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Service
Workshop Manual
FABIA 2000
1.4/55 ; 1.4/74 Engine - Fuel Injection
Edition 08.99
Engine code
The Workshop Manual is intended only for use within the Organisation koda.
It is not permitted to pass it on to other persons.
KODA AUTO a. s.
Service
FABIA 2000
1.4/55 ; 1.4/74 Engine - Fuel Injection
Edition 08.99
Supplement
Subject
Article Number
08.99
Basic Edition
S00.5309.00.20
07.00
S00.5309.01.20
03.01
S00.5309.02.20
06.02
S00.5309.03.20
06.04
S00.5309.04.20
Edition 06.04
S00.5309.04.20
Edition
List of Supplements
List of Supplements
Edition 06.04
S00.5309.04.20
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1
page
page
page
- Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the
dash panel insert ...................................................................................... 01-1
page
page
- Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for
engine electronics ..................................................................................... 01-1
page
- Interrogating and erasing fault memory of engine control unit ................................. 01-1
page
page
page
page
page
page
page
page
page
page
page
page
page
page
page
- Measured value blocks, display groups 001...006 - Basic functions .......................... 01-5
page
page
page
page
- Measured value blocks, display groups 030...049, 099 - Lambda control .................... 01-6
page
page
page
- Measured value blocks, display groups 050...069 - Speed control ............................ 01-7
page
- Measured value blocks, display groups 070...075 - exhaust gas recirculation .............. 01-7
page
- Measured value blocks, display group 100 - readiness code .................................. 01-7
page
page
page
- Installed location overview for engines with the engine codes AUA, AUB ................... 24-1
page
- Installed location overview for engines with the engine codes BBY, BBZ, BKY ............. 24-1
page
page
page
page
page 10
page 11
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Table of Contents
page 12
page 13
page
page
page
page
page
page
page
page
page
- Testing the intake system for tightness (unmetered air) ........................................ 24-3
page
page
page
page
page
- Testing lambda probe and lambda control upstream of catalytic converter .................. 24-4
page
page
- Testing lambda probe and lambda control after catalyst ........................................ 24-4
page
page 10
page 11
page
- Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-5
page
page
page
page
page
- Adjusting the engine control unit to the throttle valve control unit ............................. 24-5
page
page
page
page
- Test brake light switch -F- and brake pedal switch -F47- ....................................... 24-6
page
page
page
page
page
page
page
page
- Removing and installing parts of the ignition system for engines with the engine codes AUA,
AUB ...................................................................................................... 28-1
page
- Removing and installing parts of the ignition system for engines with the engine codes BBZ,
BBY, BKY ............................................................................................... 28-1
page
page
page
- Checking the ignition transformer (for engines with the engine codes AUA, AUB) ......... 28-1
page
28 Ignition System
II
Table of Contents
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page 8
page 11
page 13
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Table of Contents
III
IV
Table of Contents
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01
01 Self-diagnosis
01-1
Self-diagnosis I
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Self-diagnosis I
01-1 page 1
01
Equipment
AUA, AUB
BBY, BBZ
BKY
MARELLI 4LV
MARELLI 4MV
MARELLI 4TV
Yes
Yes
Yes
Self-diagnosis
Yes
Yes
Yes
Actuator diagnosis
Yes
Yes
Yes
Permanent memory1)
Permanent memory1)
Permanent memory1)
Volatile memory2)
Volatile memory2)
Volatile memory2)
2 probes
2 probes
2 probes
1 Knock sensor
1 Knock sensor
1 Knock sensor
No
No
No
Camshaft adjustment
No
No
No
Boost-pressure control
No
No
No
No
No
No
Yes
Yes
Yes
System denomination
Exhaust limits conforming to
Fault memory
Memory for initialisation values
Lambda control
Knock control
1)
2)
Functions available when using the vehicle system tester -V.A.G 1552Note
The preconditions for selecting the desired functions are
given in the following table.
Operation
Function on the vehicle system tester
-V.A.G 1552 01
02
03
Actuator diagnosis
Precondition
Engine not running, ignition
switched on
Engine idling
Normal driving
yes
yes
yes
yes1)
yes
yes
yes
no
no
04
Basic
setting2)
yes
yes
yes
05
yes
yes
yes
06
Ending output
yes
yes
yes
07
yes
no
no
08
yes
yes
yes
15
yes
yes
yes
1)
2)
Only to be carried out with the ignition switched on and if the engine does not start (activate starter for at least 6 seconds).
To be carried out after the following operations: replacing of engine control unit, throttle valve control unit, exhaust gas recirculation valve or
engine or disconnecting of battery. The air conditioning and the ACF system are automatically switched off in function 04.
01-1 page 2
Self-diagnosis I
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01
Functional test:
CHECK
S01-0090
Note
The exhaust warning light may flash or come on as a
CHECK
S01-0091
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Self-diagnosis I
01-1 page 3
01
a fault which deteriorates the exhaust gas quality. Interrogate the engine control or the automatic gearbox
fault memory.
If there is a driving behaviour problem or a customer
Functional test:
Test conditions
Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
56 and 61 must be o.k.
1
2
3
4
5
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
01-1 page 4
Self-diagnosis I
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01
Procedure
7
C
HELP
V.A.G. 1552
2615 ->
WSC XXXXX
control unit version see spare part catalogue)89MARELLI 4LV = description of system and
version
which the last coding was performed (WSC 00000 appears provided the factory-entered coding has not
been changed)
Note
If the control unit version displayed does not corre-
jolts etc.)
Increase in fuel consumption
Increase in pollution
Storage of non-existent faults in fault memory
Impossibility of performing certain functions (lambda
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Self-diagnosis I
01-1 page 5
01
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics
01-1 page 4.
Only if the engine does not start:
X faults detected
If no fault is stored:
Press
key.
HELP
Note
If the ignition was switched off between Interrogate fault
memory and Erase fault memory, the fault memory is
not erased.
Erase the fault memory and then carry out a test drive.
During the test drive the following operating conditions
must be fulfilled:
The coolant temperature should rise beyond 80C.
Once this temperature is reached, the following oper-
01-1 page 6
Self-diagnosis I
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01
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1715 Diode test lamp e.g. -V.A.G 1527B Measuring tool set e.g. -V.A.G 1594C Current flow diagram
Test conditions
Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
56 and 61 must be o.k.
1
2
3
4
5
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
1)
Ignore
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Self-diagnosis I
01-1 page 7
01
Note
The actuator diagnosis can only be carried out when
Procedure
Actuator diagnosis
Throttle valve positioner-V60
->
Q.
Readout on display:
The throttle valve positioner should open and close the
throttle valve until the next actuator is activated by pressing key
.
If the throttle valve does not move:
Press
key.
Actuator diagnosis
->
Sol.valve 1 for act. char.filter -N80
Readout on display:
The solenoid valve (on right, at suspension strut dome)
must continue clicking until the next control element is actuated by pressing the
key.
Blow into the auxiliary hose during the final control diagnosis (in the direction of the throttle valve control
unit). The valve must open and close.
If the solenoid valve does not click:
01-1 page 8
Self-diagnosis I
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01
Press
key.
Readout on display:
Actuator diagnosis
Exhaust gas recirculation valve -N18
->
Actuator diagnosis
Engine speed sender -G28
->
Actuator diagnosis
Fuel pump relay-J17
->
The exhaust gas recirculation valve (left engine compartment at cylinder head) must click until the next actuator is
activated by pressing
key.
If the exhaust gas recirculation valve does not click:
Press
key.
Readout on display:
Press
key.
Readout on display:
The fuel pump relay (on the relay plate) must be activated
and deactivated until the next control element is actuated
by pressing the
key.
Note
During activation of the fuel pump relay the fuel pump
should also be heard to run at intervals. The door contact
switch must not be actuated during the test.
If the relay does not click:
Press
key.
