Fuel Injection AZL

Service 5
Workshop Manual
FABIA 2000 ➤
2.0/85 Engine, Fuel Injection
Edition 03.01
Engine code AZL
Service Department. Technical Information Printed in Czech Republic

S00.5310.00.20
5 Service
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5310.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ➤ 2.0/85 Engine, Fuel Injection
List of Supplements to Workshop Manual

FABIA 2000 ➤
2.0/85 Engine, Fuel Injection
Edition 03.01
Supple-
Edition Subject Article Number
ment
03.01 Basic Edition S00.5310.00.20
1 11.04 S00.5310.01.20
Edition 11.04 List of Supplements

S00.5310.01.20
List of Supplements Edition 11.04

S00.5310.01.20
Table of Contents
01 – Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 page 1
- Properties of the self-diagnosis ..................................................................... 01-1 page 1
- Technical data of self-diagnosis ..................................................................... 01-1 page 1
- Meaning of the exhaust gas warning light -K83- .................................................. 01-1 page 3
- Connecting vehicle system tester -V.A.G 1552- and selecting engine electronics control
unit ....................................................................................................... 01-1 page 4
- Interrogating and erasing fault memory of engine control unit ................................. 01-1 page 5
- Automatic test sequence ............................................................................. 01-1 page 5
- Performing actuator diagnosis ....................................................................... 01-1 page 6
Self-diagnosis II ......................................................................................... 01-2 page 1
- Readiness code ........................................................................................ 01-2 page 1
- Reading Readiness Code ............................................................................ 01-2 page 1
- Generating readiness code .......................................................................... 01-2 page 2
Self-diagnosis III ........................................................................................ 01-3 page 1
- Fault table, fault codes 16485...17606 ............................................................. 01-3 page 1
Self-diagnosis IV ....................................................................................... 01-4 page 1
- Fault table, fault codes 17621...18104 ............................................................. 01-4 page 1
Self-diagnosis V ........................................................................................ 01-5 page 1
- Reading measured value block ..................................................................... 01-5 page 1
- Reading measured value blocks, display groups 001 to 029 ................................... 01-5 page 2
Self-diagnosis VII ....................................................................................... 01-6 page 1
- Reading measured value block, display groups 030 to 062 .................................... 01-6 page 1
Self-diagnosis VIII ...................................................................................... 01-7 page 1
- Reading measured value blocks, display groups 66 to 126 .................................... 01-7 page 1
24 – Fuel Formation, Injection

Repairing the injection system ...................................................................... 24-1 page 1
- General notes on the injection system ............................................................. 24-1 page 1
- Overview of fitting location ........................................................................... 24-1 page 2
- Removing and installing parts of the injection system ........................................... 24-1 page 3
- Disassembling and assembling bottom part of intake manifold ................................ 24-1 page 5
- Disassembling and assembling the air filter ....................................................... 24-1 page 6
- Safety measures ....................................................................................... 24-1 page 7
- Rules of cleanliness ................................................................................... 24-1 page 7
Testing components ................................................................................... 24-2 page 1
- Testing throttle valve control unit -J338- ........................................................... 24-2 page 1
- Testing accelerator pedal position sender ......................................................... 24-2 page 2
- Testing injection valves ............................................................................... 24-2 page 3
- Test fuel pressure regulator and holding pressure ............................................... 24-2 page 4
Testing functions II .................................................................................... 24-3 page 1
- Testing lambda probe -G39- and lambda control upstream of catalytic converter .......... 24-3 page 1
- Testing lambda probe ageing upstream of catalytic converter -G39- ......................... 24-3 page 2
- Testing lambda probe -G130- and lambda control downstream of catalytic converter ..... 24-3 page 3
Engine control unit ..................................................................................... 24-4 page 1
Edition 11.04 Table of Contents I

S00.5310.01.20
- Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-4 page 1
- Testing voltage supply for engine control unit .................................................... 24-4 page 1
- Procedure after voltage supply has been interrupted ............................................ 24-4 page 2
- Replacing engine control unit .. ...................................................................... 24-4 page 3
- Coding engine control unit ........................................................................... 24-4 page 4
- Adjusting the engine control unit to the throttle valve control unit ............................. 24-4 page 5
Testing auxiliary signals ............................................................................. 24-5 page 1
- Testing the speed signal ............................................................................. 24-5 page 1
- Test data bus .......................................................................................... 24-5 page 1
- Activating and deactivating cruise control system (CCS) ....................................... 24-5 page 2
28 – Ignition System
Repairing ignition system ............................................................................ 28-1 page 1
- General notes on the ignition system .............................................................. 28-1 page 1
- Safety measures ...................................................................................... 28-1 page 1
- Removing and installing parts of the ignition system ............................................ 28-1 page 2
- Testing camshaft position sensor -G163- ......................................................... 28-1 page 3
Table of Contents Edition 11.04

II S00.5310.01.20
FABIA 2000 ➤ 2.0/85 Engine, Fuel Injection 01
01 – Self-diagnosis
01-1 Self-diagnosis I
Properties of the self-diagnosis
Note
The self-diagnosis monitors only a part of the injection
and ignition system. The „Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations“ binder should
always be used for fault finding.
The MOTRONIC engine control unit -J220- is equipped
with a fault memory.
If malfunctions occur in the monitored sensors or compo-
nents, they are stored in the fault memory with indication
of the fault type.
The engine control unit analyses the information and dis-
tinguishes different fault codes ⇒ Chap. 01-3 or 01-4 and
stores these until the contents of the fault memory are
erased.
Faults that only occur temporarily (sporadically) are out-
put with the suffix „sporadically occurred fault“. On the
display these faults are indicated by the suffix „SP“. Pos-
sible causes of sporadic faults are e.g. a loose contact or
a momentary line interruption. If a sporadic fault no longer
occurs within 40 warming-up phases (engine started at a
temperature of 50°C and switched off at more than 72
°C), the fault is then automatically erased fom the fault
memory.
After the fault or faults have been rectified, it is necessary
to erase the fault memory ⇒ 01-1 page 5 and also to re-
generate the readiness code ⇒ Chapter 01-2.
Note
♦ The following description only relates to vehicle sys-
tem tester -V.A.G 1552- using the program card -5.0-,
or higher.
♦ If fault read-out scan tool -V.A.G 1551- with program
card -8.0- or higher and integrated printer, or if vehicle
system tester -V.A.S 5051- is used, slight variations in
the readouts in the display are possible.
Technical data of self-diagnosis
Control unit identification:

The control unit version is displayed when the vehicle
system tester -V.A.G 1552- is connected and address
word 01 „Engine electronics“ is selected ⇒ 01-1 page 4.
Edition 11.04 Self-diagnosis I 01-1 page 1

S00.5310.01.20
01 FABIA 2000 ➤ 2.0/85 Engine, Fuel Injection
Equipment
Engine identification characters AZL

System denomination Motronic 7.5 ME
Exhaust limits conforming to EU4, EU3 DDK, EU2 DDK
Electronic throttle system Yes
Self-diagnosis Yes
Actuator diagnosis Yes
Fault memory Permanent memory1)
Memory for initialisation values Volatile memory2)
Lambda control 2 probes
Knock control 2 knock sensors
Intake manifold change-over No
Camshaft adjustment No
Boost-pressure control No
Secondary air system Yes
Exhaust gas recirculation No
1) Independent of the voltage supply.
2) The values are erased if the voltage supply is interrupted.
Functions available when using the vehicle sys-

tem tester -V.A.G 1552-
Note
The preconditions for selecting the desired functions are
given in the following table.
Operation Precondition
Function on the vehicle system tester Engine not run- Engine idling Normal driving
-V.A.G 1552- ning, ignition
switched on
01 Interrogating control unit version yes yes yes
02 Interrogating fault memory yes1) yes yes
03 Actuator diagnosis yes no no
04 Basic setting2) yes yes yes
05 Erasing fault memory yes yes yes
06 Ending output yes yes yes
07 Coding control unit yes no no
08 Reading measured value block yes yes yes
15 Reading Readiness Code yes yes yes
1) Only to be carried out with the ignition switched on and if the engine does not start (activate starter for at least 6 seconds).
2) To be carried out after the following operations: replacing engine control unit, throttle valve control unit, or after disconnecting battery. The air
conditioning and the ACF system are automatically switched off in function 04.
Self-diagnosis I Edition 11.04

01-1 page 2 S00.5310.01.20
Meaning of the exhaust gas warning light
-K83-
For engines complying with exhaust emission stand-
ard EU-4, EU-3 DDK
If the engine control unit detects faults, which impair the
exhaust gases, this is indicated by the lighting up of the
exhaust warning lamp -K83-.
Fitting location of exhaust warning light:
CHECK
Note
♦ The exhaust warning light -K83- may flash or come on
as a steady light. The fault memory must be interro-
gated whatever happens ⇒ 01-1 page 5.
♦ The warning light flashes: There is a fault, which is
likely to damage the catalytic converter in this driving CHECK
condition. In this driving condition only low perform-

ance driving is allowed!
♦ The warning light comes on as a steady light: There is
a fault which deteriorates the exhaust gas quality.
Read fault memory of engine control unit.
S01-0091
♦ There is a vehicle performance fault or the customer
is making a complaint and the exhaust warning light
-K83- does not light up so the fault memory should be
interrogated since there may be faults stored there
which do not immediately switch on the exhaust warn-
ing light -K83-.
Check for proper operation

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

light -K83- ⇒ Electrical equipment; Rep. Gr. 90.
If the exhaust gas warning light -K83- comes on when the
ignition is switched on:
– Start engine and run in idle.

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

remove any faults which exist and delete the fault
memory ⇒ 01-1 page 5.

S00.5310.01.20
Connecting vehicle system tester

-V.A.G 1552- and selecting engine elec-
tronics control unit 1 6
11
12
17
18
23 31
24 32
2 7 13 19 25 33
3
Special tools, test and measuring equipment and 4
8 14 20 26 34
9 15 21 27
auxiliary items required 5 10 16 22 28
35
36
39 29 37
49
♦ Vehicle system tester -V.A.G 1552- with cable 59
30 38
40 50 60
-V.A.G 1551/3, 3A, 3B oder 3C- 41 51 61
42 52 62
43 53 63
Test conditions 44 54 64
45 55
• The fuses must be in proper order.
65
46 56 66
• Battery voltage must be at least 11.5 volts. 47

48
57
58
67
68
• Assembly earth connections o.k. S01-0094
Procedure
– Fold back trim panel -1-.
– Connect vehicle system tester -V.A.G 1552-.
– Enter address word 01 „Engine electronics“.
2 3
1
4 5 6
7
C
8
O
9
Q HELP V.A.G. 1552
The control unit identification number and the coding are 06A906032CC 2.0l R4/2V G 3658 ->
shown on the vehicle system tester display, e.g.: Coding 00071 WSC XXXXX
♦ 06A906032CC = Part No. of the control unit (for cur-
rent version see spare part catalogue)
♦ 2.0 l R4/2V = Displacement 2.0 l, 4-cyl. inline engine,
2 valves per cylinder
♦ G = CCS activated (if nothing is displayed at this point,
CCS is not active)
♦ 3658 = programme number
♦ Coding 00001 = Coding of control unit ⇒ Chap. 24-4
♦ WSC xxxxx = Workshop code of the -V.A.G 1552-
with which the last coding was performed
Note
♦ If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit
⇒ Chapter 24-4.
♦ 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

01-1 page 4 S00.5310.01.20
♦ Storage of non-existent faults in fault memory
♦ Impossibility of performing certain functions (lambda
control, actuation of activated charcoal filter system,
etc.)
Interrogating and erasing fault memory

of engine control unit
Interrogate and erase the fault memories of al control
units ⇒ 01-1 page 5.
Special tools, test and measuring equipment and

auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and enter address word 01 „Engine electronics“
⇒ 01-1 page 4.
Only if the engine does not start:
– Operate starter for about 6 seconds. after this do not

switch off ignition.
– Select function 02 „Interrogate fault memory“.
X faults detected
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If no fault is stored:
– Press → key.
If one or several faults are stored:
– Rectify the faults displayed by referring to the fault ta-

ble ⇒ Chap. 01-3 or 01-4.
Vehicle system test HELP
– Select function 05 „Erase fault memory“. The fault memory is erased
Note
The fault memory is not erased if the ignition was
switched off during the functions of „Interrogating fault
memory“ and „Erasing fault memory“.
– Select function 06 „End output“ and switch ignition off.

– Read out readiness code ⇒ Chap. 01-2. If the fault
memory has been erased or if the continuous voltage
supply from the engine control unit was interrupted, it
is then necessary to re-generate the readiness code.
Automatic test sequence

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

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– Enter address word 00 „Automatic Test Sequence“.

The tester -V.A.G 1552- sends all known address
words in sequence.
If a control unit responds with its identification, the display
will indicate the number of faults in the memory or „No
fault detected“.
– Erase the fault memory and then carry out a test drive.
During the test drive the following operating conditions
must be fulfilled:
♦ The coolant temperature should rise beyond 80°C.
♦ Once this temperature is reached, the following oper-
ating states must be reached several times: Idling,
part load, full load, overrun, enrichment.
♦ In case of full load the speed should be increased be-
yond 3500 rpm.
– Once again interrogate the fault memories of all the

control units with the address word 00 „Automatic test
sequence“.
Note
If no fault has been recognized by the self-diagnosis, pro-
ceed with fault finding as specified in the „Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations“
binder.
Performing actuator diagnosis

With the actuator diagnosis the following parts are acti-
vated in the sequence indicated:
1. Activated charcoal filter system solenoid valve 1 -N80-
2. Secondary air pump relay -J299-
3. Injector cyl. 1 -N30-

-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
♦ Measuring tool set e.g. -V.A.G 1594 A, B oder C-
♦ Current flow diagram

01-1 page 6 S00.5310.01.20
Test conditions
• The fuses must be in proper order.
• Battery voltage must be at least 11.5 volts. 1 6
11
12
17
18
23 31
24 32
• All electrical consumers, e.g. lights and rear window 2
3
7
8
13
14
19
20
25
26
33
34
heater, must be switched off. 4 9 15 21 27 35
5 10 16 22 28 36
39 29 37
49 59
Note 40 50 60
30 38
41 51 61
♦ The actuator diagnosis can only be carried out when 42 52 62
the engine is not running and the ignition is switched 43 53 63
on. 44 54 64
45 55
♦ The final control diagnosis is aborted when the engine 65
46 56 66
is started or when a moment of momentum is detect- 47 57 67
ed. 48 58 68
S01-0094
♦ During the actuator diagnosis the individual actuators
remain activated until the next actuator is selected by
pressing key → .
♦ The electric fuel delivery unit runs during the entire fi-
nal control diagnosis.
♦ The actuators are tested acoustically or by touch.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ 01-1 page 4.
Vehicle system test Q
– Select function 03 „final control diagnosis“. 03 - Actuator diagnosis
Activate solenoid valve 1 for activated charcoal

filter system -N80-:
– Press → key.
Actuator diagnosis ->
Readout on display:
Tank vent valve -N80
The solenoid valve (on right, at suspension strut dome)
must continue clicking until the next control element is ac-
tuated by pressing the → key.
– Detach hose from the activated charcoal filter at the

solenoid valve.
– Fit auxiliary hose onto the free connection of the
valve.
– Blow into this hose during final control diagnosis. The
valve must open and close.
If the solenoid valve does not click:
– Test resistance at solenoid valve -N80- ⇒ Chap. 24-

1.
– Test cables for open circuit, short circuit to earth and
to positive ⇒ Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
Actuate secondary air pump relay -J299-:

– Press → key.

