diagnostyka 1Z AFN

Technical data
Engine data
Code letters 1Z AFN AHU AVG
Manufactured 12.95 ... 07.96 10.96 ▸ 08.96 ▸ 08.99 ▸
Capacity ltr. 1.9 1.9 1.9 1.9
Output kW at rpm 66/4000 81/4150 66/4000 81/4150
Torque Nm at rpm 202/1900 235/1900 202/1900 235/1900
Bore ø mm 79.5 79.5 79.5 79.5
Stroke mm 95.5 95.5 95.5 95.5
Compression ratio 19.5 19.5 19.5 19.5
CN min. 45 45 45 45
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Catalyst x x x x
Exhaust gas recirculation x x x x
Charging x x x x
Charge air cooling x x x x
Self-diagnosis
Features of self-diagnosis
The control unit for the Diesel direct injection system is equipped with a fault memory.
If faults occur in the sensors and components being monitored, they will be stored in the fault memory
together with an indication of the type of fault.
Faults which only occur sporadically will have the addendum "sporadic fault" on the print out. These faults
will be indicated on the display by the addendum "/SP". The cause of sporadic faults can be e.g. a loose
contact or a brief open circuit. If a sporadic fault does not occur again within 50 engine starts, it will be
erased from the fault memory.
If faults are recognized, that affect the driving condition then the glow period warning lamp flashes.
The faults stored can be read-out with the fault reader V.A.G 1551 or the vehicle system tester V.A.G
1552 => Page 01-7 .
The fault memory must be erased after the faults has been eliminated => Page 01-7 .
Note:
General information for self-diagnosis is in the fault reader V.A.G 1551 and the vehicle system
tester V.A.G 1552 instruction manuals.
Self-diagnosis
Technical data of self-diagnosis
Equipment
 ◆ The data transfer between control unit and fault reader V.A.G 1551 or vehicle system tester
V.A.G 1552 is carried out in the operating mode "Rapid data transfer".
 ◆ The fault memory is equipped with a non-volatile memory.
Interrogating control unit versions
The control unit version is displayed when the fault reader V.A.G 1551 or the vehicle system tester V.A.G
1552 is connected and engine electronics control unit selected => Page 01-4 .
Selectable functions when using the fault reader V.A.G 1551 or V.A.G 1552
The prerequisites for selecting the desired functions can be taken from the following table.
Function Ignition switched on Engine idling

01 Interrogating control unit version yes yes
02 Interrogating fault memory yes yes
03 Final control diagnosis yes yes
04 Basic setting no yes
05 Erasing fault memory yes yes
06 Ending output yes yes
07 Coding control unit yes no
08 Read measured value block yes yes
Self-diagnosis
Connecting fault reader V.A.G 1551 and selecting engine control unit
Special tools, testers, measuring instruments and auxiliary items required
 ◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3
Note:
The vehicle system tester V.A.G 1552 can be used instead of the fault reader V.A.G 1551, however a
print-out is not possible.
Test conditions
 ● Battery voltage OK.

 ● Fuse 22 OK.
 ● Earth connections on engine
and gearbox OK.
Work sequence
 ‒ → Open ashtray -3-.

 ‒ Press ashtray cover -1- on
both sides in direction of
arrows. The ashtray -2- springs
out slightly and can be
removed.
 ‒ Pull open ashtray housing
out of centre console.
 ‒ Connect fault reader V.A.G
1551 with cable V.A.G 1551/3.
After the fault reader has been

connected:
 ‒ Depending upon desired

function:
Switch ignition on
or
Start engine => Page 01-2 ,
Table "Selectable functions".
Notes:
 ◆ If the display does not

indicate as described in the
work sequence:
=> Fault reader operating instructions
 ◆ If due to an input fault "Fault

in the data transfer!" is
displayed, pull wire off fault
reader, reconnect and repeat
work step.
→ Indicated on display: V.A.G - Self-diagnosis

HELP
1 - Rapid data transfer*
2 - Flash code output*
* Appears alternately
 ‒ Operate fault reader taking into account the information on the

display:
 ‒ Press key 1 for "Rapid data transfer".
 ‒ Press keys 0 and 1 for address word "Engine electronics" and

confirm entry with Q key.
→ The fault reader V.A.G 1551 display will show the control unit 028906021P 1.9 ltr. R4 EDC
identification, e.g.: SG D3E ⇒
Coding 0000 WSC00000
 ◆ 028906021P = Part No. of the control unit (for up-to-date

control unit versions see parts catalogue)
 ◆ 1.9 ltr. = Engine capacity
 ◆ R4 = Type of engine (4 Cyl. in-line engine)
 ◆ EDC = Injection system (Electronic Diesel Control)
 ◆ SG = Gearbox type: manual gearbox
(AG = automatic gearbox)
 ◆ D3E = Control unit software version
 ◆ Coding 00000 coding variant
 ◆ WSC...Dealership number of the V.A.G dealer
 ‒ Press the ⇒key.
→ Indicated on display: Rapid data transfer HELP
Select function XX
 ‒ Further measures see repair procedures.
Self-diagnosis
Interrogating fault memory
 ◆ Fault reader V.A.G 1551 (or vehicle system tester V.A.G 1552) with cable V.A.G 1551/3
Work sequence
 ‒ Connect fault reader V.A.G 1551 (V.A.G 1552) and with the "Address word" 01 select the
engine electronics control unit. When doing this the engine should be idling.
(Connecting fault reader and selecting engine electronics control unit => Page 01-4 .)
Only when engine does not start:
 ‒ Switch ignition on.
 ‒ Switch on fault reader printer with the print key. The warning lamp in key must light up.
→ Indicated on display: Rapid data transfer

HELP
Select function XX

display:
 ‒ Press keys 0 and 2 for function "Interrogate fault memory" and

→ The number of faults stored or "No fault recognised!" will be shown on the X Faults recognised!
display.
If one or more faults are stored:
The stored faults will be displayed and printed out one after the other.
→ After the stored faults have been printed out, the display will show: Rapid data transfer
HELP
Select function XX
 ‒ Locate and eliminate faults printed out as per fault table => Page
01-9 .
 ‒ Afterwards erase fault memory => Page 01-49
If no fault is stored:
→ Indicated on display: Rapid data

transfer HELP
Select function XX
 ‒ Press keys 0 and 6 for the "End data transfer" function and confirm
input with the Q key.
Note:
If the self-diagnosis has not detected a fault, use the appropriate fault table in
"Fault finding engine" binder for further fault finding.
Self-diagnosis
Fault table
Notes:
 ◆ The fault tables are listed according to the 5 digit fault code on the left.
 ◆ Explanation of the fault types (e.g. "open circuit/short circuit to earth"):
=> Fault reader operating instructions
 ◆ If components are indicated as faulty:

First check the wiring and connectors to these components as well as the system earth
connections according to current flow diagram. This is particularly relevant if faults are output as
"occurring sporadically" (SP).
Fault codes 00513 ... 01269
V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00513
Engine speed sender
-G28
- G28 defective
- Distance speed - Fault lamp lights up
sender/sender wheel too - Engine does not start - Check G28
implausible signal
large - Various running problems =>Page 23-36
- Metal swarf on G28 or including engine will not start
mounting pedestal loose
- G28 defective
No signal - Wiring open or short
circuit
00519
Intake manifold
pressure sender -G71
- Charge pressure control
solenoid valve (N75)
defective
- Reduced output - Check N75
implausible signal - Control unit defective
- Increased emission figures =>Page 23-38
- Hose connections
interchanged, not
connected
Short to positive
Open/short circuit
to earth
- Wiring open or short
Voltage supply
circuit
00522
Coolant temperature
sender -G62
- Black exhaust when starting
- G62 defective - Check G62
Short to earth - Glow period always approx.
- Wiring short to earth =>Page 23-40
20 sec.
- G62 defective
Open circuit/ short
- Wiring open circuit or
to positive
short to positive
00527
Intake manifold
temperature sender -
G72
Short to earth
- Wire has short to earth =>Page 23-51
- G72 defective
Open circuit/short
- Open circuit or short to
to positive
positive
00532
Supply voltage
- Check current supply
- Current supply relay
- Various running problems for Diesel direct injection
implausible signal terminal 30 (J317)
including engine will not start system control unit
defective
=>Page 23-55
00539
Fuel temperature
sender -G81
Short to earth - Increased emission figures
- Wiring short to earth => Page 23-56
- G81 defective
Open circuit/short
to positive
short to positive
00542
Needle lift sender -
G80
- Fault lamp lights up
- G80 defective
- Engine runs rough - Check G80
Input open - Wiring open or short
- Reduced output => Page 23-68
circuit
- Increased emission figures
Open circuit/short
to positive
Short to earth
- G80 defective
- Injection system wiring to
Implausible signal 3rd cylinder not OK.
- Fuel shortage
- Air in fuel system
00545
Engine/gearbox
electrical connection
- Check signals from/to
Implausible signal - Wiring open/short circuit - Harder gear selection automatic gearbox =>
Seite 23-103
00550
Injection
commencement
regulation
- Commencement of - Engine runs rough
injection valve (N108) - Reduced output
- Check N108
Control difference defective - Poor cold start
=>Page 23-25
- Needle lift sender (G80) characteristics
defective - Increased emission figures
- Fuel tank empty
- Fuel supply not OK., fuel
shortage
- Air in fuel system
- Start of delivery not OK
00553
Air mass meter -G70
- Check exhaust gas
- Reduced output
recirculation and air
implausible signal - G70 defective - Black exhaust
mass meter function
- No exhaust gas recirculation
=>Page 23-89
- G70 defective
Open circuit/short
to earth
short to earth
- G70 defective
Short to positive - Wiring open circuit or
short to positive
Voltage supply - Wiring open/short circuit
00575
Intake manifold
pressure
- Solenoid valve for charge
pressure control (N75)
defective - Check N75
Control difference - Reduced output
- Hose connections =>Page 23-79
interchanged, not
connected
00625
Speed signal
- Speedometer display not
OK.
- No signal from - Cruise control system
- Check signal from G21
speedometer (G21) or switched off
implausible signal or G22
speedometer sender - Vehicle jerks when changing
=>Page 23-96
(G22) gear
- Air conditioner is switched
off
00626
Glow period warning
lamp -K29
- Check glow period
warning lamp -K29
- Glow period warning lamp => Current flow
Short to positive - Short to positive
not functioning diagrams, Electrical fault
finding and Fitting
locations binder
00668
Vehicle voltage
terminal 30
- Check Diesel direct
- Current supply relay - Engine will not start
injection system control
Signal too small terminal 30 (J317) - Various running problems
unit current supply
defective including engine will not start
=>Page 23-55
implausible signal
Ouput on V.A.G
Possible causes of fault Possible effects Fault remedy
1551 printer
00671
CCS Switch -E45
- Check cruise control
system
undefined switch - E45 defective - Cruise control system => Current flow
position - Wiring open/short circuit switched off diagrams, Electrical fault
finding and Fitting
locations binder
00741
Brake pedal
monitoring
- Brake light switch (F)
defective - Fault lamp lights up - Check F and F47
implausible signal
- Brake pedal switch (F47) - Brake light defective =>Page 23-43
defective
00765
Modulating piston
movement sender -
G149
- Injection pump defective - Check G149
- Various running problems
- Wiring open/short circuit => Page 23-61
- Engine will not start
00777
Accelerator position
sender -G79
- G79 defective - Fault lamp lights up - Check G79
implausible signal
- G79 incorrectly set - Increased idling speed => Page 23-18
- G79 defective
Short to positive
- Wiring short to positive
01028
Fan relay -J323
- Check J323
Open circuit/short - Wiring open circuit
- Fan run-on not functioning =>Page 01-51 , final
to earth - Relay defective
control diagnosis
- Short to earth - Fan runs permanently
Short to positive - Short to positive - Fan run-on not functioning
01044
Control unit
incorrectly coded
- Code control unit
- Invalid control unit coding
=>Page 23-108
01117
Load signal for
alternator terminal DF
- Wiring open or short - Check alternator
circuit => Current flow diagram,
- Additional heater not
implausible signal - Alternator defective Electrical fault finding
operating
- Voltage regulator and Fitting locations
defective binder
01180
Engine/air conditioner
cut-off electrical
connection
Short to positive - Short in the wiring - Vehicle acceleration - Check air conditioner
reduced, when air conditioner compressor cut-in
=>Page 01-51 , final
is switched on
control diagnosis
01208
Data
- Fault in data - Vehicle loses registration - Renew J248
changed
- Data manipulated (Germany) => Page 23-5 , item 9
01237
Fuel cut-off valve -
N109
- Check N109
- N109 defective, leaking - Reduced output
Mechanical fault =>Page 01-51 , Final
or sticking - Engine will not start
control diagnosis
- N109 defective
Open/short circuit
- Wiring open circuit/short
to earth
to earth
01242
Control unit output
stages
- Check exhaust gas
- Exhaust gas recirculation - Increased emission values recirculation and air
implausible signal
valve (N18) defective - Reduced output mass meter function
=>Page 23-89
- Perform final control
diagnosis =>Page 01-51
- All components activated Check wiring
Open circuit/short - Various running problems
by the final control connections to control
to positive - Engine will not start
diagnosis elements
If control elements OK,
control unit defective
01262
Charge pressure
control solenoid valve
-N75
- Check N75
Open circuit/short - Wiring open circuit - Reduced output
=>Page 01-51 , Final
to earth - Solenoid valve defective - Charge pressure too low
control diagnosis
- Reduced output
- Short to earth
- Charge pressure too high
- Reduced output
- Charge pressure too low
01265
Exhaust gas
recirculation valve -
N18
- Wiring open circuit - Check N18
Open circuit/short
- Exhaust gas recirculation - No exhaust gas recirculation =>Page 01-51 , Final
to earth
valve defective control diagnosis
- Too much exhaust gas
recirculation
- Short to earth
- Reduced output, black
smoke
Short to positive - Short to positive - No exhaust gas recirculation
01266
Glow plug relay -J52
- Check J52
Open circuit/short - Wiring open circuit - Glow plug system not
to earth - Glow plug relay defective working
control diagnosis
- Glow plug system
- Short to earth
permanently on
- Glow plug system not
working
01268
Metering adjuster -
N146
- Injection pump defective - Check N146
Control difference - Various running problems
- Wiring open/short circuit =>Page 23-61
- Quantity adjuster - Black smoke
Lower limit value
incorrectly set - Rough idling
- Quantity adjuster
Upper limit value - Jerking, poor performance
incorrectly set
01269
Commencement of
injection valve -N108
- Engine knocks at idling,
Open circuit/short because commencement of
- Commencement of =>Page 01-51 , Final
to earth injection is constantly
injection valve defective control diagnosis
"advanced"
- Poor performance, because
- Short to earth commencement of injection is
constantly "retarded"
because commencement of
injection is constantly
"advanced"
Fault codes 16485 ... 65535
Note:
In the following table, new fault codes which describe fault causes more precisely than before have been
listed in place of the familiar five-digit V.A.G fault codes. The fault text has not changed greatly. In
addition a new type of fault code, the so called P codes e.g. P0101, is listed and positioned next to the
existing codes. These P codes have no significance at present, but will be required by self-diagnosis
systems in the future.
16485P0101
Air mass meter -G70
- G70 defective - Reduced output - Check air mass meter
Implausible signal
- Wiring open circuit or short to earth - Black smoke => Page 23-89
V.A.G 1551 print-

