00055009920-TDI Diesel Injection and Glow Plug System (4-Cyl) 08 99 Ä

Service
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Audi A4 1995 ➤
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
TDI diesel injection and glow plug system (4-cyl.) 08.99

➤
Engine ID AFF AFN AHH AHU AVG
Edition 08.1999
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Audi A4 1995 ➤
TDI diesel injection and glow plug system (4-cyl.) 08.99
➤
Repair Group
01 - Self-diagnosis
23 - Mixture preparation, Injection
28 - Glow plug system
Technical information should always be available to the foremen and mechanics, because their careful
and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In
addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course,
be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt 00055009920

Audi A4 1995 ➤
TDI diesel injection and glow plug system (4-cyl.) 08.99 ➤ - Edition 08.1999
Contents
01 - Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Technical data of self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Connecting vehicle diagnostic, testing and information system VAS 5051 or fault reader
V.A.G 1551 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Interrogating and erasing fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2
Protected by copyright. Final
Copying control
for private diagnosis
or commercial . . . in. .part
purposes, . .or. in. .whole,
. . . is. not
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.1
with respect to Finalofcontrol
the correctness informationdiagnosis . . Copyright
in this document. . . . . . .by. AUDI. . . AG.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3 Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.1 Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4 Coding control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.1 Coding control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.1 Reading measured value block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.2 Readout specifications for general vehicle inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.3 Readout specifications for injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.4 Readout specifications for engine idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.5 Readout specifications for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.6 Readout specifications for temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.7 Readout specifications for engine power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
5.8 Readout specifications for charge pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

1 Servicing Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.1 Servicing Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1.4 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
1.5 Servicing injection pump: engine code AFF, AHU, AFN, AVG . . . . . . . . . . . . . . . . . . . . . . . .45
1.6 Servicing injection pump: engine code AHH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
1.7 Removing and installing injection pump: engine codeAFF, AHU, AFN,AVG . . . . . . . . . . . .53
1.8 Dynamically checking and adjusting commencement of injection: engine code AFF, AHU,
AFN, AVG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
1.9 Removing and installing injection pump: engine code AHH . . . . . . . . . . . . . . . . . . . . . . . . . .60
1.10 Dynamically checking and adjusting commencement of injection: engine code AHH . . . . . .65
1.11 Removing, installing and testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
1.12 Renewing injection timing device cover O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
1.13 Wiring and component check with test box V.A.G 1598/31 . . . . . . . . . . . . . . . . . . . . . . . . . .69
1.14 Renewing engine electronics control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
2 Testing injection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2.1 Testing injection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2.2 Checking injection timing control range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2.3 Checking commencement of injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
2.4 Checking fuel temperature sender -G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
3 Checking control unit input values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
3.1 Checking control unit input values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
3.2 Checking Diesel direct injection system voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
3.3 Checking engine speed sender -G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
3.4 Checking air mass meter -G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.5 Checking needle lift sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
3.6 Testing coolant temperature sender -G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Contents i
Audi A4 1995 ➤
3.7 Checking intake manifold temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

3.8 Checking modulating piston movement sender -G149 and quantity adjuster -N146 . . . . . .86
4 Testing auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
4.1 Testing auxiliary signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
4.2 Testing signals from and to air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
4.3 Testing speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
4.4 Testing engine speed signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
4.5 Testing a "two-wire data bus system" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.2 Testing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
1.3 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
ii Contents
Audi A4 1995 ➤
01 - Self-diagnosis
1 - Self-diagnosis
1.1 - Self-diagnosis
1.2 - Technical data of self-diagnosis
Equipment
◆ Fault memory: Non-volatile memory and volatile memory1)

◆ Rapid data transfer
1) Will be cancelled after 50th engine start if fault has not occurred again.
Selectable functions
Function Ignition switched Engine idling

on
01 Interrogating x x
control
unit version
02 Interrogate fault - x
memory
03 Final control di‐ - x
agnosis
04 Basic setting - x
05 Erase fault mem‐ x x
ory
06 End output x x
07 Code control unit x x
08 Read measured x x
value block
1.1 - Self-diagnosis 1
Audi A4 1995 ➤
1.3 - Connecting vehicle diagnostic, testing and information system VAS 5051 or fault reader
V.A.G 1551 and selecting functions
Test conditions
• Battery voltage at least 11 V

• Fuse OK.
- -> Open rear ashtray (in centre console) and remove cover for diagnostic connector.
- -> Connect up vehicle diagnostic, testing and information system VAS 5051 with diagnostic cable VAS
5051/1. Alternatively, connect fault reader V.A.G 1551 using diagnostic cable V.A.G 1551/3A.
Warning:
◆ When carrying out road tests using vehicle diagnostic, testing and information system VAS 5051 or fault
reader V.A.G
Note:
The following description only covers the procedure for performing self-diagnosis with fault reader V.A.G 1551.
If using vehicle diagnostic, testing and information system VAS 5051, follow the operating instructions supplied
with the equipment.
-> Indicated on display:
V.A.G - SELF DIAGNOSIS HELP
1 - Rapid data transfer*
2 - Flash code output*
* Appears alternately
Note:
If the display remains blank:
=> Fault reader operating instructions
Depending on the function required:
- Switch on ignition
2 01 - Self-diagnosis
Audi A4 1995 ➤
or
Start engine => Page 1 , Table "Selectable functions".
- Switch on printer with the Print button

(Warning lamp in button lights up).
- Press key 1 for "Rapid data transfer".

Rapid data transfer HELP
Enter address word XX
-
Rapid data transfer Q
01 - Engine electronics
-> Press keys 0 and 1 for address word "Engine electronics" and confirm entry by pressing the Q key.
-> If the display shows one of the messages reproduced here, run through the fault-finding procedure as de‐
scribed in the Fault-Finding Programme for diagnosis wiring.
Control unit does not answer
=> Current Flow Diagrams, Electrical Fault-Finding and Fitting Locations

Fault in communication build up

K wire not switching to earth

K wire not switching to positive
-> The display on fault reader permitted
V.A.G 1551 will show the control unit identification. For example:
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
038906018.. 1.9l R4 EDC
G00SG 0203 " Coding 00002 WSC
12345
- 038906018.. Control unit number (see also Parts

List)
- 1.9 ltr. Engine capacity
- R4 In-line engine, 4 cylinders
- EDC Electronic Diesel Control
-G Vehicle with or without cruise control
- or no display
- 00 Control unit maps
- AG Automatic gearbox
- SG Manual gearbox
- 0203 Software version of control unit
- Coding 00002 Control unit coding
- WSC 12345 Workshop Code of V.A.G 1551 which
was used to perform the last coding
- Press ⇒key.

Select function XX
1.3 - Connecting vehicle diagnostic, testing and information system VAS 5051 or fault
reader V.A.G 1551 and selecting functions 3

Audi A4 1995 ➤
1.4 - Interrogating and erasing fault memory

- Connect vehicle diagnostic, testing and information system VAS 5051 (or fault reader V.A.G 1551) and
select engine electronics control unit by entering address word "01" (=> Page 2 ).
When doing this the engine must be running at idling speed.
Only when engine does not start:

- Interrogate fault memory with ignition switched on.

Select function XX
- Press keys 0 and 2 for function "Interrogate fault memory" and confirm entry with Q key.
-> The display will show either the number of faults stored or the message "No fault recognised!".
X Faults recognised!
If no fault is stored: with respect to the correctness of information in this document. Copyright by AUDI AG.
- Press ⇒key.
If one or more faults are stored:

The faults stored will be displayed and printed out one after the other.
-> Then the display will show:
Select function XX
- Locate and eliminate faults printed out as per fault table => Page 4 .
- Press keys 0 and 5 for the function "Erase fault memory" and confirm entry with Q key.

Rapid data transfer
Fault memory is erased!
Note:
If the ignition is switched off between interrogating fault memory and erasing fault memory, the fault memory
will not be erased.
- Press ⇒key.

Select function XX
- Press keys 0 and 6 for the "End data transfer" function and confirm input with the Q key.
1.5 - Fault table
Notes:
◆ If faults occur in the sensors and components being monitored, they will be stored in the fault memory
together with an indication of the type of fault.
◆ The fault table is arranged according to the 5-digit fault codes in the left-hand column.
◆ Sporadically occurring faults (temporary faults) will be indicated on the V.A.G 1551 display as "SP".
◆ If a fault is stored in the fault memory and then does not occur again during the next 50 engine warm-up
phases, the fault code will be automatically erased.
Audi A4 1995 ➤
◆ Before renewing components indicated as being faulty, check the wiring and connectors to these compo‐
nents as well as the earth connections using the current flow diagrams.
V.A.G 1551 print-out Possible causes of fault Possible effects Fault remedy
16485 P0101
Air mass meter -G70
Implausible signal - Air mass meter defective - Loss of power, jolting - Test air mass meter
=> Page 81
- Engine has been stalled - Erase fault memory and
(within the last 50 starts) continue to monitor vehicle
- Battery low - Loss of power - Test battery
- Constant air mass readout
in measured value block
- Sporadic open circuit in wir‐ - Misfiring, jolting - Test needle lift sender =>
ing to needle lift sender -G80 - Fault reading: Needle lift Page 83
(break in wiring) sender open circuit/short to
positive might be displayed
- Air cleaner blocked - Rough idling, loss of power - Test intake system
- Vacuum hose system for ex‐ Check vacuum hoses
haust gas recirculation incor‐ => 4-Cyl. Diesel direct injec‐
rectly connected, or mechan‐ tion engine (TDI), Mechan‐
ical exhaust gas recirculation ics; Repair group 26
valve constantly open
16705 P0321
Engine speed sender -G28
Implausible signal - Sender disc bent or loose - Engine stops - Remove sump and check sender
disc
- -G28 defective - Engine stops - Test engine speed sender => Page
80
- Open circuit in screening
16706P0322
Engine speed sender -G28
No signal - -G28 defective - Check engine speed sender =>
-permitted
Openunless
circuit or short Page 80
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
16885 P0501
Road speed signal
Implausible signal - Open circuit between - Cruise control not working - Test speed signal
speedometer sender -G22 - Air conditioner not working => Page 91
and dash panel insert - Load change jolts Test speedometer sender
- -G22 defective => Electrical System; Repair
- Speedometer -G21 defec‐ Group 90
tive
- Open circuit between dash
panel insert and engine con‐
trol unit
16955 P0571
Brake light switch -F
1.5 - Fault table 5

Audi A4 1995 ➤
Implausible signal - Switch incorrectly set - No throttle response at - Test and adjust -F and -
- Open circuit times, complete loss of pow‐ F47
- -F or -F47 defective er Check brake lights
- Fuse defective - Glow period warning lamp => Electrical system; Repair
- Both brake lights defective flashes group 94
16989 P0605
Control unit defective - Internal fault in control unit - Engine running problems - Fit a new control unit
- Engine will not run => Page 71
17552 P1144
Air mass meter -G70
Open/short circuit to earth - -G70 defective - Loss of power - Test air mass meter
- Open circuit or short to - Black exhaust smoke possi‐ => Page 81
earth ble when accelerating from
low engine speeds
17553 P1145
Air mass meter -G70
Short circuit to positive - -G70 defective - Loss of power - Test air mass meter
- Short circuit to positive - Black exhaust smoke possi‐ => Page 81
ble when accelerating from
low engine speeds
17554 P1146
Air mass meter -G70
Voltage supply - Open circuit or short circuit - Loss of power - Test air mass meter
Protected by copyright. Copying for private -orBlack exhaust
commercial purposes,smoke possi‐
in part or in whole, is =>
not Page 81
ble AG
permitted unless authorised by AUDI AG. AUDI when
does accelerating from
not guarantee or accept any liability
low inengine
with respect to the correctness of information speeds
this document. Copyright by AUDI AG.
17563 P1155
Intake manifold pressure sender -
G71
Short circuit to positive - Open circuit or short - Loss of power - Test intake manifold pres‐
- -G71 defective sure sender
=> 4-Cyl. Diesel direct injec‐
tion engine (TDI), Mechanics;
Repair group 21
17564 P1156
G71
Open/short circuit to earth - Open circuit - Loss of power - Test intake manifold pres‐
- -G71 defective sure sender
=> 4-Cyl. Diesel direct injec‐
Repair group 21
17565 P1157
G71
Voltage supply - Open circuit or short - Loss of power - Test intake manifold pres‐
sure sender
=>4-Cyl. Diesel direct injec‐
Repair group 21
Audi A4 1995 ➤
17568P1160
Intake manifold temperature
sender -G72
Short circuit to earth - -G72 defective - Engine pre-heating - Test intake manifold
- Short to earth not working temperature sender
=>Page 85
17569 P1161
Intake manifold temperature
sender -G72
Open/short circuit to posi‐ - -G72 defective - Engine pre-heating - Test intake manifold
tive - Open circuit or short to not working temperature sender
positive =>Page 85
17570 P1162
Fuel temperature sender -
G81
Short circuit to earth - -G81 defective - Reduced power - Test fuel temperature
- Short circuit to earth sender
=> Page 75
17571 P1163
Fuel temperature sender -
G81
Open/short circuit to posi‐ - -G81 defective - Reduced power - Test fuel temperature
tive - Open circuit or short to sender
positive => Page 75
- Plug for injection pump - Several faults recorded - Check injection pump
disconnected - Engine stops connection
17653 P1245
Needle lift sender -G80
Short circuit to - -G80 defective - Glow period warning lamp - Test needle lift sender
earth - Short circuit lights up => Page 83
- Engine running rough
- Reduced power
17654 P1246
Implausible signal - Fuel feed interrupted (inter‐ - Fault 17656 (Commence‐ - Check fuel system
mittently); tank was run dry, ment of injection control;
supply pipe or filter blocked, Control difference) may be
air entering fuel system recorded
- Misfiring, jolting
- (Sporadic) open circuit in - Engine stops - Check wiring and plug
wiring to fuel cut-off valve - Misfiring connections to injection
pump
17654 P1246
Implausible signal - Sender disc of engine - Misfiring at exactly 3000 - Remove sump and check
speed sender is bent or rpm sender disc
loose
- -G80 defective - Misfiring, jolting (especially - Fit a new needle lift send‐
at high engine speeds) er
1.5 - Fault table 7

