Service

Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets)
Engine ID AER ALL

Edition 09.1998

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets)

Repair Group
01 - Self-diagnosis
24 - Mixture preparation, Injection
28 - Ignition system

Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Contents

01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 General to self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 General to self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Features of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Connecting fault reader V.A.G 1551 and selecting engine electronics control unit . . . . . . . .2
1.5 Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and selecting
engine electronics control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 Fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Interrogating and erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Fault table, fault codes 00282...00537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1 Fault table, fault codes 00282...00537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Fault table, fault codes 00543...65535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.1 Fault table, fault codes 00543...65535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.1 Final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.2 Performing final control diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.1 Measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.3 Read measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6.4 Evaluating measured value blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.1 Servicing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.2 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
1.3 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
1.4 Removing and installing parts of the injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
1.5 Dismantling and assembling intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
1.6 Dismantling and assembling fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.7 Dismantling and assembling air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.8 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
1.9 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
1.10 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.1 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.2 Checking Lambda probe heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
2.3 Checking throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
2.4 Checking intake manifold pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
2.5 Checking intake air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2.6 Checking coolant temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
2.7 Idling speed boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
2.8 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
2.9 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2.10 Checking intake air system for leaks (unmetered air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
2.11 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3 Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3.1 Checking functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3.2 Checking Lambda probe and Lambda control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
3.3 Checking engine operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
4 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Contents i
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

4.1 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

4.2 Checking control unit voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
4.3 Replacing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
4.4 Adapting engine control unit to throttle valve control part . . . . . . . . . . . . . . . . . . . . . . . . . .86
4.5 Matching engine control unit to electronic immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
5 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.1 Checking additional signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.2 Checking speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
5.3 Checking signal from/to air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.1 Servicing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.2 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
1.3 Removing and installing parts of the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
1.4 Dismantling and assembling distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
1.6 Adjustment data, Spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
1.7 Checking and adjusting ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
1.8 Checking Hall sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
1.9 Checking ignition transformer and output stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.10 Checking knock sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

ii Contents
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

01 - Self-diagnosis

1 - General to self-diagnosis
1.1 - General to self-diagnosis

Note:
The self-diagnosis monitors only a part of the injection and ignition system. For fault finding the binder "Fault
finding engine" must also be used in every case.

1.2 - Features of self-diagnosis

The engine control unit (Motronic control unit J220) 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.

After evaluating the information the engine control unit decides between 24 differing fault codes => Fault table
Page 13 and stores these faults until the contents of the fault memory is erased.

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.

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 7 , interrogating and erasing fault memory.

The fault memory must be erased after the faults have been rectified => Page 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.

1.3 - Technical data of self-diagnosis

Control unit identification

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 2 .

Technical data

Engine code AER ALL

System designation Motronic MP 9.0 Motronic MP 9.0
Exhaust emissions fulfil MVEG II D3 Standard
Self-diagnosis yes yes
Final control diagnosis yes yes
Operating mode of data transfer to V.A.G 1551/1552 Rapid data transfer Rapid data transfer

1.1 - General to self-diagnosis 1

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Coding control unit V.A.G 1551/1552 V.A.G 1551/1552

Fault memory Non-volatile memory1) Non-volatile memory1)
Memory for learnt values Volatile memory2) Volatile memory2)
Lambda control yes yes
Knock control 1 knock sensor 1 knock sensor
Twin path intake manifold no no
Variable valve timing no no
Charge pressure control no no

1) Independent of voltage supply.

2) Values are erased when voltage supply is interrupted.
Selectable functions when using fault readers V.A.G 1551 or V.A.G 1552

Note:
The following table shows which preconditions are necessary to be able to select the desired functions.
Function Prerequisite
Functions on fault reader V.A.G 1551 or Engine stopped, igni‐ Engine running at Vehicle being driven
on system tester V.A.G 1552 tion switched on idling speed
01 Interrogate control yes yes yes
unit version
02 Interrogate fault mem‐ yes1) yes yes
ory
03 Final control diagno‐ yes no no
sis
04 Basic setting2) yes yes3)4) no
05 Erase fault memory yes yes yes
06 End output yes yes yes
08 Read measured value yes yes yes
block

1) Only carry out with ignition switched on, when engine does not start.
2) Must be performed after carrying out the following: Replacing engine control unit, throttle valve control
part or engine.
3) Not possible until the coolant temperature reaches 80 °C. Prior to this the function is blocked.
4) Must be performed to be able to check and adjust the ignition timing.

1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit

2 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ -> V.A.G 1551 Fault reader

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.

◆ -> V.A.G 1551/3A Cable

Test conditions

• -> The fuses SB1, SB3, SB31, SB32, SB37 and SB39 must be OK.
• The battery voltage must be at least 11.5 V.
• Earth connections on front of clutch housing/on cylinder head OK.

Work sequence

- -> Pull cover -1- off in direction of arrow.

- Connect fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A.

1.4 - Connecting fault reader V.A.G 1551 and selecting engine electronics control unit 3
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
After the fault reader has been connected:
- Depending on the desired function either switch ignition on
or
start engine and run at idling speed. Selectable functions => Page 2 .

Notes:
◆ If the display remains blank, check voltage supply for diagnostic connection according to fault finding pro‐
gramme:

=> Current flow diagrams, Electrical fault finding and Fitting locations
◆ 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.

- Operate fault reader taking into account the information on the display:

-> 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 identification, e.g.:
030906027AL MOTRONIC MP 9.0 2263
⇒
◆ 030 906 027AL = Part No. of control unit
◆ Motronic MP 9.0 = System designation and version
◆ 2263 = Programme level number

Note:
Replace control unit if the control version displayed does not correspond to the vehicle
=> Page 85 .
- Press ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX
- Further measures see repair procedures.

1.5 - Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and selecting
engine electronics control unit

4 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
All functions which could be done with V.A.G 1551/1552 can also be done with the new tester VAS 5051 in the
operating mode: "vehicle self-diagnosis":
=> Operating instructions for vehicle diagnosis, Testing and Information system VAS 5051.
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ -> VAS 5051 Vehicle diagnosis, Testing and Information system

Test conditions

• -> The fuses SB1, SB3, SB31, SB32, SB37 and SB39 must be OK.
• The battery voltage must be at least 11.5 V.
• Earth connections on front of clutch housing/on cylinder head OK.

Work sequence

- -> Pull cover -1- off in direction of arrow.

- Connect tester VAS 5051 with diagnosis cable VAS 5051/1 or VAS 5051/3 as follows:
- Fit diagnosis cable connector onto diagnosis connector.
- Depending on the desired function either switch ignition on
or
start engine and run at idling speed. Selectable functions => Page 2 .

Note:

1.5 - Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and

selecting engine electronics control unit 5

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
◆ The display fields will be displayed from top to bottom in functions 04 - Basic settings or 08 - Read data
block.
◆ If the display does not indicate as described in the work sequence:

=> Operating instructions for Vehicle Diagnosis, Testing and Information System VAS 5051.
-> Indicated on display:
Selecting operating mode:
- Press key 1 for "Rapid data transfer".

-> Indicated on display:

Selecting vehicle system:
- Press "01 - Engine electronics" on display -arrow-.

-> The control unit identification and coding -arrow- is shown on display e.g.:
Note:
Replace control unit if the control version displayed does not correspond to the vehicle
=> Page 85 .

6 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
-> Indicated on display:

Selecting diagnosis function:

At this point all diagnosis functions are available.

- Press desired function on display.

- Further measures see repair procedures.

2 - Fault memory
2.1 - Fault memory

2.2 - Interrogating and erasing fault memory

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A

Work sequence

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

Only when engine does not start:

- Operate starter for approx. 6 seconds and then do not switch off the ignition.

- 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

- Operate fault reader taking into account the information on the display:
- Press keys 0 and 2 for function "Interrogate fault memory" and confirm entry with Q key.

-> The number of faults stored or "No fault recognised!" will be shown on the display.
X Faults recognised!

If no fault is stored:

- Press ⇒key.

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

- Press keys 0 and 5 for the function "Erase fault memory" and confirm entry with Q key.

-> Indicated on display:

1.5 - Connecting Vehicle Diagnosis, Testing and Information system VAS 5051 and

selecting engine electronics control unit 7

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Rapid data transfer

Fault memory is erased!

Note:
If the ignition is switched off between "Interrogate fault memory" and "Erase fault memory" the fault memory
will not be erased.
- Press ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

-> Indicated on display:

Rapid data transfer HELP
Enter address word XX

- Switch off ignition.

- Rectify the faults printed out using the fault table:
Fault code 00282...00537 => Page 13 .

Automatic test sequence

During test and assembly work faults can be recognised from other control units like e.g. plug disconnected.
Therefore, on completion, the fault memories of all control units must be interrogated and erased. To do this:

- Press key 0 twice for address word "Automatic test sequence" and confirm entry with Q key. The V.A.G
1551 transmits all known address words one after the other.

When a control unit answers with its identification the number of stored faults appears on the display or "No
fault recognised".

Any system faults that are stored will be displayed one after the other and printed out. The V.A.G 1551 will then
transmit the next address word.

-> The automatic test sequence has ended when following is indicated on display:
Rapid data transfer HELP
Enter address word XX

- Erase all fault memories and then carry out a road test.

During the road test the following operating conditions must be fulfilled:
- The coolant temperature must exceed 80 °C .
- When the temperature is reached, the operating conditions
Idling
Part throttle
Full throttle
Overrun
must be attained several times.
- At full throttle the speed must exceed 3500 rpm.

- Again interrogate the fault memories of all control units using the "automatic test sequence".

If no fault is stored:

- Press the ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

8 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

-> Indicated on display:

Rapid data transfer HELP
Enter address word XX

- Switch off ignition.

Note:
If the self-diagnosis has not detected a fault, use the appropriate fault table in "Fault finding engine" binder for
further fault finding.

3 - Fault table, fault codes 00282...00537

3.1 - Fault table, fault codes 00282...00537

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 ac‐
cording to current flow diagram. This is particularly relevant if faults are output as "occurring
sporadically" (SP).

V.A.G 1551 print out, e.g.:

00523 030
Intake air temperature sender -G42
Short to earth
Sporadically occurring fault
Explanation:
◆ 00523 = Fault code
◆ 030 = Fault type as number
◆ Intake air temperature sender -G42 = Faulty current path or incorrect location
◆ Short to earth = Fault type as text
◆ Sporadic faults = Faults that are not always present e.g. loose contact

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00282
Throttle valve positioner -
V601)
Output does not switch/ - Wire(s) to positioning - Cold starting problem - Check V60
short to earth motor, short to earth - Cold idling speed prob‐ =>Page 47 , Checking
lems throttle valve control part
Output does not switch/ - Wire(s) to positioning - Hard load changes
short to positive motor, short to battery - Idling speed problems
positive
- Wire(s) open circuit
- Idling speed control
control limit exceeded

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2.2 - Interrogating and erasing fault memory 9

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Short circuit - Short between wiring to
positioning motor
- Short in positioning mo‐
tor

1) The throttle valve positioner (V60) is a component of the throttle valve control part (J338).