Readout on display:
Edition 06.04
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Actuator diagnosis
->
Engine/air cond.compr.electr.connect.
Self-diagnosis I
01-1 page 9
01
S01-0092
Check wiring between the test box and the 2-pin plug
for interruption according to the Current Flow Diagram:
Plug contact
64
01-1 page 10
Self-diagnosis I
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01
Unplug the 6-pin plug from the exhaust gas recirculation valve -N18- -arrow- (on the front left cylinder
head).
Check wiring between the test box and the 6-pin plug
for interruption according to the Current Flow Diagram:
Plug contact
114
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Self-diagnosis I
01-1 page 11
01
01-1 page 12
Self-diagnosis I
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01
01-2
Self-diagnosis II
Readiness code
Reading Readiness Code
Operation
The readiness code is an 8-digit numerical code that provides information on the status of the emission-relevant
diagnosis.
If the diagnosis for a system (e.g. tank ventilation system)
was successfully performed, the relevant position of the
numerical code is set from 1 to 0.
This diagnosis is performed at regular intervals during
normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate
the readiness code as this guarantees that the systems
operate according to the specifications. If a fault is detected during the diagnosis it is entered in the fault memory.
The readiness code is erased if the fault memory is
erased or if there is an interruption to the voltage supply.
Special tools, test and measuring equipment and
auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
Procedure
Readiness code
00000000 - Test complete
Press
key.
Generate readiness code 01-2 page 2.
Meaning of the 8-digit numerical block of the readiness code
The readiness code is only generated if all the display positions show 0
1
8
0
0
0
0
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Diagnosis function
Catalytic converter
Catalytic converter heater (no diagnosis at present/always 0)
Activated charcoal filter system
Secondary air injection system (no diagnosis at present/always 0)
Self-diagnosis II
01-2 page 1
01
The readiness code is only generated if all the display positions show 0
0
0
Test conditions
Vehicle stationary
On vehicles with an automatic gearbox the selector lever must be in position P or N.
All electrical consumers such as lights and rear window heater switched off
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Work step 1: Interrogating fault memory
X faults detected
Press
key.
01-2 page 2
Self-diagnosis II
->
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01
Note
The readiness code is reset or erased each time the
Press
key.
Note
The engine must not be readjusted during the work sequence.
Work step 3: Activated charcoal filter system diagnosis
TEV O.K.
Press
C key.
30
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Self-diagnosis II
01-2 page 3
01
Note
The 3rd bit in display field 2 is only set to 1 under partial
load (2500...4000 rpm).
Maintain speed between 20003000 rpm until display in display field 4 switches from Test OFF to
Test ON. Catalytic converter temperature in display
field 2 must be at least 300 C.
Further maintain speed between 2000...3000 rpm until the nominal result of the test CatB1 o.k is displayed in display field 4.
Note
It may also take a few minutes until the readout is
changed from Test ON to Cat B1 o.k.
If the specified values are not reached:
Press
C key.
01-2 page 4
Self-diagnosis II
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01
75
Test OFF
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Self-diagnosis II
01-2 page 5
01
01-2 page 6
Self-diagnosis II
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01-3
01
Self-diagnosis III
on the dash panel insert by the fault lamp for the electronic accelerator control EPC warning lamp).
Faults related to the exhaust are indicated by the ex-
memory Chapter 01-1 and re-generate the readiness code Chapter 01-2.
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Self-diagnosis III
01-3 page 1
01
Rectifying fault
16496
Intake manifold temperature
sender -G72-1)
16497
Intake manifold temperature
sender -G72-1)
Read measured value block, display group 004, display field 4 Chapter 01-5
Implausible signal
16500
Sender for the coolant temperature -G62-1)
Read measured value block, display group 001, display field 2 Chapter 01-5
Test coolant thermostat 1.4/55; 1.4/74 Engine Mechanical Components; Rep. Gr. 19
16505
Throttle valve potentiometer
-G69-1)
Implausible signal
16506
Throttle valve potentiometer
-G69-1)
16507
Throttle valve potentiometer
-G69-1)
16514
Bank 1 probe 11)
16518
Bank 1 probe 11)
No activity
16519
Bank 1, probe 1
16520
Bank 1 probe 21)
16521
Bank 1 probe 21)
01-3 page 2
Self-diagnosis III
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01
Rectifying fault
16522
Bank 1 probe 21)
16524
Bank 1 probe 21)
No activity
16525
Bank 1 probe 21)
Malfunction
16554
Bank 1, fuel metering system1)
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4
24-4
16585
Injector cyl. 1 -N30-2)
16586
Injector cyl. 2 -N31-2)
16587
Injector cyl. 3 -N32-2)
16588
Injector cyl. 4 -N33-2)
16603
16605
Angle sender 2 for TV drive
-G188-1)2)
Implausible signal
16606
Angle sender 2 for TV drive
-G188-1)2)
16607
Angle sender 2 for TV drive
-G188-1)2)
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Chapter 01-7
Self-diagnosis III
01-3 page 3
01
Rectifying fault
16611
Sender for accelerator pedal
position -G79-1)2)
16612
Sender for accelerator pedal
position -G79-1)2)
16646
Injector cyl. 1 -N30-1)
16649
Injector cyl. 2 -N31-1)
16652
Injector cyl. 3 -N32-1)
16655
Injector cyl. 4 -N33-1)
166841)
Combustion misfiring
detected
Chapter 01-7
16685
Cylinder 11)
Combustion misfiring
detected
16686
Cyl. 21)
Combustion misfiring
detected
16687
Cyl. 31)
Combustion misfiring
detected
16688
Cyl. 41)
Combustion misfiring
detected
16705
Engine speed sender -G28-1)
Implausible signal
16706
Engine speed sender -G28-1)
No signal
16708
Knock control
16709
Knock sensor 1 -G6116710
Knock sensor 1 -G61-
Malfunction
Implausible signal
16711
Knock sensor 1 -G61-
16712
Knock sensor 1 -G61-
01-3 page 4
Self-diagnosis III
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01
Rectifying fault
16725
Camshaft position sensor
sender -G40-1)
Implausible signal
16726
Camshaft position sensor
sender -G40-1)
16727
Camshaft position sensor
sender -G40-1)
16735
Ignition control cyl. 11)
Malfunction
16736
Ignition control cyl. 21)
Malfunction
16737
Ignition control cyl. 31)
Malfunction
16738
Ignition control cyl. 41)
Malfunction
16785
Exhaust gas recirculation
system1)
16786
Exhaust gas recirculation
system1)
16787
Exhaust gas recirculation
valve -N18-1)
Malfunction
16788
Exhaust gas recirculation
system1)
Control difference
16791
Potentiometer for exhaust gas
recirculation -G212-1)
16792
Potentiometer for exhaust gas
recirculation -G212-1)
16804
Bank 1, catalytic converter
system1)
Test exhaust gas recirculation valve -N18 Chapter 01-1, final control diagnosis
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4
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Self-diagnosis III
01-3 page 5
01
Rectifying fault
16827
Tank ventilation valve -N80-1)
16828
Tank ventilation valve -N80-
Open circuit
16829
Tank ventilation valve -N80-
Short circuit
16845
Fuel level signal
Implausible signal
16885
Vehicle speed signal1)
Implausible signal
Remove open circuit in wiring or short circuit according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
16897
Engine control unit
Blocked
16916
Pressure sensor for air conditioning system
16917
Pressure sensor for air conditioning system
16946
Voltage supply
