1z Ahu Diesel Tdi Servicing
1z Ahu Diesel Tdi Servicing
1z Ahu Diesel Tdi Servicing
page 01-
page 01-47 .
23-2
Safety precautions
WARNING!
Fire hazard! Do not have anything in the area
that can ignite Diesel fuel. To guard against
personal injury, and damage to vehicle
components.
Be sure the ignition is switched OFF, when:
Disconnecting or connecting Diesel fuel
injection and glow plug system wiring or test
equipment
Disconnecting the battery
BEFORE cranking the engine at starting RPM
(such as for compression testing):
Disconnect the harness connector for fuel
cut-off valve -N109- on the Diesel injection
pump.
After the work is completed, check and erase
Diagnostic Trouble Code (DTC) memory.
CAUTION!
23-3
23-4
page
23-5
1 - Wastegate bypass regulator valve -N752 - EGR vacuum regulator solenoid valve N183 - Diesel Direct Fuel Injection (DFI) Engine
Control Module (ECM) -J248With Manifold Absolute Pressure (MAP)
sensor -G71With Barometric Pressure (BARO) sensor F964 - Exhaust Gas Recirculation (EGR) valve
5 - Fuel injector
With needle lift sensor -G806 - Coolant glow plug relay -J3257 - Intake Air Temperature (IAT) sensor -G728 - Harness connector
For needle lift sensor -G809 - Harness connector
For engine speed (RPM) sensor -G28-
23-6
23-7
page 23-19
3 - Woodruff key
Make sure it fits securely
4 - Oil seal
Always replace
5 - Banjo bolt
25 Nm (18 ft lb)
6 - Supply hose
From fuel filter
23-8
7 - Injection pump
With:
Quantity adjuster -N146Modulating piston displacement sensor G149Fuel temperature sensor -G818 - O-ring
Replace if damaged
9 - Fuel cut-off valve
40 Nm (30 ft lb)
10 - Union
For return line
11 - 25 Nm (18 ft lb)
12 - Return hose
To control valve/fuel filter
13 - Injector lines
25 Nm (18 ft lb)
Remove using 3035 tubing wrench
Always remove injector lines as an
assembly
23-9
14 - Fuel injector
For 3rd cylinder with needle lift sensor
Removing and installing
Servicing
page 23-29
page 23-31
15 - 20 Nm (15 ft lb)
16 - Dished washer
17 - Retainer
18 - Mounting
19 - 3-pin harness connector
For fuel cut-off valve and cold start injector
20 - Union
With pressure valve
45 Nm (33 ft lb)
21 - Timing control cover
If leaking, replace O-ring
page 23-33
23-10
22 - Heat shield
Always replace
23 - 10 Nm (7 ft lb)
24 - Cold start injector N108
Checking
page 01-51
25 - Strainer
26 - Retainer
27 - Sleeve
Tapered
28 - 25 Nm (18 ft lb)
Nut with taper
29 - Console
23-11
23-12
8 - Fuel filter
Arrow marks direction of flow
Do not interchange connections
Replace if damaged
9 - Gasket
Replace if damaged
10 - Water drain plug
To bleed, remove mounting clip and control
valve as a complete assembly (with fuel
lines attached)
Loosen and allow fluid to drain (approx.
100 cc or 3-4 fl. oz.)
23-13
page 23-
23-14
23-15
23-16
- Check attachment to make sure that dimensions -a- and -b- are as
specified when facing forward (arrow -c-).
a = 22
0.05 mm (0.866
0.002 in.)
b = 41
0.05 mm (1.614
0.002 in.)
Note:
The cable cam eye must be parallel to the forward direction.
- Install sensor with bracket.
- Install accelerator pedal cable and mount cable cam eye to pin on
accelerator pedal.
Adjusting
- Connect VAG1551 or VAG1552 scan tool.
- Switch ignition on.
- Press buttons -0- and -1- to insert the "Engine Electronics" address
word 01 page 01-9 .
Rapid data transfer
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08, and press -Q- button to confirm input.
Read Measuring Value Block
HELP
Indicated on display
- Press buttons -0-, -0- and -2- to input display group no. 2 (002), and
press -Q- button to confirm input.
