Skoda Octavia Mk1 - 05 - Drive Unit

SKODA OCTAVIA
MK1
Drive Unit
1.6 ltr./74 kW Engine, Simos 2 injection
and ignition system
1.6 LTR./74 KW ENGINE - MECHANICAL COMPONENTS.........................................................5

TECHNICAL DATA....................................................................................................................................... 5
Engine number.................................................................................................................................. 5
Engine characteristics....................................................................................................................... 6
ENGINE ASSY,CYLINDER BLOCK,CRANKCASE.......................................................................7
REMOVING AND INSTALLING ENGINE.............................................................................................................. 7
Removing.......................................................................................................................................... 7
Securing the engine to the assembly stand....................................................................................17
Install.............................................................................................................................................. 19
Tightening torques.......................................................................................................................... 20
Align unit mounting for engine - gearbox........................................................................................ 21
Assembly bracket............................................................................................................................ 22
ENGINECRANKSHAFT GROUP, PISTONS.............................................................................24
DISASSEMBLING AND ASSEMBLING ENGINE.................................................................................................... 24
Removing and installing V-ribbed belt............................................................................................. 24
Removing and installing, tightening the timing belt........................................................................28
Inspecting semi-automatic tensioning pulley..................................................................................35
REMOVING AND INSTALLING CRANKSHAFT...................................................................................................... 36
Replacing gasket ring for crankshaft -on the belt pulley side-.........................................................41
Removing and installing pressure plate.......................................................................................... 44
Removing and installing drive plate................................................................................................ 44
Removing and installing the front sealing flange............................................................................47
DISASSEMBLING AND ASSEMBLING PISTON AND CONROD..................................................................................50
ENGINE CYLINDER HEAD, VALVE GEAR..............................................................................55
REMOVING AND INSTALLING CYLINDER HEAD.................................................................................................. 55
Removing and installing upper part of collecting intake manifold...................................................58
removing and installing cylinder head cover...................................................................................61
Removing cylinder head.................................................................................................................. 61
Inspecting the cylinder head for distortion......................................................................................65
Reworking a cylinder head.............................................................................................................. 65
Installing cylinder head................................................................................................................... 66
Testing the compression.................................................................................................................. 67
REPAIRING VALVE GEAR............................................................................................................................ 69
Replacing camshaft gasket ring...................................................................................................... 73
Removing and installing camshaft.................................................................................................. 75
Testing hydraulic bucket tappets..................................................................................................... 77
Replacing valve stem seals............................................................................................................. 78
Inspect valve guides........................................................................................................................ 80
Replacing the valve guides............................................................................................................. 80
Reworking valve seats..................................................................................................................... 81
ENGINE LUBRICATION...................................................................................................... 85
REMOVING AND INSTALLING PARTS OF THE LUBRICATION SYSTEM........................................................................85
Disassembling and assembling oil filter holder...............................................................................87
Removing and installing oil pan...................................................................................................... 88
Testing oil pressure and oil pressure switch....................................................................................90
ENGINE COOLING............................................................................................................ 94
REMOVING AND INSTALLING PARTS OF THE COOLING SYSTEM.............................................................................94
Parts of the Cooling System............................................................................................................ 94
Draining and filling up coolant......................................................................................................... 95
Removing and installing radiator..................................................................................................... 98
Removing and installing coolant pump......................................................................................... 101

Removing and installing, testing coolant thermostat....................................................................103
Installing coolant pipe................................................................................................................... 105
Checking the coolant system for tightness....................................................................................105
FUEL SUPPLY, GAS OPERATION.......................................................................................107
REMOVING AND INSTALLING PARTS OF THE FUEL SUPPLY SYSTEM......................................................................107
Removing and installing fuel tank with attached parts and fuel filter............................................107
Safety precautions when working on the fuel supply system........................................................111
Rules of cleanliness....................................................................................................................... 111
Removing and installing the fuel delivery unit..............................................................................111
Removing and installing the fuel gauge sender............................................................................113
Removing and installing the fuel tank........................................................................................... 113
Connecting remote control............................................................................................................ 115
Check the fuel delivery unit........................................................................................................... 116
Check fuel flow rate...................................................................................................................... 118
Removing and installing activated charcoal filter system.............................................................119
Repairing the accelerator control.................................................................................................. 120
Adjust accelerator control............................................................................................................. 120
EXHAUST SYSTEM......................................................................................................... 122
REMOVING AND INSTALLING PARTS OF THE EXHAUST SYSTEM..........................................................................122
Removing and installing front exhaust pipe..................................................................................124
Removing and installing exhaust manifold....................................................................................125
Replacing front or rear silencer..................................................................................................... 126
Aligning exhaust system free of stress.......................................................................................... 127
Checking the exhaust system for leaks......................................................................................... 128
1.6 LTR./74 KW ENGINE, SIMOS 2 INJECTION AND IGNITION SYSTEM................................130
SELF DIAGNOSIS, V.A.G INSPECTION SERVICE..............................................................................................130
Operation...................................................................................................................................... 130
Technical data of self-diagnosis..................................................................................................... 130
Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for engine
electronics..................................................................................................................................... 131
Interrogating and erasing fault memory........................................................................................ 133
Actuator diagnosis......................................................................................................................... 134
Coding control unit........................................................................................................................ 136
SELF-DIAGNOSIS I.................................................................................................................................. 138
Fault table..................................................................................................................................... 138
SELF-DIAGNOSIS II................................................................................................................................. 159
Reading measured value block..................................................................................................... 159
Read measured value block; display groups 000 to 010...............................................................159
Read measured value block: display groups 011 to 099...............................................................171
REPAIR SIMOS 2 INJECTION SYSTEM........................................................................................................... 186
Safety measures........................................................................................................................... 186
Rules of cleanliness....................................................................................................................... 186
Technical data............................................................................................................................... 186
Overview of fitting locations.......................................................................................................... 187
For vehicles 07.97.................................................................................................................................. 187
For vehicles 08.97 .................................................................................................................................. 189
REMOVING AND INSTALLING PARTS OF THE INJECTION SYSTEM.........................................................................191

Disassembling and assembling top part of intake manifold..........................................................196
Disassembling and assembling fuel distributor.............................................................................197
Disassembling and assembling the air filter..................................................................................197
Removing and installing engine covers......................................................................................... 198
Testing lines and components with the test box -V.A.G 1598/22-..................................................198
Replacing engine control unit........................................................................................................ 199
Adapt the engine control unit to the electronic immobiliser..........................................................200
TESTING COMPONENTS AND FUNCTIONS..................................................................................................... 202

Idle testing.................................................................................................................................... 202
Test fuel pressure regulator and holding pressure.........................................................................203
Testing injection valves................................................................................................................. 205
Inspecting the injection rate, tightness and jet formation of the injectors.....................................208
Test fuel pump relay and control................................................................................................... 210
Test air mass meter -G70-............................................................................................................. 213
Testing the intake system for tightness (unmetered air)...............................................................216
Test voltage supply of engine control unit.....................................................................................217
Test intake air temperature sender............................................................................................... 218
Test coolant temperature sender -G62-......................................................................................... 222
CHECKING LAMBDA CONTROL................................................................................................................... 225
Irregularities of the engine after cold start....................................................................................225
Check the function of the lambda control......................................................................................227
Check lambda probe heater.......................................................................................................... 230
Test lambda probe signal line and lambda probe control unit.......................................................231
CHECKING THE FUEL TANK VENTING........................................................................................................... 233
Testing activated charcoal filter system solenoid valve 1..............................................................233
INSPECTING THROTTLE VALVE CONTROL UNIT............................................................................................... 236
Check throttle valve control unit for vehicles 07.97..................................................................237
Check throttle valve control unit for vehicles 08.97 ..................................................................240
Adapt the engine control unit to the throttle valve control unit.....................................................246
TEST INTAKE MANIFOLD CHANGEOVER........................................................................................................ 249
Inspect the vacuum system.......................................................................................................... 249
Test variable intake manifold changeover valve -N156-................................................................250
TESTING AUXILIARY SIGNALS..................................................................................................................... 253
Inspecting AC compressor disconnection......................................................................................253
1.6 ltr./74 kW Engine - Mechanical Components

Technical Data
Engine number
The engine number (engine identification

characters and serial number) is located at the
joint separating the engine and the gearbox.
In addition, a sticker with the engine
identification characters and serial number is
affixed to the toothed belt guard.
The engine code letters are also listed on the
vehicle data sticker.
Engine characteristics
Engine identification characters
Manufactured
Displacement
AEH
AKL
04.97 ?
08.97 ?
1,595
1,595
Power output
kW at rpm
74/5600
74/5600
Torque
Nm at rpm
145/3800
145/3800
mm
81,0
81,0
mm
77,4
77,4
Compression
10,3:1
10,3:1
Firing order
1-3-4-2
1-3-4-2
Fuel - RON
95 unleaded Note
95 unleaded Note
Simos 2
Simos 2
Knock control
Autodiagnostic
Lambda control
Catalytic converter
Exhaust gas recirculation
Turbocharging
EU-2/ECE
EU-3D
Bore
Stroke
Ignition system/fuel injection
Exhaust limits conforming to
1)
At least 91 RON in exceptional cases, although engine output is reduced
Engine assy,cylinder block,crankcase

Removing and Installing Engine
Special tools and workshop equipment required

t
Workshop crane (e.g. - V.A.G 1202 A-)
t
Catch pan (e.g. -V.A.G 1306 -)
t
Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331 -)
t Torque wrench 40 to 200 Nm (e.g. -V.A.G 1332 -)
t
Engine/gearbox jack (e.g. -V.A.G 1383 A -)
t
Pliers for spring strap clips
t
Engine mount -T10012t
Engine mount -MP 1-202t
Repair stand -MP 9-101t
Suspension fixture -MP 9-201 t
Grease -G 000 100- (for vehicles with gearbox)
t
Cable strap
Removing
Note
The engine is removed downwards together with the gearbox.
All cable straps that have been loosened or cut open when the engine was removed must
be fitted again in the same location when the engine is installed again.
The hose connections are secured with screw-type clips, spring-type clips or clamp-type
clips.
t Always replace clamp-type clips with spring-type clips or screw -type clips.
t
t
Fuel hoses at the engine must only be secured with spring-type clips. The use of clamptype or screw-type clips is not allowed.
Use pliers for spring strap clips to fit the spring strap clips.
t Pay attention to the correct assignment of the connectors, if necessary mark.

Procedure
On models fitted with a coded radio set, pay attention to the coding; determine if
necessary.
Remove the battery: Electrical System, Rep. Gr. 27; Removing and installing the battery
Remove battery tray -arrows-.
Open the cap of the coolant expansion

reservoir.
Raise vehicle with a lift platform, pay

attention to the following points:
The arms of the lift platform must be

positioned under the frame side rail.
WARNING
Under no circumstances may the arms of

the lift platform be positioned under the
sills, the front or rear axles.
Both jacking up points at front are located

on both front frame side rails at the height
of the marking on the sill.
WARNING
Never start the engine or engage a gear

when the vehicle is raised, while even one
driving wheel is still in contact with the
ground.
Both rear jacking up points are located on

both front frame side rails at the height of
the marking on the sill.
Remove noise insulation panel -arrows-.
Position drip tray (e.g. -V.A.G 1306-)

under the engine.
Turn drain valve -arrow- at radiator to the

left and pull to the rear, fit auxiliary hose
if necessary.
Remove bottom coolant hose on the oil

cooler -arrow- and drain residual coolant.
Remove caps for nuts and remove

engine cover -arrows-.
Detach air guide hose at throttle valve

connection and at vent housing of the
crankcase ventilation -arrows-.
Detach vent hose -1- and unplug

10
connector from air mass meter -2-.
Unscrew screws -3- and -4-, remove air

filter box completely.
Remove wiper arms Electrical System
Rep.- Gr. 92; windscreen wiper and
washer system
Remove the cooling water tank cover.

Body Work; Rep.-Gr. 66; Trim panels
Unplug the 28-pin connector at engine

control unit -J361-.
Open the cable duct below the air filter

unplug the 10-pin connector.
Detach wiring harness from the engine

and attach to the engine.
Unbolt earth strap -1-.
Detach cables -3- and -4- at starter.
Separate plug connection -2- and pull out

of fixture.
Detach cables from fixture at starter and

lay to the side, unscrew the fixture.
Unbolt cable -1- of terminal 30/B+ at

alternator.
Unplug connector -2- of terminal D+.
Unscrew cable lug -3-.

Detach cable from the fixture.
Unplug connector from monitoring switch

for coolant temperature sensor -F14(only for vehicles with air conditioning
system).
11
Unhook throttle control cable

-arrows-.
Vehicles fitted with a manual gearbox
Press off shift rods -1- and -2- with a

screwdriver.
Unbolt shift mechanism at gearbox

-arrows-.
Remove the slave cylinder -arrows- and

lay aside, secure with wire, do not open
the line system.
Note
Do not depress the clutch pedal.
Unplug connector from reversing light

switch -F4 -.
Detach wiring loom for the fixtures and

run out to the side.
Vehicles with automatic gearbox
12
Use screwdriver to press off selector

lever cable -1- at gearbox selector lever
-4-, pull off securing clasp -3- at support
bearing.
Take off selector lever cable and place to

the side.
Unbolt bracket for pressure line of powerassisted steering at gearbox support.
Disconnect the following plug

connections:
1-
for solenoid valves
2-
for vehicle speed sender - G68-
3-
for multi-function switch -F125 -
4-
for gearbox speed sender -G38 -
Unplug the connector from the

speedometer sender -G22-.
Detach cable harness for the fixtures and

All vehicles
WARNING
The fuel system is under pressure! Before

opening the system lay cleaning cloths
around the connection point. Reduce
pressure by carefully releasing the
connection point.
13
Remove fuel feed line -1- and fuel feed

line -2-, to do so press latch clips at the
separation point. Lines and release
buttons are colour-coded.
Detach hose -3- at the ACF tank.

Detach coolant hoses:
to expansion reservoir (at front coolant

pipe)
to thermostat housing (at bottom of

radiator and at thermostat housing)
to top radiator (at left flange on cylinder

head)
to heating system heat exchanger (each

t 1 hose at coolant pipe and left at cylinder
head)
t
lateral at coolant pipe
t at throttle valve supports (2 hoses)

t
at ATF radiator (vehicles with an

automatic gearbox)
Disconnect the vacuum line from the

brake servo unit.
Note
Mark the rotation direction before

removing the V-ribbed belt. Reversing the
rotation direction of an already used belt
may destroy it. Pay attention to the correct
position of the V-ribbed belt in the belt
pulley when installing it.
14
Swing the the tensioning device in -the

direction of the arrow- detension the Vribbed belt.
Remove the V-ribbed belt.

Remove 2 brackets for the pressure line
of power-assisted steering (on left at
gearbox and below starter).
Remove the belt pulley of the vane
pump.
Unbolt the vane pump of power-assisted

steering and tie up to the front of the
vehicle. The lines on the vane pump
remain connected up.
Vehicles with air conditioning
WARNING
Do not open the refrigerant circuit of the air

conditioning system.
Unscrew the holder for refrigerant hoses.
Remove AC compressor and tie up

together with the connected refrigerant
hoses to the towing lug on the inside of
the bumper -arrow-.
Note
Protect the bumper with soft base from

damage.
All vehicles
15
Remove pendulum support -arrows-.
Remove the drive shafts from the

gearbox flanges.
Lay both drive shafts to the rear and

secure with wire to the body.
Remove front exhaust pipe Chapter.

Insert engine mount -T10012- into
engine/gearbox jack (e.g. -V.A.G 1383 A
-).
Screw engine mount - T10012- to the

cylinder block with fixing nuts and bolts
M10 to 40 Nm.
Slightly raise the engine and gearbox
with the engine/gearbox jack (e.g.
-V.A.G 1383 A -).
Unbolt engine support from engine

mount -arrows-.
Note
Use the double ladder (e.g. -VAS 5085-) for

removing the fixing bolts.
16
Slacken the screws from gearbox mount

from the top -arrows-.
Carefully lower the engine with gearbox.

Note
Engine with gearbox must be guided

carefully, in order to avoid damage and
body damage.
Securing the engine to the assembly stand

Secure the engine with the engine and gearbox mount -MP 1-202- and on the assembly
stand before performing assembly work.
Note
When measuring the cylinder bore Fig. the engine must not be fixed to the assembly
stand.
Procedure
Position the engine and gearbox with the

engine/gearbox jack e.g. -V.A.G 1383 A onto the storage table.
Lower the engine with gearbox in such a
way that the gearbox is positioned on the
support.
Release screws -1 through 8- at

engine/gearbox flange.
Pull off plug in hole of torque converter

17
cover plate.
Unscrew 3 nuts -arrow- from torque

converter, rotate crankshaft each time 1/3
revolution for this step.
After separating engine and gearbox,
secure torque converter in gearbox to
prevent it dropping out.
All vehicles
Hook on the suspension fixture -MP 9201- as follows and raise slightly with the
workshop crane (e.g. -1202A-).
On the belt pulley side: 1st hole of the

perforated bar in position 1
On the flywheel side: 4th hole of the

perforated bar in position 5
WARNING
Use securing pins on the hooks and rig

pins.
Secure engine with engine mount -MP 1202- to the assembly stand.
Install
Note
t
t
Always replace the seals and gaskets during assembly work.

Always replace self-locking nuts.
Procedure
Installation is performed in the reverse order. Pay attention to the following points:
Check whether the dowel sleeves for centering the engine/gearbox are present in the
cylinder block; insert if necessary.
18
Insert intermediate plate on sealing flange and push onto the dowel sleeves -arrows-.
Lubricate the drive shaft serration lightly with grease -G 000 100 -.
If necessary check the centering of the clutch disc.
Install slave cylinder: 5 speed Manual gearbox 02K; Rep. Gr. 30; Repairing the clutch
control.
Installing shift mechanism: 5 speed Manual gearbox 02K; Rep. Gr. 34; Repairing the
gearshift mechanism.
Setting the shift mechanism: 5 speed Manual gearbox 02K; Rep. Gr. 34; Setting the
gearshift mechanism.
Only use nuts which are approved in the parts list, for attaching torque converter to the
driver disc.
Install AC compressor: Heating, Air conditioning, Rep. Gr. 87; Air conditioning; Removing
and installing compressor from holder.
All vehicles
Install the vane pump for the power-assisted steering: Running gear, Rep. Gr. 48;
Removing and installing the vane pump for power-assisted steering.
Install drive shafts: Running gear, Rep. Gr. 40; Repairing front wheel suspension;
Removing and installing the drive shaft.
Install the front exhaust pipe and the exhaust system so that they are not under tension
Chapter.
Align unit mounting Chapter.

Install the V-ribbed belt Chapter.
Install coolant hose Chapter.
Filling system with coolant Chapter.
The drained off coolant must only be then re-used if the cylinder head, cylinder block,
radiator or heat exchanger were not replaced.
Place connecting harness for engine into cable duct and connect the 10-pin plug
connection.
Connect the 28-pin connector at engine control unit -J361-.
Fit cooling water tank cover. Body Work; Rep.-Gr. 66; Trim panels
Install windscreen wiper arms Electrical System Rep.- Gr. 92; windscreen wiper and
19
washer system.
Electrical connections and laying of cables: Current flow diagrams and Fitting locations
Adjusting throttle control cable Chapter.

Install the engine cover.
Check oil level before starting the engine Octavia.
Note
If the battery earth strap is disconnected and connected, carry out additional operations
Electrical System, Rep. Gr. 27.
Tightening torques
Note
Tightening torques apply only for lightly greased, oiled, phosphatized or blackened nuts
and screws.
t Other lubricants such as engine and gearbox oil are allowed. Do not use Molykote.
t
t
Do not use degreased parts.

Unless otherwise indicated the following tightening torques apply:
Component
Nm
Screws/nuts
M6
M7
13
M8
20
M10
40
M12
70
In variation of this:
Driver plate on the torque converter
60
Engine mounting, gearbox mount, pendulum support

Connecting bolts for the engine/the gearbox
5-speed manual gearbox 02K; Rep. Gr. 34
Automatic gearbox; Rep. Gr. 37
20
Chapter
Align unit mounting for engine - gearbox
WARNING
Before slackening the bolts, the unit must be secured with the supporting device -MP 9-200-.
Engine mounting
a = 14.0 mm
b = at least 10.0 mm
Both bolt heads -1- must end flush with the edge
-c-.
Gearbox mounting
The edges -a- and -b- must be positioned parallel
to each other.
Assembly bracket
Tightening torques
21
Engine assembly bracket
1-
40 Nm + 90 (1/4 turn) Note
2-
25 Nm
3-
100 Nm Note
Gearbox assembly bracket
1-
40 Nm + 90 (1/4 turn) Note
2-
25 Nm
3-
100 Nm Note
22
Hinged bracket
1-
40 Nm +45 Note
2-
40 Nm +45 Note
3-
20 Nm + 90 (1/4 turn) Note
1)
Replace bolts
23
Enginecrankshaft group, pistons

Disassembling and assembling engine
Removing and installing V-ribbed belt
Special tools and workshop equipment
required
t
Torque wrench
Locating bolts -T10060Note
The following figure shows the belt drive

of vehicles without air conditioning.

t
may destroy it. Pay attention to the
correct position of the V-ribbed belt in the
belt pulley when installing it.
Removing and installing the air
t conditioning compressor Heating, Air
conditioning; Rep. Gr. 87.
1-
V-ribbed belt
before removing mark running direction
check for wear
do not kink
routing of ribbed V-belt on vehicles

without air conditioning Fig.
routing of ribbed V-belt on vehicles with

air conditioning Fig.
Removing and installing ribbed V-belt

Anchor
Engines fitted with an AC compressor are

equipped with a double ribbed V-belt.
2-
25 Nm
3 - Tensioning device for ribbed V-belt
swivel tensioning device for V-ribbed belt

with open-end wrench to slacken the Vribbed belt Anchor
24
4-
Belt pulley
can be installed only in one position

5-
45 Nm
6-
AC generator
to facilitate the positioning of the AC

generator on the holder drive the
threaded bushings of the retaining
screws slightly backwards
7
AC compressor
Do not open refrigerant circuit
to facilitate the positioning of the AC

compressor on the holder drive the
89-
Distance sleeve
Support
10
45 Nm
order of tightening Fig.
11 -
Hollow screw, 30 Nm
12 -
Gasket ring
replace
13 14 -
Pressure line
The vane pump for the power-assisted
steering
to facilitate the positioning of the

hydraulic pump on the holder drive the
removing and installing: Running gear;

rep. size 48
15
16 -
Belt pulley
for vane pump
Fixing screw
Screw with firmness 8.8; 25 Nm - replace,

as replacement, use a screw with
firmness 10.9 Electronic Catalogue of
Original Parts
25
Screw with firmness 10.9: 40 Nm
Combining different firmness is not

permissible
Routing of ribbed V-belt on vehicles without

air conditioning
Routing of ribbed V-belt on vehicles with air

conditioning
Note

Tightening sequence of the compact holder

screws
Removing the V-ribbed belt
Note

may destroy it. Pay attention to the correct
position of the V-ribbed belt in the belt
pulley when installing it.
26
Swivel tensioning device in -direction of

arrow- to slacken the V-ribbed belt and
secure with locating bolts -T10060-.
Note
The tensioning device can also be locked

using a 3 mm hexagon wrench.
Remove the V-ribbed belt.
Installing the V-ribbed belt

Note
Before installing the ribbed V-belt, ensure

that all components (alternator, AC
compressor, hydraulic pump) are properly
installed.
Fit the ribbed V-belt.
Slacken ribbed V-belt tensioning device.

Pull out locating bolts -T10060--arrows-.
Start engine and check belt run.
Note

27
Removing and installing, tightening the

timing belt
Note
Before removing the timing belt, mark

direction of running. Reversing the rotation
direction of an already used belt may
destroy it.
1
Bottom toothed belt guard
unscrew to remove the vibration

dampener Chapter
2-
Middle toothed belt guard
3-
10 Nm
replace
Engine support bracket

removing Anchor
567-
45 Nm
Top toothed belt guard
Timing belt
before removing mark running direction
check for wear
do not kink
removing Anchor
installing Anchor
8-
25 Nm
9-
Washer
10
100 Nm
to release and tighten use the

counterholder -MP 1-216-
11 -
Camshaft sprocket
with sensor rotor for the Hall sensor

-G40-
Removing and installing timing belt

Anchor
Installation position fixed by woodruff

28
key -pos. 1412 -
Toothed belt guard
13 -
10 Nm
14 -
Woodruff key
check tightness
15
Hall sender -G40-
when bolting on, ensure base plate is

centered
16 17 -
10 Nm
Rear timing belt guard
18 -
20 Nm
19 - Semi-automatic tensioning pulley
check semi-automatic tensioning pulley

Chapter
Fitting position Fig.
20
Coolant pump
removing and installing Chapter
21 -
15 Nm
22 -
Timing belt gear - crankshaft
there must not be any oil present on

contact surface between timing belt
sprocket and the crankshaft
can be installed only in one position

23
90 Nm + torque a further 1/4 turn

(90)
replace
counter-hold Chapter with counterholder -T30004- or counterholder -MP 1310- for slackening and tightening
29
Fitting position of the semi-automatic

tensioning pulley
The angle bracket -arrow- must engage in
the recess at the cylinder head.
required
t
Torque wrench
Counterholder -MP 1-216-
Two-hole nut turner -T10020-
Supporting device - MP 9-200-
Removing toothed belt
Engine installed
Remove V-ribbed belt Chapter.
Remove ribbed V-belt tensioning device.
Rotate crankshaft to TDC of cylinder 1

-arrow- (vehicles with manual gearbox).
TDC marking on flywheel and reference

mark must be aligned.
30
Rotate crankshaft to TDC cylinder 1

-arrow- (vehicles with automatic
gearbox).
TDC marking on drive plate and reference
Note
When engine removed, position vibration

damper to TDC cylinder 1 -arrows-.
Remove engine cover.
Insert supporting device -MP 9-200- and

take up weight of engine with the spindle
of the supporting device (only on right).
Remove vibration damper.
Remove top, bottom and middle timing

belt guard.
Unscrew the reservoir for the powerassisted steering.

console and engine console from body
-arrows-.
Mark the rotation direction of the timing
31
belt.
Slacken semi-automatic tensioning pulley

and take off toothed belt.
Turn crankshaft slightly back.
-arrows-.
Note
To slacken the front bolt of the engine

t support, raise engine slightly with spindle
of supporting device -MP 9-200-.
To take off engine support, raise or lower
t engine, respectively with the supporting
device -MP 9-200-.
Installing toothed belt, tensioning (setting
timing)
Note
Also when carrying out repairs which

necessitate taking the toothed belt only
t off the camshaft sprocket, it is then
necessary to carry out the installation of
the toothed belt as follows.
When rotating the camshaft, the
crankshaft must not be positioned at TDC.
t
Risk of damaging valves and piston
crowns.
Precondition
l
The pistons must not be positioned at top

dead centre.
32
Bring the marking on the camshaft

sprocket in line with the marking on the
rear timing belt guard -arrows-.
Position crankshaft to TDC cylinder 1
(except when engine removed) Anchor.
Fit timing belt onto the crankshaft timing
belt sprocket (pay attention to direction of
running) Chapter.
Note
When engine removed, install bottom

toothed belt guard and vibration damper.
Position crankshaft to TDC of cylinder 1
arrows.
Fit timing belt onto tensioning pulley and

onto camshaft sprocket.
Pay attention to installation position of

semi-automatic tensioning pulley:
The angle bracket -arrow- must engage in

the recess at the cylinder head.
33
Tighten the timing belt. Turn with

-T10020- at centering piece to the left (in
direction of arrow) up to the stop.
Slacken the timing belt until the notch -1 and the pointer -2- are positioned
opposite.
Tighten clamping sleeve securing semiautomatic tensioning pulley to 25 Nm.
Turn the crankshaft fully twice and check

the setting.
Install bottom timing belt guard.
Install vibration damper (pay attention to

fitting position: hole of the vibration
damper is above the lobe on the timing
belt sprocket).
Note
Before installing engine support, insert

bolts into engine support.
Install engine support Anchor.
Install engine mount Chapter.
Remove supporting device.
Install middle and top timing belt guard.
Install tensioning device for V-ribbed

belt. Tightening torque:
Install the V-ribbed belt Anchor.
Inspecting semi-automatic tensioning pulley
Test condition
l
Toothed belt fitted on and tensioned.
34
Load timing belt by firmly pressing down with

thumb -arrows-. The pointer -2- must move to
the side.
Relieve the toothed belt again. The tensioning
roller must go back again to its initial position.
(The notch -1- and the pointer -2- are again
standing opposite to each other.)
Note
Use mirror.
35
Removing and installing crankshaft
Note
Repairs to the clutch: 5 speed Manual

t gearbox 02K; Rep. Gr. 30; Repairing the
clutch.
The engine should be attached to the
engine repair stand with engine holder
t
-MP 1-202- for carrying out removal and
installation work.
1-
15 Nm
2-
Gasket ring
replace Chapter
pay attention to different version Fig.

