Fuel Injection AMF PDF

Service
Workshop Manual
FABIA 2000
1.4/55 TDI Engine, Fuel Injection

Edition 07.03
Engine code
AMF
Service Department. Technical Information
Printed in Czech Republic

S00.5326.00.20
The Workshop Manual is intended only for use within the Organisation koda.
It is not permitted to pass it on to other persons.
KODA AUTO a. s.
Service
Printed in Czech Republic

S00.5326.00.20
FABIA 2000 1.4/55 TDI Engine, Fuel Injection
List of Supplements to Workshop Manual
FABIA 2000
1.4/55 TDI Engine, Fuel Injection
Edition 07.03
Supplement
1
Edition 04.04
S00.5326.01.20
Edition
Subject
Article Number
07.03
Basic Edition
S00.5326.00.20
04.04
Modifications in Rep. Gr. 01 a 23
S00.5326.01.20
List of Supplements
List of Supplements
Edition 04.04
S00.5326.01.20
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1
page
- Properties of the self-diagnosis ..................................................................... 01-1
page
- Technical data of self-diagnosis ..................................................................... 01-1
page
- Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine
electronics .............................................................................................. 01-1
page
- Interrogating and erasing fault memory ............................................................ 01-1
page
- Actuator diagnosis ..................................................................................... 01-1
page
Self-diagnosis II ......................................................................................... 01-2
page
- Fault codes 515 to 19561 ............................................................................ 01-2
page
Self-diagnosis III ........................................................................................ 01-3
page
- Readiness code ........................................................................................ 01-3
page
- Reading readiness code .............................................................................. 01-3
page
- Generating readiness code .......................................................................... 01-3
page
Self-diagnosis IV ....................................................................................... 01-4
page
- Reading measured value block ..................................................................... 01-4
page
- Display groups 001 to 022, engine idling .......................................................... 01-4
page
- Display groups 004 through 011 at full load ....................................................... 01-4
page 10
- Display group 125 - CAN databus .................................................................. 01-4
page 12
23 Fuel Formation, Injection

Diesel Direct Injection System ...................................................................... 23-1
page
- Safety measures ....................................................................................... 23-1
page
- Rules of cleanliness ................................................................................... 23-1
page
- Overview of fitting locations .......................................................................... 23-1
page
- Disassembling and assembling intake manifold .................................................. 23-1
page
- Removing and installing air filter .................................................................... 23-1
page
- Disassembling and assembling the air filter ....................................................... 23-1
page
Disassembling and assembling the unit injector ............................................... 23-2
page
- Summary of components ............................................................................. 23-2
page
- Removing and installing O-rings for unit injector ................................................. 23-2
page
- Removing and installing the unit injector .......................................................... 23-2
page
Testing components ................................................................................... 23-3
page
- Test wiring and components with Test box -V.A.G 1598/31- ................................... 23-3
page
- Test diesel direct injection system relay -J322- .................................................. 23-3
page
- Testing unit injector valve ............................................................................ 23-3
page
Testing exhaust gas recirculation .................................................................. 23-4
page
- Connect vacuum hoses at valve block ............................................................. 23-4
page
- Testing exhaust gas recirculation ................................................................... 23-4
page
Engine control unit ..................................................................................... 23-5
page
- Testing voltage supply for engine control unit .................................................... 23-5
page
- Replacing diesel direct injection system control unit -J248- .................................... 23-5
page
- Coding diesel direct injection system control unit -J248- ........................................ 23-5
page
- Activating and deactivating cruise control system (CCS) ....................................... 23-5
page
Testing auxiliary signals .............................................................................. 23-6
page
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Table of Contents
28 Glow Plug System

Testing preheating system ........................................................................... 28-1
II
Table of Contents
page
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01
01 Self-diagnosis
01-1
Self-diagnosis I
Properties of the self-diagnosis

The control unit for the diesel direct injection system is
equipped with a fault memory. The fault memory is designed as a permanent memory.
If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication
of the fault type. Fault table Chap. 01-2.
Faults which occur only temporarily (sporadically) are
displayed with the suffix /SP. Possible causes of sporadic faults are e.g. a loose contact or a temporary line interruption. If a sporadic fault no longer occurs after 50
engine starts, it is automatically erased.
If faults are detected that are likely to influence the driving
behaviour, the glow period warning lamp -K29- flashes.
The stored faults can be read out with the vehicle system
tester -V.A.G 1552-, -V.A.G 1551- or -VAS 5051 01-1 page 2.
After the fault(s) has(have) been removed the fault memory must be erased 01-1 page 3.
Note
The following description only relates to vehicle system
tester -V.A.G 1552- using the current program card 5.0.
When not using the current program card or when using
the fault read-out scan tool -V.A.G 1551- with integrated
printer or using the vehicle diagnosis, measurement and
information system -VAS 5051- a minor deviation in the
display is possible.
Technical data of self-diagnosis

Interrogating control unit version
The control unit version is displayed once the vehicle system tester -V.A.G 1552- is connected and the engine
electronics control unit is selected 01-1 page 2.
Available functions when using the vehicle system tester -V.A.G 1552The conditions under which the desired functions can be
selected are given in the following table.
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Self-diagnosis I
01-1 page 1
01
Condition
Operation
Engine not running,

ignition switched on
Engine idling
Normal driving
01
Interrogating control unit

version
yes
yes
yes
02
Interrogating fault memory
yes1)
yes
yes
03
Actuator diagnosis
yes
yes
no
04
Basic setting
no
yes
no
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
11
Login procedure
yes
no
no
1)
Only perform with the ignition on, if the engine does not start.
Connecting vehicle system tester

-V.A.G 1552- and selecting the control
unit for engine electronics
Special tools, test and measuring equipment and
auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Battery voltage at least 11.5 volts

Earth connection to engine and gearbox O.K.
Fuses according to current flow diagram O.K.
Procedure
Connect vehicle system tester -V.A.G 1552- with appropriate cable.

Once the vehicle system tester has been connected:
V.A.G 1552
Switch on ignition or start 01-1 page 1 engine depending on the function desired.
V.A.G 1551/3
Note
If data transfer errors are displayed as a result of an
S01-0087
incorrect entry, disconnect cable at vehicle system

tester, connect it in again and repeat all the steps.
If one of the following messages appears in the dis-
play, test the diagnostic cable Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
or Operating Instructions of vehicle system tester.
01-1 page 2
Vehicle system test

The control unit does not respond
Self-diagnosis I
HELP
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01
Operate the vehicle system tester by referring to the
Vehicle system test

Fault in communication set-up
HELP
Vehicle system test

K cable does not connect to earth
HELP
Vehicle system test

HELP
K cable does not connect to pos. term.
read-out on the display:

Vehicle system test
Enter address word XX
Readout on display:
HELP
Enter address word 01 Engine electronics and confirm entry with Q .

The control unit identification appears in the display, e.g.:
045906019BM 1.4l R3
Coding 00008
EDC G000SG 4958 ->

WSC XXXXX
045906019BM = Part No. of the control unit (for cur-
rent control unit version see spare part catalogue)

1.4 ltr. = engine displacement
R3 = engine version (3 cyl. in-line engine)
EDC = Injection system (Electronic Diesel Control)
CC = Cruise control system activated (only on models
with CCS)
000 = Control unit ID
MG = Manual gearbox
4958 = Data status (Software version of the control
unit)
Coding 00002 = Coding variant of the control unit
WSC XXXXX = Workshop code
Note
If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit

Chapter 23-5.
Incorrect coding of the engine control unit results in:
Handling problems (jerky gear change, load change
jolts etc.)
Increase in fuel consumption
Increase in pollution
Storage of non-existent faults in fault memory
Interrogating and erasing fault memory

-V.A.G 1551/3, 3A, 3B oder 3C-
Interrogating fault memory
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics
01-1 page 2.
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Self-diagnosis I
01-1 page 3
01
Only if the engine does not start:
Switch on ignition.
Select function 02 Interrogate fault memory and confirm with Q .
The number of stored faults or No fault recognised appears in the display.
X faults detected!
If no fault is stored:
Select function 06 End output and confirm with
Q.
If one or several faults are stored:
Press
.
->
Readout on display, e.g.:
Press
Fault number: 16685
044
Fault source and fault type appear in the display, e.g.:
Press
P0301
Cylinder 1
Combustion misfiring detected
->
Vehicle system test

Fault memory was erased
->
The stored faults are displayed in sequence.
Select function 06 End output and confirm with Q .

