Fuel Injection Aua,Aub,Bby,Bbz,Bky
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5
Service
Workshop Manual FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Edition 08.99 Engine code
AUA AUB BBY BBZ BKY
Service Department. Technical Information
Printed in Czech Republic S00.5309.00.20
5
The Workshop Manual is intended only for use within the Organisation Škoda. It is not permitted to pass it on to other persons. © ŠKODA AUTO a. s.
Service
Printed in Czech Republic S00.5309.00.20
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
List of Supplements to Workshop Manual
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Edition 08.99 Supplement
Subject
Article Number
08.99
Basic Edition
S00.5309.00.20
1
07.00
Supplement to Basic Edition
S00.5309.01.20
2
03.01
Modifications in Rep. Gr. 01 and 24
S00.5309.02.20
3
06.02
Additions to engines with the engine codes BBY, BBZ
S00.5309.03.20
4
06.04
Supplement to engines with the engine codes BKY
S00.5309.04.20
Edition 06.04 S00.5309.04.20
Edition
List of Supplements
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
List of Supplements
Edition 06.04 S00.5309.04.20
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Table of Contents 01 – Self-diagnosis Self-diagnosis I ......................................................................................... 01-1
page
1
- Properties of the self-diagnosis ..................................................................... 01-1
page
1
- Technical data of self-diagnosis ..................................................................... 01-1
page
1
- Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the dash panel insert ...................................................................................... 01-1
page
3
- Meaning of the exhaust gas warning light -K83- .................................................. 01-1
page
3
- Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics ..................................................................................... 01-1
page
4
- Interrogating and erasing fault memory of engine control unit ................................. 01-1
page
5
- Automatic test sequence ............................................................................. 01-1
page
6
- Performing actuator diagnosis ....................................................................... 01-1
page
7
Self-diagnosis II ......................................................................................... 01-2
page
1
- Readiness code ........................................................................................ 01-2
page
1
- Reading Readiness Code ............................................................................ 01-2
page
1
- Generating readiness code .......................................................................... 01-2
page
2
Self-diagnosis III ........................................................................................ 01-3
page
1
- Fault table, fault codes 16496...17566 ............................................................. 01-3
page
1
Self-diagnosis IV ....................................................................................... 01-4
page
1
- Fault table, fault codes 17573...18100 ............................................................. 01-4
page
1
Self-diagnosis V ........................................................................................ 01-5
page
1
- Measured value blocks ............................................................................... 01-5
page
1
- Safety measures ....................................................................................... 01-5
page
1
- Reading measured value block ..................................................................... 01-5
page
1
- Measured value blocks, display groups 001...006 - Basic functions .......................... 01-5
page
2
- Measured value blocks, display groups 010...029 - Ignition .................................... 01-5
page
8
Self-diagnosis VI ....................................................................................... 01-6
page
1
- Measured value blocks ............................................................................... 01-6
page
1
- Measured value blocks, display groups 030...049, 099 - Lambda control .................... 01-6
page
1
Self-diagnosis VII ....................................................................................... 01-7
page
1
- Measured value blocks ............................................................................... 01-7
page
1
- Measured value blocks, display groups 050...069 - Speed control ............................ 01-7
page
1
- Measured value blocks, display groups 070...075 - exhaust gas recirculation .............. 01-7
page
5
- Measured value blocks, display group 100 - readiness code .................................. 01-7
page
7
- Measured value blocks, display groups 120...129 - Communication .......................... 01-7
page
8
Repairing the injection system ...................................................................... 24-1
page
1
- Installed location overview for engines with the engine codes AUA, AUB ................... 24-1
page
1
- Installed location overview for engines with the engine codes BBY, BBZ, BKY ............. 24-1
page
2
- General notes on the injection system ............................................................. 24-1
page
3
- Removing and installing parts of the injection system ........................................... 24-1
page
4
- Disassembling and assembling intake manifold .................................................. 24-1
page
6
- Disassembling and assembling fuel distributor with injectors .................................. 24-1
page 10
- Disassembling and assembling the air filter ....................................................... 24-1
page 11
24 – Fuel Formation, Injection
Edition 06.04 S00.5309.04.20
Table of Contents
I
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection - Safety measures ...................................................................................... 24-1 - Rules of cleanliness ................................................................................... 24-1
page 12 page 13
Testing components ................................................................................... 24-2
page
1
- Testing throttle valve control unit ................................................................... 24-2
page
1
- Testing accelerator pedal position sender ......................................................... 24-2
page
2
- Testing the intake manifold pressure sender ..................................................... 24-2
page
4
- Testing intake manifold temperature sender ...................................................... 24-2
page
6
- Testing coolant temperature sender ................................................................ 24-2
page
8
Testing components I ................................................................................. 24-3
page
1
- Test engine speed sender ........................................................................... 24-3
page
1
- Testing injection valves ............................................................................... 24-3
page
2
- Testing the intake system for tightness (unmetered air) ........................................ 24-3
page
7
- Testing intake manifold preheating ................................................................. 24-3
page
8
- Idle testing .............................................................................................. 24-3
page
8
Testing components II ................................................................................ 24-4
page
1
- Test lambda probe heating before catalyst ........................................................ 24-4
page
1
- Testing lambda probe and lambda control upstream of catalytic converter .................. 24-4
page
3
- Test lambda probe heating after catalyst .......................................................... 24-4
page
5
- Testing lambda probe and lambda control after catalyst ........................................ 24-4
page
7
- Check lambda probe ageing before catalyst ...................................................... 24-4
page 10
- Testing the engine operating conditions ........................................................... 24-4
page 11
Engine control unit .................................................................................... 24-5
page
1
- Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-5
page
1
- Testing voltage supply for engine control unit .................................................... 24-5
page
1
- Procedure after voltage supply has been interrupted ............................................ 24-5
page
2
- Replacing engine control unit ........................................................................ 24-5
page
3
- Coding engine control unit ........................................................................... 24-5
page
5
- Adjusting the engine control unit to the throttle valve control unit ............................. 24-5
page
6
Testing auxiliary signals ............................................................................. 24-6
page
1
- Testing the speed signal ............................................................................. 24-6
page
1
- Testing signals from/to the air conditioning system .............................................. 24-6
page
2
- Test brake light switch -F- and brake pedal switch -F47- ....................................... 24-6
page
2
- Testing clutch pedal switch -F36- ................................................................... 24-6
page
4
- Activating and deactivating cruise control system (CCS) ....................................... 24-6
page
5
- Testing CCS ............................................................................................ 24-6
page
5
- Testing gear signal .................................................................................... 24-6
page
6
- Test data bus .......................................................................................... 24-6
page
7
Repairing ignition system ............................................................................ 28-1
page
1
- General notes on the ignition system .............................................................. 28-1
page
1
- Removing and installing parts of the ignition system for engines with the engine codes AUA, AUB ...................................................................................................... 28-1
page
2
- Removing and installing parts of the ignition system for engines with the engine codes BBZ, BBY, BKY ............................................................................................... 28-1
page
3
- Safety measures ...................................................................................... 28-1
page
3
- Testing hall sender .................................................................................... 28-1
page
4
- Checking the ignition transformer (for engines with the engine codes AUA, AUB) ......... 28-1
page
6
28 – Ignition System
II
Table of Contents
Edition 06.04 S00.5309.04.20
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection - Check ignition coils with power output stage (engines with engine codes BBY, BKY, BBZ) 28-1 - Testing knock sensor ................................................................................. 28-1
page 8 page 11
- Test combustion misfiring ............................................................................ 28-1
page 13
Edition 06.04 S00.5309.04.20
Table of Contents
III
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
IV
Table of Contents
Edition 06.04 S00.5309.04.20
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01
01 – Self-diagnosis 01-1
Self-diagnosis I
Properties of the self-diagnosis Note The self-diagnosis monitors only a part of the injection and ignition system. The „Current Flow Diagrams, Fault Finding and Fitting Locations“ binder should always be used for fault finding. The engine control unit -J537- 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. The engine control unit analyses the information and distinguishes between the different fault codes ⇒ Fault Table ⇒ Chapter 01-3 and ⇒ Chapter 01-4, and stores these until the fault memory is erased. Faults that only occur temporarily (sporadically) are output with the suffix „sporadically occurred fault“. On the display these faults are indicated by the suffix „SP“. Possible causes of sporadic faults are e.g. a loose contact or a momentary line interruption. If a sporadic fault no longer occurs within 40 warming-up phases (engine started at a temperature of 50°C and switched off at more than 72 °C), the fault is then automatically erased fom the fault memory. The stored faults can be read out with the vehicle system tester -V.A.G 1552- using programme card -6.0- and higher version or fault reader -V.A.G 1551- using programme card -9.0- and higher version or vehicle diagnosis, measurement and information system -VAS 5051-. After the fault or faults have been rectified, it is necessary to erase the fault memory ⇒ 01-1 page 5 and also to regenerate the readiness code ⇒ Chapter 01-2. Note General information on self-diagnosis is provided in the operating instructions for the diagnostic devices -V.A.G 1551-, -V.A.G 1552- or -VAS 5051-.
Technical data of self-diagnosis Control unit identification: The control unit version is displayed when the vehicle system tester -V.A.G 1552- is connected and address word 01 „Engine electronics“ is selected ⇒ 01-1 page 4.
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Self-diagnosis I
01-1 page 1
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Equipment
Engine identification characters
AUA, AUB
BBY, BBZ
BKY
MARELLI 4LV
MARELLI 4MV
MARELLI 4TV
EU-4, EU-3DDK, EU2DDK
EU4, EU-3DDK, EU2DDK
EU4, EU-3DDK, EU2DDK
Electronic throttle system
Yes
Yes
Yes
Self-diagnosis
Yes
Yes
Yes
Actuator diagnosis
Yes
Yes
Yes
Permanent memory1)
Permanent memory1)
Permanent memory1)
Volatile memory2)
Volatile memory2)
Volatile memory2)
2 probes
2 probes
2 probes
1 Knock sensor
1 Knock sensor
1 Knock sensor
Intake manifold change-over
No
No
No
Camshaft adjustment
No
No
No
Boost-pressure control
No
No
No
Secondary air system
No
No
No
Exhaust gas recirculation
Yes
Yes
Yes
System denomination Exhaust limits conforming to
Fault memory Memory for initialisation values Lambda control Knock control
1) 2)
Independent of voltage supply The values are erased if the voltage supply is interrupted.
Functions available when using the vehicle system tester -V.A.G 1552Note The preconditions for selecting the desired functions are given in the following table.
Operation Function on the vehicle system tester -V.A.G 1552 01
Interrogating control unit version
02
Interrogating fault memory
03
Actuator diagnosis
Precondition Engine not running, ignition switched on
Engine idling
Normal driving
yes
yes
yes
yes1)
yes
yes
yes
no
no
04
Basic
setting2)
yes
yes
yes
05
Erasing fault memory
yes
yes
yes
06
Ending output
yes
yes
yes
07
Coding control unit
yes
no
no
08
Reading measured value block
yes
yes
yes
15
Reading readiness code
yes
yes
yes
1) 2)
Only to be carried out with the ignition switched on and if the engine does not start (activate starter for at least 6 seconds). To be carried out after the following operations: replacing of engine control unit, throttle valve control unit, exhaust gas recirculation valve or engine or disconnecting of battery. The air conditioning and the ACF system are automatically switched off in function 04.
01-1 page 2
Self-diagnosis I
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the dash panel insert „EPC“ is the abbreviation of Electronic Power Control, which in German is written Elektronische MotorleistungsRegelung (E-Gas). Fitting location of the EPC warning lamp: If faults are detected on the EPC system during operation of the engine, the dashboard insert switches the EPC warning light on. (These faults are identified in the fault table). There is a simultaneous entry in the fault memory of the engine control unit.
Functional test:
CHECK
– Switch on ignition: the EPC warning lamp must light up. If the EPC warning lamp does not light up when the ignition is switched on:
S01-0090
– Check the dash panel insert and the EPC warning lamp ⇒ Electrical System; Rep. Gr. 90.
If the EPC warning lamp lights up when the ignition is switched on:
– Start engine and run in idle. The EPC warning lamp should go out after a few seconds. If the EPC warning lamp does not go out:
– Interrogate fault memory, rectify any faults existing and erase the fault memory ⇒ 01-1 page 5.
Meaning of the exhaust gas warning light -K83Only for engines complying with exhaust emission standard EU 4 and EU 3DDK If the engine control unit detects a fault, this is indicated by the lighting up of the exhaust warning lamp Fitting location of exhaust warning light: CHECK
Note ♦ The exhaust warning light may flash or come on as a
steady light. The fault memory must be interrogated whatever happens ⇒ 01-1 page 5. ♦ The warning light flashes: There is a fault, which is
likely to damage the catalytic converter in this driving condition. In this driving condition only low performance driving is allowed!
CHECK
S01-0091
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Self-diagnosis I
01-1 page 3
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
♦ The warning light comes on as a steady light: There is
a fault which deteriorates the exhaust gas quality. Interrogate the engine control or the automatic gearbox fault memory. ♦ If there is a driving behaviour problem or a customer
complaint and the exhaust gas warning light does not light up, the fault memory should be interrogated since it also possible that faults are stored there which do not immediately switch on the exhaust gas warning light.
Functional test:
– Switch on ignition: The exhaust warning light must light up. If the gas warning light does not come on when the ignition is switched on:
– Check the dash panel insert and the exhaust gas
warning light ⇒ Electrical equipment; Rep. Gr. 90 .
If the gas warning light comes on when the ignition is switched on:
– Start engine and run in idle. The gas warning light must go out after a few seconds. If the gas warning light does not go out:
– Interrogate fault memory, rectify any faults existing and erase the fault memory ⇒ 01-1 page 5.
Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-.
Test conditions
• Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52, 56 and 61 must be o.k.
• Battery voltage must be at least 11.5 volts. • Earth connections between engine (at gearbox housing) and body (below battery) o.k.
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
S01-0094
01-1 page 4
Self-diagnosis I
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Procedure
– Fold back trim panel -1-. – Connect vehicle system tester -V.A.G 1552- with appropriate cable.
– Select address word 01 „Engine electronics“. 3
2
1
9
8
7 C
The control unit identification number and the coding are shown on the vehicle system tester display, e.g.:
6
5
4
O
Q
HELP
V.A.G. 1552
036906034T MARELLI 4LV Coding 00031
2615 -> WSC XXXXX
♦ 036906034T = Part No. of the control unit (for current
control unit version see spare part catalogue)89MARELLI 4LV = description of system and version ♦ ♦ Coding 00031 = coding of control unit with code ver-
sions ⇒ Chapter 24-5
♦ WSC xxxxx = workshop code the -V.A.G 1552-, with
which the last coding was performed (WSC 00000 appears provided the factory-entered coding has not been changed) Note ♦ If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit ⇒ Chapter 24-5. ♦ Incorrect coding of the engine control unit results in: ♦ Handling problems (jerky gear change, load change
jolts etc.) ♦ Increase in fuel consumption ♦ Increase in pollution ♦ Storage of non-existent faults in fault memory ♦ Impossibility of performing certain functions (lambda
control, actuation of activated charcoal filter system, etc.)
Interrogating and erasing fault memory of engine control unit Interrogate and erase the fault memories of al control units ⇒ 01-1 page 6. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-.
Edition 06.04 S00.5309.04.20
Self-diagnosis I
01-1 page 5
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 „Engine electronics“ ⇒ 01-1 page 4. Only if the engine does not start:
– Operate starter for about 6 seconds. after this do not switch off ignition.
– Select function 02 „Interrogate fault memory“. The number of stored faults or „No fault recognised“ appears in the display.
X faults detected
If no fault is stored:
– Press
key.
If one or several faults are stored: Vehicle system test The fault memory is erased
– Select function 05 „Erase fault memory“.
HELP
Note If the ignition was switched off between „Interrogate fault memory“ and „Erase fault memory“, the fault memory is not erased.
– Select function 06 „End output“ and switch ignition off. – Rectify the faults displayed by referring to the fault table ⇒ Chapter 01-3 and ⇒ Chapter 01-4.
– Read out readiness code ⇒ Chap. 01-2. If the fault memory has been erased or if the continuous voltage supply from the engine control unit was interrupted, it is then necessary to re-generate the readiness code.
Automatic test sequence During testing and installation other control units may also detect faults, e.g. pulled-out connectors. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:
– Select address word 00 „Automatic Test Sequence“. The tester -V.A.G 1552- sends all known address words in sequence. If a control unit responds with its identification, the display will indicate the number of faults in the memory or „No fault detected“.
– Erase the fault memory and then carry out a test drive. During the test drive the following operating conditions must be fulfilled: ♦ The coolant temperature should rise beyond 80°C. ♦ Once this temperature is reached, the following oper-
ating states must be reached several times: Idling, part load, full load, overrun, enrichment. ♦ In case of full load the speed should be increased be-
yond 3500 rpm.
01-1 page 6
Self-diagnosis I
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Once again interrogate the fault memories of all the control units with the address word 00 „Automatic test sequence“. If no fault is stored:
– Select function 06 „End output“ and switch ignition off. Note If no fault has been recognized by the self-diagnostic system proceed with fault finding as specified in the corresponding fault table in the „Current Flow Diagrams, Electrical Fault Finding and Fitting Locations“ binder.
Performing actuator diagnosis With the actuator diagnosis the following parts are activated in the sequence indicated: 1. Throttle valve positioner -V602. Activated charcoal filter system solenoid valve 1 -N803. Exhaust gas recirculation valve -N184. Engine speed sender -G28- 1) 5. Fuel pump relay -J176. Engine/air conditioning compressor electrical connection1) Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1715♦ Diode test lamp e.g. -V.A.G 1527B♦ Measuring tool set e.g. -V.A.G 1594C♦ Current flow diagram
Test conditions
• Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52, 56 and 61 must be o.k.
• Battery voltage must be at least 11.5 volts. • All electrical consumers, e.g. lights and rear window heater, must be switched off.
• Throttle valve drive angle senders -G187- and -G188o.k
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
S01-0094
1)
Ignore
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Self-diagnosis I
01-1 page 7
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
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 aborted when the engine
is started or when a moment of momentum is detected. ♦ During the actuator diagnosis the individual actuators
remain activated until the next actuator is selected by pressing key . ♦ The actuators are tested acoustically or by touch.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine electronics“ ⇒ 01-1 page 4.
– Select function 03 „final control diagnosis“. Readout on display:
Vehicle system test 03 - Actuator diagnosis
Q
Actuator diagnosis Throttle valve positioner-V60
->
Activate throttle valve positioner -V60-:
– Confirm the entry with key
Q.
Readout on display: The throttle valve positioner should open and close the throttle valve until the next actuator is activated by pressing key . If the throttle valve does not move:
– Test throttle valve positioner ⇒ Chapter 24-2, test throttle valve control unit.
Activate solenoid valve 1 for activated charcoal filter system -N80-:
– Press
key. Actuator diagnosis -> Sol.valve 1 for act. char.filter -N80
Readout on display: The solenoid valve (on right, at suspension strut dome) must continue clicking until the next control element is actuated by pressing the key.
– Detach hose from the activated charcoal filter at the solenoid valve.
– Fit auxiliary hose onto the free connection of the valve.
– Blow into the auxiliary hose during the final control diagnosis (in the direction of the throttle valve control unit). The valve must open and close. If the solenoid valve does not click:
– Continue test ⇒ 01-1 page 10.
01-1 page 8
Self-diagnosis I
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Activate exhaust gas recirculation valve -N18-:
– Press
key.
Readout on display:
Actuator diagnosis Exhaust gas recirculation valve -N18
->
Actuator diagnosis Engine speed sender -G28
->
Actuator diagnosis Fuel pump relay-J17
->
The exhaust gas recirculation valve (left engine compartment at cylinder head) must click until the next actuator is activated by pressing key. If the exhaust gas recirculation valve does not click:
– Continue test ⇒ 01-1 page 11. Engine speed sender -G28-: (Ignore)
– Press
key.
Readout on display:
Activate fuel pump relay -J17-:
– Press
key.
Readout on display: The fuel pump relay (on the relay plate) must be activated and deactivated until the next control element is actuated by pressing the key. Note During activation of the fuel pump relay the fuel pump should also be heard to run at intervals. The door contact switch must not be actuated during the test. If the relay does not click:
– Select function 06 „End output“ and switch ignition off. – Testing fuel pump relay ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Engine/air conditioning compressor electrical connection (ignore)
– Press
key.
Readout on display:
Edition 06.04 S00.5309.04.20
Actuator diagnosis -> Engine/air cond.compr.electr.connect.
Self-diagnosis I
01-1 page 9
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Continuing test if the activated charcoal filter solenoid valve 1 does not click:
– Unplug 2-pin plug from solenoid valve 1 -N80- -arrow-.
S01-0092
– Connect diode testing lamp to the unplugged plug. – LED must flash. The LED flashes:
– Proceed with the final control diagnosis up to the end. – Switch off ignition. – Replace solenoid valve 1 -N80-. The LED does not flash:
– Proceed with the final control diagnosis up to the end. – Switch off ignition. – Connect test box -V.A.G 1598/31- to wiring loom to engine control unit ⇒ Chapter 24-5. Do not connect up the engine control unit.
– Check wiring between the test box and the 2-pin plug for interruption according to the Current Flow Diagram: Plug contact
Test box bush -V.A.G 1598/31-
2
64
– Line resistance: max. 1.5 Ω – Additionally check the cable for a short circuit to battery positive and to earth. Specified value: ∞ Ω.
– Check the cable between 2-pin plug contact 1 and the fuel pump relay -J17- for interruption according to the Current Flow Diagram.
– Line resistance: max. 1.5 Ω If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
01-1 page 10
Self-diagnosis I
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01
Continuing test if the exhaust gas recirculation valve does not click:
– Unplug the 6-pin plug from the exhaust gas recirculation valve -N18- -arrow- (on the front left cylinder head).
– Connect up the diode test lamp using adapter cables onto the contacts 1+ 5 of the removed plug connection.
– LED must flash. The LED flashes:
– Proceed with the final control diagnosis up to the end. – Switch off ignition. – Replace the EGR valve -N18- ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26. The LED does not flash:
– Proceed with the final control diagnosis up to the end. – Switch off ignition. – Connect test box -V.A.G 1598/31- to wiring loom to engine control unit ⇒ Chapter 24-5. Do not connect up the engine control unit.
