Display group 014 - ignition misfiring detection

Driving

xxxx xxx xxx Text
rpm %
Misfiring detection activated ---
(activated, deactivat-
ed)
Sum of ignition misfiring x ⇒ 01-5 page 10
Engine load 0,0…100,0 % ---
Engine speed — ⇒ 01-5 page 12
Note on display field 3:

♦ The nominal value is not entered since any ignition misfirings are continuously being monitored from the engine
control unit. A fault is stored once the fault threshold is exceeded and the exhaust gas warning light begins to blink
or lights up.

S00.5323.03.20
Display group 015 - ignition misfiring detection cylinders 1 to 3

Driving

xxx xxx xxx Text
Misfiring detection activated ---
(activated, deactivat-
ed)
Ignition misfiring cylinder 3 x ⇒ 01-5 page 10
Note on display fields 1 to 3:

♦ The nominal value is not entered since any ignition misfirings are continuously being monitored from the engine
control unit. A fault is stored once the fault threshold is exceeded and the exhaust gas warning light begins to blink
or lights up.
Analysis: Display groups 014 and 015 - ignition misfiring

-V.A.G 1552 -
the fault code ♦ Spark plug defective – Test spark plugs ⇒ Chapter 28-1.
which may be gen- ♦ Ignition coils with power output stage
erated for the igni- – Test ignition coils with power output stage
-N70-, -N291-, -N127- defect -N70-, -N127-, -N291- ⇒ Chapter 28-1.
tion misfiring will be
continuously added ♦ Injection valve defective – Check the resistance values of the injector
to the fault memory (12…17 Ω at approx. 20 °C).
– Test wiring and plug connections to injec-
tors according to current flow diagram.
⇒ Chapter 24-2.
Display group 020 - Ignition angle retardation

Driving

xx.x° xx.x° xx.x°
BTDC BTDC BTDC
no display
Ignition angle relief cylinder 3 0,0…15.0 CA ⇒ 01-5 page 11
through knock control
Ignition angle relief cylinder 2 through knock 0,0…15.0 CA ⇒ 01-5 page 11
control
Ignition angle relief cylinder 1 through knock control 0,0…15.0 CA ⇒ 01-5 page 11

S00.5323.03.20
Notes on display fields 1 to 3:

♦ The value shown in indicator fields 1 to 3 are an actual value needed to reduce the ignition angle in individual cyl-
inders on the basis of the knock regulation. The ignition angle in °CA (angle of the crankshaft) in the direction "re-
tardation". The indicated values „BTDC“ (before TDC) are not be taken into account.
♦ The indicated value when idling must be 0.0 °CA.
Analysis: Display group 020, display fields 1, 2 and 3- ignition angle retardation

-V.A.G 1552 -
all cylinders a con- ♦ Knock sensor defective – Test wiring and plug connections to knock
stant 15.0° CA sensor -G61- according to current flow di-
♦ Plug connection at knock sensor corrod-
agram.
ed
♦ Knock sensor incorrectly tightened – Slacken knock sensor and tighten again to
20 Nm.
♦ Engine parts loose – Tighten loose parts.
♦ poor fuel quality – Change type of fuel used.
one cylinder differs ♦ Plug connection at knock sensor -G61- – Test wiring and plug connections to knock
significantly from corroded sensor -G61- according to current flow di-
the others agram.
♦ Engine damaged – Test compression ⇒ 1.2/40, 1.2/47 En-
gine, Mechanical Components;
Rep. Gr. 15.
♦ Engine parts loose – Tighten loose parts.
Display group 026 - Knock sensor voltage signal

Engine idling

x.xxx x.xxx x.xxx
V V V
no display ---
Knock sensor voltage signal cyl. 0,200…2.000 V ---
3
Knock sensor voltage signal cyl. 2 0,200…2.000 V ---
Knock sensor voltage signal cyl. 1 0,200…2.000 V ---

S00.5323.03.20
Display group 028 - Knock control

Fault read-out device in function 04 - basic setting
Driving
System in basic setting 28 → < Readout on display

xxxx xxx.x xxx.x Text
rpm % °C
Result of knock con- System OK ---
trol
(Test ON, Test OFF,
System OK, System
not OK)
Engine load 40…100 % ---
Engine speed 610...5820 rpm ---
1)580...6020 rpm 2)

S00.5323.03.20
01-6 Self-diagnosis VI
Reading measured value block - display groups 030 to 126
Display group 030 - lambda control

Engine idling

xxx xxx
no display ---
no display ---
Status of lambda probe after catalytic con- 11x ⇒ 01-6 page 1
verter and lamda control
Status of lambda probe before the catalytic converter 111 ⇒ 01-6 page 1
and lambda control
Analysis: Display group 030, display field 1 and

2 - status of lambda control
X X X Meaning
1 Lambda probe operational
1 Lambda controller (trim control as re-
quired) active
Display group 031 - Lambda control - lambda

learned values upstream of catalytic converter
Engine idling
AWY, BMD, BME

x.xxxx x.xxxx
no display --- ---
no display --- ---
Lambda probe voltage downstream of cata- 0,0000…1,0000 ---
lytic converter
Lambda probe voltage upstream of catalytic converter 0,0000…1,0000 ---
For engine with engine identification characters AZQ
Edition 01.05 Self-diagnosis VI 01-6 page 1

S00.5323.03.20

x.xxxx x.xxxx
no display --- ---
no display --- ---
Lambda nominal value - Bank 1 0,9900…1,0100 ---
Lambda actual value - Bank 1 0,9600…1,0400 ---
Display group 033 - Lambda control - Lambda probe upstream of catalytic converter
Engine idling

xx.x x.xx
% V
no display ---
no display ---
Lambda probe voltage upstream of catalytic 0,00…1.00 V 1) ---
converter 1.40…1.60 V 2)
Control value of the lambda control -15,0…15,0 % ⇒ Chapter 01-5
1) For engines with engine identification characters AWY, BMD, BME
2) for engines with engine identification characters AZQ
For engines with engine identification characters

AWY, BMD, BME
Note
♦ Re display field 2:
♦ Voltage signal „Mixture rich (low level of residual oxy-
gen)“ is at approx. 0.7...1.0 V.
♦ Voltage signal „Mixture lean (high level of residual ox-
ygen)“ is at approx. 0.0...0.3 V.
♦ A voltage jump from 0.7...1.0 V to 0.0...0.3 V or vice
versa takes place at the transition from „rich“ to „lean“
and vice versa (λ = 1.0).
♦ In view of the steep voltage jump the lambda control
is not able to maintain constant the ideal mixture com-
position which corresponds to λ = 1.0. The control
constantly fluctuates back and forward between the
„slightly too lean“ and „slightly too rich“ states.
♦ The displayed value falls occasionally below 0.3 V
and exceeeds 0.6 V. Displayed value below 0.45 V
means lean, over 0.45 V rich.
♦ At idling speed, the lambda probe voltage upstream of
the catalytic converter must fluctuate between a rich
and leaner mixture. The lambda probe voltage down-
stream of the catalytic converter should indicate a
constant rich or lean mixture. If the voltage also fluctu-
01-6 page 2 Self-diagnosis VI Edition 01.05

S00.5323.03.20
ates downstream of the catalytic converter, either the
catalytic converter is faulty (⇒ Read measured value
block 046 ⇒ 01-6 page 6) or the probes have been
wrongly connected (irregular engine running). Lamb-
da control varies between -15...15 %.
Voltage of the 4-pin lambda probe in U λ in mV
A: Lambda probe voltage high

rich mixture (fuel surplus or air shortage)
high CO value
B: Lambda probe voltage low
lean mixture (fuel shortage or air surplus)
low CO value
For engines with engine identification characters
AZQ
Note
♦ Re display field 2:
♦ Display 1.50 V equals approx. Lambda 1.
♦ Voltage signal „Mixture rich“ (low level of residual ox-
ygen) is at approx. 0.13...1.50 V.
♦ Voltage signal „Mixture rich“ (high level of residual ox-
ygen) is at approx. 1.50...4.80 V.
♦ Lambda probe enables through its structure constant
lambda control due to the permanent signal for the de-
viation of λ = 1.
♦ The control is dynamic, as the deviation from the
specification is current and is known as the concrete
value.
Display group 034 - diagnosis of lambda probe before catalyst (ageing test)
Engine idling

xxxx xxx.x x.xx Text
rpm °C
Result of test of lamb- B1-S1 OK ⇒ 01-6 page 4
da probe ageing up-
stream of catalytic
converter (Test OFF,
Test ON, B1-S1 OK,
B1-S1 not OK)
Disregard display --- ---
Catalytic converter temperature xxx.x °C ---
Engine speed xxxx rpm ---

