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Workshop Manual
OCTAVIA
1.9-ltr. / 66 kW (TDI) Engine
Fuel Injection and Glow Plug System
Edition 08.96
The Workshop Manual is intended only for use within the KODA
Organisation; it is not permitted to pass it on to third parties.
1996 KODA, automobilov a.s.
Service
List of Supplements to
Workshop Manual OCTAVIA
Edition: 01.04
1.9 l/66 kW (TDI) Engine, Fuel Injection and Glow Plug System
Replaces List of Supplements - Edition: 09.03
Supplement
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Edition
08.96
05.97
03.98
02.99
12.00
09.03
01.04
Subject
Article Number
S00.5111.50.20
S00.5111.51.20
S00.5111.52.20
S00.5111.53.20
S00.5111.54.20
S00.5111.55.20
S00.5111.56.20
Printed in CR
S00.5111.56.20
OCTAVIA
01
Contents
Service
Self-Diagnosis
Self-Diagnosis ..............................................................................................................................
- Properties of the self-diagnosis ................................................................................................
- Technical data of self-diagnosis ...............................................................................................
- Connecting tester V.A.G 1552 and select engine electronics control unit ................................
- Interrogating and erasing fault memory ....................................................................................
- Fault table .................................................................................................................................
Page
01-1
01-1
01-1
01-2
01-5
01-8
01-18
01-18
01-21
01-23
01-28.2
01-28.2
01-29
01-38
01-46
01-49
01-51
01-52
01-58
23
Fuel Formation/Injection
Edition 01.04
S00.5111.56.20
01-24
01-24
01-26
Page
23-1
23-1
23-1
23-2
23-2.2
23-3.1
23-4
23-5
23-6
23-7
23-7.2
23-8
23-13
23-16
23-19
23-20
23-22
23-22
23-24
23-25
23-26
23-27
23-28
23-28
23-29
23-30
------------ I ------------
Service
OCTAVIA
23-32
23-32
23-34
23-35
23-37
23-38
23-38
23-41
23-42
23-43
23-44
23-45
23-47
23-56
23-57
23-59
28
------------ II ------------
23-49
23-49
23-51
23-52
23-53
23-54
23-55
23-55.3
Page
28-1
28-1
28-2
28-2
Edition 01.04
S00.5111.56.20
OCTAVIA
01
Self-diagnosis
Self-diagnosis
Features of self-diagnosis
The diesel direct injection system control unit is
equipped with a fault memory. The fault memory
is designed as a permanent memory and as a
volatile memory.
If faults occur in the monitored sensors or components, these are stored in the fault memory
together with an indication of the fault type.
The engine control unit analyses this fault information and distinguishes the fault types page
01-8, Fault Table, and stores these faults until
the contents of the fault memory are erased.
Faults which occur only temporarily (sporadically), are displayed as sporadic by the addition /SP. The cause of a sporadic fault may
be, for example, a loose contact or a temporary
open circuit in the wiring. If a sporadic fault no
longer occurs within 50 engine starts, it is automatically erased from the fault memory.
The stored faults can be read out with the vehicle system tester V.A.G 1552 or V.A.G 1551, or
also with VAS 5051 page 01-5.
After any faults have been rectified, it is then
necessary to erase the fault memory page
01-6.
Notes:
The description which follows relates only to
the vehicle system tester V.A.G 1552 using
the programme card version 5.0.
If see info in literature appears in the display of the vehicle system tester, look for the
appropriate text in the fault table on the basis of the fault code.
Use of the fault reader V.A.G 1551 (with programme card version 8.0) with integrated
printer, or VAS 5051, is similar. Slight variations are possible in the readouts in the display.
Edition 12.00
S00.5111.54.20
01
OCTAVIA
Self-diagnosis
Condition
Engine not
running,
ignition on
Engine
idling
yes
yes
yes1)
yes
yes
yes
yes
yes
yes
no
04 Basic setting
06 End output
no
yes
yes
yes
yes
yes
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis
K-
HELP
HELP
HELP
HELP
HELP
Edition 12.00
S00.5111.54.20
Note:
K Readout in display:
-
Enter address word 01 for Engine electronics and confirm the entry with the key Q.
------------
------------
01
OCTAVIA
Self-Diagnosis
1.9 l
R4
EDC
Engine displacement
G or no
display
MG
AG
Manual gearbox
Automatic gearbox
00
2112
Software
version
Starting date
038906018B
1002
08.97
038906018BC
1822
038906018GM
2162
038906018BQ
08.98
2112
08.98 04.99
038906012F
3313
08.00
038906012HA
4922
038906012H
1)
3315
05.99 07.00
08.00
08.03
Notes:
If the control unit version displayed does not
correspond to the vehicle, replace the control
unit page 23-20.