Rectify the faults displayed by referring to the fault table Chapter 01-2.
Note
When carrying out testing and removal and installation
operations faults such as connector unplugged or CAN
bus faults, may also be detected by other control units.
This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:
Select function 00 for Automatic test sequence and

confirm with Q .
The Vehicle system tester -V.A.G 1552- sends all the
known address words one after the other.
Erasing fault memory

Test conditions
Fault eliminated
Fault memory interrogated 01-1 page 3
Note
After fault elimination the fault memory must again be interrogated and subsequently erased.
Select function 05 Erase fault memory and confirm

with Q .
Readout on display:
01-1 page 4
Self-diagnosis I
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01
Note
If the ignition is switched off during Interrogating fault
memory and Erasing fault memory, the fault memory is
not erased.

Perform a test drive. Then, once again interrogate the
fault memory. No fault must be displayed.
Actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated:
1 - Exhaust gas recirculation valve -N182 - AC compressor engagement
3 - Solenoid valve for charge pressure control
-N754 - Changeover valve for intake manifold flap
-N2395 - Glow period warning lamp -K296 - Glow plug relay -J527 - Low heat output relay -J3598 - High heat output relay -J3609 - Fault lamp
Note
Actuation of the individual control elements is limited
to 30 seconds.
If the actuator diagnosis must be repeated without the
engine being started in the meantime, switch off ignition for about 20 seconds.
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Fuses according to current flow diagram O.K.

Procedure
01-1 page 2.
Select function 03 final control diagnosis.

Readout on display:
Actuator diagnosis
Exhaust gas recirculation valve -N18
->
The valve must click.
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Self-diagnosis I
01-1 page 5
01
Note
The clicking of the valve cannot be heard because of the
engine noise and can therefore only be checked.
If the valve does not click:
Testing Exhaust gas recirculation valve -N18 Chap. 23-1.
Press
.
Actuator diagnosis
AC compressor engagement
Readout on display:
->
This test step is also activated on vehicles without AC

system.
Disregard display.
Press
.
Actuator diagnosis
->
Charge press.control solenoid valve -N75
Readout on display:
The valve must click.
Note
The clicking of the valve cannot be heard because of the
engine noise and can therefore only be checked.
If the valve does not click:
Test charge pressure control solenoid valve -N75 Chap. 23-1.
Press
.
Actuator diagnosis
->
Intake manif.flap change-over valve-N239
Readout on display:
The engine must stop.
If the engine does not stop:
Switch off ignition.

Inspecting Intake manifold flap change-over valve
-N239- Chap. 23-1.
Continue final control diagnosis with the engine off

and the ignition switched on.
Press
Readout on display:
Actuator diagnosis
Glow period warning lamp -K29
->
Actuator diagnosis
Glow plug relay -J52
->
The warning light for glow period must flash.

If the warning light for glow period does not flash:
Testing Glow period warning lamp -K29- Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
Readout on display:
The relay must click.
01-1 page 6
Self-diagnosis I
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01

It is also possible to observe the relay switching on and
off by the interior light becoming brighter or darker
(caused by the high power consumption of glow plugs).
If the relay does not click:
Test glow plug relay -J52- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
Press
.
Actuator diagnosis
Low heat output relay J359
Readout on display:
->

Test low heat output relay -J359- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
.
Actuator diagnosis
High heat output relay
Readout on display:
->
-J360

Test high heat output relay -J360- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
.
Actuator diagnosis
Fault lamp
Readout on display:
->
The exhaust emission warning lamp must flash.

If the exhaust emission warning lamp does not flash:
Test exhaust emission warning lamp Current Flow

Diagrams, Electrical Fault Finding and Fitting Locations.
Press
.
Vehicle system test
Select function XX
Readout on display:
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HELP
Q.
Self-diagnosis I
01-1 page 7
01
01-1 page 8
Self-diagnosis I
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01
01-2
Self-diagnosis II
Fault codes 515 to 19561

Note
The fault table is ordered according to the 5-digit fault code on the left.
The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only
valid for USA).

Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the ve-
hicle system tester.

If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth
connections according to current flow diagram. Only if no fault is detected here should the part be replaced. This
applies in particular if faults are shown as sporadic (SP).
If Info in literature appears in the display of the vehicle system tester - V.A.G 1552- look for the text required in
the fault table under the fault code.

Readout on -V.A.G 1552-
Rectifying fault
00515
Hall sensor -G40
Test camshaft position sensor -G40- Current Flow Diagrams,
no signal or signal not within

the tolerance
Electrical Fault Finding and Fitting Locations
Remove open circuit in wiring or short circuit according to current
flow diagram Current Flow Diagrams, Electrical Fault Finding and

Fitting Locations
Inspect position of camshaft and rotor 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15
00671
Cruise control system
switch -E45
undefined
switch status
Test cruise control system Chap. 01-4, display groups 006 and
00741
Brake pedal monitoring
Implausible signal
Test brake light switch - F- and brake pedal switch -F47- Chap.
01117
Load signal for alternator terminal DF
Implausible signal
Test wiring and generator Current Flow Diagrams, Electrical Fault
022
01-4, display group 006
Finding and Fitting Locations
01193
Open circuit or
Low heat output relay - short circuit to
J359
earth
Test low heat output relay -J359- with final control diagnosis
01194
-J360
Open circuit or
short circuit to
earth
Test high heat output relay -J360- with final control diagnosis
01282
Intake manifold flap
change-over valve N239
Open circuit or
short circuit to
earth
Test intake manifold flap changeover valve -N239- with final control
16485
Air mass meter -G70
Implausible signal
Test air mass meter -G70 - Chap. 01-4, display group 003
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Chap. 01-1
Chap. 01-1
diagnosis Chap. 01-1
Self-diagnosis II
01-2 page 1
01
Rectifying fault
16684
Combustion misfiring
detected
Inspecting compression pressure 1.4/55 TDI Engine, Mechanics;

Rep. Gr. 15
Check unit injector Chap. 23-3
16685
Cyl. 1 combustion misfirings detected
16686
16687
16705
Implausible sigEngine speed sender - nal
G28
Inspecting Engine speed sender -G28- Chap. 23-1
16706
No signal
Engine speed sender G28
Inspecting Engine speed sender -G28- Chap. 23-1

Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248 - Chap.

23-5
16725
Camshaft pos. sensor
=> Sender -G40
Implausible signal


Fitting Locations
16885
Vehicle speed signal
Implausible signal
Test vehicle speed signal Chapter 23-6
16944
Voltage supply
Implausible signal
Test cables to diesel direct injection system control unit - J248- ac-
16946
Voltage supply
Voltage too low
16947
Voltage supply
Voltage too high
16955
Brake light switch -F
Implausible signal
cording to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test brake light switch - F- and brake pedal switch -F47- Chap.
01-4, display group 006
16989
Control unit defective
23-5
17068
Glow period control
unit 1
Implausible signal
Test glow plug relay -J52- with final control diagnosis Chap. 01-1
17552
Air mass meter -G70
Open circuit or
short circuit to
earth
Test air mass meter -G70- Chap. 01-4, display group 003
Check wiring according to current flow diagram Current Flow Dia-
17553
Air mass meter -G70
Short circuit to
positive
17554
Air mass meter -G70
Supply voltage
01-2 page 2
grams, Electrical Fault Finding and Fitting Locations

23-5
Self-diagnosis II
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01

Rectifying fault
17563
Intake manifold pressure sender -G71
Short circuit to
positive
Test intake manifold pressure sender -G71- Current Flow Dia-
17564
Open circuit or
short circuit to
earth
17565
Supply voltage
17568
Intake manifold temperature sender -G72
Short circuit to
earth
17569
Intake manifold temperature sender -G72
Open circuit/
Short circuit to
positive
17570
Fuel temperature
sender -G81
Short circuit to
earth
17571
Fuel temperature
sender -G81
Open circuit/
Short circuit to
positive
17663
Coolant temperature
sender -G62
Open circuit/
Short circuit to
positive
17664
Coolant temperature
sender -G62
Short circuit to
earth
17668
Unit injector solenoid
valve cyl. 1 -N240
Implausible signal
17669
valve cyl. 1 -N240
Regulating limit
exceeded
17670
valve cyl. 1 -N240
Regulating limit
not reached
17671
valve cyl. 2 -N241
Implausible signal
17672
valve cyl. 2 -N241
Regulating limit
exceeded
17673
valve cyl. 2 -N241
Regulating limit
not reached
17674
valve cyl. 3 -N242
Implausible signal
17675
valve cyl. 3 -N242
Regulating limit
exceeded
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grams, Electrical Fault Finding and Fitting Locations