out
16705P0321
Engine speed
sender -G28
Implausible signal - G28 defective - Engine will not start - Check G28
- Engine stops
- Gap speed sender/sender
- Glow period warning lamp
wheel too large
flashes =>Page 23-36
- Metal swarf on G28 or
- No indication on rev.
mounting loose
counter
16706P0322
Engine speed
sender -G28
- G28 defective - Engine stops
- Check G28
No signal - Wiring open circuit or short - Glow period warning lamp
=>Page 23-36
circuit flashes
- Rev. counter no display
V.A.G 1551 print-
out
16885P0501
Road speed signal
- Speedometer display not
OK.
- Cruise control system - Check signal from G22:
- No signal from switched off => Repair group 90;
Implausible signal
speedometer sender (G22) - Vehicle jerks when Checking speedometer
selecting gear sender
off
16989P0605
Control unit -J248 - Control unit internally - Various running problems
- Replace J248
defective defective - Engine stops
17552P1144
Air mass meter -G70
- G70 defective
Open circuit/short - Reduced output - Check air mass meter
- Wiring open circuit or short
to earth - Black smoke => Page 23-89
to earth
V.A.G 1551 print-
out
17553P1145
Air mass meter -G70
- G70 defective
- Reduced output - Check air mass meter
Short to positive - Wiring open circuit or short
- Black smoke => Page 23-89
to positive
17554P1146
Air mass meter -G70
- Operating voltage to high
- Reduced output - Check air mass meter
Voltage supply or too low
- Black smoke => Page 23-89
- Wiring open circuit
17563P1155
Intake manifold
pressure sender -
G71
- Check intake manifold
- Short to positive
Short to positive - Reduced output pressure sender
- G71 defective
=>Page 23-38
V.A.G 1551 print-
out
17564P1156
Intake manifold
pressure sender -
G71
Open circuit/short - G71 defective - Reduced output - Check intake manifold
- Wiring open circuit or short pressure sender
to earth - Increased emission figures
to earth =>Page 23-38
17565P1157
Intake manifold
pressure sender -
G71
- G71 defective - Check intake manifold
- Reduced output
Voltage supply - Wiring open circuit or short pressure sender
circuit =>Page 23-38
V.A.G 1551 print-
out
17568P1160
Intake manifold
G72
- G72 defective - Goes to predetermined - Check G72
Short to earth
- Wiring short to earth value 136.8 °C =>Page 23-51
17569P1161
Intake manifold
G72
- G72 defective
Open circuit/short - Goes to predetermined - Check G72
- Wiring open circuit or short
to positive value 136.8 °C =>Page 23-51
to positive
17570P1162
Fuel temperature
sender -G81
Short to earth - Increased emission figures
- Wiring short to earth => Page 23-56
V.A.G 1551 print-
out
17571P1163
Fuel temperature
sender -G81
- G81 defective
Open circuit/short - Check G81
- Wiring open circuit or short - Increased emission figures
to positive => Page 23-56
to positive
17653P1245
G80
- Glow period warning lamp
flashes
- G80 defective - Check G80 => Page
Short to earth - Engine running rough
- Wiring short to earth 23-68
- Reduced output
V.A.G 1551 print-
out
17654P1246
G80
- G80 defective - Glow period warning lamp
- Injector pipe to No. 3 Cyl. flashes
- Check G80 => Page
Implausible signal not OK - Engine running rough
23-68
- Reduced fuel - Reduced output
- Air in fuel system - Increased emission figures
17655P1247
G80
Open circuit/short - G80 defective - Glow period warning lamp - Check G80 => Page
flashes
- Wiring open circuit or short - Engine running rough
to positive 23-68
circuit - Reduced output
V.A.G 1551 print-
out
17656P1248
Injection
commencement
regulation
- Commencement of
injection valve (N108)
defective - Engine running rough
- Needle lift sender (G80) - Reduced output
- Check N108
Control difference defective - Increased emission values
=>Page 23-25
- Fuel tank empty - Poor cold start
- Fuel supply not OK., characteristics
reduced fuel
- Start of delivery not OK.
17659P1251
Commencement of
- Check N108
because commencement of
Short to positive - Short to positive =>Page 01-51 , Final
injection is constantly
control diagnosis
"advanced"
V.A.G 1551 print-
out
17660P1252
Commencement of
Open circuit/short because commencement of
- Commencement of =>Page 01-51 , Final
to earth injection is constantly
injection valve defective control diagnosis
"advanced"
- Poor performance, because
- Short to earth commencement of injection
is constantly "retarded"
17663P1255
Coolant temperature
sender -G62
- Black smoke when starting
Short to earth - Glow period is always
- Wiring short to earth =>Page 23-40
approx. 20 seconds
17664P1256
Coolant temperature
sender -G62
- G62 defective - Black smoke when starting
Open circuit/short - Check G62
- Wiring open circuit or short - Glow period is always
to positive =>Page 23-40
to positive approx. 20 seconds
V.A.G 1551 print-
out
17762P1354
Modulating piston
movement sender -
G149
Electrical fault in - Injection pump defective - Glow period warning lamp - Check G149
current circuit - Wiring open circuit or short flashes => Page 23-61
circuit - Various running problems
- Engine stops
17795P1387
Control unit - Control unit internally - Various running problems
- Replace J248
17810P1402
Exhaust gas
N18
- Check N18
- No exhaust gas
recirculation
control diagnosis
V.A.G 1551 print-
out
17849 P1441
Exhaust gas
N18
Open circuit/short - No exhaust gas
- Exhaust gas recirculation =>Page 01-51 , Final
to earth recirculation
valve defective control diagnosis
- Too much exhaust gas
recirculation
- Short to earth
- Reduced output, black
smoke
17946 P1538
Fuel cut-off valve -
N109
- N109 defective - Check N109
Open circuit/short - Reduced output
- Wiring open circuit or short =>Page 01-51 , final
to earth - Engine stops
to earth control diagnosis
V.A.G 1551 print-
out
17948P1540
Road speed signal
- Cruise control system not
OK
- Cruise control system
- Road speed more than
switched off - Check signal from G22
Signal too large 260 km/h
- Vehicle jerks when =>Page 23-96
- Dash panel insert defective
selecting gear
off
17954P1546
Charge pressure
control solenoid
valve -N75
- Check N75
- Reduced output
- Charge pressure too low
control diagnosis
V.A.G 1551 print-
out
17957P1549
Charge pressure
control solenoid
valve -N75
- Check N75
Open circuit/short - Wiring open circuit - Reduced output
to earth - Solenoid valve defective - Charge pressure too low
control diagnosis
- Short to earth - Reduced output
- Charge pressure too high
17958P1550
Charge pressure
- Charge pressure control
solenoid valve (N75)
defective
- Hose connections
interchanged, not connected
Control difference - Reduced output - Check N75
- Leaks between
turbocharger and engine
(routing through
ducting/cooler)
- Turbocharger defective
V.A.G 1551 print-
out
17969P1561
Metering adjuster -
N146
- Pre glow warning lamp
- Injection pump defective flashes - Check N146
Control difference
- Wiring open/short circuit - Various running problems =>Page 23-61
- Engine stops
17970P1562
Metering adjuster -
N146
- Metering control (N146)
- Reduced output - Check N146
Upper stop value defective/blocked
Jerking =>Page 23-61
Upper stop value obtained
17971P1563
Metering adjuster -
N146
- Metering device (N146)
- Black smoke - Check N146
Lower stop value defective/blocked
Rough idling =>Page 23-61
Lower stop value obtained
V.A.G 1551 print-
out
17978P1570
- Start attempted with a non-
authorised key.
- Match engine control
- Attempted manipulation
unit to electronic
- Short in communication
immobilizer => Page 23-
wire - Engine starts briefly and
112
Engine control unit - Incorrect coding then stops again
Check electronic
blocked - Fault in immobilizer system - Glow period warning lamp
immobilizer:
- Immobilizer control unit flashes
=> Repair group 96;
defective/missing
Servicing electronic
- Engine control unit has
immobilizer
been replaced and not
matched to the immobilizer.
18008P1600
Voltage supply
terminal 15
- Check voltage supply
for terminal 15
- No current supply when - Various running problems => Current flow
Implausible signal
ignition is on (terminal 15) including engine will not start diagrams, Electrical fault
finding and Fitting
locations binder
V.A.G 1551 print-
out
18026P1618
- No glow period
- Check J52
- Wiring short to positive - Poor cold starting
Short to positive =>Page 01-51 , Final
- J52 defective - Glow period warning lamp
control diagnosis
(K29) flashes
18027P1619
- No glow period
- Wiring open circuit or short - Check J52
Open circuit/short - Poor cold starting
to earth => Page 01-51 , Final
to earth - Glow period warning lamp
- J52 defective control diagnosis
(K29) flashes
V.A.G 1551 print-
out
18039P1631
sender -G79
Signal too large - G79 defective - Increased idling speed - Check G79 and adjust
18040P1632
sender -G79
- Operating voltage too high - Glow period warning lamp
Voltage supply or too low flashes - Check G79 and adjust
- Wiring open circuit - Increased idling speed
V.A.G 1551 print-
out
18047P1639
sender 1/2
-G79+G1851)
Implausible signal - G79 defective - Increased idling speed - Check G79 and adjust
18048P1640
- Replace J248
65535
- Replace J248
1) Incorrect fault text display. Display must indicate:
Accelerator pedal position sender -G79
implausible signal
Self-diagnosis
Erasing fault memory
 ◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3
Test conditions
 ● Fault eliminated
Note:
After eliminating faults the fault memory must be interrogated again as follows and then erased.
Work sequence
 ‒ Connect fault reader V.A.G 1551 (V.A.G 1552) and select engine electronics control unit with
the "Address word" 01. When doing this the engine must be running at idling speed.

HELP
Select function XX
 ‒ Press keys 0 and 2 for function "Interrogate fault memory" and

→ Press ⇒key until all faults still stored have appeared and the display Rapid data transfer
reads: HELP
Select function XX
 ‒ Press keys 0 and 5 for the function "Erase fault memory" and confirm
entry with Q key.

⇒
Fault memory is
erased!
 ‒ If the fault memory will not erase there is a fault still in the system and
this must be rectified.

HELP
Select function XX
 ‒ Carry out a road test and interrogate fault memory again. No faults
should be shown.
Self-diagnosis
Final control diagnosis
Test requirements for vehicles with air conditioning system
 ● Vehicle at room temperature (warmer than + 15 °C)

 ● Air conditioning system switched on
 ● Select lowest temperature and highest blower speed
The final control diagnosis activates the following components in the stated sequence:
1. Commencement of injection valve (N108)
2. Exhaust gas recirculation valve (N18)
3. Conditioner compressor interruption
4. Fuel cut-off valve (N109)
5. Solenoid valve for boost pressure control (N75)
6. Glow plug relay (J52)
7. Glow period warning lamp (K29)
8. Fan relay (J323)
Notes:
 ◆ Activation of individual control elements is limited to 30 seconds but can be stopped at any time
by pressing the ⇒button.
 ◆ The ignition must be switched off before repeating the final control diagnosis.
Work sequence

HELP
Select function XX

display:
 ‒ Press keys 0 and 3 for the function "Final control diagnosis".
→ Indicated on display: Rapid data transfer Q
03 Final control diagnosis
 ‒ Confirm input with Q key.
→ Indicated on display: Final control diagnosis ⇒
Commencement of injection valve

-N108
 Activating the valve, influences the noise of combustion

considerably (pre-ignition).
If no changes in the combustion noises are heard:
 ‒ Check injection adjuster control range

=> Page 23-70
→ Indicated on display: Final control diagnosis

⇒
Exhaust gas recirculation

valve -N18
 The valve must click.
Notes:
 ◆ Because of engine noises the clicking of the valve cannot be heard

and therefore must be felt to detect its operation.
 ◆ The piston movement of the mechanical exhaust gas recirculation
valve is visible in the side slot.
Valve does not click:
 ‒ Check exhaust gas recirculation and air mass meter function =>
Page 23-89
→ Indicated on display: Final control

diagnosis ⇒
Air conditioner
compressor cut-in
 Air conditioner compressor switch-off is checked.

 The test step is also called on vehicles without air conditioner system.
 The conditioner compressor must stop within 5 seconds (visual check)
then start approx. every 5 seconds and then stop.
If the conditioner compressor is not switched off:
 ‒ Check conditioner compressor cut-off:
=> Current flow diagrams, Electrical fault finding and Fitting locations binder

⇒
Fuel cut-off valve -N109
 The engine must stop.
If the engine does not stop:
 ‒ Switch off ignition.

 ‒ Unscrew fuel cut-off valve and remove any metal particles or dirt.
 ‒ Repeat final control diagnosis and if the engine will not stop replace
fuel cut-off valve.
 ‒ Continue final control diagnosis with engine stopped and ignition
switched on.
Charge pressure control solenoid

valve -N75
 The solenoid valve must click.
Note:
The clicking of the valve is difficult to hear and is therefore best

checked by touch.
If the solenoid valve does not click:
 ‒ Check charge pressure limiting solenoid valve (N75) =>

Page 23-79 .
→ Indicated on display: Final control

diagnosis ⇒
Glow plug relay -

J52
 The relay must click.