– Check wiring between the test box and the 6-pin plug for interruption according to the Current Flow Diagram: Plug contact
Test box bush -V.A.G 1598/31-
5
114
– Line resistance: max. 1.5 Ω – Check the cable between 6-pin plug contact 1 and the fuel pump relay -J17- for interruption according to the Current Flow Diagram.
– Line resistance: max. 1.5 Ω – Additionally check the cable for a short circuit to battery positive and to earth. Specified value: ∞ Ω If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
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Self-diagnosis I
01-1 page 11
01
01-1 page 12
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Self-diagnosis I
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01-2
Self-diagnosis II
Readiness code Reading Readiness Code Operation The readiness code is an 8-digit numerical code that provides information on the status of the emission-relevant diagnosis. If the diagnosis for a system (e.g. tank ventilation system) was successfully performed, the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that the systems operate according to the specifications. If a fault is detected during the diagnosis it is entered in the fault memory. The readiness code is erased if the fault memory is erased or if there is an interruption to the voltage supply. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, oder 3C-.
Procedure
– Connect vehicle system tester -V.A.G 1552- and enter address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 15 „Readiness code“. If all diagnoses were performed successfully, the display must indicate the following:
Readiness code 00000000 - Test complete
– Select function 06 „End output“ and switch ignition off. Readiness code 00101101 - Test not complete
If the following readout appears in the display: One of the available diagnoses cannot be completed successfully.
– Press key. – Generate readiness code ⇒ 01-2 page 2. Meaning of the 8-digit numerical block of the readiness code
The readiness code is only generated if all the display positions show 0 1
2
3
4
5
6
7
8 0
0 0 0
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Diagnosis function Catalytic converter Catalytic converter heater (no diagnosis at present/always „0“) Activated charcoal filter system Secondary air injection system (no diagnosis at present/always „0“)
Self-diagnosis II
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
The readiness code is only generated if all the display positions show 0 0 0
Air conditioning system (no diagnosis at present/always „0“) Lambda probe
0
Lambda probe heater
0
Exhaust gas recirculation
Generating readiness code Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, oder 3C-.
Test conditions
• Vehicle stationary • On vehicles with an automatic gearbox the selector lever must be in position „P“ or „N“.
• All electrical consumers such as lights and rear window heater switched off
• Intake air temperature must be below 60 °C ⇒ display group 004, display field 4
• Coolant temperature at least 80 °C ⇒ display group 004, display block 3
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1. Work step 1: Interrogating fault memory
– Select function 02 „Interrogate fault memory“. The number of stored faults or „No fault recognised“ appears in the display.
X faults detected
If a fault is stored in the memory:
– Rectify the faults displayed by referring to the fault table: Fault table ⇒ Chap. 01-3 and ⇒ Chap. 01-4. If no fault is stored:
– Press
key.
Work step 2: Erasing fault memory
– Select function 05 „Erase fault memory“.
01-2 page 2
Vehicle system test The fault memory is erased
Self-diagnosis II
->
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note ♦ The readiness code is reset or erased each time the
fault memory is erased. ♦ If the ignition was switched off between „Interrogate
fault memory“ and „Erase fault memory“, the fault memory is not erased.
– Press
key.
Note The engine must not be readjusted during the work sequence. Work step 3: Activated charcoal filter system diagnosis
– Select function 04 „Basic setting“ and display group 070.
– Depress neither brake nor clutch pedal. If the diagnosis is initiated by the engine control unit the display in display field 4 will switch from „Test OFF“ to „Test ON“.
– Leave engine running at idling speed until „TVV o.k.“ is read out in display field 4.
System in basic setting 70 29% 65% 342mbar
TEV O.K.
If the display does not occur as described:
– Interrogating fault memory. – Blip throttle about 3 times and repeat the process. If the display occurs as described:
– Press
C key.
Work step 4: Lambda probe-ageing diagnosis (interval monitoring)
– Select function 04 „Basic setting“ and display group 034.
– Depress accelerator pedal twice above 5000 rpm. – Maintain speed between 1500...3900 rpm until display in display field 4 switches from „Test OFF“ to „Test ON“.
System in basic setting 34 1830/min 120 C 0.00s Test OFF
– Leave engine running at idling speed until „B1-S1 o.k.“ is displayed in display field 4.
– Select function 08 „Read measured value block“ and display group number 030.
Read measured value block 111 110
30
– Check operating state of lambda control upstream of catalytic converter (display field 1): Specified value: 111
– Check operating state of lambda control downstream of catalytic converter (display field 2): Specified value: 110
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note The 3rd bit in display field 2 is only set to 1 under partial load (2500...4000 rpm).
Meaning of 3-digit numerical block in the display fields 1 and 2: Meaning, if display positions = 1 1 2 3 1 Lambda control active (partial load) 1
Lambda probe operational
1
Lambda probe heater switched on
If the specified values are not reached:
– Interrogate fault memory ⇒ Chapter 01-1. If the specified values are reached: Work step 5: Catalyst diagnosis Note This diagnosis is only successfully completed if no faults relating to the lambda probes or the activated charcoal filter system exist.
– Select function 04 „initiating basic Setting“ and then display group 046.
– Maintain speed between 2000…3000 rpm until display in display field 4 switches from „Test OFF“ to „Test ON“. Catalytic converter temperature in display field 2 must be at least 300 °C.
System in basic setting 46 2830/min 328,0 C 0.00s Test OFF
– Further maintain speed between 2000...3000 rpm until the nominal result of the test „CatB1 o.k“ is displayed in display field 4. Note It may also take a few minutes until the readout is changed from „Test ON“ to „Cat B1 o.k.“ If the specified values are not reached:
– Interrogate fault memory ⇒ Chapter 01-1. If the specified values are reached:
– Press
C key.
Work step 6: Diagnosis of exhaust gas recirculation system
– Select function 04 „initiating basic Setting“ and then display group 075.
– Depress neither brake nor clutch pedal. – Briefly blip throttle about 5 times up to max. speed.
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection If the diagnosis is initiated by the engine control unit the display in display field 4 will switch from „Test OFF“ to „Test ON“.
System in basic setting 4830/min 371mbar 0mbar
75 Test OFF
– Leave engine running at idling speed until „Syst. O.K.“ is displayed in display field 4. If the display does not occur as described:
– Interrogate fault memory ⇒ Chapter 01-1. If the display occurs as described:
– Select function 06 „End output“ and switch ignition off. – Read out readiness code ⇒ 01-2 page 1.
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01
01-2 page 6
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Self-diagnosis II
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01-3
01
Self-diagnosis III
Fault table, fault codes 16496...17566 Note ♦ Faults related to the electronic throttle are indicated
on the dash panel insert by the fault lamp for the electronic accelerator control „EPC warning lamp“). ♦ Faults related to the exhaust are indicated by the „ex-
haust gas warning lamp“ in the dash panel insert. ♦ Explanations regarding fault types (e.g. „open circuit
or short-circuit to earth“) ⇒ Operating instructions for the vehicle system tester.
♦ If parts are output as faulty: First test all of the cables
and plug connections to these components as well as the earth cables of the system according to the current flow diagram. Only if no fault is detected here should the part be replaced. This applies in particular if faults are shown as „sporadic“ (SP). ♦ Once the fault has been corrected erase the fault
memory ⇒ Chapter 01-1 and re-generate the readiness code ⇒ Chapter 01-2.
Printer edition e.g.: 16497 P0113 035 Intake manifold temperature sender -G72Signal too high sporadically occurring fault Explanations: 16497 = fault code P0113 = Ignore the SAE code that may appear next to the fault code. 035 = fault type as digit Intake manifold temperature sender -G72- = faulty current path or fault location Signal too great = fault type as text Sporadically occurring fault = fault not always present, e.g. loose contact
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Self-diagnosis III
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 1552-
Rectifying fault
16496 Intake manifold temperature sender -G72-1)
Signal too low
16497 Intake manifold temperature sender -G72-1)
Signal too high
– Read measured value block, display group 004, display field 4 ⇒ Chapter 01-5
– Inspecting intake manifold temperature sender ⇒ Chap. 24-2
– Replace engine control unit ⇒ Chapter 24-5
Implausible signal 16500 Sender for the coolant temperature -G62-1)
– Read measured value block, display group 001, display field 2 ⇒ Chapter 01-5
– Check the coolant temperature sender -G62⇒ Chapter 24-2
– Replace engine control unit ⇒ Chapter 24-5 – Read measured value block, display group 001, dis-
Signal too low 16501 Sender for the coolant temperature -G62-1)
play field 2 ⇒ Chapter 01-5
– Check the coolant temperature sender -G62⇒ Chapter 24-2
Signal too high 16502 Sender for the coolant temperature -G62-1)
– Test coolant thermostat ⇒ 1.4/55; 1.4/74 Engine Mechanical Components; Rep. Gr. 19
16505 Throttle valve potentiometer -G69-1)
Implausible signal
16506 Throttle valve potentiometer -G69-1)
Signal too low
16507 Throttle valve potentiometer -G69-1)
Signal too high
16514 Bank 1 probe 11)
Electrical fault in the circuit
– Replace engine control unit ⇒ Chapter 24-5 – Test throttle valve control unit ⇒ Chapter 24-2
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Remove short-circuit or line interruption ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. 16517 Bank 1 probe 1 elect.1)
Signal too low
16518 Bank 1 probe 11)
No activity
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Reading measured value block, display group 030 ⇒ Chap. 01-6
– Reading measured value block, display group 031 ⇒ Chap. 01-6
16519 Bank 1, probe 1
Heating circuit electrical fault
– Testing lambda probe and lambda control upstream
16520 Bank 1 probe 21)
Electrical fault in the circuit
– Test lambda probe heater downstream of catalytic
16521 Bank 1 probe 21)
Voltage too low
– Test lambda control before catalytic converter
of catalytic converter ⇒ Chapter 24-4 converter ⇒ Chapter 24-4 ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Readout on -V.A.G 1552-
Rectifying fault
– Test lambda probe heater downstream of catalytic
16522 Bank 1 probe 21)
Voltage too high
16524 Bank 1 probe 21)
No activity
16525 Bank 1 probe 21)
Heating circuit electrical fault
converter ⇒ Chapter 24-4
– Test lambda probe after catalytic converter ⇒ Chapter 24-4
– Test lambda control before catalytic converter ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
– Check fuel filter with regulating valve ⇒ 1.4/55, 1.4/
Malfunction 16554 Bank 1, fuel metering system1)
74 Engine - Mechanics; Rep. Gr. 20
– Testing lambda control before catalyst ⇒ Chapter 24-4
– Reading measured value block, display group 030 ⇒ Chap. 01-6
– Reading measured value block, display group 031 ⇒ Chap. 01-6
– Check fuel filter with regulating valve ⇒ 1.4/55, 1.4/
System too lean 16555 Bank 1, fuel metering system1)
74 Engine - Mechanics; Rep. Gr. 20
– Test injection valves ⇒ Chapter 24-3 – Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
– Test injection valves ⇒ Chapter 24-3 – Testing lambda control before catalyst ⇒ Chapter
System too rich 16556 Bank 1, fuel metering system1)
24-4
– Reading measured value block, display group 030 ⇒ Chap. 01-6
– Test lambda control before catalytic converter ⇒ Chapter 24-4
– Test injection valves ⇒ Chapter 24-3
16585 Injector cyl. 1 -N30-2)
Electrical fault in the circuit
16586 Injector cyl. 2 -N31-2)
Electrical fault in the circuit
16587 Injector cyl. 3 -N32-2)
Electrical fault in the circuit
16588 Injector cyl. 4 -N33-2)
Electrical fault in the circuit
16603
Maximum engine speed exceeded
– Rectify any mechanical engine damage
16605 Angle sender 2 for TV drive -G188-1)2)
Implausible signal
– Read measured value block, display group 062
16606 Angle sender 2 for TV drive -G188-1)2)
Signal too low
16607 Angle sender 2 for TV drive -G188-1)2)
Signal too high
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⇒ Chapter 01-7
– Test throttle valve control unit ⇒ Chapter 24-2
Self-diagnosis III
01-3 page 3
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 1552-
Rectifying fault
– Read measured value block, display group 062
16611 Sender for accelerator pedal position -G79-1)2)
Signal too low
16612 Sender for accelerator pedal position -G79-1)2)
Signal too high
16646 Injector cyl. 1 -N30-1)
Short circuit to positive
16649 Injector cyl. 2 -N31-1)
Short circuit to positive
16652 Injector cyl. 3 -N32-1)
Short circuit to positive
16655 Injector cyl. 4 -N33-1)
Short circuit to positive
166841)
Combustion misfiring detected
⇒ Chapter 01-7
– Test accelerator pedal position sender ⇒ Chapter 24-2
– Test injection valves ⇒ Chapter 24-3
– Test injection valves ⇒ Chapter 24-3 – Test ignition leads and spark plugs ⇒ Chapter 28-1 – Testing ignition transformer with power amplifier ⇒ Chapter 28-1
– Inspecting misfiring detection ⇒ Chapter 28-1 – Test injection valves ⇒ Chapter 24-3
16685 Cylinder 11)
Combustion misfiring detected
16686 Cyl. 21)
Combustion misfiring detected
16687 Cyl. 31)
Combustion misfiring detected
16688 Cyl. 41)
Combustion misfiring detected
16705 Engine speed sender -G28-1)
Implausible signal
– Check engine speed sender -G28- ⇒ Chapter 24-3
16706 Engine speed sender -G28-1)
No signal
– Remove line interruption or short-circuit ⇒ Current
16708 Knock control 16709 Knock sensor 1 -G6116710 Knock sensor 1 -G61-
Flow Diagrams, Electrical Fault Finding and Fitting Locations
– – Malfunction – – Electrical fault in the cir- – cuit – Implausible signal
16711 Knock sensor 1 -G61-
Signal too low
16712 Knock sensor 1 -G61-
Signal too high
01-3 page 4
Check engine speed sender -G28- ⇒ Chapter 24-3 Replace engine control unit ⇒ Chapter 24-5 Inspecting knock sensor ⇒ Chapter 28-1 Read measured value block 028 ⇒ Chapter 01-5 Inspecting knock sensor ⇒ Chapter 28-1 Read measured value block 028 ⇒ Chapter 01-5
Self-diagnosis III
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Readout on -V.A.G 1552-
Rectifying fault
16725 Camshaft position sensor ⇒ sender -G40-1)
Implausible signal
16726 Camshaft position sensor ⇒ sender -G40-1)
Signal too low
16727 Camshaft position sensor ⇒ sender -G40-1)
Signal too high
16735 Ignition control cyl. 11)
Malfunction
16736 Ignition control cyl. 21)
Malfunction
16737 Ignition control cyl. 31)
Malfunction
16738 Ignition control cyl. 41)
Malfunction
16785 Exhaust gas recirculation system1)
Flow rate too low
16786 Exhaust gas recirculation system1)
Flow rate too great
16787 Exhaust gas recirculation valve -N18-1)
Malfunction
16788 Exhaust gas recirculation system1)
Control difference
16791 Potentiometer for exhaust gas recirculation -G212-1)
Signal too low
16792 Potentiometer for exhaust gas recirculation -G212-1)
Signal too high
16804 Bank 1, catalytic converter system1)
Efficiency too low
– Inspecting hall sender ⇒ Chapter 28-1
– Test combustion misfiring ⇒ Chapter 28-1
– Test exhaust gas recirculation valve -N18⇒ Chapter 01-1, final control diagnosis
– Perform basic setting (measured value block 074 and 075) ⇒ Chapter 01-7
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
– Testing intake system for tightness ⇒ Chapter 24-3 – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Check catalytic converter ⇒ 1.4/55; 1.4/74 Engine Mechanics; Rep. Gr. 26 16825 Tank ventilation system1)
Flow rate incorrect
– Testing solenoid valve 1 for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
– Inspect hoses and connection pipes from fuel tank up to injection rail ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing intake system for tightness ⇒ Chapter 24-3
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 1552-
Rectifying fault
16827 Tank ventilation valve -N80-1)
Electrical fault in the circuit
16828 Tank ventilation valve -N80-
Open circuit
16829 Tank ventilation valve -N80-
Short circuit
16845 Fuel level signal
Implausible signal
16885 Vehicle speed signal1)
Implausible signal
– Testing solenoid valve 1 for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
– Testing signal of fuel gauge sender ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Test speed signal ⇒ Chapter 24-6 – Read measured value block, display group 005, display field 3 ⇒ Chapter 01-5
– Remove open circuit in wiring or short circuit according to current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Adapt engine control unit to control unit for electronic
16897 Engine control unit
Blocked
16916 Pressure sensor for air conditioning system
Signal too low
16917 Pressure sensor for air conditioning system
Signal too high
16946 Voltage supply
Voltage too low
– testing voltage supply ⇒ Chapter 24-5
16947 Voltage supply
Voltage too high
– testing voltage supply ⇒ Chapter 24-5
16955 Brake light switch -F-
Implausible signal
– Test brake light switch and brake pedal switch
immobiliser ⇒ Electrical System; Rep. Gr. 96.
– Test G65 ⇒ Air conditioning system; Rep. Gr. 87
⇒ Chapter 24-6
– Replace engine control unit -J537- ⇒ Chapter 24-5
16988 Control unit defective1) 16989 Control unit defective1) 16990 Control unit defective2) 16991 Throttle valve control unit -J338-2)
Undervoltage on basic settings
– Adapt engine control unit to throttle valve control unit
17022 Throttle valve control unit -J338-1)2)
Implausible signal
– Check battery, if necessary charge ⇒ Electrical Sys-
⇒ Chapter 24-5
tem; Rep. Gr. 27
– Test throttle valve control unit ⇒ Chapter 24-2 – Testing signals from and to the air conditioning sys-
17029 Air conditioning system inlet/ outlet
tem ⇒ Electrical System; Rep. Gr. 90
17034 Exhaust gas warning light -K83-
Electrical fault in the circuit
– Testing signals from and to the warning light -K83-
17040 Fuel consumption signal
Electrical fault in the circuit
– Check the fuel consumption signal ⇒ Electrical Sys-
⇒ Electrical System; Rep. Gr. 90
tem; Rep. Gr. 90.
– Test CAN databus ⇒ Chap. 24-6.
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Readout on -V.A.G 155217510 Bank 1, probe 1 heating circuit1)
Rectifying fault Short circuit to positive
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
– Remove short-circuit according to Current Flow Diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
17513 Bank 1, probe 2 heating circuit1)
Short circuit to positive
17523 Bank 1, probe 1 heating circuit1)
Short circuit to earth
17524 Bank 1, probe 1 heating circuit1)
Open circuit
– Replace engine control unit ⇒ Chapter 24-5 – Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
– Replace engine control unit ⇒ Chapter 24-5 – Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
– Replace engine control unit ⇒ Chapter 24-5 – Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
– Remove line interruption according to Current Flow
Diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Replace engine control unit ⇒ Chapter 24-5 17525 Bank 1, probe 2 heating circuit1)
Short circuit to earth
17526 Bank 1, probe 2 heating circuit1)
Open circuit
17550 Load detection
– Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
– Replace engine control unit ⇒ Chapter 24-5 – Test injection valves ⇒ Chapter 24-3 – Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
– Replace engine control unit ⇒ Chapter 24-5 – Adapt engine control unit to throttle valve control unit
Below limit
⇒ Chapter 24-5
– Test throttle valve control unit ⇒ Chapter 24-2 – Test accelerator pedal position sender ⇒ Chapter 24-2
17559 Bank 1, mixture adaptation range 11)
Below leanness limit
17560 Bank 2, mixture adaptation range 21)
Below leanness limit
– – – –
Test air filter ⇒ Chapter 24-1 Check engine mechanics Test injection valves ⇒ Chapter 24-3 Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing intake system for tightness ⇒ Chapter 24-3 – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Check exhaust gas recycling system ⇒ 1.4/55; 1.4/ 74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 1552-
Rectifying fault
17563 Intake manifold pressure sender -G71-1)2)
Short circuit to positive
17564 Intake manifold pressure sender -G71-1)2)
Open circuit/Short-circuit to earth
17566 Intake manifold pressure sender -G71-1)2)
Implausible signal
1)
2)
– Testing intake manifold pressure sender ⇒ Chap. 24-2
– Testing intake system for tightness (unmetered air) ⇒ Chapter 24-3.
If this fault occurs the engine control unit switches on the exhaust gas warning lamp in the dash panel insert. Meaning of the exhaust gas warning lamp ⇒ Chapter 01-1 If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp ⇒ Chapter 01-1
01-3 page 8
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01-4
Self-diagnosis IV
Fault table, fault codes 17573...18100 Readout on -V.A.G 1552-
Rectifying fault
17573 Bank 1, mixture adaptation range 11)
Above richness limit
17574 Bank 1, mixture adaptation range 21)
Above richness limit
– Test injection valves ⇒ Chapter 24-3 – Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing intake system for tightness ⇒ Chapter 24-3 – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Check exhaust gas recirculation system ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
17579 Angle sender 2 for TV drive -G188-1)2)
Implausible signal
17580 Angle sender 2 for TV drive -G188-1)2)
Signal too low
17581 Angle sender 2 for TV drive -G188-1)2)
Signal too high
– Test throttle valve control unit -J338- ⇒ Chapter 242.
– Replace engine control unit ⇒ Chapter 24-5. – Test throttle valve control unit ⇒ Chapter 24-2 – Adapt throttle valve control unit ⇒ Chapter 24-5.