16947
Voltage supply
16955
Brake light switch -F-
Implausible signal
Chapter 24-6
16988
Control unit defective1)
16989
Control unit defective1)
16990
Control unit defective2)
16991
Throttle valve control unit
-J338-2)
Undervoltage on basic
settings
17022
Throttle valve control unit
-J338-1)2)
Implausible signal
Chapter 24-5
17029
Air conditioning system inlet/
outlet
17034
Exhaust gas warning light
-K83-
17040
Fuel consumption signal
01-3 page 6
Self-diagnosis III
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01
Rectifying fault
Short circuit to positive
Remove short-circuit according to Current Flow Diagram Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
17513
Bank 1, probe 2 heating
circuit1)
17523
Bank 1, probe 1 heating
circuit1)
17524
Bank 1, probe 1 heating
circuit1)
Open circuit
17526
Bank 1, probe 2 heating
circuit1)
Open circuit
17550
Load detection
Below limit
Chapter 24-5
17559
Bank 1, mixture adaptation
range 11)
17560
Bank 2, mixture adaptation
range 21)
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4
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Self-diagnosis III
01-3 page 7
01
Rectifying fault
17563
Intake manifold pressure
sender -G71-1)2)
17564
Intake manifold pressure
sender -G71-1)2)
17566
Intake manifold pressure
sender -G71-1)2)
Implausible signal
1)
2)
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 warning lamp Chapter 01-1
If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp
Chapter 01-1
01-3 page 8
Self-diagnosis III
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01
01-4
Self-diagnosis IV
Rectifying fault
17573
Bank 1, mixture adaptation
range 11)
17574
Bank 1, mixture adaptation
range 21)
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4
17579
Angle sender 2 for TV drive
-G188-1)2)
Implausible signal
17580
Angle sender 2 for TV drive
-G188-1)2)
17581
Angle sender 2 for TV drive
-G188-1)2)
17582
Deviation of the injecBank 1, fuel metering system1) tion periods
Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4
Regulating limit
17584
Bank1, lambda correction ac- reached
cording to catalytic converter1)
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Self-diagnosis IV
01-4 page 1
01
Rectifying fault
17586
Linear lambda probe/pump
current1)
Open circuit
17587
Linear lambda probe/pump
current1)
17588
Linear lambda probe/pump
current1)
17589
Linear lambda probe/reference voltage1)
Open circuit
17590
Linear lambda probe/reference voltage1)
17591
Linear lambda probe/reference voltage1)
17598
Linear lambda probe/reference voltage1)
implausible
17604
Bank 1, probe 1, heating
circuit1)
Electrical fault
17606
Bank 1, probe 2, heating
circuit1)
Electrical fault
17621
Injector cyl. 1 -N30-1)
17622
Injector cyl. 2 -N31-1)
17623
Injector cyl. 3 -N32-1)
17624
Injector cyl. 4 -N33-1)
17645
Injector cyl. 1 -N30-1)
Open circuit
17646
Injector cyl. 2 -N31-1)
Open circuit
17647
Injector cyl. 3 -N32-1)
Open circuit
17648
Injector cyl. 4 -N33-1)
Open circuit
17661
Fuel consumption signal
17662
Fuel consumption signal
17743
Engine torque monitoring 21)2)
01-4 page 2
Self-diagnosis IV
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01
Rectifying fault
17745
Bank 1, camshaft pos. sensor
-G40-
17746
Bank 1, camshaft pos. sensor
-G40-
17749
Ignition outlet 11)
17750
Ignition outlet 11)
17751
Ignition outlet 21)
17752
Ignition outlet 21)
17756
Ignition outlet 11)
Open circuit
17757
Ignition outlet 21)
Open circuit
17763
Ignition control cyl. 1
Open circuit3)
ing to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
17764
Ignition control cyl. 1
17765
Ignition control cyl. 1
17766
Ignition control cyl. 2
Open circuit3)
17767
Ignition control cyl. 2
17768
Ignition control cyl. 2
17769
Ignition control cyl. 3
Open circuit3)
17770
Ignition control cyl. 3
17771
Ignition control cyl. 3
17772
Ignition control cyl. 4
Open circuit3)
17773
Ignition control cyl. 4
17774
Ignition control cyl. 4
17793
Control unit defective1)
Remove short-circuit according to Current Flow Diagram Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
17796
Control unit defective1)2)
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Self-diagnosis IV
01-4 page 3
01
Rectifying fault
17806
Engine speed signal, TD
17807
Engine speed signal, TD
17809
Exhaust gas recirculation
valve -N18-1)
17810
Exhaust gas recirculation
valve -N18-1)
17811
Exhaust gas recirculation
system1)
Control difference
17812
Basic setting not perExhaust gas recirculation sys- formed
tem
17818
Tank ventilation valve -N80-1)
17833
Tank ventilation valve -N80-1)
17834
Tank ventilation valve -N80-1)
Open circuit
17847
Potentiometer for exhaust gas
recirculation -G212-1)
17848
Exhaust gas recirculation
valve -N18-1)
Open circuit
17850
Potentiometer for exhaust gas
recirculation -G212-1)
17851
Potentiometer for exhaust gas
recirculation -G212-1)
17909
Fuel pump relay -J17-
17910
Fuel pump relay -J17-
17912
Air intake system2)
Leak detected
Remove open circuit in wiring or short circuit according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check the EGR valve 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26.
Test fuel pump relay -J17- Chapter 01-1, final control diagnosis
Test fuel pump relay Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
17949
Fuel pump relay -J17-
Open circuit
17950
Angle sender for TV drive
-G187-2)
Implausible signal
01-4 page 4
Self-diagnosis IV
Edition 06.04
S00.5309.04.20
01
Rectifying fault
17951
Angle sender for TV drive
-G187-1)2)
17952
Angle sender for TV drive
-G187-1)2)
17953
Throttle valve control 1)2)
Malfunction
17961
Level sender/intake manifold
pressure signal2)
implausible ratio
17962
Throttle valve control unit
-J338-2)
17967
Throttle valve control unit
-J338-1)2)
17968
Maximum engine speed exceeded
17972
Throttle valve control unit
-J338-2)
Chapter 24-5
Undervoltage on basic
settings
17973
Throttle valve control unit
17977
CCS switch -E45-
Implausible signal
17978
Engine control unit blocked1)2)
18010
Voltage supply tml. 30
18019
Fault lamp requirement on
Chapter 24-5
24-5
18020
Engine control unit
Edition 06.04
S00.5309.04.20
Incorrectly coded
Self-diagnosis IV
01-4 page 5
01
Rectifying fault
Open circuit/Short circuit to positive
18034
Data BUS drive
18038
Sender for accelerator pedal
position -G79-1)2)
18039
Sender for accelerator pedal
position -G79-1)2)
18041
Sender 2 for accelerator pedal
position -G185-1)2)
18042
Sender 2 for accelerator pedal
position -G185-1)2)
18043
Data BUS drive
18044
Data BUS drive
24-2
Rep. Gr. 01
18045
Data BUS drive
18047
Sender 1/2 for accelerator
pedal position -G79- +
-G185-2)
Implausible signal
24-2
18048
Control unit defective1)
24-5
18049
Read out fault memory of air
conditioning CU
18056
Data BUS drive
defective
18057
Data BUS drive
18058
Data BUS drive
18060
Read out fault memory of
gearbox CU
01-4 page 6
Self-diagnosis IV
Edition 06.04
S00.5309.04.20
01
Rectifying fault
18061
Read out fault memory of ABS
CU
18062
Read out fault memory of the
combi-instrument
Rep. Gr. 45
18064
Air conditioning system inlet/
outlet
18065
Air conditioning system inlet/
outlet
18081
Vehicle speed signal
18087
Open circuit
Fault lamp for electr. accelerator control -K132-1)
18097
Databus drive
Implausible message
from electron. CU
18099
Exhaust gas warning light
-K83-
Open circuit
18100
Exhaust gas warning light
-K83-
18101
Exhaust gas warning light
-K83-
1)
2)
3)
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 warning lamp Chapter 01-1.
If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp
Chapter 01-1.
The faults related to the "ignition control..." regarding the cables between the engine control unit and the power output stage in the ignition coil,
with which the power output stages are actuated by the engine control unit.
