Service 5

Workshop Manual
FABIA 2000 ³
1.4/55 TDI Engine, Fuel Injection
Edition 07.03
Engine code AMF

Service Department. Technical Information Printed in Czech Republic

S00.5326.00.20
5 Service

The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5326.00.20

© ŠKODA AUTO a. s.
FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

List of Supplements to Workshop Manual

FABIA 2000 ³
1.4/55 TDI Engine, Fuel Injection
Edition 07.03

Supple-
Edition Subject Article Number
ment
07.03 Basic Edition S00.5326.00.20
1 04.04 Modifications in Rep. Gr. 01 a 23 S00.5326.01.20

Edition 04.04 List of Supplements

S00.5326.01.20
 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

List of Supplements Edition 04.04

S00.5326.01.20
FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

Table of Contents

01 – Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 page 1
- Properties of the self-diagnosis ..................................................................... 01-1 page 1
- Technical data of self-diagnosis ..................................................................... 01-1 page 1
- Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine
electronics .............................................................................................. 01-1 page 2
- Interrogating and erasing fault memory ............................................................ 01-1 page 3
- Actuator diagnosis ..................................................................................... 01-1 page 5
Self-diagnosis II ......................................................................................... 01-2 page 1
- Fault codes 515 to 19561 ............................................................................ 01-2 page 1
Self-diagnosis III ........................................................................................ 01-3 page 1
- Readiness code ........................................................................................ 01-3 page 1
- Reading readiness code .............................................................................. 01-3 page 1
- Generating readiness code .......................................................................... 01-3 page 2
Self-diagnosis IV ....................................................................................... 01-4 page 1
- Reading measured value block ..................................................................... 01-4 page 1
- Display groups 001 to 022, engine idling .......................................................... 01-4 page 1
- Display groups 004 through 011 at full load ....................................................... 01-4 page 10
- Display group 125 - CAN databus .................................................................. 01-4 page 12

23 – Fuel Formation, Injection

Diesel Direct Injection System ...................................................................... 23-1 page 1
- Safety measures ....................................................................................... 23-1 page 1
- Rules of cleanliness ................................................................................... 23-1 page 1
- Overview of fitting locations .......................................................................... 23-1 page 2
- Disassembling and assembling intake manifold .................................................. 23-1 page 4
- Removing and installing air filter .................................................................... 23-1 page 5
- Disassembling and assembling the air filter ....................................................... 23-1 page 6
Disassembling and assembling the unit injector ............................................... 23-2 page 1
- Summary of components ............................................................................. 23-2 page 1
- Removing and installing O-rings for unit injector ................................................. 23-2 page 2
- Removing and installing the unit injector .......................................................... 23-2 page 3
Testing components ................................................................................... 23-3 page 1
- Test wiring and components with Test box -V.A.G 1598/31- ................................... 23-3 page 1
- Test diesel direct injection system relay -J322- .................................................. 23-3 page 1
- Testing unit injector valve ............................................................................ 23-3 page 2
Testing exhaust gas recirculation .................................................................. 23-4 page 1
- Connect vacuum hoses at valve block ............................................................. 23-4 page 1
- Testing exhaust gas recirculation ................................................................... 23-4 page 1
Engine control unit ..................................................................................... 23-5 page 1
- Testing voltage supply for engine control unit .................................................... 23-5 page 1
- Replacing diesel direct injection system control unit -J248- .................................... 23-5 page 1
- Coding diesel direct injection system control unit -J248- ........................................ 23-5 page 2
- Activating and deactivating cruise control system (CCS) ....................................... 23-5 page 3
Testing auxiliary signals .............................................................................. 23-6 page 1

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28 – Glow Plug System

Testing preheating system ........................................................................... 28-1 page 1

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01 – Self-diagnosis

01-1 Self-diagnosis I

Properties of the self-diagnosis

The control unit for the diesel direct injection system is
equipped with a fault memory. The fault memory is de-
signed as a permanent memory.
If malfunctions occur in the monitored sensors or compo-
nents, they are stored in the fault memory with indication
of the fault type. Fault table ⇒ Chap. 01-2.
Faults which occur only temporarily (sporadically) are
displayed with the suffix „/SP“. Possible causes of spo-
radic faults are e.g. a loose contact or a temporary line in-
terruption. If a sporadic fault no longer occurs after 50
engine starts, it is automatically erased.
If faults are detected that are likely to influence the driving
behaviour, the glow period warning lamp -K29- flashes.
The stored faults can be read out with the vehicle system
tester -V.A.G 1552-, -V.A.G 1551- or -VAS 5051-
⇒ 01-1 page 2.
After the fault(s) has(have) been removed the fault mem-
ory must be erased ⇒ 01-1 page 3.

Note
The following description only relates to vehicle system
tester -V.A.G 1552- using the current program card 5.0.
When not using the current program card or when using
the fault read-out scan tool -V.A.G 1551- with integrated
printer or using the vehicle diagnosis, measurement and
information system -VAS 5051- a minor deviation in the
display is possible.

Technical data of self-diagnosis

Interrogating control unit version

The control unit version is displayed once the vehicle sys-
tem tester -V.A.G 1552- is connected and the engine
electronics control unit is selected ⇒ 01-1 page 2.

Available functions when using the vehicle sys-

tem tester -V.A.G 1552-
The conditions under which the desired functions can be
selected are given in the following table.

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Condition
Operation Engine not running, Engine idling Normal driving
ignition switched on
01 Interrogating control unit yes yes yes
version
02 Interrogating fault mem- yes1) yes yes
ory
03 Actuator diagnosis yes yes no
04 Basic setting no yes no
05 Erasing fault memory yes yes yes
06 Ending output yes yes yes
07 Coding control unit yes no no
08 Reading measured val- yes yes yes
ue block
11 Login procedure yes no no
1) Only perform with the ignition on, if the engine does not start.

Connecting vehicle system tester

-V.A.G 1552- and selecting the control
unit for engine electronics
Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

Test conditions
• Battery voltage at least 11.5 volts
• Earth connection to engine and gearbox O.K.
• Fuses according to current flow diagram O.K.

Procedure
– Connect vehicle system tester -V.A.G 1552- with ap-
propriate cable.
Once the vehicle system tester has been connected:
V.A.G 1552
– Switch on ignition or start ⇒ 01-1 page 1 engine de-
pending on the function desired.
V.A.G 1551/3
Note
♦ If „data transfer errors“ are displayed as a result of an S01-0087
incorrect entry, disconnect cable at vehicle system
tester, connect it in again and repeat all the steps.
Vehicle system test HELP
♦ If one of the following messages appears in the dis-
The control unit does not respond
play, test the diagnostic cable ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
or ⇒ Operating Instructions of vehicle system tester.

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Vehicle system test HELP

Fault in communication set-up

Vehicle system test HELP

K cable does not connect to earth

Vehicle system test HELP

K cable does not connect to pos. term.
– Operate the vehicle system tester by referring to the
read-out on the display:
Vehicle system test HELP
Readout on display: Enter address word XX
– Enter address word 01 „Engine electronics“ and con-
firm entry with Q .
045906019BM 1.4l R3 EDC G000SG 4958 ->
The control unit identification appears in the display, e.g.:
Coding 00008 WSC XXXXX
♦ 045906019BM = Part No. of the control unit (for cur-
rent control unit version see spare part catalogue)
♦ 1.4 ltr. = engine displacement
♦ R3 = engine version (3 cyl. in-line engine)
♦ EDC = Injection system (Electronic Diesel Control)
♦ CC = Cruise control system activated (only on models
with CCS)
♦ 000 = Control unit ID
♦ MG = Manual gearbox
♦ 4958 = Data status (Software version of the control
unit)
♦ Coding 00002 = Coding variant of the control unit
♦ WSC XXXXX = Workshop code

Note
♦ If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit
⇒ Chapter 23-5.
♦ Incorrect coding of the engine control unit results in:
♦ Handling problems (jerky gear change, load change
jolts etc.)
♦ Increase in fuel consumption
♦ Increase in pollution
♦ Storage of non-existent faults in fault memory

Interrogating and erasing fault memory

Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

Interrogating fault memory

– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select address word 01 „Engine electronics“
⇒ 01-1 page 2.

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Only if the engine does not start:

– Switch on ignition.
– Select function 02 „Interrogate fault memory“ and con-
firm with Q .
X faults detected!
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If no fault is stored:

– Select function 06 „End output“ and confirm with Q.

If one or several faults are stored:

– Press →.
->
Readout on display, e.g.: Fault number: 16685 P0301 044
– Press →.
Cylinder 1 ->
Fault source and fault type appear in the display, e.g.: Combustion misfiring detected
– Press →.

The stored faults are displayed in sequence.

– Select function 06 „End output“ and confirm with Q .

– Rectify the faults displayed by referring to the fault ta-
ble ⇒ Chapter 01-2.

Note
When carrying out testing and removal and installation
operations faults such as connector unplugged or CAN
bus faults, may also be detected by other control units.
This is why, when the work is concluded, that it is neces-
sary to interrogate and erase the fault memory on all con-
trol units. For this you must proceed as follows:

– Select function 00 for „Automatic test sequence“ and

confirm with Q .
The Vehicle system tester -V.A.G 1552- sends all the
known address words one after the other.

