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Service 5
Service Department. Technical Information Printed in Czech RepublicS00.5310.00.20
Workshop ManualFABIA 2000
2.0/85 Engine, Fuel InjectionEdition 03.01Engine code AZL
Service5
The Workshop Manual is intended only for use within the Organisation Škoda.It is not permitted to pass it on to other persons.
© ŠKODA AUTO a. s.
Printed in Czech RepublicS00.5310.00.20
FABIA 2000 2.0/85 Engine, Fuel Injection
List of SupplementsEdition 11.04S00.5310.01.20
List of Supplements to Workshop Manual
FABIA 2000
2.0/85 Engine, Fuel InjectionEdition 03.01
Supple-ment Edition Subject Article Number
03.01 Basic Edition S00.5310.00.20
1 11.04 S00.5310.01.20
FABIA 2000 2.0/85 Engine, Fuel Injection
List of Supplements Edition 11.04S00.5310.01.20
FABIA 2000 2.0/85 Engine, Fuel Injection
Table of ContentsEdition 11.04S00.5310.01.20
I
Table of Contents
01 – Self-diagnosisSelf-diagnosis I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Properties of the self-diagnosis ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Technical data of self-diagnosis ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Meaning of the exhaust gas warning light -K83- . ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting vehicle system tester -V.A.G 1552- and selecting engine electronics control unit ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Interrogating and erasing fault memory of engine control unit ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Automatic test sequence ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Performing actuator diagnosis ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Readiness code ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reading Readiness Code ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Generating readiness code ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fault table, fault codes 16485...17606 ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis IV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fault table, fault codes 17621...18104 ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reading measured value block ...... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reading measured value blocks, display groups 001 to 029 ........ . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reading measured value block, display groups 030 to 062 .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-diagnosis VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Reading measured value blocks, display groups 66 to 126 .. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 – Fuel Formation, InjectionRepairing the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General notes on the injection system ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Overview of fitting location ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing and installing parts of the injection system ......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembling and assembling bottom part of intake manifold ....... . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembling and assembling the air filter ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Safety measures ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rules of cleanliness ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing throttle valve control unit -J338- ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing accelerator pedal position sender ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing injection valves ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Test fuel pressure regulator and holding pressure ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing functions II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing lambda probe -G39- and lambda control upstream of catalytic converter ..... .. . . .
- Testing lambda probe ageing upstream of catalytic converter -G39- ...... . . . . . . . . . . . . . . . . . . .
- Testing lambda probe -G130- and lambda control downstream of catalytic converter .....
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01-1 page 1
01-1 page 1
01-1 page 1
01-1 page 3
01-1 page 4
01-1 page 5
01-1 page 5
01-1 page 6
01-2 page 1
01-2 page 1
01-2 page 1
01-2 page 2
01-3 page 1
01-3 page 1
01-4 page 1
01-4 page 1
01-5 page 1
01-5 page 1
01-5 page 2
01-6 page 1
01-6 page 1
01-7 page 1
01-7 page 1
24-1 page 1
24-1 page 1
24-1 page 2
24-1 page 3
24-1 page 5
24-1 page 6
24-1 page 7
24-1 page 7
24-2 page 1
24-2 page 1
24-2 page 2
24-2 page 3
24-2 page 4
24-3 page 1
24-3 page 1
24-3 page 2
24-3 page 3
24-4 page 1
FABIA 2000 2.0/85 Engine, Fuel Injection
Table of Contents Edition 11.04S00.5310.01.20
II
- Wiring and Component Test with Test Box V.A.G. 1598/31 ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing voltage supply for engine control unit ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Procedure after voltage supply has been interrupted ... ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing engine control unit .. ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Coding engine control unit ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Adjusting the engine control unit to the throttle valve control unit ... .. . . . . . . . . . . . . . . . . . . . . . . . .
Testing auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing the speed signal ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Test data bus ..... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Activating and deactivating cruise control system (CCS) ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 – Ignition SystemRepairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General notes on the ignition system ....... .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Safety measures ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing and installing parts of the ignition system ... ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Testing camshaft position sensor -G163- .. ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24-4 page 124-4 page 1
24-4 page 2
24-4 page 3
24-4 page 4
24-4 page 5
24-5 page 1
24-5 page 1
24-5 page 1
24-5 page 2
28-1 page 1
28-1 page 1
28-1 page 1
28-1 page 2
28-1 page 3
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IEdition 11.04S00.5310.01.20
01-1 page 1
01
01-1 Self-diagnosis I
Properties of the self-diagnosis
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.
♦ 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.
01 – Self-diagnosis
Note
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis I Edition 11.04S00.5310.01.20
01-1 page 2
01
Equipment
Functions available when using the vehicle sys-tem tester -V.A.G 1552-
The preconditions for selecting the desired functions are given in the following table.
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)
1) Independent of the voltage supply.
Memory for initialisation values Volatile memory2)
2) The values are erased if the voltage supply is interrupted.
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
Note
Operation Precondition
Function on the vehicle system tester -V.A.G 1552-
Engine not run-ning, ignition switched on
Engine idling Normal driving
01 Interrogating control unit version yes yes yes
02 Interrogating fault memory yes1)
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).
yes yes
03 Actuator diagnosis yes no no
04 Basic setting2)
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.
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
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IEdition 11.04S00.5310.01.20
01-1 page 3
01
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:
♦ 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 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.
♦ 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.
S01-0091
CHECK
CHECKNote
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis I Edition 11.04S00.5310.01.20
01-1 page 4
01
Connecting vehicle system tester -V.A.G 1552- and selecting engine elec-tronics control unit
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
• The fuses must be in proper order.
• Battery voltage must be at least 11.5 volts.
• Assembly earth connections o.k.
Procedure
– Fold back trim panel -1-.
– Connect vehicle system tester -V.A.G 1552-.
– Enter address word 01 „Engine electronics“.
– Switch on ignition.
The control unit identification number and the coding are shown on the vehicle system tester display, e.g.:
♦ 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
♦ 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
S01-0094
12345
6789
10
111213141516
171819202122
2324252627282930
3132333435363738
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
1552V.A.G.HELPQOC
987
654
321
06A906032CC 2.0l R4/2V G 3658 ->Coding 00071 WSC XXXXX
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IEdition 11.04S00.5310.01.20
01-1 page 5
01
♦ 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“.
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.
– Select function 05 „Erase fault memory“.
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:
X faults detected
→
Vehicle system test HELPThe fault memory is erased
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis I Edition 11.04S00.5310.01.20
01-1 page 6
01
– 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“.
If no fault is stored:
– Select function 06 „End output“ and switch ignition off.
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-
4. Injector cyl. 3 -N32-
5. Injector cyl. 4 -N33-
6. Injector cyl. 2 -N31-
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-
♦ 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
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IEdition 11.04S00.5310.01.20
01-1 page 7
01
Test conditions
• The fuses must be in proper order.
• Battery voltage must be at least 11.5 volts.
• All electrical consumers, e.g. lights and rear window heater, must be switched off.
♦ The actuator diagnosis can only be carried out when the engine is not running and the ignition is switched on.
♦ The final control diagnosis is aborted when the engine is started or when a moment of momentum is detect-ed.
♦ 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.
– Select function 03 „final control diagnosis“.
Activate solenoid valve 1 for activated charcoal filter system -N80-:
– Press key.
Readout on display:
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.
S01-0094
12345
6789
10
111213141516
171819202122
2324252627282930
3132333435363738
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
Note
→
Vehicle system test Q03 - Actuator diagnosis
→
Actuator diagnosis ->Tank vent valve -N80
→
→
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis I Edition 11.04S00.5310.01.20
01-1 page 8
01
Readout on display:
The secondary air pump relay must continue clicking until 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:
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.
– Test cables for open circuit, short circuit to earth and to positive ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Select function 06 „End output“ and switch ignition off.
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.
Actuator diagnosis ->Secondary air pump relay -J299
→
→Actuator diagnosis ->Injector cylinder 1 -N30
→
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIEdition 11.04S00.5310.01.20
01-2 page 1
01
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.
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- and enter address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 15 „Readiness code“.
If all diagnoses were performed successfully, the display must indicate the following:
– Select function 06 „End output“ and switch ignition off.
If the following readout appears in the display:
– Press key.
– Generate readiness code ⇒ 01-2 page 2.
Readiness code →00000000 - Test complete 01101101
Readiness code →01101101 - Test not complete 01101101
→
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis II Edition 11.04S00.5310.01.20
01-2 page 2
01
Meaning of the 8-digit numerical block of the readiness code
Generating readiness code
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
• 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
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine elec-tronics“ ⇒ Chap. 01-1.
Work step 1: Interrogating fault memory
– Select function 02 „Interrogate fault memory“.
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.
If no fault is stored:
– Press key.
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“)
X faults detected
→
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIEdition 11.04S00.5310.01.20
01-2 page 3
01
Work step 2: Erasing fault memory
– Select function 05 „Erase fault memory“.
♦ 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
– Select function 04 „Initiate basic setting“ and display 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
– Start engine and run in idle.
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 changes from „Test OFF“ to „Test ON“.
– Leave engine idling until the following readout ap-pears in display field 4: „Syst. o.k.“.
If the specified values are not reached:
– Interrogate fault memory ⇒ Chapter 01-1.
If the specified values are reached:
– Press key.
Work step 5: Diagnosis of activated charcoal filter system (tank vent system)
– Enter display group 070.
After initiating diagnosis the message in display field 4 changes from „Test OFF“ to „Test ON“.
– Leave engine running at idling speed until „TVV o.k.“ is displayed in display field 4.