S00.5323.03.20
Analysis: Display group 034, display field 4 - test result concerning lambda probe ageing before the
catalytic converter

-V.A.G 1552 -
Test OFF ♦ the test has not been activated before
and also the conditions for automatic exe- – Activate test ⇒ Chapter 01-4.
cution have not been fulfilled
B1-S1 not OK ♦ the test undertaken delivered an unsatis- – Interrogate the fault memory ⇒ Chapter
factory result 01-1.
Display group 041 - Lambda control of the lambda probe heating

Engine idling
Read measured value block 41 → ⇐ Read out on display:

— Text xxx ohms Text
1 2 3 4 ⇐ Display field Specification Analysis:
Lambda probe Ht. after c. ON
heater down- Ht. after c. OFF
—
stream of catalytic
converter
Resistance in lambda probe
heater downstream of catalyt- — —
ic converter
Lambda probe heater upstream of cata- Ht. bf. c. ON
—
lytic converter Ht. bf. c. OFF
— —
Note
Depending on the operating condition of the engine the
lambda probe heatings are switched on or off. This
means the displays in display fields 2 or 4 may indicate
either „Htg b(a)C.ON“ or „Htg b(a)C.ON/Htgb(a)C.OFF“.

S00.5323.03.20
Display group 043 - diagnosis of lambda probe after catalyst (ageing test)
Engine idling

rpm °C V
Result of ageing test B1-S2 OK ⇒ 01-6 page 5
of lambda probe
downstream of cata-
lytic converter (Test
OFF, Test ON, B1-S2
OK, B1-S2 not OK)
Lambda probe voltage down- 0,00…1.00 V ⇒ 01-6 page 5
stream of catalytic converter
Analysis: Display group 043, display field 3 - lambda probe voltage downstream of catalytic con-
verter

-V.A.G 1552 -
constant 1.10 V ♦ Short circuiting of the signal line after the
positive terminal through the lambda
probe, lambda probe cable or engine con-
trol unit
constant between ♦ Interruption of the signal or earth line
– Test lambda probe -G130 - and lambda
0.40…0.50 V through the lambda probe, probe cable or control downstream of catalytic converter
engine control unit ⇒ Chapter 24-3.
constant 0.00 V ♦ Short circuiting of the signal line after the

earth through the lambda probe, probe
cable or engine control unit
Analysis: Display group 043, display field 4 - test result concerning lambda probe ageing after the
catalytic converter

-V.A.G 1552 -
B1-S2 not OK ♦ the test undertaken delivered an unsatis- – Interrogate the fault memory ⇒ Chapter

S00.5323.03.20
Display group 046 - diagnosis of catalyst efficiency

Engine idling

rpm °C
Result of catalytic Cat B1 OK ⇒ 01-6 page 6
converter test (Test
OFF, Test ON, Cat B1
OK, Cat B1 not OK)
Catalyst efficiency 0,50…1,00 ---
Analysis: Display group 046, display field 4 - result of the catalytic converter test

-V.A.G 1552 -
Cat B1 not OK ♦ the test undertaken delivered an unsatis- – Interrogate the fault memory ⇒ Chapter
Display group 050 - increasing engine speed

Engine idling

xxx xxx Text Text
rpm rpm
Operating condition Compr. ON or Compr. ---
of the AC compressor OFF
Operating state of air condition- ON or OFF ---
ing
The engine speed (idling speed - specified ---
value)
Air-conditioning unit OFF 700 rpm 1)
670 rpm 2)
Air-conditioning unit ON 900 rpm 1)2)
The engine speed (actual value) ⇒ Chapter 01-5
Air-conditioning unit OFF 610…830 rpm 1)
580...800 rpm 2)
Air-conditioning unit ON 800...1020 rpm 1)2)

S00.5323.03.20

The specified value for the engine speed is shown which is determined by the engine control unit (the value is valid
for a coolant temperature above 80°C, for generator load below 30%, for battery voltage above 12.4 V and for oil tem-
perature (calculated) above 80 and lower than 115°C. If one of the parameters is outside this tolerance, the control
unit sets dependent on the memory an increased idling speed.
„Compr. OFF“ is always displayed on vehicles without air conditioning system.
Display group 055 - dling speed stabilisation

Engine idling

xxxx xx xx.x xxxxx
rpm % %
Operating conditions xxxxx ⇒ 01-6 page 7
Initialisation value idle stabilizer -10,0...10,0 % ---
Idling regulator 5…40 % ---
Engine speed (idling speed) --- ⇒ Chapter 01-5

♦ The display shows to what extent the idling stabilizer has »forgotten« the design-based given mean value. On a
new engine the value is in the positive region because of the higher friction, on a run-in engine it is in the negative
region.
Meaning of 5-digit numerical block
X X X X X Meaning
x No meaning
x No meaning
1 Air conditioning switched on
x No meaning
1 Air conditioning compressor on

S00.5323.03.20
Display group 060 - the EPC system

Engine idling

xx.x xx.x x Text
% %
Adaption status ADP. OK ---
(ADP runs, ADP.
o.k. or ERROR)
Adjustment status 0 ---
Throttle valve angle (potentiometer 2 xx.x % ---
-G188-)
Throttle valve angle (potentiometer 1 -G187-) xx.x % ---
Notes on display group 060:

♦ The adaptation of the throttle valve control unit occurs with the ignition switched on.
♦ The engine control unit is adjusted to the throttle valve control unit by selecting display group 060 under function
04 „Basic setting“. This adjustment must always be performed if a different throttle valve control unit (or completely
different engine) or a different engine control unit has been fitted.
♦ During adaptation the counter in display field 3 counts up to 9.
♦ If the message „ADP OK“ is not shown in display field 4 then one should interrogate the fault memory, possibly
remove the fault and then undertake adjustment of the throttle valve control unit.
Display group 062 - checking the sender for the accelerator pedal position and the throttle valve an-
gle
Ignition switched ON, engine switched off

xx.x xx.x xx.x xx.x
% % % %
Do not actuate Actuate pedal
pedal
Sender 2 for accel- 3…10 % 35,0…50,0 % ---
erator pedal posi-
tion -G185-
Sender 1 for accelerator pedal 6…20 % 67,0…97,0 % ---
position -G79-
Throttle valve angle (potentiometer 2 82,0…97,0 % 3,0…16,0 % ---
-G188-)
Throttle valve angle (potentiometer 1 -G187-) 3,0…16,0 % 82,0…93,0 % ---

♦ The potentiometers of the throttle valve control unit and of the accelerator position sensor are duplicated for safety
reasons. The engine control unit permanently inspects the correctness of the potentiometer.
♦ The value of sensor 2 for accelerator pedal position -G185- must always be half of the value of sender 1 for accel-
erator pedal position -G79-.

S00.5323.03.20
♦ The potentiometers of the throttle valve control unit contra-rotate. The value of both potentiometers together must
always be approx. 100%.
♦ The specifications stated above are not fully utilised.
Display group 066 - condition of the brake and clutch pedal switch, cruise control system (CCS)
Engine idling

xxx xxxxxxxx xxx xxxxxxxx
km/h km/h
Switch position on xxxx 1) ⇒ 01-6 page 10
the actuating lever of 0000xxxx 2)
the CCS
Driving speed (nominal), last val- x ---
ue stored by the CCS
Status of the brake and clutch pedal switch xxxxx000 1) ⇒ 01-6 page 9
xxxx1000 2)
Vehicle speed (actual value) x ---
Analysis: Display group 066, indicator field 2 - condition of the brake and clutch pedal switch
X X X X X X X X Meaning
0 not assigned
0 not assigned
0 not assigned
0 not assigned
0 for engine with engine identification characters AWY, BMD do not ob-
serve, for engine with engine identification characters AZQ, BME: 1
CCS function activated, 0 CCS function blocked
1 Actuate clutch pedal (clutch pedal switch)
1 Actuate brake pedal (brake switch)
1 Actuate brake pedal (brake switch)

S00.5323.03.20
Analysis: Display group 066, display field 4 -

switch position of CCS
X X X X Meaning
0 0 0 0 Switch -B- locked to „OFF“
0 0 0 1 Switch -B- to „OFF“ before operating point
0 0 1 1 Switch -B- to „ON“
1 0 1 1 Switch -B- to „RES“
0 1 1 1 Switch -A- pressed (switch -B- to „ON“)
Display group 070 - diagnosis of the tank venting valve

Engine idling
Coolant temperature minimum 60°C

xxx.x xx.x xx.x Text
% % %
Result of diagnosis TVV OK ---
(Test ON, Test OFF,
TVV OK, TVV not
OK)
Idling speed controller variation -5,0…5,0 % ---
during TVV diagnosis
Lambda controller variation during TVV di- -15,0…15,0 % ---
agnosis
Controlling solenoid valve 1 for the active charcoal con- 0,0…100,0 % ---
tainer
Note
TVV is the abbreviation for tank venting valve. The diagnosis can only be undertaken just once each time the engine
is started.
♦ Lambda controller variation in negative range: activated charcoal filter full.
♦ Lambda controller - variation in the positive range: activated charcoal filter empty.