17582 Deviation of the injecBank 1, fuel metering system1) tion periods
– Test injection valves ⇒ Chapter 24-3 – Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing intake system for tightness ⇒ Chapter 24-3 – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Check exhaust gas recirculation system ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
Regulating limit 17584 Bank1, lambda correction ac- reached cording to catalytic converter1)
– Testing intake system for tightness ⇒ Chapter 24-3 – Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
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Self-diagnosis IV
01-4 page 1
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 1552-
Rectifying fault
– Testing lambda probe and lambda control upstream
17586 Linear lambda probe/pump current1)
Open circuit
17587 Linear lambda probe/pump current1)
Short circuit to positive
17588 Linear lambda probe/pump current1)
Short circuit to positive
17589 Linear lambda probe/reference voltage1)
Open circuit
17590 Linear lambda probe/reference voltage1)
Short circuit to earth
17591 Linear lambda probe/reference voltage1)
Short circuit to positive
17598 Linear lambda probe/reference voltage1)
implausible
17604 Bank 1, probe 1, heating circuit1)
Electrical fault
17606 Bank 1, probe 2, heating circuit1)
Electrical fault
17621 Injector cyl. 1 -N30-1)
Short circuit to positive
17622 Injector cyl. 2 -N31-1)
Short circuit to positive
17623 Injector cyl. 3 -N32-1)
Short circuit to positive
17624 Injector cyl. 4 -N33-1)
Short circuit to positive
17645 Injector cyl. 1 -N30-1)
Open circuit
17646 Injector cyl. 2 -N31-1)
Open circuit
17647 Injector cyl. 3 -N32-1)
Open circuit
17648 Injector cyl. 4 -N33-1)
Open circuit
17661 Fuel consumption signal
Short circuit to earth
17662 Fuel consumption signal
Short circuit to positive
17743 Engine torque monitoring 21)2)
Regulating limit exceeded
of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
– Test ignition leads and spark plugs ⇒ Chapter 28-1 – Test combustion misfiring ⇒ Chapter 28-1
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
– Test injection valves ⇒ Chapter 24-3
– Test injection valves ⇒ Chapter 24-3
– Test dash panel insert ⇒ Electrical System; Rep. Gr. 90
– Testing intake system for tightness ⇒ Chap. 24-3. – Inspect accelerator pedal position sender -G79- and -G185- ⇒ Chap. 24-2.
– Test throttle valve control unit -J338- ⇒ Chapter 242.
01-4 page 2
Self-diagnosis IV
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Readout on -V.A.G 1552-
Rectifying fault
17745 Bank 1, camshaft pos. sensor -G40-
Short circuit to earth
– Inspecting hall sender ⇒ Chapter 28-1
17746 Bank 1, camshaft pos. sensor -G40-
Short circuit to positive
– Check camshaft position sensor -G40- ⇒ Chap. 28-1 – Remove open circuit in wiring or short circuit accord-
17749 Ignition outlet 11)
Short circuit to earth
17750 Ignition outlet 11)
Short circuit to positive
17751 Ignition outlet 21)
Short circuit to earth
17752 Ignition outlet 21)
Short circuit to positive
17756 Ignition outlet 11)
Open circuit
17757 Ignition outlet 21)
Open circuit
17763 Ignition control cyl. 1
Open circuit3)
ing to current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
– Inspect ignition transformer ⇒ Chapter 28-1 – Remove open circuit in wiring or short circuit according to current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
– Inspect ignition transformer ⇒ Chapter 28-1 – Remove line interruption according to Current Flow
Diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
17764 Ignition control cyl. 1
Short circuit to positive3)
17765 Ignition control cyl. 1
Short circuit to earth3)
17766 Ignition control cyl. 2
Open circuit3)
17767 Ignition control cyl. 2
Short circuit to positive3)
17768 Ignition control cyl. 2
Short circuit to earth3)
17769 Ignition control cyl. 3
Open circuit3)
17770 Ignition control cyl. 3
Short circuit to positive3)
17771 Ignition control cyl. 3
Short circuit to earth3)
17772 Ignition control cyl. 4
Open circuit3)
17773 Ignition control cyl. 4
Short circuit to positive3)
17774 Ignition control cyl. 4
Short circuit to earth3)
17793 Control unit defective1)
– Check the ignition coils with power output stage ⇒ Chapter 28-1.
– Remove short-circuit according to Current Flow Diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
– Replace engine control unit ⇒ Chapter 24-5
17796 Control unit defective1)2)
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01-4 page 3
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 1552-
Rectifying fault
17806 Engine speed signal, TD
Short circuit to earth
17807 Engine speed signal, TD
Short circuit to positive
17809 Exhaust gas recirculation valve -N18-1)
Short circuit to earth
17810 Exhaust gas recirculation valve -N18-1)
Short circuit to positive
17811 Exhaust gas recirculation system1)
Control difference
– Test engine speed sender ⇒ Chapter 24-3 – Remove open circuit in wiring or short circuit according to current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Test exhaust gas recirculation valve ⇒ Chapter 01-1, final control diagnosis.
– Check the EGR valve ⇒ 1.4/55; 1.4/74 Engine - Me-
17812 Basic setting not perExhaust gas recirculation sys- formed tem 17818 Tank ventilation valve -N80-1)
Short circuit to positive
17833 Tank ventilation valve -N80-1)
Short circuit to earth
17834 Tank ventilation valve -N80-1)
Open circuit
17847 Potentiometer for exhaust gas recirculation -G212-1)
Incorrect basic setting
17848 Exhaust gas recirculation valve -N18-1)
Open circuit
17850 Potentiometer for exhaust gas recirculation -G212-1)
Signal too high
17851 Potentiometer for exhaust gas recirculation -G212-1)
Signal too low
17909 Fuel pump relay -J17-
Short circuit to earth
17910 Fuel pump relay -J17-
Short circuit to positive
17912 Air intake system2)
Leak detected
chanics; Rep. Gr. 26.
– Conduct basic setting (measured value block 074) ⇒ Chapter 01-7
– Test solenoid valve for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
– Remove open circuit in wiring or short circuit according to current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
– Conduct basic setting (measured value block 074) ⇒ Chapter 01-7
– Check the EGR valve ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26.
– Test exhaust gas recirculation valve ⇒ Chapter 01-1, final control diagnosis.
– Test fuel pump relay -J17- ⇒ Chapter 01-1, final control diagnosis
– Test fuel pump relay ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
– Inspect intake air system for leaks (unmetered air) ⇒ Chapter 24-3
– Check exhaust gas recirculation system ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Testing solenoid valve 1 for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
– Test throttle valve control unit ⇒ Chapter 24-2 – Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
17949 Fuel pump relay -J17-
Open circuit
17950 Angle sender for TV drive -G187-2)
Implausible signal
01-4 page 4
trical Fault Finding and Fitting Locations
– Test throttle valve control unit ⇒ Chapter 24-2 – Replace engine control unit ⇒ Chapter 24-5
Self-diagnosis IV
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Readout on -V.A.G 1552-
Rectifying fault
17951 Angle sender for TV drive -G187-1)2)
Signal too low
17952 Angle sender for TV drive -G187-1)2)
Signal too high
17953 Throttle valve control 1)2)
Malfunction
17961 Level sender/intake manifold pressure signal2)
implausible ratio
– Test throttle valve control unit ⇒ Chapter 24-2
– Testing intake manifold pressure sender ⇒ Chap. 242
– Testing intake system for tightness (unmetered air) ⇒ Chapter 24-3.
– Check exhaust gas recirculation system ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 26
– Testing solenoid valve 1 for activated charcoal filter ⇒ Chapter 01-1, final control diagnosis
17962 Throttle valve control unit -J338-2) 17967 Throttle valve control unit -J338-1)2)
– Test throttle valve control unit ⇒ Chapter 24-2 Requirements for basic – Adapt engine control unit to throttle valve control unit setting not fulfilled Incorrect basic setting
– Repair mechanical damage
17968 Maximum engine speed exceeded 17972 Throttle valve control unit -J338-2)
⇒ Chapter 24-5
Undervoltage on basic settings
– Test battery, charge if necessary ⇒ Electrical System; Rep. Gr. 27
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-5
17973 Throttle valve control unit
Bottom limit not reached
17977 CCS switch -E45-
Implausible signal
– Check throttle valve for damage or dirt – Test throttle valve control unit ⇒ Chapter 24-2 – Inspecting cruise control system ⇒ Chap. 24-6 – Test throttle valve control unit ⇒ Chapter 24-2 – Adapt engine control unit to electronic immobiliser
17978 Engine control unit blocked1)2)
⇒ Electrical System; Rep. Gr. 96.
– Test electronic immobiliser ⇒ Electrical System; Rep. Gr. 96 17989 Throttle valve control unit -J338-
Basic setting not performed
– Adapt engine control unit to throttle valve control unit
18010 Voltage supply tml. 30
Voltage too low
– Perform procedure for voltage interruption ⇒ Chap.
18019 Fault lamp requirement on
Short circuit to earth
⇒ Chapter 24-5
24-5
– Inspect databus ⇒ Chapter 24-6 – Test exhaust gas warning lamp ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
18020 Engine control unit
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Incorrectly coded
– Code engine control unit ⇒ Chapter 24-5
Self-diagnosis IV
01-4 page 5
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Readout on -V.A.G 155218021 Fault lamp requirement on
Rectifying fault Open circuit/Short circuit to positive
– Inspect databus ⇒ Chapter 24-6 – Test exhaust gas warning lamp ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
18034 Data BUS drive
Missing message from gearbox CU
– Inspect databus ⇒ Chapter 24-6
18038 Sender for accelerator pedal position -G79-1)2)
Signal too low
– Test accelerator pedal position sender ⇒ Chapter
18039 Sender for accelerator pedal position -G79-1)2)
Signal too high
18041 Sender 2 for accelerator pedal position -G185-1)2)
Signal too low
18042 Sender 2 for accelerator pedal position -G185-1)2)
Signal too high
18043 Data BUS drive
Missing message from air conditioning system CU
– Inspect databus ⇒ Chapter 24-6 – Testing air conditioning system CU ⇒ Heating and
Missing message from airbag CU
– Inspect databus ⇒ Chapter 24-6 – Test airbag control unit ⇒ Body Fitting Work;
18044 Data BUS drive
24-2
Air conditioning; Rep. Gr. 87
Rep. Gr. 01 18045 Data BUS drive
missing message form electron. CU
– Inspect databus ⇒ Chapter 24-6 – Read out fault memory of electrical system control unit ⇒ Electrical System; Rep. Gr. 90
18047 Sender 1/2 for accelerator pedal position -G79- + -G185-2)
Implausible signal
24-2
– Inspect engine control unit power supply ⇒ Chapter
18048 Control unit defective1)
24-5
– Replace engine control unit -J537- ⇒ Chapter 24-5 – Read out air conditioning system control unit fault
18049 Read out fault memory of air conditioning CU 18056 Data BUS drive
– Test accelerator pedal position sender ⇒ Chapter
memory ⇒ Heating, Air conditioning; Rep. Gr. 01
– Inspect databus ⇒ Chapter 24-6 – Read out fault memories of all control units (automat-
defective
ic test sequence) ⇒ Chapter 01-1
18057 Data BUS drive
Missing message from ABS CU
– Inspect databus ⇒ Chapter 24-6 – Read out fault memories of all control units (automatic test sequence) ⇒ Chapter 01-1
18058 Data BUS drive
Missing message from combiinstrument
– Inspect databus ⇒ Chapter 24-6 – Test dash panel insert ⇒ Electrical System; Rep. Gr. 90
18060 Read out fault memory of gearbox CU
01-4 page 6
– Self-diagnosis of automatic gearbox CU ⇒ Automatic Gearbox; Rep. Gr. 01
Self-diagnosis IV
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Readout on -V.A.G 1552-
Rectifying fault
18061 Read out fault memory of ABS CU
– Self-diagnosis of ABS control unit ⇒ Running Gear;
18062 Read out fault memory of the combi-instrument
– Self-diagnosis of the dash panel insert control unit
Rep. Gr. 45
⇒ Electrical System; Rep. Gr. 90
18064 Air conditioning system inlet/ outlet
Short circuit to earth
18065 Air conditioning system inlet/ outlet
Short circuit to positive
18081 Vehicle speed signal
Error message from ABS CU
– Testing air conditioning system ⇒ Heating, Air conditioning; Rep. Gr. 87
Short circuit to positive 18085 Fault lamp for electr. accelerator control -K132-1) Short circuit to earth 18086 Fault lamp for electr. accelerator control -K132-1)
– Inspect databus ⇒ Chapter 24-6
– Self-diagnosis of ABS control unit ⇒ Chassis; Rep. Gr. 45
– Inspect databus ⇒ Chapter 24-6 – Test dash panel insert ⇒ Electrical System; Rep. Gr. 90
18087 Open circuit Fault lamp for electr. accelerator control -K132-1) 18097 Databus drive
Implausible message from electron. CU
– Test CAN databus cables ⇒ Chap. 24-6 – Inspecting vehicle voltage control unit -J519⇒ Electrical System; Rep. Gr. 90.
– Inspect databus ⇒ Chapter 24-6
18099 Exhaust gas warning light -K83-
Open circuit
18100 Exhaust gas warning light -K83-
Short circuit to earth
18101 Exhaust gas warning light -K83-
Short circuit to positive
1)
2)
3)
If this fault occurs the engine control unit switches on the exhaust gas warning lamp in the dash panel insert. Meaning of the exhaust gas warning lamp ⇒ Chapter 01-1. If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp ⇒ Chapter 01-1. The faults related to the "ignition control..." regarding the cables between the engine control unit and the power output stage in the ignition coil, with which the power output stages are actuated by the engine control unit.
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Self-diagnosis IV
01-4 page 7
01
01-4 page 8
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Self-diagnosis IV
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01-5
Self-diagnosis V
Measured value blocks Safety measures If test and measuring devices are required during test drives observe the following: ♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.
Reading measured value block Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The coolant temperature must be at least 80°C ⇒ display group 004, display field 3.
• All electrical consumers, e.g. lights and rear window heater, must be switched off (radiator fan must not run).
• If vehicle is equipped with air conditioning, this must be switched off.
• On vehicles with an automatic gearbox the selector lever must be in position „P“ or „N“.
• No fault must be present in the fault memory ⇒ Chap. 01-1, interrogate fault memory and erase.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and the desired display group number.
Read measured value block HELP Enter display group number XXX
Note Display group number 004 is an example to represent the sequence.
Read measured value block 850 rpm 13.9V 88 C
4 41 C
Note Proceed according to the following table to switch to another display group:
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Self-diagnosis V
01-5 page 1
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Display group
-V.A.G 1551-
-V.A.G 1552-
higher
3 Press key
Press key
lower
1 Press key
Press key
skip
C Press key
C Press key
– If the specifications are achieved in all the display fields, press key
.
– Select function 06 „End output“ and switch ignition off.
Measured value blocks, display groups 001...006 - Basic functions Display group 001 - Basic functions:
• Engine idling 1→
Read measured value block
⇐ Read out on display:
xxxx rpm
xx.x °C
xx.x %
xxxxxxxx
1
2
3
4
⇐ Display field
Specification
Analysis:
Setting requirements
10111111
⇒ 01-5 page 2
-15...15 %
⇒ 01-5 page 8
80...110 °C
⇒ 01-5 page 3
Lambda control value Coolant temperature
⇒ 01-5 page 3
Engine speed (idling speed) Vehicles with engine code AUA
650...850 rpm1)
Vehicles with the engine codes BBY, BKY
660...860 rpm1)
Vehicles with automatic gearbox (engine codes AUA, BBY, BKY)
580...780 rpm1)
Vehicles with engine code AUB
740...940 rpm1)
Vehicles with engine code BBZ
580...780 rpm1)
Current value ⇒ Inspection and Maintenance
1)
Meaning of 8-digit numerical block
Meaning if display = 1 1
2
3
4
5
6
7
8 1
1 1 1 1
01-5 page 2
Meaning Coolant temperature more than 80°C Engine speed less than 2000 rpm Throttle valve closed Lambda control o.k. Operating state - idling
Self-diagnosis V
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection Meaning if display = 1 1
2
3
4
5
1
6
7
8
Meaning AC compressor disconnected Catalyst hot (over 300 °C)
1 1
No fault detected in self-diagnosis
Analysis of display group 001, engine speed (idling speed)
Display field
Readout on display:
Possible cause of fault
Rectifying fault
1
less than nominal value
♦ Throttle valve control unit jams/defective
– Test throttle valve control unit ⇒ Chapter
greater than nominal value
♦ Throttle valve control unit jams/defective
24-2 ♦ Air filter element very dirty
♦ Large unmetered air volume (cannot be
compensated by idle stabilizer)
– Replace air filter element ⇒ Chap. 24-1 – Interrogate fault memory ⇒ Chapter 01-1 – Testing intake system for tightness ⇒ Chapter 24-3
– Test throttle valve control unit ⇒ Chapter 24-2
– Performing idling test ⇒ Chap. 24-3
Analysis of display group 001, coolant temperature
Display field
Readout on display:
Possible cause of fault
Rectifying fault
2
less than 80 °C
♦ Engine too cold
– Conduct test drive if necessary – Test coolant temperature sender
♦ Sender for coolant temperature or wiring
⇒ Chapter 24-2
to engine control unit ♦ Coolant regulator defective
– Test coolant thermostat ⇒ 1.4/55, 1.4/74 Engine - Mechanical Components; Rep. Gr. 19
greater than 110 °C
♦ Radiator dirty ♦ Radiator fan not operational
– Clean radiator – Inspect proper operation ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
♦ Coolant regulator defective
– Test coolant thermostat ⇒ 1.4/55, 1.4/74 Engine - Mechanical Components; Rep. Gr. 19
♦ Sender for coolant temperature or wiring
– Test coolant temperature sender ⇒ Chapter 24-2
to engine control unit
Display group 002 - Basic functions:
• Engine idling
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Self-diagnosis V
01-5 page 3
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
2→
Read measured value block xxxx rpm
xx %
x.x ms
xxx mbar
1
2
3
4
⇐ Read out on display: ⇐ Display field
Specification
Analysis:
Intake manifold pressure
240...420 mbar
⇒ 01-5 page 4
2.0...4.0 ms
⇒ 01-5 page 4
10...20 %
⇒ 01-5 page 8
xxxx rpm1)
⇒ 01-5 page 3
Injection period Engine load Engine speed (idling speed) 1)
Display group 001, display field 1 ⇒ 01-5 page 2.
Analysis of display group 002, injection period
Display field
Readout on display:
Possible cause of fault
Rectifying fault
3
less than 2.0 ms
♦ High fuel volume from the activated char-
– Testing solenoid valve 1 for activated
charcoal filter ⇒ Chapter 01-1, final control diagnosis
coal filter system
– Test injection valves ⇒ Chapter 24-3
♦ Incorrect injection valve with too great flow
rate fitted
– Check part No. of the injection valves ⇒ Spare parts catalogue
greater than 4.0 ms
♦ Increased engine load due to electric con-
– Eliminate load (air conditioning, power
sumers, air conditioning system, engaged driving position or power steering to the stop ♦ Incorrect injection valves with too small flow
steering etc.)
– Test injection valves ⇒ Chapter 24-3
rate fitted
– Check part No. of the injection valves ⇒ Spare parts catalogue
Analysis of display group 002 intake manifold pressure
Display field
Readout on display:
Possible cause of fault
Rectifying fault
4
less than 240 mbar
♦ Large volume of unmetered air between in-
– Eliminate unmetered air
greater than 420 mbar
♦ Driving position engaged (automatic gear-
take manifold and air filter
– Put selector lever in P or N
box) ♦ Engine loaded by auxiliary equipment
– Eliminate load (air conditioning, power steering etc.)
– Replace air filter element ⇒ Chap. 24-1
♦ Air filter element very dirty
Display group 003 - Basic functions:
• Engine idling
01-5 page 4
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Read measured value block xxxx rpm xxx mbar 1
2
3→
xx °
xx °
3
4
⇐ Read out on display: ⇐ Display field
Specification
Analysis:
Ignition angle
0...10 ° BTDC
—
0...11 °
⇒ 01-5 page 8
240...420 mbar
⇒ 01-5 page 4
xxxx rpm1)
⇒ 01-5 page 3
Throttle valve angle (potentiometer 1 -G187-) Intake manifold pressure Engine speed (idling speed) 1)
Display group 001, display field 1 ⇒ 01-5 page 2.
Display group 004 - Basic functions:
• Engine idling Read measured value block
4→
xxxx rpm
xx.x V
xxx °C
xxx °C
1
2
3
4
⇐ Read out on display: ⇐ Display field
Specification
Analysis:
Intake manifold temperature
-40...120 °C
⇒ 01-5 page 6
80...110 °C
⇒ 01-5 page 6
12.5...14.5 V
⇒ 01-5 page 6
xxxx rpm1)
⇒ 01-5 page 3
Coolant temperature Supply voltage of the engine control unit Engine speed (idling speed) 1)
Display group 001, display field 1 ⇒ 01-5 page 2.
Note ♦ Re display field 3: ♦ As soon as a fault concerning the coolant temperature
sender -G62- is stored in the fault memory, the engine control unit uses the intake manifold temperature as a replacement value to start the engine (starting temperature - replacement value) The temperature then rises according to a model sequence stored in the control unit. If the engine is warm after a certain period a fixed replacement value is displayed. This fixed substitute value depends on the intake air temperature. ♦ Re display field 4: ♦ The overall temperature range is indicated as nominal
value. The nominal value must be higher than the ambient temperature.
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Self-diagnosis V
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Analysis of display group 004, engine control unit voltage supply
Display field
Readout on display:
Possible cause of fault
Rectifying fault
2
less than 12.5 V
♦ Generator defective, battery heavily dis-
– Inspect generator and battery voltage, charge battery ⇒ Electrical System; Rep. Gr. 27
charged ♦ Battery heavily loaded just after start by a
minutes and switch off additional consumers
♦ Transition resistance in the power supply or
– Inspect engine control unit power supply
earth connection for engine control unit ♦ Current consumption with ignition off
greater than 14.5 V
– Increase engine speed slightly for a few
high charge current or by auxiliary equipment
♦ Voltage regulator on generator defective
⇒ Chapter 24-5
– Eliminate current consumption – Check voltage regulator, if necessary replace ⇒ Electrical System; Rep. Gr. 27
♦ Overvoltage due to starting aid or quick
charger
– Interrogate fault memory ⇒ Chapter 011
Analysis of display group 004, coolant temperature
Display field
Readout on display:
Possible cause of fault
Rectifying fault
3
less than ♦ Engine too cold 80 °C ♦ Coolant temperature sender or cable connection to engine control unit faulty ♦ Coolant regulator defective
– Conduct test drive if necessary – Test coolant temperature sender ⇒ Chapter 24-2
– Test coolant thermostat ⇒ 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 19
greater than 110 °C
♦ Radiator dirty ♦ Radiator fan not operational
– Clean radiator – Inspect proper operation ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
♦ Coolant regulator defective
– Test coolant thermostat ⇒ 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 19
♦ Sender for coolant temperature or wiring
constant - 40 °C
♦ Open circuit or short circuit to positive
constant 120 °C
♦ Short circuit to earth
01-5 page 6
– Test coolant temperature sender ⇒ Chapter 24-2
to engine control unit
– Test coolant temperature sender ⇒ Chapter 24-2
Self-diagnosis V
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Analysis of display group 004, intake manifold temperature
Display field
Readout on display:
Possible cause of fault
Rectifying fault
4
constant - 40 °C
♦ Open circuit or short circuit to positive
– Inspecting intake manifold temperature
constant 120 °C
♦ Short circuit to earth
sender ⇒ Chap. 24-2
Display group 005 - Basic functions:
• Engine idling Read measured value block
5→
xxxx rpm
xx %
xxx km/h
Text
1
2
3
4
⇐ Read out on display: ⇐ Display field Operating condition (idling, partial load, enrichment, trailing throttle)
Driving speed Engine load Engine speed (idling speed) 1)
Specification
Analysis:
Idling — 0 km/h
—
10...20 %
⇒ 01-5 page 8
rpm1)
⇒ 01-5 page 3
xxxx
Display group 001, display field 1 ⇒ 01-5 page 2.
