manual fabia- asy

Service

5

Workshop ManualFABIA 2000Edition 08.99Engine code

1.9/47 SDI Engine, Fuel InjectionASY

Service Department. Technical Information

Printed in Czech Republic S00.5312.00.20

5

Service

The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.

Printed in Czech Republic S00.5312.00.20

FABIA 2000

1.9/47 SDI Engine, Fuel Injection

List of Supplements to Workshop Manual

FABIA 20001.9/47 SDI Engine, Fuel InjectionEdition 08.99Supplement 1 2

Edition 08.99 06.00 12.03

Subject Basic Edition Supplement to Basic Edition Modifications in Rep. Gr. 01, 23

Article Number S00.5312.00.20 S00.5312.01.20 S00.5312.02.20

Edition 12.03 S00.5312.02.20

List of Supplements

FABIA 2000


List of Supplements

Edition 12.03 S00.5312.02.20

FABIA 2000


Table of Contents01 Self-diagnosisSelf-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics .............................................................................................. 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Performing actuator diagnosis ....................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault table .............................................................................................. 01-2 Self-diagnosis III ........................................................................................ 01-3 - Readiness code ........................................................................................ 01-3 - Reading readiness code .............................................................................. 01-3 - Generating readiness code .......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Reading measured value block ..................................................................... 01-4 - Display groups 000 through 019 in idle ............................................................ 01-4 - Display groups 000 through 008 under full load .................................................. 01-4 - Display group 125 CAN databus .................................................................... 01-4 page page page page page page page page page page page page page page page 1 1 1 2 3 5 1 1 1 1 1 2 1 1 1

page 10 page 12

23 Fuel Formation, InjectionDiesel Direct Injection System ...................................................................... 23-1 - Safety measures ...................................................................................... 23-1 - Cleanliness rules ...................................................................................... 23-1 - Overview of fitting location ........................................................................... 23-1 - Disassembling and assembling intake manifold .................................................. 23-1 - Disassembling and assembling the air filter ....................................................... 23-1 - Removing and installing air filter .................................................................... 23-1 - Removing and installing and testing the injection nozzles ...................................... 23-1 Disassembling and assembling the injection pump ........................................... 23-2 - Summary of components ............................................................................. 23-2 - Removing and installing injection pump ........................................................... 23-2 Testing components ................................................................................... 23-3 - Testing lines and components with test box -V.A.G 1598/31- .................................. 23-3 - Testing Diesel direct injection system relay -J322- .............................................. 23-3 - Testing Coolant temperature sender -G62- ....................................................... 23-3 - Testing Intake manifold temperature sender -G72- .............................................. 23-3 - Testing Engine speed sender -G28- ............................................................... 23-3 - Testing Intake manifold flap motor -V157- ......................................................... 23-3 - Testing Accelerator pedal position sender -G79- ................................................ 23-3 Testing injection control .............................................................................. 23-4 - Dynamically testing and setting the commencement of injection .............................. 23-4 - Inspecting the injection-timing range ............................................................... 23-4 - Testing Fuel shut-off valve -N109- .................................................................. 23-4 - Testing Commencement of injection valve -N108- ............................................... 23-4 page page page page page page page page page page page page page page page page page page page page page page page page 1 1 1 2 4 5 5 6 1 1 2 1 1 1 3 4 6 7 8 1 1 3 4 5

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I

FABIA 2000

1.9/47 SDI Engine, Fuel Injection page page page page page page page page page page page page page page page page page page page 6 8 9 1 1 1 2 1 1 2 3 5 1 1 2 3 5 7 8

- Testing Fuel temperature sender -G81- ........................................................... 23-4 - Testing Needle lift sender -G80- ................................................................... 23-4 - Testing Modulating piston movement sender -G149- and Metering adjuster -N146- ....... 23-4 Exhaust gas recirculation system .................................................................. 23-5 - Piping diagram for exhaust gas recirculation ..................................................... 23-5 - Testing exhaust gas recirculation ................................................................... 23-5 - Testing Exhaust gas recirculation valve -N18- .................................................... 23-5 Engine control unit .................................................................................... 23-6 - Test power supply for engine control unit ......................................................... 23-6 - Replacing diesel direct injection system control unit -J248- .................................... 23-6 - Coding diesel direct injection system control unit -J248- ........................................ 23-6 - Activating and deactivating cruise control system (CCS) ....................................... 23-6 Testing auxiliary signals ............................................................................. 23-7 - Testing signals from the air conditioning system ................................................. 23-7 - Testing the speed signal ............................................................................. 23-7 - Testing Brake light switch -F- and Brake pedal switch -F47- ................................... 23-7 - Testing clutch pedal switch -F36- ................................................................... 23-7 - Checking the data BUS .............................................................................. 23-7 - Testing cruise control system ....................................................................... 23-7

28 Glow Plug SystemTesting preheating system ........................................................................... 28-1 - Inspect proper operation ............................................................................. 28-1 - Checking glow plugs .................................................................................. 28-1 page page page 1 1 2

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Table of Contents

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01

01 Self-diagnosis01-1 Self-diagnosis I

Properties of the self-diagnosisThe control unit for the diesel direct injection system is equipped with a fault memory. The fault memory is designed as a permanent memory. If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication of the fault type. Faults which occur only temporarily (sporadically) are displayed with the suffix SP. Possible causes of sporadic faults are e.g. a loose contact or a momentary line interruption. If a sporadic fault no longer occurs 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 vehicle system tester -V.A.G 1552-, with the fault read-out scan tool -V.A.G 1551- or with vehicle diagnosis, measurement and informations system -VAS 5051- 01-1 page 2. After the fault(s) has(have) been removed the fault memory 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-diagnosisInterrogating control unit versionThe control unit version is displayed once the vehicle system 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 system tester -V.A.G 1552The conditions under which the desired functions can be selected are given in the following table.

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Self-diagnosis I

01-1 page 1

01

FABIA 2000


Precondition Operation 01 02 03 04 05 06 07 08 111)

Engine not running, ignition switched on yes yes1) yes no yes yes yes yes yes

Engine idling yes yes yes yes yes yes no yes no

Normal driving yes yes no no yes yes no yes no

Interrogating control unit version Interrogating fault memory Actuator diagnosis Initiating basic setting Erasing fault memory Ending output Coding control unit Reading measured value block Login procedure

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 electronicsSpecial 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.ProcedureThe diagnostic connection is located on the left next to the storage compartment on the driver's side.

Unclip cover and remove downward. Connect vehicle system tester -V.A.G 1552- with diagnostic cable. Once the vehicle system tester has been connected:

Ignition must be switched on or engine must be start-

ed depending on the function desired 01-1 page 1.

V.A.G 1552 V.A.G 1551/3S01-0087

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01

Note If data transfer errors are displayed as a result of an

incorrect entry, disconnect cable at vehicle system tester, connect it in again and repeat all the steps. If one of the following messages appears in the dis-

play, carry out fault finding as specified in the fault finding program diagnostic cable. Current flow diagrams, fault finding electrical system, fitting locations or operating instructions of the vehicle system tester.

Vehicle system test The control unit does not respond

HELP

Vehicle system test Fault in communication build-up Vehicle system test K cable does not connect to earth

HELP

HELP

Operate the vehicle system tester by referring to theread-out on the display: Readout on display:

Vehicle system test HELP K cable does not connect to pos. term. Vehicle system test Enter address word XX HELP

Enter the address word

0 1 and exit with Q . 038906012AN 1.9l R4 Coding 00002 EDC G00SG 2901 -> WSC XXXXX

The vehicle system tester -V.A.G 1552- displays the control unit identification, e. g.: 038906012AN = Part No. of the control unit (for cur-

rent control unit version see spare parts catalogue) 1.9 ltr. = engine displacement R4 = engine version (4 cyl. in-line engine) EDC = Injection system (Electronic Diesel Control) CC = Cruise control system activated (only on models

with CCS) 00 = Control unit mapping GB = gearbox; AG = automatic gearbox 1) 2901 = Data status (Software version of the control

unit) Coding 00002 = Coding variant of the control unit WSC XXXXX = Workshop code

Press

. Vehicle system test Select function XX HELP

Readout on display:

Further procedure, see repair sequences.

