Workshop Manual - TDI Engine Fuel Ingection AMF

Service
Workshop Manual
FABIA 2000
Edition 07.03
Engine code
1.4/55 TDI Engine, Fuel Injection

AMF
Service Department. Technical Information
Printed in Czech Republic S00.5326.00.20
Service
The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.
Printed in Czech Republic S00.5326.00.20
FABIA 2000 1.4/55 TDI Engine, Fuel Injection
List of Supplements to Workshop Manual
FABIA 2000
1.4/55 TDI Engine, Fuel Injection
Edition 07.03
Supplement 1
Edition 07.03 04.04
Subject Basic Edition Modifications in Rep. Gr. 01 a 23
Article Number S00.5326.00.20 S00.5326.01.20
Edition 04.04 S00.5326.01.20
List of Supplements
List of Supplements
Edition 04.04 S00.5326.01.20
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics .............................................................................................. 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Actuator diagnosis ..................................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault codes 515 to 19561 ............................................................................ 01-2 Self-diagnosis III ........................................................................................ 01-3 - Readiness code ........................................................................................ 01-3 - Reading readiness code .............................................................................. 01-3 - Generating readiness code .......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Reading measured value block ..................................................................... 01-4 - Display groups 001 to 022, engine idling .......................................................... 01-4 - Display groups 004 through 011 at full load ....................................................... 01-4 - Display group 125 - CAN databus .................................................................. 01-4 page page page page page page page page page page page page page page page 1 1 1 2 3 5 1 1 1 1 1 2 1 1 1
page 10 page 12
23 Fuel Formation, Injection

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

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

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

Interrogating control unit version
The control unit version is displayed once the vehicle system tester -V.A.G 1552- is connected and the engine electronics control unit is selected 01-1 page 2.
Available functions when using the vehicle system tester -V.A.G 1552The conditions under which the desired functions can be selected are given in the following table.
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Self-diagnosis I
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01
Condition Operation 01 02 03 04 05 06 07 08 11
1)
Engine not running, ignition switched on yes yes1) yes no yes yes yes yes yes
Engine idling yes yes yes yes yes yes no yes no
Normal driving yes yes no no yes yes no yes no
Interrogating control unit version Interrogating fault memory Actuator diagnosis Basic setting Erasing fault memory Ending output Coding control unit Reading measured value block Login procedure
Only perform with the ignition on, if the engine does not start.
Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics
Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Battery voltage at least 11.5 volts Earth connection to engine and gearbox O.K. Fuses according to current flow diagram O.K.
Procedure
Connect vehicle system tester -V.A.G 1552- with appropriate cable. Once the vehicle system tester has been connected:
Switch on ignition or start 01-1 page 1 engine depending on the function desired. Note
If data transfer errors are displayed as a result of an
V.A.G 1552 V.A.G 1551/3

S01-0087
incorrect entry, disconnect cable at vehicle system tester, connect it in again and repeat all the steps.
If one of the following messages appears in the dis-
play, test the diagnostic cable Current Flow Diagrams, Electrical Fault Finding and Fitting Locations or Operating Instructions of vehicle system tester.
Vehicle system test The control unit does not respond
HELP
01-1 page 2
Self-diagnosis I
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Vehicle system test Fault in communication set-up Vehicle system test K cable does not connect to earth HELP
01
HELP
Operate the vehicle system tester by referring to the

read-out on the display: Readout on display:
Vehicle system test HELP K cable does not connect to pos. term. Vehicle system test Enter address word XX HELP
Enter address word 01 Engine electronics and confirm entry with Q . The control unit identification appears in the display, e.g.:
045906019BM = Part No. of the control unit (for cur045906019BM 1.4l R3 Coding 00008 EDC G000SG 4958 -> WSC XXXXX
rent control unit version see spare part catalogue)

1.4 ltr. = engine displacement R3 = engine version (3 cyl. in-line engine) EDC = Injection system (Electronic Diesel Control) CC = Cruise control system activated (only on models
with CCS)
000 = Control unit ID MG = Manual gearbox 4958 = Data status (Software version of the control
unit)
Coding 00002 = Coding variant of the control unit WSC XXXXX = Workshop code
Note
If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit Chapter 23-5.

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

-V.A.G 1551/3, 3A, 3B oder 3C-
Interrogating fault memory
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
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Self-diagnosis I
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01
Only if the engine does not start:
Switch on ignition. Select function 02 Interrogate fault memory and confirm with Q . The number of stored faults or No fault recognised appears in the display. If no fault is stored:
X faults detected!
Select function 06 End output and confirm with

If one or several faults are stored:
Q.
Press Press Press
. -> Fault number: 16685 P0301 044 ->
Readout on display, e.g.:

.
Fault source and fault type appear in the display, e.g.:

.
Cylinder 1 Combustion misfiring detected
The stored faults are displayed in sequence.
Select function 06 End output and confirm with Q . Rectify the faults displayed by referring to the fault table Chapter 01-2. Note When carrying out testing and removal and installation operations faults such as connector unplugged or CAN bus faults, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:
Select function 00 for Automatic test sequence and

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

Test conditions
Fault eliminated Fault memory interrogated 01-1 page 3

Note After fault elimination the fault memory must again be interrogated and subsequently erased.
Select function 05 Erase fault memory and confirm

with Q . Readout on display:
Vehicle system test Fault memory was erased ->
01-1 page 4
Self-diagnosis I
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01
Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Select function 06 End output and confirm with Q . Perform a test drive. Then, once again interrogate the
fault memory. No fault must be displayed.
Actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 1 - Exhaust gas recirculation valve -N182 - AC compressor engagement 3 - Solenoid valve for charge pressure control -N754 - Changeover valve for intake manifold flap -N2395 - Glow period warning lamp -K296 - Glow plug relay -J527 - Low heat output relay -J3598 - High heat output relay -J3609 - Fault lamp Note
Actuation of the individual control elements is limited
to 30 seconds.
If the actuator diagnosis must be repeated without the
engine being started in the meantime, switch off ignition for about 20 seconds. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Fuses according to current flow diagram O.K.

Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
Select function 03 final control diagnosis.

Readout on display: The valve must click.
Actuator diagnosis Exhaust gas recirculation valve -N18 ->
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Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Testing Exhaust gas recirculation valve -N18 Chap. 23-1.

. Actuator diagnosis AC compressor engagement ->
Press
Readout on display: This test step is also activated on vehicles without AC system. Disregard display.
Press
. Actuator diagnosis -> Charge press.control solenoid valve -N75
Readout on display: The valve must click. Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Test charge pressure control solenoid valve -N75 Chap. 23-1.