Display group 006 - Basic functions:
• Engine idling 6→
Read measured value block xxxx rpm
xx %
xxx °C
xx.x %
1
2
3
4
⇐ Read out on display: ⇐ Display field
Specification
Level correction factor
-30,0...5,0 %
Intake manifold temperature Engine load Engine speed (idling speed) 1)
Analysis: —
-40...120 °C
⇒ 01-5 page 7
10...20 %
⇒ 01-5 page 8
rpm1)
⇒ 01-5 page 3
xxxx
Display group 001, display field 1 ⇒ 01-5 page 2.
Note ♦ Re display field 3: ♦ The overall temperature range is indicated as nominal
value. The display value must be higher than the ambient temperature.
Edition 06.04 S00.5309.04.20
Self-diagnosis V
01-5 page 7
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Measured value blocks, display groups 010...029 - Ignition Display group 010 ignition:
• Engine idling Read measured value block
10 →
xxxx rpm
xx %
xx %
xx.x °
1
2
3
4
⇐Read out on display: ⇐ Display field Ignition angle
Throttle valve angle (potentiometer 1 -G187-) Engine load Engine speed (idling speed) 1)
Specification
Analysis:
0...10.0 ° BTDC
—
0...11 %
⇒ 01-5 page 8
10...20 %
⇒ 01-5 page 8
xxxx rpm1)
⇒ 01-5 page 3
Display group 001, display field 1 ⇒ 01-5 page 2.
Analysis of display group 010, engine load
Display field
Readout on display:
Possible cause of fault
Rectifying fault
2
less than 10 %
♦ Lower value can only occur during trailing
throttle driving
♦ Poor idling (engine not running on all cylingreater ders) than 20 %
– Test injection valves ⇒ Chapter 24-3 – Test ignition leads and spark plugs ⇒ Chapter 28-1
♦ Electrical consumers on ♦ Steering wheel at limit stop ♦ Driving position engaged (automatic gear-
– Disconnect electric consumer – Put steering wheel in centre position – Put selector lever in P or N
box)
Analysis of display group 010, throttle valve angle
Display field
Readout on display:
Possible cause of fault
Rectifying fault
3
♦ Engine control unit not adapted to throttle greater valve control unit than 11 % ♦ Throttle valve potentiometer in throttle valve
control unit defective
control unit ⇒ Chapter 24-5
– Test throttle valve control unit ⇒ Chapter 24-2
♦ Throttle valve blocked ♦ Air filter element very dirty
01-5 page 8
– Adapt engine control unit to throttle valve
Self-diagnosis V
– Eliminate cause – Replace air filter element ⇒ Chap. 24-1
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Display group 014 - Ignition, sum of misfiring detection:
• Driving Read measured value block
14 →
xxxx rpm
xxx %
xxx
Text
1
2
3
4
⇐ Read out on display: ⇐ Display field Combustion misfiring detection (activated, deactivated)
Specification
Analysis:
activated — 0
⇒ 01-5 page 9
12…100 %
—
Vehicles with engine code AUA
650…5700 rpm
—
Vehicles with the engine codes BBY, BKY
660…5700 rpm
—
Vehicles with automatic gearbox (engine codes AUA, BBY, BKY)
580…5700 rpm
Vehicles with engine code AUB
740…6600 rpm
—
Vehicles with engine code BBZ
580…6600 rpm
—
Sum of ignition misfiring Engine load Engine speed
—
Analysis of display group 014, sum of ignition misfiring
Display field
Readout on display:
Possible cause of fault
Rectifying fault
3
greater than 0
♦ Spark plug defective
– Test spark plugs and spark cables with
♦ Spark plug connector defective ♦ Ignition transformer defective
spark plug connector ⇒ Chap. 28-1
– Inspect ignition transformer ⇒ Chapter 28-1
– Test injection valves ⇒ Chapter 24-3 Exhaust gas recirculation valve jams/soiled – Test exhaust gas recirculation valve
♦ Injection valve defective ♦
⇒ Chapter 01-1, final control diagnosis.
Display group 015 - ignition, cylinder misfiring 1 to 3:
• Driving
Edition 06.04 S00.5309.04.20
Self-diagnosis V
01-5 page 9
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Read measured value block
15 →
xxx
xxx
xxx
Text
1
2
3
4
⇐Read out on display: ⇐ Display field Combustion misfiring detection (activated, deactivated)
Ignition misfiring cylinder 3 Ignition misfiring cylinder 2 Ignition misfiring cylinder 1
Specification
Analysis:
activated — 0
⇒ 01-5 page 10
0
⇒ 01-5 page 10
0
⇒ 01-5 page 10
Display group 016 - ignition, cylinder misfiring 4:
• Driving Read measured value block
16 →
xxx
—
—
Text
1
2
3
4
⇐ Read out on display: ⇐ Display field Combustion misfiring detection (activated, deactivated)
Ignition misfiring cylinder 4
Specification
Analysis:
activated — —
—
—
—
0
⇒ 01-5 page 10
Analysis of display groups 015 and 016, ignition misfiring cyl. 1 to cyl. 4
Display fields
Readout on display:
Display group 15 display field 1 to 3
greater than 0
and display group 16 display field 1
Possible cause of fault
♦ Spark plug defective
Rectifying fault
– Test spark plugs and spark cables with
♦ Spark plug connector defective
spark plug connector ⇒ Chap. 28-1
♦ Ignition transformer defective
– Inspect ignition transformer ⇒ Chapter 28-1 ♦ Injection valve defective ♦ Exhaust gas recirculation valve jams/dirty
– Test injection valves ⇒ Chapter 24-3 – Test exhaust gas recirculation valve
⇒ Chapter 01-1, final control diagnosis.
Display group 022 ignition, knock control:
• Driving
01-5 page 10
Self-diagnosis V
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
22 →
Read measured value block xxxx rpm
xxx %
xx.x °
xx.x °
1
2
3
4
⇐ Read out on display: ⇐ Display field
Specification
Analysis:
Ignition angle relief cylinder 2 through knock control
0...14 °
⇒ 01-5 page 12
Ignition angle relief cylinder 1 through knock control
0...14 °
⇒ 01-5 page 12
15...100 %
—
Vehicles with engine code AUA
650…5700 rpm
—
Vehicles with the engine codes BBY, BKY
660…5700 rpm
—
Vehicles with automatic gearbox (engine codes AUA, BBY, BKY)
580…5700 rpm
Vehicles with engine code AUB
740…6600 rpm
—
Vehicles with engine code BBZ
580…5700 rpm
—
Engine load Engine speed
—
Note ♦ Notes on display groups 3 and 4: ♦ When idling the display value must be 0.0 . ♦ 14
is the largest ignition angle relief.
Display group 023 - ignition, knock control:
• Driving 23 →
Read measured value block xxxx rpm
xxx %
xx.x °
xx.x °
1
2
3
4
⇐Read out on display: ⇐ Display field Ignition angle relief cylinder 4 through knock control
Ignition angle relief cylinder 3 through knock control Engine load Engine speed
Edition 06.04 S00.5309.04.20
Specification
Analysis:
0...14 °
⇒ 01-5 page 12
0...14 °
⇒ 01-5 page 12
15...100 %
—
Vehicles with engine code AUA
650…5700 rpm
Vehicles with the engine codes BBY, BKY
660…5700 rpm
Vehicles with automatic gearbox (engine codes AUA, BBY, BKY)
580…5700 rpm
Vehicles with engine code AUB
740…6600 rpm
—
Vehicles with engine code BBZ
580…6600 rpm
—
Self-diagnosis V
— — —
01-5 page 11
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note ♦ Notes on display groups 3 and 4: ♦ When idling the display value must be 0.0 . ♦ 14
is the largest ignition angle relief.
Analysis of display groups 022/023, ignition angle relief
Display field
Readout on display:
Possible cause of fault
Rectifying fault
3 and 4
All 14 ° cylinder
♦ Knock sensor defective
– Inspecting knock sensor ⇒ Chapter 28-1 – Check knock sensor plug connection
♦ Plug connection corroded
⇒ Chap. 28-1
♦ Knock sensor incorrectly tightened
♦ Plug connection corroded
– – – –
♦ Engine damage
– Test compression ⇒ 1.4/55; 1.4/74 Engine -
♦ Component parts on engine loose ♦ Poor fuel quality
Once cylinder clearly deviates from the others
Release knock sensor and tighten (20 Nm) Attach component parts Change fuel type Check knock sensor plug connection ⇒ Chap. 28-1 Mechanical Components; Rep. Gr. 15.
♦ Component parts on engine loose
– Attach component parts
Display group 028 - ignition, knock control:
• Driving • Diagnostic device in function 04 - basic setting System in basic setting 28 →
⇐ Read out on display:
xxxx rpm
xx %
xxx.x °C
Text
1
2
3
4
⇐ Display field Result knock sensor test (Test ON/ Test OFF/Syst. o.k./Syst. n.o.k.)
Coolant temperature Engine load Engine speed
01-5 page 12
Self-diagnosis V
Specification
Analysis:
Syst. o.k.
—
60...110 °C
⇒ 01-5 page 6
50...70 %
—
2000...4000 rpm
—
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01-6
Self-diagnosis VI
Measured value blocks Measured value blocks, display groups 030...049, 099 - Lambda control Display group 030 - lambda control:
• Engine idling Read measured value block
30 →
xxx
xxx
—
—
1
2
3
4
⇐ Read out on display: ⇐ Display field
Specification
Analysis:
—
—
—
—
Status lambda control downstream of catalytic converter
110
⇒ 01-6 page 1
Status lambda control upstream of catalytic converter
111
⇒ 01-6 page 1
Note ♦ Re display field 2: ♦ The 3rd display position is only set to 1 in the partial
load region.
Meaning of the 3-digit numerical block display field 1:
Meaning if display positions = 1 1
2
3 1
1 1
Lambda control active Lambda probes operational Lambda probe heating on
Display group 031 - lambda control, lambda values upstream of catalytic converter:
• Engine idling • Coolant temperature ≥ 80 °C
Edition 06.04 S00.5309.04.20
Self-diagnosis VI
01-6 page 1
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Read measured value block x.xxxx
x.xxxx
1
2
3
31 → 4
< Readout on display < Display field No display
No display Lambda nominal value - Bank 1 Lambda actual value - Bank 1
Specification
Analysis:
---
---
---
---
0,9900…1,0100
---
0,9600…1,0400
---
Display group 032 - Lambda control, Lambda initialisation values:
• Engine idling Read measured value block xx.x %
xx.x %
1
2
32 →
—
—
3
4
⇐Read out on display: ⇐ Display field
Lambda learned value under partial load (multiplicative) upstream of catalytic converter Lambda learned value in idling (additive) upstream of catalytic converter
Specification
Analysis:
—
—
—
—
-10,0...10,0 %
⇒ 01-6 page 3
-10,0...10,0 %
⇒ 01-6 page 3
Note ♦ Re display fields 1 and 2: ♦ Low readouts indicate that the engine is running too
rich and the lambda control therefore produces a leaner mixture. ♦ High readouts mean that the engine is running too
lean and the lambda control therefore produces a richer mixture. ♦ If the control unit is dead all initialisation values are re-
set. ♦ add = additive - The effect of the fault (e.g. unmetered
air) becomes increasingly less as engine speed rises. In the case of an additive initialisation value the injection period is changed by a fixed rate. This rate is independent of the basic injection period. ♦ mul = multiplicative - The effect of the fault (e.g. faulty
injector) becomes greater as engine speed rises. The multiplicative learned value is a percentage change in the injection period. This change is dependent on the basic injection period. ♦ Initialisation conditions for partial load. Coolant tem-
perature at least 75 C, intake air temperature max. 90 C, driving mode.
01-6 page 2
Self-diagnosis VI
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Analysis of display group 032, Lambda control, Lambda learned values
Display field
Readout on display:
Possible cause of fault
Rectifying fault
1 and 2
low lambda learned values
♦ Low learned values in idling at normal
– Disappears after motorway driving or oil
learned values in partial load: Oil dilution (higher fuel content in the oil) possible
change
– Test injection valves ⇒ Chapter 24-3 – Test fuel pressure regulator and holding
♦ Injection valve leaks ♦ Fuel pressure too high
pressure ⇒ Engine 1.4/55; 1.4/74 Mechanics; Rep. Gr. 20.
♦ Solenoid valve 1 for activated charcoal filter
– Testing solenoid valve 1 for activated
charcoal filter ⇒ Chapter 01-1, final control diagnosis
-N80- constantly open ♦ Lambda probe heating defective or lambda
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
probe dirty
Display field
Readout on display:
Possible cause of fault
Rectifying fault
1 and 2
high lambda initialisation values
♦ High learned values in idling at less high
– Testing intake system for tightness ⇒ Chapter 24-3
learned values in partial load: Unmetered air in intake manifold region possible ♦ Unmetered air between air filter and throttle
– Eliminate cause
valve ♦ Unmetered air at the exhaust manifold gas-
– Eliminate cause
ket ♦ Injection valve blocked
– Test injection valves ⇒ Chapter 24-3
♦ Fuel pressure too low
– Test fuel pressure regulator and holding pressure ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20.
♦ Lambda probe heating defective or lambda
– Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
probe dirty
Display group 033 - Lambda control, Lambda control values:
• Engine idling Read measured value block
33 →
xx.x %
x.xxx V
—
—
1
2
3
4
⇐ Read out on display: ⇐ Display field
Lambda probe voltage before catalyst Lambda control before catalyst
Edition 06.04 S00.5309.04.20
Specification —
—
—
—
0.4...0.5 V
—
-15,0...15,0 %
Self-diagnosis VI
Analysis:
⇒ 01-6 page 4
01-6 page 3
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note ♦ Re display field 1: ♦ The display must oscillate around 0. If 0 is constantly
displayed, the lambda control has switched from closed-loop to open-loop control because of a fault in the lambda control. Interrogate fault memory ⇒ Chapter 01-1. Note ♦ Re display field 2: ♦ Display 0.450 V equals approx.
= 1.0.
♦ Voltage signal „Mixture rich“ (low level of residual ox-
ygen) is below 0.45...V. ♦ Voltage signal „Mixture lean“ (a lot of residual oxygen)
is above 0.45...V. ♦ Through its structure the wide-band lambda probe en-
ables a permanent lambda control due to the signal routing for deviations as of = 1. ♦ The control is performed dynamic, as the deviation
from the specification is current and is known as the concrete value.
Analysis of display group 033, lambda control upstream of catalytic converter
Display field
Readout on display:
Possible cause of fault
Rectifying fault
1
not within tolerance
♦ Minimum range: Engine too rich, lambda
– wait 30 seconds until the display has
control leans off
stabilised
♦ Plus range: Engine too lean, lambda control
enriches ♦ Unmetered air
– Testing intake system for tightness ⇒ Chapter 24-3
♦ Injection valve defective
– Test injection valve ⇒ Chap. 24-3
♦ Lambda learned values on limit
– Test lambda initialisation values in display group 032 ⇒ 01-6 page 3
Display group 034 - Lambda control, diagnosis of lambda probe upstream of catalytic converter (ageing test over amplitude quality grade)
– Blip two short accelerations above 5000 rpm • Vehicle standing, engine running at high speed • Diagnostic device in function 04 - basic setting
01-6 page 4
Self-diagnosis VI
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
System in basic setting 34 → xxxx rpm
xxx.x °C
1
2
x.x s 3
⇐ Read out on display: Text 4
⇐ Display field Result of test of lambda probe ageing upstream of catalytic converter (Test OFF/Test ON/B1 S1 o.k./B1 S1 n.o.k.)
Period of lambda probe upstream of catalytic converter Catalytic converter temperature Engine speed
Specification
Analysis:
B1 S1 o.k.
—
max. 1.0 s
—
—
—
1500…3900 rpm
—
Specification
Analysis:
—
—
—
—
Note ♦ regarding display fields 3 and 4: ♦ The period duration indicates the time between two
voltage jumps (e.g. rich - lean - rich) of the lambda probe and is thus an indication of the age condition of the lambda probe. If the given time is exceeded, display field 4 = B1 S1 N.O.K.
Display group 036 - lambda control, operation after catalyst
• Vehicle standing, brake pedal activated, engine running at raised idling (1500….4000 rpm)
• Diagnostic device in function 04 - basic setting System in basic setting 36 →
⇐ Read out on display:
x.xxx V
Text
—
—
1
2
3
4
⇐ Display field
Test lambda probe downstream of catalytic converter (Test OFF/Test ON/B1 S2 n.o.k.) Lambda probe voltage after catalytic converter
Edition 06.04 S00.5309.04.20
Self-diagnosis VI
B1 S2 o.k. — 0.000...1.000 V
⇒ 01-6 page 6
01-6 page 5
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Analysis of display group 036, lambda probe voltage, lambda probe downstream of catalytic converter
Display field
Readout on display:
Possible cause of fault
Rectifying fault
1
constant 1.100 V
♦ Short-circuit to positive terminal in: Lambda
– Test basic voltage of the lambda probe
probe, lambda probe cable, earth lead, engine control unit
downstream of catalytic converter ⇒ Chap. 24-4
– Test lambda probe after catalytic converter ⇒ Chapter 24-4
constant between 0.400 ...0.500 V
♦ Line interruption in: Lambda probe, lambda
constant 0.000 V
♦ Short-circuit to earth in: Lambda probe,
probe cable, earth lead, engine control unit
lambda probe cable, earth lead, engine control unit
Display group 037 - Lambda control, Lambda probes downstream of catalytic converter:
• Driving • Diagnostic device in function 04 - basic setting System in basic setting 37 →
⇐ Read out on display:
xx.x %
x.xxx V
x.x %
Text
1
2
3
4
⇐ Display field
Specification
Analysis:
Test lambda probes (Test ON/Test OFF/Syst. o.k./ Syst. n.o.k.)
Syst. o.k.
—
—
—
0.000...1.000 V
⇒ 01-6 page 6
12,0...40,0 %
⇒ Chapter 01-5
Ignore Lambda probe voltage after catalytic converter Engine load
Note ♦ Re display field 2: ♦ Voltage signal „Mixture rich (low level of residual oxy-
gen)“ is at approx. 0.7...1.0 V. ♦ Voltage signal „Mixture lean (high level of residual ox-
ygen)“ is at approx. 0.0...0.3 V. ♦ A voltage jump from 0.7...1.0 V to 0.0...0.3 V or vice
versa takes place at the transition from „rich“ to „lean“ and vice versa ( = 1.0).
01-6 page 6
Self-diagnosis VI
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection ♦ 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 „slightly too lean“ and „slightly too rich“ states. ♦ The readout must in some cases be less than 0.3 V
and in some cases more than 0.6 V. The readout below 0.45 V indicates a lean mixture while above 0.45 V indicates a rich mixture. ♦ At idling speed, the voltage of the lambda probe up-
stream of the catalytic converter -G39- must fluctuate between a rich and leaner mixture. The voltage of the lambda probe downstream of the catalytic converter -G130- should indicate a constant rich or lean mixture. If the voltage also fluctuates downstream of the catalytic converter, either the catalytic converter is faulty (Read measured value block 046 ⇒ 01-6 page 8) or the probes have been wrongly connected (irregular engine running). Lambda control varies between 15...15 %. Voltage of the 4-pin lambda probe in U in mV A: Lambda probe voltage high rich mixture (fuel surplus or air shortage) high CO value B: Lambda probe voltage low lean mixture (fuel shortage or air surplus) low CO value
Display group 041 - lambda control, lambda probe heating:
• Engine idling Read measured value block
41 →
—
Text
xxx ohms
Text
1
2
3
4
⇐Read out on display: ⇐ Display field Lambda probe heating downstream of catalytic converter
Resistance lambda probe heating downstream of catalytic converter Lambda probe heating upstream of catalytic converter
Edition 06.04 S00.5309.04.20
Self-diagnosis VI
Specification Ht. after c. ON Ht. after c. OFF
Analysis: —
—
—
Ht. bf. c. ON Ht. bf. c. OFF
—
—
—
01-6 page 7
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note Depending on the operating state of the engine the lambda probe heaters are switched on or off, i.e. the readouts in display field 2 and 4 may show either „Htg.u(d)C.ON“ or „Htg.u(d)C.OFF“.
Display group 46 - Lambda control, Diagnosis of catalyst (conversion test):
• Diagnostic device in function 04 - basic setting • Vehicle standing, engine running at high speed • No fault in fault memory, coolant temperature 60...120 °C, lambda control active and stable
System in basic setting 46 →
⇐ Read out on display:
xxxx rpm
xxx.x °C
xx.x %
Text
1
2
3
4
⇐ Display field Result of the catalyst conversion test (Test OFF/Test ON/Cat B1 O.K./ Cat B1 N.O.K.)
Measured value catalytic conversion Catalytic converter temperature Engine speed
Specification
Analysis:
Cat B1 o.k.
—
at least 60 %
—
at least 300 °C
—
1500…3900 rpm
—
Display group 099 - Lambda control, Operating condition of lambda control:
• Engine idling Read measured value block
99 →
xxxx rpm
xxx °C
xx.x %
Text
1
2
3
4
⇐Read out on display: ⇐ Display field Operating condition of lambda control
Lambda control before catalyst Coolant temperature Engine speed (idling speed) 1)
Specification
Analysis:
OFF ON
—
-15,0...15,0 %
⇒ 01-6 page 4
80...110 °C
⇒ Chapter 01-5
rpm1)
⇒ Chapter 01-5
xxxx
Display group 001, display field 1 ⇒ Chap. 01-5.