S00.5323.03.20
Display group 074 - adaptation of exhaust gas recirculation valve

Ignition switched ON, engine switched off
System in basic setting 74 → < Readout on display

x.x x.x xxx.x Text
V V %
Adaption status ADP. OK ---
(ADP. runs, ADP. OK
or ERROR)
Current poti value 0,0…100,0 % ---
Max. stop 3,0…4.8 V ---
Zero position 0,3…1.5 V ---

♦ The adaptation of the exhaust gas recirculation valve occurs with the ignition on.
♦ The engine control unit is adapted to the exhaust gas recirculation valve by selecting display group 074 under func-
tion 04 „Basic setting“. This adaption must always be performed if another EGR valve (or completely different en-
gine) or another engine control unit has been installed.
Display group 075 - Exhaust gas recirculation

Engine idling
– Perform 5 short heavy accelerations up to max. speed
System in basic setting 75 → ⇐ Read out on display:

xxx mbar xxx mbar xx.x % Text
1 2 3 4 ⇐ Display field Specification Analysis:
Result: Test run/ Test System OK
OFF / Syst. O.K. / Syst. —
N.O.K.
EGR opening dimension 15...35 % —
Intake manifold pressure difference below 10 mbar —
Intake manifold pressure difference for diagnosis flow 0 mbar
—
rate

S00.5323.03.20
Display group 100 - readiness code

Engine idling

xxxxxxxx xxx.x xxx xxxxxxxx
°C s
Diagnosis status --- ---
Time since engine start --- ---
Coolant temperature 80,0…115.0°C ⇒ Chapter 01-5
Readiness code 00000000 ⇒ 01-6 page 12
Meaning of the digits in the 8-digit numerical block, display field 1 - readiness code
X X X X X X X X Tested part of the system (the readiness code will be generated when all of
the responsible locations show a "0")
0 Exhaust gas recirculation (for engine with identification characters AWY, BMD al-
ways 0)
0 Lambda probes
0 Air conditioning system (currently no diagnosis/always „0“)
0 Secondary air injection system (not available, always „0“)
0 Tank ventilation system
0 Catalytic converter heating (no diagnosis at present/always „0“)
0 Catalytic converter
Display group 125, Databus messages

Text Text Text
Status of the air con- Clima 1 ⇒ 01-6 page 13
ditioning system con-
trol unit 1)
Status of the dash panel insert Combi 1 ⇒ 01-6 page 13
Status of the ABS control unit2) ABS 1 ⇒ 01-6 page 13
---
1) Only for vehicles with an air conditioning system.
2) Only for vehicles with ABS.

S00.5323.03.20
Display group 126, Databus messages

Text Text
Status of the vehicle El. CR 1 ⇒ 01-6 page 13
voltage control unit
Status of the airbag control unit Airbag 1 ⇒ 01-6 page 13
--- --- ---
--- --- ---
Note on display groups 125 and 126:

Nominal value = 1; the control units with an active data bus are displayed.
Analysis: Display groups 125 and 126

-V.A.G 1552 -
if 0 displayed in- ♦ CAB-BUS wiring defective – Perform the automatic test sequence for
stead of 1 ♦ Databus lines CAN-BUS - control unit not all fault memories.
used
♦ Databus lines CAB-BUS - control unit de-
fective

S00.5323.03.20

S00.5323.03.20
24 – Fuel Formation, Injection
24-1 Fuel Injection System
Safety measures
Caution!
The fuel system is under pressure! Place a cloth
around the connecting point before releasing hose
connections or opening the system. Then reduce the
pressure by carefully removing the hose or cap.
Observe the following points to prevent injury to persons

and/or damage to the injection system:
♦ Do not touch or remove ignition coils with the engine
running or at start speed.
♦ Disconnect and connect wires of the injection system
and measuring device wires when the ignition is
switched off.
♦ Do not carry out engine wash unless the ignition is
switched off.
♦ Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV con-
trol unit.
♦ If the engine must be operated at start speed without
the engine starting:
– Disconnect all 4-pin plug connections from ignition

coils with a power output stage -N70-, -N127-, -N291-
⇒ Chapter 28-1.
– Disconnect all plug connections for the injectors.
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there. If the test and measuring equipment is operated
from the front passenger seat, this can result in inju-
ries to the persons sitting on that seat in the event of
an accident which involves the front passenger airbag
being deployed.
Rules of cleanliness
Pay careful attention to the following rules of cleanliness
when working on the fuel supply or fuel injection systems.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
Edition 01.05 Fuel Injection System 24-1 page 1

S00.5323.03.20
♦ Only install clean parts: Remove spare parts from

their wrapping immediately before fitting. Do not use
parts that have been stored without wrapping (e.g. in
tool cabinets etc.).
♦ When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.
♦ Electrical plug connections which have been separat-
ed: Protect from dirt and moisture. The plug connec-
tions must only be plugged in a dry condition.
Overview of fitting locations
Note
♦ Components marked with an * are tested by self-diagnosis ⇒ Chap. 01-1.
♦ Components marked with ** are tested by final control diagnosis ⇒ Chapter 01-1.
For engine with engine identification characters AWY
1 - Activated charcoal filter sys-

tem solenoid valve 1 -N80-*/**
T resistance: 22…30 Ω
2 - Injection valves -N30…N32-*
T resistance: 12…17 Ω (at ap-
prox. 20 °C)
T testing injected quantity,
leaktightness and spray pat-
tern of injectors ⇒ Chap. 24-
2
3 - Fuel pressure regulator
T inspect ⇒ Chapter 24-2
4 - Engine speed sender -G28-*
T Fitting location: on the suc-
tion side of the crankcase
5 - Intake manifold pressure
sender -G71- with intake air
temperature sender -G42-*
T Fitting location: on the intake
manifold
T resistances for intake air
temperature sender -G42-
⇒ 24-1 page 23
6 - Throttle valve control unit
-J338-*
7 - Engine control unit*
T Control unit Simos -J361-
8 - coolant temperature sender
-G62-*
T resistances ⇒ 24-1 page 24
9 - 4-pin plug connection
T Brown
T for lambda probe downstream of catalytic converter -G130- and lambda probe downstream of catalytic con-
verter -Z29-
T for engines complying with exhaust emission standard EU-4 and EU-3 DDK
24-1 page 2 Fuel Injection System Edition 01.05

S00.5323.03.20
T black
T black for lambda probe upstream of catalytic converter -G39- and lambda probe upstream of catalytic con-
verter -Z19-
11 - Camshaft position sensor -G163-*
12 - Knock sensor I -G61-*
T Fitting location: on the suction side of the crankcase
13 - Lambda probe upstream of catalytic converter -G39 -, 50 Nm*
T Pay attention to part number
T Fitting location: in the exhaust manifold
T Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chapter 24-3
14 - Ignition coils with power output stage -N70-, -N127-, -N291-*
T resistances ⇒ Chapter 28-1
15 - Earth point -19-
T on the cylinder head cover
16 - The vacuum regulating valve (PCV valve)
T for crankcase ventilation
For engine with engine identification characters BMD

2 - Injection valves -N30…N32-*
prox. 20 °C)
2
3 - Vent valve
T Vent the fuel system ⇒ 1.4/
55; 1.4/74 Engine, Mechani-
cal Components;
Rep. Gr. 20
manifold
⇒ 24-1 page 23
-J338-*
T Control unit Simos -J361 -

S00.5323.03.20
8 - coolant temperature sender -G62-*

T Brown
verter -Z29-
T for engines complying with exhaust emission standard EU-4
T black
verter -Z19-
12 - Knock sensor I - G61-*
16 - The vacuum regulating valve (PCV valve)
T sealed for northern countries