Erasing fault memory

Test conditions

• Fault eliminated
• Fault memory interrogated ⇒ 01-1 page 3

Note
After fault elimination the fault memory must again be in-
terrogated and subsequently erased.

– Select function 05 „Erase fault memory“ and confirm

with Q .
Vehicle system test ->
Readout on display:
Fault memory was erased

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Note
If the ignition is switched off during „Interrogating fault
memory“ and „Erasing fault memory“, the fault memory is
not erased.

– Select function 06 „End output“ and confirm with Q .

– Perform a test drive. Then, once again interrogate the
fault memory. No fault must be displayed.

Actuator diagnosis
With the actuator diagnosis the following parts are acti-
vated in the sequence indicated:
1 - Exhaust gas recirculation valve -N18-
2 - AC compressor engagement
3 - Solenoid valve for charge pressure control
-N75-
4 - Changeover valve for intake manifold flap
-N239-
5 - Glow period warning lamp -K29-
6 - Glow plug relay -J52-
7 - Low heat output relay -J359-
8 - High heat output relay -J360-
9 - Fault lamp

Note
♦ Actuation of the individual control elements is limited
to 30 seconds.
♦ If the actuator diagnosis must be repeated without the
engine being started in the meantime, switch off igni-
tion for about 20 seconds.

Special tools, test and measuring equipment and

auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

Test conditions
• Fuses according to current flow diagram O.K.

Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select address word 01 „Engine electronics“
⇒ 01-1 page 2.
– Select function 03 „final control diagnosis“.
Actuator diagnosis ->
Readout on display:
Exhaust gas recirculation valve -N18
The valve must click.

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Note
The clicking of the valve cannot be heard because of the
engine noise and can therefore only be checked.
If the valve does not click:

– Testing Exhaust gas recirculation valve -N18-

⇒ Chap. 23-1.
– Press →.
Actuator diagnosis ->
Readout on display: AC compressor engagement
This test step is also activated on vehicles without AC
system.
Disregard display.

– Press →.
Actuator diagnosis ->
Readout on display: Charge press.control solenoid valve -N75
The valve must click.

Note
The clicking of the valve cannot be heard because of the
engine noise and can therefore only be checked.
If the valve does not click:

– Test charge pressure control solenoid valve -N75 -

⇒ Chap. 23-1.
– Press →.
Actuator diagnosis ->
Readout on display: Intake manif.flap change-over valve-N239
The engine must stop.
If the engine does not stop:

– Switch off ignition.

– Inspecting Intake manifold flap change-over valve
-N239- ⇒ Chap. 23-1.
– Continue final control diagnosis with the engine off
and the ignition switched on.
– Press →.
Actuator diagnosis ->
Readout on display: Glow period warning lamp -K29
The warning light for glow period must flash.
If the warning light for glow period does not flash:

– Testing Glow period warning lamp -K29- ⇒ Current

Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.
– Press →.
Actuator diagnosis ->
Readout on display:
Glow plug relay -J52
The relay must click.

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It is also possible to observe the relay switching on and
off by the interior light becoming brighter or darker
(caused by the high power consumption of glow plugs).
If the relay does not click:

– Test glow plug relay -J52- ⇒ Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
– Press →.
Actuator diagnosis ->
Readout on display: Low heat output relay J359
The relay must click.
If the relay does not click:

– Test low heat output relay -J359- ⇒ Current Flow Di-

agrams, Electrical Fault Finding and Fitting Locations.
– Press →.
Actuator diagnosis ->
Readout on display: High heat output relay -J360
The relay must click.
If the relay does not click:

– Test high heat output relay -J360- ⇒ Current Flow Di-

agrams, Electrical Fault Finding and Fitting Locations.
– Press →.
Actuator diagnosis ->
Readout on display: Fault lamp
The exhaust emission warning lamp must flash.
If the exhaust emission warning lamp does not flash:

– Test exhaust emission warning lamp ⇒ Current Flow

Diagrams, Electrical Fault Finding and Fitting Loca-
tions.
– Press →.
Vehicle system test HELP
Readout on display: Select function XX
– Select function 06 „End output“ and confirm with Q.

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01-2 Self-diagnosis II

Fault codes 515 to 19561

Note
♦ The fault table is ordered according to the 5-digit fault code on the left.
♦ The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only
valid for USA).
♦ Explanations regarding fault types (e.g. „open circuit or short-circuit to earth“) ⇒ Operating instructions for the ve-
hicle system tester.
♦ If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth
connections according to current flow diagram. Only if no fault is detected here should the part be replaced. This
applies in particular if faults are shown as „sporadic“ (SP).
♦ If „Info in literature“ appears in the display of the vehicle system tester - V.A.G 1552- look for the text required in
the fault table under the fault code.

Readout on -V.A.G 1552- Rectifying fault

00515 no signal or sig- – Test camshaft position sensor -G40- ⇒ Current Flow Diagrams,
Hall sensor -G40 nal not within Electrical Fault Finding and Fitting Locations
the tolerance
– Remove open circuit in wiring or short circuit according to current
flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations
– Inspect position of camshaft and rotor ⇒ 1.4/55 TDI Engine, Me-
chanics; Rep. Gr. 15
00671 undefined – Test cruise control system ⇒ Chap. 01-4, display groups 006 and
Cruise control system switch status 022
switch -E45
00741 Implausible sig- – Test brake light switch - F- and brake pedal switch -F47- ⇒ Chap.
Brake pedal monitor- nal 01-4, display group 006
ing
01117 Implausible sig- – Test wiring and generator ⇒ Current Flow Diagrams, Electrical Fault
Load signal for alter- nal Finding and Fitting Locations
nator terminal DF
01193 Open circuit or – Test low heat output relay -J359- with final control diagnosis
Low heat output relay - short circuit to ⇒ Chap. 01-1
J359 earth
01194 Open circuit or – Test high heat output relay -J360- with final control diagnosis
High heat output relay short circuit to ⇒ Chap. 01-1
-J360 earth
01282 Open circuit or – Test intake manifold flap changeover valve -N239- with final control
Intake manifold flap short circuit to diagnosis ⇒ Chap. 01-1
change-over valve - earth
N239
16485 Implausible sig- – Test air mass meter -G70 - ⇒ Chap. 01-4, display group 003
Air mass meter -G70 nal

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Readout on -V.A.G 1552- Rectifying fault

16684 – Inspecting compression pressure ⇒ 1.4/55 TDI Engine, Mechanics;
Combustion misfiring Rep. Gr. 15
detected
– Check unit injector ⇒ Chap. 23-3
16685
Cyl. 1 combustion mis-
firings detected
16686
Cyl. 2 combustion mis-
firings detected
16687
Cyl. 3 combustion mis-
firings detected
16705 Implausible sig- – Inspecting Engine speed sender -G28- ⇒ Chap. 23-1
Engine speed sender - nal
G28
16706 No signal – Inspecting Engine speed sender -G28- ⇒ Chap. 23-1
Engine speed sender -
G28 – Check wiring according to current flow diagram ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
– Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
16725 Implausible sig- – Test camshaft position sensor -G40- ⇒ Current Flow Diagrams,
Camshaft pos. sensor nal Electrical Fault Finding and Fitting Locations
=> Sender -G40
– Remove open circuit in wiring or short circuit according to current
flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations
– Inspect position of camshaft and rotor ⇒ 1.4/55 TDI Engine, Me-
chanics; Rep. Gr. 15
16885 Implausible sig- – Test vehicle speed signal ⇒ Chapter 23-6
Vehicle speed signal nal
16944 Implausible sig- – Test cables to diesel direct injection system control unit - J248- ac-
Voltage supply nal cording to the current flow diagram ⇒ Current Flow Diagrams, Elec-
16946 Voltage too low trical Fault Finding and Fitting Locations
Voltage supply
16947 Voltage too high
Voltage supply
16955 Implausible sig- – Test brake light switch - F- and brake pedal switch -F47- ⇒ Chap.
Brake light switch -F nal 01-4, display group 006
16989 – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
Control unit defective 23-5
17068 Implausible sig- – Test glow plug relay -J52- with final control diagnosis ⇒ Chap. 01-1
Glow period control nal
unit 1
17552 Open circuit or – Test air mass meter -G70- ⇒ Chap. 01-4, display group 003
Air mass meter -G70 short circuit to
earth – Check wiring according to current flow diagram ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
17553 Short circuit to
Air mass meter -G70 positive – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
17554 Supply voltage
Air mass meter -G70

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Readout on -V.A.G 1552- Rectifying fault