01-6 page 8
Self-diagnosis VI
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
01-7
Self-diagnosis VII
Measured value blocks Measured value blocks, display groups 050...069 - Speed control Display group 050 - Speed control, Operating conditions:
• Engine idling Read measured value block
50 →
xxxx rpm xxxx rpm
Text
Text
3
4
1
2
⇐ Read out on display: ⇐ Display field Operating state of AC compressor
Operating condition of air conditioning system
Specification
Analysis:
ON OFF
—
ON OFF
—
Engine speed (idling speed - specified value) Vehicles with engine code AUA
750 rpm (830 rpm)1)
Vehicles with engine code AUB
840 rpm (870 rpm)1)
Vehicles with the engine codes BBY and BKY
760 rpm
Vehicles with engine code BBZ
680 rpm
Vehicles with automatic gearbox Engine speed (idling speed - actual value) 1) 2)
680 rpm (800 rpm)1) xxxx rpm2)
⇒ Chapter 01-5
Air conditioning switched on Display group 001, display field 1 ⇒ Chap. 01-5
Note ♦ Re display field 2: ♦ The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is displayed. ♦ The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely overheated. Note ♦ regarding display fields 3 and 4: ♦ „OFF“ is always displayed on vehicles without air con-
ditioning system.
Edition 06.04 S00.5309.04.20
Self-diagnosis VII
01-7 page 1
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Display group 054 - Lambda control:
• Driving Read measured value block
54 →
xxxx rpm
Text
xxx %
xxx %
1
2
3
4
⇐Read out on display: ⇐ Display field Throttle valve angle (potentiometer 1 -G187-)
Sender 1 for accelerator pedal position -G79-
Specification
Analysis:
3...97 % — 3...97 %
Operating position: Idling, part load, enrichment, overrun, full load
—
—
—
Vehicles with engine code AUA
650 ... 5700 rpm
—
Vehicles with the engine codes BBY, BKY
660 ... 5700 rpm
—
Vehicles with automatic gearbox (engine codes AUA, BBY, BKY)
580 ... 5700 rpm
—
Vehicles with engine code AUB
740 ... 6600 rpm
—
Vehicles with engine code BBZ
580 ... 6600 rpm
—
Engine speed
Note ♦ Re display field 2: ♦ The operating condition is displayed according to the
speed or load. As of increased speed „trailing throttle“ with closed throttle valve is only displayed up to 1450 rpm, after that it returns to idling.
Display group 055 - Speed control, idle stabilizer:
• Engine idling Read measured value block
55 →
xxxx rpm
xx Nm
xx.x %
xxxxx
1
2
3
4
⇐ Read out on display: ⇐ Display field
Specification
Analysis:
xxxxx
⇒ 01-7 page 3
Air conditioning on
-6,0...8,0 %
—
Air conditioning off
-3,0...8,0 %
Operating conditions Initialisation value idling control
Idling control
-10…0 Nm
Engine speed (idling speed) 1)
xxxx
rpm1)
— ⇒ Chapter 01-5
Display group 001, display field 1 ⇒ Chap. 01-5
01-7 page 2
Self-diagnosis VII
Edition 06.04 S00.5309.04.20
01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note ♦ Re display field 3: ♦ The display shows to what extent the idling stabilizer
has „disinitialised“ from the constructively given mean value. On a new engine the value is in the positive region because of the higher friction, on a run-in engine it is in the negative region.
Display field 4 - Operating conditions, meaning of the digits in the 5-digit number block
Meaning if display positions = 1 1
2
3
4
5 1
1 1
Meaning Air conditioning compressor on Driving position engaged Air conditioning switched on
x
No meaning
x
No meaning
Display group 056 - engine speed control, idling speed stabilisation:
• Engine idling Read measured value block
56 →
xxxx rpm
xxxx rpm
xx Nm
xxxxx
1
2
3
4
⇐Read out on display: ⇐ Display field Operating conditions
Idling control
Specification
Analysis:
xxxxx
⇒ 01-7 page 3
-10...0 Nm
—
Engine speed (idling speed - specified value) Vehicles with engine code AUA
750 rpm (830 rpm)1)
Vehicles with engine code AUB
840 rpm (870 rpm)1)
Vehicles with the engine codes BBY and BKY
760 rpm
Vehicles with engine code BBZ
680 rpm
Vehicles with automatic gearbox: Engine speed (idling speed - actual value) 1) 2)
680 rpm (800 rpm)1) xxxx rpm2)
⇒ Chapter 01-5
Air conditioning switched on Display group 001, display field 1 ⇒ Chap. 01-5
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Note ♦ Re display field 2: ♦ The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is displayed. ♦ The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely overheated.
Display group 60 - Speed control, Electronic Throttle Adaptation:
• Ignition on, engine stopped • Diagnostic device in function 04 „basic setting“ 60 →
Read measured value block xxx %
xxx %
xx
Text
1
2
3
4
⇐Read out on display: ⇐ Display field Adaption state (ADP runs, ADP o.k. or ADP n.o.k.)
Initialisation step counter Throttle valve angle (potentiometer 2 -G188-) Throttle valve angle
Specification
Analysis:
ADP o.k.
—
0...12
—
3...97% 3...97%
— —
Potentiometer 1 -G187-
Note ♦ To display group 60: ♦ The adaptation of the throttle valve control unit occurs
with the ignition switched on and accelerator pedal not depressed. ♦ The engine control unit is adjusted to the throttle valve
control unit by selecting display group under function 04 „Basic setting“. This adjustment must always be performed if a different throttle valve (or completely different engine) or a different engine control unit has been fitted. ♦ If the power supply was interrupted (battery discon-
nected) an adaptation must also be carried out ⇒ Chap. 24-5. Work sequence after a power supply interruption. ♦ During adaptation the counter in display field 3 counts
up to 12. ♦ The basic setting may only be ended once the counter
in display field 3 has reached step 12.
Display group 61 - engine speed control, EPC:
• Driving
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Read measured value block
61 →
xxxx rpm
—
xxx.x %
xxxxx
1
2
3
4
⇐Read out on display: ⇐ Display field Operating conditions
Throttle valve angle (potentiometer 1 -G187-)
Specification
Analysis:
xxxxx
⇒ 01-7 page 3
0...100 %
—
—
—
Vehicles with engine code AUA
650…5700 rpm
—
Vehicles with the engine codes BBY, BKY
660…5700 rpm
—
Vehicles with automatic gearbox (engine codes AUA, BBY, BKY)
580…5700 rpm
Vehicles with engine code AUB
740…6600 rpm
—
Vehicles with engine code BBZ
580…6600 rpm
—
Specification
Analysis:
Engine speed
—
Display group 062 - engine speed control, EPC:
• Ignition on, engine stopped Read measured value block
62 →
xx %
xx %
xx %
xx %
1
2
3
4
⇐Read out on display: ⇐ Display field Sender 2 for accelerator pedal position -G185-
0...100 %
Sender 1 for accelerator pedal position -G79-
0...100 %
Throttle valve angle (potentiometer 2 -G188-) Throttle valve angle (potentiometer 1 -G187-)
—
3...97 % 3...97 %
— — —
Measured value blocks, display groups 070...075 - exhaust gas recirculation Display group 070 - Exhaust gas reduction, Activated charcoal filter system diagnosis (tank ventilation system):
• Engine idling • Coolant temperature minimum 80 °C • Diagnostic device in function 04 „basic setting“
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Read measured value block
70 →
xx %
xx %
xxx mbar
Text
1
2
3
4
⇐Read out on display: ⇐ Display field Result of the activated charcoal filter system diagnosis (Test OFF/Test ON/TVV O.K./ TVV N.O.K.)
Intake manifold pressure Result of current diagnosis Opening level
Specification
Analysis:
TVV o.k.
—
240…420 mbar
—
> 25 %
—
13…25 %
—
Specification
Analysis:
Note TVV means Tank Vent Valve (activated charcoal filter solenoid valve 1). Note ♦ Re display field 1: ♦ During diagnosis the display fluctuates in the region
from 13...25 % to approx. 6 %.
Display group 074 - Exhaust gas reduction, Exhaust gas recirculation valve adaptation:
• Ignition on, engine stopped • Diagnostic device in function 04 „basic setting“ Read measured value block
74 →
x.x V
x.x V
x.xxx V
Text
1
2
3
4
⇐ Read out on display: ⇐ Display field Adaption state (ADP runs, ADP o.k. or ADP n.o.k.)
Current pot voltage value
ADP o.k. — 0,300…4.600 V
—
100 %- Position
2,9…4.6 V
—
0 - Position (basic setting)
0,3…1.3 V
—
Note ♦ To display group 074: ♦ The adaptation of the exhaust gas recirculation valve
occurs with the ignition on. ♦ The engine control unit is adapted to the exhaust gas
recirculation valve by selecting display group 074 under function 04 „Basic position“. This adaption must
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01
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection always be performed if another EGR valve (or completely different engine) or another engine control unit has been installed.
Display group 075 - Exhaust gas recirculation:
• Engine idling • Diagnostic device in function 04 „basic setting“ – Briefly blip throttle 5 times up to max. speed. Read measured value block
75 →
xxxx rpm xxx mbar
xxx mbar
Text
3
4
1
2
⇐ Read out on display: ⇐ Display field
Specification
Result: Test ON/ Test OFF, Syst. o.k./Syst. n.o.k.
Analysis:
Syst. o.k. —
Intake manifold pressure difference
min. 50 mbar
Intake manifold pressure Engine speed
—
240…420 mbar
—
1800…5600 rpm
—
Specification
Analysis:
—
—
—
—
80.0...110.0 °C
⇒ Chapter 01-5
00000000
⇒ 01-7 page 7
Note ♦ Re display field 3: ♦ An error can already occur under 140 mbar.
Measured value blocks, display group 100 - readiness code Display group 100 - readiness code:
• Engine idling 100 → ⇐ Read out on display:
Read measured value block xxxxxxxx
xxx.x °C
xxx s
xxxxxxxx
1
2
3
4
⇐ Display field Diagnosis status
Time since engine start Coolant temperature Readiness code
Display field 1 - Readiness code - Meaning of the digits in the 8-digit numerical block
The readiness code is only generated if all the display positions show 0 1
2
3
4
5
6
7
8 0
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Diagnosis function Catalytic converter Catalytic converter heating (no diagnosis at present/always „0“) Self-diagnosis VII
01-7 page 7
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
The readiness code is only generated if all the display positions show 0 0
Activated charcoal filter system (tank ventilation system)
0
Secondary air injection system (not fitted/always „0“)
0
Air conditioning system (currently no diagnosis/always „0“)
0
Lambda probes
0
Lambda probe heater
0
Exhaust gas recirculation
Measured value blocks, display groups 120...129 - Communication Display group 120 - traction control system (TCS):
• Driving Read measured value block
120 →
xxxx rpm
xxx Nm
xxx Nm
Text
1
2
3
4
⇐ Read out on display: ⇐ Display field Status
Actual engine load Nominal engine load Engine speed 1)
Specification
Analysis:
active/inactive
—
—
—
—
—
xxxx rpm1)
⇒ Chapter 01-5
Specification
Analysis:
Engine ctl./ no ctl.
—
—
—
—
—
Display group 001, display field 1 ⇒ Chap. 01-5
Display group 122 - Gearbox (only automatic):
• Driving Read measured value block
122 → ⇐ Read out on display:
xxxx rpm
xxx Nm
xxx Nm
Text
1
2
3
4
⇐ Display field Status
Actual engine load Nominal engine load Engine speed 1)
xxxx
rpm1)
⇒ Chapter 01-5
Display group 001, display field 1 ⇒ Chap. 01-5
Display group 125 - communication, databus messages
• Engine idling
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Read measured value block
125 → ⇐ Read out on display:
Text
Text
Text
Text
1
2
3
4
⇐ Display field Status airbag
Status of combiinstrument Status gearbox Status ABS
Specification
Analysis:
Airbag 1
—
Combi 1
—
Gearbox 1
—
ABS 1
—
Note ♦ To display group 125: ♦ Nominal value = 1; the control units with active data
bus are displayed.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Self-diagnosis VII
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
24 – Fuel Formation, Injection 24-1
Repairing the injection system
Installed location overview for engines with the engine codes AUA, AUB 1 - Activated charcoal filter system solenoid valve 1 -N80- */** ❑ inspecting ⇒ Chap. 01-1 2 - 3-pin connector ❑ for engine speed sender -G283 - Intake manifold pressure sender -G71- * with intake manifold temperature sender -G72- ** 4 - Intake manifold
3 1
6 2
4
9 7 8
5
5 - Injector - (N30…N33)- * 6 - Knock sensor -G61- * ❑ Fitting location: Cylinderblock intake side ❑ inspect ⇒ Chapter 28-1 7 - Engine control unit * 8 - Throttle valve control unit -J338- *
14
12
A
16
D
11
13
C
10 - Ignition transformer -N152- * ❑ with identification for ignition leads, do not switch ❑ inspect ⇒ Chapter 28-1 11 - 6-pin connector ❑ for wide band lambda probe with lambda probe heating before catalyst
B
9 - Engine speed sender -G28- * ❑ inductive pickup ❑ Fitting location: Cylinderblock intake side
10
15
S24-0333
12 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- * 1.4/74 Engine - Mechanics; Rep. Gr. 26
1.4/55;
13 - Sender for coolant temperature -G62- * ❑ inspect ⇒ Chapter 24-2 14 - Hall sender - G40- * ❑ inspect ⇒ Chapter 28-1 15 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm ❑ Fitting location: in the exhaust manifold ❑ 6-pin connector 16 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm ❑ Fitting location: downstream of catalytic converter ❑ 4-pin connector
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24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Installed location overview for engines with the engine codes BBY, BBZ, BKY 1 - Activated charcoal filter system solenoid valve 1 -N80- */** ❑ inspecting ⇒ Chap. 01-1 2 - 3-pin connector ❑ for engine speed sender -G283 - The vacuum regulating valve (PCV valve) ❑ for crankcase ventilation 4 - Heating resistor of crankcase ventilation -N795 - Intake manifold pressure sender -G71- * with intake manifold temperature sender -G72- ** 6 - Intake manifold 7 - Injectors -(N30…N33)- * 8 - Knock sensor -G61- * ❑ Fitting location: Cylinderblock intake side ❑ inspect ⇒ Chapter 28-1 9 - Engine control unit * 10 - Throttle valve control unit -J338- * 11 - Engine speed sender -G28- * ❑ inductive pickup ❑ Fitting location: Cylinderblock intake side 12 - 6-pin connector ❑ Observe current flow diagram ❑ for wide band lambda probe with lambda probe heating before catalyst 13 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- * 1.4/74 Engine - Mechanics; Rep. Gr. 26
1.4/55;
14 - Sender for coolant temperature -G62- * ❑ inspect ⇒ Chapter 24-2 15 - Hall sender -G40- * ❑ inspect ⇒ Chapter 28-1 16 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm ❑ pay attention to the spare part number ❑ in exhaust manifold - engines BBY, BBZ ❑ exhaust tube front - engine BKY ❑ 6-pin connector - pay attention to different connections for engines with the engine codes BKY EU-4 and EU2DDK 05.04 ➤ 17 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm ❑ Fitting location: downstream of catalytic converter ❑ 4-pin connector 18 - Ignition coils with a power output stage -N70, N127, N291 und N292❑ remove with extractor -T 10094-
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24
General notes on the injection system Repairing the ignition ⇒ Rep. Gr. 28. ♦ The engine control unit is equipped with a self-diagno-
sis system. The first step, before commencing repairs or fault finding, is to interrogate the fault memories of all the control units using the automatic test sequence. This is necessary because different control units are interconnected via data bus. Also check the vacuum hoses and connections (unmetered air). ♦ Fuel hoses in the engine compartment must be se-
cured with spring band clamps. The use of clamp-type or screw-type clips is not allowed. ♦ Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit. ♦ Components marked with an * are checked by self-di-
agnosis ⇒ Chapter 01-1.
♦ Components marked with
** can be tested with the final control diagnosis ⇒ Chap. 01-1.
♦ A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components. ♦ Do not use sealants containing silicone. Traces of sil-
icone elements drawn in by the engine are not burnt in the engine and damage the lambda probes. ♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit. The fault memory must then be interrogated and if necessary adapted to the control unit ⇒ Chapter 245. ♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary erase ⇒ Chapter 01-1. ♦ Vehicles fitted with airbags are equipped with a crash
fuel shut-off. It is intended to reduce the risk of a vehicle fire after a crash as the fuel pump is disconnected by the fuel pump relay. This installation also enhances the starting behaviour of the engine. When opening the door the fuel pump is activated for 2 seconds in order to build up the pressure in the fuel system. Safety measures ⇒ 24-1 page 12. Cleanliless rules ⇒ 24-1 page 13. Inspect intake air system for leaks (unmetered air) ⇒ Chap. 24-3. Inspecting engine operating conditions ⇒ Chapter 24-4.
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24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Removing and installing parts of the injection system 1 - Plug 33 ❑ pay attention to correct installation position 32 2 - Air filter ❑ disassembling and assem31 bling ⇒ 24-1 page 11 30 3 - Cable guide ❑ clipped on to fuel rail 4 - 10 Nm 5 - Vent valve 6 - Fuel rail with injection valves 26 ❑ disassembling and assem22 bling ⇒ 24-1 page 10 7 - 20 Nm 8 - from brake servo unit 9 - Connector 25 ❑ 6-pin 24 ❑ for throttle valve control unit -J33823 ❑ Contacts of connector goldplated 10 - Activated charcoal filter system solenoid valve 1 -N80- */** ❑ ⇒ 1.4/55; 1.4/74 Engine Mechanical Components; Rep. Gr. 20 11 - Intake manifold ❑ disassembling and assembling ⇒ 24-1 page 6 12 - Gasket ❑ replace 13 - 10 Nm 14 - Connecting tube ❑ to exhaust gas recirculation valve
1 29
2
28
3
27
4 5 6 7
26
8 9
22 21 20
10 11
19
12 13 18
17
16
15
14
S24-0338
15 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm ❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body ❑ with 4-pin connector ❑ Contacts 3 and 4 gilded ❑ Power supply for lamda probe heating supplied via fuel pump relay -J17❑ Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4 ❑ Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4 ❑ Fitting location: downstream of main catalytic converter 16 - Connector for lambda probe downstream of catalytic converter ❑ 4-pin 17 - Lambda probe 1 upstream of catalytic converter -G39-*, 50 Nm ❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body ❑ pay attention to the spare part number ❑ with 6-pin connector ❑ contacts gold-plated ❑ Power supply for lamda probe heating supplied via fuel pump relay -J17❑ Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4 ❑ Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4 ❑ Fitting location: Engines BBY, BBZ in the exhaust manifold, engine BKY in the front exhaust pipe
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24
18 - Connector for lambda probe upstream of catalytic converter ❑ 6-pin - pay attention to different connections for engines with the engine codes BKY EU-4 and EU-2DDK 05.04 ➤ 19 - Engine speed sender -G28- * ❑ inspect ⇒ Chapter 24-3 20 - 5 Nm 21 - Gasket ❑ replace 22 - Retaining clip ❑ check tightness 23 - Connector ❑ black, 2 pin ❑ for sender for coolant temperature -G62❑ contacts gold-plated 24 - Sender for coolant temperature -G62- * ❑ before removing, reduce pressure in cooling system ❑ inspect ⇒ Chapter 24-2 25 - Plug ❑ before removing, reduce pressure in cooling system 26 - O-ring ❑ replace if damaged 27 - 10 Nm 28 - Coolant regulator housing 29 - Fuel-intake hose ❑ secure with spring strap clamps ❑ check for firm seating ❑ from fuel filter ⇒ 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20 30 - Connector ❑ for engine control unit ❑ insert or remove only when the ignition is switched off 31 - Engine control unit* ❑ testing voltage supply ⇒ Chapter 24-5 ❑ Procedure to follow after power supply interruption has occurred ⇒ Chapter 24-5 ❑ replacing ⇒ Chapter 24-5 ❑ coding ⇒ Chapter 24-5 ❑ Fitting location ⇒ 24-1 page 1, overview of the engine compartment 32 - Retaining frame 33 - 2 Nm
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24-1 page 5
24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Disassembling and assembling intake manifold Engines with engine codes AUA and BBY; vehicles mit engines BBY and manual gearbox ➤ 08.03 1 - Throttle valve control unit -J338- * ❑ inspect ⇒ Chapter 24-2 ❑ if replaced adapt engine control unit ⇒ Chapter 24-5 ❑ if replaced adapt automatic gearbox control unit ⇒ chap. 24-5 2 - 10 Nm 3 - Gasket ❑ Check fitting position ❑ replace 4 - Induction pipe 5 - Gasket ring ❑ replace if damaged 6 - 20 Nm 7 - Gasket ring ❑ replace 8 - Guide plate ❑ pay attention to correct installation position ❑ replace if damaged 9 - O-ring ❑ replace if damaged 10 - 3 Nm 11 - Intake manifold pressure sender -G71- * with intake manifold temperature sender -G72- ** ❑ Testing intake manifold pressure sender ⇒ Chap. 24-2 ❑ Inspecting intake manifold temperature sender ⇒ Chap. 24-2 12 - Intake manifold ❑ out of plastic ❑ pay attention to the spare part number ❑ removing and installing ⇒ 24-1 page 4
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24
Engines with engine code AUB 1 - Throttle valve control unit -J338- * ❑ inspect ⇒ Chapter 24-2 ❑ if replaced adapt engine control unit ⇒ Chapter 24-5 2 - Gasket ring ❑ replace if damaged 3 - 10 Nm 4 - 20 Nm 5 - Intake manifold ❑ Aluminium casting ❑ pay attention to the spare part number ❑ removing and installing ⇒ 24-1 page 4 6 - Gasket ring ❑ replace 7 - Guide plate ❑ pay attention to correct installation position ❑ replace if damaged 8 - O-ring ❑ replace if damaged 9 - Intake manifold pressure sender -G71- * with intake manifold temperature sender -G72- ** ❑ Testing intake manifold pressure sender ⇒ Chap. 24-2 ❑ Inspecting intake manifold temperature sender ⇒ Chap. 24-2 10 - 3 Nm
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24-1 page 7
24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Engines with engine codes BBZ; vehicles mit engines BBY and manual gearbox 09.03 ➤ 1 - Intake manifold ❑ out of plastic ❑ pay attention to the spare part number ❑ removing and installing ⇒ 24-1 page 4 2 - Throttle valve control unit -J338- * ❑ inspect ⇒ Chapter 24-2 ❑ if replaced adapt engine control unit ⇒ Chapter 24-5 3 - 10 Nm 4 - Gasket ring ❑ replace if damaged 5 - 20 Nm 6 - Gasket ring ❑ replace 7 - Guide plate ❑ pay attention to correct installation position ❑ replace if damaged 8 - O-ring ❑ replace if damaged 9 - 3 Nm 10 - Intake manifold pressure sender -G71- * with intake manifold temperature sender -G72- ** ❑ Testing intake manifold pressure sender ⇒ Chap. 24-2 ❑ Inspecting intake manifold temperature sender ⇒ Chap. 24-2
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24
Engines with engine identification letters BKY 1 - Intake manifold ❑ out of plastic ❑ pay attention to the spare part number ❑ removing and installing ⇒ 24-1 page 4 2 - Throttle valve control unit -J338- * ❑ inspect ⇒ Chapter 24-2 ❑ if replaced adapt engine control unit ⇒ Chapter 24-5 ❑ if replaced adapt automatic gearbox control unit ⇒ chap. 24-5 3 - 7 Nm 4 - Gasket ❑ replace if damaged 5 - 20 Nm 6 - Gasket ring ❑ replace 7 - O-ring ❑ replace if damaged 8 - Intake manifold pressure sender -G71- * with intake manifold temperature sender -G72- ** ❑ Testing intake manifold pressure sender ⇒ Chap. 24-2 ❑ Inspecting intake manifold temperature sender ⇒ Chap. 24-2
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24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Disassembling and assembling fuel distributor with injectors 1 - Fuel-intake hose ❑ secure with spring strap clamps ❑ check for firm seating 2 - 10 Nm 3 - Fuel distributor 4 - Vent valve 5 - Retaining clip ❑ check tightness on the injection valve and fuel distributor 6 - O-ring ❑ replace ❑ before fitting moisten lightly with clean engine oil
1
2
3
2 4 5 6 7
*
7 - Injector -N30-…-N33❑ inspect ⇒ Chapter 24-3 ❑ Resistor 14...17 Ω at 20 °C
6
5 7
S24-0339
Removing
– Unplug connector -arrows- of the injectors.