23-5
Test charge pressure Chap. 01-4, display group 010

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

23-5
Test fuel temperature sender -G81- Chap. 01-4, display group

007

23-5
Test coolant temperature sender -G62- Chap. 01-4, display group

007

23-5

Inspecting fuel supply 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 20

Rep. Gr. 20
Self-diagnosis II
01-2 page 3
01
Rectifying fault
17676
valve cyl. 3 -N242

Regulating limit
not reached
Rep. Gr. 20
17795
23-5
Test exhaust gas recirculation valve -N18- with final control diagno-
17810
Short circuit to
positive
17849
Open circuit or
short circuit to
earth
17910
Fuel pump relay -J17
Short circuit to
positive
Testing fuel pump relay -J17- Current Flow Diagrams, Electrical
17911
Load signal for alternator terminal DF
Implausible signal
Test generator Electrical System; Rep. Gr. 27

Reading measured value block, display group 016 Chap. 01-4
17931
Crash signal from airbag CU
Implausible signal
Perform airbag system self-diagnosis Body Fitting Work;
17948
Vehicle speed signal
Signal too high
sis Chap. 01-1
Inspecting exhaust gas recirculation Chap. 23-4
Fault Finding and Fitting Locations
Rep. Gr. 01
Test vehicle speed signal Chapter 23-6
Test CAN databus lines Chapter 23-6
Test dash panel insert Electrical System; Rep. Gr. 90
17954
Charge pressure control solenoid valve N75
Short circuit to
positive
17957
Charge pressure control solenoid valve N75
Open circuit or
short circuit to
earth
17958
Charge pressure
Control difference
Test charge pressure control solenoid valve - N75- with final control
17964
Charge pressure control
Regulating limit
not reached
Test charge pressure control 1.9 l/96 kW (TDI) Engine, Mechani-
17965
Charge pressure control
Regulating limit
exceeded
17977
Cruise control system
switch -E45
Implausible signal
Test charge pressure control solenoid valve -N75- with final control
cal Components; Rep. Gr. 21
Analyse measured value block, display groups 006 and 022

Chap. 01-4
Read out fault memory of the electrical system control unit

Electrical System; Rep. Gr. 90
Adapt diesel direct injection system control unit - J248- to electronic
17978
Engine control unit
blocked1)
immobiliser Electrical System; Rep. Gr. 96
18008
Voltage supply terminal 15
Voltage too low
18009
Voltage supply relay
terminal 30 -J3172)
Implausible signal
01-2 page 4
Test immobiliser Electrical System; Rep. Gr. 96

Test voltage supply for diesel direct injection system control unit
-J248- Chap. 23-5
Test diesel direct injection system relay -J322- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Self-diagnosis II
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01

Rectifying fault
18017
Crash disconnect activated
Read out fault memory of airbag control unit Body Fitting Work;
Rep. Gr. 01
Replace airbag control unit Body Fitting Work; Rep. Gr. 69

Code diesel direct injection system control unit -J248- Chap. 23-5
18020
Engine control unit
Incorrectly coded
18024
Glow period warning
lamp -K29
Short circuit to
positive
18025
Glow period warning
lamp -K29
Open circuit/
Short-circuit to
earth
18026
Short circuit to
positive
18027
Short circuit to
earth
18034
Data BUS drive
Missing message from gearbox CU
18039
Accelerator pedal position sender -G79
Signal too high
Test accelerator pedal position sender -G79- Chap. 01-4, display
18040
Accelerator pedal position sender -G79
Supply voltage
18043
Data BUS drive
Missing message from air

conditioning
system CU

Read out air conditioning system control unit fault memory
18044
Data BUS drive
Missing message from airbag CU

Read out fault memory of airbag CU Body Work; Rep. Gr. 01
18045
Data BUS drive
missing message form electron. CU

Read out fault memory of electrical system control unit Electrical
18047
Implausible sig1/2 for accelerator
nal
pedal position sender G79+G185
18048
Test glow period warning lamp -K29- with final control diagnosis
Chap. 01-1
Test glow plug relay -J52 - with final control diagnosis Chap. 01-1
group 002
Heating, Air conditioning; Rep. Gr. 87
System; Rep. Gr. 90

group 002

23-5
23-5
18056
Data BUS drive
defective
18057
Data BUS drive
Missing message from ABS

CU
18058
Data BUS drive
Missing message from combiinstrument

Read out fault memory of dash panel insert Electrical System;
18062
Read out fault memory
of combiinstrument
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Read out fault memory of engine CU Chapter 01-1
Read out fault memory of ABS control unit Running Gear;
Rep. Gr. 45
Rep. Gr. 90
Perform self-diagnosis of the dash panel insert Electrical System;

Rep. Gr. 90
Self-diagnosis II
01-2 page 5
01
Rectifying fault
18065
Air conditioning system inlet/outlet
Short circuit to
positive
Test AC compressor control with final control diagnosis Chap. 01-
18071
Actuation of unit injector solenoid valve
Short circuit to
positive
18072
Electrical fault in
the circuit
18073
Mechanical fault
Replace unit injector Chap. 23-2
18074
valve cyl. 1 -N240
Electrical fault in
the circuit
18075
valve cyl. 2 -N241
Electrical fault in
the circuit
18076
valve cyl. 3 -N242
Electrical fault in
the circuit
18090
Data BUS drive
implausible
message from
ABS CU

Read out fault memory of ABS control unit Running Gear;
Implausible
message from
electron. CU

Read out fault memory of electrical system control unit Electrical
Missing message from combiinstrument
18097
Data BUS drive
19456
Glow period warning
lamp -K29-
Rep. Gr. 45
System; Rep. Gr. 90
19458
Implausible sigKick-down switch -F8- nal
19459
Short circuit to
Low heat output relay - positive
J359
Test low heat output relay -J359 - with final control diagnosis
19461
-J360
Short circuit to
positive
Test high heat output relay -J360 - with final control diagnosis
19463
=> Sender -G40
No signal
group 002
Chap. 01-1
Chap. 01-1
01-2 page 6
Self-diagnosis II
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01

Rectifying fault
19464
=> Sender -G40
Signal outside
tolerance

Fitting Locations
19560
Short circuit to
positive
19561
Open circuit or
short circuit to
earth
1)
2)
Test intake manifold flap changeover valve -N239- with final control
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.
Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.
Edition 07.03
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Self-diagnosis II
01-2 page 7
01
01-2 page 8
Self-diagnosis II
Edition 07.03
S00.5326.00.20
01
01-3
Self-diagnosis III
Readiness code
Reading readiness code
Operation
The readiness codes are two 8-digit numerical codes
which indicate the status of the emission-relevant diagnoses.
If the diagnosis for a system was successfully performed
(e.g. exhaust gas recirculation system), the relevant position of the numerical code is set from 1 to 0.
This diagnosis is performed at regular intervals during
normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate
the readiness code as this guarantees that the systems
operate according to the specifications. If a fault is detected during diagnosis, it is then stored in the fault memory.
The readiness code is erased through deletion of the fault
memory, that is all relevant points will be set to 1.
Generation of readiness code refers to the activation of
the diagnostic functions such as diagnosis of fuel supply,
diagnosis of other systems etc.
Procedure
-V.A.G 1551/3, 3A, 3B oder 3C-
Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine electronics Chap.
01-1.
Select function 08 Read measured value block and

display group number 017.