. Actuator diagnosis -> Intake manif.flap change-over valve-N239
Press
Readout on display: The engine must stop. If the engine does not stop:
Switch off ignition. Inspecting Intake manifold flap change-over valve

-N239- Chap. 23-1.
Continue final control diagnosis with the engine off

and the ignition switched on.
Press
. Actuator diagnosis Glow period warning lamp -K29 ->
Readout on display: The warning light for glow period must flash. If the warning light for glow period does not flash:
Testing Glow period warning lamp -K29- Current

Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis Glow plug relay -J52 ->
Readout on display: The relay must click.
01-1 page 6
Self-diagnosis I
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection It is also possible to observe the relay switching on and off by the interior light becoming brighter or darker (caused by the high power consumption of glow plugs). If the relay does not click:
01
Test glow plug relay -J52- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis Low heat output relay J359 ->
Readout on display: The relay must click. If the relay does not click:
Test low heat output relay -J359- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis High heat output relay -> -J360
Readout on display: The relay must click. If the relay does not click:
Test high heat output relay -J360- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis Fault lamp ->
Readout on display: The exhaust emission warning lamp must flash. If the exhaust emission warning lamp does not flash:
Test exhaust emission warning lamp Current Flow

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

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

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

If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth
connections according to current flow diagram. Only if no fault is detected here should the part be replaced. This applies in particular if faults are shown as sporadic (SP).
If Info in literature appears in the display of the vehicle system tester - V.A.G 1552- look for the text required in
the fault table under the fault code. Readout on -V.A.G 155200515 Hall sensor -G40 no signal or signal not within the tolerance Rectifying fault
Test camshaft position sensor -G40- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations
Remove open circuit in wiring or short circuit according to current Inspect position of camshaft and rotor 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
00671 Cruise control system switch -E45 00741 Brake pedal monitoring 01117 Load signal for alternator terminal DF
undefined switch status Implausible signal Implausible signal
Test cruise control system Chap. 01-4, display groups 006 and
022
Test brake light switch - F- and brake pedal switch -F47- Chap.
01-4, display group 006
Test wiring and generator Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations
01193 Open circuit or Low heat output relay - short circuit to J359 earth 01194 High heat output relay -J360 01282 Intake manifold flap change-over valve N239 16485 Air mass meter -G70 Open circuit or short circuit to earth Open circuit or short circuit to earth Implausible signal
Test low heat output relay -J359- with final control diagnosis
Chap. 01-1
Test high heat output relay -J360- with final control diagnosis
Chap. 01-1
Test intake manifold flap changeover valve -N239- with final control
diagnosis Chap. 01-1
Test air mass meter -G70 - Chap. 01-4, display group 003
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Self-diagnosis II
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01
Readout on -V.A.G 155216684 Combustion misfiring detected 16685 Cyl. 1 combustion misfirings detected 16686 Cyl. 2 combustion misfirings detected 16687 Cyl. 3 combustion misfirings detected 16705 Implausible sigEngine speed sender - nal G28 16706 No signal Engine speed sender G28 Rectifying fault
Inspecting compression pressure 1.4/55 TDI Engine, Mechanics;

Rep. Gr. 15
Check unit injector Chap. 23-3
Inspecting Engine speed sender -G28- Chap. 23-1 Inspecting Engine speed sender -G28- Chap. 23-1 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248 - Chap.

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

16885 Vehicle speed signal 16944 Voltage supply 16946 Voltage supply 16947 Voltage supply 16955 Brake light switch -F 16989 Control unit defective 17068 Glow period control unit 1 17552 Air mass meter -G70 17553 Air mass meter -G70 17554 Air mass meter -G70
Implausible signal Implausible signal Voltage too low Voltage too high Implausible signal
Test vehicle speed signal Chapter 23-6 Test cables to diesel direct injection system control unit - J248- according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test brake light switch - F- and brake pedal switch -F47- Chap.
01-4, display group 006

23-5 Implausible signal Open circuit or short circuit to earth Short circuit to positive Supply voltage
Test glow plug relay -J52- with final control diagnosis Chap. 01-1 Test air mass meter -G70- Chap. 01-4, display group 003 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

23-5
01-2 page 2
Self-diagnosis II
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection Readout on -V.A.G 155217563 Intake manifold pressure sender -G71 17564 Intake manifold pressure sender -G71 17565 Intake manifold pressure sender -G71 17568 Intake manifold temperature sender -G72 17569 Intake manifold temperature sender -G72 17570 Fuel temperature sender -G81 17571 Fuel temperature sender -G81 17663 Coolant temperature sender -G62 17664 Coolant temperature sender -G62 17668 Unit injector solenoid valve cyl. 1 -N240 17669 Unit injector solenoid valve cyl. 1 -N240 17670 Unit injector solenoid valve cyl. 1 -N240 17671 Unit injector solenoid valve cyl. 2 -N241 17672 Unit injector solenoid valve cyl. 2 -N241 17673 Unit injector solenoid valve cyl. 2 -N241 17674 Unit injector solenoid valve cyl. 3 -N242 17675 Unit injector solenoid valve cyl. 3 -N242 Short circuit to positive Open circuit or short circuit to earth Supply voltage Rectifying fault
01
Test intake manifold pressure sender -G71- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

23-5
Test charge pressure Chap. 01-4, display group 010 Test intake manifold temperature sender -G72- Chap. 01-4, display group 007
Short circuit to earth Open circuit/ Short circuit to positive Short circuit to earth Open circuit/ Short circuit to positive Open circuit/ Short circuit to positive Short circuit to earth

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

007

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

007

23-5
Implausible signal Regulating limit exceeded Regulating limit not reached Implausible signal Regulating limit exceeded Regulating limit not reached Implausible signal Regulating limit exceeded
Check unit injector Chap. 23-3 Inspecting fuel supply 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 20
Rep. Gr. 20
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Self-diagnosis II
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01
Readout on -V.A.G 155217676 Unit injector solenoid valve cyl. 3 -N242 17795 Control unit defective 17810 Exhaust gas recirculation valve -N18 17849 Exhaust gas recirculation valve -N18 17910 Fuel pump relay -J17 17911 Load signal for alternator terminal DF 17931 Crash signal from airbag CU 17948 Vehicle speed signal Short circuit to positive Open circuit or short circuit to earth Short circuit to positive Implausible signal Implausible signal Signal too high Regulating limit not reached Rectifying fault
Rep. Gr. 20