Vehicle system test ->The fault memory is erased
Note
→
System in basic setting 60 ->xx % xx % 8 ADP runs
→
Note
System in basic setting 77 ->xxx/min xx.x g/s xx.x % Test ON
C
System in basic setting 70 → 29% 65% 342% Test ON
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis II Edition 11.04S00.5310.01.20
01-2 page 4
01
If the specified values are not reached:
– Blip throttle about 3 times and repeat the process.
– Interrogate fault memory ⇒ Chapter 01-1.
If the specified values are reached:
– 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:
– Maintain engine speed at 2800...3200 rpm until the catalytic converter temperature in display field 2 is more than 352 °C.
This may take a few mlnutes.
– Press key.
– Enter display group 030.
– Check operating state of lambda control upstream of catalytic converter (display field 1):
Specified value: 111
– Check operating state of lambda control downstream of catalytic converter (display field 2):
Specified value: 110
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:
If the specified values are not reached:
→
Reading measured value block 34 ->3000 rpm 352 °C xx.xx Text
Note
C
Reading measured value block 30 ->111 110
Note
Meaning, if display positions = 1
1 2 3
1 Lambda control active (partial load)
1 Lambda probe operational
1 Lambda probe heater switched on
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIEdition 11.04S00.5310.01.20
01-2 page 5
01
– Interrogate fault memory ⇒ Chapter 01-1.
If the specified values are reached:
– 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 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.“
If the specified values are not reached:
– Interrogate fault memory ⇒ Chapter 01-1.
If the specified values are reached:
– Press key.
Work step 8: Catalyst diagnosis
This diagnosis is only successfully completed if no faults relating to the lambda probe or the activated charcoal fil-ter system exist.
– Enter display group 046.
– Depress brake pedal and accelerator simultaneously.
– Engine speed is increased and the readout in display field 4 switches from „Test OFF“ to „Test ON“.
Catalytic converter temperature in display field 2 must be at least 352 °C.
– Continue running engine until „Cat B1 o.k.“ is dis-played.
It may also take a few minutes until the readout is changed from „Test ON“ to „Cat B1 o.k.“
If the specified values are not reached:
– Interrogate fault memory ⇒ Chapter 01-1.
If the specified values are reached:
– Press key.
Work step 9: Reading Readiness Code
→
System in basic setting 34 ->1600 rpm 352 °C 1.99 Test OFF
C
Note
System in basic setting 46 →2300 rpm 328.0°C 0.00 Test OFF
Note
→
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis II Edition 11.04S00.5310.01.20
01-2 page 6
01
– Read out readiness code ⇒ 01-2 page 1.
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIIEdition 11.04S00.5310.01.20
01-3 page 1
01
01-3 Self-diagnosis III
Fault table, fault codes 16485...17606
♦ 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.
♦ 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
Note
Note
Readout on -V.A.G 1552-
Rectifying fault
16485 Air mass meter -G70-
Implausible signal
– Read measured value block, display group 005 ⇒ Chapter 01-5
– Check wiring to meter -G70- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
16486 Air mass meter -G70-
Signal too low – Read measured value block, display group 005 ⇒ Chapter 01-5
– Testing the intake system for tightness (unmetered air)
– Replace air filter element
– Check wiring to meter -G70- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
16487 Air mass meter -G70-
Signal too high
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis III Edition 11.04S00.5310.01.20
01-3 page 2
01
16496 Intake air temperature sender -G42-
Signal too low – Read measured value block, display group 004 ⇒ Chap. 01-5
– Test resistance of intake air temperature sender -G42 - ⇒ Chap. 24-1
16497 Intake air temperature sender -G42-
Signal too high
16500 Sender for the coolant temperature -G62-
Implausible signal
– Read measured value block, display group 004 ⇒ Chap. 01-5
– Test resistance of coolant temperature sender -G42 - ⇒ Chap. 24-1
– Test coolant thermostat ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 19
16501 Sender for the coolant temperature -G62-
Signal too low
16502 Sender for the coolant temperature -G62-
Signal too high
16505 Throttle valve potenti-ometer -G69-
Implausible signal
– Test throttle valve control unit ⇒ Chapter 24-2
16506 Throttle valve potenti-ometer -G69-
Signal too low
16507 Throttle valve potenti-ometer -G69-
Signal too high
16514 Bank 1 - probe 1
Electrical fault in the circuit
– Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chapter 24-3
16516 Bank 1 - probe 1
Voltage too high
16517 Bank 1 - probe 1
Signal too slow
16518 Bank 1 - probe 1
No activity
16519 Bank 1 - probe 1, heat-ing circuit
Electrical fault
16520 Bank 1 - probe 2
Electrical fault in the circuit
– Test lambda probe -G130- and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
16521 Bank 1 - probe 2
Voltage too low
16522 Bank 1 - probe 2
Voltage too high
16523 Bank 1 - probe 2
Signal too slow
16524 Bank 1 - probe 2
No activity
16525 Bank 1 - probe 2, heat-ing circuit
Electrical fault
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIIEdition 11.04S00.5310.01.20
01-3 page 3
01
16554 Bank 1, fuel metering system
Malfunction – Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– 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 system for leaks ⇒ 2.0/85 kW Engine, Mechan-ical Components; Rep. Gr. 26
– Inspect vacuum lines for leaks
– Inspect intake system for leaks
16555 Bank 1, fuel metering system
System too lean
16556 Bank 1, fuel metering system
System too rich
– Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Test injection valves ⇒ Chapter 24-2
– Test solenoid valve for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
16585 Injector cyl. 1 -N30-
Electrical fault in the circuit
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
16586 Injector cyl. 2 -N31-
Electrical fault in the circuit
16587 Injector cyl. 3 -N32-
Electrical fault in the circuit
16588 Injector cyl. 4 -N33-
Electrical fault in the circuit
16603 Maximum en-gine speed exceeded
– Rectify any mechanical damage
16605 Angle sender 2 for TV drive -G188-
Implausible signal
– Read measured value block, display group 062 ⇒ Chapter 01-6
– Test throttle valve control unit ⇒ Chapter 24-2
16606 Angle sender 2 for TV drive -G188-
Signal too low
16607 Angle sender 2 for TV drive -G188-
Signal too high
16610 Angle sender for 1/2 accelerator pedal posi-tion -G79- + -G185-
Implausible signal
– Read measured value block, display group 062 ⇒ Chapter 01-6
– Test accelerator pedal position sender ⇒ Chapter 24-2
16611 Sender for accelerator pedal position -G79-
Signal too low
16612 Sender for accelerator pedal position -G79-
Signal too high
16614 Fuel pump relay -J17-
Electrical fault in the circuit
– Test fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis III Edition 11.04S00.5310.01.20
01-3 page 4
01
16645 Injector cyl. 1 -N30-
Short circuit to earth
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
16646 Injector cyl. 1 -N30-
Short circuit to positive
16648 Injector cyl. 2 -N31-
Short circuit to earth
16649 Injector cyl. 2 -N31-
Short circuit to positive
16651 Injector cyl. 3 -N32-
Short circuit to earth
16652 Injector cyl. 3 -N32-
Short circuit to positive
16654 Injector cyl. 4 -N33-
Short circuit to earth
16655 Injector cyl. 4 -N33-
Short circuit to positive
16684 Combustion misfiring de-tected
– Test combustion misfiring, display group 014, 015, 016 ⇒ Chap. 01-5
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
– Test ignition leads and spark plugs ⇒ Chapter 28-1
– Inspect ignition transformer ⇒ Chapter 28-1
16685 Cyl. 1
Combustion misfiring de-tected
– Test combustion misfiring, display group 015 ⇒ Chap. 01-5
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
– Test ignition leads and spark plugs ⇒ Chapter 28-1
– Inspect ignition transformer ⇒ Chapter 28-1
16686 Cyl. 2
Combustion misfiring de-tected
16687 Cyl. 3
Combustion misfiring de-tected
16688 Cyl. 4
Combustion misfiring de-tected
– Test combustion misfiring, display group 016 ⇒ Chap. 01-5
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
– Test ignition leads and spark plugs ⇒ Chapter 28-1
– Inspect ignition transformer ⇒ Chapter 28-1
16705 Engine speed sender -G28-
Implausible signal
– Test resistance of engine speed sender -G28- ⇒ Chap. 24-1
16706 Engine speed sender -G28-
No signal
16708 Knock control
Malfunction – Read measured value block, display group 026 ⇒ Chap. 01-5
16711 Knock sensor 1 -G61-
Signal too low
16712 Knock sensor 1 -G61-
Signal too high
16716 Knock sensor 2 -G66-
Signal too low
16717 Knock sensor 2 -G66-
Signal too high
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIIEdition 11.04S00.5310.01.20
01-3 page 5
01
16724 Camshaft position/crankshaft position sen-sor
Incorrect as-signment
– Test camshaft position sensor -G163- ⇒ Chapter 28-1
16725 Camshaft position sen-sor ⇒ sender -G40 -
Implausible signal
16726 Camshaft position sen-sor ⇒ sender -G40 -
Signal too low
16727 Camshaft position sen-sor ⇒ sender -G40 -
Signal too high
16735 Ignition control cyl. 1
Malfunction – Test ignition leads and spark plugs ⇒ Chapter 28-1
– Inspect ignition transformer ⇒ Chapter 28-1
– Read measured value block, display group 014 ⇒ Chapter 01-516736 Ignition control cyl. 2
Malfunction
16737 Ignition control cyl. 3
Malfunction
16738 Ignition control cyl. 4
Malfunction
16795 Secondary air system
Flow rate in-correct
– Read measured value block, display group 077 ⇒ Chap. 01-7
– 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 Secondary air pump re-lay -J299-
Malfunction – Test the relay or the secondary air pump ⇒ Chapter 01-1, final control diagnosis
16804 Bank 1, catalytic con-verter system
Efficiency too low
– Generate readiness code ⇒ Chapter 01-2
– Check emission levels if the same faults are displayed ⇒ Inspection and Maintenance; Rep. Gr. 02
16806 Bank 1, main catalytic converter
Efficiency too low
16824 Tank ventilation system
Malfunction – Test solenoid valve for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
– Inspect hoses and connection pipes from fuel tank up to injection rail ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
16825 Tank ventilation system
Flow rate in-correct
16885 Vehicle speed signal
Implausible signal
– Test vehicle speed signal ⇒ Chapter 24-5
16890 Idling control
Speed under nominal value
– Test throttle valve control unit ⇒ Chapter 24-2
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
– Inspect intake system for leaks16891 Idling control
Speed above nominal value
16894 Idling speed switch -F60-
Malfunction – Test throttle valve control unit ⇒ Chapter 24-2
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis III Edition 11.04S00.5310.01.20
01-3 page 6
01
16897 Immobilizer
incorrect code number
– Adapt engine control unit to electronic immobiliser ⇒ Electrical Sys-tem; Rep. Gr. 96.