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00516
Idling switch -F601)
Short to earth - Wire has short to earth - Idling speed problems - Adapt engine control unit to
- F60 defective - Engine running problems throttle valve control part
when pulling away =>Page 86
Open circuit/short to pos‐ - Open circuit in earth wire - Check F60
itive - Wire short to positive =>Page 47 , Checking
- F60 defective throttle valve control part

1) The idling speed switch (F60) is a component of the throttle valve control part (J338).

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00518
Throttle valve potentiometer
-G691)
Short to earth - Wire has short to earth - Poor throttle response - Adapt engine control unit
- G69 defective - Hard load changes to throttle valve control part
- Increased emission val‐ =>Page 47 , Checking
ues throttle valve control part
- No full throttle recognition
- Loss of output and torque
Open circuit/short to - Open circuit in earth
positive wire
- Wire short to positive
- G69 defective

1) The throttle valve potentiometer (G69) is a component of the throttle valve control part (J338).

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00519
Intake manifold pressure sender -G71
Short to earth - Wire short to earth - Increased emission values - Check G71
- G71 defective =>Page 55
Open circuit/short to positive - Open circuit in earth wire - Poor throttle response
- Wire short to positive - Hard load changes
- G71 defective
Signal too small - G71 defective - Increased emission values - Renew G71
Signal too large - G71 defective - Poor throttle response
- Engine running problems

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00522
Coolant temperature sender -G62
Short to earth - Wire short to earth - Poor cold starting - Check G62
- G62 defective - Poor hot starting =>Page 60
- No idling speed adaption
- Increased emission values
- Increased fuel consumption

10 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Open circuit/short to positive - Open circuit in earth wire - Poor hot starting
- Wire short to positive - Increased emission values
- G62 defective

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00523
Intake air temperature sender -G42
Short to earth - Wiring has short to earth - Poor hot starting - Check G42
- G42 defective - Increased emissions values =>Page 56
Open circuit/short to positive - Open circuit in earth wire
- Wire short to positive
- G42 defective

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00524
Knock sensor 1 -G61
Open circuit/short to - Wire open circuit or - Ignition timing retarded ap‐ - Check G61
earth short to earth prox. 12 < ° => Page 104
- G61 defective - Reduced output
- Increased fuel consump‐
tion
00525
Lambda probe -G39
no signal - Wire open circuit - No Lambda control - Check Lambda probe and
- G39 defective - Fuel odours Lambda control
Short to earth - Wire short to earth - Increased fuel consump‐ - =>Page 77
- G39 defective tion
Short to positive - Wire short to positive - Engine running problems
- G39 defective - Increased emission values

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00530
Throttle valve positioner/poten‐
tiometer -G881)
Open circuit/short to - Open circuit in earth - Cold starting problems - Check G88
positive wire - Idling speed not within =>Page 47 , Checking
- Wire short to positive tolerances throttle valve control part
- G88 defective
Short to earth - Wiring has short to - Cold idling problems
earth - Uneven idling speed
- G88 defective
00532
Supply voltage
Signal too large - Battery voltage above --- - Check alternator
16 V
Signal too small - Battery voltage below - Idling speed is in‐ - Check battery charge
10 V creased condition

1) The throttle valve positioner/potentiometer (G88) is a component of the throttle valve control part (J338).

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00533
Idling speed control

3.1 - Fault table, fault codes 00282...00537 11

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Control limit exceeded - Wire open circuit to throt‐ - Idling speed not within - Check V60
tle valve positioner -V60 tolerances =>Page 47 , Checking
- Upper or lower idling throttle valve control part
speed limit reached
- V60 sticking
Adaption limit exceeded - Throttle valve housing of - Idling speed not within - Clean throttle valve con‐
throttle valve control part tolerances trol part throttle valve hous‐
dirty ing
Adaption limit not reached - Intake system leaking - Idling speed not within - Check intake system for
tolerances leaks (unmetered air) =>
Page 76

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00537
Lambda control
Control limit exceeded - Exhaust system between - Increased emission val‐ - Check exhaust system:
cylinder head and catalyst ues => Repair group 26; Re‐
leaking - Increased fuel con‐ moving and installing parts
sumption of exhaust system
- Engine running prob‐
lems
- Misfiring - Check components of ig‐
nition part => Page 93
- Injector(s) (N30...N33) de‐ - Check N30...N33
fective => Page 66 , checking in‐
jectors
- Fuel pressure too low - Check fuel pressure regu‐
lator => Page 72
- Insufficient fuel in fuel tank - Fill with fuel
Continued on next page - Intake system leaking - Check intake system for
leaks (unmetered air) =>
Page 76

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
Continued - Solenoid valve1 for activa‐ - Check N80
ted charcoal filter (N80) stuck => Page 15 , Final control
(always open) diagnosis
- Lambda probe (G39) defec‐ - Check Lambda probe and
tive Lambda control
=>Page 77
Control limit not at‐ - Fuel pressure too high - Increased emission val‐ - Check fuel pressure regu‐
tained ues lator
- Engine running prob‐ => Page 72
lems
- Injector(s) (N30...N33) de‐ - Check N30...N33
fective => Page 66 , checking in‐
jectors
- Lambda probe (G39) defec‐ - Check Lambda probe and
tive Lambda control
=>Page 77

12 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

4 - Fault table, fault codes 00543...65535

4.1 - Fault table, fault codes 00543...65535

Notes on fault table =>Page 9

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00543
Maximum revs exceeded - Speed above 6520 rpm - Possible damage to - Check engine for dam‐
(e.g. selector fault) valves and pistons (con‐ age and erase fault mem‐
tact) ory
00561
Mixture adaptation
Adaptation limit (add.) ex‐ As 00537, Lambda control
ceeded However, when fault finding the following must be observed:
- Faults in Lambda control are recognized immediately a change in the system
occurs e.g. vacuum hose has fallen off.
- Faults in mixture adaption are only recognized after a lengthy period of change
in the system, e.g. wear of individual components.
Adaptation limit (add.) not
reached
Adaptation limit (mul.) ex‐
ceeded
Adaptation limit (mul.) not
reached

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
00625
Speed signal
implausible signal - No signal from speed sen‐ - Speedometer display not - Check signal from G21 or
sor (G21) or speedometer OK. G22 =>Page 88 , Check‐
sender (G22) - Engine running problems ing speed signal
01013
Compressor load signal
Signal too high - G65 defective --- - Check G65:
=> Heating, Air conditioning;
Repair group 87
Signal too low - G65 defective

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01087
Basic setting not completed
Fault in basic setting - The engine control unit is - Idling speed not within - Adapt engine control unit
not matched to throttle tolerances to throttle valve control part
valve control part - Idling speed fluctuates =>Page 86
- The adaption of the en‐
gine control unit to the
throttle valve control part
was interrupted. Cause
could be that the starter or
accelerator pedal was op‐
erated during the adaption
procedure.

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01247
Activated charcoal filter solenoid valve 1
-N80

4.1 - Fault table, fault codes 00543...65535 13

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
defective - N80 defective - Fuel odours - Check N80
- Wiring open circuit => Page 15 , Final
- Wiring short circuit control diagnosis
- Hose from N80 to acti‐ - Check hose
vated charcoal filter
blocked

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01249
No.1 cyl. injector -N30
Short to positive - Wire to control unit has
short to battery positive
- Injector defective, short
circuit
Short to earth - Wire to control unit has
short to earth
Open circuit/short to - Wire open circuit to - Increased emission val‐ - Check N30...N33
positive control unit ues => Page 66 , checking in‐
- Poor starting jectors
- Engine running problems
- Poor throttle response
- Uneven idling speed
01250
No. 2 cyl. injector -N31
Short to positive see fault code 01249, Cyl. 1

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
01251
No. 3 cyl. injector -N32
Short to positive see fault code 01249, Cyl. 1
01252
No. 4 cyl. injector -N33
Short to positive see fault code 01249, Cyl. 1

V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
17978
Engine control unit blocked - Attempted manipulation - Engine starts briefly and - Adapt engine control unit
- Short in communication then stops again to electronic immobilizer
cable => Page 87
- Incorrect coding Check electronic immobil‐
- Immobilizer control unit izer:
defective/missing => Repair group 96; Serv‐
icing electronic immobilizer
65535
Control unit defective - Control unit internally de‐ - Engine running prob‐ - Renew engine control
fective lems unit
- Attempted manipulation - Engine will not start => Page 85
of control unit

14 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

5 - Final control diagnosis

5.1 - Final control diagnosis

5.2 - Performing final control diagnosis

The final control diagnosis activates the activated charcoal filter solenoid valve 1.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Diode test lamp V.A.G 1527
◆ Adapter set V.A.G 1594
◆ Test box V.A.G 1598/18

◆ Current flow diagram

Check conditions

• -> The fuses SB28, SB31, SB32, SB37 and SB39 must be OK.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating must be switched off.

Notes:

◆ The final control diagnosis can only be carried out if the engine is stationary and ignition switched on.
◆ The final control diagnosis will be aborted if the engine is started or a rotational impulse is recognised.
◆ If the final control diagnosis is to be repeated without first starting the engine, the ignition must be switched
off for approx. 20 seconds.

Work sequence

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Operate fault reader taking into account the information on the display:
- Press keys 0 and 3 for the function "Final control diagnosis".

-> Indicated on display:

5.1 - Final control diagnosis 15

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Rapid data transfer Q

03 Final control diagnosis

- Confirm input with Q key.

-> Indicated on display:

Final control diagnosis
Activ. charcoal filter solenoid valve
1 -N80

The solenoid valve (right suspension turret) must click.

- Pull hose off activated charcoal filter at solenoid valve.

- Connect an auxiliary hose to the vacant valve connection.
- Blow into auxiliary hose during final control diagnosis (in direction of throttle valve control part).
Valve must open and close

If the solenoid valve clicks, opens and closes:

- Press ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

If the solenoid valve does not click:

- -> Pull the 2 pin connector off solenoid valve 1 (N80) -arrow-.

- -> Connect diode test lamp V.A.G 1527 using adapter cables from V.A.G 1594 to detached connector.
The LED must flash (bright/darker)

16 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
LED flashes:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

- Replace solenoid valve 1 (N80):

=> Repair group 20; Activated charcoal filter system; Removing and installing parts of activated charcoal filter
system Activated charcoal filter system Removing and installing parts of activated charcoal filter system

LED does not flash:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

- -> Check wire for open circuit between test box socket 3 and 2 pin connector contact 1, using current flow
diagram.
Wire resistance: max. 1.5 ω
- Additionally check wire for short to battery positive and earth.
Specification: ∞ω
- Check wire between 2 pin connector contact 2 and the fuel pump relay (J17) for open circuit using current
flow diagram.
Wire resistance: max. 1.5 ω

If no wiring fault is detected:

- Replace engine control unit

=> Page 85 .

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5.2 - Performing final control diagnosis 17

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

6 - Measured value blocks

6.1 - Measured value blocks

6.2 - 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.

6.3 - Read measured value block

The measured values in the functions read measured value block and basic setting are described during the
individual component test. This table serves only as an overview.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A

Test conditions

• All electrical consumers, e.g. lights and rear window heating must be switched off.
• If the vehicle is equipped with an air conditioner, this must be switched off.
• No faults must be stored in fault memory => Page 7 , interrogating and erasing fault memory.
• Coolant temperature must be at least 80 °C, =>display group 1, display zone 2.

Work sequence

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Select required display group number.

Note:
The display group number 0 is an example, to illustrate the sequence.
- Press keys 0, 0 and 0 for "Display group number 0" and confirm entry with Q key.