Audi A4 1995 ➤
- Injection pump defective - Fault 17969 recorded - Fit a new injection pump
(Quantity adjuster; Control
difference)
- Engine running rough, mis‐
firing
- No throttle response after
overrun
17655 P1247
Open/short circuit to - -G80 defective - Glow period warning - Test needle lift sender
positive - Open circuit or short cir‐ lamp lights up => Page 83
cuit - Engine running rough
- Reduced power
- Sporadic open circuit - Misfiring, jolting
(break in wiring)
17656 P1248
Injection commencement
regulation
Regulating difference - Start of delivery not OK - Loss of power at high - Check and adjust com‐
engine speeds mencement of injection
- Engine difficult to start =>Page 59
- Control range of injection - Loss of power at high - Check control range of
pump blocked (dirt, metal engine speeds injection timing control
particles) => Page 72
- Engine has been stalled - Erase fault memory and
(within the last 50 starts) continue to monitor vehi‐
cle
17656 P1248
Injection commencement regu‐
lation
Control difference - Fuel feed interrupted - Fault 17654 (implausi‐ - Check fuel system
(intermittently); tank was ble signal for needle lift
run dry, supply pipe or fil‐ sender) may be have
ter blocked, air entering been recorded
fuel system
- Open circuit in wiring to - Engine knocks when - Test commencement
commencement of injec‐ idling because com‐ of injection valve =>
tion valve -N108 mencement of injection Page 72
is constantly advanced
- Several faults may - Test fuse
have been recorded
17659 P1251
Commencement of injection
valve -N108
Short circuit to positive - Short circuit to positive - Engine knocks when - Test commencement of
idling because com‐ injection valve
mencement of injection is => Page 72
constantly advanced
17660 P1252
Audi A4 1995 ➤
Commencement of injection
valve -N108
Open/short circuit to - Open circuit (fuse) - Engine knocks when - Test commencement of
earth - Valve defective idling because com‐ injection valve => Page
mencement of injection is 72
constantly advanced
- Several faults may be - Test fuse
recorded
- Short circuit to earth - Loss of power because - Test commencement of
commencement of injec‐ injection valve => Page
Protected by copyright. Copying for private or commercial purposes, in part ortion is constantly
in whole, is not retarded 72
17663 P1255
Coolant temperature sender
-G62
Short circuit to earth - -G62 defective - Black exhaust smoke - Test coolant temperature
- Short to earth when starting sender
- Engine pre-heating not =>Page 84
functioning
- Glow period always ap‐
prox. 20 seconds
17664 P1256
Coolant temperature sender
-G62
Open/short circuit to pos‐ - -G62 defective - Black exhaust smoke - Test coolant temperature
itive - Open circuit or short to when starting sender
positive - Engine pre-heating not =>Page 84
functioning
- Glow period always ap‐
prox. 20 seconds
V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

fault
17762 P1354
Modulating piston movement sender -
G149
- Connector for injec‐ - Several faults recor‐ - Check connector for
tion pump disconnec‐ ded injection pump
ted - Engine will not run
- Injection pump de‐ - Engine running - Test modulating pis‐
fective problems ton movement sender
- Open circuit or short - Engine will not run => Page 86
circuit
17795 P1387
Control unit defective - Internal fault in con‐ - Engine running - Fit a new control unit
trol unit problems => Page 71
- Engine will not run
17810 P1402
Exhaust gas recirculation valve
-N18-
1.5 - Fault table 9

Audi A4 1995 ➤
Short circuit to positive - Short circuit to positive - No exhaust gas recircu‐ - Test exhaust gas recir‐
lation culation valve
=> 4-Cyl. Diesel direct in‐
jection engine (TDI), Me‐
chanics; Repair group 26
17849 P1441
Exhaust gas recirculation valve
-N18-
Open/short circuit to - Open circuit - No exhaust gas recircu‐ - Test exhaust gas recir‐
earth - Solenoid defective lation culation valve
=> 4-Cyl. Diesel direct in‐
- Short circuit to earth - Too much exhaust gas
recirculation
- Reduced power, black
exhaust smoke
17911 P1503
Load signal for alternator terminal
DF
Implausible signal - Open circuit or short - Engine pre-heating - Check wiring
circuit not working => Current flow diagrams,
Electrical fault-finding and
Fitting locations binder
17931 P1523
Crash signal from airbag CU
Implausible signal - Open circuit or short - Test crash signal =>Car‐
circuit ry out final control diagno‐
sis in airbag control unit
Check wiring
permitted unless authorised by AUDI AG. AUDI=> Current flow diagrams,
AG does not guarantee or accept any liability
with respect to the correctness of informationElectrical fault-finding
in this document. andAG.
Copyright by AUDI
17945 P1537
Fuel cut-off valve -N109
Mechanical fault - N109 defective, leaking or - Reduced output - Check N109
sticking - Engine will not start =>Page 16 , Final control di‐
agnosis
17946 P1538
Open/short circuit to earth - -N109 defective - Engine stops - Check wiring
- Open circuit in wiring or => Current flow diagrams,
short circuit to earth Electrical fault-finding and Fit‐
ting locations
17948 P1540
Road speed signal
Audi A4 1995 ➤
Signal too high - -G22 defective - Cruise control not - Test speed signal
- Speedometer -G21 de‐ working => Page 91
fective - Air conditioner not Test speedometer
working sender
- Load change jolts => Electrical system;
Repair group 90
17954 P1546
Charge pressure control solenoid
valve -N75
Short circuit to positive - Short circuit to positive - Reduced power - Test charge pressure
- Boost pressure too low control solenoid valve
=> 4-Cyl. Diesel direct
injection engine (TDI),
Mechanics; Repair
group 21
17957 P1549
Charge pressure control solenoid
valve -N75
Open/short circuit to - Open circuit - Reduced power - Test charge pressure
earth - Solenoid defective - Boost pressure too control solenoid valve
low => 4-Cyl. Diesel direct
Mechanics; Repair
group 21
- Short circuit to earth - Reduced power
- Boost pressure too
high
17964 P1556
Charge pressure control
Regulating limit not - Hoses wrongly connec‐ - Sudden complete - Test charge pressure
reached ted, disconnected, loss of power Check charge pressure
blocked or leaking - Reduced power hose connections
- Pressure unit for turbo‐ => 4-Cyl. Diesel direct
charger defective injection engine (TDI),
- Solenoid valve for Mechanics; Repair
charge pressure control - group 21
N75 defective
17965 P1557
Charge pressure control
Regulating limit surpassed - Hoses wrongly connec‐ - Sudden complete loss - Test charge pressure
ted, disconnected, blocked of power Check charge pressure
or leaking - Reduced power hose connections
- Pressure unit for turbo‐ => 4-Cyl. Diesel direct in‐
charger defective jection engine (TDI), Me‐
- Solenoid valve for charge chanics; Repair group 21
pressure control -N75 de‐
fective
17969 P1561
Metering device -N146
Regulating difference - Injectionpermitted
pumpunlessdefective
authorised -byEngine
AUDI AG. running
AUDI AG doesprob‐ - Test
not guarantee quantity
or accept adjuster
any liability
- Open circuit or short
with respect to thecir‐ lemsof information in this document. Copyright
correctness =>Page 86 AG.
by AUDI
cuit - Engine stops Fit a new injection pump
1.5 - Fault table 11

Audi A4 1995 ➤
17970 P1562
Upper stop value - Quantity adjuster incorrectly - Engine stops (safety cut-out) - Test quantity adjuster
set =>Page 86
Replace injection pump
17971 P1563
Lower stop value - Quantity adjuster incorrectly - Engine stops (safety cut-out) - Test quantity adjuster
set =>Page 86
Replace injection pump
17977 P1569
CCS Switch -E45
Implausible signal - Cruise control system - Cruise control system - Test cruise control sys‐
switch -E45 defective switched off tem
- Open circuit or short in => Electrical system; Re‐
wiring pair group 27
17978
Engine control unit blocked
- Attempted tampering - Engine starts but cuts out - Adapt control unit for en‐
again immediately gine electronics to elec‐
tronic immobilizer
- Short in the communica‐ - Check electronic immo‐
tion wire bilizer:
=> Repair group 96; Serv‐
icing electronic immobiliz‐
er
18008 P1600
Voltage supply,
terminal 15
Voltage too low - Control unit was connected - Erase fault memory and
while ignition was switched continue to monitor vehicle
on
- Open circuit or short - Engine will not start - Test power supply to diesel
- Engine stops direct injection system
=>Page 76
18009 P1601
Vehicle voltage Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
terminal 30 with respect to the correctness of information in this document. Copyright by AUDI AG.
Implausible signal - Relay for diesel direct injec‐ - Engine will not start (safe‐ - Check power supply to die‐
tion system -J322 sticking ty cut-out) sel direct injection system
=>Page 76
18020 P1612
Engine control unit
Wrong coding - Invalid control unit coding - Glow period warning - Code control unit
lamp flashes => Page 22
18026 P1618
Audi A4 1995 ➤
Glow plug relay -J52

Short circuit to positive - Short circuit to positive - Glow plug system not - Test wiring
working => Current flow diagrams,
Fitting locations
18027 P1619
Open/short circuit to earth - Open circuit - Glow plug system not - Check wiring
- Relay defective working => Current flow diagrams,
Fitting locations
- Short circuit to earth - Glow plug system re‐
mains on constantly
18034 P1626
Drive train data bus
No message from gear‐ - Open circuit in wiring to - Gearbox in emergency - Check wiring
box CU gearbox CU running mode => Current flow diagrams,
Fitting locations
18039 P1631 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Accelerator position sender
permitted-G79
Signal too high - Open circuit or short - Safety governing at ap‐ - Test accelerator posi‐
circuit to positive prox. 1100 rpm tion sender
- -G79 defective - No throttle response => 4-Cyl. Diesel direct
Mechanics; Repair
group 20
18040 P1632
Accelerator position sender -G79
Voltage supply - Open circuit or short - Safety governing at ap‐ - Test accelerator posi‐
circuit prox. 1100 rpm tion sender
- No throttle response => 4-Cyl. Diesel direct
Mechanics; Repair
group 20
18044 P1636
No message from air‐ - Open circuit in wiring to - Check wiring
bag CU airbag CU => Current flow diagrams,
18047 P1639
Accelerator position sender -
G79 + G185

Audi A4 1995 ➤
Implausible signal - Open circuit - Safety governing at ap‐ - Test accelerator position
- -G79 defective (idling prox. 1100 rpm sender
speed switch) - No throttle response => 4-Cyl. Diesel direct in‐

fault
18048 P1640
Control unit defective - Internal fault in con‐ - Engine running prob‐ - Fit a new control unit
trol unit lems => Page 71
- Engine will not run
18050 P1642
Please interrogate fault memory of
airbag CU
permitted unless authorised - Fault
by AUDIin
AG.airbag
AUDI AGsys‐
does not guarantee or accept any liability - Investigate and elimi‐
tem of information in this document. Copyright by AUDI AG.
with respect to the correctness nate cause of fault in air‐
bag system
18056 P1648
Hardware defective - Open circuit or short - Engine running prob‐ - Check wiring
circuit to earth/positive lems => Current flow dia‐
grams, Electrical fault-
finding and Fitting loca‐
tions binder
18057 P1649
Message from ABS con‐ - Open circuit in wiring to - ASR warning lamp (trac‐ - Check wiring
trol unit missing ABS control unit tion control system) lights => Current flow diagrams,
up Electrical fault-finding and
- Traction control system Fitting locations binder
(ASR) not working
18058 P1650
Message from combi-in‐ - Open circuit in wiring to - Check wiring
strument missing combi-instrument (dash => Current flow diagrams,
panel insert) Electrical fault-finding and

fault
18062 P1654
Please interrogate fault memory of
combi-instrument
- Fault in combi-in‐ - Investigate and elimi‐
strument (dash panel nate cause of fault in
insert) combi-instrument (dash
panel insert)
18067 P1659
Activation 1 for radiator fan
Audi A4 1995 ➤
Short to positive - Short to positive - Fan run-on not - Test radiator fan run-
working on control unit -J138
=> Current flow dia‐
grams, Electrical fault-
finding and Fitting loca‐
tions binder
18080 P1672
Activation 1 for radiator fan
Open /short circuit to earth - Open circuit - Fan run-on not working - Test radiator fan run-on
- Relay defective control unit -J138
=> Current flow diagrams,
- Short circuit to earth - Radiator fan remains on
constantly
18090 P1682
Implausible signal from - Signal malfunction - ASR warning lamp (trac‐ - Check wiring
ABS CU tion control system) glows => Current flow diagrams,
- Traction control system Electrical fault-finding and
(ASR) not working Fitting locations binder
19458 P3002
Kick-down switch -F8
Implausible signal - Open circuit - Test accelerator position
- -G79 defective (kick- sender
down switch) => 4-Cyl. Diesel direct in‐
19459 P3003
Low heating output relay -
J359
Short circuit to positive - Short circuit to positive - Engine pre-heating not - Check wiring
19460 P3004
Low heating output relay -
J359 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Open/shortwith
circuit
respectto - Open
to the correctness circuit inin this
of information wiring
document.- Copyright
Enginebypre-heating
AUDI AG. not - Check wiring
earth - Low heating output re‐ working => Current flow diagrams,
lay -J359 defective Electrical fault-finding and
Fitting locations
- Short circuit to earth - Engine pre-heating re‐
mains on constantly
19461 P3005
High heating output relay -
J360

Audi A4 1995 ➤
Short circuit to positive - Short circuit to positive - Engine pre-heating not - Check wiring
Fitting locations
19462 P3006
High heating output relay -
J360
Open/short circuit to - Open circuit - Engine pre-heating not - Check wiring
earth - High heating output re‐ working => Current flow diagrams,
lay -J360 defective Electrical fault-finding and
Fitting locations
- Short circuit to earth - Engine pre-heating re‐
mains on constantly
2 - Final control diagnosis

2.1 - Final control diagnosis
Test requirements for vehicles with air conditioning system
• Vehicle at room temperature (warmer than + 15 °C)

• Air conditioning system switched on
• Select lowest temperature and highest blower speed
The final control diagnosis activates the following components in the stated sequence:
1. Commencement of injection valveby(N108)

Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
2. Exhaust gas recirculation valve (N18)

3. Conditioner compressor interruption
4. Fuel cut-off valve (N109)
5. Solenoid valve for boost pressure control (N75)
6. Glow plug relay (J52)
7. Glow period warning lamp (K29)
8. Low heating output relay (J359)
(only on vehicles with manual gearbox)
9. High heating output relay (J360)
10. Fan relay (J323)
(engine code AFN and AVG only)
Audi A4 1995 ➤

Select function XX
- Press keys 0 and 3 for the function "Final control diagnosis".