16944 Voltage supply
Implausible signal
– Inspect engine control unit power supply ⇒ Chapter 24-4
– Test battery and alternator ⇒ Electrical System; Rep. Gr. 27
– procedure if voltage interrupted ⇒ Chapter 24-416946 Voltage supply
Voltage too low
16947 Voltage supply
Voltage too high
16952 CCS switch -E45-
Implausible signal
– Test cruise control system (CCS), display group 066 ⇒ Chap. 01-7
16955 Brake light switch -F-
Implausible signal
– Read measured value block, display group 066 ⇒ Chapter 01-7
16984 Databus drive
missing mes-sage
– Read measured value block, display group 125 ⇒ Chap. 01-7
– Inspect databus ⇒ Chapter 24-5
– Perform automatic test sequence ⇒ Chapter 01-1
16985 Control unit defective
– Replace engine control unit -J220- ⇒ Chapter 24-4
16986 Control unit program-ming
Malfunction – Check parts of the engine control unit and the gearbox control unit and replace the control unit if necessary
16988 Control unit defective
– Replace engine control unit -J220- ⇒ Chapter 24-4
16989 Control unit defective
16990 Control unit defective
17022 Throttle valve control unit -J338-
Implausible signal
– Test throttle valve control unit ⇒ Chapter 24-2
17026 Knock control
Control unit defective
– Replace engine control unit ⇒ Chapter 24-4
17069 Main relay ⇒ -J271-
Open circuit – Test the power supply relay -J271- for the engine control unit ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Loca-tions17070
Main relay ⇒ -J271-Short circuit to earth
17071 Main relay ⇒ -J271-
Short circuit to positive
17510 Bank 1 - probe 1, heat-ing circuit
Short circuit to positive
– Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chapter 24-3
17511 Bank 1 - probe 1, heat-ing circuit
Output too small
17513 Bank 1 - probe 2, heat-ing circuit
Short circuit to positive
– Test lambda probe -G130- and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIIEdition 11.04S00.5310.01.20
01-3 page 7
01
17519 Lambda control (bank 1)
System too lean
– Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chapter 24-3
17520 Lambda control (bank 1)
System too rich
17523 Bank 1 - probe 1, heat-ing circuit
Short circuit to earth
17524 Bank 1 - probe 1, heat-ing circuit
Open circuit
17525 Bank 1 - probe 2, heat-ing circuit
Short circuit to earth
– Test lambda probe -G130- and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
17526 Bank 1 - probe 2, heat-ing circuit
Open circuit
17535 Bank 1, mixture adap-tation (mult.)
System too rich
– Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Test injection valves ⇒ Chapter 24-2
– Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-nal control diagnosis
17536 Bank 1, mixture adap-tation (mult.)
System too lean
– Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Test injection valves ⇒ Chapter 24-2
– Test fuel delivery unit ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
– Inspect intake system for leaks
– 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 Load detection
implausible value
– Test throttle valve control unit ⇒ Chapter 24-2
– Test accelerator pedal position sender ⇒ Chapter 24-2
– Test injection valves ⇒ Chapter 24-2
– Inspect intake system for leaks
– Read measured value block, display group 005 ⇒ Chapter 01-5
17550 Load detection
Below limit
17551 Load detection
Above limit
17553 Air mass meter -G70-
Short circuit to positive
– Read measured value block, display group 005 ⇒ Chapter 01-5
17557 Lambda control (bank 1)
implausible control value
– Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chapter 24-3
17559 Bank 1, mixture adap-tation range 1
Below lean-ness limit
– Testing the intake system for tightness (unmetered air)
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis III Edition 11.04S00.5310.01.20
01-3 page 8
01
17560 Bank 1, mixture adap-tation range 2
Below lean-ness limit
– Inspect secondary air injection system for leaks ⇒ 2.0/85 kW Engine, Mechanical Components; Rep. Gr. 26
– Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Test injection valves ⇒ Chapter 24-2
– Test fuel delivery unit ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
17573 Bank 1, mixture adap-tation range 1
Above rich-ness limit
– Test fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Test injection valves ⇒ Chapter 24-2
– Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-nal control diagnosis
17574 Bank 1, mixture adap-tation range 2
Above rich-ness limit
17579 Angle sender 2 for TV drive -G188-
Implausible signal
– Check angle sender in measured value block, display group 060 ⇒ Chapter 01-6
– Test throttle valve control unit ⇒ Chapter 24-217580 Angle sender 2 for TV drive -G188-
Signal too low
17581 Angle sender 2 for TV drive -G188-
Signal too high
17584 Bank1, lambda correc-tion according to cata-lytic converter
Regulating limit reached
– Test lambda probe ageing upstream of catalytic converter ⇒ Chapter 24-3
– Test lambda probe -G130- and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
Readout on -V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IIIEdition 11.04S00.5310.01.20
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01
♦ 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.
17586 Linear lambda probe/pump current
Open circuit – Test lambda probe -G39- and lambda control upstream of catalytic converter ⇒ Chapter 24-3
17587 Linear lambda probe/pump current
Short circuit to earth
17588 Linear lambda probe/pump current
Short circuit to positive
17589 Linear lambda probe/reference voltage
Open circuit
17590 Linear lambda probe/reference voltage
Short circuit to earth
17591 Linear lambda probe/reference voltage
Short circuit to positive
17592 Linear lambda probe/combined earth cable
Open circuit
17593 Linear lambda probe/combined earth cable
Short circuit to earth
17594 Linear lambda probe/combined earth cable
Short circuit to positive
17606 Bank 1 - probe 2, heat-ing circuit
Electrical fault – Test lambda probe -G130- and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
Readout on -V.A.G 1552-
Rectifying fault
Note
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FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis IVEdition 11.04S00.5310.01.20
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01-4 Self-diagnosis IV
Fault table, fault codes 17621...18104
Readout on - V.A.G 1552-
Rectifying fault
17621 Injector cyl. 1 -N30-
Short circuit to positive
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
17622 Injector cyl. 2 -N31-
Short circuit to positive
17623 Injector cyl. 3 -N32-
Short circuit to positive
17624 Injector cyl. 4 -N33-
Short circuit to positive
17633 Injector cyl. 1 -N30-
Short circuit to earth
17634 Injector cyl. 2 -N31-
Short circuit to earth
17635 Injector cyl. 3 -N32-
Short circuit to earth
17636 Injector cyl. 4 -N33-
Short circuit to earth
17645 Injector cyl. 1 -N30-
Open circuit
17646 Injector cyl. 2 -N31-
Open circuit
17647 Injector cyl. 3 -N32-
Open circuit
17648 Injector cyl. 4 -N33-
Open circuit
17704 Cooling system
Fault – Test coolant temperature sender ⇒ Chapter 24-1
– Test coolant thermostat ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 19
17708 Combustion misfiring detected
Reason: Fuel short-age
– Refuel
– Test signal from fuel gauge sender
17733 Knock control Cyl. 1
Regulating limit reached
– Read measured value block, display group 026 ⇒ Chap. 01-5
– Eliminate abnormal engine running noises (loose ancillaries, bracket or bolt bent)
– Check wiring and plug connections according to the current flow dia-gram
– Slacken knock sensors and then tighten again to 20 Nm
– Change type of fuel
17734 Knock control Cyl. 2
Regulating limit reached
17735 Knock control Cyl. 3
Regulating limit reached
17736 Knock control Cyl. 4
Regulating limit reached
17743 Engine torque monitor-ing 2
Regulating limit exceed-ed
– Read measured value block, display group 005 ⇒ Chapter 01-5
– Inspect vacuum lines for leaks
– Inspect intake system for leaks
– Test resistance of coolant temperature sender -G42 - ⇒ Chap. 24-1
– Test resistance of intake air temperature sender -G42 - ⇒ Chap. 24-1
17744 Engine torque monitor-ing
Regulating limit exceed-ed
FABIA 2000 2.0/85 Engine, Fuel Injection
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01
17745 Bank 1, camshaft posi-tion sensor ⇒-G163
Short circuit to earth
– Test camshaft position sensor -G163- ⇒ Chapter 28-1
17746 Bank 1, camshaft posi-tion sensor ⇒-G163
Open circuit/Short circuit to positive
17747 Crankshaft position.- / engine speed sensor
Wrongly con-nected
– Test camshaft position sensor -G163- ⇒ Chapter 28-1
– Test resistance of engine speed sender -G28- ⇒ Chap. 24-1
17748 Camshaft position/crankshaft position sensor
Incorrect as-signment
– Inspect camshaft position sensor -G163- for tight installation
17763 Ignition control cyl. 1
Open circuit – Inspect ignition transformer ⇒ Chapter 28-1
17764 Ignition control cyl. 1
Short circuit to positive
17765 Ignition control cyl. 1
Short circuit to earth
17766 Ignition control cyl. 2
Open circuit
17767 Ignition control cyl. 2
Short circuit to positive
17768 Ignition control cyl. 2
Short circuit to earth
17769 Ignition control cyl. 3
Open circuit
17770 Ignition control cyl. 3
Short circuit to positive
17771 Ignition control cyl. 3
Short circuit to earth
17772 Ignition control cyl. 4
Open circuit
17773 Ignition control cyl. 4
Short circuit to positive
17774 Ignition control cyl. 4
Short circuit to earth
17794 Control unit defective
– Replace engine control unit -J220- ⇒ Chapter 24-4
– Test earth cables according to current flow diagram ⇒ Current Flow Di-agrams, Electrical Fault Finding and Fitting Locations17795