23-5
Test exhaust gas recirculation valve -N18- with final control diagnosis Chap. 01-1
Inspecting exhaust gas recirculation Chap. 23-4
Testing fuel pump relay -J17- Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations
Test generator Electrical System; Rep. Gr. 27 Reading measured value block, display group 016 Chap. 01-4 Perform airbag system self-diagnosis Body Fitting Work;
Rep. Gr. 01
17954 Charge pressure control solenoid valve N75 17957 Charge pressure control solenoid valve N75 17958 Charge pressure 17964 Charge pressure control 17965 Charge pressure control 17977 Cruise control system switch -E45 17978 Engine control unit blocked1) 18008 Voltage supply terminal 15 18009 Voltage supply relay terminal 30 -J3172)
Short circuit to positive
Test vehicle speed signal Chapter 23-6 Test CAN databus lines Chapter 23-6 Test dash panel insert Electrical System; Rep. Gr. 90 Test charge pressure control solenoid valve -N75- with final control diagnosis Chap. 01-1
Open circuit or short circuit to earth Control difference Regulating limit not reached Regulating limit exceeded Implausible signal
Test charge pressure control solenoid valve - N75- with final control
Test charge pressure control 1.9 l/96 kW (TDI) Engine, Mechanical Components; Rep. Gr. 21
Analyse measured value block, display groups 006 and 022

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

Electrical System; Rep. Gr. 90
Adapt diesel direct injection system control unit - J248- to electronic

immobiliser Electrical System; Rep. Gr. 96
Voltage too low
Test immobiliser Electrical System; Rep. Gr. 96 Test voltage supply for diesel direct injection system control unit
-J248- Chap. 23-5
Implausible signal
Test diesel direct injection system relay -J322- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
01-2 page 4
Self-diagnosis II
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection Readout on -V.A.G 155218017 Crash disconnect activated 18020 Engine control unit 18024 Glow period warning lamp -K29 18025 Glow period warning lamp -K29 18026 Glow plug relay -J52 18027 Glow plug relay -J52 18034 Data BUS drive 18039 Accelerator pedal position sender -G79 18040 Accelerator pedal position sender -G79 18043 Data BUS drive Incorrectly coded Short circuit to positive Open circuit/ Short-circuit to earth Short circuit to positive Short circuit to earth Missing message from gearbox CU Signal too high Rectifying fault
01
Read out fault memory of airbag control unit Body Fitting Work;
Rep. Gr. 01
Replace airbag control unit Body Fitting Work; Rep. Gr. 69 Code diesel direct injection system control unit -J248- Chap. 23-5 Test glow period warning lamp -K29- with final control diagnosis
Chap. 01-1
Test glow plug relay -J52 - with final control diagnosis Chap. 01-1
Test CAN databus lines Chapter 23-6 Test accelerator pedal position sender -G79- Chap. 01-4, display
group 002
Supply voltage
Missing message from air conditioning system CU Missing message from airbag CU missing message form electron. CU
Test CAN databus lines Chapter 23-6 Read out air conditioning system control unit fault memory
Heating, Air conditioning; Rep. Gr. 87
18044 Data BUS drive 18045 Data BUS drive
Test CAN databus lines Chapter 23-6 Read out fault memory of airbag CU Body Work; Rep. Gr. 01 Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90
18047 Implausible sig1/2 for accelerator nal pedal position sender G79+G185 18048 Control unit defective 18056 Data BUS drive 18057 Data BUS drive 18058 Data BUS drive 18062 Read out fault memory of combiinstrument defective Missing message from ABS CU Missing message from combiinstrument
Test accelerator pedal position sender -G79- Chap. 01-4, display

group 002

23-5

23-5
Test CAN databus lines Chapter 23-6 Read out fault memory of engine CU Chapter 01-1 Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Running Gear; Rep. Gr. 45
Test CAN databus lines Chapter 23-6 Read out fault memory of dash panel insert Electrical System;
Rep. Gr. 90
Perform self-diagnosis of the dash panel insert Electrical System;

Rep. Gr. 90
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01
Readout on -V.A.G 155218065 Air conditioning system inlet/outlet 18071 Actuation of unit injector solenoid valve 18072 Actuation of unit injector solenoid valve 18073 Actuation of unit injector solenoid valve 18074 Unit injector solenoid valve cyl. 1 -N240 18075 Unit injector solenoid valve cyl. 2 -N241 18076 Unit injector solenoid valve cyl. 3 -N242 18090 Data BUS drive 18097 Data BUS drive 19456 Glow period warning lamp -K29Short circuit to positive Short circuit to positive Electrical fault in the circuit Mechanical fault Rectifying fault
Test AC compressor control with final control diagnosis Chap. 011
Replace unit injector Chap. 23-2 Check unit injector Chap. 23-3
Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit implausible message from ABS CU Implausible message from electron. CU Missing message from combiinstrument
Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Running Gear;
Rep. Gr. 45
Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90
Test CAN databus lines Chapter 23-6 Test accelerator pedal position sender -G79- Chap. 01-4, display
group 002
19458 Implausible sigKick-down switch -F8- nal 19459 Short circuit to Low heat output relay - positive J359 19461 High heat output relay -J360 19463 Camshaft pos. sensor => Sender -G40 Short circuit to positive No signal
Test low heat output relay -J359 - with final control diagnosis
Chap. 01-1
Test high heat output relay -J360 - with final control diagnosis
Chap. 01-1

Inspect position of camshaft and rotor 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15
01-2 page 6
Self-diagnosis II
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection Readout on -V.A.G 155219464 Camshaft pos. sensor => Sender -G40 Signal outside tolerance Rectifying fault
01

19560 Intake manifold flap change-over valve N239 19561 Intake manifold flap change-over valve N239
1)
Short circuit to positive
Test intake manifold flap changeover valve -N239- with final control
Open circuit or short circuit to earth
2)
When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key the fault is changed to a sporadic fault. Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.
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Self-diagnosis II
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01-3
Self-diagnosis III
Readiness code Reading readiness code

Operation The readiness codes are two 8-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system was successfully performed (e.g. exhaust gas recirculation system), the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that the systems operate according to the specifications. If a fault is detected during diagnosis, it is then stored in the fault memory. The readiness code is erased through deletion of the fault memory, that is all relevant points will be set to 1. Generation of readiness code refers to the activation of the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems etc. Procedure Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine electronics Chap. 01-1. display group number 017. Readout on display:
Select function 08 Read measured value block and

Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 1 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Diagnosis of other systems Diagnosis of fuel supply Ignore Meaning
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Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system Meaning
If the specified values are not reached, generate readiness code 01-3 page 2.
Press key. Select function 06 End output and switch ignition off.
Generating readiness code

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

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

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

007, display block 4.
Procedure
Connect vehicle system tester -V.A.G 1552-. Select
address word 01 Engine electronics Chapter 011. Note
Certain work steps must be carried out twice, in order to achieve the readiness code.
Work step 1: Interrogating fault memory
Select function
confirm with Q .
0 2 Interrogate fault memory and X faults detected
The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
01-3 page 2
Self-diagnosis III
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01
Rectify the faults by referring to the fault table

Chapter 01-2. If no fault is stored:
Press
Work step 2: Erasing fault memory
Select function
firm with Q . Note
0 5 Erase fault memory and con-
Readiness code is erased each time the fault memory is erased. Readout on display: Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Vehicle system test The fault memory is erased ->
Press
Work step 3: Switch off ignition
Wait at least 5 seconds with ignition OFF.