Edition 06.04
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Self-diagnosis IV
01-4 page 7
01
01-4 page 8
Self-diagnosis IV
Edition 06.04
S00.5309.04.20
01
01-5
Self-diagnosis V
Test conditions
The coolant temperature must be at least 80C display group 004, display field 3.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Note
Display group number 004 is an example to represent the
sequence.
4
41 C
Note
Proceed according to the following table to switch to another display group:
Edition 06.04
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Self-diagnosis V
01-5 page 1
01
Display
group
-V.A.G 1551-
-V.A.G 1552-
higher
3 Press key
Press key
lower
1 Press key
Press key
skip
C Press key
C Press key
Engine idling
1
xxxx rpm
xx.x C
xx.x %
xxxxxxxx
Display field
Specification
Analysis:
Setting requirements
10111111
01-5 page 2
-15...15 %
01-5 page 8
80...110 C
01-5 page 3
01-5 page 3
650...850 rpm1)
660...860 rpm1)
580...780 rpm1)
740...940 rpm1)
580...780 rpm1)
1)
Meaning if display = 1
1
8
1
1
1
1
1
01-5 page 2
Meaning
Coolant temperature more than 80C
Engine speed less than 2000 rpm
Throttle valve closed
Lambda control o.k.
Operating state - idling
Self-diagnosis V
Edition 06.04
S00.5309.04.20
01
Meaning
AC compressor disconnected
Catalyst hot (over 300 C)
1
1
Display
field
Readout
on display:
Rectifying fault
less than
nominal
value
greater
than
nominal
value
24-2
Air filter element very dirty
Display
field
Readout
on display:
Rectifying fault
less than
80 C
Chapter 24-2
greater
than 110
C
Radiator dirty
Radiator fan not operational
Clean radiator
Inspect proper operation Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
Engine idling
Edition 06.04
S00.5309.04.20
Self-diagnosis V
01-5 page 3
01
xx %
x.x ms
xxx mbar
Specification
Analysis:
Intake manifold
pressure
240...420 mbar
01-5 page 4
2.0...4.0 ms
01-5 page 4
10...20 %
01-5 page 8
xxxx rpm1)
01-5 page 3
Injection period
Engine load
Engine speed (idling speed)
1)
Display
field
Readout
on display:
Rectifying fault
less than
2.0 ms
rate fitted
greater
than 4.0
ms
steering etc.)
rate fitted
Display
field
Readout
on display:
Rectifying fault
less than
240 mbar
greater
than 420
mbar
box)
Engine loaded by auxiliary equipment
Engine idling
01-5 page 4
Self-diagnosis V
Edition 06.04
S00.5309.04.20
01
xx
xx
Specification
Analysis:
Ignition angle
0...10 BTDC
0...11
01-5 page 8
240...420 mbar
01-5 page 4
xxxx rpm1)
01-5 page 3
Engine idling
Read measured value block
xxxx rpm
xx.x V
xxx C
xxx C
Specification
Analysis:
Intake manifold
temperature
-40...120 C
01-5 page 6
80...110 C
01-5 page 6
12.5...14.5 V
01-5 page 6
xxxx rpm1)
01-5 page 3
Coolant temperature
Supply voltage of the engine control unit
Engine speed (idling speed)
1)
Note
Re display field 3:
As soon as a fault concerning the coolant temperature
value. The nominal value must be higher than the ambient temperature.
Edition 06.04
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Self-diagnosis V
01-5 page 5
01
Display
field
Readout
on display:
Rectifying fault
less than
12.5 V
charged
Battery heavily loaded just after start by a
greater
than 14.5
V
Chapter 24-5
charger
Display
field
Readout on
display:
Rectifying fault
greater
than 110
C
Radiator dirty
Radiator fan not operational
Clean radiator
Inspect proper operation Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
constant
- 40 C
constant
120 C
01-5 page 6
Self-diagnosis V
Edition 06.04
S00.5309.04.20
01
Display
field
Readout on
display:
Rectifying fault
constant
- 40 C
constant
120 C
Engine idling
Read measured value block
xxxx rpm
xx %
xxx km/h
Text
Driving speed
Engine load
Engine speed (idling speed)
1)
Specification
Analysis:
Idling
0 km/h
10...20 %
01-5 page 8
rpm1)
01-5 page 3
xxxx
Engine idling
6
xx %
xxx C
xx.x %
Specification
Level correction
factor
-30,0...5,0 %
Analysis:
-40...120 C
01-5 page 7
10...20 %
01-5 page 8
rpm1)
01-5 page 3
xxxx
Note
Re display field 3:
The overall temperature range is indicated as nominal
value. The display value must be higher than the ambient temperature.
Edition 06.04
S00.5309.04.20
Self-diagnosis V
01-5 page 7
01
Engine idling
Read measured value block
10
xxxx rpm
xx %
xx %
xx.x
Specification
Analysis:
0...10.0 BTDC
0...11 %
01-5 page 8
10...20 %
01-5 page 8
xxxx rpm1)
01-5 page 3
Display
field
Readout
on display:
Rectifying fault
less than
10 %
throttle driving
Electrical consumers on
Steering wheel at limit stop
Driving position engaged (automatic gear-
box)
Display
field
Readout
on display:
Rectifying fault
01-5 page 8
Self-diagnosis V
Eliminate cause
Replace air filter element Chap. 24-1
Edition 06.04
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01
Driving
Read measured value block
14
xxxx rpm
xxx %
xxx
Text
Specification
Analysis:
activated
01-5 page 9
12100 %
6505700 rpm
6605700 rpm
5805700 rpm
7406600 rpm
5806600 rpm
Display
field
Readout
on display:
Rectifying fault
greater
than 0
Driving
Edition 06.04
S00.5309.04.20
Self-diagnosis V
01-5 page 9
01
15
xxx
xxx
xxx
Text
Specification
Analysis:
activated
01-5 page 10
01-5 page 10
01-5 page 10
Driving
Read measured value block
16
xxx
Text
Specification
Analysis:
activated
01-5 page 10
Analysis of display groups 015 and 016, ignition misfiring cyl. 1 to cyl. 4
Display
fields
Readout
on display:
Display
group
15
display
field 1
to 3
greater
than 0
and
display
group
16
display
field 1
Rectifying fault
Driving
01-5 page 10
Self-diagnosis V
Edition 06.04
S00.5309.04.20
01
22
xxx %
xx.x
xx.x
Specification
Analysis:
0...14
01-5 page 12
0...14
01-5 page 12
15...100 %
6505700 rpm
6605700 rpm
5805700 rpm
7406600 rpm
5805700 rpm
Engine load
Engine speed
Note
Notes on display groups 3 and 4:
When idling the display value must be 0.0 .
14
Driving
23
xxx %
xx.x
xx.x
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Specification
Analysis:
0...14
01-5 page 12
0...14
01-5 page 12
15...100 %
6505700 rpm
6605700 rpm
5805700 rpm
7406600 rpm
5806600 rpm
Self-diagnosis V
01-5 page 11
01
Note
Notes on display groups 3 and 4:
When idling the display value must be 0.0 .
14
Display
field
Readout
on display:
Rectifying fault
3 and
4
All 14
cylinder
Chap. 28-1
Engine damage
Once cylinder
clearly
deviates
from the
others
Driving
Diagnostic device in function 04 - basic setting
System in basic setting 28
xxxx rpm
xx %
xxx.x C
Text
Display field
Result knock sensor test (Test ON/
Test OFF/Syst.
o.k./Syst. n.o.k.)
Coolant temperature
Engine load
Engine speed
01-5 page 12
Self-diagnosis V
Specification
Analysis:
Syst. o.k.