Control unit defective
17796 Control unit defective
17818 Tank ventilation valve -N80-
Short circuit to positive
– Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-nal control diagnosis
17832 Bank 1, secondary air system
Leak detect-ed
– Read measured value block, display group 077 ⇒ Chap. 01-7
– Test secondary air system for leaks
Readout on - V.A.G 1552-
Rectifying fault
FABIA 2000 2.0/85 Engine, Fuel Injection
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01
17833 Tank ventilation valve -N80-
Short circuit to earth
– Test activated charcoal filter solenoid valve 1 -N80- ⇒ Chap. 01-1, Fi-nal control diagnosis
17834 Tank ventilation valve -N80-
Open circuit
17841 Secondary air pump re-lay -J299-
Open circuit – Test the relay or the secondary air pump -J299- ⇒ Chapter 01-1, final control diagnosis
17842 Secondary air pump re-lay -J299-
Short circuit to positive
17843 Secondary air pump re-lay -J299-
Short circuit to earth
17860 Secondary air system
Open circuit
17908 Fuel pump relay -J17-
Electrical fault in the circuit
– Test fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Test fuel delivery unit ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 2017909
Fuel pump relay -J17-Short circuit to earth
17910 Fuel pump relay -J17-
Short circuit to positive
17921 2nd valve for variable intake manifold changeover -N261-
Short circuit to positive
– Check wiring and plug connections according to the current flow dia-gram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Lo-cations
17922 2nd valve for variable intake manifold changeover -N261-
Short circuit to earth
17923 Valve for variable in-take manifold changeo-ver -N156-
Short circuit to earth
17925 Main relay ⇒ -J271-
Electrical fault in the circuit
– Test the power supply relay for Motronic -J271- ⇒ Current Flow Dia-grams, Electrical Fault Finding and Fitting Locations
– Read measured value block, display group 004 ⇒ Chap. 01-517926 Main relay ⇒ -J271-
Short circuit to positive
17931 Crash signal from air-bag CU
Implausible signal
– Test airbag ⇒ Body Work; Rep. Gr. 01
17947 Clutch pedal switch -F36-
Implausible signal
– Read measured value block, display group 066 ⇒ Chapter 01-7
17949 Fuel pump relay -J17-
Open circuit – Test fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Readout on - V.A.G 1552-
Rectifying fault
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Self-diagnosis IV Edition 11.04S00.5310.01.20
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01
17950 Angle sender for TV drive -G187-1)
Implausible signal
– Read measured value block, display group 062 ⇒ Chapter 01-6
– Test throttle valve control unit -J338- ⇒ Chap. 24-2
17951 Angle sender for TV drive -G187-2)
Signal too low
17952 Angle sender for TV drive -G187-2)
Signal too high
17953 Throttle valve control
Malfunction
17966 Throttle valve drive -G186-1)
Electrical fault in the circuit
17967 Throttle valve control unit -J338-
Incorrect ba-sic setting
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
17968 Maximum engine speed exceeded
– Inspect engine for mechanical damage and erase fault memory ⇒ Chapter 01-1
17972 Throttle valve control unit -J338-
Undervolt-age on basic setting
– Test alternator and battery ⇒ Electrical System; Rep. Gr. 27
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
17973 Throttle valve control unit -J338-
Bottom limit not reached
– Read measured value block, display group 062 ⇒ Chapter 01-6
– Inspect throttle valve for damage and dirt
– Test throttle valve control unit -J338- ⇒ Chap. 24-217976 Throttle valve control unit -J338-
Mechanical fault
17977 CCS switch -E45-
Implausible signal
– Read measured value block, display group 066 ⇒ Chapter 01-7
17978 Engine control unit in-hibited
– Adapt engine control unit to electronic immobiliser ⇒ Electrical Sys-tem; Rep. Gr. 90.
17987 Throttle valve control unit -J338-
Adaptation was not initi-ated
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
– Test throttle valve control unit -J338- ⇒ Chap. 24-2
18010 Voltage supply tml. 30
Voltage too low
– Inspect engine control unit power supply ⇒ Chapter 24-4
– Test alternator and battery ⇒ Electrical System; Rep. Gr. 27
18011 Control unit defective
– Replace engine control unit ⇒ Chapter 24-4
18014 Poor road info/engine spec. torque from ABS CU
Electrical fault in the circuit
– Read out fault memory of ABS control unit ⇒ Chassis; Rep. Gr. 45
– Inspect databus ⇒ Chapter 24-5
18017 Deactivation actuated in case of an accident
– Interrogate fault memory of airbag control unit and erase ⇒ Body Work; Rep. Gr. 01
18018 Control unit defective
– Replace engine control unit ⇒ Chapter 24-4
18020 Engine control unit
Incorrectly coded
– Code engine control unit ⇒ Chapter 24-4
Readout on - V.A.G 1552-
Rectifying fault
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18034 Databus drive
Missing mes-sage from gearbox CU
– Inspect databus ⇒ Chapter 24-5
18038 Sender for accelerator pedal position -G79-
Signal too low
– Test accelerator pedal position sender ⇒ Chapter 24-2
18039 Sender for accelerator pedal position -G79-
Signal too high
18041 Sender 2 for accelera-tor pedal position -G185-
Signal too low
– Read measured value block, display group 062 ⇒ Chapter 01-6
– Test accelerator pedal position sender ⇒ Chapter 24-2
18042 Sender 2 for accelera-tor pedal position -G185-
Signal too high
18044 Databus drive
Missing mes-sage from airbag CU
– Inspect databus ⇒ Chapter 24-5
18047 Sender 1/2 for acceler-ator pedal position -G79- + -G185-
Implausible signal
– Test accelerator pedal position sender ⇒ Chapter 24-2
18048 Control unit defective
– Replace engine control unit ⇒ Chapter 24-4
18056 Databus drive
defective – Inspect databus ⇒ Chapter 24-5
– Read out fault memories of all control units (automatic test sequence) ⇒ Chapter 01-118057
Databus driveMissing mes-sage from ABS CU
18058 Databus drive
Missing mes-sage from combiinstru-ment
18090 Databus drive
implausible message from ABS CU
18091 Databus drive
implausible message from airbag-SG
18104 Databus drive
implausible message 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-.
Readout on - V.A.G 1552-
Rectifying fault
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♦ 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.
Note
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01-5 Self-diagnosis V
Reading measured value block
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
• 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
– Connect vehicle system tester -V.A.G 1552-. Start en-gine and select the address word 01 „Engine electron-ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and the desired display group number.
Display group number 004 is an example to represent the sequence.
Proceed according to the following table to switch to an-other display group:
– If the specifications are achieved in all the display
fields, press key .
– Select function 06 „End output“ and switch ignition off.
Read measured value block HELPEnter display group number XXX
NoteRead measured value block 4 →
Note
Display group
-V.A.G 1551- -V.A.G 1552-
higher Press key Press key
lower Press key Press key
skip Press key Press key
3 ↑
1 ↓
C C
→
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Reading measured value blocks, display groups 001 to 029
Display group 001 - Basic functions
♦ 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)
Analysis of display group 001, display field 2 - coolant temperature
• 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-lytic converter
-10,0...10,0 % ⇒ 01-5 page 3
Coolant temperature 80.0...110.0 °C ⇒ 01-5 page 2
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Note
Readout on -V.A.G 1552- Rectifying fault
less than 680 rpm – Test throttle valve control unit ⇒ Chapter 24-2
– Inspect intake system for leaks
greater than 880 rpm – Interrogate fault memory ⇒ Chapter 01-1
– Inspect intake system for leaks
– Test throttle valve control unit ⇒ Chapter 24-2
Readout on -V.A.G 1552- Rectifying fault
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
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Analysis of display group 001, display field 3 - lambda controller upstream of catalytic converter
Analysis of display group 001, display field 4 - operating states
Display group 002 - basic functions - air mass meter
♦ Re display field 4:
♦ 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
Readout on -V.A.G 1552- Rectifying fault
Signal outside tolerance – Wait 30 seconds until readout has stabilised
– Inspect intake system for leaks
– Test injectors ⇒ Chapter 01-1, Final control diagnosis
– Check lambda learned values in display group 032 ⇒ Chapter 01-6
1 2 3 4 5 6 7 8 Meaning, if display positions = 1
1 Coolant temperature more than 80°C1 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
• Engine idling
Read measured value block 2 → ← Readout on display
xxxx rpm xxx % x.xx ms x.x g/s
1 2 3 4 ← Display fields Specification Analysis
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
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Note
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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
♦ 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
Analysis of display group 002, display field 4 - inducted air mass
Readout on -V.A.G 1552- Rectifying fault
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
– Test throttle valve control unit ⇒ Chapter 24-2
Note
Readout on -V.A.G 1552- Rectifying fault
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.)