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

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

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

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

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

Work step 7: Switch off ignition
Wait at least 5 seconds with ignition OFF.

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

Work step 9: 2. Testing fuel supply and other systems
Start engine. Function

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

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

rpm for at least 10 seconds. Readout on display:
Press Select
C. 0 1 7 for display group 017. Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Readout on display: Specification in display field 2: 00000110 Specification in display field 4: 00000000
Press . If the specified values are not reached, once again repeat procedure for generating readiness code 01-3 page 2.
Work step 11: Interrogating fault memory
Select function
confirm with Q .
0 2 Interrogate fault memory and X faults detected
The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
Rectify the faults by referring to the fault table
Chapter 01-2 and generate readiness code again 01-3 page 2.
01-3 page 4
Self-diagnosis III
Edition 04.04 S00.5326.01.20
FABIA 2000 1.4/55 TDI Engine, Fuel Injection If no fault is stored:
01
Press
. Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Readiness code was successfully generated, if no fault is stored after two work sequences of the test procedure in the fault memory for the engine control unit and if the following values are displayed in the display group 017.
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Self-diagnosis III
01-3 page 5
01
01-3 page 6
Self-diagnosis III
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01
01-4
Self-diagnosis IV
Reading measured value block

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Coolant temperature must be at least 80 C. All electrical consumers, e.g. lights and rear window
heater, must be switched off.
If vehicle is equipped with air conditioning, this must

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

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

Display group 001 in idle (engine warm, coolant temperature not below 80C)
Read measured value block 1 xxx rpm 1 xx.x mg/s 2 x.xx KW 3 xxx.x C 4 < Display field Coolant temperature Fuel delivery duration (set value) Injection rate Idling speed Specification 80.0110.0 C 4...7 KW 3.09.0 mg/s 800970 rpm Analysis ---- 01-4 page 1 --< Readout on display
Analysis: Display group 001, display field 2 - Injection rate

Display -V.A.G 1552below 3.0 mg/s above 9.0 mg/s Rectifying fault
Check unit injector Chap. 23-3. Warm up engine by running at high revs and repeat test. Check unit injector Chap. 23-3.
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Self-diagnosis IV
01-4 page 1
01
Read measured value block 2 xxx rpm 1 xxx.x % 2 xxx 3 xxx.x C 4 < Display field Coolant temperature Operating position Accelerator pedal position Idling speed Specification 80.0110.0 C 010 0.0 % --Analysis -- 01-4 page 2 01-4 page 2 01-4 page 1 < Readout on display
Analysis: Display group 002, display field 2 - Accelerator pedal position

Display -V.A.G 15521100.0 % Rectifying fault
Test accelerator pedal position sender -G79- Current Flow Diagrams,

Analysis: Display group 002, display field 3 - Operating position

Meaning, if display positions = 1 X X 1 1 X 1 Operating position Air conditioning switched on Idling switch closed (accelerator pedal not pressed) Ignore
Read measured value block 3 xxx rpm 1 xxx mg/s 2 xxx mg/s 3 xxx % 4 < Display field On/off ratio (actuation) of exhaust gas recirculation valve drawn in air mass (actual) drawn in air mass (nominal) Idling speed Specification 3080 % Analysis --< Readout on display
258...410 mg/s 278...390 mg/s ---
01-4 page 3 01-4 page 3 01-4 page 1
01-4 page 2
Self-diagnosis IV
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01
Analysis: Display group 003, display field 2 - inducted air mass (set value)
Display -V.A.G 1552above 390 mg/s Rectifying fault
Warm up engine by running at high revs and repeat test.
Analysis: Display group 003, display field 3 - inducted air mass (actual value)
Display -V.A.G 1552below 258 mg/s above 410 mg/s Rectifying fault
Test exhaust gas recirculation Chap. 23-4. Inspect intake system for leaks. Warm up engine by running at high revs and repeat test. Engine idles for too long, briefly blip throttle. Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3 xx.x KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Idling speed Specification -3+3 KW 4.07.0 KW 39 b. TDC --Analysis 01-4 page 3 -- 01-4 page 3 01-4 page 1 < Readout on display
Analysis: Display group 004, display field 2 - commencement of injection (set value)
Display -V.A.G 1552less than 3 BTDC Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Analysis: Display group 004, display field 4 - Synchronizing angle

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

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

Rep. Gr. 15
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Self-diagnosis IV
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01
Read measured value block 5 xxx rpm 1 xx.x mg/s 2 xx.x b. (n.) TDC 3 xxx.x C 4 < Display field Coolant temperature Synchronisation when starting drawn in air mass when starting Idling speed Specification 80110 C 1 915 mg/s --Analysis ------ 01-4 page 1 < Readout on display
Read measured value block 6 xxx km/h 1 xxx 2 xx.x % 3 xxx 4 < Display field Operating condition of the cruise control system Accelerator pedal position Status of the brake and clutch pedal switch Vehicle speed Specification xxx 0% 000 0 km/h Analysis 01-4 page 4 01-4 page 2 01-4 page 4 --< Readout on display
Analysis: Display group 006, display field 2 Brake pedal or clutch pedal monitoring
Meaning, if display positions = 1 X X X 1 1 1 Operating position Brake light switch -F- closed (brake pedal operated) Brake pedal switch -F47- opened (brake pedal operated) Clutch pedal switch -F36- opened (clutch pedal operated)
Analysis: Display group 006, display field 4 - Operating condition of cruise control system
Display 0 1 255 Operating position Vehicles with activated cruise control system, switch in position OFF Vehicles with activated cruise control system, switch in position ON Vehicle without cruise control system or cruise control system function in engine control unit not activated
Self-diagnosis IV Edition 04.04 S00.5326.01.20
01-4 page 4
01
Display group 007 with ignition switched on (engine cool and standing)
Read measured value block 7 xxx.x C 1 xxx % 2 xxx.x C 3 xxx.x C 4 < Display field Coolant temperature Intake manifold temperature Status of the fuel cooling Fuel temperature
1)
< Readout on display
Specification approx. ambient temperature 1) approx. ambient temperature 1) 0% approx. ambient temperature 1)
Analysis 01-4 page 5 01-4 page 5 -- 01-4 page 5
It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intake manifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant sender.
Analysis: Display group 007, display field 1 - Fuel temperature