60...110 C
01-5 page 6
50...70 %
2000...4000 rpm
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01
01-6
Self-diagnosis VI
Engine idling
Read measured value block
30
xxx
xxx
Specification
Analysis:
110
01-6 page 1
111
01-6 page 1
Note
Re display field 2:
The 3rd display position is only set to 1 in the partial
load region.
3
1
1
1
Display group 031 - lambda control, lambda values upstream of catalytic converter:
Engine idling
Coolant temperature 80 C
Edition 06.04
S00.5309.04.20
Self-diagnosis VI
01-6 page 1
01
x.xxxx
31
4
No display
Lambda nominal value - Bank 1
Lambda actual value - Bank 1
Specification
Analysis:
---
---
---
---
0,99001,0100
---
0,96001,0400
---
Engine idling
Read measured value block
xx.x %
xx.x %
32
Specification
Analysis:
-10,0...10,0 %
01-6 page 3
-10,0...10,0 %
01-6 page 3
Note
Re display fields 1 and 2:
Low readouts indicate that the engine is running too
set.
add = additive - The effect of the fault (e.g. unmetered
01-6 page 2
Self-diagnosis VI
Edition 06.04
S00.5309.04.20
01
Display
field
Readout
on display:
Rectifying fault
1 and
2
low lambda
learned
values
change
probe dirty
Display
field
Readout
on display:
Rectifying fault
1 and
2
high
lambda
initialisation values
Eliminate cause
valve
Unmetered air at the exhaust manifold gas-
Eliminate cause
ket
Injection valve blocked
probe dirty
Engine idling
Read measured value block
33
xx.x %
x.xxx V
Edition 06.04
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Specification
0.4...0.5 V
-15,0...15,0 %
Self-diagnosis VI
Analysis:
01-6 page 4
01-6 page 3
01
Note
Re display field 1:
The display must oscillate around 0. If 0 is constantly
= 1.0.
is above 0.45...V.
Through its structure the wide-band lambda probe en-
Display
field
Readout
on display:
Rectifying fault
not within
tolerance
stabilised
enriches
Unmetered air
01-6 page 4
Self-diagnosis VI
Edition 06.04
S00.5309.04.20
01
xxx.x C
x.x s
3
Display field
Result of test of
lambda probe ageing upstream of
catalytic converter
(Test OFF/Test
ON/B1 S1 o.k./B1
S1 n.o.k.)
Specification
Analysis:
B1 S1 o.k.
max. 1.0 s
15003900 rpm
Specification
Analysis:
Note
regarding display fields 3 and 4:
The period duration indicates the time between two
Vehicle standing, brake pedal activated, engine running at raised idling (1500.4000 rpm)
x.xxx V
Text
Display field
Edition 06.04
S00.5309.04.20
Self-diagnosis VI
B1 S2 o.k.
0.000...1.000 V
01-6 page 6
01-6 page 5
01
Analysis of display group 036, lambda probe voltage, lambda probe downstream of catalytic converter
Display
field
Readout
on display:
Rectifying fault
constant
1.100 V
constant
between
0.400
...0.500 V
constant
0.000 V
Driving
Diagnostic device in function 04 - basic setting
System in basic setting 37
xx.x %
x.xxx V
x.x %
Text
Display field
Specification
Analysis:
Test lambda
probes
(Test ON/Test
OFF/Syst. o.k./
Syst. n.o.k.)
Syst. o.k.
0.000...1.000 V
01-6 page 6
12,0...40,0 %
Chapter 01-5
Ignore
Lambda probe voltage after catalytic
converter
Engine load
Note
Re display field 2:
Voltage signal Mixture rich (low level of residual oxy-
01-6 page 6
Self-diagnosis VI
Edition 06.04
S00.5309.04.20
01
is not able to maintain constant the ideal mixture composition which corresponds to = 1.0. The control
constantly fluctuates back and forward between the
slightly too lean and slightly too rich states.
The readout must in some cases be less than 0.3 V
and in some cases more than 0.6 V. The readout below 0.45 V indicates a lean mixture while above 0.45
V indicates a rich mixture.
At idling speed, the voltage of the lambda probe up-
Engine idling
Read measured value block
41
Text
xxx ohms
Text
Edition 06.04
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Self-diagnosis VI
Specification
Ht. after c. ON
Ht. after c. OFF
Analysis:
Ht. bf. c. ON
Ht. bf. c. OFF
01-6 page 7
01
Note
Depending on the operating state of the engine the lambda probe heaters are switched on or off, i.e. the readouts
in display field 2 and 4 may show either Htg.u(d)C.ON
or Htg.u(d)C.OFF.
xxxx rpm
xxx.x C
xx.x %
Text
Display field
Result of the catalyst conversion
test
(Test OFF/Test
ON/Cat B1 O.K./
Cat B1 N.O.K.)
Specification
Analysis:
Cat B1 o.k.
at least 60 %
at least 300 C
15003900 rpm
Engine idling
Read measured value block
99
xxxx rpm
xxx C
xx.x %
Text
Specification
Analysis:
OFF
ON
-15,0...15,0 %
01-6 page 4
80...110 C
Chapter 01-5
rpm1)
Chapter 01-5
xxxx
01-6 page 8
Self-diagnosis VI
Edition 06.04
S00.5309.04.20
01
01-7
Self-diagnosis VII
Engine idling
Read measured value block
50
Text
Text
Specification
Analysis:
ON
OFF
ON
OFF
750 rpm
(830 rpm)1)
840 rpm
(870 rpm)1)
760 rpm
680 rpm
680 rpm
(800 rpm)1)
xxxx rpm2)
Chapter 01-5
Note
Re display field 2:
The nominal engine speed specified by the engine
ditioning system.
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Self-diagnosis VII
01-7 page 1
01
Driving
Read measured value block
54
xxxx rpm
Text
xxx %
xxx %
Specification
Analysis:
3...97 %
3...97 %
Engine speed
Note
Re display field 2:
The operating condition is displayed according to the
Engine idling
Read measured value block
55
xxxx rpm
xx Nm
xx.x %
xxxxx
Specification
Analysis:
xxxxx
01-7 page 3
Air conditioning on
-6,0...8,0 %
-3,0...8,0 %
Operating conditions
Initialisation value idling control
Idling control
-100 Nm
xxxx
rpm1)
Chapter 01-5
01-7 page 2
Self-diagnosis VII
Edition 06.04
S00.5309.04.20
01
Note
Re display field 3:
The display shows to what extent the idling stabilizer
Display field 4 - Operating conditions, meaning of the digits in the 5-digit number block
5
1
1
1
Meaning
Air conditioning compressor on
Driving position engaged
Air conditioning switched on
No meaning
No meaning
Engine idling
Read measured value block
56
xxxx rpm
xxxx rpm
xx Nm
xxxxx
Idling control
Specification
Analysis:
xxxxx
01-7 page 3
-10...0 Nm
750 rpm
(830 rpm)1)
840 rpm
(870 rpm)1)
760 rpm
680 rpm
680 rpm
(800 rpm)1)
xxxx rpm2)
Chapter 01-5
Edition 06.04
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Self-diagnosis VII
01-7 page 3
01
Note
Re display field 2:
The nominal engine speed specified by the engine
xxx %
xx
Text
Specification
Analysis:
ADP o.k.
0...12
3...97%
3...97%
Potentiometer 1 -G187-
Note
To display group 60:
The adaptation of the throttle valve control unit occurs
up to 12.
The basic setting may only be ended once the counter
Driving
01-7 page 4
Self-diagnosis VII
Edition 06.04
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01
61
xxxx rpm
xxx.x %
xxxxx
Specification
Analysis:
xxxxx
01-7 page 3
0...100 %
6505700 rpm
6605700 rpm
5805700 rpm
7406600 rpm
5806600 rpm
Specification
Analysis:
Engine speed
62
xx %
xx %
xx %
xx %
0...100 %
0...100 %
3...97 %
3...97 %
Engine idling
Coolant temperature minimum 80 C
Diagnostic device in function 04 basic setting
Edition 06.04
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Self-diagnosis VII
01-7 page 5
01
70
xx %
xx %
xxx mbar
Text
Specification
Analysis:
TVV o.k.
