Fuel Injection Aua, Aub, Bby, BBZ, Bky

5
Service
Workshop Manual
FABIA 2000
1.4/55 ; 1.4/74 Engine - Fuel Injection
Edition 08.99
Engine code
AUA AUB BBY BBZ BKY
Service Department. Technical Information
Printed in Czech Republic

S00.5309.00.20
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
Printed in Czech Republic

S00.5309.00.20
FABIA 2000 1.4/55 ; 1.4/74 Engine - Fuel Injection
List of Supplements to Workshop Manual
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
Supplement to Basic Edition
S00.5309.01.20
03.01
Modifications in Rep. Gr. 01 and 24
S00.5309.02.20
06.02
Additions to engines with the engine codes BBY, BBZ
S00.5309.03.20
06.04
Supplement to engines with the engine codes BKY
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
- Properties of the self-diagnosis ..................................................................... 01-1
page
- Technical data of self-diagnosis ..................................................................... 01-1
page
- Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the
dash panel insert ...................................................................................... 01-1
page
- Meaning of the exhaust gas warning light -K83- .................................................. 01-1
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
- Automatic test sequence ............................................................................. 01-1
page
- Performing actuator diagnosis ....................................................................... 01-1
page
Self-diagnosis II ......................................................................................... 01-2
page
- Readiness code ........................................................................................ 01-2
page
- Reading Readiness Code ............................................................................ 01-2
page
- Generating readiness code .......................................................................... 01-2
page
Self-diagnosis III ........................................................................................ 01-3
page
- Fault table, fault codes 16496...17566 ............................................................. 01-3
page
Self-diagnosis IV ....................................................................................... 01-4
page
- Fault table, fault codes 17573...18100 ............................................................. 01-4
page
Self-diagnosis V ........................................................................................ 01-5
page
- Measured value blocks ............................................................................... 01-5
page
- Safety measures ....................................................................................... 01-5
page
- Reading measured value block ..................................................................... 01-5
page
- Measured value blocks, display groups 001...006 - Basic functions .......................... 01-5
page
- Measured value blocks, display groups 010...029 - Ignition .................................... 01-5
page
Self-diagnosis VI ....................................................................................... 01-6
page
page
- Measured value blocks, display groups 030...049, 099 - Lambda control .................... 01-6
page
Self-diagnosis VII ....................................................................................... 01-7
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
- Measured value blocks, display groups 120...129 - Communication .......................... 01-7
page
Repairing the injection system ...................................................................... 24-1
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
- General notes on the injection system ............................................................. 24-1
page
- Removing and installing parts of the injection system ........................................... 24-1
page
- Disassembling and assembling intake manifold .................................................. 24-1
page
- Disassembling and assembling fuel distributor with injectors .................................. 24-1
page 10
- Disassembling and assembling the air filter ....................................................... 24-1
page 11
24 Fuel Formation, Injection
Edition 06.04
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Table of Contents

- Safety measures ...................................................................................... 24-1
- Rules of cleanliness ................................................................................... 24-1
page 12
page 13
Testing components ................................................................................... 24-2
page
- Testing throttle valve control unit ................................................................... 24-2
page
- Testing accelerator pedal position sender ......................................................... 24-2
page
- Testing the intake manifold pressure sender ..................................................... 24-2
page
- Testing intake manifold temperature sender ...................................................... 24-2
page
- Testing coolant temperature sender ................................................................ 24-2
page
Testing components I ................................................................................. 24-3
page
- Test engine speed sender ........................................................................... 24-3
page
- Testing injection valves ............................................................................... 24-3
page
- Testing the intake system for tightness (unmetered air) ........................................ 24-3
page
- Testing intake manifold preheating ................................................................. 24-3
page
- Idle testing .............................................................................................. 24-3
page
Testing components II ................................................................................ 24-4
page
- Test lambda probe heating before catalyst ........................................................ 24-4
page
- Testing lambda probe and lambda control upstream of catalytic converter .................. 24-4
page
- Test lambda probe heating after catalyst .......................................................... 24-4
page
- Testing lambda probe and lambda control after catalyst ........................................ 24-4
page
- Check lambda probe ageing before catalyst ...................................................... 24-4
page 10
- Testing the engine operating conditions ........................................................... 24-4
page 11
Engine control unit .................................................................................... 24-5
page
- Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-5
page
- Testing voltage supply for engine control unit .................................................... 24-5
page
- Procedure after voltage supply has been interrupted ............................................ 24-5
page
- Replacing engine control unit ........................................................................ 24-5
page
- Coding engine control unit ........................................................................... 24-5
page
- Adjusting the engine control unit to the throttle valve control unit ............................. 24-5
page
Testing auxiliary signals ............................................................................. 24-6
page
- Testing the speed signal ............................................................................. 24-6
page
- Testing signals from/to the air conditioning system .............................................. 24-6
page
- Test brake light switch -F- and brake pedal switch -F47- ....................................... 24-6
page
- Testing clutch pedal switch -F36- ................................................................... 24-6
page
- Activating and deactivating cruise control system (CCS) ....................................... 24-6
page
- Testing CCS ............................................................................................ 24-6
page
- Testing gear signal .................................................................................... 24-6
page
- Test data bus .......................................................................................... 24-6
page
Repairing ignition system ............................................................................ 28-1
page
- General notes on the ignition system .............................................................. 28-1
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
- Safety measures ...................................................................................... 28-1
page
- Testing hall sender .................................................................................... 28-1
page
- Checking the ignition transformer (for engines with the engine codes AUA, AUB) ......... 28-1
page
28 Ignition System
II
Table of Contents
Edition 06.04
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- Check ignition coils with power output stage (engines with engine codes BBY, BKY, BBZ) 28-1
- Testing knock sensor ................................................................................. 28-1
page 8
page 11
- Test combustion misfiring ............................................................................ 28-1
page 13
Edition 06.04
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Table of Contents
III
IV
Table of Contents
Edition 06.04
S00.5309.04.20
01
01 Self-diagnosis
01-1
Self-diagnosis I
Properties of the self-diagnosis

Note
The self-diagnosis monitors only a part of the injection
and ignition system. The Current Flow Diagrams, Fault
Finding and Fitting Locations binder should always be
used for fault finding.
The engine control unit -J537- is equipped with a fault
memory.
If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication
of the fault type.
The engine control unit analyses the information and distinguishes between the different fault codes Fault Table Chapter 01-3 and Chapter 01-4, and stores
these until the fault memory is erased.
Faults that only occur temporarily (sporadically) are output with the suffix sporadically occurred fault. On the
display these faults are indicated by the suffix SP. Possible causes of sporadic faults are e.g. a loose contact or
a momentary line interruption. If a sporadic fault no longer
occurs within 40 warming-up phases (engine started at a
temperature of 50C and switched off at more than 72
C), the fault is then automatically erased fom the fault
memory.
The stored faults can be read out with the vehicle system
tester -V.A.G 1552- using programme card -6.0- and
higher version or fault reader -V.A.G 1551- using programme card -9.0- and higher version or vehicle diagnosis, measurement and information system -VAS 5051-.
After the fault or faults have been rectified, it is necessary
to erase the fault memory 01-1 page 5 and also to regenerate the readiness code Chapter 01-2.
Note
General information on self-diagnosis is provided in the
operating instructions for the diagnostic devices
-V.A.G 1551-, -V.A.G 1552- or -VAS 5051-.
Technical data of self-diagnosis

Control unit identification:
The control unit version is displayed when the vehicle
system tester -V.A.G 1552- is connected and address
word 01 Engine electronics is selected 01-1 page 4.
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Self-diagnosis I
01-1 page 1
01
Equipment
Engine identification characters
AUA, AUB
BBY, BBZ
BKY
MARELLI 4LV
MARELLI 4MV
MARELLI 4TV
EU-4, EU-3DDK, EU2DDK
EU4, EU-3DDK, EU2DDK
EU4, EU-3DDK, EU2DDK
Electronic throttle system
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
Intake manifold change-over
No
No
No
Camshaft adjustment
No
No
No
Boost-pressure control
No
No
No
Secondary air system
No
No
No
Exhaust gas recirculation
Yes
Yes
Yes
System denomination
Exhaust limits conforming to
Fault memory
Memory for initialisation values
Lambda control
Knock control
1)
2)
Independent of voltage supply

The values are erased if the voltage supply is interrupted.
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
Interrogating control unit version
02
Interrogating fault memory
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
Erasing fault memory
yes
yes
yes
06
Ending output
yes
yes
yes
07
Coding control unit
yes
no
no
08
Reading measured value block
yes
yes
yes
15
Reading readiness code
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
Meaning of the EPC warning lamp (fault

lamp for electric accelerator control
-K132-) in the dash panel insert
EPC is the abbreviation of Electronic Power Control,
which in German is written Elektronische MotorleistungsRegelung (E-Gas).
Fitting location of the EPC warning lamp:
If faults are detected on the EPC system during operation
of the engine, the dashboard insert switches the EPC
warning light on. (These faults are identified in the fault
table). There is a simultaneous entry in the fault memory
of the engine control unit.
Functional test:
CHECK
Switch on ignition: the EPC warning lamp must light

up.
If the EPC warning lamp does not light up when the ignition is switched on:
S01-0090
Check the dash panel insert and the EPC warning

lamp Electrical System; Rep. Gr. 90.
If the EPC warning lamp lights up when the ignition is

switched on:
Start engine and run in idle. The EPC warning lamp

should go out after a few seconds.
If the EPC warning lamp does not go out:
Interrogate fault memory, rectify any faults existing

and erase the fault memory 01-1 page 5.
Meaning of the exhaust gas warning light

-K83Only for engines complying with exhaust emission
standard EU 4 and EU 3DDK
If the engine control unit detects a fault, this is indicated
by the lighting up of the exhaust warning lamp
Fitting location of exhaust warning light:
CHECK
Note
The exhaust warning light may flash or come on as a
steady light. The fault memory must be interrogated

whatever happens 01-1 page 5.
The warning light flashes: There is a fault, which is
likely to damage the catalytic converter in this driving

condition. In this driving condition only low performance driving is allowed!
CHECK
S01-0091
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Self-diagnosis I
01-1 page 3
01
The warning light comes on as a steady light: There is
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
complaint and the exhaust gas warning light does not

light up, the fault memory should be interrogated since
it also possible that faults are stored there which do
not immediately switch on the exhaust gas warning
light.
Functional test:
Switch on ignition: The exhaust warning light must

light up.
If the gas warning light does not come on when the ignition is switched on:
Check the dash panel insert and the exhaust gas
warning light Electrical equipment; Rep. Gr. 90 .
If the gas warning light comes on when the ignition is

switched on:
Start engine and run in idle. The gas warning light

must go out after a few seconds.
If the gas warning light does not go out:
Interrogate fault memory, rectify any faults existing

and erase 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
Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
56 and 61 must be o.k.
Battery voltage must be at least 11.5 volts.

Earth connections between engine (at gearbox housing) and body (below battery) 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
Fold back trim panel -1-.

Connect vehicle system tester -V.A.G 1552- with appropriate cable.
Select address word 01 Engine electronics.

3
7
C
The control unit identification number and the coding are

shown on the vehicle system tester display, e.g.:
HELP
V.A.G. 1552
036906034T MARELLI 4LV

Coding 00031
2615 ->
WSC XXXXX
036906034T = Part No. of the control unit (for current
control unit version see spare part catalogue)89MARELLI 4LV = description of system and
version
Coding 00031 = coding of control unit with code ver-
sions Chapter 24-5
WSC xxxxx = workshop code the -V.A.G 1552-, with
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-
spond to the vehicle, replace the control unit

Chapter 24-5.
Incorrect coding of the engine control unit results in:
Handling problems (jerky gear change, load change
jolts etc.)
Increase in fuel consumption
Increase in pollution
Storage of non-existent faults in fault memory
Impossibility of performing certain functions (lambda
control, actuation of activated charcoal filter system,

etc.)
Interrogating and erasing fault memory

of engine control unit
Interrogate and erase the fault memories of al control
units 01-1 page 6.
-V.A.G 1551/3, 3A, 3B oder 3C-.
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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:
Operate starter for about 6 seconds. after this do not

switch off ignition.
Select function 02 Interrogate fault memory.

The number of stored faults or No fault recognised appears in the display.
X faults detected
If no fault is stored:
Press
key.
If one or several faults are stored:

Vehicle system test
The fault memory is erased
Select function 05 Erase fault memory.
HELP
Note
If the ignition was switched off between Interrogate fault
memory and Erase fault memory, the fault memory is
not erased.
Select function 06 End output and switch ignition off.

Rectify the faults displayed by referring to the fault table Chapter 01-3 and Chapter 01-4.
Read out readiness code Chap. 01-2. 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.
Automatic test sequence

During testing and installation other control units may
also detect faults, e.g. pulled-out connectors. This is why,
when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units.
For this you must proceed as follows:
Select address word 00 Automatic Test Sequence.

The tester -V.A.G 1552- sends all known address
words in sequence.
If a control unit responds with its identification, the display
will indicate the number of faults in the memory or No
fault detected.
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-
ating states must be reached several times: Idling,

part load, full load, overrun, enrichment.
In case of full load the speed should be increased be-
yond 3500 rpm.
01-1 page 6
Self-diagnosis I
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01
Once again interrogate the fault memories of all the

control units with the address word 00 Automatic test
sequence.

Note
If no fault has been recognized by the self-diagnostic system proceed with fault finding as specified in the corresponding fault table in the Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations binder.
Performing actuator diagnosis

With the actuator diagnosis the following parts are activated in the sequence indicated:
1. Throttle valve positioner -V602. Activated charcoal filter system solenoid valve 1 -N803. Exhaust gas recirculation valve -N184. Engine speed sender -G28- 1)
5. Fuel pump relay -J176. Engine/air conditioning compressor electrical
connection1)
-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.
Battery voltage must be at least 11.5 volts.

All electrical consumers, e.g. lights and rear window
heater, must be switched off.
Throttle valve drive angle senders -G187- and -G188o.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
the engine is not running and the ignition is switched

on.
The final control diagnosis is aborted when the engine
is started or when a moment of momentum is detected.

During the actuator diagnosis the individual actuators
remain activated until the next actuator is selected by

pressing key
.
The actuators are tested acoustically or by touch.
Procedure
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics 01-1 page 4.
Select function 03 final control diagnosis.

Readout on display:
Vehicle system test

03 - Actuator diagnosis
Actuator diagnosis
Throttle valve positioner-V60
->
Activate throttle valve positioner -V60-:
Confirm the entry with key
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:
Test throttle valve positioner Chapter 24-2, test

throttle valve control unit.
Activate solenoid valve 1 for activated charcoal

filter system -N80-:
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.
Detach hose from the activated charcoal filter at the

solenoid valve.
Fit auxiliary hose onto the free connection of the

valve.
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:
Continue test 01-1 page 10.
01-1 page 8
Self-diagnosis I
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01
Activate exhaust gas recirculation valve -N18-:
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:
Continue test 01-1 page 11.

Engine speed sender -G28-: (Ignore)
Press
key.
Readout on display:
Activate fuel pump relay -J17-:
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:

Testing fuel pump relay Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
Engine/air conditioning compressor electrical

connection (ignore)
Press
key.
Readout on display:
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Actuator diagnosis
->
Engine/air cond.compr.electr.connect.
Self-diagnosis I
01-1 page 9
01
Continuing test if the activated charcoal filter

solenoid valve 1 does not click:
Unplug 2-pin plug from solenoid valve 1 -N80- -arrow-.
S01-0092
Connect diode testing lamp to the unplugged plug.