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Repairing the injection system
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24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Pull out the fuel feed hose -arrow- and catch the fuel which flows out with a cleaning cloth.
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.
– Remove the fuel distributor with injectors from the inlet manifold.
Installing S10-0099
– Installation is carried out in the reverse order. Note ♦ Replace O-rings. ♦ before fitting moisten O-rings lightly with clean engine
oil
Disassembling and assembling the air filter 1 - Air filter top part 2 - Gasket ❑ replace if damaged 3 - Filter insert 4 - Air filter bottom part 5 - Rubber holder 6 - 3 Nm 7 - Gasket ring ❑ check for firm seating ❑ replace if damaged 8 - Inlet connection with control flap ❑ Inspecting intake manifold preheating ⇒ Chapter 24-3
4
5
6
7 5 6
8
3
1
2
S24-0331
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24-1 page 11
24 Fig. 1:
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Resistance values for the coolant temperature sender -G62-
The diagram is divided into two temperature ranges: A - from 0...50 °C B - from 50...105 °C Read out examples: ♦ 30 °C is in range A and corresponds to a resistance of
1.5...2.0 kΩ ♦ 80 °C is in range B and corresponds to a resistance of
275...375 Ω
Fig. 2:
Resistances for intake manifold pressure sender -G72-
The diagram is divided into two temperature ranges: A - from 0...50 °C B - from 50...105 °C Read out examples: ♦ 20 °C is in range A and corresponds to a resistance of
2.3...2.6 kΩ ♦ 80 °C is in range B and corresponds to a resistance of
290...330 Ω
Fig. 3:
Removing and installing an engine cover with air filter
Removing
– Pull off hose -1- (engines 04.02 ➤) and remove engine cover -2- with air filter upwards -arrows-.
Installing
– Installation of the engine cover with air filter occurs in reverse order.
Safety measures 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. Observe the following points to prevent injury to persons and/or damage to the injection and ignition system:
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24
♦ For reasons of safety fuse no. 40 must be removed
from the fuse holder before opening the fuel system, as the door contact switch could activate the fuel pump. ♦ Do not touch or remove ignition leads with the engine
running or at start speed. ♦ Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and ignition system as well as of test equipment. If test and measuring devices are required during test drives observe the following: ♦ Always secure the test and measuring devices on the
rear seat and also have a second person operate them there. If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident. ♦ If the engine must be operated at start speed without
the engine starting: For engines with the engine codes AUA, AUB
– Unplug the 4-pin connector -arrow- from the ignition transformer. For engines with the engine codes BBY, BKY, BBZ
– Pull out all ignition coils using the extractor -T 10094-. For all vehicles
– Unplug connector -arrows- of the injectors.
Rules of cleanliness When working on the fuel supply/fuel injection system, pay careful attention to the following „5 rules“ for cleanliness. ♦ Thoroughly clean the connection points and their sur-
roundings before releasing. ♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths! ♦ Carefully cover or close opened components if the re-
pair is not completed immediately. ♦ Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use any parts which have been stored unwrapped, e.g. on a shelf or in a tool box. ♦ When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Repairing the injection system
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24
Testing components
Testing throttle valve control unit Components for throttle valve control unit -J338-: Throttle valve drive -G186-, throttle valve drive angle sender 1 -G187- and throttle valve drive angle sender 2 -G188-. Note ♦ If the throttle valve control unit is replaced, it is then
essential to adapt this new throttle valve control unit to the engine control unit ⇒ Chap. 24-5. ♦ On vehicles with an automatic gearbox the gearbox
control unit must also be replaced ⇒ Chap. 24-5.
Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test condition
• Throttle valve is not damaged or dirty. Test sequence
– Unplug the 6-pin connector from the throttle valve control unit.
– Measure resistance of throttle valve drive between contacts 3 + 5. Specified value: 3...200 Ω If the specified value is not reached:
– Replace throttle valve control unit -J338-. If the specified value is reached:
– Test voltage supply of throttle valve control unit and cables to engine control unit ⇒ 24-2 page 1.
If the power supply and wiring is O.K.:
– Replace engine control unit ⇒ Chapter 24-5. Testing voltage supply and wiring to the control unit
– Unplug the 6-pin connector from the throttle valve control unit.
– Connect the multimeter for voltage measurement to contacts 2 + 6 of the connector.
– Switch on ignition. Edition 06.04 S00.5309.04.20
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Specified value: min. 4,5 V
– Switch off ignition. – Connect the multimeter for voltage measurement to contact 2 of the connector and to earth.
– Switch on ignition. Specified value: min. 4,5 V
– Switch off ignition. If the specified values are not reached:
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 6-pin plug for interruption: Plug contact
Test box bush -V.A.G. 1598/31-
1
92
2
83
3
117
4
84
5
118
6
91
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other. – Additionally check the cable for a short circuit to battery positive and to earth. If the lines are not found to be faulty:
– Inspect engine control unit power supply ⇒ Chapter 24-5.
Testing accelerator pedal position sender Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Test box -V.A.G 1598/31♦ Current flow diagram
Operation The two accelerator pedal position senders -G79- and -G185- are located at the accelerator pedal and pass on the driver input to the engine control unit completely independently of each other (when accelerator is depressed). Both senders are located in a housing.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test condition
• Battery voltage at least 11.5 V. Test sequence
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and display group 062.
– Test the nominal value of sender 1 -G79- at idle stop in display field 3:
Reading measured value block 2% 2% 14%
62 14%
->
Specified value: 3...100 %
– Test the nominal value of sender 2 -G185- at idle stop in display field 4: Specified value: 3...100 % Note The engine control unit converts the voltage values of the throttle valve drive angle sender in percentage (in relation to 5 Volts) (5 Volts power supply correspond to 100%).
– Slowly press the accelerator pedal while observing the values in the display fields 3 and 4. Sollwert: 3…100 % If the specified value is not reached:
– Test the voltage supply and the wiring of the accelerator pedal position sender ⇒ 24-2 page 3.
– Select function 06 „End output“ and switch ignition off. Testing voltage supply and wiring to the control unit
– Remove storage compartment on driver side ⇒ Body Fitting Work; Rep. Gr. 68.
– Disconnect the 6 pin plug connection from the accelerator pedal position sender.
– Switch on ignition. – Connect the multimeter for voltage measurement to the following contacts of the connector: Contact 1 + earth Contact 1 + 5 Contact 2 + earth Contact 2 + 3 Specified value: min. 4,5 V
– Switch off ignition. If the specified values are not reached:
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the plug for interruption according to the Current Flow Diagram: Plug contact
Test box bush -V.A.G. 1598/31-
1
72
2
73
3
36
4
35
5
33
6
34
Line resistance: max. 1.5 Ω
– Additionally check the cable for a short circuit to battery positive and to earth.
– Test the cables for short circuiting with each other. If the lines are not found to be faulty:
– Replace accelerator pedal position sender.
Testing the intake manifold pressure sender Note Only use gilded contacts to repair contacts in the plug connection of the sender. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group number 003.
– Read off intake manifold pressure values indicated in display field 2.
Reading measured value block 840/min 365mbar
3
-> 2
Specified value: 240…420 mbar
– Briefly open throttle valve. The intake manifold pressure value in display field 2 must increase briefly.
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24
If 91 mbar or 1254 mbar is always indicated: Display
Cause
Continue test
91 mbar
Line interruption or short-circuit to earth
⇒ 24-2 page 5
1254 mbar
Short circuit to positive
⇒ 24-2 page 6
Continuation of the test if the display reads 91 mbar:
– Disconnect the 4-pin plug connection from the intake manifold pressure sender - G71- with intake manifold temperature sender -G72- -arrow- (engine may stall).
– Bridge contacts 3 + 4 of the plug connection and observe the read-out on the display. If the display jumps to 1254 mbar:
– Select function 06 „End output“ and switch ignition off. – Replace the intake manifold pressure sender -G71with intake manifold temperature sender -G72⇒ Chap. 24-1. If the display remains at 91 mbar:
– Select function 06 „End output“ and switch ignition off. – Connect test box -V.A.G 1598/31- to wiring loom of control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 4-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G. 1598/31-
3
98
4
109
Line resistance: max. 1.5 Ω
– Also test wire contact 4 for short-circuit to earth and to contact 1. Specified value: ∞ Ω If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Continuation of the test if the display reads 1254 mbar:
– Disconnect the 4-pin plug connection from the intake manifold pressure sender - G71- with intake manifold temperature sender -G72- -arrow- (engine may stall). If the display jumps to 91 mbar:
– Select function 06 „End output“ and switch ignition off. – Replace the intake manifold pressure sender -G71with intake manifold temperature sender -G72⇒ Chap. 24-1. If the display remains at 1254 mbar:
– Select function 06 „End output“ and switch ignition off. – Unlock connector at control unit and unplug. – Check the wires for plug of control unit at 4-pin plug contact 4 for short-circuit to wire contact 3 as well as after positive battery. Specified value: ∞ Ω If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
Testing intake manifold temperature sender Note Only use gilded contacts to repair contacts in the plug connection of the sender. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester e.g. -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and display group 004.
– Read off intake manifold temperature value in display field 4.
Reading measured value block 840 rpm 13.6V 91 C
4
-> 62 C
Specified value: Ambient temperature 1) 1)
If a temperature is displayed that is below the ambient temperature of the sender, check the sender wires for transition impedances. Make sure that the sender heats up or is heated by radiant heat.
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24
If implausible value appears in the display:
– Select function 06 „End output“ and switch ignition off. – Disconnect the 4-pin plug connection from the intake manifold temperature sender -G72- with intake manifold pressure sender -G71- -arrow-.
– Connect the multimeter for resistance measurement to contacts 1 and 2 of the intake manifold temperature sender. Specified value:
The nominal value in field A applies for temperature range 0...50 °C, nominal value in field B applies for temperature range 50...105 °C. Example: ♦ For a temperature of 20 °C the specification is
2.3...2.6 kΩ ♦ For a temperature of 80 °C the specification is
290...330 Ω
If the specified value is not reached:
– Replace the intake manifold pressure sender -G71with intake manifold temperature sender -G72⇒ Chap. 24-1. If the specified value is reached:
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 4-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G. 1598/31-
1
108
2
85
Line resistance: max. 1.5 Ω
– Additionally check the cable for a short circuit to battery positive. Specified value: ∞ Ω If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing coolant temperature sender Special tools, test and measuring equipment and aids required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group 001.
– Read off coolant temperatur value indicated in display
Reading measured value block 840/min 88 C 4.0%
1 -> 00111111
field 2. Specified value: Coolant temperature If implausible value appears in the display:
– Select function 06 „End output“ and switch ignition off. – Unplug the 2-pin plug for the coolant temperature sensor -G62- -arrow-.
– Connect the multimeter for resistance measurement to contacts 1 and 2 of the coolant temperature sender. Specified value:
S24-0349
The nominal value in field A applies for temperature range 0...100 °C, nominal value in field B applies for temperature range 50...105 °C. Example: ♦ For a temperature of 30 °C the specification is
1500...2000 Ω
♦ For a temperature of 80 °C the specification is
275...375 Ω
If the specified value is not reached:
– Replace the coolant temperature sender -G62⇒ Chapter 24-1
If the specified value is reached:
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Check wiring between the test box and the 2-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G. 1598/31-
1
93
2
108
Line resistance: max. 1.5 Ω
– Additionally check the cable for a short circuit to battery positive. Specified value: ∞ Ω
1
2 S24-0341
If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing components
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
24-3
Testing components I
Test engine speed sender The engine speed sender -G28- is a speed and reference marking sender. If the speed signal fails with the engine running this could result in an engine stoppage. Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1715♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test condition
• Battery voltage at least 11.5 V. Test sequence
– Disconnect the 3-pin plug connection from the engine
V
speed sender -G28- ⇒ Chap. 24-1.
– Connect the multimeter for voltage measurement to contact 1 (positive) and 3 (earth) of the plug for engine speed sender.
– Switch on ignition. Specified value: min. 4.5 V
– Switch off ignition. If no voltage is present:
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 3-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G 1598/31-
1
87
2
82
3
108
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other. Specified value: ∞ Ω If no fault was detected in the wiring and if there was no voltage between contact 1 + 3:
– Replace engine speed sender -G28- ⇒ Chapter 24-1.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
If no fault was detected in the wiring and if there was no voltage between contact 1 + 3:
– Replace engine control unit ⇒ Chapter 24-5.
Testing injection valves Test control Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1715♦ Diode test lamp e.g. -V.A.G 1527♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram ♦ Extractor -T 10094-
Test conditions
• Fuse 35 must be OK • Earth connections between the engine (on gearbox
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
S01-0094
housing) and body (under battery) are o.k.
• • • •
Battery voltage at least 11.5 V. Engine speed sender o.k.; check ⇒ 24-3 page 1. Check that the Hall sender is o.k. ⇒ Chapter 28-1. Fuel pump relay OK
Test sequence
– Pull off hose -1- (engines 04.02 ➤) and remove engine cover -2- with air filter upwards -arrows-. Engines with the engine codes AUA, AUB
– Unplug the 4-pin connector -arrow- from the ignition transformer. Engines with the engine codes BBY, BBZ, BKY
– Pull out all ignition coils using the extractor -T 10094-. For all vehicles
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Unplug connector -arrows- of the injectors.
– Connect up the diode test lamp to the contacts of the plug for cylinder 1.
– Actuate the starter and check the power supply to the injection valve of cylinder 1. LED must flash. 1
– Repeat test on the plug connections for the injection valves on cylinder 2 to 4.
– Switch off ignition. If the LED does not light up on any cylinder:
S24-0344
2
– Connect the diode test lamp to the plug connection on cylinder 1, contact 1 and earth.
– Actuate the starter and check the power supply to the injection valve of cylinder 1. LED must flash.
– Repeat test on the plug connections for the injection valves on cylinder 2 to 4. If the LED does not flash:
– Switch off ignition. – Check the cable between 2-pin plug contact 1 and the fuel pump relay -J17- for interruption according to the Current Flow Diagram.
1 S24-0345
Line resistance: max. 1.5 Ω If the LED does not light up on one or more cylinders:
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 2-pin plugs
1
2
on the injection valves for interruption according to the Current Flow Diagram. Injector
Plug contact
Test box bush -V.A.G 1598/31-
1
2
96
2
2
97
3
2
88
4
2
89
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other.
S24-0343
Specified value: ∞ Ω
– Check wiring between contacts 1 of the plug connection on the injection valves for interruption of each other. Line resistance: max. 1.5 Ω
Testing resistances of the injection valves Test sequence
– Check resistance of the individual injection valves. Specification at 20 °C: 14,0...17,0 Ω If the engine is warm the resistance increases by approximately 4 to 6 Ω. If the specified value is not reached:
– Replace the defective injection valve ⇒ Chapter 24-1. Test spray pattern, leak tightness and injected quantity Special tools, test and measuring equipment and auxiliary items required ♦ Torque wrench ♦ Measuring tool set, e.g. -V.A.G 1594 C♦ Remote control, e.g. -V.A.G 1348/3 A♦ Adapter, e.g. -V.A.G 1348/3-2♦ Digital potentiometer, e.g. -V.A.G 1630♦ Measuring vessel, for example -V.A.G 1602-
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test conditions
• The fuel pressure must be OK, test it ⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20.
• Fuel pump relay o.k., testing ⇒ Chap. 01-1, final control diagnosis.
• Fuel temperature 15... 20 °C, the fuel must conform to the valid standards.
Test sequence
– Pull off hose -1- (engines 04.02 ➤) and remove engine cover -2- with air filter upwards -arrows-.
– Completely remove the fuel rail with all injection valves from the intake manifold (the fuel hose remains connected) ⇒ Chapter 24-1.
Testing jet formation and tightness
– Unplug the 2-pin plug for the coolant temperature sensor -G62- -arrow-.
S24-0349
– Connect up digital potentiometer V.A.G -1630- to contacts 1 + 2 of the plug connection and set the connected side to 15 kΩ.
V.A.G 1630
2
1 S24-0342
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Hold measuring vessel under the injection valve to be tested and disconnect the plug on the other injection valves.
– Have a 2nd mechanic actuate the starter. The injection valve must emit a pulsed jet of fuel.
– Repeat test at the other injectors. Make sure that only the valve to be tested is connected. The jet must be the same for all valves.
– Then check the injection valve for leaks. No more than 2 drops/min may trickle out. If the fuel loss is greater than this:
– Switch off ignition. – Replace the defective injection valve ⇒ Chapter 24-1.
S24-0340
Testing fuel injected quantity Note When testing the injection rate also check the jet formation. The jet must be the same for all injection valves.
– Insert injector to be tested in a measuring glass, e.g. -V.A.G 1602-.
– Connect a contact of the injector to be tested with adapter cables to the battery earth.
– Connect the second contact of the injector to be tested with remote control and adapter cable to positive battery.
– Connect battery positive (+) and fuse socket No. 61 with adapter cable and adapter -V.A.G 1348/3-2-. The fuel delivery unit must start running.
– Activate remote control for 30 seconds. – Repeat the measurement on all injectors. Always use
S24-0340
a new measuring glass.
– After the measurement of all valves, deactivate the voltage supply of the fuel delivery unit.
– Place the measuring glasses on a flat surface and compare the quantities of fuel injected. Nominal value per injection valve: 1.4/55 kW Engine: 57 ... 65 ml 1.4/74 kW Engine: 88 ... 98 ml If the measurement obtained for one injector is not within the specification:
– Replace the defective injection valve ⇒ Chapter 24-1. The injectors are installed in the reverse order for removal. Pay attention to the following:
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection ♦ Replace the O-rings on all the injectors and moisten
lightly with clean engine oil. ♦ Fit the fuel rail with the installed injection valves to the
intake manifold and tighten screws uniformly to 10 Nm.
Testing the intake system for tightness (unmetered air) Testing with engine leak search spray Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Engine leak search spray (e.g. G 001 800 A1)
Test condition
• Coolant temperature must be at least 80 °C
⇒ Chapter 01-5 display group 001, display field 2.
Test sequence Note ♦ Because of the vacuum in the intake system the leak
search spray is sucked in with the unmetered air. The leak search spray reduces the ignition performance of the mixture. This results in a drop in engine speed and a change in the lambda probe voltage. ♦ You must comply with the safety instructions on the
box.
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group 033.
– Observe the control value in display field 1. – Systematically spray parts of the intake system with
Reading measured value block 2.0% 0.462V
33
->
engine leak search spray. If the engine speed drops or if the control values changes:
– Check the sprayed location of the intake system for leaks and if necessary eliminate the fault. If the engine speed or control value does not change:
– Select function 06 „End output“ and switch ignition off.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing intake manifold preheating Special tools, test and measuring equipment and auxiliary items required ♦ Cooling spray
Testing control flap
– Remove air filter ⇒ Chap. 24-1. – Check position of the regulating flap -1-. ♦ Above +23 °C the flap must close the hot air connec-
tion ♦ Below +10 °C the flap opens the hot air connection.
Note Operation of the thermo-element -2- can easily be tested by spraying on a cooling spray.
1
Idle testing 2
Note
S24-0332
♦ The idling speed, ignition point and CO content are
only measured as they cannot be adjusted. ♦ The idling speed is set to nominal value by the throttle
valve positioner together with the DLS function. ♦ The CO content is set to nominal value by the lambda
control. Faults in the lambda control are detected by the self-diagnostic system and stored in the fault memory. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The exhaust system between the cylinder head and the catalyst must be tight.
• Coolant temperature at least 80 °C ⇒ Chapter 01-5 display group 004, display field 3.
• All electrical components such as lights and rear window heater must be switched off.
• If vehicle is equipped with air conditioning, this must be switched off.
• On vehicles with an automatic gearbox the selector lever must be in position „P“ or „N“.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Interrogate fault memory, rectify any faults and then erase the fault memory ⇒ Chapter 01-1.
Testing idling speed
– Select function 08 „Read measured value block“ and display group 056.
– Check the operating condition in indicator field 4.
Reading measured value block 750/min 750/min 5Nm
56
-> 00000
Specified value: 00000 (meaning ⇒ Chapter 01-7).
– Check nominal idling speed in display field 2. Specified value: Vehicles with engine code AUA: 750 rpm Vehicles with the engine codes BBY, BKY: 760 rpm Vehicles with automatic gearbox (engine codes AUA, BBY, BKY): 680 rpm Vehicles with engine code AUB: 840 rpm Vehicles with engine code BBZ: 680 rpm Note The idling speed of the engine is increased if the battery is heavily discharged or the engine is extremely overheated.
– Check idling speed in display field 1. Specified value: Vehicles with engine code AUA: 650 ... 850 rpm 1) Vehicles with the engine codes BBY, BKY: 660 ... 860 rpm1) Vehicles with automatic gearbox 580... 780 rpm1) Vehicles with engine code AUB: 740 ... 940 rpm1) Vehicles with engine code BBZ: 580 ... 780 rpm1)
– Select function 06 „End output“ and switch ignition off. If the idling speed is not reached:
– Adapt engine control unit to throttle valve control unit ⇒ Chapter 24-5.
– Perform a test drive. – Interrogate the fault memory on the control unit again. – Repeat idling speed test. If the nominal values are again not reached:
– Test throttle valve control unit ⇒ Chapter 24-2. – Inspecting engine operating conditions ⇒ Chapter 24-4.
– Testing intake system for tightness ⇒ Chap. 24-3. 1)
Current value ⇒ Inspection and Maintenance.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing components I
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24-4
Testing components II
Test lambda probe heating before catalyst Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test conditions 1 2 3 4 5
• Fuses No. 3 and 9 must be O.K. • Battery voltage at least 11.5 V. • The fuel pump relay must be OK.
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
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49
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50
60
Test sequence
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– Connect vehicle system tester -V.A.G 1552-. Start en-
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gine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
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46
56
66
Engine idling.
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68
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31 32 33 34 35 36 37 38
S01-0094
– Select function 08 „Read measured value block“ and display group 041.
– Check status of the lambda probe heater in display field 2.
Reading measured value block 41 -> Ht. before c. ON 15 Ohm Ht. after c. ON
Specified value: „Ht. before c. ON“. Note Depending on the operating state of the engine the lambda probe heaters are switched on or off, i.e. the readouts in display field 2 may show either „Htg. before C.ON“ or „Htg. before C.OFF“. If the specified value is not reached:
– Remove the 6-pin plug -arrow- to the lambda probe before the catalyst -G39-. Note Depending on the lambda probe version, the heater can be connected to contacts 1 + 2 or 3 + 5 of the 6-pin plug (only on engines with code letters BKY EU-4 and EU2DDK 05.04 ➤; the instructions for these engines are listed below in the brackets).
S24-0347
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Check probe heater at connector for lambda probe, contact 1 + 2 (3 + 5) for continuity.
1
3
5
2
4
6
Note At ambient temperature the resistance of the heating element should be approx. 1...5 . The resistance increases considerably even if the temperature rises only slightly. If there is an interruption in the lambda probe heating:
– Replace lambda probe upstream of the catalyst -G39-. If the probe heating has continuity: S24-0346
– Switch the multimeter to voltage measurement and connect it to contacts 1 + 2 (3 + 5) of the connector to the engine control unit.
– Start engine and run in idle. – Measure the voltage supply and at the same time observe display group 041, display field 2. Display: „Ht. before c. ON.“ Specified value: 11.0...14.5 V or Display: „Ht. bf. c. ON“/„Ht. bf. c. OFF“ (alternately) Specified value: fluctuating between 0...14.5 V
– Select function 06 „End output“ and switch ignition off. If no voltage is present:
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 6-pin plug for interruption: Plug contact
Test box bush -V.A.G. 1598/31-
1 (3)
5
Specified value - line resistance: max. 1.5 Ω If the specified value is reached:
– Check wiring from contact 2 (5) to fuel pump relay -J17- according to the Current Flow Diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations. If wiring is o.k.:
– Replace engine control unit ⇒ Chapter 24-5.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing lambda probe and lambda control upstream of catalytic converter Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B, 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test conditions
• Coolant temperature at least 80 °C ⇒ display group 004, display block 3.
• The exhaust system must be tight between the catalyst and the cylinder head.
Check for proper operation
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group number 030.
– Check status of the lambda control before catalyst (display field 1): Reading measured value block 111 110
Specified value: 111
30
->
Meaning of the 3-digit numerical block display field 1: Meaning, if display positions = 1 1 2 3 1 Lambda control active 1
Lambda probe operational
1
Lambda probe heating on
Note The first digit of the 3-digit numerical block (heating) fluctuates between 0 and 1. If the specified value is not reached:
– Test lambda probe heating before catalyst ⇒ 24-4 page 1. If the specified value is reached:
– Select function 04 „Basic setting“ and display group 034.
System in basic setting 34 2350/min 244.0 C 0.25s
-> Test ON
– Blip 2 accelerations above 5000 rpm.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Set engine speed to 1500...3900 rpm. – Maintain speed until „Test ON“ is displayed in display field 4.
– Run engine at this speed until display field indicates specified value „B1-S1 O.K.“. If „B1-S1 nok“ is shown in display field 4:
– Press key. – Select function 08 „Read measured value block“ and display group 033.
– Observe lambda control in display field 1. The readout must fluctuate in the region from -10.0...10.0 %.
Reading measured value block 2.0% 0.462 V
33
->
– Read off voltage in display block 2. The voltage must oscillate at least 20 times per minute in the region between 0 to 1.0 V. If the display in display field 2 remains constantly on one value:
– Continue test according to the following table: Display
Cause
Continue test
between 0.400 .... 0.500 V
Open circuit
Check voltage ⇒ 24-4 page 4
1.105 V
Short circuit to positive
0.000 V
Short circuit to earth
Check lambda probe wiring ⇒ 24-4 page 4
If the lambda control in display field 1 does not oscillate in the given region:
– Select function 06 „End output“ and switch ignition off. – Conduct test drive and repeat test. Comply with the applicable safety instructions for a test drive ⇒ Chap. 24-1. If the nominal value in display field 1 is still not reached after a test drive or if the value does not fluctuate by at least 2 %:
– Test basic voltage. Test basic voltage
– Remove the 6-pin plug to the lambda probe before the catalyst -G39-. Note Depending on the wide-band lambda probe version, it can be connected to contacts 3+ 4 +5 + 6 or 2 + 1 + 4 + 6 of the 6-pin plug (only on engines with code letters BKY EU-4 and EU-2DDK 05.04 ➤; the instructions for these engines are listed below in the brackets). S24-0347
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
24
– Connect the multimeter for voltage measurement to contacts 3 + 4 (2 + 1) of the connector at the engine wiring harness.
– Switch on ignition and measure voltage. Specified value: 0.40...0.50 V
– Switch off ignition. If the specified value is reached:
– Replace lambda probe upstream of the catalyst -G39-. If the specified value is not reached:
– Check lambda probe wiring. Check lambda probe wire upstream of catalytic converter
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 6-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G. 1598/31-
3 (2)
52
4 (1)
71
5 (4)
70
6 (6)
51
Line resistance: max. 1.5 Ω
– Check wiring at plug contact 3 + 4 (2 + 1) for short-circuit to contact 1 + 2 (3 + 5). If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
Test lambda probe heating after catalyst Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526.A♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test conditions
• Fuses No. 3 and 9 must be O.K. • Battery voltage at least 11.5 V. • The fuel pump relay must be OK.
1 2 3 4 5
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
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6 7 8 9 10
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S01-0094
display group 041.
– Check status of the lambda probe heater in display field 4.
Reading measured value block 41 -> Ht. before c. ON 15 Ohm Ht. after c. ON
Specified value: „Ht. after c. ON“. Note Depending on the operating state of the engine the lambda probe heaters are switched on or off, i.e. the readouts in display field 4 may show either „Htg. after C.ON“ or „Htg. after C.OFF“. If the specified value is not reached:
– Remove the 4-pin plug to the lambda probe -G130-arrow-.
S24-0348
– Check probe heater at connector for lambda probe, contact 1 + 2 for continuity. Note At ambient temperature the resistance of the heating element should be approx. 1...5 . The resistance increases considerably even if the temperature rises only slightly. If there is an interruption in the probe heating:
– Replace lambda probe after catalyst -G130-. If the probe heating has continuity:
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Connect multimeter for voltage measurement to contacts 1 + 2 (plug at engine wiring harness).
– Start engine and run in idle. – Measure the voltage supply and at the same time ob-
V
serve display group 041, display field 4. Display: „Ht. after c. ON“ Specified value: 11.0...14.5 V or Display: „Ht. after c. ON“ / „Ht. after c. OFF“ (alternately) Specified value: fluctuating between 0.0....14.5 V
– Select function 06 „End output“ and switch ignition off. If no voltage is present:
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 4-pin plug for interruption: Plug contact
Test box bush -V.A.G. 1598/31-
2
63
Line resistance: max. 1.5 Ω If the specified value is reached:
– Check the cable between 4-pin plug contact 1 and the fuel pump relay -J17- for interruption according to the Current Flow Diagram. If wiring is o.k.:
– Replace engine control unit ⇒ Chapter 24-5.
Testing lambda probe and lambda control after catalyst Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test conditions
• The coolant temperature must be at least 80°C, ⇒ display group 004, display field 3.
• The exhaust system between the cylinder head and the catalyst must be tight. Edition 06.04 S00.5309.04.20
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Check for proper operation
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group number 030.
– Check status of the lambda control after catalyst (display field 2):
Reading measured value block 111 110
30
->
Specified value: 110 Note The 3rd bit in display field 2 is only set to 1 under partial load (2500...4000 rpm).
Meaning of the 3-digit numerical block display field 2: Meaning, if display positions = 1 1 2 3 x Lambda control active; specified value: 1/0 1
Lambda probe operational
1
Lambda probe heating on
Note ♦ The lambda control of the lambda probe after catalyst
(B1-S2) is inactive without load. ♦ The first digit of the 3-digit numerical block (heating)
fluctuates between 0 and 1. If the specified value is not reached:
– Test lambda probe heating after catalyst ⇒ 24-4 page 5. If the specified value is reached:
– Select function 04 „Basic setting“ and display group 036.
– Depress brake pedal and hold pressed. The speed automatically increases. System in basic setting 0.856 V Test ON
„ B1-S2 O.K.“ appears in display field 2.
36
->
If „B1-S2 n.o.k“ is shown in display field 2:
– Test lambda probe voltage 2 at idle in display field 1. Specified value: 0,000…1.000 V
– Continue test according to the following table:
24-4 page 8
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Display
Cause
Continue test
between 0.400.... 0.500 V
Open circuit
Check voltage ⇒ 24-4 page 9
1.105 V
Short circuit to positive
0.000 V
Short circuit to earth
Check lambda probe wiring ⇒ 24-4 page 9
If the lambda control in display field 1 does not oscillate in the given region:
– Select function 06 „End output“ and switch ignition off. – Conduct test drive and repeat test. Comply with the applicable safety instructions for a test drive ⇒ Chap. 24-1. If the nominal value in display field 1 is still not reached after a test drive or if the value does not fluctuate by at least 2 %:
– Test basic voltage. Test basic voltage S24-0348
– Remove the 4-pin plug to the lambda probe -G130-arrow-.
– Connect multimeter for voltage measurement to contacts 3 + 4 (plug at engine wiring harness).
– Switch on ignition and measure voltage. Specified value: 0,40…0.50 V
– Switch off ignition. If the specified value is reached:
– Replace lambda probe after catalyst -G130-. If the specified value is not reached:
– Check lambda probe wire downstream of catalytic converter.
Check lambda probe wire downstream of catalytic converter
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 4-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G. 1598/31-
3
68
4
69
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Line resistance: max. 1.5 Ω
– Check wiring of contact 3 + 4 of the plug for short-circuit to contact 1 + 2. If the lines are not found to be faulty:
– Replace engine control unit ⇒ Chapter 24-5.
Check lambda probe ageing before catalyst Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The exhaust system between the cylinder head and the catalyst must be tight.
• The coolant temperature must be at least 80°C, ⇒ display group 004, display field 3.
Check for proper operation
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 04 „Basic setting“ and display group 034.
System in basic setting 34 -> 2300/min 244.0 C 0.25s Test ON
– Blip 2 accelerations above 5000 rpm. – Set engine speed to 1500...3900 rpm. – Maintain this speed until the value in display field 4 jumps from „Test ON“ to „B1-S1 o.k.“. Note This may take a few mlnutes.
– Check period in display field 3: Specified value: maximum 1.0 s
– Maintain the speed at 1500...3900 rpm until display field 4 indicates nominal value „B1 S1 O.K.“.
– Select function 06 „End output“ and switch ignition off. If the specified values are not reached:
– Conduct a test drive in order to eliminate any residues on the lambda probe and repeat the test. Comply with the applicable safety instructions for a test drive ⇒ Chap. 24-1. If the specified value is again not reached:
– Replace lambda probe upstream of the catalyst -G39-.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing the engine operating conditions Note Test whether the engine control unit detects the operating conditions idling, trailing throttle, partial load, enrichment and full load of the engine. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• The coolant temperature must be at least 80°C, ⇒ display group 004, display field 3.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group number 005.
– Test whether the control unit recognizes the operating conditions (display field 4):
Reading measured value block 840/min 20% 0km/h
5
-> Idling
♦ Idling
As long as the engine is idling, the following must be displayed: Idling. ♦ Trailing throttle
– Engine speed must increase to more than 3000 rpm. – Suddenly close the throttle valve. As long as the speed is above 1400 rpm the following must be displayed. Trailing throttle. Note Once engine speed is below 1400 rpm idling is again displayed. ♦ Partial load
– Accelerate constantly. As long as the acceleration is constant the following must be displayed: Partial load. ♦ Enrichment
– Push the accelerator pedal down sharply to the stop. When accelerating the following must be briefly displayed: Enrichment. Comply with the applicable safety instructions for a test drive ⇒ Chap. 24-1.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Select function 06 „End output“ and switch ignition off. If the specified values are not reached:
– Interrogate fault memory, rectify any faults and erase fault memory ⇒ Chap. 01-1.
– Test throttle valve control unit ⇒ Chapter 24-1.
24-4 page 12
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
24-5
Engine control unit
Wiring and Component Test with Test Box V.A.G. 1598/31 Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31-
Note ♦ The test box -V.A.G 1598/31- is designed in such a
way that it can be simultaneously connected to the wiring loom of the engine control unit and to the actual engine control unit. ♦ The advantage being that the electronic engine con-
trol remains fully operational with the test box connected (e.g. measuring signals while the engine is running). ♦ Whether the control unit remains connected to the test
box or not, is described in the relevant test procedures. ♦ The contact numbers of the connector of the control
unit and the socket numbers of the test box are identical.
– Switch off ignition. – Release the connector catches and unplug the control unit connectors.
– Connect test box -V.A.G 1598/31- to connector of wiring loom. The earth clip of the test box must be connected to the negative battery terminal.
– Perform test as described in the relevant repair sequences.
DANGER! To avoid damaging the electronic components, switch on the relevant measuring range before connecting the measuring cables and comply with the test conditions.
V.A.G. 1598/31
Testing voltage supply for engine control unit
S01-0089
Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
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Engine control unit
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test conditions
• Battery voltage at least 11.5 V. • Fuses No. 3, 14, 17, 48, and 56 must be OK. • AC generator o.k., test: ⇒ Electrical system;
1 2 3 4 5
Rep. Gr. 27.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
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49
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50
60
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– Select function 08 „Read measured value block“ and
S01-0094
display group 004.
– Read off readout in display field 2.
Reading measured value block 840 rpm 13.6V 91 C
Specified value: min. 11.5 V
4
-> 62 C
– Select function 06 „End output“ and switch ignition off. If the specified value is not reached:
– Connect test box -V.A.G 1598/31- to connector of wiring loom ⇒ 24-5 page 1. The engine control unit is not connected here.
Testing voltage of terminal 30
– Measure supply voltage between sockets 1 + 3 of the test box: Specified value: min. 11.5 V If the specified value is not reached:
– Test cable connections to relay plate according to the
current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Testing voltage of terminal 15
– Use multimeter to measure voltage between sockets 2 + 4 at the test box.
– Switch on ignition. Specified value: min. 11.5 V If the specified value is not reached:
– Test cable connections to relay plate according to the
current flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Procedure after voltage supply has been interrupted If the power supply is interrupted the engine control unit forgets all initialisation or basic setting values and the Readiness Code is erased. Depnding on the mileage
24-5 page 2
Engine control unit
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection which the vehicle has driven, this may result in considerable driveability problems. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure After the voltage supply has been interrupted, it is necessary to carry out the following steps:
– Switch ignition on for at least 10 seconds. – Switch ignition off for at least 30 seconds. – Adapt engine control unit to throttle valve control unit ⇒ 24-5 page 6.
– Performing idling test ⇒ Chap. 24-4. On vehicles with an automatic gearbox the gearbox control unit must also be adapted.
– Conduct a lengthy test drive until the problems have been rectified. During the test drive the following operating conditions must be fulfilled: ♦ The coolant temperature should rise beyond 80°C. ♦ After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a number of times: Idling, part load, full load, overrun. ♦ In case of full load the speed should be increased be-
yond 3500 rpm.
Replacing engine control unit Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
– Enter the control unit identification and thus also the coding of the previous control unit as follows:
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1. The control unit identification number and the coding are shown on the display, e.g.:
Edition 06.04 S00.5309.04.20
036906034T MARELLI 4LV Coding 00031
Engine control unit
2615 -> WSCXXXXX
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Select function 06 „End output“ and switch ignition off. – Release the connector catches and unplug the connector -arrow- from the control unit.
S10-0111
– Press open the latches of the fixture -arrows A- and pull the engine control unit forward -arrow B-.
A
– Release the catch of the second connector and unplug the connector from the control unit. Installation is carried out in the reverse order.
B
– Check current coding and code new control unit ⇒ 24-5 page 5.
A
– Adapt engine control unit to control unit for electronic immobiliser ⇒ Electrical System; Rep. Gr. 96.
– Activate cruise control system function in engine control unit (on vehicles with CCS the lever for the CCS is located on the left below the steering wheel) ⇒ Chap. 24-6.
S24-0337
– Adapt the new control unit to the throttle valve control unit ⇒ 24-5 page 6.
– Adapt potentiometer for exhaust gas recirculation. – Select function 04 „Basic setting“ and display group 070 when ignition is switched on.
System in basic setting 0.9V 3.8V 0.968V
74
-> ADP. O.K.
Specification in display field 4: ADP runs ADP O.K.
– Deactivate adaptation by pressing the button
.
Note On vehicles with an automatic gearbox the gearbox control unit must also be adapted.
– Finally interrogate the fault memory of the new engine control unit and if necessary erase.
– Performing idling test ⇒ Chap. 24-4. – Generate readiness code ⇒ Chapter 01-2.
24-5 page 4
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Coding engine control unit Note ♦ A 5-digit code must always be displayed during the
time the control unit identification is shown. ♦ If the code displayed does not match the vehicle, or if
the control unit has been replaced, it is then necessary to code the control unit as follows. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 07 „coding control unit“. – Enter the relevant code number of the vehicle and
Code control unit Enter code number XXXXX
Q (0-00127)
confirm with button Q . Code number
for vehicles with
00001
Gearbox
00011
Gearbox and ABS
00021
Gearbox and airbag
00031
Gearbox, ABS and airbag
00041
Gearbox and air conditioning system
00051
Gearbox, air conditioning system and ABS
00061
Gearbox, air conditioning system and airbag
00071
Gearbox, air conditioning system, ABS and airbag
00003
Automatic gearbox
00013
Automatic gearbox and ABS
00023
Automatic gearbox and airbag
00033
Automatic gearbox, ABS and airbag
00043
Automatic gearbox and air conditioning system
00053
Automatic gearbox, air conditioning system and ABS
00063
Automatic gearbox, air conditioning system and airbag
00073
Automatic gearbox, air conditioning system, ABS and airbag
The control unit identification number and the coding are shown on the display, e.g.: If this display appears, an incorrect code number has been entered. Edition 06.04 S00.5309.04.20
036906034T MARELLI 4LV Coding 00031 Function unknown or cannot be carried out at the moment
Engine control unit
2615 -> WSCXXXXX ->
24-5 page 5
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Select function 06 „End output“ and switch ignition off. Note ♦ The engine control unit does not use the code entered
and shown in the display until after the ignition has been switched off. Incorrect coding results in: ♦ Handling problems (jerky gear change, load change
jolts etc.) ♦ Increase in fuel consumption ♦ Increase in pollution ♦ Storage of non-existent faults in fault memory ♦ non-execution of functions (lambda control, activated
charcoal filter system actuation, etc.) ♦ On front-wheel-drive vehicles the Traction Control
System does not operate (TCS warning light on) ♦ Reduction of the gearbox life
Adjusting the engine control unit to the throttle valve control unit This adaptation teaches the engine control unit the various positions of the throttle valve with the ignition on and the engine stopped. These positions are stored in the engine control unit. The feedback of the throttle valve position is provided by the two angle sensors for the throttle valve drive. Adaptation must be performed if: ♦ the power supply was interrupted ♦ the throttle valve control unit was removed and in-
stalled ♦ the throttle valve control unit was replaced ♦ if another engine or another throttle valve control unit
was installed Note On vehicles with an automatic gearbox the gearbox control unit must also be adapted. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• There must not be any fault present in the fault memory ⇒ Chap. 01-1, Interrogating fault memory.
• • • •
Battery voltage at least 11.5 V. Engine not running, ignition switched on. Accelerator pedal fully released. The throttle valve must be in idling speed position.
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Engine control unit
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
• The coolant temperature must be 5...95 °C ⇒ display group 004, display field 3.
• When using the cruise control system, it must be correctly set.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch ignition on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 04 „Basic setting“ and display group 060.
System in basic setting 2% 95% 5
60 -> ADP. running
System in basic setting 2% 95% 12
60
In this state, the throttle valve is moved by a mechanical spring integrated in the throttle valve control unit, into an emergency running position. The values generated by the two angle senders in this emergency position are stored by the engine control unit. Subsequently the throttle valve is opened at a given value. If this value is reached, the throttle valve positioner is again switched dead. Now the mechanical spring must close the throttle valve within a given period in the previously initialised emergency position (spring test). The throttle valve is subsequently closed by the throttle valve positioner: the values sent by the angle sender to the throttle valve control unit are stored in the engine control unit. If during driving the engine control unit switches the throttle valve positioner dead, this is indicated by a fluctuating increased idling speed. The engine then has a very poor throttle response.
– Check the specified values for the throttle valve positioner control unit in display fields 3 and 4.
-> ADP o.k.