Readout on -V.A.G 1552- Rectifying fault
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.)
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Display group 003 - basic functions - air mass meter
Analysis of display group 003, display field 3 - throttle valve angle
Readout when accelerator pedal fully depressed is (90...100 %).
Display group 004 - Basic functions
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-
• Engine idling
Read measured value block 3 → ← Readout on display
xxxx rpm x.x g/s x.x % xx.x ° BTDC
1 2 3 4 ← Display fields Specification Analysis
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
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Readout on -V.A.G 1552- Rectifying fault
greater than 5.0 % – Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-4
– Interrogate fault memory ⇒ Chapter 01-1
– Test throttle valve control unit ⇒ Chapter 24-2
Note
• Engine idling
Read measured value block 4 → ← Readout on display
xxxx rpm xx.xxx V xxx.x °C xxx.x °C1 2 3 4 ← Display fields Specification Analysis
Intake manifold tempera-ture
-45.0...140.0 °C ⇒ 01-5 page 6
Coolant temperature 85.0...110.0 °C ⇒ 01-5 page 2
Supply voltage of the engine control unit 12.500...14.500 V
⇒ 01-5 page 6
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Note
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01
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
Analysis of display group 004, display field 4 - intake air temperature
Display group 005 - basic functions
Testing speed signal ⇒ Chap. 24-5.
Readout on -V.A.G 1552- Rectifying fault
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
Readout on -V.A.G 1552- Rectifying fault
approx. 140.0 °C – Test resistance of intake air temperature sender -G42 - ⇒ Chap. 24-1
– Test cables to intake air temperature sender -G42- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
approx. -46.5 °Capprox. 140 °C
(readout appears only for a short time and then jumps to 19.5 °C)
• Engine idling
Read measured value block 5 → ← Readout on display
xxxx rpm xxx % xxx km/h Text
1 2 3 4 ← Display fields Specification Analysis
Operating state (idling, part load, full load, enrich-ment, overrun)
Idling —
Vehicle speed 0 km/h —
Engine load 10...35 % ⇒ 01-5 page 4
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Note
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01
Display group 006 - Basic functions
♦ Re display field 2:
♦ 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
Read measured value block 6 → ← Readout on display
xxxx rpm xx.x % xxx.x °C x.x %
1 2 3 4 ← Display fields Specification Analysis
Level correction factor — —
Intake manifold temperature -45.0...140.0 °C —
Engine load 15,0...35,0 % ⇒ 01-5 page 4
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
Note
• Engine idling
Read measured value block 10 → ← Readout on display
xxxx rpm xx.x % x.x % xx.x ° BTDC
1 2 3 4 ← Display fields Specification Analysis
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
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
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Display group 014 - ignition misfiring detection
Display group 015 - ignition misfiring detection cylinders 1 to 3
Display group 016 - ignition misfiring detection cyl. 4
• Engine idling
Read measured value block 14 → ← Readout on display
xxxx rpm xx.x % xxx Text
1 2 3 4 ← Display fields Specification Analysis
Status of misfiring detec-tion (activated, deactivat-ed)
activated —
Total of ignition misfirings 0...5 ⇒ 01-5 page 9
Engine load 15,0...35,0 % ⇒ 01-5 page 4
Engine speed (idling speed) 680...880 rpm ⇒ 01-5 page 2
• Engine idling
Read measured value block 15 → ← Readout on display
xxx xxx xxx Text
1 2 3 4 ← Display fields Specification Analysis
Status of misfiring detec-tion (activated, deactivat-ed)
activated —
Total of ignition misfirings cyl. 3 0 ⇒ 01-5 page 9
Total of ignition misfirings cyl. 2 0 ⇒ 01-5 page 9
Total of ignition misfirings cyl. 1 0 ⇒ 01-5 page 9
• Engine idling
Read measured value block 16 → ← Readout on display
xxx — — Text
1 2 3 4 ← Display fields Specification Analysis
Status of misfiring detec-tion (activated, deactivat-ed)
activated —
— —
— —
Total of ignition misfirings cyl. 4 0 ⇒ 01-5 page 9
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Analysis of display groups 014, 015, 016 - total of ignition misfiring cyl. 1 to 4
Display group 022, ignition - knock control
Display group 023, ignition - knock control
Readout on -V.A.G 1552- Rectifying fault
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
• Normal driving
Read measured value block 22 → ← Readout on display
xxxx rpm xxx.x % xx.x °CA xx.x °CA
1 2 3 4 ← Display fields Specification Analysis
Ignition angle retarded in cylinder 2 by knock con-trol
0...15.0 °CA ⇒ 01-5 page 10
Ignition angle retarded in cylinder 1 by knock control
0...15.0 °CA ⇒ 01-5 page 10
Engine load 0,0...100,0 % —
Engine speed 680...6500 rpm —
• Normal driving
Read measured value block 23 → ← Readout on display
xxxx rpm xxx.x % xx.x °CA xx.x °CA
1 2 3 4 ← Display fields Specification Analysis
Ignition angle retarded in cylinder 4 by knock con-trol
0...15.0 °CA ⇒ 01-5 page 10
Ignition angle retarded in cylinder 3 by knock control
0...15.0 °CA ⇒ 01-5 page 10
Engine load 0,0...100,0 % —
Engine speed 680...6500 rpm —
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis V Edition 11.04S00.5310.01.20
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01
♦ 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
Display group 026, ignition - knock sensor
♦ 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.
Note
Readout on -V.A.G 1552- Rectifying fault
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-ers
– Test knock sensors -G61- and -G66-
– Testing compression: ⇒ 2.0/85 TDI Engine, Mechanical Compo-nents; Rep. Gr. 15
– Tighten up loose parts
• Normal driving
Read measured value block 26 → ← Readout on display
x.xxx V x.xxx V x.xxx V x.xxx V
1 2 3 4 ← Display fields Specification Analysis
Knock sensor voltage sig-nal cyl. 4
0.400...2.000 V —
Knock sensor voltage signal cyl. 3 0.400...2.000 V —
Knock sensor voltage signal cyl. 2 0.400...2.000 V —
Knock sensor voltage signal cyl. 1 0.400...2.000 V —
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VEdition 11.04S00.5310.01.20
01-5 page 11
01
Display group 028, ignition - testing knock sensor
• Normal driving
Read measured value block 28 → ← Readout on display
xxxx rpm xxx.x % xxx.x °C Text
1 2 3 4 ← Display fields Specification Analysis
Test Knock sensor (Test OFF, Test ON, Syst. o.k., Syst. n.o.k.)
Syst. o.k. —
Coolant temperature 80.0...100.0 °C ⇒ 01-5 page 2
Engine load 20,0...100,0 % —
Engine speed 2500...6500 rpm —
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FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIEdition 11.04S00.5310.01.20
01-6 page 1
01
01-6 Self-diagnosis VII
Reading measured value block, display groups 030 to 062
Display group 030 - lambda control
Meaning of 3-digit numerical block in display fields 1 and 2:
Display group 031, lambda control - lambda values upstream of catalytic converter
• Engine idling
• Catalytic converter temperature at least 352 °C (display group 34, display field 2)
Read measured value block 30 → ← Readout on display
xxx xxx
1 2 3 4 ← Display fields Specification Analysis
Status lambda control downstream of catalytic converter
110 ⇒ 01-6 page 1
Status lambda control upstream of catalytic converter 111 ⇒ 01-6 page 1
1 1 1 Meaning, if display positions = 1
Lambda control active
Lambda probe operational
Lambda probe heater switched on
• Engine idling
Read measured value block 31 → ← Readout on display
x.xx x.xx — —
1 2 3 4 ← Display fields Specification Analysis
— —
— —
Lambda nominal value - Bank 1 0,99...1,01 —
Lambda actual value - Bank 1 0,96...1,04 —
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VII Edition 11.04S00.5310.01.20
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Display group 032, lambda control - lambda learned values
♦ 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.
• Engine idling
Read measured value block 32 → ← Readout on display
xx.x % xx.x % — —
1 2 3 4 ← Display fields Specification Analysis
— —
— —
Lambda learned value at part load upstream of catalytic converter (multiplicative)
-10,0...10,0 % ⇒ 01-6 page 3
Lambda learned value at idling speed upstream of catalytic converter (additive)
-10,0...10,0 % ⇒ 01-6 page 3
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIEdition 11.04S00.5310.01.20
01-6 page 3
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Analysis of display group 032, display fields 1 and 2 - lambda learned values
Display group 033, lambda control upstream of catalytic converter - lambda control values
♦ Re display field 1:
♦ 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.
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 fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– 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 fuel pressure regulator and holding pressure ⇒ Chap. 24-2
– Inspect intake system for leaks
– Test exhaust manifold ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 26
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-3
• Engine idling
Read measured value block 33 → ← Readout on display
xx.x % x.xxx V — —
1 2 3 4 ← Display fields Specification Analysis
— —
— —
Lambda probe voltage upstream of catalytic con-verter
1.400 V...1.600 V ⇒ 01-6 page 4
Lambda control before catalyst -10,0...10,0 % ⇒ Chap. 01-5, dis-play group 001, display field 3
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VII Edition 11.04S00.5310.01.20
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01
♦ Re display field 2:
♦ 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 group 034, lambda control - diagnosis of lambda probe upstream of catalytic converter
♦ Re display field 3:
♦ 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.