LED must flash.
The LED flashes:
Proceed with the final control diagnosis up to the end.

Switch off ignition.
Replace solenoid valve 1 -N80-.
The LED does not flash:

Connect test box -V.A.G 1598/31- to wiring loom to
engine control unit Chapter 24-5. Do not connect
up the engine control unit.
Check wiring between the test box and the 2-pin plug
for interruption according to the Current Flow Diagram:
Plug contact
Test box bush

-V.A.G 1598/31-
64
Line resistance: max. 1.5

Additionally check the cable for a short circuit to battery positive and to earth.
Specified value: .
Check the cable between 2-pin plug contact 1 and the

fuel pump relay -J17- for interruption according to the
Current Flow Diagram.

If the lines are not found to be faulty:
Replace engine control unit Chapter 24-5.
01-1 page 10
Self-diagnosis I
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01
Continuing test if the exhaust gas recirculation

valve does not click:
Unplug the 6-pin plug from the exhaust gas recirculation valve -N18- -arrow- (on the front left cylinder
head).
Connect up the diode test lamp using adapter cables

onto the contacts 1+ 5 of the removed plug connection.
LED must flash.

The LED flashes:

Replace the EGR valve -N18- 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26.
The LED does not flash:

Connect test box -V.A.G 1598/31- to wiring loom to
engine control unit Chapter 24-5. Do not connect
up the engine control unit.
Plug contact
Test box bush

-V.A.G 1598/31-
114


Specified value:
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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.
-V.A.G 1551/3, 3A, 3B, oder 3C-.
Procedure
Connect vehicle system tester -V.A.G 1552- and enter

address word 01 Engine electronics Chap. 01-1.
Select function 15 Readiness code.

If all diagnoses were performed successfully, the display
must indicate the following:
Readiness code
00000000 - Test complete

Readiness code
00101101 - Test not complete
If the following readout appears in the display:

One of the available diagnoses cannot be completed successfully.
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
Edition 06.04
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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
0
0
Air conditioning system (no diagnosis at present/always 0)

Lambda probe
Lambda probe heater
Generating readiness code

-V.A.G 1551/3, 3A, 3B, oder 3C-.
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
Intake air temperature must be below 60 C display

group 004, display field 4
Coolant temperature at least 80 C display group

004, display block 3
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
Select function 02 Interrogate fault memory.

The number of stored faults or No fault recognised appears in the display.
X faults detected
If a fault is stored in the memory:
Rectify the faults displayed by referring to the fault table:

Fault table Chap. 01-3 and Chap. 01-4.
Press
key.
Work step 2: Erasing fault memory
Select function 05 Erase fault memory.
01-2 page 2
Vehicle system test

The fault memory is erased
Self-diagnosis II
->
Edition 06.04
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01
Note
The readiness code is reset or erased each time the
fault memory is erased.

If the ignition was switched off between Interrogate
fault memory and Erase fault memory, the fault

memory is not erased.
Press
key.
Note
The engine must not be readjusted during the work sequence.
Work step 3: Activated charcoal filter system diagnosis
Select function 04 Basic setting and display group

070.
Depress neither brake nor clutch pedal.

If the diagnosis is initiated by the engine control unit the
display in display field 4 will switch from Test OFF to
Test ON.
Leave engine running at idling speed until TVV o.k.

is read out in display field 4.
System in basic setting 70

29%
65%
342mbar
TEV O.K.
If the display does not occur as described:
Interrogating fault memory.

Blip throttle about 3 times and repeat the process.
If the display occurs as described:
Press
C key.
Work step 4: Lambda probe-ageing diagnosis (interval monitoring)

034.
Depress accelerator pedal twice above 5000 rpm.

Maintain speed between 1500...3900 rpm until display
in display field 4 switches from Test OFF to Test
ON.

1830/min
120 C
0.00s
Test OFF
Leave engine running at idling speed until B1-S1 o.k.

is displayed in display field 4.
Select function 08 Read measured value block and

display group number 030.
Read measured value block

111
110
30
Check operating state of lambda control upstream of

catalytic converter (display field 1):
Specified value: 111
Check operating state of lambda control downstream

of catalytic converter (display field 2):
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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).
Meaning of 3-digit numerical block in the display

fields 1 and 2:
Meaning, if display positions = 1
1 2 3
1 Lambda control active (partial load)
1
Lambda probe operational
Lambda probe heater switched on
If the specified values are not reached:
Interrogate fault memory Chapter 01-1.

If the specified values are reached:
Work step 5: Catalyst diagnosis
Note
This diagnosis is only successfully completed if no faults
relating to the lambda probes or the activated charcoal filter system exist.
Select function 04 initiating basic Setting and then

display group 046.
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.
System in basic setting

46
2830/min
328,0 C
0.00s
Test OFF
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.

Press
C key.
Work step 6: Diagnosis of exhaust gas recirculation

system
Select function 04 initiating basic Setting and then

display group 075.
Depress neither brake nor clutch pedal.

Briefly blip throttle about 5 times up to max. speed.
01-2 page 4
Self-diagnosis II
Edition 06.04
S00.5309.04.20
01

If the diagnosis is initiated by the engine control unit the
display in display field 4 will switch from Test OFF to
Test ON.

4830/min
371mbar
0mbar
75
Test OFF
Leave engine running at idling speed until Syst. O.K.

is displayed in display field 4.
If the display does not occur as described:

If the display occurs as described:

Read out readiness code 01-2 page 1.
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Self-diagnosis II
01-2 page 5
01
01-2 page 6
Self-diagnosis II
Edition 06.04
S00.5309.04.20
01-3
01
Self-diagnosis III
Fault table, fault codes 16496...17566

Note
Faults related to the electronic throttle are indicated
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-
haust gas warning lamp in the dash panel insert.

Explanations regarding fault types (e.g. open circuit
or short-circuit to earth) Operating instructions for

the vehicle system tester.
If parts are output as faulty: First test all of the cables
and plug connections to these components as well as

the earth cables of the system according to the current
flow diagram. Only if no fault is detected here should
the part be replaced. This applies in particular if faults
are shown as sporadic (SP).
Once the fault has been corrected erase the fault
memory Chapter 01-1 and re-generate the readiness code Chapter 01-2.
Printer edition e.g.:

16497 P0113 035
Intake manifold temperature sender -G72Signal too high
sporadically occurring fault
Explanations:
16497 = fault code
P0113 = Ignore the SAE code that may appear next to the
fault code.
035 = fault type as digit
Intake manifold temperature sender -G72- = faulty current path or fault location
Signal too great = fault type as text
Sporadically occurring fault = fault not always present,
e.g. loose contact
Edition 06.04
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Self-diagnosis III
01-3 page 1
01
Readout on -V.A.G 1552-
Rectifying fault
16496
Intake manifold temperature
sender -G72-1)
Signal too low
16497
sender -G72-1)
Signal too high
Read measured value block, display group 004, display field 4 Chapter 01-5
Inspecting intake manifold temperature sender

Chap. 24-2
Replace engine control unit Chapter 24-5
Implausible signal
16500
Sender for the coolant temperature -G62-1)
Check the coolant temperature sender -G62 Chapter 24-2

Read measured value block, display group 001, dis-
Signal too low

16501
play field 2 Chapter 01-5
Check the coolant temperature sender -G62 Chapter 24-2
Signal too high

16502
Test coolant thermostat 1.4/55; 1.4/74 Engine Mechanical Components; Rep. Gr. 19
16505
Throttle valve potentiometer
-G69-1)
Implausible signal
16506
-G69-1)
Signal too low
16507
-G69-1)
Signal too high
16514
Bank 1 probe 11)
Electrical fault in the circuit

Test throttle valve control unit Chapter 24-2
Testing lambda probe and lambda control upstream

of catalytic converter Chapter 24-4
Remove short-circuit or line interruption Current

Flow Diagrams, Electrical Fault Finding and Fitting
Locations.
16517
Bank 1 probe 1 elect.1)
Signal too low
16518
Bank 1 probe 11)
No activity

Reading measured value block, display group 030

Chap. 01-6

Chap. 01-6
16519
Bank 1, probe 1
Heating circuit electrical

fault
16520
Bank 1 probe 21)
Test lambda probe heater downstream of catalytic
16521
Bank 1 probe 21)
Voltage too low
Test lambda control before catalytic converter

converter Chapter 24-4
Chapter 24-4

01-3 page 2
Self-diagnosis III
Edition 06.04
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01

Rectifying fault
16522
Bank 1 probe 21)
Voltage too high
16524
Bank 1 probe 21)
No activity
16525
Bank 1 probe 21)
Heating circuit electrical

fault
Test lambda probe after catalytic converter

Chapter 24-4

Chapter 24-4

Check fuel filter with regulating valve 1.4/55, 1.4/
Malfunction
16554
Bank 1, fuel metering system1)
74 Engine - Mechanics; Rep. Gr. 20
Testing lambda control before catalyst Chapter

24-4

Chap. 01-6

Chap. 01-6
Check fuel filter with regulating valve 1.4/55, 1.4/
System too lean

16555
Test injection valves Chapter 24-3

Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4

Testing lambda control before catalyst Chapter
System too rich

16556
24-4

Chap. 01-6

Chapter 24-4
16585
Injector cyl. 1 -N30-2)
16586
16587
16588
16603
Maximum engine speed

exceeded
Rectify any mechanical engine damage
16605
Angle sender 2 for TV drive
-G188-1)2)
Implausible signal
Read measured value block, display group 062
16606
-G188-1)2)
Signal too low
16607
-G188-1)2)
Signal too high
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Chapter 01-7
Self-diagnosis III
01-3 page 3
01
Rectifying fault
Read measured value block, display group 062
16611
Sender for accelerator pedal
position -G79-1)2)
Signal too low
16612
position -G79-1)2)
Signal too high
16646
Short circuit to positive
16649
16652
16655
166841)
Combustion misfiring
detected
Chapter 01-7
Test accelerator pedal position sender Chapter

24-2

Test ignition leads and spark plugs Chapter 28-1
Testing ignition transformer with power amplifier
Chapter 28-1
Inspecting misfiring detection Chapter 28-1

16685
Cylinder 11)
detected
16686
Cyl. 21)
detected
16687
Cyl. 31)
detected
16688
Cyl. 41)
detected
16705
Engine speed sender -G28-1)
Implausible signal
Check engine speed sender -G28- Chapter 24-3
16706
Engine speed sender -G28-1)
No signal
Remove line interruption or short-circuit Current
16708
Knock control
16709
Knock sensor 1 -G6116710
Knock sensor 1 -G61-
Flow Diagrams, Electrical Fault Finding and Fitting

Locations
Malfunction
Electrical fault in the cir-

cuit
Implausible signal
16711
Signal too low
16712
Signal too high
01-3 page 4
Check engine speed sender -G28- Chapter 24-3

Inspecting knock sensor Chapter 28-1
Read measured value block 028 Chapter 01-5
Read measured value block 028 Chapter 01-5
Self-diagnosis III
Edition 06.04
S00.5309.04.20
01

Rectifying fault
16725
Camshaft position sensor
sender -G40-1)
Implausible signal
16726
sender -G40-1)
Signal too low
16727
sender -G40-1)
Signal too high
16735
Ignition control cyl. 11)
Malfunction
16736
Malfunction
16737
Malfunction
16738
Malfunction
16785
system1)
Flow rate too low
16786
system1)
Flow rate too great
16787
valve -N18-1)
Malfunction
16788
system1)
Control difference
16791
Potentiometer for exhaust gas
recirculation -G212-1)
Signal too low
16792
Signal too high
16804
Bank 1, catalytic converter
system1)
Efficiency too low
Inspecting hall sender Chapter 28-1
Test combustion misfiring Chapter 28-1
Test exhaust gas recirculation valve -N18 Chapter 01-1, final control diagnosis
Perform basic setting (measured value block 074

and 075) Chapter 01-7

Testing intake system for tightness Chapter 24-3

Inspect exhaust system for leaks 1.4/55; 1.4/74
Engine - Mechanics; Rep. Gr. 26
Check catalytic converter 1.4/55; 1.4/74 Engine Mechanics; Rep. Gr. 26

16825
Tank ventilation system1)
Flow rate incorrect
Testing solenoid valve 1 for activated charcoal filter

Chapter 01-1, final control diagnosis
Inspect hoses and connection pipes from fuel tank

up to injection rail 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
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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

Testing signal of fuel gauge sender Current Flow

Diagrams, Electrical Fault Finding and Fitting Locations
Test speed signal Chapter 24-6

Remove open circuit in wiring or short circuit according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Adapt engine control unit to control unit for electronic
16897
Engine control unit
Blocked
16916
Pressure sensor for air conditioning system
Signal too low
16917
Pressure sensor for air conditioning system
Signal too high
16946
Voltage supply
Voltage too low
testing voltage supply Chapter 24-5
16947
Voltage supply
Voltage too high
16955
Brake light switch -F-
Implausible signal
Test brake light switch and brake pedal switch
immobiliser Electrical System; Rep. Gr. 96.
Test G65 Air conditioning system; Rep. Gr. 87
Chapter 24-6
Replace engine control unit -J537- Chapter 24-5
16988
Control unit defective1)
16989
16990
16991
Throttle valve control unit
-J338-2)
Undervoltage on basic
settings
Adapt engine control unit to throttle valve control unit
17022
-J338-1)2)
Implausible signal
Check battery, if necessary charge Electrical Sys-
Chapter 24-5
tem; Rep. Gr. 27

Testing signals from and to the air conditioning sys-
17029
Air conditioning system inlet/
outlet
tem Electrical System; Rep. Gr. 90
17034
Exhaust gas warning light
-K83-
Testing signals from and to the warning light -K83-
17040
Fuel consumption signal
Check the fuel consumption signal Electrical Sys-
Electrical System; Rep. Gr. 90
tem; Rep. Gr. 90.
Test CAN databus Chap. 24-6.
01-3 page 6
Self-diagnosis III
Edition 06.04
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01

Readout on -V.A.G 155217510
Bank 1, probe 1 heating
circuit1)
Rectifying fault
Testing lambda probe heater upstream of catalytic

Remove short-circuit according to Current Flow Diagram Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
17513
circuit1)
17523
circuit1)
Short circuit to earth
17524
circuit1)
Open circuit



Remove line interruption according to Current Flow
Diagram Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations

17525
circuit1)
17526
circuit1)
Open circuit
17550
Load detection



Below limit
Chapter 24-5

24-2
17559
Bank 1, mixture adaptation
range 11)
Below leanness limit
17560
range 21)
Below leanness limit
Test air filter Chapter 24-1

Check engine mechanics
Test fuel pump 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20

Check exhaust gas recycling system 1.4/55; 1.4/

Inspect activated charcoal container system for

leaks 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20

Edition 06.04
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Self-diagnosis III
01-3 page 7
01
Rectifying fault
17563
Intake manifold pressure
sender -G71-1)2)
17564
sender -G71-1)2)
Open circuit/Short-circuit to earth
17566
sender -G71-1)2)
Implausible signal
1)
2)
Testing intake manifold pressure sender Chap.