S00.5323.03.20

2 - The vacuum regulating valve
(PCV valve)
3 - Injection valves -N30…N32 -*
prox. 20 °C)
2
manifold
⇒ 24-1 page 23
-J338-*
7 - coolant temperature sender
-G62-*
T resistances ⇒ 24-1 page 24 S24-0528
T Control unit Simos -J361 -
T Brown
verter -Z29-
10 - Plug connection
T 6-pin plug connection for engine with identification characters AZQ
T 4-pin plug connection for engine with identification characters BME
T black
verter -Z19-
11 - EGR valve -N18- with EGR potentiometer -G212-*
T inspecting ⇒ Chap. 01-1
12 - Knock sensor I -G61-*

S00.5323.03.20


Fig. 1: Foot controls - installed location
1 - Clutch pedal switch -F36- 3
2 - Brake light switch -F- and Brake pedal switch -F47-
3 - Accelerator pedal position sender -G79- and accel-
erator pedal position sender 2 -G185- 2
General notes on the injection system

Repairing the ignition ⇒ Rep. Gr. 28.
The engine control unit is equipped with a self-diagnosis
system. Before commencing repairs and also for fault 1
finding, first of all interrogate the fault memory. Also
check the vacuum hoses and connections (unmetered S24-0459
air).
A minimum voltage of 11.5 V is required for perfect func-
tioning of the electrical components.
If after fault finding, repair or inspection of components
the engine starts briefly and then stops again, it is possi-
ble that the immobiliser blocks the 4AV control unit. Then
interrogate the fault memory and if necessary adapt the
control unit.
Certain inspections may cause the control unit to detect
and store a fault. It is therefore necessary to interrogate
the fault memory after having completed all inspections
and repairs, and if necessary erase ⇒ Chapter 01-1.
Safety measures ⇒ 24-1 page 1.
Cleanliless rules ⇒ 24-1 page 1.
Test data, spark plugs ⇒ Inspection and Maintenance.

S00.5323.03.20
Removing and installing parts of the injection system
Note
Components marked with an * are tested by self-diagnosis ⇒ Chap. 01-1.
1 - Engine cover with air filter

T removing and installing
⇒ 24-1 page 19
T disassembling and assem-
bling ⇒ 24-1 page 21
2 - Warm-type clamp
3 - Air intake hose
T to the lock carrier
4 - Plug connection
T only for vehicles with extend-
ed service intervals (WIV)
T 3-pin
T for the oil level/temperature
sender -G266-
5 - Intake hose
T black with a white marking
T secure with spring strap
clamps
T check for firm seating
T from fuel filter ⇒ 1.2/40; 1.2/
47 Engine, Mechanical Com-
ponents; Rep. Gr. 20
6 - Plug connection
T 2-pin
T for injection valves
-N30…N32-
7 - Cable guide
T clipped onto the intake mani-
fold
8 - 8 Nm
9 - Return-flow hose
T blue or with blue marking
T secure with spring strap clamps
T for fuel pump ⇒ 1.2/40; 1.2/47 Engine, Mechanics; Rep. Gr. 20
10 - Hose from air filter
11 - 20 Nm
12 - 15 Nm
13 - Intake manifold
T disassembling and assembling ⇒ 24-1 page 16
T coat only thread with hot bolt paste -G 052 112 A3-; hot bolt paste must not get into the slot of the probe body
T Test lambda probe upstream of catalytic converter -G39- and lambda control ⇒ Chapter 24-3
T for lambda probe upstream of catalytic converter -G39-
T 4-pin

S00.5323.03.20
T black
T Fitting location ⇒ 24-1 page 2
T for lambda probe downstream of catalytic converter -G130-
T 4-pin
T Brown
17 - Lambda probe downstream of catalytic converter -G130-, 50 Nm*
T Fitting location: downstream of catalytic converter
T Test lambda probe downstream of catalytic converter - G130- and lambda control ⇒ Chapter 24-3
T before removing, reduce pressure in cooling system if necessary
19 - Retaining clip
T check tightness
20 - Fuel rail with injection valves
21 - coolant regulator housing
T disassembling and assembling ⇒ 1.2/40; 1.2/47 Engine, Mechanical Components; Rep. Gr. 19
22 - O-ring
T replace
23 - 8 Nm
24 - 81-pin and 40-pin connector
T for control unit Simos -J361-
T only insert or remove plug when the ignition is switched off
T unlock the multi-pin connector before pulling out
T Check supply voltage ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
T replacing ⇒ Chapter 24-5
T coding ⇒ Chapter 24-5
T Adjust engine control unit to throttle valve control unit -J338- ⇒ Chapter 24-5
26 - Retaining frame
27 - 2 Nm

S00.5323.03.20
1 - Connecting hose
2 - Warm-type clamp
3 - Air filter
4 - Intake manifold
5 - Cable guide
fold
6 - Plug connection
T 3-pin
sender -G266-
7 - Plug connection
T 2-pin
-N30…N32-
8 - Intake hose
clamps
ponents; Rep. Gr. 20
10 - 10 Nm
11 - Vent valve
55; 1.4/74 Engine, Mechanical Components; Rep. Gr. 20
12 - 20 Nm
14 - Lambda probe before catalyst -G39-, 50 Nm
T 4-pin
T black
T Fitting location: ⇒ 24-1 page 2
T Test lambda probe downstream of catalytic converter -G130- and lambda control ⇒ Chapter 24-3

S00.5323.03.20
T 4-pin
T Brown
T Fitting location: ⇒ 24-1 page 2
19 - Retaining clip
T check tightness
20 - O-ring
T replace
25 - 2 Nm

S00.5323.03.20
1 - Engine cover with air filter

T removing and installing
⇒ 24-1 page 19
2 - Cable guide
fold
3 - Plug connection
T 3-pin
sender -G266-
4 - Plug connection
T 2-pin
-N30…N32-
5 - Connection for fuel supply
hose
ponents; Rep. Gr. 20.
6 - 10 Nm
8 - 20 Nm
9 - Intake manifold
10 - Lambda probe upstream of
catalytic converter -G39 -, 50 Nm*
T 6-pin for engine with identification characters AZQ
T 4-pin for engine with identification characters BME
T black
T Test lambda probe downstream of catalytic converter -G130- and lambda control ⇒ Chapter 24-3
T 4-pin
T Brown
14 - coolant temperature sender -G62 -*

S00.5323.03.20
15 - O-ring
T replace
16 - Retaining clip
T check tightness
17 - 8 Nm
19 - Retaining clip
T check tightness
23 - 2 Nm

S00.5323.03.20
Disassembling and assembling fuel distributor with injectors
Note
Components marked with an * are tested by self-diagnosis ⇒ Chap. 01-1.

hose
2 - Fuel distributor
3 - Connection for fuel return
hose
T for electrical fuel pump
⇒ 1.2/40; 1.2/47 Engine,
Mechanics; Rep. Gr. 20
4 - O-ring
T replace
T mount with a retaining clip
T before fitting O-rings moisten
lightly with clean engine oil
2
prox. 20 °C)
6 - Retaining clip
T check tightness on the injec-
tion valve and fuel distributor
7 - Connection for the pressure
hose to the air filter
8 - Fuel pressure regulator
9 - Retaining clip
T check for correct seating on the fuel pressure regulator and fuel distributor
10 - 8 Nm

S00.5323.03.20

hose
3 - O-ring
T replace
2
prox. 20 °C)
5 - Retaining clip
6 - Vent valve
cal Components;
Rep. Gr. 20
7 - Cap for vent valve
8 - Retaining clip
T pay attention to the correct
position on the supports of
the vent valve and the fuel
distributor
9 - 8 Nm

S00.5323.03.20
1 - Bleeder supports
cal Components;
Rep. Gr. 20
3 - O-ring
T replace
2
prox. 20 °C)
5 - Retaining clip
6 - Feed line
T black with a white marking
clamps
T from fuel filter
7 - 10 Nm

S00.5323.03.20
Disassembling and assembling intake manifold

1 - 8 Nm
-J338-
T when replacing the engine
control unit perform adapta-
tion ⇒ Chapter 24-5
T 6-pin plug connection
3 - O-ring
T pay attention to correct in-
stallation position
T replace
4 - From activated charcoal filter
system solenoid valve 1 -N80-
5 - From vacuum regulating
valve (PCV valve)
6 - Gasket ring
T replace
7 - 20 Nm
8 - 2 Nm
⇒ 24-1 page 23
T contacts gold-plated
10 - O-ring
T replace if damaged
11 - 15 Nm
12 - Elastic sleeve
13 - Insert
14 - Intake manifold support
15 - Gasket ring
T replace
17 - Retaining clip
18 - Intermediate piece

S00.5323.03.20
1 - 8 Nm
-J338-
3 - O-ring
T pay attention to correct in-
stallation position
T replace
4 - From activated charcoal filter
system solenoid valve 1 -N80-
5 - From vacuum regulating
valve (PCV valve)
6 - Intermediate piece
7 - Gasket ring
T replace
8 - 20 Nm
9 - 2 Nm
⇒ 24-1 page 23
11 - O-ring
12 - Retaining clip
T with integrated intermediate piece

S00.5323.03.20
1 - Intake manifold
2 - 20 Nm
-J338-
4 - 8 Nm
5 - Gasket ring
6 - Gasket ring
7 - Connecting piece
T for exhaust gas recirculation
8 - 10 Nm
9 - Gasket ring
10 - O-ring
⇒ 24-1 page 23
12 - 2 Nm

S00.5323.03.20
Removing and installing an engine cover with air filter
2 3
5 4
S24-0502
– Remove the air guide -4- from the lock carrier and the hose from the retaining clips -1-.
– Pull of hoses -2- and -3- and remove the engine cover with air filter -5-.
Installation is carried out in the reverse order.

