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Service 5
Service Department. Technical Information Printed in Czech RepublicS00.5326.00.20
Workshop ManualFABIA 2000
1.4/55 TDI Engine, Fuel InjectionEdition 07.03Engine code
AMF
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Service5
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.
Printed in Czech RepublicS00.5326.00.20
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
List of SupplementsEdition 04.04S00.5326.01.20
List of Supplements to Workshop Manual
FABIA 2000
1.4/55 TDI Engine, Fuel InjectionEdition 07.03
Supple-ment Edition Subject Article Number
07.03 Basic Edition S00.5326.00.201 04.04 Modifications in Rep. Gr. 01 a 23 S00.5326.01.20
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List of Supplements Edition 04.04S00.5326.01.20
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Table of ContentsEdition 04.04S00.5326.01.20
I
Table of Contents
01 Self-diagnosisSelf-diagnosis I .........................................................................................- Properties of the self-diagnosis .... .... ..... ..... .... ..... .... .... ..... ..... ..... ..... ..... .... .....- Technical data of self-diagnosis .... .... ..... ..... .... ..... .... .... ..... ..... ..... ..... ..... .... .....- Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine
electronics .............. ................. ................. .................. ................. ...........- Interrogating and erasing fault memory ..... .... .... ..... ..... .... ..... .... ..... ..... .... ..... .....- Actuator diagnosis ................ ................. ................. ................ ............... ....Self-diagnosis II .........................................................................................- Fault codes 515 to 19561 .............. ................. ................. ................. ...........Self-diagnosis III ........................................................................................- Readiness code ................ ................. ................. ................. ................ .....- Reading readiness code ................ ................. ................. ................. ...........- Generating readiness code ................ ................. ................. ................. .......Self-diagnosis IV .......................................................................................- Reading measured value block ............... ................. ................. ............... .....- Display groups 001 to 022, engine idling ..... .... ..... ..... ..... ..... ..... ..... ..... ..... .... .....- Display groups 004 through 011 at full load .... .... ..... ..... .... ..... .... ..... ..... .... ..... .....- Display group 125 - CAN databus ................. ............... ................. .................
23 Fuel Formation, InjectionDiesel Direct Injection System ......................................................................- Safety measures .............. ................. ................. ................. ................. .....- Rules of cleanliness ................. ................. ............... ................ ................. .- Overview of fitting locations ..... ..... .... ..... ..... .... ..... ..... .... .... ..... .... ..... ..... .... .....- Disassembling and assembling intake manifold ... ... ... ... ... .. ... ... ... ... .. ... ... ... ... .. ... ..- Removing and installing air filter ..... ..... ..... .... ..... ..... ..... ..... ..... ..... ..... .... ..... .....- Disassembling and assembling the air filter ..... .... ..... .... .... ..... ..... .... ..... ..... .... .....Disassembling and assembling the unit injector ...............................................- Summary of components ............... ................. ................. ................. ...........- Removing and installing O-rings for unit injector ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ..- Removing and installing the unit injector .... ..... ..... ..... ..... .... ..... ..... .... ..... ..... .... ..Testing components ...................................................................................
- Test wiring and components with Test box -V.A.G 1598/31- .. ... ... ... ... .. ... ... ... ... .. ... ..- Test diesel direct injection system relay -J322- ... ... ... ... ... .. ... ... ... ... .. ... ... ... ... .. ... ..- Testing unit injector valve .............. ................. ................. ................. ...........Testing exhaust gas recirculation ..................................................................- Connect vacuum hoses at valve block ..... ..... .... ..... ..... .... ..... .... ..... ..... .... ..... .....- Testing exhaust gas recirculation .... ..... ..... .... .... ..... ..... .... ..... ..... .... ..... ..... .... ...Engine control unit .....................................................................................- Testing voltage supply for engine control unit .... .... ..... ..... .... ..... ..... .... ..... ..... .... ..- Replacing diesel direct injection system control unit -J248- ... ... ... ... ... .. ... ... ... ... .. ... ..
- Coding diesel direct injection system control unit -J248- ... ... ... ... ... ... ... ... ... ... ... .. ... ..- Activating and deactivating cruise control system (CCS) ... ... ... ... ... ... .. ... ... ... ... .. ... ..Testing auxiliary signals ..............................................................................
01-1 page 101-1 page 101-1 page 1
01-1 page 201-1 page 301-1 page 501-2 page 101-2 page 101-3 page 101-3 page 101-3 page 101-3 page 201-4 page 101-4 page 101-4 page 101-4 page 1001-4 page 12
23-1 page 123-1 page 123-1 page 123-1 page 223-1 page 423-1 page 523-1 page 623-2 page 123-2 page 123-2 page 223-2 page 323-3 page 123-3 page 123-3 page 123-3 page 223-4 page 123-4 page 123-4 page 123-5 page 123-5 page 123-5 page 1
23-5 page 223-5 page 323-6 page 1
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Table of Contents Edition 04.04S00.5326.01.20II
28 Glow Plug SystemTesting preheating system ........................................................................... 28-1 page 1
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01-1 page 1
01
01-1 Self-diagnosis I
Properties of the self-diagnosisThe control unit for the diesel direct injection system isequipped with a fault memory. The fault memory is de-signed as a permanent memory.
If malfunctions occur in the monitored sensors or compo-nents, they are stored in the fault memory with indicationof the fault type. Fault table Chap. 01-2.
Faults which occur only temporarily (sporadically) aredisplayed with the suffix /SP. Possible causes of spo-radic faults are e.g. a loose contact or a temporary line in-terruption. If a sporadic fault no longer occurs after 50engine starts, it is automatically erased.
If faults are detected that are likely to influence the drivingbehaviour, the glow period warning lamp -K29- flashes.
The stored faults can be read out with the vehicle systemtester -V.A.G 1552-, -V.A.G 1551- or -VAS 5051- 01-1 page 2.
After the fault(s) has(have) been removed the fault mem-ory must be erased 01-1 page 3.
The following description only relates to vehicle systemtester -V.A.G 1552- using the current program card 5.0.When not using the current program card or when usingthe fault read-out scan tool -V.A.G 1551- with integrated
printer or using the vehicle diagnosis, measurement andinformation system -VAS 5051- a minor deviation in thedisplay is possible.
Technical data of self-diagnosis
Interrogating control unit version
The control unit version is displayed once the vehicle sys-tem tester -V.A.G 1552- is connected and the engineelectronics control unit is selected 01-1 page 2.
Available functions when using the vehicle sys-tem tester -V.A.G 1552-
The conditions under which the desired functions can beselected are given in the following table.
01 Self-diagnosis
Note
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Connecting vehicle system tester-V.A.G 1552- and selecting the controlunit for engine electronics
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Battery voltage at least 11.5 volts Earth connection to engine and gearbox O.K. Fuses according to current flow diagram O.K.
Procedure
Connect vehicle system tester -V.A.G 1552- with ap-propriate cable.
Once the vehicle system tester has been connected:
Switch on ignition or start 01-1 page 1 engine de-pending on the function desired.
If data transfer errors are displayed as a result of anincorrect entry, disconnect cable at vehicle systemtester, connect it in again and repeat all the steps.
If one of the following messages appears in the dis-
play, test the diagnostic cable Current Flow Dia-grams, Electrical Fault Finding and Fitting Locationsor Operating Instructions of vehicle system tester.
OperationCondition
Engine not running,ignition switched on
Engine idling Normal driving
01 Interrogating control unitversion
yes yes yes
02 Interrogating fault mem-ory yes1)
1) Only perform with the ignition on, if the engine does not start.
yes yes03 Actuator diagnosis yes yes no04 Basic setting no yes no05 Erasing fault memory yes yes yes06 Ending output yes yes yes07 Coding control unit yes no no08 Reading measured val-
ue blockyes yes yes
11 Login procedure yes no no
V.A.G 1552
V.A.G 1551/3
S01-0087
Note
Vehicle system test HELPThe control unit does not respond
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Operate the vehicle system tester by referring to theread-out on the display:
Readout on display:
Enter address word 01 Engine electronics and con-firm entry with .
The control unit identification appears in the display, e.g.:
045906019BM = Part No. of the control unit (for cur-rent control unit version see spare part catalogue)
1.4 ltr. = engine displacement R3 = engine version (3 cyl. in-line engine) EDC = Injection system (Electronic Diesel Control) CC = Cruise control system activated (only on models
with CCS) 000 = Control unit ID MG = Manual gearbox 4958 = Data status (Software version of the control
unit) Coding 00002 = Coding variant of the control unit WSC XXXXX = Workshop code
If the control unit version displayed does not corre-spond to the vehicle, replace the control unit Chapter 23-5.