23-17
page 01-41 .
page 01-47 .
23-18
guard.
- Remove cylinder head cover.
- Rotate crankshaft to TDC for cylinder 1 (arrow).
- Lock camshaft with 2065A setting bar.
23-19
- Hold onto sprocket and tap lightly on puller spindle to release sprocket
from injection pump tapered shaft (arrow).
23-20
23-21
Installing
- Insert injection pump into bracket and then
tighten mounting bolt on rear support with
conical nut first.
- Align so injection pump is centered in elongated
holes in bracket, and hand-tighten in this
position.
Note:
Adjust start of injection dynamically using
VAG1551 scan tool.
- Install injection pump sprocket and lock into position using 2064 lock
pin. Make sure spring washer is correctly seated.
- Tighten mounting nut.
Tightening torque: 55 Nm (41 ft lb)
- Loosen camshaft sprocket mounting bolt 1/2-turn.
- Place drift through hole in rear belt guard, tap carefully with hammer to
release sprocket from tapered end of camshaft, and remove camshaft
sprocket.
- Check to make sure that TDC mark on flywheel and reference mark on
transmission housing are aligned.
- Place belt on injection pump sprocket and tensioner roller.
23-22
page 01-41 .
page 01-47 .
23-23
23-24
HELP
Indicated on display
Select function XX
- Press buttons -0- and -4- to select "Basic Setting" function 04.
- Press -Q- button to confirm input.
Basic Setting
HELP
Indicated on display
- Press -0- button three times to input display group no. 0 (000).
- Press -Q- button to confirm input.
23-25
display fields)
Note:
The start of injection value in display field 2 varies depending on the fuel
temperature value in display field 9.
A - Display field 2-Start of injection value
B - Display field 9-Fuel temperature value
C - Specified range for start of injection
(depending on fuel temperature)
Example:
The fuel temperature value "B" in display field 9 (e.g. 90) corresponds to
the start of injection value "A" in display field 2, which should fall within the
range "C" between 34 and 73.
Notes:
If, when checking the start of injection, the results fall within zone -C-,
no adjustment is required.
After repairs e.g. removing and installing Diesel injection pump, set
the start of injection to the mean value (dashed line) of the specified
zone -C-.
If the start of injection is too far advanced, adjust by turning the
injection pump in the direction of engine rotation.
23-26
button.
page 01-
page 01-47 .
23-27
- Turn camshaft until one end of bar contacts cylinder head, then use
feeler gauge to measure gap at other end of bar.
- Place another feeler gauge (thickness = 1/2 measured gap) between
setting bar and cylinder head.
23-28
- Check to make sure that TDC mark on flywheel and reference mark on
transmission housing are aligned (arrow).
If markings do not align, set crankshaft to TDC for cylinder 1.
page 23-23 .
page 01-41 .
page 01-47 .
23-29
23-30
Removing
- Remove fuel injection lines with 3035 injector
line wrench.
Note:
Always remove injector lines as a complete set.
Do not bend or otherwise alter the shape of the
fuel lines.
- Remove mounting nut, take off retainer, and
remove fuel injector.
Installing
Note:
Always replace the heat shield located between
the cylinder head and each of the fuel injectors.
- Insert fuel injector.
- Make sure that mounting is seated correctly in
cylinder head.
- Install retainer.
Tightening torques:
page 01-
page 01-47 .
23-31
complications.
23-32
23-33
23-34
23-35
page 01-43 .
23-36
page 01-47 .
If resistance is OK:
- Connect VAG1598/18 test box to Diesel DFI
ECM harness connector
page 23-34 .
- Check wiring for open circuit between 3-pin connector and test box,
using wiring diagram:
Terminal 1 + test box socket 33
Terminal 2 + test box socket 8
Terminal 3 + test box socket 1
Wire resistance: 1.5 ohms ( ) maximum
- Check wiring for short circuit between terminals at 3-pin connector,
using wiring diagram.
Specification:
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Display readiness code
If DTC memory was erased:
page 01-43 .
page 01-47 .
23-37
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08, and press -Q- button to confirm input.