Rapid data transfer Q
03 Final control diagnosis
- Confirm input with Q key.

-> Indicated
permitted on display:
Final control diagnosis
Commencement of injection valve -N108
Activating the valve has a noticeable effect on the noise of combustion (pre-ignition).
If no changes in the combustion noises are heard:
- Check injection adjuster control range

=> Page 72
- Press ⇒key.

Exhaust gas recirculation valve -N18
The valve must click.
Notes:
◆ Because of engine noises the clicking of the valve cannot be heard and therefore must be felt to detect its
operation.
◆ The piston movement of the mechanical exhaust gas recirculation valve is visible in the side slot.
If the valve does not click:
- Test exhaust gas recirculation valve
=> 4-Cyl. Diesel Direct Injection (TDI), Mechanics; Repair Group 26; Testing exhaust gas recirculation system;
Testing exhaust gas recirculation valve Testing exhaust gas recirculation system Testing exhaust gas recircu‐
lation valve
- Press ⇒key.

Air conditioner compressor cut-out
Air conditioner compressor switch-off is checked.

The test step is also recalled on vehicles without air conditioner system.
The conditioner compressor must stop within 5 seconds (visual check) then start approx. every 5 seconds
and then stop.
If the conditioner compressor is not switched off:
- Check conditioner compressor shut-off

=> Page 90
- Press ⇒key.
2.1 - Final control diagnosis 17

Audi A4 1995 ➤

The engine must stop.
If the engine does not stop:
- Switch off ignition.

- Unscrew fuel cut-off valve and remove any metal particles or dirt.
- Repeat final control diagnosis and if the engine will not stop replace fuel cut-off valve.
- Press ⇒key.

Charge pressure control solenoid valve -
N75
The solenoid valve must click.
Note:
The clicking of the valve is difficult to hear and is therefore best checked by touch.
If the solenoid valve does not click:
- Check boost (charge) pressure control solenoid valve
=> 4-Cyl. Diesel Direct Injection (TDI), Mechanics; Repair Group 21; Testing charge pressure system; Testing
charge pressure control solenoid valve Testing charge pressure system Testing charge pressure control sol‐
enoid valve
- Press ⇒key.

The relay must click.

Fitting location: Relay position 4 of central electrics
Switching on and off the relay can also be observed as the interior light becomes brighter and darker as a
result of the glow plug high power consumption.
If the relay does not click:

- Check glow plug relay: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
=> Current flow diagrams, Electrical fault finding and Fitting locations binder
- Press ⇒key.

Glow period warning lamp -K29
The control lamp must flash.
Control lamp does not flash:
- Check glow period warning lamp
Audi A4 1995 ➤
- Press ⇒key.

Low heating output relay -J359

Fitting location: electronics box in plenum chamber
If the relay does not click:
- Test low heating output relay
- Press ⇒key.

High heating output relay -J360

Fitting location: electronics box in plenum chamber
If the relay
permitted does
unless not click:
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- Test high heating output relay
- Press ⇒key.

Blower relay -J323
The radiator fan should come on and switch off again.

(engine code AFN and AVG only)
Note:
The radiator fan can also be activated by the temperature level at the thermoswitch, the automatic gearbox or
the air conditioner. When performing the final control diagnosis, make sure that the fan has not been activated
for this reason.
- If necessary, allow engine to cool down.
If the radiator fan is not activated:
- Test radiator fan run-on control unit -J138

Select function XX
- Press keys 0 and 6 for the function "End output" and confirm entry with the Q key.
2.1 - Final control diagnosis 19

Audi A4 1995 ➤
3 - Basic setting
3.1 - Basic setting
Test conditions
• Coolant temperature must be at least 80 °C.

• All electrical consumers like e.g. rear window heating must be switched off.
• If the vehicle is equipped with an air conditioner, this must be switched off.
• On vehicles with an automatic gearbox the selector lever must be in P or N.

Select function XX
- Press keys 0 and 4 for function "Basic setting" and confirm entry by pressing Q.

Basic setting Q
Enter display group number XXX
- Press key 0 three times to select display group "00" and confirm entry by pressing key Q.

Basic setting 0 Q
1 2 3 4 5 6 7
8 9 10
Specifications for display group 00
This display group is used for the dynamic test of the commencement of injection. The commencement of
injection valve -N108 is activated constantly so that the injection timing control will move to the retarded position.
Basic setting 0 ⇒ ◂Indicated on display
40 46 0 20 90 201 64 153 127 83
(Ignore)
Fuel temperature: approx. 40 °C (not reached if outside temperature
is low; no specified value)
(Ignore)
Coolant temperature: approx. 90 °C
(Ignore)
(Ignore)
(Ignore)
Accelerator pedal position: 0
Commencement of injection depends on fuel temperature
Specifications => Page 21
Idling speed: 37...40
Audi A4 1995 ➤
- -> The commencement of injection value in display zone 2 varies in accordance with the fuel temperature
value in display zone 9.
Specification: => range C in illustration

A - Zone 2 commencement of injection permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
B - Zone 9 fuel temperature with respect to the correctness of information in this document. Copyright by AUDI AG.
Notes:
◆ If the commencement of injection is advanced turn injection pump in engine direction of rotation, if the
commencement of injection is retarded turn against direction of rotation.
◆ If when checking the commencement of injection the specifications are within zone -C- then no adjustment
is required. After repairs e.g. removing and installing injection pump, adjusting timing then the commence‐
ment of injection is to be set to the mean valve (dashed line) of specification zone -C-.
If the specifications within zone C are not met:
- Adjust commencement of injection => Page 59 .
Display Group 03 at idling speed
This display group is used for testing the exhaust gas recirculation. The exhaust gas recirculation valve -N18
opens and closes alternately for periods of 10 seconds.
System in basic setting 3 ⇒ ◂ Indicated on display

860 rpm EGR active 200 mg/H 99 %
Duty cycle (activation) of exhaust gas recirculation valve
Intake air mass
Exhaust gas recirculation valve -N18 open
Engine speed

860 rpm EGRn.active 420 mg/H 0 %
Intake air mass
Exhaust gas recirculation valve -N18 closed
Engine speed
3.1 - Basic setting 21

Audi A4 1995 ➤
Display Group 11 at idling speed
This display group is used for testing the boost (charge) pressure control. The boost pressure control solenoid
valve -N75 opens and closes alternately for periods of 10 seconds.

860 rpm On 969 mbar 0%
Activation of boost pressure control solenoid valve
Boost pressure
Boost pressure control solenoid valve open
Engine speed

860 rpm Off 948 mbar 99 %
Activation of boost pressure control solenoid valve
Boost pressure
permittedBoost pressure
unless authorised control
by AUDI AG. AUDIsolenoid
AG does notvalve closed
guarantee or accept any liability
Engine speed
4 - Coding control unit

4.1 - Coding control unit
If the appropriate code for the vehicle is not displayed or if the control unit has been renewed, the control unit
must be coded as follows.
select engine electronics control unit by entering address word "01" ( => Page 2 .)
When doing this the ignition must be switched on.

Select function XX
- Press keys 0 and 7 for the function "Code control unit" and confirm entry with Q key.

Code control unit Q
Enter code number xxxxx (0-32000)
- Enter the appropriate code number for this vehicle and confirm with Q key.
Coding For vehicles with

00001 Automatic gearbox
with and without ESP
00002 Manual gearbox (front-wheel drive)
without ESP
Audi A4 1995 ➤
Coding For vehicles with

00003 Manual gearbox (four-wheel drive)
without ESP
00005 Manual gearbox (front-wheel drive)
with ESP
00006 Manual gearbox (four-wheel drive)
with ESP
-> The display on fault reader V.A.G 1551 will show the control unit coding, as in this example.
038906018.. 1.9l R4 EDC
G00SG 0203 "
Coding 00002 WSC 12345
- Switch ignition off and then on again.
Note:
The next time the ignition is switched on the newly entered coding will be activated.
If the ignition is not switched off and then on again after the correct coding has been entered, it will not be
possible to erase fault 18020 ("Control unit incorrectly coded").
- Press ⇒key.

Select function XX
5 - Reading measured value block

5.1 - Reading measured value block
Safety precautions
Observe the following points if test and measuring instruments are required during a test drive:
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
Procedure

Select function XX
- Press by
Protected keys 0 and
copyright. 8 for
Copying the function
for private or commercial"Read measured
purposes, value
in part or in whole, block"
is not and confirm entry with Q key.
4.1 - Coding control unit 23

Audi A4 1995 ➤
Read measured value block HELP

Enter display group number XXX
- Enter relevant display group number and confirm entry with Q key.

Read measured value block 0
1 2 3 4 5 6
7 8 9 10
Display group overview
Display Gr. number Indicated on display Meaning

00 Read measured value 1 = Engine speed
block 0
General 1 2 3 4 5 6 7 8 9 10 2 = Commencement of injection
vehicle inspection 3 = Accelerator pedal position
4 = Injection quantity
5 = Intake manifold pressure (charge/boost pressure)
6 AG. = Atmospheric pressure (ambient air pressure)
permitted unless authorised by AUDI AUDI AG does not guarantee or accept any liability
7of information
with respect to the correctness = Coolant in thistemperature
document. Copyright by AUDI AG.
8 = Intake manifold temperature

9 = Fuel temperature
10 = Intake air mass
block 1
Injection 1234 2 = Injection quantity
quantity
3 = Voltage from modulating piston movement sender -G149
4 = Coolant temperature

02 Read measured value block 2 1 = Engine speed
Idling speed 1234 2 = Accelerator pedal position
3 = Operating status:
X X 1 Air conditioner signal on
X 1 X Idling speed switch closed
1 X X Increased idling speed:
▪ because required by air con‐
ditioner 1)
▪ because acceleration and
braking detected
▪ because additional heater is
on
03 Read measured value block 3 1 = Engine speed
Exhaust gas recirculation 1 2 3 4 2 = Intake air mass (specified)
3 = Intake air mass (actual)
4 = Duty cycle (activation) of exhaust gas recircula‐
tion valve -N18
1) The idling speed is not increased with all control units. However, a "1" will appear if this condition is required
by the air conditioner.
Audi A4 1995 ➤

block 4
Start of injection 1 2 3 4 2 = Commencement of injection (specified)
3 = Commencement of injection (actual)
4 = Duty cycle (activation) of commencement of injection valve
-N108
block 5
Start conditions 1234 2 = Injection quantity for starting (recorded from last start)
3 = Commencement of injection
06 Read measured value 1 = Road speed
block 6
Switch positions 1234 2 = Brake pedal monitoring:
Brake light switch and brake pedal switch are a combined
component
X X 1 Brake light switch -F
closed
X 1 X Brake pedal switch
open
1 X X Clutch pedal switch -
F36 open

06 Read measured value block 6 3 = Cruise control system (CCS) operating inputs:
Switch positions permitted
1 2 3 4unless authorised by AUDI AG. AUDI AG does not X guarantee
X X X orXaccept1 CCS on
any liability
X X X X 1 X CCS off with memory
X X X 1 X X Speed reduction
X X 1 X X X Resume/accelerate
X 1 X X X X Brake pedal depressed
1 X X X X X Clutch pedal depressed
4 = Operating status of cruise control system:
0 Control unit with CCS function
1 CCS off
2 Accelerate
4 Decelerate
8 Resume
1 6 Brake depressed
3 2 Maintain speed
6 4 (Ignore)
1 2 8 (Ignore)
2 5 5 Control unit without CCS function
Display Gr. Indicated on Meaning

number display
07 Read meas‐ 1 = Fuel temperature
ured value
block 7
Temperatures 1 2 3 4 2 = No display
3 = Intake manifold temperature
5.1 - Reading measured value block 25

Audi A4 1995 ➤
08 Read meas‐ 1 = Engine speed

ured value
block 8
Injection 1234 2 = Desired injection quantity (driver's requirement via accelerator pedal)
quantity limita‐ 3 = Injection quantity limitation via engine speed (torque limitation)
tion
4 = Injection quantity limitation based on intake air mass (avoidance of ex‐
haust smoke)
ured value
block 9
Injection 1234 2 = Injection quantity (cruise control system activated)
quantity 3 = Injection quantity limitation by automatic gearbox during gear change
limitation Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 = Voltage from modulating piston movement sender