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
Interrogating and erasing fault memory
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- with cable-V.A.G 1551/3, 3A, 3B oder 3C-
Interrogating fault memory
Connect vehicle system tester -V.A.G 1552-. Start en-gine and select address word 01 Engine electronics 01-1 page 2.
Vehicle system test HELPFault in communication set-up
Vehicle system test HELPK cable does not connect to earth
Vehicle system test HELP
K cable does not connect to pos. term.
Vehicle system test HELPEnter address word XX
Q
045906019BM 1.4l R3 EDC G000SG 4958 -> Coding 00008 WSC XXXXX
Note
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Only if the engine does not start:
Switch on ignition. Select function 02 Interrogate fault memory and con-
firm with .
The number of stored faults or No fault recognised ap-pears in the display.
If no fault is stored:
Select function 06 End output and confirm with .If one or several faults are stored:
Press .Readout on display, e.g.:
Press .Fault source and fault type appear in the display, e.g.:
Press .The stored faults are displayed in sequence.
Select function 06 End output and confirm with . Rectify the faults displayed by referring to the fault ta-
ble Chapter 01-2.
When carrying out testing and removal and installationoperations faults such as connector unplugged or CAN
bus faults, may also be detected by other control units.This is why, when the work is concluded, that it is neces-sary to interrogate and erase the fault memory on all con-trol units. For this you must proceed as follows:
Select function 00 for Automatic test sequence andconfirm with .
The Vehicle system tester -V.A.G 1552- sends all theknown address words one after the other.
Erasing fault memory
Test conditions Fault eliminated Fault memory interrogated 01-1 page 3
After fault elimination the fault memory must again be in-terrogated and subsequently erased.
Select function 05 Erase fault memory and confirmwith .
Readout on display:
QX faults detected!
Q
-> Fault number: 16685 P0301 044
Cylinder 1 -> Combustion misfiring detected
Q
Note
Q
Note
Q
Vehicle system test -> Fault memory was erased
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If the ignition is switched off during Interrogating faultmemory and Erasing fault memory, the fault memory isnot erased.
Select function 06 End output and confirm with .
Perform a test drive. Then, once again interrogate thefault memory. No fault must be displayed.
Actuator diagnosisWith the actuator diagnosis the following parts are acti-vated in the sequence indicated:
1 - Exhaust gas recirculation valve -N18-
2 - AC compressor engagement
3 - Solenoid valve for charge pressure control-N75-
4 - Changeover valve for intake manifold flap-N239-
5 - Glow period warning lamp -K29-
6 - Glow plug relay -J52-
7 - Low heat output relay -J359-
8 - High heat output relay -J360-
9 - Fault lamp
Actuation of the individual control elements is limitedto 30 seconds.
If the actuator diagnosis must be repeated without theengine being started in the meantime, switch off igni-tion for about 20 seconds.
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- with cable-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Fuses according to current flow diagram O.K.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start en-gine and select address word 01 Engine electronics 01-1 page 2.
Select function 03 final control diagnosis.
Readout on display:The valve must click.
Note
Q
Note
Actuator diagnosis -> Exhaust gas recirculation valve -N18
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The clicking of the valve cannot be heard because of theengine noise and can therefore only be checked.
If the valve does not click:
Testing Exhaust gas recirculation valve -N18- Chap. 23-1.
Press .Readout on display:
This test step is also activated on vehicles without ACsystem.
Disregard display.
Press .Readout on display:
The valve must click.
The clicking of the valve cannot be heard because of theengine noise and can therefore only be checked.
If the valve does not click:
Test charge pressure control solenoid valve -N75 - Chap. 23-1.
Press .
Readout on display:The engine must stop.
If the engine does not stop:
Switch off ignition. Inspecting Intake manifold flap change-over valve
-N239- Chap. 23-1. Continue final control diagnosis with the engine off
and the ignition switched on.
Press .
Readout on display:The warning light for glow period must flash.
If the warning light for glow period does not flash:
Testing Glow period warning lamp -K29- CurrentFlow Diagrams, Electrical Fault Finding and Fitting Lo-cations.
Press .Readout on display:
The relay must click.
Note
Actuator diagnosis -> AC compressor engagement
Actuator diagnosis -> Charge press.control solenoid valve -N75
Note
Actuator diagnosis -> Intake manif.flap change-over valve-N239
Actuator diagnosis -> Glow period warning lamp -K29
Actuator diagnosis -> Glow plug relay -J52
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It is also possible to observe the relay switching on andoff by the interior light becoming brighter or darker(caused by the high power consumption of glow plugs).
If the relay does not click:
Test glow plug relay -J52- Current Flow Diagrams,Electrical Fault Finding and Fitting Locations.
Press .Readout on display:
The relay must click.
If the relay does not click:
Test low heat output relay -J359- Current Flow Di-agrams, Electrical Fault Finding and Fitting Locations.
Press .Readout on display:
The relay must click.If the relay does not click:
Test high heat output relay -J360- Current Flow Di-agrams, Electrical Fault Finding and Fitting Locations.
Press .Readout on display:
The exhaust emission warning lamp must flash.
If the exhaust emission warning lamp does not flash:
Test exhaust emission warning lamp Current FlowDiagrams, Electrical Fault Finding and Fitting Loca-tions.
Press .Readout on display:
Select function 06 End output and confirm with .
Actuator diagnosis -> Low heat output relay J359
Actuator diagnosis -> High heat output relay -J360
Actuator diagnosis -> Fault lamp
Vehicle system test HELPSelect function XX
Q
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01-2 Self-diagnosis II
Fault codes 515 to 19561
The fault table is ordered according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only
valid for USA). Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the ve-
hicle system tester. If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth
connections according to current flow diagram. Only if no fault is detected here should the part be replaced. Thisapplies in particular if faults are shown as sporadic (SP).
If Info in literature appears in the display of the vehicle system tester - V.A.G 1552- look for the text required inthe fault table under the fault code.
Readout on -V.A.G 1552- Rectifying fault
00515Hall sensor -G40 no signal or sig-nal not withinthe tolerance
Test camshaft position sensor -G40- Current Flow Diagrams,Electrical Fault Finding and Fitting Locations Remove open circuit in wiring or short circuit according to current
flow diagram Current Flow Diagrams, Electrical Fault Finding andFitting Locations
Inspect position of camshaft and rotor 1.4/55 TDI Engine, Me-chanics; Rep. Gr. 15
00671Cruise control systemswitch -E45
undefinedswitch status
Test cruise control system Chap. 01-4, display groups 006 and022
00741Brake pedal monitor-ing
Implausible sig-nal
Test brake light switch - F- and brake pedal switch -F47- Chap.01-4, display group 006
01117Load signal for alter-nator terminal DF
Implausible sig-nal
Test wiring and generator Current Flow Diagrams, Electrical FaultFinding and Fitting Locations
01193Low heat output relay -J359
Open circuit orshort circuit toearth
Test low heat output relay -J359- with final control diagnosis Chap. 01-1
01194High heat output relay-J360
Open circuit orshort circuit toearth
Test high heat output relay -J360- with final control diagnosis Chap. 01-1
01282Intake manifold flapchange-over valve -N239
Open circuit orshort circuit toearth
Test intake manifold flap changeover valve -N239- with final controldiagnosis Chap. 01-1
16485 Air mass meter -G70
Implausible sig-nal
Test air mass meter -G70 - Chap. 01-4, display group 003
Note
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16684Combustion misfiringdetected
Inspecting compression pressure 1.4/55 TDI Engine, Mechanics;Rep. Gr. 15
Check unit injector Chap. 23-316685Cyl. 1 combustion mis-firings detected
16686Cyl. 2 combustion mis-firings detected16687Cyl. 3 combustion mis-firings detected16705Engine speed sender -G28
Implausible sig-nal
Inspecting Engine speed sender -G28- Chap. 23-1
16706Engine speed sender -G28
No signal Inspecting Engine speed sender -G28- Chap. 23-1 Check wiring according to current flow diagram Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations Replace diesel direct injection system control unit -J248 - Chap.
23-516725Camshaft pos. sensor=> Sender -G40
Implausible sig-nal
Test camshaft position sensor -G40- Current Flow Diagrams,Electrical Fault Finding and Fitting Locations
Remove open circuit in wiring or short circuit according to currentflow diagram Current Flow Diagrams, Electrical Fault Finding andFitting Locations
Inspect position of camshaft and rotor 1.4/55 TDI Engine, Me-chanics; Rep. Gr. 15
16885Vehicle speed signal Implausible sig-nal Test vehicle speed signal Chapter 23-616944Voltage supply
Implausible sig-nal
Test cables to diesel direct injection system control unit - J248- ac-cording to the current flow diagram Current Flow Diagrams, Elec-trical Fault Finding and Fitting Locations16946
Voltage supplyVoltage too low
16947Voltage supply
Voltage too high
16955Brake light switch -F
Implausible sig-nal
Test brake light switch - F- and brake pedal switch -F47- Chap.01-4, display group 006
16989
Control unit defective Replace diesel direct injection system control unit -J248 - Chap.