00000000 00000110 10000000
Readout on display:
17
->
00000000
Meaning of 8-digit numerical block for readiness code in display field 2

1
8
0
1
1
0
0
0
0
0
Edition 04.04
S00.5326.01.20
Meaning
Ignore
Ignore
Ignore
Ignore
Ignore
Diagnosis of other systems
Diagnosis of fuel supply
Ignore
Self-diagnosis III
01-3 page 1
01
Meaning of 8-digit numerical block for readiness code in display field 4

1
8
0
0
0
0
0
Meaning
Ignore
Ignore
Ignore
Ignore
Ignore
Ignore
Ignore
Diagnosis of exhaust gas recirculation system
If the specified values are not reached, generate readiness code 01-3 page 2.
Press key.
Select function 06 End output and switch ignition off.
Generating readiness code

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
All electrical consumers, e.g. lights and rear window

heater switched off.
Intake air temperature must be below 60C display

group 007, display field 3.
Coolant temperature at least 83C display group

007, display block 4.
Procedure
Connect vehicle system tester -V.A.G 1552-. Select
address word 01 Engine electronics Chapter 011.

Note
Certain work steps must be carried out twice, in order to

achieve the readiness code.
Work step 1: Interrogating fault memory
Select function
0 2 Interrogate fault memory and
confirm with Q .
X faults detected
If a fault is stored in the memory:
01-3 page 2
Self-diagnosis III
Edition 04.04
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01
Rectify the faults by referring to the fault table

Chapter 01-2.
Press
Work step 2: Erasing fault memory
Select function
0 5 Erase fault memory and con-
firm with Q .
Note
Readiness code is erased each time the fault memory is
erased.
Vehicle system test
The fault memory is erased
Readout on display:
->
Note
If the ignition is switched off during Interrogating fault
memory and Erasing fault memory, the fault memory is
not erased.
Press
Work step 3: Switch off ignition
Wait at least 5 seconds with ignition OFF.

Note
This point is important, because with certain diagnoses
the slowing down of the control unit must be ended. Otherwise readiness code cannot be generated.
Work step 4: Switch on ignition
Wait at least 10 seconds with ignition ON.

Charge pressure sender is adapted to atmospheric pressure sender.
Work step 5: 1. Testing fuel supply and other

systems
Start engine.
Function
0 8 Read measured value block and then
select display group 001.
Increase engine speed for 5 seconds to 2500 rpm and

then run engine at idling speed.
Reading measured value block 1
2500 rpm
4.6 mg/s
2.0CA
Readout on display:
->
94.2 C
Work step 6: 1. Testing exhaust gas recirculation
Maintain speed constant between 1600 rpm to 1700

rpm for at least 10 seconds.
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Self-diagnosis III
01-3 page 3
01
Readout on display:
In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for
generation of readiness code for exhaust gas recirculation).

1650 rpm
4.1 mg/s
4.0CA
->
93.2 C

2500 rpm
4.6 mg/s
2.0CA
->
94.2 C

1650 rpm
4.1 mg/s
4.0CA
->
93.2 C
Work step 7: Switch off ignition
Wait at least 5 seconds with ignition OFF.

Work step 8: Switch on ignition
Wait at least 10 seconds with ignition ON.

Work step 9: 2. Testing fuel supply and other
systems
Start engine.
Function
0 8 Read measured value block and then

select display group 001.
Increase engine speed for 5 seconds to 2500 rpm and

then run engine at idling speed.
Readout on display:
Work step 10: 2. Test of exhaust gas recirculation
Maintain speed constant between 1600 rpm to 1700

rpm for at least 10 seconds.
Readout on display:
Press
C.
Select
0 1 7 for display group 017.

00000000 00000110 10000000
Readout on display:
17
->
00000000
Specification in display field 2: 00000110

Specification in display field 4: 00000000
Press .
If the specified values are not reached, once again repeat procedure for generating readiness code
01-3 page 2.
Work step 11: Interrogating fault memory
Select function
0 2 Interrogate fault memory and
confirm with Q .
X faults detected
If a fault is stored in the memory:
Rectify the faults by referring to the fault table
Chapter 01-2 and generate readiness code again

01-3 page 2.
01-3 page 4
Self-diagnosis III
Edition 04.04
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01

Press
Readiness code was successfully generated, if no fault is

stored after two work sequences of the test procedure in
the fault memory for the engine control unit and if the following values are displayed in the display group 017.
Edition 04.04
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00000000 00000110 10000000
Self-diagnosis III
17
->
00000000
01-3 page 5
01
01-3 page 6
Self-diagnosis III
Edition 04.04
S00.5326.01.20
01
01-4
Self-diagnosis IV

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Coolant temperature must be at least 80 C.

All electrical consumers, e.g. lights and rear window
heater, must be switched off.
If vehicle is equipped with air conditioning, this must

be switched off.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Select function 08 Read measured value block and

confirm the entry with key Q .
Enter display group 01-4 page 1.
Display groups 001 to 022, engine idling

Display group 001 in idle (engine warm, coolant temperature not below 80C)
Read measured value block 1
< Readout on display
xxx
rpm
xx.x
mg/s
x.xx
KW
xxx.x
C
< Display field

Coolant temperature
Fuel delivery duration (set value)

Injection rate
Idling speed
Specification
Analysis
80.0110.0 C
---
4...7 KW
---
3.09.0 mg/s
01-4 page 1
800970 rpm
---
Analysis: Display group 001, display field 2 - Injection rate

Display -V.A.G 1552below 3.0 mg/s
above 9.0 mg/s
Edition 04.04
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Rectifying fault
Check unit injector Chap. 23-3.

Warm up engine by running at high revs and repeat test.
Check unit injector Chap. 23-3.
Self-diagnosis IV
01-4 page 1
01
xxx
rpm
xxx.x
%
xxx
xxx.x
C
< Display field

Coolant temperature
Operating position
Accelerator pedal position
Idling speed
Specification
Analysis
80.0110.0 C
---
010
01-4 page 2
0.0 %
01-4 page 2
---
01-4 page 1
Analysis: Display group 002, display field 2 - Accelerator pedal position

Display -V.A.G 1552-
Rectifying fault
Test accelerator pedal position sender -G79- Current Flow Diagrams,
1100.0 %
Analysis: Display group 002, display field 3 - Operating position

Meaning, if display positions = 1
X
Operating position
Air conditioning switched on
Idling switch closed (accelerator pedal

not pressed)
Ignore
xxx
rpm
xxx
mg/s
xxx
mg/s
xxx
%
< Display field

On/off ratio (actuation) of
exhaust gas recirculation
valve
drawn in air mass (actual)

drawn in air mass (nominal)
Idling speed
01-4 page 2
Self-diagnosis IV
Specification
Analysis
3080 %
---
258...410 mg/s
01-4 page 3
278...390 mg/s
01-4 page 3
---
01-4 page 1
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01
Analysis: Display group 003, display field 2 - inducted air mass (set value)
Rectifying fault
above 390 mg/s
Analysis: Display group 003, display field 3 - inducted air mass (actual value)
Rectifying fault
below 258 mg/s

above 410 mg/s
Test exhaust gas recirculation Chap. 23-4.

Inspect intake system for leaks.
Engine idles for too long, briefly blip throttle.
Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
xxx
rpm
xx.x
b. TDC
xx.x
KW
xx.x
KW
< Display field
Specification
Analysis
Synchronizing angle
-3+3 KW
01-4 page 3
4.07.0 KW
---
39 b. TDC
01-4 page 3
---
01-4 page 1

Commencement of injection (set value)
Idling speed
Analysis: Display group 004, display field 2 - commencement of injection (set value)
Display -V.A.G 1552less than 3 BTDC
Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Analysis: Display group 004, display field 4 - Synchronizing angle

Display -V.A.G 1552above 3KW or under -3KW
Rectifying fault
Test camshaft position sensor -G40- Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations.
Inspect position of camshaft and rotor 1.4/55 TDI Engine - Mechanics;