3
Thrust washers
pay attention to different version
in bearing 3, for cylinder block or

bearing cap
lubricating grooves point outwards
Front sealing flange
Bearing shell
Identification for ordering replacement

parts Fig.
for cylinder block with lubricating groove
do not mix up used bearing shells

(mark)
6
7-
Sprocket
for oil pump drive
Crankshaft
Axial play when new: 0.07...0.21 mm
Wear limit: 0.30 mm
Crankshaft bearing journal: 54.00 mm

Conrod bearing journal 47.80 mm
36
8-
Bearing shell
Identification for ordering replacement

parts Fig.
for bearing cap without lubricating

groove

(mark)
9 - 40 Nm + torque a further 1/4 turn (90)
replace
10 -
Bearing caps
Bearing cover 1; on the belt pulley side

Fitting position: retaining lugs of the
bearing shells of the cylinder
block/bearing cap must be on top of one
another
11
Rotor
replace if damaged
for engine speed sender -G28 -
assembly only possible in one position

-holes offset-
Removing and installing sensor rotor

Fig.
12

(90)
replace
13 -
Pressure plate/driver disc
Removing and installing pressure plate

Chapter
removing and installing drive plate

Chapter
14 -
Washer
Check fitting position
15 -

(90)
replace
37
16
Gasket ring
replace
17 -
Screw plug - 100 Nm
18 -
Intermediate plate
inserted on sealing flange Fig.
must be positioned on dowel sleeves
do not damage/bend during assembly

work
19 -
15 Nm
20 - Rear sealing flange with gasket ring
must be replaced completely
must be positioned on dowel sleeves

remove oil pan Chapter for removing
clean sealing surface before installing
the sealing flange with PTFE gasket ring

is supplied as a spare part
install gasket ring dry, the crankshaft

stub must be free of grease
fit new sealing flange with guide bushing

(do not pull guide bushing out of gasket
ring before fitting)
Installing intermediate plate

Insert intermediate plate on sealing
flange and push onto the dowel sleeves
-arrows-.
38
Gasket ring versions
I Elastomer gasket ring

1 sealing lip -1-; with garter spring
II PTFE gasket ring
multiple sealing lips -2-; without garter spring
Note
Do no moisten the PTFE gasket ring with oil before inserting. The shaft must also be free
from oil and grease.
Never install an elastomer gasket ring (old version), if a PTFE gasket ring (new version)
was fitted.
An elastomer gasket ring can be replaced by a PTFE gasket ring.
39
Marking on crankshaft bearing for ordering

replacement parts
The crankshaft bearing shells are factoryclassified. Align the top crankshaft bearing
shells according to the marking on the
cylinder block (stamped letters).
Note
t -Arrow- points to the belt pulley.

t
Identification of the bearing is visible

without removal of the oil pan.
Colour coding of bearing shells matches the

letters on the cylinder block
red
yellow
blue
white
The bottom crankshaft bearing shells are always supplied as replacement parts with the
colour coding yellow.
Removing and installing sensor rotor
Replace sensor rotor -2- and bolt -1- each

time they are slackened.
Note
After being attached a second time, the

attachment point in the sensor rotor -2- is
sufficiently misshapen that the bolt head
t
-1- rests against crankshaft -3--arrowsand the sensor rotor is positioned loosely
below the screw.
t Assembly only possible in one position
40
-holes offset-.
Replacing gasket ring for crankshaft -on the belt pulley sideSpecial tools and workshop equipment required
t
t
t
Torque wrench
Counterholder -T30004- or Counterholer -MP 1-310 Gasket ring extractor -MP 1-226-
Insertion sleeve -MP 1-314-
Insertion sleeve -MP 1-315-
Guide bushing -T10053/1-
Pressure bushing -T10053-
Removing
Removing timing belt Chapter.
Remove crankshaft timing belt sprocket.

Lock toothed belt gear - crankshaft with
counterholder -T30004- or counterholder
-MP 1-310 -.
When screwing on the counterholder

place 2 washers between the timing belt
gear and the counterholder.
Screw central screw of timing belt again
into the crankshaft.
Unscrew inner part of the gasket ring

extractor -MP 1-226- two turns (approx. 3
mm) out of the outer part and lock with
knurled screw.
41
Oil the thread head of the gasket ring

extractor -MP 1-226-, position and forcely
screw into the gasket ring as far as
possible.
Slacken knurled bolt and turn inner part

against the crankshaft until the gasket
ring is pulled out.
Install elastomer gasket ring.
Lightly oil the sealing lip of the gasket

ring.
Fit insertion sleeve from -MP 1-314- on

the crankshaft stub.
Slide gasket ring over the insertion

sleeve.
Press in the gasket flush using the central

screw -1- and press in the insertion
sleeve from -MP 1-315-.
Install PTFE gasket ring.

Note
The sealing lips of the gasket ring must be

neither oiled nor greased.
Remove oil residue on the crankshaft

stub with a clean cloth.
42
Install -T10053/1- guide bushing on the

crankshaft stub.
Slide gasket ring over the guide bushing

onto the crankshaft stub.
Press in gasket ring with pressure

bushing -T10053- up to the stop. Use the
old central screw for the crankshaft
timing belt sprocket for this purpose.
Proceed as follows for both versions
Install timing belt gear onto the
crankshaft and lock with counterholder MP 1-310-.
Note
Replace central screw for toothed belt

gear.
Tighten central screw to 90 Nm and

torque a further 1/4 turn (90).
Installing the timing belt Chapter.

Removing and installing pressure plate

t
Counterholder for clutch -MP 1-221-
43
Put the counterholder -MP 1-221- into the bore

hole on the cylinder block and screw onto the
pressure plate.
Release screws for pressure plate.
Note
Replace screws for pressure plate.
Tighten bolts to 60 Nm and torque a further
90 1/4 turn.
Removing and installing drive plate

t
Counterholder for clutch -MP 1-221-
Depth gauge
Removing
Attach counterholder -MP 1-221- with

M8x45 bolt to the drive plate. Place two
M10 nuts between the counterholder and
the driver disc -1-.
Release screws for driver disc.
Install
Remove the intermediate plate

Anchor.
44
Only insert the drive

plate using the
washer with recesses
-1-.
Insert bolts -3- and

tighten to 30 Nm.
Inspect installed dimension of drive plate

at the 3 mounting holes for the torque
converter and calculate mean value.
t Nominal value -a- 19.5...21.1 mm

Note
The measurement is made through the 3

outer holes of the drive plate to the milled
surface of the cylinder block.
If the specified value is reached:
Installing the drive plate.
Installing intermediate plate.
Attach drive plate with washer and new

screws, torque 60 Nm + 1/4 turn (90).
If the measurement is less than the

specification:
Remove the driver plate.
Installing intermediate plate.
45
Place spacer washer

-2- between
crankshaft and drive
plate.
Lock drive plate with
spacer washer -1 and attach new bolts
-3- to 60 Nm +
torque a further 1/4
turn (90).
Removing and installing the front sealing flange

t
Torque wrench 5 - 50 Nm (e.g. -V.A.G 1331 -)
Torque wrench 40 - 200 Nm (e.g. -V.A.G 1332 -)
Counterholder -T30004- or Counterholer -MP 1-310 -
t
t
t
Insertion sleeve from -MP 1-314Hand-held power drill with plastic brush insert
Silicone sealant -D 176 404 A2 -
Flat scraper
Removing
Removing timing belt Chapter.
46
Remove crankshaft timing belt sprocket.

Lock toothed belt gear - crankshaft with
counterholder -MP 1-310- or
counterholder -T30004 -.
Note
When screwing on the counterholder place

2 washers between the timing belt gear
and the counterholder.
Drain engine oil.
Removing the oil pan Chapter.
Unscrew front sealing flange.
Remove sealing flange, if necessary

release by applying slight blows with a
rubber-headed hammer.
Use a flat scraper to remove sealant
residues on the cylinder block.
Use a rotating plastic brush to remove

sealant residues on the sealing flange
(wear protective goggles).
Clean sealing surfaces, they must be free
of oil and grease.
Install
Note
The sealing flange must be installed within

5 minutes after applying the silicone
sealant.
47
Cut off tip of tube at the front marking (

of opening approx. 3 mm).
Thickness of sealant bead -arrows-: 2 to 3

mm.
Note
The sealant bead must not be thicker than

3 mm otherwise excess sealant may get
into the oil pan and clogg the strainer in
the oil suction pipe.
Apply silicone sealant bead to the clean

sealing surface of the sealing flange, as
shown in the illustration.
Fit sealing flange immediately and lightly
tighten all bolts.
Note
For version with PTFE gasket ring ( Fig.),

the crankshaft stub must be free of oil
t
and grease and the gasket ring must not
be oiled.
When installing the sealing flange with
t the gasket ring fitted use the following
devices:
t Elastomer gasket ring - -MP 1-314 t
PTFE gasket ring - -T10053/1-
Tighten the screws crosswise to 15 Nm.
Install oil pan Chapter.

Note
After installing, allow the sealant to dry for

about 30 minutes. Only then may engine oil
be filled in.
Install the crankshaft timing belt

sprocket.
48
Note
Replace central screw of toothed belt gear.
Tighten central screw to 90 Nm and

torque a further 1/4 turn (90).
Installing the timing belt Chapter.
49
Disassembling and assembling piston and

conrod
Note
The engine should be attached to the

engine repair stand with engine holder
-MP 1-202- for carrying out removal and
installation work.
1
Piston rings
Offset joint 120
use piston ring pliers for removing and

installing
marking TOP must face towards piston

crown
inspect gap clearance Fig.
inspect end clearance Fig.
Piston
check Fig.
mark installation position relative to

conrod and mark matching cylinder with
waterproof felt pen
arrow on piston crown faces towards the

belt pulley side
use piston ring tensioning strap for

installing
Piston 80.965 mm
3-
Conrod
always replace as a set only
mark assignment to cylinder -B-
Fitting position: Markings -A- must be

positioned one above the other and point
to the belt pulley side
with oil drilling for lubricating piston pin

4-
Conrod cap
50
mark assignment to cylinder -BFitting position: Markings -A- must be

positioned one above the other and point
to the belt pulley side
5 - 30 Nm + torque a further 90 (1/4 turn)
replace with conrod bolt -pos. 10-
oil thread and head contact surface

6
Pressure relief valve, 27 Nm
opens at: test pressure 0.13...0.16 MPa

(1.3...10.6 bar) positive pressure
replace without sealant
7-
Oil injection nozzle
For piston cooling
8-
Bearing shell

(mark)
ensure tightly located in retaining lugs
Axial play when new: 0.10...0.35 mm,

wear limit: 0.40 mm
with oil drilling for lubricating piston pin

9
Cylinder block
inspect cylinder bore Fig.
Cylinder 81.01 mm
10
Conrod bolt
replace together with nut; -Pos. 5-
11 12 -
Circlip
Piston pin
if stiff, heat piston to approx. 60C
with drift -VW 222 A - removing and

installing
51
Inspecting piston ring gap clearance

Special tools, test equipment as well as
aids required
t
Feeler gauge
Test sequence
Push in ring at right angles to the cylinder
wall from the top through to the bottom
cylinder opening, about 15 mm from the
cylinder edge.
Piston ring
dimensions in mm
new
Wear limit
1st compression ring
0.20 to 0.40
0,8
2. Compression ring
0.20 to 0.40
0,8
Oil scraper ring
0.25 to 0.50
0,8
Inspect piston ring

end clearance
Special tools and
workshop equipment
required
t
Feeler gauge
Clean annular
groove before
measurement is
taken.
52
Piston ring
dimensions in mm
new
Wear limit
1st Compression ring
0.06 to 0.09
0,20
2nd Compression ring
0.05 to 0.08
0,20
Oil scraper ring
0.03 to 0.06
0,15
Inspecting pistons
required
t External micrometer 75...100 mm
Test sequence
Measure about 10 mm from the lower
edge, offset at right angles to the piston
pin shaft.
t
Variations compared to nominal diameter

max. 0.04 mm
Inspecting cylinder bore

required
t
Internal precision measuring instrument

50...100 mm
Test sequence
Measure at three points crosswise in a
transverse direction -A- and lengthwise
-B-.
t
Variations compared to nominal

dimension max. 0.08 mm
Note
Do not measure the cylinder bore if the

cylinder block is fixed to the assembly
stand with the engine mount -MP 1-202-, as
this may result in incorrect measurements.
53
Different versions of conrods
Cut open conrod -A- = locating face

smooth
Split conrod -B- = locating face

coarse
54
Engine cylinder head, valve gear

Removing and installing cylinder head
Removing and installing timing belt Chapter.
Testing compression pressure Chapter.
Note
Always replace cylinder head bolts.
When installing an exchange cylinder head with the camshaft installed, it is necessary to
t oil the contact surfaces between bucket tappets and the cam track after installing the
head.
t
Do not remove the plastic bases supplied as a protection for the open valves until just
before fitting on the cylinder head.
t If the cylinder head is replaced, the system must be completely filled with fresh coolant.
Cylinder heads with cracks between the valve seats or between a valve seat ring and the
spark plug thread may continue to be used without any reduction in life provided these are
t
slight initial cracks which are not more than 0.3 mm wide, or cracks exist only at the first 4
turns of the spark plug thread.
55
1-
15 Nm
2-
20 Nm
34q
q
q
Rear timing belt guard

Cylinder head
after replacing fill entire system with fresh coolant
removing Chapter
check for distortion Chapter
rework Chapter
installing Chapter
5q
Cylinder head bolt

replace
pay attention to order for slackening Anchor
pay attention to order for tightening Anchor

56
6-
Oil separator
7-
Gasket for cylinder head cover
q
q
replace if damaged
before fitting, coat surface of cylinder head cover and cylinder head surface with -D 454
300 A2-
8-
Reinforcing strip
9-
Cylinder head cover
10 11 q
q
10 Nm
Upper part of collecting intake manifold
with variable intake manifold changeover
q Check function of variable intake manifold changeover 1.6 ltr./74kW engine, Simos 2
Injection and ignition system ; Rep. Gr. 24
12 -
Cap
13 14 -
Gasket
Breather housing
q remove cylinder head cover Item for removing, release spring ends and turn breather
housing to the left
15 q
Gasket
replace if damaged
16 -
Support
17 q
18 -
Gasket
replace if damaged
Lower part of collecting intake manifold
19 q
20 q
21 q
22 -
Gasket
replace
Screw plug - 15 Nm
replace
Gasket ring
replace
Flange
57
23 -
Gasket
replace
24 -
Lifting eye
25 -
Cylinder head gasket
replace Chapter
Removing and installing upper part of collecting intake manifold

t
Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-)
2 hose clamps -MP 7-602 -
Cable strap
Removing
Note
All cable straps which are detached or cut open when removing, should be fitted on again in
the same place when installing.
necessary.
Disconnect the earth strap from the battery with the ignition off.

58


Unscrew bolts -3- and -4- and remove air

filter housing.
Disconnect the vacuum line from the

brake servo unit.
Disconnect wiring/plug:
1-
Plug for intake air temperature sender

-G42-
2-
Unplug connector for throttle valve

control unit -J338-
Detach hose to the ACF tank.
Unhook throttle control cable -arrows-.
Unscrew earth strap at cylinder head

cover.
Pinch off and disconnect 2 coolant hoses

for throttle valve supports with hose
clamps -MP 7-602- (first of all drain
pressure from cooling system).
Disconnect plug -1- from valve for

variable intake manifold changeover
-N156-.
Release vacuum hose -2-.

Release left and right retaining lugs at
collecting intake manifold -arrow-.
59
Release on left and right each one screw

-arrow- of the rear intake manifold
suspension.
Press off upper part of collecting intake

manifold to the rear from lower part of
collecting intake manifold.
Note
Seal the intake passages in the bottom

part of the collecting intake manifold with
plug (clean cloth).
Install
Note
Replace seals if damaged.
Insert upper part of collecting intake

manifold onto the bottom part.
Allow to clip left and right retaining eyes.
Coat screws of rear intake manifold

suspension at collar with commercially
available lubricant and tighten to 10 Nm.
Adjusting throttle control cable

Chapter.
If necessary, top up with coolant

Chapter.
Interrogate fault memory, perform basic

setting: 1.6 ltr./74 kW engine, Simos 2
Injection and ignition system; Rep. Gr. 01;

Self-diagnosis; Interrogate and erase fault
memory, Basic setting of engine
removing and installing cylinder head cover

t
Removing
Remove upper part of collecting intake manifold Chapter.

Remove top toothed belt guard.
Unscrew nuts for cylinder head cover.
60
Remove reinforcing strips, bracket, toothed belt guard and cylinder head cover.
Install
Note
Replace seals if damaged.
Remove cylinder head cover, reinforcing strips, toothed belt guard and bracket.
Tighten the nuts crosswise to 10 Nm.
Removing cylinder head

Note
All cable straps which are detached or cut open when removing, should be fitted on again in
the same place when installing.
t
Catch pan (e.g. -V.A.G 1306-)
Wrench for cylinder head bolts (e.g. 3452)
Engine installed
necessary.
Open the cap of the coolant expansion reservoir.
61
Remove noise dampening in the middle

as well as on the left -arrows-.
Unbolt front exhaust pipe from exhaust

manifold Chapter.
Turn drain valve -arrow- at radiator to the

left and pull to the rear, fit auxiliary hose
onto connection if necessary.
62
Remove further the bottom coolant hose

on the oil cooler -arrow- and drain
residual coolant.


Unscrew bolts -3- and -4- and remove air

filter housing.

-arrow- (vehicles with manual gearbox).
TDC marking on flywheel and reference
Marking on flywheel and reference mark
must be aligned.
63

-arrow- (vehicles with automatic
gearbox). TDC marking on drive plate
and reference mark must be aligned.
TDC marking on drive plate and reference
Note
When engine removed, position vibration

damper to TDC cylinder 1 -arrows-.

Slacken tensioning pulley and take timing
belt off camshaft sprocket.
WARNING
The fuel system is under pressure! Before

opening the system lay cleaning cloths
around the connection point. Reduce
pressure by carefully releasing the
connection point.
Detach fuel feed line -1- and fuel return flow line -2- by pressing on the release
buttons. Lines and line connections are
colour-coded.
Detach hose -3- at the ACF tank.
Disconnect plug at phase sensor (Hall

sender -G40-) and at all four injection
valves.
Detach cable harness for the fixtures and

Remove the spark plug connector and

place to the side.
Unscrew M8 bolts for rear toothed belt

guard.
Detach left coolant hose at cylinder

64
head.
Unscrew left coolant flange at cylinder

head.
Pull out coolant pipe towards the left.

Remove cylinder head cover Chapter.
Release the cylinder head bolts in the

order 1 to 10.
Remove cylinder head with cylinder head

gasket.
Inspecting the cylinder head for distortion

t
Feeler gauge
t
Knife-edge straightedge
Test sequence
Inspect cylinder head at several points for

distortion using a knife-edge straightedge and
feeler gauge.
t max. permissible distortion: 0.1 mm
Reworking a cylinder head
Procedure
65
Reworking of the cylinder head (facegrinding) is only permissible up to

minimum dimension -a-.
t Minimum dimension a: 132.6 mm

Note
If the sealing surface is reworked, the

valves should be set lower by the same
amount (rework valve seat rings) otherwise
the valves will strike the pistons. Ensure
that the maximum permissible dimensions
are maintained Fig..
Installing cylinder head

Note
t
t
t
Always replace the cylinder head bolts.

Remove sealant residues. When doing this, ensure that no scores or scratches are
produced. When using emery paper the grain must not be less than 100.
Carefully remove any emery and sanding residues.
t Remove the new cylinder head seal from its wrapping immediately before fitting.
t
Treat the new seal with the utmost care. Damage to the silicone layer and in the area of
the bead results in leakages.
There must be no oil or coolant in the blind holes of the cylinder head bolts in the cylinder
block.

t
t
t
Torque wrench
Wrench for cylinder head bolts (e.g. 3452)
Procedure
Set the crankshaft and camshaft to TDC for cylinder 1 before attaching the cylinder head
Anchor.
Position the cylinder head gasket and lock the dowel sleeves. The legend (spare part no.)
must be legible.
Insert new cylinder head bolts and tighten by hand.

66
Tighten the cylinder head screws in two

stages in the indicated tightening
sequence as follows:
1st Stage: 40 Nm
2nd stage: tighten further with a rigid
wrench: torque a further 180 (1/2 turn) 2
x 90 is not permissible
Note
Tightening up the cylinder head bolts after

doing repair work is not necessary.

timing) Chapter.

Install cylinder head cover Chapter.
Install upper part of collecting intake

manifold Chapter.
Adjusting throttle control cable

Chapter.

Interrogate fault memory, perform basic
setting: 1.6 ltr./74 kW engine, Simos 2
Injection and ignition system; Rep. Gr. 01;

Self-diagnosis; Interrogate and erase fault
memory, Basic setting of engine.
Testing the compression

Test condition
l
Engine oil temperature at least 30C

t
t
Compression tester (e. g. -V.A.G 1381- or -V.A.G 1763-)

Spark plug wrench
Test sequence
If the ignition is switched off, disconnect plug at all four injection valves.
If the ignition is switched off, disconnect plug at the ignition coils with power amplifier.
Unscrew the spark plugs with spark plug wrench.

67
Open throttle valve fully.
Test compression with compression tester (e.g. -V.A.G 1381- and/or -V.A.G 1763-).
Note
Use of tester: Operating Instructions
Operate starter until the tester no longer indicates a pressure rise.
Compression readings:
New engine
Wear limit
Pressure difference between individual cylinders
1.0 to 1.3 MPa
0.75 MPa
max. 0.3 MPa
Interrogating fault memory: 1.6 ltr./74 kW engine, Simos 2 Injection and ignition system;
Rep. Gr. 01; Self-diagnosis; Interrogate and erase fault memory.
Note
Separating the plug connections causes faults to be stored. After the test, interrogate the
fault memory and delete it as required.
68
Repairing Valve Gear

Note
Cylinder heads with cracks between the

valve seats or between a valve seat ring
and the spark plug thread may continue
to be used without any reduction in life
t
provided these are slight initial cracks
which are not more than 0.3 mm wide, or
cracks exist only at the first 4 turns of the
spark plug thread.
After installing new bucket tappets, the
engine must not be started for about 30
t
minutes (otherwise place the valves on
the pistons).
After carrying out work on the valve gear,
carefully crank engine at least 2
t revolutions to ensure that no valve
touches the piston when the engine is
started.
1
100 Nm
to release and tighten use the

counterholder -MP 1-216-
2-
Camshaft sprocket
with sensor rotor for the phase sensor

(Hall sender -G40-)
for removing and installing, remove

toothed belt Chapter
Installation position fixed by woodruff

key -pos. 4-
Gasket ring
replace Chapter

4
56
Woodruff key
check tightness
20 Nm
Bearing caps
order of installation Chapter
69
Lightly coat head contact surface 1 with

sealant -AMV 174 004 01-
Camshaft
inspecting axial play Fig.
Slack: max. 0.05 mm
8-
Bucket tappets
do not interchange
with hydraulic valve clearance
compensation
check Chapter
lay aside with contact surface facing

down
before installing check axial play of the

camshaft Fig.
oil contact surface
9-
Valve collets
10 -
Valve spring retainer
11 -
Valve spring
removing and installing

with cylinder head removed: with -MP 1211- and -MP 1-213- with valve
supporting plate -MP 1-218-
with cylinder head installed: Chapter

12
Valve stem seal

replace Chapter
13 -
Valve guide
check Chapter
replace Chapter
Repair of the guide with a collar
14 -
Cylinder head
pay attention to the notes Anchor
reworking valve seats Chapter

70
15
Valve
do not rework, only grinding in is

permissible
Valve dimensions Fig.
inspect camshaft, axial play

required
t Universal dial gauge holder -MP 3-447t
Dial gauge
Wear limit: max. 0.15 mm

Perform measurement with the bucket
tappets removed and the first and last
bearing cap fitted.
Fitting position of the

camshaft bearing cap
Pay attention to centre
displacement. Before
installing the camshaft
fit bearing cap and
determine the fitting
position.
71
Valve dimensions
Note
Valves must not be reworked. Only grinding

in is permissible.
Dimension
Inlet valve
Exhaust valve
mm
39,5 0,15
32,9 0,15
mm
6,92 0,02
6,92 0,02
mm
91,85
91,15
45
45
Replacing camshaft gasket ring

t
t
t
Counterholder -MP 1-216Gasket ring extractor -MP 1-215Insertion tool -MP 1-214-
Torque wrench
Pressure bushing -T10071-
Guide bushing -T10071/1-
Removing

Loosen the camshaft sprocket (use counterholder -MP 1-216-).
72
Position camshaft sprocket to TDC

marking of cylinder 1 by rotating at
crankshaft. Marking on camshaft sprocket

must be aligned with arrow on the
toothed belt guard.
Slacken tensioning pulley and take off

timing belt.
Remove camshaft sprocket.
Remove Woodruff key from the camshaft.
Screw in bolt for attaching camshaft

sprocket fully into the camshaft.
Set the inner part of the sealing ring
extractor -MP 1-215- flush with the outer
part and interlock with the knurled screw.
Oil the thread head of the gasket ring
extractor, position and forcely screw into
the gasket ring as far as possible.
Slacken knurled screw and turn inner
part against the camshaft until the
gasket ring is pulled out.
Install elastomer gasket ring
Lightly oil the sealing lip of the gasket

ring.
Apply the gasket ring with guide bushing

made out of -MP 1-214- and press in flush
using a pressure bushing made out of
-MP 1-214-.
Install PTFE gasket ring

Note
Do not oil sealing lips of the gasket ring.
Remove oil residue on the camshaft stud

with a clean cloth.
73
Insert guide bushing -T10071/1- on the

camshaft stub.
Position gasket ring over the guide

bushing onto the camshaft stub and
remove sleeve.
Press in the gasket ring with pressure

bushing -T10071- and screw -T10071/2up to the stop.
Proceed as follows for both versions
Insert Woodruff key.
Install camshaft sprocket and tighten to

100 Nm (use counterholder -MP 1-216-).
Installing and tensioning toothed belt

(setting timing) Chapter.
Removing and installing camshaft

t
t
Torque wrench
Removing

Loosen the camshaft sprocket (use counterholder -MP 1-216-).
74
Position camshaft sprocket to TDC

marking of cylinder 1 by rotating at
crankshaft. Marking on camshaft sprocket

must be aligned with arrow on the
toothed belt guard.
Slacken tensioning pulley and take off

timing belt.
Remove upper part of collecting intake
manifold and cylinder head cover
Chapter or Chapter.
Remove camshaft sprocket.
Remove Woodruff key from the camshaft.
First remove bearing caps 1, 3 and 5.

Release bearing caps 2 and 4 alternately
and crosswise.
Install
Note
t
t
Replacing camshaft gasket ring.

When fitting the camshaft the cams of
cylinder 1 must point upwards.
When installing the

bearing caps pay
attention to the
centre displacement
t of the bores, before
installing insert
bearing cap and
determine fitting
position.
When installing the
bearing cap 1, lightly
t coat the contact
surface with sealant
-AMV 174 004 01-.
Oil contact surfaces

of camshafts.
Screw in bearing
caps 2 and 4
alternately crosswise
and tighten to 20
Nm.
75
Install bearing caps

5, 1 and 3 and also
tighten to 20 Nm.
Set the Woodruff key
in the camshaft.
Install camshaft
sprocket and tighten
to 100 Nm (use
counterholder -MP 1216-).
Installing and
tensioning toothed
belt (setting timing)
Chapter.
Note
After installing the

camsaft, the engine
must not be started
for about 30
minutes. The
t hydraulic clearance
compensation
elements must settle
(otherwise valves
would strike the
pistons).
After carrying out
work on the valve
gear, carefully crank
engine at least 2
t revolutions to ensure
that no valve
touches the piston
when the engine is
started.
Testing hydraulic bucket tappets

t
Feeler gauge
Wooden or plastic wedge
76
Note
t Always replace bucket tappet complete (cannot be adjusted or repaired).

t
t
Irregular valve noises when starting engine are normal.