S00.5310.01.20
Readout on display:
The secondary air pump relay must continue clicking until Secondary air pump relay -J299
the next control element is actuated by pressing the →
key.
If the relay does not click:
– Test secondary air pump relay -J299- and cables for

open circuit, short circuit to earth and to positive
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations.
Actuate injectors -N30- to -N33-:

– Press → key.
Readout on display: Injector cylinder 1 -N30
The injector closes 5x.
– The next injector is operated by pressing the → but-

ton.
– Test all the injectors one after the other in this way.
If one of the injectors is not actuated:
– Test resistance of injector ⇒ Chap. 24-1.

Note
The ignition must be switched off after final control diag-
nosis is ended. If the ignition is not switched off before the
engine is started, the engine will not start as the injectors
and the ignition transformer are not operated.

01-1 page 8 S00.5310.01.20
01-2 Self-diagnosis II
Readiness code
Reading Readiness Code

Operation
The readiness code is an 8-digit numerical code that pro-
vides information on the status of the emission-relevant
diagnosis.
If the diagnosis is performed for a system, the corre-
sponding digit of the numerical code switches from 1 to 0.
This diagnosis is performed at regular intervals during
normal driving. If repairs have been done on a system rel-
evant for the exhaust gas it is recommended to generate
the readiness code as this guarantees that the systems
operate according to the specifications. If a fault is detect-
ed during the diagnosis it is entered in the fault memory.
The readiness code is erased if the fault memory is
erased or if there is an interruption to the voltage supply.

-V.A.G 1551/3, 3A, 3B oder 3C-.
Procedure
– Connect vehicle system tester -V.A.G 1552- and enter
address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 15 „Readiness code“.
Readiness code →
If all diagnoses were performed successfully, the display 00000000 - Test complete 01101101
must indicate the following:

Readiness code →
If the following readout appears in the display:
01101101 - Test not complete 01101101
– Press → key.
– Generate readiness code ⇒ 01-2 page 2.
Edition 11.04 Self-diagnosis II 01-2 page 1

S00.5310.01.20
Meaning of the 8-digit numerical block of the readiness code
The readiness code is only generated if all the display positions show 0
1 2 3 4 5 6 7 8 Diagnosis function
0 Catalytic converter
0 Catalytic converter heater (no diagnosis at present/always „0“)
0 Activated charcoal filter system
0 Secondary air system
0 Air conditioning system (no diagnosis at present/always „0“)
0 Lambda probes
0 Lambda probe heater
0 Exhaust gas recirculation (no diagnosis at present/always „0“)
Generating readiness code

-V.A.G 1551/3, 3A, 3B oder 3C-.
Test conditions
• Vehicle stationary.
• All electrical consumers, e.g. lights and rear window
heater switched off.
• Air conditioning switched off.
• Intake air temperature less than 60 °C ⇒ display
group 004, display block 4.
• Coolant temperature at least 80 °C ⇒ display group
004, display block 3.
Procedure
tronics“ ⇒ Chap. 01-1.
Work step 1: Interrogating fault memory
– Select function 02 „Interrogate fault memory“.

X faults detected
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If a fault is stored in the memory:
– Rectify the faults displayed by referring to the fault ta-

ble:
Fault table ⇒ Chap. 01-3 or 01-4.
– Press → key.
Self-diagnosis II Edition 11.04

01-2 page 2 S00.5310.01.20
Work step 2: Erasing fault memory
Vehicle system test ->
– Select function 05 „Erase fault memory“. The fault memory is erased
Note
♦ The readiness code is reset or erased each time the
fault memory is erased.
♦ The fault memory is not erased if the ignition was
switched off during the functions of „Interrogating fault
memory“ and „Erasing fault memory“.
– Press → key.
Work step 3: Adjusting the engine control unit to the

throttle valve control unit
System in basic setting 60 ->
– Select function 04 „Initiate basic setting“ and display xx % xx % 8 ADP runs
group 060.
– Display field 4:
Specified value: ADP runs, ADP o.k.
– End adjustment only after 30 seconds have passed by

pressing the → key.
If the specified values are not reached:
– Test throttle valve control unit ⇒ Chapter 24-2.

Work step 4: Diagnosis of secondary air injection
system
Note
The engine must not be switched off during the entire pe-
riod.
– Select function 04 „Initiate basic setting“ and display

group 077.
After initiating diagnosis the message in display field 4 xxx/min xx.x g/s xx.x % Test ON
changes from „Test OFF“ to „Test ON“.
– Leave engine idling until the following readout ap-

pears in display field 4: „Syst. o.k.“.
– Interrogate fault memory ⇒ Chapter 01-1.

If the specified values are reached:
– Press C key.
Work step 5: Diagnosis of activated charcoal filter

system (tank vent system)
– Enter display group 070.

System in basic setting 70 →
After initiating diagnosis the message in display field 4
29% 65% 342% Test ON
changes from „Test OFF“ to „Test ON“.
– Leave engine running at idling speed until „TVV o.k.“

is displayed in display field 4.

S00.5310.01.20
– Blip throttle about 3 times and repeat the process.

– Press → key.
Work step 6: Testing operating state of lambda con-

trol
The lambda control can only be tested at a catalytic con-
verter temperature of more than 352 °C.
To achieve this, engine speed must be increased for sev-
eral minutes to 2800...3200 rpm. Read off the catalytic
converter temperature in measured value block 034.
– Select function 08 „Read measured value block“ and

display group 034.
– Set engine speed to 2800...3200 rpm:
Reading measured value block 34 ->
– Maintain engine speed at 2800...3200 rpm until the 3000 rpm 352 °C xx.xx Text
catalytic converter temperature in display field 2 is
more than 352 °C.
Note
This may take a few mlnutes.
– Press C key.
Reading measured value block 30 ->
– Check operating state of lambda control upstream of 111 110
catalytic converter (display field 1):
Specified value: 111
– Check operating state of lambda control downstream

of catalytic converter (display field 2):
Specified value: 110
Note
Bits in display field 2 are only set to value 1 once the
lambda probe downstream of the catalytic converter is
active. The catalytic converter temperature must be more
than 352 °C.
Meaning of 3-digit numerical block in the display

fields 1 and 2:
Meaning, if display positions = 1

1 2 3
1 Lambda control active (partial load)
1 Lambda probe operational
1 Lambda probe heater switched on

01-2 page 4 S00.5310.01.20
– Press → key.
Work step 7: Diagnosis of lambda probe ageing

(monitoring period)
– Select function 04 „Basic setting“ and display group

034.
– Depress brake pedal and accelerator simultaneously.
– Engine speed is increased and the readout in display 1600 rpm 352 °C 1.99 Test OFF
field 4 switches from „Test OFF“ to „Test ON“.
Catalytic converter temperature in display field 2 must be
at least 352 °C.
– Check period in display field 3.

Specified value: maximum 2.2 s
Specification in display field 4: „B1 S1 o.k.“

– Press C key.
Work step 8: Catalyst diagnosis
Note
This diagnosis is only successfully completed if no faults
relating to the lambda probe or the activated charcoal fil-
ter system exist.

– Engine speed is increased and the readout in display
field 4 switches from „Test OFF“ to „Test ON“.
System in basic setting 46 →
Catalytic converter temperature in display field 2 must be 2300 rpm 328.0°C 0.00 Test OFF
at least 352 °C.
– Continue running engine until „Cat B1 o.k.“ is dis-

played.
Note
It may also take a few minutes until the readout is
changed from „Test ON“ to „Cat B1 o.k.“

– Press → key.
Work step 9: Reading Readiness Code

S00.5310.01.20
– Read out readiness code ⇒ 01-2 page 1.

01-2 page 6 S00.5310.01.20
01-3 Self-diagnosis III

Fault table, fault codes 16485...17606
Note
♦ The fault table is arranged according to the 5-digit
fault code on the left.
♦ Faults related to the electronic throttle are indicated
on the dash panel insert by the fault lamp for the elec-
tronic accelerator control „EPC warning lamp“).
♦ 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 vehicle system tester.
♦ If parts are output as faulty: First of all, test all the ca-
bles and plug connections to these components as
well as the earth cables of the system according to the
current flow diagram. Replace the component only if
this test does not reveal any fault. This applies in par-
ticular if the fault is shown as sporadic (SP).
♦ When testing senders and other components of the
fuel injection system and when testing electric cables,
proceed according to appropriate current flow dia-
gram ⇒ Current Flow Diagrams, Electrical Fault Find-
ing and Fitting Locations.
Note
♦ 16486 = Fault denomination
♦ P0113 = next fault code (at present only applicable for
USA)
♦ 035 = fault type as number
♦ air mass meter -G70- = current path or fault point de-
fective
♦ Signal too small = designate fault type with text
♦ „SP“ sporadically occurring fault = fault which does not
occur often, e.g. a loose contact
Readout on Rectifying fault

-V.A.G 1552-
16485 Implausible – Read measured value block, display group 005 ⇒ Chapter 01-5
Air mass meter -G70- signal
– Check wiring to meter -G70- ⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
16486 Signal too low – Read measured value block, display group 005 ⇒ Chapter 01-5
Air mass meter -G70-
– Testing the intake system for tightness (unmetered air)
16487 Signal too
Air mass meter -G70- high – Replace air filter element
– Check wiring to meter -G70- ⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
Edition 11.04 Self-diagnosis III 01-3 page 1

S00.5310.01.20

-V.A.G 1552-
16496 Signal too low – Read measured value block, display group 004 ⇒ Chap. 01-5
Intake air temperature
sender -G42- – Test resistance of intake air temperature sender -G42 - ⇒ Chap. 24-1
16497 Signal too
Intake air temperature high
sender -G42-
16500 Implausible – Read measured value block, display group 004 ⇒ Chap. 01-5
Sender for the coolant signal
temperature -G62- – Test resistance of coolant temperature sender -G42 - ⇒ Chap. 24-1
16501 Signal too low – Test coolant thermostat ⇒ 2.0/85 Engine, Mechanical Components;
Sender for the coolant Rep. Gr. 19
temperature -G62-
16502 Signal too
Sender for the coolant high
temperature -G62-
16505 Implausible – Test throttle valve control unit ⇒ Chapter 24-2
Throttle valve potenti- signal
ometer -G69-
16506 Signal too low
Throttle valve potenti-
ometer -G69-
16507 Signal too
Throttle valve potenti- high
ometer -G69-
16514 Electrical fault – Test lambda probe -G39- and lambda control upstream of catalytic
Bank 1 - probe 1 in the circuit converter ⇒ Chapter 24-3
16516 Voltage too
Bank 1 - probe 1 high
16517 Signal too
Bank 1 - probe 1 slow
16518 No activity
Bank 1 - probe 1
16519 Electrical fault
Bank 1 - probe 1, heat-
ing circuit
16520 Electrical fault – Test lambda probe -G130- and lambda control downstream of catalyt-
Bank 1 - probe 2 in the circuit ic converter ⇒ Chapter 24-3
16521 Voltage too
Bank 1 - probe 2 low
16522 Voltage too
Bank 1 - probe 2 high
16523 Signal too
Bank 1 - probe 2 slow
16524 No activity
Bank 1 - probe 2
ing circuit
Self-diagnosis III Edition 11.04

01-3 page 2 S00.5310.01.20

-V.A.G 1552-
16554 Malfunction – Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
Bank 1, fuel metering
system – Test injection valves ⇒ Chapter 24-2
16555 System too – Test fuel delivery unit ⇒ 2.0/85 Engine, Mechanical Components;
Bank 1, fuel metering lean Rep. Gr. 20
system – Inspect exhaust system for leaks ⇒ 2,0/85 kW Engine, Mechanical
Components; Rep. Gr. 26
– Inspect secondary air system for leaks ⇒ 2.0/85 kW Engine, Mechan-
ical Components; Rep. Gr. 26
– Inspect vacuum lines for leaks
– Inspect intake system for leaks
16556 System too – Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
Bank 1, fuel metering rich
system – Test injection valves ⇒ Chapter 24-2
– Test solenoid valve for activated charcoal filter ⇒ Chapter 01-1, final
control diagnosis
16585 Electrical fault – Test injectors ⇒ Chapter 01-1, Final control diagnosis
Injector cyl. 1 -N30- in the circuit
16603 Maximum en- – Rectify any mechanical damage
gine speed
exceeded
Angle sender 2 for TV signal
drive -G188- – Test throttle valve control unit ⇒ Chapter 24-2
Angle sender 2 for TV
drive -G188-
16607 Signal too
Angle sender 2 for TV high
drive -G188-
Angle sender for 1/2 signal
accelerator pedal posi- – Test accelerator pedal position sender ⇒ Chapter 24-2
tion -G79- + -G185-
Sender for accelerator
pedal position -G79-
16612 Signal too
Sender for accelerator high
16614 Electrical fault – Test fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical Fault
Fuel pump relay -J17- in the circuit Finding and Fitting Locations

S00.5310.01.20

-V.A.G 1552-
16645 Short circuit – Test injectors ⇒ Chapter 01-1, Final control diagnosis
Injector cyl. 1 -N30- to earth
16646 Short circuit
Injector cyl. 1 -N30- to positive
16648 Short circuit
16649 Short circuit
16651 Short circuit
16652 Short circuit
16654 Short circuit
16655 Short circuit
16684 Combustion – Test combustion misfiring, display group 014, 015, 016 ⇒ Chap. 01-5
misfiring de-
tected – Test injectors ⇒ Chapter 01-1, Final control diagnosis
– Test ignition leads and spark plugs ⇒ Chapter 28-1
– Inspect ignition transformer ⇒ Chapter 28-1
16685 Combustion – Test combustion misfiring, display group 015 ⇒ Chap. 01-5
Cyl. 1 misfiring de-
16686 Combustion – Test ignition leads and spark plugs ⇒ Chapter 28-1
Cyl. 2 misfiring de- – Inspect ignition transformer ⇒ Chapter 28-1
tected
16687 Combustion
tected
16688 Combustion – Test combustion misfiring, display group 016 ⇒ Chap. 01-5
– Test ignition leads and spark plugs ⇒ Chapter 28-1
16705 Implausible – Test resistance of engine speed sender -G28- ⇒ Chap. 24-1
Engine speed sender signal
-G28-
16706 No signal
Engine speed sender
-G28-
16708 Malfunction – Read measured value block, display group 026 ⇒ Chap. 01-5
Knock control
Knock sensor 1 -G61-
16712 Signal too
Knock sensor 1 -G61- high
Knock sensor 2 -G66-
16717 Signal too
Knock sensor 2 -G66- high