240420 mbar
> 25 %
1325 %
Specification
Analysis:
Note
TVV means Tank Vent Valve (activated charcoal filter solenoid valve 1).
Note
Re display field 1:
During diagnosis the display fluctuates in the region
Display group 074 - Exhaust gas reduction, Exhaust gas recirculation valve adaptation:
74
x.x V
x.x V
x.xxx V
Text
ADP o.k.
0,3004.600 V
100 %- Position
2,94.6 V
0,31.3 V
Note
To display group 074:
The adaptation of the exhaust gas recirculation valve
recirculation valve by selecting display group 074 under function 04 Basic position. This adaption must
01-7 page 6
Self-diagnosis VII
Edition 06.04
S00.5309.04.20
01
Engine idling
Diagnostic device in function 04 basic setting
Briefly blip throttle 5 times up to max. speed.
Read measured value block
75
xxx mbar
Text
Specification
Analysis:
Syst. o.k.
min. 50 mbar
240420 mbar
18005600 rpm
Specification
Analysis:
80.0...110.0 C
Chapter 01-5
00000000
01-7 page 7
Note
Re display field 3:
An error can already occur under 140 mbar.
Engine idling
100 Read out on display:
xxx.x C
xxx s
xxxxxxxx
Display field
Diagnosis status
Display field 1 - Readiness code - Meaning of the digits in the 8-digit numerical block
The readiness code is only generated if all the display positions show 0
1
8
0
0
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Diagnosis function
Catalytic converter
Catalytic converter heating (no diagnosis at present/always 0)
Self-diagnosis VII
01-7 page 7
01
The readiness code is only generated if all the display positions show 0
0
Lambda probes
Driving
Read measured value block
120
xxxx rpm
xxx Nm
xxx Nm
Text
Specification
Analysis:
active/inactive
xxxx rpm1)
Chapter 01-5
Specification
Analysis:
Driving
Read measured value block
xxxx rpm
xxx Nm
xxx Nm
Text
Display field
Status
xxxx
rpm1)
Chapter 01-5
Engine idling
01-7 page 8
Self-diagnosis VII
Edition 06.04
S00.5309.04.20
01
Text
Text
Text
Text
Display field
Status airbag
Status of combiinstrument
Status gearbox
Status ABS
Specification
Analysis:
Airbag 1
Combi 1
Gearbox 1
ABS 1
Note
To display group 125:
Nominal value = 1; the control units with active data
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Self-diagnosis VII
01-7 page 9
01
01-7 page 10
Self-diagnosis VII
Edition 06.04
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24
Installed location overview for engines with the engine codes AUA, AUB
1 - Activated charcoal filter system solenoid valve 1 -N80- */**
inspecting Chap. 01-1
2 - 3-pin connector
for engine speed sender
-G283 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
4 - Intake manifold
3
1
6
2
9
7 8
5 - Injector - (N30N33)- *
6 - Knock sensor -G61- *
Fitting location: Cylinderblock intake side
inspect Chapter 28-1
7 - Engine control unit *
8 - Throttle valve control unit
-J338- *
14
12
16
11
13
10
15
S24-0333
12 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- *
1.4/74 Engine - Mechanics; Rep. Gr. 26
1.4/55;
Edition 06.04
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24-1 page 1
24
Installed location overview for engines with the engine codes BBY, BBZ, BKY
1 - Activated charcoal filter system solenoid valve 1 -N80- */**
inspecting Chap. 01-1
2 - 3-pin connector
for engine speed sender
-G283 - The vacuum regulating valve
(PCV valve)
for crankcase ventilation
4 - Heating resistor of crankcase
ventilation -N795 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
6 - Intake manifold
7 - Injectors -(N30N33)- *
8 - Knock sensor -G61- *
Fitting location: Cylinderblock intake side
inspect Chapter 28-1
9 - Engine control unit *
10 - Throttle valve control unit
-J338- *
11 - Engine speed sender -G28- *
inductive pickup
Fitting location: Cylinderblock intake side
12 - 6-pin connector
Observe current flow diagram
for wide band lambda probe
with lambda probe heating before catalyst
13 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- *
1.4/74 Engine - Mechanics; Rep. Gr. 26
1.4/55;
24-1 page 2
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24
necting the battery, as this may damage the 4AV control unit.
Components marked with an * are checked by self-di-
nents the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit.
The fault memory must then be interrogated and if
necessary adapted to the control unit Chapter 245.
Certain inspections may cause the control unit to de-
tect 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.
Vehicles fitted with airbags are equipped with a crash
fuel shut-off. It is intended to reduce the risk of a vehicle fire after a crash as the fuel pump is disconnected
by the fuel pump relay. This installation also enhances
the starting behaviour of the engine. When opening
the door the fuel pump is activated for 2 seconds in order to build up the pressure in the fuel system.
Safety measures 24-1 page 12.
Cleanliless rules 24-1 page 13.
Inspect intake air system for leaks (unmetered air)
Chap. 24-3.
Inspecting engine operating conditions Chapter 24-4.
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24
1
29
28
27
4
5
6
7
26
8
9
22
21
20
10
11
19
12
13
18
17
16
15
14
S24-0338
24-1 page 4
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24
24-1 page 6
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24
Engines with engine codes BBZ; vehicles mit engines BBY and manual gearbox 09.03
1 - Intake manifold
out of plastic
pay attention to the spare
part number
removing and installing
24-1 page 4
2 - Throttle valve control unit
-J338- *
inspect Chapter 24-2
if replaced adapt engine control unit Chapter 24-5
3 - 10 Nm
4 - Gasket ring
replace if damaged
5 - 20 Nm
6 - Gasket ring
replace
7 - Guide plate
pay attention to correct installation position
replace if damaged
8 - O-ring
replace if damaged
9 - 3 Nm
10 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
Testing intake manifold pressure sender Chap. 24-2
Inspecting intake manifold
temperature sender
Chap. 24-2
24-1 page 8
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24
2
4
5
6
7
5
7
S24-0339
Removing
24-1 page 10
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Pull out the fuel feed hose -arrow- and catch the fuel
which flows out with a cleaning cloth.
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing
the connection point.
Installing
S10-0099
oil
7
5
6
S24-0331
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24
Fig. 1:
1.5...2.0 k
80 C is in range B and corresponds to a resistance of
275...375
Fig. 2:
2.3...2.6 k
80 C is in range B and corresponds to a resistance of
290...330
Fig. 3:
Removing
Pull off hose -1- (engines 04.02 ) and remove engine cover -2- with air filter upwards -arrows-.
Installing
Safety measures
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing
the connection point.
Observe the following points to prevent injury to persons
and/or damage to the injection and ignition system:
24-1 page 12
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and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
If test and measuring devices are required during test
drives observe the following:
Always secure the test and measuring devices on the
Rules of cleanliness
When working on the fuel supply/fuel injection system,
pay careful attention to the following 5 rules for cleanliness.
Thoroughly clean the connection points and their sur-
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24
24-1 page 14
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24
Testing components
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test condition
Switch on ignition.
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24-2 page 1
24
Switch on ignition.
Specified value: min. 4,5 V
Check wiring between the test box and the 6-pin plug
for interruption:
Plug contact
92
83
117
84
118
91
-V.A.G 1551/3, 3A, 3B oder 3C Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Test box -V.A.G 1598/31 Current flow diagram
Operation
The two accelerator pedal position senders -G79- and
-G185- are located at the accelerator pedal and pass on
the driver input to the engine control unit completely independently of each other (when accelerator is depressed).
Both senders are located in a housing.