Interrogating and erasing fault memorySpecial 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-

1)

Not available at present

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Self-diagnosis I

01-1 page 3

01Interrogating fault memory

FABIA 2000


Connect vehicle system tester -V.A.G 1552-. Start engine and enter address word 01 engine electronics 01-1 page 2. Only if the engine does not start:

Switch off ignition. Enter0 2 for the function Interrogate fault memory and confirm with Q . X faults detected

The number of stored faults or No fault recognised! appears in the display. If no fault is stored:

Enter function 06 End output and confirm withIf one or several faults are stored:

Q.

Press Press Press

. Source of interference: 17653 Needle lift sender -G80 Short circuit to earth -> P1245 ->

Readout on display, e.g.:.

Fault source and fault type appear in the display, e.g.:.

The stored faults are displayed in sequence.

Enter function 06 End output and confirm with Q . Rectify the faults displayed by referring to the fault table Chapter 01-2. Note During testing and installation other control units may also detect faults, e.g. pulled-out connectors. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:

Enter twice

0 for address word Automatic test se-

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

Erasing fault memoryTest condition

Fault eliminated Fault memory interrogated 01-1 page 4Note After fault elimination the fault memory must again be interrogated and subsequently erased.

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Self-diagnosis I

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1.9/47 SDI Engine, Fuel Injection0 5 Erase fault memory and confirm Vehicle system test Fault memory erased! ->

01

Enter functionwith Q .

Readout on display: Note If the ignition is switched off between Interrogate fault memory and Erase fault memory, the fault memory is not erased.

Enter function 06 End output and confirm with Q . Perform a test drive. Then, again interrogate the faultmemory. No fault must be displayed.

Performing actuator diagnosisWith the actuator diagnosis the following parts are activated in the sequence indicated: 1. Commencement of injection valve -N1082. Exhaust gas recirculation solenoid valve -N183. AC compressor engagement 4. Intake manifold flap motor -V1575. Fuel shut-off valve -N1096. Glow plug relay -J527. Glow period warning lamp -K298. Low heat output relay -J3599. High heat output relay -J36010. Fault lamp Note The control of the individual actuators is limited to 30 s, however this can be extended by pressing and on vehicle system tester -V.A.G 1552-. If the actuator diagnosis must be repeated without the

engine being started in the meantime, switch off ignition 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-

Procedure

Connect vehicle system tester -V.A.G 1552-. Start engine and enter address word 01 engine electronics 01-1 page 2.

Enter function 03 Final control diagnosis.Readout on display:Actuator diagnosis -> Commencement of injection valve -N108

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Self-diagnosis I

01-1 page 5

01The valve control produces and audible change in the combustion sound (knocking sound). If no difference in sound can be heard:

FABIA 2000


Inspecting the injection-timing range Chap. 23-4. Press. Actuator diagnosis Exhaust gas recirculation valve -N18 ->

Readout on display: 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:

Inspecting exhaust gas recirculation solenoid valve-N18- Chap. 23-5.. Actuator diagnosis AC compressor engagement ->

Press

Readout on display: This test step is also activated on vehicles without AC system.

Disregard display. Press. Actuator diagnosis Intake manifold flap motor -V157 ->

Readout on display: Activating the Intake manifold flap motor -V157- generates differences in the combustion sound (the control motor opens and closes the intake manifold flap). If no difference in combustion sound can be heard:

Inspecting Intake manifold flap motor -V157- Chap.23-3.

Press

. Actuator diagnosis Fuel shut-off valve -N109 ->

Readout on display: The engine must stop. If the engine does not stop:

Switch off ignition. Unscrew fuel shut-off valve -N109- and remove possible swarf and dirt.

Repeat final control diagnosis. If the engine still does Continue final control diagnosis with the engine offand the ignition switched on.

not stop, test fuel shut-off valve -N109- Chap. 23-4.

Press

. Actuator diagnosis Glow plug relay -J52 ->

Readout on display: The relay must click. The activation and de-activation of the relay can be observed indirectly. Because of the high consumption of the

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Self-diagnosis I

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01

glow plugs, on the brightening and dimming of the interior lighting. If the relay does not click:

Testing Glow plug relay -J52- Current Flow Diagrams, Fault Finding Electrics, Fitting Locations.

Press

. Actuator diagnosis Glow period warning lamp -K29 ->

Readout on display: The warning light for glow period must flash. If the warning light for glow period does not flash:

Testing Glow period warning lamp - K29- CurrentFlow Diagrams, Fault Finding Electrics, Fitting Locations.

Press

. Actuator diagnosis Low heat output relay -J359 ->

Readout on display: The relay must click. If the relay does not click:

Testing Low heat output relay -J359- Current FlowDiagrams, Fault Finding Electrics, Fitting Locations.

Press

. Actuator diagnosis High heat output relay -> -J360

Readout on display: The relay for high heat output must click. If the relay does not click:

Testing High heat output relay -J360- Current FlowDiagrams, Fault Finding Electrics, Fitting Locations.

Press

. Actuator diagnosis Fault lamp ->

Readout on display: The fault lamp must flash. If the fault lamp does not flash:

Test fault lamp Current Flow Diagrams, ElectricalFault Finding, Fitting Locations.

Press

. Vehicle system test Select function XX Q. HELP

Readout on display:

Enter function 06 End output and confirm with

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01

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01-1 page 8

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01

01-2

Self-diagnosis II

Fault tableNote 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 on fault types (e.g. interruption/short-circuit to earth) Operating instructions of vehicle system

tester. If parts are output as faulty: First check the cables and connectors to these parts as well as the earth leads of the

system by referring to the current diagram. Replace component only if these tests do not reveal any fault. This applies in particular for faults that are output as sporadically occurred (SP) faults. 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 according to the fault code indicated. Display -V.A.G 155216705 Engine speed sender -G28 Implausible signal Possible cause of fault Engine speed send-

Possible effects Engine does not start Engine stalls Glow period warning

Rectifying fault

er - G28- supplies implausible signal caused by loose contact or corrosion due to humidity in the connector. Distance between

Inspecting Enginespeed sender -G28 Chap. 23-3

lamp -K29- flashes No display on rev

counter

engine speed sender/flywheel too great Metallic swarf on en-

gine speed sender -G2816706 Engine speed sender -G28 No signal Engine speed send-

er -G28- defective Line interruption or

Inspecting Enginespeed sender -G28 Chap. 23-3

short-circuit Metallic swarf on en-

gine speed sender -G28 Signal input in Diesel

direct injection system control unit -J248- defective (control unit defective)

Replace diesel directinjection system control unit -J248 Chap. 23-6

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Self-diagnosis II

01-2 page 1

01Display -V.A.G 155216885 Vehicle speed signal Implausible signal Possible cause of fault Speedometer sender

FABIA 2000 Possible effects

1.9/47 SDI Engine, Fuel Injection Rectifying fault

Speed display NOK Cruise control system

-G22- defective Line interruption or

Test vehicle speed

not operational Vehicle jerks when

signal Chapter 237

short-circuit between Speedometer sender -G22- and dash panel insert Line interruption or

shifting gears Malfunction on sys-

short-circuit between dash panel insert and Diesel direct injection system control unit -J248 Dash panel insert

tems using the speed signal

defective 16944 Voltage supply 16946 Voltage supply 16947 Voltage supply Implausible signal Control unit was fit Engine does not start Engine stoppage

ted on with the ignition switched on

Test cables to dieseldirect injection system control unit -J248- according to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

Voltage too low Line interruption or short-circuit Voltage too high Control unit defec-

tive

Inspect AC generator Replace diesel directinjection system control unit -J248 Chap. 23-6 16955 Brake light switch -F Implausible signal Brake light switch -F Poor vehicle handling Brake light not opera-

defective CC system brake

Inspect Brake lightswitch -F- and CC system brake pedal switch -F47- Chap. 23-7

tional Glow period warning

pedal switch -F47defective Line interruption

lamp -K29 - flashes Incorrect driving be-

16989 Control unit defective

Diesel direct injec-

tion system control unit -J248- internally defective

haviour when engine is stopped Glow period warning


lamp -K29 - flashes

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Self-diagnosis II

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FABIA 2000

1.9/47 SDI Engine, Fuel Injection Possible cause of fault Short-circuit to earth

01Possible effects Diesel direct injection

Display -V.A.G 155217568 Intake manifold temp. sender G72 Short circuit to earth

Rectifying fault

in the wiring between Intake manifold temperature sender -G72- and Diesel direct injection system control unit -J248 -G72- defective Signal input in Diesel

system control unit -J248- operates with bakkup temperature

Test intake manifoldtemperature sender - G72- Chap. 23-3

direct injection system control unit -J248- defective (control unit defective) 17569 Intake manifold temp. sender G72 Open circuit/ Short circuit to positive Interruption or short Diesel direct injection


circuit to positive in the wiring between Intake manifold temperature sender -G72- and Diesel direct injection system control unit -J248 -G72- defective Earth distribution to

system control unit - J248- operates with bakkup temperature

Test intake manifoldtemperature sender - G72- Chap. 23-3

-G72- defective Signal input in Diesel

direct injection system control unit -J248- defective (control unit defective)