Display Gr. number Indicated on dis‐ Meaning

play
10 Read measured 1 = Intake air mass
value block 10
Air quantities 1234 2 = Atmospheric pressure (ambient pressure)
3 = Intake manifold pressure (charge pressure)
4 = Accelerator pedal position
11 Read measured 1 = Engine speed
value block 11
Charge 1234 2 = Charge pressure (specified)
pressure control
3 = Charge pressure (actual)
4 = Duty cycle (activation) of charge pressure control solenoid -N75
12 Read measured 1 = (Ignore)
value block 12
Glow plug 1234 2 = Glow period (in seconds)
system
3 = Supply voltage from control unit
Display Gr. num‐ Indicated on Meaning

ber display
13 Read meas‐ 1 = Difference between injection quantities for cylinders 4 and 3
ured value
block 13
Smooth 1234 2 = Difference between injection quantities for cylinders 2 and 3
idling control 3 = Difference between injection quantities for cylinders 1 and 3
4 = No display
14 Read meas‐ No display
ured value
block 14
(Unallocated)
ured value
block 15
Fuel consump‐ 1 2 3 4 2 = Injection quantity (actual)
tion
3 = Fuel consumption
Audi A4 1995 ➤
4 = Desired injection quantity (driver's requirement via accelerator pedal)

16 Read measured value block 16 1 = Alternator load
Additional heater 1 2 3 4 2 = Additional heater switched off because:
X X X X X X X 1 Coolant temperature above 70 °C...
80 °C1)
or intake air temperature above 5 °C
X X X X X X 1 X Alternator defective
X X X X X 1 X X Battery voltage less than 9 V
X X X X 1 X X X Engine speed less than 800 rpm
X X X 1 X X X X Engine started within the last 10 sec‐
onds
X X 1 X X X X X Coolant temperature sender (G62)
or intake manifold temperature send‐
er (G72) defective
X 1 X X X X X X (Ignore)
1 X X X X X X X (Ignore)
3 = Heater element activation
X 1 Low heating output relay (J359) on
1 X High heating output relay (J360) on
4 = Supply voltage from control unit
1) If the intake air temperature is 5 °C when the engine is started, the additional heater will switch off when
the coolant temperature reaches 70 °C. If the air temperature is -10°C, the additional heater will not switch off
until the coolant temperature reaches 80 °C.
Display Gr. Indicated on dis‐ Meaning

number play
17 Read measured No display
value block 17
(Unallocated)
18 Read measured (Ignore)
value block 18
1234
19 Read measured 1 = Lower stop value (voltage from modulating piston movement sender)
value block 19
Quantity adjust‐ 1 2 3 4 2 = Upper stop value (voltage from modulating piston movement sender)
er
3 = No display
4 = No display
5.2 - Readout specifications for general vehicle inspection
Display group 00 at idling speed (engine warm, coolant temperature not below +85 °C)
Engine code: AFF, AHU, AHH, AFN, AVG

Read measured value block 0 ⇒ ◂Indicated on display

40 50 0 20 90 201 64 153 127 83
5.1 - Reading measured value block 27

Audi A4 1995 ➤
Intake air mass: 70...110 okay

▪ If outside tolerance => Display Group 03, Page 33
Fuel temperature: no specification
Intake manifold temperature: no specification
Coolant temperature: 80...51 okay
▪ > 80: run engine till warm
Ambient air pressure: no specification
Charge pressure: ignore
Injection quantity: 10...30 okay
Accelerator pedal position: 0
Commencement of injection: 20...60 okay
Idling speed: 37...42 okay
Display group 00 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 °C)
- Engine code AFF
Note: the fault reader must be secured on the rear seat and operated from this position. Always follow the safety
precautions relating to test drives =>Page 39 .

186 225 255 154 186 201 64 138 175 233
Intake air mass: > 210 okay
▪ < 210: => Display Group 10, Page 36
▪ >Protected
80: run engineCopying
by copyright. till warm
for private or commercial purposes, in part or in whole, is not
Ambient airwithpressure:
respect to theignore
correctness of information in this document. Copyright by AUDI AG.
Charge pressure: 171...191 okay
Injection quantity:145...158 (injection quantity at full throttle) okay
▪ 125: emergency quantity - system fault detected => interrogate fault memory, Page 4
Accelerator pedal: 255 (fully depressed)
Commencement of injection: 170...245 (depending on engine speed)
Engine speed: 160...190 (do not exceed 4000 rpm; engine speed is governed)
- Engine code AHU, AHH

186 225 255 199 190 201 64 138 175 255
Audi A4 1995 ➤

Ambient air pressure: ignore
- Engine code AFN,permitted
AVG unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

186 225 255 199 190 201 64 138 175 255
Ambient air pressure: ignore
5.3 - Readout specifications for injection pump
Read measured value block 1 ⇒ ◂ Indicated on display

860 rpm 5.6 mg/H 1.680 V 87.3 °C
5.2 - Readout specifications for general vehicle inspection 29

Audi A4 1995 ➤
Coolant temperature
▪ 85...100 °C okay
▪ < 85 °C: => run engine till warm
Voltage from modulating piston movement sender -G149
▪ 1.250...1.750 V okay
▪ < 1.250 V: injection pump too rich => fit a new injection pump
▪ > 1.750 V: engine load => switch off consumers
Engine too cold => run engine till warm (see display zone 4)
Injection pump too lean => fit a new injection pump
Injection quantity
▪ 2.0...9.0 mg/H (mg/stroke) okay
▪ < 2.0 mg/H: injection pump too rich => fit a new injection pump
▪ > 9.0 mg/H: engine load => switch off consumers
Engine too cold => run engine till warm (see display zone 4)
Injection pump too lean => fit a new injection pump
Engine speed
▪ 780...900 rpm okay
Display group 01 with attempted start (if engine does not start)1)

230 rpm 37.4 mg/H 2.780 V 14.3 °C
Coolant temperature
Voltage from modulating piston movement sender -G149
(quantity adjuster informs control unit of position of modulating
piston)
▪ Voltage increases periodically: okay (pump is injecting)
▪ < 1.000 V: quantity adjuster closed =>monitor display zone
2.
▪ Only fit a new injection pump if injection quantity is as speci‐
fied.
Specified injection quantity (control unit activating
by AUDI AG. quantity adjuster in injection
or accept anypump)
permitted unless authorised AUDI AG does not guarantee liability
▪ Injection quantity increases periodically:
with respect okay
to the correctness (pumpinisthisbeing
of information activated)
document. Copyright by AUDI AG.
▪ 0.0 mg/H (mg/stroke): system fault => interrogate fault memory, Page 4
Engine speed
1) If the voltage of the electrical system falls below 10.8 V during the attempted start, fault reader V.A.G 1551
will terminate the diagnosis.
Display group 19 with ignition on

0.780 V 4.350 V
No display
No display
Audi A4 1995 ➤
Voltage at modulating piston movement sender with quantity adjuster

at maximum stop
▪ 4.150...4.720 V okay
▪ If outside tolerance: contact resistance in wiring => test, Page 87
Quantity adjuster in injection pump incorrectly set => fit a new injection
pump
Voltage at modulating piston movement sender with quantity adjuster at minimum stop
▪ 0.500...0.970 V okay
▪ If outside tolerance: contact resistance in wiring => test, Page 87
Quantity adjuster in injection pump incorrectly set => fit a new injection pump

860 rpm 0.9 ° BTDC 0.9 ° BTDC 23 %
Duty cycle (activation) of commencement of injection valve
▪ No specification
Current commencement of injection
▪ 2° ATDC...4° BTDC okay
▪ Later than 2° ATDC: injection timing control jammed
Commencement of injection valve defective
Injection pump set at extreme retard position
=> check injection timing control range, Page 72
Commencement of injection specified by control unit
▪ 2° ATDC...4° BTDC
Protected okayCopying for private or commercial purposes, in part or in whole, is not
by copyright.
Engine speed permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
▪ 780...900 rpm okay


4060 rpm 16.3°BTDC 16.1°BTDC 84 %
Duty cycle (activation) of commencement of injection valve
Current commencement of injection
▪ If as specified in display zone 2 (tolerance ±2°): okay
▪ If outside tolerance: commencement of injection incorrect
=> test commencement of injection, Page 72
Commencement of injection specified by control unit
▪ 14...18 ° BTDC okay
Engine speed
▪ 3800...4200 rpm okay
5.3 - Readout specifications for injection pump 31

Audi A4 1995 ➤
5.4 - Readout specifications for engine idling speed

860 rpm 0.0 % 010 88.4 °C
Coolant temperature
▪ 85...100 °C okay
▪ < 85 °C: => run engine till warm
Operating status
▪ XX1: Air conditioner signal => switch off air conditioner
▪ X1X: Okay (idling speed switch closed)
▪ 1XX: Increased idling speed (air conditioner switched on)
=> switch off air conditioner
Acceleration and braking detected => check brake pedal switch
Accelerator pedal position
▪ 0.0 % okay
▪ > 0.0 %: accelerator pedal position sender incorrectly set or defective => adjust
Engine speed
▪ 780...900 rpm okay

0.82 mg/H -0.12 mg/H 0.49 mg/H
No display
Difference between injection quantities for cylinders 4, 2,
1 and cylinder 3
▪ -1.5 mg/H...+1.5 mg/H (mg/stroke) okay
▪ All display zones too high: cylinder 3 strong
▪ All display zones too low: cylinder 3 weak
Protected by copyright. Copying for private or commercial purposes, in part orDifference
in whole, is notbetween injection quantities for cylinder 1 and
cylinder
3
▪ > +1.5 mg/H: cylinder 1 weak
▪ < -1.5 mg/H: cylinder 1 strong
Difference between injection quantities for cylinder 2 and cylinder 3
Difference between injection quantities for cylinder 4 and cylinder 3
Audi A4 1995 ➤
Notes on display group 13:

◆ The injection system is equipped with an idling speed smooth running control. There may be power differ‐
ences between the individual cylinders (component tolerances, injector delivery, compressions etc.) which
are recognised and equalized via selective injected quantities at idling speed.
◆ Recognition at idling speed is via the signal from the engine speed sender which delivers four signals per
crankshaft revolution to the control unit. If the signals are delivered at the same rhythm then all cylinders
work the same. If one cylinder is weaker then the crankshaft takes longer for the next half revolution. Con‐
versely a more powerful cylinder accelerates the crankshaft so less time is taken.
◆ If the control unit recognises a difference, then the relevant cylinder is given more or less fuel, until the
engine runs evenly again.
◆ The measured value block displays the amounts by which the quantity of fuel injected at the individual
cylinders is varied as compared with No. 3 cylinder to achieve an even engine idling speed.
◆ +... mg/H: The relevant cylinder is less powerful than No. 3 cylinder and is therefore supplied with more fuel.
◆ -... mg/H: The relevant cylinder is more powerful than No. 3 cylinder and is therefore supplied with less fuel.
5.5 - Readout specifications for exhaust gas recirculation

860 rpm 290 mg/H 308 mg/H 54 %
Intake air mass (actual value)
▪ If as specified in display zone 2 (tolerance ±20mg/H (mg/stroke)): okay
▪ Air mass too small: unmetered air in intake tract
Excessive exhaust gas recirculation => test
▪ Air mass too great: too little exhaust gas recirculation => test
If engine has been idling for 10 minutes or more => press accelerator briefly
▪ Constant substitute value => interrogate fault memory
Air mass specified by control unit
▪ 230...370 mg/H (mg/stroke) okay
▪ > 370 mg/H: engine too cold => run engine till warm
Injection quantity too great => readout specifications for injection pump
Intake manifold temperature very high => correction not possible
Engine speed
▪ 780...900 rpm okay
5.6 - Readout specifications for temperature senders
Display group 07 with ignition switched on (engine cold and not running)

5.4 - Readout specifications for engine idling speed 33

Audi A4 1995 ➤

15.4 °C 15.9 °C 16.7 °C
Coolant temperature (at coolant temperature sender -G62)
▪ If the wiring has an open circuit the approximate fuel temperature
(display zone 1) will be displayed as a substitute value, test sender
=>Page 84
Intake manifold temperature (at intake manifold temperature sender -G72)
▪ If the wiring has an open circuit, a constant temperature of 136.8 °C will be
displayed as a substitute value, test sender =>Page 85
No display
Fuel temperature (at fuel temperature sender -G81)
▪ If the wiring has an open circuit, a constant temperature of -5.4 °C will be displayed as a
substitute value, test sender =>Page 75
Notes:
◆ No specifications can be given for temperature values.
◆ When the engine is cold, the temperatures of the fuel, intake manifold and coolant should be approximately
the same as the ambient temperature. If one of the temperature readings differs noticeably, test the relevant
sender.
5.7 - Readout specifications for engine power output
-Engine code AFF


3990 rpm 38.4 mg/H 31.0 mg/H 35.7 mg/H
Injection quantity limitation
according to recognised air
mass
> 35 mg/H (mg/stroke) okay
▪ < 35 mg/H: recognised air
mass too small
=> test air mass meter, Page
81
Exhaust gas recirculation at
full throttle => test
Injection quantity limitation according to engine speed (tor‐
que limitation)
29.0...31.5 mg/H (mg/stroke) okay
▪ < 29.0 mg/H: engine speed too high or too low
▪ > 31.5 mg/H: injection quantity has been increased by
engine tuning
Desired injection quantity (accelerator pedal position) > 36 mg/H (mg/stroke) okay
▪ < 36 mg/H: accelerator pedal not fully depressed, incorrectly adjusted or defective,
test
=> 4-Cylinder diesel direct injection engine (TDI), Mechanics; Repair group 20; Testing
accelerator pedal position sender -G79; Vehicles with 4-cylinder engine Testing ac‐
celerator pedal position sender -G79; Vehicles with 4-cylinder engine
Engine speed 2800...4000 rpm okay
Audi A4 1995 ➤
-Engine code AHU, AHH