24-2
Testing intake system for tightness (unmetered air)

Chapter 24-3.
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
01-3 page 8
Self-diagnosis III
Edition 06.04
S00.5309.04.20
01
01-4
Self-diagnosis IV
Fault table, fault codes 17573...18100

Rectifying fault
17573
range 11)
Above richness limit
17574
range 21)
Above richness limit

Test fuel pump 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20

Check exhaust gas recirculation system 1.4/55;

1.4/74 Engine - Mechanics; Rep. Gr. 26
Inspect activated charcoal container system for leaks

1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20

17579
-G188-1)2)
Implausible signal
17580
-G188-1)2)
Signal too low
17581
-G188-1)2)
Signal too high
Test throttle valve control unit -J338- Chapter 242.

Adapt throttle valve control unit Chapter 24-5.
17582
Deviation of the injecBank 1, fuel metering system1) tion periods

Test fuel pump 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20


Inspect activated charcoal container system for leaks

1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20

Regulating limit
17584
Bank1, lambda correction ac- reached
cording to catalytic converter1)


Edition 06.04
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Self-diagnosis IV
01-4 page 1
01
Rectifying fault
17586
Linear lambda probe/pump
current1)
Open circuit
17587
current1)
17588
current1)
17589
Linear lambda probe/reference voltage1)
Open circuit
17590
17591
17598
implausible
17604
Bank 1, probe 1, heating
circuit1)
Electrical fault
17606
Bank 1, probe 2, heating
circuit1)
Electrical fault
17621
17622
17623
17624
17645
Open circuit
17646
Open circuit
17647
Open circuit
17648
Open circuit
17661
17662
17743
Engine torque monitoring 21)2)
Regulating limit exceeded



Test ignition leads and spark plugs Chapter 28-1

Test combustion misfiring Chapter 28-1


Test dash panel insert Electrical System;

Rep. Gr. 90
Testing intake system for tightness Chap. 24-3.

Inspect accelerator pedal position sender -G79- and
-G185- Chap. 24-2.
Test throttle valve control unit -J338- Chapter 242.
01-4 page 2
Self-diagnosis IV
Edition 06.04
S00.5309.04.20
01

Rectifying fault
17745
Bank 1, camshaft pos. sensor
-G40-
Inspecting hall sender Chapter 28-1
17746
Bank 1, camshaft pos. sensor
-G40-
Check camshaft position sensor -G40- Chap. 28-1

Remove open circuit in wiring or short circuit accord-
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.
Inspect ignition transformer Chapter 28-1

Remove open circuit in wiring or short circuit according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Inspect ignition transformer Chapter 28-1

Remove line interruption according to Current Flow
Diagram Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations.
17764
Short circuit to positive3)
17765
Short circuit to earth3)
17766
Open circuit3)
17767
17768
17769
Open circuit3)
17770
17771
17772
Open circuit3)
17773
17774
17793
Check the ignition coils with power output stage

Chapter 28-1.
Remove short-circuit according to Current Flow Diagram Current Flow Diagrams, Electrical Fault
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
valve -N18-1)
17810
valve -N18-1)
17811
system1)
Control difference
Test engine speed sender Chapter 24-3

Test exhaust gas recirculation valve Chapter 01-1,

final control diagnosis.
Check the EGR valve 1.4/55; 1.4/74 Engine - Me-
17812
Basic setting not perExhaust gas recirculation sys- formed
tem
17818
17833
17834
Open circuit
17847
Incorrect basic setting
17848
valve -N18-1)
Open circuit
17850
Signal too high
17851
Signal too low
17909
Fuel pump relay -J17-
17910
17912
Air intake system2)
Leak detected
chanics; Rep. Gr. 26.
Conduct basic setting (measured value block 074)

Chapter 01-7
Test solenoid valve for activated charcoal filter

Conduct basic setting (measured value block 074)

Chapter 01-7
Check the EGR valve 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26.
Test exhaust gas recirculation valve Chapter 01-1,

final control diagnosis.
Test fuel pump relay -J17- Chapter 01-1, final control diagnosis
Test fuel pump relay Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Inspect intake air system for leaks (unmetered air)

Chapter 24-3



Test fuel pump relay Current Flow Diagrams, Elec-
17949
Open circuit
17950
Angle sender for TV drive
-G187-2)
Implausible signal
01-4 page 4
trical Fault Finding and Fitting Locations

Self-diagnosis IV
Edition 06.04
S00.5309.04.20
01

Rectifying fault
17951
-G187-1)2)
Signal too low
17952
-G187-1)2)
Signal too high
17953
Throttle valve control 1)2)
Malfunction
17961
Level sender/intake manifold
pressure signal2)
implausible ratio
Testing intake manifold pressure sender Chap. 242
Testing intake system for tightness (unmetered air)

Chapter 24-3.


17962
-J338-2)
17967
-J338-1)2)

Requirements for basic Adapt engine control unit to throttle valve control unit
setting not fulfilled
Incorrect basic setting
Repair mechanical damage
17968
Maximum engine speed exceeded
17972
-J338-2)
Chapter 24-5
Undervoltage on basic
settings
Test battery, charge if necessary Electrical System; Rep. Gr. 27

Chapter 24-5
17973
Bottom limit not

reached
17977
CCS switch -E45-
Implausible signal
Check throttle valve for damage or dirt

Inspecting cruise control system Chap. 24-6
Adapt engine control unit to electronic immobiliser
17978
Engine control unit blocked1)2)
Electrical System; Rep. Gr. 96.
Test electronic immobiliser Electrical System;

Rep. Gr. 96
17989
-J338-
Basic setting not performed
18010
Voltage supply tml. 30
Voltage too low
Perform procedure for voltage interruption Chap.
18019
Fault lamp requirement on
Chapter 24-5
24-5
Inspect databus Chapter 24-6

Test exhaust gas warning lamp Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
18020
Engine control unit
Edition 06.04
S00.5309.04.20
Incorrectly coded
Code engine control unit Chapter 24-5
Self-diagnosis IV
01-4 page 5
01
Readout on -V.A.G 155218021

Fault lamp requirement on
Rectifying fault
Open circuit/Short circuit to positive

Test exhaust gas warning lamp Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
18034
Data BUS drive
Missing message from

gearbox CU
18038
position -G79-1)2)
Signal too low
18039
position -G79-1)2)
Signal too high
18041
Sender 2 for accelerator pedal
position -G185-1)2)
Signal too low
18042
position -G185-1)2)
Signal too high
18043
Data BUS drive

air conditioning system
CU

Testing air conditioning system CU Heating and

airbag CU

Test airbag control unit Body Fitting Work;
18044
Data BUS drive
24-2
Air conditioning; Rep. Gr. 87
Rep. Gr. 01
18045
Data BUS drive
missing message form

electron. CU

Read out fault memory of electrical system control
unit Electrical System; Rep. Gr. 90
18047
Sender 1/2 for accelerator
pedal position -G79- +
-G185-2)
Implausible signal
24-2
Inspect engine control unit power supply Chapter
18048
24-5
Replace engine control unit -J537- Chapter 24-5

Read out air conditioning system control unit fault
18049
Read out fault memory of air
conditioning CU
18056
Data BUS drive
memory Heating, Air conditioning; Rep. Gr. 01

Read out fault memories of all control units (automat-
defective
ic test sequence) Chapter 01-1
18057
Data BUS drive

ABS CU

Read out fault memories of all control units (automatic test sequence) Chapter 01-1
18058
Data BUS drive

combiinstrument

Rep. Gr. 90
18060
Read out fault memory of
gearbox CU
01-4 page 6
Self-diagnosis of automatic gearbox CU

Automatic Gearbox; Rep. Gr. 01
Self-diagnosis IV
Edition 06.04
S00.5309.04.20
01

Rectifying fault
18061
Read out fault memory of ABS
CU
Self-diagnosis of ABS control unit Running Gear;
18062
Read out fault memory of the
combi-instrument
Self-diagnosis of the dash panel insert control unit
Rep. Gr. 45
Electrical System; Rep. Gr. 90
18064
outlet
18065
outlet
18081
Vehicle speed signal
Error message from

ABS CU
Testing air conditioning system Heating, Air conditioning; Rep. Gr. 87

18085
Fault lamp for electr. accelerator control -K132-1)
18086
Self-diagnosis of ABS control unit Chassis;

Rep. Gr. 45

Rep. Gr. 90
18087
Open circuit
18097
Databus drive
Implausible message
from electron. CU
Test CAN databus cables Chap. 24-6

Inspecting vehicle voltage control unit -J519 Electrical System; Rep. Gr. 90.
18099
-K83-
Open circuit
18100
-K83-
18101
-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.
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Self-diagnosis IV
01-4 page 7
01
01-4 page 8
Self-diagnosis IV
Edition 06.04
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01
01-5
Self-diagnosis V
Measured value blocks

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 devices are operated from the
passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
The coolant temperature must be at least 80C display group 004, display field 3.
All electrical consumers, e.g. lights and rear window

heater, must be switched off (radiator fan must not
run).
If vehicle is equipped with air conditioning, this must

be switched off.
No fault must be present in the fault memory Chap.

01-1, interrogate fault memory and erase.
Procedure

the desired display group number.

HELP
Enter display group number XXX
Note
Display group number 004 is an example to represent the
sequence.

850 rpm
13.9V
88 C
4
41 C
Note
Proceed according to the following table to switch to another display group:
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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
If the specifications are achieved in all the display

fields, press key
Measured value blocks, display groups

001...006 - Basic functions
Display group 001 - Basic functions:
Engine idling
1
Read out on display:
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
Lambda control value

Coolant temperature
01-5 page 3
Engine speed (idling speed)

Vehicles with engine code AUA
650...850 rpm1)
Vehicles with the engine codes BBY, BKY
660...860 rpm1)
Vehicles with automatic gearbox

(engine codes AUA, BBY, BKY)
580...780 rpm1)
Vehicles with engine code AUB
740...940 rpm1)
Vehicles with engine code BBZ
580...780 rpm1)
Current value Inspection and Maintenance
1)
Meaning of 8-digit numerical block
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
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01

Meaning if display = 1
1
Meaning
AC compressor disconnected
Catalyst hot (over 300 C)
1
1
No fault detected in self-diagnosis
Analysis of display group 001, engine speed (idling speed)
Display
field
Readout
on display:
Possible cause of fault
Rectifying fault
less than
nominal
value
Throttle valve control unit jams/defective
Test throttle valve control unit Chapter
greater
than
nominal
value
Throttle valve control unit jams/defective
24-2
Air filter element very dirty
Large unmetered air volume (cannot be
compensated by idle stabilizer)
Replace air filter element Chap. 24-1

Interrogate fault memory Chapter 01-1
Testing intake system for tightness
Chapter 24-3

24-2
Performing idling test Chap. 24-3
Analysis of display group 001, coolant temperature
Display
field
Readout
on display:
Rectifying fault
less than
80 C
Engine too cold
Conduct test drive if necessary

Test coolant temperature sender
Sender for coolant temperature or wiring
Chapter 24-2
to engine control unit

Coolant regulator defective
Test coolant thermostat 1.4/55, 1.4/74

Engine - Mechanical Components;
Rep. Gr. 19
greater
than 110
C
Radiator dirty
Radiator fan not operational
Clean radiator
Inspect proper operation Current Flow
Test coolant thermostat 1.4/55, 1.4/74

Rep. Gr. 19

Chapter 24-2
Engine idling
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Self-diagnosis V
01-5 page 3
01

xxxx rpm
xx %
x.x ms
xxx mbar

Display field
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
1)
Display group 001, display field 1 01-5 page 2.
Analysis of display group 002, injection period
Display
field
Readout
on display:
Rectifying fault
less than
2.0 ms
High fuel volume from the activated char-
Testing solenoid valve 1 for activated
charcoal filter Chapter 01-1, final control diagnosis
coal filter system
Incorrect injection valve with too great flow
rate fitted
Check part No. of the injection valves

Spare parts catalogue
greater
than 4.0
ms
Increased engine load due to electric con-
Eliminate load (air conditioning, power
sumers, air conditioning system, engaged

driving position or power steering to the stop
Incorrect injection valves with too small flow
steering etc.)
rate fitted
Check part No. of the injection valves

Spare parts catalogue
Analysis of display group 002 intake manifold pressure
Display
field
Readout
on display:
Rectifying fault
less than
240 mbar
Large volume of unmetered air between in-
Eliminate unmetered air
greater
than 420
mbar
Driving position engaged (automatic gear-
take manifold and air filter
Put selector lever in P or N
box)
Engine loaded by auxiliary equipment
Eliminate load (air conditioning, power

steering etc.)
Engine idling
01-5 page 4
Self-diagnosis V
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01

xxxx rpm xxx mbar
1
xx
xx

Display field
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
Throttle valve angle (potentiometer 1 -G187-)

1)
Engine idling
xxxx rpm
xx.x V
xxx C
xxx C

Display field
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
1)
Note
Re display field 3:
As soon as a fault concerning the coolant temperature
sender -G62- is stored in the fault memory, the engine

control unit uses the intake manifold temperature as a
replacement value to start the engine (starting temperature - replacement value) The temperature then
rises according to a model sequence stored in the
control unit. If the engine is warm after a certain period
a fixed replacement value is displayed. This fixed substitute value depends on the intake air temperature.
Re display field 4:
The overall temperature range is indicated as nominal
value. The nominal value must be higher than the ambient temperature.
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Self-diagnosis V
01-5 page 5
01
Analysis of display group 004, engine control unit voltage supply
Display
field
Readout
on display:
Rectifying fault
less than
12.5 V
Generator defective, battery heavily dis-
Inspect generator and battery voltage,

charge battery Electrical System;
Rep. Gr. 27
charged
Battery heavily loaded just after start by a
minutes and switch off additional consumers
Transition resistance in the power supply or
Inspect engine control unit power supply
earth connection for engine control unit

Current consumption with ignition off
greater
than 14.5
V
Increase engine speed slightly for a few
high charge current or by auxiliary equipment
Voltage regulator on generator defective
Chapter 24-5
Eliminate current consumption

Check voltage regulator, if necessary replace Electrical System; Rep. Gr. 27
Overvoltage due to starting aid or quick
charger
Interrogate fault memory Chapter 011
Analysis of display group 004, coolant temperature
Display
field
Readout on
display:
Rectifying fault
less than Engine too cold

80 C
Coolant temperature sender or cable connection to engine control unit faulty
Conduct test drive if necessary

Chapter 24-2
Test coolant thermostat 1.4/55; 1.4/74

Rep. Gr. 19
greater
than 110
C
Radiator dirty
Radiator fan not operational
Clean radiator
Inspect proper operation Current Flow
Test coolant thermostat 1.4/55; 1.4/74

Rep. Gr. 19
constant
- 40 C
Open circuit or short circuit to positive
constant
120 C
01-5 page 6

Chapter 24-2

Chapter 24-2
Self-diagnosis V
Edition 06.04
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01
Analysis of display group 004, intake manifold temperature
Display
field
Readout on
display:
Rectifying fault
constant
- 40 C
Open circuit or short circuit to positive
Inspecting intake manifold temperature
constant
120 C
sender Chap. 24-2
Engine idling
xxxx rpm
xx %
xxx km/h
Text

Display field
Operating condition (idling, partial
load, enrichment,
trailing throttle)
Driving speed
Engine load
1)
Specification
Analysis:
Idling
0 km/h
10...20 %
01-5 page 8
rpm1)
01-5 page 3
xxxx
Engine idling
6

xxxx rpm
xx %
xxx C
xx.x %

Display field
Specification
Level correction
factor
-30,0...5,0 %

Engine load
1)
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.
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Self-diagnosis V
01-5 page 7
01

