1,8ltr110kW,engine,motronicfuelinjectionandignitionsystem

Service

Workshop Manual

Service Department. Technical InformationS00.5124.50.20 Edition 07.98

1.8-ltr./110 kW Engine,Motronic Fuel Injection and IgnitionSystem

The Workshop Manual is intended only for use within the Škoda Organisation;it is not permitted to pass it on to third parties.

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24 Fuel Formation/Fuel Injection

Edition 07.98

Procedure after interruption to volt-age supply

If the voltage supply has been interrupted, theengine control unit „forgets” all the learned val-ues and basic setting values. This may result inconsiderable drivability problems, depending onthe mileage of the vehicle.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

Procedure

After the voltage supply has been interrupted,carry out the following operations:

- Switch on the ignition for at least 10 seconds.

- Switch off the ignition.

- Adapt the engine control unit to the throttlevalve control unit ⇒ page 24-72.

- Perform the idling speed test ⇒ page 24-13.

Note:

During the idling speed test the activated char-coal filter solenoid valve and the air condition-ing are switched off and the learning process ofthe lambda control is initiated.

- Conduct a lengthy road test until the drivabilityproblems have been eliminated.

During this road test, the following operatingconditions must be met:

♦ The coolant temperature must rise to morethan 85 °C.

♦ Once this temperature has been reached,the following operating states

IdlingPart throttleFull throttle enrichmentFuel shut-off on overrun

must be achieved several times.

♦ Engine speed must have risen to more than3500 rpmat full throttle.

Fuel Formation/Fuel Injection 24

Edition 07.98

Testing fuel pressure regulator andholding pressure

Special tools, testers and aids required

♦ Pressure measuring device e.g. V.A.G 1318

♦ Pressure hose with connections e.g. V.A.G1318/8

♦ Adapter e.g. V.A.G 1318/9

♦ Adapter e.g. V.A.G 1318/17

Test conditions

Delivery of fuel pump o.k.; testing:⇒ 1.8-ltr./110 kW Engine, Mechanical Compo-

nents; Repair Group 20, Testing fuel pump

Fuel pump relay o.k.; testing ⇒ page 24-52.

Fuel filter o.k.

Battery voltage o.k.

Test procedure

Note:

The fuel pressure regulator regulates the fuelpressure in line with the intake manifold pres-sure.

Warning!

Fuel system is pressurized! Place cleaning ragsaround the connection point before opening thesystem and then release the pressure by carefullydetaching the connection point.

- Detach the fuel feed hose -1- at the feed line.

24 Fuel Formation/Fuel Injection

Edition 07.98

- Connect the pressure measuring deviceV.A.G 1318 to the feed line using the adapt-ers 1318/8, 1318/9 and 1318/17.

- Open the shut-off cock of the pressure meas-uring device. The lever points in the direc-tion of flow.

- Start the engine and run at idling speed.

- Measure the fuel pressure.

Specification: approx. 0.25 MPa.

- Detach the vacuum hose from the fuel pres-sure regulator. The fuel pressure must riseto approx. 0.3 MPa.

If the specification is not achieved:

- Test delivery of the fuel pump.⇒ 1.8-ltr./110 kW Engine, Mechanical Compo-

nents; Repair Group 20, Testing fuel pump

If the specification is achieved:

- Switch off the ignition.

- Test the leaktightness and the holding pres-sure by checking the pressure drop at thegauge. There must still be a pressure of atleast 0.20 MPa present after 10 minutes.

If the holding pressure drops below 0.20 MPa:

- Start the engine and run at idling speed.

- After pressure has been built up, switch offthe ignition and at the same time close theshut-off cock of pressure measuring deviceV.A.G 1318 (lever at right angles to directionof flow).

- Check the pressure drop at the gauge.

Fuel Formation/Fuel Injection 24

Edition 07.98

If the pressure does not drop:

- Test the check valve of the fuel pump.⇒ 1.8-ltr./110 kW Engine, Mechanical Compo-

nents; Repair Group 20, Testing fuel pump

If the pressure again drops:

- Open the shut-off cock of the pressure meas-uring device V.A.G 1318 (lever in directionof flow).

- Start the engine and run at idling speed.

- Once the pressure has built up, switch offthe ignition and at the same time clamp thereturn-flow hose together until tight and thenagain open the passage in the return-flowhose.

If the pressure does not drop:

- Replace the fuel pressure regulator.

If the pressure again drops:

- Inspect the line connections, O-rings at thefuel rail and injectors for leaks.

- Inspect the pressure measuring device forleaks.

Note:

Before disconnecting the pressure measuringdevice, release the fuel pressure by opening theshut-off cock. Hold a vessel in front of the con-nection for this step.

Testing injected quantity, leaktight-ness and spray pattern of the injec-tors

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Remote control V.A.G 1348/3A with adaptercable V.A.G 1348/3-2

♦ Tester for injected quantity e.g. V.A.G 1602

24 Fuel Formation/Fuel Injection

Edition 07.98

Test condition

Fuel pressure o.k.; testing ⇒ page 24-45.

Test procedure:

- Unplug the connectors at all the injectors.

- Then, remove the fuel rail complete.

- Detach vacuum hose from the fuel pressureregulator.

- Lift off fuel rail and injectors at the intakemanifold and support.

Testing for leaks

- Initiate final control diagnosis and operate in-jector of cyl. 1 (N30) ⇒ page 01-33; the fuelpump should run.

Note:

This step is intended merely to operate the fuelpump when the engine is not running. The idlingspeed switch must remain closed during this testotherwise the injector selected will eject fivetimes.

- Inspect injectors for leaks (visual inspection).When the fuel pump is running, only 1...2drips a minute should flow out of each injec-tor.

- If the fuel loss is greater, switch off fuel pump(end final control diagnosis) and replace thefaulty injector.

Note:

Always replace the seals.

- Once again initiate final control diagnosis, ifnecessary.

Note:

The final control diagnosis cannot be repeateduntil the ignition has been switched off for a shortmoment.

Testing injected quantity

- Insert the injector to be tested in a measur-ing glass of the injected quantity tester e.g.V.A.G 1602.

Fuel Formation/Fuel Injection 24

Edition 07.98

- Connect one contact of the injector to en-gine earth using the test cable and crocodileclamp from V.A.G 1594.

- Connect the second contact of injector topositive using remote control V.A.G 1348/3 A,adapter cable V.A.G 1348/3-2 and auxiliarycable.

- Initiate final control diagnosis (function 03)⇒ page 01-33. The fuel pump should run.

- Operate the remote control V.A.G 1348/3 Afor 30 seconds.

- Carry out the measurement at all the injec-tors.

- After all four injectors have been operated,place the measuring glasses on a flat sur-face.

Specification: 110...130 ml

- If the measurement obtained from one orseveral injectors is not within the tolerancerange, switch off fuel pump (end final con-trol diagnosis) and replace the faulty injec-tor.

- If the measurements obtained from all theinjectors are not within the tolerance range,test fuel pressure ⇒ page 24-45.

Note:

When testing the injected quantity, also test thespray pattern. The spray ejected should be thesame at all the injectors.

Before installing, pay attention to the followingpoints regarding the injectors:

Replace the O-rings at all the opened con-nection points. (The plastic cap must not beremoved from the injector head to replacethe front O-ring; lift the O-ring over the plas-tic cap).

Moisten O-rings with clean engine oil.

Ensure the injectors are properly installed.

Ensure the retaining clips are correctly in-stalled.

- Installation is carried out in the reverse or-der to removing.