 Switching on and off the relay can also be observed as the interior light
becomes brighter and darker as a result of the glow plug high power
consumption.
If the relay does not click:
 ‒ Check glow plug relay:
Glow period warning lamp -K29
 The control lamp must flash.
Control lamp does not flash:
 ‒ Check glow period warning lamp:
=> Current flow diagrams, Electrical fault finding and Fitting locations
binder
Fan relay J323

 The fan must run every 5 seconds and then stop again.
If the fan does not run:
 ‒ Check the fan relay:

HELP
Select function XX
Self-diagnosis
Reading measured value block
Test conditions
 ● Coolant temperature must be at least 80 °C.

 ● All electrical consumers like e.g. rear window heating must be switched off.
 ● If the vehicle is equipped with an air conditioner, this must be switched off.
 ● On vehicles with an automatic gearbox the selector lever must be in P or N.
 ● No faults must be stored in fault memory
=> Page 01-7 , interrogating fault memory
Work sequence

HELP
Select function XX
 ‒ Press keys 0 and 8 for the function "Read measured value block" and
→ Indicated on display: Read measured value block

HELP
Input display group number

XXX
Note:
The display group number 001 is an example, to illustrate the sequence.
 ‒ Press keys 0, 0 and 1 for "Display group number 1" and confirm
entry with Q key.
→ Indicated on display: Read measured value block 1 ⇒

(1...4 = Display zones)
1 2 3 4
 ‒ Press ⇒key.

HELP
Select function XX
 ‒ Press keys 0 and 6 for the function "End output" and confirm entry
with the Q key.
Note:
To change to another display group proceed as follows:
Display group V.A.G 1551 V.A.G 1552

Higher Press key 3 Press ↑key
Lower Press key 1 Press ↓key
Skip Press key C Press key C
Self-diagnosis
Evaluating measured value blocks, engine codes AHU, 1Z
Display group 000 at idling speed (engine warm, coolant temperature not below 80 °C)
Display group 000 (decimal value displayed)

▪ Engine running at idling speed
Read measured value block 0 [ltrif ] Indicated on display
x x x x x x x x x x
1 2 3 4 5 6 7 8 9 10 [ltrif ] Display zones Specification Corresponds to
Air mass1) 69...111 230...370 mg/H
Fuel temperature 91...201 20...80°C
Intake manifold temperature 182...50 10...100°C
Coolant temperature 80...35 80...110°C
Atmospheric pressure Not relevant ---
Intake manifold pressure Not relevant ---
Injected quantity 11...45 2.2...9 mg/H
Accelerator pedal position 0 0%
Commencement of injection 0...88 3°ATDC...4°BTDC
Engine speed 41...45 861...945 rpm
1) The measured values require the exhaust gas recirculation (EGR) to be switched on. The EGR is
switched off after approx. 10 minutes at idling speed, therefore give burst on throttle or restart engine.
Display group 001 -Injected quantity-

Read measured value block 1 ⇒ [ltrif ] Indicated on display
xxxx rpm xx.x mg/H x.xx V xxx.x °C
1 2 3 4 [ltrif ] Display zones Specification Evaluation
Coolant temperature 80...110 °C ---
Modulating piston movement sender
1.25...1.70 V => Page 01-62
voltage
Injected quantity 2.2...9 mg/H => Page 01-62
Engine speed 861...945 rpm ---
Evaluation: Injected quantity display
V.A.G 1551 display Possible fault cause Fault elimination

Below 2.2 mg/H - Injection pump too rich - Renew injection pump => Page 23-19
- Run engine at increased speed to warm up and repeat
Above 9 mg/H - Engine too cold
check
- Injection pump too lean - Renew injection pump => Page 23-19
Evaluation: Modulating piston movement sender voltage display

Below 1.25 V - Injection pump too rich - Renew injection pump => Page 23-19
Above 1.70 V - Engine too cold
test
Display group 002 -idling speed-

xxxx rpm xxx.x % xxx xxx.x °C
Operating condition 010 => Page 01-64
Accelerator pedal position 0% => Page 01-64
Evaluation: Accelerator pedal position display
V.A.G 1551
Possible fault cause Fault elimination
display
- Check G-79 and adjust if
- Accelerator position sender -G79 incorrectly set or
1...100 % necessary
defective
=>Page 23-98
- Wiring open circuit to G79
Evaluation: Operating condition display
Significance of figures in 3-digit number block for engine operating condition:

Significance when display = 1
x x x Engine operating condition
1 Air conditioner compressor switched on
1 Idling switch closed
1 Increased idling speed because air conditioner is switched on
Display group 003 -Exhaust gas recirculation-

xxxx rpm xxx mg/H xxx mg/H xxx %
Duty cycle from exhaust gas
10...90 % ---
recirculation valve
Air mass drawn in (actual)1) 230...370 mg/H => Page 01-66
Air mass drawn in (specified) 230...420 mg/H => Page 01-65
1) The measured values require the exhaust gas recirculation (EGR) to be switched on. The EGR is
switched off after approx. 10 minutes at idling speed, therefore give burst on throttle or restart engine.
Evaluation: Air mass drawn in (specified) display

check.
Evaluation: Air mass drawn in (actual) display
V.A.G 1551
display
Below 230 - Excessive exhaust gas - Checking exhaust gas recirculation
mg/H recirculation => Page 23-89
- Unmetered air - Check intake air system for leaks.
Above 370
- Engine too cold - Run engine at increased speed to warm up and repeat check.
mg/H
- Insufficient exhaust - Engine running at idling speed for 10 mins., give burst on
gas recirculation throttle.
- Check exhaust gas recirculation and air mass meter function =>
Page 23-89
- Air mass meter -G70
If a fault is present the measured value block indicates a constant
defective
air mass value of approx. 425 mg/H over the complete rpm and
load range.
Display group 004 -Commencement of injection-

xxxx xx.x ° xx.x °
xxx %
rpm B/ATDC B/ATDC
Commencement of injection
2...10 %1) =>Page 01-69
valve duty cycle
=> Page 01-
Commencement of injection (actual) 3°ATDC...4°BTDC
68
=> Page 01-
Commencement of injection (specified) 3°ATDC...4°BTDC
68
1) The duty cycle can be up to 50 % on new vehicles or vehicles with a new engine.
Evaluation: Commencement of injection (specified) display

Earlier than 4°BTDC - Engine too cold
check.
Evaluation: Commencement of injection display (actual)
V.A.G 1551
display
Earlier than - Run engine at increased speed to warm up and
- Engine too cold
4°BTDC repeat check.
- Check and adjust commencement of injection
- Injection pump set too "advanced"
dynamically => Page 23-25
- Commencement of injection valve - - Check -N108 => Page 01-51 , final control
N108 defective diagnosis
Later than - Injection pump set extremely - Check and adjust commencement of injection
3°ATDC "retarded" dynamically => Page 23-25
- Check -N108 => Page 01-51 , final control
- Injection adjustment blocked
diagnosis
- Commencement of injection valve -
N108 defective
Evaluation: Commencement of injection valve duty cycle
V.A.G 1551
display
Earlier than 10 - Injection pump set extremely - Check and adjust commencement of injection
%1) "retarded" dynamically => Page 23-25
Display group 005
The values displayed are not relevant for fault finding within the service department.
Display group 005 -Starting conditions-

xx.x °
xxxx rpm xx.x mg/H xxx.x °C
B/ATDC
Coolant temperature --- ---
Commencement of injection (actual) --- ---
Starting quantity --- ---
Engine speed --- ---
Display group 006 with ignition switched on
Display group 006 -Switch positions-

xxx km/h xxx xxxxxx xxx
1 2 3 4[ltrif ] Display zones Specification Evaluation
Cruise control system1) --- ---
Cruise control system => Page 01-71
Brake pedal monitor => Page 01-71
Speed --- ---
1) 0 = Cruise control system free
1 = Cruise control system off
2 = Accelerating
4 = Delay
8 = Speed accepted again
16 = Brake pedal depressed
32 = Hold speed
64 = Not relevant
128 = Not relevant
255 = Cruise control system blocked
Evaluation: Brake pedal monitor display
Significance of figures in 3-digit number block for brake pedal monitor:

x x x Brake pedal monitor
1 Brake light switch -F- closed
1 Brake pedal switch -F-47- open
1 Clutch pedal switch -F36- open
Evaluation: Cruise control system display
Significance of figures in 6-digit number block for cruise control system:
"1" signifies:
x x x x x x Cruise control system
1 Cruise control system "switched off" (button in OFF position)1)
1 1 Cruise control system switched on
1 1 1 SET-button operated
1 1 1 Resuming set speed
1) If the cruise control system switch is in "OFF" position, then "000000" is displayed in number block 3.
Display group 007 with ignition switched on (engine cold and not running)
Display group 007 -Temperatures-

Read measured value [ltrif ] Indicated on
⇒
block 7 display
xxx.x °C xxx.x °C xxx.x °C
Approx. ambient
Coolant temperature => Page 01-73
temperature1)
Approx. ambient
Intake manifold temperature => Page 01-73
temperature1)
No display
Approx. ambient
Fuel temperature => Page 01-73
temperature1)
1) Details of temperature specifications are not possible. When the engine is cold the fuel, intake air
and coolant temperatures must equate approximately to ambient temperature. If a temperature deviates
noticeably then the relevant sender must be checked.
Evaluation: Fuel temperature display
V.A.G 1551
display
- Short circuit or fuel - Check G81 => Page 23-56
- 5.6 °C temperature sender If a fault is present the measured value block shows a
- -G81 defective fuel temperature of -5.6 °C
Evaluation: Intake manifold temperature display
V.A.G 1551
display
- Check G72 => Page 23-51
- Intake manifold temperature
Approx. 19 °C If a fault is present the measured value block shows a
sender -G72 defective
constant intake manifold temperature of approx.19°C an
Evaluation: Coolant temperature display

Large deviation from - Short circuit or coolant temperature
If a fault is present the fuel temperature
ambient temperature sender -G62 defective
is displayed alternatively
Display group 009
Display group 009 -Injected quantity limitation-

xxxx rpm xx.x mg/H xx.x mg/H x.xx V
--- ---
voltage
Injected quantity limitation from automatic
--- ---
gearbox during gear change
Injected quantity (cruise control system active) --- ---
Display group 012

Display group 012 -Glow plug system-

xxxx xx.xx sek. xx.x V xxx.x °C
Supply voltage from control unit --- ---
Pre-glow period --- ---
Not relevant --- ---
Display group 014 -Smooth idling speed control-

x.xx mg/H x.xx mg/H x.xx mg/H
No display ---
Different quantity injected Cyl. 1
- 2.0...+ 2.0 mg/H => Page 01-77
and Cyl. 3
Different quantity injected Cyl. 2 and Cyl. 3 - 2.0...+ 2.0 mg/H => Page 01-77
Evaluation: Idling speed smooth running control display
The injection system is equipped with an idling speed smooth running control. There may be power
differences between the individual cylinders (component tolerances, injector delivery,
compressions etc.) which are recognised and equalized via selective injected quantities.
Recognition at idling speed is via the signal from the engine speed sender which delivers four
signals per crankshaft revolution to the control unit. If the signals are delivered at the same
rhythm then all cylinders work the same. If one cylinder is weaker then the crankshaft takes
longer for the next half revolution. Conversely a more powerful cylinder accelerates the
crankshaft so less time is taken.
If the control unit recognises a difference, then the relevant cylinder is given more or less fuel, until
the engine runs evenly again.
The measured value block displays the injected quantity differences of the individual cylinders
compared with No. 3 cylinder that is required to ensure an even engine idling speed.
+... mg/H: The relevant cylinder is less powerful than No. 3 cylinder and is therefore supplied with
more fuel.
-... mg/H: The relevant cylinder is more powerful than No. 3 cylinder and is therefore supplied with
less fuel.
Display group 000 at full throttle (test drive in 3rd gear, coolant temperature not below 80 °C)
Notes:
 ◆ When testing, accelerate vehicle at full throttle.

 ◆ The measured values must be printed out or read (2nd person required) when the revolutions
reach 3,000 rpm.
Display group 000 (decimal displayed value)
▪ Engine speed 2900...3100 rpm
x x x x x x x x x x
Air mass 225...255 750...850 mg/H
Intake manifold pressure 165...189 1380...1575 mbar
Injected quantity 174...180 35...36 mg/stroke
Accelerator pedal position 255 100 %
Commencement of injection 138...188 8...12°BTDC
Engine speed 136...150 2850...3150 rpm
Notes:

reach 3,000 rpm.

xxx %
rpm B/ATDC B/ATDC
Commencement of => Page 01-
60...90 %
injection valve duty cycle 80
Commencement of injection Approx. Commencement => Page 01-
(actual) of inj. (specified) 80
Commencement of injection (specified) 8...12°BTDC ---
Evaluation: Commencement of injection (actual) display

For large deviation from - Commencement of injection - Check -N108 => Page 01-51 , final
specified value (approx. 5°) valve -N108 defective control diagnosis
- Check commencement of injection
- Injection pump timing way off
dynamically and adjust => Page 23-25
- Air in fuel system - Check fuel supply system
Evaluation: Duty cycle from commencement of injection valve display
V.A.G 1551
display
Below 60 or - Commencement of injection valve - - Check -N108 => Page 01-51 , final control
above 90 % N108 defective diagnosis
- Check commencement of injection dynamically
and adjust => Page 23-25
- Check fuel supply system
Notes:

reach 3,000 rpm.