Lay aside removed bucket tappets with the contact surface (camshaft side) facing down
onto a clean surface.
After installing new bucket tappets, the engine must not be started for about 30 minutes.
t The hydraulic clearance compensation elements must settle (otherwise valves would strike
the pistons).
t
After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to
ensure that no valve touches the piston when the engine is started.
Test sequence
Start engine and allow to run until the radiator fan has cut in once.
Increase engine speed to about 2500
necessary.
rpm for 2 minutes and undertake a test drive if
Note
If the irregular valve noises disappear but occur regularly during short trips then the oil
retaining valve must be replaced. The installed location of the oil retaining valve: In the oil
filter holder Chapter.
If the bucket tappets are still loud, check the faulty tappet as follows:
Remove upper part of collecting intake manifold and cylinder head cover Chapter or
Chapter.
Turn the crankshaft clockwise until the cam of the bucket tappet to be tested is positioned
on top.
Press down the bucket tappet using a

wooden or plastic wedge. If a 0.20 mm
feeler gauge can be inserted between the

camshaft and the bucket tappet, the
tappet must be replaced.
77
Replacing valve stem seals

l
Cylinder head fitted

t
t
Extractor -MP 1-206Pressure hose -MP 1-210-
Valve lever -MP 1-211-
Insertion tool -MP 1-212-
Assembly device for valves -MP 1-213-
Removing
Remove the camshaft Chapter.

Remove bucket tappets (do not interchange) and lay aside with the contact surface facing
down.
Unscrew the spark plugs.
Position piston of the relevant cylinder in bottom dead centre.
Insert the assembly device -MP 1-213 and adjust bearing to the stay bolt
height.
Screw the pressure hose -MP 1-210- into
the spark plug thread and apply constant
pressure of at least 0.6 MPa (6 bar) in the
cylinder.
Remove valve springs with valve lever

-MP 1-211 -.
Note
If valve collets are tight, slacken with slight

blows of a hammer on the valve lever.
78
Use pulling device -MP 1-206- to pull off

valve stem seals.
Install
To avoid damaging the new valve stem

seals insert plastic bushing -A- on the
valve stem.
Insert valve stem seal -B- in the insertion

tool -MP 1-212-, oil sealing lip and
carefully push onto the valve guide.
Remove plastic sleeve.
Note
After installing the camsaft, the engine

must not be started for about 30
minutes. The hydraulic clearance
t
compensation elements must settle
(otherwise valves would strike the
pistons).
After carrying out work on the valve gear,
carefully crank engine at least 2
t revolutions to ensure that no valve
touches the piston when the engine is
started.
Inspect valve guides

t
Universal dial gauge holder -MP 3-447t
Dial gauge
Procedure
79
Insert valve into guide. End of valve stem must

be flush with guide.
Determine valve rock.

Wear limit
Inlet valve
1.0 mm
Exhaust valve
1.3 mm
Note
If the wear limit is exceeded, repeat measurement with new valves. If the wear limit is again exceeded,
replace valve guide.
t If the valve is replaced when carrying out repair work, use a new valve for the measurement.
t
Replacing the valve guides

t
t
Driver - MP 1-205Reamer - MP 1-204- and diluted soluble oil
Removing
Clean the cylinder head and check it. Heads whose valve seat rings can no longer be
reworked or cylinder heads which have already been machined down to their minimum
dimension are unsuitable for replacing the valve guides.
Press out worn valve guides with -MP 1-205- from the camshaft side (valve guides with
guides with a collar requiring repair from the combustion chamber side).
Install
Press the new guides which have been wetted with oil into the cold cylinder head using the
driver -MP 1-205-, from the camshaft side up to the collar.
Note
Once the guide has been pressed against the collar then the pressing in pressure should not
be increased above 10 kN since otherwise the collar can break off.
Ream the valve guides using the hand broach -MP 1-204-. It is essential to use dilute
80
soluble oil while doing this.
Install new valves.

Rework the valve seats Chapter.
Reworking valve seats

t
t
Depth gauge/caliper gauge

NAC milling cutter for reworking valve seats
Grinding paste
Note
When carrying out repairs on engines with leaking valves, it is not sufficient to machine or
t replace the valve seats and valves. It is also necessary to inspect the valve guides for
wear, particularly on engines with a high mileage.
Rework valve seats only sufficiently in order to obtain a proper contact pattern. Calculate
the maximum permissible reworking dimension before commencing. If the reworking
t
dimension is exceeded, the proper operation of the hydraulic valve clearance
compensation is no longer ensured. If this is the case replace the cylinder head.
Calculating maximum permissible reworking dimension
Insert valve and press firmly against the valve seat.

Note
If the valve is replaced when carrying out repair work, use a new valve for the measurement.
Measure distance -a- between the end of

the valve stem and the upper face of the
cylinder head.
Calculate max. permissible reworking
dimension from the distance -ameasured and the minimum dimension.
Minimum dimension: Inlet valve .... 33.8

mm
Outlet valve .... 34.1 mm
Distance measured -a- minus minimum
dimension = max. permissible reworking
dimension.
Example:
81
distance measured -aMinimum dimension
34.5 mm
33.8 mm
= Max. permissible reworking dimension
0.7 mm
Note
If the max. permissible reworking dimension is 0 mm, repeat measurement with a new valve.
If the max. permissible reworking dimension is again 0 mm, replace cylinder head.
Reworking valve seats
Dimension
Valve seats
mm Valve seat diameter
mm
mm Valve seat width
39.2 -0.1 - inlet valve

32.4 -0.1 - exhaust valve
Max. permissible reworking dimension

1.9 up to 2.1 - inlet valve
2.3 up to 2.5 - exhaust valve
Bottom edge of cylinder head
45
Valve seat angle
30
Top correction angle
Procedure
Reworking can be carried out with a machine or by hand. The following conditions must be
met:
l Wear limit of valve guides must not exceed the permissible dimension Chapter.
l
Use NAC milling cutter with carbide metal tips (min. 90 HRC).
82
Reworking valve seats with NAC milling

cutter
Place cylinder head on a felt base and

secure to prevent it from turning.
Match diameter of guide drift to diameter

of valve guide.
Valve guide
Guide drift in mm
Inlet valve
7,0 -0,01
Exhaust valve
Match diameter of milling cutter to diameter of valve seat.

Valve seat
Milling cutter 90 mm
Milling cutter 120 mm
Inlet valve
41
41
Exhaust valve
34
34
Milling sequence
1. Mill valve seat with 90 milling tool
until until a perfect contact pattern is
achieved. (Do not exceed maximum
permissible reworking dimension!)
2. Initially mill top correction angle with
120 milling cutter until the valve seat
diameter a or valve seat width c is
achieved Anchor.
83
Grind in valve/valve seat -arrows- with

fine grinding paste until a perfect contact
pattern is achieved.
Check tightness of valves.
The inspection can be carried out with

water colour (perfect contact pattern over
entire circumference) or by filling fuel into
the combustion chamber (no fuel must flow
out at the valve seat).
Note
After installing the cylinder head, check the

hydraulic bucket tappets Chapter.
84
Engine lubrication
Removing and installing parts of the lubrication system
Note
If considerable quantities of metal swarf

or abrasion is found in the engine oil
when carrying out engine repairs,
t
carefully clean the oil galleries in order to
avoid consequential damage and
additionally replace the oil cooler.
The engine oil level must never exceed
t the max. marking - risk of damage to
catalytic converter!
Check the engine oil, amount of oil, oil
specification: Octavia
1
Oil pump
Duocentric pump with pressure relief

valve 1.2 MPa (12 bar)
Before installing, check whether both
dowel sleeves for centering oil
pump/cylinder block are present
if there is any scoring on contact

surfaces and gears, replace
Torque of oil pump cover at oil pump

housing: 10 Nm
Oil pump sprocket

Fits onto oil pump shaft in one position

only
3-
20 Nm
4-
Oil pump chain
5-
Sealing flange
coat with silicone sealant -D 176 404 A2 Chapter
replace the gasket ring for the crankshaft

Chapter
6-
15 Nm
85
7-
Collar screw, 15 Nm
8-
Bush
Chain tensioner
together with pos. 7, 8, 10 and 11
10 -
Spring
11 -
Washer
12 -
Sprocket
13 -
O ring
replace
14 -
15 Nm
15 -
Suction line
Clean strainer if dirty
16 -
Baffle
17 -
15 Nm
18 -
15 Nm
loosen and tighten with hinged wrench

and socket insert
19
Oil pan
install with silicone sealant

-D 176 404 A2- Chapter
20
21 -
Gasket ring
replace
Oil drain plug, 30 Nm
Disassembling and assembling oil filter holder
86
Insert into lugs on oil cooler

87
17
Oil cooler
ensure clearance to surrounding

components
pay attention to the notes Chapter

18 -
25 Nm
19 -
Oil filter
slacken with tensioning strap

tighten by hand
pay attention to installation instructions
on oil filter
Removing and installing oil pan

t
Flexible-head wrench 3185
t
Socket insert 3249
t
Hand-held power drill with plastic brush insert
t
Flat scraper
t
Silicone sealant - D 176 404 A2Removing
88
Remove noise insulation panel in middle as

well as on left and right -arrows-.
Drain engine oil.
Unbolt oil pan.

Note
Slacken oil pan bolts at flywheel side with hinged

wrench -3185- and unscrew with wrench socket
-3249-.
Remove oil pan, if necessary release by
applying slight blows with a rubber-headed
hammer.
Use a flat scraper to remove sealant residues on
the cylinder block.
Use a rotating plastic brush to remove sealant

residues on the oil pan (wear protective
goggles).
Clean sealing surfaces, they must be free of oil
and grease.
Install
Note
The oil pan must be installed within 5 minutes
after applying the silicone sealant.
Use socket insert - 3249- to insert the oil pan
t bolts at flywheel side and tighten with hinged
wrench -3185 -.
The assistance of a second mechanic is required
t
to install the oil pan.
t
89
Cut off nozzle tube of the silicone sealant

-D 176 404 A2 - at the front marking ( of
nozzle approx. 3 mm).
t Thickness of sealant bead: 2 to 3 mm
The sealant must be run past on the inside in the
t
area of the bolt holes -arrows-.
Note
The sealant bead must not be thicker than 3 mm
otherwise excess sealant may get into the oil pan
and clogg the strainer in the oil suction pipe.
Apply silicone sealant to the clean sealing

surface of the oil pan, as shown in the
illustration.
Note
Take particular care when applying sealant bead
in the area of the sealing flange at the rear
-arrows-.
Fit on oil pan immediately and tighten the bolts
as follows:
1. Tighten all the bolts of oil pan/cylinder block
slightly diagonally across.
2. Tighten the three bolts of oil pan/cylinder
block slightly.
slightly diagonally across.
4. Tighten the three bolts of oil pan/gearbox to
45 Nm.
diagonally across to 15 Nm.
Note
When installing the oil pan with the engine
t removed, ensure that the oil pan is flush with
the cylinder block at the flywheel side.
After installing the oil pan, allow the sealant to
t dry for about 30 minutes. Only then may
engine oil be filled in.
Testing oil pressure and oil pressure switch

t
Oil pressure testing device (e. g. - V.A.G 1342-)

90
Voltage tester (e.g. - V.A.G 1527-)
Measuring tool set (e.g. -V.A.G 1594-)
Current flow diagram
Function of dynamic oil pressure warning system if oil pressure low

The oil pressure switch is opened when pressureless and closed when the switching pressure
is reached.
The oil pressure warning is activated for about 10 seconds after the ignition is switched on
(terminal 15 on).
Activation delay of oil pressure warning system: approx. 3 s.
De-activation delay of the oil pressure warning system: approx. 5 s.
Test warning light
After the ignition is switched on and engine not running, the oil pressure warning light in the
dash panel insert must light up for about 3 s and then go out. The check is ended when the
engine is started.
Warning criteria
The visual oil pressure warning (oil pressure warning lamp flashes) is activated and the
audible warning buzzer sounds 3 times if one of the following conditions exists:
l
Ignition on, engine not running, oil pressure switch closed
Engine speed above 1500 rpm, oil pressure switch open
At an engine speed above 5000 1 rpm, the oil pressure warning is also not cancelled if the
oil pressure switch is closed. The oil pressure warning is cancelled once engine speed is
below 5000 1 rpm.
If the oil pressure switch is opened for only 0.5 to 3 s at an engine speed of above 500
rpm, it is stored in the combination processor of the dash panel insert. If this condition
occurs 3 times when the engine is running, the oil pressure warning is immediately
activated and is not cancelled below 1500 rpm. The oil pressure warning is cancelled if the
oil pressure switch is closed for more than 5 s at a speed of more than 1500 rpm, or at
Ignition off.
Test conditions
l
l
Engine oil level o.k., test Octavia

Oil pressure warning light -K3- must come on for about 3 seconds when the ignition is
switched on.
l Engine oil temperature at least 80C (radiator fan must have run at least once)
Testing oil pressure switch
Detach cable from oil pressure switch.
91
Unscrew oil pressure switch and screw in

oil pressure tester (e.g. - V.A.G 1342-).
Screw oil pressure switch -2- into the test

equipment -V.A.G 1342-.
Connect brown cable -1- of tester to

earth (-).
Connect voltage tester to oil pressure

switch -2- and to battery positive (+).
The LED must not light up.
The oil pressure switch must be replaced

if the LED lights up.
Start engine and slowly increase engine

speed.
The LED must come on at an

overpressure of 0.12 to 0.16 MPa (1.2 to
1.6 bar). The oil pressure switch must be
replaced if it does not come on.
Testing oil pressure
Unscrew oil pressure switch and screw in

the tester - V.A.G 1342-.
Screw oil pressure switch into the tester

-V.A.G 1342 -.
Start engine (engine oil temperature at

least 80C).
Oil pressure when engine idling: min. 0,2

MPa (2 bar)
Oil pressure at 2000 rpm: 0.30 to 0.45

MPa (3 to 4.5 bar)
If the specified values are not reached:
Eliminate any mechanical damage, e. g.

bearing damage.
Replace pressure relief valve in the oil

filter holder Chapter.
At a higher engine speed the oil pressure

must not be greater than 0.7 MPa (7 bar).
If the specified pressure is exceeded:
Inspect oil galleries.
Replace if necessary pressure relief valve

92
in the oil filter holder Chapter.
93
Engine cooling
Removing and installing parts of the cooling system
Parts of the Cooling System
Note
When the engine is warm the cooling

t system is under pressure. Reduce
pressure before repairs.
The hose connections are secured with
t spring-type clips. In the event of repairs
only use spring-type clips.
t
Use pliers for spring strap clips to fit the

spring strap clips.
t Always replace seals and gasket rings.

When installing fit the coolant hoses free
of stress, without them touching any
t other components (pay attention to the
marking on the coolant connection and
hose).
t
Draining and filling up coolant

Chapter.
t Coolant mixing ratios Anchor.

t
Checking the coolant system for

tightness.
after replacing fill entire system with

fresh coolant
Coolant pump, coolant regulator
Removing and installing coolant pump

Chapter
Oil cooler
Radiator
check smooth operation

Removing and installing coolant
regulator Chapter
4-
test, data Chapter

Cylinder block
94
5-
Expansion reservoir
6-
Intake manifold
7 - Heating for throttle valve supports

8-
Heat exchanger
9-
Gearbox oil cooler
for ATF
only for vehicles with automatic gearbox
Draining and filling up coolant

Coolant capacity approx. 5.0 litres
Special tools, test equipment as well as aids required
t
Catch pan (e.g. -V.A.G 1306-)
antifreeze tester
Draining
WARNING
Hot steam may escape when the compensation bottle is opened. Cover the cap with a cloth
and open carefully.
95
Remove noise insulation in middle

-arrows- in top half of Fig.
Position drip tray (e.g. -V.A.G 1306-)

under the engine.
Turn the drain plug -arrow- on the radiator

to the left and draw backwards, if
necessary fit auxiliary hose onto
connection.
96
In addition, detach coolant hose at

bottom of oil cooler -arrow- and allow
remaining coolant to drain.
Note
Collect drained coolant for proper

disposal.
Observe the disposal instructions for

coolant.
Filling up
Select the appropriate coolant additive from
the catalogue of original parts koda or
from the list of allowed coolant additives
Octavia.
Recommended mixture ratios:
Antifreeze protection down to Antifreeze concentration Note Note Drinking water Note
-25C
-35C
1)
2)
40% (2.0 ltr.)

50% (2.5 ltr.)
60% (3.0 ltr.)

50% (2.5 ltr.)
The proportion of coolant additive must not go below 30% due to corrosion protection
considerations but must also not exceed 60% otherwise the frost protection effect will be
reduced and the cooling effect worsened.
The coolant amount may differ according to the version of the vehicle.
Screw in drain valve for coolant.
Attach coolant hose to bottom of oil cooler.
Fill up coolant gradually up to the max
marking on the compensation bottle.
Start engine and run for not more than 2

minutes at approx. 1500 rpm; while
doing so top up coolant in the expansion
reservoir up to overflow opening.
Seal expansion reservoir.
Run engine until fan starts.

WARNING
Hot steam may escape when the

compensation bottle is opened. Cover the
97
cap with cloths and open carefully.

Inspect coolant level. When engine is at
operating temperature the coolant level
must be at the maximum marking, when

engine is cold between the minimum and
the maximum markings.
Removing and installing radiator

Note
t
t
Always replace seals and gasket rings.

Raise vehicle with the lift platform Chapter.

t
Removing
Drain coolant Chapter.
Unplug connector -1- from thermoswitch

-F18- and separate plug connections -2and -3- at fan shroud (press catches).
Separate coolant hoses at connection
fittings of radiator (pull off retaining clip).
98
Unscrew the 4 bolts -arrows- attaching

the condenser.
WARNING
Do not open the refrigerant circuit of the

air conditioning system.
Note
In order to avoid damage to the condenser

as well as to the refrigerant lines and
hoses, ensure that the lines and hoses are
not over-tensioned, kinked or bent.
Take off retaining clip attaching

refrigerant line.
For all vehicles
Remove both headlights: Electrical

System, Rep. Gr. 94; Removing and
installing headlight
Unscrew 4 bolts -arrows- attaching top

radiator mount.
99
Unscrew 4 bolts -arrows- attaching

bottom radiator mount.
For vehicles with air conditioning

Pull out radiator and condenser slightly.
Take off bracket -arrow- for refrigerant

line.
For all vehicles
Remove fan shroud (4 bolts).

Note
When removing and installing the fan

shroud, ensure that the radiator fins are
not damaged.
Carefully remove radiator downward.
Install
Installation is performed in the reverse
order. Pay attention to the following points:
Tighten thermoswitch -1- to 35 Nm.
shown.

100
Install headlight: Electrical System,

Rep. Gr. 94; Removing and installing
headlight.
Electrical connections and laying of
cables: Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations (Binder)
Removing
and
installing
coolant
pump required
Special
tools
and
workshop
equipment
Removing

101
Install noise insulation; -arrows- in the

lower part of the figure.
Remove ribbed V-belt tensioning device

Chapter.
Remove top and middle toothed belt

guard Chapter.
Position crankshaft on TDC cylinder 1

Chapter.
Take toothed belt off camshaft sprocket

Chapter.
Note
The vibration damper and the bottom

toothed belt guard can remain installed.
The timing belt remains fitted onto the

timing belt crankshaft sprocket.
Pay attention to instructions for the

t removal and installation of the timing
belt Chapter.
Release screws -1- and -5- and remove

timing belt guard at rear -2-.
Unscrew coolant pump -4- and carefully

guide out along the engine support.
Install
Clean sealing surface for O-ring or

smoothen.
Moisten new O-ring -3- with coolant

102
additive.
Attach the coolant pump. Fitting position:

Plugs in housing point downwards.
Insert rear toothed belt guard, tighten

screw -1- to 20 Nm.
Tighten screws -5- of coolant pump: 15

Nm.

timing) Chapter.
Removing and installing, testing coolant thermostat

t
t

Note

Removing
Detach coolant hose from connection

fitting -3-.
Release bolts -4-, remove connection

fitting with O-ring -2- and thermostat
-1-.
Testing coolant thermostat
Heat up regulator in a water bath.
Start of opening
End of opening
(cannot be tested)
Opening stroke
approx. 87C
approx. 102C
min. 7 mm
103
Install
Clean sealing surface for O-ring.

Insert coolant thermostat. Fitting position: The clamp of the coolant thermostat must be
positioned vertically.
Moisten new O-ring with coolant additive.
Tighten bolts to 15 Nm.
Filling system with coolant Anchor.
Installing coolant pipe

t Torque wrench 5 to 50 Nm (e.g. -V.A.G 1331-)
t
Note
Moisten O-ring -1- with coolant additive and

slide onto coolant pipe -2-.
Push the coolant pipe into the bore hole on the
cylinder block.
Tighten bracket for coolant pipe to 10 Nm.
Checking the coolant system for tightness

t
Coolant system tester (e.g.-V.A.G 1274-)
t
Adapter (e.g. -V.A.G 1274/8-)
t
Adapter (e.g. -V.A.G 1274/9-)
Test conditions
l
Engine must be warm
Test sequence
104
WARNING
Hot steam may escape when the compensation bottle is opened. Cover the cap with cloths and open
carefully.

Position coolant system tester -V.A.G 1274 with adapter -V.A.G 1274/8- on the
compensation bottle.
With the hand pump of the tester generate an
overpressure of approx. 0.1 MPa.

If the pressure drops determine position of the
leak and repair.

Testing the pressure relief valve in the cap
Screw cap onto tester with adapter
-V.A.G 1274/9-.
With the hand pump of the tester generate an
overpressure of approx. 0.15 MPa.

The pressure relief valve must open for an
overpressure of 0.12 to 0.15 MPa.
105
Fuel supply, gas operation

Removing and installing parts of the fuel supply system
Note
The hose connections are secured with screw-type clips, spring-type clips or clamp-type
clips.
t Always replace clamp-type clips with screw-type clips or spring-type clips.

t
Fuel lines on the engine must always be secured with spring-type clips. The use of clamptype or screw-type clips is not allowed.
Use pliers for spring strap clips to fit the spring strap clips.
Observe safety measures Chapter.

Observe rules for cleanliness Chapter.
Removing and installing parts of the activated charcoal filter system Chapter.
Accelerator control Chapter.
Adjust accelerator control Chapter.
Removing and installing fuel tank with attached parts and fuel filter
106
12q
3q
q
4q
5q
Overflow hose
O ring
replace
Gravity valve
to remove, unclip valve and lift up and out of the filler neck
inspect valve for blockage, valve in a vertical position: open, valve tilted 45: closed
Vent line
to the activated charcoal filter system Anchor
Fuel filler cap
Replace seal if damaged
6-
Tensioning ring
7-
Rubber bowl
107
8q
9-
Vent valve
check Fig.
Earth connection
10 -
10 Nm
11 -
Vent line
12 -
Fuel tank
13 -
Circlip
removing: turn left
Installing: tighten to 2 Nm
14 q
Heat shield
for fuel tank
15 -
20 Nm + torque a further 1/4 turn (90)
16 -
Clamping screw
Installing: tighten to 2 Nm
17 q
18 q
Cover
for fuel tank
Tensioning strap
pay attention to different lengths
19 -
Feed line
black
q
q
to fuel rail
to remove, press release button at connecting piece
20 q
21 q
22 q
q
23 -
Fuel filter
Fitting position: arrow points in direction of flow
Retaining clip
for fuel filter
Gasket ring
moisten with fuel before installing
replace if damaged
Fuel delivery unit
108
Check the fuel delivery unit Chapter.
removing and installing fuel gauge sensor Chapter
q Test holding pressure: 1.6 ltr./74 kW Motor, Simos 2 Injection and ignition system; Rep.
Gr. 24; test fuel pressure regulator
24 q
Union nut
use wrench -MP 1-227- for removing and installing
25 -
Feed line
black
to fuel filter
q
q
to the connection with marking V at closing flange

to remove from connecting flange press release button on the connecting part
26 -
Return-flow line
q
q
q
q
blue
from fuel rail
to the connection with marking R at closing flange
to remove from connecting flange press release button on the connecting part
Inspect vent valve

Lever in off position: Valve closed
Lever pushed in direction of arrow: Valve
open
Safety precautions when working on the fuel supply system
109
WARNING
The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection
point. Reduce pressure by carefully releasing the connection point.
Pay attention to the following points when removing and installing the fuel gauge sensor or the fuel delivery
unit from the fuel tank:
t
The fuel tank must not be more than 2/3 full.
The extraction hose of an exhaust extraction system which is switched on, must be positioned close to the
assembly opening of the fuel tank in order to extract the released fuel gases, even before the work is
t
commenced. If no exhaust extraction system is available, a radial fan (motor not in air flow of fan) with a
delivery volume of more than 15 m3/h must be used.
t Avoid skin contact with fuel! Wear fuel-resistant gloves!
Rules of cleanliness
Carefully observe the following 5 rules for cleanliness when working on the fuel supply and injection
system:
t Thoroughly clean the connection points and their surroundings before releasing.
t Place removed parts on a clean surface and cover. Do not use fuzzy cloths!
t Carefully cover or close opened components if the repair is not completed immediately.
Only install clean components: Remove spare parts from their wrapping immediately before fitting. Do
t
not use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
t When the system is open: Avoid using compressed air. Avoid moving the vehicle.
Removing and installing the fuel delivery unit
t
Wrench for union nut -MP 1-227 -
Removing
necessary.
Unscrew cover (below rear seat).
Detach feed and return-flow line from flange of fuel delivery unit (press release buttons).
Unlock and unplug 4-pin connector of flange at fuel tank.
110
Unscrew union nut with wrench -MP 1227 -.
Pull the fuel delivery unit and the gasket

ring out of the opening of the fuel tank.
Note
If the delivery unit is still filled with fuel,

empty it before replacing.
Install
Note
When installing the fuel delivery unit,

t ensure that the fuel gauge sensor is not
bent.
t
Moisten the gasket ring of the flange with

fuel before fitting.
t Make sure the fuel hoses fit tightly.
check fitting position:
Marking on closing flange must be aligned

with marking on fuel tank -arrows-.
Blue return-flow line -1- on the connection

with the marking -R-.
Black feed line -2- on the connection with

the marking -V-.
Removing and installing the fuel gauge sender

Removing
Removing fuel delivery unit Chapter.
111
Unlatch and disconnect lines -3- and -4-.
Raise catches -1- and -2- with a

screwdriver and remove the fuel gauge
sender towards the bottom -arrow-.
Install
Insert the fuel gauge sender in the fuel

delivery unit guides and press upwards
until they latch into position.
Removing and installing the fuel tank

t
Engine/gearbox jack (e.g. -V.A.G 1383 A -)
Fuel extraction device (e.g. -V.A.G 1433 A-)
Removing
necessary.
Empty fuel tank with fuel extraction equipment (e. g. -V.A.G 1433 A -).
Remove rear axle: Running gear, Rep. Gr. 42; Repairing rear axle; Removing and
installing the rear axle
Unlock and unplug 4-pin connector of flange at fuel tank.
Open the fuel tank cap, lever out tensioning ring in rubber bowl (around filler neck).
Press through rubber bowl to the inside.
Remove rear right wheelhouse liner.
Unscrew fuel filler neck below wheelhouse liner.
112
Remove cover below fuel tank -arrows(if fitted).
Separate return-flow line -2- (blue), feed

line -1- (black) and vent line -3- (white) at
front right of fuel tank (press release
button).
Position engine/gearbox jack (e. g.

-V.A.G 1383 A-) below the fuel tank for
supporting.
Detach bolted connections -arrows- at

front left and at the retaining straps.
Lower the fuel tank.
Install
Connect fuel lines to the flange of the fuel

delivery unit:
t blue return-flow line -1- on the connection

113
with the marking -Rt
black feed line -2- on the connection with

the marking -V-.
Connecting remote control

t Remote control -V.A.G 1348/3A - with adapter cable -V.A.G 1348/3-2 Procedure
Open cover of fuse holder on left side of dash panel.

Remove fuse 28 at fuse holder (left row, 5th large fuse from top).
Connect remote control -V.A.G 1348/3A- with

adapter cable -V.A.G 1348/3-2- to fuse socket
no. 28 -arrow-.
Connect alligator clip to vehicle battery (+).
Check the fuel delivery unit

t
Handheld multimeter (e.g. -V.A.G 1526 -)
Measuring tool set (e.g. -V.A.G 1594-)
t
t
t
Remote control -V.A.G 1348/3A - with adapter cable -V.A.G 1348/3-2Wrench for union nut -MP 1-227 Current flow diagram
Test conditions
l
Battery voltage at least 12 volts
Fuse no. 28 o.k.
Fuel filter o.k.
Test sequence
Switch on ignition.
114
The fuel delivery unit must be heard to start running. (A second person is required for this
purpose if the level of surrounding noise is high).
If the fuel delivery unit does not run:
Switch off ignition.
Connect remote control -V.A.G 1348/3A- with adapter cable -V.A.G 1348/3-2- Chapter.
Activate remote control.
If the fuel delivery unit runs:

Testing fuel pump relay: 1.6 ltr./74 kW Motor, Simos 2 Injection and ignition system; Rep.
Gr. 24; test fuel pressure regulator and holding pressure
If the fuel delivery unit does not run:

Unlock 4-pin connector of flange at fuel tank.
Connect hand-held multimeter (e. g.