24 Fuel Formation/Fuel Injection

Edition 07.98

Testing injectors

Special tools, testers and aids required

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set V.A.G 1594 A

♦ Current flow diagram

Test conditions

Engine speed sender o.k.

Fuel pump relay o.k.

Fuse 32 for injectors o.k.

Test procedure

- Initiate final control diagnosis ⇒ page 01-33.

If one or several injectors do not click:

Testing actuation of voltage supply

- Unplug connector at the injector to be tested.

- Connect the diode test lamp to the contactsof the connector of cylinder 1.

- Initiate final control diagnosis and actuateinjector of cylinder 1 (N30) ⇒ page 01-33;the fuel pump must run.

Diode test lamp must flash.

Note:

Diode test lamps with a low current consump-tion do not go out fully between the flash pulsesbut continue glowing a little and become brighterduring a flash pulse.

Fuel Formation/Fuel Injection 24

Edition 07.98

- Repeat the test at the connectors of injec-tors cylinders 2...4.

- Switch off the ignition.

If the LED does not flash at any of the cylinders:

- Connect diode test lamp to the connector ofcylinder 1, contact 1 and earth.

- Initiate final control diagnosis and actuateinjector of cylinder 1 (N30) ⇒ page 01-33.

The LED must come on:

- Repeat the test at the connectors of the in-jectors of cylinders 2...4.

If the LED does not come on:

- Switch off the ignition.

- Test cable between 2-pin connector contact1 and fuel pump relay (J17) for open circuitaccording to the current flow diagram.

Specification: max. 1.5 If the LED does not flash at one or several cylin-ders:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test cable connection between contact 2 ofthe connector of the relevant injector andengine control unit for continuity and for shortcircuit to positive.

Contact 2 at con- Test box V.A.Gnector of injector 1598/22, socket

1 73

2 80

3 58

4 65

- In addition, test the cables for short circuit toeach other

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder.

24 Fuel Formation/Fuel Injection

Edition 07.98

- Rectify any open circuit in the wiring or shortcircuit.

- If the cable connection is o.k., replace en-gine control unit ⇒ page 24-69.

- If no fault can be found in the actuation andvoltage supply, test the resistances of theinjectors.

Testing resistances of the injectors

- Unplug the connector at the injector to betested.

- Perform a resistance measurement betweenthe contacts of the injector.

Specification: 12...15

.

The resistance is increased by about 4...6

ifthe engine is at operating temperature.

If the specification is not achieved:

- Replace the faulty injector.

Testing fuel pump relay and actua-tion

Special tools, testers and aids required

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

Note:

The fuel pump relay is located in the electricalcentre in the interior of the vehicle behind thedriver footwell storage compartment, relay po-sition 4.

A - Testing fuel pump relay -J17

- Remove the storage compartment in thefront left footwell.

Fuel Formation/Fuel Injection 24

Edition 07.98

- Take out fuse 28 at fuse holder and connectdiode test lamp between earth and one ofthe two contacts of fuse 28.

- Briefly operate the starter.

The fuel pump relay must operate (can be feltand heard), the diode test lamp must come on.

- If the diode test lamp does not come on al-though the fuel pump relay operates, repeatthe test at the other contact.

- If the diode test lamp again does not comeon, test cable connection between contact23 at relay position 4 and fuse 28 for conti-nuity and rectify any open circuit.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

- If no open circuit is found, replace fuel pumprelay.

- If the fuel pump relay does not operate, testactuation ⇒ page 24-53.

- If the voltage supply and the actuation areo.k., replace fuel pump relay.

B - Testing voltage supply and actuation offuel pump relay

- Remove fuel pump relay J17 from the elec-trical centre, relay position 4.

Testing voltage supply

- Switch on the ignition.

Warning!

Switch on the relevant measuring range and payattention to the test conditions before connectingthe test cables in order to avoid damaging the elec-tronic components.

- Connect the hand-held multimeter in turn tocontacts 19 (positive) and earth as well asto 17 (positive) and earth of the relay base.

Specification in each case: approx. battery volt-age

24 Fuel Formation/Fuel Injection

Edition 07.98

- If the specifications are not achieved, rectifyopen circuit in wiring.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

Testing actuation

- Connect the diode test lamp to contact 16(earth) and to positive.

- When the starter is operated, the diode testlamp must come on and remain on.

Note:

Diode test lamps with a low current consump-tion do not go out fully but glow weakly until thestarter is operated.

If the diode test lamp does not come on, testthe cable as follows:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Connect the hand-held multimeter betweencontact 16 of the relay base and socket 4 ofthe test box and test the cable connectionfor continuity.

- Rectify any open circuit in the wiring.⇒ Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations binder

- If no open circuit is present and the diodetest lamp does not come on, replace enginecontrol unit ⇒ page 24-69.

- If actuation of the fuel pump relay and thecable connection are o.k., replace fuel pumprelay.

- Re-insert fuse 28.

Fuel Formation/Fuel Injection 24

Edition 07.98

Testing air mass meter

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set V.A.G 1594 A

♦ Current flow diagram

Test conditions

Fuse 43 is o.k.

The coolant temperature is at least 85 °C.

All electrical components are switched off.

Air conditioning system, if fitted to vehicle, isswitched off.

Selector lever of automatic gearbox, if fittedto vehicle, is in position „P” or „N”.

Testing operation

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒ page 01-3; en-gine is idling during this step.

- Read measured value block (function 08)and select display group 003 ⇒ page 01-45.

- Check in display block 3 whether the cool-ant temperature is more than 85 °C.

- Select display group 002.

- Check the inducted air mass in display block 4.

Specification: 1.8...4.0 g/s

Read measured value block 3 →

860 rpm 14 V 90 °C 40 °C

Read measured value block 2 →

860 rpm 1.2 ms 1.7 ms 2 g/s

24 Fuel Formation/Fuel Injection

Edition 07.98

- If the specifications are not achieved or if afault regarding the air mass meter is storedin the fault memory:

- Test the voltage supply of the air mass me-ter ⇒ page 24-56.

Testing voltage supply of air mass meter (G70)

- Test fuse for air mass meter.⇒ Current Flow Diagrams, Electrical Fault

Finding and Fitting Locations binder

- Unplug the 4-pin connector -1- at the airmass meter -2-.

- If the fuse is o.k., connect the multimeter fora voltage measurement to contact 3 of theconnector and to engine earth.

Warning!

Switch on the relevant measuring range and payattention to the test conditions before connectingthe test cables in order to avoid damaging the elec-tronic components.

- Briefly operate the starter (engine may alsostart for a short time); the diode test lampshould come on.

Specification: 11...15 V

- Switch off the ignition.

If the specification is not achieved:

- Test the cable connection from contact 3 ofthe connector to the fuse for open circuit andfor short circuit to earth and rectify if neces-sary.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

- If the fuse and cable connection are o.k., testfuel pump relay ⇒ page 24-52.

If the voltage supply is o.k.:

- Test the signal wires ⇒ page 24-57.

Fuel Formation/Fuel Injection 24

Edition 07.98

Testing signal wire of air mass meter

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test cable connection from the connector atthe air mass meter to the engine control unitfor open circuit and for short circuit to posi-tive and to earth, and repair if necessary:

Contact at 4-pin Test box V.A.Gconnector of air 1598/22, socketmass meter G70

1 2

2 12

4 13

- If the cable connection is o.k., replace theair mass meter (G70).