S00.5323.03.20
– Compress the end part -arrows- and pull off the hose to the camshaft housing ventilation -1-.
– Pull off hose -2-.
– Remove engine cover with air filter -3- upwards.
Installation is carried out in the reverse order.

S00.5323.03.20
Disassembling and assembling the air filter
1 - Inlet connection
2 - Bottom part of the air filter
cover 1 2
T with regulating flap
T Inspecting intake manifold
preheating ⇒ Chapter 24-2
3 - Filter insert
4 - Top part of air filter cover
5 - 3 Nm
5
S24-0503

S00.5323.03.20
1- Connecting hose
2- Spring strap clip
3- Top part of air filter cover
4- 10 Nm
5- Air filter element
6- Air filter bottom part
7- 4 Nm
8- Intake manifold

S00.5323.03.20
1 - Bottom part of the air filter

cover
2 - Rubber bowl
3 - Filter insert
4 - Top part of air filter cover
5 - Vacuum hose
T from cylinder head cover
6 - 3 Nm
Resistances for intake air temperature

sender -G42-
The nominal value in field -A- applies for the temperature
range 0…50°C; the nominal value in field -B- applies for
the temperature range 50…100°C.
Read out examples:
♦ 20 °C is within the range -A- and equals a resistance
of 2.3…2.6 kΩ.
♦ 80 °C is within the range -B- and equals a resistance
of 290…330 Ω.

S00.5323.03.20
Check resistance values for the intake air temperature

sender -G42- between the contacts 1 + 2.
4 1
Resistances for the coolant temperature S24-0497

sender -G62-
The nominal value in field -A- applies for the temperature
range 0…50°C; the nominal value in field -B- applies for
the temperature range 50…100°C.
Read out examples:
♦ 30 °C is within the range -A- and equals a resistance
of 1.5…2.0 kΩ.
♦ 80 °C is within the range -B- and equals a resistance
of 275…375 Ω.

S00.5323.03.20
24-2 Testing components
Testing lines and components with test

box -V.A.G 1598/31-
⇒ 1.4/55; 1.4/74 Engine, Fuel Injection; Rep. Gr. 24
Inspecting the injection rate, tightness

and jet formation of the injectors
♦ Remote control, e.g. -V.A.G 1348/3A-
♦ Adapter, e.g. -V.A.G 1348/3-2-
♦ Digital potentiometer, e.g. -V.A.G 1630-
♦ Measuring tool set, e.g. -V.A.G 1594 A, B oder C-
♦ Measuring cylinder, e.g. -V.A.G 1602-
♦ Torque wrench
Test condition
• Check that the fuel pump relay is OK ⇒ Chapter 01-1,
final control diagnosis
• Check that the fuel pump is OK ⇒ 1.4/55; 1.4/74 kW
Engine, Mechanics; Rep. Gr. 20
• Fuel temperature 15...20 °C, fuel must conform to the
valid standards
Test sequence
– If necessary remove engine cover with air filter
⇒ Chapter 24-1.
– Remove the fuel rail together with the installed injec-
tors ⇒ Chapter 24-1. Fuel hoses remain connected.
Testing jet formation and tightness

– Unplug connector at coolant temperature sender
-G62- ⇒ Chapter 24-1.
– Connect up the digital potentiometer with auxiliary
lines on both contacts of the plug connection and set
to the connected side 15 kΩ. V.A.G 1630
1
S24-0342
Edition 01.05 Testing components 24-2 page 1

S00.5323.03.20
– Hold a small vessel under the injection valve to be

tested and disconnect the plug connection from the
other injection valves.
– Operate the starter (a second person is needed here).
The injection valve must emit a pulsed jet of fuel.
– Repeat test at the other injectors. Always check that it
is only the checked valve which is connected up.
– After this inspect injectors for leaks. No more than 2
drops/min may trickle out.
If the fuel loss is greater than this:
– Switch off ignition.

– Replace the defective injection valve ⇒ Chapter 24-1.
S24-0498
Testing fuel injected quantity
Note
When testing the injection rate also check the jet forma-
tion. It must be the same for all valves.
– Insert injector to be tested in a measuring cylinder.

– Connect one contact of injector to the battery earth.
– Connect the second contact of the injector to the re-
mote control.
– Connect terminal to battery positive terminal.
– Connect the battery positive terminal and the fuse

holder No. 61 via the adapter cables to the adapter
-V.A.G 1348/3-2-. 11 17 23 31
1 6 12 18 24 32
2 7 13
The fuel pump must run. 3
19 25 33
8 14 20 26 34
4 9 15 21 27 35
– Operate remote control for 30 seconds. 5 10 16 22 28 36
39 29 37
– Repeat test at the other injectors. Always use new 49 59
30 38
40 50 60
measuring cylinder. 41 51 61
– Once all the injectors have been driven, position all 42 52 62
43 53 63
the measuring cylinders on an even base. 44 54 64
– Disconnect voltage supply for fuel pump. 45 55 65
46 56 66
– Compare the individual quantities of fuel injected. 47 57 67
48 58 68
For engine with engine identification characters S01-0094
AWY, BMD
Specified value: 74...80 ml per valve.
AZQ, BME
Specified value: 77...83 ml per valve.
For all vehicles
If the measurement obtained for one or several injectors
is not within the specification:
24-2 page 2 Testing components Edition 01.05

S00.5323.03.20
– Replace the defective injection valve ⇒ Chapter 24-1.
Installation of the injector occurs in reverse order. Pay at-
tention to the following:
♦ Replace the O-rings and all the injectors and moisten
lightly with clean engine oil.
♦ Insert injectors vertically and into the correct position
in the fuel rail and secure with retaining clips.
♦ Fit fuel distributor with the secured injection valves
onto the cylinder head and and screw up at the same
time ⇒ Chapter 24-1.
Testing fuel pressure regulator and hold-

ing pressure
The fuel pressure regulator regulates the fuel pressure in
the injection rail in line with the intake manifold pressure.

♦ Pressure gauge e.g. -V.A.G 1318-
♦ Adapter e.g. -V.A.G 1318/9-
♦ Adapter e.g. -V.A.G 1318/17-
Test condition 1 2
• Delivery of fuel pump o.k., testing ⇒ 2.0/85 Engine,
Mechanical Components; Rep. Gr. 20.
Test sequence
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
S24-0499
– Disconnect the connection of the fuel supply hose -1-
(with white marking) and catch fuel leaking out with
cloth.
V.A.G 1318/17
– Connect up the pressure gauge -V.A.G 1318- with
adapter -V.A.G 1318/9 - and -V.A.G 1318/17- to the
feed line the hose to the fuel rail.
– Open shut-off cock of the pressure measuring device.
Level in position -A-.
– Measure fuel pressure.
Specified value: approx. 0.3 MPa (3 bar)
If the specified value is reached:

V.A.G 1318/17

S00.5323.03.20
– Test for leaks and holding pressure. Observe pres-

sure drop at gauge. A pressure of at least 0.2 MPa
(2.0 bar) must be indicated on the gauge after 10 min-
utes.
If the pressure drops below 0.2 MPa (2 bar):

– Switch off the ignition after the pressure increase. At V.A.G 1318/17
the same time close the shut-off cock at the pressure
measuring device (lever in position -B-).
– Observe pressure drop at gauge.
If the pressure does not drop:
– Test non-return valve of fuel pump ⇒ 2.0/85 kW En-

If the pressure again drops:
– Open the shut-off cock of the pressure gauge appli-

ance - V.A.G 1318- (lever in position -A-). V.A.G 1318/17
– Switch off the ignition after the pressure increase. At
the same time press together the return-flow hose
firmly.
If the pressure does not drop:
– Replace fuel pressure regulator.