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01-2 page 3

01Display -V.A.G 155217570 Fuel temperature sender G81 Short circuit to earth Possible cause of fault Interruption or short-



Poor performance Increased emission

circuit in the wiring between Fuel temperature sender -G81- and Diesel direct injection system control unit -J248 -G81- defective Signal input in Diesel

Inspecting Fuel temperature sender -G81- Chap. 23-4

levels Diesel direct injection

system control unit - J248- operates with bakkup temperature

Replace diesel directinjection system control unit - J248 Chap. 23-6

direct injection system control unit -J248- defective (control unit defective) 17571 Fuel temperature sender G81 Open circuit/ Short circuit to positive Interruption or short-

circuit to positive in the wiring between Fuel temperature sender -G81- and Diesel direct injection system control unit -J248 -G81- defective Signal input in Diesel

direct injection system control unit -J248- defective (control unit defective) 17653 Short circuit to Needle lift send- earth er -G80 Interruption or short Poor performance Increased emission

circuit in the wiring between Needle lift sender -G80- and Diesel direct injection system control unit -J248 -G80- defective Needle lift sender

Inspecting Needle liftsender -G80 Chap. 23-4

levels Glow period warning

lamp -K29 - flashes no exhaust gas recir-

culation rough engine running

17654 Implausible Needle lift send- signal er -G80

- G80- defective Injection line to injec-

tion nozzle with Needle lift sender -G80N.O.K. Fuel shortage Air in fuel system

17655 Open circuit/ Needle lift send- Short circuit to er -G80 positive

Interruption or short-

circuit to positive in the wiring between Needle lift sender -G80- and Diesel direct injection system control unit -J248 -G80- defective

01-2 page 4

Self-diagnosis II

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FABIA 2000

1.9/47 SDI Engine, Fuel Injection Possible cause of fault Commencement of

01Possible effects Poor vehicle handling Increased emission

Display -V.A.G 155217656 Injection commencement control Control difference

Rectifying fault

injection valve -N108- defective Needle lift sender

Testing Commencement of injection valve -N108 Chap. 23-4.

levels Cold start problems rough engine running Poor performance

- G80- defective Fuel tank empty Fuel supply N.O.K.,

Inspecting Needle liftsender -G80 Chap. 23-4

fuel shortage Fuel filter or fuel line

Inspecting and setting commencement of injection Chap. 23-4. Engine jerks when

blocked 17659 Commencement of injection valve -N108 Short circuit to positive Short-circuit to posi-

tive in the wiring between Commencement of injection valve -N108- and Diesel direct injection system control unit -J248 -N108- defective Interruption or short-

idling Poor performance

Testing Commencement of injection valve - N108 Chap. 23-4

17660 Commencement of injection valve -N108

Open circuit/ Short-circuit to earth

circuit in the wiring between Commencement of injection valve -N108 and Diesel direct injection system control unit - J248 -N108- defective Short-circuit to earth Black smoke when

17663 Short circuit to Coolant temper- earth ature sender G62

in the wiring between Coolant temperature sender -G62- and Diesel direct injection system control unit -J248 -G62- defective Interruption or short-

starting preheating always oc-

Inspecting coolanttemperature sender -G62- Chap. 23-3

curs for approx. 20 seconds

17664 Open circuit/ Coolant temper- Short circuit to ature sender positive G62

circuit to positive in the wiring between Coolant temperature sender -G62and Diesel direct injection system control unit -J248 -G62- defective

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Self-diagnosis II

01-2 page 5

01Display -V.A.G 155217762 Modulating piston movement sender -G149 Electrical fault in the circuit Possible cause of fault Interruption or short-



Incorrect driving be-

circuit to earth or positive in the wiring between Modulating piston movement sender -G149- and Diesel direct injection system control unit -J248 Disconnect 10 pin


Inspecting Modulating piston movement sender -G149 Chap. 23-4

lamp -K29 - flashes

Check 10 pin plugconnection of injection pump

plug connection of injection pump -G149- defective Injection pump de-

fective 17795 Control unit defective 17810 Exhaust gas recirculation valve -N18 Short circuit to positive Diesel direct injec-

tion system control unit -J248- internally defective Short-circuit to posi no exhaust gas recir-

Replace diesel directinjection system control unit -J248 Chap. 23-6 culation

tive in the wiring between Exhaust gas recirculation valve -N18- and Diesel direct injection system control unit -J248 -N18- defective Interruption or short-

Testing Exhaust gasrecirculation valve -N18- Chap. 23-5

Inspecting exhaustgas recirculation Chap. 23-5 no exhaust gas recir-

17849 Exhaust gas recirculation valve -N18


circuit to earth in the wiring between Exhaust gas recirculation valve -N18- and Diesel direct injection system control unit -J248 -N18- defective Voltage regulator on

culation Poor performance Black smoke

17911 Load signal for alternator terminal DF

Implausible signal

PTC heating not oper-

AC generator defective AC generator defec-

ational

Inspect AC generator Current Flow Diagrams, Electrical Fault Finding and Fitting Locations value block, display group 016 Chap. 01-3

tive Wiring between AC

Reading measured

generator and Diesel direct injection system control unit -J248- defective

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Self-diagnosis II

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FABIA 2000

1.9/47 SDI Engine, Fuel Injection Possible cause of fault Fuel shut-off valve

01Possible effects Poor performance Engine stoppage

Display -V.A.G 155217945 Fuel shut-off valve -N109 17946 Fuel shut-off valve -N109 Malfunction

Rectifying fault

- N109- defective, dirty, leaking or jammed Open circuit/ Short-circuit to earth Interruption or short-

Inspecting Fuel shutoff valve -N109 Chap. 23-4

circuit to earth in the wiring between Fuel shut-off valve -N109and Diesel direct injection system control unit -J248 -N109- defective

17948 Vehicle speed signal

Signal too high Speedometer sender Speed display NOK -G22- defective Cruise control system Line interruption or not operational short-circuit be Vehicle jerks when tween Speedometer shifting gears sender -G22- and Malfunction on sysdash panel insert tems using the speed Line interruption or signal short-circuit between dash panel insert and Diesel direct injection system control unit -J248 Dash panel insert

Test speed signal Chapter 23-7

defective 17969 Control differMetering adjust- ence er -N146 Interruption or short Incorrect driving be-

circuit to earth or positive in the wiring between Metering adjuster -N146- and Diesel direct injection system control unit -J248 Injection pump de-


Inspecting Meteringadjuster -N146 Chap. 23-4

lamp -K29 - flashes

fective 17970 upper limit valMetering adjust- ue er -N146 17971 lower limit valMetering adjust- ue er -N146 Metering adjuster Poor performance Jerking Glow period warning

-N146- defective or blocks Metering adjuster

Inspecting Meteringadjuster -N146 Chap. 23-4

lamp -K29 - flashes Black smoke irregular idling Glow period warning

-N146- defective or blocks

lamp -K29 - flashes

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01-2 page 7

01Display -V.A.G 155217977 Cruise control system switch E45 Implausible signal Possible cause of fault CC system switch



Cruise control system

-E45- defective Wiring to CC system

not operational

Analyse measuredvalue block, display group number 006 Chap. 01-3

switch -E45- defective

Check wiring to CCsystem switch - E45for interruption or short-circuit to earth or positive Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

17978 Engine control unit blocked 1)

Start attempt with a

Engine starts and

non-authorised key non-authorised ma-

stops immediately Glow period warning

Adapt diesel direct injection system control unit -J248- to electronic immobiliser Electrical System; Rep. Gr. 96.

nipulation attempt wrong coding in Die-

lamp -K29 - flashes

sel direct injection system control unit -J248 fault in the immobi-

Test electronic immobiliser Electrical System; Rep. Gr. 96

lizer system Dash panel insert

defective 2) Diesel direct injec-

tion system control unit -J248- was replaced and not adapted to the immobilizer 18008 Supply voltage tml. 15 18009 Terminal 30 3) supply voltage relay Voltage too low No voltage when iginition on (Terminal 15) Implausible signal Diesel direct injec Incorrect driving be-

haviour when engine is stopped

Test voltage supply ofdiesel direct injection system control unit J248- Chap. 23-6

tion system relay -J322- jams or defective Wiring to -J322- de-

Inspecting Diesel direct injection system relay -J322- Chap. 23-3

fective 18017 Crash disconnect activated Crash disconnect Engine does not start

activated by Airbag control unit (e.g. after an accident) Airbag control unit

Read fault memoryAirbag control unit Body Work; Rep. Gr. 01

defective 18020 Engine control unit Incorrectly coded incorrect coding Engine does not start

Replacing Airbag control unit Body Work; Rep. Gr. 01

Code diesel direct injection system control unit -J248 Chap. 23-6.