-> Indicated on display:

18 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
(1...10 = Display zones)
Read measured value block 0
1 2 3 4 5 6
7 8 9 10

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

- If the specifications in all display zones are obtained, press ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.

-> Indicated on display:

Rapid data transfer HELP
Enter address word XX

- Switch off ignition.

Note:
Measured value blocks which are not described in this chapter are currently only intended for the research and
development and production. The values displayed are not relevant for service department fault finding.

6.4 - Evaluating measured value blocks

Display group 0 (decimal displayed value)

Test conditions
▪ Engine runs at idling speed
▪ The coolant temperature is at least 80 °C
▪ The electrical consumers are switched off
Display zones Specification Corresponds to
1 2 3 4 5 6 7 8 9 10 Engine speed 66...74 660...740 rpm
Injection period 8...21 3.1...8.1 ms
Throttle valve angle 7...15 3.1...6.7 <°
Lambda probes status 0...4 ---
Lambda integrator 102...154 128 = Lambda 1
Lambda probe signal 0...205 0...1.0 V
Engine load 30...60 1.5...3.0 ms
Coolant temperature 176...229 80...115 °C
Battery voltage 170...206 12.0...14.5 V
Intake air temperature 75...158 15...70 °C

Display zones
1 2 3 4
Display group 1
Display xxxxrpm xx.x °C x.x V xxxxxxxx

6.3 - Read measured value block 19

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Indicated Engine speed Coolant temperature Lambda probe voltage Adjustment conditions2)
660...7402) 80...115 0...1.0 fluctuating 00000000
Display group 2
Display xxxx rpm xx.x ms xx.x V xx.x °C
Indicated Engine speed Injection period Battery voltage Intake air temperature
Specification1) 660...7402) 3.1...8.1 12.0...14.5 V 15...70

1) The specifications must be attained when:

- engine runs at idling speed,

- the coolant temperature is at least 80 °C and

- electrical consumers are switched off

2) The control unit increases idling speed under following conditions:

- When the battery voltage is too low

- After a long full throttle drive and at higher temperatures

- When the air conditioner is switched on

-When the heated rear window is switched on

-When the steering is at full lock (P.A.S pressure switch is switched on). In this case the normal idling speed is
attained,

when the engine has been restarted or the vehicle is driven faster than 15 km/h (approx. 9.4 mph).

3) Significance of numbers in 8 digit number block => Page 22 .

Display zones
1 2 3 4
Display group 3
Display xxxx rpm xx.x ms xx <° xx.x V
Indicated Engine speed Engine load Throttle valve angle Voltage value for throttle valve opening from
throttle valve potentiometer
Specification1) 660...7402) 1.5...3.0 3.1...6.7 ---
Display group 4
Display xxxx rpm xx.x ms xxx km/h xxxxxxxx
Indicated Engine speed Engine load Speed Operating condition3)

20 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Display zones
Specification1) 660...7402) 1.5...3.0 --- ---

1) The specifications must be attained when:

- engine runs at idling speed,

- the coolant temperature is at least 80 °C and

- electrical consumers are switched off

2) The control unit increases idling speed under following conditions:

- When the battery voltage is too low

- After a long full throttle drive and at higher temperatures

- When the air conditioner is switched on

-When the heated rear window is switched on

-When the steering is at full lock (P.A.S pressure switch is switched on). In this case the normal idling speed is
attained,

when the engine has been restarted or the vehicle is driven faster than 15 km/h (approx. 9.4 mph).

3) Significance of numbers in 8 digit number block => Page 22 .

Display zones
1 2 3 4
Display group 5
Display xxxx rpm xxx % x.xx x
Indicated Engine speed Activated charcoal filter sol‐ Activated charcoal filter sol‐ Activated charcoal filter sol‐
enoid valve 1 duty cycle enoid valve 1 adaptation enoid valve 1 flushing rate
value
No specification for service departments

Display zones
1 2 3 4
Display group 6
Display x.xx x.xx x.x V x.x V
Indicated Mixture correction val‐ Mixture correction Throttle valve potenti‐ Value stored during ba‐
ue "learned" value ometer voltage value sic setting for the throt‐
for throttle valve open‐ tle valve potentiometer
ing position: Throttle valve
closed
No specification for service departments
Display group 7 = Display group 1

Display group 8
Display x.x V x.x V x.x V x.x V
Indicated Actual value from throt‐ Throttle valve emergency Throttle valve control Throttle valve control
tle valve potentiometer running profile unit min. stop unit max. stop
No specification for service departments
Display group 9
Display x.xx x.xx x.xx V x.xx
Indicated Lambda integrator Lambda adaptation Lambda adaptation Lambda adaptation

6.4 - Evaluating measured value blocks 21

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Display zones
No specification for service departments

Display zones
1 2 3 4
Display group 981)
Display x.xxx V x.xxx V Text Text
Indicated Throttle valve (G69) volt‐ Voltage for throttle valve Engine operating State of adaption
age positioner potentiometer mode
(G88)
Specification1) 0.500...5.000 V 0.500...5.000 V Idling or part load ADP. running or
ADP. OK. or ADP
ERROR

1) Matching throttle valve control part to engine control unit => Page 86 .

Note on display group 98:

The throttle valve control part will be matched to the engine control unit when the display group 98 under function
04 "Basic setting" is selected. This matching must always be carried out when a different throttle valve control
part (or other complete engine) or a different engine control unit is fitted.

If the voltage supply is interrupted (battery disconnected), adaption need not be performed.

Significance of figures in 8 digit number block

Significance when displayed digit = 1

x x x x x x x x Adjustment conditions (display group 1) Operating condition (display group 4)
1 Fault in fault memory Overrun
1 Gear engaged (not relevant) Idling
1 Air conditioner switched on Part load
1 Idling switch open Full load
1 Fault in Lambda control Acceleration enrichment
1 Throttle valve open Weakening delayed
1 Speed above 2500 rpm Air conditioner compressor switched on
1 Coolant temperature below 80 °C No. 1 cylinder recognized

22 01 - Self-diagnosis
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

24 - Mixture preparation, Injection

1 - Servicing injection system

1.1 - Servicing injection system

1.2 - Fitting locations overview

1 Activated charcoal filter solenoid valve 1 (N80)
◆ Activated charcoal filter system

=> Repair group 20; Removing and installing parts of the fuel supply system; Servicing parts of the activated
charcoal filter system Removing and installing parts of the fuel supply system Servicing parts of the activated
charcoal filter system
2 Intake manifold pressure sender (G71) with intake air temperature sender (G42)
3 Engine control unit

1.1 - Servicing injection system 23

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
(Motronic control unit -J220)
◆ Location: In plenum chamber, right
4 Air cleaner
◆ Note tightening sequence
◆ Dismantling and assembling => Page 40
◆ Removing and installing air cleaner
=> Page 43 , Fig. 3

5 Throttle valve control part (J338)

6 Knock sensor 1 (G61)
◆ Fitting location: cylinder block intake side
◆ =>Page 96
7 Ignition transformer (N152)
◆ =>Page 94
8 Fuel rail
9 Fuel pressure regulator
10 Distributor
◆ =>Page 95
11 4 pin connector
◆ Black
◆ For Lambda probe and Lambda probe heating
◆ On bracket in front of gearbox
12 Earth connection

24 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

13 Coolant temperature sender (G62)

◆ With coolant temperature gauge sender (G2)
14 Lambda probe (G39), 50 Nm
◆ In exhaust manifold
15 Injector (N30...N33)
16 Spark plug, 25 Nm
◆ =>Page 98
17 Oil pressure switch
18 Activated charcoal filter
◆ In right-hand wheel housing
◆ Activated charcoal filter system

=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
the activated charcoal filter system

19 Air intake housing with regulating flap

◆ For intake air preheating

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.2 - Fitting locations overview 25

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.3 - General notes on injection

Servicing ignition part:

=> Repair group 28

◆ The engine control unit is equipped with self-diagnosis. Before carrying out repairs and fault finding the fault
memory must be interrogated. Also the vacuum hoses and connections must be checked (unmetered air).
◆ Fuel hoses in engine compartment must only be secured with spring type clips. The use of clamp or screw
type clips is not permissible.
◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
engine control unit could be damaged.
◆ Components marked with * are checked via the self diagnosis
=> Page 7 , interrogating and erasing fault memory.
◆ Components marked with **can be checked with the final control diagnosis => Page 15 .
◆ For trouble-free operation of the electrical components, a voltage of at least 11.5 V is necessary.
◆ Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the
engine and damage the Lambda probe.
◆ If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests,
then the fault may lie with the immobilizer which is blocking the engine control unit. The fault memory must
be interrogated and if necessary the control unit matched => Page 87 .
◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after com‐
pleting all checks and repairs the fault memory must be interrogated and if necessary erased.
=> Page 7 , interrogating and erasing fault memory
◆ Vehicles with an airbag are fitted with a crash/fuel shut-off. It reduces the risk of a vehicle burning in the
event of a crash in that the fuel pump is switched off by the fuel pump relay. At the same time this device
improves the starting of the engine because as soon as the door is opened the fuel pump is activated to
build-up pressure in the fuel system.

Safety precautions =>Page 43

Rules for cleanliness => Page 44

Technical data => Page 44

Checking intake system for leaks (unmetered air) => Page 76 .

Checking engine operating mode => Page 81

26 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.4 - Removing and installing parts of the injection system

1 Air intake housing with regulating flap

◆ Checking intake air preheating => Page 77
2 10 Nm
3 Air cleaner
◆ Note tightening sequence
◆ Dismantling and assembling => Page 40
◆ Removing and installing air cleaner
=> Page 43 , Fig. 3
4 3 Nm
◆ Notes on installing => Page 43
5 To oil separator:

=> Repair group 17; Removing and installing parts of lubrication system Removing and installing parts of lu‐
brication system

6 Warm air intake

◆ To warm air collecting plate on exhaust manifold

1.4 - Removing and installing parts of the injection system 27

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

7 Connector
◆ Black, 4 pin
◆ For intake manifold pressure sender and sender for intake air temperature in intake manifold
◆ Fitting location => Page 23 , engine compartment overview
8 Connector
◆ Grey, 8 pin
◆ For throttle valve control part (J338)
◆ Connector contacts are gold-plated
9 Cable guide
◆ Clipped on fuel manifold
10 10 Nm
11 Fuel manifold with injectors
◆ Dismantling and assembling => Page 38

28 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

12 T-piece
13 To brake servo
14 Return hose
◆ Blue or blue markings
◆ Clip in lower intake manifold
◆ Secure with spring-type clips
◆ Check securely seated
◆ To the fuel delivery unit in fuel tank

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing fuel tank
with attachments and fuel filter Removing and installing parts of fuel supply system Removing and installing
fuel tank with attachments and fuel filter

15 20+1 Nm
◆ Tighten bolts from inside to outside
◆ Ensure tightening torque is correct, otherwise the intake manifold bushes will work into the cylinder head

1.4 - Removing and installing parts of the injection system 29

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

16 Intake manifold
◆ Dismantling and assembling => Page 35
17 O ring
◆ Renew
18 Thermostat housing
19 O ring
◆ Renew if damaged
20 Coolant temperature sender (G62)*
◆ For engine control unit
◆ With coolant temperature gauge sender (G2)
◆ If necessary release pressure in cooling system before removing
◆ Checking =>Page 60
◆ Resistance graph
=>Page 42 , Fig. 1