3990 rpm 38.4 mg/H 35.0 mg/H 35.7 mg/H
Injection quantity limitation
according to recognised air
mass
mass too small
81
que limitation)
engine tuning
test
-Engine code AFN, AVG

3990 rpm 43.4 mg/H 40.4 mg/H 42.0 mg/H
Protected by copyright. Copying for private or commercial purposes, in part or in whole,Injection
is not quantity limitation
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any according
liability to recognised air
mass

mass too small
81
5.7 - Readout specifications for engine power output 35

Audi A4 1995 ➤

que limitation)
engine tuning
test
Display group10 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 °C)
-Engine code AFF, AHU, AHH permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

830 mg/H 1030 mbar 1968 mbar 100 %
Accelerator pedal position: 100 % okay
▪ < 100 %: accelerator pedal not fully depressed
Accelerator pedal position sender -G79 incorrectly adjusted
or defective => test
=> 4-Cylinder diesel direct injection engine (TDI), Mechanics; Re‐
pair group 20; Testing accelerator pedal position sender -G79;
Vehicles with 4-cylinder engine Testing accelerator pedal position
sender -G79; Vehicles with 4-cylinder engine
Current charge pressure: 1800...2050 mbar okay
If outside tolerance: charge pressure control defective
=> Display Group 11, Page 37
Current air pressure: no specification
Intake air mass: 750...850 mg/H (mg/stroke) okay
▪ < 750 mg/H: Engine speed below 2000 rpm or above 4000 rpm
Charge pressure too low => monitor display zone 3 =>Page 33
Unmetered air between air mass meter and turbocharger
Air mass meter defective
Display group10 at full throttle (test drive in 3rd or 4th gear, coolant temperature not below +85 °C)

963 mg/H 1030 mbar 1968 mbar 100 %
Audi A4 1995 ➤
Accelerator pedal position: 100 % okay

▪ < 100 %: accelerator pedal not fully depressed
Accelerator pedal position sender -G79 incorrectly adjusted
or defective => test
=> 4-Cylinder diesel direct injection engine (TDI), Mechanics; Re‐
pair group 20; Testing accelerator pedal position sender -G79;
Vehicles with 4-cylinder engine Testing accelerator pedal position
sender -G79; Vehicles with 4-cylinder engine
Current charge pressure: 1800...2250 mbar okay
If outside tolerance: charge pressure control defective
=> Display Group 11 Page 37
Current air pressure: no specification
Intake air mass: 800...1100 mg/H (mg/stroke) okay
▪ < 800 mg/H: Engine speed below 2000 rpm or above 4000 rpm
Charge pressure too low => monitor display zone 3
Unmetered air between air mass meter and turbocharger
Air mass meter defective
5.8 - Readout specifications for charge pressure control
Display group 11 at full throttle (test drive in 3rd and 4th gear, coolant temperature not below +85 °C)
-Engine code AFF, AHU, AHH

3340 rpm 1830 mbar 1850 mbar 57 %
Duty cycle (activation) of charge pres‐
sure control solenoid valve -N75
Current charge pressure
▪ If as specified in display zone 2 (tolerance ±100mbar): okay
Protected by copyright. Copying for ▪ Charge
private pressure
or commercial tooin low:
purposes, part or no charge
in whole, is not pressure control => test
permitted unless authorised by AUDI ▪ AG.
Charge
AUDI AG pressure too high:
does not guarantee solenoid
or accept any liabilityvalve -N75 jamming
with respect to the correctness ofPressure
information inhose for charge
this document. Copyrightpressure
by AUDI AG.control detached or blocked
Vacuum unit defective => test charge pressure
=> 4-Cylinder diesel direct injection engine (TDI), Mechanics; Repair group
21; Testing charge air system; Testing solenoid valve for charge pressure
control Testing charge air system; Testing solenoid valve for charge pres‐
sure control
Charge pressure required by control unit
▪ 1800...2050 mbar okay
▪ > 2050 mbar: charge pressure has been increased by engine tuning
5.7 - Readout specifications for engine power output 37

Audi A4 1995 ➤
Display group 11 at full throttle (test drive in 3rd and 4th gear, coolant temperature not below +85 °C)

3340 rpm 1948 mbar 1917 mbar 57 %
Duty cycle (activation) of charge pres‐
sure control solenoid valve -N75
Current charge pressure
▪ If as specified in display zone 2 (tolerance ±100mbar): okay
▪ Charge pressure too low: no charge pressure control => test
▪ Charge pressure too high: solenoid valve -N75 jamming
Pressure hose for charge pressure control detached or blocked
Vacuum unit defective => test charge pressure
=> 4-Cylinder diesel direct injection engine (TDI), Mechanics; Repair group
21; Testing charge air system; Testing solenoid valve for charge pressure
control Testing charge air system; Testing solenoid valve for charge pres‐
sure control
Charge pressure required by control unit
▪ 1800...2250 mbar okay
▪ > 2250 mbar: charge pressure has been increased by engine tuning
Audi A4 1995 ➤
23 - Mixture preparation, Injection
1 - Servicing Diesel direct injection system

1.1 - Servicing Diesel direct injection system
1.2 - Safety precautions
To prevent injuries to persons and/or damage to the injection and glow plug system, note the following points:
◆ The ignition must be switched off before connecting or disconnecting injection or glow plug system wiring
or tester cables.
◆ If the engine is to be turned at starter speed without starting, e.g. when checking compressions, pull con‐
nector off injection pump.
◆ Before disconnecting battery,
with respect obtain radio
to the correctness codeinfor
of information this radios
document.fitted
Copyrightwith anti-theft
by AUDI AG. coding.
◆ Disconnecting and connecting the battery must only be undertaken when the ignition switched off otherwise
the Diesel direct injection system control unit may be damaged.
Observe the following precautions if test and measuring instruments are required during a test drive:
◆ Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from front passenger's seat and the vehicle is involved in
an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the
airbag is triggered.
Warning!
Secure fault reader to rear seat and operate from this position.
1.3 - Rules for cleanliness
When working on the fuel supply/injection system, pay careful attention to the following "basic rules":
◆ Thoroughly clean all unions and the adjacent areas before disconnecting.
◆ Place parts that have been removed on a clean surface and cover them over. Do not use fluffy cloths.
◆ Carefully cover over or seal opened components if the repair cannot be completed immediately.
◆ Only install clean components:
Only unpack replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in tool boxes etc.).
◆ When the system is open:
Do not work with compressed air if this can be avoided.
Do not move vehicle unless absolutely necessary.
◆ Also ensure that no diesel fuel runs onto the coolant hoses. Hoses coming in contact with fuel must be
cleaned immediately. Damaged hoses must be replaced.
1.1 - Servicing Diesel direct injection system 39

Audi A4 1995 ➤
1.4 - Fitting locations overview
Components A to E are not shown in the illustration.
A - Glow plug relay (J52)

◆ Central electrics, relay position 4
B - Accelerator pedal position sender (G79)
◆ In footwell on accelerator pedal
C - Brake light switch (F) and brake pedal switch
◆ In footwell on brake pedal
◆ Combined as one unit
D - Clutch pedal switch (F36)
◆ In footwell on clutch pedal
E - Low/High heating output relay
(Additional heater)
◆ Electronics box in plenum chamber
◆ Only on vehicles with manual gearbox
40 23 - Mixture preparation, Injection

Audi A4 1995 ➤
1 Mechanical exhaust gas recirculation valve

2 Coolant temperature sender (G62)
3 Exhaust gas recirculation valve (N18)
4 Connector
◆ 3 pin
◆ For engine speed sender (G28)
5 Connector
◆ 2 pin
◆ For needle lift sender (G80)
6 Intake manifold pressure sender (G71) and intake manifold temperature sender (G72)
1.4 - Fitting locations overview 41

Audi A4 1995 ➤
Note:
Some vehicles are equipped with a 10-pin connector instead of an 8-pin and 3-pin connector (Item 7 and 8).
7 Connector
◆ 8-pin
◆ For fuel temperature sender (G81)
◆ For quantity adjuster (N146)
◆ For modulating piston movement sender (G149)
8 Connector
◆ 3 pin
◆ For commencement of injection valve (N108)
◆ For fuel shut-off valve (N109)

Audi A4 1995 ➤
9 Electronics box
◆ Diesel direct injection system control unit (J248) with altitude sender (F96)
◆ Diesel direct injection system relay (J322)
◆ Fuse for glow plugs
◆ Low/High heating output relay
10 Engine speed sender (G28)
11 Injection pump
◆ With commencement of injection valve (N108)
◆ With fuel shut-off valve (N109)
◆ With fuel temperature sender
◆ With quantity adjuster (N146)
◆ With modulating piston movement sender (G149)
1.4 - Fitting locations overview 43

Audi A4 1995 ➤
12 Injector with needle lift sender (G80)

13 Charge pressure control solenoid valve (N75)
14 Air mass meter (G70)

Audi A4 1995 ➤
1.5 - Servicing injection pump: engine code AFF, AHU, AFN, AVG
◆ Note safety precautions

=>Page 39
◆ Observe rules for cleanliness
=>Page 39
◆ Removing and installing injection pump
=>Page 53
◆ Dynamically checking and adjusting injection pump =>Page 59
1 45 Nm
2 Injection pump sprocket
3 Woodruff key
4 Seal
◆ Renew
5 Banjo bolt, 25 Nm
1.5 - Servicing injection pump: engine code AFF, AHU, AFN, AVG 45
Audi A4 1995 ➤
6 Supply hose
◆ From fuel filter
7 Injection pump
◆ With quantity adjuster (N146)
◆ With modulating piston movement sender (G149)
◆ With fuel temperature sender
8 O-Ring
◆ Renew if damaged
9 Fuel shut off valve
◆ 20 Nm
10 Pipe union
◆ For return pipe
◆ 28 Nm
11 25 Nm
12 Return hose
◆ To control valve/fuel filter

Audi A4 1995 ➤
13 Injector pipes
◆ Tighten to 25 Nm
◆ Remove with 3035
◆ Always remove pipework complete
◆ Do not alter shape
14 Injector
◆ For 3rd cylinder with needle lift sender
◆ Removing, installing and testing
=> Page 67
15 20 Nm
16 Dished washer
17 Retainer
18 Mounting
19 Connector
◆ 3 pin
◆ For commencement of injection valve (N108)
◆ For fuel shut-off valve (N109)
1.5 - Servicing injection pump: engine code AFF, AHU, AFN, AVG 47
Audi A4 1995 ➤
20 Constant pressure valve

◆ 45 Nm
21 Timing control cover
◆ If leaking, replace O-ring =>Page 69
22 Copper seal
◆ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
23 12 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
24 Commencement of injection valve (N108)

25 Strainer
26 Retainer
27 Sleeve
◆ Tapered
28 25 Nm
◆ Nut with taper
29 Console

Audi A4 1995 ➤
1.6 - Servicing injection pump: engine code AHH
◆ Note safety precautions

=>Page 39
◆ Observe rules
Protected by for Copying
copyright. cleanliness
=>Page 39 authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
◆ Removing and
with respect installing
to the injection
correctness of informationpump
in this document. Copyright by AUDI AG.
=>Page 53
◆ Dynamically checking and adjusting injection pump =>Page 59
1 Stretch bolt
◆ Always renew
◆ 20 Nm + 1/4 turn (90°)
2 Injection pump sprocket
3 Hub nut
◆ Never slacken
4 25 Nm
1.6 - Servicing injection pump: engine code AHH 49

Audi A4 1995 ➤
5 Supply pipe
◆ From fuel filter
6 Fuel shut off valve
◆ 20 Nm
7 Pipe union
◆ For return pipe
◆ 28 Nm
8 Return pipe
◆ To control valve/fuel filter
9 25 Nm
10 Injector pipes
◆ Tighten to 25 Nm
◆ Remove with 3035
◆ Always remove pipework complete
◆ Do not alter shape
11 Pressure valve with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ 45 Nm
12 25 Nm

Audi A4 1995 ➤
13 Injector
◆ For 3rd cylinder with needle lift sender
◆ Removing, installing and testing
=> Page 67
14 20 Nm
15 Retainer
16 Mounting
17 Copper seal
18 12 Nm
19 Commencement of injection valve (N108)
20 Strainer
21 O-Ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
22 25 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
1.6 - Servicing injection pump: engine code AHH 51

Audi A4 1995 ➤
23 Timing control cover

◆ If leaking, replace O-ring =>Page 69
24 Console
25 25 Nm

Audi A4 1995 ➤
1.7 - Removing and installing injection pump: engine codeAFF, AHU, AFN,AVG
Removing injection pump
- Move lock carrier to service position
=> General body repairs, Exterior; Repair group 50; Body, front; Lock carrier - service position Body, front Lock
carrier - service position
- Remove upper toothed belt guard and cylinder head cover.

- Turn crankshaft to TDC No. 1 cylinder.
-> TDC on vehicles with manual gearbox
-> TDC on vehicles with automatic gearbox
Engine removed - vehicles with manual gearbox:
- -> Install adjustment device 2068 A as shown.

- Set adjustment device to 107 mm -arrow -. The left-hand mark on the scale is the reference point.
1.7 - Removing and installing injection pump: engine codeAFF, AHU, AFN,AVG 53
Audi A4 1995 ➤
- Turn crankshaft until TDC marking on flywheel aligns with point of setting device.
Engine removed - vehicles with automatic gearbox:

- Set adjustment device to 99 mm -arrow-. The left-hand mark on the scale is the reference point.
- -> Lock camshaft with setting bar.