-V.A.G 1526-) with adapter cables (e. g.
from -V.A.G 1594-) to the outer contacts of
the connector.
Activate remote control. Specified value:

approx. battery voltage
If the specified value is not reached:

Determine and remove open circuit in the
wiring according to the current flow
diagram: Current flow diagrams and
Fitting locations
Unscrew union nut with wrench -MP 1227 -.

Check whether the electric cables are
connected between flange and fuel pump,
and test for open circuit if necessary.
If no open circuit was detected:

Fuel delivery unit defective.
Replacing fuel delivery unit Chapter.
Check fuel flow rate

115
t
t
t
Remote control -V.A.G 1348/3A - with adapter cable -V.A.G 1348/3-2 Adapter -V.A.G 1318/17Measuring vessel
Test conditions
l
Battery voltage at least 12 volts
Voltage supply o.k.
Fuel filter o.k.
Test sequence
Connect remote control -V.A.G 1348/- 3A with adapter cable -V.A.G 1348/3-2- Chapter.
Remove fuel filler cap from fuel filler neck.

WARNING
The fuel system is under pressure! Before opening the system lay cleaning cloths around the
connection point. Reduce pressure by carefully releasing the connection point.
Detach fuel return-flow line -2- (press

release button).
Connect auxiliary hose to adapter

-V.A.G 1318/17 - and fit onto fuel return
line from engine and hold in a measuring
vessel.
Operate remote control for 15 seconds

(press and hold button).
116
Compare the fuel rate with the specified

value.
Minimum flow rate cm3/15 seconds
**
Voltage at fuel delivery unit when engine

not running and delivery unit operating
(approx. 2 volts less than battery voltage)
Removing and installing activated charcoal filter system
1-
Activated charcoal filter system

solenoid valve 1 -N80-
Inspecting proper operation and

actuation: 1.6 ltr./74 kW Motor, Simos
2 Injection and ignition system; Rep. Gr.

24; test fuel tank venting; test activated
charcoal filter system solenoid valve
2-
Connector
3-
Vent line
from gravity valve Itemto fuel tank
to remove, press release button at

connecting piece
4-
Throttle valve control unit
5-
Activated charcoal filter
with activated charcoal filter system

solenoid valve 1 -N80 -
Fitting location: in right of engine

compartment
to remove, first of all remove PAS

reservoir and press to the side
6-
Spring nut
117
Repairing the accelerator control
Throttle control cable
adjust by reconnecting the fuse to the

plug-in catch Chapter
2-
Retaining clip
3-
Accelerator pedal
4-
Spacer bush
5-
Bushing
6-
Washer
7-
Stop screw
8-
20 Nm
Adjust accelerator control
Note
t The throttle control cable is very sensitive to bents and must be handled very carefully when installing.
Already a slight bent can lead later on to a fracture while driving. Throttle control cables, which were
t
bent, must therefore not be installed.
During installation, make sure that the throttle control cable is aligned between its supports and the
t
traction fixing points.
t
Spring expansion rod
Procedure
Hook on throttle control cable at accelerator pedal and at the cam disc of the throttle valve control unit.
Detach fuse for throttle control cable at the plug-in catch.
Press accelerator pedal in full throttle position.

Note
A second person is required for this purpose or support accelerator pedal with spring expansion rod against
the steering wheel.
Adjust throttle control cable by reconnecting the plug-in catch at support in such a way that the full
throttle position is achieved at the throttle valve lever.

118
Adjust throttle control cable by reconnecting the plug-in catch at support in such a way that the throttle
valve is fully opened and the kick-down switch clicks audibly.
All vehicles
Release the accelerator pedal or remove the expansion rod.
After the setting, check the idle and full throttle stop on the throttle valve.
119
Exhaust system
Removing and installing parts of the exhaust system
Note
Always replace gaskets and self-locking

nuts.
Use a screwdriver to slacken and tighten

t the clamps of the heat shield. Tightening
torque: 2 Nm
1
Tunnel bridge
with hole for aligning exhaust system

Chapter
Hanger
34-
25 Nm
Front exhaust pipe
pay attention to different version
with oxidation catalytic converter
with separation point
protect against shocks and blows

Avoid a large deflection, max. deflection
10

40 Nm
replace
coat with hot bolt paste -G 052 112 A36

7
8
Gasket
replace
Exhaust manifold
25 Nm
replace
120
coat with hot bolt paste -G 052 112 A39-
Washer
10
Lambda probe, 50 Nm
coat only thread with hot bolt paste

-G 052 112 A3-; hot bolt paste must not
get into the slot of the probe body
test: 1.6 ltr./74 kW Motor, Simos 2
Injection and ignition system; Rep. Gr. 24
Plug connection for lambda probe is

located below the protective cover
Anchor
11
Clamping sleeve
Align exhaust system free of stress

before tightening Chapter
Fitting position: synchronous running to

vehicle floor, bolted connection pointing
to left
Tighten bolted connections evenly
12 -
40 Nm
13 -
Hanger
14 -
Front and rear silencer
Replace individually when carrying out

repairs Chapter

Chapter
Installed position of the hanger

The angled side -arrow- at the base of the
hanger points in direction of travel.
121
Removing and installing front exhaust pipe

t
Removing
Note
t
t
Avoid a large deflection of decoupling element, max. deflection 10 .

Unbolt protective cover -arrows-,

separate plug connection for lambda
probe.
Unscrew front heat shield.
Unscrew clamping sleeve.
Unbolt front exhaust pipe from exhaust

manifold.
Swivel front exhaust pipe down 180 and

take off.
Install
Tightening order of front exhaust pipe to

exhaust manifold
Components
Nm
Front exhaust pipe to exhaust manifold
40 Note
Lambda probe to front exhaust pipe
50 Note
Nuts for clamping sleeve
40
122
Shielding for drive shaft to cylinder block
1)
35
Coat with hot bolt paste -G 052 112 A3-.

Align exhaust system free of stress Chapter.
Interrogating fault memory: 1.6 ltr./74 kW Motor, Simos 2 Injection and ignition system;
Rep. Gr. 01
Removing and installing exhaust manifold

t
Removing

Remove front exhaust pipe Chapter.
Unscrew nuts -1- for shield -3-, take off

washers -2-.
Unscrew nuts -8- on both brackets -4-,

take off washers -7-.
Unscrew remaining nuts at exhaust

manifold -6-, take off washers.
Take off exhaust manifold and gasket -5for exhaust manifold.
Install
Note
Only use 4 mm thick washers.
t Replace gasket for exhaust manifold.

t Always replace self-locking nuts.
Components
Nm
Shield to exhaust manifold
25
Exhaust manifold to cylinder block
25 Note
123
1)
Coat with hot bolt paste -G 052 112 A3-.

Align exhaust system free of stress Chapter.
Install front exhaust pipe Chapter.
Replacing front or rear silencer

t
t

Body saw (e.g. -V.A.G 1523-)
A separation point is provided for repair purposes for replacing the front silencer or rear
silencer.
Separate exhaust pipe at right angles at

the separation point -arrow 2- with body
saw (e.g. -V.A.G 1523 -).
When installing clamping sleeve -4 position on the side markings -arrows 1

and 3-.

Chapter.
Align rear silencer horizontally.
Tighten bolted connections of clamping
sleeve evenly to 40 Nm.
Installation position of clamping sleeve:
horizontal in vehicle, bolted connections
pointing forward.
Aligning exhaust system free of stress

t
Procedure
l
The exhaust system is aligned when cold.
124
Shop-make screw from an M10 bolt to

the dimensions stated for aligning the
exhaust system.
Dimension -X- = 4 mm
Dimension -Y- = 25 mm
Note
A second person is required for aligning the

exhaust system.
Slacken bolted connections of clamping

sleeve between catalytic converter and
front silencer.
Insert shop-made screw through the rear

hole -arrow- of tunnel bridge, the flat
point points toward the hanger pin of the
exhaust system.
Note
The exhaust system is pretensioned in the

direction of travel when the shop-make
screw is inserted.
Align front and rear silencers

horizontally:
The hanger pin at the exhaust system

must be parallel to the tunnel bridge
(dimension -X- on left and right identical).
Note
On vehicles with separation point

Chapter inspect horizontal position of
rear silencer additionally at tail pipe.
125
Position clamping sleeve with a clearance

of about 5 mm to the line of the
particular marking and tighten evenly in
horizontal position to 40 Nm.
Different markings apply depending on the
gearbox version:
t
Arrow 1 - Vehicles fitted with automatic

gearbox
t Arrow 2 - Vehicles with a manual gearbox

The screwed connection of the clamping
sleeve must point forwards.
Checking the exhaust system for leaks
Start engine and run in idle.

Seal off tail pipe for the duration of the leak check (e.g. with cloth or plug).
Check the connection points for leaks by listening: Cylinder head/exhaust manifold, exhaust
manifold/catalytic converter, etc.
Eliminate any leak found.
126
1.6 ltr./74 kW Engine, Simos 2 injection and ignition system

Self diagnosis, V.A.G Inspection Service
Operation
The control unit for the injection and ignition system is equipped with a fault memory.
If malfunctions occur in the monitored sensors or components, they are stored in the fault
memory with indication of the fault type.
Stored information regarding the faults can be interrogated according to the instruction
Chapter.
After the fault(s) has(have) been removed the fault memory must be erased Chapter.
A test drive of min. 10 minutes must be performed in order to interrogate the information
regarding the fault according to the lambda control.
Faults due to a temporary line interruption or loose contact are also stored. These so-called
temporary (sporadic) faults are shown as SP and if they do no longer occur during 40
vehicle starts, they are erased automatically in the fault memory.
Note
The following description applies only for vehicle system tester -V.A.G 1552- used in
combination with program card version 5.0.
If Info in literature appears in the display, look for the text required in the fault table
under the fault code.
The use of fault read-out scan tool -V.A.G 1551- with program card version 8.0 with
integrated printer is similar. A minor deviation on the display read-out is possible.
Technical data of self-diagnosis

Equipment
t
1)
Fault memory: permanent memory and volatile memory Note

If the fault does no longer occur, it is erased after 40 starts.
Control unit identification Chapter.

Available functions
Operation
Precondition
Engine not running, ignition switched on Engine idling
01 Interrogating control unit version
yes
yes
02 Interrogating fault memory
yes1)
yes
03 Actuator diagnosis
yes
no
127
04 Initiating basic setting
yes2)
no
05 Erasing fault memory
yes
yes
06 Ending output
yes
yes
07 Coding control unit
yes
no
08 Reading measured value block
yes
yes
1)
Only if the engine does not start (operate starter for at least 6 seconds).
2)
It must be carried out after the following operations: if the engine control unit -J220-, the
throttle valve control unit -J338- or the engine are replaced.
Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for
engine electronics
t
Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3-
Test conditions
l
l
Battery voltage at least 11 V.

Earth connection to engine and gearbox O.K.
Fuses o.k.
Procedure
Connect vehicle system tester

-V.A.G 1552- with cable -V.A.G 1551/3 -.
Readout on display:
Vehicle system test

HELP
Select function XX
Note
128
If there is nothing on the display: Operating

instructions of vehicle system tester
Depending on the function which must be carried out:
Switch on the ignition or start the engine Anchor.
Enter address word 01 for Engine electronics and

confirm entry with the Q key.
The vehicle system tester - V.A.G 1552- displays the control

unit identification, e. g.:
06A 906 019 B = Part No. of the control unit (current
t control unit version Electronic catalogue of original
parts)
t
1.6 ltr. = engine displacement
t 2V/R4 = engine version (4 cyl./2 valves in-line engine)

t SIMOS = Identification of the injection and ignition system
t HS = Manual gearbox, AT = Automatic gearbox
t
t
t
XXXX = Data status (hardware and software version) of

the control unit
06A906019B 1.6ltr. 2V/R4

SIMOS HSXXXX ->
Coding 00000
WSC XXXXX
Coding = Coding version of control unit

WSC = Workshop code
If the code does not match the version of the vehicle:
Check code of engine control units Chapter.

Press key.
Readout on display:
Vehicle system test

Select function XX
HELP
Interrogating and erasing fault memory

t
Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine
electronics. Engine idling.
Only if the engine does not start:
Switch on ignition.
Readout on display:
Enter 02 for the function Interrogate fault memory
and confirm with key Q.
Vehicle system test

HELP
Select function XX
The number of stored faults or No fault recognised appears in the

129
X faults detected!
display.
If no fault is stored:
Press key.
If one or several faults are stored:

The stored faults are displayed in sequence.
Then the following appears in the display:
Enter 05 for the function Erase fault memory and

confirm with the key Q.
Vehicle system test

HELP
Select function XX
Readout on display:
Note
Vehicle system
test
If the ignition is switched off between "Interrogate fault memory" and
->
"Erase fault memory", the fault memory is not erased. Therefore carefully Fault memory
erased!
observe the work procedure; i.e first of all interrogate the fault memory
and only then erase.
Press key.
Readout on display:
Enter 06 for the function End output and confirm

with key Q.
Search for displayed faults according to fault table

and rectify Chapter.
Vehicle system test

HELP
Select function XX
Actuator diagnosis
Note
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 interrupted if the engine is started or if an engine speed pulse
is detected.
During the final control diagnosis the individual actuators remain activated for approx. 50
seconds unless the following actuator is activated earlier by pressing the key.
The actuators are tested acoustically or by touch.
Before repeating final control diagnosis without briefly running the engine in-between,
switch the ignition off for about 2 seconds.
After the final control diagnosis has been carried out, the engine can be started after the
ignition is switched off and on again.
130
t The ignition and injection system is locked during the final control diagnosis.
With the actuator diagnosis the following parts are activated in the sequence indicated:
1.Fuel pump relay -J172.Activated charcoal filter system solenoid valve 1 -N803.Exhaust gas return valve -N18-, (two-way valve) Note
4.Valve for variable intake manifold changeover -N156-
1)
At present not in use

t
Procedure
Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine
electronics. The ignition must be switched on during this operation.
Readout on display:
Operate the vehicle system tester by referring to the

read-out on the display.
Vehicle system test

HELP
Select function XX
Enter 03 for the function Actuator diagnosis.
Readout on display:
Activate fuel pump relay - J17-:
Vehicle system test

03 - Actuator diagnosis
Confirm the entry with the key Q.

Readout on display:
The fuel pump relay is activated for approx. 50seconds
unless the following actuator is activated earlier by pressing
the key.
Note
Actuator diagnosis
->
During activation of the fuel pump relay the fuel pump should Fuel pump relay J17
also be heard to run at intervals.

If the relay does not activate:
Test fuel pump relay and control Chapter.

Press key.
Readout on display:
The activated charcoal filter system solenoid valve 1 -N80- is
activated audibly for approx. 50seconds unless the following
131
Actuator diagnosis
->
Solenoid valve 1 for
activated charcoal filter
system N80
actuator is activated earlier by pressing the key.

If the valve is not actuated (does not activate), check
activated charcoal filter system solenoid valve 1 -N80 Chapter.
Press key.
Readout on display:
Note
Do not pay attention to the display (at

present not in use).
Actuator diagnosis
->
Exhaust-gas recirculation valve N18
Press key.
Readout on display:
This valve must be activated for approx. 50seconds
unless the following actuator is activated earlier by
pressing the key.
If the valve is not actuated (does not activate), test
valve for variable intake manifold changeover -N156 Chapter.
Actuator diagnosis
->
Valve for variable intake
manifold changeover N156
Press key.
Readout on display:
The final control diagnosis is ended.
Press key.
Function unknown or cannot

->
be carried out at the moment
Note
Before the function 03 final control diagnosis is

selected again, switch off ignition for approx. 2 seconds.
Coding control unit
If the code displayed does not match the vehicle, or if the control unit has been replaced, it is then
necessary to code it.
Connect vehicle system tester -V.A.G 1552- and select address word 01 Engine electronics. The
ignition must be switched on during this operation.

Readout on display:
Vehicle system test
HELP
Enter 07 for the function Coding control unit and confirm
Select function XX
entry with key Q.
Code control unit
Readout on display:
Q
Enter the relevant code number for this vehicle and confirm
Enter code number XXXXX
(0
with the key Q.
3200)
Overview of the possible coding versions which can be selected:
132
For vehicles 04.99

Code number
04000
04030
04900
For vehicles 05.99
Code number
00001
00003
00011
00013
00021
00023
00031
00033
Gearbox
Gearbox
Automatic gearbox
Gearbox
Gearbox
Gearbox
Automatic gearbox
Gearbox
Automatic gearbox
Gearbox
Automatic gearbox
Gearbox
Automatic gearbox
For all vehicles

The vehicle system tester - V.A.G 1552- displays the control
unit coding, e. g.:
Note
Equipment
ABS
without ABS
Equipment
ABS
ABS
Airbag
Airbag
Airbag + ABS
Airbag + ABS
06A906019B 1.6ltr. 2V/R4 SIMOS

HS2556
->
Coding 04000
WSC
12345
If a non-approved code number was entered:

Readout on display:
Function unknown or cannot
Repeat the procedure, enter the correct coding. be carried out at the moment
Press key.
Readout on display:
Enter 06 for the function End output and confirm with
key Q.
Note
Vehicle system test
HELP
Select function XX
t Incorrect coding results in:

t
Handling problems
t Increase in fuel consumption
t
Increase in pollution
t Storage of non-existent faults in fault memory
t Reduction of the gearbox life
133
->
Self-diagnosis I
Fault table
Note
All the possible faults which can be detected by the dash panel insert and can be displayed
by -V.A.G 1552- are listed according to the fault code.
If Info in literature appears in the display of the vehicle system tester, look for the text
required in the fault table under the fault code.
t The fault table is arranged according to the 5-digit fault code on the left.
t
If a fault occurs only sporadically or if the fault memory was not erased after eliminating
the fault, this sporadic fault is shown as SP on the display.
Explanations on fault types (e.g. interruption/short-circuit to earth): Operating

instructions of vehicle system tester
Before replacing components found to be defective first check the wiring and plug
t connections to these components as well as the earth cables according to the current flow
diagram. This applies in particular if faults are shown as sporadic (SP).
Readout on
-V.A.G 1552-
Possible cause of fault
Possible effects
Rectifying fault
00282
Throttle valve
positioner
-V60- Note
Short circuit
Line interruption or shortCold start

t
circuit to earth or positive
problems
t
and/or mutual line shortcircuit
blocked or
dead
t -V60- jams or defective
Connection
via plug
upper limit
value
t Control unit defective
Cable mix-up
Cold idling
problems
Rough load
alteration
Remove open circuit in wiring

or short circuit according to
current flow diagram

Current flow diagrams and
Fitting locations.
Inspecting throttle valve

control unit Chapter.
Replacing engine control unit

Chapter.
mechanical
emergency
t
running -J338detected
Signal outside
134
tolerance
Control
difference
00305
Fuel
consumption
display signal
Short circuit
to positive
1)
Short circuit to positive in

the cable connection
t between the engine
control unit and the
onboard computer
Check fuel consumption

display signal Current flow
diagrams and Fitting
locations.
The throttle valve positioner -V60 - is a component part of the throttle valve control unit
-J338 -.
Readout on
-V.A.G 1552-
Possible
effects
Rectifying fault
00513
Engine speed
sender -G28no signal
Signal line is interrupted or shortcircuited to earth or positive
Earth lead is interrupted or shortcircuited to positive
Line interruption to shielding of

-G28-
Engine
stalls
Check -G28 Chapter.
Engine
t does not
start
-G28- defective
Signal input in the engine control

t unit defective (engine control unit
defective)
implausible
signal
Steel swarfs on the engine speed

sender -G28-
Distance between -G28- and sensor

rotor too great
135
Replacing engine
control unit
Chapter.
t
Engine
stalls
Engine
t does not
start
Check -G28 Chapter.
Note
t
t
t
Regarding fault code 00513:

Additional signals can be generated by metal swarfs.
Signals may not be generated or be too weak and therefore not be detected due to a too
large distance of the sender to the sensor rotor or by a damaged sensor rotor.
t The signal routing can be irregular due to a loose sensor rotor (or loose sensor).
Readout on
-V.A.G 1552-
Possible effects
Rectifying fault
no signal
Voltage supply or
t earth distribution to
-G40- defective
Engine does no longer Check -G40- Chapter.

reach the deactivation
t
speed (speed limiter
at approx. 5100/rpm)
implausible
signal
Signal input in the

Engine does not start
engine control unit
or starts poorly when
t
t
defective (engine
cold (cold-start
control unit defective) difficulties)
defective
Line interruption or
short-circuit to
positive or earth
t
between -G40- and
the engine control
unit
Engine does not start

or starts poorly when
t
warm (hot-start
difficulties)
t reduced performance
00515
Hall sender
-G40-
-G40- defective
Toothed belt skipped

(signal is not
t
generated at the
expected time)
t
Replacing engine control

unit Chapter.
Remove open circuit in

wiring or short circuit
according to current flow
diagram Current flow
locations.
Check timing of the engine

1.6 ltr./74 kW Engine,
Mechanics Rep. Gr.13.
Loose contact
00516
Idling switch
-F60- Note
Open
t Line interruption or
circuit/Short
short-circuit to earth
circuit to
or positive between
-F60- and the engine
Poor vehicle handling

when starting


136
positive
control unit
Short circuit t
to earth
-F60- defective

locations.
Poor vehicle handling
when proceeding to
t
idling/overrun at
partial load
Check the throttle cable

setting 1.6 ltr./74 kW
Engine, Mechanics Rep.
Gr.20.
t Throttle valve jams

t
Foot mat presses onto Idling speed not within

t
accelerator pedal
the specified value
t Throttle cable setting

Humidity in the plug
connection for the
t
throttle valve control
unit
t Acceleration jerks
t
Check plug connections.
Idling control
behaviour unstable
Load alteration shock

t when releasing the
accelerator
Signal input in the
engine control unit
t
defective (engine
control unit defective)
2)

unit Chapter.
The idling switch -F60- is a component part of the throttle valve control unit -J338-.
Readout on
-V.A.G 1552-
Possible effects
Rectifying fault
00518
Throttle valve
potentiometer
-G69- Note
Short circuit to
positive
Short circuit to
Line interruption in the

earth line
Line short-circuit to
positive
-G69- defective
-G69- defective
Rough load
alteration
137
Check -G69 Chapter.
earth
t
Current flow diagrams

and Fitting locations
Line interruption
Short circuit to earth in

cable connection between
t
- G69- and engine control
unit
implausible
signal
Loose contact
-G69- defective

and Fitting locations
Humidity and/or corrosion t Acceleration jerks

Check plug
t in the plug connection at

connections.
Idling
control
the potentiometer
t behaviour
unstable
Load alteration
shock when
t
releasing the
accelerator
Signal input in the engine
control unit defective
t
(engine control unit
defective)
3)
Replacing engine
The throttle valve potentiometer - G69- is a component part of the throttle valve control
unit -J338 -.
Readout on
-V.A.G 1552-
Possible effects
Rectifying fault
00520
Air mass/volume
measurement
-G70/G19Short circuit to
positive
Open circuit/Shortcircuit to earth
Poor vehicle
Check -G70t
short-circuit to positive
handling
Chapter.
t or earth between -G70Engine does not
and the engine control
start or starts poorly
unit
t
when cold (coldstart difficulties)
t
Voltage supply for

-G70- defective
t Engine does not

Read measured
start or starts poorly value block,
when warm (hotdisplay group 000
138
start difficulties)
t
-G70- defective
Chapter.
Irregular idling or no
idling in coldt
running or warmingup phase
Signal input in the

engine control unit
t
defective (engine
-G70- replace.
Idling speed not

Replacing engine
within the tolerance control unit

Chapter.
00522
Coolant temperature
sender -G62Open circuit/Short
circuit to positive
Cold-start
short-circuit to positive t difficulties at very
t or earth between -G62- low temperatures
and the engine control
Poor driveability
unit
t
during warm-up
Short circuit to earth
implausible signal
Read measured
value block,
display group 000
Chapter.
-G62- defective
Earth distribution to
-G62- defective
Signal input in the

engine control unit
t
defective (engine
Loose contact or
corrosion due to
t
humidity in the
connector
Increased fuel
consumption
Check -G62 Chapter.
Increased emission
Replacing engine
levels
control unit
Chapter.
t Poor performance
00523
Intake air temperature
sender -G42Short circuit to earth
Poor hot-start
t
performance
t or earth between -G42and the engine control
unit
Open circuit/Short
circuit to positive
-G42- defective
Read measured
value block,
display group 000
Chapter.
t Poor throttle
Check -G42
response of the
Chapter.
engine during coldrunning or warming139
up phase, transient
malfunctions
t
-G42- defective
Signal input in the

engine control unit
t
defective (engine
Irregular idling or no Replacing engine
idling in coldcontrol unit

t
running or warming- Chapter.
up phase
00524
Knock sensor 1 -G61defective
implausible signal
Knock sensor loose or

t corrosion at the
connector
-G61- defective
Check -G61 Chapter.
reduced
performance
Increased fuel
t
consumption
or to earth and/or to
t shielding of the signal
line between the knock
sensor and the engine
control unit
Signal input in the

engine control unit
t
defective (engine
Remove open
circuit in wiring or
short circuit
according to
current flow
diagram Current
flow diagrams and
Fitting locations.
Replacing engine
control unit
Chapter.
loose ancillaries
through which the
t knock sensor detects
additional signals
(vibrations)
00525
Lambda probe -G39Output open
t no lambda control
short-circuit to earth or
t positive between -G39and the engine control
unit
140
Remove open
circuit in wiring or
short circuit
according to
current flow
diagram Current
flow diagrams and
Fitting locations.
implausible signal
Signal outside
tolerance
-G39- defective
Corrosion due to
humidity in the plug
t connection for lambda
probe heater -Z19- or
lambda probe -G39 t
t
Lambda probe heater

does not operate
-G39- defective
Poor idling
Checking lambda
control Chapter.
Increased fuel
consumption
Read measured
value block, display
group 001
Chapter or 099
Chapter.
Sooting of spark
plugs
Increased emission
levels
Signal input in the

engine control unit
t
defective (engine
Replacing engine
control unit
Chapter.
00530
Throttle valve
positioner/potentiomet
er -G88- Note
Open circuit/Short
circuit to positive
Open circuit in wiring

between -G88- and the
t
engine control unit or
short-circuit to positive t
The idle regulator is Perform adaptation

deactivated; engine of the throttle
runs in idle with
valve control unit
mechanically
Chapter.
defined amount of
air through the
emergency gap
changed idling
speed
Open circuit/Shortcircuit to earth
Open circuit in wiring

t Cold start problems Inspecting throttle
between -G88- and the

valve control unit
t
Cold
idling
engine control unit or
Chapter.
t
problems
short-circuit to earth
implausible signal
-G88- defective/loose
Rough load
t
contact in plug
alteration
t
connection for throttle
valve control unit -J338Signal input in the
engine control unit
t
defective (engine
141
reduced
performance
Replacing engine
control unit
Chapter.
Transition impedances t
due to humidity in the
t plug connection for the
throttle valve control
unit -J338t
incorrect plug
assignment
Throttle valve
positioner -V60- jams
irregular idling
00533
Idling control
upper limit value
lower limit value
4)
Air filter blocked
Unmetered air to
throttle valve
Injection valve
defective
Fuel pressure regulator

defective
Poor vehicle
handling
Increased fuel
consumption
Smell of fuel
Inspecting throttle
valve control unit
Chapter.
Testing the intake

system for
tightness
(unmetered air)
Chapter.
Testing injection
valves Chapter.
Replace the fuel

pressure regulator.
The throttle valve positioner/potentiometer -G88- is a component part of the throttle valve
control unit - J338-. The throttle valve positioner/potentiometer (variable resistance,
activated by the throttle valve positioner) notifies the position of the throttle valve to the
engine control unit.
Readout on Possible cause of fault

-V.A.G 1552-
Possible
effects
Rectifying fault
00537
Lambda
control
upper limit
value
Line short-circuit to earth in the

no lambda
Checking lambda control
t
t signal line from the engine control

control
Chapter.
unit to the lambda probe
t Injection valve(s) defective
t Poor
142
Testing injection valves
(blocked)
vehicle
handling
t Fuel pressure regulator defective
lower limit
value
Unmetered air
Fuel tank empty
Activated charcoal filter system

t solenoid valve 1 -N80- leaking,
jams
t
Fuel pump defective
Chapter.
Injection valve(s) defective

(always open)
Test fuel pressure

regulator and holding
pressure Chapter.
Test fuel pump 1.6
ltr./74 kW Engine,
Mechanics Rep. Gr.20.
Check induction pipe for
leaks.
Fill up vehicle.
no lambda
Check -N80- Chapter,
control
Chapter.
Poor
t vehicle
handling

Chapter.
Test fuel pressure

pressure Chapter.
Note
If the fault lambda control top limit is detected, the lambda control has reached the
t regulating limit in direction of enrich. However the lambda probe still evaluates lean
mixture.
t
If the fault lambda control bottom limit is detected, the lambda control has reached the
regulating limit in direction of lean. The lambda probe still evaluates rich mixture.
Readout on
-V.A.G 1552-
Possible effects
Rectifying fault
t see workshop
manual automatic
gearbox

00545
Engine/gearbox
electrical
connection
Short circuit to t Short-circuit to
positive
positive between
engine control unit
143
and automatic
gearbox control unit
Short circuit to
earth
Short-circuit to earth
between engine
t control unit and
automatic gearbox
control unit
undefined
switch status
Fault on automatic
gearbox or on
t
automatic gearbox
control unit
automatic
gearbox Rep.
Gr.01

locations.
Signal output in the

engine control unit

unit Chapter.
t defective (engine
control unit
defective)
Interrogate the fault
memory of the automatic
gearbox control unit

automatic gearbox
Rep. Gr.01.
For vehicles
08.97
00557
PAS pressure
switch -F88 Note
Short circuit to t Short circuit to earth
earth
t -F88- defective
the engine stalls at

t maximum steering
angle
Test signal of PAS pressure

switch Chapter.
Short circuit to Short circuit to

t
positive
positive
t
-F88- defective
00609
Ignition outlet 1
Short circuit to
positive
short-circuit between
t engine control unit
and end stage to the
ignition coil
t Starting problems

greatly irregular
t engine running in all diagram Current flow
load ranges
locations.
t great loss of power
Earth connection of
t the end stage to the
ignition coil defective
t
Check dual spark ignition

system with two ignition
coils Chapter.
End stage to the

ignition coil defective
t Engine control unit

144
defective
5)
unit Chapter.
If the fault 00557 is stored, the fault 00533 can also be stored as a follow-up fault.