01-3 page 4 S00.5310.01.20

-V.A.G 1552-
16724 Incorrect as- – Test camshaft position sensor -G163- ⇒ Chapter 28-1
Camshaft position/ signment
crankshaft position sen-
sor
16725 Implausible
Camshaft position sen- signal
sor ⇒ sender -G40 -
Camshaft position sen-
16727 Signal too
Camshaft position sen- high
16735 Malfunction – Test ignition leads and spark plugs ⇒ Chapter 28-1
Ignition control cyl. 1
16736 Malfunction
Ignition control cyl. 2 – Read measured value block, display group 014 ⇒ Chapter 01-5
16737 Malfunction
16738 Malfunction
16795 Flow rate in- – Read measured value block, display group 077 ⇒ Chap. 01-7
Secondary air system correct
– Test secondary air injection pump ⇒ 2.0/85 Engine, Mechanical Com-
ponents; Rep. Gr. 26
– Test combination valve ⇒ 2.0/85 Engine, Mechanical Components;
Rep. Gr. 26
– Inspect hoses and connection pipes to individual components, and
also between components ⇒ 2.0/85 Engine, Mechanical Compo-
nents; Rep. Gr. 26
16802 Malfunction – Test the relay or the secondary air pump ⇒ Chapter 01-1, final control
Secondary air pump re- diagnosis
lay -J299-
16804 Efficiency too – Generate readiness code ⇒ Chapter 01-2
Bank 1, catalytic con- low
verter system – Check emission levels if the same faults are displayed ⇒ Inspection
and Maintenance; Rep. Gr. 02
16806 Efficiency too
Bank 1, main catalytic low
converter
16824 Malfunction – Test solenoid valve for activated charcoal filter ⇒ Chapter 01-1, final
Tank ventilation system control diagnosis
16825 Flow rate in- – Inspect hoses and connection pipes from fuel tank up to injection rail
Tank ventilation system correct ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
16885 Implausible – Test vehicle speed signal ⇒ Chapter 24-5
Vehicle speed signal signal
16890 Speed under – Test throttle valve control unit ⇒ Chapter 24-2
Idling control nominal value
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
16891 Speed above
Idling control nominal value – Inspect intake system for leaks
16894 Malfunction – Test throttle valve control unit ⇒ Chapter 24-2
Idling speed switch
-F60-

S00.5310.01.20

-V.A.G 1552-
16897 incorrect code – Adapt engine control unit to electronic immobiliser ⇒ Electrical Sys-
Immobilizer number tem; Rep. Gr. 96.
16944 Implausible – Inspect engine control unit power supply ⇒ Chapter 24-4
Voltage supply signal
– Test battery and alternator ⇒ Electrical System; Rep. Gr. 27
16946 Voltage too
Voltage supply low – procedure if voltage interrupted ⇒ Chapter 24-4
16947 Voltage too
Voltage supply high
16952 Implausible – Test cruise control system (CCS), display group 066 ⇒ Chap. 01-7
CCS switch -E45- signal
Brake light switch -F- signal
16984 missing mes- – Read measured value block, display group 125 ⇒ Chap. 01-7
Databus drive sage
– Inspect databus ⇒ Chapter 24-5
– Perform automatic test sequence ⇒ Chapter 01-1
16985 – Replace engine control unit -J220- ⇒ Chapter 24-4
Control unit defective
16986 Malfunction – Check parts of the engine control unit and the gearbox control unit
Control unit program- and replace the control unit if necessary
ming
16989
16990
17022 Implausible – Test throttle valve control unit ⇒ Chapter 24-2
Throttle valve control signal
unit -J338-
17026 Control unit – Replace engine control unit ⇒ Chapter 24-4
Knock control defective
17069 Open circuit – Test the power supply relay -J271- for the engine control unit
Main relay ⇒ -J271- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Loca-
17070 Short circuit tions
Main relay ⇒ -J271- to earth
17071 Short circuit
Main relay ⇒ -J271- to positive
17510 Short circuit – Test lambda probe -G39- and lambda control upstream of catalytic
Bank 1 - probe 1, heat- to positive converter ⇒ Chapter 24-3
ing circuit
17511 Output too
Bank 1 - probe 1, heat- small
ing circuit
17513 Short circuit – Test lambda probe -G130- and lambda control downstream of catalyt-
Bank 1 - probe 2, heat- to positive ic converter ⇒ Chapter 24-3
ing circuit

01-3 page 6 S00.5310.01.20

-V.A.G 1552-
17519 System too – Test lambda probe -G39- and lambda control upstream of catalytic
Lambda control (bank lean converter ⇒ Chapter 24-3
1)
17520 System too
Lambda control (bank rich
1)
17523 Short circuit
Bank 1 - probe 1, heat- to earth
ing circuit
17524 Open circuit
ing circuit
17525 Short circuit – Test lambda probe -G130- and lambda control downstream of catalyt-
Bank 1 - probe 2, heat- to earth ic converter ⇒ Chapter 24-3
ing circuit
17526 Open circuit
ing circuit
Bank 1, mixture adap- rich
tation (mult.) – Test injection valves ⇒ Chapter 24-2
– Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-
nal control diagnosis
Bank 1, mixture adap- lean
tation (mult.) – Test injection valves ⇒ Chapter 24-2
– Test fuel delivery unit ⇒ 2.0/85 Engine, Mechanical Components;
Rep. Gr. 20
– Inspect exhaust system for leaks ⇒ 2.0/85 kW Engine, Mechanical
Components; Rep. Gr. 26
– Inspect secondary air injection system for leaks ⇒ 2.0/85 kW Engine,
Mechanical Components; Rep. Gr. 26
– Inspect vacuum lines for leaks
17549 implausible – Test throttle valve control unit ⇒ Chapter 24-2
Load detection value
– Test accelerator pedal position sender ⇒ Chapter 24-2
17550 Below limit
Load detection – Test injection valves ⇒ Chapter 24-2
17551 Above limit – Inspect intake system for leaks
Load detection – Read measured value block, display group 005 ⇒ Chapter 01-5
17553 Short circuit – Read measured value block, display group 005 ⇒ Chapter 01-5
Air mass meter -G70- to positive
17557 implausible – Test lambda probe -G39- and lambda control upstream of catalytic
Lambda control (bank control value converter ⇒ Chapter 24-3
1)
17559 Below lean- – Testing the intake system for tightness (unmetered air)
Bank 1, mixture adap- ness limit
tation range 1

S00.5310.01.20

-V.A.G 1552-
17560 Below lean- – Inspect secondary air injection system for leaks ⇒ 2.0/85 kW Engine,
Bank 1, mixture adap- ness limit Mechanical Components; Rep. Gr. 26
tation range 2
– Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Test injection valves ⇒ Chapter 24-2
Rep. Gr. 20
17573 Above rich- – Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
Bank 1, mixture adap- ness limit
tation range 1 – Test injection valves ⇒ Chapter 24-2
17574 Above rich- – Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-
Bank 1, mixture adap- ness limit nal control diagnosis
tation range 2
17579 Implausible – Check angle sender in measured value block, display group 060
Angle sender 2 for TV signal ⇒ Chapter 01-6
drive -G188-
– Test throttle valve control unit ⇒ Chapter 24-2
Angle sender 2 for TV
drive -G188-
17581 Signal too
Angle sender 2 for TV high
drive -G188-
17584 Regulating – Test lambda probe ageing upstream of catalytic converter ⇒ Chapter
Bank1, lambda correc- limit reached 24-3
tion according to cata-
lytic converter – Test lambda probe -G130- and lambda control downstream of catalyt-
ic converter ⇒ Chapter 24-3

01-3 page 8 S00.5310.01.20

-V.A.G 1552-
17586 Open circuit – Test lambda probe -G39- and lambda control upstream of catalytic
Linear lambda probe/ converter ⇒ Chapter 24-3
pump current
17587 Short circuit
Linear lambda probe/ to earth
pump current
17588 Short circuit
Linear lambda probe/ to positive
pump current
17589 Open circuit
Linear lambda probe/
reference voltage
17590 Short circuit
reference voltage
17591 Short circuit
reference voltage
17592 Open circuit
Linear lambda probe/
combined earth cable
17593 Short circuit
17594 Short circuit
17606 Electrical fault – Test lambda probe -G130- and lambda control downstream of catalyt-
Bank 1 - probe 2, heat- ic converter ⇒ Chapter 24-3
ing circuit
Note
♦ re fault codes 16505 and 16506:
♦ As soon as one of these faults is detected, the engine
control unit uses a substitute value which is generated
from the engine speed and the inducted air mass.

S00.5310.01.20

01-3 page 10 S00.5310.01.20
01-4 Self-diagnosis IV
Fault table, fault codes 17621...18104

- V.A.G 1552-
17621 Short circuit – Test injectors ⇒ Chapter 01-1, Final control diagnosis
17622 Short circuit
17623 Short circuit
17624 Short circuit
17633 Short circuit
17634 Short circuit
17635 Short circuit
17636 Short circuit
17645 Open circuit
Injector cyl. 1 -N30-
17646 Open circuit
17647 Open circuit
17648 Open circuit
17704 Fault – Test coolant temperature sender ⇒ Chapter 24-1
Cooling system
– Test coolant thermostat ⇒ 2.0/85 Engine, Mechanical Components;
Rep. Gr. 19
17708 Reason: – Refuel
Combustion misfiring Fuel short-
detected age – Test signal from fuel gauge sender
17733 Regulating – Read measured value block, display group 026 ⇒ Chap. 01-5
Knock control Cyl. 1 limit reached
– Eliminate abnormal engine running noises (loose ancillaries, bracket or
17734 Regulating bolt bent)
– Check wiring and plug connections according to the current flow dia-
17735 Regulating gram
17736 Regulating
– Slacken knock sensors and then tighten again to 20 Nm
Knock control Cyl. 4 limit reached– Change type of fuel
17743 Regulating – Read measured value block, display group 005 ⇒ Chapter 01-5
Engine torque monitor- limit exceed-
ing 2 ed – Inspect vacuum lines for leaks
17744 Regulating – Inspect intake system for leaks

Engine torque monitor- limit exceed- – Test resistance of coolant temperature sender -G42 - ⇒ Chap. 24-1
ing ed
– Test resistance of intake air temperature sender -G42 - ⇒ Chap. 24-1
Edition 11.04 Self-diagnosis IV 01-4 page 1

S00.5310.01.20

- V.A.G 1552-
17745 Short circuit – Test camshaft position sensor -G163- ⇒ Chapter 28-1
Bank 1, camshaft posi- to earth
tion sensor ⇒-G163
17746 Open circuit/
Bank 1, camshaft posi- Short circuit
tion sensor ⇒-G163 to positive
17747 Wrongly con- – Test camshaft position sensor -G163- ⇒ Chapter 28-1
Crankshaft position.- / nected
engine speed sensor – Test resistance of engine speed sender -G28- ⇒ Chap. 24-1
17748 Incorrect as- – Inspect camshaft position sensor -G163- for tight installation
Camshaft position/ signment
crankshaft position
sensor
17763 Open circuit – Inspect ignition transformer ⇒ Chapter 28-1
17764 Short circuit
Ignition control cyl. 1 to positive
17765 Short circuit
Ignition control cyl. 1 to earth
17766 Open circuit
17767 Short circuit
17768 Short circuit
17769 Open circuit
17770 Short circuit
17771 Short circuit
17772 Open circuit
17773 Short circuit
17774 Short circuit
– Test earth cables according to current flow diagram ⇒ Current Flow Di-
17795 agrams, Electrical Fault Finding and Fitting Locations
17796
17818 Short circuit – Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-
Tank ventilation valve to positive nal control diagnosis
-N80-
17832 Leak detect- – Read measured value block, display group 077 ⇒ Chap. 01-7
Bank 1, secondary air ed
system – Test secondary air system for leaks
Self-diagnosis IV Edition 11.04

01-4 page 2 S00.5310.01.20

- V.A.G 1552-
17833 Short circuit – Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-
Tank ventilation valve to earth nal control diagnosis
-N80-
17834 Open circuit
Tank ventilation valve
-N80-
17841 Open circuit – Test the relay or the secondary air pump -J299- ⇒ Chapter 01-1, final
Secondary air pump re- control diagnosis
lay -J299-
17842 Short circuit
Secondary air pump re- to positive
lay -J299-
17843 Short circuit
Secondary air pump re- to earth
lay -J299-
17860 Open circuit
Secondary air system
17908 Electrical – Test fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical Fault
Fuel pump relay -J17- fault in the Finding and Fitting Locations
circuit
17909 Short circuit Rep. Gr. 20
Fuel pump relay -J17- to earth
17910 Short circuit
Fuel pump relay -J17- to positive
17921 Short circuit – Check wiring and plug connections according to the current flow dia-
2nd valve for variable to positive gram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Lo-
intake manifold cations
changeover -N261-
17922 Short circuit
2nd valve for variable to earth
intake manifold
changeover -N261-
17923 Short circuit
Valve for variable in- to earth
take manifold changeo-
ver -N156-
17925 Electrical – Test the power supply relay for Motronic -J271- ⇒ Current Flow Dia-
Main relay ⇒ -J271- fault in the grams, Electrical Fault Finding and Fitting Locations
circuit
– Read measured value block, display group 004 ⇒ Chap. 01-5
17926 Short circuit
Main relay ⇒ -J271- to positive
17931 Implausible – Test airbag ⇒ Body Work; Rep. Gr. 01
Crash signal from air- signal
bag CU
Clutch pedal switch signal
-F36-
17949 Open circuit – Test fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical Fault
Fuel pump relay -J17- Finding and Fitting Locations