23-517068Glow period controlunit 1
Implausible sig-nal
Test glow plug relay -J52- with final control diagnosis Chap. 01-1
17552 Air mass meter -G70
Open circuit orshort circuit toearth
Test air mass meter -G70- Chap. 01-4, display group 003 Check wiring according to current flow diagram Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations Replace diesel direct injection system control unit -J248 - Chap.
23-5
17553 Air mass meter -G70
Short circuit topositive
17554 Air mass meter -G70
Supply voltage
Readout on -V.A.G 1552- Rectifying fault
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17563Intake manifold pres-sure sender -G71
Short circuit topositive
Test intake manifold pressure sender -G71- Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248 - Chap.23-5 Test charge pressure Chap. 01-4, display group 010
17564Intake manifold pres-sure sender -G71
Open circuit orshort circuit toearth
17565Intake manifold pres-sure sender -G71
Supply voltage
17568Intake manifold tem-perature sender -G72
Short circuit toearth
Test intake manifold temperature sender -G72- Chap. 01-4, dis-play group 007
Check wiring according to current flow diagram Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248 - Chap.23-5
17569Intake manifold tem-perature sender -G72
Open circuit/Short circuit topositive
17570Fuel temperaturesender -G81
Short circuit toearth
Test fuel temperature sender -G81- Chap. 01-4, display group007
Check wiring according to current flow diagram Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248 - Chap.23-5
17571Fuel temperaturesender -G81
Open circuit/Short circuit topositive
17663Coolant temperaturesender -G62
Open circuit/Short circuit topositive
Test coolant temperature sender -G62- Chap. 01-4, display group007
Check wiring according to current flow diagram Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248 - Chap.23-5
17664Coolant temperaturesender -G62
Short circuit toearth
17668Unit injector solenoidvalve cyl. 1 -N240
Implausible sig-nal
Check unit injector Chap. 23-3
17669Unit injector solenoidvalve cyl. 1 -N240
Regulating limitexceeded
17670Unit injector solenoidvalve cyl. 1 -N240
Regulating limitnot reached
Check unit injector Chap. 23-3 Inspecting fuel supply 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 2017671Unit injector solenoidvalve cyl. 2 -N241
Implausible sig-nal
Check unit injector Chap. 23-3
17672Unit injector solenoidvalve cyl. 2 -N241
Regulating limitexceeded
17673Unit injector solenoidvalve cyl. 2 -N241
Regulating limitnot reached
Check unit injector Chap. 23-3 Inspecting fuel supply 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 2017674Unit injector solenoidvalve cyl. 3 -N242
Implausible sig-nal
Check unit injector Chap. 23-3
17675Unit injector solenoidvalve cyl. 3 -N242
Regulating limitexceeded
Readout on -V.A.G 1552- Rectifying fault
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17676Unit injector solenoidvalve cyl. 3 -N242
Regulating limitnot reached
Check unit injector Chap. 23-3 Inspecting fuel supply 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 2017795Control unit defective
Replace diesel direct injection system control unit -J248 - Chap.23-5
17810Exhaust gas recircula-tion valve -N18
Short circuit topositive Test exhaust gas recirculation valve -N18- with final control diagno-sis Chap. 01-1
Inspecting exhaust gas recirculation Chap. 23-417849Exhaust gas recircula-tion valve -N18
Open circuit orshort circuit toearth
17910Fuel pump relay -J17
Short circuit topositive
Testing fuel pump relay -J17- Current Flow Diagrams, ElectricalFault Finding and Fitting Locations
17911Load signal for alter-nator terminal DF
Implausible sig-nal
Test generator Electrical System; Rep. Gr. 27 Reading measured value block, display group 016 Chap. 01-4
17931Crash signal from air-bag CU
Implausible sig-nal Perform airbag system self-diagnosis Body Fitting Work;
Rep. Gr. 01
17948Vehicle speed signal
Signal too high Test vehicle speed signal Chapter 23-6 Test CAN databus lines Chapter 23-6 Test dash panel insert Electrical System; Rep. Gr. 90
17954Charge pressure con-trol solenoid valve -N75
Short circuit topositive
Test charge pressure control solenoid valve -N75- with final controldiagnosis Chap. 01-1
17957Charge pressure con-trol solenoid valve -N75
Open circuit orshort circuit toearth
17958Charge pressure
Control differ-ence
Test charge pressure control solenoid valve - N75- with final controldiagnosis Chap. 01-1
Test charge pressure control 1.9 l/96 kW (TDI) Engine, Mechani-cal Components; Rep. Gr. 21
17964Charge pressure con-trol
Regulating limitnot reached
17965Charge pressure con-trol
Regulating limitexceeded
17977Cruise control systemswitch -E45
Implausible sig-nal Analyse measured value block, display groups 006 and 022 Chap. 01-4 Read out fault memory of the electrical system control unit
Electrical System; Rep. Gr. 9017978Engine control unitblocked1)
Adapt diesel direct injection system control unit - J248- to electronicimmobiliser Electrical System; Rep. Gr. 96
Test immobiliser Electrical System; Rep. Gr. 9618008Voltage supply termi-nal 15
Voltage too low Test voltage supply for diesel direct injection system control unit-J248- Chap. 23-5
18009Voltage supply relayterminal 30 -J3172)
Implausible sig-nal Test diesel direct injection system relay -J322-
Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
Readout on -V.A.G 1552- Rectifying fault
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18017Crash disconnect acti-vated
Read out fault memory of airbag control unit Body Fitting Work;Rep. Gr. 01
Replace airbag control unit Body Fitting Work; Rep. Gr. 6918020Engine control unit
Incorrectly cod-ed
Code diesel direct injection system control unit -J248- Chap. 23-5
18024Glow period warninglamp -K29
Short circuit topositive Test glow period warning lamp -K29- with final control diagnosis Chap. 01-1 18025
Glow period warninglamp -K29
Open circuit/Short-circuit toearth
18026Glow plug relay -J52
Short circuit topositive
Test glow plug relay -J52 - with final control diagnosis Chap. 01-1
18027Glow plug relay -J52
Short circuit toearth
18034
Data BUS drive
Missing mes-
sage from gear-box CU
Test CAN databus lines Chapter 23-6
18039 Accelerator pedal po-sition sender -G79
Signal too high Test accelerator pedal position sender -G79- Chap. 01-4, displaygroup 002
18040 Accelerator pedal po-sition sender -G79
Supply voltage
18043Data BUS drive
Missing mes-sage from airconditioningsystem CU
Test CAN databus lines Chapter 23-6 Read out air conditioning system control unit fault memory
Heating, Air conditioning; Rep. Gr. 87
18044Data BUS drive
Missing mes-sage from air-bag CU
Test CAN databus lines Chapter 23-6 Read out fault memory of airbag CU Body Work; Rep. Gr. 01
18045Data BUS drive
missing mes-sage form elec-tron. CU
Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90180471/2 for acceleratorpedal position sender -G79+G185
Implausible sig-nal
Test accelerator pedal position sender -G79- Chap. 01-4, displaygroup 002
Replace diesel direct injection system control unit -J248 - Chap.23-5
18048Control unit defective Replace diesel direct injection system control unit -J248 - Chap.23-518056Data BUS drive
defective Test CAN databus lines Chapter 23-6 Read out fault memory of engine CU Chapter 01-1
18057Data BUS drive
Missing mes-sage from ABSCU
Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Running Gear;
Rep. Gr. 4518058Data BUS drive
Missing mes-sage from com-biinstrument
Test CAN databus lines Chapter 23-6 Read out fault memory of dash panel insert Electrical System;
Rep. Gr. 9018062Read out fault memoryof combiinstrument
Perform self-diagnosis of the dash panel insert Electrical System;Rep. Gr. 90
Readout on -V.A.G 1552- Rectifying fault
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18065 Air conditioning sys-tem inlet/outlet
Short circuit topositive
Test AC compressor control with final control diagnosis Chap. 01-1
18071 Actuation of unit injec-tor solenoid valve
Short circuit topositive
Check unit injector Chap. 23-3
18072 Actuation of unit injec-tor solenoid valve
Electrical fault inthe circuit
18073 Actuation of unit injec-tor solenoid valve
Mechanical fault Replace unit injector Chap. 23-2
18074Unit injector solenoidvalve cyl. 1 -N240
Electrical fault inthe circuit
Check unit injector Chap. 23-3
18075Unit injector solenoidvalve cyl. 2 -N241
Electrical fault inthe circuit
18076Unit injector solenoidvalve cyl. 3 -N242
Electrical fault inthe circuit
18090Data BUS drive
implausiblemessage from
ABS CU
Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Running Gear;
Rep. Gr. 4518097Data BUS drive
Implausiblemessage fromelectron. CU
Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 9019456Glow period warninglamp -K29-
Missing mes-sage from com-biinstrument
Test CAN databus lines
Chapter 23-6
19458Kick-down switch -F8-
Implausible sig-nal
Test accelerator pedal position sender -G79- Chap. 01-4, displaygroup 002
19459Low heat output relay -J359
Short circuit topositive
Test low heat output relay -J359 - with final control diagnosis Chap. 01-1
19461High heat output relay-J360
Short circuit topositive
Test high heat output relay -J360 - with final control diagnosis Chap. 01-1
19463Camshaft pos. sensor=> Sender -G40
No signal Test camshaft position sensor -G40- Current Flow Diagrams,Electrical Fault Finding and Fitting Locations
Inspect position of camshaft and rotor 1.4/55 TDI Engine, Me-chanics; Rep. Gr. 15
Readout on -V.A.G 1552- Rectifying fault
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19464Camshaft pos. sensor=> Sender -G40
Signal outsidetolerance
Test camshaft position sensor -G40- Current Flow Diagrams,Electrical Fault Finding and Fitting Locations
Remove open circuit in wiring or short circuit according to currentflow diagram Current Flow Diagrams, Electrical Fault Finding andFitting Locations
Inspect position of camshaft and rotor
1.4/55 TDI Engine, Me-chanics; Rep. Gr. 1519560Intake manifold flapchange-over valve -N239
Short circuit topositive
Test intake manifold flap changeover valve -N239- with final controldiagnosis Chap. 01-1
19561Intake manifold flapchange-over valve -N239
Open circuit orshort circuit toearth
1) When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpatedkey the fault is changed to a sporadic fault.
2) Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.
Readout on -V.A.G 1552- Rectifying fault
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01-3 Self-diagnosis III
Readiness code
Reading readiness codeOperation
The readiness codes are two 8-digit numerical codeswhich indicate the status of the emission-relevant diag-noses.
If the diagnosis for a system was successfully performed(e.g. exhaust gas recirculation system), the relevant po-sition of the numerical code is set from 1 to 0.
This diagnosis is performed at regular intervals duringnormal driving. If repairs have been done on a system rel-evant for the exhaust gas it is recommended to generatethe readiness code as this guarantees that the systems
operate according to the specifications. If a fault is detect-ed during diagnosis, it is then stored in the fault memory.
The readiness code is erased through deletion of the faultmemory, that is all relevant points will be set to 1.
Generation of readiness code refers to the activation ofthe diagnostic functions such as diagnosis of fuel supply,diagnosis of other systems etc.
Procedure
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- with cable-V.A.G 1551/3, 3A, 3B oder 3C-
Connect vehicle system tester -V.A.G 1552- and se-lect address word 01 Engine electronics Chap.01-1.
Select function 08 Read measured value block anddisplay group number 017.
Readout on display:Reading measured value block 17 -> 00000000 00000110 10000000 00000000
Meaning of 8-digit numerical block for readiness code in display field 21 2 3 4 5 6 7 8 Meaning
0 Ignore1 Ignore
1 Ignore0 Ignore
0 Ignore0 Diagnosis of other systems
0 Diagnosis of fuel supply0 Ignore
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If the specified values are not reached, generate read-iness code 01-3 page 2.
Press key. Select function 06 End output and switch ignition off.
Generating readiness code
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- with cable-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
All electrical consumers, e.g. lights and rear windowheater switched off.
Intake air temperature must be below 60 C displaygroup 007, display field 3.
Coolant temperature at least 83 C display group007, display block 4.
Procedure
Connect vehicle system tester -V.A.G 1552-. Selectaddress word 01 Engine electronics Chapter 01-1.
Certain work steps must be carried out twice, in order toachieve the readiness code.
Work step 1: Interrogating fault memory
Select function Interrogate fault memory andconfirm with .
The number of stored faults or No fault recognised ap-pears in the display.
If a fault is stored in the memory:
Meaning of 8-digit numerical block for readiness code in display field 4
1 2 3 4 5 6 7 8 Meaning0 Ignore
0 Ignore0 Ignore
0 Ignore0 Ignore
0 Ignore0 Ignore
0 Diagnosis of exhaust gas recirculation system
Note
0 2
Q
X faults detected
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Rectify the faults by referring to the fault table Chapter 01-2.
If no fault is stored:
Press .
Work step 2: Erasing fault memory
Select function Erase fault memory and con-firm with .
Readiness code is erased each time the fault memory iserased.
Readout on display:
If the ignition is switched off during Interrogating faultmemory and Erasing fault memory, the fault memory isnot erased.
Press .
Work step 3: Switch off ignition
Wait at least 5 seconds with ignition OFF.
This point is important, because with certain diagnosesthe slowing down of the control unit must be ended. Oth-erwise readiness code cannot be generated.
Work step 4: Switch on ignition
Wait at least 10 seconds with ignition ON.Charge pressure sender is adapted to atmospheric pres-sure sender.
Work step 5: 1. Testing fuel supply and other
systems Start engine. Function Read measured value block and then
select display group 001. Increase engine speed for 5 seconds to 2500 rpm and
then run engine at idling speed.
Readout on display:
Work step 6: 1. Testing exhaust gas recircula-tion
Maintain speed constant between 1600 rpm to 1700rpm for at least 10 seconds.
0 5
Q
Note
Vehicle system test -> The fault memory is erased
Note
Note
0 8
Reading measured value block 1 -> 2500 rpm 4.6 mg/s 2.0 CA 94.2 C
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Readout on display:
In this speed range, the exhaust gas recirculation is ac-tive and the control difference is checked. (Condition forgeneration of readiness code for exhaust gas recircula-tion).
Work step 7: Switch off ignition
Wait at least 5 seconds with ignition OFF.
Work step 8: Switch on ignition
Wait at least 10 seconds with ignition ON.
Work step 9: 2. Testing fuel supply and othersystems
Start engine.
Function Read measured value block and thenselect display group 001. Increase engine speed for 5 seconds to 2500 rpm and
then run engine at idling speed.
Readout on display:
Work step 10: 2. Test of exhaust gas recircula-tion
Maintain speed constant between 1600 rpm to 1700rpm for at least 10 seconds.
Readout on display: Press . Select for display group 017.Readout on display:
Specification in display field 2: 00000110
Specification in display field 4: 00000000
Press . If the specified values are not reached, once again re-
peat procedure for generating readiness code 01-3 page 2.
Work step 11: Interrogating fault memory
Select function Interrogate fault memory andconfirm with .
The number of stored faults or No fault recognised ap-pears in the display.
If a fault is stored in the memory:
Rectify the faults by referring to the fault table Chapter 01-2 and generate readiness code again 01-3 page 2.
Reading measured value block 1 -> 1650 rpm 4.1 mg/s 4.0 CA 93.2 C
0 8
Reading measured value block 1 -> 2500 rpm 4.6 mg/s 2.0 CA 94.2 C
Reading measured value block 1 -> 1650 rpm 4.1 mg/s 4.0 CA 93.2 C
C
0 1 7
Reading measured value block 17 -> 00000000 00000110 10000000 00000000
0 2
Q
X faults detected
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If no fault is stored:
Press .Readiness code was successfully generated, if no fault isstored after two work sequences of the test procedure inthe fault memory for the engine control unit and if the fol-lowing values are displayed in the display group 017.
Reading measured value block 17 -> 00000000 00000110 10000000 00000000
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01-4 Self-diagnosis IV
Reading measured value block
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- with cable-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Coolant temperature must be at least 80 C. All electrical consumers, e.g. lights and rear window
heater, must be switched off. If vehicle is equipped with air conditioning, this must
be switched off.
Procedure Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 Engine electron-ics Chapter 01-1.
Select function 08 Read measured value block andconfirm the entry with key .
Enter display group 01-4 page 1.