30 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

21 Connector
◆ Black, 4 pin
◆ For coolant temperature sender (G62) and coolant temperature gauge sender (G2)
22 Retaining clip
23 Lambda probe (G39)*, 50 Nm
◆ Grease only the threads with "G 052 112 A3"; "G 052 112 A3" must not get into the slots on the probe
body
◆ Remove and install with ring spanner 3337
◆ Checking Lambda control
=> Page 77
◆ Probe heating voltage supply via fuel pump relay (J17)
◆ Checking Lambda probe heating => Page 45
◆ Check probe heating for continuity
◆ Fitting location => Page 23 , fitting location overview

1.4 - Removing and installing parts of the injection system 31

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

24 4-pin connector
◆ Black
◆ For Lambda probe and Lambda probe heating
◆ Connector contacts 3 and 4 are gold-plated
◆ Fitting location => Page 23 , fitting location overview
25 To fuel tank
26 10 Nm
27 Securing plate
28 Connector
◆ Only disconnect or connect with ignition switched off

32 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

29 Engine control unit*

◆ For injection system, Lambda regulation, activated charcoal filter solenoid valve, knock control, governed
speed, ignition and self-diagnosis
◆ Checking voltage supply => Page 83
◆ If replaced carry out basic setting => Page 86
◆ On replacement, the control unit must be matched to the electronic immobilizer => Page 87
◆ Renew => Page 85
◆ Fitting location => Page 23 , engine compartment overview

1.4 - Removing and installing parts of the injection system 33

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

30 Supply hose
◆ Black with white marks
◆ Secure with spring-type clips
◆ Check securely seated
◆ From fuel filter:

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing fuel tank
with attachments and fuel filter Removing and installing parts of fuel supply system Removing and installing
fuel tank with attachments and fuel filter

34 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.5 - Dismantling and assembling intake manifold

1 Intake manifold pressure sender (G71)* with intake air temperature sender (G42)*
◆ Intake air temperature sender resistance values between contacts 1 and 2=>Page 42 , Fig. 2
◆ Checking intake manifold pressure sender
=>Page 55
◆ Checking intake air temperature sender =>Page 56
◆ Connector contacts are gold-plated
2 O ring
◆ Renew if damaged
3 Guide tube
◆ For dipstick
4 3 Nm

1.5 - Dismantling and assembling intake manifold 35

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

5 Throttle valve control part (J338)*

◆ Components of the throttle valve control part (J338):
Throttle valve positioner (V60), throttle valve potentiometer (G88), throttle valve potentiometer (G69) and
idling switch (F60)
◆ Checking => Page 47
◆ If replaced match engine control unit => Page 86
◆ Connector contacts are gold-plated
6 10 Nm
7 Earth wire
◆ For throttle valve control part
8 Intake manifold
◆ Removing and installing
=>Page 27 , removing and installing parts of the injection system

36 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

9 Return hose
◆ Blue or blue markings
◆ Clip in lower intake manifold
◆ Secure with spring-type clips
◆ Check securely seated
◆ To the fuel delivery unit in fuel tank

=> Repair Group 20; Removing and installing parts of fuel supply system; Removing and installing fuel tank
with attachments and fuel filter Removing and installing parts of fuel supply system Removing and installing
fuel tank with attachments and fuel filter

10 3 Nm
11 To activated charcoal filter solenoid valve 1 (N80)
◆ Activated charcoal filter system

=> Repair group 20, removing and installing parts of the fuel supply system, removing and installing parts of
the activated charcoal filter system

1.5 - Dismantling and assembling intake manifold 37

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.6 - Dismantling and assembling fuel rail with injectors

1 Fuel manifold
◆ Removing and installing
=>Page 69 , checking spray pattern and injectors for leaks
2 Retaining clip
◆ Ensure seated correctly at injector and fuel rail
3 Retaining clip
4 Fuel pressure regulator
◆ Checking => Page 72 , checking fuel pressure regulator and holding pressure

38 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

5 O ring
◆ Renew if damaged
6 Injectors (N30...N33)*
◆ Checking => Page 66
◆ Resistance 14.0...17.0 ω

1.6 - Dismantling and assembling fuel rail with injectors 39

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.7 - Dismantling and assembling air cleaner

Removing and installing air cleaner => Page 43 , Fig. 3

1 Air cleaner cover

2 Filter element
3 Temperature regulator
◆ For intake air preheating
◆ Note installation position
4 Gasket
◆ Renew if damaged
5 Air cleaner lower part
6 Gasket
◆ Renew if damaged
7 Retaining clip

40 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

8 Crankcase breather hose

◆ From oil separator:

=> Repair group 17; Removing and installing parts of lubrication system Removing and installing parts of lu‐
brication system

9 Connecting hose
10 Warm air intake hose
◆ From warm air collector plate:

=> Repair group 26; Removing and installing parts of exhaust system Removing and installing parts of exhaust
system

11 Air intake housing with regulating flap

◆ Check intake air preheating => Page 77

1.7 - Dismantling and assembling air cleaner 41

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

-> Fig. 1 Resistance values for coolant temperature sender (G62)

The diagram is divided into two temperature ranges:

A- From 0...50 °C
B- From 50...105 °C

Examples:
◆ 30 °C is in range A and corresponds to a resistance of 1.5...2.0 kω
◆ 80 °C is in range B and corresponds to a resistance of 275...375 ω

-> Fig.2 Resistance values for intake air temperature sender (G42)

The diagram is divided into two temperature ranges:

A- From 0...50 °C
B- From 50...105 °C

Examples:
◆ 20 °C is in range A and corresponds to a resistance of 2.3...2.6 kω
◆ 80 °C is in range B and corresponds to a resistance of 290...330 ω

42 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
-> Fig. 3 Removing and installing air cleaner

Removing

- Loosen air cleaner at securing screws marked by arrows.

- Pull the vacuum hose off the vacuum unit for the regulating flap.
- Pull the hose for the crankcase breather off the air cleaner and the vacuum hose to brake servo non-return
valve of the T-piece.
- Remove air cleaner.

Installing

Install in reverse order but note following:

◆ Tighten the securing bolts evenly and diagonally as shown in Fig. N24-0926.

Note:

Self-tapping screws/bolts are used to secure the air cleaner to plastic intake pipe as well as to secure the air
cleaner cover to the air cleaner lower part. When these screws/bolts are loosed or tightened using a power tool
the threads in the intake manifold or the air cleaner lower part may be damaged.

For this reason the use of a power tool can only be authorized when:

◆ The power tool maximum speed is 200 rpm.

◆ The tightening torque is set to a maximum of 3 Nm.

1.8 - Safety precautions

Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
noted:

◆ For safety reasons the fuse No. 40 must be removed from the fuse holder before opening the fuel system,
otherwise the fuel pump can be activated by the door contact switch.
◆ Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
◆ The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or
tester cables.
◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull plug
off Hall sender (distributor).

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.

1.7 - Dismantling and assembling air cleaner 43

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.9 - 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.

1.10 - Technical data

Engine code AER ALL

Idling speed2) rpm 660...7401) 660...7401)
Engine control unit for injection and ignition system3)
Control unit version3) Motronic 9.0 Motronic 9.0
Part No.4) Manual gearbox 030 906 027AR 030 906 027AL
Autom. gearbox --- ---
Governed speed rpm 5800...6250 5800...6250

1) Up-to-date specifications:

=> Exhaust emissions test binder

2) The control unit increases idling speed under following conditions:

- When the battery voltage is too low

- After a long full throttle drive and at higher temperatures

- When the air conditioner is switched on

-When the heated rear window is switched on

-When the steering is at full lock (P.A.S pressure switch is switched on). In this case the normal idling speed is
attained,

when the engine has been restarted or the vehicle is driven faster than 15 km/h (approx. 9.4 mph).

3) Replacing engine control unit => Page 85

4) For latest part number for engine control unit:

=> Parts film

44 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

2 - Checking components
2.1 - Checking components

2.2 - Checking Lambda probe heating

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715

◆ Adapter set V.A.G 1594
◆ Current flow diagram

Check conditions

• -> Fuse SB1 must be OK.

• The battery voltage must be at least 11.5 V.
• Fuel pump relay must be OK

Test sequence

- -> Separate 4 pin connector to Lambda probe (G39) -1-.

2.1 - Checking components 45

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

- -> Check probe heating for continuity at Lambda probe connector contacts 1 and 2.

Note:
The heater element resistance is approx. 1...5 ω at room temperature. Even slight increases in room temper‐
ature increase the resistance greatly.
If it is determined that probe heating has an open circuit:
- Renew Lambda probe (G39)
=>Page 31 , item 23 .

If probe heating has continuity:

Checking voltage supply
- Set multimeter to "Voltage measurement" range.

- -> Connect multimeter using aux. cables from V.A.G 1594 to measure voltage at contacts 1+2 (connector
to engine control unit).
- Start engine and run at idling speed.

Specification: 11.0...15.0 V

- Switch off ignition.

If no voltage is present:

46 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- -> Check wiring between 4 pin connector contact 2 and engine earth for open circuit
Wire resistance: Max. 1.5 ω

If the specification is obtained:

- Check wire between 4 pin connector contact 1 and fuel pump relay (J17) for open circuit using current flow
diagram.
Wire resistance: max. 1.5 ω

2.3 - Checking throttle valve control part

Components of the throttle valve control part (J338):

Throttle valve positioner (V60), throttle valve positioner potentiometer (G88), throttle valve potentiometer (G69)
and idling switch (F60)

Notes:
◆ Only gold-plated contacts may be used when servicing the throttle valve control part connector contacts.

If the throttle valve control part is replaced, the following must be carried out:
◆ Match engine control unit to the throttle valve control part => Page 86

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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

Checking idling switch

Test sequence

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 9 and 8 for "Display group number 98" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 98
1 2 3 4

- Check the operating mode display in display zone 3.

Display: Idling

- Slowly open throttle valve. After free travel, a stop is reached when opening throttle valve further the 4th
position from left must jump to part throttle

2.2 - Checking Lambda probe heating 47

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Display: Part throttle

Display constantly remains on one operating condition:

Display Cause Continuation of

check
Part throttle Open circuit or short => Page 48
to positive
Idling Short to earth => Page 49

Continuation of check when display constantly shows part throttle

- -> Pull 8 pin connector off throttle valve control part -arrow-.

- -> Bridge connector contacts 3+7 with aux. cables from V.A.G 1594 and observe display.

If display jumps to idling:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Replace throttle valve control part
=>Page 36 , item 5 .

If display remains on idling:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check voltage supply of throttle valve control part and wiring to control unit => Page 53 .

If the voltage supply and wiring is OK:

- Replace engine control unit

48 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
=> Page 85 .

Continuation of check when display constantly shows idling

- -> Pull 8 pin connector off throttle valve control part -arrow-.

If display jumps to part throttle:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Replace throttle valve control part
=>Page 36 , item 5 .

If display remains on part throttle:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check voltage supply of throttle valve control part and wiring to control unit => Page 53 .

If the voltage supply and wiring is OK:

- Replace engine control unit

=> Page 85 .

Checking throttle valve positioner and throttle valve positioner potentiometer

Test conditions

• Coolant temperature must be at least 80 °C, =>display group 1, display zone 2.