17563 Short circuit to – Test intake manifold pressure sender -G71- ⇒ Current Flow Dia-
Intake manifold pres- positive grams, Electrical Fault Finding and Fitting Locations
sure sender -G71
– Check wiring according to current flow diagram ⇒ Current Flow Dia-
17564 Open circuit or grams, Electrical Fault Finding and Fitting Locations
Intake manifold pres- short circuit to
sure sender -G71 earth – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
17565 Supply voltage
Intake manifold pres- – Test charge pressure ⇒ Chap. 01-4, display group 010
sure sender -G71
17568 Short circuit to – Test intake manifold temperature sender -G72- ⇒ Chap. 01-4, dis-
Intake manifold tem- earth play group 007
perature sender -G72
– Check wiring according to current flow diagram ⇒ Current Flow Dia-
17569 Open circuit/ grams, Electrical Fault Finding and Fitting Locations
Intake manifold tem- Short circuit to
perature sender -G72 positive – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
17570 Short circuit to – Test fuel temperature sender -G81- ⇒ Chap. 01-4, display group
Fuel temperature earth 007
sender -G81
– Check wiring according to current flow diagram ⇒ Current Flow Dia-
17571 Open circuit/ grams, Electrical Fault Finding and Fitting Locations
Fuel temperature Short circuit to
sender -G81 positive – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
17663 Open circuit/ – Test coolant temperature sender -G62- ⇒ Chap. 01-4, display group
Coolant temperature Short circuit to 007
sender -G62 positive
– Check wiring according to current flow diagram ⇒ Current Flow Dia-
17664 Short circuit to grams, Electrical Fault Finding and Fitting Locations
Coolant temperature earth
sender -G62 – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
17668 Implausible sig- – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid nal
valve cyl. 1 -N240
17669 Regulating limit
Unit injector solenoid exceeded
valve cyl. 1 -N240
17670 Regulating limit – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid not reached
valve cyl. 1 -N240 – Inspecting fuel supply ⇒ 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 20
17671 Implausible sig- – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid nal
valve cyl. 2 -N241
17672 Regulating limit
Unit injector solenoid exceeded
valve cyl. 2 -N241
17673 Regulating limit – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid not reached
valve cyl. 2 -N241 – Inspecting fuel supply ⇒ 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 20
17674 Implausible sig- – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid nal
valve cyl. 3 -N242
17675 Regulating limit
Unit injector solenoid exceeded
valve cyl. 3 -N242

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Readout on -V.A.G 1552- Rectifying fault

17676 Regulating limit – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid not reached
valve cyl. 3 -N242 – Inspecting fuel supply ⇒ 1.4/55 TDI Engine, Mechanics;
Rep. Gr. 20
17795 – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
Control unit defective 23-5
17810 Short circuit to – Test exhaust gas recirculation valve -N18- with final control diagno-
Exhaust gas recircula- positive sis ⇒ Chap. 01-1
tion valve -N18
– Inspecting exhaust gas recirculation ⇒ Chap. 23-4
17849 Open circuit or
Exhaust gas recircula- short circuit to
tion valve -N18 earth
17910 Short circuit to – Testing fuel pump relay -J17- ⇒ Current Flow Diagrams, Electrical
Fuel pump relay -J17 positive Fault Finding and Fitting Locations
17911 Implausible sig- – Test generator ⇒ Electrical System; Rep. Gr. 27
Load signal for alter- nal
nator terminal DF – Reading measured value block, display group 016 ⇒ Chap. 01-4
17931 Implausible sig- – Perform airbag system self-diagnosis ⇒ Body Fitting Work;
Crash signal from air- nal Rep. Gr. 01
bag CU
17948 Signal too high – Test vehicle speed signal ⇒ Chapter 23-6
Vehicle speed signal
– Test CAN databus lines ⇒ Chapter 23-6
– Test dash panel insert ⇒ Electrical System; Rep. Gr. 90
17954 Short circuit to – Test charge pressure control solenoid valve -N75- with final control
Charge pressure con- positive diagnosis ⇒ Chap. 01-1
trol solenoid valve -
N75
17957 Open circuit or
Charge pressure con- short circuit to
trol solenoid valve - earth
N75
17958 Control differ- – Test charge pressure control solenoid valve - N75- with final control
Charge pressure ence diagnosis ⇒ Chap. 01-1
17964 Regulating limit – Test charge pressure control ⇒ 1.9 l/96 kW (TDI) Engine, Mechani-
Charge pressure con- not reached cal Components; Rep. Gr. 21
trol
17965 Regulating limit
Charge pressure con- exceeded
trol
17977 Implausible sig- – Analyse measured value block, display groups 006 and 022
Cruise control system nal ⇒ Chap. 01-4
switch -E45
– Read out fault memory of the electrical system control unit
⇒ Electrical System; Rep. Gr. 90
17978 – Adapt diesel direct injection system control unit - J248- to electronic
Engine control unit immobiliser ⇒ Electrical System; Rep. Gr. 96
blocked1)
– Test immobiliser ⇒ Electrical System; Rep. Gr. 96
18008 Voltage too low – Test voltage supply for diesel direct injection system control unit
Voltage supply termi- -J248- ⇒ Chap. 23-5
nal 15
18009 Implausible sig- – Test diesel direct injection system relay -J322- ⇒ Current Flow Dia-
Voltage supply relay nal grams, Electrical Fault Finding and Fitting Locations
terminal 30 -J3172)

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Readout on -V.A.G 1552- Rectifying fault

18017 – Read out fault memory of airbag control unit ⇒ Body Fitting Work;
Crash disconnect acti- Rep. Gr. 01
vated
– Replace airbag control unit ⇒ Body Fitting Work; Rep. Gr. 69
18020 Incorrectly cod- – Code diesel direct injection system control unit -J248- ⇒ Chap. 23-5
Engine control unit ed
18024 Short circuit to – Test glow period warning lamp -K29- with final control diagnosis
Glow period warning positive ⇒ Chap. 01-1
lamp -K29
18025 Open circuit/
Glow period warning Short-circuit to
lamp -K29 earth
18026 Short circuit to – Test glow plug relay -J52 - with final control diagnosis ⇒ Chap. 01-1
Glow plug relay -J52 positive
18027 Short circuit to
Glow plug relay -J52 earth
18034 Missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive sage from gear-
box CU
18039 Signal too high – Test accelerator pedal position sender -G79- ⇒ Chap. 01-4, display
Accelerator pedal po- group 002
sition sender -G79
18040 Supply voltage
Accelerator pedal po-
sition sender -G79
18043 Missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive sage from air
conditioning – Read out air conditioning system control unit fault memory
system CU ⇒ Heating, Air conditioning; Rep. Gr. 87
18044 Missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive sage from air-
bag CU – Read out fault memory of airbag CU ⇒ Body Work; Rep. Gr. 01
18045 missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive sage form elec-
tron. CU – Read out fault memory of electrical system control unit ⇒ Electrical
System; Rep. Gr. 90
18047 Implausible sig- – Test accelerator pedal position sender -G79- ⇒ Chap. 01-4, display
1/2 for accelerator nal group 002
pedal position sender -
G79+G185 – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
23-5
18048 – Replace diesel direct injection system control unit -J248 - ⇒ Chap.
Control unit defective 23-5
18056 defective – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive
– Read out fault memory of engine CU ⇒ Chapter 01-1
18057 Missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive sage from ABS
CU – Read out fault memory of ABS control unit ⇒ Running Gear;
Rep. Gr. 45
18058 Missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive sage from com-
biinstrument – Read out fault memory of dash panel insert ⇒ Electrical System;
Rep. Gr. 90
18062 – Perform self-diagnosis of the dash panel insert ⇒ Electrical System;
Read out fault memory Rep. Gr. 90
of combiinstrument

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Readout on -V.A.G 1552- Rectifying fault

18065 Short circuit to – Test AC compressor control with final control diagnosis ⇒ Chap. 01-
Air conditioning sys- positive 1
tem inlet/outlet
18071 Short circuit to – Check unit injector ⇒ Chap. 23-3
Actuation of unit injec- positive
tor solenoid valve
18072 Electrical fault in
Actuation of unit injec- the circuit
tor solenoid valve
18073 Mechanical fault – Replace unit injector ⇒ Chap. 23-2
Actuation of unit injec-
tor solenoid valve
18074 Electrical fault in – Check unit injector ⇒ Chap. 23-3
Unit injector solenoid the circuit
valve cyl. 1 -N240
18075 Electrical fault in
Unit injector solenoid the circuit
valve cyl. 2 -N241
18076 Electrical fault in
Unit injector solenoid the circuit
valve cyl. 3 -N242
18090 implausible – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive message from
ABS CU – Read out fault memory of ABS control unit ⇒ Running Gear;
Rep. Gr. 45
18097 Implausible – Test CAN databus lines ⇒ Chapter 23-6
Data BUS drive message from
electron. CU – Read out fault memory of electrical system control unit ⇒ Electrical
System; Rep. Gr. 90
19456 Missing mes- – Test CAN databus lines ⇒ Chapter 23-6
Glow period warning sage from com-
lamp -K29- biinstrument
19458 Implausible sig- – Test accelerator pedal position sender -G79- ⇒ Chap. 01-4, display
Kick-down switch -F8- nal group 002
19459 Short circuit to – Test low heat output relay -J359 - with final control diagnosis
Low heat output relay - positive ⇒ Chap. 01-1
J359
19461 Short circuit to – Test high heat output relay -J360 - with final control diagnosis
High heat output relay positive ⇒ Chap. 01-1
-J360
19463 No signal – Test camshaft position sensor -G40- ⇒ Current Flow Diagrams,
Camshaft pos. sensor Electrical Fault Finding and Fitting Locations
=> Sender -G40
– Inspect position of camshaft and rotor ⇒ 1.4/55 TDI Engine, Me-
chanics; Rep. Gr. 15

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Readout on -V.A.G 1552- Rectifying fault

19464 Signal outside – Test camshaft position sensor -G40- ⇒ Current Flow Diagrams,
Camshaft pos. sensor tolerance Electrical Fault Finding and Fitting Locations
=> Sender -G40
– Remove open circuit in wiring or short circuit according to current
flow diagram ⇒ Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations
– Inspect position of camshaft and rotor ⇒ 1.4/55 TDI Engine, Me-
chanics; Rep. Gr. 15
19560 Short circuit to – Test intake manifold flap changeover valve -N239- with final control
Intake manifold flap positive diagnosis ⇒ Chap. 01-1
change-over valve -
N239
19561 Open circuit or
Intake manifold flap short circuit to
change-over valve - earth
N239
1) When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated
key the fault is changed to a sporadic fault.
2) Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.