HELP
Indicated on display
- Press buttons -0-, -1- and -0- to select display group no. 10 (010).
23-38
button.
- Press buttons -0- and -6- to select "End Output" function 06, and press
-Q- button to confirm input.
- Switch ignition off.
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .
23-39
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
23-40
HELP
Indicated on display
- Press buttons -0-, -0- and -7- to input display group no. 7 (007).
- Press -Q- button to confirm input.
Read Measuring Value Block 7
15.4
15.9
C 16.7
- Indicated on display
C
button.
- Press buttons -0- and -6- to select "End Output" function 06.
- Press -Q- button to confirm input.
- Switch ignition off.
23-41
) resistance
page 01-43 .
page 01-47 .
If resistance is OK:
- Connect VAG1598/18 test box to Diesel DFI ECM connector.
23-42
- Check wiring for open circuit between 4-pin connector and test box,
using wiring diagram.
Terminal 1 + test box socket 33
Terminal 3 + test box socket 14
Wire resistance: 1.5 ohms ( ) maximum
- Check wiring for short circuit between terminals at 4-pin connector.
Specification:
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Check and erase DTC memory
Note:
Disconnecting the engine coolant temperature sensor always generates a
DTC, which must be erased.
23-43
23-44
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
- Press -Q- button to confirm input.
Read Measuring Value Block
HELP
Indicated on display
- Press buttons -0-, -0- and -6- to input display group no. 6 (006).
- Press -Q- button to confirm input.
- Check value in display field 2.
Read Measuring Value Block 6
0 km/h 0 0 0 000000 255
Specified display: 0 0 0
Center display element = Brake vacuum vent valve switch
Right display element = Brake light switch
- Press brake pedal slowly.
Specified display: 0 1 1
Note:
Both display elements must change from "0" to "1" at the same time.
23-45
button.
- Press buttons -0- and -6- to select "End Output" function 06, and press
-Q- button to confirm input.
- Switch ignition off.
- Disconnect harness connector from brake vacuum vent valve switch 1-.
- Measure resistance across switch terminals.
Specifications:
Brake pedal not depressed: less than 10 ohms (
Brake pedal depressed:
(no continuity)
23-46
page 01-43 .
page 01-47 .
- Check wiring for open circuit between test box and harness connector,
using wiring diagrams:
Terminal 1 and test box socket 20
Terminal 2 and test box socket 33
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
If the right display element in display field 2 (brake light switch) does not
change:
- Press
button.
23-47
page 01-43 .
page 01-47 .
23-48
HELP
Indicated on display
23-49
HELP
Indicated on display
- Press buttons -0-, -0- and -6- to input display group no. 6 (006), and
press -Q- button to confirm input.
- Check value in display field 2.
Read Measuring Value Block 6
Specification: 0 0 0
button.
- Press buttons -0- and -6- to select "End Output" function 06, and press
-Q- button to confirm input.
- Switch ignition off.
- Disconnect harness connector from clutch vacuum vent valve switch
page 23-4 .
- Measure resistance across switch terminals. Specifications:
(no continuity)
23-50
page 01-43 .
page 01-47 .
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .
23-51
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
- Press -Q- button to confirm input.
23-52
HELP
Indicated on display
- Press buttons -0-, -0- and -7- to input display group no. 7 (007).
- Press -Q- button to confirm input.
Read Measuring Value Block 7
15.4
C 15.9
C 16.7
- Indicated on display
button.
- Press buttons -0- and -6- to select "End Output" function 06.
- Press -Q- button to confirm input.
- Switch ignition off.
- Disconnect harness connector -1- from intake air temperature sensor 2-.
23-53
) resistance
page 01-43 .
page 01-47 .
If resistance is OK:
- Connect VAG1598/18 test box to Diesel DFI ECM connector.
23-54
- Check wiring for open circuit between test box and harness connector,
using wiring diagrams:
Terminal 1 and test box socket 64
Terminal 2 and test box socket 33
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .
23-55
23-56
page 23-5 ,
page 01-43 .
page 01-47 .
23-57
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
- Press -Q- button to confirm input.