010...029 - Ignition
Display group 010 ignition:
Engine idling
10
xxxx rpm
xx %
xx %
xx.x

Display field
Ignition angle

Engine load
1)
Specification
Analysis:
0...10.0 BTDC
0...11 %
01-5 page 8
10...20 %
01-5 page 8
xxxx rpm1)
01-5 page 3
Analysis of display group 010, engine load
Display
field
Readout
on display:
Rectifying fault
less than
10 %
Lower value can only occur during trailing
throttle driving
Poor idling (engine not running on all cylingreater

ders)
than 20 %

Test ignition leads and spark plugs
Chapter 28-1
Electrical consumers on
Steering wheel at limit stop
Driving position engaged (automatic gear-
Disconnect electric consumer

Put steering wheel in centre position
Put selector lever in P or N
box)
Analysis of display group 010, throttle valve angle
Display
field
Readout
on display:
Rectifying fault
Engine control unit not adapted to throttle

greater
valve control unit
than 11 %
Throttle valve potentiometer in throttle valve
control unit defective
control unit Chapter 24-5

24-2
Throttle valve blocked

01-5 page 8
Adapt engine control unit to throttle valve
Self-diagnosis V
Eliminate cause
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01
Display group 014 - Ignition, sum of misfiring detection:
Driving
14
xxxx rpm
xxx %
xxx
Text

Display field
Combustion misfiring detection
(activated, deactivated)
Specification
Analysis:
activated
01-5 page 9
12100 %
6505700 rpm
6605700 rpm

5805700 rpm
7406600 rpm
5806600 rpm
Sum of ignition misfiring

Engine load
Engine speed
Analysis of display group 014, sum of ignition misfiring
Display
field
Readout
on display:
Rectifying fault
greater
than 0
Spark plug defective
Test spark plugs and spark cables with
Spark plug connector defective

Ignition transformer defective
spark plug connector Chap. 28-1
Inspect ignition transformer Chapter

28-1

Exhaust gas recirculation valve jams/soiled Test exhaust gas recirculation valve
Injection valve defective
Chapter 01-1, final control diagnosis.
Display group 015 - ignition, cylinder misfiring 1

to 3:
Driving
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Self-diagnosis V
01-5 page 9
01
15
xxx
xxx
xxx
Text

Display field
Ignition misfiring cylinder 3

Specification
Analysis:
activated
01-5 page 10
01-5 page 10
01-5 page 10
Display group 016 - ignition, cylinder misfiring 4:
Driving
16
xxx
Text

Display field
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
Spark plug defective
Rectifying fault
Test spark plugs and spark cables with
Spark plug connector defective
spark plug connector Chap. 28-1
Ignition transformer defective
Inspect ignition transformer Chapter

28-1
Exhaust gas recirculation valve jams/dirty

Test exhaust gas recirculation valve
Chapter 01-1, final control diagnosis.
Display group 022 ignition, knock control:
Driving
01-5 page 10
Self-diagnosis V
Edition 06.04
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01
22

xxxx rpm
xxx %
xx.x
xx.x

Display field
Specification
Analysis:
Ignition angle relief

cylinder 2 through
knock control
0...14
01-5 page 12
Ignition angle relief cylinder 1

through knock control
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
is the largest ignition angle relief.
Display group 023 - ignition, knock control:
Driving
23

xxxx rpm
xxx %
xx.x
xx.x

Display field
through knock
control

through knock control
Engine load
Engine
speed
Edition 06.04
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Specification
Analysis:
0...14
01-5 page 12
0...14
01-5 page 12
15...100 %
6505700 rpm
Vehicles with the engine codes BBY,

BKY
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
is the largest ignition angle relief.
Analysis of display groups 022/023, ignition angle relief
Display
field
Readout
on display:
Rectifying fault
3 and
4
All 14
cylinder
Knock sensor defective

Check knock sensor plug connection
Plug connection corroded
Chap. 28-1
Knock sensor incorrectly tightened
Plug connection corroded
Engine damage
Test compression 1.4/55; 1.4/74 Engine -
Component parts on engine loose

Poor fuel quality
Once cylinder
clearly
deviates
from the
others
Release knock sensor and tighten (20 Nm)

Attach component parts
Change fuel type
Check knock sensor plug connection
Chap. 28-1
Mechanical Components; Rep. Gr. 15.
Component parts on engine loose
Attach component parts
Display group 028 - ignition, knock control:
Driving
Diagnostic device in function 04 - basic setting
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

030...049, 099 - Lambda control
Display group 030 - lambda control:
Engine idling
30
xxx
xxx

Display field
Specification
Analysis:
Status lambda control downstream of catalytic converter
110
01-6 page 1
Status lambda control upstream of catalytic converter
111
01-6 page 1
Note
Re display field 2:
The 3rd display position is only set to 1 in the partial
load region.
Meaning of the 3-digit numerical block display field 1:
Meaning if display positions = 1

1
3
1
1
1
Lambda control active

Lambda probes operational
Lambda probe heating on
Display group 031 - lambda control, lambda values upstream of catalytic converter:
Engine idling
Coolant temperature 80 C
Edition 06.04
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Self-diagnosis VI
01-6 page 1
01

x.xxxx
x.xxxx
31
4
< Readout on display

< Display field
No display
No display
Lambda nominal value - Bank 1
Lambda actual value - Bank 1
Specification
Analysis:
---
---
---
---
0,99001,0100
---
0,96001,0400
---
Display group 032 - Lambda control, Lambda initialisation values:
Engine idling
xx.x %
xx.x %
32

Display field
Lambda learned value under partial load

(multiplicative) upstream of catalytic converter
Lambda learned value in idling (additive) upstream
of catalytic converter
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
rich and the lambda control therefore produces a leaner mixture.

High readouts mean that the engine is running too
lean and the lambda control therefore produces a richer mixture.

If the control unit is dead all initialisation values are re-
set.
add = additive - The effect of the fault (e.g. unmetered
air) becomes increasingly less as engine speed rises.

In the case of an additive initialisation value the injection period is changed by a fixed rate. This rate is independent of the basic injection period.
mul = multiplicative - The effect of the fault (e.g. faulty
injector) becomes greater as engine speed rises. The

multiplicative learned value is a percentage change in
the injection period. This change is dependent on the
basic injection period.
Initialisation conditions for partial load. Coolant tem-
perature at least 75 C, intake air temperature max. 90

C, driving mode.
01-6 page 2
Self-diagnosis VI
Edition 06.04
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01
Analysis of display group 032, Lambda control, Lambda learned values
Display
field
Readout
on display:
Rectifying fault
1 and
2
low lambda
learned
values
Low learned values in idling at normal
Disappears after motorway driving or oil
learned values in partial load: Oil dilution

(higher fuel content in the oil) possible
change

Test fuel pressure regulator and holding
Injection valve leaks

Fuel pressure too high
pressure Engine 1.4/55; 1.4/74 Mechanics; Rep. Gr. 20.
Solenoid valve 1 for activated charcoal filter
Testing solenoid valve 1 for activated
charcoal filter Chapter 01-1, final control diagnosis
-N80- constantly open

Lambda probe heating defective or lambda
Testing lambda probe heater upstream

probe dirty
Display
field
Readout
on display:
Rectifying fault
1 and
2
high
lambda
initialisation values
High learned values in idling at less high

Chapter 24-3
learned values in partial load: Unmetered

air in intake manifold region possible
Unmetered air between air filter and throttle
Eliminate cause
valve
Unmetered air at the exhaust manifold gas-
Eliminate cause
ket
Injection valve blocked
Fuel pressure too low
Test fuel pressure regulator and holding

pressure 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20.
Lambda probe heating defective or lambda
Testing lambda probe heater upstream of

catalytic converter Chapter 24-4
probe dirty
Display group 033 - Lambda control, Lambda

control values:
Engine idling
33
xx.x %
x.xxx V

Display field
Lambda probe voltage before catalyst

Lambda control before catalyst
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
displayed, the lambda control has switched from

closed-loop to open-loop control because of a fault in
the lambda control. Interrogate fault memory
Chapter 01-1.
Note
Re display field 2:
Display 0.450 V equals approx.
= 1.0.
Voltage signal Mixture rich (low level of residual ox-
ygen) is below 0.45...V.

Voltage signal Mixture lean (a lot of residual oxygen)
is above 0.45...V.
Through its structure the wide-band lambda probe en-
ables a permanent lambda control due to the signal

routing for deviations as of = 1.
The control is performed dynamic, as the deviation
from the specification is current and is known as the

concrete value.
Analysis of display group 033, lambda control upstream of catalytic converter
Display
field
Readout
on display:
Rectifying fault
not within
tolerance
Minimum range: Engine too rich, lambda
wait 30 seconds until the display has
control leans off
stabilised
Plus range: Engine too lean, lambda control
enriches
Unmetered air

Chapter 24-3
Test injection valve Chap. 24-3
Lambda learned values on limit
Test lambda initialisation values in display group 032 01-6 page 3
Display group 034 - Lambda control, diagnosis

of lambda probe upstream of catalytic converter
(ageing test over amplitude quality grade)
Blip two short accelerations above 5000 rpm

Vehicle standing, engine running at high speed
01-6 page 4
Self-diagnosis VI
Edition 06.04
S00.5309.04.20
01

xxxx rpm
xxx.x C
x.x s
3

Text
4
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.)
Period of lambda probe upstream of catalytic converter

Catalytic converter temperature
Engine speed
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
voltage jumps (e.g. rich - lean - rich) of the lambda

probe and is thus an indication of the age condition of
the lambda probe. If the given time is exceeded, display field 4 = B1 S1 N.O.K.
Display group 036 - lambda control, operation

after catalyst
Vehicle standing, brake pedal activated, engine running at raised idling (1500.4000 rpm)

x.xxx V
Text
Display field
Test lambda probe downstream of catalytic converter

(Test OFF/Test ON/B1 S2 n.o.k.)
Lambda probe voltage after catalytic converter
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
Short-circuit to positive terminal in: Lambda
Test basic voltage of the lambda probe
probe, lambda probe cable, earth lead, engine control unit
downstream of catalytic converter

Chap. 24-4
Test lambda probe after catalytic converter Chapter 24-4
constant
between
0.400
...0.500 V
Line interruption in: Lambda probe, lambda
constant
0.000 V
Short-circuit to earth in: Lambda probe,
probe cable, earth lead, engine control unit
lambda probe cable, earth lead, engine control unit
Display group 037 - Lambda control, Lambda

probes downstream of catalytic converter:
Driving
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-
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 ( = 1.0).
01-6 page 6
Self-diagnosis VI
Edition 06.04
S00.5309.04.20
01

In view of the steep voltage jump the lambda control
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-
stream of the catalytic converter -G39- must fluctuate

between a rich and leaner mixture. The voltage of the
lambda probe downstream of the catalytic converter
-G130- should indicate a constant rich or lean mixture.
If the voltage also fluctuates downstream of the catalytic converter, either the catalytic converter is faulty
(Read measured value block 046 01-6 page 8) or
the probes have been wrongly connected (irregular
engine running). Lambda control varies between 15...15 %.
Voltage of the 4-pin lambda probe in U 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
Display group 041 - lambda control, lambda

probe heating:
Engine idling
41
Text
xxx ohms
Text

Display field
Lambda probe
heating downstream of catalytic
converter
Resistance lambda probe

heating downstream of catalytic converter
Lambda probe heating upstream of catalytic converter
Edition 06.04
S00.5309.04.20
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.
Display group 46 - Lambda control, Diagnosis of

catalyst (conversion test):

Vehicle standing, engine running at high speed
No fault in fault memory, coolant temperature 60...120
C, lambda control active and stable
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.)
Measured value catalytic conversion

Catalytic converter temperature
Engine speed
Specification
Analysis:
Cat B1 o.k.
at least 60 %
at least 300 C
15003900 rpm
Display group 099 - Lambda control, Operating

condition of lambda control:
Engine idling
99
xxxx rpm
xxx C
xx.x %
Text

Display field
Operating condition of lambda
control
Lambda control before catalyst

Coolant temperature
1)
Specification
Analysis:
OFF
ON
-15,0...15,0 %
01-6 page 4
80...110 C
Chapter 01-5
rpm1)
Chapter 01-5
xxxx
Display group 001, display field 1 Chap. 01-5.
01-6 page 8
Self-diagnosis VI
Edition 06.04
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01
01-7
Self-diagnosis VII

050...069 - Speed control
Display group 050 - Speed control, Operating
conditions:
Engine idling
50
xxxx rpm xxxx rpm
Text
Text

Display field
Operating state of
AC compressor
Operating condition of air

conditioning system
Specification
Analysis:
ON
OFF
ON
OFF
Engine speed (idling speed - specified

value)
Vehicles with engine code
AUA
750 rpm
(830 rpm)1)

AUB
840 rpm
(870 rpm)1)
Vehicles with the engine

codes BBY and BKY
760 rpm

BBZ
680 rpm

Engine speed (idling speed - actual value)
1)
2)
680 rpm
(800 rpm)1)
xxxx rpm2)
Chapter 01-5
Air conditioning switched on

Display group 001, display field 1 Chap. 01-5
Note
Re display field 2:
The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is

displayed.
The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely overheated.

Note
regarding display fields 3 and 4:
OFF is always displayed on vehicles without air con-
ditioning system.
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Self-diagnosis VII
01-7 page 1
01
Display group 054 - Lambda control:
Driving
54
xxxx rpm
Text
xxx %
xxx %

Display field

position -G79-
Specification
Analysis:
3...97 %
3...97 %
Operating position: Idling, part load, enrichment, overrun, full load
650 ... 5700 rpm
660 ... 5700 rpm

580 ... 5700 rpm
740 ... 6600 rpm
580 ... 6600 rpm
Engine speed
Note
Re display field 2:
The operating condition is displayed according to the
speed or load. As of increased speed trailing throttle

with closed throttle valve is only displayed up to 1450
rpm, after that it returns to idling.
Display group 055 - Speed control, idle stabilizer:
Engine idling
55
xxxx rpm
xx Nm
xx.x %
xxxxx

Display field
Specification
Analysis:
xxxxx
01-7 page 3
Air conditioning on
-6,0...8,0 %
Air conditioning off
-3,0...8,0 %
Operating conditions
Initialisation value idling control
Idling control
-100 Nm

1)
xxxx
rpm1)
Chapter 01-5
01-7 page 2
Self-diagnosis VII
Edition 06.04
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01
Note
Re display field 3:
The display shows to what extent the idling stabilizer
has disinitialised from the constructively 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.
Display field 4 - Operating conditions, meaning of the digits in the 5-digit number block
Meaning if display positions = 1

1
5
1
1
1
Meaning
Air conditioning compressor on
Driving position engaged
No meaning
No meaning
Display group 056 - engine speed control, idling

speed stabilisation:
Engine idling
56
xxxx rpm
xxxx rpm
xx Nm
xxxxx

Display field
Idling control
Specification
Analysis:
xxxxx
01-7 page 3
-10...0 Nm
Engine speed (idling speed - specified

value)
AUA
750 rpm
(830 rpm)1)

AUB
840 rpm
(870 rpm)1)
Vehicles with the engine

codes BBY and BKY
760 rpm

BBZ
680 rpm
Vehicles with automatic gearbox:

Engine speed (idling speed - actual value)
1)
2)
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
control unit (calculated value internal to control unit) is

displayed.
The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely overheated.
Display group 60 - Speed control, Electronic

Throttle Adaptation:
Ignition on, engine stopped

Diagnostic device in function 04 basic setting
60

xxx %
xxx %
xx
Text

Display field
Adaption state
(ADP runs, ADP
o.k. or ADP n.o.k.)
Initialisation step counter

Throttle valve angle (potentiometer 2
-G188-)
Throttle valve angle
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
with the ignition switched on and accelerator pedal not

depressed.
The engine control unit is adjusted to the throttle valve
control unit by selecting display group under function

04 Basic setting. This adjustment must always be
performed if a different throttle valve (or completely
different engine) or a different engine control unit has
been fitted.
If the power supply was interrupted (battery discon-
nected) an adaptation must also be carried out

Chap. 24-5. Work sequence after a power supply
interruption.
During adaptation the counter in display field 3 counts
up to 12.
The basic setting may only be ended once the counter
in display field 3 has reached step 12.
Display group 61 - engine speed control, EPC:
Driving
01-7 page 4
Self-diagnosis VII
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01
61
xxxx rpm
xxx.x %
xxxxx

Display field
Specification
Analysis:
xxxxx
01-7 page 3
0...100 %
6505700 rpm
6605700 rpm

5805700 rpm
7406600 rpm
5806600 rpm
Specification
Analysis:
Engine speed
Display group 062 - engine speed control, EPC:

62
xx %
xx %
xx %
xx %

Display field
Sender 2 for accelerator pedal position -G185-
0...100 %
Sender 1 for accelerator pedal position -G79-
0...100 %
Throttle valve angle (potentiometer 2

-G188-)
3...97 %
3...97 %

070...075 - exhaust gas recirculation
Display group 070 - Exhaust gas reduction, Activated charcoal filter system diagnosis (tank ventilation system):
Engine idling
Coolant temperature minimum 80 C
Edition 06.04
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Self-diagnosis VII
01-7 page 5
01
70
xx %
xx %
xxx mbar
Text

Display field
Result of the activated charcoal filter system
diagnosis
(Test OFF/Test
ON/TVV O.K./
TVV N.O.K.)