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Self-diagnosis II

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FABIA 2000

1.9/47 SDI Engine, Fuel Injection Possible cause of fault Short-circuit to posi-

01Possible effects no preheating poor cold start behav-

Display -V.A.G 155218026 Glow plug relay -J52 Short circuit to positive

Rectifying fault

tive in the wiring between Glow plug relay -J52- and Diesel direct injection system control unit -J248 -J52- defective Interruption or short-

Inspecting Glow plugrelay -J52- Chap. 01-1

iour Glow period warning

lamp -K29 - flashes

18027 Glow plug relay -J52


circuit to earth in the wiring between Glow plug relay -J52- and Diesel direct injection system control unit -J248 -J52- defective Datalines faulty Poor vehicle handling

18034 Databus drive 18034 Databus drive

Missing message from gearbox CU Missing message from gearbox CU

Test CAN databus

lines Chapter 23-7

Datalines faulty

18039 Signal too high Accelerator pedal position sender Accelerator ped-G79- defective al position sender -G79 18040 Supply voltage Accelerator pedal position sender -G79 Supply voltage too

increased idling speed Glow period warning

Inspecting Accelerator pedal position sender -G79- 1.9/ 47 SDI Engine - Mechanics; Rep. Gr. 20

lamp -K29 - flashes

great or too small Interruption or short-


circuit to earth or positive in the wiring between Accelerator pedal position sender -G79-and Diesel direct injection system control unit -J248 Fault in databus wir Air conditioning sys-

18043 Databus drive

missing message from AC CU

ing wrong or defective

tem switched off PTC heating not oper-

Check data bus

Chapter 23-7 tioning system control unit fault memory Heating, Air conditioning ; Rep. Gr. 01

AC CU

ational

Read out air condi-

18044 Databus drive

Missing message from airbag CU

Fault in databus wir-

Crash disconnect not


operational

Check data bus

Chapter 23-7 ry of air conditioning system control unit Body Work; Rep. Gr. 01

airbag CU

Read out fault memo-

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01-2 page 9

01Display -V.A.G 155218045 Databus drive missing message form electron. CU Possible cause of fault Fault in databus wir-



ing Wrong or faulty vehi-

Check data bus

Chapter 23-7 ry of vehicle voltage control unit Electrical System; Rep. Gr. 90

cle voltage control unit -J519-


18047 Implausible 1/2 for accelera- signal tor pedal position sender G79+G185

Interruption or short-

increased idling speed Glow period warning

circuit to earth or positive in the wiring between Accelerator pedal position sender -G79 -G79- defective Diesel direct injec-


lamp -K29 - flashes

18048 Control unit defective

Incorrect driving be-

tion system control unit -J248- internally defective defective Fault in databus wir-



lamp -K29 - flashes 18056 Databus drive Poor vehicle handling

ing databus compatible

Check data BUS Chapter 23-7.

control unit defective 18057 Databus drive Missing message from ABS CU Fault in databus wir-

Read out fault memory of all control units



ABS CU

Read out the faultmemory of the ABS control unit Chassis; Rep. Gr. 45 Glow period warning

18058 Databus drive

Missing message from combiinstrument



lamp -K29- not operational

Check data bus

Chapter 23-7 ry of dash panel insert Electrical System; Rep. Gr. 90

dash panel insert


18090 Databus drive

implausible message from ABS CU


Poor vehicle handling



ABS CU

Read out the faultmemory of the ABS control unit Chassis; Rep. Gr. 45

18097 Databus drive

Implausible message from electron. CU


ing Wrong or faulty vehi-

Check data bus

Chapter 23-7 ry of electrical system control unit Electrical System; Rep. Gr. 90

cle voltage control unit -J519-


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FABIA 2000

1.9/47 SDI Engine, Fuel Injection Possible cause of fault Fault in databus wir-

01Possible effects Rectifying fault

Display -V.A.G 155219456 Glow period warning lamp -K2919456 Glow period warning lamp -K2919459 Low heat output relay -J359 Missing message from combiinstrument Missing message from combiinstrument Short circuit to positive

ing to dash panel insert Fault in databus wir-

Test CAN databus

lines Chapter 23-7

ing to dash panel insert Short-circuit to posi PTC heating not oper-

tive in the wiring between Low heat output relay -J359and Diesel direct injection system control unit -J248 -J359- defective Short-circuit to posi-

ational

Inspecting Low heatoutput relay -J359 Chap. 01-1

19461 Short circuit to High heat output positive relay -J360

tive in the wiring between High heat output relay -J360and Diesel direct injection system control unit -J248 -J360- defective Short-circuit to posi no exhaust gas recir-

Inspecting High heatoutput relay -J360 Chap. 01-1

19556 Intake manifold flap motor V157

Short circuit to positive

Inspecting Intake

tive in the wiring between Intake manifold flap motor -V157- and Diesel direct injection system control unit -J248 -V157- defective Interruption or short-

culation Intake manifold flap

manifold flap motor -V157- Chap. 23-3

fully open

19557 Intake manifold flap motor V157


Inspecting Intake

circuit to earth in the wiring between Intake manifold flap motor -V157- and Diesel direct injection system control unit -J248 -V157- defective Intake manifold flap

manifold flap motor -V157- Chap. 23-3

19559 Intake manifold flap motor V157 19586 Exhaust gas recirculation system 19587 Exhaust gas recirculation system1)

defective

motor -V157- defective Regulating lim- Fault in charge pres- Poor vehicle handling sure control it not reached Poor performance Increased emission

Testing Exhaust gasrecirculation valve -N18- Chap. 23-5

Regulating limit exceeded

levels

Inspecting exhaustgas recirculation Chap. 23-5

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.

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012) 3)

FABIA 2000


The immobilizer control unit is a component part of the dash panel insert and therefore must not be replaced individually. Relay for voltage supply - terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.

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01

01-3

Self-diagnosis III

Readiness code Reading readiness codeOperation The readiness codes are two 8-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system is successfully performed (e.g. exhaust gas recirculation system), the relevant position of the readiness code switches from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that these systems operate according to the specifications. If a fault is detected 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 the readiness code means to activate 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 enteraddress word 01 Engine electronics Chap. 01-1. display group number 017. Readout on display:

Select function 08 read measured value block andReading measured value block 00000000 00000110 10000000 17 -> 00000000

Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 1 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Diagnosis of other systems Diagnosis of fuel supply Ignore Meaning

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FABIA 2000


Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system Meaning

If the specified values are not reached, generate readiness code 01-3 page 2.

Press key. Select function 06 End output and switch ignition off.

Generating readiness codeSpecial 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 windowheater switched off.

Intake air temperature must be below 60C displaygroup number 007, display field 3

Coolant temperature at least 83C display groupnumber 007, display block 4

Procedure

Connect vehicle system tester -V.A.G 1552-. Select

address word 01 Engine electronics Chapter 011. Note

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

Work step 1: Interrogating fault memory

Enter function

0 2 Interrogate fault memory and X faults detected

confirm with Q . The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:

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01

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

Press

.

Work step 2: Erasing fault memory

Enter functionwith Q . Note

0 5 Erase fault memory and confirm

Readiness code is erased each time the fault memory is erased. Readout on display: Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.Vehicle system test The fault memory is erased ->

Press

.

Work step 3: Switch off ignition

Min. Wait 5 seconds with ignition OFF.Note This point is important, because with certain diagnoses the slowing down of the control unit must be ended. Otherwise readiness code cannot be generated.

Work step 4: Switch on ignition

Min. Wait 10 seconds with ignition ON.Charge pressure sender is adapted with atmospheric charge pressure sender.