23-58
HELP
Indicated on display
- Press buttons -0-, -0- and -7- to input display group no. 7 (007).
- Press -Q- button to confirm input.
Read Measuring Value Block 7
15.4
C 15.9 5C 16.7
- Indicated on display
If an implausible value appears in display field 1, or a substitute value of 5.4 C is displayed, check fuel temperature sensor and sensor and
wiring:
- Press
button.
- Press buttons -0- and -6- to select "End Output" function 06.
- Press -Q- button to confirm input.
- Switch ignition off.
- Disconnect fuel temperature sensor harness connector (connection to
Diesel injection pump metering control).
23-59
) resistance
page 23-18 .
page 01-43 .
page 01-47 .
23-60
- Check wiring for open circuit between test box and harness connector,
using wiring diagrams:
Terminal 7 and test box socket 63
Terminal 4 and test box socket 33
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .
23-61
23-62
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08, and press -Q- button to confirm input.
Read Measuring Value Block
HELP
Indicated on display
- Press buttons -0-, -0- and -1- to input display group no. 1 (001), and
press -Q- button to confirm input.
Indicated on display
page 23-65 .
page 23-63 .
23-63
button.
page 23-18 .
page 01-43 .
page 01-47 .
If resistance is OK:
- Connect VAG1598/18 test box to Diesel DFI ECM connector.
23-64
- Check wiring for open circuit between test box and harness connector,
using wiring diagrams:
Terminal 1 and test box socket 29
Terminal 2 and test box socket 7
Terminal 3 and test box socket 52
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .
23-65
button.
page 23-18 .
page 01-43 .
page 01-47 .
23-66
- Check wiring for open circuit between test box and harness connector,
using wiring diagrams:
Terminal 5 and test box socket 23
Terminal 5 and test box socket 45
Terminal 5 and test box socket 68
Terminal 6 and test box socket 4
Terminal 6 and test box socket 5
Terminal 6 and test box socket 49
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .
23-67
23-68
page 01-47 .
If resistance is OK:
- Connect VAG1598/18 test box to Diesel DFI ECM connector.
(no continuity)
page 01-
23-69
23-70
Checking
- Connect VAG1551 or VAG1552 scan tool
page 01-9 .
- Start engine and let idle.
- Press buttons -0- and -1- to insert the "Engine
Electronics" address word 01.
Rapid data transfer
HELP
Indicated on display
Select function XX
- Press buttons -0- and -3- to select "Output Diagnostic Test Mode"
function 03, and press -Q- button to confirm input.
Rapid data transfer
Indicated on display
Note:
Individual DTM components are activated for 30seconds. Various work
sequences must be carried out with the scan tool within this period as well
as reading the displayed values. Read over the following work sequence
first to familiarize yourself with the procedure.
- Press -Q- button to confirm input.
Output Diagnostic Test Mode
Cold Start Injector-N108
Indicated on display
23-71
HELP
Indicated on display
- Press buttons -0-, -0- and -4- to input display group no. 4 (004).
- Press -Q- button to confirm input.
Read Measuring Value Block 4
Indicated on display
Note:
BTDC 0.9
BTDC 3 %
ATDC to 4.0
BTDC
BTDC
23-72
button.
page 01-43 .
page 01-47 .
23-73
If resistance is OK:
- Connect VAG1598/18 test box to Diesel DFI ECM connector.
- Check wiring for open circuit between test box and 3-pin harness
connector, using wiring diagrams:
Terminal 2 and test box socket 51
Terminal 3 and test box socket 68
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
23-74
If wiring is OK:
- Replace Diesel DFI ECM -J248item 17 .
- Display readiness code
page 23-5 ,
page 01-43 .
page 01-47 .
23-75
23-76
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
- Press -Q- button to confirm input.
HELP
Indicated on display
- Press buttons -0-, -1- and -1- to input display group no. 11 (011).
- Press -Q- button to confirm input.
23-77
- Indicated on display
- Accelerate vehicle in 3rd gear from about 1500 RPM using wide open
throttle.
- Press "PRINT" button on VAG1551 at about 3000 RPM.
23-78
page 01-43 .
page 01-47 .