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01-3 Self-diagnosis III

Readiness code

Reading readiness code

Operation
The readiness codes are two 8-digit numerical codes
which indicate the status of the emission-relevant diag-
noses.
If the diagnosis for a system was successfully performed
(e.g. exhaust gas recirculation system), the relevant po-
sition of the numerical code is set from 1 to 0.
This diagnosis is performed at regular intervals during
normal driving. If repairs have been done on a system rel-
evant for the exhaust gas it is recommended to generate
the readiness code as this guarantees that the systems
operate according to the specifications. If a fault is detect-
ed during diagnosis, it is then stored in the fault memory.
The readiness code is erased through deletion of the fault
memory, that is all relevant points will be set to 1.
Generation of readiness code refers to the activation of
the diagnostic functions such as diagnosis of fuel supply,
diagnosis of other systems etc.
Procedure

Special tools, test and measuring equipment and

auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

– Connect vehicle system tester -V.A.G 1552- and se-

lect address word 01 „Engine electronics“ ⇒ Chap.
01-1.
– Select function 08 „Read measured value block“ and
display group number 017. Reading measured value block 17 ->
00000000 00000110 10000000 00000000
Readout on display:

Meaning of 8-digit numerical block for readiness code in display field 2

1 2 3 4 5 6 7 8 Meaning
0 Ignore
1 Ignore
1 Ignore
0 Ignore
0 Ignore
0 Diagnosis of other systems
0 Diagnosis of fuel supply
0 Ignore

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Meaning of 8-digit numerical block for readiness code in display field 4

1 2 3 4 5 6 7 8 Meaning
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Ignore
0 Diagnosis of exhaust gas recirculation system

– If the specified values are not reached, generate read-

iness code ⇒ 01-3 page 2.
– Press → key.
– Select function 06 „End output“ and switch ignition off.

Generating readiness code

Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

Test conditions
• All electrical consumers, e.g. lights and rear window
heater switched off.
• Intake air temperature must be below 60°C ⇒ display
group 007, display field 3.
• Coolant temperature at least 83°C ⇒ display group
007, display block 4.

Procedure
– Connect vehicle system tester -V.A.G 1552-. Select
address word 01 „Engine electronics“ ⇒ Chapter 01-
1.

Note
Certain work steps must be carried out twice, in order to
achieve the readiness code.

Work step 1: Interrogating fault memory

– Select function 0 2 „Interrogate fault memory“ and
confirm with Q .
X faults detected →
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If a fault is stored in the memory:

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– Rectify the faults by referring to the fault table
⇒ Chapter 01-2.
If no fault is stored:

– Press →.

Work step 2: Erasing fault memory

– Select function 0 5 „Erase fault memory“ and con-
firm with Q .

Note
Readiness code is erased each time the fault memory is
erased.
Vehicle system test ->
Readout on display: The fault memory is erased

Note
If the ignition is switched off during „Interrogating fault
memory“ and „Erasing fault memory“, the fault memory is
not erased.

– Press →.

Work step 3: Switch off ignition

– Wait at least 5 seconds with ignition OFF.

Note
This point is important, because with certain diagnoses
the slowing down of the control unit must be ended. Oth-
erwise readiness code cannot be generated.

Work step 4: Switch on ignition

– Wait at least 10 seconds with ignition ON.
Charge pressure sender is adapted to atmospheric pres-
sure sender.

Work step 5: 1. Testing fuel supply and other

systems
– Start engine.
– Function 0 8 „Read measured value block“ and then
select display group 001.
– Increase engine speed for 5 seconds to 2500 rpm and
then run engine at idling speed.
Reading measured value block 1 ->
Readout on display:
2500 rpm 4.6 mg/s 2.0°CA 94.2 °C

Work step 6: 1. Testing exhaust gas recircula-

tion
– Maintain speed constant between 1600 rpm to 1700
rpm for at least 10 seconds.

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Readout on display:
Reading measured value block 1 ->
In this speed range, the exhaust gas recirculation is ac- 1650 rpm 4.1 mg/s 4.0°CA 93.2 °C
tive and the control difference is checked. (Condition for
generation of readiness code for exhaust gas recircula-
tion).

Work step 7: Switch off ignition

– Wait at least 5 seconds with ignition OFF.

Work step 8: Switch on ignition

– Wait at least 10 seconds with ignition ON.

Work step 9: 2. Testing fuel supply and other

systems
– Start engine.
– Function 0 8 „Read measured value block“ and then
select display group 001.
– Increase engine speed for 5 seconds to 2500 rpm and
then run engine at idling speed.
Reading measured value block 1 ->
Readout on display: 2500 rpm 4.6 mg/s 2.0°CA 94.2 °C

Work step 10: 2. Test of exhaust gas recircula-

tion
– Maintain speed constant between 1600 rpm to 1700
rpm for at least 10 seconds.
Reading measured value block 1 ->
Readout on display: 1650 rpm 4.1 mg/s 4.0°CA 93.2 °C
– Press C.

– Select 0 1 7 for display group 017.

Reading measured value block 17 ->
Readout on display: 00000000 00000110 10000000 00000000
Specification in display field 2: 00000110
Specification in display field 4: 00000000

– Press → .
– If the specified values are not reached, once again re-
peat procedure for generating readiness code
⇒ 01-3 page 2.

Work step 11: Interrogating fault memory

– Select function 0 2 „Interrogate fault memory“ and
confirm with Q .
X faults detected →
The number of stored faults or „No fault recognised“ ap-
pears in the display.
If a fault is stored in the memory:

– Rectify the faults by referring to the fault table

⇒ Chapter 01-2 and generate readiness code again
⇒ 01-3 page 2.

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If no fault is stored:

– Press →.
Reading measured value block 17 ->
Readiness code was successfully generated, if no fault is 00000000 00000110 10000000 00000000
stored after two work sequences of the test procedure in
the fault memory for the engine control unit and if the fol-
lowing values are displayed in the display group 017.

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01-4 Self-diagnosis IV

Reading measured value block

Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

Test conditions
• Coolant temperature must be at least 80 °C.
• All electrical consumers, e.g. lights and rear window
heater, must be switched off.
• If vehicle is equipped with air conditioning, this must
be switched off.

Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
confirm the entry with key Q .
– Enter display group ⇒ 01-4 page 1.

Display groups 001 to 022, engine idling

Display group 001 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 1 → < Readout on display

xxx xx.x x.xx xxx.x
rpm mg/s °KW °C
1 2 3 4 < Display field Specification Analysis
Coolant temperature 80.0…110.0 °C ---
Fuel delivery duration (set value) 4...7 °KW ---
Injection rate 3.0…9.0 mg/s ⇒ 01-4 page 1
Idling speed 800…970 rpm ---

Analysis: Display group 001, display field 2 - Injection rate

Display -V.A.G 1552- Rectifying fault

below 3.0 mg/s – Check unit injector ⇒ Chap. 23-3.
above 9.0 mg/s – Warm up engine by running at high revs and repeat test.
– Check unit injector ⇒ Chap. 23-3.

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Display group 002 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 2 → < Readout on display

xxx xxx.x xxx xxx.x
rpm % °C
1 2 3 4 < Display field Specification Analysis
Coolant temperature 80.0…110.0 °C ---
Operating position 010 ⇒ 01-4 page 2
Accelerator pedal position 0.0 % ⇒ 01-4 page 2
Idling speed --- ⇒ 01-4 page 1

Analysis: Display group 002, display field 2 - Accelerator pedal position

Display -V.A.G 1552- Rectifying fault

1…100.0 % – Test accelerator pedal position sender -G79- ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.

Analysis: Display group 002, display field 3 - Op-

erating position

Meaning, if display positions = 1

X X X Operating position
1 Air conditioning switched on
1 Idling switch closed (accelerator pedal
not pressed)
1 Ignore

Display group 003 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 3 → < Readout on display

xxx xxx xxx xxx
rpm mg/s mg/s %
1 2 3 4 < Display field Specification Analysis
On/off ratio (actuation) of 30…80 % ---
exhaust gas recirculation
valve
drawn in air mass (actual) 258...410 mg/s ⇒ 01-4 page 3
drawn in air mass (nominal) 278...390 mg/s ⇒ 01-4 page 3
Idling speed --- ⇒ 01-4 page 1

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Analysis: Display group 003, display field 2 - inducted air mass (set value)

Display -V.A.G 1552- Rectifying fault

above 390 mg/s – Warm up engine by running at high revs and repeat test.