- Centralize setting bar as follows:
Turn arrested camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge es‐
tablish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between
setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd
feeler gauge, of same thickness, at the other end between setting bar and cylinder head.
- Remove idler roller.
- Remove tensioning roller nut.
- Relieve tooth belt tension and take off camshaft and injection pump sprockets.
- Lock injection pump sprocket with pin 2064.
- Remove injection pump sprocket securing nut.

Audi A4 1995 ➤
- -> Loosen puller arms and offer up.
- Locate puller arms through holes in injection pump sprocket and tighten.
- Place injection pump sprocket under tension with puller.
- -> Release injection pump sprocket from injection pump taper by tapping lightly on puller spindle -arrow-
(when doing this hold sprocket so that it does not fall off).
- Unbolt all fuel lines at fuel pump.
- Cover openings with a clean cloth.
Note: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Use slotted ring spanner 3035 to remove high pressure fuel pipes.
- Unplug connector for fuel cut-off valve/commencement of injection valve.

- Disconnect quantity adjuster connector and unclip connector from retainer.
- -> Remove securing bolts from console -arrows-.
- -> Then remove bolt from rear support -arrow-.

- Take off injection pump.
Audi A4 1995 ➤
Installing injection pump
- Insert injection pump into console and then tighten securing bolt on rear support with conical nut first.
- Align injection pump to central position in console elongated holes and secure hand tight.
- -> Install injection pump sprocket and lock in position with pin 2064. When installing observe spring washer
seating.
- Tighten securing nut to 45 Nm.
- Loosen camshaft sprocket securing bolt a half turn.
- -> Place a drift through hole in the rear of the toothed belt guard and release the camshaft sprocket from
camshaft taper with a blow from a hammer.
- Take camshaft sprocket off.
- Check whether TDC mark on flywheel and reference mark are aligned.
- Place tooth belt on injection pump sprocket and tensioning roller.
- Fit camshaft sprocket into toothed belt and secure sprocket so that the camshaft can still turn.
- Install idler roller.

- Remove locking pin from injection pump sprocket.
- -> Tension toothed belt. Using pin wrench (e.g. Matra V159) on eccentric turn clockwise until the notch and
the raised mark -arrows- align.

Audi A4 1995 ➤
- Check TDC mark on flywheel again.
- Tighten camshaft sprocket securing bolt to

45 Nm.
- Remove setting bar 2065A from camshaft.
- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
Adjusting injection pump
Checking and adjustment conditions
• Mechanical engine basic setting OK.

• Toothed belt tension OK.
• Engine at TDC.
- -> Remove screw plug on injection pump and screw in adapter 3313 for dial gauge.
- Insert dial gauge with needle plunger into adapter.
- Pre-load dial gauge to about 2 mm and tighten adjusting nut on adapter.
- -> Rotate crankshaft slowly in direction -A- (against direction of engine revolution) until needle on dial gauge
stops moving.
- Slacken dial gauge, then re-tighten with a pre-load of about 1 mm.
- Set measuring scale to 0.
- -> Rotate crankshaft slowly in direction -B- (direction of engine revolution) until marking -0- on flywheel aligns
with reference mark or edge of setting bar.
Note:
Alignment with the TDC mark is achieved by rotating the crankshaft in the direction of engine revolution. If the
crankshaft is rotated too far by mistake (i.e. beyond the TDC mark), adjust as follows:
Audi A4 1995 ➤
- Rotate crankshaft in opposite direction until dial gauge reads 0 again, then rotate again until TDC mark is
reached.
- -> Read off commencement of delivery on dial gauge.
Specification: 0.7 ±0.02 mm stroke
- Adjust commencement of delivery by turning injection pump.
Tightening torques:
Securing bolts for injection pump: 25 Nm

Screw plug: 20 Nm
- Reconnect injection pipes, fuel supply pipe and electrical wiring.
-> Fill injection pump with clean diesel fuel as follows:
- Screw adapter V.A.G 1318/10 into return pipe connection on injection pump.
- Connect vacuum hand pump V.A.G 1390 to return pipe connection together with bleeder container V.A.G
1390.
- Operate vacuum hand pump until bubble-free fuel comes out of return pipe connection. Do not allow the
fuel to enter the vacuum pump.
Reconnect return pipe to injection pump (with tightening torque of 25 Nm).
Install toothed belt guard and cylinder head cover.
Dynamically check and adjust commencement of injection
=>Page 59 .

Audi A4 1995 ➤
1.8 - Dynamically checking and adjusting commencement of injection: engine code AFF,
AHU, AFN, AVG
Notes:
◆ The commencement of injection must always be checked after renewing the toothed belt or loosening the
injection pump bolts or toothed belt sprockets and if necessary adjusted.
◆ Dynamically checking and correcting commencement of injection is only possible in function 04 "Engine
basic setting". This is because in function 04 the commencement of injection valve is activated continuously
and therefore the injection timing control is set to "late" (retarded).
- Initiate basic setting, Display Group 00, engine at idling speed

=> Page 20 .

System in basic setting 0
1 2 3 4 5 6 7
8 9 10
- Monitor the display in display zone 7 (coolant temperature).
Specification: less than 73 (corresponds to 85°C)
Do not continue with the test until the coolant has reached the specified temperature.

A - Zone 2 commencement of injection
B - Zone 9 fuel temperature
Notes:
◆ If the commencement of injection is advanced turn injection pump in engine direction of rotation, if the
commencement of injection is retarded turn against direction of rotation.
◆ If when checking the commencement of injection the specifications are within zone -C- then no adjustment
is required. After repairs e.g. removing and installing injection pump, adjusting timing then the commence‐
ment of injection is to be set to the mean valve (dashed line) of specification zone -C-.
If the commencement of injection (timing) is outside the specification tolerances, adjust commencement of
injection as follows:
Adjusting commencement of injection
- Remove upper toothed belt guard, if it has not already been removed.
- Loosen injection pump securing bolts approx. one turn, leaving the easiest bolt to reach till last.
- Hold injection pump by hand under tension in direction to be adjusted.

- Carefully loosen last securing bolt until the pump can be turned slightly and then retighten securing bolt.
1.8 - Dynamically checking and adjusting commencement of injection: engine code AFF,
AHU, AFN, AVG 59

Audi A4 1995 ➤
- Check setting in function "Basic setting 04".

1 2 3 4 5 6 7
8 9 10
- Observe readout in display zone 2 and if necessary adjust again until the readout settles on the mean value
shown in specification range -C-=>Page 59 .
- Tighten injection pump securing bolts to 25 Nm.
- Check commencement of injection again.
Note:
Loosen and re-tighten (25 Nm) the injection pipes on the injection pump after dynamically adjusting the injection
pump. This relieves the strain on pipes and prevents vibration breakages.
1.9 - Removing and installing injection pump: engine code AHH
Removinginjection pump
- Move lock carrier to service position
=> General body repairs, Exterior; Repair group 50; Body, front; Lock carrier - service position Body, front Lock
carrier - service position
- Remove upper toothed belt guard and cylinder head cover.

- Turn crankshaft to TDC of No. 1 cylinder.
-> TDC on vehicles with manual gearbox
-> TDC on vehicles with automatic gearbox

Audi A4 1995 ➤
Engine removed - vehicles with manual gearbox:

Engine removed - vehicles with automatic gearbox:

- -> Lock camshaft with setting bar.

- Centralize setting bar as follows:
Turn arrested camshaft so that one end of setting bar contacts the cylinder head. Using feeler gauge es‐
tablish the gap at the other end of the setting bar. Place a feeler gauge corresponding to half the gap between
setting bar and cylinder head. Turn camshaft until the setting bar contacts the feeler gauge. Place a 2nd
feeler gauge, of same thickness, at the other end between setting bar and cylinder head.
1.9 - Removing and installing injection pump: engine code AHH 61

Audi A4 1995 ➤
- -> Loosen securing bolts -1- for injection pump sprocket.

- Remove tensioning roller nut.
- Remove toothed belt from camshaft and injection pump sprockets.
=> Repair group 13; Dismantling and assembling engine; Removing and installing toothed belt and adjusting
tension. Dismantling and assembling engine Removing and installing toothed belt and adjusting tension.
- Unscrew injection pipes from pump using open ring spanner 3035.
- Cover openings with a clean cloth.
- -> Remove securing bolts -1- from console -arrows-.
Note:
On no account must hub nut -2- be loosened, otherwise the injection pump basic setting will be altered and this
cannot be reset with normal workshop equipment.
- -> Then remove bolt from rear support -arrow-.

- Take off injection pump.

Audi A4 1995 ➤
Installing injection pump
- Insert injection pump into console and then tighten securing bolt on rear support with conical nut first.
- Insert front securing bolts and tighten to 25 Nm.

- Fit injection pump sprocket to hub using new securing bolts but do not tighten the bolts.
- Align injection pump sprocket to central position in elongated holes.
- -> Lock injection pump sprocket with mandrel 3359.
- Loosen camshaft sprocket securing bolt a half turn.
- -> Place a drift through hole in the rear of the toothed belt guard and release the camshaft sprocket from
camshaft taper with a blow from a hammer.
- Check whether TDC mark on flywheel and reference mark are aligned.
- Place tooth belt on injection pump sprocket and tensioning roller.
- -> Tension toothed belt. Using pin wrench (e.g. Matra V159) on eccentric turn clockwise until the notch and
the raised mark -arrows- align.

Audi A4 1995 ➤
Note:
-> Make sure that the holding claw is correctly positioned.

- Check TDC mark on flywheel again.
- Tighten the new securing bolts for the injection pump sprocket to 20 Nm.
Notes:
◆ After the dynamic check of the commencement of injection, tighten the bolts by 1/4 turn (90°).
◆ The securing bolts are stretch bolts and can therefore only be used once.
- Tighten camshaft sprocket securing bolt to

45 Nm.
- Remove mandrel 3359.
- Remove setting bar 2065 A from camshaft.
- Turn crankshaft two rotations in engine D.O.R. until crankshaft is set to TDC No. 1 cylinder again.
- Reconnect injection pipes, fuel supply pipe and electrical wiring.
-> Fill injection pump with clean diesel fuel as follows:
- Screw pipe union 1318/10 into return pipe connection on injection pump.
- Connect vacuum hand pump V.A.G 1390 with bleeder container V.A.G 1390/1 to return pipe connection.

Audi A4 1995 ➤
- Operate vacuum hand pump until fuel comes out of return pipe connection. Do not allow the fuel to enter
the vacuum pump.
- Connect return pipe.

- Install cylinder head cover.
- Dynamically check and adjust commencement of injection
=>Page 65 .
1.10 - Dynamically checking and adjusting commencement of injection: engine code AHH
Notes:
◆ The commencement of injection must always be checked after renewing the toothed belt or loosening the
injection pump bolts or toothed belt sprockets and if necessary adjusted.
◆ Dynamically checking and correcting commencement of injection is only possible in function 04 "Engine
basic setting". This is because in function 04 the commencement of injection valve is activated continuously
and therefore the injection timing control is set to "late" (retarded).
- Initiate basic setting, Display Group 00, engine at idling speed

=> Page 20 .

(1...10 = Display zones)
Basic setting 0
1 2 3 4 5 6 7
8 9 10
- Monitor the display in display zone 7 (coolant temperature).

Specification: less than 73 (corresponds with
to 85°C)
respect to the correctness of information in this document. Copyright by AUDI AG.
Do not continue with the test until the coolant has reached the specified temperature.

A - Zone 2 commencement of injection
B - Zone 9 fuel temperature
Note:
If the commencement of injection is within the specified range -C- when tested, no adjustment is required.
If the commencement of injection is outside the specified range, adjust the injection pump as follows:

- Remove upper toothed belt guard.

Audi A4 1995 ➤
- Check toothed belt tension.
The marks must be aligned.
If markings do not align:

- Adjust toothed belt tension:
=> Repair group 13; Dismantling and assembling engine; Removing and installing toothed belt and adjusting
tension. Dismantling and assembling engine Removing and installing toothed belt and adjusting tension.
- -> Slacken two of the injection pump sprocket securing bolts -1-.
- Apply a ring spanner (22 mm A/F) to hub nut -2- to hold the pump shaft in position.
- Slacken the third securing bolt on the injection pump sprocket and turn the pump shaft slightly:
Anticlockwise => commencement of injection later (retarded)

(display value in display zone 2 decreases)
Clockwise => commencement of injection earlier (advanced)
(display value in display zone 2 increases)
Note:
On no account must hub nut -2- be slackened, otherwise the injection pump basic setting will be altered and
this cannot be reset with normal workshop equipment.
- Tighten the new securing bolts for the injection pump sprocket to 20 Nm.
Note:
The securing bolts are stretch bolts and can therefore only be used once.
- Again check whether commencement of injection is as specified.
If commencement of injection is still outside tolerance range:
- Correct the setting at the injection pump sprocket once again.
If the commencement of injection is within the specified range:
- Renew the three securing bolts (stretch bolts) one after the other and tighten them to 20 Nm.
- Then tighten the three securing bolts (stretch bolts) for injection pump sprocket by a further1/4turn (90°).
- Install toothed belt guard.