Note
Display field: 1 Rectifying fault
constant 0.000...1.400 V
or constant 1.600...3.000 V
– Testing lambda probe and lambda control upstream of catalytic con-verter ⇒ Chapter 24-3
constant 3.600 V
constant 0.000 V
• 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
1 2 3 4 ← Display fields Specification Analysis
Result of test of lambda probe ageing upstream of catalytic converter (Test OFF /Test ON/B1 S1 o.k./B1 S1 n.o.k.)
B1 S1 o.k. ---
Period of lambda probe upstream of catalytic converter
max. 2.2 ---
Catalytic converter temperature min. 352 °C ---
Engine speed 1400...2800 rpm ---
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIEdition 11.04S00.5310.01.20
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Display group 036, lambda control - operation downstream of catalytic converter
Analysis of display group 036, display field 1 - lambda probe voltage, lambda probe downstream of catalytic converter
♦ 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-
• Engine idling
Read measured value block 36 → ← Readout on display
x.xxx V Text — —
1 2 3 4 ← Display fields Specification Analysis
— —
— —
Test lambda probe downstream of catalytic con-verter (B1 S2 o.k./B1 S2 n.o.k.)
B1 S2 o.k. —
Lambda probe voltage after catalytic converter 0.000...1.000 V ⇒ 01-6 page 5
Display field: 1 Rectifying fault
constant 0.000...0.300 V
or constant 0.700...1.000 V
– Testing lambda probe and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
constant 1.000 V
– Testing lambda probe and lambda control downstream of catalyt-ic converter ⇒ Chapter 24-3
constant 0.400 ...0.500 V
constant 0.000 V
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VII Edition 11.04S00.5310.01.20
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01
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
• Control unit in function 04 - initiate basic setting
System in basic setting 37 → ← Readout on display
xx.x % x.xxx V x.xxx Text
1 2 3 4 ← Display fields Specification Analysis
Test lambda probe down-stream of catalytic con-verter (Test ON / Test OFF, Syst. o.k. / Syst. n.o.k.)
Syst. 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 % —
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIEdition 11.04S00.5310.01.20
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Display group 041, lambda control - lambda probe heating
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
• Engine idling
Read measured value block 41 → ← Readout on display
— Text — Text
1 2 3 4 ← Display fields Specification Analysis
Heater of lambda probe downstream of catalytic converter (Heating.aC.OFF, heat-ing.aC.ON)
Htg dC.OFF Htg dC.ON
—
— —
Heater of lambda probe upstream of catalytic con-verter (Heating.bC.OFF/heating.bC.ON)
Htg.uC.OFF Htg.uC.ON
—
— —
Note
• Brake pedal and accelerator depressed
• Vehicle stationary, engine running at fast idling
• Control unit in function 04 - initiate basic setting
System in basic setting 46 → ← Readout on display
xxxx rpm xxx.x °C x.xx Text
1 2 3 4 ← Display fields Specification Analysis
Result of test of catalytic conversion (Test OFF / Test ON / Cat B1 o.k. / Cat B1 n.o.k.)
Cat B1 o.k. —
Amplitude ratio 0,00...0,55 —
Catalytic converter temperature min. 352.0 °C —
Engine speed 2000...3200 rpm —
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VII Edition 11.04S00.5310.01.20
01-6 page 8
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Display group 050, engine speed control - operating states
♦ Re display field 2:
♦ 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).
♦ Re display field 3:
♦ A/C High = air conditioning switched on to high heat-ing or cooling capacity
♦ A/C Low = air conditioning not switched on
♦ Re display field 4:
♦ „Compr. OFF“ is always displayed on vehicles without air conditioning system.
• Engine idling
Read measured value block 50 → ← Readout on display
xxxx rpm xxxx rpm Text Text
1 2 3 4 ← Display fields Specification Analysis
Operating condition air conditioning compressor ON/OFF
Compr. ON or Compr. OFF
—
Operating condition of air condition-ing system
A/C High or A/C 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
Note
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIEdition 11.04S00.5310.01.20
01-6 page 9
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Display group 054, engine speed control - operating states
Display group 055, engine speed control - idling speed stabilisation
Meaning of the 4-digit numerical block display field 4
• Engine idling
Read measured value block 54 → ← Readout on display
xxxx rpm Text xxx.x % xxx.x %
1 2 3 4 ← Display fields Specification Analysis
Throttle valve positioner angle
0...100 % —
Sender for accelerator pedal position 3...97 % ⇒ Chapter 01-5, display group 003,
display field 3
Operating state (idling, part load, full load, enrich-ment, overrun)
Idling —
Engine speed (idling speed) 680...880 rpm ⇒ Chap. 01-5, dis-play group 001, display field 1
• Engine idling
Read measured value block 55 → ← Readout on display
xxxx rpm x.xx % x.xx % xxxxx
1 2 3 4 ← Display fields Specification Analysis
Operating conditions xxxxx ⇒ 01-6 page 9
Initialisation value idling regulator -1,50...1,50 % —
Idling regulator -2,00...2,00 %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.
—
Engine speed (idling speed) 680...880 rpm ⇒ Chap. 01-5, dis-play group 001, display field 1
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
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VII Edition 11.04S00.5310.01.20
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Display group 056, engine speed control - idling speed stabilisation
Display group 060, engine speed control - adapting throttle valve control unit
♦ 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.
• Engine idling
Read measured value block 56 → ← Readout on display
xxxx rpm xxxx rpm x.xx % xxxxx
1 2 3 4 ← Display fields Specification Analysis
Operating conditions xxxxx ⇒ 01-6 page 9
Idling regulator -2,00...2,00 % —
Engine speed (idling speed - specified value) 780 rpm —
Engine speed (idling speed) 680...880 rpm ⇒ Chap. 01-5, dis-play group 001, display field 1
• Ignition switched on, engine switched off
• Control unit in function 04 - initiate basic setting
System in basic setting 60 → ← Readout on display
xx % xx % x Text
1 2 3 4 ← Display fields Specification Analysis
Adaption state (ADP runs, ADP o.k. or ADP ERROR)
ADP o.k. —
Operating state of engine Counter of learning steps
0...8 —
Throttle valve angle potentiometer -G188- 97...3 % —
Throttle valve angle potentiometer -G187- 3...97 % ⇒ Chapter 01-5, display group 003,
display field 3
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIEdition 11.04S00.5310.01.20
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Display group 061 - engine speed control, EPC
Display group 062 - engine speed control, EPC
• Engine idling or vehicle driven
Read measured value block 61 → ← Readout on display
xxxx rpm xx.xxx V xxx.x % xxxxx
1 2 3 4 ← Display fields Specification Analysis
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 —
Engine speed 680...6500 rpm —
• Ignition on or engine running
Read measured value block 62 → ← Readout on display
xx % xx % xx % xx %
1 2 3 4 ← Display fields Specification Analysis
Sender for accelerator pedal position -G185-
3...50 % —
Sender for accelerator pedal position -G79-
6...97 % —
Throttle valve angle potentiometer -G188- 97...3 % —
Throttle valve angle potentiometer -G187- 3...97 % —
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FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIIEdition 11.04S00.5310.01.20
01-7 page 1
01
01-7 Self-diagnosis VIII
Reading measured value blocks, display groups 66 to 126
Display group 066 - cruise control system (only models with CCS)
Meaning of digits in 4-digit numerical block, display field 2, brake and clutch pedal switch, CCS switch
Meaning of digits in 4-digit numerical block, dis-play field 4, CCS switch
• Engine idling
Read measured value block 66 → ← Readout on display
x km/h xxxxxxxx x km/h xxxxxxxx
1 2 3 4 ← Display fields Specification Analysis
CCS switch position 0000xxxx ⇒ 01-7 page 1
Specified vehicle speed (value last stored by CCS) x km/h
—
Brake pedal, clutch pedal and CCS position 0000xxxx ⇒ 01-7 page 1
Vehicle speed x km/h —
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
1 2 3 4 Meaning if display position
1 CCS sliding switch in OFF position (only if closed)
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIII Edition 11.04S00.5310.01.20
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Display group 070 - exhaust gas reduction - diagnosis of activated charcoal filter system
TVV means Tank Vent Valve (activated charcoal filter so-lenoid valve). Diagnosis can only be initiated once each time the engine is started.
♦ Lambda regulator variation in negative range: activat-ed charcoal filter full.
♦ Lambda regulator variation in positive range: activat-ed charcoal filter empty.
1 CCS sliding switch in OFF position (closes or closed)
1 CCS pushbutton SET operated
1 CCS sliding switch -B- in RES position
• Engine idling
• Coolant temperature at least 40 °C (display group 001, display field 2)
• Control unit in function 04 - initiate basic setting
System in basic setting 70 → ← Readout on display
xxx.x % xx.x % xxx.x % Text
1 2 3 4 ← Display fields Specification Analysis
Result of diagnosis (Test ON / Test OFF or TVV O.K. / TVV N.O.K)
TVV o.k. —
Idling speed controller variation dur-ing TVV diagnosis
0...150,0 % —
Lambda controller variation during TVV diagnosis -7,8...7,8 % —
On/off ratio of activated charcoal filter solenoid valve 0,0...100,0 % —
1 2 3 4 Meaning if display position
Note
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIIEdition 11.04S00.5310.01.20
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01
Display group 077 - exhaust gas reduction - diagnosis of secondary air injection system
Display group 100 - readiness code
Meaning of 8-digit numerical block for readiness code, display field 1
• Engine idling
• Control unit in function 04 - initiate basic setting
System in basic setting 77 → ← Readout on display
xxxx rpm xx.x g/s xx.x % Text
1 2 3 4 ← Display fields Specification Analysis
Result of diagnosis (Test ON / Test OFF, Syst. o.k. / Syst. n.o.k.)