If the pressure drops:
– Inspect connections, O-rings, injectors and fuel dis-

tributor for leaks.
– Inspect pressure measuring device for leaks.
Note
Before taking off the pressure measuring device, place
cleaning cloths around the loose hoses of the feed line.
AZQ, BMD, BME
Inspecting the operating and holding pressure of the fuel,
inspecting the non-return valve of the fuel pump ⇒ 1.4/
55; 1.4/74 Engine, Mechanical Components;
Rep. Gr. 20.
Testing intake manifold preheating

AWY, BME

♦ Cooling spray
Testing control flap

– Remove engine cover with air filter ⇒ Chapter 24-1.

S00.5323.03.20
– Check position -1- of the regulating flap.

AZQ, BME
1
S24-0504
– Check position of the regulating flap -1-.

♦ The flap must close off the warm air connection when
the temperature exceeds 23 °C.
♦ The flap must open the warm air connection when the
temperature is below 10°C.
Note
The operation of the thermo-element -2- can easily be
tested by spraying on a cooling spray.
Inspect intake system for leaks (unme-

tered air)
⇒ 1.0/37; 1.4/44; 1.4/50 Engine, fuel injection;
Rep. Gr. 24
Testing idling speed

⇒ 1.0/37; 1.4/44; 1.4/50 Engine, fuel injection;
Rep. Gr. 24

S00.5323.03.20

S00.5323.03.20
24-3 Lambda control

The lambda probe compares the oxygen content of the
air with the residual oxygen in the exhaust gas and sup-
plies a voltage signal to the control unit.
There is only one lamda control but it uses two lamda
probes whereby the second one is for the so-called „trim
control“ and serves for diagnostic purposes.
Further information can be found in the self-study pro-
grammes:
• Self-study programme 46
• SSP 39 - Euro-On-Board-Diagnosis
Testing lambda probe -G39- and lambda

control upstream of catalytic converter
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Handheld multimeter (e.g. -V.A.G 1715-)
♦ Measuring tool set (e.g. -V.A.G 1594 A, B oder C-)
Test conditions
• Fuel pump relay O.K., inspecting ⇒ Chap. 01-1, final 11 17 23 31
control diagnosis 1 6 12 18 24 32
2 7 13
• Fuse No. 9 OK
19 25 33
3 8 14 20 26 34
4 9 15 21
• Coolant temperature must be at least 80 °C
27 35
5 10 16 22 28 36
29
• No leaks in exhaust system between catalytic convert- 39 49 59 37
30 38
40 50 60
er and cylinder head 41 51 61
42 52 62
43 53 63
Test sequence 44 54 64
45 55 65
For engine with engine identification characters 46 56 66
AWY, BMD, BME 47 57 67
48 58 68
Check the function of lambda probe upstream of the cat- S01-0094
alytic converter -G39- and the lamda control function
„Reading measured value block“, check indicator groups
030 and 033 ⇒ Chapter 01-6.
If the specified values are not reached: 1
– Disconnect the 4-pin plug connector from the lambda
probe -G39- -arrow-.
– Measure the resistance using a hand-held multimeter 1 4
between contacts 1 + 2 of the plug connection -1-. 1 4
2
Note
At ambient temperature (approx. 20 °C) the heating ele-
ment resistance is of approx. 1 to 5 Ω. The resistance in-
creases considerably even if the temperature rises only S24-0500
slightly.
Edition 01.05 Lambda control 24-3 page 1

S00.5323.03.20
Replace the lambda probe -G39- if an open circuit is de-

tected.
– Check the supply voltage or lines to the lambda probe

heating -Z19- according to the current diagram.
If the resistance and the supply voltage are OK:
– Connect handheld multimeter for voltage measure-

ment to contacts 3 + 4 of plug connector -2-. 1
– Start-up the engine and measure the voltage.
♦ Specified value: 0.40...0.50 V
– Switch off ignition. 1 4

If the specified value is reached: 1 4
– Replace lambda probe -G39- ⇒ 1.2/40; 1.2/47 En- 2
If the specified value is not reached:
– Test wiring and plug connections according to current S24-0500

flow diagram.
If no fault was found:

For engine with engine identification characters AZQ
Check the function of lambda probe upstream of the cat-
alytic converter -G39- and the lamda control function
„Reading measured value block“, check indicator groups
030, 031, 033 and 041 ⇒ Chapter 01-6.
If the specified values are not reached:

probe -G39-.
– Measure the resistance using a hand-held multimeter
between contacts 3 and 4 of the plug connection -1-.
Note
creases considerably even if the temperature rises only
slightly.
Replace the lambda probe - G39- if an open circuit is de-
tected.

heating -Z19- according to the current diagram.

ment to contacts 1 + 5 of plug connector -2-.
– Start engine and measure supply voltage.
24-3 page 2 Lambda control Edition 01.05

S00.5323.03.20
– Replace lambda probe -G39- ⇒ 1.2/40; 1.2/47 En-


flow diagram.
Testing lambda probe -G130- and lamb-

da control downstream of catalytic con-
verter
Note
There is only one lamda control but it uses two lamda
probes whereby the lamda control after the catalytic con-
verter is for the so-called „trim control“ (improvement con-
trol) and serves for diagnostic purposes. It takes priority
over the lambda control upstream of the catalytic convert-
er.

11 17 23 31
♦ Vehicle system tester -V.A.G 1552- with cable 1 6 12 18 24 32
2 7 13 19
-V.A.G 1551/3, 3A, 3B oder 3C- 3 8
25 33
14 20 26 34
♦ Handheld multimeter (e.g. -V.A.G 1715-) 4 9 15 21 27 35
5 10 16 22 28 36
♦ Measuring tool set (e.g. -V.A.G 1594 A, B oder C-) 39 49 59
29 37
30 38
40 50 60
41 51 61
Test conditions 42 52 62
43 53 63
• Fuel pump relay O.K., inspecting ⇒ Chap. 01-1, final 44 54 64
control diagnosis 45 55 65
46
• Fuse No. 9 OK
56 66
47 57 67
• Coolant temperature must be at least 80 °C 48 58 68

S01-0094
• No leaks in exhaust system between catalytic convert-
er and cylinder head
Test sequence
Check the function of lambda probe -G130- and the lam-
da control downstream of catalytic converter with the
function „Reading measured value block“, indicator
groups 030 and 043 ⇒ Chapter 01-6.
1 4
– Switch off ignition. 1 4
probe -G130- -arrow-.
– Measure the resistance using a hand-held multimeter
between contacts 1 + 2 of the plug connection -1-. 1 2 S24-0501

S00.5323.03.20
Note
creases considerably even if the temperature rises only
slightly.
If there is an interruption, replace the lambda probe after
catalyst -G130-.

heating downstream of the catalytic converter -Z29-
according to the current diagram.

ment to contacts 3 + 4 of plug connector -2-.
– Start-up the engine and measure the voltage.

1 4
– Replace lambda probe downstream of catalytic con- 1 4
verter -G130- ⇒ 1.2/40; 1.2/47 Engine, Mechanical
Components; Rep. Gr. 26.
1 2 S24-0501
flow diagram.
Test of ageing of lambda probe upstream

of catalytic converter -G39-
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• Fuel pump relay O.K., inspecting ⇒ Chap. 01-1, final 1 6
11
12
17
18
23 31
24 32
control diagnosis 2 7 13 19 25 33
3 8 14
• Fuse No. 9 OK
20 26 34
4 9 15 21 27 35
5 10 16 22 28
• Coolant temperature must be at least 80 °C 39 49 59
29
36
37
30 38
• No leaks in exhaust system between catalytic convert- 40
41
50 60
51 61
er and cylinder head 42 52 62
43 53 63
44 54 64
Check for proper operation 45 55 65
46 56 66
– Connect vehicle system tester -V.A.G 1552-. Start en- 47 57 67
gine and select the address word 01 „Engine electron- 48 58 68
ics“ ⇒ Chapter 01-1. S01-0094

S00.5323.03.20
– Enter function 04 „Basic setting“ and select display
group 034.
Note
The test only begins when the engine has been running
for at least 2 minutes.