24 Fuel Formation/Fuel Injection

Edition 07.98

Testing intake system for leaks(unmetered air)

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Engine leak detection spray G 001 800 A1

Test procedure

Notes:

♦ As a result of the vacuum in the intake sys-tem, the leak detection spray is inducted to-gether with the unmetered air. The leak de-tection spray reduces the ignition perform-ance of the fuel mixture which in turn resultsin a drop in engine speed and a change inthe lambda probe readout.

♦ It is essential to observe the safety instruc-tions stated on the can.

- Connect vehicle system tester V.A.G 1552and select engine electronics control unit(address word 01) ⇒ page 01-3; engine isidling for this step.

- Press keys 0 and 8 for the function „Readmeasured value block” and confirm the en-try with the key Q.

- Press keys 0, 0 and 9 for „Display groupnumber 9” and confirm the entry with the keyQ.

Readout in display:(1...4 = display blocks)

- Note the engine speed shown in display block1.

- Note the lambda probe voltage shown in dis-play block 3 and the range within which itvaries.

- Spray the parts of the intake system system-atically with engine leak detection spray.

If there is no change to the engine speed or tothe lambda probe voltage:

- Press the → key.

- Press keys 0 and 6 for the function „Endoutput“ and confirm the entry with the key Q.

Read measured value block 9 →

860 rpm -8% 0.9 V +8%

Fuel Formation/Fuel Injection 24

Edition 07.98

If engine speed drops or if there is a change tothe lambda probe voltage:

- Press the → key.

- Press keys 0 and 6 for the function „Endoutput“ and confirm the entry with the key Q.

- Inspect the sprayed point of the intake sys-tem for leaks and rectify the fault.

Testing lambda control

The lambda probe compares the oxygen con-centration of the air with the residual oxygen inthe exhaust and supplies a voltage signal to thecontrol unit.

The voltage signal „rich mixture (low level ofresidual oxygen)“ is at approx. 0.7...1.0 V (re-lated to reference earth).

The voltage signal „lean mixture (high level ofresidual oxygen)“ is at approx. 0.0...0.3 V (re-lated to reference earth).

A voltage jump from 0.7...1.0 V to 0.0...0.3 Vand vice versa takes place at the transition from„rich mixture“ to „lean mixture“ and vice versa.

In view of the sharp voltage jump, the lambdacontrol is not able to hold constant the ideal mix-ture composition which corresponds to λ = 1.0.

A so-called reference voltage of approx. 0.4...0.5V is programmed in the engine control unit foranalysing the signal supplied by the lambdaprobe. The control constantly fluctuates backand forward between the „slightly too lean“ and„slightly too rich“ states.

The control must operate at least 30 times aminute when an engine at normal operating tem-perature is running at idling speed.

If the voltage does not change, or only sluggishly,the following faults may exist:

♦ Slots or holes in probe head blocked.

♦ The vent hole at the probe in the area of con-nection cable is sealed off.

♦ Probe has been subjected to excessive ther-mal stresses.

♦ The probe has been damaged by leaded fuel.

24 Fuel Formation/Fuel Injection

Edition 07.98

♦ Contact resistance in the signal wire.

♦ Probe too cold, probe heater not operating.

♦ Lambda control switched off (engine controlunit has detected fault at the injection system⇒ Interrogate fault memory and also Readmeasured value block, display group 021).

♦ Probe damaged by contact spray or similarproducts. (The contact spray is drawn intothe probe through the fine cavities in the elec-tric cables as a result of the thermal varia-tions and the capillary effect).

♦ Probe damaged by silicone vapours. (If seal-ants containing silicone are used, traces ofsilicone elements are inducted by the engine.These silicone elements are not combustedand damage the lambda probe).

♦ The lambda probe has been damaged by oilelements escaping from the crankcase ven-tilation or as a result of leaks in the engine.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

Fuel Formation/Fuel Injection 24

Edition 07.98

Testing drivability problems aftercold start

Test condition

No fault regarding lambda control stored;rectify any fault and erase fault memory.

The time which elapses until the control is acti-vated (probe temperature required approx.300 °C) is determined primarily by the followingfactors:

♦ Ambient temperature (summer/winter)

♦ Operating conditions after start

♦ Operation of probe heater

If faults occur after a cold start, it is necessaryto first of all determine whether the problemoccurs prior to or only after the control systemhas been activated.

Test vehicle under cold start conditions:

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒ page 01-3.

- Select the function Read measured valueblock (function 08) and display group 009⇒ page 01-53.

- Now, conduct a road test and check theprobe voltage shown in display block 3.

Read measured value block 9 →

1860 rpm -8% 0.750 V -8%

Read measured value block 9 →

860 rpm -8% 0.5 V -8%

Warning!

Have a 2nd person operate V.A.G 1552.

When the vehicle is cold or when the lambdacontrol is not operated, the voltage must be

0.45...0.50 V.

Once the lambda control is activated, the volt-

age signal in display block 3 should vary be-

tween0.0...1.0 V.

Notes:

♦ Voltage readouts of more than 0.7 V indi-cate a rich mixture composition (low level ofoxygen in exhaust).

♦ Voltage readouts below 0.3 V indicate a leanmixture composition (high level of oxygen inexhaust).

24 Fuel Formation/Fuel Injection

Edition 07.98

Read measured value block 3 →

860 rpm 14 V 90°C 40°C

- If the drivability problem occurs before thelambda control has been activated, thelambda control is not the cause of the prob-lem.

- If the drivability problem does not occur untilafter the lambda control has been activated,test operation of lambda probe ⇒ page 24-62.

Notes:

♦ If a problem is not as bad after the lambdacontrol has been activated, the cause of theproblem (e.g. unmetered air, faulty injector,etc.) is counteracted by activation of thelambda control. This can be recognized byreading the lambda learned values.

- Read measured value block (function 08)and select display group 008 ⇒ page 01-51.If the specifications are not achieved, rectifyfault.

- In addition, read the measured value blockin function 04 (Basic setting). In this functionthe solenoid valve of the activated charcoalfilter -N80 is closed.

♦ It is possible to specifically switch the lambdacontrol off and on using display group 099. Itis possible to switch back and forward be-tween „Basic setting” (lambda control off) and„Read measured value block” (lambda con-trol on) by pressing the keys 4 and 8, re-spectively.

Testing operation of lambda control

Test conditions

Engine control unit adapted to throttle valvecontrol unit ⇒ page 24-72.

Coolant temperature at least 85 °C.

No leak in exhaust system between catalyticconverter and cylinder head.

- Connect vehicle system tester V.A.G 1552and select engine electronics control unit⇒ page 01-3; engine is idling for this step.

- Select function 08 „Read measured valueblock” and display group 003 ⇒ page 01-45.

Readout in display:

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Read measured value block 9 →

860 rpm -8% 0.5 V -8%

Do not continue the test until the coolant tem-perature in display block 3 is at least 80 °C.

- Press key C.

- Press keys 0, 0 and 9 for „Display groupnumber 009” and confirm the entry with thekey Q.

Readout in display:

- Check the lambda probe voltage in displayblock 3. The voltage should vary at least 30times a minute within the range from 0...1.0 V.

If the lambda control does not vary within thestated range:

- Clear lambda probe using a road test andrepeat the test.

If the specification is again not achieved:

- Test lambda probe heater ⇒ page 24-65.

- Analyse the measured value blocks 007 to009 ⇒ page 01-50.

- If the voltage change takes place moreslowly, the following faults are possible:

♦ The slots or holes in the probe head areblocked.

♦ The vent hole at the probe in the area of theconnection cable is sealed off.

♦ The probe has been subjected to excessivethermal stresses (glazed).