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

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

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

In the event of a fault the fuel temperature is displayed instead.
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Self-diagnosis IV
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01
Read measured value block 10 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field Accelerator pedal position Charge pressure (actual) Atmospheric pressure drawn in air mass (actual) Specification 0.0 % 900...1150 mbar 900...1100 mbar 258...410 mg/s Analysis 01-4 page 2 ---- 01-4 page 3 < Readout on display
Read measured value block 11 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual) Charge pressure (nominal) Idling speed Specification 2595 % Analysis -- < Readout on display
9001150 mbar 9001100 mbar ---
---- 01-4 page 1
Read measured value block 13 x.xx mg/s 1 x.xx mg/s 2 x.xx mg/s 3 4 < Display field Specification -3+3 mg/s -3+3 mg/s -3+3 mg/s Analysis 01-4 page 6 01-4 page 6 01-4 page 6 < Readout on display
Smooth running control - injected quantity cylinder 3 Smooth running control - injected quantity cylinder 2 Smooth running control - injected quantity cylinder 1
Analysis: Display group 013, display field 1 through 3 - Idle smoothness regulator
The injection system has an idle smoothness regula-
tor. It is possible to detect differences in performance between individual cylinders (part tolerances, injector
01-4 page 6
Self-diagnosis IV
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection flow, compression etc.) and to compensate for these by selectively metering the quantity injected in the idling speed range.
Differences are detected in the idling speed range on
01
the basis of the signal supplied by the engine speed sender which supplies three signals to the control unit for each crankshaft revolution. If the signals have the same rhythm, the cylinder have the same output. If a cylinder has a lower output, the crankshaft will need more time for the next half crankshaft rotation. As opposed to this a high output cylinder will accelerate the crankshaft to such an extent that it will need less time.
Once the control unit has identified a deviation, the
relevant cylinder will immediately be supplied with a greater or smaller injection rate until the engine again runs smoothly.
+ mg/s: The relevant cylinder has less output and is
therefore supplied with more fuel.

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

Read measured value block 16 xxx % 1 xxxxxxxx 2 xx 3 4 < Readout on display xx.x V < Display field Supply voltage of the engine control unit Heating element control Auxiliary heating Generator capacity Specification 13.514.5 V xx 1x000001 595 % Analysis 01-4 page 8 01-4 page 8 01-4 page 7 ---
Analysis: Display group 016, display field 2 - Auxiliary heating

Meaning, if display positions = 1 X X X X X X X X 1 1 1 1 1 1 1 1 Additional heating deactivated, because: Coolant temperature greater than 7080C or intake air temperature greater than +5C Generator defective Battery voltage below 9 V Engine speed less than 800 rpm Engine start within the last 10 seconds Coolant temperature sender -G62- or Intake manifold temperature sender -G72- defective Ignore Ignore
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Analysis: Display group 016, display field 3 Control of the heating elements
Meaning, if display positions = 1 X 1 X 1 Operating position Low heat output relay -J359- on High heat output relay -J360- on
Analysis: Display group 016, display field 4 - supply voltage of engine control unit
Display -V.A.G 1552below 13.5 V Rep. Gr. 27. Rectifying fault
Test generator and battery voltage, charge battery Electrical System; Increase engine speed slightly for a few minutes and switch off additional
consumers.
Test supply voltage of engine control unit Chap. 23-5. Rectify any current drain.
above 14.5 V
Test voltage regulator, replace if necessary Electrical System;

Rep. Gr. 27.
Remove start aid cable or quick charger.
Display group 018 in idle

Read measured value block 18 xx 1 xx 2 xx 3 xx 4 < Display field Ignore Unit injector solenoid valve cyl. 3 Unit injector solenoid valve cyl. 2 Unit injector solenoid valve cyl. 1 0 0 0 01-4 page 8 01-4 page 8 01-4 page 8 Specification Analysis < Readout on display
Analysis: Display group 018, display field 1 through 3 - Display of the conditon of the unit injectors
Display -V.A.G 1552If number instead of zero Rectifying fault
Test injector unit Chap. 23-3. Inspecting fuel supply 1.4 ltr./55 TDI Engine, Mechanics; Rep. Gr. 20.
Display group 022, engine idling

Read measured value block 22 < Readout on display
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection x 1 xxxxxx 2 x 3 x 4 < Display fields Operating state of air conditioning Operating state of charge pressure control Operating state of cruise control Operating condition of the cruise control system Specification 0 0 xxxxxx x Analysis
01
01-4 page 9 01-4 page 9
Analysis: Display group 022, display field 1 - operating state of cruise control system
Operating condition of the cruise control system 0 1 9 Vehicle without CCS or CCS function in engine control unit not activated Vehicles with activated CCS, switch in position OFF Vehicles with activated CCS, switch in position ON
Analysis: Display group 022, display field 2 - operating state of cruise control system
Cruise control Switch B on ON Switch B on RES Switch A operated Switch B to OFF before operating point Switch B to OFF locked
Display field 2 000011 001011 000111 000001 000000
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Self-diagnosis IV
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01
Display groups 004 through 011 at full load
Note
Accelerate vehicle at full throttle before inspecting. The measured values must be read off or printed out
once an engine speed of 3000 rpm is reached (2nd person required).

Pay attention to safety precautions for test drives
Chapter 23-1.
Display group 004 under full load (test drive in 3rd gear, coolant temperature not below 80C)
Read measured value block 4 xxxx rpm 1 xx.x b. TDC 2 xx.x KW 3 x.xx KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification --1724 KW 15 BTDC25 BTDC 28003200 rpm Analysis --------< Readout on display
Display group 008 under full load (test drive in 3rd gear, coolant temperature not below 80C)
Read measured value block 8 xxxx rpm 1 xx.x mg/s 2 xx.x mg/s 3 xx.x mg/s 4 < Display field Injection rate limit based on drawn in air mass (smoke prevention) Injection rate limit based on engine speed (torque limit) Injection rate (driver's instruction) Engine speed Specification 45.055.0 mg/s Analysis 01-4 page 11 < Readout on display
40.049.0 mg/s 60.069.0 mg/s 28003200 rpm
01-4 page 11 01-4 page 10 01-4 page 10
Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
Display -V.A.G 1552below 60.0 mg/s Rectifying fault
Repeat test at full throttle. Test accelerator pedal position sender -G79- Current Flow Diagrams,
01-4 page 10
Self-diagnosis IV
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01
Analysis: Display group 008, display field 3 - Injection rate limit over speed (torque limit)
Display -V.A.G 1552below 40.0 mg/s Rectifying fault
Read off set value at 3000 rpm.
Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
Display -V.A.G 1552below 45.0 mg/s ing and Fitting Locations. Rectifying fault
Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find Test exhaust gas recirculation Chap. 23-4.
Display group 011 under full load (test drive in 3rd gear coolant temperature not below 80C)
Read measured value block 11 xxxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 4095 % Analysis --< Readout on display
18002200 mbar 18002100 mbar 28003200 rpm
01-4 page 11 -----
Analysis: Display group 011, display field 3 - intake manifold temperature (charge pressure)
Display -V.A.G 1552below 1800 mbar or over 2200 mbar Rep. Gr. 21. Rectifying fault
Inspecting charge pressure control 1.4/55 TDI Engine, Mechanics;
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Self-diagnosis IV
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01
Display group 125 - CAN databus
Display group 125 with ignition switched on
Read measured value block 125 ABS 1 1 2 Combi 1 3 4 Airbag 1 < Display field
< Readout on display Specification Airbag 1 Combi 1 ABS 1 --Analysis 01-4 page 12 01-4 page 12 01-4 page 12 ---
Airbag control unit Dash panel insert CU ABS control unit not assigned
Analysis: Display group 125, display field 2, 3 or 4

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

23-1 Diesel Direct Injection System
Safety measures
Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Disconnect and connect wires of the injection and pre-
heating system and measuring device wires when the ignition is switched off.
When the battery is disconnected and reconnected,
carry out rework Electrical System; Rep. Gr. 27.
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
Rules of cleanliness
Pay careful attention to the following rules of cleanliness when working on the fuel supply or fuel injection systems:
Thoroughly clean the connection points and their sur-
roundings before releasing.