S00.5310.01.20

- V.A.G 1552-
Angle sender for TV signal
drive -G187-1)
– Test throttle valve control unit -J338- ⇒ Chap. 24-2
17951 Signal too
Angle sender for TV low
drive -G187-2)
17952 Signal too
Angle sender for TV high
drive -G187-2)
17953 Malfunction
Throttle valve control
17966 Electrical
Throttle valve drive fault in the
-G186-1) circuit
17967 Incorrect ba- – Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
Throttle valve control sic setting
unit -J338-
17968 – Inspect engine for mechanical damage and erase fault memory
Maximum engine ⇒ Chapter 01-1
speed exceeded
17972 Undervolt- – Test alternator and battery ⇒ Electrical System; Rep. Gr. 27
Throttle valve control age on basic
unit -J338- setting – Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
17973 Bottom limit – Read measured value block, display group 062 ⇒ Chapter 01-6
Throttle valve control not reached
unit -J338- – Inspect throttle valve for damage and dirt
17976 Mechanical – Test throttle valve control unit -J338- ⇒ Chap. 24-2
Throttle valve control fault
unit -J338-
CCS switch -E45- signal
17978 – Adapt engine control unit to electronic immobiliser ⇒ Electrical Sys-
Engine control unit in- tem; Rep. Gr. 90.
hibited
17987 Adaptation – Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
Throttle valve control was not initi-
unit -J338- ated – Test throttle valve control unit -J338- ⇒ Chap. 24-2
18010 Voltage too – Inspect engine control unit power supply ⇒ Chapter 24-4
Voltage supply tml. 30 low
– Test alternator and battery ⇒ Electrical System; Rep. Gr. 27
18011 – Replace engine control unit ⇒ Chapter 24-4
18014 Electrical – Read out fault memory of ABS control unit ⇒ Chassis; Rep. Gr. 45
Poor road info/engine fault in the
spec. torque from ABS circuit – Inspect databus ⇒ Chapter 24-5
CU
18017 Deactivation – Interrogate fault memory of airbag control unit and erase ⇒ Body
actuated in Work; Rep. Gr. 01
case of an
accident
18020 Incorrectly – Code engine control unit ⇒ Chapter 24-4
Engine control unit coded

01-4 page 4 S00.5310.01.20

- V.A.G 1552-
18034 Missing mes- – Inspect databus ⇒ Chapter 24-5
Databus drive sage from
gearbox CU
18038 Signal too – Test accelerator pedal position sender ⇒ Chapter 24-2
Sender for accelerator low
18039 Signal too
Sender for accelerator high
18041 Signal too – Read measured value block, display group 062 ⇒ Chapter 01-6
Sender 2 for accelera- low
tor pedal position – Test accelerator pedal position sender ⇒ Chapter 24-2
-G185-
18042 Signal too
Sender 2 for accelera- high
tor pedal position
-G185-
18044 Missing mes- – Inspect databus ⇒ Chapter 24-5
airbag CU
18047 Implausible – Test accelerator pedal position sender ⇒ Chapter 24-2
Sender 1/2 for acceler- signal
ator pedal position
-G79- + -G185-
18056 defective – Inspect databus ⇒ Chapter 24-5
Databus drive
– Read out fault memories of all control units (automatic test sequence)
18057 Missing mes- ⇒ Chapter 01-1
ABS CU
18058 Missing mes-
combiinstru-
ment
18090 implausible
Databus drive message
from ABS
CU
18091 implausible
from airbag-
SG
18104 implausible
from steer-
ing column
1) Throttle valve drive (electronic power control) -G186- is also known as throttle valve positioner (for intake manifold) -V60-.
2) Angle sensor for throttle valve drive (electronic power control) -G187- is also known as throttle valve position sender -G127-.

S00.5310.01.20
Note
♦ regarding fault code 17978:
♦ The immobilizer control unit is located in the dash
panel insert and cannot be replaced individually.
♦ When attempting to start with a non-adapted key a
static fault is stored in the memory. If a subsequent
start attempt occurs with an adpated key the fault is
changed to a sporadic fault.

01-4 page 6 S00.5310.01.20
01-5 Self-diagnosis V
Reading measured value block
-V.A.G 1551/3, 3A, 3B oder 3C-.
Test conditions
• The coolant temperature must be at least 80°C ⇒ dis-
play group 004, display field 3.
• 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.
• There must not be any faults present in the fault mem-
ory ⇒ Chapter 01-1.
Procedure
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
Read measured value block HELP
– Select function 08 „Read measured value block“ and Enter display group number XXX
the desired display group number.
Note
Read measured value block 4
Display group number 004 is an example to represent the
→
sequence.
Note
Proceed according to the following table to switch to an-
other display group:
Display -V.A.G 1551- -V.A.G 1552-

group
higher 3 Press key ↑ Press key
lower 1 Press key ↓ Press key
skip C Press key C Press key
– If the specifications are achieved in all the display

fields, press key → .
Edition 11.04 Self-diagnosis V 01-5 page 1

S00.5310.01.20
Reading measured value blocks, display groups 001 to 029
Display group 001 - Basic functions
• Engine idling
Read measured value block 1 → ← Readout on display
xxxx rpm xx.x °C xx.x % xxxxxx
1 2 3 4 ← Display fields Specification Analysis
Operating conditions 11111111 ⇒ 01-5 page 3

Lambda regulator upstream of cata- -10,0...10,0 % ⇒ 01-5 page 3
lytic converter
Coolant temperature 80.0...110.0 °C ⇒ 01-5 page 2
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Note
♦ Re display field 3:
♦ Readout must fluctuate around zero. If zero is always
displayed, the lambda control has switched from
closed-loop to open-loop control because of a fault in
the lambda control. Interrogate fault memory
⇒ Chapter 01-1.
Analysis of display group 001, display field 1 - engine speed (idling speed)
Readout on -V.A.G 1552- Rectifying fault

less than 680 rpm – Test throttle valve control unit ⇒ Chapter 24-2
greater than 880 rpm – Interrogate fault memory ⇒ Chapter 01-1
Analysis of display group 001, display field 2 - coolant temperature

less than 80 °C – Conduct test drive if necessary
– Test resistance of coolant temperature sender ⇒ Chap. 24-1
greater than 110 °C – Clean radiator
– Test function of the radiator fan
– Test coolant thermostat, replace if necessary ⇒ 2.0/85 kW Engine,
Mechanical Components; Rep. Gr. 19
– Test resistance of coolant temperature sender ⇒ Chap. 24-1
Self-diagnosis V Edition 11.04

01-5 page 2 S00.5310.01.20
Analysis of display group 001, display field 3 - lambda controller upstream of catalytic converter

Signal outside tolerance – Wait 30 seconds until readout has stabilised
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
– Check lambda learned values in display group 032 ⇒ Chapter 01-6
Analysis of display group 001, display field 4 - operating states
1 2 3 4 5 6 7 8 Meaning, if display positions = 1

1 Coolant temperature more than 80°C
1 Speed below 2000 rpm
1 Throttle valve closed
1 Lambda control o.k.
1 Operating state - idling
1 AC compressor disconnected
1 No meaning
1 No fault detected in self-diagnosis
Display group 002 - basic functions - air mass meter
• Engine idling
xxxx rpm xxx % x.xx ms x.x g/s
Drawn in air mass 2.0...5.0 g/s ⇒ 01-5 page 4

Injection period 2.00...5.50 ms ⇒ 01-5 page 4
Engine load 15...35 % ⇒ 01-5 page 4
Note
♦ What is displayed is the inducted air mass which is de-
termined by the air mass meter.
♦ If a fault is detected at the air mass meter by the en-
gine control unit, the substitute value of the throttle
valve potentiometer in g/s is displayed.
♦ In the emergency mode resulting from a fault at the
throttle valve control unit, the engine runs without
idling speed stabilisation at a higher idling speed

S00.5310.01.20
which is dependent on the throttle valve position in an

emergency mode position (approx. 1100...1500 rpm).
Drawn in air mass approx. 4.5...5.5 g/s.
Analysis of display group 002, display field 2 - engine load

less than 15 % – Test throttle valve control unit ⇒ Chapter 24-2
greater than 35 % – Test injectors ⇒ Chapter 01-1, Final control diagnosis
– If necessary, replace spark plugs
– Disconnect electric consumer
Note
♦ The maximum engine load decreases approximately
10 % for each 1000 m above mean sea level.
♦ The maximum engine load decreases by up to 10 %
at high temperatures.
♦ The following readouts must be reached when driving
at full throttle: at 4000 rpm approx. 78 %, at 6000 rpm
approx. 75 %.
Analysis of display group 002, display field 3 - injection time

less than 2.00 ms – Test drive without full load for at least 10 minutes
– Test solenoid valve for activated charcoal filter ⇒ Chapter 01-1, fi-
nal control diagnosis
– Test injection valves ⇒ Chapter 24-2
– inspect fuel pressure regulator ⇒ Chapter 24-2
greater than 5.50 ms – Eliminate increased load (air conditioning, power steering etc.)
Analysis of display group 002, display field 4 - inducted air mass

less than 2.0 g/s – Inspect intake system for leaks
greater than 5.0 g/s – Eliminate load (AC, el. components switched on, etc.)

01-5 page 4 S00.5310.01.20
Display group 003 - basic functions - air mass meter
• Engine idling
xxxx rpm x.x g/s x.x % xx.x °
BTDC
Ignition angle 0...12.0 °BTDC —

Throttle valve angle 0,2...5,0 % ⇒ 01-5 page 5
Drawn in air mass 2.0...5.0 g/s ⇒ 01-5 page 4
Analysis of display group 003, display field 3 - throttle valve angle

greater than 5.0 % – Adapt engine control unit to throttle valve control unit ⇒ Chapter
24-4
– Interrogate fault memory ⇒ Chapter 01-1
Note
Readout when accelerator pedal fully depressed is
(90...100 %).
• Engine idling
xxxx rpm xx.xxx V xxx.x °C xxx.x °C
Intake manifold tempera- -45.0...140.0 °C ⇒ 01-5 page 6

ture
Supply voltage of the engine control unit 12.500...14.500 ⇒ 01-5 page 6
V
Note
If a fault relating to the coolant temperature sender -G62-
is stored in the fault memory, the engine control unit uses
the intake air temperature as a substitute value (start
temperature - substitute value) when the engine is start-

S00.5310.01.20
ed. The temperature then rises according to a model se-

quence stored in the control unit. Once the engine has
reached normal operating temperature a fixed substitute
value is displayed after a certain time. This fixed substi-
tute value depends on the intake air temperature.
The readout must be higher than the temperature of the
ambient air.
Analysis of display group 004, display field 2 - supply voltage to the engine control unit

less than 12.500 V – Test generator and battery voltage, charge battery ⇒ Electrical Sys-
tem; Rep. Gr. 27
– Increase engine speed slightly for a few minutes and switch off ad-
ditional consumers
– Inspect engine control unit power supply ⇒ Chapter 24-4
– Eliminate current consumption
greater than 14.500 V – Test voltage, replace voltage regulator if necessary
– Interrogate fault memory ⇒ Chapter 01-1
Analysis of display group 004, display field 4 - intake air temperature

approx. 140.0 °C – Test resistance of intake air temperature sender -G42 - ⇒ Chap.
approx. -46.5 °C 24-1
approx. 140 °C – Test cables to intake air temperature sender -G42- ⇒ Current Flow
(readout appears only for a short time and Diagrams, Electrical Fault Finding and Fitting Locations
then jumps to 19.5 °C)
Display group 005 - basic functions
• Engine idling
xxxx rpm xxx % xxx km/h Text
Operating state (idling, Idling —

part load, full load, enrich-
ment, overrun)
Vehicle speed 0 km/h —
Engine load 10...35 % ⇒ 01-5 page 4
Note
Testing speed signal ⇒ Chap. 24-5.

01-5 page 6 S00.5310.01.20
• Engine idling
xxxx rpm xx.x % xxx.x °C x.x %
Level correction factor — —

Intake manifold temperature -45.0...140.0 °C —
Engine load 15,0...35,0 % ⇒ 01-5 page 4
Note
♦ The maximum engine load decreases approximately
10 % for each 1000 m above mean sea level.
♦ The maximum engine load decreases by up to 10 %
at high temperatures.
♦ The following readouts must be reached when driving
at full throttle: at 4000 rpm approx. 78 %, at 6000 rpm
approx. 75 %.
Display group 010 ignition
• Engine idling
xxxx rpm xx.x % x.x % xx.x °
BTDC
Ignition angle 0...12 °BTDC —

Throttle valve angle 0,2...5,0 % ⇒ 01-5 page 5
Engine load 15,0...35,0 % ⇒ 01-5 page 4

S00.5310.01.20
Display group 014 - ignition misfiring detection
• Engine idling
xxxx rpm xx.x % xxx Text
Status of misfiring detec- activated —

tion (activated, deactivat-
ed)
Total of ignition misfirings 0...5 ⇒ 01-5 page 9
Engine load 15,0...35,0 % ⇒ 01-5 page 4
Display group 015 - ignition misfiring detection cylinders 1 to 3
• Engine idling
xxx xxx xxx Text

ed)
Total of ignition misfirings cyl. 3 0 ⇒ 01-5 page 9
Display group 016 - ignition misfiring detection cyl. 4
• Engine idling
xxx — — Text

ed)
— —
— —

01-5 page 8 S00.5310.01.20
Analysis of display groups 014, 015, 016 - total of ignition misfiring cyl. 1 to 4

greater than 5 – Inspect ignition transformer ⇒ Chapter 28-1
– Test spark plugs and spark cables with spark plug connector
– Test injectors ⇒ Chapter 01-1
– Check fuel level in tank
Display group 022, ignition - knock control
• Normal driving
xxxx rpm xxx.x % xx.x °CA xx.x °CA
Ignition angle retarded in 0...15.0 °CA ⇒ 01-5 page 10

cylinder 2 by knock con-
trol
Ignition angle retarded in cylinder 1 0...15.0 °CA ⇒ 01-5 page 10
by knock control
Engine load 0,0...100,0 % —
Engine speed 680...6500 rpm —
Display group 023, ignition - knock control
• Normal driving
xxxx rpm xxx.x % xx.x °CA xx.x °CA
Ignition angle retarded in 0...15.0 °CA ⇒ 01-5 page 10

cylinder 4 by knock con-
trol
Ignition angle retarded in cylinder 3 0...15.0 °CA ⇒ 01-5 page 10
by knock control
Engine load 0,0...100,0 % —

S00.5310.01.20
Note
♦ Knock control active from an engine load of more than
40 %.
♦ If an engine load of 40 % is exceeded, the current re-
tardation of the ignition angles are displayed. If the en-
gine load was not reached, the values last used are
displayed.
♦ If knocking can be heard without any retardation of the
ignition angle detectable, increase engine speed for
5 seconds to more than 3500 rpm in order to activate
the knock sensor fault detection (for self-diagnosis).
Analysis of display groups 022/023, display fields 3 and 4 - ignition angle retardation

all cylinders greater than 15 °CA – Test knock sensors -G61- and -G66-
– Slacken knock sensor and tighten again to 20 Nm
– Tighten up loose parts
– Change type of fuel
one cylinder clearly deviates from the oth- – Test knock sensors -G61- and -G66-
ers
– Testing compression: ⇒ 2.0/85 TDI Engine, Mechanical Compo-
nents; Rep. Gr. 15
– Tighten up loose parts
Display group 026, ignition - knock sensor
• Normal driving
x.xxx V x.xxx V x.xxx V x.xxx V
Knock sensor voltage sig- 0.400...2.000 V —

nal cyl. 4
Knock sensor voltage signal cyl. 3 0.400...2.000 V —
Note
♦ If no fault is found when testing the knock sensor, the
wiring and the plug connections, inspect the ancillar-
ies or the engine for damage.
♦ At higher engine speeds the readout of the knock sen-
sor voltage signal may be as much as 5.1 V.
♦ If a difference of more than 50 % exists between the
smallest and largest knock sensor signal, the cause
may be corrosion at the plug connection.