Read measured value
⇒ [ltrif ] Indicated on display
block 8
xxxx xx.x xx.x xx.x
rpm mg/H mg/H mg/H
Injected quantity limitation due to
=> Page 01-
mass of air drawn in (smoke 35...38 mg/H
82
prevention)
Injected quantity limitation via revs. (torque 34.2...35.2 => Page 01-
limitation) mg/H 82
=> Page 01-
Injected quantity (driver's requirement) 36...42 mg/H
82
Evaluation: Injected quantity (driver's requirement) display
V.A.G 1551
display
Below 36 mg/H - No full throttle - Repeat check at full throttle
- Check G-79 and if necessary
- Accelerator pedal position sender -G79 incorrectly
adjust
adjusted or defective
=>Page 23-98
Evaluation: Injected quantity limitation via revs. (torque limitation) display

Below 34.2 mg/H - Speed too high or too low - Read off specified value at 3000 rpm
Evaluation: Injection quantity limitation due to air mass drawn in (smoke prevention) display
V.A.G 1551
display
- Check exhaust gas recirculation and air mass meter
Below 35 mg/H - Air mass drawn in insufficient
function => Page 23-89
- Excessive exhaust gas - Check exhaust gas recirculation and air mass meter
recirculation function =>Page 23-89
Notes:
 ◆ When testing, accelerate the vehicle at full throttle.

reach 3,000 rpm.
Display group 010 -Air quantities-
xxx mg/H xxxx mbr xxxx mbr xxx.x %
Accelerator pedal position 100 % => Page 01-85
Intake manifold pressure (charge
1720...1950 mbar => Page 01-85
pressure)
Atmospheric pressure (ambient pressure) No specification ---
Air mass drawn in 750...850 mg/H => Page 01-84
Evaluation: Air mass drawn in display
V.A.G 1551 Possible fault

Fault elimination
display cause
Below 750 - Revs. too low or
- Read off specified value at 3000 rpm.
mg/H too high
- Charge pressure - Check charge pressure control
too low =>Page 23-79
- Air mass meter Page 23-89
defective If a fault is present the measured value block indicates a constant air
mass value of approx. 425 mg/H over the total speed and load range
Evaluation: Intake manifold pressure (charge pressure) display
V.A.G 1551
display
- Check charge pressure
Below 1720 mbar - Charge pressure control defective control
=>Page 23-79
- Charge pressure limitation solenoid valve -N75
sticking
- Pressure hose of charge pressure control fallen off or
Above 1950 mbar control
blocked
=> Page 23-79
sticking
V.A.G 1551
display
Below 100 % - No full throttle - Repeat test at full throttle.
adjust
=>Page 23-98
Notes:
 ◆ When testing, accelerate the vehicle at full throttle.

reach 3,000 rpm.
Display group 011 -Charge pressure control-

Read measured value block
11
xxxx rpm xxxx mbr xxxx mbr xxx %
Duty cycle from charge pressure
30...75 % ---
limitation valve
Charge pressure (actual) 1720...1950 mbar => Page 01-87
Charge pressure (specified) 1750...1950 mbar ---
Evaluation: Charge pressure display (actual)
V.A.G 1551
display
Below 1720 mbar - Charge pressure control defective control
=>Page 23-79
- Connect charge pressure
- Charge pressure hose not connected to control unit
hose
- Pressure hose of charge pressure control fallen off or
Above 1950 mbar control
blocked
=> Page 23-79
sticking
Self-diagnosis
Evaluating measured value blocks, engine codes AFN, AVG

▪ Engine running at idling speed
x x x x x x x x x x
Air mass1) 69...135 230...450 mg/H
Intake manifold pressure Not relevant ---
Injected quantity 11...45 2.2...9 mg/H
Accelerator pedal position 0 0%
Commencement of injection 0...88 3°ATDC...4°BTDC
40...432) 840...903 rpm2)
Engine speed
38...413) 800...860 rpm3)
1) The measured values are only valid when the exhaust gas recirculation (EGR) is switched on. The
EGR is switched off after approx. 3 minutes at idling speed, therefore give burst on throttle or restart
engine.
2) Vehicles with manual gearbox
3) Vehicles with automatic gearbox
Display group 001 -Injected quantity-

xxxx rpm xx.x mg/H x.xx V xxx.x °C
1.45...1.90 V => Page 01-90
voltage
Injected quantity 2.2...9 mg/H => Page 01-90
840...903 rpm1)
Engine speed ---
800...860 rpm2)
Evaluation: Injected quantity display

Below 2.2 mg/H - Injection pump too rich - Renew injection pump => Page 23-19
check
Evaluation: Modulating piston movement sender voltage display

Below 1.45 V - Injection pump too rich - Renew injection pump => Page 23-19
Above 1.90 V - Engine too cold
check
Display group 002 -Idling speed-

2
xxxx rpm xxx.x % xxx xxx.x °C
Operating mode 010 => Page 01-92
Accelerator pedal position 0% => Page 01-92
840...903 rpm1)
Engine speed ---
800...860 rpm2)
V.A.G 1551
display
- Check G-79 and adjust if
- Accelerator position sender -G79 incorrectly set or
1...100 % necessary
defective
=>Page 23-98
- Wiring open circuit to G79
Evaluation: Operating condition display
Relevance of figures in 3-digit number block for engine operating condition:

x x x Engine operating condition
1 Air conditioner compressor switched on
1 Idling switch closed
1 Increased idling speed because air conditioner is switched on
Display group 003 -Exhaust gas recirculation-

xxxx rpm xxx mg/H xxx mg/H xxx %
Duty cycle from exhaust gas
4...95 % ---
recirculation valve
Air mass drawn in (actual) 230...450 mg/H => Page 01-94
Air mass drawn in (specified) 230...450 mg/H => Page 01-93
840...903 rpm1)
Engine speed ---
800...860 rpm2)
Evaluation: Air mass drawn in (specified) display

check.
Evaluation: Air mass drawn in (actual) display
V.A.G 1551
display
Below 230 - Excessive exhaust gas - Check exhaust gas recirculation
mg/H recirculation => Page 23-89
- Unmetered air - Check intake air system for leaks.
Above 450
- Engine too cold - Run engine at increased speed to warm up and repeat check.
mg/H
- Insufficient exhaust
- Engine running at idling speed for 3 mins., give burst on throttle.
gas recirculation
Page 23-89
- Air mass meter -G70
If a fault is present the measured value block indicates a constant
defective
air mass value of approx. 550 mg/H over the total speed and load
range.

xxx %
rpm B/ATDC B/ATDC
Duty cycle from
commencement of injection 2...95 % ---
valve
=> Page 01-
Commencement of injection (actual) 3°ATDC...4°BTDC
96
=> Page 01-
Commencement of injection (specified) 3°ATDC...4°BTDC
96
840...903 rpm1)
Engine speed ---
800...860 rpm2)
Evaluation: Commencement of injection (specified) display

Earlier than 4°BTDC - Engine too cold
check.
V.A.G 1551
display
Earlier than 4° - Run engine at increased speed to warm up and
- Engine too cold
BTDC repeat check.
- Injection pump set too "advanced"
- Commencement of injection valve - - Check -N108 => Page 01-51 , final control
N108 defective diagnosis
Later than - Injection pump set extremely - Check commencement of injection dynamically
3°ATDC "retarded" and adjust => Page 23-25
- Check -N108 => Page 01-51 , final control
- Injection adjustment blocked
diagnosis
- Commencement of injection valve -
N108 defective
Display group 005

Display group 005 -Starting conditions-

xx.x °
xxxx rpm xx.x mg/H xxx.x °C
B/ATDC
Commencement of injection (actual) --- ---
Starting quantity --- ---
Display group 006 with ignition switched on
Display group 006 -Switch positions-

xxx km/h xxx xxxxxx xxx
Cruise control system1) --- ---
Cruise control system => Page 01-99
Brake pedal monitor => Page 01-98
Speed --- ---
1) 0 = Vehicles with cruise control system
255 = Vehicles without cruise control system
Evaluation: Brake pedal monitor display
Relevance of figures in 3-digit number block for brake pedal monitor:

x x x Brake pedal monitor
1 Brake light switch -F- closed
1 Brake pedal switch -F-47- open
1 Clutch pedal switch -F36- open
Evaluation: Cruise control system display
Relevance of figures in 6-digit number block for cruise control system:
"1" signifies:
x x x x x x Cruise control system
1 1 Cruise control system switched on
1 1 1 Setting speed
1 1 1 Resuming setting speed
1 OFF button operated
Display group 007 with ignition switched on (engine cold and not running)
Display group 007 -Temperatures-

Read measured value ⇒ [ltrif ] Indicated on
block 7 display
xxx.x °C xxx.x °C xxx.x °C
Approx. ambient
Coolant temperature => Page 01-101
temperature1)
Approx. ambient
Intake manifold temperature => Page 01-101
temperature1)
No display
Approx. ambient
Fuel temperature => Page 01-101
temperature1)
1) Details of temperature specifications are not possible. When the engine is cold the fuel, intake air
and coolant temperatures must equate approximately to ambient temperature. If a temperature deviates
noticeably then the relevant sender must be checked.
Evaluation: Fuel temperature display
V.A.G 1551
display
- Short circuit or fuel temperature
- 5.4 °C If a fault is present the measured value block
sender -G81 defective
indicates a fuel temperature of -5.4 °C
Evaluation: Intake manifold temperature display
V.A.G 1551
display
Approx. 136.8 - Intake manifold temperature
If a fault is present the measured value block indicates
°C sender -G72 defective
a fuel temperature of approx.136.8 °C
Evaluation: Coolant temperature display

Large deviation from - Short circuit or coolant temperature
If a fault is present the fuel
ambient temperature sender -G62 defective
temperature is shown alternatively
Display group 009

xxxx rpm xx.x mg/H xx.x mg/H x.xx V
No display --- ---
Injected quantity limitation from automatic
--- ---
gearbox during gear change
Injected quantity (cruise control system active) --- ---
Display group 012
Display group 012 -Glow plug system-
xxxx xx.xx sek. xx.x V xxx.x °C
Supply voltage from control unit --- ---
Pre-glow period --- ---
Not relevant --- ---
Display group 013 -Idling speed smooth running control-

x.xx mg/H x.xx mg/H x.xx mg/H
No display ---
Different quantity injected Cyl. 1
- 2.0...+ 2.0 mg/H => Page 01-105
and Cyl. 3
Evaluation: Idling speed smooth running control display
The injection system is equipped with an idling speed smooth running control. There may be power
differences between the individual cylinders (component tolerances, injector delivery,
compressions etc.) which are recognised and equalized via selective injected quantities.
Recognition at idling speed is via the signal from the engine speed sender which delivers four
signals per crankshaft revolution to the control unit. If the signals are delivered at the same
rhythm then all cylinders work the same. If one cylinder is weaker then the crankshaft takes
longer for the next half revolution. Conversely a more powerful cylinder accelerates the
crankshaft so less time is taken.
If the control unit recognises a difference, then the relevant cylinder is given more or less fuel, until
the engine runs evenly again.
The measured value block displays the injected quantity differences of the individual cylinders
compared with No. 3 cylinder that is required to ensure an even engine idling speed.
+... mg/H: The relevant cylinder is less powerful than No. 3 cylinder and is therefore supplied with
more fuel.
-... mg/H: The relevant cylinder is more powerful than No. 3 cylinder and is therefore supplied with
less fuel.
Display group 015
Display group 015 -Fuel consumption-

Read measured value
block 15
xxxx xx.x xx.x
xx.xx l/h
rpm mg/H mg/H
Injected quantity requirement (driver's
--- ---
requirement via accelerator pedal)
Fuel consumption --- ---
Injected quantity (actual) --- ---
Notes:
 ◆ When testing, accelerate vehicle at full throttle, but do not operate kickdown on automatic
gearboxes.
reach 3,000 rpm.

▪ Engine speed 2900...3100 rpm
x x x x x x x x x x
Air mass 240...255 800...850 mg/H
Intake manifold pressure 168...219 1747...2250 mbar
Injected quantity 190...215 38...43 mg/stroke
Accelerator pedal position 255 100 %
Commencement of injection 112...213 6...14°BTDC
Engine speed 138...148 2900..3100 rpm
Display group 004 at full throttle (test drive in 3rd gear/3rd driving range, coolant temperature not
below 80 °C)
Notes:
gearboxes.
reach 3,000 rpm.

xxx %
rpm B/ATDC B/ATDC
Duty cycle from
=> Page 01-
commencement of 60...95 %
109
injection valve
Commencement of injection Approx. commencement => Page 01-
(actual) of inj. (specified) 109
Commencement of injection (specified) 6...14°BTDC ---

For large deviation from - Commencement of injection - Check -N108 => Page 01-51 , final
specified value (approx. 5°) valve -N108 defective control diagnosis
- Check commencement of injection
- Injection pump timing way off
dynamically and adjust => Page 23-25
- Air in fuel system - Check fuel supply system
Evaluation: Duty cycle from commencement of injection valve display
V.A.G 1551
display
Below 60 or - Commencement of injection valve - - Check -N108 => Page 01-51 , final control
above 95 % N108 defective diagnosis
- Check fuel supply system
below 80 °C)
Notes:
gearboxes.
reach 3,000 rpm.