♦ The probe has been damaged by leaded fuel.

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- If the lambda probe voltage remains con-stant, the following faults are possible:

Read measured value block 8 →

2 ms -0.7 % -0.5 % TB active

Readout Cause Continue test

between Open circuit ⇒ page 24-67,0.4...0.5 V Test base volt-

age

1.1 V Short circuit ⇒ page 24-68,to positive Test lambda

0.00 V Short circuitprobe cable

to earth

0.0...0.3 V Mixture too leanMixture control moved against con-trol stop in direction of „richer mix-ture”, but lambda probe still detects”mixture too lean”

0.7...1.0 V Mixture too richMixture control has moved againstcontrol stop in direction of „leanermixture”, but lambda probe still de-tects „mixture too rich”

- Press the key C.

- If the lambda probe is operating properly,check lambda learned values.

- Select display group 008 and confirm theentry with the key Q.

Readout in display:

The mixture adaptation is adaptive, in other wordsit is able to „learn” differences between enginecylinders (nozzle flow, compression, fuel pressure,etc.) through the lambda control and to compen-sate for these by adapting the basic injection timesprogrammed in the map. The injection times areextended or shortened until a mixture of λ = 1 isachieved. The variation of the actual injection timefrom the basic injection time programmed in themap is stated in %.

♦ Positive learned value (+...%): Programmedbasic injection time too short, actual injec-tion time extended by ...% so that λ = 1 isachieved.

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♦ Negative learned value (-...%): Programmedbasic injection time too long, actual injectiontime shortened by ...% so that λ = 1 isachieved.

Specifications: ⇒

page 01-51.

Testing lambda probe heater

- The heating circuit of the lambda probe ismonitored by the self-diagnosis.

- Interrogate fault memory ⇒

page 01-5.

Test conditions

Fuse 43 is o.k.

Battery voltage is at least 11.5 V.

Fuel pump relay is o.k.

Test procedure

- Unscrew the protective cover -arrows- andseparate the 4-pin plug connection (black)to the lambda probe upstream of the cata-lytic converter (G39).

- Conduct a continuity test (resistance meas-urement) between contacts 1 and 2 of theprobe connector.

Warning!

Switch on the relevant measuring range beforeconnecting the test cables and pay attention to thetest conditions in order to avoid damaging the elec-tronic components.

Note:

At room temperature the resistance of the heat-ing element is approx. 1...5 . The resistancerises sharply as soon as there is a slight rise intemperature.

- If an open circuit is found, replace lambdaprobe (G39).

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If the heating element has continuity, test volt-age supply for lambda probe heater as follows:

- Set the multimeter to voltage measurementand connect it to contacts 1 + 2 of the con-nector to the control unit.

- Briefly operate the starter (engine may alsostart for a short time).

Specification: 11...15 V

If the specification is not achieved:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test the cable connection from contact 2 ofthe connector at the wiring loom (earth ca-ble) to contact 27 at engine control unit forcontinuity and rectify any open circuit.

- Test the cable connection from contact 1 ofthe connector at the wiring loom to the fusefor open circuit and for short circuit to earth,and repair if necessary.

If the cable connections are o.k.:

- Test the cable connection from contact 1 tothe fuel pump relay (J17) according to thecurrent flow diagram.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

- Test fuel pump relay ⇒ page 24-52.

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Testing basic voltage

- Unscrew protective cover -arrows- and sepa-rate the 4-pin plug connection (black) to thelambda probe upstream of the catalytic con-verter (G39).

- Switch on the ignition.

- Conduct a voltage measurement betweencontacts 3 and 4 of the connector at the wir-ing loom.

Specification: 0.40...0.50 V

- Switch off the ignition.

If the specification is not achieved:

- Test the lambda probe cables ⇒ page 24-68.

If the specification is achieved:

- Replace the lambda probe (G39).

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Testing lambda probe cables

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test the following cable connections for opencircuit, short circuit to positive and to earth,and repair if necessary:

Connector at wiring Test box V.A.Gloom, contact 1598/22, socket

3 25

4 26

- If no fault is found in the wiring, replace en-gine control unit ⇒ page 24-69.

Removing and installing lambdaprobe

Special tools, testers and aids required

♦ Wrench for lambda probe e.g. 3337

♦ Assembly paste e.g. G 052 112 A3

Removing

- Unscrew the protective cover -arrows- andseparate the 4-pin plug connection (black)to the lambda probe upstream of the cata-lytic converter.

- Unscrew the lambda probe, using e.g. 3337.

When installing, pay attention to the followingpoints:

Notes:

♦ Tightening torque 50 Nm.

♦ Coat the thread of the lambda probe withassembly paste e.g. G 052 112 A3. Thispaste must not get into the openings of theprobe.

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Replacing, coding and adapt-ing engine control unit

Replacing engine control unit

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

Note:

When the connectors are unplugged from theengine control unit, the learned values areerased but the contents of the fault memory areretained.

- Connect vehicle system tester V.A.G 1552and select engine electronics control unit⇒ page 01-3.

- Enter control unit identification.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

Removing

- Switch off the ignition.

- Unscrew the windscreen wiper arms andremove the cover of the plenum chamber.

Notes:

♦ When removing the cover, detach the hoseand the connector for the spray nozzles.

♦ In order to connect test box V.A.G 1598/22which is required for testing the components,release the connector catches and unplugthe control unit connectors.

- Release the connector catches and unplugthe control unit connectors.

- Use a screwdriver to push the catch of thefixture to the side and pull the engine controlunit forward.

Installing

Installation is carried out in the reverse order.

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Notes:

♦ During the initial learning phase of enginebasic setting, slightly irregular idling as wellas slight jerking when driving are possible.

♦ The following steps must be carried out af-ter installing the engine control unit:

- After completing the work, interrogate thefault memory of the new engine control unitand erase the fault memory if necessary.

- Perform coding of the new engine control unit⇒ page 24-70.

- Adapt engine control unit to the throttle valvecontrol unit (J338) ⇒ page 24-72.

- Adapt engine control unit to the electronicimmobiliser ⇒ page 24-71.

- Perform the idling speed test ⇒ page 24-13.

Coding engine control unit

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

If the code which is displayed does not corre-spond to the vehicle or if the control unit hasbeen replaced, it is then necessary to code thecontrol unit as follows:

- Connect vehicle system tester V.A.G 1552and select engine electronics control unit⇒ page 01-3; the engine should be switchedon for this step.

Readout in display:

- Select function 07 „Code control unit” andconfirm the entry with the key Q.

Readout in display:

- Enter the relevant code number for this ve-hicle and confirm the entry with the key Q.

Test of vehicle systems HELPSelect function XX

Code control unit QEnter code number xxxxx (0-32000)

Code number For models with

04030 Automatic gearbox

04000 Manual gearbox

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The control unit identification appears in the dis-

play of the vehicle system tester V.A.G 1552,

e.g.:

- Switch off the ignition and switch it on again.

Note:

The coding entered is activated when the igni-tion is next switched on.

- Press the → key.

Readout in display:

- Press the keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

Adapting engine control unit toelectronic immobiliser

Special tools, testers and aids required♦Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

Test condition

Authorized car key available

Procedure

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒

page 01-3.

- Switch on the ignition.

- Press keys 1 and 7 for the address word„Dash panel insert” and confirm the entry withthe key Q.

- Press the → key.

Readout in display:

- Press the → key.

Readout in display:

- Press the → key.

Readout in display:

- Press keys 1 and 0 for the function „Adapta-tion” and confirm the entry with the key Q.