OK“).
If „B1-S1 not OK“ is shown in display field 4:
– Conduct a test drive in order to eliminate any residues

on the lambda probe and repeat the test.
– Pay attention to safety precautions for test drives
⇒ Chapter 24-1.
If the nominal values are again not reached:
– Replace lambda probe upstrem of catalytic converter

-G39- ⇒ Engine 1.2/40; 1.2/47 Engine, Mechanical
Components; Rep. Gr. 26.

S00.5323.03.20

S00.5323.03.20
24-4 Electronic Power Control

(electronic throttle)
Function of the Electronic Throttle Sys-

tem
⇒ 1.0/37; 1.4/44; 1.4/50 engine - fuel injection.;
Rep. Gr. 24
Testing throttle valve control unit -J338-

The housing of the throttle valve control unit -J338- con-
tains the following components:
♦ Throttle valve drive -G186-. What we are dealing with
here is an engine control unit controlled electric motor.
This electric motor opens the throttle valve against a
spring force.
♦ Angle sender 1 for the throttle valve drive -G187-
♦ Angle sender 2 for the throttle valve drive -G188-
Note
♦ The housing of the throttle valve control unit -J338-
must not be opened.
♦ The angle senders are designed a potentiometers
(variable resistors). The senders indicate the position
of the throttle valve on the engine control unit fully in-
dependently from one another.
♦ The potentiometers cannot be mechanically adjusted.
The setting is undertaken with the vehicle system test-
er -V.A.G 1552- in function 04 „Initiate basic setting“.

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Hand multimeter (e.g. -V.A.G 1715-)
♦ Adapter cable set (e.g. -V.A.G 1594 A- or
-V.A.G 1594 C-)
Test conditions
• The throttle valve must neither be damaged nor soiled
• The coolant temperature must be at least 80 °C
Test sequence
– The functional test of the throttle valve control unit
-J338- can be tested with the function „Read meas-
ured value block“, display group 062 ⇒ Chapter 01-6.

– Disconnect plug connection of the throttle valve con-
trol unit -J338 - ⇒ Chapter 24-1.
Edition 04.02 Electronic Power Control (electronic throttle) 24-4 page 1

S00.5323.00.20
– Measure the resistance of the throttle valve drive on

the throttle valve control unit - J338- between contacts 1 3 5
3 + 5.
Specified value: 1…5 Ω
– Replace throttle valve control unit -J338-.

– Test voltage supply ⇒ 24-4 page 2 and cables to

throttle valve control unit -J338-. Pay special attention
to the plug connections that may be loose or corroded.
Testing the voltage supply to the throttle valve S24-0346

2 4 6
control unit -J338 -
– Disconnect plug connection of the throttle valve con-
trol unit -J338 - ⇒ Chapter 24-1.
– Connect up the hand multimeter and measure the 2 4 6
voltage being applied according to the following pro-
cedure:
6-pin plug connection Specification

on the wiring loom, con-
tact
2 + earth approx. 4.5 V
2+6 approx. 4.5 V 5
If the specified values are reached:
– Afterwards test the wiring from the engine control unit

to the throttle valve control unit -J338- ⇒ Current Flow 1 3 A24-0139
Diagrams, Electrical Fault Finding and Fitting Loca-
tions.
– Check the cable guide from the engine control unit to

the throttle valve control unit -J338- ⇒ Current Flow
Diagrams, Electrical Fault Finding and Fitting Loca-
tions.
If no fault is found:
Testing Accelerator pedal position send-

er
The two accelerator pedal position senders -G79- and
-G185- are located on the accelerator pedal and pass on
the driver input to the engine control unit completely inde-
pendently of each other (when accelerator is depressed).
Both senders are located in the same housing.
24-4 page 2 Electronic Power Control (electronic throttle) Edition 04.02

S00.5323.00.20
-V.A.G 1551/3, 3A, 3B oder 3C-
-V.A.G 1594 C-)
Functional test
– The functional test of the accelerator pedal position
sender can be undertaken with the function „Read
measured value block“, display group 062 ⇒ Chapter
01-6.
– Test the voltage supply ⇒ 24-4 page 3 and the wiring

of the accelerator pedal position sender .
Testing the power supply of the accelerator ped-

al position sender
– Remove lower part of the dash panel insert (on the
driver's side) ⇒ Body work; Rep. Gr. 70.
– Disconnect the plug connectors of the accelerator
pedal position sender.
– Connect up the hand multimeter and measure the
voltage being applied according to the following pro-
cedure:

tact
1+5 approx. 4.5 V
2+3 approx. 4.5 V
If the specified values are reached:
– Subsequently test the wiring from the engine control

unit to the accelerator pedal position senders
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
– Test the wiring from the engine control unit to the ac-
celerator pedal position senders ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations.
Edition 04.02 Electronic Power Control (electronic throttle) 24-4 page 3

S00.5323.00.20
24-4 page 4 Electronic Power Control (electronic throttle) Edition 04.02

S00.5323.00.20
24-5 Engine control unit
Operation
After analysing the input signals the engine control unit
controls the:
♦ injection
♦ Lambda control
♦ Ignition
♦ Tank ventilation
♦ Electronic power control
♦ Self-diagnosis
Replacing engine control unit

-V.A.G 1551/3, 3A, 3B nebo 3C-
Procedure
tronics“ ⇒ Chapter 01-1.
03D906032A 1.2l/2V SIMOS 3 00HS 1501 ->
The vehicle system tester -V.A.G 1552 - displays the Coding 00031 WSC XXXXX
control unit identification, e. g.:
– Note Part No. of control unit and coding.

– Select function 06 „End output“ and confirm entry with
Q.
Removing
– Release the plug locks and unplug the plug connector
of the engine control unit.
– Press of the clips -arrows- and pull out the engine con-
trol unit to the side.
Installing
Installation undertaken in the reverse order.
After installing the engine control unit, carry out the fol-
lowing steps:
– Code the engine control unit ⇒ 24-5 page 2.

– Adapt the engine control unit to the immobilizer con-
trol unit ⇒ Electrical System; Rep. Gr. 96.
– Undertake adjustment of the throttle valve control unit S24-0373
-J338 - ⇒ 24-5 page 3.
– Generate readiness code ⇒ Chapter 01-4.
Edition 04.03 Engine control unit 24-5 page 1

S00.5323.01.20
– Adapt solenoid valve for exhaust gas recirculation

⇒ 24-5 page 3.
– Interrogate fault memory of the engine control unit and
erase fault memory, rectify any faults stored
⇒ Chapter 01-1.
– Perform a test drive.
Note
Pay attention to safety precautions for test drives
⇒ Chapter 24-1.
During this test drive the following conditions must be ful-
filled:
♦ The coolant temperature should rise beyond 80°C.
♦ Once the desired temperature has been reached the
following operating conditions must be reached a
number of times:
Idling speed
partial load
enrichment
full load
overrun
♦ At „full load“ engine speed must be increased to more
than 3500 rpm.
– Interrogate the fault memory of the engine control unit

again.
Coding engine control unit

If the code displayed does not match the vehicle, or if the
control unit has been replaced, it is then necessary to
code the control unit as follows.

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
– Select function 07 „coding control unit“.
Coding control unit
Readout on display:
Enter code number xxxxx (0-32767)
– Enter code number by referring to table of codes and
confirm entry with Q key.
24-5 page 2 Engine control unit Edition 04.03

S00.5323.01.20
Table of codes:
Code number Combination

00001 Manual gearbox
00011 Gearbox + ABS
00021 Gearbox + airbag
00031 Gearbox + ABS + airbag
00041 Gearbox + air conditioning
00051 Gearbox + air conditioning + ABS
00061 Gearbox + air conditioning + airbag
00071 Gearbox + air conditioning + ABS + airbag
The vehicle system tester -V.A.G 1552 - displays the 03D906032A 1.2l/2V SIMOS 3 G00HS 3553 ->
control unit identification, e. g.: Coding 00031 WSC XXXXX
– Press → key.
– Select function 06 „End output“ and confirm entry with
Q.
Note
♦ The engine control unit stores the entered and dis-
played coding only after the ignition has been
switched off for at least 25 seconds. Incorrect coding
results in:
♦ poor driveability (jerking when changing gears, load
alteration shock etc.)
♦ Increase in fuel consumption
♦ Increase in pollution
♦ Storage of non-existent faults in fault memory
♦ Functions not being performed (lambda control, actu-
ation of the active charcoal filter system, etc.)
♦ Reduction of the gearbox life
Adjusting the engine control unit to the

throttle valve control unit -J338-
⇒ 1.0/37; 1.4/44; 1.4/50 Engine - fuel injection;
Rep. Gr. 24
Adapting EGR valve