Test sequence

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

2.3 - Checking throttle valve control part 49

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
-> Indicated on display:
(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Check whether the coolant temperature is above 80 °C in display zone 2.

- Change to display group 98 as follows:
- Press C key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 9 and 8 for "Display Group 98" and confirm entry by pressing Q.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 98
1 2 3 4

- Check voltage value from throttle valve positioner sender in display zone 2. The voltage must be between
0.500...5.000 V

If the specification is not obtained:

- Press the ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

- -> Pull 8 pin connector off throttle valve control part -arrow-.

- -> Measure throttle valve positioner resistance between connector contacts 1+2.
Specification: 3...200 ω

If the specification is not obtained:

50 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Replace throttle valve control part
=>Page 36 , item 5 .

If the specification is obtained:

- Check voltage supply of throttle valve control part and wiring to control unit => Page 53 .

Checking throttle valve potentiometer

Test conditions

• Coolant temperature must be at least 80 °C, =>display group 1, display zone 2.

Test sequence

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Check whether the coolant temperature is above 80 °C in display zone 2.

- Change to display group 3 as follows:
V.A.G 1551: Press key 3 twice
V.A.G 1552: Press key ↑twice

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 3
1 2 3 4

- Read off throttle valve angle in display zone 3.

Throttle valve in start position: 3.1...6.7<°
- Slowly open throttle valve slowly until fully open and observe angle display in display zone 3. The figure
must increase uniformly over
the complete range
up to a min. 75 <°.
- Press the ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

Note:

The displayed figure is dependent on the tolerances of the throttle valve potentiometer and does not correspond
to the actual opening angle.

2.3 - Checking throttle valve control part 51

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
If the figure does not increase uniformly:

- Replace throttle valve control part

=>Page 36 , item 5 .

If the display constantly shows 0 <° or is above 90 <°:

Display Cause Continuation of check

0 <° Open circuit or short to => Page 52
positive
above Short to earth => Page 53
90 <°

Continuation of check when display shows 0 <°:

- -> Pull 8 pin connector off throttle valve control part -arrow-.

- -> Bridge connector contacts 5+7 with auxiliary cables from V.A.G 1594 and observe display.

If display jumps above 90 <°:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Replace throttle valve control part
=>Page 36 , item 5 .

If display remains at 0 <°:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check voltage supply of throttle valve control part and wiring to control unit => Page 53 .

52 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
If the voltage supply and wiring is OK:

- Replace engine control unit

=> Page 85 .

Continuation of check when display is above 90 <°:

- -> Pull 8 pin connector off throttle valve control part -arrow-.

If display jumps to 0 <°:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Replace throttle valve control part
=>Page 36 , item 5 .

If display remains above 90 <°:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check voltage supply of throttle valve control part and wiring to control unit => Page 53 .

If the voltage supply and wiring is OK:

- Replace engine control unit

=> Page 85 .

Checking voltage supply and wiring to control unit

Test conditions

• The battery voltage must be at least 11.5 V.

2.3 - Checking throttle valve control part 53

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Test sequence
- -> Pull 8 pin connector off throttle valve control part -arrow-.

- -> Connect multimeter to measure voltage using aux. cables from V.A.G 1594 to connector contacts 4+7.
- Switch on ignition.
Specification: min. 4.5 V
- Switch off ignition.
- Connect multimeter to measure voltage at connector contacts 3+7.
- Switch on ignition.
Specification: min. 9.0 V
- Switch off ignition.

If no voltage is present:

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

- -> Check wiring between test box and connector for open circuit according to current flow diagram.
Contact 1+socket 2
Contact 2+socket 26

54 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Contact 3+socket 10
Contact 4+socket 14
Contact 5+socket 41
Contact 7+socket 17
Contact 8+socket 16
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another.
Specification: ∞ω

If no wiring fault is detected:

- Check voltage supply of engine control unit => Page 83 .

2.4 - Checking intake manifold pressure sender

Note:
Only gold-plated contacts may be used when servicing the sender connector contacts
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ 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 conditions
• Fault "00519 intake manifold pressure sender -G71" recognized by self-diagnosis

Note:
If sender or connecting wiring is defective then the control unit uses a substitute value.
Test sequence

- -> Pull 4 pin connector off intake manifold pressure sender (G71) with intake air temperature sender (G42)
-arrow-.
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

2.3 - Checking throttle valve control part 55

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

- -> Check wiring between test box and connector for open circuit using current flow diagram.
Contact 3+socket 37
Contact 4+socket 18
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
Specification: ∞ω

If no wiring fault is detected:

- Renew the intake manifold pressure sender (G71) with intake air temperature sender (G42)
=> Page 35 , item 1 .

2.5 - Checking intake air temperature sender

Note:

Only gold-plated contacts may be used when servicing the sender connector contacts

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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
◆ Chilling spray (commercially available)

Note:

If sender or connecting wiring is defective the control unit operates with a substitute temperature of 20 °C.

Test sequence

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

56 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Read measured value block HELP

Input display group number XXX

- Press keys 0, 0 and 2 for "Display group number 2" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 2
1 2 3 4

- Read off intake air temperature value in display zone 4.

Display Cause Continuation of

check
approx. -33 °C Open circuit or => Page 57
short to positive
approx. 20 °C Short to earth => Page 59
Approx. ambient --- => Page 60
temperature1)

1) If a temperature is displayed which is below the ambient air temperature of the sender, check sender
wiring for transfer resistances. Note when doing this that sender is heated from external sources, e.g. radiated
heat when engine is not running.

Continuation of check when display reads approx. -33 °C:

- -> Pull 4 pin connector off intake air temperature sender (G42) with intake manifold pressure sender (G71)
-arrow-.

- -> Bridge connector contacts 1+2 using aux. cables from V.A.G 1594 and observe display.

If the display jumps to 20 °C:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

2.5 - Checking intake air temperature sender 57

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Switch off ignition.
- Renew the intake manifold pressure sender (G71) with intake air temperature sender (G42)
=> Page 35 , item 1 .

If the display remains at approx. -33 °C:

- Press ⇒key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

- -> Check the wiring between test box and 4 pin connector for open circuit using current flow diagram.
Contact 1+socket 17
Contact 2+socket 43
Wire resistance: Max. 1.5 ω
- Check wiring additionally for short circuit to battery positive.
Specification: ∞ω

If no wiring fault is detected:

- Replace engine control unit

=> Page 85 .

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Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Continuation of check when display shows 20 °C:

- -> Pull 4 pin connector off intake air temperature sender (G42) with intake manifold pressure sender (G71)
-arrow-.

If the display jumps to approx. -33°C:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Renew the intake manifold pressure sender (G71) with intake air temperature sender (G42)
=> Page 35 , item 1 .

If the display remains at 20°C:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

- Switch off ignition.

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

2.5 - Checking intake air temperature sender 59

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- -> Check the wiring between test box and 4 pin connector for open circuit using current flow diagram.
Contact 1+socket 17
Contact 2+socket 43
Wire resistance: Max. 1.5 ω
- Check wiring additionally for short circuit to battery positive.
Specification: ∞ω

If no wiring fault is detected:

- Replace engine control unit

=> Page 85 .

Continuation of check when display = ambient temperature:

Functional check of sender

- -> Remove intake air temperature sender together with intake manifold pressure sender (connector remains
connected).
- Note intake air temperature value in display zone 4.
- Spray sender with commercial chilling agent whilst observing the temperature value. The temperature value
must
decrease.
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

If the specification is not obtained:

- Renew the intake manifold pressure sender (G71) with intake air temperature sender (G42)
=> Page 35 , item 1 .

2.6 - Checking coolant temperature sender

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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 conditions

• Fault "00522 coolant temperature sender G62" recognized by self-diagnosis

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 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Notes:

◆ If the sender or wiring is defective, the control unit works using a substitute temperature. This substitute
temperature is calculated by the control unit using the operating conditions from the time the engine was
started.
◆ If the fault is stored in the fault memory as "occurring sporadically/SP":

- Additionally check the function of sender

=> Page 62 . To do this, the engine must be cold.

Test sequence

- -> Pull the 4 pin connector off coolant temperature sender (G62) with coolant temperature gauge sender
(G2) -arrow-.
- Measure resistance between sender contacts 1+3.

-> Specification see diagram

The diagram is divided into two temperature ranges:

A- From 0...50 °C
B- From 50...105 °C

Examples:

◆ 30 °C is in range A and corresponds to a resistance of 1.5...2.0 kω

◆ 80 °C is in range B and corresponds to a resistance of 275...375 ω

If the specification is not obtained:

- Replace coolant temperature sender (G62) with coolant temperature gauge sender (G2) =>Page 30 , item
20 .

Volkswagen Technical Site: http://vwts.ru http://vwts.info

2.6 - Checking coolant temperature sender 61

 Lupo 1999 ➤
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If the specification is obtained:

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

- -> Check the wiring between test box and 4 pin connector for open circuit using current flow diagram.
Contact 1+socket 17
Contact 3+socket 42
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
Specification: ∞ω

If no wiring fault is detected:

- Replace engine control unit

=> Page 85 .

Additional check when fault is stored as "Sporadic fault /SP":

Test conditions

• Engine must be cold.

Functional check of sender

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

62 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Rapid data transfer HELP

Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Observe coolant temperature value in display zone 2, whilst engine is running. The temperature figure must
increase uniformly and without interruption.

Notes:

◆ If the display on fault reader jumps by 2...5 °C, it is a control unit fault and not caused by a defective sender.
◆ If irregular engine running occurs in certain temperature ranges and the temperature figure does not increase
without interruption, the temperature signal is temporarily interrupted and the sender must be renewed.

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

If the specification is not obtained:

- Replace coolant temperature sender (G62) with coolant temperature gauge sender (G2) =>Page 30 , item
20 .

2.7 - Idling speed boost

When the steering is at full lock and also when the heated rear window is switched on the speed is increased
to approx. 900 rpm.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

2.6 - Checking coolant temperature sender 63

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Read measured value block HELP

Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Read idling speed value in display zone 1 and note value.

- Switch heated rear window on. The speed must increase to
approx. 900 rpm.
- Switch off rear window and give short bursts of throttle. The speed must then drop to the noted value.

Vehicles with power assisted steering

- Turn steering quickly onto full lock. The speed must increase to 900 rpm again when P.A.S. pump achieves
max. pressure. The idling speed remains at the higher value until the vehicle is driven faster than 15 km/h
(approx. 9.4 mph).

If the speed is increased as described:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

If the speed is not increased when steering is at full lock:

- -> Pull connector -1- off P.A.S pressure switch (F88) -2- and bridge connector contacts with aux. cables
from V.A.G. 1594.

If the speed increases:

- Press ⇒ key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Renew pressure switch.

If the speed does not increase:

- Press ⇒ key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

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 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring between test box and connector for open circuit according to current flow diagram.
Contact 1+socket 11
Contact 2+socket 17
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another, to vehicle earth and to battery positive.
Specification: ∞ω

If no wiring fault is detected:

- Replace engine control unit

=> Page 85 .

Continued for all vehicles

If the speed is not increased with heated rear window switched on:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Set multimeter scale to measure voltage and connect between test box sockets 1+12.
- Switch on heated rear window.
Approx. battery voltage
must be displayed.

If approx. battery voltage is displayed:

- Replace engine control unit

=> Page 85 .