Rep. Gr. 15
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Self-diagnosis IV
01-4 page 3
01

xxx
rpm
xx.x
mg/s
xx.x
b. (n.)
TDC
xxx.x
C
< Display field
Specification
Analysis
Coolant temperature
80110 C
---
---
915 mg/s
---
---
01-4 page 1
Synchronisation when starting

drawn in air mass when starting
Idling speed

xxx
km/h
xxx
xx.x
%
xxx
< Display field

Operating condition of the
cruise control system

Status of the brake and clutch pedal switch
Vehicle speed
Specification
Analysis
xxx
01-4 page 4
0%
01-4 page 2
000
01-4 page 4
0 km/h
---
Analysis: Display group 006, display field 2 Brake pedal or clutch pedal monitoring
X
Operating position
Brake light switch -F- closed (brake

pedal operated)
Brake pedal switch -F47- opened

(brake pedal operated)
Clutch pedal switch -F36- opened

(clutch pedal operated)
Analysis: Display group 006, display field 4 - Operating condition of cruise control system
Display
Operating position
Vehicles with activated cruise control system,

switch in position OFF
Vehicles with activated cruise control system,

switch in position ON
255
Vehicle without cruise control system or

cruise control system function in engine control unit not activated
01-4 page 4
Self-diagnosis IV
Edition 04.04
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01
Display group 007 with ignition switched on (engine cool and standing)

xxx.x
C
xxx
%
xxx.x
C
xxx.x
C
< Display field

Coolant temperature
Intake manifold temperature
Specification
Analysis
approx. ambient
temperature 1)
01-4 page 5
approx. ambient
temperature 1)
01-4 page 5
0%
---
approx. ambient
temperature 1)
01-4 page 5
Status of the fuel cooling

Fuel temperature
1)
It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intake
manifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant
sender.
Analysis: Display group 007, display field 1 - Fuel temperature

Display -V.A.G 155240.5 C
Rectifying fault
Inspecting Fuel temperature sender -G81- Chap. 23-1.
Analysis: Display group 007, display field 3 - Intake manifold temperature

Display -V.A.G 1552approx. 135.9 C
Rectifying fault
Inspecting Intake manifold temperature sender -G72- Chap. 23-1.
Analysis: Display group 007, display field 4 - Coolant temperature

Display -V.A.G 1552-5.4 C
Rectifying fault
Inspecting coolant temperature sender -G62- Chap. 23-1.

In the event of a fault the fuel temperature is displayed instead.
Edition 04.04
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Self-diagnosis IV
01-4 page 5
01

xxx
rpm
xxxx
mbar
xxxx
mbar
xxx
%
< Display field

Charge pressure (actual)

Atmospheric pressure
drawn in air mass (actual)
Specification
Analysis
0.0 %
01-4 page 2
900...1150 mbar
---
900...1100 mbar
---
258...410 mg/s
01-4 page 3

xxx
rpm
xxxx
mbar
xxxx
mbar
xx
%
< Display field

solenoid valve for charge
pressure control -N75-
Charge pressure (actual)

Charge pressure (nominal)
Idling speed
Specification
Analysis
2595 %
---
9001150 mbar
---
9001100 mbar
---
---
01-4 page 1

x.xx
mg/s
x.xx
mg/s
x.xx
mg/s
< Display field
Smooth running control - injected

quantity cylinder 3
Smooth running control - injected quantity cylinder 2
Smooth running control - injected quantity cylinder 1
Specification
Analysis
-3+3 mg/s
01-4 page 6
-3+3 mg/s
01-4 page 6
-3+3 mg/s
01-4 page 6
Analysis: Display group 013, display field 1

through 3 - Idle smoothness regulator
The injection system has an idle smoothness regula-
tor. It is possible to detect differences in performance

between individual cylinders (part tolerances, injector
01-4 page 6
Self-diagnosis IV
Edition 04.04
S00.5326.01.20
01

flow, compression etc.) and to compensate for these
by selectively metering the quantity injected in the
idling speed range.
Differences are detected in the idling speed range on
the basis of the signal supplied by the engine speed

sender which supplies three signals to the control unit
for each crankshaft revolution. If the signals have the
same rhythm, the cylinder have the same output. If a
cylinder has a lower output, the crankshaft will need
more time for the next half crankshaft rotation. As opposed to this a high output cylinder will accelerate the
crankshaft to such an extent that it will need less time.
Once the control unit has identified a deviation, the
relevant cylinder will immediately be supplied with a

greater or smaller injection rate until the engine again
runs smoothly.
+ mg/s: The relevant cylinder has less output and is
therefore supplied with more fuel.

- mg/s: The relevant cylinder has more output and
is therefore supplied with less fuel.
Display group 016 in idle


xxx %
xxxxxxxx
xx
xx.x V
< Display field
Specification
Analysis
Supply voltage of the engine control unit
13.514.5 V
01-4 page 8
xx
01-4 page 8
1x000001
01-4 page 7
595 %
---
Heating element control

Auxiliary heating
Generator capacity
Analysis: Display group 016, display field 2 - Auxiliary heating

X
1
1
1
1
1
1
1
Edition 04.04
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Additional heating deactivated, because:
Coolant temperature greater than 7080C or intake air temperature greater

than +5C
Generator defective
Battery voltage below 9 V
Engine speed less than 800 rpm
Engine start within the last 10 seconds
Coolant temperature sender -G62- or Intake manifold temperature sender
-G72- defective
Ignore
Ignore
Self-diagnosis IV
01-4 page 7
01
Analysis: Display group 016, display field 3 Control of the heating elements
X
1
Operating position
Low heat output relay -J359- on

High heat output relay -J360- on
Analysis: Display group 016, display field 4 - supply voltage of engine control unit
Rectifying fault
Test generator and battery voltage, charge battery Electrical System;
below 13.5 V
Rep. Gr. 27.
Increase engine speed slightly for a few minutes and switch off additional
consumers.
Test supply voltage of engine control unit Chap. 23-5.

Rectify any current drain.
Test voltage regulator, replace if necessary Electrical System;
above 14.5 V
Rep. Gr. 27.
Remove start aid cable or quick charger.
Display group 018 in idle


xx
xx
xx
xx
< Display field
Specification
Analysis
01-4 page 8
01-4 page 8
01-4 page 8
Ignore
Unit injector solenoid valve cyl. 3
Analysis: Display group 018, display field 1 through 3 - Display of the conditon of the unit injectors
Display -V.A.G 1552If number instead of zero
Rectifying fault
Test injector unit Chap. 23-3.

Inspecting fuel supply 1.4 ltr./55 TDI Engine, Mechanics; Rep. Gr. 20.
Display group 022, engine idling

01-4 page 8
Self-diagnosis IV
Edition 04.04
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01

x
xxxxxx
< Display fields
Specification
Analysis
Operating state of air conditioning

Operating state of charge pressure
control
Operating state of cruise control
0
xxxxxx
01-4 page 9
01-4 page 9
Operating condition of the cruise control system
Analysis: Display group 022, display field 1 - operating state of cruise control system
Operating condition of the cruise control system
0
Vehicle without CCS or CCS function in engine control unit not activated
Vehicles with activated CCS, switch in position OFF
Vehicles with activated CCS, switch in position ON
Analysis: Display group 022, display field 2 - operating state of cruise control system
Cruise control
Display field 2
Switch B on ON
000011
Switch B on RES
001011
Switch A operated
000111
Switch B to OFF before operating point
000001
Switch B to OFF locked
000000
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Self-diagnosis IV
01-4 page 9
01
Display groups 004 through 011 at full

load
Note
Accelerate vehicle at full throttle before inspecting.
The measured values must be read off or printed out
once an engine speed of 3000 rpm is reached (2nd

person required).
Pay attention to safety precautions for test drives
Chapter 23-1.
Display group 004 under full load (test drive in 3rd gear, coolant temperature not below 80C)

xxxx
rpm
xx.x
b. TDC
xx.x
KW
x.xx
KW
< Display field

Synchronizing angle

Commencement of injection (set value)
Engine speed
Specification
Analysis
---
---
1724 KW
---
15 BTDC25
BTDC
---
28003200 rpm
---
Display group 008 under full load (test drive in 3rd gear, coolant temperature not below 80C)

xxxx
rpm
xx.x
mg/s
xx.x
mg/s
xx.x
mg/s
< Display field

Injection rate limit based
on drawn in air mass
(smoke prevention)
Injection rate limit based on engine

speed (torque limit)
Injection rate (driver's instruction)
Engine speed
Specification
Analysis
45.055.0 mg/s
01-4 page 11
40.049.0 mg/s
01-4 page 11
60.069.0 mg/s
01-4 page 10
28003200 rpm
01-4 page 10
Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
Display -V.A.G 1552below 60.0 mg/s
Rectifying fault
Repeat test at full throttle.