01-5 page 10 S00.5310.01.20
Display group 028, ignition - testing knock sensor
• Normal driving
xxxx rpm xxx.x % xxx.x °C Text
Test Knock sensor Syst. o.k. —

(Test OFF, Test ON,
Syst. o.k., Syst. n.o.k.)
Engine load 20,0...100,0 % —

S00.5310.01.20

01-5 page 12 S00.5310.01.20
01-6 Self-diagnosis VII

Reading measured value block, display groups 030 to 062
Display group 030 - lambda control
• Engine idling
• Catalytic converter temperature at least 352 °C (display group 34, display field 2)
xxx xxx
Status lambda control downstream of catalytic 110 ⇒ 01-6 page 1

converter
Status lambda control upstream of catalytic converter 111 ⇒ 01-6 page 1
Meaning of 3-digit numerical block in display fields 1 and 2:
1 1 1 Meaning, if display positions = 1

Lambda control active
Lambda probe operational
Lambda probe heater switched on
Display group 031, lambda control - lambda values upstream of catalytic converter
• Engine idling
x.xx x.xx — —
— —
— —
Lambda nominal value - Bank 1 0,99...1,01 —
Lambda actual value - Bank 1 0,96...1,04 —
Edition 11.04 Self-diagnosis VII 01-6 page 1

S00.5310.01.20
Display group 032, lambda control - lambda learned values
• Engine idling
xx.x % xx.x % — —
— —
— —
Lambda learned value at part load upstream of -10,0...10,0 % ⇒ 01-6 page 3
catalytic converter (multiplicative)
Lambda learned value at idling speed upstream of catalytic -10,0...10,0 % ⇒ 01-6 page 3
converter (additive)
Note
♦ to the display fields 1 and 2:
♦ Low readouts indicate that the engine is running too
rich and the lambda control therefore produces a lean-
er mixture.
♦ High readouts mean that the engine is running too
lean and the lambda control therefore produces a rich-
er mixture.
♦ If the control unit is dead all initialisation values are re-
set.
♦ Condition for part load learning: Coolant temperature
at least 75 °C, intake air temperature max. 90 °C, driv-
ing mode.
♦ add = additive - The effect of the fault (e.g. unmetered
air) becomes increasingly less as engine speed rises.
In the case of an additive initialisation value the injec-
tion period is changed by a fixed rate. This rate is in-
dependent of the basic injection period.
♦ mul = multiplicative - The effect of the fault (e.g. faulty
injector) becomes greater as engine speed rises. The
multiplicative learned value is a percentage change in
the injection period. This change is dependent on the
basic injection period.
Self-diagnosis VII Edition 11.04

01-6 page 2 S00.5310.01.20
Analysis of display group 032, display fields 1 and 2 - lambda learned values
Readout on -V.A.G 1552 - Rectifying fault

low learned values – Disappears after driving on motorway or changing oil
– Test injectors ⇒ Chapter 01-1
– Test activated charcoal filter solenoid valve ⇒ Chapter 01-1
– Test air mass meter
– Testing lambda probe heater upstream of catalytic converter
⇒ Chapter 24-3
high learned values – Inspect intake system for leaks
– Test injected quantity ⇒ Chapter 24-2
– Test air mass meter
– Test exhaust manifold ⇒ 2.0/85 Engine, Mechanical Components;
Rep. Gr. 26
– Testing lambda probe heater upstream of catalytic converter
⇒ Chapter 24-3
Display group 033, lambda control upstream of catalytic converter - lambda control values
• Engine idling
xx.x % x.xxx V — —
— —
— —
Lambda probe voltage upstream of catalytic con- 1.400 V...1.600 V ⇒ 01-6 page 4
verter
Lambda control before catalyst -10,0...10,0 % ⇒ Chap. 01-5, dis-
play group 001,
display field 3
Note
♦ Readout must fluctuate around zero. If zero is always
displayed, the lambda control has switched from
closed-loop to open-loop control because of a fault in
the lambda control. Interrogate fault memory
⇒ Chapter 01-1.

S00.5310.01.20
Note
♦ Voltage signal „Mixture rich“ (low level of residual ox-
ygen) is between 0.130...1.500 V.
♦ Voltage signal „Mixture rich“ (high level of residual ox-
ygen) is at approx. 1.500...4.800 V.
Analysis of display group 033, display field 2 - lambda probe voltage upstream of catalytic converter
Display field: 1 Rectifying fault

constant – Testing lambda probe and lambda control upstream of catalytic con-
0.000...1.400 V verter ⇒ Chapter 24-3
or constant
1.600...3.000 V
constant
3.600 V
constant
0.000 V
Display group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter
• Brake pedal and accelerator depressed

• Vehicle stationary, engine running at fast idling
• Control unit in function 04 - initiate basic setting
System in basic setting 34 → ← Readout on display
xxxx rpm xxx.x °C x.x s Text
Result of test of lambda B1 S1 o.k. ---

probe ageing upstream of
catalytic converter (Test
OFF /Test ON/B1 S1 o.k./
B1 S1 n.o.k.)
Period of lambda probe upstream of max. 2.2 ---
catalytic converter
Catalytic converter temperature min. 352 °C ---
Engine speed 1400...2800 rpm ---
Note
♦ The period indicates the time between two jumps (e.g.
rich - lean - rich mixture) and is thus a measure of the
status of the lambda probe ageing. If the specified
time is exceeded, the following appears in display field
4: B1 S1 n.o.k.

01-6 page 4 S00.5310.01.20
Display group 036, lambda control - operation downstream of catalytic converter
• Engine idling
x.xxx V Text — —
— —
— —
Test lambda probe downstream of catalytic con- B1 S2 o.k. —
verter (B1 S2 o.k./B1 S2 n.o.k.)
Lambda probe voltage after catalytic converter 0.000...1.000 V ⇒ 01-6 page 5
Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of
catalytic converter
Display field: 1 Rectifying fault

constant – Testing lambda probe and lambda control downstream of catalyt-
0.000...0.300 V ic converter ⇒ Chapter 24-3
or constant
0.700...1.000 V
constant – Testing lambda probe and lambda control downstream of catalyt-
1.000 V ic converter ⇒ Chapter 24-3
constant
0.400 ...0.500 V
constant
0.000 V
Note
♦ Voltage signal „Mixture rich (low level of residual oxy-
gen)“ is at approx. 0.7...1.0 V.
♦ Voltage signal „Mixture lean (high level of residual ox-
ygen)“ is at approx. 0.0...0.3 V.
♦ A voltage jump from 0.7...1.0 V to 0.0...0.3 V or vice
versa takes place at the transition from „rich“ to „lean“
and vice versa (λ = 1.0).
♦ In view of the steep voltage jump the lambda control
is not able to maintain constant the ideal mixture com-
position which corresponds to λ = 1.0. The control
constantly fluctuates back and forward between the
„slightly too lean“ and „slightly too rich“ states.
♦ The readout must in some cases be less than 0.3 V
and in some cases more than 0.6 V. The readout be-
low 0.45 V indicates a lean mixture while above 0.45
V indicates a rich mixture.
♦ At idling speed, the lambda probe voltage upstream of
the catalytic converter must fluctuate between a rich
and leaner mixture. The lambda probe voltage down-
stream of the catalytic converter should indicate a
constant rich or lean mixture. If the voltage also fluctu-

S00.5310.01.20
ates downstream of the catalytic converter, either the

catalytic converter is faulty (⇒ Read measured value
block 046 ⇒ 01-6 page 7) or the probes have been
wrongly connected (irregular engine running). Lamb-
da control varies between -10...10 %.
Voltage of the 4-pin lambda probe in U λ in mV
A: Lambda probe voltage high

rich mixture (fuel surplus or air shortage)
high CO value
B: Lambda probe voltage low
lean mixture (fuel shortage or air surplus)
low CO value
Display group 037, lambda control - operation downstream of catalytic converter
• Engine idling
xx.x % x.xxx V x.xxx Text
Test lambda probe down- Syst. o.k. —

stream of catalytic con-
verter (Test ON / Test
OFF, Syst. o.k. / Syst.
n.o.k.)
Waiting time of lambda control up- — —
stream of catalytic converter
Lambda probe voltage after catalytic converter 0.000...1.000 V ⇒ 01-6 page 5
Engine load 15,0...35,0 % —

01-6 page 6 S00.5310.01.20
Display group 041, lambda control - lambda probe heating
• Engine idling
— Text — Text
Heater of lambda probe Htg dC.OFF —

downstream of catalytic Htg dC.ON
converter
(Heating.aC.OFF, heat-
ing.aC.ON)
— —
Heater of lambda probe upstream of catalytic con- Htg.uC.OFF —
verter Htg.uC.ON
(Heating.bC.OFF/heating.bC.ON)
— —
Note
Depending on the operating state of the engine the lamb-
da probe heaters are switched on or off, i.e. the readouts
in display field 2 and 4 may show either Htg.u(d)C.ON or
Htg.u(d)C.OFF.
Display group 046, lambda control - diagnosis of catalytic converter
• Brake pedal and accelerator depressed

• Vehicle stationary, engine running at fast idling
xxxx rpm xxx.x °C x.xx Text
Result of test of catalytic Cat B1 o.k. —

conversion (Test OFF /
Test ON / Cat B1 o.k. / Cat
B1 n.o.k.)
Amplitude ratio 0,00...0,55 —
Catalytic converter temperature min. 352.0 °C —

S00.5310.01.20
Display group 050, engine speed control - operating states
• Engine idling
xxxx rpm xxxx rpm Text Text
Operating condition air Compr. ON or —

conditioning compressor Compr. OFF
ON/OFF
Operating condition of air condition- A/C High or A/C —
ing system Low
Engine speed (idling speed - specified value) 780 rpm —
Engine speed (idling speed) 680...880 rpm ⇒ Chapter 01-5
display group 001,
display field 1
Note
♦ What is displayed is the specification for the engine
speed which is fixed by the engine control unit (inter-
nal computed value in control unit).
Note
♦ A/C High = air conditioning switched on to high heat-
ing or cooling capacity
♦ A/C Low = air conditioning not switched on
Note
♦ „Compr. OFF“ is always displayed on vehicles without
air conditioning system.

01-6 page 8 S00.5310.01.20
Display group 054, engine speed control - operating states
• Engine idling
xxxx rpm Text xxx.x % xxx.x %
Throttle valve positioner 0...100 % —

angle
Sender for accelerator pedal position 3...97 % ⇒ Chapter 01-5,
display group 003,
display field 3
Operating state (idling, part load, full load, enrich- Idling —
ment, overrun)
Engine speed (idling speed) 680...880 rpm ⇒ Chap. 01-5, dis-
play group 001,
display field 1
Display group 055, engine speed control - idling speed stabilisation
• Engine idling
xxxx rpm x.xx % x.xx % xxxxx
Operating conditions xxxxx ⇒ 01-6 page 9

Initialisation value idling regulator -1,50...1,50 % —
Idling regulator -2,00...2,00 %1) —
play group 001,
display field 1
1) On a new engine the value is in the positive region because of the higher friction, on a run-in engine it is in the negative region.
Meaning of the 4-digit numerical block display field 4
1 2 3 4 5 Meaning if display position

1 Air conditioning compressor on
1 No meaning
1 Air conditioning switched on
1 No meaning
1 No meaning

S00.5310.01.20
Display group 056, engine speed control - idling speed stabilisation
• Engine idling
xxxx rpm xxxx rpm x.xx % xxxxx
Operating conditions xxxxx ⇒ 01-6 page 9

Idling regulator -2,00...2,00 % —
Engine speed (idling speed - specified value) 780 rpm —
play group 001,
display field 1
Display group 060, engine speed control - adapting throttle valve control unit
• Ignition switched on, engine switched off

xx % xx % x Text
Adaption state (ADP runs, ADP o.k. —

ADP o.k. or ADP ERROR)
Operating state of engine 0...8 —
Counter of learning steps
Throttle valve angle potentiometer -G188- 97...3 % —
Throttle valve angle potentiometer -G187- 3...97 % ⇒ Chapter 01-5,
display group 003,
display field 3
Note
♦ When display group 060 is selected in function 04 „In-
itiate basic setting“, the engine control unit is adapted
to the throttle valve control unit. This adjustment must
always be performed if a different throttle valve control
unit (or completely different engine) or a different en-
gine control unit has been fitted.
♦ The ignition should be switched on in order to carry
out the adaptation of the throttle valve control unit.
♦ If the voltage supply has been interrupted (battery dis-
connected), it is also necessary to carry out adaption
⇒ Chap. 24-4.

