Fuel injection AMF.pdf

7/24/2019 Fuel injection AMF.pdf

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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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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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28 Glow Plug SystemTesting preheating system ........................................................................... 28-1 page 1


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Self-diagnosis IEdition 04.04S00.5326.01.20

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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01-1 page 3

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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


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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01-1 page 5

01

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.



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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01-1 page 6

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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.


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.


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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01-1 page 7

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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.


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.


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.


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.


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


Test high heat output relay -J360- with final control diagnosis Chap. 01-1

01282Intake manifold flapchange-over valve -N239


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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01

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


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



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


Short circuit topositive


Supply voltage



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01-2 page 3

01

17563Intake manifold pres-sure sender -G71


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




Supply voltage

17568Intake manifold tem-perature sender -G72

Short circuit toearth

Test intake manifold temperature sender -G72- Chap. 01-4, dis-play group 007


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


Test fuel temperature sender -G81- Chap. 01-4, display group007



17571Fuel temperaturesender -G81


17663Coolant temperaturesender -G62


Test coolant temperature sender -G62- Chap. 01-4, display group007



17664Coolant temperaturesender -G62


17668Unit injector solenoidvalve cyl. 1 -N240

Implausible sig-nal

Check unit injector Chap. 23-3


Regulating limitexceeded


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







Rep. Gr. 2017674Unit injector solenoidvalve cyl. 3 -N242

Implausible sig-nal






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01-2 page 4

01




Rep. Gr. 2017795Control unit defective


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


17910Fuel pump relay -J17


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


Test charge pressure control solenoid valve -N75- with final controldiagnosis Chap. 01-1

17957Charge pressure con-trol solenoid valve -N75


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


17965Charge pressure con-trol


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



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01-2 page 5

01

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


Test glow plug relay -J52 - with final control diagnosis Chap. 01-1

18027Glow plug relay -J52


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


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



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01-2 page 6

01

18065 Air conditioning sys-tem inlet/outlet


Test AC compressor control with final control diagnosis Chap. 01-1

18071 Actuation of unit injec-tor solenoid valve




Electrical fault inthe circuit


Mechanical fault Replace unit injector Chap. 23-2








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


Test low heat output relay -J359 - with final control diagnosis Chap. 01-1

19461High heat output relay-J360


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




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01

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


Test intake manifold flap changeover valve -N239- with final controldiagnosis Chap. 01-1

19561Intake manifold flapchange-over valve -N239


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-.



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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



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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Self-diagnosis III Edition 04.04S00.5326.01.20

01-3 page 2

01

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



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 .


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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01-3 page 3

01

Rectify the faults by referring to the fault table Chapter 01-2.


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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01-3 page 4

01

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 .


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.


0 8



C

0 1 7

Reading measured value block 17 -> 00000000 00000110 10000000 00000000

0 2

Q

X faults detected


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01-3 page 5

01


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


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01-4 Self-diagnosis IV

Reading measured value block



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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01


Analysis: Display group 002, display field 2 - Accelerator pedal position

Analysis: Display group 002, display field 3 - Op-erating position



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


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


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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01-4 page 3

01

Analysis: Display group 003, display field 2 - inducted air mass (set value)

Analysis: Display group 003, display field 3 - inducted air mass (actual value)


Analysis: Display group 004, display field 2 - commencement of injection (set value)

Analysis: Display group 004, display field 4 - Synchronizing angle


above 390 mg/s Warm up engine by running at high revs and repeat test.


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.


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



less than 3 BTDC Engine too cold, warm up engine by running at high revs and repeat test.


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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01-4 page 4

01



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


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 ---


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 ---


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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01-4 page 5

01

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


40.5 C Inspecting Fuel temperature sender -G81- Chap. 23-1.


approx. 135.9 C Inspecting Intake manifold temperature sender -G72- Chap. 23-1.


-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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01-4 page 6

01




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


xxxxmbar

xxxxmbar

xxx%


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 ---


Read measured value block 13 < Readout on displayx.xxmg/s

x.xxmg/s

x.xxmg/s


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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01-4 page 7

01

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 % ---


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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01-4 page 8

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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


X X Operating position

1 Low heat output relay -J359- on1 High heat output relay -J360- on


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


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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01-4 page 10

01

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 ---


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


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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01-4 page 11

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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)


below 40.0 mg/s Read off set value at 3000 rpm.


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.


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 ---


below 1800 mbar or over 2200mbar

Inspecting charge pressure control 1.4/55 TDI Engine, Mechanics;Rep. Gr. 21.


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01-4 page 12

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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 --- ---


0 Test CAN databus Chap. 23-6.


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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

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23

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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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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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


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:



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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23-1 page 5

23

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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23-1 page 6

23

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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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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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


Assembling sleeves -T10056-

Removing

Lever off the old O-rings from the slots of the unit injector 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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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


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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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 injector.

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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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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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

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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.


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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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

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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


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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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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Engine control unitEdition 04.04S00.5326.01.20

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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-


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

Fuel injection AMF.pdf

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