06A906018CF 1.8l R4/5VT MOTR HS D03 →

Coding 04000 WSC 06388

Test of vehicle systems HELPSelect function XX

Test of vehicle systems HELPSelect function XX

IMMO-IDENTNR: AUZXXXXXXXXXX →

8L0919860. AB-KOMBIINSTR. VDO... →

Coding XXXXX WSC 12345

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Readout in display:

- Press the key 0 twice for „Channel number0” and confirm the entry with the key Q.

Readout in display:

- Confirm the entry with the key Q.

Readout in display:

- Complete adaptation by pressing the → key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

Note:

When the ignition is next switched on, the iden-tification of the engine control unit is entered inthe immobiliser control unit.

Adapting engine control unit tothrottle valve control unit

Special tools, testers and aids required♦Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

When adaptation is performed, with the ignitionswitched on and the engine not running, theengine control unit learns the stop positions ofthe throttle valve control unit and a comparativecurve between throttle valve potentiometer andthrottle valve positioner sender.

Adaptation must be performed if:♦the supply voltage has been interrupted♦the throttle valve control unit (J338) has beenremoved and installed♦the throttle valve control unit (J338) has beenreplaced.

AdaptationEnter channel number XX

Adaptation QErase learned values?

Adaptation →

Learned values are erased

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Test conditions

No fault stored in fault memory⇒ page 01-5, Interrogating fault memory

Battery voltage is at least 11.5 V

All electrical components such as lights andrear window heater are switched off

The throttle valve is in the idling position

The setting of the cruise control system, iffitted, is correct

Procedure

- Connect vehicle system tester V.A.G 1552and select engine electronics control unit withthe address word 01 ⇒ page 01-3; the igni-tion should be switched on for this step.

Readout in display:

- Press key 0 and 4 for the function „Initiatebasic setting” and confirm the entry with thekey Q.

Readout in display:

- Press the keys 0, 9 and 8 for „Display groupnumber 98” and confirm the entry with thekey Q.

Readout in display:

After the key Q is pressed, the throttle valvepositioner moves to the Min., Max. and to fiveintermediate positions and the control unit storesthe particular throttle valve angle in the perma-nent memory. This procedure takes not morethan 10 seconds. After this, the throttle valveremains in the start position for a short time andthen closes.

Readout in display:

If one of the following messages appears in the

display, adaptation has been aborted.System in basic setting 98→

2.20 V 2.80 V Idling ADP ERROR

System in basic setting 98→2.20 V 2.80 V Idling ADP. O.K.

System in basic setting 98→2.20 V 2.80 V Idling ADP. runs

Basic setting HELPEnter display group number XXX

Test of vehicle systems HELPSelect function XX

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Notes:

If the basic setting has been aborted by the con-trol unit, this may be caused by one of the fol-lowing points:

♦ The throttle valve does not reach the me-chanical idling speed stop because of dirt,e.g. oil carbon deposits or an incorrectly setthrottle cable.

♦ The battery voltage is too low.

♦ The throttle valve control unit or a cable con-nection is faulty.

After the basic setting has been aborted, fault„17967 or 17973” is entered in the fault memory.The next time the ignition is switched on, thebasic setting is once again performed automati-cally.

- End adaptation by pressing the →

key.

- Check the specifications of the throttle valvecontrol unit in display group 023 ⇒ page01-62, Analysing measured value blocks. Ifthe specifications are not achieved, repeatadaptation.

- Interrogate fault memory (function 02) ⇒

page01-5.

- If no fault is detected, check whether theidling speed switch opens and closes whenthe accelerator is operated ⇒ page 24-22,Testing idling speed switch.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

Performing basic setting of enginecontrol unit

The following operation can be carried out withthe basic setting when the engine is not run-ning:

♦ Adaptation of throttle valve control unit toengine control unit ⇒ page 01-66, Displaygroup 098.

The following operations can be carried out withthe basic setting when the engine is running:

♦ Learning process of lambda control⇒ any display group

♦ Fault finding by specifically switching lambdacontrol on and off ⇒ page 01-67, Displaygroup 099

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Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

Test conditions for operations when enginerunning

Coolant temperature at lest 80 °C.

Electrical components switched off (radiatorfan must not run during the test).

Air conditioning switched off.

Selector lever in position P or N.

No fault stored in fault memory.

- Connect vehicle system tester V.A.G 1552and select the engine electronics control unitwith address word 01 ⇒ page 01-3. The ig-nition should be switched on for this step.

Readout in display:

- Press keys 0 and 4 for the function „Basicsetting” and confirm the entry with the keyQ.

Readout in display:

- Select the desired display group numberfrom the list of display groups in „Readingmeasured value block”.

Note:

Display group number 001 is an example forpresenting the sequence.

- Enter 001 for the function „Display groupnumber 01”.

- Confirm the entry with the key Q.

Readout in display:

Test of vehicle systems HELPSelect function XX

Basic setting HELPEnter display group number XXX

System in basic setting 1 →

1 2 3 4

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Notes:

♦ In the case of display group number 000, themeasured values are shown in decimal form.

♦ Each time the PRINT key is pressed (onV.A.G 1551), the current readout in the dis-play is printed out.

♦ Press key C before selecting further displaygroups.

- If the specifications are achieved in all thedisplay blocks, press the →

key.

Readout in display:

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

Test of vehicle systems HELPSelect function XX

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Testing additional signals

Testing signals from to air condi-tioning

AC compressor signal:Voltage is supplied to the engine control unit justbefore the AC compressor switches on. Theeffect of the signal is that the engine control unitmaintains a constant idling speed even if thepower demanded by the air conditioning sys-tem varies.

AC compressor cut-off:The AC compressor is switched off by the en-gine control unit for about 6 seconds when ac-celerating from a standing start and from a lowspeed (1st gear) to ensure that full engine poweris available for accelerating. If the acceleratorpedal is released before this time, the time isreduced to at least 3 seconds. The AC compres-sor is switched off by the gearbox control unit(kickdown switch) at full throttle.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

Test conditions

Air conditioning operating properly

Air conditioning is switched off

No fault stored in fault memory of enginecontrol unit

Interior temperature higher than +15 °C

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒ page 01-3; en-gine should be idling for this step.

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- Read measured value block (function 08)and select display group 020 ⇒ page 01-61.

Readout in display:

Specification in display block 4: Compr. OFF

- Switch on the air conditioning.

- Set the lowest temperature and the highestblower speed.

Specification in display block 3: A/C-High

Specification in display block 4: Compr. ON

The compressor should run.

- Depress the accelerator suddenly and re-lease it again (brief blip of throttle).

When the accelerator is depressed rapidly, thereadout in display block 4 must jump from „ON“to „OFF“ for a few seconds (compressor switchedoff when vehicle accelerated).

- Press the →

key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

If the readout does not change:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test the cable connection from contact 8 ofengine control unit to contact 3 at the radia-tor fan control unit (J293) for short circuit toearth and to positive and also for open cir-cuit according to the current flow diagram.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

- If there is no fault in the cable connection,replace the radiator fan control unit (J293).

⇒ Heating and Air Conditioning; Repair Group87.

Read measured value block 20→

860 rpm Neutral A/C-High Compr. OFF

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Read measured value block 20 →

860 rpm Neutral A/C-High Compr. OFF

Testing engine speed adaptation byswitching on air conditioning

Notes:♦When the air conditioning is switched on, apositive signal is supplied to contact 10 ofthe engine control unit.♦The effect of this signal is that the enginecontrol unit maintains a constant idling speedeven if the power demanded by the air con-ditioning system varies.