Read measured value
block 8
xxxx xx.x xx.x xx.x
rpm mg/H mg/H mg/H
Injected quantity limitation due to
=> Page 01-
mass of air drawn in (smoke Above 39 mg/H
111
prevention)
Injected quantity limitation via revs. (torque => Page 01-
39...42 mg/H
limitation) 111
=> Page 01-
Injected quantity (driver's requirement) Above 39 mg/H
111
Evaluation: Injected quantity (driver's requirement) display
V.A.G 1551
display
Below 39 mg/H - No full throttle - Repeat check at full throttle
adjust
=>Page 23-98
Evaluation: Injected quantity limitation via revs. (torque limitation) display

Below 39 mg/H - Speed too high or too low - Read off specified value at 3000 rpm.
Evaluation: Injected quantity limitation due to air mass drawn in (smoke prevention) display
V.A.G 1551
display
- Air mass drawn in - Check exhaust gas recirculation and air mass meter
Below 39 mg/H
insufficient function => Page 23-89
- Excessive exhaust gas - Check exhaust gas recirculation and air mass meter
recirculation function =>Page 23-89
below 80 °C)
Notes:
gearboxes.
reach 3,000 rpm.
Display group 010 -Air quantities-

xxx mg/H xxxx mbr xxxx mbr xxx.x %
Accelerator pedal position 100 % => Page 01-114
Intake manifold pressure (charge
1747...2250 mbar => Page 01-113
pressure)
Atmospheric pressure (ambient pressure) No specification ---
Air mass drawn in 800...1150 mg/H => Page 01-113
Evaluation: Air mass drawn in display
V.A.G 1551 Possible fault

Fault elimination
display cause
Below 800 - Speed too low or
- Read off specified value at 3000 rpm.
mg/H too high
- Charge pressure - Check charge pressure control
too low => Page 23-79
- Air mass meter Page 23-89
defective If a fault is present the measured value block indicates a constant air
mass value of approx. 550 mg/H over the total speed and load range
Evaluation: Intake manifold pressure (charge pressure) display

- Check charge pressure control
Below 1747 mbar - Charge pressure control defective
=> Page 23-79
Above 2250 mbar - Turbocharger defective
V.A.G 1551
display
Below 100 % - No full throttle - Repeat check at full throttle.
- Accelerator pedal position sender -G79 incorrectly - Check G-79 and if necessary
adjust
=>Page 23-98
below 80 °C)
Notes:
gearboxes.
reach 3,000 rpm.
Display group 011 -Charge pressure control-

11
xxxx rpm xxxx mbr xxxx mbr xxx %
Duty cycle from charge pressure
45...95 % ---
limitation valve
Charge pressure (actual) 1747...2250 rpm => Page 01-116
Charge pressure (specified) 1747...2250 mbar ---
Evaluation: Charge pressure (actual) display

Below 1747 mbar - Charge pressure control defective
=>Page 23-79
- Charge pressure hose not connected to control
- Connect charge pressure hose
unit
Above 2250 mbar - Turbocharger defective
=>Page 23-79
Servicing Diesel direct injection system

The Diesel direct injection system control unit is equipped with a fault memory. Before starting repairs,
adjustments and fault finding, the fault memory must be interrogated and final control diagnosis
completed =>Page 01-7 .
Note:
When performing check and adjustment operations the control unit may recognized and store faults.
For this reason after completing all check and adjustment operations it is necessary to erase fault
memory
=>Page 01-49 .

Safety precautions
Observe following if test and measuring instruments are required during a test drive:
 ◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person
from this location.
 If test and measuring instruments are operated from front passenger's seat and the vehicle is
involved in an accident, there is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
Warning!
Secure fault reader to rear seat and operate from this position.
To prevent injuries to persons and/or damage to the injection and glow plug system, the following must be
noted:
 ◆ The ignition must be switched off before connecting or disconnecting injection or glow plug
system wiring or tester cables.
 ◆ If the engine is to be turned at starter speed, without starting, e.g. when checking
compressions:
For engine codes AHU,1Z pull connector off fuel shut-off valve (N109) on injection pump.
For engine codes AFN, AVG disconnect 10 pin connector on injection pump.
 ◆ Before disconnecting battery, obtain radio code for radios fitted with anti-theft coding.
 ◆ Disconnecting and connecting the battery must only be undertaken when the ignition switched
off otherwise the Diesel direct injection system control unit may be damaged.

Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "5 rules":
 ◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
 ◆ Place parts that have been removed on a clean surface and cover. Do not use fluffy cloths!
 ◆ Carefully cover opened components or seal, if the repair cannot be carried out immediately.
 ◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
 ◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
 ◆ Also ensure that no diesel fuel runs onto the coolant hoses. Hoses coming in contact with fuel
must be cleaned immediately. Damaged hoses must be replaced.

Fitting locations overview
1. Air mass meter

(G70)
2. Heater pipe
o ◆ Resistanc
e between
contacts:
4...17 ω
(at ambient
temperature)
o ◆ Voltage
supply via
terminal 15
3. Injector with needle

lift sender (G80)
4. Exhaust gas
recirculation valve
(N18)
5. Clutch pedal switch

(F36)
6. Brake pedal switch

(F47)
7. Brake light switch

(F)
8. Accelerator pedal
position sender
(G79)
9. Diesel direct
injection system
control unit (J248)
o ◆ Location
: behind
dash panel
insert in
passenger
compartme
nt
o ◆ With
sender for
intake
manifold
pressure
(G71)
o ◆ With
elevation
sender
(F96)
o ◆ Renew
=> Page
23-106
10. Charge pressure

limiting solenoid
valve (N75)
11. Intake manifold

temperature
sender (G72)
12. Multi-pin
connector
o ◆ For fuel
temperatur
e sender
(G81)
o ◆ For
quantity
adjuster
(N146)
o ◆ For
modulating
piston
movement
sender
(G149)
o ◆ For
engine
codes
AFN, AVG
additionally
for fuel
shut-off
valve
(N109) and
commence
ment of
injection
valve
(N108)
13. Coolant
temperature
sender (G62)
14. Speedometer
sender (G22)
15. Central
connector
16. 2 pin connector

o ◆ For
needle
lift
sender
(G80)
17. 3 pin connector

o ◆ For
engine
speed
sender
18. Engine speed

sender (G28)
19. 3 pin connector

o ◆ Engin
e codes
AHU, 1Z
o ◆ For
fuel shut-
off valve
(N109)
o ◆ For
commen
cement
of
injection
valve
(N108)
20. Fuel cut-off

valve (N109)
21. Injection
pump
metering
control
o ◆ Wit
h fuel
tempe
rature
sende
r
o ◆ Wit
h
quantit
y
adjust
er
(N146
)
o ◆ Wit
h
modul
ating
piston
move
ment
sende
r
(G149
)

Servicing injection pump
 ◆ Observe rules for

cleanliness
=>Page 23-3
 ◆ Removing and
installing injection
pump
=>Page 23-19
 ◆ Dynamically
checking and
adjusting injection
pump =>Page 23-25
1. 55 Nm
2. Injection pump
sprocket
o ◆ Removin
g =>
Removing
injection
pump Page
23-19
3. Woodruff key
o ◆ Check
seated
securely
4. Seal
o ◆ Renew
5. Banjo bolt, 25 Nm
6. Supply hose
o ◆ From
fuel filter
7. Injection pump
o ◆ With
quantity
adjuster
(meterin
g)
o ◆ With
quantity
adjuster
(N146)
o ◆ With
modulati
ng piston
moveme
nt
sender
(G149)
o ◆ With
fuel
temperat
ure
sender
8. O-Ring
o ◆ Rene
w if
damage
d
9. Fuel shut off

valve, 40 Nm
10. Pipe union

o ◆ For
return
pipe
11. 25 Nm
12. Return hose
o ◆ To
control
valve/fue
l filter
13. Injector pipes

o ◆ Tighten to
25 Nm
o ◆ Remove
with 3035
o ◆ Always
remove
pipework
complete
o ◆ Do not
alter shape
14. Injector
o ◆ For 3rd
cylinder with
needle lift
sender
o ◆ Removin
g and
installing
=> Page 23-
32
o ◆ Servicing
=> Page 23-
34
15. 20 Nm
16. Dished washer
17. Retainer
18. Mounting
19. 3 pin connector

o ◆ Engine
codes AHU,
1Z
o ◆ For fuel
cut-off and
commence
ment of
injection
valves
20. Pipe union, 45 Nm

o ◆ With
pressure
valve
21. Timing control

cover
o ◆ If
leaking,
replace O-
ring
=>Page
23-35
22. Heat insulation

seal
o ◆ Renew
23. 10 Nm
24. Commencement
of injection valve
(N108)
o ◆ Checkin
g =>Page
01-51 ,
final control
diagnosis
25. Strainer
26. Retainer
27. Sleeve
o ◆ Tapered
28. 25 Nm
o ◆ Nut with
taper
29. Console

Servicing fuel filter
1. Return pipe
o ◆ Secur
e with
spring-
type clips
o ◆ From
injection
pump
2. Supply pipe
o ◆ Secur
e with
spring-
type clips
o ◆ To
injection
pump
3. O-Ring
o ◆ Renew
4. Control valve
o ◆ Installatio
n position:
arrow points
towards fuel
tank
o ◆ When
changing
filter, remove
securing clip
and take
control valve
off complete
with fuel
pipes
o ◆ Below +
15 °C:
Passageway
to filter open
o ◆ Over + 31
°C:
Passageway
to filter
closed
5. Securing clip
6. Return pipe
o ◆ Secure
with spring-
type clips
o ◆ To fuel
tank
7. Supply pipe
o ◆ Secure
with spring-
type clips
o ◆ From fuel
tank
8. Fuel filter
o ◆ Fill
with
diesel
before
installing
o ◆ Flow
direction
is
marked
by an
arrow
o ◆ Do not
interchan
ge
connectio
ns
o ◆ Renew
if
damaged
9. Gasket
o ◆ Renew
if
damaged
10. Water drain plug

o ◆ To
bleed
remove
securing
clip and
take
control
valve off
complete
with fuel
pipes
attached
o ◆ Loose
n and
allow
approx.
100 cm3
fluid to
drain

Servicing accelerator linkage
1. 10 Nm
2. Spring washer
3. Cable cam
o ◆ Installing
=>Page
23-17 , Fig.
1
4. Accelerator pedal
position sender
(G79)
o ◆ Checkin
g =>Page
23-98
o ◆ Adjusting
=>Page
23-18
5. Console
6. Adjustment bolt, 7
Nm
7. Circlip
8. Bush
9. Mounting
pedestal
10. Accelerator
pedal
11. Bush
12. Torsion
spring
→ Fig.1 Installing cable cam
 ‒ Secure cable cam to sender

so that the dimensions shown
are adhered to as seen from
direction of travel.
a = 22mm
b = 23 mm
c = Direction of travel
Note:
The cable cam eye must be parallel to

the forward direction.

Checking sender adjustment
Work sequence
 ‒ Connect the fault reader V.A.G 1551 (V.A.G 1552) and with ignition switched on select engine
electronics control unit with the "Address word" 01.

HELP
Select function XX

HELP

XXX
entry with Q key.
→ Check accelerator pedal position display in display zone 2. The Read measured value block
accelerator pedal must not be depressed. 2 ⇒
Specification: 0.0 %
0 rpm 0.0 % 0 1
0 18.4 5C
→ Depress accelerator pedal fully, slowly and observe display zone 2. The Read measured value
value for the accelerator pedal position must increase continuously and block 2 ⇒
shortly before full throttle stop reach
100 %. 0 rpm 100 %
0 1 0 18.4 5C
 ‒ → Loosen adjustment bolt -

6-.
 ‒ Turn mounting pedestal -9-
with accelerator pedal position
sender -4- so that when
accelerator pedal is not
depressed (idling position)
0.0 %
and with accelerator pedal
depressed to just before full
throttle position
100 %
is displayed.
 ‒ Tighten adjustment bolt -6-

to 7 Nm.
Removing and installing injection pump
 ◆ Setting bar 2065 A

 ◆ Pin 2064
 ◆ Pin wrench Matra V159
 ◆ Puller 3032
 ◆ Ring spanner 3035
 ◆ V.A.G 1331 Torque wrench (5...50 Nm)
 ◆ V.A.G 1332 Torque wrench

(40...200 Nm)
Removing
 ‒ Remove air cleaner.

 ‒ Remove balance weight from
engine mounting.
 ‒ → Remove securing bolts -1-
and -2- and remove engine
mounting -3-.
 ‒ Remove upper toothed belt

guard and cylinder head cover.
 ‒ → Turn crankshaft to TDC

No. 1 cylinder -arrow-.
 ‒ Lock camshaft with setting
bar.
 ‒ Centralize setting bar as
follows:
Turn arrested camshaft so that
one end of setting bar contacts
the cylinder head. Using feeler
gauge establish the gap at the
other end of the setting bar.
Place a feeler gauge
corresponding to half the gap
between setting bar and
cylinder head. Turn camshaft
until the setting bar contacts
the feeler gauge. Place a 2nd
feeler gauge, of same
thickness, at the other end
cylinder head.
 ‒ Remove idler roller.
 ‒ Remove tensioning roller
nut.
 ‒ Relieve tooth belt tension
and take off camshaft and
injection pump sprockets.
 ‒ Lock injection pump sprocket
with pin 2064.
 ‒ Remove injection pump

sprocket securing nut.
 ‒ → Loosen puller arms and

offer up.
 ‒ Locate puller arms through
holes in injection pump
sprocket and tighten.
 ‒ Place injection pump
sprocket under tension with
puller.
 ‒ Release injection pump
sprocket from injection pump
taper by tapping lightly on
puller spindle -arrow- (when
doing this hold sprocket so that
it does not fall off).
 ‒ Unbolt all fuel lines at fuel
pump.
 ‒ Cover openings with a clean
cloth.
Note:
Use slotted ring spanner 3035 to

remove high pressure fuel pipes.
 ‒ Disconnect fuel cut-off

valve/commencement of
injection valve connector.
 ‒ Disconnect quantity adjuster
connector and unclip connector
from retainer.
 ‒ → Remove securing bolts

from console -arrows-.
 ‒ → Then remove bolt from

rear support -arrow-.
 ‒ Take off injection pump.
Installing
 ‒ Insert injection pump into

console and then tighten
securing bolt on rear support
with conical nut first.
 ‒ Align injection pump to
central position in console
elongated holes and secure
hand tight.
Note:
The commencement of injection is set

dynamically with V.A.G 1551.
 ‒ → Install injection pump
sprocket and lock in position
with pin 2064. When installing
observe spring washer seating.
 ‒ Tighten securing nut to 55
Nm.
 ‒ Loosen camshaft sprocket
securing bolt a half turn.
 ‒ Place a drift through hole in
the rear of the toothed belt
guard and release the
camshaft sprocket from
camshaft taper with a blow
from a hammer.
 ‒ Take camshaft sprocket off.
 ‒ Check whether TDC mark on
flywheel and reference mark
are aligned.
 ‒ Place tooth belt on injection
pump sprocket and tensioning
roller.
 ‒ Fit camshaft sprocket into
toothed belt and secure
sprocket so that the camshaft
can still turn.
 ‒ Install idler roller.
 ‒ Remove locking pin from

injection pump sprocket.
 ‒ → Tension toothed belt.