2.7 - Idling speed boost 65

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
No voltage is displayed:

- Check wiring to contact 12 using current flow diagram.

2.8 - Checking injectors

Checking activation

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Test box V.A.G 1598/18

◆ Hand multimeter V.A.G 1526 or multimeter V.A.G 1715
◆ Diode test lamp V.A.G 1527
◆ Adapter set V.A.G 1594
◆ Current flow diagram

Test conditions

• The battery voltage must be at least 11.5 V.

• Hall sender must be OK, checking
=>Page 100 .
• Fuel pump relay must be OK

Test sequence

- Remove air cleaner => Page 43 , Fig. 3 .

- -> Pull plug -arrows- off all injectors.

- -> Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 to connector contacts of Cyl. 1.
- Operate starter.
The LED must flicker
- Repeat check at the injector connectors for Cyls. 2...4.

66 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Switch off ignition.

The LED does not flicker on any cylinder:

- -> Connect diode test lamp to Cyl. 1 connector, contact 1 and earth.
- Operate the starter and check the voltage supply for No. 1 cylinder injector.
The LED must light up
- Repeat check at the injector connectors for Cyls. 2...4.

If the LED does not light up:

- Switch off ignition.
- Check wire between 2 pin connector contact 1 and fuel pump relay (J17) for open circuit according to current
flow diagram.
Wire resistance: max. 1.5 ω

The LED flickers on one or several cylinders:

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

2.8 - Checking injectors 67

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Check wiring between test box and 2-pin connectors for injectors for open circuit according to current flow
diagram.
Cyl. 1 connector, contact 2+socket 7
Cyl. 2 connector, contact 2+socket 6
Cyl. 3 connector, contact 2+socket 28
Cyl. 4 connector, contact 2+socket 4
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another.
Specification: ∞ω
- Check wiring between connector contacts 1 of injectors for open circuit to one another.
Wire resistance: Max. 1.5 ω

Checking resistance of injectors

Test sequence

- -> Check resistance of injectors individually

Specification: 14.0...17.0 ω(at 20° C)

When the engine is warm the resistance will be approx. 4...6 ωhigher.

If the specification is not attained:

- Renew defective injector

Page 39 , item 6 .

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 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Checking spray pattern and for leaks

Special tools, workshop equipment, test and measuring appliances and aux. items required

◆ V.A.G 1331 Torque wrench (5...50 Nm)

◆ V.A.G 1594 A Adapter set
◆ V.A.G 1630 Digital potentiometer
◆ Measuring container

Test conditions

• The fuel pressure must be in order, checking

=> Page 72 , checking fuel pressure regulator and holding pressure.

2.8 - Checking injectors 69

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Test sequence

- Remove air cleaner => Page 43 , Fig. 3 .

- -> Pull 3-pin connector off ignition transformer -arrow-.

- -> Pull the 4 pin connector off coolant temperature sender (G62) with coolant temperature gauge sender
(G2) -arrow-.

- -> Connect digital potentiometer V.A.G 1630 using aux. cables from V.A.G 1594 to connector contacts 1+3
and set connected side to 15 kω.
- Pull connector off throttle valve control part, oil pressure switch and intake manifold pressure sender, and
unclip wiring at intake pipe and coolant regulator housing.

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 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

- -> Pull the vacuum hose off fuel pressure regulator -arrow-.
- Remove fuel rail complete with all injectors from intake manifold (fuel hoses remain connected)
Page 28 , item 11 .

- -> Hold a small container under the injector to be checked and pull connectors off all other injectors.
- Operate starter, using a 2nd person. Injector must spray pulsatingly.
- Repeat check with other injectors ensuring that injector to be checked is only connected.
- Switch off ignition and afterwards check injectors for leaks. No more than
2 drops/min
may leak from each injector.

If the fuel loss is greater:

- Switch off ignition.

- Renew defective injector
Page 39 , item 6 .

Perform installation of injectors in reverse order. When doing this note the following:

◆ Renew O-rings on all injectors and lightly moisten with clean engine oil.
◆ Fit fuel rail with secured injectors onto intake manifold and tighten evenly.

2.8 - Checking injectors 71

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

2.9 - Checking fuel pressure regulator and holding pressure

The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure.

The specification for the check is dependent upon the working pressure of the fuel pump. This is

approx. 3.0 bar

Special tools, workshop equipment, test and measuring appliances and aux. items required

◆ V.A.G 1318 Pressure gauge

◆ V.A.G 1318/10 Adapter
◆ V.A.G 1318/11 Adapter
◆ V.A.G 1318/16 Hose adapter
◆ V.A.G 1921 Spring-type clip pliers

72 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Test sequence

- Pull fuel pump fuse No. 40 out of fuse holder.

- -> Pull off the supply hose -1- (with white marking) and catch the fuel which runs out in a cloth.

Warning!
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release
pressure by carefully loosening the connection.

- -> Connect pressure gauge V.A.G 1318 with adapter V.A.G 1318/10 to supply hose -1- and with adapter
V.A.G 1318/11 and hose adapter V.A.G 1318/16 to supply pipe.
- Open measured device cut-off tap. (The handle points in throughflow direction -arrow-).
- Insert fuel pump fuse No. 40 into fuse holder.
- Start the engine and run at idling speed.
- Measure fuel pressure.
Specification: Approx. 2.5 bar

2.9 - Checking fuel pressure regulator and holding pressure 73

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

- -> Pull vacuum hose off fuel pressure regulator -arrow-. The fuel pressure must increase to
approx. 3.0 bar.
- Switch off ignition.

If the specification is not obtained:

- Check quantity supplied by fuel pump.

=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump

If the specification is obtained:

- Check for leaks and holding pressure by observing pressure drop on gauge. After 10 minutes there must
be
a residual pressure of
at least 2.0 bar.

If the holding pressure drops below 2 bar:

- Start the engine and run at idling speed.

- -> Switch ignition off after the pressure has built-up. At the same time close pressure measured device cut-
off tap (handle cross throughflow direction -arrow-).
- Observe pressure drop on gauge.

74 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

If the pressure does not drop:

- Check fuel pump non-return valve.

=> Rep. Gr. 20; Removing and installing parts of fuel system; checking fuel pump

If the pressure drops again:

- -> Open pressure gauge V.A.G 1318 shut-off tap (handle in throughflow direction).
- Start the engine and run at idling speed.

- -> Switch ignition off after the pressure has build-up. At the same time clamp-off the return hose (with blue
marking) -2-.

If the pressure does not drop:

- Renew fuel pressure regulator

=>Page 38 , item 4 .

If the pressure drops again:

- Check pipe connections, O-rings on fuel manifold and injectors for leaks.
- Check pressure gauge for leaks.

Note:

Before removing pressure gauge place a cloth around the connections to be loosened.

2.9 - Checking fuel pressure regulator and holding pressure 75

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

2.10 - Checking intake air system for leaks (unmetered air)

Checking with engine leak detector spray G 001 800 A1

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ Engine leak detector spray G 001 800 A1

Test conditions

• Coolant temperature must be at least 80 °C, =>display group 1, display zone 2.

Test sequence

Notes:
◆ The vacuum in the intake system will cause the leak detector spray to be drawn in with the unmetered air.
The leak detector spray reduces the ignitability of the mixture. This leads to a drop in engine speed and to
a change of Lambda probe voltage.
◆ The safety precautions listed on the container must be adhered to.

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

Only continue with the test when

• The coolant temperature is above 80 °C

-Display zone 2-

- Observe the engine speed in display zone 1 and the Lambda probe voltage in display zone 3.
- Systematically spray parts of the intake system with engine leak detector spray.

If the engine speed drops or the Lambda probe voltage changes:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.
- Check sprayed areas of intake system for leaks and rectify if necessary.

Engine speed or Lambda probe voltage does not change:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

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 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Switch off ignition.

2.11 - Checking intake air preheating

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ Hand vacuum pump V.A.G 1390

Checking function of regulating flap

- -> Pull the vacuum hose -1- off the vacuum unit -2-.
- Pull off the hose for warm air intake -3-.
- Connect the hand vacuum pump V.A.G 1390 to the vacuum unit -2- and operate the hand vacuum pump
approx. 2 times.
The regulating flap must open (check by feeling in intake duct).
- Pull the hand vacuum pump hose off the vacuum connection.
The regulating flap must return to its original position.

Checking temperature regulator

Test conditions
• Intake housing OK.
• Engine max. hand warm
• Vacuum hoses connected

- Start engine and run at idling speed.

Regulating flap must be pulled open
- Pull vacuum hose off temperature regulator on vacuum pipe non return valve to brake servo.
Regulating flap must return to its original position after
max. 20 seconds.

3 - Checking functions
3.1 - Checking functions

3.2 - Checking Lambda probe and Lambda control

Note:
Only gold-plated contacts may be used when servicing Lambda probe connector contacts 3 and 4.
Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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

2.10 - Checking intake air system for leaks (unmetered air) 77

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
◆ Current flow diagram

Check conditions
• The engine control unit must be matched to the throttle valve control part=> Page 86
• Coolant temperature must be at least 80 °C, =>display group 1, display zone 2.
• Exhaust system between catalyst and cylinder head must be free of leaks

Functional check
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

Only continue with the test when

• The coolant temperature is above 80 °C
-Display zone 2-
• The engine has then run for a further 2 minutes at idling speed

- Note Lambda probe voltage in display zone 3. The voltage must

fluctuate at least 10 times per minute
in range of
0... 1.0 V.

If the Lambda regulation does not fluctuate as stated:

- Carry out road test and burn Lambda probes clean and repeat check.

If the voltage change is slower, determine cause of fault. => Page 80 .

- -> Pull the 4 pin connector off coolant temperature sender (G62) with coolant temperature gauge sender
(G2) -arrow-.
- The probe voltage must

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 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
increase
and then decrease to the old control range.
- Reconnect connector. The probe voltage must
decrease
and then increase to the old control range.

Note:

The throttle valve must not be operated during the check, otherwise the connector disconnected from the control
unit will be recognised as a fault.

If no control is detected:

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

- Switch off ignition.

- Check the Lambda probe heating
=> Page 45 .

Checking basic voltage

- -> Separate 4 pin connector to Lambda probe (G39) -1-.

- -> Connect multimeter with aux. cables from V.A.G 1594 to measure voltage at contacts 3+4 (connector to
engine control unit).
- Switch on ignition and measure basic voltage.
Specification: 0.45 V
- Switch off ignition.

If the specification is not obtained:

- Check Lambda probe wiring

=> Page 80

3.2 - Checking Lambda probe and Lambda control 79

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Checking Lambda probe wiring

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

- -> Check wiring between test box and 4 pin connector (to control unit) for open circuit using current flow
diagram.
Contact 3+socket 15
Contact 4+socket 38
Wire resistance: Max. 1.5 ω
- Check wiring at connector contacts 3+4 for short circuit to contacts 1+2 according to current flow diagram.
Specification: ∞ω

If no wiring fault is detected:

- Renew Lambda probe (G39)

=>Page 31 , item 23 .

Possible causes of fault if probe control frequency is too slow:

◆ The slots or holes in probe body are blocked

◆ The probe vent hole in area of connecting wire is blocked
◆ The probe has been overheated (glazed)
◆ The probe has been damaged by leaded fuel

80 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

3.3 - Checking engine operating mode

Note:

Check whether engine control unit recognises the engine operating modes (idling speed, part throttle, full throt‐
tle, overrun).