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

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

Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately. Replace immediately any hoses which have suffered damage.
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Diesel Direct Injection System
23-1 page 1
23
Overview of fitting locations
Components A through H are not represented in the overview figure. A - Diesel direct injection system relay -J322 on relay carrier Fig. 2 in 23-1 page 3 B - Glow plug relay -J52 on relay carrier Fig. 2 in 23-1 page 3 C - Low heat output relay -J359 on relay carrier Fig. 2 in 23-1 page 3 D - High heat output relay -J360 on relay carrier Fig. 2 in 23-1 page 3 E - Fuel pump relay -J17 on relay carrier Fig. 2 in 23-1 page 3 F - Accelerator pedal position sender -G79 in footwell on the accelerator pedal Fig. 1 in 23-1 page 3 G - Brake light switch -F- and Brake pedal switch -F47 in footwell on the brake pedal Fig. 1 in 23-1 page 3 H - Clutch pedal switch -F36 in footwell on the clutch pedal Fig. 1 in 23-1 page 3 1 - Valve block Component parts of the valve block are: change-over valve for intake manifold flap -N239-, specified resistance: 25...45 Exhaust gas recirculation valve -N18-, specified resistance: 14...20 Charge pressure control solenoid valve -N75-, specified resistance: 25...45 2 - Mechanical exhaust gas recirculation valve at the induction pipe with the intake manifold flap 3 - Sender for the coolant temperature -G62 Specified resistance Fig. 3 in 23-1 page 4 4 - Air mass meter -G705 - Diesel direct injection system control unit -J2486 - Fuel temperature sender -G81 Specified resistance Fig. 4 in 23-1 page 4 7 - Plug connection 3-pin, grey for engine speed sender -G28 3-pin, black for the camshaft position sensor -G408 - Engine speed sender -G28 specified resistance between contacts 1 and 2: 450...550 9 - Camshaft position sensor -G40-
23-1 page 2
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FABIA 2000 1.4/55 TDI Engine, Fuel Injection 10 - Intake manifold pressure sender -G71- with intake manifold temperature sender - G72 Specified resistance Fig. 3 in 23-1 page 4 11 - Fuel filter repairing 1.4/55 TDI Engine, Mechanics; Rep. Gr. 20
23
Fig. 1:
Components in footwell
1 - Clutch pedal switch -F362 - Brake light switch -F- and Brake pedal switch -F473 - Accelerator pedal position sender -G79-
3 2
1
S24-0374
Fig. 2: 12345-
Relay carrier
Fuel pump relay -J17Diesel direct injection system relay -J322Glow plug relay -J52Low heat output relay -J359High heat output relay -J360-
1 2 3 4 5
S23-0139
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23-1 page 3
23
Fig. 3: Resistance of coolant temperature sender -G62- and of intake manifold temperature sender -G72-
The specification in field -A- applies to the temperature range 0 to 50 C, specification in field -B- applies to the temperature range 50 to 100C. Read out examples:
The specification for a temperature of 30C is 1500 to
2000 375
Fig. 4:
Resistance of fuel temperature sender -G81-
The specification in field -A- applies to the temperature range 0 to 65C, specification in field -B- applies to the temperature range 65 to 100C. Read out examples:
4270 660
Disassembling and assembling intake manifold

The intake manifold flap closes for about 3 seconds after switching off the engine and then opens again. This reduces the switch-off impact.
23-1 page 4
Edition 04.04 S00.5326.01.20
FABIA 2000 1.4/55 TDI Engine, Fuel Injection 1 - Intake manifold 2 - O-ring replace 3 - Induction pipe with mechanical exhaust gas recirculation valve and intake manifold flap 4 - Mechanical exhaust gas recirculation valve 5 - 10 Nm 6 - Bracket 7 - Vacuum setting element For intake manifold flap 8 - 25 Nm 9 - Connection pipe for exhaust gas recirculation to exhaust manifold 10 - Gasket replace
23
Removing and installing air filter

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

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

mass meter -3-.
1 2 3 4 5
Remove the air deflector -4- from the air filter. Unscrew the fixing screw -5- from the air filter (tightening torque: 8 Nm).
Carefully remove air filter from the top.

Installing
Note Pay attention to correct positioning of the stop buffer on the bottom part of the air filter (front and rear side).
S23-0125
Installation is carried out in the reverse order.

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23
Disassembling and assembling the air filter
1 - Air guide hose to induction pipe at intake manifold Check fitting position 2 - Spring strap clip 3 - 2 Nm 4 - Top part of air filter cover 5 - Filter insert 6 - Bottom part of the air filter cover 7 - Air deflector to the lock carrier 8 - Air mass meter -G70-
23-1 page 6
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23
23-2
Disassembling and assembling the unit injector
Summary of components
Note
Observe the rules for cleanliness Chapter 23-1. Always replace heat-protection seals and O-rings. Always replace screws tightened to turning angle.
1 - 20 Nm + torque a further 1/4 turn (90 ) replace 2 - Valve-lever shaft with valve levers removing and installing 23-2 page 3 3 - Lock nut, 30 Nm 4 - Adjusting screw pay attention to different version replace when replacing the unit injector and where wear marks are visible Grease the contact surfaces of the unit injector to ball pins using grease -G 000 1005 - Ball pin pay attention to different version 6 - Unit injector pay attention to different version removing and installing 23-2 page 3 Check ball pins for wear marks and replace if necessary Grease the contact surface to the adjusting screw using grease -G 000 100 Valve resistance: Nominal value approx. 0.5 when measuring directly at the valve, when measuring via the 8-pin plug connection at the cylinder head 0.8 ... 1.0 7 - Top O-ring replace 23-2 page 2 8 - Centre O-ring replace 23-2 page 2 9 - Bottom O-ring replace 23-2 page 2 10 - Heat-protection seal replace 11 - Circlip 12 - Cylinder head
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23-2 page 1
23
13 - Clamping pad 14 - 12 Nm + torque a further 3/4 turn (270) replace
Removing and installing O-rings for unit injector