Result of current diagnosis
Opening level
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
from 13...25 % to approx. 6 %.
Display group 074 - Exhaust gas reduction, Exhaust gas recirculation valve adaptation:

74
x.x V
x.x V
x.xxx V
Text

Display field
Adaption state
(ADP runs, ADP
o.k. or ADP n.o.k.)
Current pot voltage value
ADP o.k.
0,3004.600 V
100 %- Position
2,94.6 V
0 - Position (basic setting)
0,31.3 V
Note
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 function 04 Basic position. This adaption must
01-7 page 6
Self-diagnosis VII
Edition 06.04
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01

always be performed if another EGR valve (or completely different engine) or another engine control unit
has been installed.
Display group 075 - Exhaust gas recirculation:
Engine idling
Briefly blip throttle 5 times up to max. speed.
75
xxxx rpm xxx mbar
xxx mbar
Text

Display field
Specification
Result: Test ON/

Test OFF, Syst.
o.k./Syst. n.o.k.
Analysis:
Syst. o.k.
Intake manifold pressure difference
min. 50 mbar

Engine speed
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.
Measured value blocks, display group

100 - readiness code
Display group 100 - readiness code:
Engine idling
100 Read out on display:

xxxxxxxx
xxx.x C
xxx s
xxxxxxxx
Display field
Diagnosis status
Time since engine start

Coolant temperature
Readiness code
Display field 1 - Readiness code - Meaning of the digits in the 8-digit numerical block
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
0
Activated charcoal filter system (tank ventilation system)
Secondary air injection system (not fitted/always 0)
Air conditioning system (currently no diagnosis/always 0)
Lambda probes
Lambda probe heater

120...129 - Communication
Display group 120 - traction control system
(TCS):
Driving
120
xxxx rpm
xxx Nm
xxx Nm
Text

Display field
Status
Actual engine load

Nominal engine load
Engine speed
1)
Specification
Analysis:
active/inactive
xxxx rpm1)
Chapter 01-5
Specification
Analysis:
Engine ctl./ no ctl.
Display group 122 - Gearbox (only automatic):
Driving
xxxx rpm
xxx Nm
xxx Nm
Text
Display field
Status
Actual engine load

Nominal engine load
Engine speed
1)
xxxx
rpm1)
Chapter 01-5
Display group 125 - communication, databus

messages
Engine idling
01-7 page 8
Self-diagnosis VII
Edition 06.04
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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
Nominal value = 1; the control units with active data
bus are displayed.
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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
24 Fuel Formation, Injection

24-1
Repairing the injection system
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 - Ignition transformer -N152- *

with identification for ignition
leads, do not switch
11 - 6-pin connector
for wide band lambda probe
with lambda probe heating
before catalyst
9 - Engine speed sender -G28- *

inductive pickup
10
15
S24-0333
12 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- *
1.4/55;
13 - Sender for coolant temperature -G62- *

14 - Hall sender - G40- *
15 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm
Fitting location: in the exhaust manifold
6-pin connector
16 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm
Fitting location: downstream of catalytic converter
4-pin connector
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24-1 page 1
24
Installed location overview for engines with the engine codes BBY, BBZ, BKY
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
-G72- **
6 - Intake manifold
7 - Injectors -(N30N33)- *
8 - Knock sensor -G61- *
9 - Engine control unit *
-J338- *
inductive pickup
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- *
1.4/55;

15 - Hall sender -G40- *
16 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm
pay attention to the spare part number
in exhaust manifold - engines BBY, BBZ
exhaust tube front - engine BKY
6-pin connector - pay attention to different connections for engines with the engine codes BKY EU-4 and EU2DDK 05.04
Fitting location: downstream of catalytic converter
4-pin connector
18 - Ignition coils with a power output stage -N70, N127, N291 und N292 remove with extractor -T 10094-
24-1 page 2
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24
General notes on the injection system

Repairing the ignition Rep. Gr. 28.
The engine control unit is equipped with a self-diagno-
sis system. The first step, before commencing repairs

or fault finding, is to interrogate the fault memories of
all the control units using the automatic test sequence.
This is necessary because different control units are
interconnected via data bus. Also check the vacuum
hoses and connections (unmetered air).
Fuel hoses in the engine compartment must be se-
cured with spring band clamps. The use of clamp-type

or screw-type clips is not allowed.
Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit.
Components marked with an * are checked by self-di-
agnosis Chapter 01-1.
Components marked with
** can be tested with the final control diagnosis Chap. 01-1.
A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components.

Do not use sealants containing silicone. Traces of sil-
icone elements drawn in by the engine are not burnt in

the engine and damage the lambda probes.
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 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 page 3
24
Removing and installing parts of the injection system

1 - Plug
33
pay attention to correct installation position
32
2 - Air filter
disassembling and assem31
bling 24-1 page 11
30
3 - Cable guide
clipped on to fuel rail
4 - 10 Nm
5 - Vent valve
6 - Fuel rail with injection valves
26
disassembling and assem22
bling 24-1 page 10
7 - 20 Nm
8 - from brake servo unit
9 - Connector
25
6-pin
24
for throttle valve control unit
-J33823
Contacts of connector goldplated
1.4/55; 1.4/74 Engine Mechanical Components;
Rep. Gr. 20
11 - Intake manifold
disassembling and assembling 24-1 page 6
12 - Gasket
replace
13 - 10 Nm
14 - Connecting tube
to exhaust gas recirculation valve
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

coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
with 4-pin connector
Contacts 3 and 4 gilded
Power supply for lamda probe heating supplied via fuel pump relay -J17 Testing lambda probe and lambda control downstream of catalytic converter Chapter 24-4
Test lambda probe heater downstream of catalytic converter Chapter 24-4
Fitting location: downstream of main catalytic converter
16 - Connector for lambda probe downstream of catalytic converter
4-pin
17 - Lambda probe 1 upstream of catalytic converter -G39-*, 50 Nm
coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
with 6-pin connector
contacts gold-plated
Power supply for lamda probe heating supplied via fuel pump relay -J17 Testing lambda probe and lambda control upstream of catalytic converter Chapter 24-4
Testing lambda probe heater upstream of catalytic converter Chapter 24-4
Fitting location: Engines BBY, BBZ in the exhaust manifold, engine BKY in the front exhaust pipe
24-1 page 4
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24
18 - Connector for lambda probe upstream of catalytic converter

6-pin - pay attention to different connections for engines with the engine codes BKY EU-4 and EU-2DDK
05.04
20 - 5 Nm
21 - Gasket
replace
22 - Retaining clip
check tightness
23 - Connector
black, 2 pin
for sender for coolant temperature -G62 contacts gold-plated
before removing, reduce pressure in cooling system
25 - Plug
before removing, reduce pressure in cooling system
26 - O-ring
replace if damaged
27 - 10 Nm
28 - Coolant regulator housing
29 - Fuel-intake hose
secure with spring strap clamps
check for firm seating
from fuel filter 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
30 - Connector
for engine control unit
insert or remove only when the ignition is switched off
31 - Engine control unit*
Procedure to follow after power supply interruption has occurred Chapter 24-5
replacing Chapter 24-5
coding Chapter 24-5
Fitting location 24-1 page 1, overview of the engine compartment
32 - Retaining frame
33 - 2 Nm
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24-1 page 5
24
Disassembling and assembling intake manifold

Engines with engine codes AUA and BBY; vehicles mit engines BBY and manual gearbox 08.03
-J338- *
if replaced adapt engine control unit Chapter 24-5
if replaced adapt automatic
gearbox control unit chap.
24-5
2 - 10 Nm
3 - Gasket
Check fitting position
replace
4 - Induction pipe
5 - Gasket ring
replace if damaged
6 - 20 Nm
7 - Gasket ring
replace
8 - Guide plate
replace if damaged
9 - O-ring
replace if damaged
10 - 3 Nm
11 - Intake manifold pressure
-G72- **
Testing intake manifold pressure sender Chap. 24-2
Inspecting intake manifold
temperature sender Chap. 24-2
12 - Intake manifold
out of plastic
removing and installing 24-1 page 4
24-1 page 6
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24
Engines with engine code AUB

-J338- *
2 - Gasket ring
replace if damaged
3 - 10 Nm
4 - 20 Nm
5 - Intake manifold
Aluminium casting
pay attention to the spare
part number
removing and installing
24-1 page 4
6 - Gasket ring
replace
7 - Guide plate
replace if damaged
8 - O-ring
replace if damaged
-G72- **
temperature sender
Chap. 24-2
10 - 3 Nm
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24-1 page 7
24
Engines with engine codes BBZ; vehicles mit engines BBY and manual gearbox 09.03
1 - Intake manifold
out of plastic
part number
24-1 page 4
-J338- *
3 - 10 Nm
4 - Gasket ring
replace if damaged
5 - 20 Nm
6 - Gasket ring
replace
7 - Guide plate
replace if damaged
8 - O-ring
replace if damaged
9 - 3 Nm
-G72- **
temperature sender
Chap. 24-2
24-1 page 8
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24
Engines with engine identification letters BKY

1 - Intake manifold
out of plastic
part number
24-1 page 4
-J338- *
if replaced adapt automatic
gearbox control unit chap.
24-5
3 - 7 Nm
4 - Gasket
replace if damaged
5 - 20 Nm
6 - Gasket ring
replace
7 - O-ring
replace if damaged
-G72- **
temperature sender
Chap. 24-2
Edition 06.04
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24-1 page 9
24
Disassembling and assembling fuel distributor with injectors

1 - Fuel-intake hose
secure with spring strap
clamps
2 - 10 Nm
3 - Fuel distributor
4 - Vent valve
5 - Retaining clip
check tightness on the injection valve and fuel distributor
6 - O-ring
replace
before fitting moisten lightly
with clean engine oil
2
4
5
6
7
7 - Injector -N30--N33 inspect Chapter 24-3

Resistor 14...17 at 20 C
5
7
S24-0339
Removing
Unplug connector -arrows- of the injectors.
24-1 page 10
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24
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.
Remove the fuel distributor with injectors from the inlet

manifold.
Installing
S10-0099
Installation is carried out in the reverse order.

Note
Replace O-rings.
before fitting moisten O-rings lightly with clean engine
oil
Disassembling and assembling the air filter

1 - Air filter top part
2 - Gasket
replace if damaged
3 - Filter insert
4 - Air filter bottom part
5 - Rubber holder
6 - 3 Nm
7 - Gasket ring
replace if damaged
8 - Inlet connection with control
flap
preheating Chapter 24-3
7
5
6
S24-0331
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24-1 page 11
24
Fig. 1:
Resistance values for the coolant temperature sender -G62-
The diagram is divided into two temperature ranges:

A - from 0...50 C
B - from 50...105 C
Read out examples:
30 C is in range A and corresponds to a resistance of
1.5...2.0 k
80 C is in range B and corresponds to a resistance of
275...375
Fig. 2:
Resistances for intake manifold pressure

sender -G72-
The diagram is divided into two temperature ranges:

A - from 0...50 C
B - from 50...105 C
Read out examples:
20 C is in range A and corresponds to a resistance of
2.3...2.6 k
80 C is in range B and corresponds to a resistance of
290...330
Fig. 3:
Removing and installing an engine cover

with air filter
Removing
Pull off hose -1- (engines 04.02 ) and remove engine cover -2- with air filter upwards -arrows-.
Installing
Installation of the engine cover with air filter occurs in

reverse order.
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
Edition 06.04
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24
For reasons of safety fuse no. 40 must be removed
from the fuse holder before opening the fuel system,

as the door contact switch could activate the fuel
pump.
Do not touch or remove ignition leads with the engine
running or at start speed.

Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
rear seat and also have a second person operate

them there.
If the engine must be operated at start speed without
the engine starting:

For engines with the engine codes AUA, AUB
Unplug the 4-pin connector -arrow- from the ignition

transformer.
For engines with the engine codes BBY, BKY, BBZ
Pull out all ignition coils using the extractor -T 10094-.

For all vehicles
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-
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.

Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use

any parts which have been stored unwrapped, e.g. on
a shelf or in a tool box.
When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.
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24-1 page 13
24
24-1 page 14
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24-2
24
Testing components
Testing throttle valve control unit

Components for throttle valve control unit -J338-: Throttle
valve drive -G186-, throttle valve drive angle sender 1
-G187- and throttle valve drive angle sender 2 -G188-.
Note
If the throttle valve control unit is replaced, it is then
essential to adapt this new throttle valve control unit to

the engine control unit Chap. 24-5.
On vehicles with an automatic gearbox the gearbox
control unit must also be replaced Chap. 24-5.

-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
Throttle valve is not damaged or dirty.

Test sequence
Unplug the 6-pin connector from the throttle valve

control unit.
Measure resistance of throttle valve drive between

contacts 3 + 5.
Specified value: 3...200
If the specified value is not reached:
Replace throttle valve control unit -J338-.

If the specified value is reached:
Test voltage supply of throttle valve control unit and

cables to engine control unit 24-2 page 1.
If the power supply and wiring is O.K.:

Testing voltage supply and wiring to the control
unit
Unplug the 6-pin connector from the throttle valve

control unit.
Connect the multimeter for voltage measurement to

contacts 2 + 6 of the connector.
Switch on ignition.
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Testing components
24-2 page 1
24
Specified value: min. 4,5 V

contact 2 of the connector and to earth.
Switch on ignition.

Connect test box -V.A.G 1598/31- to wiring loom of
control unit Chapter 24-5. The engine control unit is

not connected here.
for interruption:
Plug contact
Test box bush

-V.A.G. 1598/31-
92
83
117
84
118
91
Test the cables for short circuiting with each other.