Work step 5: 1. Testing fuel supply and other systems

Start engine. Function0 8 Read measured value block and then

select display group number 001.

For 5 seconds increase the engine speed to 2500 rpmand then run engine at idling speed. Readout on display:Reading measured value block 1 2500 rpm 4.6 mg/s 2 0CA 94.2 C ->

Work step 6: 1. Testing exhaust gas recirculation

Increase engine speed to 1600 rpm up to 1700 rpmand maintain it for at least 10 seconds in this range.

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01-3 page 3

01Readout on display: In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for readiness code to generate exhaust gas recirculation).

FABIA 2000

1.9/47 SDI Engine, Fuel Injection->

Reading measured value block 1 1650 rpm 4.1 mg/s 4 0CA

93.2 C

Work step 7: Switch off ignition

Min. Wait 5 seconds with ignition OFF.Work step 8: Switch on ignition

Min. Wait 10 seconds with ignition ON.Work step 9: 2. Testing fuel supply and other systems

Start engine. Function0 8 Read measured value block and then select display group number 001.

For 5 seconds increase the engine speed to 2500 rpmand then run engine at idling speed. Readout on display:Reading measured value block 1 2500 rpm 4.6 mg/s 2 0CA 94.2 C ->

Work step 10: 2. Testing exhaust gas recirculation

Increase engine speed to 1600 rpm up to 1700 rpmand maintain it for at least 10 seconds in this range. Readout on display:Reading measured value block 1 1650 rpm 4.1 mg/s 4 0CA 93.2 C ->

Press Enter

C.

0 1 7 for display group number 017 and read readiness code. Reading measured value block > 17 -

Readout on display: Specification in display field 2: 00000110 Specification in display field 4: 00000000

Press . If the specified values are not reached, once again repeat procedure for generating readiness code 01-3 page 2.

Work step 11: Interrogating fault memory

Enter function

0 2 Interrogate fault memory and X faults detected

confirm with Q . The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:

Rectify the faults by referring to the fault table

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

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01

If no fault is stored:

Press

. Reading measured value block > 17 -

Readiness code was successfully generated, if no fault is stored after two work sequences of the test procedure in the fault memory for the engine control unit and if the following display appears in the channel 017.

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01

FABIA 2000


01-3 page 6

Self-diagnosis III

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01

01-4

Self-diagnosis IV

Reading measured value blockSpecial tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable

-V.A.G 1551/3, 3A, 3B oder 3C-

Test conditions

The coolant temperature should rise beyond 80C. All electrical consumers such as e.g. rear windowheater must be switched off.

Test sequence

Connect vehicle system tester -V.A.G 1552-. Thenstart the engine and enter address word 01 Engine electronics Chapter 01-1.

Enter display group 01-4 page 1.

Display groups 000 through 019 in idleDisplay group 000 in idle (engine warm, coolant temperature not below 80 C)Reading measured value block 0 x 1 x 2 x 3 x 4 x 5 x 6 x 7 x 8 x 9 x 10 < Display field Display irrelevant Fuel temperature Intake manifold temperature Coolant temperature Atmospheric pressure Intake manifold pressure Injection rate Accelerator pedal position Commencement of injection Engine speed Specification Ignore 91 to 201 138 to 190 80 to 35 181 to 222 Ignore 15 to 45 0 37 to 75 41 to 45 corresponds to --20 to 80 C 5 to 40 C 80 to 110 C 900 to 1100 mbar --3.0 through to 9.0 mg/h 0% 0 TDC to 3 before TDC 860 to 950 rpm < Readout on display

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FABIA 2000


Display group 001 in idle (engine warm, coolant temperature not below 80C)Reading measured value block 1 xxxx rpm 1 xx.x mg/s 2 x.xxx V 3 xxx.x C 4 < Display field Coolant temperature Voltage from modulating piston movement sender Injection rate Engine speed Specification 80.0 to 110.0 C 1.500 to 2.100 V 3.0 through to 9.0 mg/h 860 to 950 minutes Analysis -- 01-4 page 2 01-4 page 2 --< Readout on display

Analysis: Display group 001, display field 2 - Injection rateDisplay -V.A.G 1552below 3.0 mg/s above 9.0 mg/s Possible cause of fault Injection pump defective Engine too cold Injection pump defective

Rectifying fault

Replacing injection pump Chap. 23-2 Warm up engine by running at high revsand repeat test

Replacing injection pump Chap. 23-2

Analysis: Display group 001, display field 3 - Voltage from modulating piston movement senderDisplay -V.A.G 1552below 1.500 V above 2.100 V Possible cause of fault Injection pump defective Engine too cold Engine loaded Injection pump defective

Rectifying fault

Replacing injection pump Chap. 23-2 Warm up engine by running at high revsand repeat test

Switch off consumers Replacing injection pump Chap. 23-2

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01

Display group 002 in idle (engine warm, coolant temperature not below 80C)Reading measured value block 2 xxxx rpm 1 xxx.x % 2 xxx 3 xxx.x C 4 < Display field Coolant temperature Operating position Accelerator pedal position Engine speed Specification 80.0 to 110.0 C 010 0,0 % 860 to 950 rpm Analysis -- 01-4 page 3 01-4 page 3 --< Readout on display

Analysis: Display group 002, display field 2 - Accelerator pedal positionDisplay -V.A.G 15521 to 100.0 % Possible cause of fault Accelerator pedal position sender -G79-

Rectifying fault

defective Line interruption to -G79-

Inspecting Accelerator pedal position

sender -G79- 1.9/47 kW SDI Engine Mechanics; Rep. Gr. 20

Analysis: Display group 002, display field 3 - Operating positionMeaning, if display positions = 1 X X 1 1 X 1 Operating position Air conditioning on Idling switch closed (accelerator pedal not pressed) Ignore

Display group 003 in idle (engine warm, coolant temperature not below 80C)Reading measured value block 3 xxxx rpm 1 2 3 xxx % 4 < Display field Mark space ratio from exhaust gas recirculation valve -N18no display no display Engine speed Specification 94 to 96 % Analysis --< Readout on display

----860 to 950 rpm

-------

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FABIA 2000


Display group 004 in idle (engine warm, coolant temperature not below 80C)Reading measured value block 4 xxxx rpm 1 xx.x b.(a.) TDC 2 xx.x b.(a.) TDC 3 xxx % < Readout on display

4

< Display field Mark space ratio from exhaust gas recirculation valve -N18-

Specification 2 to 80 %

Analysis ---

Commencement of injection (Actual val- 0.0 to 3.0 b. TDC ue) Commencement of injection (set value) Engine speed 0.0 to 3.0 b. TDC 860 to 950 rpm

01-4 page 4 01-4 page 4 ---

Analysis: Display group 004, display field 2 - commencement of injection (set value)Display -V.A.G 1552above 3.0 b. TDC Possible cause of fault Engine too cold

Rectifying fault

Warm up engine by running at high revsand repeat test

Analysis: Display group 004, display field 4 - Commencement of injection (Actual value)Display -V.A.G 1552above 3.0 b. TDC Possible cause of fault Engine too cold Injection pump stops too soon Commencement of injection valve -N108-

Rectifying fault

Warm up engine by running at high revsand repeat test

Dynamically test and set commencementof injection Chap. 23-4 - N108- Chap. 01-1

defective below 0.0 b. TDC Injection pump stops too late Injection timing blocked Commencement of injection valve -N108-

Testing Commencement of injection valve Dynamically test and set commencementof injection Chap. 23-4 Chap. 23-4

Inspecting the injection-timing range Testing Commencement of injection valve- N108- Chap. 01-1

defective

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01

Display group 006 with ignition onReading measured value block 6 xxx km/ h 1 xxx 2 xxxxxx 3 xxx 4 < Display field Operating condition of the cruise control system Operating condition of the cruise control system control Operating condition of the brake and clutch pedal Vehicle speed Specification xxx xxxxxx 000 0 Analysis 01-4 page 5 01-4 page 5 01-4 page 5 --< Readout on display

Analysis: Display group 006, display field 2 Brake pedal and clutch pedal monitoringMeaning, if display positions = 1 X X X 1 1 1 Operating position Brake light switch -F- closed (brake pedal operated) Brake light switch -F47- opened (brake pedal operated) Clutch pedal switch -F36- opened (clutch pedal operated)

Analysis: Display group 002, display field 3 - operating state of cruise control system controlCruise control system control Switch B engaged on OFF Switch B on OFF before the activation point Switch B on ON Switch B on RES Switch A operated Brake pedal actuated Clutch pedal actuated Display field 3 000000 000001 000011 001011 000111 010011 100011