24-2 page 2
Testing components
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24
Test condition
62
14%
->
Test the voltage supply and the wiring of the accelerator pedal position sender 24-2 page 3.
Disconnect the 6 pin plug connection from the accelerator pedal position sender.
Switch on ignition.
Connect the multimeter for voltage measurement to
the following contacts of the connector:
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3
Specified value: min. 4,5 V
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24
Check wiring between the test box and the plug for interruption according to the Current Flow Diagram:
Plug contact
72
73
36
35
33
34
Additionally check the cable for a short circuit to battery positive and to earth.
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
->
2
Briefly open throttle valve. The intake manifold pressure value in display field 2 must increase briefly.
24-2 page 4
Testing components
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24
Cause
Continue test
91 mbar
Line interruption
or short-circuit to
earth
24-2 page 5
1254 mbar
Short circuit to
positive
24-2 page 6
Bridge contacts 3 + 4 of the plug connection and observe the read-out on the display.
If the display jumps to 1254 mbar:
Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
98
109
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24-2 page 5
24
-V.A.G 1551/3, 3A, 3B, 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test sequence
->
62 C
If a temperature is displayed that is below the ambient temperature of the sender, check the sender wires for transition impedances. Make sure
that the sender heats up or is heated by radiant heat.
24-2 page 6
Testing components
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24
2.3...2.6 k
For a temperature of 80 C the specification is
290...330
Replace the intake manifold pressure sender -G71with intake manifold temperature sender -G72 Chap. 24-1.
If the specified value is reached:
Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
108
85
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24-2 page 7
24
-V.A.G 1551/3, 3A, 3B, 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
1
->
00111111
field 2.
Specified value: Coolant temperature
If implausible value appears in the display:
S24-0349
1500...2000
275...375
24-2 page 8
Testing components
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Check wiring between the test box and the 2-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
93
108
2
S24-0341
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24
24-2 page 10
Testing components
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24-3
Testing components I
Test condition
Switch on ignition.
Specified value: min. 4.5 V
Check wiring between the test box and the 3-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
87
82
108
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24-3 page 1
24
Test conditions
Fuse 35 must be OK
Earth connections between the engine (on gearbox
1
2
3
4
5
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
Test sequence
Pull off hose -1- (engines 04.02 ) and remove engine cover -2- with air filter upwards -arrows-.
Engines with the engine codes AUA, AUB
24-3 page 2
Testing components I
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24
S24-0344
1
S24-0345
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Testing components I
24-3 page 3
24
Check wiring between the test box and the 2-pin plugs
Plug contact
96
97
88
89
S24-0343
Specified value:
Check wiring between contacts 1 of the plug connection on the injection valves for interruption of each other.
Line resistance: max. 1.5
24-3 page 4
Testing components I
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24
Test conditions
Fuel pump relay o.k., testing Chap. 01-1, final control diagnosis.
Test sequence
Pull off hose -1- (engines 04.02 ) and remove engine cover -2- with air filter upwards -arrows-.
Unplug the 2-pin plug for the coolant temperature sensor -G62- -arrow-.
S24-0349
Connect up digital potentiometer V.A.G -1630- to contacts 1 + 2 of the plug connection and set the connected side to 15 k.
V.A.G 1630
1
S24-0342
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24-3 page 5
24
Have a 2nd mechanic actuate the starter. The injection valve must emit a pulsed jet of fuel.
S24-0340
Connect the second contact of the injector to be tested with remote control and adapter cable to positive
battery.
S24-0340
24-3 page 6
Testing components I
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24
-V.A.G 1551/3, 3A, 3B oder 3C Engine leak search spray (e.g. G 001 800 A1)
Test condition
Test sequence
Note
Because of the vacuum in the intake system the leak
box.
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
33
->
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24-3 page 7
24
tion
Below +10 C the flap opens the hot air connection.
Note
Operation of the thermo-element -2- can easily be tested
by spraying on a cooling spray.
Idle testing
2
Note
S24-0332
Test conditions
All electrical components such as lights and rear window heater must be switched off.
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
24-3 page 8
Testing components I
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56
->
00000
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Testing components I
24-3 page 9
24
24-3 page 10
Testing components I
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24-4
Testing components II
-V.A.G 1551/3, 3A, 3B, 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test conditions
1
2
3
4
5
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
Test sequence
41
51
61
42
52
62
43
53
63
44
54
64
gine and select the address word 01 Engine electronics Chapter 01-1.
45
55
65
46
56
66
Engine idling.
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
S24-0347
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Testing components II
24-4 page 1
24
Note
At ambient temperature the resistance of the heating element should be approx. 1...5 . The resistance increases
considerably even if the temperature rises only slightly.
If there is an interruption in the lambda probe heating:
Check wiring between the test box and the 6-pin plug
for interruption:
Plug contact
1 (3)
24-4 page 2
Testing components II
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24
-V.A.G 1551/3, 3A, 3B, 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test conditions
The exhaust system must be tight between the catalyst and the cylinder head.
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
30
->
Note
The first digit of the 3-digit numerical block (heating) fluctuates between 0 and 1.
If the specified value is not reached:
->
Test ON
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Testing components II
24-4 page 3
24
Press
key.
Select function 08 Read measured value block and
display group 033.
33
->
Cause
Continue test
between
0.400 ....
0.500 V
Open circuit
Check voltage
24-4 page 4
1.105 V
0.000 V
Check lambda
probe wiring
24-4 page 4
24-4 page 4
Testing components II
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24
Check wiring between the test box and the 6-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
3 (2)
52
4 (1)
71
5 (4)
70
6 (6)
51
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526.A Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
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24-4 page 5
24
Test conditions
1
2
3
4
5
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
S24-0348
24-4 page 6
Testing components II
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Connect multimeter for voltage measurement to contacts 1 + 2 (plug at engine wiring harness).
Check wiring between the test box and the 4-pin plug
for interruption:
Plug contact
63
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test conditions
Testing components II
24-4 page 7
24
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Check status of the lambda control after catalyst (display field 2):
30
->
Note
The lambda control of the lambda probe after catalyst
36
->
24-4 page 8
Testing components II
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24
Display
Cause
Continue test
between
0.400....
0.500 V
Open circuit
Check voltage
24-4 page 9
1.105 V
0.000 V
Check lambda
probe wiring
24-4 page 9
Connect multimeter for voltage measurement to contacts 3 + 4 (plug at engine wiring harness).
Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
68
69
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24-4 page 9
24
Test conditions
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
24-4 page 10
Testing components II
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24
Test condition
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
->
Idling
Idling
Accelerate constantly.
As long as the acceleration is constant the following must
be displayed: Partial load.
Enrichment
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Testing components II
24-4 page 11
24
24-4 page 12
Testing components II
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24
24-5
Note
The test box -V.A.G 1598/31- is designed in such a
trol remains fully operational with the test box connected (e.g. measuring signals while the engine is
running).
Whether the control unit remains connected to the test
unit and the socket numbers of the test box are identical.
Connect test box -V.A.G 1598/31- to connector of wiring loom. The earth clip of the test box must be connected to the negative battery terminal.
DANGER!
To avoid damaging the electronic components,
switch on the relevant measuring range before
connecting the measuring cables and comply with
the test conditions.
V.A.G. 1598/31
S01-0089
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 B Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Edition 06.04
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24-5 page 1
24
Test conditions
1
2
3
4
5
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
->
62 C
Connect test box -V.A.G 1598/31- to connector of wiring loom 24-5 page 1. The engine control unit is
not connected here.
current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Switch on ignition.
Specified value: min. 11.5 V
If the specified value is not reached:
current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
24-5 page 2
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24
Procedure
After the voltage supply has been interrupted, it is necessary to carry out the following steps:
Procedure
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WSCXXXXX
24-5 page 3
24
S10-0111
Release the catch of the second connector and unplug the connector from the control unit.