Inspect engine control unit power supply Chapter

24-5.
Testing accelerator pedal position sender

-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
Battery voltage at least 11.5 V.

Test sequence

ignition on and select address word 01 Engine electronics Chap. 01-1.

display group 062.
Test the nominal value of sender 1 -G79- at idle stop

in display field 3:

2%
2%
14%
62
14%
->
Specified value: 3...100 %
Test the nominal value of sender 2 -G185- at idle stop

in display field 4:
Specified value: 3...100 %
Note
The engine control unit converts the voltage values of the
throttle valve drive angle sender in percentage (in relation
to 5 Volts) (5 Volts power supply correspond to 100%).
Slowly press the accelerator pedal while observing

the values in the display fields 3 and 4.
Sollwert: 3100 %
Test the voltage supply and the wiring of the accelerator pedal position sender 24-2 page 3.

Testing voltage supply and wiring to the control
unit
Remove storage compartment on driver side Body

Fitting Work; Rep. Gr. 68.
Disconnect the 6 pin plug connection from the accelerator pedal position sender.
Switch on ignition.
the following contacts of the connector:
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3

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Testing components
24-2 page 3
24

not connected here.
Check wiring between the test box and the plug for interruption according to the Current Flow Diagram:
Plug contact
Test box bush

-V.A.G. 1598/31-
72
73
36
35
33
34

Replace accelerator pedal position sender.
Testing the intake manifold pressure

sender
Note
Only use gilded contacts to repair contacts in the plug
connection of the sender.
Test sequence

Read off intake manifold pressure values indicated in

display field 2.

840/min
365mbar
->
2
Specified value: 240420 mbar
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
If 91 mbar or 1254 mbar is always indicated:

Display
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
Continuation of the test if the display reads 91

mbar:
Disconnect the 4-pin plug connection from the intake

manifold pressure sender - G71- with intake manifold
temperature sender -G72- -arrow- (engine may stall).
Bridge contacts 3 + 4 of the plug connection and observe the read-out on the display.
If the display jumps to 1254 mbar:

Replace the intake manifold pressure sender -G71with intake manifold temperature sender -G72 Chap. 24-1.
If the display remains at 91 mbar:

not connected here.
for interruption according to the Current Flow Diagram.
Plug contact
Test box bush

-V.A.G. 1598/31-
98
109
Also test wire contact 4 for short-circuit to earth and to

contact 1.
Specified value:
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Testing components
24-2 page 5
24
Continuation of the test if the display reads 1254

mbar:

manifold pressure sender - G71- with intake manifold
temperature sender -G72- -arrow- (engine may stall).
If the display jumps to 91 mbar:

If the display remains at 1254 mbar:

Unlock connector at control unit and unplug.
Check the wires for plug of control unit at 4-pin plug
contact 4 for short-circuit to wire contact 3 as well as
after positive battery.
Specified value:
Testing intake manifold temperature

sender
Note
Vehicle system tester e.g. -V.A.G 1552- with cable
-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


display group 004.
Read off intake manifold temperature value in display

field 4.

840 rpm
13.6V
91 C
->
62 C
Specified value: Ambient temperature 1)

1)
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
Edition 06.04
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24
If implausible value appears in the display:

manifold temperature sender -G72- with intake manifold pressure sender -G71- -arrow-.
Connect the multimeter for resistance measurement

to contacts 1 and 2 of the intake manifold temperature
sender.
Specified value:
The nominal value in field A applies for temperature

range 0...50 C, nominal value in field B applies for temperature range 50...105 C.
Example:
For a temperature of 20 C the specification is
2.3...2.6 k
290...330

not connected here.
Plug contact
Test box bush

-V.A.G. 1598/31-
108
85
Additionally check the cable for a short circuit to battery positive.

Specified value:
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Testing components
24-2 page 7
24
Testing coolant temperature sender

Special tools, test and measuring equipment
and aids required
Test sequence

display group 001.
Read off coolant temperatur value indicated in display

840/min
88 C
4.0%
1
->
00111111
field 2.
Specified value: Coolant temperature
If implausible value appears in the display:

Unplug the 2-pin plug for the coolant temperature sensor -G62- -arrow-.

to contacts 1 and 2 of the coolant temperature sender.
Specified value:
S24-0349
The nominal value in field A applies for temperature

range 0...100 C, nominal value in field B applies for temperature range 50...105 C.
Example:
1500...2000
275...375
Replace the coolant temperature sender -G62 Chapter 24-1

not connected here.
24-2 page 8
Testing components
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24
Plug contact
Test box bush

-V.A.G. 1598/31-
93
108
Additionally check the cable for a short circuit to battery positive.

Specified value:
2
S24-0341
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Testing components
24-2 page 9
24
24-2 page 10
Testing components
Edition 06.04
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24
24-3
Testing components I
Test engine speed sender

The engine speed sender -G28- is a speed and reference
marking sender. If the speed signal fails with the engine
running this could result in an engine stoppage.
Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1715 Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Test condition

Test sequence
Disconnect the 3-pin plug connection from the engine
speed sender -G28- Chap. 24-1.

contact 1 (positive) and 3 (earth) of the plug for engine
speed sender.
Switch on ignition.
Specified value: min. 4.5 V

If no voltage is present:

not connected here.
Plug contact
Test box bush

-V.A.G 1598/31-
87
82
108

Specified value:
If no fault was detected in the wiring and if there was no
voltage between contact 1 + 3:
Replace engine speed sender -G28- Chapter 24-1.
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24-3 page 1
24

Testing injection valves

Test control
Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1715 Diode test lamp e.g. -V.A.G 1527 Measuring tool set e.g. -V.A.G 1594 C Current flow diagram
Extractor -T 10094-
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
housing) and body (under battery) are o.k.

Engine speed sender o.k.; check 24-3 page 1.
Check that the Hall sender is o.k. Chapter 28-1.
Fuel pump relay OK
Test sequence
Engines with the engine codes AUA, AUB

transformer.
Engines with the engine codes BBY, BBZ, BKY
Pull out all ignition coils using the extractor -T 10094-.

For all vehicles
24-3 page 2
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24
Connect up the diode test lamp to the contacts of the

plug for cylinder 1.
Actuate the starter and check the power supply to the

injection valve of cylinder 1.
LED must flash.
1
Repeat test on the plug connections for the injection

valves on cylinder 2 to 4.

If the LED does not light up on any cylinder:
S24-0344
Connect the diode test lamp to the plug connection on

cylinder 1, contact 1 and earth.
Actuate the starter and check the power supply to the

injection valve of cylinder 1.
LED must flash.
Repeat test on the plug connections for the injection

valves on cylinder 2 to 4.
If the LED does not flash:

1
S24-0345

If the LED does not light up on one or more cylinders:
Edition 06.04
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24-3 page 3
24

not connected here.
Check wiring between the test box and the 2-pin plugs
on the injection valves for interruption according to the

Injector
Plug contact
Test box bush

-V.A.G 1598/31-
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.
Testing resistances of the injection valves

Test sequence
Check resistance of the individual injection valves.

Specification at 20 C: 14,0...17,0
If the engine is warm the resistance increases by approximately 4 to 6 .
Replace the defective injection valve Chapter 24-1.

Test spray pattern, leak tightness and injected
quantity
Torque wrench
Measuring tool set, e.g. -V.A.G 1594 C Remote control, e.g. -V.A.G 1348/3 A Adapter, e.g. -V.A.G 1348/3-2 Digital potentiometer, e.g. -V.A.G 1630 Measuring vessel, for example -V.A.G 1602-
24-3 page 4
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24
Test conditions
The fuel pressure must be OK, test it 1.4/55; 1.4/74

Engine - Mechanics; Rep. Gr. 20.
Fuel pump relay o.k., testing Chap. 01-1, final control diagnosis.
Fuel temperature 15... 20 C, the fuel must conform to

the valid standards.
Test sequence
Completely remove the fuel rail with all injection

valves from the intake manifold (the fuel hose remains
connected) Chapter 24-1.
Testing jet formation and tightness
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
Hold measuring vessel under the injection valve to be

tested and disconnect the plug on the other injection
valves.
Have a 2nd mechanic actuate the starter. The injection valve must emit a pulsed jet of fuel.
Repeat test at the other injectors. Make sure that only

the valve to be tested is connected.
The jet must be the same for all valves.
Then check the injection valve for leaks. No more than

2 drops/min may trickle out.
If the fuel loss is greater than this:

S24-0340
Testing fuel injected quantity

Note
When testing the injection rate also check the jet formation. The jet must be the same for all injection valves.
Insert injector to be tested in a measuring glass, e.g.

-V.A.G 1602-.
Connect a contact of the injector to be tested with

adapter cables to the battery earth.
Connect the second contact of the injector to be tested with remote control and adapter cable to positive
battery.
Connect battery positive (+) and fuse socket No. 61

with adapter cable and adapter -V.A.G 1348/3-2-.
The fuel delivery unit must start running.
Activate remote control for 30 seconds.

Repeat the measurement on all injectors. Always use
S24-0340
a new measuring glass.
After the measurement of all valves, deactivate the

voltage supply of the fuel delivery unit.
Place the measuring glasses on a flat surface and

compare the quantities of fuel injected.
Nominal value per injection valve:
1.4/55 kW Engine: 57 ... 65 ml
1.4/74 kW Engine: 88 ... 98 ml
If the measurement obtained for one injector is not within
the specification:

The injectors are installed in the reverse order for removal. Pay attention to the following:
24-3 page 6
Edition 06.04
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24

Replace the O-rings on all the injectors and moisten
lightly with clean engine oil.

Fit the fuel rail with the installed injection valves to the
intake manifold and tighten screws uniformly to 10

Nm.
Testing the intake system for tightness

(unmetered air)
Testing with engine leak search spray
-V.A.G 1551/3, 3A, 3B oder 3C Engine leak search spray (e.g. G 001 800 A1)
Test condition
Coolant temperature must be at least 80 C
Chapter 01-5 display group 001, display field 2.
Test sequence
Note
Because of the vacuum in the intake system the leak
search spray is sucked in with the unmetered air. The

leak search spray reduces the ignition performance of
the mixture. This results in a drop in engine speed and
a change in the lambda probe voltage.
You must comply with the safety instructions on the
box.

display group 033.
Observe the control value in display field 1.

Systematically spray parts of the intake system with

2.0%
0.462V
33
->
engine leak search spray.

If the engine speed drops or if the control values changes:
Check the sprayed location of the intake system for

leaks and if necessary eliminate the fault.
If the engine speed or control value does not change:
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24-3 page 7
24
Testing intake manifold preheating

Cooling spray
Testing control flap
Remove air filter Chap. 24-1.

Check position of the regulating flap -1-.
Above +23 C the flap must close the hot air connec-
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
The idling speed, ignition point and CO content are
only measured as they cannot be adjusted.

The idling speed is set to nominal value by the throttle
valve positioner together with the DLS function.

The CO content is set to nominal value by the lambda
control. Faults in the lambda control are detected by

the self-diagnostic system and stored in the fault
memory.
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
The exhaust system between the cylinder head and

the catalyst must be tight.
Coolant temperature at least 80 C Chapter 01-5

display group 004, display field 3.
All electrical components such as lights and rear window heater must be switched off.
If vehicle is equipped with air conditioning, this must

be switched off.
Test sequence
24-3 page 8
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24
Interrogate fault memory, rectify any faults and then

erase the fault memory Chapter 01-1.
Testing idling speed

display group 056.
Check the operating condition in indicator field 4.

750/min
750/min
5Nm
56
->
00000
Specified value: 00000 (meaning Chapter 01-7).
Check nominal idling speed in display field 2.

Specified value:
Vehicles with engine code AUA: 750 rpm
Vehicles with the engine codes BBY, BKY: 760 rpm
Vehicles with automatic gearbox (engine codes AUA,
BBY, BKY): 680 rpm
Vehicles with engine code AUB: 840 rpm
Vehicles with engine code BBZ: 680 rpm
Note
The idling speed of the engine is increased if the battery
is heavily discharged or the engine is extremely overheated.
Check idling speed in display field 1.

Specified value:
Vehicles with engine code AUA: 650 ... 850 rpm 1)
Vehicles with the engine codes BBY, BKY: 660 ... 860
rpm1)
Vehicles with automatic gearbox 580... 780 rpm1)
Vehicles with engine code AUB: 740 ... 940 rpm1)
Vehicles with engine code BBZ: 580 ... 780 rpm1)

If the idling speed is not reached:

Chapter 24-5.
Perform a test drive.

Interrogate the fault memory on the control unit again.
Repeat idling speed test.
If the nominal values are again not reached:
Test throttle valve control unit Chapter 24-2.

Inspecting engine operating conditions Chapter
24-4.
Testing intake system for tightness Chap. 24-3.

1)
Current value Inspection and Maintenance.
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24
24-3 page 10
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24
24-4
Testing components II
Test lambda probe heating before catalyst

Test conditions
1
2
3
4
5
Fuses No. 3 and 9 must be O.K.

The fuel pump relay must be OK.
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
Connect vehicle system tester -V.A.G 1552-. Start en-
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

display group 041.
Check status of the lambda probe heater in display

field 2.

41
->
Ht. before c. ON 15 Ohm Ht. after c. ON
Specified value: Ht. before c. ON.

Note
in display field 2 may show either Htg. before C.ON or
Htg. before C.OFF.
Remove the 6-pin plug -arrow- to the lambda probe

before the catalyst -G39-.
Note
Depending on the lambda probe version, the heater can
be connected to contacts 1 + 2 or 3 + 5 of the 6-pin plug
(only on engines with code letters BKY EU-4 and EU2DDK 05.04 ; the instructions for these engines are listed below in the brackets).
S24-0347
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24-4 page 1
24
Check probe heater at connector for lambda probe,

contact 1 + 2 (3 + 5) for continuity.
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:
Replace lambda probe upstream of the catalyst

-G39-.
If the probe heating has continuity:
S24-0346
Switch the multimeter to voltage measurement and

connect it to contacts 1 + 2 (3 + 5) of the connector to
the engine control unit.
Start engine and run in idle.

Measure the voltage supply and at the same time observe display group 041, display field 2.
Display: Ht. before c. ON.
Specified value: 11.0...14.5 V
or
Display: Ht. bf. c. ON/Ht. bf. c. OFF (alternately)
Specified value: fluctuating between 0...14.5 V


not connected here.
for interruption:
Plug contact
Test box bush

-V.A.G. 1598/31-
1 (3)
Specified value - line resistance: max. 1.5

Check wiring from contact 2 (5) to fuel pump relay

-J17- according to the Current Flow Diagram
Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
If wiring is o.k.:
24-4 page 2
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24
Testing lambda probe and lambda control upstream of catalytic converter

Test conditions
Coolant temperature at least 80 C display group

004, display block 3.
The exhaust system must be tight between the catalyst and the cylinder head.
Check for proper operation

Check status of the lambda control before catalyst

(display field 1):
111
110
30
->
Meaning of the 3-digit numerical block display

field 1:
1 2 3
1 Lambda control active
1
Note
The first digit of the 3-digit numerical block (heating) fluctuates between 0 and 1.
Test lambda probe heating before catalyst 24-4

page 1.

034.

2350/min
244.0 C
0.25s
->
Test ON
Blip 2 accelerations above 5000 rpm.
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24
Set engine speed to 1500...3900 rpm.