01-6 page 10 S00.5310.01.20
Display group 061 - engine speed control, EPC
• Engine idling or vehicle driven

xxxx rpm xx.xxx V xxx.x % xxxxx
Operating conditions xxxxx ⇒ 01-6

page 9
Activate throttle valve positioner 0,0...100,0 % —
Supply voltage of the engine control unit 12,500...14,500 V —
Display group 062 - engine speed control, EPC
• Ignition on or engine running

xx % xx % xx % xx %
Sender for accelerator pedal 3...50 % —

position -G185-
Sender for accelerator pedal position 6...97 % —
-G79-

S00.5310.01.20

01-6 page 12 S00.5310.01.20
01-7 Self-diagnosis VIII

Reading measured value blocks, display groups 66 to 126
Display group 066 - cruise control system (only models with CCS)
• Engine idling
x km/h xxxxxxxx x km/h xxxxxxxx
CCS switch position 0000xxxx ⇒ 01-7 page 1

Specified vehicle speed (value last —
x km/h
stored by CCS)
Brake pedal, clutch pedal and CCS position 0000xxxx ⇒ 01-7 page 1
Vehicle speed x km/h —
Meaning of digits in 4-digit numerical block, display field 2, brake and clutch pedal switch, CCS
switch
1 2 3 4 Meaning if display position

1 Brake pedal depressed (brake light switch)
1 Brake pedal depressed (brake pedal switch)
1 Clutch depressed
1 CCS actuated
Meaning of digits in 4-digit numerical block, dis-

play field 4, CCS switch

1 CCS sliding switch in OFF position (only if closed)
Edition 11.04 Self-diagnosis VIII 01-7 page 1

S00.5310.01.20

1 CCS sliding switch in OFF position (closes or closed)
1 CCS pushbutton SET operated
1 CCS sliding switch -B- in RES position
Display group 070 - exhaust gas reduction - diagnosis of activated charcoal filter system
• Engine idling
• Coolant temperature at least 40 °C (display group 001, display field 2)
xxx.x % xx.x % xxx.x % Text
Result of diagnosis (Test TVV o.k. —

ON / Test OFF or TVV
O.K. / TVV N.O.K)
Idling speed controller variation dur- 0...150,0 % —
ing TVV diagnosis
Lambda controller variation during TVV diagnosis -7,8...7,8 % —
On/off ratio of activated charcoal filter solenoid valve 0,0...100,0 % —
Note
TVV means Tank Vent Valve (activated charcoal filter so-
lenoid valve). Diagnosis can only be initiated once each
time the engine is started.
Note
♦ Lambda regulator variation in negative range: activat-
ed charcoal filter full.
♦ Lambda regulator variation in positive range: activat-
ed charcoal filter empty.
Self-diagnosis VIII Edition 11.04

01-7 page 2 S00.5310.01.20
Display group 077 - exhaust gas reduction - diagnosis of secondary air injection system
• Engine idling
xxxx rpm xx.x g/s xx.x % Text
Result of diagnosis (Test Syst. o.k. —

ON / Test OFF, Syst. o.k. /
Syst. n.o.k.)
Air mass ratio, secondary air injection -7,0...7,0 % —
system
Air mass 1.0...10.0 g/s —
play group 001,
display field 1
Display group 100 - readiness code
• Engine idling
xxxxxxxx xxx.x °C xxxx s xxxxxxxx
Diagnosis status — —
Time since engine start — —
Coolant temperature 80.0...110.0 °C ⇒ Chap. 01-6, dis-
play group 001,
display field 2
Readiness code 00000000 ⇒ 01-7 page 3
Meaning of 8-digit numerical block for readiness code, display field 1
1 2 3 4 5 6 7 8 Diagnosis function
0 Catalytic converter
0 Catalytic converter heater (no diagnosis at present/always „0“)
0 Activated charcoal filter (tank vent system)
0 Secondary air system
0 Air conditioning system (no diagnosis at present/always „0“)
0 Lambda probes
0 Lambda probe heater
0 Exhaust gas recirculation (not fitted/always „0“)

S00.5310.01.20
Note
The Readiness code is only generated when all display
positions are 0.
Display group 120 - traction control system -TCS-
• Driving
xxxx rpm xxx Nm xxx Nm Text
Status TCS active / TCS —

n. active
Actual engine load 0...260 Nm —
Nominal engine load 0...399 Nm —
Display group 125 - communication, databus messages
• Engine idling
— Text Text Text
Status of the air-condition- Clima 1 ⇒ 01-7 page 5

ing system
Status of combiinstrument Combi 1 ⇒ 01-7 page 5
Status ABS ABS 1 ⇒ 01-7 page 5
— —
Display group 126 - communication, databus messages
• Engine idling
— — Text Text
Status of the electrical El. CU 1 ⇒ 01-7 page 5

system control unit
Status airbag Airbag 1 ⇒ 01-7 page 5
— —
— —
Note on display fields 125 and 126:

Nominal value = 1; the control units with active data bus are displayed.

01-7 page 4 S00.5310.01.20
Analysis: Display groups 125 and 126
Readout on Possible cause of fault Rectifying fault

-V.A.G 1552-
if 0 displayed in- ♦ CAN databus connection defective – Perform the automatic test sequence for
stead of 1 ♦ no CAN databus cables used - control interrogation of all fault memories.
unit
♦ CAN databus cables defective - control
unit

S00.5310.01.20

01-7 page 6 S00.5310.01.20
24 – Fuel Formation, Injection
24-1 Repairing the injection

system
General notes on the injection system

Repairing the ignition: ⇒ Rep. Gr. 28.
♦ The engine control unit is equipped with a self-diagno-
sis. The first step, before commencing repairs or fault
finding, is to interrogate the fault memories of all the
control units using the automatic test sequence. This
is necessary because different control units are inter-
connected via data bus. Also check the vacuum hoses
and connections (unmetered air).
♦ Fuel hoses in the engine compartment must be se-
cured with spring band clamps. The use of clamp-type
or screw-type clips is not allowed.
♦ The ignition must always be switched off before dis-
connecting and re-connecting the battery otherwise
the engine control unit may be damaged.
♦ Components marked with an * are checked by self-di-
agnosis ⇒ Chap. 01-1.
♦ Components marked with **
can be tested with the fi-
nal control diagnosis ⇒ Chap. 01-1.
♦ A minimum voltage of 11.5 V is required for the perfect
functioning of the electric components.
♦ Do not use sealants containing silicone. Traces of sil-
icone elements drawn in by the engine are not burnt in
the engine and damage the lambda probe.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to inter-
rogate the fault memory after having completed all
inspections and repairs, and if necessary erase
⇒ Chap. 01-1.
♦ Vehicles fitted with airbags are equipped with a crash
fuel shut-off. It is intended to reduce the risk of a vehi-
cle fire after a crash as the fuel pump is disconnected
by the fuel pump relay. This installation also enhances
the starting behaviour of the engine. When opening
the door the fuel pump is activated for 2 seconds in or-
der to build up the pressure in the fuel system.
Safety measures ⇒ 24-1 page 7.
Cleanliless rules ⇒ 24-1 page 7.
Edition 03.01 Repairing the injection system 24-1 page 1

S00.5310.00.20
Overview of fitting location

1 - Solenoid valve 1 for activated
charcoal filter -N80-*/**
❑ Resistance 22...30 Ω
❑ Test ⇒ 2.0/85 Engine, Me-
chanical Components;
Rep. Gr. 20
2 - 4-pin plug connector
❑ for lambda probe and lamb-
da probe heater downstream
of catalytic converter
3 - 6-pin plug and socket connec- 1 2 3 4 5 6 7
tor
❑ for lambda probe and lamb-
da probe heater upstream of
catalytic converter
4 - Throttle valve control unit
-J338- *
5 - Sender for coolant tempera-
ture -G62- *
❑ resistances ⇒ Fig. 1 in 24-1
page 6
6 - Air mass meter -G70- * with in-
take air temperature sender
-G42-**
❑ Resistances for intake air
temperature sender -G42-
⇒ Fig. 1 in 24-1 page 6
7 - Engine control unit *
❑ Control unit for Motronic fuel
injection system - J220- 16 15 14 13 12 11 10 9 8
❑ testing voltage supply
⇒ Chap. 24-4 S24-0487
❑ procedure if voltage inter-
rupted ⇒ Chap. 24-4
❑ replacing ⇒ Chap. 24-4.
❑ coding ⇒ Chap. 24-4
8 - Engine speed sender -G28-*
❑ ⇒ item 15 in 24-1 page 3
9 - Ignition transformer *
❑ with power output stage - N112-
❑ with ignition coils -N-, -N128-
❑ inspecting ⇒ Chap. 28-1
10 - Injectors -N30-...-N33-*
❑ ⇒ item 8 in 24-1 page 5
11 - Secondary air pump -V101-
❑ secondary air injection system ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 26
12 - Knock sensor 2 -G66- *
13 - Connecting plug
❑ 3-pin, grey
❑ for engine speed sender -G28 -
14 - Knock sensor 1 -G61- *
15 - Fuel pressure regulator
16 - Camshaft position sensor -G163 - *
Repairing the injection system Edition 03.01

24-1 page 2 S00.5310.00.20
❑ inspecting ⇒ Chap. 28-1
Removing and installing parts of the injection system

1 - Top part of intake manifold
2 - Connecting plug
❑ 81-pin 1 2 3
❑ insert or remove plug when
the ignition is switched off 26
❑ unlock for removing 4
3 - Engine control unit -J220-*
❑ fitting location ⇒ 24-1
page 2 25
❑ testing voltage supply
⇒ Chap. 24-4 5
❑ procedure if voltage inter- 6
rupted ⇒ Chap. 24-4 7
❑ replacing ⇒ Chap. 24-4
9
❑ coding ⇒ Chap. 24-4
24
23
4 - Connecting plug
❑ 40-pin 8
❑ insert or remove plug when
the ignition is switched off
❑ unlock for removing 22
5 - Air filter 6
❑ disassembling and assem-
bling ⇒ 24-1 page 6 21 20
6 - 10 Nm
19 17
7 - to air guide pipe
❑ ⇒ item 7 in 24-1 page 5 12 10
8 - Air intake hose
14 6
❑ to secondary air pump 16 11
-V101 -
9 - 10 Nm 15 13
10 - Connecting plug 18 S24-0486
❑ 2-pin
❑ to coolant temperature sender - G62-
11 - Sender for coolant temperature -G62-*
❑ resistances ⇒ Fig. 1 in 24-1 page 6
❑ before removing, reduce pressure in cooling system if necessary
12 - Retaining clip
❑ check tightness
13 - Connecting plug
❑ 3-pin, grey
❑ for engine speed sender -G28 -
14 - O-ring
❑ replace if damaged
15 - Engine speed sender -G28-*
❑ specified resistance between contacts 2 + 3: 730...990 Ω (at 20 °C) resistance higher when engine at normal
operating temperature
16 - Lambda probe downstream of catalytic converter -G130 - *, 50 Nm
❑ coat only thread with „G 052 112 A3“; paste must not get into the slots of the probe body
❑ with 4-pin connector

S00.5310.00.20
❑ contacts 3 and 4 gold-plated

❑ Voltage of lambda probe heater supplied through fuel pump relay -J17-
❑ test lambda probe -G130- and lambda control downstream of catalytic converter ⇒ Chap. 24-3
17 - Plug connection for lambda probe downstream of catalytic converter
18 - Lambda probe upstream of catalytic converter -G39-*, 50 Nm
❑ coat only thread with „G 052 112 A3“; paste must not get into the slots of the probe body
❑ with 6-pin connector
❑ contacts gold-plated
❑ Voltage of lambda probe heater supplied through fuel pump relay -J17-
❑ Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chap. 24-3
❑ Fitting location: in the exhaust manifold
19 - Plug connection for lambda probe upstream of catalytic converter
20 - Bottom part of intake manifold
❑ disassembling and assembling ⇒ 24-1 page 5
21 - Fuel rail with injection valves
❑ disassemble and assemble bottom part of intake manifold ⇒ 24-1 page 5
22 - Fuel return-flow line
❑ blue
❑ secure with spring band clams
❑ check fitting position
❑ to fuel pump in fuel tank ⇒ 2.0 l/85 Engine, Mechanical Components; Rep. Gr. 20
23 - Fuel feed line
❑ black
❑ secure with spring band clams
❑ from fuel filter ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
24 - Gasket
25 - To crankcase vent valve
26 - Air intake hose

24-1 page 4 S00.5310.00.20
Disassembling and assembling bottom part of intake manifold
1 - Fuel pressure regulator
❑ testing fuel pressure regula-
tor and pressure in system 1 2 3
⇒ Chap. 24-2
2 - Vacuum hose
3 - Cable rail
❑ for connectors of injectors
- N30-...-N33-
4 - Bottom part of intake mani-
fold
5 - 10 Nm
6 - O-ring
❑ replace if damaged 11 12 7
7 - To intake hose
13 9
❑ ⇒ item 7 in 24-1 page 3
6 6
8 - Injectors -N30-...-N33-*/**
❑ resistance: 14,0...17,0 Ω (at 4
20 °C), resistance is about 4
to 6 Ω higher when engine is
at normal operating tempera-
ture Ω
8
9 - Retaining clip 9
❑ check tightness 10
10 - Fuel distributor
11 - Fuel return-flow line
12 - Fuel feed line
13 - Air guide pipe
❑ to injectors
5 5
S24-0308

S00.5310.00.20
Disassembling and assembling the air filter

1 - 6 Nm
2 - Air mass meter -G70-* with in- 1 2 3 4 1 5
take air temperature sender
- G42-*
❑ Resistances for intake air
temperature sender -G42-
⇒ Fig. 1 in 24-1 page 6
3 - Gasket
4 - Air filter top part
5 - Air deflector
1
❑ in air filter top part
6 - Filter insert
7 - Air filter bottom part 6
8 - 10 Nm
9 - Air deflector
7
8
1
9 S24-0484
Fig. 1: Resistances for coolant temperature sender A B

-G62- and intake air temperature sender
900
-G62-
800
♦ Coolant temperature sender - G62- at contacts 1 + 2.
7000 700
♦ Intake air temperature sender -G42- at contacts 1 + 3.
6000 600
The diagram is divided into two temperature ranges: 5000 500
A - from 0 to 50 °C 4000 400
B - from 50 to 105 °C 3000 300

2000 200
Read out examples:
1000 100
♦ For a temperature of 30 °C the specification is
1500...2000 Ω 0 10 20 30 40 50 60 70 80 90 100°C
N24-0157
♦ For a temperature of 80 °C the specification is
275...375 Ω

24-1 page 6 S00.5310.00.20
Fig. 2: Removing and installing engine trim panel
Removing
– Withdraw dipstick.
– Remove engine trim panel in direction of -arrows-.
Safety measures
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing S24-0485
the connection point.
Observe the following points to prevent injury to persons

and/or damage to the injection and ignition system:
♦ For reasons of safety fuse No. 61 must be removed
from the fuse holder before opening the fuel system,
as the door contact switch could activate the fuel
pump.
♦ Do not touch or remove ignition leads with the engine
running or at start speed.
♦ Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and igni-
tion system as well as of test equipment.
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
If the test and measuring devices are operated from the
passenger seat the passenger could be injured by the re-
lease of the passenger airbag in the event of an accident.
♦ If the engine must be operated at start speed without
the engine starting:
– Unplug the 4-pin connector from ignition transformer

-arrow-.
– Remove fuse 35 for injectors and fuse 61 for fuel
pump. 11 17 23 31
1 6 12 18 24 32
2 7 13 19 25 33
Rules of cleanliness 3
4
8
9
14
15
20
21
26
27
34
35
5 10 16 22 28 36
When working on the fuel supply/fuel injection system, 39 29 37
49 59
pay careful attention to the following „5 rules“ for cleanli- 40 50 60
30 38
ness. 41 51 61
42 52 62
♦ Thoroughly clean the connection points and their sur- 43 53 63
roundings before releasing. 44 54 64
45 55 65
♦ Place removed parts on a clean surface and cover. Do 46 56 66
not use fuzzy cloths! 47 57 67
♦ Carefully cover or close opened components if the re- 48 58 68
S01-0094
pair is not completed immediately.

S00.5310.00.20
♦ Only install clean parts. Remove spare parts from

their wrapping immediately before fitting. Do not use
any parts which have been stored unwrapped, e.g. on
a shelf or in a tool box.
♦ When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.