Audi A4 1995 ➤
1.11 - Removing, installing and testing injectors
Note:
Defective injectors cause the following faults:
◆ Loss of power
◆ Excessive black exhaust smoke
◆ Excessive blue smoke when starting from cold
◆ Higher fuel consumption
◆ Engine over-heating
◆ Knocking in one or more cylinders
◆ Misfiring
Removing injectors
- Remove injection pipes with open ring spanner 3035.
Note:
Always remove pipe set complete. Do not alter pipe shape.
- Remove securing nut, take off retainer and take out injector.
If the injectors are seized, construct the following auxiliary tool:
- Saw off an injection pipe about 5 cm away from the injector union nut.
- Braze an M6 nut onto the sawn-off end of the pipe section.
- Clean the auxiliary tool thoroughly. Any dirt will make the injector unusable.
- -> Screw the union nut end of the auxiliary tool to the seized injector, then apply special tool 3364 to the end
with the brazed-on nut.
Installing injectors
Note:
Always renew copper seals between cylinder head and injectors.
- Insert injectors.
- Check mounting is seated correctly in cylinder head.
- Fit retainer.
Tightening torques:
Injection pipes: 25 Nm
Bolt for retainer: 20 Nm
Testing injectors
- ->
1.11 - Removing, installing and testing injectors 67

Audi A4 1995 ➤

0.82mg/H -0.12mg/H 0.49mg/H
Read measured value block, Display Group 13, engine at idling speed => Page 32
Specification: -1.50 mg/H...+1.50 mg/H (milligrams per stroke)
- If one or more of the values is outside the tolerance, swap round the injectors (except the injector for cylinder
3).
- If the fault moves along with the injector, fit a new injector.
- If the fault remains on the same cylinder, swap round the pressure valves.
- If the fault moves with the pressure valve, fit a new pressure valve with oil seal
=>Servicing injection pump - Page 45 .
Notes:
◆ When removing the sealing ring from the pump, always use a soft object (plastic or wood) in order not to
scratch the sealing surface.
◆ After 15,000 km the pressure valves must always be renewed as a complete set.
- If the fault remains on the same cylinder, check the compression.
This engine is equipped with dual spring injectors. The fuel injected therefore occurs in 2 stages.
If faults occur with these injectors then they are to be exchanged as neither servicing nor pressure setting is
possible.
-> Test injectors using V.A.G 1322 and pressure pipe V.A.G 1322/2.
Warning!
When testing injectors ensure that the jet of fuel does not contact the hands as the high pressure will cause
the fuel to penetrate the skin and may cause severe injuries.
• Pressure gauge on with respect to the correctness of information in this document. Copyright by AUDI AG.
- Move pump lever down slowly. When injection begins, read off spray pressure. If the pressure does not
match the specification, fit a new injector.
Engine code: AFF, AHU, AFN, AVG
New injectors 190...200 bar

Wear limit 170 bar
Engine code: AHH
New injectors 220...230 bar

Wear limit 200 bar

Audi A4 1995 ➤
Checking for leaks
• Pressure gauge on
- Move pump lever down slowly and maintain a pressure of approx. 150 bar for 10 seconds. No fuel should
leak from the nozzle tip.
- If injector leaks, replace.
1.12 - Renewing injection timing device cover O-ring
- Place a clean cloth under the injection pump.

- -> Remove cover screws -1- with commercially available key for Torx socket head screws, e.g. Hazet 2115-
T30.
- Remove cover -2- and clean it.
- Renew O-ring -3- and install cover with existing shim -4-.
1.13 - Wiring and component check with test box V.A.G 1598/31
Notes:
◆ Test box V.A.G 1598/31 is designed so that it can be connected to the wiring harness for the engine control
unit and to the engine control unit itself at the same time.
◆ This has the advantage of enabling the engine management system to remain fully operational even with
the test box connected (for example, when testing signals while the engine is running).
◆ The instructions for performing the individual tests indicate whether or not the engine control unit itself also
needs to be connected to the test box.
1.11 - Removing, installing and testing injectors 69

Audi A4 1995 ➤
◆ Always use adapter set V.A.G 1594A to connect test equipment (e.g. voltage tester V.A.G 1527B, hand-
held multimeter V.A.G 1526A etc.).

- -> Remove rubber seal from the front -arrow-.
- Remove plenum chamber cover -1- from the front.
- Remove cover for electronics box in plenum chamber.
- -> Carefully lever off the retainer bar with a screwdriver -arrow-.
- Release catches and unplug control unit connectors.
Warning!
To prevent damage to the electronic components, switch to the respective measuring range before connecting
the measuring cable and observe the test prerequisites.
- -> Connect test box V.A.G 1598/31 to wiring harness connector. Also connect earth clamp on test box to
battery negative terminal. The instructions for performing the individual tests indicate whether or not the
engine control unit itself also needs to be connected to the test box.
- Carry out test as described in the repair instructions.

Audi A4 1995 ➤
1.14 - Renewing engine electronics control unit
Removing engine control unit
- -> Remove rubber seal from the front -arrow-.

- Remove plenum chamber cover -1- from the front.
- Remove cover for electronics box in plenum chamber.
- -> Carefully lever off the retainer bar with a screwdriver -arrow-.
- Release catches and unplug control unit connectors.
Installing engine control unit
Installation is performed in the reverse sequence.
The following operations must be carried out after installing the engine control unit:
- Code control unit => Page 22 .

- Adapt immobiliser to engine control unit
- On vehicles equipped with cruise control system (CCS): cruise control system must be activated
=> Electrical system; Self-diagnosis of cruise control system (CCS) -diesel engine-; Testing cruise control sys‐
tem (CCS).
- Perform basic setting on vehicles equipped with automatic gearbox:
=> Automatic gearbox 01N Self-diagnosis; Repair group 01; Performing self-diagnosis; Performing basic setting
Performing self-diagnosis Performing basic setting
1.14 - Renewing engine electronics control unit 71

Audi A4 1995 ➤
2 - Testing injection control

2.1 - Testing injection control
2.2 - Checking injection timing control range

- Start final control diagnosis and activate commencement of injection valve => Page 16 .

Commencement of injection valve -N108
Activating the valve has a noticeable effect on the combustion noise (diesel knock).
- Initiate basic setting, Display Group 00 => Page 20 .
-> Indicated on display (for example):

42 46 0 20 90 201
64 153 127 83
- If necessary, correct the commencement of injection

=> Page 59 .
- Remove fuse for engine electronics from electronics box.
- Observe display in display zone 2.
Basic setting 0
42 255 0 20 90 201
64 153 127 83
-> The display should go up to 255.
Note:
The break in the power supply will cause the commencement of injection valve to close. The interior pressure
in the pump cannot be reduced further, and therefore the full pressure is applied to the injection timing control
piston. This moves the injection timing control to the "early" (fully advanced) stop position.
If the specification is not obtained: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- Replace injection pump. with respect to the correctness of information in this document. Copyright by AUDI AG.
- Interrogate and erase fault memory=> Page 4 .
2.3 - Checking commencement of injection valve

Audi A4 1995 ➤
Electrical test of commencement of injection valve
- Unplug connector for commencement of injection valve

=>Fitting locations overview, Page 40 .
Measuring resistance on vehicles with 3-pin connector:
- -> Connect hand-held multimeter (resistance test range) between contacts 2 and 3.
Specification: 12...20ω
Measuring resistance on vehicles with 10-pin connector:
- -> Connect hand-held multimeter (resistance test range) between contacts 9 and 10.
Specification: 12...20 ω
If the specification is not obtained:
- Renew commencement of injection valve (N108).
If the specification is obtained:
Testing voltage supply of commencement of injection valve
Measuring voltage on vehicles with 3-pin connector:
- -> Connect hand-held multimeter (voltage test range) between engine earth and contact 3 on the connector.
- Switch ignition on.
2.3 - Checking commencement of injection valve 73

Audi A4 1995 ➤
Specification: approx. battery voltage
Measuring voltage on vehicles with 10-pin connector:

- -> Connect hand-held multimeter (voltage test range) between engine earth and contact 10 on the connector.

- Connect test box V.A.G 1598/31 to wiring harness for engine control unit. Do not connect to the engine
control unit itself.
=> Page 69 .
The following wiring connections are to be checked for open circuits and/or short to positive or negative.
-> Testing wiring connection on vehicles with 3-pin connector.
3-pin connector on wiring Test box V.A.G 1598/31,
harness, contact socket
2 114
3 1 and 2

Audi A4 1995 ➤
-> Testing wiring connections on vehicles with 10-pin connector.
10-pin connector on wir‐ Test box V.A.G 1598/31,

ing harness, contact socket
9 114
10 1 and 2
- Rectify any open/short circuit as necessary.
2.4 - Checking fuel temperature sender -G81

- Read measured value block, Display Group 07, engine cold and not running => Page 33 .

15.4 5C 15.9 5C 16.7 5C
If the wiring to the sender has an open circuit, a substitute value of -5.4 °C will be displayed.
If an implausible value or a substitute value of 5.4 °C is displayed:
=> Page 69 .
- Unplug connector on injection pump=>Fitting locations overview, Page 40 .

4 103
7 111
2.3 - Checking commencement of injection valve 75

Audi A4 1995 ➤
10-pin connector on wir‐ Test box V.A.G 1598/31,

ing harness, contact socket

4 103
7 111
3 - Checking control unit input values

3.1 - Checking control unit input values
3.2 - Checking Diesel direct injection system voltage supply
The injection system receives its current supply via the Diesel direct injection system relay (J322).
In order for the relay (J322) to close, a voltage must be applied to the Diesel direct injection system control unit
via terminal 15. This means that the relay (J322) is only earthed (via the Diesel direct injection system control
unit) if a voltage is applied to the control unit via terminal 15.
Test conditions
• Battery voltage OK.
Testing voltage supply at terminal 15
=> Page 69 .
- Connect multimeter (voltage test range) between earth and socket 37 of the test box.
- Check the wiring.

Audi A4 1995 ➤
Testing earth activation for Diesel direct injection system relay -J322
Test conditions

• Terminal 15 voltage supply OK
- Open electronics box in plenum chamber.

-> Specification: Diesel direct injection system relay (electronics box, relay position 3) should pick up.
Note:
The clicking of the valve is difficult to hear and is therefore best checked by touching the relay.
If the relay does not pick up:
=> Page 69 .
- Connect together sockets 18 and 4 on the test box using an auxiliary cable from V.A.G 1594.
-> Specification: Diesel direct injection system relay (electronics box, relay position 3) should pick up.
If the relay picks up now but not when the control unit is connected:
3.2 - Checking Diesel direct injection system voltage supply 77

Audi A4 1995 ➤
- Replace Diesel direct injection system control unit.

If the relay does not pickunless
permitted up:authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

- -> Unplug Diesel direct injection system relay -J322 from relay panel (electronics box, relay position 3).
Electronics box, relay Test box V.A.G 1598/31,

position 3, contact socket
9 18

Audi A4 1995 ➤
Testing voltage supply at terminal 30
Test conditions

• Terminal 15 voltage supply OK
• Earth activation for relay -J322 OK

- -> Unplug Diesel direct injection system relay -J322 from relay panel (electronics box, relay position 3).
- Connect multimeter (voltage test range) between the following contacts on the relay panel:
Electronics box, relay position Specification

3, contact
2 + earth approx. battery voltage
- Check the wiring.
- Plug relay back into relay panel (electronics box, relay position 3).
=> Page 69 .
- Connect together sockets 18 and 4 on the test box using an auxiliary cable from V.A.G 1594.
- Connect multimeter (voltage test range) between the following contacts on the test box:
Test box V.A.G 1598/31, Specification

socket
1+4 approx. battery voltage
2 + 4 approx.
Protected by copyright. Copying for private or battery
commercialvoltage
purposes, in part or in whole, is not
1 + 5 approx. battery voltage
2+5 approx. battery voltage
3.2 - Checking Diesel direct injection system voltage supply 79

Audi A4 1995 ➤
- Check the wiring.
3.3 - Checking engine speed sender -G28
The engine speed sender is both a speed sender and a reference mark sender. If it fails the engine will cut out.

- Disconnect sender connector
- -> Connect multimeter (resistance test range) between contacts 1 and 2 on the sender connector.
Specification: approx. 1 kω
- Replace engine speed sender (G28).
=> Page 69 .

1 102

Audi A4 1995 ➤

2 110
3 86
3.4 - Checking air mass meter -G70
The signal from the air mass meter is required by the control unit to calculate the required injection quantity
and to control the exhaust gas recirculation. The weaker the signal from the air mass meter, the less fuel can
be injected.
Important:
Secure fault reader to rear seat and operate from this location. When doing this, always observe the relevant
safety precautions => Page 39 .
- Read measured value block, Display Group 10, engine running at idling speed => Page 36

309 mg/H 1030 mbar 1011
mbar 0.0 %

309 mg/H 1030 mbar 1011 mbar
0.0 %
-> Specification: 230...370 mg/H (mg/stroke)

- Check exhaust gas recirculation:
=> 4-Cyl. Diesel Direct Injection Engine (TDI), Mechanics; Repair Group 26; Testing exhaust gas recirculation
system Testing exhaust gas recirculation system
- Accelerate vehicle from approx. 1500 rpm
permitted at authorised
unless full throttle; inAG.
by AUDI second
AUDI AGgear forguarantee
does not manual gearbox
or accept or second
any liability
driving range for automatic gearbox.with respect to the correctness of information in this document. Copyright by AUDI AG.
- Press PRINT key on V.A.G 1551 at approx. 3000 rpm. The accelerator pedal must be fully depressed at
this moment in time.

830 mg/H 1030 mbar 1850 mbar
100 %
-> Specification for display zone 4: 100 % (accelerator pedal position)

- Repeat test and accelerate vehicle at full throttle.

830 mg/H 1030 mbar 1850 mbar
100 %
-> Specification for display zone 3: (charge pressure)
3.3 - Checking engine speed sender -G28 81

Audi A4 1995 ➤
Engine code AFF, AHU, AHH:

1800...2050 mbar
Engine code AFN, AVG:
1800...2250 mbar
- Test charge pressure
=> 4-Cyl. Diesel Direct Injection Engine (TDI), Mechanics; Repair Group 21; Testing charge pressure system
Testing charge pressure system

830 mg/H 1030 mbar 1850 mbar
100 %
-> Specification for display zone 1: intake air mass

Engine code AFF, AHU, AHH:
> 750 mg/H (mg/stroke)
Engine code AFN, AVG:
> 800 mg/H (mg/stroke)
- Renew air mass meter (G70).
If display zone 1 shows a fixed substitute value:

- Disconnect connector for air mass meter
- -> Connect hand-held multimeter (voltage range) between the following contacts on the connector:
5-pin connector on wiring harness, Specification

contact
2 + earth Battery voltage
2+3 Battery voltage
4 + earth approx. 5 V
4+3 approx. 5 V
If the specifications are not obtained:
=> Page 69 .