Specification in display field 3: 12 Specification in display field 4: ADP runs ADP O.K. If the specified values are reached: The adaptation was successfully performed. To store the values:
– Switch ignition off for at least 30 seconds. Note ♦ If the basic setting is aborted by the control unit, this
may be due to the following reasons: ♦ The throttle valve does not reach the mechanical
idling limit due to dirt, e.g. carbon deposits or another mechanical fault. ♦ The battery voltage is too low.
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Engine control unit
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
♦ The throttle valve control unit or the cable connection
is faulty, test ⇒ Chapter 24-2.
♦ If the basic setting is aborted, the fault is still in the
fault memory. When the ignition is switched on again the basic setting is automatically performed again.
– Select function 06 „End output“ and switch ignition off.
24-5 page 8
Engine control unit
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
24-6
Testing auxiliary signals
Testing the speed signal Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Diode test lamp e.g. -V.A.G 1527 B♦ Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
• Battery voltage must be at least 11.5 V. • Speedometer o.k., testing ⇒ Electrical System; Rep. Gr. 90.
• Fuse 56 o.k. Test sequence Note ♦ The vehicle must be driven in order to test the vehicle
speed signal. The assistance of a second person is required. ♦ Pay attention to safety precautions for test drives
⇒ Chap. 24-1.
– Connect vehicle system tester -V.A.G 1552 -. Leave the engine on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 08 „Reading measured value block“ and display group number 005.
– Determine by means of a test drive whether the driving speed is displayed in display field 3.
Reading measured value block 5 1380 rpm 20 % 15 km/h
-> Enrich-
– Select function 06 „End output“ and switch off ignition. If the specified values are not reached:
– Connect the test box-V.A.G 1598/31- to the wiring
loom on the engine control unit ⇒ Chap. 24-5. The engine control unit is not connected.
– Connect the multimeter for voltage measurement between the bushes 4 (Term. 15) + 54 (speed signal) of the test box.
– Switch on the ignition. – Raise the front left side of the vehicle. – Turn the front left wheel by hand. Diode test lamp must flash (very short signal). If the diode test lamp does not flash:
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Test the wiring to the speedometer and to the speedometer sender ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Testing signals from/to the air conditioning system Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The air conditioning system must be switched off. • There must not be any fault in the fault memory, interrogate fault memory ⇒ Chap. 01-1.
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Leave the engine on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and display group number 050. Reading measured value block 50 830/min 840/min off
– Readout on display: – Observe display field 2.
-> off
Specified value: 840/min Specifications in display fields 3 and 4: „off“
– Switch on the air conditioning system. – Observe display field 2. Specified value: 870/min Specifications in display fields 3 and 4: „on“ If the specified values are reached:
– Select function 06 „End output“ and switch off ignition. If the specified values are not reached:
– Test the air conditioning system ⇒ Heating, Air Conditioning; Rep. Gr. 01.
– Check the CAN databus ⇒ 24-6 page 7.
Test brake light switch -F- and brake pedal switch -F47Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31-
24-6 page 2
Testing auxiliary signals
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24
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection ♦ Handheld multimeter, e.g. -V.A.G 1526 A♦ Adapter cable set, e.g. -V.A.G 1594 A-
Test conditions
• Fuses Nos. 2 and 28 O.K. Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Switch the ignition on and select address word 01 „Engine Electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and display group number 066. Reading measured value block 66 0 km/h 0000 0 km/h
– Check the display value in display field 2.
-> 0000
Specified value: „x x 0 0“
– Operate brake pedal Specified value: „x x 1 1“ If the specified values are reached:
– Select function 06 „End output“ and switch off ignition. If the specified value is not reached:
– Remove the bottom part of the dash panel on driver side ⇒ Body Fitting Work; Rep. Gr. 70.
– Unplug the connector from the brake light/brake pedal switch.
– Connect the multimeter for resistance measurement between contact 1 and 4. Specified value: ∞ Ω
– Operate brake pedal Specified value: max. 1.5 Ω
4
1
– Connect the multimeter for resistance measurement between contact 2 and 3. Specified value: max. 1.5 Ω
– Operate brake pedal Specified value: ∞ Ω
S24-0458
If the specified values are not reached:
– Replace the brake light/brake pedal switch. If the specified values are reached:
– Test the cable to the sender for open circuit and for
short circuit to battery positive or earth ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Testing clutch pedal switch -F36Signal from clutch pedal switch -F36- is used for avoiding engine overrevving and load change jolts when the clutch is released. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 A-
1 2 3 4 5
♦ Adapter cable set, e.g. -V.A.G 1594 A-
Test condition
• Fuse 28 must be o.k.
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
Test sequence
63
44
54
64
45
55
– Connect vehicle system tester -V.A.G 1551 -. Switch
65
46
56
66
the ignition on and select address word 01 „Engine Electronics“ ⇒ Chap. 01-1.
47
57
67
48
58
68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
S01-0094
– Select function 08 „Read measured value block“ and display group number 066. Reading measured value block 66 0 km/h 0000 0 km/h
– Check the display value in display field 2.
-> 0000
Specified value: x0xx
– Operate clutch pedal. Specified value: x1xx If the specified values are reached:
– Select function 06 „End output“ and switch off ignition. If the specified values are not reached:
– Remove the bottom part of the dash panel on driver side ⇒ Body Fitting Work; Rep. Gr. 70.
– Unplug the connector at the clutch pedal switch. – Connect the multimeter for resistance measurement between contact 2 and 3. Specified value: max. 1.5 Ω
– Operate clutch pedal.
4
1
Specified value: ∞ Ω If the specified values are not reached:
– Replace the clutch pedal switch -F36-. If the specified values are reached:
– Test the cable to the sender for open circuit and for
S24-0458
short circuit to battery positive or earth ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
24-6 page 4
Testing auxiliary signals
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Activating and deactivating cruise control system (CCS) Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• There must not be any fault in the fault memory ⇒ Chap. 01-1, Interrogating fault memory.
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Switch the ignition on and select address word 01 „Engine Electronics“ ⇒ Chap. 01-1. Readout on display, e.g.:
036906034F MARELLI 4LV G Coding 00031
2615 -> WSC XXXXX
036906034F MARELLI 4LV Coding 00031
2615 -> WSC XXXXX
If „MARELLI 4LV G“ is displayed, CCS is activated. Readout on display, e.g.: If „MARELLI 4LV“ is displayed, CCS is not activated.
– Press
and select function 11 „Login procedure“.
Login procedure Enter code number
XXXXX
Enter the code number by referring to table below and confirm entry with Q . Code number Cruise control system (CCS) 11463
Cruise control system (CCS) is activated
16167
Cruise control system (CCS) is deactivated
– Select function 06 „End output“ and switch off ignition. Conduct a test drive after activating the CCS.
Testing CCS With the exception of an operating switch the CCS does not have any components of its own. All functions are performed by the engine control unit. The minimum vehicle speed for the CCS function is 30 km/h. Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• Activate CCS ⇒ 24-6 page 5.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Leave the engine on and select address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and display group number 066.
– Read off the values in display fields 2 and 4.
Reading measured value block 66 0 km/h 0000 0 km/h
-> 0000
Display field 2 Specified value: 1xxx - CCS activated 0xxx - CCS deactivated Display field 4 Test condition
Display field 4
Switch -B- locked to „OFF“
0000
Switch -B- to „OFF“ before operating point
00011)
Switch -B- to „ON“
0011
Switch -B- to „RES“
1011
Switch -A- pressed (switch -B- to „ON“)
0111
1)
Not active at present.
A
If the specified values are not reached:
B
N23-0199
– Select function 06 „End output“ and switch off ignition. – Test wiring to CCS switch for open circuit as well as short circuit to earth and to positive ⇒ Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Testing gear signal Only for vehicles with autom. gearbox The engine control unit receives from the gearbox control unit the information: Gear engaged (selector lever in 1/2/ 3/R/D) or no gear engaged (selector lever in P or N) Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552 - with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• The selector lever of the automatic gearbox must be in position „P“ or „N“.
• Air conditioning switched off.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Switch the ignition on and select address word 01 „Engine Electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and display group number 056. Reading measured value block 56 840 rpm 840 rpm 5 Nm
– Test the value in display field 4.
-> 00000
Specified value: 00000 (selector lever in P or N) 00010 (selector lever in 1/2/3/R/D) If the specified value is reached:
– Select function 06 „End output“ and switch off ignition. If the specified value is not reached:
– Check the data bus ⇒ 24-6 page 7.
Test data bus Operation The engine control unit communicates over a CAN databus with all the control units with databus capability. The 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.
Test condition
• A fault is detected by the CAN databus by self-diagnosis. Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 A♦ Adapter cable set, e.g. -V.A.G 1594 A-
Test sequence
– Switch off the ignition. – Release the connector of the engine control unit and unplug it.
– Connect test box -V.A.G 1598/31 - to engine control unit ⇒ Chap. 24-5. Wiring loom to control unit is not connected.
– Test the central terminating resistor in the engine control unit.
– To to this, conduct a resistance measurement between test box sockets 58 and 60. Specified value: 60...72 Ω Edition 03.01 S00.5309.02.20
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
If the resistance value is not within the nominal value range:
– Replace the motronic control unit ⇒ Chap. 24-5. If the resistance value is within the nominal value range:
– Test the CAN databus ⇒ Electrical System; Rep. Gr. 90.
24-6 page 8
Testing auxiliary signals
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28
28 – Ignition System 28-1
Repairing ignition system
General notes on the ignition system ♦ This section specially deals with the components in
the ignition system. For other components of the injection and ignition system ⇒ Rep. Gr.24. ♦ Switch off the ignition before disconnecting and con-
necting the battery, as this may damage the 4AV control unit. ♦ The engine control unit is equipped with a self-diagno-
sis system. ♦ Components marked with an * are checked by self-di-
agnosis ⇒ Chapter 01-1.
♦ A minimum voltage of 11.5 V is required for perfect
functioning of the electrical components. ♦ Before repairs and for fault finding interrogate the fault
memory ⇒ Chap. 01-1.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to interrogate the fault memory after having completed all inspections and repairs, and if necessary erase ⇒ Chapter 01-1. ♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is possible that the immobiliser blocks the 4AV control unit. The fault memory must then be interrogated and if necessary adapted to the engine control unit ⇒ Chapter 24-5. Safety measures ⇒ 28-1 page 3. Setting data, spark plugs ⇒ Inspection and Maintenance.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Removing and installing parts of the ignition system for engines with the engine codes AUA, AUB 1 - Ignition lead ❑ with shielded plug and sparkplug ❑ Resistor 4.8...7.2 kΩ 2 - Ignition transformer -N152❑ with identification for ignition leads: A = Cylinder 1 B = Cylinder 2 C = Cylinder 3 D = Cylinder 4 ❑ check ⇒ 28-1 page 6 ❑ Fitting location ⇒ Chapter 24-1 3 - Connector ❑ 4-pin ❑ for ignition transformer -N1524 - 10 Nm 5 - Connector ❑ 2-pin ❑ for knock sensor 1 -G61❑ Contacts of connector goldplated 6 - Knock sensor 1 -G61- * ❑ check ⇒ 28-1 page 11 ❑ Fitting location ⇒ Chapter 24-1 7 - 20 Nm ❑ The tightening torque influences the knock sensor function 8 - Connector ❑ 3-pin ❑ for hall sender -G409 - Hall sender -G40- * ❑ check ⇒ 28-1 page 4 ❑ Fitting location ⇒ Chapter 24-1 10 - O-ring ❑ replace if damaged 11 - Ignition lead guide 12 - Spark-plug, 30 Nm ❑ use of the spark plug wrench e.g. -3122 B- for removing and installing ❑ type and electrode gap ⇒ Inspection and Maintenance
28-1 page 2
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Removing and installing parts of the ignition system for engines with the engine codes BBZ, BBY, BKY 1 - Connector ❑ 4-pin 2 - Ignition coils with a power output stage -N70, N127, N291, N292❑ remove with extractor -T 10094❑ check ⇒ 28-1 page 8 3 - Connector ❑ 2-pin ❑ for knock sensor 1 -G61❑ contacts gold-plated 4 - Knock sensor 1 -G61- * ❑ check ⇒ 28-1 page 11 ❑ Fitting location ⇒ Chapter 24-1 5 - 20 Nm ❑ The tightening torque influences the knock sensor function 6 - Connector ❑ 3-pin ❑ for hall sender -G407 - Hall sender -G40- * ❑ check ⇒ 28-1 page 4 ❑ Fitting location ⇒ Chapter 24-1 8 - O-ring ❑ replace if damaged 9 - 10 Nm 10 - Spark-plug, 30 Nm ❑ use of the spark plug wrench e.g. -3122 B- for removing and installing ❑ type and electrode gap ⇒ Inspection and Maintenance 11 - Bracket ❑ Tighten at cylinder head cover to 5 Nm
Safety measures Observe the following points to prevent injury to persons and/or damage to the injection and ignition system: ♦ Do not touch or remove ignition leads with the engine
running or at start speed. ♦ Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and ignition system as well as of test equipment. If test and measuring devices are required during test drives observe the following:
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
♦ Always secure the test and measuring devices on the
rear seat and also have a second person operate them there. If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident. ♦ If the engine must be operated at start speed without
the engine starting: Engines with the engine codes AUA, AUB
– Unplug the 4-pin connector -arrow- from the ignition transformer. Engines with the engine codes BBY, BBZ, BKY
– Remove the connector and pull out all ignition coils with extractor -T 10094-. For all vehicles
– Unplug connector -arrows- of the injectors.
Testing hall sender Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1715♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
Test condition
• Battery voltage at least 11.5 V. Test sequence
– Pull off hose -1- (engines 04.02 ➤) and remove engine cover -2- with air filter upwards -arrows-.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
– Disconnect the 3-pin plug connection from Hall sender -arrow-.
– Connect the multimeter for voltage measurement to contact 1 (positive) and 3 (earth) of the plug for the Hall sender.
V
– Switch on ignition. Specified value: min. 4.5 V
– Switch off ignition. If no voltage is present:
– Connect test box -V.A.G 1598/31- to wiring loom of control unit ⇒ Chapter 24-5.
– Check wiring between the test box and the 3-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G 1598/31-
1
98
2
86
3
108
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other. Specified value: ∞ Ω If no fault was found in the cables and the specified voltage measured between contacts 1 + 3:
– Replace hall sender -G40-. If no fault was detected in the wiring and if there was no voltage between contact 1 + 3:
– Replace engine control unit ⇒ Chapter 24-5.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Checking the ignition transformer (for engines with the engine codes AUA, AUB) Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1715♦ Measuring tool set e.g. -V.A.G 1594 C♦ Diode test lamp e.g. -V.A.G 1527♦ Current flow diagram
Test conditions
• Battery voltage at least 11.5 V. • The hall sender must be OK, test it ⇒ 28-1 page 4. • The engine speed sender must be O.K., test it ⇒ Chapter 24-3.
Test sequence
– Unplug the 4-pin connector -arrow- from the ignition transformer.
Checking voltage supply 1 2 3 4 5
Test condition
• Fuse 52 must be o.k.
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
39
49
59
40
50
60
41
51
61
42
52
62
43
53
63
44
54
64
45
55
65
46
56
66
47
57
67
48
58
68
23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38
S01-0094
– Measure power supply between contacts 2 + 4 of the removed plug using the multimeter.
V
– Switch on ignition. Specified value: min. 11.5 V
– Switch off ignition. If no voltage is present:
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28
– Check the cable between 4-pin plug contact 2 and the relay plate for interruption according to the Current Flow Diagram. Line resistance: max. 1.5 Ω
– Check the cable between 4-pin plug contact 4 and the earth for interruption according to the Current Flow Diagram. Line resistance: max. 1.5 Ω
Test control WARNING! During the following test do not touch neither the connecting parts of the ignition transformer nor the auxiliary cables.
– Unplug connector -arrows- of the injectors.
– Connect the diode test lamp to contacts 1 + 4 (ignition outlet 1) and contacts 3 + 4 (ignition outlet 2) of the removed plug.
– Actuate the starter and check the ignition signal on the engine control unit. The LED must flash.
– Switch off ignition. If the LED flashes and there is a voltage existing between contact 2 and 4:
– Replace ignition transformer -N152- ⇒ item 2 in 28-1 page 2. If the LED does not flash:
– Test wiring ⇒ 28-1 page 8.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Checking wires
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 4-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G 1598/31-
1
102
3
103
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other. Specified value: ∞ Ω If no fault was detected in the wiring and if there is a voltage detected between contact 2 and 4:
– Replace engine control unit ⇒ Chapter 24-5. Testing secondary resistances
– Test secondary resistances on terminal 4 between cylinder 1 + cylinder 4 and cylinder 2 + cylinder 3. Specified value: 4,0 ... 6.0 kΩ (at 20 °C) If the specified values are not reached:
– Replace ignition transformer -N152- ⇒ item 2 in 28-1 page 2.
Check ignition coils with power output stage (engines with engine codes BBY, BKY, BBZ) Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1526 B♦ Measuring tool set e.g. -V.A.G 1594 C♦ Diode test lamp e.g. -V.A.G 1527 B♦ Current flow diagram
Test sequence Note Ignition coil and power output stage form a building unit. Cylinder, which does not operate or misfire, determine as follows:
– Test combustion misfiring ⇒ 28-1 page 13.
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If a combustion misfiring was detected:
– Proceed with test on cylinder determined as defective. If no combustion misfiring was detected:
– Successively remove contacts of the injectors while engine is running and monitor engine run, or
– Compare spark plugs of all cylinders and pay attention to contaminated (covered with soot) electrodes. If a defective cylinder was determined:
– Replace the spark plug of the defective cylinder with the one of another cylinder. If the fault on this spark plug still exists:
– Replace spark plug. If the given cylinder is still defective:
– Replace the ignition coil of the defective cylinder with the one of another cylinder. If the fault on this ignition coil still exists:
– Replace ignition coil. If the given cylinder is still defective:
– Remove the 4-pin plug -1...4- from the ignition coils and check wiring ⇒ Current Flow Diagrams, Fault Finding and Fitting Locations.
Checking voltage supply
– Unplug the 4 pin plug connections from all ignition coils.
Test condition
• The fuses of the ignition system must be in proper order ⇒ Current Flow Diagrams, Fault Finding and Fitting Locations.
– Measure the voltage supply beween contacts 2 + 4 and 3 + 1 of the removed plug using the multimeter and the adapter cables from the measuring tool set.
– Switch on ignition. Specified value: min. 11.5 V
– Switch off ignition. If no voltage is present:
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– Check the cable between 4-pin plug contact 3 and the relay plate for interruption according to the Current Flow Diagram. Line resistance: max. 1.5 Ω
– Check the cable between 4-pin plug contact 2 + earth and contact 1 + earth for interruption according to the Current Flow Diagram. Line resistance: max. 1.5 Ω
Test control WARNING! Caution! During the following test do not touch neither the connecting parts of the ignition coils nor the auxiliary cables.
– Unplug connector -arrows- of the injectors.
– Connect the diode test lamp V.A.G 1527 with adapter cables from V.A.G 1594 to contacts 1 + 4 of the removed plug.
– Actuate the starter and check the ignition signal on the engine control unit. The LED must light up.
– Switch off ignition. If the diode lights up and there is a voltage existing between contacts 1 + 4:
– Replace ignition coil. If the LED does not light up:
– Check wires.
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Checking wires
– Connect test Box V.A.G. 1598/31 to wiring loom of the control unit. The engine control unit is not connected.
– Check wiring between the test box and the 4-pin plug for interruption according to the Current Flow Diagram: Plug contact 4 cylinder:
Test box bush -V.A.G 1598/31-
1
102
2
103
3
94
4
95
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other. Specified value: ∞ Ω If no fault has been determined on the wiring and there is a voltage between contacts 2 + 3:
– Replace engine control unit ⇒ Chapter 24-5.
Testing knock sensor Note ♦ The perfect functioning of the knock sensor requires
an exact tightening torque of 20 Nm. ♦ Only use gilded contacts to repair contacts in the plug
connection of the sender. Special tools, test and measuring equipment and auxiliary items required ♦ Test box -V.A.G 1598/31♦ Handheld multimeter, e.g. -V.A.G 1715♦ Measuring tool set e.g. -V.A.G 1594 C♦ Current flow diagram
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test condition
• Faults on the knock sensor detected by self-diagnosis
⇒ Chapter 01-1, interrogate fault memory and erase.
Test sequence
– Disconnect the 2-pin plug from the knock sender -arrow-.
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is not connected here.
– Check wiring between the test box and the 2-pin plug for interruption according to the Current Flow Diagram. Plug contact
Test box bush -V.A.G 1598/31-
1
106
2
99
Line resistance: max. 1.5 Ω
– Test the cables for short circuiting with each other. Specified value: ∞ Ω If the lines are not found to be faulty:
– Slacken knock sensor and then tighten again to 20 Nm.
– Perform a test drive. Comply with the safety instructions for a test drive ⇒ 28-1 page 3. During the test drive the following operating conditions must be fulfilled: ♦ The coolant temperature should rise beyond 80°C. ♦ After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a number of times: Idling, part load, full load, overrun. ♦ In case of full load the speed should be increased be-
yond 3500 rpm.
– Interrogate the fault memory on the control unit again. If the fault still exists:
– Replace knock sensor -G61-.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Test combustion misfiring Special tools, test and measuring equipment and auxiliary items required ♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
• Driving Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 „Engine electronics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and display group 014. Reading measured value block 840/min 17% 0
– Read off value in display block 4.
14 -> activated
Specified value: „activated“.
– Check the number of combustion misfirings in indicator field 3. Specified value: 0. If the specified value is reached:
– Select function 06 „End output“ and switch ignition off. If the specified value is not reached:
– Changeover in indicator group 015. – Read off value in display block 4.
Reading measured value block 15 -> 0 0 0 activated
Specified value: „activated“.
– Check misfiring combustion in the indicator fields 1 to 3, cyl. 1...3. Nominal values: 0.
– Changeover in indicator group 016. – Read off value in display block 4. Reading measured value block 16 -> 0 activated
Specified value: „activated“
– Check the number of combustion misfirings in indicator field 1, cyl. 4. Specified value: 0. If the nominal values in the display groups 015 and 016 are achieved:
– Select function 06 „End output“ and switch ignition off. If the specified values are not reached:
– Eliminate fault ⇒ Chapter 01-3, Analysing display group 015 and 016.
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FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Repairing ignition system
Edition 06.04 S00.5309.04.20
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