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A

Check conditions

• Coolant temperature must be at least 80 °C, =>display group 1, display zone 2.

• Throttle cable adjustment must be OK, checking:

=> Repair group 20; Throttle controls; Adjusting throttle cable Throttle controls Adjusting throttle cable

Test sequence

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Check whether the coolant temperature is above 80 °C in display zone 2.

- Press C key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 4 for "Display group number 4" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 4
1 2 3 4

- Observe -8 digit number block- in display zone 4 :

(The right-hand 4 digits are of no consequence)

Display in operating mode

◆ Idling:

3.3 - Checking engine operating mode 81

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
With throttle valve closed, 2nd position from left must display 1
Display: 01000000

◆ Part throttle:

- Rev up evenly.

3rd position from left must display 1

Display: 00100000

◆ Full throttle:

- Briefly open throttle fully (throttle burst).

4th position from left must briefly display 1

Display: 00010000

Note:

A test drive may have to be performed to show "Full throttle" in display.

A 2nd person is required when performing a test drive.

Warning!
Secure fault reader to rear seat and operate from this position.

Observe the valid safety measures during a test drive => Page 43 .

◆ Overrun mode:

- Increase engine speed to above 3000 rpm.

- Close throttle valve abruptly.

As long as the engine speed is above 1200 rpm 1st position from left must display 1
Display: 11000000 (briefly)

Note:

Below 1200 rpm idling speed is again recognised.

- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
- Switch off ignition.

If the specifications are not attained:

- Interrogate fault memory, if necessary, repair any faults and then erase fault memory => Page 7 , inter‐
rogating and erasing fault memory.
- Check accelerator mechanism for ease of operation.
- Check throttle valve potentiometer
=> Page 47 , Checking throttle valve control part.

82 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

4 - Engine control unit

4.1 - Engine control unit

4.2 - Checking control unit voltage supply

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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

Check conditions

• -> Fuses SB32 and SB37 must be OK.

• The battery voltage must be at least 11.5 V.
• If the vehicle is equipped with an air conditioner, this must be switched off.
• All electrical consumers, e.g. lights and rear window heating must be switched off.
• Alternator OK, checking:

=> Current flow diagrams, Electrical fault finding and Fitting locations

Test sequence

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 2 for "Display group number 2" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)

4.1 - Engine control unit 83

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

Read measured value block 2

1 2 3 4

- Read off figure displayed in display zone 3.

Specification: At least 11.5 V
- Press the ⇒key.
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
- Switch off ignition.

If the specification is not attained:

- Remove the wiper arms and the cowl panel:

=> Electrical system; Repair group 92; Windscreen wiper system; Removing and installing windscreen wiper
system Windscreen wiper system Removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.

Checking voltage supply terminal 30

- Measure supply voltage between test box sockets 1+21 using multimeter and adapter cables from V.A.G
1594:
Specification: at least 11.5 V

If the specification is not attained:

- Check wiring connections to relay plate according to current flow diagram.

=> Current flow diagrams, Electrical fault finding and Fitting locations

Checking voltage supply terminal 15

- Measure supply voltage between test box sockets 2+23 using multimeter and adapter cables from V.A.G
1594.
- Switch on ignition.
Specification: min. 11.5 V

If the specification is not attained:

- Check wiring connections to relay plate according to current flow diagram.

=> Current flow diagrams, Electrical fault finding and Fitting locations

84 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

4.3 - Replacing engine control unit

The engine control unit regulates the injection, throttle valve control part, Lambda control, ignition, knock control,
activated charcoal filter solenoid valve 1, engine speed governor via injectors or fuel pump relay, as well as
self-diagnosis.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

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

Removing

- First print out the control unit identification and thereby the previous control unit coding as follows:
- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> The fault reader V.A.G 1551 display will show the control unit identification, e.g.:
030906027AL MOTRONIC MP 9.0 2263
⇒

- Print out the control unit identification by pressing the fault reader print button.
- Press the ⇒key.

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

-> Indicated on display:

Rapid data transfer HELP
Enter address word XX

- Switch off ignition.

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- Release lock on engine control unit connector and pull off.

- -> Remove the securing screws -arrows- and take control unit off retaining frame.

Installing

- Place the new control unit into the retaining frame.

4.3 - Replacing engine control unit 85

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Note:

When installing the control unit ensure it locates properly on the retaining lugs on retaining frame.

- Secure the control unit to the retaining frame.

- Install control unit connector and lock.
- Match new control unit to throttle valve control part => Page 86
- Match new control unit to the electronic immobilizer => Page 87
- Then subsequently interrogate the fault memory of the new engine control unit again and erase the fault
memory if necessary => Page 7 , interrogating and erasing fault memory.

4.4 - Adapting engine control unit to throttle valve control part

When matching with ignition switched on but engine not running the engine control unit learns the throttle valve
control part limit positions and a comparison curve between throttle valve potentiometer and throttle valve
positioner.

Adapting sequence must be performed if:

◆ The throttle valve control unit is removed and installed

◆ The throttle valve control unit is renewed
◆ The engine control unit is replaced
◆ If when installing another engine another throttle valve control unit is installed

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A

Test conditions

• No faults must be stored in fault memory => Page 7 , interrogating and erasing fault memory.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating must be switched off.
• The throttle valve must be at idling speed position.
• Throttle cable adjustment must be OK, checking:

=> Repair group 20; Throttle controls; Adjusting throttle cable Throttle controls Adjusting throttle cable

Work sequence

- Connect the fault reader V.A.G 1551 (V.A.G 1552). Then switch ignition on and select engine control unit
with the "Address word" 01.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.

-> Indicated on display:

Basic setting
Input display group number XXX

- Press keys 0, 9 and 8 for "Display group number 98" and confirm entry with Q key.

-> Indicated on display:

System in basic setting 98
x.xxx V x.xxx V Idling ADP.
runs

86 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
After pressing the Q-key the throttle valve positioner is driven to Min., Max. and five intermediate positions and
the relevant throttle valve angle stored in non-volatile memory. This procedure takes approx. 10 seconds. The
throttle valve then remains in the start position for a brief period then closes.
-> Indicated on display:
System in basic setting 98
x.xxx V x.xxx V Idling ADP.
OK.

Matching has been performed successfully.

To store the values:
- Switch off ignition.

Note:
If the basic setting of the control unit is interrupted, the cause could be one of the following:
◆ Throttle valve cannot reach the mechanical stop because of contamination e.g. oil deposits or an incorrectly
adjusted throttle cable.
◆ Battery voltage too low.
◆ Throttle valve control unit or wiring is defective. Checking => Page 47 .

After an interruption the possible faults are stored in fault memory. When next switching on ignition the basic
setting is automatically performed again.
- End the engine basic setting by pressing the⇒ key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

4.5 - Matching engine control unit to electronic immobilizer

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A

Conditions
• -> Fuses SB29, SB32 and SB37 must be OK.
• Authorized vehicle key required.

Work sequence

4.4 - Adapting engine control unit to throttle valve control part 87

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- -> Pull cover -1- off in direction of arrow.
- Connect fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A.
- Switch on ignition.
- Operate fault reader or vehicle system tester 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.
- After the immobilizer control unit has registered, press ⇒ key.

-> Indicated on display:

Rapid data transfer 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?

- Confirm input with Q key.

-> Indicated on display:

Adaption
Learnt values have been erased

- Conclude adaption by pressing ⇒ key.

- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

-> Indicated on display:

Rapid data transfer HELP
Enter address word XX

- Switch off ignition.

Note:

The identity of the engine control unit is read into the immobilizer control unit when next switching the ignition
on.

5 - Checking additional signals

5.1 - Checking additional signals

5.2 - Checking speed signal

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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

88 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
◆ Current flow diagram

Check conditions
• The battery voltage must be at least 11.5 V.
• No faults must be stored in fault memory => Page 7 , interrogating and erasing fault memory.
• Speedometer must be OK., checking speedometer:

=> Electrical system; Repair group 90

Test sequence
Note:
To check the speed signal the vehicle must be driven. To do this a second person is necessary.
Warning!
Secure fault reader to rear seat and operate from this position.
Observe the valid safety precautions when carrying out a road test => Page 43 .
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

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

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 4 for "Display group number 4" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 4
1 2 3 4

- Carry out test drive with a 2nd person to observe display.

- Observe figure displayed in display zone 3:
Specification: approx. driven speed
- Drive slower. The displayed value must
decrease.
- Press the ⇒key.
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
- Switch off ignition.

If no speed is indicated or the display values reduce when driving slowly:

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

5.2 - Checking speed signal 89

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Set multimeter scale to measure voltage and connect between test box sockets 1+36.
- Switch on ignition.
- Lift vehicle at front left.
- Rotate front wheel and observe voltage display.
Specification: between 0 and at least 4 Volt fluctuating

If the display does not fluctuate:

- Check wiring to speedometer/speedometer sender:

=> Current flow diagrams, Electrical fault finding and Fitting locations

5.3 - Checking signal from/to air conditioning system

These signals from the air conditioner cause the initial control value for the idling stabilization to be increased
when the air conditioner compressor switches in. Thereby the idling stabilization remains in the middle of the
regulating range.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A
◆ 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 conditions

• -> Fuse SB27 must be OK.

• Air conditioner functioning OK.
• Air conditioner must be switched off
• All electrical consumers, e.g. lights and rear window heating must be switched off.
• Vehicle at room temperature (warmer than + 15 °C).
• No faults must be stored in fault memory => Page 7 , interrogating and erasing fault memory.

Test sequence

- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

90 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Press keys 0 and 8 for the function "Read measured value block" and confirm entry with Q key.

-> Indicated on display:

Read measured value block HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 1
1 2 3 4

- Observe -8 digit number block- in display zone 4 :

3rd position from left must display 0

Display: 00000000

- Switch on air conditioning system.

3rd position from left must display 1

Display: 10100000

- Change to display group 4. To do this press:

V.A.G 1551: key 3 three times
V.A.G 1552: key ↑ three times

-> Indicated on display:

(1...4 = Display zones)
Read measured value block 4
1 2 3 4

- Select lowest temperature and highest blower speed.

- Observe 8 digit number block in display zone 4. 2nd position from right must display 1.
Display: 01000011
- Press the ⇒key.
- Press keys 0 and 6 for the "End output" function and confirm input with the Q key.
- Switch off ignition.

If the display does not indicate as described:

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring between test box sockets 35 and air conditioner for open circuit according to current flow
diagram.

5.3 - Checking signal from/to air conditioning system 91

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Wire resistance: Max. 1.5 ω

If no fault can be found in the wiring:

- Check function of air conditioning:

=> Heating, air conditioning; Repair group 87; Air conditioner Air conditioner

92 24 - Mixture preparation, Injection

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

28 - Ignition system

1 - Servicing ignition system

1.1 - Servicing ignition system

1.2 - General notes on ignition system

◆ Only the components which specifically relate to the ignition system are dealt with here. For the other com‐
ponents of the injection and ignition system => Repair group 24.
◆ Disconnecting and connecting the battery must only be done with the ignition switched off, otherwise the
engine control unit could be damaged.
◆ The engine control unit is equipped with self diagnosis.
◆ Components marked with * are checked via the self diagnosis
=> Page 7 , interrogating and erasing fault memory.
◆ For trouble-free operation of the electrical components a voltage of at least 11.5 V is necessary.
◆ Before carrying out repairs and for fault finding, interrogate fault memory => Page 7 , interrogating and
erasing fault memory
◆ During some checks it is possible that the control unit will recognise and store a fault. Therefore after com‐
pleting all checks and repairs the fault memory must be interrogated and if necessary erased.
=> Page 7 , interrogating and erasing fault memory

◆ If the engine starts, runs for a short period and then stops, after fault finding, repairs or component tests,
then the fault may lie with the immobilizer which is blocking the engine control unit. The fault memory must
be interrogated and if necessary the control unit matched => Page 87 .