24-1 page 8 S00.5310.00.20
24-2 Testing components

Testing throttle valve control unit -J338-
Components for throttle valve control unit -J338-: Throttle
valve drive -V60-, throttle valve drive angle sender 1
-G187- and throttle valve drive angle sender 2 -G188-.
Note
If the throttle valve control unit is replaced, then adapt this
throttle valve control unit to the engine control unit
⇒ Chapter 24-4.

Test condition
• Throttle valve is not damaged or dirty.
Test sequence
– Unplug the 6-pin connector at the throttle valve control 1 3 5
unit.
– Measure resistance of throttle valve drive between
contacts 3 + 5.
Specified value: 1...5 Ω
If the specified value is not reached:
– Replace throttle valve control unit -J338-.

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

cables to engine control unit ⇒ 24-2 page 1.
S24-0346
Checking voltage supply 2 4 6
– Unplug the 6-pin connector at the throttle valve control

unit.
– Connect the multimeter for voltage measurement to
contacts 2 + 6 of the connector.
Specified value: min. 4,5 V
– Switch off ignition.

contact 2 of the connector and to earth.
Edition 11.04 Testing components 24-2 page 1

S00.5310.01.20


If wiring is o.k.:
– Replace engine control unit ⇒ Chapter 24-4.
Testing accelerator pedal position send-

er
♦ Test box -V.A.G 1598/31-
Operation
The two accelerator pedal position senders -G79- and
-G185- are located at the accelerator pedal and pass on
the driver input to the engine control unit completely inde-
pendently of each other (when accelerator is depressed).
Both senders are located in a housing.
Test condition
• Battery voltage at least 11.5 V.
Test sequence
– Remove storage compartment on driver side ⇒ Body
Work; Rep. Gr. 68.
– Separate the 6-pin plug connection of the accelerator
pedal position sender.
the following contacts of the connector:
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3


Testing components Edition 11.04

24-2 page 2 S00.5310.01.20
If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-4.
Testing injection valves
Inspecting the injection rate, tightness and jet

formation of the injectors

♦ Remote control -V.A.G 1348/3A-
♦ Adapter -V.A.G 1348/3-2-
♦ Measuring glasses, e.g. -V.A.G 1602-
♦ Measuring tool set, e.g. -V.A.G 1594 A, B oder C-
Test condition
• Fuel pump relay -J17- O.K. ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
• The fuel pressure must be OK, test ⇒ 24-2 page 4
• Fuel temperature 15...20 °C, fuel must according to
the valid standards
Test sequence
– Unplug connectors at all the injectors.
– Remove fuel rail together with injectors.
– Detach vacuum hose from fuel pressure regulator.
– Lift fuel rail together with injectors off intake manifold
and support.
Check tightness
– Initiate final control diagnosis and actuate injector of
cylinder 1 -N30- ⇒ Chapter 01-1; the fuel delivery unit
must run.
– Test the tightness of the injectors (visual inspection).
With the fuel delivery unit running, only 1 to 2 drops a
minute should drip out at each valve.
If the fuel loss is greater than this:
– End final control diagnosis and replace the leaking in-

jector.
Note
Replace seals at the same time.
Test injected quantity and spray pattern
Note
When testing the injection rate also check the jet forma-
tion. The jet must be the same for all valves.

S00.5310.01.20
– Insert injector to be tested in a measuring glass.

– Connect one contact of injector to engine earth.
– Connect the second contact of the injector to the re-
mote control.
– Connect terminal to battery positive (+).
– Connect battery positive (+) and fuse socket No. 61

with adapter cable and adapter -V.A.G 1348/3-2-.
11 17 23 31
The fuel delivery unit must start running. 1 6 12 18 24 32
2 7 13 19 25 33
– Operate remote control for 30 seconds. 3
4
8
9
14
15
20
21
26 34
27 35
– Repeat test at the other injectors. Always use a new 5 10 16 22 28
29
36
39 37
measuring glass. 49 59
30 38
40 50 60
– Once all the injectors have been driven, position the 41 51 61
graduated measuring glasses on an even base. 42 52 62

43 53 63
– Switch off voltage supply of fuel delivery unit. 44 54 64
45 55 65
– Compare the individual quantities of fuel injected. 46 56 66
47 57 67
Specified value: 88...98 ml per valve 48 58 68
S01-0094
If the measurement obtained for one or several injectors
is below or above the specification:
– Replace the defective injection valve ⇒ Chapter 24-1.

The injectors are installed in the reverse order. Pay atten-
tion to the following:
♦ Replace the O-rings and all the injectors and moisten
lightly with clean engine oil.
♦ Insert injectors vertically and into the correct position
in the fuel rail and secure with retaining clips.
♦ Fit fuel rail with secured injectors onto intake manifold
and press down evenly.
Test fuel pressure regulator and holding

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

♦ Pressure measuring device -V.A.G 1318-
♦ Adapter -V.A.G 1318/10-

24-2 page 4 S00.5310.01.20
Test condition
• Delivery rate of fuel delivery unit o.k., testing ⇒ 2.0/85
Engine, Mechanical Components; Rep. Gr. 20
Test sequence
WARNING!
The fuel system is under pressure! Place a cloth
around the connecting point before releasing hose
connections or when opening the system. Then re-
lease pressure by carefully detaching.
– Pull off the fuel feed line -1- and gather residual fuel in
a cloth.
– Connect up the pressure measuring device.
– Open shut-off cock of the pressure measuring device.
Lever points in direction of flow.
– Measure fuel pressure.
Specified value: approx. 0.25 MPa (2.5 bar).
– Detach vacuum hose -1- from connection -2-.

The fuel pressure must rise to approx. 0.3 MPa (3.0 bar).

If the pressure does not rise:
– Test for leaks and holding pressure. Observe pres-

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

S00.5310.01.20

– After the pressure has been built up, switch ignition
off. At the same time close the shut-off cock of the
pressure measuring device (lever at right angles to di-
rection of flow of fuel -arrow-).
– Observe pressure drop at gauge.
If the pressure again drops:
– Test non-return valve of fuel delivery unit ⇒ 2.0/85

kW Engine, Mechanical Components; Rep. Gr. 20.
If the pressure does not drop:
– Open shut-off cock of pressure measuring device

-V.A.G 1318- (lever in direction of flow of fuel).
– After the pressure has been built up, switch ignition
off. Press together the return-flow hose at the same
time.
If the pressure does not drop:
– Replace the fuel pressure regulator.

If the pressure again drops:
– Inspect connections, O-rings and fuel distributor for

leaks.
– Inspect pressure measuring device for leaks.
Note
Before taking off the pressure measuring device, place
cleaning cloths around the loose hoses of the feed line.

24-2 page 6 S00.5310.01.20
24-3 Testing functions II

Testing lambda probe -G39- and lambda
control upstream of catalytic converter
♦ Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
• Fuse 43 must be o.k.
• Battery voltage at least 11.5 V. 8 12 16 20
• The fuel pump relay must be o.k. 5 9 13 17 21

1 3 6 10 14 18 22
2 4 7 11 15 19 23
Test sequence 24 31 38
– Connect vehicle system tester -V.A.G 1552-. Start en- 25 32 39
26 33 40
gine and select address word 01 „Engine electronics“
⇒ Chap. 01-1. 27 34 41
28 35 42
– Check display groups 030, 031, 032, 033, 034 and 29 36 43
036 ⇒ Chap. 01-6.
30 37 44

S97-0319
– Test resistance of heating element between contacts
3 + 4, voltage supply for heater and cables to -Z19-
⇒ Current Flow Diagrams, Electrical Fault Finding
and Fitting Locations, as necessary.
Note
At ambient temperature the resistance of the heating ele-
ment should be approx. 1...5 Ω. The resistance increases
considerably even if the temperature rises only slightly.
– Test voltage supply of heater and cables to -Z19-.

If the specified resistance and voltage supply for heater
and cables to -Z19- are o.k.
– Use handheld multimeter to measure voltage between 2 4 6

the contacts 1 and 5 of connector -2- at the wiring
loom.
– Start engine.
Specified value: 0.40...0.50 V

– Replace lambda probe -G39-.

– Test cables between engine control unit and connec- 1 3 5 M24-0056

tor of lambda probe ⇒ Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations
Edition 03.01 Testing functions II 24-3 page 1

S00.5310.00.20
If the cable is not found to be faulty:
– Replace engine control unit ⇒ Chap. 24-4.
Testing lambda probe ageing upstream

of catalytic converter -G39-
♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• Coolant temperature at least 80 °C ⇒ Read measured
value block 004, display field 3 ⇒ Chap. 01-5
Inspect proper operation

gine and select address word 01 „Engine electronics“
⇒ Chap. 01-1.
– Select function 04 for „Initiate basic setting“ and dis-
play group 034.
– Engine speed is raised to 1400...2800 rpm. 1600 rpm 355 °C 2.20 s B1 S1 o.k.
Note
This may take a few minutes.
– Maintain engine speed at 1400...2800 rpm until the re-

adout in display field 4 switches from „Test off.“ to
„Test runs“. Catalytic converter temperature in display
field 2 must be at least 352 °C.
– Check period in display field 3:
Specified value: max. 2.20 sec.
– Maintain engine speed at 1400...2800 rpm until the re-

adout in display field 4 shows ”B1 S1 o.k.”.
– Conduct a test drive in order to eliminate any residues

on the lambda probe and repeat the test.
Pay attention to safety measures during the road test
⇒ Chap. 24-1.
If the specified value is again not reached:
– Replace lambda probe upstream of catalytic converter

-G39-.
Testing functions II Edition 03.01

24-3 page 2 S00.5310.00.20
Testing lambda probe -G130- and lamb-
da control downstream of catalytic con-
verter
Test conditions
• Fuse 43 must be o.k.
• The fuel pump relay must be o.k. 5 9 13 17 21

1 3 6 10 14 18 22
• Coolant temperature at least 80 °C ⇒ Read measured 2 4 7 11 15 19 23
value block 004, display field 3 ⇒ Chap. 01-5 24 31 38
25 32 39
27 34 41
– Check display groups 030, 031, 036 and 037 ⇒ Chap. 28 35 42
01-6. 29 36 43
If the specified values are not reached: 30 37 44
– Test resistance of heating element between contacts S97-0319

1 + 2, voltage supply for heater and cables to -Z29-,
as necessary.
Note
At ambient temperature the resistance of the heating ele-
ment should be approx. 1...5 Ω. The resistance increases
considerably even if the temperature rises only slightly.
If the specified resistance and voltage supply and cables
to -Z29- are o.k.
– Use handheld multimeter to measure voltage between

the contacts 3 and 4 of connector at the wiring loom.
– Start engine.
Specified value: 0.40...0.50 V

– Replace lambda probe downstream of catalytic con-

verter -G130 -.
1 4
– Test cables to lambda probe -G130- ⇒ Current Flow A24-0094
Diagrams, Electrical Fault Finding and Fitting Loca-
tions.
If the cable is not found to be faulty:
Edition 03.01 Testing functions II 24-3 page 3

S00.5310.00.20
Testing functions II Edition 03.01

24-3 page 4 S00.5310.00.20
24-4 Engine control unit

Wiring and Component Test with Test
Box V.A.G. 1598/31
♦ Test box -V.A.G 1598/31-
Note
♦ The test box -V.A.G 1598/31- is designed in such a
way that it can be simultaneously connected to the
wiring loom of the engine control unit and to the actual
engine control unit.
♦ The advantage being that the electronic engine con-
trol remains fully operational with the test box con-
nected (e.g. measuring signals while the engine is
running).
♦ Refer to the relevant test procedures to determine
whether the control unit is connected to the test box or
not.
♦ The contact numbers of the connector of the control
unit and the socket numbers of the test box are iden-
tical.

– Release the connector catches and unplug the control
unit connectors.
– Connect test box -V.A.G 1598/31- to connector of wir-
ing loom. The earth clip of the test box must be con-
nected to the negative battery terminal.
– Perform test as described in the relevant repair se-
quences.
DANGER!
To avoid damaging the electronic components,
switch on the relevant measuring range before
connecting the measuring equipment and comply
with the test conditions.
V.A.G. 1598/31
S01-0089
Testing voltage supply for engine con-
trol unit
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
Edition 11.04 Engine control unit 24-4 page 1

S00.5310.01.20
Test conditions
• Fuses no. 3, 14, 17, 48, 52 and 56 must be in proper 1
2
6
7
12
13
18
19
24 32
25 33
order. 3 8 14 20 26 34
4 9 15 21
• Generator o.k., test ⇒ Current Flow Diagrams, Elec-
27 35
5 10 16 22 28 36
trical Fault Finding and Fitting Locations. 39 49 59
29 37
30 38
40 50 60
41 51 61
42 52 62
44 54 64
– Connect vehicle system tester -V.A.G 1552-. Start en- 45 55 65
gine and select the address word 01 „Engine electron- 46 56 66
ics“ ⇒ Chapter 01-1. 47 57 67

48 58 68
– Select function 08 „Read measured value block“ and S01-0094
display group 004.
– Read off readout in display field 2. Reading measured value block 4 ->
840 rpm 13.6V 95.0°C 62.0°C
Specified value: min. 11.5 V

– Connect test box -V.A.G 1598/31- to connector of wir-

ing loom ⇒ 24-4 page 1. The engine control unit is
not connected here.
Testing voltage of terminal 30

– Measure supply voltage between sockets 1 + 62 of the
test box:
– Test cable connections to relay plate according to the

current flow diagram ⇒ Current Flow Diagrams, Elec-
trical Fault Finding and Fitting Locations.
Testing voltage of terminal 15

– Use multimeter to measure voltage between sockets
1 + 121 at the test box.
– Test cable connections to relay plate according to cur-

rent flow diagram: ⇒ Current Flow Diagrams, Electri-
cal Fault Finding and Fitting Locations.
Procedure after voltage supply has been

interrupted
If the power supply is interrupted the engine control unit
forgets all initialisation or basic setting values and the
Readiness Code is erased. Depnding on the mileage
Engine control unit Edition 11.04

24-4 page 2 S00.5310.01.20
which the vehicle has driven, this may result in consider-
able driveability problems.

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
After the voltage supply has been interrupted, it is neces-
sary to carry out the following steps:
– Switch ignition on for at least 10 seconds.

– Switch ignition off for at least 30 seconds.
– Adapt engine control unit to throttle valve control unit
⇒ 24-4 page 5.
– Perform idling speed test ⇒ Chap. 01-5, display
group 001, display field 1.
– Conduct a lengthy test drive until the problems have
been rectified.
During the test drive the following operating conditions
must be fulfilled:
♦ The coolant temperature should rise beyond 80°C
♦ Once this temperature is reached, the operating
states of idling speed, part load, fuel shut-off on over-
run, must be reached several times.
♦ in case of full load the speed should be increased be-
yond 3500 rpm.
– Read out readiness code ⇒ Chap. 01-2.
Replacing engine control unit

-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
– Enter the control unit identification and thus also the
coding of the previous control unit as follows:
06A906032CC 2.0l R4/2V 3658 ->
The control unit identification number and the coding are
Coding 00001 WSCXXXXX
shown on the display, e.g.:

Remove air filter ⇒ Chap. 24-1.