Maintain speed until Test ON is displayed in display
field 4.
Run engine at this speed until display field indicates

specified value B1-S1 O.K..
If B1-S1 nok is shown in display field 4:
Press
key.
display group 033.
Observe lambda control in display field 1. The readout

must fluctuate in the region from -10.0...10.0 %.

2.0%
0.462 V
33
->
Read off voltage in display block 2. The voltage must

oscillate at least 20 times per minute in the region between 0 to 1.0 V.
If the display in display field 2 remains constantly on one
value:
Continue test according to the following table:

Display
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
If the lambda control in display field 1 does not oscillate

in the given region:

Conduct test drive and repeat test.
Comply with the applicable safety instructions for a test
drive Chap. 24-1.
If the nominal value in display field 1 is still not reached
after a test drive or if the value does not fluctuate by at
least 2 %:
Test basic voltage.

Test basic voltage
Remove the 6-pin plug to the lambda probe before the

catalyst -G39-.
Note
Depending on the wide-band lambda probe version, it
can be connected to contacts 3+ 4 +5 + 6 or 2 + 1 + 4 +
6 of the 6-pin plug (only on engines with code letters BKY
EU-4 and EU-2DDK 05.04 ; the instructions for these
engines are listed below in the brackets).
S24-0347
24-4 page 4
Edition 06.04
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24

contacts 3 + 4 (2 + 1) of the connector at the engine
wiring harness.
Switch on ignition and measure voltage.



-G39-.
Check lambda probe wiring.

Check lambda probe wire upstream of catalytic
converter

not connected here.
Plug contact
Test box bush

-V.A.G. 1598/31-
3 (2)
52
4 (1)
71
5 (4)
70
6 (6)
51
Check wiring at plug contact 3 + 4 (2 + 1) for short-circuit to contact 1 + 2 (3 + 5).

Test lambda probe heating after catalyst

-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
Edition 06.04
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24-4 page 5
24
Test conditions
Fuses No. 3 and 9 must be O.K.

The fuel pump relay must be OK.
1
2
3
4
5
Test sequence
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
display group 041.
Check status of the lambda probe heater in display

field 4.

41
->
Ht. before c. ON 15 Ohm Ht. after c. ON
Specified value: Ht. after c. ON.

Note
in display field 4 may show either Htg. after C.ON or
Htg. after C.OFF.
Remove the 4-pin plug to the lambda probe -G130-arrow-.
S24-0348
Check probe heater at connector for lambda probe,

contact 1 + 2 for continuity.
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 probe heating:
Replace lambda probe after catalyst -G130-.

If the probe heating has continuity:
24-4 page 6
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24
Connect multimeter for voltage measurement to contacts 1 + 2 (plug at engine wiring harness).
Start engine and run in idle.

Measure the voltage supply and at the same time ob-
serve display group 041, display field 4.

Display: Ht. after c. ON
or
Display: Ht. after c. ON / Ht. after c. OFF (alternately)
Specified value: fluctuating between 0.0....14.5 V


not connected here.
for interruption:
Plug contact
Test box bush

-V.A.G. 1598/31-
63


If wiring is o.k.:
Testing lambda probe and lambda control after catalyst

Test conditions
The coolant temperature must be at least 80C,


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24-4 page 7
24

Check status of the lambda control after catalyst (display field 2):

111
110
30
->

Note
The 3rd bit in display field 2 is only set to 1 under partial
load (2500...4000 rpm).
Meaning of the 3-digit numerical block display

field 2:
1 2 3
x Lambda control active; specified value: 1/0
1
Note
The lambda control of the lambda probe after catalyst
(B1-S2) is inactive without load.

The first digit of the 3-digit numerical block (heating)
fluctuates between 0 and 1.

Test lambda probe heating after catalyst 24-4

page 5.

036.
Depress brake pedal and hold pressed. The speed

automatically increases.
0.856 V Test ON
B1-S2 O.K. appears in display field 2.
36
->
If B1-S2 n.o.k is shown in display field 2:
Test lambda probe voltage 2 at idle in display field 1.

Specified value: 0,0001.000 V
Continue test according to the following table:
24-4 page 8
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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
If the lambda control in display field 1 does not oscillate

in the given region:

Conduct test drive and repeat test.
drive Chap. 24-1.
If the nominal value in display field 1 is still not reached
after a test drive or if the value does not fluctuate by at
least 2 %:
Test basic voltage.

Test basic voltage
S24-0348
Remove the 4-pin plug to the lambda probe -G130-arrow-.
Connect multimeter for voltage measurement to contacts 3 + 4 (plug at engine wiring harness).
Switch on ignition and measure voltage.

Specified value: 0,400.50 V

Replace lambda probe after catalyst -G130-.

Check lambda probe wire downstream of catalytic

converter.
Check lambda probe wire downstream of catalytic converter

not connected here.
Plug contact
Test box bush

-V.A.G. 1598/31-
68
69
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24-4 page 9
24
Check wiring of contact 3 + 4 of the plug for short-circuit to contact 1 + 2.

Check lambda probe ageing before catalyst

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



034.

34
->
2300/min
244.0 C
0.25s
Test ON
Blip 2 accelerations above 5000 rpm.

Set engine speed to 1500...3900 rpm.
Maintain this speed until the value in display field 4
jumps from Test ON to B1-S1 o.k..
Note
This may take a few mlnutes.
Check period in display field 3:

Specified value: maximum 1.0 s
Maintain the speed at 1500...3900 rpm until display

field 4 indicates nominal value B1 S1 O.K..

Conduct a test drive in order to eliminate any residues

on the lambda probe and repeat the test.
drive Chap. 24-1.
If the specified value is again not reached:

-G39-.
24-4 page 10
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24
Testing the engine operating conditions

Note
Test whether the engine control unit detects the operating
conditions idling, trailing throttle, partial load, enrichment
and full load of the engine.
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition

Test sequence

Test whether the control unit recognizes the operating

conditions (display field 4):

840/min
20%
0km/h
->
Idling
Idling
As long as the engine is idling, the following must be displayed: Idling.

Trailing throttle
Engine speed must increase to more than 3000 rpm.

Suddenly close the throttle valve.
As long as the speed is above 1400 rpm the following
must be displayed. Trailing throttle.
Note
Once engine speed is below 1400 rpm idling is again displayed.
Partial load
Accelerate constantly.
As long as the acceleration is constant the following must
be displayed: Partial load.
Enrichment
Push the accelerator pedal down sharply to the stop.

When accelerating the following must be briefly displayed: Enrichment.
drive Chap. 24-1.
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24-4 page 11
24

Interrogate fault memory, rectify any faults and erase

fault memory Chap. 01-1.
Test throttle valve control unit Chapter 24-1.
24-4 page 12
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24
24-5
Engine control unit
Wiring and Component Test with Test

Box V.A.G. 1598/31
Test box -V.A.G 1598/31-
Note
The test box -V.A.G 1598/31- is designed in such a
way that it can be simultaneously connected to the

wiring loom of the engine control unit and to the actual
engine control unit.
The advantage being that the electronic engine con-
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
box or not, is described in the relevant test procedures.

The contact numbers of the connector of the control
unit and the socket numbers of the test box are identical.

Release the connector catches and unplug the control
unit connectors.
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.
Perform test as described in the relevant repair sequences.
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
Testing voltage supply for engine control unit
S01-0089

Edition 06.04
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Engine control unit
24-5 page 1
24
Test conditions

Fuses No. 3, 14, 17, 48, and 56 must be OK.
AC generator o.k., test: Electrical system;
1
2
3
4
5
Rep. Gr. 27.
Test sequence
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
display group 004.
Read off readout in display field 2.

840 rpm
13.6V
91 C
->
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.
Testing voltage of terminal 30
Measure supply voltage between sockets 1 + 3 of the

test box:
Test cable connections to relay plate according to the
current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Testing voltage of terminal 15
Use multimeter to measure voltage between sockets

2 + 4 at the test box.
Switch on ignition.
Test cable connections to relay plate according to the
current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Procedure after voltage supply has been

interrupted
If the power supply is interrupted the engine control unit
forgets all initialisation or basic setting values and the
Readiness Code is erased. Depnding on the mileage
24-5 page 2
Engine control unit
Edition 06.04
S00.5309.04.20
24

which the vehicle has driven, this may result in considerable driveability problems.
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
After the voltage supply has been interrupted, it is necessary to carry out the following steps:
Switch ignition on for at least 10 seconds.

Switch ignition off for at least 30 seconds.
24-5 page 6.
Performing idling test Chap. 24-4.

On vehicles with an automatic gearbox the gearbox control unit must also be adapted.
Conduct a lengthy test drive until the problems have

been rectified.
must be fulfilled:
After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a

number of times: Idling, part load, full load, overrun.
yond 3500 rpm.
Replacing engine control unit

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Enter the control unit identification and thus also the

coding of the previous control unit as follows:

shown on the display, e.g.:
Edition 06.04
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Coding 00031
Engine control unit
2615 ->
WSCXXXXX
24-5 page 3
24

Release the connector catches and unplug the connector -arrow- from the control unit.
S10-0111
Press open the latches of the fixture -arrows A- and

pull the engine control unit forward -arrow B-.
Release the catch of the second connector and unplug the connector from the control unit.
Installation is carried out in the reverse order.
Check current coding and code new control unit

24-5 page 5.
Adapt engine control unit to control unit for electronic

immobiliser Electrical System; Rep. Gr. 96.
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
Adapt the new control unit to the throttle valve control

unit 24-5 page 6.
Adapt potentiometer for exhaust gas recirculation.

070 when ignition is switched on.

0.9V
3.8V
0.968V
74
->
ADP. O.K.
Specification in display field 4:

ADP runs
ADP O.K.
Deactivate adaptation by pressing the button
Note
Finally interrogate the fault memory of the new engine

control unit and if necessary erase.
Performing idling test Chap. 24-4.

Generate readiness code Chapter 01-2.
24-5 page 4
Engine control unit
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24
Coding engine control unit

Note
A 5-digit code must always be displayed during the
time the control unit identification is shown.

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.

Enter the relevant code number of the vehicle and
Code control unit

Enter code number XXXXX
Q
(0-00127)
confirm with button Q .

Code
number
for vehicles with
00001
Gearbox
00011
Gearbox and ABS
00021
Gearbox and airbag
00031
Gearbox, ABS and airbag
00041
Gearbox and air conditioning system
00051
Gearbox, air conditioning system and ABS
00061
Gearbox, air conditioning system and airbag
00071
Gearbox, air conditioning system, ABS and

airbag
00003
Automatic gearbox
00013
Automatic gearbox and ABS
00023
Automatic gearbox and airbag
00033
Automatic gearbox, ABS and airbag
00043
Automatic gearbox and air conditioning

system
00053
Automatic gearbox, air conditioning system

and ABS
00063
Automatic gearbox, air conditioning system

and airbag
00073
Automatic gearbox, air conditioning system, ABS and airbag

shown on the display, e.g.:
If this display appears, an incorrect code number has
been entered.
Edition 06.04
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Coding 00031
Function unknown or cannot
be carried out at the moment
Engine control unit
2615 ->
WSCXXXXX
->
24-5 page 5
24

Note
The engine control unit does not use the code entered
and shown in the display until after the ignition has

been switched off. Incorrect coding results in:
Handling problems (jerky gear change, load change
jolts etc.)
Increase in fuel consumption
Increase in pollution
Storage of non-existent faults in fault memory
non-execution of functions (lambda control, activated
charcoal filter system actuation, etc.)

On front-wheel-drive vehicles the Traction Control
System does not operate (TCS warning light on)

Reduction of the gearbox life
Adjusting the engine control unit to the

throttle valve control unit
This adaptation teaches the engine control unit the various positions of the throttle valve with the ignition on and
the engine stopped. These positions are stored in the engine control unit. The feedback of the throttle valve position is provided by the two angle sensors for the throttle
valve drive.
Adaptation must be performed if:
the power supply was interrupted
the throttle valve control unit was removed and in-
stalled
the throttle valve control unit was replaced
if another engine or another throttle valve control unit
was installed
Note
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
There must not be any fault present in the fault memory Chap. 01-1, Interrogating fault memory.

Engine not running, ignition switched on.
Accelerator pedal fully released.
The throttle valve must be in idling speed position.
24-5 page 6
Engine control unit
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24
The coolant temperature must be 5...95 C display

group 004, display field 3.
When using the cruise control system, it must be correctly set.
Procedure


060.

2%
95%
5
60
->
ADP. running

2%
95%
12
60
In this state, the throttle valve is moved by a mechanical

spring integrated in the throttle valve control unit, into an
emergency running position. The values generated by
the two angle senders in this emergency position are
stored by the engine control unit.
Subsequently the throttle valve is opened at a given value. If this value is reached, the throttle valve positioner is
again switched dead. Now the mechanical spring must
close the throttle valve within a given period in the previously initialised emergency position (spring test).
The throttle valve is subsequently closed by the throttle
valve positioner: the values sent by the angle sender to
the throttle valve control unit are stored in the engine control unit.
If during driving the engine control unit switches the throttle valve positioner dead, this is indicated by a fluctuating
increased idling speed. The engine then has a very poor
throttle response.
Check the specified values for the throttle valve positioner control unit in display fields 3 and 4.
->
ADP o.k.
Specification in display field 3: 12

Specification in display field 4:
ADP runs
ADP O.K.
The adaptation was successfully performed.
To store the values:
Switch ignition off for at least 30 seconds.

Note
If the basic setting is aborted by the control unit, this
may be due to the following reasons:

The throttle valve does not reach the mechanical
idling limit due to dirt, e.g. carbon deposits or another

mechanical fault.
The battery voltage is too low.
Edition 06.04
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Engine control unit
24-5 page 7
24
The throttle valve control unit or the cable connection
is faulty, test Chapter 24-2.
If the basic setting is aborted, the fault is still in the
fault memory. When the ignition is switched on again

the basic setting is automatically performed again.
24-5 page 8
Engine control unit
Edition 06.04
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24
24-6
Testing auxiliary signals
Testing the speed signal

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 Diode test lamp e.g. -V.A.G 1527 B Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
Battery voltage must be at least 11.5 V.

Speedometer o.k., testing Electrical System;
Rep. Gr. 90.
Fuse 56 o.k.
Test sequence
Note
The vehicle must be driven in order to test the vehicle
speed signal. The assistance of a second person is

required.
Pay attention to safety precautions for test drives
Chap. 24-1.
Connect vehicle system tester -V.A.G 1552 -. Leave

the engine on and select address word 01 Engine
electronics Chap. 01-1.
Select function 08 Reading measured value block

and display group number 005.
Determine by means of a test drive whether the driving speed is displayed in display field 3.
Reading measured value block 5

1380 rpm
20 %
15 km/h
->
Enrich-
Select function 06 End output and switch off ignition.

Connect the test box-V.A.G 1598/31- to the wiring
loom on the engine control unit Chap. 24-5. The

engine control unit is not connected.
Connect the multimeter for voltage measurement between the bushes 4 (Term. 15) + 54 (speed signal) of
the test box.
Switch on the ignition.

Raise the front left side of the vehicle.
Turn the front left wheel by hand.
Diode test lamp must flash (very short signal).
If the diode test lamp does not flash:
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
Testing signals from/to the air conditioning system

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
The air conditioning system must be switched off.

There must not be any fault in the fault memory, interrogate fault memory Chap. 01-1.
Test sequence


830/min
840/min
off
Readout on display:
Observe display field 2.
->
off
Specified value: 840/min

Specifications in display fields 3 and 4: off
Switch on the air conditioning system.