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

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

Observe the correct allocation of the O-rings to the
channels: the ring thickness reduces in the direction of the injection nozzle.
Avoid rolling the O-rings when sliding them on. The O-
rings must not be turned inwards on the slots of the unitinjector.
Remove the heat-protection seal along with the circlip. Clean the seating surfaces for the O-rings in the unit
injector with great care.
Insert the assembling sleeve -T10056/1- on the unit

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

sleeve and into the groove of the unit injector.
Remove assembly sleeve. Insert the assembling sleeve -T10056/2- on the unit
Carefully slide the middle O-ring onto the assembling

sleeve and in the groove of the unit injector.
Remove assembly sleeve.
23-2 page 2
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23
Insert the assembling sleeve -T10056/3- on the unit

Carefully slide the lower O-ring onto the assembling

sleeve and in the groove of the unit injector.
Remove assembly sleeve. Slide on a new heat-protection seal together with the
circlip.
Removing and installing the unit injector

Extractor -T10055 Universal dial gauge holder -MP 3-447 Dial gauge Torque wrench
Note On vehicles with WIV the adjusting screw -1- and the ball pin -2- was changed On old engines with WIV, both variants can be combined.
Removing
Remove upper timing belt cover and cylinder head

while doing so all valve levers must point upwards evenly.
cover 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15.
Rotate the crankshaft approx. in the TDC cylinder 1, Release the counternuts of the adjusting screws -1and unscrew the adjusting screws until the relevant valve lever rests against the tappet spring of the unit injector.
Screw out fixing screws -2- for the valve-lever shaft

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

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

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

For any work procedure involving an adjustment of the
unit injector it is necessary to clean the adjusting screw in the valve lever and also the ball pin of the unit injector and to check them for traces of wear. If there is any wear replace the ball pin and the adjusting screw.
Grease the contact surfaces between the ball pin and
the adjusting screw using -G 000 100-.

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

the stop by exerting a uniform pressure.
Place the clamping pad in the side slot of the unit injector. Note If the unit injector is not perpendicular to the clamping pad the fixing screw may loosen and cause damage to the unit injector or cylinder head.
Align the unit injector as follows: Screw the clamping pad with the new fixing screw until
the unit injector can still easily be turned.
Set the unit injector at a right angle to the bearing shell

of the camshaft.
23-2 page 4
Edition 04.04 S00.5326.01.20
23
Using a caliper gauge, check dimension -a- from the

outer side of the cylinder head to the cylinder surface of the solenoid valve for the unit injector. Removing and installing the unit injector with the old solenoid valve nut Cylinder 1 2 3 Dimension -a244.2 0.8 mm 156.2 0.8 mm 64.8 0.8 mm
Removing and installing the unit injector with the new solenoid valve nut Cylinder 1 2 3 Dimension -a245.0 0.8 mm 157.0 0.8 mm 65.6 0.8 mm
Adjust the unit injector as required, tighten the fixing

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

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

injector.
Turn the crankshaft in the running direction of the engine until the roller of the valve lever is on the drive cam tip.
Roller side -arrow A- is on the highest point. Dial gauge -arrow B- is on the lowest point.
Edition 04.04 S00.5326.01.20
23-2 page 5
23
Remove the dial gauge. Turn the adjusting screw in the valve lever until one
feels a significant resistance (the unit injector is against the stop).
Turn the adjusting screw in the opposite direction from

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

tighten up the lock nut using a torque of 30 Nm.
Place connector onto the unit injector, install the cylinder head cover and insert the upper timing belt cover.
23-2 page 6
Edition 04.04 S00.5326.01.20
23
23-3
Testing components
Test wiring and components with Test box -V.A.G 1598/31 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
Test diesel direct injection system relay -J322The power supply of the injection system occurs via the diesel direct injection system relay - J322-. The precondition for closing of the relay is a voltage supply via terminal 15 to the diesel direct injection system control unit -J248-. This means that diesel direct injection system relay -J322- receives ground (via the Diesel direct injection system control unit -J248-), if the control unit -J248- receives a voltage supply via terminal 15.
Fitting location
The diesel direct injection system relay - J322- is located on the relay carrier in the driver's footwell on the left, relay base 12. Special tools, test and measuring equipment and auxiliary items required
Hand multimeter (e.g. -V.A.G 1526 A-) Adapter cable set (e.g. -V.A.G 1594 C-) Test box -V.A.G 1598/31-
1 5 10 11 6
2 7 12
3 8 13
4 9 14 15
Test conditions
Battery voltage at least 11.5 volts Fuses in fuse holder on battery are O.K.
Check for proper operation
S97-1373
Remove lower part of the dash panel insert on the

driver's side Body work; Rep. Gr. 70.
Switch on ignition.
Diesel direct injection system relay -J322 - must close. Note The clicking of the relay is hardly audible and can therefore best be felt. If the relay does not close:
Test control
Switch off ignition. Connect test box -V.A.G 1598/31 - to wiring loom to
engine control unit 23-3 page 1.
Edition 07.03 S00.5326.00.20
Testing components
23-3 page 1
23
Interconnect bush 18 and bush 4 of the test box using
an auxiliary line. The relay must be closed. If the relay is now closed but did not open during the functional test:
Replace diesel direct injection system control unit

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

the relay carrier.
2 9 6
Connect handheld multimeter for voltage measurement to contact 2 and earth. Specified value: approx. battery voltage If the specified value is not reached:
Testing the wiring Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. If the specified value is reached:
S23-0101
Switch off ignition. Check the following wire for interruption or short-circuit to earth or positive: Contact Test box - V.A.G 1598/31contact 18
2 9 6
If necessary eliminate wire interruption or short-circuit.

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

- J322-.
S23-0101
Testing unit injector valve

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

1234567Connection air filter/exhaust turbocharger to vacuum reservoir at exhaust turbocharger To turbocharger To intake manifold flap To air filter from non-return valve for brake servo unit to mechanical exhaust gas recirculation valve

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

group number 003. Note After selecting display group number 003 and confirming with Q , the idling speed is increased by the engine control unit in display field 1 to 13801420 rpm. The display in display field 2 must switch between EGRn.active and EGR.active every 10 seconds. The following readouts must fluctuate in display fields 3 and 4: Note If a constant value of 539 mg/stroke and higher is shown in display field 3, test the air mass meter Chapter 23-3.
System in basic setting 3 1400 rpm EGRn.active 500 mg/s
-> 20
Edition 07.03 S00.5326.00.20
23-4 page 1
23
EGRn.active: Specification in display field 3: 450600 mg/H specified value in display field 4: 1822 % EGRactive. Specification in display field 3: 160310 mg/H specified value in display field 4: 6367 % If the specified values are not reached:
Inspecting mechanical exhaust gas recirculation valve

1.4/55 TDI Engine, Mechanics; Rep. Gr. 26. 23-4 page 1.
Inspect the connection diagram for the vacuum hoses Test exhaust gas recirculation valve -N18- with final
control diagnosis Chap. 01-1.
23-4 page 2
Edition 07.03 S00.5326.00.20
23
23-5
Engine control unit
Testing voltage supply for engine control unit

Replacing diesel direct injection system control unit -J248Special tools, test and measuring equipment and auxiliary items required
Procedure
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics Chap. 01-1. The vehicle system tester -V.A.G 1552- displays the control unit identification, e. g.:
045906019BM 1.4l R3 Coding 00008 EDC G000SG 4958 -> WSC XXXXX
Note Part No. of control unit and coding.