Display groups 001 to 022, engine idling
Display group 001 in idle (engine warm, coolant temperature not below 80 C)
Analysis: Display group 001, display field 2 - Injection rate
Q
Read measured value block 1 < Readout on displayxxxrpm
xx.xmg/s
x.xx KW
xxx.x C
1 2 3 4 < Display field Specification AnalysisCoolant temperature 80.0110.0 C ---
Fuel delivery duration (set value) 4...7 KW ---Injection rate 3.09.0 mg/s 01-4 page 1
Idling speed 800970 rpm ---
Display -V.A.G 1552- Rectifying fault
below 3.0 mg/s Check unit injector Chap. 23-3.above 9.0 mg/s Warm up engine by running at high revs and repeat test.
Check unit injector Chap. 23-3.
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Display group 002 in idle (engine warm, coolant temperature not below 80 C)
Analysis: Display group 002, display field 2 - Accelerator pedal position
Analysis: Display group 002, display field 3 - Op-erating position
Display group 003 in idle (engine warm, coolant temperature not below 80 C)
Read measured value block 2 < Readout on displayxxxrpm
xxx.x%
x x x xxx.x C
1 2 3 4 < Display field Specification Analysis
Coolant temperature 80.0110.0 C ---Operating position 0 1 0 01-4 page 2
Accelerator pedal position 0.0 % 01-4 page 2Idling speed --- 01-4 page 1
Display -V.A.G 1552- Rectifying fault
1100.0 % Test accelerator pedal position sender -G79- Current Flow Diagrams,Electrical Fault Finding and Fitting Locations.
Meaning, if display positions = 1
X X X Operating position
1 Air conditioning switched on
1 Idling switch closed (accelerator pedalnot pressed)1 Ignore
Read measured value block 3 < Readout on displayxxxrpm
xxxmg/s
xxxmg/s
xxx%
1 2 3 4 < Display field Specification AnalysisOn/off ratio (actuation) ofexhaust gas recirculationvalve
3080 % ---
drawn in air mass (actual) 258...410 mg/s 01-4 page 3drawn in air mass (nominal) 278...390 mg/s 01-4 page 3
Idling speed --- 01-4 page 1
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Analysis: Display group 003, display field 2 - inducted air mass (set value)
Analysis: Display group 003, display field 3 - inducted air mass (actual value)
Display group 004 in idle (engine warm, coolant temperature not below 80 C)
Analysis: Display group 004, display field 2 - commencement of injection (set value)
Analysis: Display group 004, display field 4 - Synchronizing angle
Display -V.A.G 1552- Rectifying fault
above 390 mg/s Warm up engine by running at high revs and repeat test.
Display -V.A.G 1552- Rectifying fault
below 258 mg/s Test exhaust gas recirculation Chap. 23-4. Inspect intake system for leaks.
above 410 mg/s Warm up engine by running at high revs and repeat test. Engine idles for too long, briefly blip throttle. Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find-
ing and Fitting Locations.
Read measured value block 4 < Readout on displayxxxrpm
xx.x b. TDC
xx.x KW
xx.x KW
1 2 3 4 < Display field Specification AnalysisSynchronizing angle -3+3 KW 01-4 page 3
Fuel delivery duration (set value) 4.07.0 KW ---Commencement of injection (set value) 39 b. TDC 01-4 page 3
Idling speed --- 01-4 page 1
Display -V.A.G 1552- Rectifying fault
less than 3 BTDC Engine too cold, warm up engine by running at high revs and repeat test.
Display -V.A.G 1552- Rectifying fault
above 3 KW or under -3 KW Test camshaft position sensor -G40- Current Flow Diagrams, ElectricalFault Finding and Fitting Locations.
Inspect position of camshaft and rotor 1.4/55 TDI Engine - Mechanics;Rep. Gr. 15
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Display group 005 in idle (engine warm, coolant temperature not below 80 C)
Display group 006 in idle (engine warm, coolant temperature not below 80 C)
Analysis: Display group 006, display field 2 -Brake pedal or clutch pedal monitoring
Analysis: Display group 006, display field 4 - Op-erating condition of cruise control system
Read measured value block 5 < Readout on displayxxxrpm
xx.xmg/s
xx.x b. (n.)
TDC
xxx.x C
1 2 3 4 < Display field Specification AnalysisCoolant temperature 80110 C ---
Synchronisation when starting 1 ---drawn in air mass when starting 915 mg/s ---
Idling speed --- 01-4 page 1
Read measured value block 6
< Readout on displayxxxkm/h
xxx xx.x%
xxx
1 2 3 4 < Display field Specification AnalysisOperating condition of thecruise control system
xxx 01-4 page 4
Accelerator pedal position 0 % 01-4 page 2Status of the brake and clutch pedal switch 000 01-4 page 4
Vehicle speed 0 km/h ---
Meaning, if display positions = 1
X X X Operating position
1 Brake light switch -F- closed (brakepedal operated)
1 Brake pedal switch -F47- opened(brake pedal operated)
1 Clutch pedal switch -F36- opened
(clutch pedal operated)
Dis-play
Operating position
0 Vehicles with activated cruise control system,switch in position OFF
1 Vehicles with activated cruise control system,switch in position ON
255 Vehicle without cruise control system orcruise control system function in engine con-trol unit not activated
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Display group 007 with ignition switched on (engine cool and standing)
Analysis: Display group 007, display field 1 - Fuel temperature
Analysis: Display group 007, display field 3 - Intake manifold temperature
Analysis: Display group 007, display field 4 - Coolant temperature
Read measured value block 7 < Readout on displayxxx.x
Cxxx%
xxx.x C
xxx.x C
1 2 3 4 < Display field Specification AnalysisCoolant temperature approx. ambient
temperature 1)
1) It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intakemanifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant
sender.
01-4 page 5
Intake manifold temperature approx. ambienttemperature 1)
01-4 page 5
Status of the fuel cooling 0 % ---Fuel temperature approx. ambient
temperature 1) 01-4 page 5
Display -V.A.G 1552- Rectifying fault
40.5 C Inspecting Fuel temperature sender -G81- Chap. 23-1.
Display -V.A.G 1552- Rectifying fault
approx. 135.9 C Inspecting Intake manifold temperature sender -G72- Chap. 23-1.
Display -V.A.G 1552- Rectifying fault
-5.4 C Inspecting coolant temperature sender -G62- Chap. 23-1.In the event of a fault the fuel temperature is displayed instead.
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Display group 010 in idle (engine warm, coolant temperature not below 80 C)
Display group 011 in idle (engine warm, coolant temperature not below 80 C)
Display group 013 in idle (engine warm, coolant temperature not below 80 C)
Analysis: Display group 013, display field 1through 3 - Idle smoothness regulator
The injection system has an idle smoothness regula-tor. It is possible to detect differences in performancebetween individual cylinders (part tolerances, injector
Read measured value block 10 < Readout on displayxxxrpm
xxxxmbar
xxxxmbar
xxx%
1 2 3 4 < Display field Specification Analysis
Accelerator pedal posi-tion
0.0 % 01-4 page 2
Charge pressure (actual) 900...1150 mbar --- Atmospheric pressure 900...1100 mbar ---
drawn in air mass (actual) 258...410 mg/s 01-4 page 3
Read measured value block 11
< Readout on displayxxxrpm
xxxxmbar
xxxxmbar
xx%
1 2 3 4 < Display field Specification AnalysisOn/off ratio (actuation) ofsolenoid valve for chargepressure control -N75-
2595 % ---
Charge pressure (actual) 9001150 mbar ---Charge pressure (nominal) 9001100 mbar ---
Idling speed --- 01-4 page 1
Read measured value block 13 < Readout on displayx.xxmg/s
x.xxmg/s
x.xxmg/s
1 2 3 4 < Display field Specification Analysis
Smooth running control - injected
quantity cylinder 3
-3+3 mg/s 01-4 page 6
Smooth running control - injected quantity cylin-der 2
-3+3 mg/s 01-4 page 6
Smooth running control - injected quantity cylinder 1 -3+3 mg/s 01-4 page 6
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flow, compression etc.) and to compensate for theseby selectively metering the quantity injected in theidling speed range.
Differences are detected in the idling speed range onthe basis of the signal supplied by the engine speedsender which supplies three signals to the control unitfor each crankshaft revolution. If the signals have thesame rhythm, the cylinder have the same output. If acylinder has a lower output, the crankshaft will needmore time for the next half crankshaft rotation. As op-posed to this a high output cylinder will accelerate thecrankshaft to such an extent that it will need less time.
Once the control unit has identified a deviation, therelevant cylinder will immediately be supplied with agreater or smaller injection rate until the engine againruns smoothly.
+ mg/s: The relevant cylinder has less output and istherefore supplied with more fuel.
- mg/s: The relevant cylinder has more output andis therefore supplied with less fuel.