-V.A.G 1552-
Possible
effects
Rectifying fault
00610
Ignition
outlet 2
Short
circuit to
positive
see fault code 00609
see fault
code
00609
see fault code 00609.
00625
Vehicle
speed signal
implausible Line interruption or shortsignal
t circuit between dash panel
insert and engine control unit
Remove open circuit in wiring or

short circuit according to current
flow diagram Current flow
diagrams and Fitting locations.
Short-circuit in the signal line

between the speedometer and
t
another control unit which
uses the speed signal
t control unit defective (engine
control unit defective).

Chapter.
Note
Regarding fault code 00609 and 00610:
The ignition outlet 1 and/or ignition outlet 2 are the outlets at the engine control unit
t which are used by the engine control unit to actuate the power output stage at the ignition
coil.
Note
t If the fault 00625 is stored, the engine control unit adopts a fixed replacement value of
145
5km/h.
Readout on
-V.A.G 1552-
Possible
effects
Rectifying fault
00635
Lambda probe
heating
upstream of
catalytic
converter
defective
Line interruption or shortcircuit to positive and/or

t earth between engine
control unit and lambda
probe
possible
t exhaust
problems
Power output stage in the

engine control unit defective
t
defective).
t Lambda probe defective
t
irregular
idling
Fuel pump relay/actuation of

fuel pump relay defective

Chapter.
Remove open circuit in wiring

current flow diagram

Fitting locations.

Chapter.
Replace lambda probe.
Test fuel pump relay and

control Chapter.
Note
t The positive voltage supply for the lambda probe heating occurs via the fuel pump relay.
t
The earth distribution for the lambda probe heating is performed by the engine control unit,
i.e the total filament current for the lambda probe heating flows via the engine control unit.

-V.A.G 1552-
Possible effects
For vehicles
08.97
00650
146
Rectifying fault
Clutch pedal
switch -F36defective
Line interruption or shortcircuit
Test the signal of the

clutch pedal switch
Chapter.
For vehicles
08.97
00668
El. syst.
voltage tml.
30
Open circuit
Line interruption/loose contact

t in the wiring to the engine
control unit
Check voltage
supply of the control
unit Current flow

locations.
Perform adaptation
of the throttle valve
control unit
Chapter.
For vehicles
08.98
01013
AC
compressor,
load signal
Open
Line interruption or shortt
circuit/Short circuit to earth
-circuit to
earth
Short circuit t
to positive
Check measured
value block 57
Chapter.
Test cable
connections for short
circuit and/or for
interruption
Current flow
locations.
Short circuit to positive
Check measured
value block 57
Chapter.
Test cable
connections for short
147
circuit and/or for

interruption
Current flow
locations.
01087
Basic setting
not
performed
implausible Conditions for the basic setting
signal
(adaptation of the throttle valve
control unit) not fulfilled:
t Ignition not switched on
t
Engine not in standstill
Idling switch not closed
The engine control

Read measured
unit cannot learn the value block, display
stop positions of the

group 001 or 098
throttle valve
Chapter or
t
because the
Chapter.
conditions are not
fulfilled for this (see Inspecting throttle
valve control unit
possible fault cause)
Chapter.
Voltage of the throttle valve

potentiometer and the throttle
valve positioner potentiometer
t implausible (cannot be
accurately detected by the
engine control unit; throttle
valve not completely closed)
t
Throttle valve positioner

jams/mechanically damaged
Battery voltage too low (below

8 V)
Fault in fault memory
Perform adaptation
of the throttle valve
control unit
Chapter.
Read measured
value block, display
group 005
Chapter.
t
Throttle valve control unit

defective
t Engine control unit defective
Interrogating fault
memory.
Replace throttle
valve control unit.
01126
Engine
speed signal
defective
Interrogating fault
memory.
t Line interruption or short148
Replacing engine
control unit
Chapter.
circuit to positive and/or earth

between engine control unit
and dash panel insert
t
Signal input on the dash panel

insert defective
Signal output in the engine

Replace dash panel

insert.
Replacing engine
control unit
Chapter.
Note
In this case, the engine speed signal is not the signal of the rotary speed sender at the
crankshaft to the engine control unit, however the signal of the engine control unit to the
t
dash panel insert which can then be used for various other systems (e.g rev counter, air
conditioning system, 0).
Readout on
-V.A.G 1552-
Possible effects Rectifying fault
01163
Breakdown of
the ignition
t
Line interruption in the

ignition circuit
Fault in the wiring to the

spark plug
irregular
t engine
running
Check dual spark ignition

system with two ignition coils
Chapter.
01177
Engine control
unit
defective
Earth lead in the engine

t control unit is
interrupted
t
Engine does
Check voltage supply of the
not start
Engine control unit

defective
01242
End stages in
the control unit
149

Chapter.
defective
Engine control unit

defective
Engine does
not start
Chapter.
Note
t
t

The engine can be restarted after erasing the fault memory Chapter.
Readout on
-V.A.G 1552-
Possible effects Rectifying fault
01243
Valve for
variable intake
manifold
changeover N156Output open
Line interruption or shortcircuit to positive or earth

between the valve for
t
variable intake manifold
changeover -N156- and the
engine control unit
Short circuit to Voltage supply for -N156t

positive
defective
Short circuit to t
earth
reduced
performance

locations.
Check -N156- Chapter.
-N156- defective


unit Chapter.
01247
Activated
charcoal filter
system
solenoid valve
1 -N80Short circuit to Line interruption or short
positive
t circuit to positive between N80- and engine control unit
150
possible
irregular idling wiring or short circuit

locations.
Short circuit to Voltage supply for -N80t
earth
defective
possible
jerking in
t
partial load
region
Output open
Vehicle may
t possibly smell
of fuel
-N80- defective


unit Chapter.

Chapter.

unit Chapter.
01249
Injector cyl. 1
-N30Short circuit to
positive
Line interruption or shortirregular

circuit to positive and/or
idling, if
t
t
earth between engine control necessary
unit and injection valve
engine stalls
Short circuit to t Injection valve defective

earth
Output open
Voltage supply for injection

valve defective

01250
Injector cyl. 2
-N31Short circuit to Cylinder 1 fault code 01249 Cylinder 1
positive
fault code
01249
Short circuit to
earth
Output open
01251
Injector cyl. 3
-N32151
Cylinder 1 fault code

01249.
Short circuit to Cylinder 1 fault code 01249 Cylinder 1

positive
fault code
01249

01249.
Short circuit to
earth
Output open
01252
Injector cyl. 4
-N33Short circuit to Cylinder 1 fault code 01249 Cylinder 1
positive
fault code
01249

01249.
Short circuit to
earth
Output open

-V.A.G 1552
-
Possible effects
Rectifying fault
01259
Fuel pump
relay -J17defective
Line interruption or short Line interruption or Remove open circuit in wiring

circuit to positive
short circuit to
t
t
between engine control

positive (no engine current flow diagram
unit and fuel pump relay running)
Fitting locations.
t
Fuel pump relay

defective
Signal output in the

engine control unit
t
defective (engine control
unit defective)
Note
152
Test fuel pump relay and

control Chapter.

Chapter.
t
t

If the fault 01259 is stored, component parts can also be displayed as faulty which are
supplied with voltage via the fuel pump relay Current flow diagrams and Fitting locations.
Readout on
-V.A.G 1552-
Possible effects
Rectifying fault
For vehicles
08.97
01312
Data bus
drive
Faults in the databus

lines
poor driveability
(jerking when
t changing gears,
load alteration
shock)
t
Test databus drive

Chapter.
Test databus drive

Chapter.
no vehicle dynamic
control
For vehicles
08.97
01315
Gearbox
Fault in the databus lines
poor driveability
t
control unit
to the engine control unit
(jerking when
no
t changing gears,
communicatio
load alteration
n
shock)
For vehicles
08.97
01316
Brake control
Faults in the databus
t
unit
lines to ABS control unit
no
communicatio
n
no vehicle dynamic
Test databus drive
control
Chapter.
01321
Airbag control Faults in the databus
unit-J234t lines to airbag control
no
unit
communicatio
n
The fuel pump is

Test data bus Chapter.
not switched off in
t case of accident
with deployment of
airbag
17978
153
Engine
control unit
blocked
t Manipulation attempt
Line interruption or short- Engine starts briefly Remove open circuit in

circuit to positive and/or t but then stops
t earth between engine
immediately
control unit and
immobilizer control unit
locations.
t
Immobilizer control unit

defective

control unit defective
t
defective)
t
Start attempt with

unauthorised ignition key
Replace dash panel

insert.

unit Chapter.
Engine control unit not

t adapted to immobilizer
control unit
Adapt ignition key

Electrical System.
Rep. Gr.96.
Adapt the engine control
unit to the immobiliser
65535
Control unit
defective
Faults within the engine

control unit
Poor vehicle
handling

unit Chapter.
t Engine stoppage
Note
The immobilizer control unit is located in the dash panel insert and cannot be replaced
individually.
154
Self-diagnosis II
Reading measured value block
Readout on display:
Enter 08 for the function Read measured value block
and confirm entry with the Q key.
Vehicle system test

HELP
Select function XX
Readout on display:
Enter the desired three-digit display group

number and confirm entry with the Q key.
Example: for selecting the display group 005,

the keys 0, 0 and 5 must be pressed.
Note

HELP
Enter display group number
XXX
To switch over to another display group proceed

as follows:
Display group
-V.A.G 1552 -
higher
Press key
lower
Press key
skip
Press the key C
Test conditions
l
l
l
l
l
No fault in fault memory Chapter.

Vehicle standing; engine idling; throttle valve closed.
Coolant temperature minimum 80 C.
All electrical components must be disconnected (the radiator fan must be off during the
test).
Air conditioning switched off.
l On vehicles with automatic gearbox the selector lever must be in position P or N.
Read measured value block; display groups 000 to 010

Note
To display group 000:

155
Analysis of display group 000 Anchor.
Display group 000 (display values in decimals)

l
Engine idling
Display fields
123456 7 8
10
Engine speed
(idling speed)
Injection period
Throttle valve angle
Operating condition of the lambda control
Determine the injection time (additive
initialisation) by the lambda control.
Corresponds to
measured value
23 to 27
760 to 880 rpm
2 to 4
2 to 4.1 ms
4 to 12
1.9 to 5.7
see measured value block 099 Note

0 to 100
0 to +0.8 ms
0 to 50
0.0 to 1.0 V
drawn in air mass
14 to 30
76 through to 164
mg/h
Coolant temperature
170 to 211
80 to 110 C
98 to 147
10 to 15 V
84 to 158
15 to 71 C
Lambda probe voltage
Test voltage supply of engine control unit

Intake manifold temperature
1)
Displayed
specified value
In display field 7, the operating condition of the lambda control is shown as a decimal
number. The operating condition of the lambda control is shown itemised with a bit
pattern in the measured value block 099, in the display field 4 (8-digit display) Anchor.
Analysis of display group 000

Displa Readout on
y field -V.A.G 1552 1
less than 84
Note
t Intake air temperature sender faulty

t
Cables to intake air temperature sender

defective
AC generator defective, battery heavily

discharged
greater than
158 Note
2
less than 98
t Vehicle voltage heavily loaded just after

156
Rectifying fault
Test intake air

temperature sender
Chapter.
start by a high charge current or by

auxiliary equipment
Transition resistance in the power supply
t or earth connection for engine control
unit
t Current consumption with ignition off
greater than t Voltage regulator on generator defective Test voltage, replace
147
regulator if necessary.
Overvoltage due to starting aid or quick
t
charger
Interrogate the fault
memory Chapter.
3
less than 170 t

t
Engine too cold
Coolant temperature sender or cable

connection to engine control unit faulty
t Coolant regulator (thermostat) defective
Conduct road test if

necessary.
Test coolant temperature

sender - G62- Chapter.
Inspect coolant regulator
(thermostat), replace if
necessary 1.6 ltr./74

kW Engine, Mechanics
Rep. Gr.19.
greater than t
211
t
Radiator dirty
Radiator fan not operational
Clean radiator.
Test function of the

radiator fan.
t Coolant regulator (thermostat) defective

Coolant temperature sender or cable
t
connection to engine control unit faulty
Inspect coolant regulator

(thermostat), replace if
necessary 1.6 ltr./74

kW Engine, Mechanics
Rep. Gr.19.
Test coolant temperature
sender -G62- Chapter.
less than 14
large quantity of unmetered air between Eliminate unmetered air.

intake manifold and air mass meter
Test air mass meter
Air mass meter or cable connection to

Chapter.
t
engine control unit faulty
t
greater than t Engine

Gear engaged
(automatic
loaded by
auxiliarygearbox)
equipment
30
Put selector lever in P or

N.
ancillaries (e.g air
conditioning system).
Test air mass meter

157
Chapter.
5
Display does
not fluctuate
(lambda
control on stop
in direction
rich or lean;
see display
group 099)
t
t
t
large unmetered air volume
Eliminate cause of
unmetered air.
Test spark plugs and

connector.
Spark plug defective

Spark plug connector defective
t Holding pressure too low or too high

t
Injection valve defective
Coolant temperature sender -G62 faulty
Activated charcoal filter solenoid valve

-N80- defective
t Lambda probe heater does not operate

t Lambda probe defective or dirty
constant 255
constant 80
constant 0
low lambda
learned values
Short circuit to positive by: Lambda

t probe -G39- or signal line or engine
control unit
Line interruption through: fuse, lambda
t probe -G39- or signal line or engine
control unit
Short circuit to positive by: Lambda
t probe -G39 - or signal line or engine
control unit
Test fuel pressure

pressure Chapter.
Chapter.
Interrogate fault memory
Chapter or check -G62 Chapter.
Perform final control
diagnosis Chapter or
check -N80- Chapter.
Check lambda probe
heater Chapter.
Interrogate fault memory
Chapter or check
lambda probe Chapter.
Read measured value

block, display group 099.
Checking lambda probe

Chapter.

Chapter.

Chapter.
low lambda idle learned values at normal Disappears after driving
lambda partial load learned values: slight on motorway or changing

t
dilution of oil (higher fuel content in the
oil.
oil)
t
Injection valve(s) leaking
Fuel pressure too high
t Solenoid valve 1 for activated charcoal

Check fuel pressure
158
filter -N80- constantly open

t
t
Air mass meter faulty -G70Lambda probe heating defective or

lambda probe dirty
high lambda
high lambda idling learned values at
initialisation
slightly higher lambda partial load
t
values
learned values: a little unmetered air in
the intake manifold
Injection valve blocked
Fuel pressure too low
Chapter.
Check -G70- Chapter.
Check lambda probe

heater Chapter.
Eliminate cause.
See display group 011,

display fields 2 and 3.
Testing injection rate

Chapter.
Check -G70- Chapter.
Unmetered air between -G70- and

throttle valve
Check fuel pressure

Chapter.
Unmetered air at the exhaust manifold

gasket
Eliminate cause of
unmetered air.
Lambda probe heating defective or

lambda probe dirty
Check lambda probe

heater Chapter.
The operating condition of the lambda control is shown itemised with a bit pattern
in the measured value block 099, in the display field 4 (8-digit display).
less than 4
Throttle valve potentiometer in the

t throttle valve control unit -J338defective or incorrectly set

control unit -J338 Chapter.
Unmetered air between the intake

Eliminate cause of
manifold and the air mass meter (results

unmetered air.
in a higher idling speed; the throttle
t
valve control unit attempts to adjust the
increased idling speed to the nominal
idling speed)
greater than
Adaptation of the throttle valve control
t
12
unit not carried out -J338Throttle valve potentiometer in the
t throttle valve control unit -J338defective or incorrectly set
t
t
Incorrect throttle cable setting

Throttle valve jams

control unit - J338 Chapter.
Adjust throttle control

cable. 1.6 ltr./74 kW
Engine, Mechanics Rep.
Gr.20.
159
Carry out adaptation of

the throttle valve control
unit - J338- Chapter.
Eliminate cause.
less than 2
high fuel volume from the activated

charcoal filter system
incorrect injection valves with too high

fuel flow rate fitted
Testing fuel injected

quantity Chapter.
Inspect fuel pressure

regulator Chapter.
greater than 4
increased engine load due to electric

consumers, air conditioning system
t
switched on, engaged driving position,
power steering up to the stop
Testing solenoid valve for

activated charcoal filter
Chapter.
Eliminate load.
Put selector lever in P or

N.

t Gear engaged (automatic gearbox)

10
less than 23
Throttle valve control unit -J338jamming or faulty
large unmetered air volume (cannot be

t compensated (equalised) by idle
stabilizer)
greater than
Throttle valve control unit -J338t
27
jamming or faulty
large unmetered air volume (cannot be
t compensated (equalised) by idle
stabilizer)
2)
Eliminate unmetered air.
Testing idling speed

Chapter.

Eliminate unmetered air.

Chapter.
Depending on the ambient temperature and the stationary time of the vehicle.
Display group 001 (basic values):

When display group 001 is selected in function 04 Basic setting, the engine control unit is
adapted to the throttle valve control unit -J338- (see display group 098). Perform adaptation
Chapter.
l
Engine runs in idling speed
Reading measured
value block 1
Readout on display
xxx rpm xxx C x.xx V xxxxx

xxx
1
Display fields
Specificat Analysis
ion
Setting condition of the throttle valve
00000010 Ancho
160
adjustment (see next page)
0.00...1.0 Chapt
0V
er
Coolant temperature
80...110 Chapt
C
er
Engine speed (idling speed)
Chapt
er
Note
Meaning of the digits in the 8-digit numerical block for the setting condition of the throttle
valve adjustment:
x x x x x x x x
1
Meaning, if display positions = 1

Fault detected by the self-diagnosis
1)
Front signal of automatic gearbox

1
Air conditioning compressor on

1
Open idling switch

1
2)
Fault in the lambda control

1
Throttle valve opened (angle detection)

1
Engine running
2)
2)
1 Coolant temperature below 80C
1)
A fault was detected by the self-diagnosis which was not yet stored in the fault memory. If
faults of the throttle valve control unit exist, an adaptation of the throttle valve control unit
for the function basic setting is not performed.
2)
If a 1 is at the relevant position, an adaptation of the throttle valve control unit is not
possible.
l
Reading measured value block 2

xxx rpm
xxx mg/s
x km/h
Readout on display
xxx
x
4 Display fields
161
Specification
Analysis
Engine operating condition

Driving speed
drawn in air mass
0100
Anchor
0 km/h
76...164 mg/s Chapter
Idling speed
Chapter
Note
Meaning of the digits in the 4-digit numerical block for the engine operating condition:
x

Trailing throttle
Idling
1
Partial load
1 Full load

l

3
xxx rpm
xxx mg/s
Readout on display
xx.x xxx
%
3
Display fields
Specification Analysis
Clock ratio throttle valve

positioner
-100...+100
%

drawn in air mass
Idling speed

162
1,9...5,7 Chapter
76...164
mg/s
Chapter
Chapter

xxx rpm
xxx mg/s
Readout on display
x.x ms x.x g/s

3
Display fields
Specification
Analysis
drawn in air mass
1.0...3.2 g/s
2...4.1 ms
Chapter
Injection period
drawn in air mass
Idling speed
Chapter

l
Readout on display
xxx rpm
xxx mg/s
x.x ms
x.x
g/s
Display fields
Specification Analysis
Intake manifold temperature

Coolant temperature
Voltage supply for engine control unit
Idling speed
15...71 C
Chapter
80...110 C Chapter
10...15 V
Chapter
Chapter
Display group 006 (height adaptation):

l

xxx rpm
xxx mg/s
Readout on display
x.x ms x.xx
3
4 Display fields
Level correction factor
163
Specification
Analysis
0,70...1,30
1,9...5,7
Chapter
drawn in air mass
76...164 mg/s
Chapter
Chapter
Idling speed
Display group 007 (idling setting):

l

7
x.x
x.xx
x.xx
xxxx
Readout on display
Display fields

Idle learned value (with gear
engaged)
Idle learned value (without gear engaged)
Specificatio
n
Analysis
0100
Anchor
0,95...1,05
0,95...1,05
1,9...5,7 Chapter
Note
Re display field 4:
t Meaning of the digits in the 4-digit numerical block for the engine operating condition:
x

Trailing throttle
Idling
1
Partial load
1 Full load
Note
164
The measured value block 007 serves only as information. Not relevant for the fault finding
in the Service Department.
Display group 008 (idling speed stabilisation):
l
xxx rpm
xxx rpm
xx %
x.x g/s
Readout on display
Display fields
Specification
Analysis
drawn in air mass
1.0...3.2 g/s
-10...+15 %
Idling regulator
Nominal idle speed for vehicle at standstill 800...840 rpm

Idling speed
Chapter
Display group 009 (idle air requirement):

l
xx %
xxxxxxxx
xxx C
xxx rpm
Readout on display
Display fields
Engine speed
Specificatio Analysis
n
-
Chapter
Coolant temperature
80 - 110 C Chapter
Adaptation status of the throttle valve control

unit
00000000 Chapter
Idling regulator
-10 to +15
%
Note
t
t
Re display field 2:
Meaning of the digits in the 8-digit numerical block for the adaptation status of the throttle
valve control unit:
165
000 xxxx
0
000
0
Adjustment status
not assigned
during the adaptation of the throttle valve control unit, a fault has occured
(interrogate fault memory Chapter)
1
Throttle valve control unit dead (clock ratio = 0)

1 Adaptation aborded due to a too low battery voltage (below 8 V)
1Idling switch separated (interrogate switch)
Display group 010 (lambda control and activated charcoal filter system):
l
Reading measured value

block 10
xx %
x.xx V
xx %
Readout on display
xx
%
4 Display fields
Specificat Analysis
ion
Lambda correction factor for active fuel tank -20...2 %

ventilation
On/Off ratio of solenoid valve 1 for activated
charcoal filter -N80Lambda probe voltage
0...20 %
0.00...1.0 Chapt
0V
er
Lambda regulator
-25...25 %
Note
Read measured value block: display groups 011 to 099

Display group 011 (lambda learned values):
166

11
x.x ms
x.xx ms
x.xx
xxxxxx
xx
Readout on display
Display fields
Specification
Analysis
00000010
Anchor
0,90...1,15
Anchor
Condition of the tank vent

valve
Lambda learned value at partial load
Lambda learned value at idling speed
-1.00...+1.00 Anchor
ms
Injection period
2...4.1 ms
Chapte
r
Note
t
t
Re display field 4:
Meaning of the digits in the 8-digit numerical block for the condition of the tank vent
valve:
x x x x x x x x
0

not assigned
Proceed to load recognition of the tank vent valve

1
Proceed to minimum operation of the tank vent valve

1
Proceed to the closing of the tank vent valve

1
Load recognition of the tank vent valve

1
Normal operation of the tank vent valve

1
Minimum operation of the tank vent valve

1 Tank vent valve closed
Analysis of display group 011, display fields 2 and 3 - lambda learned value
167
Readout on
-V.A.G 1552 -
outside tolerance Minus value: mixture too rich,

t
field
lambda control leans off
t
Rectifying fault
Wait approx. 30 seconds until the

value stabilises.
Plus value: mixture too lean, lambda

control enriches
Chapter.
Injection valve defective
large unmetered air volume
Eliminate cause of unmetered

air.
Display group 012 (lambda learned values):

l

xxx rpm
xxx mg/s
Readout on display
xx % x.xx V
3
Display fields
Specification
Analysis
0.00...1.00 V
Chapter
-25...25 %
Lambda regulator
drawn in air mass
Idling speed

-
Chapter
Display fields
Specification
Analysis
Fuel consumption
0.50...2.00 l/h
0 km/h
Display group 013 (fuel consumption):

l
xxx rpm
xxx mg/s
xxx km/h
x.xx l/h
Readout on display
Driving speed
drawn in air mass
Idling speed
168
Chapter
Note
Display group 014 (knock control):
l
Normal driving

block 14
x.x
CA
x.x
CA
x.x
CA
Readout on display
x.
x
C
A
4 Display fields
n
Ignition angle relief cylinder 4 through

knock control
0.0...12.0 Anch
KW
or
Ignition angle relief cylinder 3 through knock

control
0.0...12.0 Anch
KW
or
Ignition angle relief cylinder 2 through knock control
Ignition angle relief cylinder 1 through knock control
0.0...12.0 Anch
KW
or
0.0...12.0 Anch
KW
or
Note
Regarding display fields 1 to 4:
At idling 0.0 CA is displayed.
Analysis of the display group 014, display fields 1 to 4 - ignition angle relief
Readout on -V.A.G 1552 -
all of the cylinders between:

Knock sensor
t
8.0...12.0 CA and of the same defective
value
Rectifying fault
Testing knock sensor Chapter
Plug connection
corroded
Knock sensor not

Slacken knock sensor and tighten
correctly tightened
again to 20 Nm
169
Component parts
on engine loose
t poor fuel quality
one cylinder clearly deviates

Plug connection
t
from the others
corroded
t Engine damaged
Component parts
on engine loose
Attach component parts
Change type of fuel
Test compression pressure: 1.6

ltr./74 kW Engine, Mechanics Rep.
Gr.15
Display group 015 (knock control cylinder 1 and 2):

l
Normal driving

block 15
xxx rpm
xxx mg/s
Readout on display
x.x x.
CA x
C
A
3
4 Display fields

knock control
0.0...12.0
KW
Anch
or

control
0.0...12.0
KW
Anch
or
760...6350
rpm
drawn in air mass

Engine speed
Display group 016 (knock control cylinder 3 and 4):

l
Normal driving

block 16
Specificatio Analysi
n
s
Readout on display
170
xxx rpm
xxx mg/s
x.x x.
CA x
C
A
3
4 Display fields
Specificatio Analysi
n
s

knock control
0.0...12.0
KW
Anch
or

control
0.0...12.0
KW
Anch
or
760...6350
rpm
drawn in air mass

Engine speed
Note
As soon as knocking effects are detected, the knock control of the ignition angle must be
deactivated, in order to avoid engine damage.
Note
t
t
Regarding display fields 3 and 4:

At idling 0.0 CA is displayed.
Analysis of display groups 015 and 016, display fields 3 and 4 - ignition angle relief
Readout on -V.A.G 1552 -
all of the cylinders between:

Knock sensor
t
8.0...12.0 CA and of the same defective
value
Rectifying fault
Plug connection
corroded
Knock sensor not

Slacken knock sensor and tighten
correctly tightened
again to 20 Nm
Component parts
on engine loose
t poor fuel quality
one cylinder clearly deviates t Plug connection

from the others
171
Change type of fuel
corroded
t Engine damaged
Component parts
on engine loose
Test compression pressure: 1.6

ltr./74 kW Engine, Mechanics Rep.
Gr.15
Display group 017 (knock control):

l

block 17
Readout on display
x.xxx Vss x.xxx Vss x.xxx Vss x.xxx

Vss
1
Display fields
Specification Analysi
s
Knock sensor voltage signal

cylinder 4
0.400...1.300
Vss
0.400...1.300
Vss
0.400...1.300
Vss
0.400...1.300
Vss
Knock sensor voltage signal cylinder 3
Note
t
t
t
Regarding display fields 1 to 4:

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.
Testing knock sensor Chapter.
If no fault is detected when the lines and the plugs are tested, the additional units must be
checked for separation or engine damage.
At a higher speed, the readout of the knock sensor voltage signal may reach the value of
as much as 5.1 V.
172
Display group 018 (torque reduction for automatic gearbox):

l
Reading measured
value block 18
xxx rpm xxx mg/s x.x

CA
1
Readout on display
xx
b. TDC
Display fields
n
Ignition angle
-6...14.0 b.
TDC
Ignition angle relief for the signal of the

automatic gearbox control unit
0.0 CA
76...164
mg/s
Chapt
er
Chapt
er
drawn in air mass
Idling speed
Note
The ignition angle relief for the signal of the automatic gearbox control unit occurs so
quickly that it is not always detected by the vehicle system tester -V.A.G 1552-. The
t
ignition angle display in the display field 4 serves however as information, yet it is not
relevant for the customer service.
Display group 019 (operating conditions) for vehicles 07.97:
l
Reading measured
value block 19
Readout on display
xxx rpm
x x
3 4 Display fields
Specificat Analysis
ion
Air conditioning compressor (0 = compressor

off; 1 = compressor on)
Air conditioning (0 = air conditioning off; 1 = air

conditioning on)
Selector lever position (0 = Neutral; 1= gear is used)

173
Idling speed
Chapt
er
Display group 019 (operating conditions) for vehicles 08.97 :

l

block 19
xxx rpm
x xxxxxxx
x
Readout on display
Display fields
Specificati Analysis
on
Operating state of AC
compressor
00000000 Anchor
Air conditioning (0 = air conditioning off;

1 = air conditioning on)
Selector lever position (0 = Neutral; 1= gear

is used)
Chapte
r
Idling speed
Note
t
t
Re display field 4:
Meaning of the digits in the 8-digit numerical block for the condition:
x x x x x x x x
0

not assigned
not assigned
0
not assigned
0
not assigned
0
not assigned
1
Clutch pedal switch F36 open (pedal pressed)

174
Power-assisted steering pressure switch active

1 Air conditioning compressor on
Display group 020 (operating state of lambda control, see also display group 099):
l

block 20
Readout on display
xxx rpm xxx mg/s xxx C xxxxx

xxx
1
Display fields
on
Operating condition of lambda

controller Note
0001011X Ancho
r
Coolant temperature
drawn in air mass
80...110 Chapt
C
er
76...164 Chapt
mg/s
er
Idling speed
1)
Chapt
er
On the points marked with X, a 0 or a 1 can be optionally displayed.