Analysis: Display group 003, display field 3 - inducted air mass (actual value)

Display -V.A.G 1552- Rectifying fault

below 258 mg/s – Test exhaust gas recirculation ⇒ Chap. 23-4.
– Inspect intake system for leaks.
above 410 mg/s – Warm up engine by running at high revs and repeat test.
– Engine idles for too long, briefly blip throttle.
– Test air mass meter -G70- ⇒ Current Flow Diagrams, Electrical Fault Find-
ing and Fitting Locations.

Display group 004 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 4 → < Readout on display

xxx xx.x xx.x xx.x
rpm ° b. TDC °KW °KW
1 2 3 4 < Display field Specification Analysis
Synchronizing angle -3…+3 °KW ⇒ 01-4 page 3
Fuel delivery duration (set value) 4.0…7.0 °KW ---
Commencement of injection (set value) 3…9° b. TDC ⇒ 01-4 page 3
Idling speed --- ⇒ 01-4 page 1

Analysis: Display group 004, display field 2 - commencement of injection (set value)

Display -V.A.G 1552- Rectifying fault

less than 3° BTDC – Engine too cold, warm up engine by running at high revs and repeat test.

Analysis: Display group 004, display field 4 - Synchronizing angle

Display -V.A.G 1552- Rectifying fault

above 3°KW or under -3°KW – Test camshaft position sensor -G40- ⇒ Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
– Inspect position of camshaft and rotor ⇒ 1.4/55 TDI Engine - Mechanics;
Rep. Gr. 15

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Display group 005 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 5 → < Readout on display

xxx xx.x xx.x xxx.x
rpm mg/s ° b. (n.) °C
TDC
1 2 3 4 < Display field Specification Analysis
Coolant temperature 80…110 °C ---
Synchronisation when starting 1 ---
drawn in air mass when starting 9…15 mg/s ---
Idling speed --- ⇒ 01-4 page 1

Display group 006 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 6 → < Readout on display

xxx xxx xx.x xxx
km/h %
1 2 3 4 < Display field Specification Analysis
Operating condition of the xxx ⇒ 01-4 page 4
cruise control system
Accelerator pedal position 0% ⇒ 01-4 page 2
Status of the brake and clutch pedal switch 000 ⇒ 01-4 page 4
Vehicle speed 0 km/h ---

Analysis: Display group 006, display field 2 -

Brake pedal or clutch pedal monitoring

Meaning, if display positions = 1

X X X Operating position
1 Brake light switch -F- closed (brake
pedal operated)
1 Brake pedal switch -F47- opened
(brake pedal operated)
1 Clutch pedal switch -F36- opened
(clutch pedal operated)

Analysis: Display group 006, display field 4 - Op-

erating condition of cruise control system

Dis- Operating position

play
0 Vehicles with activated cruise control system,
switch in position „OFF“
1 Vehicles with activated cruise control system,
switch in position „ON“
255 Vehicle without cruise control system or
cruise control system function in engine con-
trol unit not activated

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Display group 007 with ignition switched on (engine cool and standing)

Read measured value block 7 → < Readout on display

xxx.x xxx xxx.x xxx.x
°C % °C °C
1 2 3 4 < Display field Specification Analysis
Coolant temperature approx. ambient ⇒ 01-4 page 5
temperature 1)
Intake manifold temperature approx. ambient ⇒ 01-4 page 5
temperature 1)
Status of the fuel cooling 0% ---
Fuel temperature approx. ambient ⇒ 01-4 page 5
temperature 1)
1) It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intake
manifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant
sender.

Analysis: Display group 007, display field 1 - Fuel temperature

Display -V.A.G 1552- Rectifying fault

40.5 °C – Inspecting Fuel temperature sender -G81- ⇒ Chap. 23-1.

Analysis: Display group 007, display field 3 - Intake manifold temperature

Display -V.A.G 1552- Rectifying fault

approx. 135.9 °C – Inspecting Intake manifold temperature sender -G72- ⇒ Chap. 23-1.

Analysis: Display group 007, display field 4 - Coolant temperature

Display -V.A.G 1552- Rectifying fault

-5.4 °C – Inspecting coolant temperature sender -G62- ⇒ Chap. 23-1.
In the event of a fault the fuel temperature is displayed instead.

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Display group 010 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 10 → < Readout on display

xxx xxxx xxxx xxx
rpm mbar mbar %
1 2 3 4 < Display field Specification Analysis
Accelerator pedal posi- 0.0 % ⇒ 01-4 page 2
tion
Charge pressure (actual) 900...1150 mbar ---
Atmospheric pressure 900...1100 mbar ---
drawn in air mass (actual) 258...410 mg/s ⇒ 01-4 page 3

Display group 011 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 11 → < Readout on display

xxx xxxx xxxx xx
rpm mbar mbar %
1 2 3 4 < Display field Specification Analysis
On/off ratio (actuation) of 25…95 % ---
solenoid valve for charge
pressure control -N75-
Charge pressure (actual) 900…1150 mbar ---
Charge pressure (nominal) 900…1100 mbar ---
Idling speed --- ⇒ 01-4 page 1

Display group 013 in idle (engine warm, coolant temperature not below 80°C)

Read measured value block 13 → < Readout on display

x.xx x.xx x.xx
mg/s mg/s mg/s
1 2 3 4 < Display field Specification Analysis

Smooth running control - injected -3…+3 mg/s ⇒ 01-4 page 6

quantity cylinder 3
Smooth running control - injected quantity cylin- -3…+3 mg/s ⇒ 01-4 page 6
der 2
Smooth running control - injected quantity cylinder 1 -3…+3 mg/s ⇒ 01-4 page 6

Analysis: Display group 013, display field 1

through 3 - Idle smoothness regulator
♦ The injection system has an idle smoothness regula-
tor. It is possible to detect differences in performance
between individual cylinders (part tolerances, injector

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 01
flow, compression etc.) and to compensate for these
by selectively metering the quantity injected in the
idling speed range.
♦ Differences are detected in the idling speed range on
the basis of the signal supplied by the engine speed
sender which supplies three signals to the control unit
for each crankshaft revolution. If the signals have the
same rhythm, the cylinder have the same output. If a
cylinder has a lower output, the crankshaft will need
more time for the next half crankshaft rotation. As op-
posed to this a high output cylinder will accelerate the
crankshaft to such an extent that it will need less time.
♦ Once the control unit has identified a deviation, the
relevant cylinder will immediately be supplied with a
greater or smaller injection rate until the engine again
runs „smoothly“.
♦ +… mg/s: The relevant cylinder has less output and is
therefore supplied with more fuel.
♦ -… mg/s: The relevant cylinder has more output and
is therefore supplied with less fuel.

Display group 016 in idle

Read measured value block 16 → < Readout on display

xxx % xxxxxxxx xx xx.x V
1 2 3 4 < Display field Specification Analysis
Supply voltage of the en- 13.5…14.5 V ⇒ 01-4 page 8
gine control unit
Heating element control xx ⇒ 01-4 page 8
Auxiliary heating 1x000001 ⇒ 01-4 page 7
Generator capacity 5…95 % ---

Analysis: Display group 016, display field 2 - Auxiliary heating

Meaning, if display positions = 1

X X X X X X X X Additional heating deactivated, because:
1 Coolant temperature greater than 70…80°C or intake air temperature greater
than +5°C
1 Generator defective
1 Battery voltage below 9 V
1 Engine speed less than 800 rpm
1 Engine start within the last 10 seconds
1 Coolant temperature sender -G62- or Intake manifold temperature sender
-G72- defective
1 Ignore
1 Ignore

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Analysis: Display group 016, display field 3 -

Control of the heating elements

Meaning, if display positions = 1

X X Operating position
1 Low heat output relay -J359- on
1 High heat output relay -J360- on

Analysis: Display group 016, display field 4 - supply voltage of engine control unit

Display -V.A.G 1552- Rectifying fault

below 13.5 V – Test generator and battery voltage, charge battery ⇒ Electrical System;
Rep. Gr. 27.
– Increase engine speed slightly for a few minutes and switch off additional
consumers.
– Test supply voltage of engine control unit ⇒ Chap. 23-5.
– Rectify any current drain.
above 14.5 V – Test voltage regulator, replace if necessary ⇒ Electrical System;
Rep. Gr. 27.
– Remove start aid cable or quick charger.

Display group 018 in idle

Read measured value block 18 → < Readout on display

xx xx xx xx
1 2 3 4 < Display field Specification Analysis
Ignore
Unit injector solenoid valve cyl. 3 0 ⇒ 01-4 page 8
Unit injector solenoid valve cyl. 2 0 ⇒ 01-4 page 8
Unit injector solenoid valve cyl. 1 0 ⇒ 01-4 page 8

Analysis: Display group 018, display field 1 through 3 - Display of the conditon of the unit injectors

Display -V.A.G 1552- Rectifying fault

If number instead of zero – Test injector unit ⇒ Chap. 23-3.
– Inspecting fuel supply ⇒ 1.4 ltr./55 TDI Engine, Mechanics; Rep. Gr. 20.