Audi A4 1995 ➤

1 -
2 1 and 2
3 49
4 30
5 68
3.5 - Checking needle lift sender
The needle lift sender signal is used to determine the commencement of injection. If it fails the commencement
of injection switches to open-loop control (according to engine speed and engine load). During normal operation
the commencement of injection is controlled by a closed-loop function (according to engine speed, engine load
and temperature).

- Disconnect connector for sender
- -> Connect hand-held multimeter (resistance test range) between the contacts on the sender connector.
Specification: 90...120ω (when the engine is hot the resistance may be up to 20 ω higher)
3.4 - Checking air mass meter -G70 83

Audi A4 1995 ➤
- Replace cylinder 3 injector with needle lift sender (G80).
=> Page 69 .

1 109
2 101
3.6 - Testing coolant temperature sender -G62

- Read measured value block, Display Group 07, engine cold and running at idling speed => Page 33

15.4 5C 15.9 5C 16.7 5C
- Check display in display zone 4 (coolant temperature).
Specification: The temperature reading should increase at a uniform rate.
If there is a fault the fuel temperature (display zone 1) will be displayed as a substitute value.

Audi A4 1995 ➤
If an implausible value is displayed in display zone 4, or if the fuel temperature is displayed as a substitute
value:

- -> Unplug connector from sender=>Fitting locations overview, Page 40 .
=> Page 69 .
4-pin connector on wiring Test box V.A.G
with respect 1598/31,
to the correctness of information in this document. Copyright by AUDI AG.
3 112
4 104
If no wiring fault is detected:
- Replace coolant temperature sender (G62).
3.7 - Checking intake manifold temperature sender

- measured value block 7
Read
15.4 5C 15.9 5C 16.7 5C
-> Read measured value block, Display Group 07, engine cold and not running => Page 33 .
If the wiring to the sender has an open circuit, a substitute value of 136.8 °C will be displayed.
3.6 - Testing coolant temperature sender -G62 85

Audi A4 1995 ➤
If an implausible value or a substitute value of 136.8 °C is displayed:
=> Page 69 .
- -> Unplug connector from sender=>Fitting locations overview, Page 40 .

1 52
2 73
If no wiring fault is detected:
- Replace intake manifold temperature sender (G72).
3.8 - Checking modulating piston movement sender -G149 and quantity adjuster -N146
The metering unit (quantity adjuster) is an electromagnetic swivelling positioner which is controlled by the con‐
trol unit via a directed duty cycle (on-off ratio). The eccentric shaft on the metering unit moves the modulating
piston on the high pressure piston and thereby regulates the quantity of fuel injected.
The modulating piston movement sender informs the control unit of the position of the modulating piston,
thereby indicating the quantity of fuel injected.
- Read measured value block, Display Group 01, engine at idling speed => Page 29

Audi A4 1995 ➤

Read measured value block 1 "
840 rpm 5.6 mg/H 1.480 V
87.3 5C
- Check display in display zone 4 (coolant temperature).

840 rpm 5.6 mg/H 1.480 V 87.3
5C
-> Specification: At least 85 °C
Continue with check when coolant temperature is attained.
- Switch off any electrical consumers that may be on (air conditioner, rear window heater, lights etc.).
- Check display in display zone 3 (voltage supplied from modulating piston movement sender).

840 rpm 5.6 mg/H 1.480 V 87.3
5C
-> Specification: 1.250...1.700 V
- Replace injection pump.
Electrical check of modulating piston movement sender (G149) and quantity adjuster (N146)

- Disconnect connector for sender=>Fitting locations overview, Page 40 .
- Connect hand-held multimeter (resistance test range) between the following contacts on the injection pump
connector:
87
Audi A4 1995 ➤
8-pin or 10-pin injection pump connector Specification

1+2 4.9...7.5 ω
3+2 4.9...7.5 ω
6+5 0.4...1.1 ω
- Replace injection pump.
Testing current supply and wiring connections

- Disconnect connector for sender=>Fitting locations overview, Page 40 .
- Connect hand-held multimeter (voltage test range) between the following contacts on the wiring harness
connector:
-> Measuring voltage on vehicles with 8-pin connector.
-> Measuring voltage on vehicles with 10-pin connector.
8-pin or 10-pin connector on Specification

wiring harness, contact
1 + earth approx. 2.5 V
3 + earth approx. 2.5 V
5 + earth approx. battery voltage

Audi A4 1995 ➤
=> Page 69 .
8-pin or 10-pin connector Test box V.A.G 1598/31,

on wiring harness, con‐ socket
tact
1 108
2 106
3 99
5 1 and 2
6 116 and 121
89
Audi A4 1995 ➤
4 - Testing auxiliary signals

4.1 - Testing auxiliary signals
4.2 - Testing signals from and to air conditioner
Testing air conditioner compressor shut-off
◆ Heavy acceleration from low speeds (control unit detects angle change at accelerator pedal position sender
and receives road speed signal)
◆ In the back-up programme (emergency running mode)
◆ If the coolant temperature rises above 120 °C
◆ For approx. 6 seconds after every engine start
Test conditions
• Air conditioner OK
• Air conditioning system switched on
• No faults recorded in fault memory
-
-> Start final control diagnosis and activate conditioner compressor interruption => Page 16 .
The air conditioner compressor should cut out within 5 seconds (visual check), then start and stop again every
5 seconds.
If the conditioner compressor is not switched off:
=> Page 69 .
Test box V.A.G 1598/31, socket Air conditioner operating and display unit, contact
29 => Current flow diagrams, Electrical fault finding and Fitting locations binder
Testing air conditioner signal
The air conditioner signal informs the engine control unit that the air conditioner needs a higher idling speed in
order to provide the desired interior temperature (both when cooling and when heating).
The increase in idling speed resulting from the air conditioner signal depends on the control unit version and
is not activated in all vehicles.
- Observe display in display zone 3, the air conditioner must not be switched on.

860 rpm 0.0 % 0 1
0 18.4 5C
- Switch on air conditioner, press the "Auto" key and select the lowest temperature.
- Select lowest temperature and highest blower speed. The air conditioner compressor must run.

Audi A4 1995 ➤
- Check display in display zone 3.

900 rpm 0.0 % 1 1 1
18.4 5C
-> Specification: X X 1 (air conditioner compressor signal)
=> Page 69 .
Test box V.A.G 1598/31, socket Air conditioner operating and display unit, contact
4.3 - Testing speed signal
The speed signal is required to ensure that the air conditioner compressor is switched off when accelerating.
It is also required for the cruise control system and to ensure smoother driving (jolt damping).
Test conditions
• Speedometer OK., checking:
=> Electrical System; Repair Group 90
Important:
Secure fault reader to rear seat and operate from this location. When doing this, always observe the relevant
safety precautions => Page 39 .

0 km/h 0
Protected by0copyright.0Copying000000
255 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- Take vehicle for a test drive.


45 km/h 0 0 0 000000 255
-> Specification: The current road speed should be displayed (compare with speedometer).
=> Page 69 .
4.2 - Testing signals from and to air conditioner 91

Audi A4 1995 ➤
Test box V.A.G 1598/31, socket Dash panel insert, contact

If no fault in wire is detected:
- Establish which electrical "consumers" (e.g. radio, automatic gearbox, air conditioner etc.) are using the
speed signal, disconnect them one by one from the dash panel insert, then keep repeating the test until the
cause of the problem has been identified.
4.4 - Testing engine speed signal
The engine speed signal is required for the rev counter, air conditioner and automatic gearbox.
However, since the signal cannot be read in the form in which it is generated by the engine speed sender (G28),
it has to be processed by the engine control unit.
Identify the engine speed signal as follows:
Dash panel insert
- Observe rev counter reading.

Specification: The current engine speed should be displayed.
Air conditioner
The signal is monitored by the self-diagnosis function (fault memory, read measured value block) of the air
conditioner.
Testing signal
=> Heating, Air Conditioner; Repair Group 01
Specification: The current engine speed should be displayed in the measured value block.
Automatic gearbox
The signal is monitored by the self-diagnosis (fault memory, read measured value block) of the automatic
gearbox control unit.
Testing signal
=> Automatic Gearbox; Repair Group 01
Specification: The current engine speed should be displayed in the measured value block.
If the engine speed signal is not as specified for all the "consumers" that use the signal, the following faults are
possible:
◆ Open circuit or short in wiring between Diesel direct injection system control unit and wiring harness con‐
nector
◆ Short circuit in wiring between wiring harness connector and "consumer"

◆ Diesel direct injection system control unit defective

Audi A4 1995 ➤
If the engine speed signal is as specified for at least one of the "consumers", the following faults are possible:
◆ Open circuit in wiring between wiring harness connector and "consumer"

◆ "Consumer" defective
4.5 - Testing a "two-wire data bus system"

- By referring to the appropriate current flow diagram, check how many control units are connected to the
CAN data bus (Controller Area Network).
- Check that the multi-pin connectors on the control units are properly seated.
- Connect fault reader V.A.G 1551 and press key 0 twice to select the function "Automatic test sequence".
Before testing the bus wires, make sure that there are no faults in any of the control units connected to the data
bus.
If a fault exists, rectify this fault first.
- Make a note of any faults and erase the fault memories of all control units.
- Rectify the faults as described in the fault table in the relevant Workshop Manual.
If communication between the control units is still not working properly when all faults have been rectified, test
the data bus wires.

- -> Disconnect the control units which are linked by the bus wires and check for a short circuit between the
bus wires
=> Current Flow Diagrams, Electrical fault Finding and Fitting Locations
- -> Check the bus wires for short to positive and short to earth.
If the bus wires do not cause the fault reading "Defective hardware", test the control units.
4.4 - Testing engine speed signal 93

Audi A4 1995 ➤
At this stage all the control units which communicate via the CAN data bus are disconnected. The ignition is
switched off.
- Connect one of the control units.

- Connect fault reader V.A.G 1551.
- Switch ignition on and erase fault memory of the control unit that has just been connected.
- Terminate fault readout by selecting function 06 "End output".
- Switch the ignition off and then on again.
- Leave the ignition switched on for 10 seconds. Then interrogate the fault memory of the control unit that has
just been connected, using the fault reader.
- If the fault "Defective hardware" is now indicated, replace the control unit which has just been connected.
- If the fault "Defective hardware" is not indicated, connect the next control unit, and repeat the above pro‐
cedure.

Audi A4 1995 ➤
28 - Glow plug system
1 - Checking glow plug system

1.1 - Checking glow plug system
1.2 - Testing operation

- Pull glow plug connectors off glow plugs.
- Connect multimeter (voltage test range) between engine earth and one of the glow plug connectors.
- Initiate final control diagnosis and activate glow plug relay
=> Page 16 .

Specification: approx. battery voltage (every 5 seconds)
1.3 - Checking glow plugs
Test conditions
• Battery voltage at least 11.5 V permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

- Pull glow plug connector off glow plug.
- -> Connect diode test lamp wire using auxiliary clips from auxiliary cable set to battery positive (+).
- Place diode test lamp probe on each glow plug one after the other.
If diode lights up: glow plug OK.
1.1 - Checking glow plug system 95

Audi A4 1995 ➤
If diode does not light up: fit a new glow plug
- Remove and install glow plugs with jointed spanner 3220.
Tightening torque: 15 Nm
96 28 - Glow plug system

00055009920-TDI Diesel Injection and Glow Plug System (4-Cyl) 08 99 Ä

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TDI diesel injection and glow plug system (4-cyl.) 08.99

Service Department. Technical Information

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Copyright © 2010 Audi AG, Ingolstadt 00055009920

23 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

3.7 Checking intake manifold temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

1.2 - Technical data of self-diagnosis

◆ Fault memory: Non-volatile memory and volatile memory1)

Function Ignition switched Engine idling

• Battery voltage at least 11 V

Depending on the function required:

- Switch on printer with the Print button

-> Indicated on display:

=> Current Flow Diagrams, Electrical Fault-Finding and Fitting Locations

Rapid data transfer HELP

Rapid data transfer HELP

- 038906018.. Control unit number (see also Parts

-> Indicated on display:

reader V.A.G 1551 and selecting functions 3

1.4 - Interrogating and erasing fault memory

Only when engine does not start:

-> Indicated on display:

If one or more faults are stored:

-> Indicated on display:

-> Indicated on display:

1.5 - Fault table

1.5 - Fault table 5

1.5 - Fault table 7

V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

1.5 - Fault table 9

1.5 - Fault table 11

Glow plug relay -J52

1.5 - Fault table 13

V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

V.A.G 1551 print-out Possible causes of Possible effects Fault remedy

1.5 - Fault table 15

2 - Final control diagnosis

Test requirements for vehicles with air conditioning system

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

1. Commencement of injection valveby(N108)

2. Exhaust gas recirculation valve (N18)

3. Conditioner compressor interruption

4. Fuel cut-off valve (N109)

5. Solenoid valve for boost pressure control (N75)

6. Glow plug relay (J52)

7. Glow period warning lamp (K29)

8. Low heating output relay (J359)

(only on vehicles with manual gearbox)

9. High heating output relay (J360)

(only on vehicles with manual gearbox)

10. Fan relay (J323)

(engine code AFN and AVG only)

-> Indicated on display:

Rapid data transfer HELP

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

-> Indicated on display: