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EnginesEdition 09.04
S00.5301.14.2002-3 page 3 02
Engine identification
charactersAMF AUB BBZ ASY
Emission standard EU3 EU4
EU2 DDK,
EU3 DDKEU4,
EU2 DDK,
EU3 DDKEU3
Manufacturing
(from...through)05.03 08.99 ... 05.02 05.02 08.99
Displacement in litres 1,4 1,4 1,9
Output (kW at rpm) 55 / 4000 74 / 6000 47 / 4000
Max. torque (Nm at rpm) 195 / 2200 126 / 4400 125 / 1600 - 2800
Bore (∅ mm) 79,5 76,5 79,5
Stroke (mm) 95,5 75,6 95,5
Compression 19,5 10,5 19,5
Hydraulic valve clearance
compensationXXX
Mixture formation Bosch PDE - injec-
torsMagneti Marelli 4LV Bosch VP
Fuel RON (minimum) -
unleaded 98
1)
1)Regular grade unleaded petrol (min. 95 ROZ) can be used although engine power output is slightly reduced.
-
Fuel CN (minimum) 49 - 49
Firing order 1-2-3 1-3-4-2 1-3-4-2
Exhaust gas recirculation X X X
Ignition system/fuel injec-
tionBosch PDE - injec-
torsMagneti Marelli 4AV Bosch VP
Self-diagnosis X X X
Catalytic converter X X X
Turbocharging X - -
Charge air cooler X - -
Lambda probe - X -
Camshaft adjustment - - -
Engine identification char-
actersATD ASZ AZL BMD BKY
Emission standard EU3 EU3 EU4,
EU2 DDK,
EU3 DDKEU4,
EU2 DDKEU4,
EU2 DDK
Manufacturing (from...through) 02.00 06.03 08.00 05.04 05.04
Displacement in litres 1,9 1,9 2,0 1,2 1,4
Output (kW at rpm) 74 / 4000 96 / 4000 85 / 5400 40 / 4750 55 / 5000
Max. torque (Nm at rpm) 240 / 1800 -
2800310 / 1900 170 / 2400 108 / 3000 126 / 3800
Bore (∅ mm) 79,5 79,5 82,5 76,5 76,5
Stroke (mm) 95,5 95,5 92,8 86,9 75,6
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EnginesEdition 09.04
S00.5301.14.2002-3 page 4 02
Engine fitted
The engine identification characters and serial number
are located in the front at the engine/gearbox joint.
In addition, a sticker with the engine identification charac-
ters and serial number is affixed to the timing belt guard.
Engine with identification characters ARV, AQV, AZE,
AZF, AME, ATZ and AQW.
Engine with identification characters AUA, AUB, BBY,
BBZ, BKY.Compression 19 19 10,5 10,3 10,5
Hydraulic valve clearance
compensationXX X X X
Mixture formation Bosch PDE -
injectorsBosch PDE -
injectorsBosch ME 7.5 Simos 3PG Magneti Marelli
4TV
Fuel RON (minimum) - -
unleaded 95
1)unleaded 951)unleaded 951)
Fuel CN (minimum) 49 49 - - -
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-2-3 1-3-4-2
Exhaust gas recirculation X X - - X
Ignition system/fuel injection Bosch PDE -
injectorsBosch PDE -
injectorsBosch ME 7.5 Simos 3PG Magneti Marelli
4TV
Self-diagnosis X X X X X
Catalytic converter X X X X X
Turbocharging X X - - -
Charge air cooler X X - - -
Lambda probe - - X X X
Camshaft adjustment - - - - -
1)Regular grade unleaded petrol (min. 91 ROZ) can be used although engine power output is slightly reduced.
Engine identification char-
actersAT D A S Z A Z L B M D B K Y
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Electrical SystemEdition 09.04
S00.5301.14.2002-6 page 4 02
Operate the vehicle system tester by referring to the
read-out on the display:
Read out on display:
–Enter 00 for address word „Automatic test sequence“
and confirm with .
The automatic test sequence is carried out with address
word 00, i.e. the fault memory of all self-diagnosable sys-
tems in the vehicle is interrogated.
If a control unit responds with its identification, the display
will show the number of faults stored in the memory or
„No fault detected!“ Eventuell gespeicherte Fehler eines
Systems werden nacheinander angezeigt.
Any faults stored for one of the systems are displayed in
sequence.
If faults are stored, it is necessary to carry out a repair
measure. Displayed faults are to be entered.
–Switch off ignition.
The vehicle system tester -V.A.G 1552 - may have to re-
main connected for the exhaust emission test and for re-
setting the service interval display.
Resetting service interval display (SID)
QG0
If the due date of a service is reached, the service event
appears in the short journey counter below the speedom-
eter as a flashing display, after the ignition is switched on.
The service event also continues flashing for about 60
seconds after the engine is started.
The following displays are possible:
OIL - Oil change service
INSP - Inspection Service
The service event is shown on the indicator when the
service interval has been reached.
The service interval display should be adapted when car-
rying out the Delivery Inspection or during every Inspec-
tion Service.
The following intervals are set when adapting the service
interval display (SID):
Vehicle system test HELP
K cable does not connect to earth
Vehicle system test HELP
K cable does not connect to pos. term.
Vehicle system test HELP
Enter address word XX
Q
Note
Service event Nominal value
(distance)Nominal value
(time)
OIL 15 000 km -
INSP 30 000 km 365 days
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Exhaust-emission AnalysisEdition 09.04
S00.5301.14.2002-8 page 1 02
02-8 Exhaust-emission Analy-
sis
The exhaust-emission analysis must be carried out ac-
cording to the relevant national legislation of the particu-
lar country.
Exhaust-Emission Analysis on Models
with Fuel Engines
Perform the following visual inspections and comply with
the setting conditions below before performing the ex-
haust-emission analysis:
Visual inspection
♦Lambda probes are connected
♦All vacuum hoses are connected
♦All wires of the activated charcoal filter system are
connected
♦All the electrical wires of the ignition and injection sys-
tem are connected
♦Hose for crankcase ventilation is connected
♦The exhaust system must be undamaged and tight
♦Catalyst must be undamaged
Test and setting conditions
•Perfect operation of the engine
•Perfect operation of the ignition system
•Intake system tight
•All electrical components are switched off (radiator fan
must not run during the test)
♦If any errors are noticed they must be repaired.
♦The idling speed, ignition point and CO content are
only measured as they cannot be adjusted.
♦The CO content is set to nominal value by the lambda
control. Faults in the lambda control are detected by
the self-diagnosis and stored in the fault memory.
♦When interrogating the fault memory (engine electron-
ics) all detected faults must be repaired and the fault
memory must be erased.
♦To prevent injury to persons and/or damage to the ig-
nition and injection system make sure the ignition is
switched off when disconnecting and connecting the
wires of the ignition system.
Connect the test equipment to the vehicle
To prevent industrial accidents or avoid causing damage
to the ignition system, pay attention to the following:
Note
Note
Note
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Exhaust-emission AnalysisEdition 09.04
S00.5301.14.2002-8 page 2 02
♦Disconnect and connect wires of the ignition system
(including high-voltage wires) when the ignition is
switched off.
–Connect the tester in compliance with the operating
instructions.
The exhaust gas probe must be fully inserted into the ex-
haust tailpipe (do not insert into the suction tube)!
–Start engine and run in idle.
–Measure idle speed and CO content.
Test Values for Exhaust-Emission Analysis on Models with Fuel Engines
Note
Engine identification
charactersARV and AQV ARV and AQV ARV and AQV AWY
Model year MY00 MY01 MY02 MY02 ➤
Oil temperature min. 80 °Cmin. 80 °C min. 80 °Cmin. 80 °C
Catalyst warming-up time2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm
Idling speed
(rpm)590 ... 790 590 ... 690 590 ... 790 600 ... 800
CO content at idle speed
(measured after catalyst)0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5%
Increased idling speed
(rpm)2400 - 2600 2400 - 2600 2400 - 2600 2400 - 2600
Lambda value
at 2850 - 2900 rpm0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03
CO content
at 2850 - 2900 rpmmax. 0.3% max. 0.3% max. 0.3% max. 0.3%
Speed for control loop
test (rpm)490 ... 890 490 ... 790 490 ... 890 500 ... 900
Lambda probe version - - - Jump probe
Voltage jump (V) - - - 0,3
DELTA-lambda 0,03 0,03 0,03 0,03
Test speed - - - Idling speed
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Exhaust-emission AnalysisEdition 09.04
S00.5301.14.2002-8 page 3 02
Engine identification
charactersAZQAZE, AZF and
AMEAT Z A Q W
Model year MY03 ➤MY00 ➤ MY03 MY00 MY01 ➤ MY03
Oil temperature min. 80 °Cmin. 80 °C min. 80 °Cmin. 80 °C
Catalyst warming-up time2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm
Idling speed
(rpm)650 ... 850 700 ... 900 700 ... 900 700 ... 900
CO content at idle speed
(measured after catalyst)0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5%
Increased idling speed
(rpm)2400 - 2600 2400 - 2600 2400 - 2600 2400 - 2600
Lambda value
at 2850 - 2900 rpm0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03
CO content