Observe display field 2.
Specified value: 870/min
Specifications in display fields 3 and 4: on

Test the air conditioning system Heating, Air Conditioning; Rep. Gr. 01.
Check the CAN databus 24-6 page 7.
Test brake light switch -F- and brake

pedal switch -F47Special tools, test and measuring equipment and
-V.A.G 1551/3, 3A, 3B oder 3C Test box -V.A.G 1598/31-
24-6 page 2
Edition 03.01
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24

Handheld multimeter, e.g. -V.A.G 1526 A Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
Fuses Nos. 2 and 28 O.K.

Test sequence
Connect vehicle system tester -V.A.G 1552 -. Switch

the ignition on and select address word 01 Engine
Electronics Chap. 01-1.

0 km/h
0000
0 km/h
Check the display value in display field 2.
->
0000
Specified value: x x 0 0
Operate brake pedal

Specified value: x x 1 1

Remove the bottom part of the dash panel on driver

side Body Fitting Work; Rep. Gr. 70.
Unplug the connector from the brake light/brake pedal

switch.

between contact 1 and 4.
Specified value:
Operate brake pedal

Specified value: max. 1.5

Operate brake pedal

Specified value:
S24-0458
Replace the brake light/brake pedal switch.

Test the cable to the sender for open circuit and for
short circuit to battery positive or earth Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Edition 03.01
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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.
-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
Adapter cable set, e.g. -V.A.G 1594 A-
Test condition
Fuse 28 must be o.k.
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

0 km/h
0000
0 km/h
Check the display value in display field 2.
->
0000
Specified value: x0xx
Operate clutch pedal.

Specified value: x1xx

Remove the bottom part of the dash panel on driver

side Body Fitting Work; Rep. Gr. 70.
Unplug the connector at the clutch pedal switch.

Operate clutch pedal.
Specified value:
Replace the clutch pedal switch -F36-.

Test the cable to the sender for open circuit and for
S24-0458
short circuit to battery positive or earth Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.
24-6 page 4
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24
Activating and deactivating cruise control system (CCS)

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
There must not be any fault in the fault memory

Chap. 01-1, Interrogating fault memory.
Test sequence

Readout on display, e.g.:
036906034F MARELLI 4LV G

Coding 00031
2615 ->
WSC XXXXX
036906034F MARELLI 4LV

Coding 00031
2615 ->
WSC XXXXX
If MARELLI 4LV G is displayed, CCS is activated.

Readout on display, e.g.:
If MARELLI 4LV is displayed, CCS is not activated.
Press
and select function 11 Login procedure.
Login procedure
Enter code number
XXXXX
Enter the code number by referring to table below and

confirm entry with Q .
Code number Cruise control system (CCS)
11463
Cruise control system (CCS) is activated
16167
Cruise control system (CCS) is deactivated

Conduct a test drive after activating the CCS.
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.
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Activate CCS 24-6 page 5.
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24-6 page 5
24
Test sequence


Read off the values in display fields 2 and 4.

0 km/h
0000
0 km/h
->
0000
Display field 2
Specified value:
1xxx - CCS activated
0xxx - CCS deactivated
Display field 4
Test condition
Display field
4
Switch -B- locked to OFF
0000
Switch -B- to OFF before operating

point
00011)
Switch -B- to ON
0011
Switch -B- to RES
1011
Switch -A- pressed (switch -B- to ON)
0111
1)
Not active at present.
N23-0199

Test wiring to CCS switch for open circuit as well as
short circuit to earth and to positive Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations.
Testing gear signal

Only for vehicles with autom. gearbox
The engine control unit receives from the gearbox control
unit the information: Gear engaged (selector lever in 1/2/
3/R/D) or no gear engaged (selector lever in P or N)
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
The selector lever of the automatic gearbox must be

in position P or N.
Air conditioning switched off.
24-6 page 6
Edition 03.01
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24
Test sequence


840 rpm
840 rpm
5 Nm
Test the value in display field 4.
->
00000
Specified value:
00000 (selector lever in P or N)
00010 (selector lever in 1/2/3/R/D)

Check the data bus 24-6 page 7.
Test data bus

Operation
The engine control unit communicates over a CAN databus with all the control units with databus capability.
The control units with databus capability are linked by two
twisted databus cables (CAN_High and CAN_Low) and
exchange information (messages). Both the engine control unit and the other CAN data bus control units detect
missing information on the data bus as faults.
Test condition
A fault is detected by the CAN databus by self-diagnosis.

Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1526 A Adapter cable set, e.g. -V.A.G 1594 A-
Test sequence
Switch off the ignition.

Release the connector of the engine control unit and
unplug it.
Connect test box -V.A.G 1598/31 - to engine control

unit Chap. 24-5. Wiring loom to control unit is not
connected.
Test the central terminating resistor in the engine control unit.
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 7
24
If the resistance value is not within the nominal value

range:
Replace the motronic control unit Chap. 24-5.

If the resistance value is within the nominal value range:
Test the CAN databus Electrical System;

Rep. Gr. 90.
24-6 page 8
Edition 03.01
S00.5309.02.20
28
28 Ignition System
28-1
Repairing ignition system
General notes on the ignition system

This section specially deals with the components in
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-
agnosis Chapter 01-1.
A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components.

Before repairs and for fault finding interrogate the fault
memory Chap. 01-1.
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.
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.
Edition 06.04
S00.5309.04.20
28-1 page 1
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
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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28
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
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
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
running or at start speed.

Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and ignition system as well as of test equipment.
Edition 06.04
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28-1 page 3
28
rear seat and also have a second person operate

them there.
If the engine must be operated at start speed without
the engine starting:

Engines with the engine codes AUA, AUB

transformer.
Engines with the engine codes BBY, BBZ, BKY
Remove the connector and pull out all ignition coils

with extractor -T 10094-.
For all vehicles
Testing hall sender

Test condition

Test sequence
28-1 page 4
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28
Disconnect the 3-pin plug connection from Hall sender

-arrow-.

contact 1 (positive) and 3 (earth) of the plug for the
Hall sender.
Switch on ignition.


control unit Chapter 24-5.
Plug contact
Test box bush

-V.A.G 1598/31-
98
86
108

Specified value:
If no fault was found in the cables and the specified voltage measured between contacts 1 + 3:
Replace hall sender -G40-.

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28
Checking the ignition transformer (for

engines with the engine codes AUA,
AUB)
Test box -V.A.G 1598/31 Handheld multimeter, e.g. -V.A.G 1715 Measuring tool set e.g. -V.A.G 1594 C Diode test lamp e.g. -V.A.G 1527 Current flow diagram
Test conditions

The hall sender must be OK, test it 28-1 page 4.
The engine speed sender must be O.K., test it
Chapter 24-3.
Test sequence

transformer.
Checking voltage supply

1
2
3
4
5
Test condition
Fuse 52 must be o.k.
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
Measure power supply between contacts 2 + 4 of the

removed plug using the multimeter.
Switch on ignition.

28-1 page 6
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28

relay plate for interruption according to the Current
Flow Diagram.

earth for interruption according to the Current Flow Diagram.
Test control
WARNING!
During the following test do not touch neither the
connecting parts of the ignition transformer nor
the auxiliary cables.
Connect the diode test lamp to contacts 1 + 4 (ignition

outlet 1) and contacts 3 + 4 (ignition outlet 2) of the removed plug.
Actuate the starter and check the ignition signal on the

engine control unit. The LED must flash.

If the LED flashes and there is a voltage existing between
contact 2 and 4:
Replace ignition transformer -N152- item 2 in 28-1

page 2.
If the LED does not flash:
Test wiring 28-1 page 8.
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28
Checking wires

not connected here.
Plug contact
Test box bush

-V.A.G 1598/31-
102
103

Specified value:
If no fault was detected in the wiring and if there is a voltage detected between contact 2 and 4:

Testing secondary resistances
Test secondary resistances on terminal 4 between

cylinder 1 + cylinder 4 and cylinder 2 + cylinder 3.
Specified value: 4,0 ... 6.0 k (at 20 C)
Replace ignition transformer -N152- item 2 in 28-1

page 2.
Check ignition coils with power output

stage (engines with engine codes BBY,
BKY, BBZ)
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 Diode test lamp e.g. -V.A.G 1527 B Current flow diagram
Test sequence
Note
Ignition coil and power output stage form a building unit.
Cylinder, which does not operate or misfire, determine as
follows:
Test combustion misfiring 28-1 page 13.
28-1 page 8
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If a combustion misfiring was detected:
Proceed with test on cylinder determined as defective.

If no combustion misfiring was detected:
Successively remove contacts of the injectors while

engine is running and monitor engine run,
or
Compare spark plugs of all cylinders and pay attention

to contaminated (covered with soot) electrodes.
If a defective cylinder was determined:
Replace the spark plug of the defective cylinder with

the one of another cylinder.
If the fault on this spark plug still exists:
Replace spark plug.

If the given cylinder is still defective:
Replace the ignition coil of the defective cylinder with

the one of another cylinder.
If the fault on this ignition coil still exists:
Replace ignition coil.

If the given cylinder is still defective:
Remove the 4-pin plug -1...4- from the ignition coils

and check wiring Current Flow Diagrams, Fault
Checking voltage supply
Unplug the 4 pin plug connections from all ignition

coils.
Test condition
The fuses of the ignition system must be in proper order Current Flow Diagrams, Fault Finding and Fitting Locations.
Measure the voltage supply beween contacts 2 + 4

and 3 + 1 of the removed plug using the multimeter
and the adapter cables from the measuring tool set.
Switch on ignition.

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28

relay plate for interruption according to the Current
Flow Diagram.
Check the cable between 4-pin plug contact 2 + earth

and contact 1 + earth for interruption according to the
Test control
WARNING!
Caution! During the following test do not touch
neither the connecting parts of the ignition coils
nor the auxiliary cables.
Connect the diode test lamp V.A.G 1527 with adapter

cables from V.A.G 1594 to contacts 1 + 4 of the removed plug.
Actuate the starter and check the ignition signal on the

engine control unit.
The LED must light up.

If the diode lights up and there is a voltage existing between contacts 1 + 4:
Replace ignition coil.

If the LED does not light up:
Check wires.
28-1 page 10
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Checking wires
Connect test Box V.A.G. 1598/31 to wiring loom of the

control unit. The engine control unit is not connected.
Plug contact 4
cylinder:
Test box bush

-V.A.G 1598/31-
102
103
94
95

Specified value:
If no fault has been determined on the wiring and there is
a voltage between contacts 2 + 3:
Testing knock sensor

Note
The perfect functioning of the knock sensor requires
an exact tightening torque of 20 Nm.


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28
Test condition
Faults on the knock sensor detected by self-diagnosis
Chapter 01-1, interrogate fault memory and erase.
Test sequence
Disconnect the 2-pin plug from the knock sender -arrow-.

not connected here.
Plug contact
Test box bush

-V.A.G 1598/31-
106
99

Specified value:
Slacken knock sensor and then tighten again to 20

Nm.
Perform a test drive.

Comply with the safety instructions for a test drive
28-1 page 3.
must be fulfilled:
After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a

number of times: Idling, part load, full load, overrun.
yond 3500 rpm.
Interrogate the fault memory on the control unit again.

If the fault still exists:
Replace knock sensor -G61-.
28-1 page 12
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28
Test combustion misfiring

-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
Driving
Test sequence

display group 014.
840/min
17%
0
Read off value in display block 4.
14
->
activated
Specified value: activated.
Check the number of combustion misfirings in indicator field 3.

Specified value: 0.

Changeover in indicator group 015.


15
->
0
0
0
activated
Specified value: activated.
Check misfiring combustion in the indicator fields 1 to

3, cyl. 1...3.
Nominal values: 0.
Changeover in indicator group 016.

16
->
0
activated
Specified value: activated
Check the number of combustion misfirings in indicator field 1, cyl. 4.

Specified value: 0.
If the nominal values in the display groups 015 and 016
are achieved:

Eliminate fault Chapter 01-3, Analysing display

group 015 and 016.
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28
28-1 page 14
Edition 06.04
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AUA AUB BBY BBZ BKY

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2000 1.4/55 ; 1.4/74 Engine - Fuel Injection

List of Supplements to Workshop Manual

Supplement to Basic Edition

Modifications in Rep. Gr. 01 and 24

Additions to engines with the engine codes BBY, BBZ

Supplement to engines with the engine codes BKY

FABIA 2000 1.4/55 ; 1.4/74 Engine - Fuel Injection

FABIA 2000 1.4/55 ; 1.4/74 Engine - Fuel Injection

- Properties of the self-diagnosis ..................................................................... 01-1

- Technical data of self-diagnosis ..................................................................... 01-1

- Meaning of the exhaust gas warning light -K83- .................................................. 01-1

- Automatic test sequence ............................................................................. 01-1

- Performing actuator diagnosis ....................................................................... 01-1

Self-diagnosis II ......................................................................................... 01-2

- Readiness code ........................................................................................ 01-2

- Reading Readiness Code ............................................................................ 01-2

- Generating readiness code .......................................................................... 01-2

Self-diagnosis III ........................................................................................ 01-3

- Fault table, fault codes 16496...17566 ............................................................. 01-3

Self-diagnosis IV ....................................................................................... 01-4

- Fault table, fault codes 17573...18100 ............................................................. 01-4

Self-diagnosis V ........................................................................................ 01-5

- Measured value blocks ............................................................................... 01-5

- Safety measures ....................................................................................... 01-5

- Reading measured value block ..................................................................... 01-5

- Measured value blocks, display groups 010...029 - Ignition .................................... 01-5

Self-diagnosis VI ....................................................................................... 01-6

- Measured value blocks ............................................................................... 01-6

Self-diagnosis VII ....................................................................................... 01-7

- Measured value blocks ............................................................................... 01-7

- Measured value blocks, display groups 120...129 - Communication .......................... 01-7

Repairing the injection system ...................................................................... 24-1

- General notes on the injection system ............................................................. 24-1

- Removing and installing parts of the injection system ........................................... 24-1

- Disassembling and assembling intake manifold .................................................. 24-1

- Disassembling and assembling fuel distributor with injectors .................................. 24-1

- Disassembling and assembling the air filter ....................................................... 24-1

24 Fuel Formation, Injection

FABIA 2000 1.4/55 ; 1.4/74 Engine - Fuel Injection

Testing components ................................................................................... 24-2

- Testing throttle valve control unit ................................................................... 24-2

- Testing accelerator pedal position sender ......................................................... 24-2

- Testing the intake manifold pressure sender ..................................................... 24-2

- Testing intake manifold temperature sender ...................................................... 24-2

- Testing coolant temperature sender ................................................................ 24-2

Testing components I ................................................................................. 24-3

- Test engine speed sender ........................................................................... 24-3

- Testing injection valves ............................................................................... 24-3

- Testing intake manifold preheating ................................................................. 24-3

- Idle testing .............................................................................................. 24-3

Testing components II ................................................................................ 24-4

- Test lambda probe heating before catalyst ........................................................ 24-4

- Test lambda probe heating after catalyst .......................................................... 24-4

- Check lambda probe ageing before catalyst ...................................................... 24-4

- Testing the engine operating conditions ........................................................... 24-4

Engine control unit .................................................................................... 24-5

- Testing voltage supply for engine control unit .................................................... 24-5

- Procedure after voltage supply has been interrupted ............................................ 24-5