Installation is carried out in the reverse order.
Activate cruise control system function in engine control unit (on vehicles with CCS the lever for the CCS is
located on the left below the steering wheel) Chap.
24-6.
S24-0337
74
->
ADP. O.K.
Note
On vehicles with an automatic gearbox the gearbox control unit must also be adapted.
24-5 page 4
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24
the control unit has been replaced, it is then necessary to code the control unit as follows.
Special tools, test and measuring equipment and
auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
Procedure
Q
(0-00127)
00001
Gearbox
00011
00021
00031
00041
00051
00061
00071
00003
Automatic gearbox
00013
00023
00033
00043
00053
00063
00073
2615 ->
WSCXXXXX
->
24-5 page 5
24
jolts etc.)
Increase in fuel consumption
Increase in pollution
Storage of non-existent faults in fault memory
non-execution of functions (lambda control, activated
stalled
the throttle valve control unit was replaced
if another engine or another throttle valve control unit
was installed
Note
On vehicles with an automatic gearbox the gearbox control unit must also be adapted.
Special tools, test and measuring equipment and
auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
Test condition
There must not be any fault present in the fault memory Chap. 01-1, Interrogating fault memory.
24-5 page 6
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24
Procedure
60
->
ADP. running
60
Check the specified values for the throttle valve positioner control unit in display fields 3 and 4.
->
ADP o.k.
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24
24-5 page 8
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24
24-6
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31 Diode test lamp e.g. -V.A.G 1527 B Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
Fuse 56 o.k.
Test sequence
Note
The vehicle must be driven in order to test the vehicle
Chap. 24-1.
Determine by means of a test drive whether the driving speed is displayed in display field 3.
->
Enrich-
Connect the multimeter for voltage measurement between the bushes 4 (Term. 15) + 54 (speed signal) of
the test box.
Edition 03.01
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24-6 page 1
24
Test the wiring to the speedometer and to the speedometer sender Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
Test conditions
Test sequence
Readout on display:
Observe display field 2.
->
off
Test the air conditioning system Heating, Air Conditioning; Rep. Gr. 01.
24-6 page 2
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24
Test conditions
->
0000
Specified value: x x 0 0
S24-0458
Test the cable to the sender for open circuit and for
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24-6 page 3
24
Testing clutch pedal switch -F36Signal from clutch pedal switch -F36- is used for avoiding
engine overrevving and load change jolts when the clutch
is released.
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 box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 A-
1
2
3
4
5
Test condition
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
Test sequence
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
->
0000
Specified value:
If the specified values are not reached:
Test the cable to the sender for open circuit and for
S24-0458
24-6 page 4
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24
Test conditions
Test sequence
2615 ->
WSC XXXXX
2615 ->
WSC XXXXX
Press
Login procedure
Enter code number
XXXXX
16167
Testing CCS
With the exception of an operating switch the CCS does
not have any components of its own. All functions are
performed by the engine control unit. The minimum vehicle speed for the CCS function is 30 km/h.
Special tools, test and measuring equipment and
auxiliary items required
Vehicle system tester -V.A.G 1552 - with cable
Test conditions
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24
Test sequence
->
0000
Display field 2
Specified value:
1xxx - CCS activated
0xxx - CCS deactivated
Display field 4
Test condition
Display field
4
0000
00011)
Switch -B- to ON
0011
1011
0111
1)
N23-0199
Test condition
24-6 page 6
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Test sequence
->
00000
Specified value:
00000 (selector lever in P or N)
00010 (selector lever in 1/2/3/R/D)
If the specified value is reached:
Test condition
Test sequence
To to this, conduct a resistance measurement between test box sockets 58 and 60.
Specified value: 60...72
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24-6 page 8
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28 Ignition System
28-1
the ignition system. For other components of the injection and ignition system Rep. Gr.24.
Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit.
The engine control unit is equipped with a self-diagno-
sis system.
Components marked with an * are checked by self-di-
tect 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.
If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit.
The fault memory must then be interrogated and if
necessary adapted to the engine control unit
Chapter 24-5.
Safety measures 28-1 page 3.
Setting data, spark plugs Inspection and Maintenance.
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28
Removing and installing parts of the ignition system for engines with the engine
codes AUA, AUB
1 - Ignition lead
with shielded plug and sparkplug
Resistor 4.8...7.2 k
2 - Ignition transformer -N152 with identification for ignition
leads:
A = Cylinder 1
B = Cylinder 2
C = Cylinder 3
D = Cylinder 4
check 28-1 page 6
Fitting location Chapter
24-1
3 - Connector
4-pin
for ignition transformer
-N1524 - 10 Nm
5 - Connector
2-pin
for knock sensor 1 -G61 Contacts of connector goldplated
6 - Knock sensor 1 -G61- *
check 28-1 page 11
Fitting location Chapter
24-1
7 - 20 Nm
The tightening torque influences the knock sensor function
8 - Connector
3-pin
for hall sender -G409 - Hall sender -G40- *
check 28-1 page 4
Fitting location Chapter 24-1
10 - O-ring
replace if damaged
11 - Ignition lead guide
12 - Spark-plug, 30 Nm
use of the spark plug wrench e.g. -3122 B- for removing and installing
type and electrode gap Inspection and Maintenance
28-1 page 2
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Removing and installing parts of the ignition system for engines with the engine
codes BBZ, BBY, BKY
1 - Connector
4-pin
2 - Ignition coils with a power
output stage
-N70, N127, N291, N292 remove with extractor
-T 10094 check 28-1 page 8
3 - Connector
2-pin
for knock sensor 1 -G61 contacts gold-plated
4 - Knock sensor 1 -G61- *
check 28-1 page 11
Fitting location Chapter
24-1
5 - 20 Nm
The tightening torque influences the knock sensor function
6 - Connector
3-pin
for hall sender -G407 - Hall sender -G40- *
check 28-1 page 4
Fitting location Chapter
24-1
8 - O-ring
replace if damaged
9 - 10 Nm
10 - Spark-plug, 30 Nm
use of the spark plug wrench
e.g. -3122 B- for removing and installing
type and electrode gap Inspection and Maintenance
11 - Bracket
Tighten at cylinder head cover to 5 Nm
Safety measures
Observe the following points to prevent injury to persons
and/or damage to the injection and ignition system:
Do not touch or remove ignition leads with the engine
and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
If test and measuring devices are required during test
drives observe the following:
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28
Test condition
Pull off hose -1- (engines 04.02 ) and remove engine cover -2- with air filter upwards -arrows-.
28-1 page 4
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Switch on ignition.
Specified value: min. 4.5 V
Check wiring between the test box and the 3-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
98
86
108
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28
Test conditions
Test sequence
Test condition
11
12
13
14
15
16
6
7
8
9
10
17
18
19
20
21
22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
S01-0094
Switch on ignition.
Specified value: min. 11.5 V
28-1 page 6
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Test control
WARNING!
During the following test do not touch neither the
connecting parts of the ignition transformer nor
the auxiliary cables.
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28
Checking wires
Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
102
103
Test sequence
Note
Ignition coil and power output stage form a building unit.
Cylinder, which does not operate or misfire, determine as
follows:
28-1 page 8
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Test condition
The fuses of the ignition system must be in proper order Current Flow Diagrams, Fault Finding and Fitting Locations.
Switch on ignition.
Specified value: min. 11.5 V
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28
Test control
WARNING!
Caution! During the following test do not touch
neither the connecting parts of the ignition coils
nor the auxiliary cables.
Check wires.
28-1 page 10
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Checking wires
Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Diagram:
Plug contact 4
cylinder:
102
103
94
95
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28
Test condition
Test sequence
Check wiring between the test box and the 2-pin plug
for interruption according to the Current Flow Diagram.
Plug contact
106
99
28-1 page 12
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Test condition
Driving
Test sequence
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
14
->
activated
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28-1 page 14
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