Special tools, testers and aids required♦Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3♦Test box V.A.G 1598/22♦Hand-held multimeter e.g. V.A.G 1526 A♦Diode test lamp e.g. V.A.G 1527♦Adapter cable set e.g. V.A.G 1594 A♦Current flow diagram

Test conditions

Engine warmed up to operating temperature

Air conditioning operating properly

No fault stored in fault memory of the airconditioning

Interior temperature higher than +15 °C

All electrical components switched off

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒ page 01-3; en-gine should be idling for this step.

- Read measured value block (function 08)and select display group 020.

Readout in display:

Display block 1: idling speed

Display block 3: signal from air conditioning

Display block 4: signal from AC compressor

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- Switch on the air conditioning with the „Auto”button. The compressor should run.

Specification in display block 4: Compr. ON

Specification in display block 3: A/C-High

Apart from a short drop in engine speed (lessthan one second) idling speed should remain ata constant level.

If idling speed is not maintained at a constantlevel, test whether the signal from the air condi-tioning system is received at the engine controlunit.

- If the signal is not received, switch off theengine and connect test box V.A.G 1598/22to the wiring loom to the engine control unit⇒ page 24-69, Replacing engine control unit.

- Test the cable connection from contact 8 ofthe engine control unit to contact 3 at theradiator fan control unit (J293) for short cir-cuit to earth and to positive and also for opencircuit on the basis of the current flow dia-gram.

- If there is no fault in the cable connection,replace the radiator fan control unit (J293).

⇒ Heating and Air Conditioning; Repair Group87.

Testing selector lever position ofautomatic gearbox

The engine control unit is supplied with the fol-lowing information from the gearbox control unit:

-gear engaged (selector lever in 2/3/4/R/D)or-no gear engaged (selector lever in P or N)

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Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter V.A.G 1526 A

♦ Diode test lamp V.A.G 1527

♦ Adapter cable set V.A.G 1594 A

♦ Current flow diagram

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒ page 01-3.

- Switch on the ignition.

- Read measured value block (function 08)and select display group 020 ⇒ page 01-61.

Readout in display:

Specification in display block 2: „Neutral“ (se-lector lever in P or N)

- Press the brake pedal and engage a gear.

Specification: „Gear ENG”

If the readout does not change:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test the cables between test box sockets29 + 41 and the automatic gearbox for opencircuit according to the current flow diagram.

- If no fault is found in the cable connection,test multifunction switch

⇒ Automatic Gearbox; Repair Group 01; Gear-box: Electrical Test.

Read measured value block 20 →

860 rpm Neutral A/C-High Compr. OFF

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Read measured value block 1 →900 rpm 1.5 ms 5 ∠

° 12° BTDC

Testing engine speed signal

Note:

The engine speed signal is output at contact 6of the engine control unit. This signal is neces-sary for various systems including the rev coun-ter indication in the dash panel insert and theoperation of other control units.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

- Connect vehicle system tester V.A.G 1552with cable V.A.G 1551/3 ⇒

page 01-3.

- Read measured value block display group001 ⇒

page 01-41; engine should be idlingfor this step.

- Check readout in display block 1.

- Briefly blip throttle.

Specification: The current engine speed mustbe displayed (even over entire engine range).This readout must agree with the speed indi-cated at the rev counter.

If the specification is not achieved:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒

page24-69, Replacing engine control unit.

- Test cable connection from contact 6 of thetest box to the dash panel insert for opencircuit according to the current flow diagram.⇒Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

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Testing cruise control system (CCS)

The CCS does not have any separate compo-nents - with the exception of the operating switch.All the functions are performed by the engine con-trol unit.Minimum vehicle speed for operation of the CCSis 30 km/h.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Test box V.A.G 1598/22

♦ Current flow diagram

Test procedure

- Connect vehicle system tester V.A.G 1552and select engine electronics control unit⇒ page 01-3. The engine should be idlingfor this step.

- Select function 08 „Read measured valueblock” and confirm the entry with the key Q.

- Select display group 066 ⇒ page 01-65.

- Readout in display:

- Check the readout in display block 2.

Specification: 1xxx

If the specification in display block 2 is notachieved with „CCS activated”:

- Replace engine control unit ⇒ page 24-69.

Read measured value block 66 →0 km/h 1000 0 km/h 0000

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Read measured value block 66 →0 km/h 1000 0 km/h 0000

- Check the readout in display block 4:

Test conditions Display Displayblock 2 block 4

CCS activated 1000 -

Clutch pedal depressed 1110 -

Brake pedal depressed 1111 -(brake pedal switch)

Brake pedal depressed 1111 -(brake light switch)

Switch B to „ON” - 0000

Switch B to „RES” - 1000

Switch A pressed - 0100

Switch B to „OFF”, - 0010before switch-on point

Switch B to „OFF”, - 0011locked

If the specification in display block 4 is notachieved although switch B is set to „ON”:

- Press the → key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

- Connect test box V.A.G 1598/22 to the wir-ing loom of the control unit.

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- Test the cable connection from the enginecontrol unit to the operating switch of the CCSfor open circuit and short circuit to earth.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

If no fault is found in the wiring:

- Replace the operating switch of the CCS⇒ Electrical System.

Testing vehicle speed signal

Notes:

♦ The vehicle speed signal is produced by thevehicle speed sender -G68 and is processedin the dash panel insert.

♦ The processed signal passes to contact 20of the engine control unit and is used for idlingspeed stabilisation and for minimising loadchange jolts during gearshifts.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Diode test lamp e.g. V.A.G 1527

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

Test conditions

Battery voltage is at least 11.5 V.

The speedometer is operated properly.

Test procedure

- Connect fault reader ⇒ page 01-3 and se-lect the engine control unit. Engine shouldbe idling for this step.

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- Read measured value block (function 08)and select display group 011 ⇒ page 01-56.

Warning!

Have a second person operate V.A.G 1552.

- Conduct a road test and check the vehiclespeed signal in display block 3.

Specification: approx. vehicle speed

- Press the →

key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

- If the vehicle speed is not displayed, raisefront left of vehicle until the wheel is clear ofthe ground.

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Connect the diode test lamp between socket3 (positive) and socket 20 (signal).

- Switch on the ignition.

- Rotate the left front wheel by hand.

Note:

The right front wheel must not rotate; hold tightif necessary.

- The diode test lamp should flash (very shortflashing signal).

- If the diode test lamp does not flash, test thecable connection from contact 20 at the con-nector of the engine control unit to the dashpanel insert for open circuit and short circuit.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

Read measured value block 11→

1860 rpm 1.5 ms 72 km/h 1.5 l/h

Fuel Formation/Fuel Injection 24

Edition 07.98

Testing ignition angle retardationduring gearshift

Only for models with automatic gearbox

Notes:

♦ When this signal is supplied by the gearboxcontrol unit, the ignition angle is retarded toa varying extent during a gearshift of theautomatic gearbox (torque reduction), de-pending on vehicle speed and engine speed,in order to minimise the gear change jolt.

♦ In view of the very brief signal, V.A.G 1552does not always detect the request to retardthe ignition angle.

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

- Connect fault reader ⇒ page 01-3 and se-lect the engine control unit. Engine shouldbe idling for this step.

- Read measured value block (function 08)and select display group 019 ⇒ page 01-60.

- Check the readout in display block 3 (3rd

position from the left).Specification: xx1x__x.