Select function 06 End output and confirm with Q . Switch off ignition. Remove air filter Chap. 23-1. Release the connector catches and unplug the connectors of the diesel direct injection control unit - J248-. the control unit to the side.
Press off the clips -arrows- to the outside and remove Insert new engine control unit.
After installing the diesel direct injection system control unit -J248-, it is then necessary to carry out the following steps:
Coding new diesel direct injection system control unit

-J248- 23-5 page 2.
Adapt the new diesel direct injection system control
unit -J248- to the immobiliser control unit Electrical System; Rep. Gr. 96.
S24-0373
For vehicles with cruise control system:
Activate CCS function 23-5 page 3. Interrogate fault memory of new engine control unit,
rectify any faults present and erase fault memory Chap. 01-1.
Each time the fault memory is erased, it is then necessary to re-generate the readiness code Chapter 013.
Perform a test drive.
Edition 04.04 S00.5326.01.20
Engine control unit
23-5 page 1
23
Note Comply with the applicable safety instructions during the test drive Chap. 23-1.
Once again interrogate the fault memory of the diesel

direct injection system control unit -J248-.
Coding diesel direct injection system control unit -J248If the code displayed does not match the vehicle or if the diesel direct injection system control unit -J248- has been replaced, it is then necessary to code the control unit as follows. Special tools, test and measuring equipment and auxiliary items required
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1.
Select function 07 coding control unit.

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

confirm with Q . Table of codes: Control unit identification 045 906 019 BM Equipment ABS/Air conditioning/ WIV/ Airbags ABS/ WIV/ Airbags Air conditioning/ WIV/ Airbags WIV/ Airbags ABS/Air conditioning/ WIV ABS/ WIV Air conditioning/ WIV WIV ABS/ Air conditioning/ Airbags ABS/ Airbags Air conditioning/ Airbags Airbags ABS/ Air conditioning ABS Air Conditioning without ABS/ without Air conditioning/ without WIV/ without Airbags Code number 00002 00005 00008 00011 00014 00017 00020 00023 00102 00105 00108 00111 00114 00117 00120 00123
23-5 page 2
Engine control unit
Edition 04.04 S00.5326.01.20
FABIA 2000 1.4/55 TDI Engine, Fuel Injection The vehicle system tester -V.A.G 1552- displays the control unit identification, e. g.:
045906019BM 1.4l R3 Coding 00005 EDC G000SG 4958 -> WSC XXXXX
23
Select function 06 End output and confirm with Switch ignition off and on again.
Note
Q.
The entered coding is activated by switching the ignition on and off again.
Activating and deactivating cruise control system (CCS)

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

Chap. 01-1
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1. Readout on display, e.g.: If G000SG is displayed, the cruise control system is active. Readout on display: If 000SG is displayed, the cruise control system is not active.
045906019BM 1.4l R3 Coding 00008 EDC 000SG 4958 -> WSC XXXXX 045906019BM 1.4l R3 Coding 00008 EDC G000SG 4958 -> WSC XXXXX
Press . Select function 11 login procedure.

Readout on display:
Login procedure Enter code number XXXXX
Enter code number as stated in the table.

Code number 11463 16167 Cruise control system (CCS) Activate CCS Deactivate CCS
Confirm with
Q. Q.
After activating the cruise control system perform a test drive as a functional test.
Edition 04.04 S00.5326.01.20
Engine control unit
23-5 page 3
23
23-5 page 4
Engine control unit
Edition 04.04 S00.5326.01.20
23
23-6
Testing auxiliary signals
Edition 07.03 S00.5326.00.20
23-6 page 1
23
23-6 page 2
Edition 07.03 S00.5326.00.20
28
28 Glow Plug System

28-1 Testing preheating system
Edition 07.03 S00.5326.00.20
Testing preheating system
28-1 page 1
28
28-1 page 2
Testing preheating system
Edition 07.03 S00.5326.00.20

Workshop Manual - TDI Engine Fuel Ingection AMF

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Service

1.4/55 TDI Engine, Fuel Injection

Service Department. Technical Information

Printed in Czech Republic S00.5326.00.20

Printed in Czech Republic S00.5326.00.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

List of Supplements to Workshop Manual

Edition 07.03 04.04

Subject Basic Edition Modifications in Rep. Gr. 01 a 23

Article Number S00.5326.00.20 S00.5326.01.20

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

23 Fuel Formation, Injection

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

28 Glow Plug System

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Properties of the self-diagnosis

Technical data of self-diagnosis

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Engine idling yes yes yes yes yes yes no yes no

Normal driving yes yes no no yes yes no yes no

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

V.A.G 1552 V.A.G 1551/3

Vehicle system test The control unit does not respond

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Operate the vehicle system tester by referring to the

rent control unit version see spare part catalogue)

spond to the vehicle, replace the control unit Chapter 23-5.

Interrogating and erasing fault memory

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

Interrogating fault memory

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Select function 06 End output and confirm with

Press Press Press

. -> Fault number: 16685 P0301 044 ->

Readout on display, e.g.:

Fault source and fault type appear in the display, e.g.:

Cylinder 1 Combustion misfiring detected

The stored faults are displayed in sequence.

Select function 00 for Automatic test sequence and

Erasing fault memory

Fault eliminated Fault memory interrogated 01-1 page 3

Select function 05 Erase fault memory and confirm

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

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

Fuses according to current flow diagram O.K.

Select function 03 final control diagnosis.

Edition 04.04 S00.5326.01.20

FABIA 2000 1.4/55 TDI Engine, Fuel Injection

Testing Exhaust gas recirculation valve -N18 Chap. 23-1.

. Actuator diagnosis -> Charge press.control solenoid valve -N75

Test charge pressure control solenoid valve -N75 Chap. 23-1.

Switch off ignition. Inspecting Intake manifold flap change-over valve

Continue final control diagnosis with the engine off

. Actuator diagnosis Glow period warning lamp -K29 ->

Testing Glow period warning lamp -K29- Current

. Actuator diagnosis Glow plug relay -J52 ->