Syst. o.k. —
Air mass ratio, secondary air injection system
-7,0...7,0 % —
Air mass 1.0...10.0 g/s —
Engine speed (idling speed) 680...880 rpm ⇒ Chap. 01-5, dis-play group 001, display field 1
• Engine idling
Read measured value block 100 → ← Readout on display
xxxxxxxx xxx.x °C xxxx s xxxxxxxx
1 2 3 4 ← Display fields Specification Analysis
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
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“)
FABIA 2000 2.0/85 Engine, Fuel Injection
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01
The Readiness code is only generated when all display positions are 0.
Display group 120 - traction control system -TCS-
Display group 125 - communication, databus messages
Display group 126 - communication, databus messages
Note on display fields 125 and 126:
Nominal value = 1; the control units with active data bus are displayed.
Note
• Driving
Read measured value block 120 → ← Readout on display
xxxx rpm xxx Nm xxx Nm Text
1 2 3 4 ← Display fields Specification Analysis
Status TCS active / TCS n. active
—
Actual engine load 0...260 Nm —
Nominal engine load 0...399 Nm —
Engine speed 680...6500 rpm —
• Engine idling
Read measured value block 125 → ← Readout on display
— Text Text Text
1 2 3 4 ← Display fields Specification Analysis
Status of the air-condition-ing system
Clima 1 ⇒ 01-7 page 5
Status of combiinstrument Combi 1 ⇒ 01-7 page 5
Status ABS ABS 1 ⇒ 01-7 page 5
— —
• Engine idling
Read measured value block 126 → ← Readout on display
— — Text Text
1 2 3 4 ← Display fields Specification Analysis
Status of the electricalsystem control unit
El. CU 1 ⇒ 01-7 page 5
Status airbag Airbag 1 ⇒ 01-7 page 5
— —
— —
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIIIEdition 11.04S00.5310.01.20
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Analysis: Display groups 125 and 126
Readout on -V.A.G 1552-
Possible cause of fault Rectifying fault
if 0 displayed in-stead of 1
♦ CAN databus connection defective
♦ no CAN databus cables used - control unit
♦ CAN databus cables defective - control unit
– Perform the automatic test sequence for interrogation of all fault memories.
FABIA 2000 2.0/85 Engine, Fuel Injection
Self-diagnosis VIII Edition 11.04S00.5310.01.20
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FABIA 2000 2.0/85 Engine, Fuel Injection
Repairing the injection systemEdition 03.01S00.5310.00.20
24-1 page 1
24
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.
24 – Fuel Formation, Injection
FABIA 2000 2.0/85 Engine, Fuel Injection
Repairing the injection system Edition 03.01S00.5310.00.20
24-1 page 2
24
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-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-
testing voltage supply ⇒ Chap. 24-4
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 - *
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inspecting ⇒ Chap. 28-1
Removing and installing parts of the injection system
1 - Top part of intake manifold2 - Connecting plug
81-pin insert or remove plug when
the ignition is switched off unlock for removing
3 - Engine control unit -J220-*
fitting location ⇒ 24-1 page 2
testing voltage supply ⇒ Chap. 24-4
procedure if voltage inter-rupted ⇒ Chap. 24-4
replacing ⇒ Chap. 24-4 coding ⇒ Chap. 24-4
4 - Connecting plug 40-pin insert or remove plug when
the ignition is switched off unlock for removing
5 - Air filter disassembling and assem-
bling ⇒ 24-1 page 6
6 - 10 Nm7 - to air guide pipe
⇒ item 7 in 24-1 page 5
8 - Air intake hose to secondary air pump
-V101 -
9 - 10 Nm10 - Connecting plug
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
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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 converter18 - 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 converter20 - 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 check fitting position from fuel filter ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
24 - Gasket replace if damaged check fitting position
25 - To crankcase vent valve26 - Air intake hose
FABIA 2000 2.0/85 Engine, Fuel Injection
Repairing the injection systemEdition 03.01S00.5310.00.20
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Disassembling and assembling bottom part of intake manifold
1 - Fuel pressure regulator testing fuel pressure regula-
tor and pressure in system ⇒ Chap. 24-2
2 - Vacuum hose3 - Cable rail
for connectors of injectors - N30-...-N33-
4 - Bottom part of intake mani-fold
5 - 10 Nm6 - O-ring
replace if damaged
7 - To intake hose ⇒ item 7 in 24-1 page 3
8 - Injectors -N30-...-N33-*/**
resistance: 14,0...17,0 Ω (at 20 °C), resistance is about 4 to 6 Ω higher when engine is at normal operating tempera-ture Ω
9 - Retaining clip check tightness
10 - Fuel distributor11 - Fuel return-flow line12 - Fuel feed line13 - Air guide pipe
to injectors
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Disassembling and assembling the air filter
1 - 6 Nm
2 - 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
3 - Gasket replace if damaged
4 - Air filter top part5 - Air deflector
in air filter top part
6 - Filter insert7 - Air filter bottom part8 - 10 Nm9 - Air deflector
Fig. 1: Resistances for coolant temperature sender -G62- and intake air temperature sender -G62-
♦ Coolant temperature sender - G62- at contacts 1 + 2.
♦ Intake air temperature sender -G42- at contacts 1 + 3.
The diagram is divided into two temperature ranges:
A - from 0 to 50 °CB - from 50 to 105 °C
Read out examples:
♦ For a temperature of 30 °C the specification is 1500...2000 Ω
♦ For a temperature of 80 °C the specification is 275...375 Ω
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Fig. 2: Removing and installing engine trim panel
Removing
– Withdraw dipstick.
– Remove engine trim panel in direction of -arrows-.
Safety measures
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.
Rules of cleanliness
When working on the fuel supply/fuel injection system, pay careful attention to the following „5 rules“ for cleanli-ness.
♦ 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.
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WARNING!
The fuel system is under pressure! Before opening the system lay cleaning cloths around the connec-tion point. Reduce pressure by carefully releasing the connection point.
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♦ Only install clean parts. Remove spare parts from their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped, e.g. on a shelf or in a tool box.
♦ When the system is open: avoid working with com-pressed air. Avoid moving the vehicle.
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24-2 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-.
If the throttle valve control unit is replaced, then adapt this throttle valve control unit to the engine control unit ⇒ Chapter 24-4.
Special tools, test and measuring equipment and auxiliary items required
♦ 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
Test condition
• Throttle valve is not damaged or dirty.
Test sequence
– Unplug the 6-pin connector at the throttle valve control 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.
Checking voltage supply
– Unplug the 6-pin connector at the throttle valve control unit.
– Connect the multimeter for voltage measurement to contacts 2 + 6 of the connector.
– Switch on ignition.
Specified value: min. 4,5 V
– Switch off ignition.
– Connect the multimeter for voltage measurement to contact 2 of the connector and to earth.
– Switch on ignition.
Specified value: min. 4,5 V
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– Switch off ignition.
If the specified values are not reached:
– Test cables for open circuit, short circuit to earth and to positive ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
If wiring is o.k.:
– Replace engine control unit ⇒ Chapter 24-4.
Testing accelerator pedal position send-er
Special tools, test and measuring equipment and auxiliary items required
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
♦ Measuring tool set e.g. -V.A.G 1594 A, B oder C-
♦ Test box -V.A.G 1598/31-
♦ Current flow diagram
Operation
The two accelerator pedal position senders -G79- and -G185- are located at the accelerator pedal and pass on the driver input to the engine control unit completely 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.
– Switch on ignition.
– Connect the multimeter for voltage measurement to the following contacts of the connector:
Contact 1 + earth
Contact 1 + 5
Contact 2 + earth
Contact 2 + 3
Specified value: min. 4,5 V
– Switch off ignition.
If the specified values are not reached:
– Test cables for open circuit, short circuit to earth and to positive ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
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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
Special tools, test and measuring equipment and auxiliary items required
♦ 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.
Replace seals at the same time.
Test injected quantity and spray pattern
When testing the injection rate also check the jet forma-tion. The jet must be the same for all valves.
Note
Note
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– 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-.
The fuel delivery unit must start running.
– Operate remote control for 30 seconds.
– Repeat test at the other injectors. Always use a new measuring glass.
– Once all the injectors have been driven, position the graduated measuring glasses on an even base.
– Switch off voltage supply of fuel delivery unit.
– Compare the individual quantities of fuel injected.
Specified value: 88...98 ml per valve
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.
Special tools, test and measuring equipment and auxiliary items required
♦ Pressure measuring device -V.A.G 1318-
♦ Adapter -V.A.G 1318/10-
♦ Adapter -V.A.G 1318/11-
♦ Adapter -V.A.G 1318/16-
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Test condition
• Delivery rate of fuel delivery unit o.k., testing ⇒ 2.0/85 Engine, Mechanical Components; Rep. Gr. 20
Test sequence
– 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.
– Start engine and run in idle.
– Measure fuel pressure.
Specified value: approx. 0.25 MPa (2.5 bar).
If the specified value is reached:
– Detach vacuum hose -1- from connection -2-.
The fuel pressure must rise to approx. 0.3 MPa (3.0 bar).
– Switch off ignition.