Note
t
t
Re display field 4:
Meaning of the digits in the 8-digit numerical block for the operating condition of the
lambda regulator:
xxxxxxxx
1

Diagnostic fault entered in the fault memory; interrogate fault memory Chapter
not assigned
0
not assigned
1
limited dynamics active

1
Lambda controller on stop

175
Lambda controller switched on

1 Lambda probe operational
1 Mixture condition;
display = 1: mixture too rich
display = 0: mixture too lean
Note
Further explanation of the 8-digit number block see display group 099 Anchor.
Display group 021 (adaptation status of the throttle valve control unit; to do so see display
group 098):
l

21
xxxxxxxx
xxx %
xxx %
Readout on display
xx
%
4 Display fields
Max. position of the throttle valve

Emergency position of the throttle
valve
Min. position of the throttle valve
Adaptation status of the throttle valve control unit
n
0...20 %
67...100 %
70...100 %
00000000 Anchor
Note
The measured value block 021 serves only as information. Not relevant for the fault finding in
the Service Department.
Note
Re display field 4:
t Meaning of the digits in the 8-digit numerical block for the adaptation status of the throttle
176
valve control unit:

000 xxxx
0
000
0
not assigned
1

Display group 022 (position of camshaft to crankshaft):

l
Reading measured
value block 22
xxx
rpm
1
Readout on display
xxx mg/s xx x
x
2
3 4 Display fields
on
Number of teeth of the rotor at the crankshaft

when changing the hall sender signal from + to -
86...90
Ancho
r
Number of teeth of the rotor at the crankshaft when

changing the hall sender signal from - to +
26...30
Ancho
r
drawn in air mass
76...164 Chapt
mg/s
er
Idling speed
Chapt
er
Note
t The speed sender at the crankshaft is a speed and reference marking sender (gaps). The
177
signal is generated by two gaps at the sensor rotor.

The trim of the hall sender at the camshaft is separated by 180, i.e if the trim is located in
t the air gap of the hall sender after half a turn, the trim leaves the air gap again after the
next half turn of the camshaft.
t
As of the moment when the trim drives into the air gap (signal change from - to +), i.e the
trim leaves the air gap (signal change from + to -), this is the start of the synchronization.
As soon as the sender recognizes the gap at the sensor rotor, the engine control unit begins
to count the teeth of the sensor rotor. After 26 to 30 teeth, the hall sender signal at the
t camshaft must change from - to +. (At this moment the trim drives into the air gap.) After
86 to 90 teeth (the crankshaft makes at this moment its second turn) the hall sender signal
must change from + to - (at this moment the trim leaves the air gap).
t
If no signal change occurs in the area of the teeth, as described above, this is an indication
that the toothed belt is skipped.
Display group 057 (vehicles with air conditioning system and high pressure switch -G65- as of
08.98):
l

block 57
Readout on display
xxx rpm
xxx rpm
Text
x
x
4 Display fields
Signal output from the pressure sender

at:
t
Compr. OFF
Compr. ON
Operating state of AC compressor (ON,

OFF)
Nominal speed at idling when AC compressor is
switched off
n
1...5 %
Ancho
10...70 %
r
Compr. ON
Compr. OFF
760....880
rpm
nominal speed at idling when AC compressor is

switched on
800...880
rpm
Idling speed
178
Chapt
er
Note
Re display field 4:
The signal output from the pressure switch (field 4) at compr. OFF does not give any
information about the condition of the cooling medium in the air conditioning system
If the fault 01013 is entered in the fault memory, 25% is always displayed in the display
field 4.
Display group 098 (adaptation of throttle valve control unit):

When display group 098 is selected in function 04 initiate basic setting, the engine control
unit is adapted to the throttle valve control unit - J338-.
The adaptation must always be performed after replacing or removing the engine control unit,
the throttle valve control unit or both components.
l

block 98
x.xx V
x.xx V
Readout on display
xxxxxxxx xx
3
4 Display fields
Operating condition of the adaptation
Adaptation status of the throttle valve

control unit
on
00
0000xxxx Ancho
r
Voltage for throttle valve positioner potentiometer -G88- 2.28...4.75

V
Throttle valve potentiometer voltage -G69-
Ancho
r
3.70...4.75
V
Note
t
t
Re display field 3:
Meaning of the digits in the 8-digit numerical block for the adaptation status of the throttle
valve control unit:
179
000 xxxx
0
000
0
not assigned
1

Note
t
t
Re display field 3:
Meaning of the digits in the 2-digit numerical block for the operating condition of the
adaptation:
xx
Operating condition of the adaptation
1 during the adaptation of the throttle valve control unit, a fault has occured (interrogate
fault memory Chapter)
1Perform adaptation of the throttle valve control unit
Display group 099 (operating condition of lambda control):

l

block 99
xxx rpm
xxx C
Readout on display
xx % xxxxx
xxx
3
Display fields
on
Operating condition of lambda

controller Note
0001011X Ancho
r
Lambda regulator
-25...+25
180
%
Coolant temperature
80...110 Chapt
C
er
Idling speed
2)
Chapt
er
On the points marked with X, a 0 or a 1 can be optionally displayed.
Note
t
t
Re display field 4:
Meaning of the digits in the 8-digit numerical block for the condition of the lambda
controller:
xxxxxxxx
1

a fault is entered in the fault memory; interrogate fault memory Chapter
not assigned
0
not assigned
1

1
Lambda controller on stop

1

1
Lambda probe operational

1 Mixture condition:
display = 1: = mixture too rich
display 0: = mixture too lean
Note
t Each individual number of the 8-digit numerical block is designated as bit.

The bit sequence (which is displayed by the 8-digit numerical block) is read from right to
t left. The first bit informs for example about the mixture condition, the eight bit displays if a
fault is stored in the fault memory or not.
t
If the fifth bit is set to 1 (limited dynamics active), however the lambda control is
controlled in a constant load range (i.e idling or drive with constant engine speed).
t Normally the first bit (mixture condition) must continuously jump between 0 and 1.
181
If the fourth bit is set to 1, (lambda controller on stop), it can be recognized after the first
bit (mixture condition) in which direction the lambda controller rests on stop.
If the first bit continuously rests on 1, the lambda controller has thus reached the stop in
direction of lean but the lambda probe still measures a fat mixture.
If the first bit continuously rests on 0, the lambda controller has thus reached the stop in
direction of fat but the lambda probe still measures a lean mixture.
The functions of the lambda probe and the lambda controller are contra-rotative, i.e if the
lambda probe measures a fat mixture, the lambda controller must be directed to lean.
t
However if the lambda probe measures a lean mixture, the lambda controller must be
directed to fat.
t
The lambda control cannot be switched on or off manually.
182
Repair Simos 2 injection system

Safety measures
WARNING
The fuel system is under pressure! Place a cloth around the connecting points before
releasing the hose connection or when opening the test connection (to fuel pressure
measurement). Then reduce the pressure by carefully removing the hose or cap.
Observe the following points to prevent injury to persons and/or damage to the injection and
ignition system:
t Do not touch or remove ignition leads with the engine running or at start speed.
t
Disconnect and connect the cables of the fuel injection and ignition system only when the
ignition is switched off. This also applies for the cables of the measuring devices.
To operate the engine at start speed without the engine starting (e.g. testing compression
t pressure), pull out the plug from the power output stage of the ignition coils. After
performing the work interrogate fault memory and erase Chapter.
t
t
Do not carry out engine wash unless the ignition is switched off.
Switch off the ignition before disconnecting and connecting the battery, as this may
damage the 4AV control unit.
Rules of cleanliness
Carefully observe the following five rules for cleanliness when working on the fuel supply/injection system:
t Thoroughly clean the connection points and their surroundings before releasing.
t Place removed parts on a clean surface and cover. Do not use fuzzy cloths!
t Carefully cover or close opened components if the repair is not completed immediately.
Only install clean parts: Remove spare parts from their wrapping immediately before installing. Do not
t
use any parts which have been stored unwrapped (e.g. in tool boxes etc.).
t When the system is opened: Avoid using compressed air. Avoid moving the vehicle.
Technical data
Engine identification characters
AEH, AKL
Idling speed
speed not adjustable, is controlled by the idle
stabilizer
760 - 880 rpm
Speed limiter
by disconnecting the injectors
Fuel pressure at idling speed
approx. 6350 rpm
Vacuum hose fitted on
Vacuum hose
183
approx. 0,25 MPa (2,5

bar)
approx. 0,3 MPa (3
disconnected
Holding pressure after 10 minutes
Injection valves
at least 0.15 MPa (1.5 bar) overpressure

Injection jet
Resistance
(ambient temperature)
Note
1)
equal for all valves

approx. 14.5
If the engine is warm the resistance of the injection valves increases by approx. 4...6 .
Overview of fitting locations

For vehicles 07.97
The components A and B are not shown on the overview figure.
Aq
bar)
Lambda probe -G39- with heating for lambda probe -Z19immediately upstream of the catalytic converter
184
B4-pin connector
q
for lambda probe and heating for lambda probe
q on the underside of the vehicle on right in direction of travel below a plastic cap
13-pin connector
q
for hall sender - G40q
black
2Hall sender -G40q
below the camshaft wheel
3Valve for variable intake manifold changeover -N1564Intake air temperature sender -G425Throttle valve control unit -J3386Control unit for Simos -J3617Coolant temperature sender -G628Air mass meter -G7093-pin connector
q
for knock sensor 1 -G6110 Ignition coils -N- and -N128- with power output stage -N12211 Engine speed sender -G2812 3-pin connector
q
for engine speed sender
q
grey
13 Knock sensor 1 -G6114 Injection valves - N30- to -N3315 Fuel pressure regulator
16 Activated charcoal filter system solenoid valve 1 -N80-
For vehicles 08.97
The component A is not shown on the overview figure.
185
AClutch pedal switch -F36q

in footwell on the clutch pedal
13-pin connector
q
for hall sender - G40q
black
2Hall sender -G40q
under top toothed belt guard
3Lambda probe -G39q
with heating for lambda probe -Z19q
Identification characters AEH: fitting location catalytic converter
q Identification characters AKL: fitting location exhaust manifold (illustration)
44-pin connector
q
q
on the driver side below a cover
5Valve for variable intake manifold changeover -N1566Control unit for Simos 2 -J361 7Throttle valve control unit -J3388Air mass meter -G70- with intake air temperature sender -G429Coolant temperature sender -G6210 Earth connection
186
q
11 q
12 13 14 q
q
15 16 17 18 19 20 -
at the gearbox
3-pin connector
for knock sensor 1 -G61Ignition coils (N and N128) with power output stage -N122Engine speed sender -G283-pin connector
for engine speed sender -G28 grey
Knock sensor 1 -G61Injection valve (- N30-...N33)
PAS pressure switch -F88Activated charcoal filter
Activated charcoal filter system solenoid valve 1 -N80-
Removing and installing parts of the injection system

Note
Removing and installing engine covers Chapter.
t Components marked with an * are checked by the self-diagnosis Chapter.

t Components marked with
**
can be tested with the final control diagnosis Chapter.
187
1-
Control unit for Simos 2 -J361 -*
Fitting location: in plenum chamber
Checking voltage supply Chapter
q
2q
q
3q
q
replace Chapter
Connector, 28 pin
Insert or remove plug when the ignition is switched off
unlock to remove
Connector, 52 pin
Insert or remove plug when the ignition is switched off
unlock to remove
4-
Air intake hose
5-
To oil filler inlet

188
Air mass meter -G70-* with intake air temperature sender - G42- *
6q
up to model year 1997, the intake air temperature sender -G42- is a separate component
part
q
q
7q
Testing the air mass meter Chapter

Test intake air temperature sender Chapter
Air filter
disassembling and assembling Chapter
8910 q
6 Nm
10 Nm
Cable strap
for cable rail Pos. 41
11 12 13 q
q
14 -
3 Nm
Bottom part of intake manifold
Feed line
secure with spring strap clamps
from fuel filter: 1.6 ltr./74 Engine, Mechanics Rep. Gr.20
Return-flow line
secure with spring strap clamps
to fuel delivery unit in fuel tank
15 q
16 -
Fuel distributor
Connector
q
q
3-pin
for hall sender -G40-
17 18 q
q
q
19 -
15 Nm
Connector
4-pin
for coolant temperature sender - G62Contacts 1 and 3 gilded
Coolant temperature sender -G62-*
q
q
blue
for engine control unit
189
q
q
q
with coolant temperature gauge sensor -G2check Chapter

before removing, reduce pressure in cooling system if necessary
20 q
Split pin
check tightness
21 q
O-ring
replace if damaged
22 -
Engine speed sender -G28-*
check Chapter
23 q
24 q
q
25 q
q
26 -
Gasket ring
replace
Connector
black, 2 pin
for injection valves (-N30-...N33)
Connector
black, 2 pin
for variable intake manifold changeover valve -N156Gasket ring
if no stops are present for correct gasket ring position at the bottom part of the intake
manifold:
q Stick gasket ring with glue -D 000 801- and hardener -D 000 802- to the bottom part of the
intake manifold.
q
27 -
Fitting position: Fig.

3-pin connector
grey
for engine speed sender
Fitting location Chapter
28 q
q
q
4-pin connector
black
Contacts 3 and 4 gilded
190
29 q
Lambda probe -G39-* 50 Nm
grease the thread with G 052 112 A3; G 052 112 A3 must not get into the slots of the
probe body
Checking lambda control Chapter
Voltage supply of the heating for lambda probe via fuel pump relay -J17-
Check heating for lambda probe Chapter
30 q
Support
between intake manifold and cylinder head
31 -
Rubber bush
32 -
Washer
33 34 35 36 -
8 Nm
to heat exchanger
from the expansion reservoir
Connector
8-pin
contacts gold-plated
for throttle valve control unit -J338-
37 -
to activated charcoal filter system solenoid valve 1 -N80- **
Activated charcoal filter system: 1.6 ltr./74 kW Engine, Mechanics Rep. Gr.20
38 -
To the brake servo unit
39 -
Top part of intake manifold
with variable intake manifold changeover
40 41 -
Body-bound rivet
Cable rail
191
Fitting location: stops for gasket ring at the

bottom part of the intake manifold -arrowsIf no stops are present at the bottom part
of the intake manifold, stick the gasket ring
with glue -D 000 801- and hardener - D 000
802- to the bottom part of the intake
manifold.
Disassembling and assembling top part of intake manifold
1-
8 Nm
2 - Throttle valve control unit -J338-*
check Chapter
adapt this for a replacement engine
control unit Chapter
3-
Gasket ring
replace if damaged
4-
Gas pressure valve
5-
Threaded insert, 8 Nm
6-
Top part of intake manifold
7-
Vacuum setting element
Testing intake manifold changeover

Chapter
Variable intake manifold changeover

valve -N156-*/**
Testing intake manifold changeover

Chapter
910 11 -
Earth strap
10 Nm
Cap
192
12 -
Plug
Disassembling and assembling fuel distributor
Split pin
check tightness on the injection valve

and fuel distributor
2-
Fuel distributor
3-
Injection valve (-N30-...N33)*
check Chapter
O-ring
replace if damaged
5-
check Chapter
Disassembling and assembling the air filter
12
6 Nm
Air mass meter - G70- with intake air
temperature sender -G42-
up to model year 1997, the intake air

temperature sender -G42- is a separate
component part
Contacts of sender and of connector
gold-plated
Testing the air mass meter Chapter
Test intake air temperature sender

Chapter
3-
Gasket ring
193
replace if damaged
4-
6 Nm
5-
Air filter top part
6-
Filter insert
7-
Air filter bottom part
8-
Air deflector
Removing and installing engine covers
Removing
Lever out the plugs -1- at the points marked

with arrows and slacken the securing nuts -2for both engine covers.
Slacken the securing nut -3- and remove the
engine covers.
Install
Installation is carried out in the reverse order. Pay
attention to the following:
Tighten securing nuts to 8 Nm and press in the
plug.
Testing lines and components with the test box -V.A.G 1598/22Note
t Use e.g. hand multimeter -V.A.G 1526A-, then voltage tester , e.g. -V.A.G 1527- for the test.
t
Use adapter cables from adapter cable set for connecting the test equipment to the test
box -V.A.G 1594A -.
The contact numbers of the connector of the control unit and the socket numbers of the
test box are identical.
Unlock connector at control unit when the ignition is switched off.
194
Connect test box to connector of wiring

loom.
Perform test as described in the relevant

repair sequences.
WARNING
To avoid damaging the electronic

components, switch on the relevant
measuring range before connecting the
measuring cables and comply with the test
conditions.
Note
After re-connecting the engine control unit
perform adaptation of the engine control
unit to the throttle valve control unit
Chapter.

Removing

Unscrew windscreen wiper arms and remove cooling water tank cover Body Work
Rep. Gr.66.
Note
When removing the cover, disconnect the hose for the washer nozzles.
Use a screwdriver to push the catch pegs

of the fixture to the side and pull the
engine control unit forward.
Release the connector catches and
disconnect the plug from the control unit.
Install
Installation is carried out in the reverse
order.
Note
After installing the engine control unit,

carry out the following steps:
t code the new engine control unit

195
Chapter
Adapt the engine control unit to the
t throttle valve control unit - J338 Chapter
t
Adapt the 4AV control unit to the

electronic immobiliser Chapter
Adapt the engine control unit to the electronic immobiliser

t Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Test condition
l
Authorised car key available
Connect vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3 -.
Switch on ignition.
Enter 17 for the address word dash panel insert and confirm the entry with Q.
1U1919034J A+-COMBIINSTR.VDO X27
->
At the display is shown e.g:
Coding
02142
WSC
xxxxx
Press key.
IMMO-IDENT NO: SK27Z0W0095705
->
At the display is shown e.g:
Press key.
The following appears in the display:
Vehicle system test
Enter 10 for the function Adaptation and confirm with HELP
Select function XX
Q.
Adjustment
Enter channel number XX
Enter 00 and confirm with the Q key.
Adaptation
Erase initialisation values?
Confirm the entry with the key Q.
End adaptation by pressing the key.
Adaptation
Note
->
Initialisation values erased
When the ignition is switched on again the engine control unit

identification is read by the immobilizer control unit.
196
Testing components and functions

Idle testing
t
Test conditions
l
l
Exhaust system shut.

Coolant temperature minimum 80C
l Throttle valve in idling speed position 1.6 ltr./74 kW Engine, Mechanics Rep. Gr.20
l
l
l
Electrical consumers must be disconnected (the radiator cooling fan must be off during this
test)
AC switched off
Selector lever in P or N (only on automatic gearbox)

Note
The idling speed cannot be adjusted.
t The idling speed is controlled by the engine control unit via the throttle valve control unit.
Interrogate the fault memory Chapter. There must not be any fault stored, if necessary
rectify any fault, erase fault memory, switch off engine and start again, conduct test drive
and interrogate the fault memory again for inspection.
Keep running engine at idling speed.
Subsequently switch off engine.
Switch off the rear window heater.
Put selector lever in P or N (vehicles with automatic gearbox).

Select 08 for the function read measured value block and display group number 001
Chapter.
->
850/rpm
90C
0.80 V
00000010
Read off idling speed in display field 1.
Specified value: Chapter; display group 000.
Press key.
Enter 06 for the function End output and confirm
with key Q.
If the specified value is not achieved, interrogate once

197
again the fault memory Chapter.

If the idling speed is too high or too low and if there is no
fault in the fault memory, perform the following
inspections:
l Check idling switch Chapter or Chapter.
l
Large quantity of unmetered air Chapter, display

group 003, 008 or 099.
l Inspecting throttle valve control unit Chapter.
Test fuel pressure regulator and holding pressure

t
Tester e. g. - V.A.G 1318-
Adapter e.g. -V.A.G 1318/8-
Test conditions
l
Fuel pump relay o.k., test Chapter
Fuel pump o.k.
Fuel filter o.k.
Battery voltage o.k.

Note
The fuel pressure regulator regulates the fuel pressure in line with the intake manifold
pressure at the throttle valve part.
WARNING
The fuel system is under pressure! Before opening the system lay cleaning cloths around the
connection point. Reduce pressure by carefully releasing the connection point.
Disconnect the fuel-intake hose (with white marking) from the feed line.
Connect the pressure measuring device -V.A.G 1318- with the adapters 1318/8, 1318/9 and
1318/17 to the fuel feed line.
Open shut-off cock of the pressure

measuring device. Lever points in
direction of flow.

198
Measure fuel pressure.
Specified value: approx. 2.5 MPa (0.25 bar)

overpressure.
Detach vacuum hose from fuel pressure

regulator. The fuel pressure must rise to
approx. 3 bar (3 MPa) overpressure.
Test for leaks and holding pressure while

observing the pressure drop on the
manometer. An overpressure of at least

1.5 bar (0.15 MPa) must be indicated on
the manometer after 10 minutes.
The pressure drops below 1.5 bar (0.15
MPa):
After the pressure has been built up,

switch ignition off. At the same time close
the shut-off cock at the pressure

measuring device -V.A.G 1318- (lever at
right angles to direction of flow).
Observe pressure drop at gauge.
If the pressure again drops:
Checking the non-return valve on the

fuel pump.
If the pressure does not drop:
199
Open shut-off cock at the pressure

measuring device -V.A.G 1318- (lever in
direction of flow of fuel).
After the pressure has been built up,

switch ignition off. At the same time the
return-flow hose (with blue marking)
must be pressed together.
If the pressure does not drop:
Replace the fuel pressure regulator.
If the pressure again drops:
Check line connections, O -rings on fuel

rail and injectors for leaks.
Inspect pressure measuring device for

leaks.
Note
Before removing the pressure gauge

appliance, reduce the fuel by opening the
shutoff cock and place a cleaning cloth
around the connection point.

t
Handheld multimeter, e.g. -V.A.G 1526 A -
Voltage tester, e.g. - V.A.G 1527-
Measuring tool set -V.A.G 1594 A -
Test box -V.A.G 1598/22-
Current flow diagram
A - Testing resistances of the injection valves
Remove fuel distributor Chapter.

Disconnect plug at the injection valve to be tested.
200
Perform resistance measurement

between the contacts of the valve with
multimeter.
Specified value: approx. 14.5 .
If the engine is warm the resistance
increases by approximately 4 to 6 .
If the nominal value is not reached,

replace the injection valve.
B - Checking voltage supply

Test conditions
l Fuel pump relay o.k., test Chapter
l
Fuse for injection valves O.K. Current

flow diagrams and Fitting locations
Disconnect plug at the injection valve to

be tested.
Connect the voltage tester between

contact 1 of the plug and the engine
mass.
Note
So that the engine does not start,

disconnect the plug at the ignition module.
Operate starter for some seconds, the

voltage tester must light up.
If the voltage tester does not light up,

check the continuity of the wiring from
contact 1 to fuse for injection valves and
if necessary eliminate open circuit
Current flow diagrams and Fitting
locations.
If the voltage tester lights up, test

actuation of the injection valves.
C - Test actuation of the injector valves
Disconnect plug at the injection valve to

be tested.
201
Connect voltage tester between contact

2 of the plug and battery positive (+).
Activate the starter.
Specified value: Voltage tester must flash.

Note
Voltage tester with low voltage

consumption do not go out fully between
the actuations of the engine control unit,
but keep on glowing and become brighter
during the actuation.
If the voltage tester does not flash
Connect test box-V.A.G 1598/22 - to the

wiring loom on the engine control unit
Chapter.
Test wiring between contact 2 of the plug

from the relevant injection valve and
engine control unit for interruption or
short circuit to positive.
Contact 2
at plug of injection valves
73
80
58
65
If necessary eliminate wire interruption or short-circuit.
If the wiring is O.K., replace engine control unit Chapter.
Inspecting the injection rate, tightness and jet formation of the injectors
t
Remote control -V.A.G 1348/3 A -
Auxiliary cable -V.A.G 1348/3-2-
Measuring glasses (e.g. -V.A.G 1602 -)

202
Test condition
l
Fuel pressure o.k., test Chapter.
Detach vacuum hose from fuel pressure regulator.
Detach the fuel feed line and return line on the quick-release fittings.
WARNING
The fuel system is under pressure!

Detach the hose which connects the solenoid valve for the activated charcoal filter with
the throttle valve control unit on the valve as well as on the control unit and unhook it at
the intake manifold.
Disconnect the plug from the valve for intake manifold changeover and from the hall
sender.
Disconnect the spark plug connectors for cylinders two and three.
Unscrew the fuel distributor from the intake manifold and remove it carefully with the
injection valves from the intake manifold.
Unclip cable harness from the cable guide and remove.
Carefully pull out the fuel distributor with injection valves, fuel feed line and return line and
ACF hose towards the right (from the ACF reservoir) from below the intake manifold and fit
again the fuel feed line and return line (blue marking).
Insert injector to be tested in a measuring glass, e.g. -V.A.G 1602-.
Lay a contact of the injection valve with

the test cable and alligator clip from the
adapter cable set -V.A.G 1594 A- on the
engine mass.
Connect the other contact of the injection
valve with remote control -V.A.G 1348/3 A
-, adapter cable -V.A.G 1348/3-2- and
auxiliary cable to battery positive.
Initiate an actuator diagnosis and select
the activated charcoal filter solenoid
valve 1 -N80- Chapter. The fuel pump
runs for approx. 50 s.
Test the tightness of the injectors (visual
inspection). With the fuel pump running
per valve only 1...2 drops (50 s) of fuel
may escape.
If the fuel loss is greater adjust the fuel

pump (end final control diagnosis) and
replace defective injector.
203
Initiate again an actuator diagnosis and

select the activated charcoal filter
solenoid valve 1 -N80-.
Note
The final control diagnosis can only be

initiated again after the ignition has been
briefly switched off.
for approx. 50 s) -V.A.G 1348/3 A-.
Note
l Moisten O rings with clean engine oil.

204
Pay attention to correct positioning of the

injectors.
l Check perfect fit of the retaining clips.
Test fuel pump relay and control

t
Test box -1598/22Note
The fuel pump relay is located in the

electrical centre in the left footwell, relay
position 4.
A - check fuel pump relay -J17 Remove storage in front left of footwell.
205
Disconnect fuse for fuel pump (fuse 28)

at the fuse holder and connect the
voltage tester between earth and one of
the two contacts of the fuse for the fuel
pump Current flow diagrams and
Fitting locations.
Switch on the starter motor for a short

time.
The fuel pump relay must be activated

(feel and hear), the voltage tester must
light up.
If the fuel pump relay does not connect,

test control Anchor.
If the voltage tester does not light up

even though the fuel pump relay is
activated, repeat the test on another
contact.
If the voltage tester does not light up
again, check the cable connection
between contact 23 at the relay position
4 and check the fuse for fuel pump for

continuity and if necessary eliminate
open circuit Current flow diagrams and
Fitting locations.
If the power supply, the actuation and

the wiring of the fuel pump relay are O.K,
replace the fuel pump relay.
B - Check voltage supply and actuation of

the fuel pump relay
Note
The actuation of the fuel pump relay can

also be checked by means of the final
control diagnosis Chapter.
Remove the fuel pump relay - J17- from

the relay carrier, relay position 4.
Checking voltage supply
Switch on ignition.
Connect the multimeter successively to

the contacts 19 (positive, terminal 15
from the ignition lock) of the relay base
and earth as well as 17 (permanent
positive, terminal 30 of the battery) of
206
the relay base and earth.

Specified value: approx. battery voltage
each
If the specified values are not reached,

eliminate line interruption Current flow
Test control
Connect the voltage tester to contact 16

of the relay base (earth control of the
engine control unit) and to positive.

time.
The voltage tester must light up

continuously when operating the starter.
Note
Voltage testers with low power

consumption do not go out fully but keep
on glowing until the starter is operated.
If the actuation of the fuel pump relay as
well as the cable connection and the
voltage supply are O.K, however the fuel

pump relay is not activated, the fuel
pump relay must be replaced.
If the voltage tester does not light up, test
wiring as follows:
Connect the test box -V.A.G 1598/22- to

the wiring loom of the engine control unit
Chapter.
Connect hand multimeter between
contact 16 of relay base and socket 4 of
the test box and test wiring for continuity.
If necessary eliminate line interruption

locations.
If there is no open circuit and the voltage

tester does not light up, replace the
engine control unit Chapter.
Re-insert the fuse for the fuel pump.
207
Test air mass meter -G70Special tools and workshop equipment required
t
t
Vehicle system tester V.A G 1552 with cable -V.A.G 1551/3Handheld multimeter, e.g. -V.A.G 1526 A -
Check for proper operation

Test conditions
l
Fuse no. 43 o.k.
l Coolant temperature at least 80C.

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

conditioning, this must be switched off.
On vehicles with automatic gearbox the

l selector lever must be in position P or
N.
l
Vehicle standing, engine idling

Select 08 for the function read
measured value block and further select
display group 001.
In display field 2 check whether the coolant

temperature is above 80C.
Change to the display group 2 by pressing

the button.

->
850/rpm
90C
0.80 V
0000010

The drawn in air mass is displayed in the display field 2
(Milligram per stroke).
Specified value: 76 up to 164 mg/s
If the specified values are not reached or if a fault regarding

the air mass meter is stored in the fault memory, check the
voltage supply of the air mass meter Anchor or Anchor.
Check the voltage supply of the air mass meter on vehicles

208

block 2
->
850/rpm
120 mg/s
0
km/s
0100
07.97.
Disconnect the plug from the air mass
meter -G70- and connect the multimeter
between contact 3 of the plug and the
engine mass.
Specified value: 11...15 V

If the voltage supply is o.k., check signal
lines and earth connection Anchor.
If no voltage is present:
Check the cable connection from contact
3 of the plug to fuse no. 43 for continuity
and/or short-circuit to earth, if necessary

repair cable connection Current flow
If fuse and wiring are o.k. but neverthless

no voltage is present, check the fuel
pump relay Chapter.
Check the signal line and the earth

connection of the air mass meter on
vehicles 07.97.

Chapter.
Test wiring from plug of air mass meter to
engine control unit for interruption or
short-circuit to positive or earth.
Plug of air mass meter G70
Test box - V.A.G 1598/22-
13
12
If the wiring is O.K., replace air mass meter -G70-.
Check the voltage supply of the air mass meter on vehicles 08.97
Disconnect the plug -1- from the air mass
meter -2- and connect the hand-held
multimeter between contact 3 of the plug
and the engine mass.

209
Specified value: 11...15 V

If the voltage supply is o.k., check signal
lines and earth connection Anchor.
If no voltage is present:
Check the cable connection from contact
3 of the plug to fuse no. 43 for continuity
and/or short-circuit to earth, if necessary

repair cable connection Current flow
If fuse and wiring are o.k. but neverthless

no voltage is present, check the fuel
pump relay Chapter.
Check signal line and earth connection on

vehicles 08.97

Chapter.
Check wiring between the test box and

the 4-pin plug for continuity according to
current flow diagram, cable resistance:
max. 1.5 .
Plug of air mass meter G70
Test box - V.A.G 1598/22-
13
12
Additionally test all wiring to each other for short-circuit.
Specified value:
210
If the lines are not found to be faulty:

Replace air mass meter -G70- with intake air temperature sender -G42- Chapter.
Testing the intake system for tightness (unmetered air)

t Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Testing with engine leak search spray -G 001 800 A1Note
Because of the vacuum in the intake system the leak search spray is sucked in with the unmetered air.
t The leak search spray reduces the ignition performance of the mixture. This results in a drop in engine
speed and a considerable increase of the CO content.
t You must comply with the safety instructions on the box.
Select 08 for the function read measured value block and further select display group 001.
Note engine speed in display field 1.
Note lambda probe voltage in display field 3 and the range
in which it fluctuates.
Systematically spray parts of the intake system with engine
leak search spray.

If the engine speed or lambda probe voltage does not change:
Press key.
->
Enter 06 for the function End output and confirm with key 850/rpm
90C
0.05V
Q.
0000010
If the engine speed drops or if the lambda probe voltage
changes:
Press key.
Enter 06 for the function End output and confirm with key
Q.
Check the sprayed location of the intake system for leaks
and if necessary eliminate the fault.

Test voltage supply of engine control unit
t
t
Handheld multimeter, e.g. -V.A.G 1526 A Test box -V.A.G 1598/22Note
For checking the voltage supply of the engine control unit see also Chapter, display group
005, display field 2.
Test conditions:
l
Fuse for engine control unit O.K

211
l
l
Battery voltage at least 11 V.

AC generator o.k.
Connect the test box -V.A.G 1598/22 - to the wiring loom of the engine control unit
Chapter.
Switch on ignition.
Connect multimeter for voltage measurement to bush 1 (positive via ignition) and earth.
Specified value: approx. battery voltage.
If the specified value is not reached, check the cable connection of contact 1 of the engine
control unit for interruption according to current flow diagram, if necessary repair
Current flow diagrams and Fitting locations.
If the specified value is not reached, connect the voltage tester to bush 1 of the plug from
the engine control unit (positive via ignition) and bush 2 of the plug from the engine
control unit (earth supply of the engine control unit).

If the specified value is not reached, check the cable connection of contact 2 of the engine
control unit to earth for continuity, if necessary eliminate open circuit Current flow
Connect multimeter for voltage measurement to bush 3 (permanent positive) and earth.
If the specified value is not reached, check the cable connection of contact 3 of the plug
from the engine control unit and electrical centre for continuity according to current flow
diagram, if necessary eliminate open circuit Current flow diagrams and Fitting locations.
Test intake air temperature sender

For vehicles 07.97
t
t
t
Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set -V.A.G 1594 A Test box -V.A.G 1598/22Note
t
t
t
For functional test of the intake air temperature sender see also Chapter, display group
Fitting position of the intake air temperature sender Chapter.
Engine cooled to room temperature (approx. 20C).
212
Disconnect the plug from the intake air temperature sender.
Connect multimeter to intake air

temperature sender.
Temperature C
Resistance k
-20
approx. 13,8
approx. 5,5
20
approx. 2,4
40
approx. 1,1
60
approx. 0.6
If the specified value is not reached, replace the intake air temperature sender.
If the specified value is reached, test wiring between sender plug and engine control unit
as follows:
Chapter.
213
Check the cable connection between the

2-pin plug of the intake air temperature
sender and the engine contol unit for
interruption as well as for short-circuit to
positive and/or to earth according to
current flow diagram.
Contact at 2-pin plug
54
67
Specified value: max. 1.5 .
If no fault was detected during the previous tests, replace the engine control unit
Chapter.
For vehicles 08.97

t
t
t
t
Test box -V.A.G 1598/22Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set -V.A.G 1594 A -
Cooling spray
Test sequence
electronics. Ignition switched on.
Select 08 for the function read measured value block and further select display group
005.
Functional test of the sender:

Read off the intake air temperature value Reading measured value block 5
->
in display field 4.
0 rpm
Display
12 V
90C
Cause
214
53C
Continue test
60 C
Open circuit/Short circuit to positive
Anchor

approx. ambient temperature Note
1)
---
Anchor
If a temperature is displayed that greatly deviates from the ambient temperature of the
sender, check the sender wires for transition impedances.
Continue test:
Chapter.
Disconnect the 4-pin plug connection -1from the air mass meter -2-.

the 4-pin plug for continuity according to
the Current Flow Diagram. Cable
resistance: max. 1.5
Plug at intake air temperature sender
12
Additionally test wiring to each other for short-circuit.
Specified value:
If the cable is not found to be faulty:
215
Check the resistance between contacts 2

+ 4 of the sender.
The range A shows the resistance values

for the temperature range 0...50 C, the
range B the values for the temperature
range 50...100 C.
Read out examples:
t
30 C corresponds to a resistance of
1500...2000
275...375
Replace air mass meter -G70- with intake

air temperature sender -G42- Chapter.
Continuing test, if display ambient

temperature:
Remove intake air hose between air
mass meter and throttle valve control
unit.
Note the intake air temperature value in

display field 4.
216
Spray sender -arrow- with cooling spray

and while doing so observe the
temperature value. The temperature
value must drop.
Press key.
Enter 06 for the function End output
and confirm with key Q.
Test coolant temperature sender -G62Special tools and workshop equipment required
t
t
t
t
t
For functional test of the coolant temperature sender see also Chapter, display group
Fitting position of the coolant temperature sender Chapter.
Disconnect plug from coolant temperature sender.
217
Check the resistance between contact 1

(earth) and 3 (signal) of the sender.
The range A shows the resistance values

for the temperature range 0 to 50 C, the
range B the values for the temperature
range 50 to 100 C.
Examples:
t
1500 to 2000
80C corresponds to a resistance of 275

to 375
If the nominal value is not reached,

replace the sender.
If the nominal value is reached, test wiring

from sender to engine control unit as
follows:
Connect the test box -V.A.G 1598/22 - to

Chapter.
Check cables for interruption if necessary
check short-circuit
218
For vehicles 07.97 (Pos. A)
67
53
For vehicles 08.97 (Pos. B)
70
53
If there is neither a line interruption nor a short-circuit and the coolant temperature sender
is o.k., replace the engine control unit Chapter.
219

The lambda probe compares the oxygen content of the air with the residual oxygen in the
exhaust gas and supplies a voltage signal to the control unit.
The voltage signal mixture too rich (little residual oxygen) is at approx. 0.7...1.0 V.
The voltage signal mixture too lean (a lot of residual oxygen) 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 ( = 1.0).
In view of the steep voltage jump the lambda control is not able to maintain constant the
ideal mixture composition which corresponds to = 1.0. The control constantly fluctuates
back and forward between the too lean and too rich states.
The lambda control (also designated as lambda controller) consists of the actual lambda
probe and a specific software which is stored in the engine control unit. Depending on the
measured values of the lambda probe, the engine control unit determines the values for other
actuators, e.g for the throttle valve control unit.
If the voltage change does not occur, or if it is too slow, the following faults may have
occurred:
t
t
t
t
Slots or holes in the probe head are clogged up.

The probe was overheated.
Transition resistance in the signal line or in the earth cable.
Probe too cold, probe heating not operating.
The lambda control is switched off (engine control unit has detected faults at the injection
t system: interrogate fault memory Chapter as well as read measured value block, display
group 099 Chapter).
Probe damaged by contact spray or similar (Because of the thermal fluctuations and the
t capillary effect the contact spray is sucked into the probe via the fine hollow spaces in the
electrical lines).
Probe damaged by silicone vapours (When using silicone sealants traces of silicone particles
t are sucked into the engine. These silicone particles are not combusted and damage the
lambda probe).
Irregularities of the engine after cold start

t
Test condition
l
No fault must be stored according to the lambda control, if necessary eliminate fault or
erase fault memory.
The time which passes until the control (necessary probe temperature approx. 300 C) is
220
introduced, is influenced mainly by the following factors:

t
Ambient temperature (summer/winter)
Operating conditions after start
Function of the probe heater
If faults occur after cold start, it must be checked if the problem occurs before or after the
control is introduced.
Test vehicle under cold start conditions:
Select 08 for the function read measured value block and select display group 099
Chapter.
The condition of the lambda control is displayed

in the display field 4.
->
850/rpm
Meaning of the 8-digit number block in the

display field 4 (see also Chapter):
Display field 4
90C
+25%
00010111
Meaning of the display
1XXXXXXX
X1XXXXXX
not assigned
XX1XXXXX
not assigned
XXX1XXXX
XXXX1XXX
Lambda controller at the stop
XXXXX1XX
XXXXXX1X
XXXXXXX1
Mixture condition;
display = 1: rich mixture
display 0: = lean mixture
At cold start:
Note
Immediately after the cold start, the lambda probe is

t not yet operational (temperature of the probe is too
low).
221

->
850/rpm
30C
+25%
00010001
The lambda controller is activated if the lambda probe

is operational.
Perform a test drive and while doing so observe the

display field 4.
WARNING
The -V.A.G 1552- should be operated by a second

person.
When inserting the lambda control, the lambda probe must be
operational and the lambda controller must be switched on.
The display for the condition of the mixture (the position on the far
right of the 8-digit numerical block) must constantly oscillate
between 0 and 1.
A 1 on the position for the condition of the mixture indicates a
rather rich mixture composition (low level of residual oxygen in the
exhaust gas).
A 0 on the position for the condition of the mixture indicates a
rather lean mixture composition (high level of residual oxygen in
the exhaust gas).
If irregularities occur before inserting the lambda control, the

lambda control cannot be the cause of the fault.
If irregularities occur only after inserting the lambda control,

check operation Chapter.

block 99
->
850/rpm
90C
+25%
00010111
Note
If the irregularities decrease after inserting the control, the cause

of the fault (e.g. unmetered air, defective injection valve, etc..) is
t
counteracted by engaging the control. This can be detected by
reading out the lambda learned values.
t
Select 08 for the function read measured value block and

display group number 011.
Compare the actual values (displayed by the tester) with the

specified values.
Check the function of the lambda control
Select 08 for the function read measured value block and display group number 001
Chapter.

Only proceed with test once the coolant temperature in
222

->
850/rpm
90C
0.80 V
the display field 2 is at least 80 C.

The signal voltage of the lambda probe is displayed in
the display field 3.
If the probe voltage fluctuates too slowly (less than 30
times per minute), test lambda probe heater
0000010
Chapter.
Press key.
Select 08 for the function read measured value
block and display group number 099 Chapter.

The condition of the lambda control is displayed
in the display field 4.
On the points marked with X, a 0 or 1 can ->

850/rpm
be optionally displayed.
90C
+25%
0001011X
Meaning of the 8-digit number block in the

display field 4 (see also Chapter):
Display field 4
1XXXXXXX
X1XXXXXX
not assigned
XX1XXXXX
not assigned
XXX1XXXX
XXXX1XXX
Lambda controller at the stop
XXXXX1XX
XXXXXX1X
XXXXXXX1
Mixture condition;
display = 1: rich mixture
display 0: = lean mixture

If the lambda controller stands against the stop (display for lambda
controller at stop on 1), the direction in which the lambda
controller stands against the stop can be recognized on the display
for the condition of the mixture.

block 99
->
850/rpm
90C
+25%
00011111
block 99
->
223
If the lambda controller stands against the stop and the display for
the condition of the mixture is shown permanently on 1, the
lambda control has reached the control stop in direction lean off,
however the lambda probe still detects mixture too rich.
850/rpm
90C
+25% 00011111

If the lambda controller stands against the stop and the display for the
condition of the mixture is shown permanently on 0, the lambda
control has reached the control stop in direction enrich, however the
lambda probe still detects mixture too lean.
Note
If the lambda controller stands at the stop for a certain period of time,
no matter if in direction rich or lean, a fault is stored in the fault
memory.
If the lambda control functions properly, check lambda learned

values.
Reading measured
value block 99
->
850/rpm
90C
+25%
00011110
Press the button C.

Enter 011 for the display group number 011 and confirm entry with
the Q key.
The mixture adaptation is adaptive, i.e. differences between the engines

(nozzle flow rate, compression, fuel pressure) are detected via the
lambda control and compensated through the adaptation of the basic
injection time programmed in the characteristic diagram. The injection
time is extended or shortened until a mixture with = 1 is achieved.
The lambda learned value is displayed in idling in the
display field 2.
positive learned value (+0ms): programmed basic
t injection time too short, actual injection time by 0ms
longer, so that = 1 is achieved.
negative learned value (-0ms): programmed basic
t injection time too long, actual injection time by 0ms
shorter, so that = 1 is achieved.
The lambda learned value is displayed in the partial load
range in the display field 3.
Values greater than 1: programmed basic injection time
t too short, actual injection time longer, so that = 1 is
achieved.
Values less than 1: programmed basic injection time too
t long, actual injection time shorter, so that = 1 is
achieved.
224

11
->
3 ms
+1.00 ms
1.00
00000010
The specified values Chapter.
Check lambda probe heater

t
Measuring tool set - V.A.G 1594 A-
Test conditions
l
The fuse no. 43 must be o.k.
Procedure
The heating circuit of the lambda probe is monitored by the self-diagnosis.
Interrogate the fault memory Chapter.

Disconnect the 4-pin plug of the lambda probe (on the underside of the vehicle on right in
direction of travel, below a cap).
Perform resistance measurement
between the contacts 1 and 2 of the
probe connector.
Note
At ambient temperature the heating

element resistance is of approx. 1 to 5.
The resistance increases considerably even
if the temperature rises only slightly.
Replace the lambda probe if an open

circuit is detected.
If there is continuity in the heating

element, check the power supply for
lambda probe heater as follows:
Connect the multimeter between contact

1 of the plug at the wiring loom and the
engine mass.
If the specified value is not reached, test

the wiring of contact 1 of the plug at
225
wiring loom for continuity and/or short

circuit to earth, if necessary repair
locations.

Chapter.
Test wiring of contact 2 of plug at wiring

loom (earth control of the engine control
unit) to contact 27 at engine control unit

for continuity, if necessary eliminate line
interruption.
If fuses and cables are o.k. but

neverthless the specified value is not
reached, test fuel pump relay Chapter.
If all previous tests which were carried
out are O.K, replace the engine control
unit Chapter.
Test lambda probe signal line and lambda probe control unit
t
Test box -V.A.G 1598/22Note
The lambda probe signal is monitored by the self-diagnosis.
Interrogate the fault memory Chapter.

If a lambda probe fault is indicated and the probe heater is o.k., disconnect the lambda
probe plug connection.
Switch on ignition.
226
Use handheld multimeter to measure

voltage between the contacts 3 and 4 of
the connector at the wiring loom.
Specified value: 1.50...1.60V

If the specified value is not reached,
connect the test box -V.A.G 1598/22- to
Chapter.
Test wiring for open circuit, short circuit
to positive and/or to earth, if necessary
repair:
Plug on wiring loom, contact
25
26
If the wiring is O.K., replace engine control unit Chapter.
227
Checking the fuel tank venting

Testing activated charcoal filter system solenoid valve 1
t
t
Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Handheld multimeter, e.g. -V.A.G 1526 A -
Check tightness
In dead condition the solenoid valve is closed.
Detach hose from activated charcoal filter solenoid valve 1 -N80-.

Connect a suitable manometer and a compressed air device (air pump) to the solenoid
valve.
Generate a visible air pressure.
Initiate an actuator diagnosis and select the activated charcoal filter solenoid valve 1
-N80- Chapter.
When the solenoid valve is opened the displayed air pressure must clearly drop and when
it is closed it must clearly rise again, if not replace the solenoid valve.
Inspect solenoid valve -N80- electrically
Pull out plug at the valve.

Perform a resistance measurement with the handheld multimeter between the valve
contacts.
Specified value: 22 to 30 .
If the specified value is not reached, replace the solenoid valve.
Test voltage supply of the solenoid valve -N80Note
The voltage supply for the solenoid valve is performed via the fuel pump relay.
Test condition
l
Fuse for ACF valve (fuse 43) o.k

Disconnect plug at solenoid valve.
228
Connect the voltage tester between

contact 1 of the plug and the engine
mass.
Activate the starter.
Specified value: The voltage tester must

light up.
If the voltage tester does not light up,
check the wiring of contact 1 to fuse for
continuity, if necessary repair Current
flow diagrams and Fitting locations.
If the wiring is o.k., test fuel pump relay

Chapter.
Test actuation of the solenoid valve -N80Connect voltage tester e.g - V.A.G 1527 between contact 2 (earth control of the
engine control unit) and positive terminal
of the battery.
Initiate an actuator diagnosis and select

the activated charcoal filter solenoid
valve 1 -N80- Chapter.
Specified value: The voltage tester must

flash.
If the voltage tester does not flash or if it
remains lit:

Chapter.
If the voltage tester lights up

permanently, check the wiring from
contact 2 of the plug at the solenoid

valve for bush 15 of the test box for
short-circuit to earth.
If the voltage tester did not flash, check
the wiring from contact 2 of the plug at
the solenoid valve for bush 15 of the test
box for short-circuit to positive.
If there is neither a line interruption nor a

short-circuit; replace engine control unit
Chapter.
229
230
Inspecting throttle valve control unit

Operation
The idle stabilizer is integrated into the throttle valve control unit.
Throttle valve potentiometer, idling switch, throttle valve positioner and throttle valve
positioner potentiometer are located in the housing opposite the control cable disc.
The housing must not be opened. This means that both potentiometers, the idling switch and
the throttle valve positioner are not mechanically set or can be replaced.
All settings are performed within the basic adaptation using the -V.A.G 1552-.
When de-energized, the throttle valve moves into a specific, mechanically fixed position,
which means that the idling speed increases when the engine is warm.
The throttle valve positioner takes over the closing damping function of the throttle valve.
The throttle valve positioner can only open the throttle valve up to a certain range i.e so that
the throttle valve positioner e.g cannot accelerate at full throttle.
Note
If the throttle valve control unit is replaced, you must:
t Adapt the engine control unit to the throttle valve control unit Chapter
t
for vehicles with automatic gearbox: Adapt gearbox control unit Automatic gearbox
Rep. Gr.01
Test conditions
For vehicles 08.97
l Earth line between throttle valve control unit and cylinder head o.k Chapter.
For all vehicles
l
Throttle valve is not damaged or dirty.

t
t
t
t
Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Handheld multimeter, e.g. -V.A.G 1526 A Measuring tool set -V.A.G 1594 A Test box -V.A.G 1598/22-
Check throttle valve control unit for vehicles 07.97

Check idling switch
231
002.
Observe display in display field 4.

Note
850/rpm
120 mg/s
0 km/s
->
0100
Meaning of the digits in the

display field 4:
Display field 4
1XXX
Trailing throttle
X1XX
Idling
XX1X
Partial load
XXX1
Full load
The read-out for the idling must be on 0100.
Slowly accelerate.

The read-out for the partial load must be on 0010. (When opening
the throttle valve, the idling switch opens at the same time).
If the specified values are not reached, switch off the ignition and
connect the test box -V.A.G 1598/22- to the wiring loom of the
Measure the resistance between the sockets 67 and 69 using a
handheld multimeter.
Specified value: continuity, max. 1.5 . (Throttle valve shut)
Slightly open throttle valve.
Specified value: (no continuity)

If the specified value is not reached, check the wiring and the
contacts for continuity, damage or contamination according to the
current flow diagram, if necessary clean or replace damaged parts
Then adapt the engine control unit to the throttle valve control unit
Chapter.
If the specified value is not reached again, check throttle valve for
dirt and/or resistance and clean if necessary.
232

block 2
->
1000/rpm
120 mg/s
0 km/s 0010
Repeat adaptation of the throttle valve control unit Chapter.
If the adaptation cannot be started or successfully completed,

replace the throttle valve control unit.
Perform adaptation of the throttle valve control unit Chapter.

Inspect sender for throttle valve positioner and throttle valve
potentiometer
Unplug the 8-pin connector from the throttle valve control unit.
Switch on ignition.
Use handheld multimeter to measure

voltage between the contacts 4 and 7 at
the 8-pin plug.
Specified value: min. 4.8 V

connect the 8-pin plug.
Start engine.
measured value block and display group
number 098 Chapter.

The values in the display field 1 (voltage of the throttle
valve positioner potentiometer) must be between 3.70 V
up to 4.75 V.
The values in the display field 2 (voltage of the throttle
valve positioner potentiometer) must be between 2.28 V
up to 4.75 V.
Connect the test box -V.A.G 1598/22 - to the wiring loom

of the engine control unit Chapter.
Unplug the 8-pin connector from the throttle valve

control unit.
233

->
4.20 V
3.48 V
00000000
00
Test wiring between the test box and the

8-pin plug with multimeter for continuity.
Test wiring with multimeter for shortcircuit relative to each other.
Contact to text box
66
59
69
62
75
67
74
Remove possible line interruptions and dirt at the contacts, erase fault memory and carry
out adaptation of the throttle valve control unit Chapter.
If the specified value is not reached again, check throttle valve for dirt and/or resistance
and clean if necessary.
Repeat adaptation of the throttle valve control unit Chapter.

If the adaptation cannot be started or successfully completed, replace the throttle valve
control unit.
Perform adaptation of the throttle valve control unit Chapter.
If the adaptation cannot be started or successfully completed, replace the engine control
unit Chapter.
If the adaptation was carried out successfully, carry out once again the adaptation with the
old (disassembled) throttle valve control unit Chapter.
Check throttle valve control unit for vehicles 08.97

234
Check idling switch
098.
Check idling switch at idle stop in the display

field 3.
1. The position from the right must always
display 0
->
4.20 V
3.48 V
00000000
Read-out: 00000000
Slowly open throttle valve. 1. The position

from the right must always display 1
Read-out: 00000001

Display
Cause
Continue test
always 1
Open circuit/Short circuit to positive
Anchor
always 0
Anchor
Continuing test if the read-out of the display is always on 1
Unplug plug -1- from the throttle valve

control unit -2-.
235
00
Bridge contacts 3 + 7 of the plug

connection with adapter cables and
observe the read-out on the display.
Display 0:
End the test using the function 06 End

output.
Replace throttle valve control unit

Chapter.
Display 1:

output.
Test voltage supply of throttle valve
control unit and cables to engine control
unit Anchor.
If the voltage supply and the wiring o.k.:

Replacing engine control unit Chapter.
Continuing test if the read-out of the
display is always on 0

control unit -2-.
Display 1:

output.

Chapter.
Display 0:

output.
unit Anchor.
If the voltage supply and the wiring o.k.:

Check operating state
Connect vehicle system tester

-V.A.G 1552- and select address word 01
Engine electronics. Engine idling.

236
measured value block and further select

display group 098.
Check the operating state of the throttle valve control
unit in display field 3.
Specified value: 00000000
Meaning of the digits in the 8-digit numerical block for
the operating condition of the throttle valve control
unit:
000 xxxx
0
000
0

->
4.20 V
3.48 V
00000000
00
not assigned
During the adaptation of the throttle valve control unit, a fault has occured
1

Adapt the engine control unit to the throttle valve control unit Chapter.
Repeat check.
If the nominal values are again not reached:
Test voltage supply of throttle valve control unit and cables to engine control unit
Anchor.
Check throttle valve potentiometer

Test condition
l
Coolant temperature at least 80 C
Test sequence
001.

temperature is above 80 C.
Switch over in display group 3 as follows:

->
0/rpm
90C 0.80 V
00000000
237
Read off throttle valve angle in display field 3.