Using pin wrench (e.g. Matra
V159) on eccentric turn
clockwise until the notch and
the raised mark -arrows- align.
 ‒ Tighten securing nut to 20
Nm.
 ‒ Check TDC mark on flywheel
again.
 ‒ Tighten camshaft sprocket
securing bolt to
45 Nm.
 ‒ Remove setting bar 2065A
from camshaft.
 ‒ Fill injection pump with clean

Diesel through return pipe
union. Quantity for new pump,
at least 180 ml.
 ‒ Reconnect injection pipes,

fuel pipes and electrical wiring.
 ‒ Install toothed belt guard and
cylinder head cover.
 ‒ → Attach engine mounting -
3- with securing bolts -1- and -
2- hand tight.
 ‒ First tighten securing bolts -
2- to 20 Nm and then securing
bolts -1- to 55 Nm.
 ‒ Attach balance weight to
engine mounting.
 ‒ Install air cleaner.
 ‒ Dynamically check
commencement of injection
and adjust if necessary
=>Page 23-25 .

Dynamically checking and adjusting commencement of injection
Notes:
 ◆ Dynamically checking and correcting commencement of injection is only possible in function 04

"Engine basic setting".
 ◆ The commencement of injection must always be checked after renewing the toothed belt or
loosening the injection pump bolts or toothed belt sprockets and if necessary adjusted.
Checking and adjustment conditions
 ● Mechanical engine basic setting OK.

 ● Toothed belt tension OK.
Work sequence

HELP
Select function XX
 ‒ Press keys 0 and 4 for the function "Introduction of basic setting" and
→ Indicated on display: Basic setting HELP

XXX
 ‒ Press key 0 three times for "Display group number 0" and confirm
entry with Q key.
→ Indicated on display: System in basic setting 0 ⇒

1 2 3 4 5 6
7 8 9 10
The commencement of injection in display zone 2 is dependent on the

fuel temperature in display zone 9.
 → A - Display zone 2
B - Display zone 9 fuel
temperature
C - Specified range for
Example:
The numerical value 90 in display zone

9 (B) corresponds to a numerical value
range of 34...73 in display zone 2 (A).
Notes:
 ◆ If the commencement of
injection is advanced turn
injection pump in engine
direction of rotation, if the
commencement of injection is
retarded turn against direction
of rotation.
 ◆ If when checking the
commencement of injection the
specifications are within zone -
C- then no adjustment is
required. After repairs e.g.
removing and installing
injection pump, adjusting
timing then the
commencement of injection is
to be set to the mean valve
(dashed line) of specification
zone -C-.
 ‒ Loosen injection pump

securing bolts approx. one
turn, leaving the easiest bolt to
reach till last.
 ‒ Hold injection pump by hand
under tension in direction to be
adjusted.
 ‒ Carefully loosen last
securing bolt until the pump
can be turned slightly and then
retighten securing bolt.
 ‒ Observe figures in display
zone 2 and if necessary adjust
again until the mean value for
specification zone -C- is
displayed.
 ‒ Tighten injection pump
securing bolts to 25 Nm.
 ‒ Check commencement of
injection again.
 ‒ Press keys 0 and 6 for the
"End data transfer" function
and confirm input with the Q
key.
Note:
Loosen and re-tighten (25 Nm) the

injection pipes on the injection pump
after dynamically adjusting the injection
pump. This relieves the strain on pipes
and prevents vibration breakages.

Checking valve timing
 ◆ Setting bar 2065 A

 ◆ Pin 2064
 ‒ Remove air cleaner.
 ‒ Unbolt balance weight from engine mounting.
 ‒ → Remove securing bolts -1-

and -2- and remove engine
mounting -3-.
 ‒ Remove upper toothed belt
guard and cylinder head cover.
 ‒ Check tension of toothed

belt.
 ‒ → Set engine to TDC No. 1

cylinder -arrow-. Setting bar
must fit into camshaft slot. If it
is not possible to insert the bar,
adjust valve timing as follows.
 ‒ Rotate camshaft so that
setting bar can be inserted.
 ‒ Centralize setting bar as

follows:
Turn arrested camshaft so that
one end of setting bar contacts
the cylinder head. Using feeler
gauge establish the gap at the
other end of the setting bar.
Place a feeler gauge
corresponding to half the gap
cylinder head. Turn camshaft
until the setting bar contacts
the feeler gauge. Place a 2nd
feeler gauge, of same
thickness, at the other end
cylinder head.
 ‒ Loosen camshaft sprocket

securing bolt a half turn.
 ‒ Place a drift through hole in

the rear of the toothed belt
guard and release the
camshaft sprocket from
camshaft taper with a blow
from a hammer.
 ‒ → Lock injection pump

sprocket with pin 2064.
 ‒ → Check crankshaft TDC

setting. The TDC marking on
the flywheel and the casting on
the clutch bell housing must
align -arrow-. If markings do
not align set crankshaft to
markings.
 ‒ Remove locking pin.
 ‒ Tighten camshaft sprocket
securing bolt to
45 Nm.
 ‒ Remove setting bar.
 ‒ Install toothed belt guard and

cylinder head cover.
 ‒ → Attach engine mounting -
3- with securing bolts -1- and -
2- hand tight.
 ‒ First tighten securing bolts -
2- to 20 Nm and then securing
bolts -1- to 55 Nm.
 ‒ Attach balance weight to
engine mounting.
 ‒ Install air cleaner.
 ‒ Dynamically check
commencement of
injection=>Page 23-25 .

Removing and installing injectors

Note:
Defective injectors cause the following faults:
 ◆ Misfiring
 ◆ Knocking in one or more cylinders
 ◆ Engine over-heating
 ◆ Loss of power
 ◆ Excessive black exhaust smoke
 ◆ Higher fuel consumption
 ◆ Excessive blue smoke when starting from cold
Defective injectors can be located by loosening the high pressure pipe union on each injector in turn with
the engine running at a fast idling speed. If engine speed remains constant after loosening a pipe union,
this indicates a defective injector.
Removing
 ‒ Remove injection pipes with an slotted ring spanner 3035.
Note:
Always remove pipe set complete. Do not alter pipe shape.
 ‒ Remove securing nut, take off retainer and take out injector.
Installing
Note:
Always renew heat insulating seal between cylinder head and injectors.
 ‒ Insert injector.
 ‒ Check mounting is seated correctly in cylinder head.
 ‒ Fit retainer.
Tightening torques:
Injection pipes = 25 Nm
Retainer nut = 20 Nm

Servicing injectors
This engine is equipped with dual spring injectors. The fuel injected therefore occurs in 2 stages.
If faults occur with these injectors then they are to be exchanged as neither servicing nor pressure setting
is possible.
 ◆ Injector test unit V.A.G 1322 with pressure pipe V.A.G 1322/2
Test conditions
 ● Pressure gauge on
Checking injection pressure
Warning!
When testing injectors ensure that
the jet of fuel does not contact the
hands as the high pressure will
cause the fuel to penetrate the skin
and may cause severe injuries.
 ‒ → Connect injector to
injector test unit.
 ‒ Move pump lever down
slowly. When spray begins,
read off opening pressure. For
deviations from specification
renew injector.
Specification:
New injectors: 190 ... 200
bar
Wear limit: 170 bar
Checking for leaks
 ‒ Move pump lever down

slowly and maintain a pressure
of approx. 150 bar for 10
seconds. No fuel should leak
from the nozzle tip.
 ‒ If injector leaks, replace.

Renewing injection timing device cover O-ring
 ‒ Place a clean cloth under the

injection pump.
 ‒ → Remove cover screws -1-
with commercially available
key for Torx socket head
screws, e.g. Hazet 2115-T30.
 ‒ Remove cover -2- and clean
it.
 ‒ Renew O-ring -3- and install

cover with existing shims -4-.

Checking engine speed sender
The engine speed sender is speed and reference mark sender. During failure the engine continues
running in an emergency programme. Replacement sender is needle lift sender -G80.
 ◆ Test box V.A.G 1598/18

 ◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
 ◆ Adapter set V.A.G 1594
 ◆ Current flow diagram
Test sequence
 ‒ → Disconnect connector -1-
for engine speed sender.
 ‒ Measure resistance between
connector contacts 1+2.
Specification: 1.0 ... 1.5 kω
If the specification is not obtained:
 ‒ Renew engine speed sender

-G28.
=> Repair group 13; Dismantling and

assembling engine
If the specification is obtained:
 ‒ Remove dash panel insert:
=> Electrical system; Repair group 90;

dash panel insert; removing and
installing dash panel insert
 ‒ → Connect test box V.A.G

1598/18 to control unit wiring
loom.
 ‒ → Check wiring between test

box and 3 pin connector for
open circuit according to
current flow diagram.
Contact 1+ socket 33
Contact 2+ socket 8
Contact 3+ socket 1
Wire resistance: max. 1.5 ω
 ‒ Check wiring at 3 pin
connector for short circuit to
one another according to
Specification: ∞ω
If no wiring fault is detected:
 ‒ Renew Diesel direct injection

system control unit (J248) =>
Page 23-5 , item 9 .
Checking intake manifold pressure sender
Both pressure senders are located in the Diesel direct injection system control unit.
 ◆ Barometer or turbocharger test unit V.A.G 1397/A
Test sequence

HELP
Select function XX

HELP

XXX
 ‒ Press keys 0, 1 and 0 for "Display group number 10" and

→ Compare display zone 2 (altitude sender -F96) with display zone 3 Read measured value block
(intake manifold pressure sender -G71). 10 ⇒
Specification: The pressures must be the same
(tolerance ± 30 mbar) 0 mg/H 1027 mbar
1013 mbar 0.0 %
o ‒ Compare pressure display with a barometer (e.g.

turbocharger test unit V.A.G 1397/A).
Tolerance ±30 mbar
Value in display zone 3 deviates:
o ‒ Pull pressure hose off control unit.
Value in display zone 3 still deviates:

 ‒ Press keys 0 and 6 for the "End data transfer" function and
confirm input with the Q key.
 ‒ Renew Diesel direct injection system control unit (J248) =>

Checking coolant temperature sender
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
→ Indicated on display: Read measured

value block 7 ⇒
15.4 5C 15.9
5C 16.7 5C
 ‒ Observe coolant temperature figure in display zone 4. The temperature figure

must
Increase uniformly and without interruption.
 ‒ In case of faults the fuel temperature is displayed as a substitute.
 ‒ If no realistic display appears in display zone 4 or the fuel temperature is
displayed as a substitute. Check coolant temperature sender and wiring
connections to sender as follows:

key.
 ‒ → Pull connector off coolant
temperature sender -1-.

sender contacts 1+3.
 → Specification see diagram
Scale A shows resistance values for

temperature range 0...50 °C and scale
B the values for temperature range
50...100 °C.
Examples:
 ◆ 30 °C corresponds to a
resistance from 1500...2000 ω
 ‒ Replace coolant temperature

sender (G62).


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 ‒ Additionally check wires for
short to one another, to vehicle
earth and to battery positive.


Checking brake light switch and brake pedal switch
Because the injection system operates with an accelerator pedal sender (potentiometer) which may be
defective, the engine is governed for reasons of safety when the brakes are operated. To do this the
control unit requires signals from brake light switch and also the brake pedal switch. This means that if
the brakes are operated when the accelerator pedal is held at a constant position the engine is
immediately reduced to idling speed.
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
 ‒ Observe display in display zone 2.

→ Specification: 0 0 0 Read measured value block 6 ⇒
0 km/h 000 000000 255
 ‒ Operate brake pedal slowly.
→ Specification: 0 1 1 Read measured value block

Both displays must change from 0 to 1 at same time. 6 ⇒
0 km/h 011
000000 255
o ‒ Centre display = Brake pedal switch

o ‒ Right-hand display = Brake light switch
Centre display does not change:

 ‒ Pull connector off brake
pedal switch =>Fitting locations
overview, Page 23-4 .
 ‒ → Measure resistance
between switch contacts.
Specification:
Brake pedal not depressed:
less than 10 ω
Brake pedal depressed:∞ω
 ‒ Replace brake pedal switch

(F47).


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box and connector for open
circuit according to current flow
diagram.
Right-hand display does not change:

key.
 ‒ Set multimeter scale to
measure voltage and connect
between test box sockets 44 +
1.
 ‒ Observe voltage display.
Specification:
Brake pedal not depressed:
0 Volt
Brake pedal depressed:
approx. battery voltage
No voltage is displayed:
 ‒ Check whether brake light

functions.
Brake light OK:
 ‒ Check wiring to brake light

switch for open/short circuit
according to current flow
diagram.
Brake light not OK:
 ‒ Replace brake light switch

(F).

Checking clutch pedal switch
The clutch pedal switch (F36) informs the control unit when the clutch is being engaged or disengaged.
This prevents the engine from jolting when disengaging and engaging and also prevents the engine from
racing during disengaging operations when the cruise control system is switched on.
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
 ‒ Observe display in display zone 2.
→ Specification: 0 0 0 Read measured value block 6 ⇒
0 km/h 0 0 0 000000
255
 ‒ Operate clutch pedal. The left-hand position must change

to 1.
→ Specification: 1 0 0 Read measured value block

6 ⇒
0 km/h 1 0 0
000000 255
If the specifications are not obtained:

 ‒ Pull connector off clutch pedal switch => Fitting locations

overview, Page 23-4 .
 ‒ → Measure resistance at
switch contacts.
Specification
Clutch not depressed: max.
10 ω
Clutch depressed: ∞ω
 ‒ Replace clutch pedal switch

(F36).
If the specifications are obtained:


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diagram.

Checking intake manifold temperature sender
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
→ Indicated on display: Read measured value

block 7 "
15.4 5C 15.9
5C 16.7 5C
If faulty the following substitute values will be displayed:

Engine codes AHU, 1Z: 18.9°C
Engine codes AFN, AVG: 136.8°C
 ‒ If no realistic value is displayed in display zone 3 or the substitute is

displayed. Check intake manifold temperature sender and wiring to
sender as follows:

 ‒ → Pull connector -1- off
intake manifold temperature
sender -2-.

sender contacts.

50...100 °C.
Examples:
 ‒ Replace intake manifold

temperature sender (G72).


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diagram.