Test accelerator pedal position sender -G79- Current Flow Diagrams,
01-4 page 10
Self-diagnosis IV
Edition 04.04
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01
Analysis: Display group 008, display field 3 - Injection rate limit over speed (torque limit)
Rectifying fault
Read off set value at 3000 rpm.
below 40.0 mg/s
Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
Rectifying fault
Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find-
below 45.0 mg/s
ing and Fitting Locations.
Test exhaust gas recirculation Chap. 23-4.
Display group 011 under full load (test drive in 3rd gear coolant temperature not below 80C)

xxxx
rpm
xxxx
mbar
xxxx
mbar
xxx
%
< Display field

solenoid valve for charge
pressure control -N75-
Charge pressure (actual value)

Charge pressure (specified value)
Engine speed
Specification
Analysis
4095 %
---
18002200
mbar
01-4 page 11
18002100
mbar
---
28003200 rpm
---
Analysis: Display group 011, display field 3 - intake manifold temperature (charge pressure)
Display -V.A.G 1552below 1800 mbar or over 2200
mbar
Edition 04.04
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Rectifying fault
Inspecting charge pressure control 1.4/55 TDI Engine, Mechanics;

Rep. Gr. 21.
Self-diagnosis IV
01-4 page 11
01
Display group 125 - CAN databus

Display group 125 with ignition switched on

ABS 1
Combi 1
Airbag 1

< Display field
Airbag control unit
Dash panel insert CU

ABS control unit
not assigned
Specification
Analysis
Airbag 1
01-4 page 12
Combi 1
01-4 page 12
ABS 1
01-4 page 12
---
---
Analysis: Display group 125, display field 2, 3 or 4

Display -V.A.G 15520
01-4 page 12
Rectifying fault
Test CAN databus Chap. 23-6.
Self-diagnosis IV
Edition 04.04
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23
23 Fuel Formation, Injection

23-1
Diesel Direct Injection

System
Safety measures
Observe the following points to prevent injury to persons
and/or damage to the injection and preheating system:
Disconnect and connect wires of the injection and pre-
heating system and measuring device wires when the

ignition is switched off.
When the battery is disconnected and reconnected,
carry out rework Electrical System; Rep. Gr. 27.
If test and measuring devices are required during 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 equipment is operated
from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of
an accident which involves the front passenger airbag
being deployed.
Rules of cleanliness
Pay careful attention to the following rules of cleanliness
when working on the fuel supply or fuel injection systems:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

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

any parts which have been stored unwrapped (e.g. in
tool boxes etc.).
When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately.

Replace immediately any hoses which have suffered
damage.
Edition 04.04
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Diesel Direct Injection System
23-1 page 1
23
Overview of fitting locations

Components A through H are not represented in the overview figure.
A - Diesel direct injection system
relay -J322T on relay carrier Fig. 2 in
23-1 page 3
B - Glow plug relay -J52T on relay carrier Fig. 2 in
23-1 page 3
C - Low heat output relay -J359T on relay carrier Fig. 2 in
23-1 page 3
D - High heat output relay -J360T on relay carrier Fig. 2 in
23-1 page 3
E - Fuel pump relay -J17T on relay carrier Fig. 2 in
23-1 page 3
F - Accelerator pedal position
sender -G79T in footwell on the accelerator
pedal Fig. 1 in 23-1
page 3
G - Brake light switch -F- and
Brake pedal switch -F47T in footwell on the brake pedal
Fig. 1 in 23-1 page 3
H - Clutch pedal switch -F36T in footwell on the clutch pedal Fig. 1 in 23-1 page 3
1 - Valve block
T Component parts of the
valve block are:
T change-over valve for intake
manifold flap -N239-, specified resistance: 25...45
T Exhaust gas recirculation valve -N18-, specified resistance: 14...20
T Charge pressure control solenoid valve -N75-, specified resistance: 25...45
2 - Mechanical exhaust gas recirculation valve
T at the induction pipe with the intake manifold flap
3 - Sender for the coolant temperature -G62T Specified resistance Fig. 3 in 23-1 page 4
4 - Air mass meter -G705 - Diesel direct injection system control unit -J2486 - Fuel temperature sender -G81T Specified resistance Fig. 4 in 23-1 page 4
7 - Plug connection
T 3-pin, grey
T for engine speed sender -G28T 3-pin, black
T for the camshaft position sensor -G408 - Engine speed sender -G28T specified resistance between contacts 1 and 2: 450...550
9 - Camshaft position sensor -G40-
23-1 page 2
Edition 04.04
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23

10 - Intake manifold pressure sender -G71- with intake manifold temperature sender - G72T Specified resistance Fig. 3 in 23-1 page 4
11 - Fuel filter
T repairing 1.4/55 TDI Engine, Mechanics; Rep. Gr. 20
Fig. 1:
Components in footwell
1 - Clutch pedal switch -F362 - Brake light switch -F- and Brake pedal switch -F473 - Accelerator pedal position sender -G79-
3
2
1
S24-0374
Fig. 2:
12345-
Relay carrier
Fuel pump relay -J17Diesel direct injection system relay -J322Glow plug relay -J52Low heat output relay -J359High heat output relay -J360-
1 2 3 4 5
S23-0139
Edition 04.04
S00.5326.01.20
23-1 page 3
23
Fig. 3:

Resistance of coolant temperature sender
-G62- and of intake manifold temperature
sender -G72-
The specification in field -A- applies to the temperature

range 0 to 50 C, specification in field -B- applies to the
temperature range 50 to 100C.
Read out examples:
The specification for a temperature of 30C is 1500 to
2000
375
Fig. 4:
Resistance of fuel temperature sender -G81-
The specification in field -A- applies to the temperature

range 0 to 65C, specification in field -B- applies to the
temperature range 65 to 100C.
Read out examples:
4270
660
Disassembling and assembling intake

manifold
The intake manifold flap closes for about 3 seconds after
switching off the engine and then opens again. This reduces the switch-off impact.
23-1 page 4
Edition 04.04
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23

1 - Intake manifold
2 - O-ring
T replace
3 - Induction pipe
T with mechanical exhaust gas
recirculation valve and intake
manifold flap
4 - Mechanical exhaust gas recirculation valve
5 - 10 Nm
6 - Bracket
7 - Vacuum setting element
T For intake manifold flap
8 - 25 Nm
9 - Connection pipe for exhaust
gas recirculation
T to exhaust manifold
10 - Gasket
T replace
Removing and installing air filter

Removing
Loosen spring strap clamp -1- on the air guide hose

and remove the hose from the air filter.
Disconnect ventilation hose -2- and the plug on the air

mass meter -3-.
Remove the air deflector -4- from the air filter.

Unscrew the fixing screw -5- from the air filter (tightening torque: 8 Nm).
Carefully remove air filter from the top.
1
2
3
Installing
Note
S23-0125
Pay attention to correct positioning of the stop buffer on

the bottom part of the air filter (front and rear side).
Installation is carried out in the reverse order.

Edition 04.04
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23-1 page 5
23
Disassembling and assembling the air filter

1 - Air guide hose
T to induction pipe at intake
manifold
T Check fitting position
2 - Spring strap clip
3 - 2 Nm
4 - Top part of air filter cover
5 - Filter insert
6 - Bottom part of the air filter
cover
7 - Air deflector
T to the lock carrier
8 - Air mass meter -G70-
23-1 page 6
Edition 04.04
S00.5326.01.20
23-2
23
Disassembling and assembling the unit injector
Summary of components
Note
Observe the rules for cleanliness Chapter 23-1.
Always replace heat-protection seals and O-rings.
Always replace screws tightened to turning angle.
1 - 20 Nm + torque a further 1/4

turn (90 )
T replace
2 - Valve-lever shaft
T with valve levers
T removing and installing
23-2 page 3
3 - Lock nut, 30 Nm
4 - Adjusting screw
T pay attention to different version
T replace when replacing the
unit injector and where wear
marks are visible
T Grease the contact surfaces
of the unit injector to ball pins
using grease -G 000 1005 - Ball pin
6 - Unit injector
T removing and installing
23-2 page 3
T Check ball pins for wear
marks and replace if necessary
T Grease the contact surface
to the adjusting screw using
grease -G 000 100T Valve resistance: Nominal
value approx. 0.5 when
measuring directly at the valve, when measuring via the 8-pin plug connection at the cylinder head 0.8 ... 1.0
7 - Top O-ring
T replace 23-2 page 2
8 - Centre O-ring
9 - Bottom O-ring
10 - Heat-protection seal
T replace
11 - Circlip
12 - Cylinder head
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23-2 page 1
23
13 - Clamping pad
14 - 12 Nm + torque a further 3/4 turn (270)
T replace
Removing and installing O-rings for unit

injector
Assembling sleeves -T10056-
Removing
Lever off the old O-rings from the slots of the unit injector with extreme care.
Make sure, above all, that the seating surfaces in the

slots of the O-rings are not damaged.
Installing
Note
Always use the assembly sleeves to install the O-
rings. Otherwise there is the danger of damaging the

O-rings.
Observe the correct allocation of the O-rings to the
channels: the ring thickness reduces in the direction of

the injection nozzle.
Avoid rolling the O-rings when sliding them on. The O-
rings must not be turned inwards on the slots of the

unitinjector.
Remove the heat-protection seal along with the circlip.