23-79
23-80
- Check wiring for open circuit between test box and 3-pin harness
connector, using wiring diagrams:
Terminal 1 and test box socket 68
Terminal 2 and test box socket 47
Wire resistance: max. 1.5 ohms ( )
- Check wiring for short circuit between connector terminals.
Specification:
(no continuity)
page 01-43 .
page 01-47 .
23-81
23-82
Checking
- Connect VAG1551 or VAG1552 scan tool.
page 01-9
- Start engine and let idle.
- Press buttons -0- and -1- to insert "Engine
Electronics" address word 01.
Rapid data transfer
HELP
Indicated on display
Select function XX
- Press buttons -0- and -3- to select "Output Diagnostic Test Mode"
function 03.
- Press -Q- button to confirm input.
Rapid data transfer
Indicated on display
Note:
Individual DTM components are activated for 30seconds. Various work
sequences must be carried out with the scan tool within this period as well
as reading the displayed values. Read over the following work sequence
first to familiarize yourself with the procedure.
Output Diagnostic Test Mode
Cold Start Injector-N108
Indicated on display
- Press
Output Diagnostic Test Mode
button.
Indicated on display
23-83
HELP
Indicated on display
- Press buttons -0-, -0- and -3- to input display group no. 3 (003).
- Press -Q- button to confirm input.
Read Measuring Value Block 3
- Indicated on display
Note:
The values in display fields 3 and 4 must fluctuate within the following
control range:
Specification display field 3:
Lower range: 230-310 mg/stroke
Upper range: 360-480 mg/stroke
Specification display field 4:
Lower range: 2 to 5%
Upper range: 90 to 95%
Note:
Due to the slow refresh rate of the VAG1551 scan tool, the displayed
values can greatly vary. Ensure that the upper and lower range values in
display fields 3 and 4 are obtained. Only regard the minimum or maximum
values!
23-84
button.
23-85
Specification
3 and Ground
3 and 5
1 and Ground
Approx. 5 Volts
1 and 5
Approx. 5 Volts
23-86
(no continuity)
If specifications obtained:
- Check EGR vacuum regulator solenoid valve
N18 as follows:
23-87
page 01-43 .
page 01-47 .
If specification obtained:
- Switch ignition on.
- Connect multimeter between connector terminal 1 and engine Ground
using adapters from VW1594 connector test kit.
Specification: approx. battery voltage
If specification not obtained:
- Switch ignition off.
23-88
(no continuity)
If wiring is OK:
- Replace Diesel DFI ECM -J248item 17 .
- Display readiness code
page 23-5 ,
page 01-43 .
page 01-47 .
23-89
Test sequence
- Connect VAG1551 or VAG1552 scan tool.
page 01-9
- Start engine and let idle.
23-90
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08.
- Press -Q- button to confirm input.
Read Measuring Value Block
HELP
Indicated on display
- Press buttons -0-, -0- and -6- to input display group no. 6 (006).
- Press -Q- button to confirm input.
Read Measuring Value Block 6
Indicated on display (1 to 4
display fields)
1234
23-91
page 01-43 .
page 01-47 .
23-92
23-93
HELP
Indicated on display
Select function XX
- Press buttons -0- and -8- to select "Read Measuring Value Block"
function 08, and press -Q- button to confirm input.
Read Measuring Value Block
HELP
Indicated on display
- Press buttons -0-, -0- and -2- to input display group no. 2 (002), and
press -Q- button to confirm input.
Read Measuring Value Block 2
RPM 0.0 % 0 1 0 18.4
23-94
page 23-4
- Switch multimeter to resistance range.
23-95
page 01-43 .
page 01-47 .
23-96
- Check following wiring connections for open circuits and/or short circuit
to positive or negative:
Terminal 1 to test box socket 15
Terminal 2 to test box socket 57
Terminal 3 to test box socket 55
Terminal 4 to test box socket 65
Terminal 5 to test box socket 62
Terminal 6 to test box socket 33
- Repair any open or short circuit as necessary.
If neither an open or short circuit exists
- Replace Diesel DFI ECM -J248- Display readiness code
page 01-43 .
page 01-47 .