Specified value: 1.9...5.7 .
Slowly open the throttle valve completely and by doing so

observe the angle indicator in display field 3. The numerical
value must increase evenly over the total range.
End the test using the function 06 End output.
Note
The indicated value is dependent on the tolerances of the

throttle valve potentiometer and does not correspond to the
actual opening angle.
The numerical value does not increase evenly:

block 3
->
0/min
0 mg/s 3.2.
%
Replace throttle valve control unit Chapter.
If the display stays at constant:
Check voltage supply and cables to throttle valve control unit

Anchor.
Check throttle valve positioner and throttle valve

potentiometer
Test condition
l
Coolant temperature at least 80 C
Test sequence
Connect vehicle system tester -V.A.G 1552- and select

address word 01 Engine electronics. Engine idling.
Select 08 for the function read measured value block and

further select display group 001.

temperature is above 80 C.
Switch over in the display group 098:

->
850/rpm
90C
0.80 V
0000010
Check the voltage value for the throttle valve opening of

the potentiometer for the throttle valve positioner in
display field 2.
->
4.20 V
3.48 V
00000000
00
Specified value: 2.28...4.75 V

Remove intake hose.

238
control unit -2-.
Measure resistance of throttle valve

positioner between the contacts 1 + 2:
Specified value: 3...200


Chapter.

unit Anchor.
Test voltage supply and cables to the

control unit

control unit -2-.
Switch on ignition.
Measure the voltage between the

contacts 4 + 7 of the plug using the
multimeter.
Specified value: min. 4.5 V
Measure the voltage between the
contacts 3 + 7 of the plug using the
multimeter.
Specified value: min. 9 V

Chapter.

the plug for continuity according to the
239
current flow diagram.

Contact to text box
66
59
69
62
75
70
74
Cable resistance: max. 1.5
Additionally test wiring to each other for short-circuit.
Specified value:
Test voltage supply of engine control unit Chapter.
Adapt the engine control unit to the throttle valve control unit
This basic setting teaches the engine control unit the stop positions of the throttle valve
control unit with the ignition on and the engine stopped.
Note
If the throttle valve control unit -J338- is removed and installed or replaced or the voltage
supply is interrupted by the engine control unit, a basic setting must always be performed.
Test conditions
l
l
l
l
No fault in fault memory Chapter

Idling switch up to stop, check Chapter or Chapter
Throttle valve closed (opening angle of the engine control unit), throttle cable setting O.K;
check 1.6ltr./74kW Engine, Mechanics Rep. Gr.20
Engine in standstill
l The voltage supply of the engine control unit greater than 8 V, check Chapter
240
Enter function 04 Initiate basic setting and further select display group 098.

After the Q key has been pressed, the throttle valve positioner
moves from the min. limit (throttle valve is closed) up to the max.
limit (throttle valve is opened).
The control unit stores the corresponding voltage value in the
permanent memory.
System in basic setting

98
->
4.20 V
3.48 V
00000000
01
This procedure takes up to 10 seconds. Afterwards, the throttle

valve positioner remains free of stress.
The adaptation of the engine control unit to the throttle
valve control unit was performed successfully.
Note

->
4.20 V
3.48 V
00000100
00
If one of the following displays is shown, a successful

adaptation could not be performed.
Note
98
4.20 V
3.48 V
00001100
->
10
Meaning of the digits in the display field

3:
Display field 3 Meaning of the display
XXXX1XXX
XXXXX1XX
XXXXXX1X
Adaptation aborded due to a too low battery voltage (below 8 V)
XXXXXXX1
Idling switch separated (interrogate switch), check Chapter or Chapter
Meaning of the digits in the display field 4:

Display field 4 Meaning of the display
1X
X1
Perform adaptation of the throttle valve control unit
Note
241
98
See fault table Chapter, fault code 01087.
The reason for an unsuccessful adaptation of the throttle valve control unit can also be
t detected by selecting the display group 001 (read measured value block, when ignition is
switched on) Chapter.
t
After an unsuccessful adaptation, the conditions for an adaptation must be checked

Chapter.
After each condition recognized as O.K, an attempt must be made to perform once again
an adaptation of the engine control unit to the throttle valve control unit Chapter.
t If the adaptation is aborted by the control unit, this may be due to the following reasons:
t
The conditions for an adaptation of the engine control unit to the throttle valve control unit
are not fulfilled; conditions for an adaptation Chapter, fault code 01087.
The throttle valve does not reach the mechanical idling limit due to dirt, e.g. carbon
deposits or an incorrectly adjusted throttle control cable.
The throttle valve control unit or the wiring is defective.
The fault 01087 is entered in the fault memory basic setting not carried out after it has
t been aborted. When the ignition is switched on again the basic setting is automatically
performed again.
End basic setting of the engine by pressing the key .

Enter function 06 End output and confirm entry with the Q key.
Test intake manifold changeover

The test should only be undertaken when the performance is not up to specification
Test condition
l
Engine must be warm
Check for proper operation
electronics.
001.
Increase the engine speed suddenly (at least to 2500 rpm) and decelerate again.
242
The vacuum box for the intake manifold

switch-over must pull in, the shift linkage
must go back again to its initial position
-arrow-.
If the change-over does not occur, perform
the following tests:
Check variable intake manifold
changeover valve -N156- (perform final
control diagnosis Chapter, if necessary
check valve and actuation Chapter).
Inspect vacuum lines for leaks

Chapter.
Inspect vacuum lines for proper

connection, leaktightness and continuity.
Check smooth operation of changeover

mechanism. (Operate shift linkage by
hand.)
Inspect the vacuum system

t Remote control, e.g -V.A.G 1348/3 A- with adapter cable, e.g -V.A.G 1348/3-2t
Hand vacuum pump, e.g. -V.A.G 1390 t
Measuring tool set, e.g. -V.A.G 1594 A Leave engine running at idling speed for 2 to 3 minutes (build up vacuum).

Disconnect plug from valve for variable intake manifold changeover.
Connect one contact of the valvewith the connection line and alligator clip from -V.A.G 1594 A- to the
engine mass.
Lay a second contact of the valve with remote
control - V.A.G 1348/3A-, adapter cable
-V.A.G 1348/3-2- and connection line to
positive terminal.
Activate the remote control -V.A.G 1348/3A for 2 to 3 minutes. During this period, the
vacuum unit must be connected.
If the vacuum unit does not return to its initial
position, check the vacuum unit as follows:
Remove the vacuum lines from the vacuum
unit for intake manifold changeover.

Connect hand vacuum pump to vacuum unit.
Actuate the hand vacuum pump and observe
the switch over procedure.

Check vacuum unit for tightness. (The vacuum
unit must not return to its initial position as
long as it is not ventilated at the hand vacuum

pump).
243
If necessary replace vacuum unit.

If the vacuum unit does not connect, test valve
-N156- for continuity as follows:
Connect one contact of the valvewith the
connection line and alligator clip from
-V.A.G 1594 A- to the engine mass.
Lay a second contact of the valve with remote

control - V.A.G 1348/3A-, adapter cable
-V.A.G 1348/3-2- and connection line to
positive terminal.
Activate remote control -V.A.G 1348/3A-.
Test valve for continuity (disconnect vacuum
lines and blow out).
If necessary replace valve for variable intake
manifold changeover.
If no fault was detected during all the previous
tests, check the vacuum system for leaks.
Test variable intake manifold changeover valve -N156Fitting location Chapter.

t
t
t
t
Handheld multimeter, e.g. -V.A.G 1526 A Voltage tester, e.g. - V.A.G 1527Measuring tool set, e.g. -V.A.G 1594 ATest box, e.g. -V.A.G 1598/22 -
Test condition
l
Fuse 34 must be OK.
Electrically test valve for variable intake manifold changeover -N156
Disconnect plug at variable intake manifold changeover valve.

Measure the resistance between the contacts of the variable intake manifold changeover
valve.
244
Specified value: 25 to 35 .
replace the variable intake manifold
changeover valve.
Test voltage supply and actuation of the
variable intake manifold changeover valve
-N156-
Disconnect plug at variable intake

manifold changeover valve.
Connect the voltage tester to contact 1

(positive) of the plug and to the engine
mass.
time. While doing so, the engine can also
start. Specified value: The voltage tester
must light up.
The diode does not light up:
Check the cable of contact 1 of the plug
at the variable intake manifold
changeover valve to fuse for continuity
according to the current flow diagram
locations.
If the fuse and the wiring are o.k, check
the actuation of the fuel pump relay
Chapter.
Connect voltage tester to contact 1
(positive) and 2 (actuation of engine
control unit) of the plug at the variable
intake manifold changeover valve.
If the voltage tester does not flash or if it

remains lit. Connect the test box
245
-V.A.G 1598/22- to the wiring loom of the

If the voltage tester lights up
continuously, test the wiring of contact 2
of the plug for variable intake manifold

changeover valve to socket 64 of the test
box for short circuit to earth.
If the voltage tester does not flash, test
the wiring of contact 2 of the plug at the
variable intake manifold changeover

valve to socket 64 of the test box for
short circuit to positive.
If necessary eliminate fault.

If there is neither a line interruption nor a
short-circuit; replace engine control unit
Chapter.
246
Testing auxiliary signals

Inspecting AC compressor disconnection
Note
t The engine control unit has the possibility to deactivate the AC compressor.
t
The deactivation of the AC compressor is performed at maximum load (full throttle) in the
first gear (on vehicles with manual gearbox).
t There is no deactivation of the AC compressor on vehicles with automatic gearbox.

t
t
t
t
Handheld multimeter, e.g. -V.A.G 1526 A Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Measuring tool set -V.A.G 1594 A Test box -V.A.G 1598/22-
Test conditions
l
l
Air conditioning system o.k.

No fault in fault memory
Note
The -V.A.G 1552- must be operated by a second mechanic during the test drive.
019.
Subsequently switch off engine.
For vehicles 07.97

Display field 3 must display 0 (air
conditioning off).
Display field 4 must display 0 (AC
compressor off).

->
850/rpm
0
0
Switch on the air conditioning system. The
AC compressor must run.

Display field 3 must display 1 (air conditioning
on).
Display field 4 must display 1 (AC compressor
247

->
850/rpm
0
1
1
on).
Conduct a test drive in the first gear (press down

the gas pedal promptly at low speed).
During the acceleration, the display in the display field 4

must show 0 (during this period the AC compressor is
switched off).
For vehicles 08.97

->
850/rpm
0
1
0
Display field 3 must display 0 (air

conditioning off).
Display field 4 must display 0 (AC
compressor off).

->
850/rpm
0
0
00000000


Display field 3 must display 1 (air conditioning
on).
Display field 4 must display 1 (AC compressor
on).

->
850/rpm
0
1
00000001
Conduct a test drive in the first gear (press down

the gas pedal promptly at low speed).

During the acceleration, the display in the display field 4 must show
0 (during this period the AC compressor is switched off).
For all vehicles
If the readout in the display is not as described, switch off the

engine and connect the test box -V.A.G 1598/22 - at wiring loom to Reading measured value
block 19
the engine control unit Chapter.
Test wiring of contact 8 of engine control unit to the air

conditioning system control unit for short-circuit to earth or
positive and/or for interruption according to the current flow
diagram Current flow diagrams and Fitting locations.
->
850/rpm
00000000
If there is no fault in the wiring, check the function of the air

conditioning system Heating and Air conditioning system Rep.
Gr.87.
Check engine speed adaptation by switching on the air conditioning system

t
Handheld multimeter, e.g. -V.A.G 1526 A 248
t
t
t
Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Measuring tool set -V.A.G 1594 A Test box -V.A.G 1598/22Note
A positive signal is applied to contact 8 at the engine control unit by switching on the air
conditioning system.
The signal ensures the engine control unit maintains the idling at a constant speed given
power supply requirement differences in the air conditioning system.
Test condition
l
l
Air conditioning system o.k.

Auxiliary consumers (e.g. rear window heating) switched off
019.
For vehicles 07.97

Display field 1: idling speed
Display field 3: signal of the air conditioning
system
Display field 4: condition of AC compressor

->
850/rpm
0
0
0

Display field 3 must display 1.

Display field 4 must display 1
(compressor on).

->
850/rpm
0
1
1
For vehicles 08.97

Display field 1: idling speed
Display field 3: signal of the air conditioning
system
Display field 4: condition of AC compressor

->
850/rpm
0
0
00000000

249

Display field 4 (1st position from right) must display 1
(compressor on).
For all vehicles
Apart from a momentary engine speed reduction, the idling speed
must remain constant.
If the speed is not maintained constant, switch off the engine
and connect the test box -V.A.G 1598/22 - at wiring loom to the

block 19
->
850/rpm
0
1
00000001
Test the wiring of contact 8 at the engine control unit to the air
conditioning system control unit for interruption or short-circuit
according to the current flow diagram Current flow diagrams
and Fitting locations.
If there is no fault in the wiring, check the function of the air
conditioning system Heating and Air conditioning system
Rep. Gr.87.
Check selector lever positions of the automatic gearbox

t
t
t
t
t
Handheld multimeter, e.g. -V.A.G 1526 A Voltage tester, e.g. - V.A.G 1527Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Measuring tool set -V.A.G 1594 A Test box -V.A.G 1598/22Note
The engine control unit receives the information if a gear is engaged (selector lever in
t 1/2/3/R/D) or not (selector lever in P or N) from the relay for starter interlock switch and
reversing light -J226-.
t
The relay for starter interlock switch and reversing light -J226- switches in the selector
lever position P or N earth to the contact 22 at the engine control unit.
019.

Display field 2 must display 0 (selector lever in P or N).
250
Reading measured
value block 19
->
850/rpm
0
Foot brake activated and engage a driving position.

If the readout in the display is not as described, connect the test
box -V.A.G 1598/22- at wiring loom to the engine control unit
Chapter.
Connect voltage tester between socket 3 (terminal 30) and socket

22.
The voltage tester must go out when engaging a driving position.
xxxxxxxx
If the voltage tester lights up continuously or not at all, test the

wiring of contact 22 at engine control unit to relay for starter lock
and reversing light -J226- for short circuit to positive or to earth as

well as for interruption Current flow diagrams and Fitting
locations.
If there is no fault in the wiring, check the multi-function switch

Automatic Gearbox. Rep. Gr.01.
Test the starter signal

t
t
t
The starter signal (terminal 50, of the ignition lock) enters at the same input of the engine
control unit as the P/N signal.
If the engine control unit detects the start signal, immediately after this the fuel pump relay
is switched on.
On vehicles fitted with automatic gearbox: pull out the relay for starter lock and reversing
light -J226-.
Chapter.
Connect the multimeter for voltage measurement between the bushes 2 (earth) and 22
(terminal 50).
Activate the starter. A min. of 8 V must be displayed at the multimeter.
Inspect the wiring to the ignition lock (terminal 50) according to the current flow diagram
251
Test engine speed signal

Note
The engine speed signal is shown at contact 6 of the engine control unit. The signal,
amongst others, is absolutely necessary for the automatic gearbox control unit for
calculating the gear-change points and for the rev counter readout in the dash panel insert.
Chapter.
Check the wiring of contact 6 of the test box to the dash panel insert for interruption
according to the current flow diagram Current flow diagrams and Fitting locations.
Inspect throttle valve position

t
t
t
t
Handheld multimeter, e.g. -V.A.G 1526 A Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3Measuring tool set, e.g. -V.A.G 1594 ATest box -V.A.G 1598/22Note
This signal serves the automatic gearbox control unit in combination with the speed to
calculate the gear-change points.
For vehicles 07.97, the signal is a rectangular signal which is given by the engine control
unit to contact 7.
For vehicles 08.97 , the signal is a rectangular signal which is given by the engine control
unit to contact 8.
Connect vehicle system tester -V.A.G 1552- Chapter.
Initiate self-diagnosis of the gearbox control unit automatic gearbox Rep. Gr.01.
If the fault 00545 engine/gearbox electrical connection is displayed by the automatic

gearbox control unit, interrogate the fault memory of the engine control unit Chapter.
If a fault related to the throttle valve potentiometer is stored in the engine control unit,
then first of all eliminate this fault. (The fault in the automatic gearbox control unit is only a
follow-up fault.)
If no fault related to the throttle valve potentiometer is displayed, connect the test box
-V.A.G 1598/22- at wiring loom to engine control unit Chapter.
For vehicles 07.97

252
Test the wiring of contact 7 of the engine control unit connector to the automatic gearbox
control unit for interruption or short-circuit Current flow diagrams and Fitting locations.
For vehicles 08.97
Test the wiring of contact 8 of the engine control unit connector to the automatic gearbox
control unit for interruption or short-circuit Current flow diagrams and Fitting locations.
Testing the speed signal

Note
The speed signal is generated by the vehicle speed sender -G68- (at gearbox) and
processed in the dash panel insert.
The processed signal passes to contact 20 of the engine control unit and is used for idling
speed stabilisation and for damping load change jolts during gearshifts.

t
t
t
t
Enter function 08 read measured value block and select display group 002.
Determine by means of a test drive whether the driving speed

is displayed in display field 3.
If the vehicle speed is not displayed, raise vehicle preferably

with the lift platform until the front left wheel is free.
Connect the test box -V.A.G 1598/22 - to the wiring loom of the
Connect the voltage tester between bush 3 (positive) and bush

20 (speed signal).
Switch on ignition and turn the left front wheel by hand.

The voltage tester must flash (very short flashing signal).
Note
The right front wheel must not turn along, if necessary hold.
253

block 2
->
850/rpm
120 mg/s
0 km/s
0100
If the voltage tester does not flash, test the wiring of contact 20
at plug of engine control unit to dash panel insert for open
circuit and/or short circuit Current flow diagrams and Fitting
locations.
Check signal for gearbox intervention during gearshifts

Note
By means of this signal from the automatic gearbox control unit, the ignition angle is
t briefly reduced (torque reduction) depending upon the speed and engine speed during
gearshifts of the automatic gearbox, in order to avoid the jerky gear change.
t
For vehicles 07.97, the signal is a rectangular signal, which arrives at contact 23 at the
For vehicles 08.97 , the signal is a rectangular signal, which arrives via the data BUS at
contact 23 at the engine control unit.
Due to the very short signal, the request for ignition angle relief from -V.A.G 1552- is not
always detected.

t
t
t
t
Procedure
Connect vehicle system tester -V.A.G 1552- Chapter.

Conduct a test drive and select the function 08 read measured value block and display
group 001 Chapter.
WARNING
The -V.A.G 1552- should be operated by a second person.

Specified value: X 0 X X X X X X = without gearbox intervention
Specified value: X 1 X X X X X X = gearbox intervention
Value: X = no meaning
Note
254

block 1
->
850/rpm
90C
0.80 V
00000010
If the automatic gearbox control unit requests an ignition angle

relief, the display quickly jumps from 0 to 1.
The wiring to the automatic gearbox control unit is monitored

by the gearbox self-diagnosis (fault code 00545).
During gearshifts, if no read-out for the torque reduction is

performed in the measured value block or the fault code 00545
(in the automatic gearbox control unit) is shown:
For vehicles 07.97
Connect the test box -V.A.G 1598/22 - to the wiring loom of

the engine control unit Chapter.
Test wiring of contact 23 of engine control unit for interruption

and/or short-circuit Current flow diagrams and Fitting
locations.
For vehicles 08.97
Test databus drive Chapter.
Test signal of PAS pressure switch

For vehicles 08.97
t
Test sequence
019.
Observe display value in display field 4.

Specified value: x x x x x x 0 x
Turn the steering wheel up to the stop and observe the
display value in the display field 4 (2nd position from
right).
Specified value: x x x x x x 1 x
Connect the test box -V.A.G 1598/22 - to the wiring

loom of the engine control unit Chapter.
255
->
850/rpm
00000000
Unplug the 2-pin connector -1- from the

PAS pressure switch -F88--2-.

the 2-pin plug for interruption according
to the current flow diagram, cable
resistance: max. 1.5 .
Contact to test box 1598/22
24
14
Additionally test all wiring to each other for short-circuit.
Specified value:
Connect multimeter for resistance measurement to the contacts of the pressure switch.
Start engine and run in idle, bring the steering wheel in its central position. Inspect
pressure switch for continuity.
Specified value:
Turn the steering wheel up to the steering angle. The pressure switch must switch to
continuity.
Replace PAS pressure switch: Chassis Rep. Gr.48.
Test the signal of the clutch pedal switch

For vehicles 08.97
Special tools, test equipment and aids required
t
Vehicle system tester -V.A.G 1552 - with cable -V.A.G 1551/3256
Test sequence
019.
Observe display value in the display field 4. (3rd position from

right).
Specified value: x x x x x 1 x x
Depress the clutch pedal and observe the display value in the
display field 4.
Specified value: x x x x x 0 x x

Connect the test box -V.A.G 1598/22 - to the wiring loom of the
Check wiring between the test box and the 2-pin plug for
continuity according to the current flow diagram.
Contact 2+bush 21
Cable resistance max. 1.5 .

Check the cables between the 2-pin plug contact 1 and the fuse
34 for interruption according to the current flow diagram. Cable
resistance: max. 1.5 Current flow diagrams and Fitting
locations
257

block 19
->
850/rpm
0
1
00000100
Test data bus

1-
Engine control unit

2
ABS control unit
Fitting location: at the hydraulic unit in

left of engine compartment
3-
Gearbox control unit

4
Databus driver
Part of control unit
Operation
The engine control unit -1- communicates
with the ABS control unit -2- and the
gearbox control unit -3- via the data bus.
At least two control units with databus
capability are linked by two twisted
databus 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.
In order for the databus to operate without
fault, the terminating resistance R must be
arranged in both control units before the
databus driver -4-. These terminating
resistances are located in the engine and
ABS control unit.
required
t
Handheld multimeter, e.g. -V.A.G 1526 A

-
t Measuring tool set, e.g. -V.A.G 1594 At
Vehicles with automatic gearbox:

t
Test conditions
258
Before starting the test, the fault

memories of the control units which are
connected to the engine control unit via
l
the data bus must be interrogated
(automatic test sequence, address word
00).
l
Self-diagnosis has determined a fault in

the data bus.
The ABS control unit is coded for the data

bus operation.
Vehicles with automatic gearbox Anchor.

Remove plenum chamber cover:

Electrical System Rep. Gr.92.
Unlock plug connection and remove from

Connect test box -V.A.G 1598/22 - at

wiring loom to the engine control unit.
Check databus cables with the

terminating resistance in the ABS control
unit:
Measure resistance between test box

sockets 29 and 31.
For vehicles 04.99

Specified value: 115...135 .
For vehicles 05.99
Specified value: 2.3...2.8 k.
For all vehicles
If the measured value corresponds to the
specified value Anchor.
If the measured value does not correspond
to the specified value:
Remove air filter:
259

ABS control unit.
Check CAN databus cables for short

circuiting with each other:

sockets 29 and 31.
Specified value: .
If the specified value is not reached (there
is a short-circuit between the cables):
Eliminate the fault in the wiring
according to the current flow diagram
locations.
If the specified value is reached (there is
no short-circuit between the cables):
Connect test box -V.A.G 1598/21 --1- to

wiring loom of the ABS control unit -2-.
Check CAN databus cables between the

test box bushes 1598/22 and 1598/21 for
interruption according to the current flow
diagram: cable resistance: max. 1.5 .
Bush to test box 1598/22
29
10
31
11
Additionally check the cable for a short circuit to positive and/or to earth.
If no fault is found:
Replace ABS control unit: Chassis Rep. Gr.45.
If the measured value corresponds to the specified value:
Remove air filter:

260
ABS control unit.
Check the cables between the engine

control unit and the ABS control unit for
short-circuit to positive and/or to earth.

Fit again plug onto engine control unit.
Connect test box -V.A.G 1598/21 --1- to

Check terminating resistance in the

engine control unit:

sockets 10 and 11.
For vehicles 04.99

For vehicles 05.99
For all vehicles
Remove plenum chamber cover:

Electrical System Rep. Gr.92.
Disconnect plug and remove from

gearbox control unit -arrow-.
261
Connect and lock the test box

-V.A.G 1598/18 --1- to wiring loom of the
gearbox control unit -1--2-.
Check CAN databus cables with the
terminating resistance in the engine and
ABS control unit:
sockets 3 and 25.
For vehicles 04.99

For vehicles 05.99
Perform the test according to the

following table:
Display
Cause
0...5
135... or
72...
Short-circuit between databus lines

Line interruption
Short circuit to positive
Transition impedances
Solution
Check wiring Anchor
Check wiring Anchor
Fit again plug at the gearbox control unit.

Switch on ignition.
Erase all faults from the fault memory and conduct a test drive.
Once again read out the fault memories of all control units using the automatic test
sequence.
If a fault is still shown on the data bus system in the engine control unit after the test drive.
Check voltage supply of the gearbox control unit Current flow diagrams and Fitting
locations.
Check the CAN databus cables for a short circuit to positive and/or to earth Anchor.
If the wires are not found to be faulty and if the voltage supply is OK:
Replace gearbox control unit: Automatic gearbox Rep. Gr.01.
Continuing test if there is a fault on the data bus system:

262
Release connector from engine control unit and unplug.
Check databus cables with the terminating resistance in the ABS control unit:
Measure the resistance between bushes 3 + 25 of the test box 1598/18.
For vehicles 04.99

For vehicles 05.99
Specified value: 2.3...2.8 k.
For all vehicles
If the measured value does not correspond to the specified value:
Test CAN databus cables Anchor.
If the wiring to the ABS unit is in proper order:
Replace ABS control unit: Chassis Rep. Gr.45.
Fit again plug onto engine control unit.

Remove air filter:
ABS control unit.
Check databus cables with the

terminating resistance in the engine
control unit:
Measure the resistance between bushes

3 + 25 of the test box 1598/18.
For vehicles 04.99

For vehicles 05.99
For all vehicles
Test CAN databus cables Anchor.
263
Test CAN databus cables

ABS control unit.
Release connector from engine control

unit and unplug.
Check CAN databus cables for short

circuiting with each other:
Measure the resistance between bushes

3 + 25 of the test box 1598/18.
Specified value: .
to the specified value (there is a shortcircuit between the cables):
Eliminate the fault according to the

current flow diagram Current flow
If the measured value does corresponds to

the specified value (there is no short-circuit
between the cables):
Check the CAN databus cables for a short

circuit to positive and/or to earth.
If no short-circuit is found:
Connect test box -V.A.G 1598/22 - at

wiring loom to the engine control unit.

test box bushes for interruption
according to the current flow diagram:
resistance: max. 1.5 .
29
31
25
264
Connect test box -V.A.G 1598/21-1- - to


test box bushes 1598/22 and 1598/21 for
interruption according to the current flow
diagram: resistance: max. 1.5 .
31
11
29
10
265
266

Skoda Octavia Mk1 - 05 - Drive Unit

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Skoda Octavia Mk1 - 05 - Drive Unit

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SKODA OCTAVIA

1.6 LTR./74 KW ENGINE - MECHANICAL COMPONENTS.........................................................5

Removing and installing coolant pump......................................................................................... 101

REMOVING AND INSTALLING PARTS OF THE INJECTION SYSTEM.........................................................................191

TESTING COMPONENTS AND FUNCTIONS..................................................................................................... 202

1.6 ltr./74 kW Engine - Mechanical Components

The engine number (engine identification

Exhaust gas recirculation

Ignition system/fuel injection

Exhaust limits conforming to

At least 91 RON in exceptional cases, although engine output is reduced

Engine assy,cylinder block,crankcase

Special tools and workshop equipment required

The engine is removed downwards together with the gearbox.

t Pay attention to the correct assignment of the connectors, if necessary mark.

Remove battery tray -arrows-.

Open the cap of the coolant expansion

Raise vehicle with a lift platform, pay

The arms of the lift platform must be

Under no circumstances may the arms of

Both jacking up points at front are located

Never start the engine or engage a gear

Both rear jacking up points are located on

Remove noise insulation panel -arrows-.

Position drip tray (e.g. -V.A.G 1306-)

Turn drain valve -arrow- at radiator to the

Remove bottom coolant hose on the oil

Remove caps for nuts and remove

Detach air guide hose at throttle valve

Detach vent hose -1- and unplug

connector from air mass meter -2-.

Unscrew screws -3- and -4-, remove air

Remove the cooling water tank cover.

Unplug the 28-pin connector at engine

Open the cable duct below the air filter

Detach wiring harness from the engine

Unbolt earth strap -1-.

Detach cables -3- and -4- at starter.

Separate plug connection -2- and pull out

Detach cables from fixture at starter and

Unbolt cable -1- of terminal 30/B+ at

Unplug connector -2- of terminal D+.

Unscrew cable lug -3-.

Unplug connector from monitoring switch

Unhook throttle control cable

Vehicles fitted with a manual gearbox

Press off shift rods -1- and -2- with a

Unbolt shift mechanism at gearbox

Remove the slave cylinder -arrows- and

Do not depress the clutch pedal.

Unplug connector from reversing light

Detach wiring loom for the fixtures and

Vehicles with automatic gearbox

Use screwdriver to press off selector

Take off selector lever cable and place to

Unbolt bracket for pressure line of powerassisted steering at gearbox support.

Disconnect the following plug

for solenoid valves

for vehicle speed sender - G68-

for multi-function switch -F125 -

for gearbox speed sender -G38 -

Unplug the connector from the

Detach cable harness for the fixtures and

The fuel system is under pressure! Before