Clean the seating surfaces for the O-rings in the unit
injector with great care.
Insert the assembling sleeve -T10056/1- on the unit

injector up to the stop.
Carefully slide the top O-ring onto the assembling

sleeve and into the groove of the unit injector.
Remove assembly sleeve.

Carefully slide the middle O-ring onto the assembling

sleeve and in the groove of the unit injector.
23-2 page 2
Edition 04.04
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23

Carefully slide the lower O-ring onto the assembling

sleeve and in the groove of the unit injector.

Slide on a new heat-protection seal together with the
circlip.
Removing and installing the unit injector

Extractor -T10055 Universal dial gauge holder -MP 3-447 Dial gauge
Torque wrench
Note
On vehicles with WIV the adjusting screw -1- and the ball
pin -2- was changed On old engines with WIV, both variants can be combined.
Removing
Remove upper timing belt cover and cylinder head
cover 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15.
Rotate the crankshaft approx. in the TDC cylinder 1,

while doing so all valve levers must point upwards
evenly.
Release the counternuts of the adjusting screws -1and unscrew the adjusting screws until the relevant
valve lever rests against the tappet spring of the unit
injector.
Screw out fixing screws -2- for the valve-lever shaft

from the outside to the inside and remove the valvelever shaft.
Separate plug connection at the removed unit injector.

Support the opposite side of the connector with your
finger in order to avoid twisting the connector.
Screw out fixing screw -3- of the clamping pad and remove the pad in the direction towards the camshaft.
Note
When removing all unit injectors turn the engine so that
the outlet cam for cylinder 1 (the first one from the belt
pulley side) points with the tip upwards. All three clamping pads can be removed in this position.
Edition 04.04
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23-2 page 3
23
Insert the extractor -T10055- instead of the clamping

pad in the slot of the unit injector.
Remove the unit injector through movements of the

sleeve at the nut up to the stop in -direction of arrow-.
Note
Do not interchange the unit injectors, if necessary mark
the assignment to each cylinder.
Installing
Note
The associated adjusting screw in the valve-lever
should be replaced when a new unit injector is being

installed.
For any work procedure involving an adjustment of the
unit injector it is necessary to clean the adjusting

screw in the valve lever and also the ball pin of the unit
injector and to check them for traces of wear. If there
is any wear replace the ball pin and the adjusting
screw.
Grease the contact surfaces between the ball pin and
the adjusting screw using -G 000 100-.

New unit injectors are supplied with O-rings and heat-
protection seal.
Before installing again the original unit injector, O-
rings, heat-protection seal and circlip must be replaced.
Before installing the unit injector check the correct position of the three O-rings, heat-protection seal and
the circlip.
Note
The O-rings must not be twisted.
Oil the O-rings and place the unit injector with the
greatest of care into the cylinder head.
Slide the unit injector into the cylinder head seat up to

the stop by exerting a uniform pressure.
Place the clamping pad in the side slot of the unit injector.
Note
If the unit injector is not perpendicular to the clamping pad
the fixing screw may loosen and cause damage to the
unit injector or cylinder head.
Align the unit injector as follows:

Screw the clamping pad with the new fixing screw until
the unit injector can still easily be turned.
Set the unit injector at a right angle to the bearing shell

of the camshaft.
23-2 page 4
Edition 04.04
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23
Using a caliper gauge, check dimension -a- from the

outer side of the cylinder head to the cylinder surface
of the solenoid valve for the unit injector.
Removing and installing the unit injector with the old
solenoid valve nut
Cylinder
Dimension -a-
244.2 0.8 mm
156.2 0.8 mm
64.8 0.8 mm
Removing and installing the unit injector with the

new solenoid valve nut
Cylinder
Dimension -a-
245.0 0.8 mm
157.0 0.8 mm
65.6 0.8 mm
Adjust the unit injector as required, tighten the fixing

screw using a torque of 12 Nm and then turn through
a further 270 (3/4 of a turn). Tightening may occur in
successive stages.
Mount valve-lever shaft and tighten up the new fixing

screws as follows.
First tighten the inside screws and then the two outside screws by hand. In the same sequence tighten to
20 Nm and turn a further 90 (1/4 turn).
Place a dial gauge on the adjusting screw of the unit

injector.
Turn the crankshaft in the running direction of the engine until the roller of the valve lever is on the drive
cam tip.
Roller side -arrow A- is on the highest point.
Dial gauge -arrow B- is on the lowest point.
Edition 04.04
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23-2 page 5
23
Remove the dial gauge.

Turn the adjusting screw in the valve lever until one
feels a significant resistance (the unit injector is
against the stop).
Turn the adjusting screw in the opposite direction from

the stop by about 225 (5/8 turn)
Firmly hold the adjusting screw in this position and

tighten up the lock nut using a torque of 30 Nm.
Place connector onto the unit injector, install the cylinder head cover and insert the upper timing belt cover.
23-2 page 6
Edition 04.04
S00.5326.01.20
23
23-3
Testing components
Test wiring and components with Test

box -V.A.G 1598/31 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
Test diesel direct injection system relay

-J322The power supply of the injection system occurs via the
diesel direct injection system relay - J322-. The precondition for closing of the relay is a voltage supply via terminal
15 to the diesel direct injection system control unit -J248-.
This means that diesel direct injection system relay
-J322- receives ground (via the Diesel direct injection
system control unit -J248-), if the control unit -J248- receives a voltage supply via terminal 15.
Fitting location
The diesel direct injection system relay - J322- is located
on the relay carrier in the driver's footwell on the left, relay
base 12.

Hand multimeter (e.g. -V.A.G 1526 A-)
2
6
3
7
4
8
Adapter cable set (e.g. -V.A.G 1594 C-)

Test box -V.A.G 1598/31-
10
11
12
13
14
15
Test conditions
Battery voltage at least 11.5 volts

Fuses in fuse holder on battery are O.K.
S97-1373
Check for proper operation
Remove lower part of the dash panel insert on the

driver's side Body work; Rep. Gr. 70.
Switch on ignition.
Diesel direct injection system relay -J322 - must close.
Note
The clicking of the relay is hardly audible and can therefore best be felt.
If the relay does not close:
Test control

Connect test box -V.A.G 1598/31 - to wiring loom to
engine control unit 23-3 page 1.
Edition 07.03
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Testing components
23-3 page 1
23
Interconnect bush 18 and bush 4 of the test box using

an auxiliary line.
The relay must be closed.
If the relay is now closed but did not open during the functional test:
Replace diesel direct injection system control unit

- J248- Chapter 23-5.
If the relay does not close:
Pull diesel direct injection system relay -J322- out of

the relay carrier.
Connect handheld multimeter for voltage measurement to contact 2 and earth.
Specified value: approx. battery voltage

If the specified value is not reached:
Testing the wiring Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
S23-0101
If the specified value is reached:

Check the following wire for interruption or short-circuit to earth or positive:
Contact
Test box
- V.A.G 1598/31contact
18
2
9
If necessary eliminate wire interruption or short-circuit.