A

B

N23-0199

Analysis: Display group 006, display field 4 - Operating condition of cruise control systemGroup 0 1 255 Test condition Vehicle with CCS, CCS switched off Vehicle with CCS, CCS switched on Vehicle without CCS, or CCS function in engine control unit not activatedSelf-diagnosis IV

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FABIA 2000


Display group 007 with ignition on (engine cool and standing)Reading measured value block 7 xxx.x C 1 2 xxx.x C 3 xxx.x C 4 < Display field Coolant temperature Intake manifold temperature no display Fuel temperature1)

< Readout on display

Specification approx. ambient temperature 1) approx. ambient temperature 1) --approx. ambient temperature 1)

Analysis 01-4 page 6 01-4 page 6 -- 01-4 page 6

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 temperatureDisplay -V.A.G 1552-5.4 C Possible cause of fault Short-circuit or Fuel temperature sender

Rectifying fault

-G81- defective

Inspecting Fuel temperature sender -G81 23-4

Analysis: Display group 007, display field 3 - Intake manifold temperatureDisplay -V.A.G 1552approx. 136.8 C Possible cause of fault Short-circuit or Intake manifold sender

Rectifying fault

-G72- defective

Test intake manifold temperature sender- G72- Chap. 23-3

Analysis: Display group 007, display field 4 - Coolant temperatureDisplay -V.A.G 1552great deviation from ambient temperature Possible cause of fault Short-circuit or Coolant temperature

Rectifying fault

sender -G62- defective

Inspecting coolant temperature sender-G62- Chap. 23-3 In the event of a fault the fuel temperature is displayed instead.

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01

Display group 013 in idle (engine warm, coolant temperature not below 80C)Reading measured value block 13 x.xx mg/s 1 x.xx mg/s 2 x.xx mg/s 3 x.xx mg/s 4 < Display field Smooth running control injected quantity cylinder 4 Smooth running control - injected quantity cylinder 3 Smooth running control - injected quantity cylinder 2 Smooth running control - injected quantity cylinder 1 Specification -1.90 through to +1.90 mg/h -1.90 through to +1.90 mg/h -1.90 through to +1.90 mg/h -1.90 through to +1.90 mg/h Analysis 01-4 page 7 < Readout on display

01-4 page 7 01-4 page 7 01-4 page 7

Analysis: Display group 013, display field 1 to 4 - idle smooth running control The injection system has an idle smoothness regula-

tor. It is possible to detect differences in performance between individual cylinders (part tolerances, injector 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 four 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 opposed 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.

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01-4 page 7

01Display group 016 in idleReading measured value block 16 xxx % 1 xxxxxxxx 2 xx 3 xx.x V 4 < Display field < Readout on display

FABIA 2000


Specification 13.5 to 14.5 V 00 1x000001 5 to 95 %

Analysis 01-4 page 9 01-4 page 8 01-4 page 8 ---

Supply voltage of the engine control unit Heating element control Auxiliary heating Generator capacity

Analysis: Display group 016, display field 2 - Auxiliary heatingMeaning, if display positions = 1 X X X X X X X X Additional heating deactivated, because: 1 Coolant temperature greater than 70 C to 80C or intake air temperature greater than +5C 1 1 1 1 1 1 1 Generator defective Battery voltage below 9 V Engine speed less than 875 rpm Engine start within the last 10 seconds Coolant temperature sender -G62- or Intake manifold temperature sender -G72- defective Ignore Ignore

Analysis: Display group 016, display field 3 Control of the heating elementsMeaning, if display positions = 1 X 1 X 1 Operating position Low heat output relay -J359- on High heat output relay -J360- on

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01

Analysis: Displaygroup 016, display field 4 - Supply voltage of the engine control unitDisplay -V.A.G 1552below 13.5 V Possible cause of fault Generator defective, battery heavily dis-

Rectifying fault

charged Battery heavily loaded just after start by a

Inspect generator and battery voltage,charge battery Electrical System; Rep. Gr. 27

high charge current or by auxiliary equipment Transition resistance in the power supply,

Increase engine speed slightly for a fewminutes and switch off additional consumers

or earth connection for engine control unit Current consumption with ignition off on generator defective

Test supply voltage of engine control unit Chapter 23-6

above 14.5 V

Eliminate current consumption Test voltage regulator, replace ifnecessary Current Flow Diagrams, Electrical Fault Finding, Fitting Locations

Overvoltage due to starting aid or quick

charger

Interrogate fault memory Chapter 01-1

Display group 019 with ignition onReading measured value block 19 x.xxx V 1 x.xxx V 2 3 4 < Display field no display no display Voltage of the Modulating piston movement sender at maximum limit of the Metering adjuster Voltage of the Modulating piston movement sender at minimum limit of the Metering adjuster Specification ----4.100 to 4.800 V Analysis ---- 01-4 page 9 < Readout on display

0.500 to 0.970 V

01-4 page 9

Analysis: Display group 019, display fields 1 and 2 - Voltage of the Modulating piston movement sender at maximum and minimum limit of the Metering adjusterDisplay -V.A.G 1552Nominal value outside tolerance Possible cause of fault Metering mechanism of the injection

Rectifying fault

pump adjusted

Replacing injection pump Chap. 23-2

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01-4 page 9

01Display groups 000 through 008 under full loadNote Accelerate vehicle at full throttle before inspecting. The measured values must be read off or printed out

FABIA 2000


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 000 under full load (test drive in 3rd or 4th gear coolant temperature not below 80 C)Reading measured value block 0 x 1 x 2 x 3 x 4 x 5 x 6 x 7 x 8 x 9 x 10 < Display field Display irrelevant Fuel temperature Intake manifold temperature Coolant temperature Atmospheric pressure Intake manifold pressure Injection rate Accelerator pedal position Commencement of injection Engine speed Specification Ignore 90 to 201 138 to 190 80 to 35 181 to 222 Ignore 100 to 135 255 113 to 150 133 to 153 corresponds to --20 to 80 C 5 to 40 C 80 to 110 C 900 to 1100 mbar --20.0 through to 27.0 mg/h 100 % 6 to 9 b. TDC 2800 to 3200 rpm < Readout on display

Display group 004 under full load (test drive in 3rd gear coolant temperature not below 80C)Reading measured value block 4 xxxx rpm 1 xx.x b.(a.) TDC 2 xx.x b.(a.) TDC 3 xxx % < Readout on display

4

< Display field Mark space ratio from commencement of injection valve

Specification 70 to 95 %

Analysis 01-4 page 11

Commencement of injection (Actual) Commencement of injection (Nominal) Engine speed

6.0 to 9.0 b. TDC 6.0 to 9.0 b. TDC 2800 to 3200 rpm

01-4 page 11 -----

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01

Analysis: Display group 004, display field 3 - Commencement of injection (Actual)Display -V.A.G 1552If deviation from nominal value is too great (approx. 5.0) Possible cause of fault Commencement of injection valve -N108-

Rectifying fault

defective Injection pump extremely maladjusted Air in fuel system

Testing Commencement of injection valve- N108- Chap. 01-1

Dynamically test and set commencementof injection Chap. 23-4

Check fuel supply Chap. 20-1

Analysis: Display group 004, display field 4 - Mark space ratio from commencement of injection valveDisplay -V.A.G 1552below 70 or above 95 % Possible cause of fault Commencement of injection valve -N108-

Rectifying fault

defective

Testing Commencement of injection valve- N108- Chap. 01-1

Dynamically test and set commencementof injection Chap. 23-4

Check fuel supply Chap. 20-1

Display group 008 under full load (test drive in 3rd gear coolant temperature not below 80C)Reading measured value block 8 xxxx rpm 1 xx.x mg/s 2 xx.x mg/s 3 xx.x mg/s 4 < Display field Fuel injection rate limit based on drawn in air mass (smoke prevention) Injection rate limit based on engine speed (torque limit) Injection rate (driver's instruction) Engine speed Specification 24.0 through to 30.0 mg/h 26.0 through to 27.0 mg/h 41.0 through to 44.0 mg/h 2800 to 3200 rpm Analysis 01-4 page 12 < Readout on display

01-4 page 12 01-4 page 11 ---

Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)Display -V.A.G 1552below 41.0 mg/s Possible cause of fault not full throttle Accelerator pedal position sender -G79-