Display group 022, engine idling

Read measured value block 22 → < Readout on display

Self-diagnosis IV Edition 04.04

01-4 page 8 S00.5326.01.20
FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 01

x xxxxxx x x
1 2 3 4 < Display fields Specification Analysis
Operating state of air con- 0 —
ditioning
Operating state of charge pressure —
0
control
Operating state of cruise control xxxxxx ⇒ 01-4 page 9
Operating condition of the cruise control system x ⇒ 01-4 page 9

Analysis: Display group 022, display field 1 - operating state of cruise control system

Operating condition of the cruise control system

0 Vehicle without CCS or CCS function in engine control unit not activated
1 Vehicles with activated CCS, switch in position „OFF“
9 Vehicles with activated CCS, switch in position „ON“

Analysis: Display group 022, display field 2 - op-

erating state of cruise control system

Cruise control Display field 2

Switch B on „ON“ 000011
Switch B on „RES“ 001011
Switch A operated 000111
Switch B to „OFF“ before operating point 000001
Switch B to „OFF“ locked 000000

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01 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

Display groups 004 through 011 at full

load

Note
♦ Accelerate vehicle at full throttle before inspecting.
♦ The measured values must be read off or printed out
once an engine speed of 3000 rpm is reached (2nd
person required).
♦ Pay attention to safety precautions for test drives
⇒ Chapter 23-1.

Display group 004 under full load (test drive in 3rd gear, coolant temperature not below 80°C)

Read measured value block 4 → < Readout on display

xxxx xx.x xx.x x.xx
rpm ° b. TDC °KW °KW
1 2 3 4 < Display field Specification Analysis
Synchronizing angle --- ---
Fuel delivery duration (set value) 17…24 °KW ---
Commencement of injection (set value) 15° BTDC…25° ---
BTDC
Engine speed 2800…3200 rpm ---

Display group 008 under full load (test drive in 3rd gear, coolant temperature not below 80°C)

Read measured value block 8 → < Readout on display

xxxx xx.x xx.x xx.x
rpm mg/s mg/s mg/s
1 2 3 4 < Display field Specification Analysis
Injection rate limit based 45.0…55.0 mg/s ⇒ 01-4 page 11
on drawn in air mass
(smoke prevention)
Injection rate limit based on engine 40.0…49.0 mg/s ⇒ 01-4 page 11
speed (torque limit)
Injection rate (driver's instruction) 60.0…69.0 mg/s ⇒ 01-4 page 10
Engine speed 2800…3200 rpm ⇒ 01-4 page 10

Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)

Display -V.A.G 1552- Rectifying fault

below 60.0 mg/s – Repeat test at full throttle.
– Test accelerator pedal position sender -G79- ⇒ Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations.

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01-4 page 10 S00.5326.01.20
FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 01
Analysis: Display group 008, display field 3 - Injection rate limit over speed (torque limit)

Display -V.A.G 1552- Rectifying fault

below 40.0 mg/s – Read off set value at 3000 rpm.

Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)

Display -V.A.G 1552- Rectifying fault

below 45.0 mg/s – Test air mass meter -G70- ⇒ Current Flow Diagrams, Electrical Fault Find-
ing and Fitting Locations.
– Test exhaust gas recirculation ⇒ Chap. 23-4.

Display group 011 under full load (test drive in 3rd gear coolant temperature not below 80°C)

Read measured value block 11 → < Readout on display

xxxx xxxx xxxx xxx
rpm mbar mbar %
1 2 3 4 < Display field Specification Analysis
On/off ratio (actuation) of 40…95 % ---
solenoid valve for charge
pressure control -N75-
Charge pressure (actual value) 1800…2200 ⇒ 01-4 page 11
mbar
Charge pressure (specified value) 1800…2100 ---
mbar
Engine speed 2800…3200 rpm ---

Analysis: Display group 011, display field 3 - intake manifold temperature (charge pressure)

Display -V.A.G 1552- Rectifying fault

below 1800 mbar or over 2200 – Inspecting charge pressure control ⇒ 1.4/55 TDI Engine, Mechanics;
mbar Rep. Gr. 21.

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01 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

Display group 125 - CAN databus

Display group 125 with ignition switched on

Read measured value block 125 → < Readout on display

ABS 1 Combi 1 Airbag 1
1 2 3 4 < Display field Specification Analysis
Airbag control unit Airbag 1 ⇒ 01-4 page 12
Dash panel insert CU Combi 1 ⇒ 01-4 page 12
ABS control unit ABS 1 ⇒ 01-4 page 12
not assigned --- ---

Analysis: Display group 125, display field 2, 3 or 4

Display -V.A.G 1552- Rectifying fault

0 – Test CAN databus ⇒ Chap. 23-6.

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23

23 – Fuel Formation, Injection

23-1 Diesel Direct Injection

System

Safety measures
Observe the following points to prevent injury to persons
and/or damage to the injection and preheating system:
♦ Disconnect and connect wires of the injection and pre-
heating system and measuring device wires when the
ignition is switched off.
♦ When the battery is disconnected and reconnected,
carry out rework ⇒ Electrical System; Rep. Gr. 27.
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there. If the test and measuring equipment is operated
from the front passenger seat, this can result in inju-
ries to the persons sitting on that seat in the event of
an accident which involves the front passenger airbag
being deployed.

Rules of cleanliness
Pay careful attention to the following rules of cleanliness
when working on the fuel supply or fuel injection systems:
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use
any parts which have been stored unwrapped (e.g. in
tool boxes etc.).
♦ When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.
♦ Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately.
Replace immediately any hoses which have suffered
damage.

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23 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

Overview of fitting locations

Components A through H are not represented in the overview figure.

A - Diesel direct injection system

relay -J322-
T on relay carrier ⇒ Fig. 2 in
23-1 page 3
B - Glow plug relay -J52-
T on relay carrier ⇒ Fig. 2 in
23-1 page 3
C - Low heat output relay -J359-
T on relay carrier ⇒ Fig. 2 in
23-1 page 3
D - High heat output relay -J360-
T on relay carrier ⇒ Fig. 2 in
23-1 page 3
E - Fuel pump relay -J17-
T on relay carrier ⇒ Fig. 2 in
23-1 page 3
F - Accelerator pedal position
sender -G79-
T in footwell on the accelerator
pedal ⇒ Fig. 1 in 23-1
page 3
G - Brake light switch -F- and
Brake pedal switch -F47-
T in footwell on the brake pedal
⇒ Fig. 1 in 23-1 page 3
H - Clutch pedal switch -F36-
T in footwell on the clutch ped-
al ⇒ Fig. 1 in 23-1 page 3
1 - Valve block
T Component parts of the
valve block are:
T change-over valve for intake
manifold flap -N239-, speci-
fied resistance: 25...45 Ω
T Exhaust gas recirculation valve -N18-, specified resistance: 14...20 Ω
T Charge pressure control solenoid valve -N75-, specified resistance: 25...45 Ω
2 - Mechanical exhaust gas recirculation valve
T at the induction pipe with the intake manifold flap
3 - Sender for the coolant temperature -G62-
T Specified resistance ⇒ Fig. 3 in 23-1 page 4
4 - Air mass meter -G70-
5 - Diesel direct injection system control unit -J248-
6 - Fuel temperature sender -G81-
T Specified resistance ⇒ Fig. 4 in 23-1 page 4
7 - Plug connection
T 3-pin, grey
T for engine speed sender -G28-
T 3-pin, black
T for the camshaft position sensor -G40-
8 - Engine speed sender -G28-
T specified resistance between contacts 1 and 2: 450...550 Ω
9 - Camshaft position sensor -G40-

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23
10 - Intake manifold pressure sender -G71- with intake manifold temperature sender - G72-
T Specified resistance ⇒ Fig. 3 in 23-1 page 4
11 - Fuel filter
T repairing ⇒ 1.4/55 TDI Engine, Mechanics; Rep. Gr. 20

Fig. 1: Components in footwell

1 - Clutch pedal switch -F36-
3
2 - Brake light switch -F- and Brake pedal switch -F47-
3 - Accelerator pedal position sender -G79-
2

1
S24-0374

Fig. 2: Relay carrier

1- Fuel pump relay -J17- 1 2 3 4 5
2- Diesel direct injection system relay -J322-
3- Glow plug relay -J52-
4- Low heat output relay -J359-
5- High heat output relay -J360-

S23-0139

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23 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

Fig. 3: Resistance of coolant temperature sender

-G62- and of intake manifold temperature
sender -G72-
The specification in field -A- applies to the temperature
range 0 to 50 °C, specification in field -B- applies to the
temperature range 50 to 100°C.
Read out examples:
♦ The specification for a temperature of 30°C is 1500 to
2000 Ω
♦ The specification for a temperature of 80°C is 275 to
375 Ω

Fig. 4: Resistance of fuel temperature sender -G81-

The specification in field -A- applies to the temperature
range 0 to 65°C, specification in field -B- applies to the
temperature range 65 to 100°C.
Read out examples:
♦ The specification for a temperature of 30°C is 3790 to
4270 Ω
♦ The specification for a temperature of 80°C is 600 to
660 Ω

Disassembling and assembling intake

manifold
The intake manifold flap closes for about 3 seconds after
switching off the engine and then opens again. This re-
duces the switch-off impact.