Safety precautions => Page 98

Test data, spark plugs => Page 98

1.1 - Servicing ignition system 93

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.3 - Removing and installing parts of the ignition system

1 Earth strap
2 Connector
◆ Black, 3-pin
3 10 Nm
4 Ignition transformer (N152)
◆ With output stage (N157)
◆ Checking => Page 101
5 Cable guide
◆ For ignition cables
6 Distributor cap
◆ Check for cracks and signs of tracking
◆ Check contact wear
◆ Clean before fitting
◆ Check carbon brush for wear and freedom of movement

94 28 - Ignition system
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

7 Screening cap
8 Rotor arm
◆ Marking: R1
◆ 0.6...1.4 kω
9 Dust cap
10 No. 1 Cyl. marking
11 Distributor with Hall sender (G40)
◆ Dismantling and assembling => Page 97
◆ Checking and adjusting ignition timing => Page 98
◆ Checking Hall sender
=> Page 100
12 O ring
◆ Renew if damaged
13 20 Nm
◆ Tightening torque influences the function of the knock sensor

1.3 - Removing and installing parts of the ignition system 95

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

14 Knock sensor 1 (G61)*

◆ Sensor and connector contacts are gold-plated
15 Connector
◆ Black, 2-pin
◆ For knock sensor 1 (G61)
◆ Connector contacts are gold-plated
16 Spark plug, 25 Nm
◆ Type and electrode gap
=> Page 98
17 H.T. cable
◆ With suppression connector and spark plug connector
◆ Resistance 4.6...7.4 kω
18 Rotating latch

96 28 - Ignition system
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.4 - Dismantling and assembling distributor

1 Distributor shaft
◆ With Hall sender rotor
◆ Pull out after removing the spring pin -7-
2 O ring
◆ Renew if damaged
3 3 Nm
4 Plastic washer
5 Shim(s)
6 Hall sender (G40)
◆ Checking => Page 100
7 Distributor body
8 Spring pin
9 Coupling
◆ Before removing mark position of drive tongue to shaft - 1 -

1.4 - Dismantling and assembling distributor 97

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

1.5 - Safety precautions

To prevent injuries to persons and/or damage to the fuel injection and ignition system, the following must be
noted:

◆ Do not touch or disconnect ignition wiring when the engine is running or being turned at starter speed.
◆ The ignition must be switched off before connecting or disconnecting injection or ignition system wiring or
tester cables.
◆ If the engine is to be turned at starter speed, without starting, e.g. when checking compressions, pull plug
off Hall sender (distributor).
◆ Do not connect a capacitor to terminal 1 (-).
◆ Do not replace 1 kω (identification: R1) with a different type even for radio interference suppression.

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.

1.6 - Adjustment data, Spark plugs

Engine code AER ALL

Ignition timing1)
Test value 3...8 ° BTDC
Adjustment value 6±1 °BTDC
Speed 1400...1600 rpm2)
Firing order 1-3-4-2
Spark plugs1)
VW/Audi 101 000 036AA; 101 000 036AA;
101 000 050AC; 101 000 050AC;
101 000 040 AD 101 000 040 AD
Manufacturer's designation BUR6ET; BUR6ET;
W7LTCR; W7LTCR;
14GH-7DTUR 14GH-7DTUR
Electrode gap BUR6ET, 14GH-7DTUR: BUR6ET, 14GH-7DTUR:
0.7...0.9 mm 0.7...0.9 mm
W7LTCR: W7LTCR:
0.9...1.1 mm 0.9...1.1 mm
Tightening torque 25 Nm

1) The up-to-date figures and the spark plug change intervals:

=> Exhaust emissions test binder

2) The rpm is increased by the engine control unit in "04 basic setting" function.

1.7 - Checking and adjusting ignition timing

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ Fault reader V.A.G 1551 or vehicle system tester V.A.G 1552 with cable V.A.G 1551/3A

98 28 - Ignition system
 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
◆ Ignition tester V.A.G 1767 or V.A.G 1367 with HT pick-up clamp V.A.G 1367/8

Check conditions

• Coolant temperature at least 80 °C

• No faults must be stored in fault memory
=> Page 7 , interrogating fault memory

Test sequence

- -> Connect ignition tester V.A.G 1767 or ignition tester V.A.G 1367 with HT pick-up clamp V.A.G 1367/8.
- Connect fault reader V.A.G 1551 (V.A.G 1552). Start engine and select "Address word" 01 of engine control
unit. When doing this the engine must be running at idling speed.
(Connecting fault reader and selecting engine control unit => Page 2 .)

-> Indicated on display:

Rapid data transfer HELP
Select function XX

- Press keys 0 and 4 for the function "Introduction of basic setting" and confirm entry with Q key.

-> Indicated on display:

Basic setting HELP
Input display group number XXX

- Press keys 0, 0 and 1 for "Display group number 1" and confirm entry with Q key.

-> Indicated on display:

(1...4 = Display zones)
System in basic setting 1
1 2 3 4

Do not continue with check until an 8 digit number block 00000000 appears in the 4th display zone.

Note:

If at one or more positions a 1 is displayed in display zone 4, the test conditions have not been fulfilled:

=>Page 22 ; Relevance of figures in 8 digit number block

- The engine control unit increases the idling speed to between 1400...1600 rpm.
- Check ignition timing.
Specification: 3...8 ° before TDC1)
- Adjust ignition timing by turning distributor, if necessary.
Adjustment figure: 6±1 ° before TDC1)

1) Up-to-date specifications:

=> Exhaust emissions test binder

1.7 - Checking and adjusting ignition timing 99

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
- Press ⇒key.
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.

1.8 - Checking Hall sender

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ 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 conditions

• The battery voltage must be at least 11.5 V.

Test sequence

- -> Pull 3-pin connector off Hall sender -arrow-.

- -> Connect multimeter to measure voltage using aux. cables from V.A.G 1594 to the outer contacts of the
connector.
- Switch on ignition.
Specification: min. 9 V
- Switch off ignition.
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

100 28 - Ignition system

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring between test box and connector for open circuit according to current flow diagram.
Contact 1+socket 17
Contact 2+socket 13
Contact 3+socket 8
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another.
Specification: ∞ω

If no wiring fault is detected and voltage was present between contacts 1+3:

- Renew Hall sender => Page 97 , item 6 .

If no wiring fault is detected and no voltage was present between contacts 1+3:

- Replace engine control unit

=> Page 85 .

1.9 - Checking ignition transformer and output stage

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required

◆ 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
◆ Diode test lamp V.A.G 1527
◆ Current flow diagram

Check conditions

• Hall sender in distributor must be OK.

1.8 - Checking Hall sender 101

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Checking ignition transformer

- Pull connector and H.T. cable off ignition transformer (N152).

- -> Check primary resistance between terminals 1 and 15.
Specification: 0.5...1.5 ω
- Check secondary resistance between terminals 4 and 15.
Specification: 2.5...4 kω

If the specifications are not attained:

- Replace ignition transformer => Page 94 , item 4 .

Checking voltage supply

- -> Pull 3-pin connector off ignition transformer -arrow-.

- -> Connect multimeter to measure voltage using aux. cables from V.A.G 1594 to the contacts 1+3 of the
disconnected connector.
- Switch on ignition.
Specification: min. 11.5 V

If no voltage is present:

- Switch off ignition.

- Check wire between 3 pin connector contact 1 and earth for open circuit according to current flow diagram.
Wire resistance: Max. 1.5 ω

102 28 - Ignition system

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998

- Check wire between 3 pin connector contact 3 and relay plate for open circuit according to current flow
diagram.
Wire resistance: Max. 1.5 ω

Checking activation
- -> Pull plug -arrows- off all injectors.

- -> Connect diode test lamp V.A.G 1527 using aux. cables from V.A.G 1594 and adapters V.A.G 1594/15 to
contacts 2+3 of the connector.
- Operate starter and check ignition signal from engine control unit.
LED must flicker

The LED does not flicker:

- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system

- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wire between test box socket 24 and 3 pin connector contact 2 for open circuit according to current
flow diagram.
Wire resistance: Max. 1.5 ω
- Additionally check wires for short to one another.

1.9 - Checking ignition transformer and output stage 103

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Specification: ∞ω

If no wiring fault is detected and voltage was present between contacts 1+3:

- Replace engine control unit

=> Page 85 .

If the voltage supply and activation is OK.:

- Connect 3 pin connector and H.T. cable to ignition transformer.
- -> Connect diode test lamp using aux. cables and clamps to the contacts 1 and 15 on ignition transformer.

Warning!
During the following test do not touch the terminals of the ignition transformer or test cables.
- Operate starter.
The LED must flicker

1.10 - Checking knock sensor

Notes:
◆ It is extremely important to keep to the tightening torque of 20 Nm to ensure the knock sensors perform
perfectly.
◆ Only gold-plated contacts may be used when servicing the knock sensor connector contacts.

Special tools, workshop equipment, testers, measuring instruments and auxiliary items required
◆ 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 conditions
• Knock sensor fault recognised by self-diagnosis =>Page 7 , interrogating and erasing fault memory.

104 28 - Ignition system

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
Test sequence
- Remove wiper arms and cowl panel:

=> Electrical system; Repair group 92; windscreen wiper system; removing and installing windscreen wiper
system windscreen wiper system removing and installing windscreen wiper system
- -> Connect test box V.A.G 1598/18 to control unit wiring loom.
- Check wiring and knock sensor for short circuit.
Sockets: 19+39, 39+45, 19+45
Specification: ∞ω

If no short is detected:
- -> Pull 2 pin connector off knock sensor -arrow-.

- -> Check wiring between test box and knock sensor for open circuit using current flow diagram.
Contact 1+socket 39
Contact 2+socket 19
Wire resistance: Max. 1.5 ω
- Measure resistance between knock sensor contacts.
Specification ∞ω

If no wiring fault is detected:

- Loosen knock sensor and tighten again to 20 Nm.
- Carry out test drive.

Observe the valid safety precautions when carrying out a test drive => Page 98 .
During the road test the following operating conditions must be fulfilled:
- The coolant temperature must exceed 80 °C .

- When the temperature is reached, the operating conditions

Idling
Part throttle
Full throttle
Overrun

Volkswagen Technical Site: http://vwts.ru http://vwts.info

1.10 - Checking knock sensor 105

 Lupo 1999 ➤
Motronic injection and ignition system (bucket tappets) - Edition 09.1998
must be attained several times.
- At full throttle the speed must exceed 3500 rpm.
Again interrogate the control unit fault memory.

If the fault is still present:

- Replace knock sensor

=>Page 96 , item 14 .

106 28 - Ignition system