Rectifying fault

defective

repeat test at full throttle Inspecting Accelerator pedal position

sender -G79- 1.9/47 kW SDI Engine Mechanics; Rep. Gr. 20

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FABIA 2000


Analysis: Display group 008, display field 3 - Injection rate limit over speedDisplay -V.A.G 1552below 26.0 mg/s Possible cause of fault Speed too high or too low

Rectifying fault

Read off set value at 3000 rpm

Analysis: Display group 008, display field 4 - Injection rate limit (smoke mapping)Display -V.A.G 1552below 24.0 mg/s Possible cause of fault Air mass drawn in too small

Rectifying fault

Inspecting Intake manifold flap motor-V157- Chap. 23-3 Chap. 23-5 Chap. 23-5

Inspecting exhaust gas recirculation Exhaust gas recirculation too high

Inspecting exhaust gas recirculation

Display group 125 CAN databusDisplay group 125 with ignition onRead measured value block 125 ABS 1 1 2 Combi 1 3 Airbag 1 4 < Display field Airbag control unit Control unit with display in dash panel insert ABS control unit not assigned Specification Airbag 1 Combi 1 ABS 1 --Analysis 01-4 page 12 01-4 page 12 01-4 page 12 --< Readout on display

Analysis: Display groups 125Display -V.A.G 1552ABS 0 Combi 0 Airbag 0 Possible cause of fault one or several control units without com-

Rectifying fault

munication with data BUS cables

Check data bus Chapter 23-7

01-4 page 12

Self-diagnosis IV

Edition 12.03 S00.5312.02.20

FABIA 2000


23

23 Fuel Formation, Injection23-1 Diesel Direct Injection System

Safety measuresObserve 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. If the engine must be operated at starter speed, with-

out it starting, e.g. during compression pressure testing, disconnect the 10-pin connector from the injection pump. After performing the work interrogate fault memory and erase. Before disconnecting the battery determine the code

of radio sets fitted with anti-theft coding. Switch off the ignition before connecting or discon-

necting the battery as this could otherwise damage the diesel direct injection system control unit. If test and measuring devices are required during test drives observe the following: Always secure the test and measuring devices on the

rear seat and have a second person operate them there. If the test and measuring devices are operated from the passenger seat the passenger could be injured by the release of the passenger airbag in the event of an accident.

Cleanliness rulesCarefully observe the following rules for cleanliness when working on the fuel supply/injection system: 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 parts which have been stored unwrapped (e.g. in tool boxes and the like). When the system is open: Avoid using compressed

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. Contaminated hoses must be replaced.

Edition 06.00 S00.5312.01.20

Diesel Direct Injection System

23-1 page 1

23Overview of fitting location

FABIA 2000


Components A through G are not represented in the overview figure. A - Diesel direct injection system relay -J3221 2 on relay carrier Fig. 2 in 23-1 page 3 B - Glow plug relay -J52on relay carrier Fig. 2 in 23-1 page 3 C - Low heat output relay -J359on relay carrier Fig. 2 in 23-1 page 3 D - High heat output relay -J360on relay carrier Fig. 2 in 23-1 page 3 E - Sender for accelerator pedal position -G79in footwell on the accelerator pedal Fig. 1 in 23-1 page 3 F - Brake light switch -F- and Brake pedal switch -F47in footwell on the brake pedal Fig. 1 in 23-1 page 3 15 14 13 12 G - Clutch pedal switch -F36in footwell on the clutch pedal Fig. 1 in 23-1 page 3 1 - Exhaust gas recirculation valve -N182 - Mechanical exhaust gas recirculation valve 3 - Injection nozzle with needle lift sender -G804 - Intake manifold flap motor -V1575 - Intake manifold temperature sender -G726 - Air filter 7 - Diesel direct injection system control unit -J2488 - Sender for coolant temperature -G62before removing, if necessary reduce pressure in cooling system 9 - Plug connection 2-pin, brown for needle lift sender -G8010 - Plug connection 3-pin, grey for engine speed sender -G2811 - Plug connection 10-pin, black for fuel temperature sender -G81for Metering adjuster -N146for modulating piston movement sender -G149for Commencement of injection valve -N108for Fuel shut-off valve -N10912 - Fuel shut-off valve -N109-

3

4

5

6

7

9 10 11S23-0089

8

23-1 page 2


Edition 06.00 S00.5312.01.20

FABIA 2000


23

13 - Commencement of injection valve -N10814 - Metering mechanism of the injection pump with fuel temperature sender -G81with Metering adjuster -N146with Modulating piston movement sender -G14915 - Fuel filter repairing 1.9/47 SDI Engine, Mechanics; Rep. Gr. 20

Fig. 1:

Components in footwell

1 - Clutch pedal switch -F362 - Brake light switch -F- and Brake pedal switch -F473 - Sender for accelerator pedal position -G79-

3 2

1S24-0374

Fig. 2: 1234-

Relay carrier

Diesel direct injection system relay -J322Glow plug relay -J52Low heat output relay -J359High heat output relay -J360-

1 2 3 4

S23-0090

Edition 06.00 S00.5312.01.20


23-1 page 3

23

FABIA 2000


Disassembling and assembling intake manifold1234525 Nm 10 Nm Warm-type clamp O-ring replace Intake manifold flap motor -V157inspecting Chap. 23-3 10 Nm Connection for crankcase ventilation 20 Nm Gasket replace Intake manifold Gasket replace Mechanical exhaust gas recirculation valve inspecting 1.9/47 SDI Engine, Mechanics; Rep. Gr. 26

4

5

2 1

3

6

678910 11 12 -

12

11

10

7

8

9

S23-0092

23-1 page 4


Edition 06.00 S00.5312.01.20

FABIA 2000


23

Disassembling and assembling the air filter1 - Air guide hose to intake manifold check fitting position 2 - Spring strap clip 3 - 2 Nm 4 - Air filter top part 5 - Filter insert 6 - Air filter bottom part 7 - 2 Nm 8 - Air deflector to lock carrier 9 - Connection for ventilation hose 10 - Retaining clip check tightness 11 - Intake manifold temperature sender -G72inspecting Chap. 23-3 12 - Gasket ring replace if damaged

1

2

3

4

3

11 12 8

10 9 7

5

6

S23-0113

Removing and installing air filterRemoving

Release the spring strap clamp -1- from the air guidehose and remove from air filter.

1 2 3 4 5

Disconnect the ventilation hose -2- and the plug of theintake manifold temperature sender -3-.

Remove the air deflector -4- from the air filter. Unscrew the fixing screw -5- from the air filter (tightening torque 8 Nm).

Carefully remove air filter from the top.InstallingNote Pay attention to the correct positioning of the stop buffer on the bottom part of the air filter (front and rear side).Edition 06.00 S00.5312.01.20 Diesel Direct Injection SystemS23-0111

23-1 page 5

23 Installation of the air filter occurs in reverse order.Note When installing pay attention to the identification on the air guide hose -arrows-.

FABIA 2000


Removing and installing and testing the injection nozzlesDefective injection nozzles cause the following malfunctions: Reduced performance Excessively black exhaust smoke Increased blue smoke during cold start Increased fuel consumption Engine overheats Knocking on one or more cylinders MisfiringS23-0112

Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3 Injection nozzle tester (e. g. -V.A.G 1322-) Pressure line (z. B. -V.A.G 1322/2-) Torque wrench 5...50 Nm (e.g. -V.A.G 1331-) Ring spanner for injection lines (e.g. -3035-) if necessary extractor for valve-stem joint -MP 1-230-

and auxiliary tool

Removing

Remove engine cover. To do so pull the front and rearengine cover upwards with a sudden motion.

Remove injection lines with the ring spanner for injection lines.

if necessary release hollow screw for return-flow line(injection nozzle cyl. 3). Note Always remove injection lines completely. Do not change bending change.

Release fixing screw, remove clamp and remove injection nozzle.

For jammed nozzles prepare the following auxiliarytool:

S10-0115

Preparing an auxiliary tool

Saw off an injection line (e.g. spare part line) approx.5 cm behind the nozzle union nut.

23-1 page 6


Edition 06.00 S00.5312.01.20

FABIA 2000


23

Hard solder an M6 bolt to the sawn off line. Thoroughly clean the auxiliary tool, the injection nozzle cannot be used if dirty!

Tighten the union nut of the auxiliary tool on thejammed nozzle and insert the extractor -MP 1-230- on the welded nut. Note Store the auxiliary tool with dust protection for future use.