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23
1 - Intake manifold
2 - O-ring
T replace
3 - Induction pipe
T with mechanical exhaust gas
recirculation valve and intake
manifold flap
4 - Mechanical exhaust gas recir-
culation valve
5 - 10 Nm
6 - Bracket
7 - Vacuum setting element
T For intake manifold flap
8 - 25 Nm
9 - Connection pipe for exhaust
gas recirculation
T to exhaust manifold
10 - Gasket
T replace

Removing and installing air filter

Removing
– Loosen spring strap clamp -1- on the air guide hose
and remove the hose from the air filter.
– Disconnect ventilation hose -2- and the plug on the air 1
mass meter -3-.
– Remove the air deflector -4- from the air filter. 2
– Unscrew the fixing screw -5- from the air filter (tighten-
ing torque: 8 Nm).
3 5
– Carefully remove air filter from the top. 4

Installing

Note S23-0125

Pay attention to correct positioning of the stop buffer on

the bottom part of the air filter (front and rear side).

– Installation is carried out in the reverse order.

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23 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

Disassembling and assembling the air filter

1 - Air guide hose
T to induction pipe at intake
manifold
T Check fitting position
2 - Spring strap clip
3 - 2 Nm
4 - Top part of air filter cover
5 - Filter insert
6 - Bottom part of the air filter
cover
7 - Air deflector
T to the lock carrier
8 - Air mass meter -G70-

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23

23-2 Disassembling and as-

sembling the unit injector

Summary of components

Note
♦ Observe the rules for cleanliness ⇒ Chapter 23-1.
♦ Always replace heat-protection seals and O-rings.
♦ Always replace screws tightened to turning angle.

1 - 20 Nm + torque a further 1/4

turn (90 °)
T replace
2 - Valve-lever shaft
T with valve levers
T removing and installing
⇒ 23-2 page 3
3 - Lock nut, 30 Nm
4 - Adjusting screw
T pay attention to different ver-
sion
T replace when replacing the
unit injector and where wear
marks are visible
T Grease the contact surfaces
of the unit injector to ball pins
using grease -G 000 100-
5 - Ball pin
T pay attention to different ver-
sion
6 - Unit injector
T pay attention to different ver-
sion
T removing and installing
⇒ 23-2 page 3
T Check ball pins for wear
marks and replace if neces-
sary
T Grease the contact surface
to the adjusting screw using
grease -G 000 100-
T Valve resistance: Nominal
value approx. 0.5 Ω when
measuring directly at the valve, when measuring via the 8-pin plug connection at the cylinder head 0.8 ... 1.0 Ω
7 - Top O-ring
T replace ⇒ 23-2 page 2
8 - Centre O-ring
T replace ⇒ 23-2 page 2
9 - Bottom O-ring
T replace ⇒ 23-2 page 2
10 - Heat-protection seal
T replace
11 - Circlip
12 - Cylinder head

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23 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

13 - Clamping pad
14 - 12 Nm + torque a further 3/4 turn (270°)
T replace

Removing and installing O-rings for unit

injector
Special tools, test and measuring equipment and
auxiliary items required
♦ Assembling sleeves -T10056-

Removing
– Lever off the old O-rings from the slots of the unit in-
jector with extreme care.
– Make sure, above all, that the seating surfaces in the
slots of the O-rings are not damaged.

Installing

Note
♦ Always use the assembly sleeves to install the O-
rings. Otherwise there is the danger of damaging the
O-rings.
♦ Observe the correct allocation of the O-rings to the
channels: the ring thickness reduces in the direction of
the injection nozzle.
♦ Avoid rolling the O-rings when sliding them on. The O-
rings must not be turned inwards on the slots of the
unitinjector.

– Remove the heat-protection seal along with the circlip.

– Clean the seating surfaces for the O-rings in the unit
injector with great care.
– Insert the assembling sleeve -T10056/1- on the unit
injector up to the stop.
– Carefully slide the top O-ring onto the assembling
sleeve and into the groove of the unit injector.
– Remove assembly sleeve.
– Insert the assembling sleeve -T10056/2- on the unit
injector up to the stop.
– Carefully slide the middle O-ring onto the assembling
sleeve and in the groove of the unit injector.
– Remove assembly sleeve.

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23
– Insert the assembling sleeve -T10056/3- on the unit
injector up to the stop.
– Carefully slide the lower O-ring onto the assembling
sleeve and in the groove of the unit injector.
– Remove assembly sleeve.
– Slide on a new heat-protection seal together with the
circlip.

Removing and installing the unit injector

Special tools, test and measuring equipment and
auxiliary items required
♦ Extractor -T10055-
♦ Universal dial gauge holder -MP 3-447-
♦ Dial gauge
♦ Torque wrench

Note
On vehicles with WIV the adjusting screw -1- and the ball
pin -2- was changed On old engines with WIV, both vari-
ants can be combined.

Removing
– Remove upper timing belt cover and cylinder head
cover ⇒ 1.4/55 TDI Engine, Mechanics; Rep. Gr. 15.
– Rotate the crankshaft approx. in the TDC cylinder 1,
while doing so all valve levers must point upwards
evenly.
– Release the counternuts of the adjusting screws -1-
and unscrew the adjusting screws until the relevant
valve lever rests against the tappet spring of the unit
injector.
– Screw out fixing screws -2- for the valve-lever shaft
from the outside to the inside and remove the valve-
lever shaft.
– Separate plug connection at the removed unit injector.
Support the opposite side of the connector with your
finger in order to avoid twisting the connector.
– Screw out fixing screw -3- of the clamping pad and re-
move the pad in the direction towards the camshaft.

Note
When removing all unit injectors turn the engine so that
the outlet cam for cylinder 1 (the first one from the belt
pulley side) points with the tip upwards. All three clamp-
ing pads can be removed in this position.

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23 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

– Insert the extractor -T10055- instead of the clamping

pad in the slot of the unit injector.
– Remove the unit injector through movements of the
sleeve at the nut up to the stop in -direction of arrow-.

Note
Do not interchange the unit injectors, if necessary mark
the assignment to each cylinder.

Installing

Note
♦ The associated adjusting screw in the valve-lever
should be replaced when a new unit injector is being
installed.
♦ For any work procedure involving an adjustment of the
unit injector it is necessary to clean the adjusting
screw in the valve lever and also the ball pin of the unit
injector and to check them for traces of wear. If there
is any wear replace the ball pin and the adjusting
screw.
♦ Grease the contact surfaces between the ball pin and
the adjusting screw using -G 000 100-.
♦ New unit injectors are supplied with O-rings and heat-
protection seal.
♦ Before installing again the original unit injector, O-
rings, heat-protection seal and circlip must be re-
placed.

– Before installing the unit injector check the correct po-

sition of the three O-rings, heat-protection seal and
the circlip.

Note
The O-rings must not be twisted.

– Oil the O-rings and place the unit injector with the
greatest of care into the cylinder head.
– Slide the unit injector into the cylinder head seat up to
the stop by exerting a uniform pressure.
– Place the clamping pad in the side slot of the unit in-
jector.

Note
If the unit injector is not perpendicular to the clamping pad
the fixing screw may loosen and cause damage to the
unit injector or cylinder head.

– Align the unit injector as follows:

– Screw the clamping pad with the new fixing screw until
the unit injector can still easily be turned.
– Set the unit injector at a right angle to the bearing shell
of the camshaft.

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23-2 page 4 S00.5326.01.20
FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23
– Using a caliper gauge, check dimension -a- from the
outer side of the cylinder head to the cylinder surface
of the solenoid valve for the unit injector.
Removing and installing the unit injector with the old
solenoid valve nut

Cylinder Dimension -a-

1 244.2 ± 0.8 mm
2 156.2 ± 0.8 mm
3 64.8 ± 0.8 mm

Removing and installing the unit injector with the

new solenoid valve nut

Cylinder Dimension -a-

1 245.0 ± 0.8 mm
2 157.0 ± 0.8 mm
3 65.6 ± 0.8 mm

– Adjust the unit injector as required, tighten the fixing

screw using a torque of 12 Nm and then turn through
a further 270° (3/4 of a turn). Tightening may occur in
successive stages.
– Mount valve-lever shaft and tighten up the new fixing
screws as follows.
– First tighten the inside screws and then the two out-
side screws by hand. In the same sequence tighten to
20 Nm and turn a further 90° (1/4 turn).
– Place a dial gauge on the adjusting screw of the unit
injector.
– Turn the crankshaft in the running direction of the en-
gine until the roller of the valve lever is on the drive
cam tip.
♦ Roller side -arrow A- is on the highest point.
♦ Dial gauge -arrow B- is on the lowest point.

Edition 04.04 Disassembling and assembling the unit injector 23-2 page 5
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23 FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection

– Remove the dial gauge.

– Turn the adjusting screw in the valve lever until one
feels a significant resistance (the unit injector is
against the stop).
– Turn the adjusting screw in the opposite direction from
the stop by about 225 ° (5/8 turn)
– Firmly hold the adjusting screw in this position and
tighten up the lock nut using a torque of 30 Nm.
– Place connector onto the unit injector, install the cylin-
der head cover and insert the upper timing belt cover.