Display group 016 in idle
Analysis: Display group 016, display field 2 - Auxiliary heating
Read measured value block 16 < Readout on displayxxx % xxxxxxxx xx xx.x V
1 2 3 4 < Display field Specification AnalysisSupply voltage of the en-gine control unit
13.514.5 V 01-4 page 8
Heating element control xx 01-4 page 8
Auxiliary heating 1x000001 01-4 page 7Generator capacity 595 % ---
Meaning, if display positions = 1
X X X X X X X X Additional heating deactivated, because:
1 Coolant temperature greater than 7080 C or intake air temperature greaterthan +5 C
1 Generator defective1 Battery voltage below 9 V
1 Engine speed less than 800 rpm1 Engine start within the last 10 seconds
1 Coolant temperature sender -G62- or Intake manifold temperature sender-G72- defective
1 Ignore1 Ignore
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Analysis: Display group 016, display field 3 -Control of the heating elements
Analysis: Display group 016, display field 4 - supply voltage of engine control unit
Display group 018 in idle
Analysis: Display group 018, display field 1 through 3 - Display of the conditon of the unit injectors
Display group 022, engine idling
Meaning, if display positions = 1
X X Operating position
1 Low heat output relay -J359- on1 High heat output relay -J360- on
Display -V.A.G 1552- Rectifying fault
below 13.5 V Test generator and battery voltage, charge battery Electrical System;Rep. Gr. 27.
Increase engine speed slightly for a few minutes and switch off additionalconsumers.
Test supply voltage of engine control unit
Chap. 23-5. Rectify any current drain.above 14.5 V Test voltage regulator, replace if necessary Electrical System;
Rep. Gr. 27. Remove start aid cable or quick charger.
Read measured value block 18 < Readout on displayxx xx xx xx1 2 3 4 < Display field Specification Analysis
IgnoreUnit injector solenoid valve cyl. 3 0 01-4 page 8
Unit injector solenoid valve cyl. 2 0 01-4 page 8Unit injector solenoid valve cyl. 1 0 01-4 page 8
Display -V.A.G 1552- Rectifying fault
If number instead of zero Test injector unit Chap. 23-3. Inspecting fuel supply 1.4 ltr./55 TDI Engine, Mechanics; Rep. Gr. 20.
Read measured value block 22 < Readout on display
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Analysis: Display group 022, display field 1 - operating state of cruise control system
Analysis: Display group 022, display field 2 - op-erating state of cruise control system
x xxxxxx x x1 2 3 4 < Display fields Specification Analysis
Operating state of air con-ditioning
0
Operating state of charge pressurecontrol 0
Operating state of cruise control xxxxxx 01-4 page 9Operating condition of the cruise control system x 01-4 page 9
Operating condition of the cruise control system
0 Vehicle without CCS or CCS function in engine control unit not activated1 Vehicles with activated CCS, switch in position OFF9 Vehicles with activated CCS, switch in position ON
Cruise control Display field 2
Switch B on ON 000011Switch B on RES 001011Switch A operated 000111Switch B to OFF before operating point 000001Switch B to OFF locked 000000
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Display groups 004 through 011 at fullload
Accelerate vehicle at full throttle before inspecting. The measured values must be read off or printed out
once an engine speed of 3000 rpm is reached (2nd person required). Pay attention to safety precautions for test drives
Chapter 23-1.
Display group 004 under full load (test drive in 3rd gear, coolant temperature not below 80 C)
Display group 008 under full load (test drive in 3rd gear, coolant temperature not below 80 C)
Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
Note
Read measured value block 4 < Readout on displayxxxxrpm
xx.x b. TDC
xx.x KW
x.xx KW
1 2 3 4 < Display field Specification AnalysisSynchronizing angle --- ---Fuel delivery duration (set value) 1724 KW ---
Commencement of injection (set value) 15 BTDC25 BTDC
---
Engine speed 28003200 rpm ---
Read measured value block 8 < Readout on displayxxxxrpm
xx.xmg/s
xx.xmg/s
xx.xmg/s
1 2 3 4 < Display field Specification AnalysisInjection rate limit basedon drawn in air mass(smoke prevention)
45.055.0 mg/s 01-4 page 11
Injection rate limit based on enginespeed (torque limit)
40.049.0 mg/s 01-4 page 11
Injection rate (driver's instruction) 60.069.0 mg/s 01-4 page 10
Engine speed 28003200 rpm 01-4 page 10
Display -V.A.G 1552- Rectifying fault
below 60.0 mg/s Repeat test at full throttle. Test accelerator pedal position sender -G79- Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.
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Self-diagnosis IVEdition 04.04S00.5326.01.20
01-4 page 11
01
Analysis: Display group 008, display field 3 - Injection rate limit over speed (torque limit)
Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
Display group 011 under full load (test drive in 3rd gear coolant temperature not below 80 C)
Analysis: Display group 011, display field 3 - intake manifold temperature (charge pressure)
Display -V.A.G 1552- Rectifying fault
below 40.0 mg/s Read off set value at 3000 rpm.
Display -V.A.G 1552- Rectifying fault
below 45.0 mg/s Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find-ing and Fitting Locations.
Test exhaust gas recirculation Chap. 23-4.
Read measured value block 11 < Readout on displayxxxxrpm
xxxxmbar
xxxxmbar
xxx%
1 2 3 4 < Display field Specification AnalysisOn/off ratio (actuation) ofsolenoid valve for chargepressure control -N75-
4095 % ---
Charge pressure (actual value) 18002200mbar
01-4 page 11
Charge pressure (specified value) 18002100mbar ---
Engine speed 28003200 rpm ---
Display -V.A.G 1552- Rectifying fault
below 1800 mbar or over 2200mbar
Inspecting charge pressure control 1.4/55 TDI Engine, Mechanics;Rep. Gr. 21.
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Self-diagnosis IV Edition 04.04S00.5326.01.20
01-4 page 12
01
Display group 125 - CAN databus
Display group 125 with ignition switched on
Analysis: Display group 125, display field 2, 3 or 4
Read measured value block 125 < Readout on display ABS 1 Combi 1 Airbag 1
1 2 3 4 < Display field Specification Analysis Airbag control unit Airbag 1 01-4 page 12
Dash panel insert CU Combi 1 01-4 page 12 ABS control unit ABS 1 01-4 page 12
not assigned --- ---
Display -V.A.G 1552- Rectifying fault
0 Test CAN databus Chap. 23-6.
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Diesel Direct Injection SystemEdition 04.04S00.5326.01.20
23-1 page 1
23
23-1 Diesel Direct InjectionSystem
Safety measuresObserve the following points to prevent injury to personsand/or damage to the injection and preheating system:
Disconnect and connect wires of the injection and pre-heating system and measuring device wires when theignition is switched off.
When the battery is disconnected and reconnected,carry out rework Electrical System; Rep. Gr. 27.
If test and measuring devices are required during testdrives observe the following:
Always secure the test and measuring devices on therear seat and have a second person operate themthere. If the test and measuring equipment is operatedfrom the front passenger seat, this can result in inju-ries to the persons sitting on that seat in the event ofan accident which involves the front passenger airbagbeing deployed.
Rules of cleanlinessPay careful attention to the following rules of cleanlinesswhen working on the fuel supply or fuel injection systems:
Thoroughly clean the connection points and their sur-roundings before releasing.
Place removed parts on a clean surface and cover. Donot use fuzzy cloths!
Carefully cover or close opened components if the re-pair is not completed immediately.
Only install clean parts. Remove spare parts fromtheir wrapping immediately before fitting. Do not useany parts which have been stored unwrapped (e.g. intool boxes etc.).
When the system is open: avoid working with com-pressed air. Avoid moving the vehicle. Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately.Replace immediately any hoses which have suffereddamage.
23 Fuel Formation, Injection
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Diesel Direct Injection System Edition 04.04S00.5326.01.20
23-1 page 2
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Overview of fitting locationsComponents A through H are not represented in the overview figure.