Checking Diesel direct injection system voltage supply
 ◆ Test box V.A.G 1598/18

Test prerequisites:
 ● Battery voltage OK.
Test sequence



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 ‒ Bridge sockets 42+46 with
auxiliary cables from V.A.G
1594.
 ‒ Measure voltage between
following sockets:
45+1, 68+1, 23+1 and
23+24
Specification: approx.
battery voltage
 ‒ Check voltage supply relay

terminal 30 (J317).
 ‒ Check wiring connections for
open circuit, short circuit and
transfer resistance at contacts
according to current flow
diagram.
If no fault is found in wiring and relay:


Checking fuel temperature sender
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.

value block 7 ⇒
15.4 5C 15.9
5C 16.7 5C
 ‒ If no realistic display appears in display zone 1 or a substitute

temperature of -5.6°C (-5.4°C for engine codes AFN, AVG) is displayed,
check fuel temperature sender and wiring connections to sender as follows:
 ‒ Press keys 0 and 6 for the "End data transfer" function and confirm input
with the Q key.
 ‒ Disconnect connector for fuel

temperature sender
(connection to injection pump
quantity adjuster) =>Fitting
locations overview, Page 23-4 .
Engine codes AFN, AVG:
 ‒ → Carry out resistance

measurement between
connector contacts 4 + 7 using
hand multimeter V.A.G 1526.
Engine codes AHU 1Z:
 ‒ → Carry out resistance

measurement between
connector contacts 4 + 7 using
hand multimeter V.A.G 1526.

50...100 °C.
Examples:
 ‒ Replace injection pump =>

Page 23-19 .


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box and connector -1- for open
diagram.

box and connector -1- for open
diagram.


Checking modulating piston movement sender and quantity adjuster
The metering unit is an electromagnetic swivelling positioner which is controlled by the control unit via a
directed duty cycle (on-off ratio). The eccentric shaft on the metering unit moves the modulating piston on
the high pressure piston and thereby regulates the quantity of fuel injected.
The modulating piston movement sender informs the control unit of the position of quantity adjuster -N146
and therefore stipulates the amount injected.
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
→ Indicated on display: Read measured value block 1 "
840 rpm 6.5 mg/H 1.480

V 87.3 5C
 ‒ Check coolant temperature in display zone 4.

Specification: at least 85 °C
Continue with check only when coolant temperature is attained.
 ‒ Check display in display zone 3 (voltage supplied from

modulating piston movement sender).
→ Specification: Read measured value block

Engine codes AHU, 1Z 1.250...1.750 V 1 ⇒
Engine codes AFN, AVG 1.450...1.900 V
840 rpm 6.5 mg/H
1.480 V 87.3 5C
 ‒ If specification is not obtained, check modulating piston movement

sender and quantity adjuster as described in following:
Checking modulating piston movement sender (G149).

 ‒ Disconnect connector for
(connection to injection pump
quantity adjuster) sender
=>Fitting locations overview
Page 23-4
between connector contacts 1
+ 2 and 2 + 3.
Specification: 5 ... 7 ω
+ 2 and 2 + 3.

Page 23-19 .



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diagram.
Contact 2+ socket 7

diagram.
Contact 2+ socket 7

Checking quantity adjuster (N146)

key.
 ‒ Disconnect connector
=>Fitting locations overview,
Page 23-4 .
between connector contacts
5+6.
Specification: 0.5...2.5 ω
5+6.
Specification: 0.5...2.5 ω

Page 23-19 .


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diagram.
Contact 5+ sockets 23, 45
and 68
Contact 6+ sockets 4, 5 and
49

diagram.
Contact 5+ sockets 23, 45
and 68
Contact 6+ sockets 4, 5 and
49


Checking needle lift sender
The needle lift sender signal is used to determine the commencement of injection. If it fails the
commencement of injection switches to open-loop control (according to engine speed and engine load).
During normal operation the commencement of injection is controlled by a closed-loop function (according
to engine speed, engine load and temperature).
 ◆ Test box V.A.G 1598/18

Test sequence

 ‒ → Disconnect connector -1-
for needle lift sender.
connector contacts.
Specification: 80...120 ω
 ‒ Replace No. 3 cylinder

injector with needle lift sender
(G80) => Page 23-10 , item
14 .


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diagram.


Checking injection timing control range
 ◆ Test box V.A.G 1598/18
Engine codes AFN, AVG
Engine codes AHU, 1Z =>Page 23-75
Test sequence

HELP
Select function XX
 ‒ Press keys 0 and 4 for the function "Introduction of basic setting" and

HELP

XXX
 ‒ Press key 0 three times for "Display group number 0" and
→ Indicated on display: System in basic setting 0 ⇒

1 2 3 4 5 6
7 8 9 10
The commencement of injection in display zone 2 is dependent on the

fuel temperature in display zone 9.
 → A - Display zone 2
B - Display zone 9 fuel
temperature
C - Specified range for
Example:
The numerical value 90 in display zone

9 (B) corresponds to a numerical value
range of 34...73 in display zone 2 (A).
If commencement of injection is not in

specified range -C-:
 ‒ Adjust commencement of
injection =>Page 23-25 .
If commencement of injection is in
specified range -C-:
 ‒ Press C key.
 ‒ Press keys 0, 0 and 4 for

"Display group number 4" and
→ Indicated on display System in basic setting 4

⇒
860 rpm 7.95 BTDC

7.95 BTDC 3%
 The displays in display zones 3 and 4 must fluctuate within

following control range:
o ‒ Specification display zone 3
7...9°BTDC
lower range 2...5%
upper range 90...95%
Because the fault reader display is slow the displayed figures vary
greatly. Therefore ensure that only in
display zone 3 the lowest figure lies between 7 and 9
and in display zone 4 the lowest figure lies between 2 and 5, and the
highest figure lies between 90 and 95.
 ‒ Check commencement of injection valve as follows:

 ‒ Disconnect connector on
injection pump =>Fitting
9+10.
 ‒ Replace commencement of
=>Page 23-11 .


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Engine codes AHU, 1Z
The control range of the injection

adjuster can be checked with help of
final control element test and at the
same time calling-up measured value
block 04. To do this it is required to
activate the control element
Commencement of injection valve -
N108 and then exiting the final control
element test with key -C-. Using this
sequence the commencement of
injection valve continues to be pulsed
so that with help of measured value
block 04 (display zone 3) the injection
adjuster control range can be read.
Test sequence

1551 (V.A.G 1552) and select
engine electronics control unit
with the "Address word" 01.
When doing this the engine
must be running at idling
speed.
(Connecting fault reader and
selecting engine electronics
control unit => Page 01-4 .)
Select function XX

transfer Q
03 Final
control
diagnosis
Note:
The individual control elements are only activated for 30 seconds. Within this period
various work sequences must be carried out with the fault reader unit as well as
reading the measured values. Therefore read the following work sequence first to
become conversant with the procedure.
Commencement of injection
valve -N108
 ‒ Press keys 0 and 8 for the function "Read measured value

block" and confirm entry with Q key.

HELP

XXX
entry with Q key.

4 ⇒
840 rpm 0.95 BTDC 0.95

BTDC 3 %
 The displays in display zones 3 and 4 must fluctuate within

following control range:
lower range 3°ATDC...4.0°BTDC
upper range 14.0...17.4°BTDC
lower range 2...5%
upper range 90...95%
Because the fault reader display is slow the displayed figures vary greatly.
Therefore ensure that only in
display zone 3 the lowest figure lies between 1.0 and 4.0 and the highest
figure lies between 14.0 and 17.4
and in display zone 4 the lowest figure lies between 2 and 5, and the
highest figure lies between 90 and 95.
 ‒ Check commencement of injection valve as follows:


 ‒ Disconnect connector on
injection pump =>Fitting
+ 3.
 ‒ Replace commencement of
=>Page 23-11 .


loom.



Checking charge pressure control
 ◆ Turbocharger tester V.A.G 1397 A
 ◆ Test box V.A.G 1598/18
Engine codes AHU, 1Z
Engine codes AFN, AVG=>Page 23-71
To enable the charge pressure control to be checked it is essential that the charge pressure is known
without charge pressure control (limiting), first
=> 4-Cyl. Diesel engine, Mechanics; Repair group 21; Check exhaust turbocharger
Test sequence
 ‒ The charge pressure is measured with the fault reader V.A.G 1551 during a test drive.
Note:
When the charge pressure is measured during a test drive, a second person is required, for reasons of
safety, to operate the fault reader.
 ‒ Connector connected to solenoid valve charge pressure control -N75.

HELP
Select function XX

HELP
Input display group number XXX
 ‒ Press keys 0, 1 and 1 for display group 11 and confirm entry

by pressing Q.
→ Indicated on display: Read measured value block 11 "
840 rpm 938 mbar 978 mbar 92

%
 ‒ Accelerate vehicle in 3rd gear from about 1500 rpm using full
throttle.
 ‒ Press PRINT key on V.A.G 1551 at approx. 3000 rpm.
→ Specification in display zone 3: 1720...1950 mbar Read measured value block

11 "
3090 rpm 1866 mbar

1917 mbar 62 %
 ‒ If the measured charge pressure is too low check charge

pressure control valve as follows:
=>Page 23-84
Check conditions
 ● No leaks on intake and exhaust systems.

 ● No faults in engine and fuel injection system, e.g.
commencement of injection, injectors and compression pressure.
 ● Engine oil temperature min. 80 °C
Test sequence
 ‒ The charge pressure is

measured with the
turbocharger tester V.A.G
1397/A and the fault reader
V.A.G 1551 during a test drive.
Note:
When the charge pressure is measured

during a test drive, for reasons of
safety, a second person is required to
operate the fault reader.
 ‒ → Pull off connecting hose

running between intake
manifold and diesel direct
injection system control unit
(J248) and using T-piece
connect in turbocharger tester
V.A.G 1397 A.
 ‒ Select measuring range l.
Notes:
 ◆ To operate turbocharger
tester see operating
instructions.
 ◆ The hoses must be
connected so that there is no
possibility of leaks.
 ◆ Ensure that the pressure
hose is not trapped between
the bonnet and the body.

1551 (V.A.G 1552) and select
engine electronics control unit
with the "Address word" 01.
When doing this the engine
must be running at idling
speed.
(Connecting fault reader and
selecting engine electronics
control unit => Page 01-4 .)

HELP
Select function XX

HELP
Input display group number XXX
 ‒ Press keys 0, 1 and 1 for display group 11 and confirm entry

by pressing Q.

11 "
840 rpm 938 mbar 978

mbar 92 %
 ‒ Accelerate vehicle in 3rd gear from about 1500 rpm using full throttle.
 ‒ Press PRINT key on V.A.G 1551 at approx. 3000 rpm and
simultaneously the memory key on V.A.G 1397/A..
Specification on V.A.G 1397/A: 1.747...2.250 bar
→ Specification on V.A.G 1551: 1747...2250 mbar (in display zone 3) Read measured value
block 11 "
3090 rpm 1866

mbar 1917 mbar 62
%
Note:
The charge pressure is determined with the turbocharger tester V.A.G 1397/A.
The fault reader V.A.G 1551 serves as a check that the charge pressure is
being recorded in the control unit.
 ‒ Carry out final control diagnosis and activate the charge pressure
control solenoid valve =>Page 01-51 .

⇒
Charge pressure control

solenoid valve -N75
The solenoid valve must function and the charge pressure control pressure
unit rod must move to and fro (at least 3...4 times, as long as there is vacuum
in vacuum reservoir).
 ‒ If the rod moves and the charge pressure specifications are not
obtained, renew turbocharger.
If rod does not move because solenoid valve is not working:
 ‒ Check solenoid valve for charge pressure control (N75) => Page 23-
84
 ‒ Check vacuum hoses => Page 23-87
If the rod does not move but the solenoid operates:
 ‒ → Connect vacuum pump

V.A.G 1390 to charge pressure
regulating valve and check rod
for ease of movement.
 ‒ If the rod does not move
easily, replace exhaust
turbocharger.
Electrically checking charge

pressure control solenoid valve
(N75)

 ‒ Pull connector off charge
pressure control solenoid
valve.

valve contacts.
→ Engine codes AHU, 1Z
→ Engine codes AFN, AVG
 ‒ Replace charge pressure

control solenoid valve (N75).


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 ‒ Check wiring between test
diagram.


Hose connection diagram for charge pressure control, engine codes AFN,
AVG
1. Air cleaner
2. Hose
o ◆ Black
3. Vacuum
reservoir
o ◆ Fittin
g
location:
Behind
coolant
expansi
on tank
4. Hose
o ◆ Black
, yellow
5. Retainer
6. Rubber bush
7. Solenoid valve
for charge
pressure
control (N75)
o ◆ Fittin
g
location:
On
bulkhea
d
8. 10 Nm
9. Hose
o ◆ Black
10. Non-return
valve
11. To vacuum
supply
12. Pressure unit

o ◆ For
charge
pressur
e
control
13. Hose
o ◆ Black
, yellow
14. Turbocharger

Checking exhaust gas recirculation and air mass meter function
The exhaust gas recirculation and air mass meter function can be checked with the help of final control
element test and at the same time calling-up measured value block 003. To do this the control element
Exhaust gas recirculation (EGR) valve -N18 must be activated and then exit the final control element test
with -C- key. Using this sequence the EGR valve continues to be pulsed so that with the help of the
measured value block 003 (display zone 3) the extreme values for the EGR (air mass meter) can be read.
 ◆ Test box V.A.G 1598/18
Test sequence
Select function XX

transfer Q
03 Final
control
diagnosis
Note:
The individual control elements are only activated for 30 seconds. Within this period
various work sequences must be carried out with the fault reader unit as well as
reading the measured values. Therefore read the following work sequence first to
become conversant with the procedure.
Commencement of injection valve -N108
Exhaust gas recirculation

valve -N18
 ‒ Press keys 0 and 8 for the function "Read measured value block"
and confirm entry with Q key.