S00.5310.01.20
– Release the plug locks and unplug control unit con-

nectors -arrow-.
S10-0111
– Press open the latches of the fixture -arrows A- and

pull the engine control unit forward -arrow B-.
– Release the second plug lock and unplug the control A
unit connector.
– Installation is carried out in the reverse order.
B
Note
A
♦ Check current coding and code new control unit
⇒ 24-4 page 4.
♦ Adapt new control unit to the electronic immobiliser
⇒ Electrical System; Rep. Gr. 90.
♦ Adapt engine control unit to throttle valve control unit
⇒ 24-4 page 5.
S24-0337
♦ Activate CCS ⇒ Chapter 24-5.
♦ Test idling speed ⇒ Chap. 01-5, display group 001,
display field 1.
♦ Interrogate fault memory, rectify any faults and erase
fault memory ⇒ Chap. 01-1.
♦ Generate readiness code ⇒ Chapter 01-2.
Coding engine control unit
Note
♦ A 5-digit code must always be displayed during the
time the control unit identification is shown.
♦ If the code displayed does not match the vehicle, or if
the control unit has been replaced, it is then neces-
sary to code the control unit as follows.

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

24-4 page 4 S00.5310.01.20
Procedure
Code control unit Q
– Select function 07 „coding control unit“. Enter code number XXXXX (0-00127)
– Enter the relevant code number of the vehicle and
confirm with button Q .
for vehicles with Code number

Air Conditioning 00001
without air conditioning 00021
06A906032CC 2.0l R4/2V 3658 ->
The control unit identification number and the coding are Coding 00001 WSCXXXXX
shown on the display, e.g.:
Function unknown or cannot ->
If this display appears, an incorrect code number has
be carried out at the moment
been entered.
Note
♦ The engine control unit does not use the code entered
and shown in the display until after the ignition has
been switched off. Incorrect coding results in:
♦ Handling problems (jerky gear change, load change
jolts etc.)
♦ Increase in fuel consumption
♦ Increase in pollution
♦ Storage of non-existent faults in fault memory
♦ non-execution of functions (lambda control, activated
charcoal filter system actuation, etc.)
♦ On front-wheel-drive vehicles the Traction Control
System does not operate (TCS warning light on)
Adjusting the engine control unit to the

throttle valve control unit
This adaptation teaches the engine control unit the vari-
ous positions of the throttle valve with the ignition on and
the engine stopped. These positions are stored in the en-
gine control unit. The feedback of the throttle valve posi-
tion is provided by the two angle sensors for the throttle
valve drive.
Adaptation must be performed if:
♦ the power supply was interrupted
♦ the throttle valve control unit was removed and in-
stalled
♦ the throttle valve control unit was replaced
♦ if another engine or another throttle valve control unit
was installed

S00.5310.01.20

-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• There must not be any fault present in the fault mem-
ory ⇒ Chap. 01-1, Interrogating fault memory.
• The throttle valve must be in idling speed position.
• Coolant temperature must be 5...95 °C ⇒ Chap. 01-5
display group 004, display field 3.
• If a cruise control system is fitted, its setting must be
O.K.
Procedure
– Select function 04 „Basic setting“ and display group 8% 60% 0 ADP runs
060.
In this state, the throttle valve is moved by a mechanical
spring integrated in the throttle valve control unit, into an
emergency running position. The values generated by
the two angle senders in this emergency position are
stored by the engine control unit.
Subsequently the throttle valve is opened at a given val-
ue. If this value is reached, the throttle valve positioner is
again switched dead. Now the mechanical spring must
close the throttle valve within a given period in the previ-
ously initialised emergency position (spring test).
The throttle valve is subsequently closed by the throttle
valve positioner: the values sent by the angle sender to
the throttle valve control unit are stored in the engine con-
trol unit.
If during driving the engine control unit switches the throt-
tle valve positioner dead, this is indicated by a fluctuating
increased idling speed. The engine then has a very poor
throttle response.
– Check specifications in display fields 3 and 4. 60% 94% 8 ADP o.k.
Specification in display field 3: 8
Specification in display field 4: ADP runs
ADP o.k.
The adaptation was successfully performed.
To store the values:
– Switch ignition off for at least 30 seconds.

24-4 page 6 S00.5310.01.20
Note
♦ If the basic setting is aborted by the control unit, this
may be due to the following reasons:
♦ The throttle valve does not reach the mechanical
idling limit due to dirt, e.g. carbon deposits or another
mechanical fault.
♦ The battery voltage is too low.
♦ The throttle valve control unit or the cable connection
is faulty, test ⇒ Chapter 24-2.
♦ If the basic setting is aborted, the fault is still in the
fault memory. When the ignition is switched on again
the basic setting is automatically performed again.

S00.5310.01.20

24-4 page 8 S00.5310.01.20
24-5 Testing auxiliary signals

Testing the speed signal
♦ Test box -V.A.G 1598/31-
♦ Diode test lamp, e.g. -V.A.G 1527 B-
Test conditions
• Speedometer o.k., testing ⇒ Electrical System;
Rep. Gr. 90.
Test sequence
– Connect test box -V.A.G 1598/31 - to wiring loom to
engine control unit ⇒ Chap. 24-4. The engine control
unit is not connected.
– Raise vehicle at front left.
– Connect diode test lamp to sockets 4 (terminal 15) +
54 (cruise control signal) of the test box.
– Rotate front left wheel and observe diode test lamp.
Specified value: the LED must flicker
If the LED does not flicker:
– Test the cables to the speedometer and to the vehicle

speed sender ⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
Test data bus

Operation
The engine control unit communicates over a CAN data-
bus with all the control units with databus capability.
The control units that are compatible with the data bus
are connected via two twisted data bus cables
(CAN_High and CAN_Low) and exchange information
(messages). Both the engine control unit and the other
CAN data bus control units detect missing information on
the data bus as faults.
Test condition
• A fault has been detected by the CAN data bus self-
diagnosis.
Edition 03.01 Testing auxiliary signals 24-5 page 1

S00.5310.00.20

♦ Test box -V.A.G 1598/31-
Test sequence
– Unlock connector at control unit and unplug.
– Connect the -V.A.G 1598/31- to the engine control
unit. The wiring loom of the control unit is not connect-
ed for this test.
– Test the central terminating resistor in the engine con-
trol unit:
– Carry out a resistance measurement for this purpose
between sockets 58 and 60 of the test box.
Specified value: 60...72 Ω
If the resistance value is not within the nominal value
range:

If the resistance value is within the nominal value range:
– Test CAN databus ⇒ Electrical System; Rep. Gr. 90
Activating and deactivating cruise con-

trol system (CCS)
♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• There must not be any faults present in the fault mem-
ory ⇒ Chap. 01-1.
Test sequence
06A906032CC 2.0 l R4/2V G 3658 ->
Readout on display, e.g.: Coding 00071 WSC XXXXX
If „2.0 l R4/2V G“ is displayed, CCS is activated.
06A906032BL 2.0 l R4/2V 3530 ->
Readout on display, e.g.: Coding 00071 WSC XXXXX
If „2.0 l R4/2V G“ is displayed, CCS is not activated.
Login procedure
– Press → key and select function 11 „Login proce-
Enter code number XXXXX
dure“.
Testing auxiliary signals Edition 03.01

24-5 page 2 S00.5310.00.20
Enter code number by referring to the table below and
confirm entry with Q key.
Code Cruise control system (CCS)

number
11463 Cruise control system (CCS) is activat-
ed
16167 Cruise control system (CCS) is deacti-
vated

After the CCS is activated, conduct a test drive as an op-
erational check.
Edition 03.01 Testing auxiliary signals 24-5 page 3

S00.5310.00.20
Testing auxiliary signals Edition 03.01

24-5 page 4 S00.5310.00.20
28 – Ignition System
28-1 Repairing ignition system
General notes on the ignition system

♦ This section deals specifically with the components
relating to the ignition system. The other components
of the fuel injection and ignition system ⇒ Chap. 24-1
and following.
♦ Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV con-
trol unit.
♦ The engine control unit is equipped with a self-diagno-
sis.
♦ Components marked with an * are checked by self-di-
agnosis ⇒ Chap. 01-1.
♦ A minimum voltage of 11.5 V is required for the perfect
functioning of the electric components.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. That is why it is necessary to in-
terrogate and erase the fault memory after completing
all test and repair work ⇒ Chap. 01-1.
Safety measures ⇒ 28-1 page 1.
Safety measures
Observe the following points to prevent injury to persons
and/or damage to the injection and ignition system:
♦ Do not disconnect or connect ignition cables when the
engine is running or operating at starting speed.
♦ Do not disconnect or connect cables of the fuel injec-
tion and ignition system, also not cables of test equip-
ment, unless the ignition is switched off.
♦ To operate the engine at starter speed without the en-
gine actually starting:
– Unplug 4-pin connector -1- from ignition transformer

-2-.
– Remove fuse 28 for the fuel pump.
If test and measuring devices are required during test 8 12 16 20
drives observe the following: 5 9 13 17 21
1 3 6 10 14 18 22
♦ Attach test and measuring equipment always on the 2 4 7 11 15 19 23
rear seat and have them operated from there by a sec-
24 31 38
ond person.
25 32 39
♦ If the test and measuring devices are operated from
26 33 40
the passenger seat the passenger could be injured by
27 34 41
the release of the passenger airbag in the event of an
28 35 42
accident.
29 36 43
30 37 44
S97-0319
Edition 03.01 Repairing ignition system 28-1 page 1

S00.5310.00.20
Removing and installing parts of the ignition system

1 - Ignition lead
❑ with shielded plug and spark-
plug
2 - Spark plug, 20-30 Nm 10
C A
❑ use special spark plug
wrench (e.g. -3122 B-) for re- B D
11
moving and installing
❑ type and electrode gap 9
⇒ Inspection and Mainte-
nance; Rep. Gr. 02
3 - 20 Nm
❑ The torque influences the 8 1
knock sensor function
4 - Knock sensor 2 -G66-*
❑ Sensor and connecting plug
contacts are gold-plated
5 - Triple-pin plug and socket 7
connector
❑ contacts gold-plated
❑ black for knock sensor 1
-G61-
❑ brown for knock sensor 2
-G66- 2
6 - Knock sensor 1 -G61-*
❑ Sensor and connecting plug
contacts are gold-plated
7 - Camshaft position sensor
-G163-*
❑ check ⇒ 28-1 page 3
8 - Connecting plug
❑ black, 3 pins 5 6 3 5 4 3
S28-0126
❑ for camshaft position sensor
-G163-
9 - Connecting plug
❑ for ignition transformer
❑ black, 4 pins
10 - Ignition transformer (N, N128)
❑ with identification for ignition leads:
A = Cylinder 1
B = Cylinder 2
C = Cylinder 3
D = Cylinder 4
❑ with power output stage - N122-
❑ resistances ⇒ Fig. 1 in 28-1 page 3
11 - 10 Nm
Repairing ignition system Edition 03.01

28-1 page 2 S00.5310.00.20
Fig. 1: Resistances of ignition coils
Specified value: 4...6 kΩ.
Testing camshaft position sensor -G163-

Test conditions
• Battery voltage 11.5 V S28-0099
Test sequence
– Unplug 3-pin connector -1- from camshaft position
sensor -2-.
– Connect handheld multimeter for voltage measure-
ment to contacts 1 + 3 of connector -1-.
2
3
Specified value: at least 4.5 V
– Switch off ignition. 2
– Test cables for open circuit, short circuit to earth and 1

If the wiring is in proper order and the desired voltage was
measured at contacts 1 + 3 1 N28-0146
– Replace camshaft position sensor -G163-.

If the wiring is in proper order and the desired voltage was
not measured at contacts 1 + 3
Edition 03.01 Repairing ignition system 28-1 page 3

S00.5310.00.20
Repairing ignition system Edition 03.01

28-1 page 4 S00.5310.00.20

Fuel Injection AZL

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Service 5

Service Department. Technical Information Printed in Czech Republic

List of Supplements to Workshop Manual

Edition 11.04 List of Supplements

List of Supplements Edition 11.04

24 – Fuel Formation, Injection

Edition 11.04 Table of Contents I

Table of Contents Edition 11.04

Properties of the self-diagnosis

Technical data of self-diagnosis

Control unit identification:

Edition 11.04 Self-diagnosis I 01-1 page 1

Engine identification characters AZL

Functions available when using the vehicle sys-

Self-diagnosis I Edition 11.04

condition. In this driving condition only low perform-

Check for proper operation

– Check dash panel insert and exhaust gas warning

– Start engine and run in idle.

– Interrogate the fault memory of the engine control unit,

Edition 11.04 Self-diagnosis I 01-1 page 3

Connecting vehicle system tester

• Battery voltage must be at least 11.5 volts. 47

• Assembly earth connections o.k. S01-0094

Self-diagnosis I Edition 11.04

Interrogating and erasing fault memory

Special tools, test and measuring equipment and

– Operate starter for about 6 seconds. after this do not

If one or several faults are stored:

– Rectify the faults displayed by referring to the fault ta-

– Select function 06 „End output“ and switch ignition off.

Automatic test sequence

Edition 11.04 Self-diagnosis I 01-1 page 5

– Enter address word 00 „Automatic Test Sequence“.

– Once again interrogate the fault memories of all the

– Select function 06 „End output“ and switch ignition off.

Performing actuator diagnosis

Special tools, test and measuring equipment and

Self-diagnosis I Edition 11.04

Activate solenoid valve 1 for activated charcoal

– Detach hose from the activated charcoal filter at the

– Test resistance at solenoid valve -N80- ⇒ Chap. 24-

Actuate secondary air pump relay -J299-:

Edition 11.04 Self-diagnosis I 01-1 page 7

– Test secondary air pump relay -J299- and cables for

Actuate injectors -N30- to -N33-:

– The next injector is operated by pressing the → but-

– Test resistance of injector ⇒ Chap. 24-1.

Self-diagnosis I Edition 11.04

Reading Readiness Code

Special tools, test and measuring equipment and

– Select function 06 „End output“ and switch ignition off.

Edition 11.04 Self-diagnosis II 01-2 page 1

Meaning of the 8-digit numerical block of the readiness code

Generating readiness code

– Select function 02 „Interrogate fault memory“.

– Rectify the faults displayed by referring to the fault ta-

Self-diagnosis II Edition 11.04

Work step 3: Adjusting the engine control unit to the

– End adjustment only after 30 seconds have passed by

– Test throttle valve control unit ⇒ Chapter 24-2.

– Start engine and run in idle.

– Select function 04 „Initiate basic setting“ and display