A - Diesel direct injection systemrelay -J322-
on relay carrier Fig. 2 in23-1 page 3
B - Glow plug relay -J52-on relay carrier Fig. 2 in23-1 page 3
C - Low heat output relay -J359-on relay carrier Fig. 2 in23-1 page 3
D - High heat output relay -J360-on relay carrier Fig. 2 in23-1 page 3
E - Fuel pump relay -J17-on relay carrier Fig. 2 in23-1 page 3
F - Accelerator pedal positionsender -G79-
in footwell on the acceleratorpedal Fig. 1 in 23-1 page 3
G - Brake light switch -F- andBrake pedal switch -F47-
in footwell on the brake pedal Fig. 1 in 23-1 page 3
H - Clutch pedal switch -F36-in footwell on the clutch ped-
al Fig. 1 in 23-1 page 31 - Valve blockComponent parts of thevalve block are:change-over valve for intakemanifold flap -N239-, speci-fied resistance: 25...45 Exhaust gas recirculation valve -N18-, specified resistance: 14...20 Charge pressure control solenoid valve -N75-, specified resistance: 25...45
2 - Mechanical exhaust gas recirculation valveat the induction pipe with the intake manifold flap
3 - Sender for the coolant temperature -G62-Specified resistance Fig. 3 in23-1 page 4
4 - Air mass meter -G70-5 - Diesel direct injection system control unit -J248-6 - Fuel temperature sender -G81-
Specified resistance Fig. 4 in23-1 page 47 - Plug connection
3-pin, greyfor engine speed sender -G28-3-pin, blackfor the camshaft position sensor -G40-
8 - Engine speed sender -G28-specified resistance between contacts 1 and 2: 450...550 9 - Camshaft position sensor -G40-
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Diesel Direct Injection SystemEdition 04.04S00.5326.01.20
23-1 page 3
23
10 - Intake manifold pressure sender -G71- with intake manifold temperature sender - G72-Specified resistance Fig. 3 in23-1 page 4
11 - Fuel filter repairing 1.4/55 TDI Engine, Mechanics; Rep. Gr. 20
Fig. 1: Components in footwell
1 - Clutch pedal switch -F36-2 - Brake light switch -F- and Brake pedal switch -F47-3 - Accelerator pedal position sender -G79-
Fig. 2: Relay carrier
1 - Fuel pump relay -J17-2 - Diesel direct injection system relay -J322-3 - Glow plug relay -J52-4 - Low heat output relay -J359-5 - High heat output relay -J360-
S24-0374
2
1
3
1 2 3 4 5
S23-0139
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Diesel Direct Injection System Edition 04.04S00.5326.01.20
23-1 page 4
23
Fig. 3: Resistance of coolant temperature sender-G62- and of intake manifold temperaturesender -G72-
The specification in field -A- applies to the temperaturerange 0 to 50 C, specification in field -B- applies to thetemperature range 50 to 100 C.
Read out examples:
The specification for a temperature of 30 C is 1500 to2000
The specification for a temperature of 80 C is 275 to375
Fig. 4: Resistance of fuel temperature sender -G81-
The specification in field -A- applies to the temperaturerange 0 to 65 C, specification in field -B- applies to thetemperature range 65 to 100 C.
Read out examples:
The specification for a temperature of 30 C is 3790 to4270
The specification for a temperature of 80 C is 600 to660
Disassembling and assembling intakemanifoldThe intake manifold flap closes for about 3 seconds afterswitching off the engine and then opens again. This re-duces the switch-off impact.
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Diesel Direct Injection SystemEdition 04.04S00.5326.01.20
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1 - Intake manifold2 - O-ring
replace3 - Induction pipe
with mechanical exhaust gasrecirculation valve and intakemanifold flap
4 - Mechanical exhaust gas recir-culation valve
5 - 10 Nm6 - Bracket7 - Vacuum setting element
For intake manifold flap8 - 25 Nm9 - Connection pipe for exhaust
gas recirculationto exhaust manifold
10 - Gasket
replace
Removing and installing air filter
Removing
Loosen spring strap clamp -1- on the air guide hoseand remove the hose from the air filter.
Disconnect ventilation hose -2- and the plug on the airmass meter -3-. Remove the air deflector -4- from the air filter. Unscrew the fixing screw -5- from the air filter (tighten-
ing torque: 8 Nm). Carefully remove air filter from the top.
Installing
Pay attention to correct positioning of the stop buffer onthe bottom part of the air filter (front and rear side).
Installation is carried out in the reverse order.
12
3
4
5
S23-0125Note
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Diesel Direct Injection System Edition 04.04S00.5326.01.20
23-1 page 6
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Disassembling and assembling the air filter
1 - Air guide hoseto induction pipe at intakemanifoldCheck fitting position
2 - Spring strap clip
3 - 2 Nm4 - Top part of air filter cover 5 - Filter insert6 - Bottom part of the air filter
cover 7 - Air deflector
to the lock carrier 8 - Air mass meter -G70-
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Disassembling and assembling the unit injector Edition 04.04S00.5326.01.20
23-2 page 1
23
23-2 Disassembling and as-sembling the unit injector
Summary of components
Observe the rules for cleanliness Chapter 23-1. Always replace heat-protection seals and O-rings. Always replace screws tightened to turning angle.
1 - 20 Nm + torque a further 1 /4 turn (90 )
replace2 - Valve-lever shaft
with valve leversremoving and installing 23-2
page 33 - Lock nut, 30 Nm4 - Adjusting screw
pay attention to different ver-sionreplace when replacing theunit injector and where wearmarks are visibleGrease the contact surfacesof the unit injector to ball pinsusing grease -G 000 100-
5 - Ball pin
pay attention to different ver-sion6 - Unit injector
pay attention to different ver-sionremoving and installing 23-2 page 3Check ball pins for wearmarks and replace if neces-saryGrease the contact surfaceto the adjusting screw usinggrease -G 000 100-Valve resistance: Nominalvalue approx. 0.5 whenmeasuring directly at the valve, when measuring via the 8-pin plug connection at the cylinder head 0.8 ... 1.0
7 - Top O-ringreplace 23-2 page 2
8 - Centre O-ringreplace 23-2 page 2
9 - Bottom O-ringreplace 23-2 page 2
10 - Heat-protection seal
replace11 - Circlip12 - Cylinder head
Note
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Disassembling and assembling the unit injector Edition 04.04S00.5326.01.20
23-2 page 2
23
13 - Clamping pad
14 - 12 Nm + torque a further 3 /4 turn (270 )replace
Removing and installing O-rings for unitinjector
Special tools, test and measuring equipment andauxiliary items required
Assembling sleeves -T10056-
Removing
Lever off the old O-rings from the slots of the unit in- jector with extreme care.
Make sure, above all, that the seating surfaces in theslots of the O-rings are not damaged.
Installing
Always use the assembly sleeves to install the O-rings. Otherwise there is the danger of damaging theO-rings.
Observe the correct allocation of the O-rings to thechannels: the ring thickness reduces in the direction ofthe injection nozzle.
Avoid rolling the O-rings when sliding them on. The O-rings must not be turned inwards on the slots of theunitinjector.
Remove the heat-protection seal along with the circlip. Clean the seating surfaces for the O-rings in the unit
injector with great care. Insert the assembling sleeve -T10056/1- on the unit
injector up to the stop. Carefully slide the top O-ring onto the assembling
sleeve and into the groove of the unit injector. Remove assembly sleeve. Insert the assembling sleeve -T10056/2- on the unit
injector up to the stop. Carefully slide the middle O-ring onto the assembling
sleeve and in the groove of the unit injector. Remove assembly sleeve.
Note
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Disassembling and assembling the unit injector Edition 04.04S00.5326.01.20
23-2 page 3
23
Insert the assembling sleeve -T10056/3- on the unitinjector up to the stop.
Carefully slide the lower O-ring onto the assemblingsleeve and in the groove of the unit injector.
Remove assembly sleeve. Slide on a new heat-protection seal together with the
circlip.
Removing and installing the unit injector
Special tools, test and measuring equipment andauxiliary items required
Extractor -T10055- Universal dial gauge holder -MP 3-447- Dial gauge Torque wrench
On vehicles with WIV the adjusting screw -1- and the ball pin -2- was changed On old engines with WIV, both vari-ants can be combined.
Removing
Remove upper timing belt cover and cylinder headcover 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15.
Rotate the crankshaft approx. in the TDC cylinder 1,
while doing so all valve levers must point upwardsevenly. Release the counternuts of the adjusting screws -1-
and unscrew the adjusting screws until the relevantvalve lever rests against the tappet spring of the unitinjector.
Screw out fixing screws -2- for the valve-lever shaftfrom the outside to the inside and remove the valve-lever shaft.
Separate plug connection at the removed unit injector.Support the opposite side of the connector with yourfinger in order to avoid twisting the connector.
Screw out fixing screw -3- of the clamping pad and re-move the pad in the direction towards the camshaft.
When removing all unit injectors turn the engine so thatthe outlet cam for cylinder 1 (the first one from the belt
pulley side) points with the tip upwards. All three clamp-ing pads can be removed in this position.
Note
Note
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Disassembling and assembling the unit injector Edition 04.04S00.5326.01.20
23-2 page 4
23
Insert the extractor -T10055- instead of the clampingpad in the slot of the unit injector.