- Conduct a road test and check the readoutin display block 3 (3rd position from the left).During a gearshift the following readoutshould be briefly displayed:Specification: xx0x__x.

Read measured value block 19 →

860 rpm 8.5 ms xx1x__x 5° BTDC

Warning!

Have a second person operate V.A.G 1552.

24 Fuel Formation/Fuel Injection

Edition 07.98

Note:

In view of the fact that the signal supplied by theautomatic gearbox is very short, it may be nec-essary to observe the signal during several gearchanges until the readout in display block 3jumps from 1 to 0.

- Press the → key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

If the readout does not change:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test the cables between test box sockets 29and 41 and the automatic gearbox for opencircuit and short circuit according to the cur-rent flow diagram.

Testing a „two-line bus system”

- Refer to the appropriate current flow diagramto determine how many control units are con-nected to the CAN (Controller Area Network)bus.

- Check the multi-pin connectors of the con-trol units to ensure they are properly con-nected.

- Connect fault reader V.A.G 1552 and presskey 0 twice for the function „Automatic testsequence”.

Before examining the bus lines, ensure thatthere is no operational fault at any of the controlunits connected to the bus.

If an operational fault exists, repair this first ofall.

- Note the faults and erase the fault memo-ries of all the control units.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

Fuel Formation/Fuel Injection 24

Edition 07.98

- Repair the operational faults by referring tothe fault table in the appropriate workshopmanuals.

If all the operational faults have been rectifiedand there is still a problem with communicationof control units, it is then necessary to inspectthe bus wires.

- Switch off the ignition.

- Unplug the connectors of the control unitslinked by the bus wires and examine the buswires to determine whether a short circuit ispresent.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

- Examine the bus wires to determine whetherthere is a short circuit to positive or to earth.

If it is not possible to determine any cause forthe fault „Hardware defect” in the bus wires,examine the control units to determine whetherone of these is responsible for this fault.

At this stage, plug connections of the controlunits which use the CAN bus for communica-tion, are still disconnected. The ignition isswitched off.

- Connect one of the control units.

- Connect fault reader V.A.G 1552.

- Switch on the ignition and erase the faultmemory of the control unit you have just con-nected.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition and on again.

- Leave the ignition switched on for 10 sec-onds. After this, read the fault memory of thecontrol unit you have just connected with thefault reader V.A.G 1552.

- If the fault „Hardware defect” is present, re-place the control unit you have just con-nected.

- If the fault „Hardware defect” is not present,connect the next control unit and repeat thetest procedure.

24 Fuel Formation/Fuel Injection

Edition 07.98

Testing signal from power steeringpressure switch

Special tools, testers and aids required

♦ Fault reader V.A.G 1552 with cable V.A.G1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Current flow diagram

- Connect fault reader ⇒ page 01-3 and se-lect the engine control unit. Engine shouldbe idling for this step.

- Read measured value block (function 08)and select display group 019 ⇒ page 01-60.

- Check the readout in display block 3 (1st

position from the left).Specification: 1xxx__x.

- Turn the steering wheel to full lock and checkthe readout in display block 3 (1st positionfrom the left).Specification: 0xxx__x.

- Press the → key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

If the specification is not achieved:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Separate 2-pin connector from the powersteering pressure switch.

Read measured value block 19 →

860 rpm 8.5 ms 1xxx__x 5° BTDC

Fuel Formation/Fuel Injection 24

Edition 07.98

- Test the following cable connections for opencircuit and for short circuit to earth or posi-tive, and repair if necessary.

Connector at cable Test box, socketsconnection, contact

1 49

2 14

- If no fault is found in the wiring, connect themultimeter to the contacts of the pressureswitch.

- Leave engine running at idling speed.

- Test the pressure switch for continuity.Specification: ∞ Ω

- Turn the steering wheel to full lock.Specification: Pressure switch should

switch to continuity.

If the specification is not achieved:

- Replace pressure switch.

If the specification is achieved:

- Replace engine control unit ⇒ page 24-69.

Testing signal from clutch pedalswitch

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Current flow diagram

- Connect the fault reader. Then, switch on theignition and select the engine control unitwith the address word 01 ⇒ page 01-3.

24 Fuel Formation/Fuel Injection

Edition 07.98

- Read measured value block (function 08)and select display group 019 ⇒ page 01-60.

- Check the readout in display block 3 (4th

position from the left).Specification: xxx1__x.

- Depress clutch pedal fully and check thereadout in display block 3 (4th position fromthe left).

Specification: xxx0__x.

- Press the →

key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

If the specification is not achieved:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Separate the connector from the clutch pedal-1-.

- Test the following cable connections for opencircuit and for short circuit to earth or posi-tive, and repair if necessary.

Connector at cable Test box, socketconnection, contact

2 9

If the specification is not achieved:

- Test the cable between contact 1 of the 2-pinconnector and the fuel pump relay accord-ing to the current flow diagram.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

Read measured value block 19→

860 rpm 8.5 ms xxx1__x 5° BTDC

Fuel Formation/Fuel Injection 24

Edition 07.98

Testing signal from brake pedalswitch and brake light switch

Special tools, testers and aids required

♦ Vehicle system tester V.A.G 1552 with cableV.A.G 1551/3

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Current flow diagram

Only for models with cruise control system(4-pin switch)

- Connect the fault reader. Then, switch on theignition and select the engine control unit withthe address word 01 ⇒ page 01-3.

- Read measured value block (function 08)and select display group 066 ⇒ page 01-65,and confirm the entry with the key Q.

- Check the readout in display block 2 (4th

position from the left).Specification: 1110.

- Depress the brake pedal and check thereadout in display block 2 (4th position fromthe left).

Specification: 1111.

- Press the → key.

- Press keys 0 and 6 for the function „Endoutput” and confirm the entry with the key Q.

- Switch off the ignition.

If the specification is not achieved:

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

Read measured value block 66 →0 km/h 1110 0 km/h 0000

24 Fuel Formation/Fuel Injection

Edition 07.98

- Unplug connector from the brake pedal -2-.

- Test the following cable connections for opencircuit and for short circuit to earth or posi-tive, and repair if necessary.

Connector at cable Test box, socketsconnection, contact

3 48

2 47

If the specification is achieved:

- Test contacts 1+2 between the 4-pin connec-tor and the fuel pump relay according to thecurrent flow diagram.

⇒ Current Flow Diagrams, Electrical FaultFinding and Fitting Locations binder

Only for models without cruise control sys-tem (2-pin switch)

- Unplug connector from brake pedal -2-.

- Test the cable between contact 1 of the con-nector (red/brown cable) and fuse 13 for opencircuit according to the current flow diagram.

- Test the cable between contact 2 of the con-nector (red/black cable) and the brake lightsfor short circuit and for open circuit accord-ing to the current flow diagram.

- Repair any faults in the wiring or replacebrake pedal switch, respectively.

If no fault is found in the wiring:

- Test the operation of the brake pedal switchwith the multimeter.

- Replace a faulty brake pedal switch.

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Ignition System 28

Edition 07.98

Test conditions

Battery voltage at least 11.5 V

Engine speed sender o.k.; testing ⇒ page24-34

Hall sender o.k.; testing ⇒ page 28-10

Fuse 29 o.k.

Earth connection o.k. ⇒ page 28-2, item 6.

Testing actuation of power output stage

- Unplug the connectors from the injectors.

- Unplug the 5-pin connector -1- from thepower output stage for the ignition coils -2-.

- Connect the diode test lamp to contacts 1 + 3using auxiliary cables from V.A.G 1594.