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

S00.5323.01.20
Test conditions
• No fault in fault memory, interrogating fault memory
⇒ Chap. 01-1
• Battery voltage at least 11.5 volts
• Throttle valve must be in the idling position
Procedure
After pressing the Q key, the adaptation is carried out au-

tomatically.
Readout on display: 0.8 V 3.8 V 2.7 % ADP runs
– Check desired adaptation value in display field 4.
Specified value: ADP. OK
– By pressing the → key, end the basic setting of the

engine.
Activating and deactivating cruise con-

trol system (CCS)
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• No fault in fault memory, interrogating fault memory
⇒ Chap. 01-1
Procedure
03E906033L 1.2l/4V SIMOS3 G00HS4726
Readout on display: Coding 00061 WSC XXXXX
If „G00HS“ is displayed the CCS is activated.
03E906033L 1.2l/4V SIMOS3 00HS4726
Readout on display: Coding 00231 WSC XXXXX
If „00HS“ is displayed the CCS is not activated.
– → Press.
– Select function 1 1 „Login procedure“ and confirm
entry with Q .
Login procedure
Readout on display: Enter code number XXXXX

S00.5323.01.20
– Enter code number as stated in the following table:
11463 Activate CCS

16167 Deactivate CCS
– Confirm with Q.
– 0 6 Press for the function „End output“ and confirm

with Q .
After the CCS is activated, conduct a test drive as an op-
erational check.

S00.5323.01.20

S00.5323.01.20
24-6 Testing auxiliary signals
Testing the speed signal

⇒ 1.0/37; 1.4/44; 1.4/50 Engine - Fuel Injection.;
Rep. Gr. 24
Checking the data BUS

⇒ 1.0/37; 1.4/44; 1.4/50 Engine - Fuel Injection;
Rep. Gr. 24
⇒ Electrical System; Rep. Gr. 90
Edition 04.02 Testing auxiliary signals 24-6 page 1

S00.5323.00.20
24-6 page 2 Testing auxiliary signals Edition 04.02

S00.5323.00.20
28 – Ignition System
28-1 Ignition System
General notes on the ignition system

♦ The engine control unit is equipped with a self-diagno-
sis system.
♦ A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to inter-
rogate the fault memory after having completed all
inspections and repairs, and if necessary delete.
♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops again, it
is possible that the immobiliser blocks the 4AV control
unit. Then interrogate the fault memory and if neces-
sary adapt the control unit.
Work safety rules

⇒ Chapter 24-1
Removing and installing ignition system
Note
Components marked with an * are tested by self-diagno-
sis ⇒ Chap. 01-1.
Edition 04.03 Ignition System 28-1 page 1

S00.5323.01.20
1 - Ignition coils with power out-

put stage -N70-, -N127-,
-N291-* 1 2 3 4
T pull out with extractor
-T10094-
2 - Plug connection
T for iIgnition coils with power
output stage -N70-, -N127-,
-N291-
T 4-pin
3 - Plug connection
T for knock sensor -G61- 5
T 2-pin
4 - 20 Nm
T The tightening torque influ- 13 6
ences the knock sensor func-
tion
5 - Knock sensors -G61-*
6 - 8 Nm 7
7 - Plug connection
T for camshaft position sensor 12
-G163-
T 3-pin 9 8
8 - Camshaft position sensor
-G163-*
T check ⇒ 28-1 page 3 10
9 - O-ring
T replace 11
T for engine speed sender S28-0132
-G28-
T 3-pin
T check ⇒ 28-1 page 4
12 - 8 Nm
13 - Spark plug, 20…30 Nm
T type and electrode gap ⇒ Inspection and Maintenance
T use spark plug wrench (e.g. -3122 B-) for removing and installing
28-1 page 2 Ignition System Edition 04.03

S00.5323.01.20
Resistance values for ignition coils with
power output stages -N70-, -N127-,
-N291-
The resistance is checked between contacts 2 + 3.
Specified value: 370...410 Ω (at approx. 20 °C)
4 1
Inspecting the camshaft position sensor
-G163-
The camshaft position sensor -G163- indicates the igni-
tion position for cylinder 1.
If it fails the knock control is deactivated and the ignition
angle is slightly reduced as a cylinder assignment is no
longer possible.
Without the signal from the camshaft position sensor the
S28-0133
engine runs on and can be started again:
♦ In the event of a fault detection the engine control unit
generates an ignition spark in each cylinder for each
crankshaft rotation.
♦ There is no noticeable effect on the injection if there is
a displacement of an engine revolution. The injection
takes place in front of the closed inlet valve instead of
in the opened inlet valve. This only has a very slight in-
fluence on the quality of the mixture formation.
Note
♦ The camshaft position sensor -G163- is identical to
the Hall sender -G40-.
♦ The correct setting of the timing can be checked in
measured value block 012 ⇒ Chapter 01-5.

-V.A.G 1594 C -)
Test sequence
– Pull out the plug of the camshaft position sensor
-G163- ⇒ Chapter 24-1, overview of fitting locations.
– Connect the hand multimeter and measure the volt-
age being applied according to the following proce-
dure:

tact
1+3 approx. 4.5 V
1 2 3
S97-1357
Edition 04.03 Ignition System 28-1 page 3

S00.5323.01.20
– Test wiring ⇒ Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations
Testing Engine speed sender -G28-

-V.A.G 1594 C -)
Test sequence
– Pull out the plug connection on the engine speed
sender -G28- ⇒ Chapter 24-1, overview of fitting loca-
tions.
– Connect the hand multimeter and measure the volt-
age being applied according to the following proce-
dure:

tact
1+3 approx. 4.5 V
– Test wiring ⇒ Current Flow Diagrams, Electrical Fault 1 2 3

Finding and Fitting Locations.
S97-1357
28-1 page 4 Ignition System Edition 04.03

S00.5323.01.20

Skoda Fabia 2000 Workshop Manual Engine Fuel Injection

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Skoda Fabia 2000 Workshop Manual Engine Fuel Injection

Uploaded by

Copyright:

Available Formats

Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 01.05 List of Supplements

List of Supplements Edition 01.05

24 – Fuel Formation, Injection

Edition 01.05 Table of Contents I

Lambda control ......................................................................................... 24-3 page 1

Table of Contents Edition 01.05

Edition 01.05 Self-diagnosis I 01-1 page 1

Technical data of self-diagnosis

Engine identification char- AWY BMD AZQ BME

Interrogating control unit version

Overview of the selectable functions on the Ve-

01-1 page 2 Self-diagnosis I Edition 01.05

Check for proper operation CHECK

– Inspect the dash panel insert and the electronic power

– Start engine and run in idle.

– Interrogate the fault memory of the engine control unit,

Meaning of the exhaust gas warning light

Edition 01.05 Self-diagnosis I 01-1 page 3

Check for proper operation

– Check the dash panel insert and the exhaust gas

– Start engine and run in idle.

– Interrogate the fault memory of the engine control unit,

Connecting up the vehicle system tester

01-1 page 4 Self-diagnosis I Edition 01.05

♦ If the readout which appears in display does not

– Select the address word 0 1 „Engine electronics“

Interrogating and erasing fault memory

If one or several faults are stored:

Edition 01.05 Self-diagnosis I 01-1 page 5

– Interrogate the fault memory on the engine control unit

Performing actuator diagnosis

1. Fuel pump relay -J17-

For engine with engine identification characters

01-1 page 6 Self-diagnosis I Edition 01.05

3. Exhaust gas recirculation valve -N18-

– Select function 0 3 „actuator diagnosis“.

– Test wiring and plug connections to the fuel pump re-

– Read measured value block, display group 070

Edition 01.05 Self-diagnosis I 01-1 page 7

connections to solenoid valve 1 for activated charcoal

For engine with engine identification characters

– Test wiring and plug connections to the exhaust gas

Continued for all engines

01-1 page 8 Self-diagnosis I Edition 01.05

Fault codes 16496 … 16990

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

Edition 04.03 Self-diagnosis II 01-2 page 1

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

01-2 page 2 Self-diagnosis II Edition 04.03

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

Edition 04.03 Self-diagnosis II 01-2 page 3

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

– Replace engine control unit ⇒ Chapter 24-5.

01-2 page 4 Self-diagnosis II Edition 04.03

01-3 Self-diagnosis III

Fault codes 17040 … 18088

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

Edition 06.04 Self-diagnosis III 01-3 page 1

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

01-3 page 2 Self-diagnosis III Edition 06.04

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