HELP

XXX
entry with Q key.

value block 3 ⇒
840 rpm 272

mg/H 268
mg/H 54 %
 The displays in display zones 3 and 4 must fluctuate within following

control range:
 ‒ Specification display zone 3

Lower range 230...310 mg/stroke
Upper range 360...480 mg/stroke
Lower range 2...5%
Upper range 90...95%

Lower range 180...340 mg/stroke
Upper range 320...550 mg/stroke
Lower range 2...5%
Upper range 90...95%
Because the fault reader display is slow the displayed figures vary greatly.
Therefore only ensure that the upper and lower range figures in display zones 3
and 4 are obtained. This means only regard the minimum or maximum values.
 ‒ Check air mass meter as follows:

 ‒ Press keys 0 and 6 for the "End data transfer" function and confirm input
with the Q key.
 ‒ → Pull connector -1- off air

mass meter -2-.
 ‒ Switch on ignition.
 ‒ → Measure air mass meter

voltage supply between
following connector contacts:
Connector on -
Specification
G70 contact
App. battery
3 + Earth
voltage
App. battery
3+5
voltage
1 + earth Approx. 5 V
1+5 Approx. 5 V


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box and connections for open
diagram.
Contact 5+ socket 1
 ‒ Check EGR valve (N18) as

follows:
 ‒ → Pull connector -1- off

exhaust gas recirculation valve
-2-.
 ‒ Measure resistance at valve.
 ‒ Replace exhaust gas

recirculation valve (N18) =>
Note:
At room temperature the resistance lies

in the the lower tolerance region and at
operating temperature in upper
tolerance region.
 ‒ → Measure supply voltage at

valve connector contact 1 and
at engine earth.
Specification: approx.
battery voltage

diagram.


Checking speedometer sender
 ◆ Test box V.A.G 1598/22
Note:
To check the speed signal the vehicle must be driven. To do this a second person is necessary.
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
 ‒ Carry out test drive and when doing this observe display (2nd
person necessary).
→ Specification display zone 1: Approx. road speed. Read measured value block
6 ⇒
0 km/h 0 0 0
000000 255
 ‒ Press keys 0 and 6 for the function "End output" and confirm
entry with the Q key.
If no speed is indicated:
=> Electrical system; Repair group 90; dash panel insert; removing and

loom.
 ‒ Check wiring from connector
contact 43 from engine control
unit to dash panel insert for
open/short circuit.
=> Current flow diagrams, Electrical

fault finding and Fitting locations binder
Checking accelerator position sender
The accelerator pedal position sender is located on accelerator pedal and passes driver's requirement
(pedal position) on further to the control unit.
 ◆ Test box V.A.G 1598/18
Test sequence

HELP
Select function XX

HELP

XXX
entry with Q key.
→ Check accelerator pedal position display in display zone 2. The Read measured value block
accelerator pedal must not be depressed. 2 ⇒
Specification: 0.0 %
0 rpm 0.0 % 0 1
0 18.4 5C
 ‒ Check additionally the idling speed switch display in display zone 3.

The centre position must show 1.
Display: 010
→ Depress accelerator pedal fully down and observe display zones 2 and Read measured value
3. block 2 ⇒
0 rpm 100 % 0
0 0 18.4 5C
 ‒ Display zone 2:
The accelerator pedal position figure must increase continuously.
Specification at full throttle position: 100 %
 ‒ Display zone 3:
The centre position must change to 0.
Display: 000
On vehicles with an automatic gearbox the kickdown switch pressure point

must be distinctly felt before the full throttle stop position is reached.
End specification value not achieved:

 ‒ Adjust accelerator pedal position sender
=>Page 23-18
Display does not change or is erratic:
 ‒ Check accelerator pedal position sender as follows:

 ‒ → Disconnect connector for

accelerator pedal position
sender -1-.
 ‒ Measure sender resistance
1+3.
Specification:
Accelerator pedal in idling
speed position: 1.0...1.5 kω
Accelerator pedal in full
throttle position: 1.5...2.5 kω
 ‒ Check idling speed switch
(F60) in accelerator pedal
position sender. To do this
measure resistance between
connector contacts 4+6.
Specification:
Accelerator pedal in idling
speed position: max.1.5 kω
Accelerator pedal
depressed: ∞ ω
 ‒ Replace accelerator pedal

position sender (G79)
=>Page 23-15 , item 4 .


loom.

diagram.

Checking gearbox intervention signal when selecting gear
 ◆ Test box V.A.G 1598/18
Note:
To check the gearbox intervention signal the vehicle must be driven. To do this a second person is
necessary.
Test sequence

HELP
Select function XX
→ Indicated on display: Read measured value

block HELP

XXX
entry with Q key.
 ‒ Carry out test drive and when doing this observe display (2nd
person necessary).
 ‒ Observe displayed figure in display zone 3 when changing 2nd
gear:
Specification: Briefly less than 51 mg/h
Note:
Because the data transfer is slow, it is possible that the display of the
specification is delayed.
 ‒ Press keys 0 and 6 for the function "End output" and confirm
entry with the Q key.

loom.
 ‒ Check wiring on connector
contact 18 from engine control
unit to automatic gearbox
control unit for open/short
circuit.

Replacing, coding and matching engine control unit

Replacing engine control unit
Work sequence
 ‒ First print out the control unit identification and thereby the previous control unit coding as
follows:
 ‒ Connect fault reader V.A.G 1551 (V.A.G 1552) and select the engine electronics control unit
with the "address word" 01
=> Page 01-4 ; Connecting fault reader and selecting engine electronics control unit.
→ Print out control unit identification by pressing print key of fault 028906021CG 1.9l R4 EDC G00SG
reader (example). 0829⇒
Coding 00002 WSC XXXXX
 ‒ Press ⇒ key.

HELP
Select function XX
 ‒ Press keys 0 and 6 for the function "End output" and confirm entry
with the Q key.
 ‒ Unscrew bulb monitor unit (above engine control unit).
 ‒ Remove cover on driver's side.
=> General body repairs; Repair group 68; Shelves, covers and trim; Removing
cover on driver's side
 ‒ → Unscrew screw -2- of

engine control unit securing
clip -1-.
 ‒ Pull out securing clip
sideways -arrow-.
 ‒ Pull vacuum hose off control
unit.
 ‒ Release and pull off control
unit connector.
 ‒ Remove old control unit.
 ‒ Before installing the
exchange control unit, note its
Part No.
 ‒ Check the previous coding
and Part No. of the old control
unit and code the exchange
control unit according to table
=> Page 23-108 .
 ‒ If the vehicle is equipped
with a cruise control system
(CCS) (recognised by a G
before gearbox version, e.g.
G00SG) then this must be
activated on exchange engine
control unit.

 ‒ Match engine control unit to

the electronic immobilizer =>
Page 23-112

Coding engine control unit
There are control units which must not be coded (engine control unit MSA12) and control units which
must be coded (engine control unit MSA15).
If the appropriate code for the vehicle is not displayed or if the control unit has been renewed, the control
unit must be coded as follows.
Warning!
Always display the the control unit identification first and print out if necessary.
An incorrect coding can have a negative effect on engine, gearbox and emissions.
Work sequence
the "Address word" 01. When doing this the ignition must be switched on.
Control unit identification of MSA12
→ If the fault reader V.A.G 1551 displays this control unit 028906021C 1.9 ltr. R4
identification, then the control unit must not be coded: EDC SG D.. ⇒
Coding 0000 WSC0000
 ◆ There are no zeros in front of the type of gearbox (MG or

AG).
 ◆ The software version begins with a letter.
Externally the MSA12 is recognised by the plastic housing.
Control unit identification of MSA15
→ If the fault reader V.A.G 1551 displays this control unit coding, then the 028906021DF 1.9l R4 EDC
control unit must be coded (example). G00SG 0602 ⇒
Coding 00002 WSC

XXXXX
 ◆ There are two zeros in front of gearbox version (SG or AG) or G if

the vehicle is equipped with a cruise control system (CCS).
 ◆ The software version is made up of a 4 digit number e.g. 0602 or
of a letter/number combination, e.g. KD09.
 ◆ The display KDxx means that the engine control unit is an
exchange engine control unit. See engine control unit print-out for
coding to be entered.
Externally the MSA15 is recognised by the aluminium housing.

HELP
Select function XX
 ‒ Press keys 0 and 7 for the function "Code control unit" and confirm
entry with Q key.
→ Indicated on display: Coding control unit Q
Enter code number xxxxx

(0-00127)
Coding when replacing a MSA 12 engine control unit with a MSA 15

engine control unit
Control unit Exchange control unit Coding for exchange control

MSA12 MSA15 unit MSA 15
028 906 021 P 028 906 021 ES 00002
Coding engine control unit MSA 15 (without display "KDxx" in control

unit identification)
 ‒ Enter the appropriate code number for this vehicle and confirm with
Q key.
Coding For vehicles with

00002 Manual gearbox
00001 Automatic gearbox
→ The fault reader V.A.G 1551 display will show the control unit 028906021ES 1.9l R4
identification, e.g.: EDC G00SG 0602 ⇒
Coding 00002 WSC

XXXXX
 ‒ Switch ignition off and then on again.
Note:
The coding entered will be activated by switching the ignition off and then on
again. If after entering the valid code the ignition is not switched off and on
again, the fault "Control unit incorrectly coded" in the fault memory cannot be
erased.
 ‒ Erasing fault memory => Page 01-49

 ‒ Activating cruise control system

Matching engine control unit to electronic immobilizer
Test conditions
 ● Authorized vehicle key required
Work sequence
 ‒ → Open ashtray -3-.

 ‒ Press ashtray cover -1- on
both sides in direction of
arrows. The ashtray -2- springs
out slightly and can be
removed.
 ‒ Pull open ashtray housing
out of centre console.
 ‒ Connect fault reader or
system tester using cable
V.A.G 1551/3 to diagnosis
connection.
 ‒ Operate fault reader taking
into account the information on
the display:
 ‒ Press key 1 for "Rapid data
transfer".
 ‒ Press keys 2 and 5 for
address word "Immobilizer"
and confirm entry with Q key.

HELP
Select function XX
 ‒ Press keys 1 and 0 for function "Adaption" and confirm entry with
Q key.
→ Indicated on display: Adaption
Feed in channel number

XX
 ‒ Press key 0 twice for "Channel number 0" and confirm entry with Q
key.
→ Indicated on display: Adaption Q
Erase learnt values?
→ Indicated on display: Adaption ⇒
Learnt values have been

erased
 ‒ Conclude adaption by pressing ⇒ key.

Note:
The identity of the engine control unit is read into the immobilizer control unit
when next switching the ignition on.
Checking glow plug system

 ◆ Hand multimeter V.A.G 1526

Test prerequisites:
 ● Battery voltage at least 11.5 V

 ● Ignition switched off
 ● Diesel direct injection system control unit (J248) OK.
 ● Glow plug strip fuse (S125) OK.
Test sequence
 ‒ → Pull connector off coolant

temperature sender -1-.
Note:
Pulling the connector off sender,

simulates engine condition "cold" and
when switching the ignition on the
relevant glow period is carried out.
 ‒ Pull glow plug connector off

glow plug.
 ‒ Connect multimeter to
measure voltage between a
glow plug connector and
vehicle earth.
 ‒ Switch on ignition for approx.
20 seconds
approx. battery voltage
must be displayed.
 ‒ If no voltage is present:


Checking glow plugs
 ◆ Diode test lamp V.A.G 1527

 ◆ Jointed spanner (key) 3220
Test prerequisites:
 ● Battery voltage at least 11.5 V

 ● Ignition switched off
Test sequence
 ‒ Pull glow plug connector off glow plug.
 ‒ → Connect diode test lamp

wire using auxiliary clips from
auxiliary cable set to battery
positive (+).
 ‒ Place diode test lamp probe
on each glow plug one after
the other.
Diode lights up: glow plug
OK.
Diode does not light up:
replace glow plug.
 ‒ Remove and install glow

plugs with jointed spanner
3220
Tightening torque: 15 Nm.

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Technical data

Interrogating control unit versions

Function Ignition switched on Engine idling

Special tools, testers, measuring instruments and auxiliary items required

 ◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

 ● Battery voltage OK.

 ‒ → Open ashtray -3-.

After the fault reader has been

 ‒ Depending upon desired

 ◆ If the display does not

=> Fault reader operating instructions

 ◆ If due to an input fault "Fault

→ Indicated on display: V.A.G - Self-diagnosis

1 - Rapid data transfer*

2 - Flash code output*

 ‒ Operate fault reader taking into account the information on the

 ‒ Press keys 0 and 1 for address word "Engine electronics" and

Coding 0000 WSC00000

 ◆ 028906021P = Part No. of the control unit (for up-to-date

 ‒ Press the ⇒key.

→ Indicated on display: Rapid data transfer HELP

 ‒ Further measures see repair procedures.

Special tools, testers, measuring instruments and auxiliary items required

Only when engine does not start:

 ‒ Switch ignition on.

→ Indicated on display: Rapid data transfer

 ‒ Operate fault reader taking into account the information on the

 ‒ Press keys 0 and 2 for function "Interrogate fault memory" and

If one or more faults are stored:

 ‒ Press the ⇒key.

→ Indicated on display: Rapid data

=> Fault reader operating instructions

 ◆ If components are indicated as faulty:

Fault codes 00513 ... 01269

Fault codes 16485 ... 65535

V.A.G 1551 print-

1) Incorrect fault text display. Display must indicate:

Accelerator pedal position sender -G79

Special tools, testers, measuring instruments and auxiliary items required

→ Indicated on display: Rapid data transfer

 ‒ Press keys 0 and 2 for function "Interrogate fault memory" and

→ Indicated on display: Rapid data transfer

 ‒ Press the ⇒key.

→ Indicated on display: Rapid data transfer

Special tools, testers, measuring instruments and auxiliary items required

 ◆ Fault reader V.A.G 1551 with cable V.A.G 1551/3

Test requirements for vehicles with air conditioning system

 ● Vehicle at room temperature (warmer than + 15 °C)

1. Commencement of injection valve (N108)

2. Exhaust gas recirculation valve (N18)

3. Conditioner compressor interruption

4. Fuel cut-off valve (N109)

5. Solenoid valve for boost pressure control (N75)

6. Glow plug relay (J52)

7. Glow period warning lamp (K29)

8. Fan relay (J323)

→ Indicated on display: Rapid data transfer

 ‒ Operate fault reader taking into account the information on the

 ‒ Press keys 0 and 3 for the function "Final control diagnosis".

→ Indicated on display: Rapid data transfer Q