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23

23-3 Testing components

Test wiring and components with Test

box -V.A.G 1598/31-
⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23

Test diesel direct injection system relay

-J322-
The power supply of the injection system occurs via the
diesel direct injection system relay - J322-. The precondi-
tion for closing of the relay is a voltage supply via terminal
15 to the diesel direct injection system control unit -J248-.
This means that diesel direct injection system relay
-J322- receives ground (via the Diesel direct injection
system control unit -J248-), if the control unit -J248- re-
ceives a voltage supply via terminal 15.

Fitting location
The diesel direct injection system relay - J322- is located
on the relay carrier in the driver's footwell on the left, relay
base 12.
1 2 3 4
Special tools, test and measuring equipment and
auxiliary items required
♦ Hand multimeter (e.g. -V.A.G 1526 A-) 5 6 7 8 9
♦ Adapter cable set (e.g. -V.A.G 1594 C-)
♦ Test box -V.A.G 1598/31-
10 11 12 13 14 15
Test conditions
• Battery voltage at least 11.5 volts
S97-1373
• Fuses in fuse holder on battery are O.K.

Check for proper operation

– Remove lower part of the dash panel insert on the
driver's side ⇒ Body work; Rep. Gr. 70.
– Switch on ignition.
Diesel direct injection system relay -J322 - must close.

Note
The clicking of the relay is hardly audible and can there-
fore best be felt.
If the relay does not close:

Test control
– Switch off ignition.
– Connect test box -V.A.G 1598/31 - to wiring loom to
engine control unit ⇒ 23-3 page 1.

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– Interconnect bush 18 and bush 4 of the test box using

an auxiliary line.
The relay must be closed.
If the relay is now closed but did not open during the func-
tional test:

– Replace diesel direct injection system control unit

- J248- ⇒ Chapter 23-5.
If the relay does not close:

– Pull diesel direct injection system relay -J322- out of

the relay carrier. 2
– Connect handheld multimeter for voltage measure-
ment to contact 2 and earth. 9 6
Specified value: approx. battery voltage
If the specified value is not reached:

– Testing the wiring ⇒ Current Flow Diagrams, Electri-

cal Fault Finding and Fitting Locations.
If the specified value is reached: S23-0101

– Switch off ignition.

– Check the following wire for interruption or short-cir-
cuit to earth or positive:

Contact Test box

- V.A.G 1598/31- 2
contact
9 18
9 6

– If necessary eliminate wire interruption or short-circuit.

If wiring is o.k.:

– Replace the diesel direct injection system relay

- J322-. S23-0101

Testing unit injector valve

⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23

Testing components Edition 07.03

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23

23-4 Testing exhaust gas recir-

culation

Connect vacuum hoses at valve block

1- Connection air filter/exhaust turbocharger
2- to vacuum reservoir at exhaust turbocharger
3- To turbocharger
4- To intake manifold flap
5- To air filter
6- from non-return valve for brake servo unit
7- to mechanical exhaust gas recirculation valve

Testing exhaust gas recirculation

Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

Test sequence
The exhaust gas recirculation function is checked in func-
tion 04 (basic setting). As a result of this procedure the
exhaust gas recirculation valve is pulsed every 10 sec-
onds, so that the extreme values for the exhaust gas re-
circulation (air mass meter) can be read off in measured
value block 003 in display field 3.

– Connect vehicle system tester -V.A.G 1552-. Start en-

gine and select address word 01 „Engine electronics“
⇒ Chapter 01-1.
– Enter function 04 „basic setting“ and select display
group number 003.

Note
After selecting display group number 003 and confirming
with Q , the idling speed is increased by the engine con-
trol unit in display field 1 to 1380…1420 rpm. System in basic setting 3 ->
1400 rpm EGRn.active 500 mg/s 20
The display in display field 2 must switch between
EGRn.active and EGR.active every 10 seconds.
The following readouts must fluctuate in display fields 3
and 4:

Note
If a constant value of 539 mg/stroke and higher is shown
in display field 3, test the air mass meter ⇒ Chapter 23-3.

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EGRn.active:
Specification in display field 3: 450…600 mg/H
specified value in display field 4: 18…22 %
EGRactive.
Specification in display field 3: 160…310 mg/H
specified value in display field 4: 63…67 %

If the specified values are not reached:

– Inspecting mechanical exhaust gas recirculation valve

⇒ 1.4/55 TDI Engine, Mechanics; Rep. Gr. 26.
– Inspect the connection diagram for the vacuum hoses
⇒ 23-4 page 1.
– Test exhaust gas recirculation valve -N18- with final
control diagnosis ⇒ Chap. 01-1.

Testing exhaust gas recirculation Edition 07.03

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23

23-5 Engine control unit

Testing voltage supply for engine con-

trol unit
⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23

Replacing diesel direct injection system

control unit -J248-
Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
045906019BM 1.4l R3 EDC G000SG 4958 ->
The vehicle system tester -V.A.G 1552- displays the con- Coding 00008 WSC XXXXX
trol unit identification, e. g.:

– Note Part No. of control unit and coding.

– Select function 06 „End output“ and confirm with Q .
– Switch off ignition.
– Remove air filter ⇒ Chap. 23-1.
– Release the connector catches and unplug the con-
nectors of the diesel direct injection control unit
- J248-.
– Press off the clips -arrows- to the outside and remove
the control unit to the side.
– Insert new engine control unit.
After installing the diesel direct injection system control
unit -J248-, it is then necessary to carry out the following
steps:

– Coding new diesel direct injection system control unit

-J248- ⇒ 23-5 page 2.
– Adapt the new diesel direct injection system control
unit -J248- to the immobiliser control unit ⇒ Electrical
System; Rep. Gr. 96.
For vehicles with cruise control system: S24-0373

– Activate CCS function ⇒ 23-5 page 3.

– Interrogate fault memory of new engine control unit,
rectify any faults present and erase fault memory
⇒ Chap. 01-1.
– Each time the fault memory is erased, it is then neces-
sary to re-generate the readiness code ⇒ Chapter 01-
3.
– Perform a test drive.

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Note
Comply with the applicable safety instructions during the
test drive ⇒ Chap. 23-1.

– Once again interrogate the fault memory of the diesel

direct injection system control unit -J248-.

Coding diesel direct injection system

control unit -J248-
If the code displayed does not match the vehicle or if the
diesel direct injection system control unit -J248- has been
replaced, it is then necessary to code the control unit as
follows.

Special tools, test and measuring equipment and

auxiliary items required
♦ Vehicle system tester -V.A.G 1552-
♦ Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-

Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
– Select function 07 „coding control unit“.
Coding control unit
Readout on display:
Enter code number xxxxx (0 -32767)
– Enter code number by referring to table of codes and
confirm with Q .
Table of codes:

Control unit identification Equipment Code number

045 906 019 BM ABS/Air conditioning/ WIV/ Airbags 00002
ABS/ WIV/ Airbags 00005
Air conditioning/ WIV/ Airbags 00008
WIV/ Airbags 00011
ABS/Air conditioning/ WIV 00014
ABS/ WIV 00017
Air conditioning/ WIV 00020
WIV 00023
ABS/ Air conditioning/ Airbags 00102
ABS/ Airbags 00105
Air conditioning/ Airbags 00108
Airbags 00111
ABS/ Air conditioning 00114
ABS 00117
Air Conditioning 00120
without ABS/ without Air conditioning/ without WIV/ 00123
without Airbags

Engine control unit Edition 04.04

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23
The vehicle system tester -V.A.G 1552- displays the con-
045906019BM 1.4l R3 EDC G000SG 4958 ->
trol unit identification, e. g.: Coding 00005 WSC XXXXX
– Select function 06 „End output“ and confirm with Q.
– Switch ignition off and on again.

Note
The entered coding is activated by switching the ignition
on and off again.

Activating and deactivating cruise con-

trol system (CCS)
Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-

Test condition
• No fault in fault memory, interrogating fault memory
⇒ Chap. 01-1

Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
045906019BM 1.4l R3 EDC G000SG 4958 ->
Readout on display, e.g.: Coding 00008 WSC XXXXX
If „G000SG“ is displayed, the cruise control system is ac-
tive.
045906019BM 1.4l R3 EDC 000SG 4958 ->
Readout on display: Coding 00008 WSC XXXXX
If „000SG“ is displayed, the cruise control system is not
active.

– Press → .
– Select function 11 „login procedure“.
Login procedure
Readout on display: Enter code number XXXXX
– Enter code number as stated in the table.

Code number Cruise control system (CCS)

11463 Activate CCS
16167 Deactivate CCS

– Confirm with Q.

– Select function 06 „End output“ and confirm with Q.

After activating the cruise control system perform a test

drive as a functional test.

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Engine control unit Edition 04.04

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 23

23-6 Testing auxiliary signals

⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23

Edition 07.03 Testing auxiliary signals 23-6 page 1

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Testing auxiliary signals Edition 07.03

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FABIA 2000 ³ 1.4/55 TDI Engine, Fuel Injection 28

28 – Glow Plug System

28-1 Testing preheating sys-

tem
⇒ 1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 28

Edition 07.03 Testing preheating system 28-1 page 1

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Testing preheating system Edition 07.03

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