If wiring is o.k.:
Replace the diesel direct injection system relay

- J322-.
S23-0101
Testing unit injector valve

1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
23-3 page 2
Testing components
Edition 07.03
S00.5326.00.20
23
23-4
Testing exhaust gas recirculation
Connect vacuum hoses at valve block

1234567-
Connection air filter/exhaust turbocharger

to vacuum reservoir at exhaust turbocharger
To turbocharger
To intake manifold flap
To air filter
from non-return valve for brake servo unit
to mechanical exhaust gas recirculation valve

Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test sequence
The exhaust gas recirculation function is checked in function 04 (basic setting). As a result of this procedure the
exhaust gas recirculation valve is pulsed every 10 seconds, so that the extreme values for the exhaust gas recirculation (air mass meter) can be read off in measured
value block 003 in display field 3.
Chapter 01-1.
Enter function 04 basic setting and select display

group number 003.
Note
After selecting display group number 003 and confirming
with Q , the idling speed is increased by the engine control unit in display field 1 to 13801420 rpm.
The display in display field 2 must switch between
EGRn.active and EGR.active every 10 seconds.
System in basic setting 3

1400 rpm EGRn.active
500 mg/s
->
20
The following readouts must fluctuate in display fields 3

and 4:
Note
If a constant value of 539 mg/stroke and higher is shown
in display field 3, test the air mass meter Chapter 23-3.
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23-4 page 1
23
EGRn.active:
Specification in display field 3: 450600 mg/H
specified value in display field 4: 1822 %
EGRactive.
Specification in display field 3: 160310 mg/H
specified value in display field 4: 6367 %
If the specified values are not reached:
Inspecting mechanical exhaust gas recirculation valve

1.4/55 TDI Engine, Mechanics; Rep. Gr. 26.
Inspect the connection diagram for the vacuum hoses

23-4 page 1.
Test exhaust gas recirculation valve -N18- with final

control diagnosis Chap. 01-1.
23-4 page 2
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23
23-5
Engine control unit
Testing voltage supply for engine control unit

Replacing diesel direct injection system

control unit -J248Special tools, test and measuring equipment and
Procedure
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics Chap. 01-1.
The vehicle system tester -V.A.G 1552- displays the control unit identification, e. g.:
045906019BM 1.4l R3
Coding 00008
EDC G000SG 4958 ->

WSC XXXXX
Note Part No. of control unit and coding.

Remove air filter Chap. 23-1.
Release the connector catches and unplug the connectors of the diesel direct injection control unit
- J248-.
Press off the clips -arrows- to the outside and remove

the control unit to the side.
Insert new engine control unit.

After installing the diesel direct injection system control
unit -J248-, it is then necessary to carry out the following
steps:
Coding new diesel direct injection system control unit

-J248- 23-5 page 2.
Adapt the new diesel direct injection system control
unit -J248- to the immobiliser control unit Electrical

System; Rep. Gr. 96.
For vehicles with cruise control system:
S24-0373
Activate CCS function 23-5 page 3.

Interrogate fault memory of new engine control unit,
rectify any faults present and erase fault memory
Chap. 01-1.
Each time the fault memory is erased, it is then necessary to re-generate the readiness code Chapter 013.
Perform a test drive.
Edition 04.04
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Engine control unit
23-5 page 1
23
Note
Comply with the applicable safety instructions during the
test drive Chap. 23-1.
Once again interrogate the fault memory of the diesel

direct injection system control unit -J248-.
Coding diesel direct injection system

control unit -J248If the code displayed does not match the vehicle or if the
diesel direct injection system control unit -J248- has been
replaced, it is then necessary to code the control unit as
follows.
Procedure

Select function 07 coding control unit.

Coding control unit
Enter code number
xxxxx (0 -32767)
Readout on display:
Enter code number by referring to table of codes and

confirm with Q .
Table of codes:
Control unit identification
Equipment
Code number
045 906 019 BM
ABS/Air conditioning/ WIV/ Airbags
00002
ABS/ WIV/ Airbags
00005
Air conditioning/ WIV/ Airbags
00008
WIV/ Airbags
00011
ABS/Air conditioning/ WIV
00014
ABS/ WIV
00017
Air conditioning/ WIV
00020
WIV
00023
ABS/ Air conditioning/ Airbags
00102
ABS/ Airbags
00105
Air conditioning/ Airbags
00108
Airbags
00111
ABS/ Air conditioning
00114
ABS
00117
Air Conditioning
00120
without ABS/ without Air conditioning/ without WIV/

without Airbags
00123
23-5 page 2
Engine control unit
Edition 04.04
S00.5326.01.20
23

The vehicle system tester -V.A.G 1552- displays the control unit identification, e. g.:

Switch ignition off and on again.
045906019BM 1.4l R3
Coding 00005
EDC G000SG 4958 ->

WSC XXXXX
045906019BM 1.4l R3
Coding 00008
EDC G000SG 4958 ->

WSC XXXXX
045906019BM 1.4l R3
Coding 00008
EDC
Q.
Note
The entered coding is activated by switching the ignition
on and off again.
Activating and deactivating cruise control system (CCS)

-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
No fault in fault memory, interrogating fault memory

Chap. 01-1
Procedure

Readout on display, e.g.:
If G000SG is displayed, the cruise control system is active.
Readout on display:
000SG 4958 ->

WSC XXXXX
If 000SG is displayed, the cruise control system is not

active.
Press .
Select function 11 login procedure.
Login procedure
Enter code number
Readout on display:
XXXXX
Enter code number as stated in the table.

Code number
Cruise control system (CCS)
11463
Activate CCS
16167
Deactivate CCS
Confirm with
Q.
Q.
After activating the cruise control system perform a test

drive as a functional test.
Edition 04.04
S00.5326.01.20
Engine control unit
23-5 page 3
23
23-5 page 4
Engine control unit
Edition 04.04
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23-6
23
Testing auxiliary signals
Edition 07.03
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23-6 page 1
23
23-6 page 2
Edition 07.03
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28
28 Glow Plug System

28-1
Testing preheating system
Edition 07.03
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28-1 page 1
28
28-1 page 2
Edition 07.03
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Service

1.4/55 TDI Engine, Fuel Injection

Service Department. Technical Information

Printed in Czech Republic

Printed in Czech Republic

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

List of Supplements to Workshop Manual

Modifications in Rep. Gr. 01 a 23

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

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

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

- Interrogating and erasing fault memory ............................................................ 01-1

- Actuator diagnosis ..................................................................................... 01-1

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

- Fault codes 515 to 19561 ............................................................................ 01-2

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

- Readiness code ........................................................................................ 01-3

- Reading readiness code .............................................................................. 01-3

- Generating readiness code .......................................................................... 01-3

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

- Reading measured value block ..................................................................... 01-4

- Display groups 001 to 022, engine idling .......................................................... 01-4

- Display groups 004 through 011 at full load ....................................................... 01-4

- Display group 125 - CAN databus .................................................................. 01-4

23 Fuel Formation, Injection

- Safety measures ....................................................................................... 23-1

- Rules of cleanliness ................................................................................... 23-1

- Overview of fitting locations .......................................................................... 23-1

- Disassembling and assembling intake manifold .................................................. 23-1

- Removing and installing air filter .................................................................... 23-1

- Disassembling and assembling the air filter ....................................................... 23-1

Disassembling and assembling the unit injector ............................................... 23-2

- Summary of components ............................................................................. 23-2

- Removing and installing O-rings for unit injector ................................................. 23-2

- Removing and installing the unit injector .......................................................... 23-2

Testing components ................................................................................... 23-3

- Test diesel direct injection system relay -J322- .................................................. 23-3

- Testing unit injector valve ............................................................................ 23-3

Testing exhaust gas recirculation .................................................................. 23-4

- Connect vacuum hoses at valve block ............................................................. 23-4

- Testing exhaust gas recirculation ................................................................... 23-4

Engine control unit ..................................................................................... 23-5

- Testing voltage supply for engine control unit .................................................... 23-5

- Activating and deactivating cruise control system (CCS) ....................................... 23-5

Testing auxiliary signals .............................................................................. 23-6

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

28 Glow Plug System

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Properties of the self-diagnosis

Technical data of self-diagnosis

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Engine not running,

Interrogating control unit

Interrogating fault memory

Erasing fault memory

Coding control unit

Reading measured value block

Connecting vehicle system tester

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

Battery voltage at least 11.5 volts

Connect vehicle system tester -V.A.G 1552- with appropriate cable.