at 2850 - 2900 rpmmax. 0.3% max. 0.3% max. 0.3% max. 0.3%
Speed for control loop
test (rpm)550 ... 950 600 ... 1000 600 ... 1000 600 ... 1000
Lambda probe version - - - -
Voltage jump (V) - - - -
DELTA-lambda 0,03 0,03 0,03 0,03
Test speed - - - -
Engine identification
charactersAUAAUA
with manual gear-
boxAUA
with automatic
gearboxBBY
with manual
gearbox
Model year MY00 and MY01 MY02 MY02 MY02 ➤
Oil temperature min. 80 °C min. 80 °C min. 80 °Cmin. 80 °C
Catalyst warming-up time2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm
Idling speed
(rpm)650 ... 850 650 ... 850 580 ... 780 660 ... 860
CO content at idle speed
(measured after catalyst)0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5%
Increased idling speed
(rpm)2400 - 2600 2400 - 2600 2400 - 2600 2400 - 2600
Lambda value
at 2850 - 2900 rpm0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03
CO content
at 2850 - 2900 rpmmax. 0.3% max. 0.3% max. 0.3% max. 0.3%
Speed for control loop
test (rpm)
550 ... 950 550 ... 950 480 ... 880 560 ... 960
Lambda probe versionWide band probe
(lambda)Wide band probe
(lambda)Wide band probe
(lambda)Wide band probe
(lambda)
Voltage jump (V) - - - -
DELTA-lambda 0,03 0,03 0,03 0,03
Test speed Idling speed Idling speed Idling speed Idling speed
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Exhaust-emission AnalysisEdition 09.04
S00.5301.14.2002-8 page 4 02
Engine identification
charactersBBY
with automatic
gearboxAUB BBZ AZL
Model year MY02 ➤MY00 ➤ MY02 MY02 ➤MY01 ➤
Oil temperature min. 80 °C min. 80 °C min. 80 °Cmin. 80 °C
Catalyst warming-up time2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm2 min.
at 2500 rpm
Idling speed
(rpm)580 ... 780 740 ... 940 580 ... 780 680 ... 880
CO content at idle speed
(measured after catalyst)0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5% 0,0 ... 0,5%
Increased idling speed
(rpm)2400 - 2600 2400 - 2600 2400 - 2600 2400 - 2600
Lambda value
at 2850 - 2900 rpm0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03 0,97 ... 1,03
CO content
at 2850 - 2900 rpmmax. 0.3% max. 0.3% max. 0.3% max. 0.3%
Speed for control loop
test (rpm)480 ... 880 640 ... 1040 480 ... 880 580 ... 980
Lambda probe versionWide band probe
(lambda)Wide band probe
(lambda)Wide band probe
(lambda)-
Voltage jump (V) - - - -
DELTA-lambda 0,03 0,03 0,03 0,03
Test speed Idling speed Idling speed Idling speed -
Engine identification
charactersBMD BKY
Model year MY04 ➤MY04 ➤
Oil temperature min. 80 °C min. 80 °C
Catalyst warming-up time2 min.
at 2500 rpm2 min.
at 2500 rpm
Idling speed
(rpm)620 ... 820 660 ... 860
CO content at idle speed
(measured after catalyst)0,0 ... 0,5% 0,0 ... 0,5%
Increased idling speed
(rpm)2400 - 2600 2400 - 2600
Lambda value
at 2850 - 2900 rpm0,97 ... 1,03 0,97 ... 1,03
CO content
at 2850 - 2900 rpmmax. 0.3% max. 0.3%
Speed for control loop
test (rpm)520 ... 920 560 ... 960
Lambda probe version Jump probeWide band probe
(lambda)
Voltage jump (V) - -
DELTA-lambda 0,03 0,03
Test speed - -
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Exhaust-emission AnalysisEdition 09.04
S00.5301.14.2002-8 page 5 02
All tubes and plug connections, which had been removed
or disconnected for the test and adjustment, must be re-
inserted or connected.
Technical data of the spark plugs Chapter 02-3.
Exhaust-Emission Analysis on Models
with Diesel Engines
♦When possible the test should be carried out immedi-
ately after the road test and also outdoors. If specific
reasons prevent this (weather conditions, excessive
noise in residential areas) the test may also be per-
formed in the workshop.
♦Secure the engine bonnet in the first stop while meas-
uring to reduce the noise.
Visual inspection
♦Hose for crankcase ventilation is connected
♦Fuel system and injection pump must be tight
♦The exhaust system must be undamaged and tight
♦All vacuum hoses are connected
Test and setting conditions
•Engine oil temperature at least 80 °C
•All electrical components disconnected
•No fault stored in the fault memory ⇒Chapter 02-6,
connect vehicle system tester and interrogate fault
memory
Correct detected faults before measuring (repair meas-
ure).
Connect the test equipment
–Connect the tester in compliance with the operating
instructions.
–Start engine, warm up to normal temperature and run
in idle.
–Perform the exhaust-emission analysis.
♦Activate and inspect auxiliary equipment such as e.g.
power steering, automatic gearbox or air conditioning
system. Check whether the engine continues to run
perfectly under this load.
♦All tubes and plug connections, which had been re-
moved or disconnected for the test and adjustment,
must be re-inserted or connected.
Note
Note
Note
Note