InstallingNote Always replace the copper joint between the cylinder head and the injection nozzles.

MP 1-230S23-0029

Replace the injection nozzles. Pay attention to the correct position of the brackets inthe cylinder head.

Insert clamp and tighten fixing screw.Tightening torques: Injection lines: 25 Nm Hollow screw for return-flow line (cyl. 3): 10 Nm Screw for clamp: 20 Nm

Inspection

Connect vehicle system tester -V.A.G 1552-. Leavethe engine on and select the engine control unit with Address word 01 Chap. 01-1.

Select function 08 read measured value block anddisplay group number 013. Nominal value: -1.90 mg/s...+1.90 mg/s (Milligram per stroke)

Reading measured value block 13 -> 0.82mg/s -0.12mg/s 0.49mg/s -0.23mg/s

If one or more actual values are outside the tolerance,interchange the injection nozzles (except for the nozzle of cylinder 3).

If the fault migrates with the nozzle, replace the injection nozzle.

If the fault remains on the cylinder, check the compression.

If the compression is O.K., replace the relevant pressure valve with gasket ring Chap. 23-2. Note The gasket ring must be removed from the pump with

a soft object (plastic, wood) as otherwise the contact surfaces may be scratched. For mileages above 15000 km replace the pressure

valves per set only.

Edition 06.00 S00.5312.01.20


23-1 page 7

23This engine is fitted with 2 spring injection nozzles. This is why the injection of the fuel quantity occurs in 2 steps. If there is a problem with these injection nozzles they must be replaced, as neither a pressure adjustment nor a repair is possible. Test injection nozzles with injection nozzle tester (e. g. -V.A.G 1322-) and pressure line (e. g. -V.A.G 1322/2-). Caution! When testing injection nozzles make sure the fuel jet does not touch your hands as fuel under high pressure penetrates the skin and may cause severe injuries.

FABIA 2000


V.A.G 1322

Pressure gauge connected Slowly press down the pump lever. Read off injectionpressure at the commencement of injection. If the injection pressure deviates from the nominal value, replace the injection nozzle. new nozzles Wear limit 1920 MPa 17 MPaS23-0108

Testing tightness

Pressure gauge connected Press the pump lever slowly down and maintain pressure for 10 seconds at approx. 15 MPa. No fuel may trickle from the nozzle opening.

If there is a leak replace injection nozzle.

23-1 page 8


Edition 06.00 S00.5312.01.20

FABIA 2000


23

23-2

Disassembling and assembling the injection pump

Summary of components Observe the safety precautions Chap. 23-1 Observe the rules for cleanliness Chap. 23-1 Removing and installing injection pump 23-2 page 2 Dynamically test and set commencement of injection Chap. 23-4.

Note Fuel hoses in the engine must only be secured with spring strap clamps. The use of clamping collars or screw clips is not allowed. 1 - Fixing screws of the injection pump gear 1 2 3 4 pay attention to different versions (spare parts No.) and tightening torque Fig. 1 in 23-2 page 2. 2 - Injection pump gear pay attention to different versions related to the fixing screws (Pos. 1) Fig. 1 in 23-2 page 2. 3 - Hub nut Must never be released. This could result in a misadjustment of the basic setting of the injection pump, which cannot be corrected with workshop tools. 4 - Connection fittings for feed line 28 Nm 5 - Gasket ring replace 6 - Fuel shut-off valve 20 Nm 7 - Connection fittings for return-flow line 28 Nm 8 - Return-flow line 25 24 to fuel filter 9 - 25 Nm 10 - Injection lines tighten with 25 Nm remove with Ring spanner for injection lines (e.g. -3035-) Do not change bending change 11 - Connection fittings with pressure valve 45 Nm 12 - 25 Nm 13 - Injection nozzle for cylinder 3 with needle lift sender -G80removing and installing and inspecting Chap. 23-1Edition 06.00 S00.5312.01.20

5

6

5

7

8

9

5

10 10 11 12 13 14 22 15 16 17 23 20 21 20 19 18S23-0144


23-2 page 1

2314 15 16 17 18 19 20 21 22 23 24 -

FABIA 2000 20 Nm Clamp Bracket Heat-protection seal replace 12 Nm Commencement of injection valve -N108O-ring Strainer 30 Nm Bush with nut Bracket for injection pump and AC generator removing and installing 1.9/47 SDI Engine, Mechanics; Rep. Gr. 13 different for vehicles with and without air conditioning 30 Nm


25 -

Fig. 1:

Versions of the fixing bolts of the injection pump gear

Version -A-: Fixing bolts with relief on the thread stem and tip -arrows Spare part No. of the fixing bolts: N 907 134 01 Tightening torque: 20 Nm + 90 torque a further (1/4

A

turn) replace fixing bolts spare part No. of the injection pump gear:

B

038 130 111 A Note Fixing bolt -A- is an antifatigue bolt and must always be replaced. Version -B-: Fixing bolts without relief on the thread stem and tip Spare part No. of the fixing bolts: N 903 285 04 Tightening torque: 25 Nm Fixing bolts need not be replaced spare part No. of the injection pump gear:

N13-0614

038 130 111 B

Removing and installing injection pumpSpecial tools, test and measuring equipment and auxiliary items required Torque wrench (5...50 Nm) (e.g. -V.A.G 1331-) Rig pin -MP 1-301 Adjusting straightedge -MP 1-312 Adjusting device for TDC -MP 1-313 Counterholder -MP 1-216- or -T30004-

23-2 page 2


Edition 06.00 S00.5312.01.20

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23

Two-arm extractor -T40001 Ring spanner for injection lines (e.g. -3035-) Hand vacuum pump -V.A.G 1390 Adapter -V.A.G 1318/10 Wrench for toothed belt-tensioning pulley (e. g.

-Matra V 159-, -Hazet 2587- or -Stahlwille 127-17-) Supporting device -MP 9-200-

Removing

Remove engine cover. To do so pull the front and rearengine cover upwards with a sudden motion.

Remove fuel lines from the injection pump.Note To release the injection lines use an open ring spanner e.g. -3035-

Cover the openings with a clean cloth. Remove top toothed belt shield and cylinder headcover.S10-0115

Removing vacuum pump for brake servo unit 1.9/47 SDI Engine, Mechanics; Rep. Gr. 15

With the engine installed

A 90

2

Position crankshaft on TDC cylinder 1.The marking on the flywheel -1- must be flush with the marking on the gearbox -2-. View from the milled surface on the gearbox -A- vertically (90) to the marking on the flywheel -1-. Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap.

1 1 2 AS13-0224

With the engine removed

Screw the adjusting device -MP 1-313- into thethreaded hole of the top starter screw.

Bo

Set adjusting device to 120 mm -arrow A-. The leftnotch on the vernier is the reference point.

Rotate crankshaft until the TDC marking on the flywheel corresponds with the tip of the adjusting device -arrow B-. Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap.

A MP 1-313

S13-0227

Edition 06.00 S00.5312.01.20


23-2 page 3

23Continued

FABIA 2000


Lock the camshaft with the adjusting straightedge-MP 1-312-. Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap -arrows-.

Centre adjusting straightedge as follows:Turn locked camshaft in such a way that one end of the adjusting straightedge strikes the cylinder head. Measure the resulting play at the other end of the adjusting straightedge with a feeler gauge. Insert feeler gauge with halved play dimension between the adjusting straightedge and the cylinder head. Now turn the camshaft in such a way that the adjusting straightedge is positioned on the feeler gauge. Insert the second feeler gauge with the same dimension at the other end between the adjusting straightedge and the cylinder head.

MP 1-312 MP 9-200

S13-0207

Install supporting device -MP 9-200- and support engine in fitting position.

S13-0225

Remove engine mounting -arrows A and B-. Remove the noise insulation. Unscrew engine support bracket from cylinder block.Note The engine with the supporting device must be slightly raised in order to remove the engine support bracket. The bottom bolt remains in the support.

A A A

B

B

S13-0226

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Edition 06.00 S00.5312.01.20

FABIA 2000


231

Unscrew the nut of the tensioning pulley. Slacken the toothed belt and remove it from thetoothed belt gears of teh camshaft and injection pump.

Unscrew the fixing screws -1- of the injection pumpgear and remove inejction pump gear from the injection pump shaft. Note The nut -2- for the hub must never be loosened. This could result in a misadjustment of the basic setting of the injection pump which cannot be corrected wi

manual fabia- asy

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