Remove the unit injector through movements of thesleeve at the nut up to the stop in -direction of arrow-.
Do not interchange the unit injectors, if necessary markthe assignment to each cylinder.
Installing
The associated adjusting screw in the valve-levershould be replaced when a new unit injector is beinginstalled.
For any work procedure involving an adjustment of theunit injector it is necessary to clean the adjusting
screw in the valve lever and also the ball pin of the unitinjector and to check them for traces of wear. If thereis any wear replace the ball pin and the adjustingscrew.
Grease the contact surfaces between the ball pin andthe adjusting screw using -G 000 100-.
New unit injectors are supplied with O-rings and heat- protection seal.
Before installing again the original unit injector, O-rings, heat-protection seal and circlip must be re-
placed.
Before installing the unit injector check the correct po-sition of the three O-rings, heat-protection seal andthe circlip.
The O-rings must not be twisted.
Oil the O-rings and place the unit injector with thegreatest of care into the cylinder head.
Slide the unit injector into the cylinder head seat up tothe stop by exerting a uniform pressure.
Place the clamping pad in the side slot of the unit in- jector.
If the unit injector is not perpendicular to the clamping padthe fixing screw may loosen and cause damage to theunit injector or cylinder head.
Align the unit injector as follows: Screw the clamping pad with the new fixing screw until
the unit injector can still easily be turned. Set the unit injector at a right angle to the bearing shell
of the camshaft.
Note
Note
Note
Note
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Disassembling and assembling the unit injector Edition 04.04S00.5326.01.20
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Using a caliper gauge, check dimension -a- from theouter side of the cylinder head to the cylinder surfaceof the solenoid valve for the unit injector.
Removing and installing the unit injector with the oldsolenoid valve nut
Removing and installing the unit injector with thenew solenoid valve nut
Adjust the unit injector as required, tighten the fixingscrew using a torque of 12 Nm and then turn througha further 270 (3/4 of a turn). Tightening may occur insuccessive stages.
Mount valve-lever shaft and tighten up the new fixingscrews as follows.
First tighten the inside screws and then the two out-side screws by hand. In the same sequence tighten to20 Nm and turn a further 90 (1/4 turn).
Place a dial gauge on the adjusting screw of the unitinjector.
Turn the crankshaft in the running direction of the en-gine until the roller of the valve lever is on the drivecam tip.
Roller side -arrow A- is on the highest point.
Dial gauge -arrow B- is on the lowest point.
Cylinder Dimension -a-
1 244.2 0.8 mm2 156.2 0.8 mm3 64.8 0.8 mm
Cylinder Dimension -a-1 245.0 0.8 mm2 157.0 0.8 mm3 65.6 0.8 mm
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Disassembling and assembling the unit injector Edition 04.04S00.5326.01.20
23-2 page 6
23
Remove the dial gauge. Turn the adjusting screw in the valve lever until one
feels a significant resistance (the unit injector isagainst the stop).
Turn the adjusting screw in the opposite direction fromthe stop by about 225 (5/8 turn)
Firmly hold the adjusting screw in this position andtighten up the lock nut using a torque of 30 Nm. Place connector onto the unit injector, install the cylin-
der head cover and insert the upper timing belt cover.
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Testing componentsEdition 07.03S00.5326.00.20
23-3 page 1
23
23-3 Testing components
Test wiring and components with Testbox -V.A.G 1598/31- 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
Test diesel direct injection system relay-J322-The power supply of the injection system occurs via thediesel direct injection system relay - J322-. The precondi-tion for closing of the relay is a voltage supply via terminal15 to the diesel direct injection system control unit -J248-.This means that diesel direct injection system relay-J322- receives ground (via the Diesel direct injectionsystem control unit -J248-), if the control unit -J248- re-ceives a voltage supply via terminal 15.
Fitting location
The diesel direct injection system relay - J322- is locatedon the relay carrier in the driver's footwell on the left, relaybase 12.
Special tools, test and measuring equipment andauxiliary items required
Hand multimeter (e.g. -V.A.G 1526 A-) Adapter cable set (e.g. -V.A.G 1594 C-) Test box -V.A.G 1598/31-
Test conditions
Battery voltage at least 11.5 volts Fuses in fuse holder on battery are O.K.
Check for proper operation
Remove lower part of the dash panel insert on thedriver's side Body work; Rep. Gr. 70.
Switch on ignition.
Diesel direct injection system relay -J322 - must close.
The clicking of the relay is hardly audible and can there-fore best be felt.
If the relay does not close:
Test control
Switch off ignition.
Connect test box -V.A.G 1598/31 - to wiring loom toengine control unit 23-3 page 1.
S97-1373
1 2 3 4
5
10
6
11
7
12
8
13
9
14 15
Note
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Testing components Edition 07.03S00.5326.00.20
23-3 page 2
23
Interconnect bush 18 and bush 4 of the test box usingan auxiliary line.
The relay must be closed.
If the relay is now closed but did not open during the func-tional test:
Replace diesel direct injection system control unit- J248- Chapter 23-5.
If the relay does not close:
Pull diesel direct injection system relay -J322- out ofthe relay carrier.
Connect handheld multimeter for voltage measure-ment to contact 2 and earth.
Specified value: approx. battery voltage
If the specified value is not reached:
Testing the wiring Current Flow Diagrams, Electri-cal Fault Finding and Fitting Locations.
If the specified value is reached:
Switch off ignition. Check the following wire for interruption or short-cir-
cuit to earth or positive:
If necessary eliminate wire interruption or short-circuit.If wiring is o.k.:
Replace the diesel direct injection system relay- J322-.
Testing unit injector valve 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
9
2
6
S23-0101
9
2
6
S23-0101
Contact Test box- V.A.G 1598/31-
contact
9 18
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Testing exhaust gas recirculationEdition 07.03S00.5326.00.20
23-4 page 1
23
23-4 Testing exhaust gas recir-culation
Connect vacuum hoses at valve block1 - Connection air filter/exhaust turbocharger 2 - to vacuum reservoir at exhaust turbocharger 3 - To turbocharger 4 - To intake manifold flap5 - To air filter 6 - from non-return valve for brake servo unit7 - to mechanical exhaust gas recirculation valve
Testing exhaust gas recirculation
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test sequence
The exhaust gas recirculation function is checked in func-tion 04 (basic setting). As a result of this procedure theexhaust gas recirculation valve is pulsed every 10 sec-onds, so that the extreme values for the exhaust gas re-circulation (air mass meter) can be read off in measuredvalue block 003 in display field 3.
Connect vehicle system tester -V.A.G 1552-. Start en-gine and select address word 01 Engine electronics Chapter 01-1.
Enter function 04 basic setting and select displaygroup number 003.
After selecting display group number 003 and confirmingwith , the idling speed is increased by the engine con-trol unit in display field 1 to 13801420 rpm.
The display in display field 2 must switch betweenEGRn.active and EGR.active every 10 seconds.The following readouts must fluctuate in display fields 3and 4:
If a constant value of 539 mg/stroke and higher is shownin display field 3, test the air mass meter Chapter 23-3.
Note
Q
System in basic setting 3 -> 1400 rpm EGRn.active 500 mg/s 20
Note
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Testing exhaust gas recirculation Edition 07.03S00.5326.00.20
23-4 page 2
23
If the specified values are not reached:
Inspecting mechanical exhaust gas recirculation valve 1.4/55 TDI Engine, Mechanics; Rep. Gr. 26.
Inspect the connection diagram for the vacuum hoses 23-4 page 1.
Test exhaust gas recirculation valve -N18- with finalcontrol diagnosis Chap. 01-1.
EGRn.active:Specification in display field 3: 450600 mg/Hspecified value in display field 4: 1822 %
EGRactive.Specification in display field 3: 160310 mg/Hspecified value in display field 4: 6367 %
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection
Engine control unitEdition 04.04S00.5326.01.20
23-5 page 1
23
23-5 Engine control unit
Testing voltage supply for engine con-trol unit 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
Replacing diesel direct injection systemcontrol unit -J248-
Special tools, test and measuring equipment andauxiliary items required
Vehicle system tester -V.A.G 1552- Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
Connect vehicle system tester -V.A.G 1552-. Switchignition on and select address word 01 Engine elec-tronics Chap. 01-1.
The vehicle system tester -V.A.G 1552- displays the con-trol unit identification, e. g.:
Note Part No. of control unit and coding. Select function 06 End output and confirm with . Switch off ignition. Remove air filter Chap. 23-1. Release the connector catches and unplug the con-
nectors of the diesel direct injection control unit- J248-.
P