- Operate the starter and test the ignition sig-nal from the engine control unit.

The LED should flicker.

- Repeat the test between contacts 2, 4, 5+ contact 3 (earth).

If the LED does not flicker:

- Test the wiring to the engine control unit⇒ page 28-6.

Testing power output stage

- Plug in the 5-pin connector again at thepower output stage.

- Unplug the 4-pin connector -1- from the out-put stage for the ignition coils -2-.

28 Ignition System

Edition 07.98

- Connect the diode test lamp to contact 1 ofthe output stage and to battery + using aux-iliary cables from V.A.G 1594.

- Operate the starter.The LED should flicker.

- Repeat the test at contacts 2, 3 and 4.

If the LED does not flicker:

- Replace the power output stage ⇒ page28-2, item 2.

Testing ignition coils

- Switch on the ignition.

- Connect the diode test lamp to contact 1 ofthe 4-pin connector and to battery + usingauxiliary cables from V.A.G 1594.

The LED should come on.

- Repeat the test at contacts 2, 3 and 4.

If the LED does not come on at one of the con-tacts:

- Test the cable between the 4-pin connectorand the corresponding connector (contact 1)of the ignition coil for open circuit accordingto the current flow diagram.

Cable resistance: max. 1.5

If no fault is found in the cable:

- Replace the appropriate ignition coil.

Testing wiring

- Switch on the ignition.

- Connect the test box V.A.G 1598/22 to thewiring loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

Ignition System 28

Edition 07.98

- Test the cables between test box and 5-pinconnector for open circuit according to thecurrent flow diagram.

Contact at 5-pin Test box V.A.Gconnector of power 1598/22, socket

output stage

1 772 703 24 785 71

Specification: max. 1.5 Ω

- Rectify any open circuit in the wiring or shortcircuit.

If no fault is found in the wiring:

- Replace engine control unit ⇒ page 24-69.

Testing knock sensors

Special tools, testers and aids required

♦ Test box V.A.G 1598/22

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

Notes:

♦ For testing the operation of the knock sen-sors, read measured value block, displaygroups 013, 014, 015 and 024.

♦ The knock sensors themselves can be testedelectrically (interrogate fault memory ⇒ page01-5).

♦ It is essential to exactly adhere to the tight-ening torque of 20 Nm to ensure proper op-eration of the knock sensors.

♦ Inspect plug connection for corrosion.

♦ Only gold-plated contacts may be used forrepairing the contacts in the plug connectionof the knock sensors.

28 Ignition System

Edition 07.98

Test condition

A fault at one or both knock sensors musthave been detected by the self-diagnosis.

Testing operation

- Operational test of the knock control systemand of the knock sensors ⇒ page 01-57,Reading measured value block, displaygroups 013 to 016 and 24.

Testing resistance and wiring

- Unplug the 3-pin connector to the knock sen-sor 1 (G61) -1-.

- Measure the resistance between contacts1+2, 1+3 and 2+3 at the connections to theknock sensors and test for short circuit toeach other.

Specification: ∞ - Unplug the 3-pin connector to the knock sen-

sor 2 (G66) -1-.

- Measure the resistance between contacts1+2, 1+3 and 2+3 at the connections to theknock sensors and test for short circuit toeach other.

Specification: ∞ - Connect test box V.A.G 1598/22 to the wir-

ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

Ignition System 28

Edition 07.98

- Test the wiring between test box and 3-pinconnector for open circuit according to cur-rent flow diagram.

Knock sensor 1

Contact at 3-pin Test box V.A.Gconnector of knock 1598/22, socket

sensor 1

1 (signal) 682 (earth) 673 (screening) 67

Knock sensor 2

Contact at 3-pin Test box V.A.Gconnector of knock 1598/22, socket

sensor 2

1 (signal) 602 (earth) 673 (screening) 67

- In addition, test wiring at socket 67 for shortcircuit to sockets 60 and 68.

Specification: ∞ Ω

If no fault is found in the wiring:

- Slacken the knock sensor and tighten it againto 20 Nm.

- Conduct a road test.

The following operating conditions must be metduring this road test:

Coolant temperature must rise to more than80 °C.

Once the temperature is reached, the follow-ing operating states must be achieved sev-eral timesidling speedpart throttlefull throttle enrichmentfuel shut-off on overrun.

Engine speed must have increased to morethan 3500 rpm at full throttle.

Once again interrogate the fault memory of thecontrol unit. If the fault is still present:

- Replace the knock sensor(s).

28 Ignition System

Edition 07.98

Testing Hall sender

Special tools, testers and aids required

♦ Test box V.A.G 1598/22

♦ Diode test lamp e.g. V.A.G 1527

♦ Hand-held multimeter e.g. V.A.G 1526 A

♦ Adapter cable set e.g. V.A.G 1594 A

♦ Current flow diagram

Test condition

Battery voltage is at least 11.5 V.

Notes:

♦ In normal operation, the engine control unitdetects the ignition position of cylinder 1 fromthe Hall sender signal.

♦ Because it is no longer possible to determinethe cylinder assignment of the knock sensorsignals if no signal is received from the Hallsender, the knock control system is switchedoff and the ignition angle is retarded slightlyto reliably avoid any knocking.

♦ If no signal is received from the Hall sender,the engine continues running and can alsobe started again for the following reasons:

♦ Ignition offset by one engine revolutiondoes not have any perceptible effect onfuel injection. Fuel injection takes place„advanced” (upstream of the closed inletvalve) when the inlet valve opens. As aresult there is only a slight effect on thequality of the mixture formation.

- Unplug the 3-pin connector -1- of the Hallsender -2-.

- Connect the hand-held multimeter to contact1 (positive) and 3 (earth) of the connector ofthe Hall sender.

- Switch on the ignition.

Specification: min. 4.5 V

- Switch off the ignition.

Ignition System 28

Edition 07.98

- Connect test box V.A.G 1598/22 to the wir-ing loom to the engine control unit ⇒ page24-69, Replacing engine control unit.

- Test the wiring between test box and 3-pinconnector for open circuit according to cur-rent flow diagram.

Contact at 3-pin Test box V.A.Gconnector of Hall 1598/22, socket

sender

1 (signal) 622 (earth) 763 (screening) 67

Specification: max. 1.5 - In addition, test the cables for short circuit to

each other.

Specification: ∞ If no fault is found in the wiring and if voltagewas present between contacts 1+3:

- Erase fault memory ⇒ page 01-5.

- If a fault relating to the camshaft sensor (Hallsender) is again displayed after erasing thefault memory as a check, although all theprevious tests were o.k., the following faultis possible:

- Rotor orifice plate for Hall sender twisted.

- Unbolt Hall sender and inspect whether therotor orifice plate to camshaft is correctly in-stalled (if incorrectly installed, the detent lugis flattened when the bolt is tightened).

- If the installation of the rotor orifice plate iso.k., check assignment of crankshaft/cam-shaft.

⇒ 1.8-ltr./110 kW Engine, Mechanical Compo-nents; Repair Group 15, Removing and in-stalling cylinder head

Note for signal test with oscilloscope:

The middle of the Hall window must be posi-tioned on the third descending slope of the en-gine speed signal after the reference mark gap.

28 Ignition System

Edition 07.98

If the specification is not achieved:

- Replace the Hall sender.

- If the specification is achieved and a faultrelating to the Hall sender is again displayedin the fault memory:

- Replace engine control unit ⇒ page 24-69.

If no fault is found in the wiring and if voltagewas present between contacts 1+3:

- Replace engine control unit ⇒ page 24-69.