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):
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.
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– Start engine and run in idle.
– 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).
– Start engine and run in idle.
– 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.
Before taking off the pressure measuring device, place cleaning cloths around the loose hoses of the feed line.
Note
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24-3 Testing functions II
Testing lambda probe -G39- and lambda control upstream of catalytic converter
Special tools, test and measuring equipment and auxiliary items required
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
♦ 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.
• The fuel pump relay must be o.k.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-gine and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Check display groups 030, 031, 032, 033, 034 and 036 ⇒ Chap. 01-6.
If the specified values are not reached:
– 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.
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 the contacts 1 and 5 of connector -2- at the wiring loom.
– Start engine.
Specified value: 0.40...0.50 V
– Switch off ignition.
If the specified values are reached:
– Replace lambda probe -G39-.
If the specified values are not reached:
– Test cables between engine control unit and connec-tor of lambda probe ⇒ Current Flow Diagrams, Elec-trical Fault Finding and Fitting Locations
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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-
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 condition
• Coolant temperature at least 80 °C ⇒ Read measured value block 004, display field 3 ⇒ Chap. 01-5
Inspect proper operation
– Connect vehicle system tester -V.A.G 1552-. Start en-gine and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 04 for „Initiate basic setting“ and dis-play group 034.
– Depress brake pedal and accelerator simultaneously.
– Engine speed is raised to 1400...2800 rpm.
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.”.
If the specified values are not reached:
– 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-.
System in basic setting 34 ->1600 rpm 355 °C 2.20 s B1 S1 o.k.
Note
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Testing lambda probe -G130- and lamb-da control downstream of catalytic con-verter
Special tools, test and measuring equipment and auxiliary items required
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
♦ 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.
• The fuel pump relay must be o.k.
• Coolant temperature at least 80 °C ⇒ Read measured value block 004, display field 3 ⇒ Chap. 01-5
Test sequence
– Check display groups 030, 031, 036 and 037 ⇒ Chap. 01-6.
If the specified values are not reached:
– Test resistance of heating element between contacts 1 + 2, voltage supply for heater and cables to -Z29-, as necessary.
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
– Switch off ignition.
If the specified value is reached:
– Replace lambda probe downstream of catalytic con-verter -G130 -.
If the specified value is not reached:
– Test cables to lambda probe -G130- ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Loca-tions.
If the cable is not found to be faulty:
– Replace engine control unit ⇒ Chap. 24-4.
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24-4 Engine control unit
Wiring and Component Test with Test Box V.A.G. 1598/31
Special tools, test and measuring equipment and auxiliary items required
♦ Test box -V.A.G 1598/31-
♦ 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.
– Switch off ignition.
– 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.
Testing voltage supply for engine con-trol unit
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 box -V.A.G 1598/31-
♦ 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
Note
V.A.G. 1598/31
S01-0089
DANGER!
To avoid damaging the electronic components, switch on the relevant measuring range before connecting the measuring equipment and comply with the test conditions.
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Test conditions
• Battery voltage at least 11.5 V.
• Fuses no. 3, 14, 17, 48, 52 and 56 must be in proper order.
• Generator o.k., test ⇒ Current Flow Diagrams, Elec-trical Fault Finding and Fitting Locations.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-gine and select the address word 01 „Engine electron-ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group 004.
– Read off readout in display field 2.
Specified value: min. 11.5 V
– Select function 06 „End output“ and switch ignition off.
If the specified value is not reached:
– 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:
Specified value: min. 11.5 V
If the specified value is not reached:
– 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.
– Switch on ignition.
Specified value: min. 11.5 V
If the specified value is not reached:
– 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
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which the vehicle has driven, this may result in consider-able driveability problems.
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
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
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
– Enter the control unit identification and thus also the coding of the previous control unit as follows:
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine elec-tronics“ ⇒ Chap. 01-1.
The control unit identification number and the coding are shown on the display, e.g.:
– Select function 06 „End output“ and switch ignition off.
Remove air filter ⇒ Chap. 24-1.
06A906032CC 2.0l R4/2V 3658 ->Coding 00001 WSCXXXXX
FABIA 2000 2.0/85 Engine, Fuel Injection
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24
– Release the plug locks and unplug control unit con-nectors -arrow-.
– 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 unit connector.
– Installation is carried out in the reverse order.
♦ 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.
♦ 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
♦ 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.
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-
S10-0111
S24-0337
A
A
BNote
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
Engine control unitEdition 11.04S00.5310.01.20
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Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine elec-tronics“ ⇒ Chap. 01-1.
– Select function 07 „coding control unit“.
– Enter the relevant code number of the vehicle and
confirm with button .
The control unit identification number and the coding are shown on the display, e.g.:
If this display appears, an incorrect code number has been entered.
– Select function 06 „End output“ and switch ignition off.
♦ 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
Code control unit QEnter code number XXXXX (0-00127)
Q
for vehicles with Code number
Air Conditioning 00001
without air conditioning 00021
06A906032CC 2.0l R4/2V 3658 ->Coding 00001 WSCXXXXX
Function unknown or cannot ->be carried out at the moment
Note
FABIA 2000 2.0/85 Engine, Fuel Injection
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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 condition
• There must not be any fault present in the fault mem-ory ⇒ Chap. 01-1, Interrogating fault memory.
• Battery voltage at least 11.5 V.
• 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
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine elec-tronics“ ⇒ Chap. 01-1.
– Select function 04 „Basic setting“ and display group 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.
Specification in display field 3: 8
Specification in display field 4: ADP runs
ADP o.k.
If the specified values are reached:
The adaptation was successfully performed.
To store the values:
– Switch ignition off for at least 30 seconds.
System in basic setting 60 -> 8% 60% 0 ADP runs
System in basic setting 60 -> 60% 94% 8 ADP o.k.
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♦ 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.
– Select function 06 „End output“ and switch ignition off.
Note
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Testing auxiliary signalsEdition 03.01S00.5310.00.20
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24-5 Testing auxiliary signals
Testing the speed signal
Special tools, test and measuring equipment and auxiliary items required
♦ Test box -V.A.G 1598/31-
♦ Diode test lamp, e.g. -V.A.G 1527 B-
♦ Adapter cable set, e.g. -V.A.G 1594 A-
♦ Current flow diagram
Test conditions
• Battery voltage at least 11.5 V.
• 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.
– Switch on ignition.
– 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.
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Special tools, test and measuring equipment and auxiliary items required
♦ Test box -V.A.G 1598/31-
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
♦ Adapter cable set, e.g. -V.A.G 1594 A-
♦ Current flow diagram
Test sequence
– Switch off ignition.
– 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:
– Replace engine control unit ⇒ Chap. 24-4.
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)
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
• There must not be any faults present in the fault mem-ory ⇒ Chap. 01-1.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine elec-tronics“ ⇒ Chap. 01-1.
Readout on display, e.g.:
If „2.0 l R4/2V G“ is displayed, CCS is activated.
Readout on display, e.g.:
If „2.0 l R4/2V G“ is displayed, CCS is not activated.
– Press key and select function 11 „Login proce-dure“.
06A906032CC 2.0 l R4/2V G 3658 ->Coding 00071 WSC XXXXX
06A906032BL 2.0 l R4/2V 3530 ->Coding 00071 WSC XXXXX
Login procedure Enter code number XXXXX
→
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Enter code number by referring to the table below and confirm entry with key.
– Select function 06 „End output“ and switch ignition off.
After the CCS is activated, conduct a test drive as an op-erational check.
Q
Code number
Cruise control system (CCS)
11463 Cruise control system (CCS) is activat-ed
16167 Cruise control system (CCS) is deacti-vated
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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 drives observe the following:
♦ Attach test and measuring equipment always on the rear seat and have them operated from there by a sec-ond person.
♦ If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.
28 – Ignition System
S97-0319
1
2
3
4
6
7
10 14
15
18
19
22
23
5
8
9
12
13
16
17
20
21
11
24
25
26
27
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29
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31
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Removing and installing parts of the ignition system
1 - Ignition lead with shielded plug and spark-
plug
2 - Spark plug, 20-30 Nm use special spark plug
wrench (e.g. -3122 B-) for re-moving and installing
type and electrode gap ⇒ Inspection and Mainte-nance; Rep. Gr. 02
3 - 20 Nm The torque influences the
knock sensor function
4 - Knock sensor 2 -G66-*
Sensor and connecting plug contacts are gold-plated
5 - Triple-pin plug and socket connector contacts gold-plated black for knock sensor 1
-G61- brown for knock sensor 2
-G66-
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 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 1B = Cylinder 2C = Cylinder 3D = Cylinder 4 with power output stage - N122- resistances ⇒ Fig. 1 in 28-1 page 3
11 - 10 Nm
S28-0126
D
C A
B
10
9
8
7
5 6 3 5 4 3
2
1
11
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Fig. 1: Resistances of ignition coils
Specified value: 4...6 kΩ.
Testing camshaft position sensor -G163-
Special tools, test and measuring equipment and auxiliary items required
♦ Handheld multimeter, e.g. -V.A.G 1526 A-
♦ Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
• Battery voltage 11.5 V
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-.
– Switch on ignition.
Specified value: at least 4.5 V
– Switch off ignition.
– Test cables for open circuit, short circuit to earth and to positive ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
If the wiring is in proper order and the desired voltage was measured at contacts 1 + 3
– Replace camshaft position sensor -G163-.
If the wiring is in proper order and the desired voltage was not measured at contacts 1 + 3
– Replace engine control unit ⇒ Chap. 24-4.
S28-0099
2
3
1
2
1 N28-0146
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