Incorrect coding of the engine control unit results in:
poor driveability (jerking when changing
gears, load alteration shock etc.)
Increase in fuel consumption
Increase in pollution
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-diagnosis
Storage of non-existent faults in fault memory
Functions not being performed
HELP
K Readout in display:
-
HELP
K Readout in display:
-
X faults recognized!
If no fault is stored:
Test of vehicle systems
Select function XX
Edition 12.00
S00.5111.54.20
HELP
Press key.
K Readout in display:
-
01
Self-Diagnosis
OCTAV1A
Press key.
Press key.
Press key.
HELP
Press key.
K Read-out on display:
-
Note:
When carrying out test and removal and installation operations, faults, such as connectors
unplugged, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and
erase the fault memory on all control units. For
this you must proceed as follows:
-
Enter 00 twice for the address word Automatic check sequence and confirm entry
with Q key. The -V.A.G 1552- sends all known
address words in sequence.
Whenever the fault memory is erased, it is necessary to generate a readiness code page
01-26.
-
Connect vehicle system tester -V.A.G 1552and select the engine electronics control unit
(address word 01). The engine must be running in idle.
(Connect vehicle system and select engine
electronics control unit page 01-2).
Edition 01.04
S00.5111.56.20
OCTAVIA
01
Self-Diagnosis
HELP
K Readout in display:
-
X faults recognized
Press the keys 0 and 2 for the function Interrogate fault memory and confirm the entry with the key Q.
HELP
K Readout in display:
Note:
If you have switched off the ignition between
Interrogating fault memory and Erasing fault
memory, the fault memory is not erased.
-
Edition 02.99
S00.5111.53.20
01
Self-Diagnosis
Fault table
Notes:
For vehicles 08.98 , different fault codes
with the same or similar texts are displayed.
The required text is to be selected in the fault
table according to the fault code.
If the display of the vehicle system tester
reads Information in the literature the required text is to be found in the fault table
according to the fault code.
The fault table is ordered according to the
fault code on the left.
Fault number
00513
new
16705
Engine speed
sender -G28
Implausible signal
No signal
00519
16706
17563
Line interruption/short-circuit
to earth
Supply voltage
17564
17565
17566
Possible effects
Poor starting
Irregular engine running,
misfiring
Increased idling speed
Glow period indicator light
flashes
Reduced performance
No display on rev counter
Engine does not start
Short-circuit to positive
-G71 defective
Poor performance
Intake manifold
sender -G71
Short-circuit to
positive
OCTAVIA
Rectifying fault
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-Diagnosis
old
Rectifying fault
new
00522
Possible effects
17663
Coolant temperature
sender -G62
-G62 faulty
Cable has short circuit to
earth
Short circuit to
earth
Open/short
circuit to positive
00527
17664
-G62 faulty
Open circuit in wiring or
cable has short circuit to
positive
17568
-G72 faulty
Cable has short circuit to
earth
17569
-G72 faulty
Open circuit in wiring or
short circuit to positive
18008
Supply voltage
Control unit was connected when ignition on
as appropriate
Edition 02.99
S00.5111.53.20
------------
Implausible signal
------------
01
OCTAVIA
Self-Diagnosis
old
Rectifying fault
new
00539
Possible effects
17570
Fuel temperature
sender -G81
-G81 faulty
Cable has short circuit to
earth
-G80 faulty
Open circuit in wiring or
short circuit
Engine stops
Misfiring
Misfiring at exactly
3000 rpm
-G80 faulty
00542
17571
Open/short
circuit to positive
Reduced output
Short circuit to
earth
-G80 faulty
Sporadic open circuit in
wiring (cable break)
-G81 faulty
Open circuit in wiring or
short circuit to positive
17653
Implausible signal
Open/short
circuit to positive
17654
17655
Edition 02.99
S00.5111.53.20
OCTAVIA
01
Self-Diagnosis
Possible effects
Rectifying fault
new
-
Poor performance at
higher revs
Engine difficult to start
00550
Hard gearshifts
Poor performance at
higher revs
17656
Commencement of
injection control
Control difference
- Test commencement of
injection valve
page 23-29
- Test fuse
- Replace commencement
of injection valve
1)
Edition 02.99
S00.5111.53.20
01
OCTAVIA
Self-Diagnosis
old
Rectifying fault
new
00553
Possible effects
16485
Battery weak
Poor performance
Air mass constantly indicated in measured value
block
- Test battery
Misfiring, jerking
Fault 00542 Needle lift
sender implausible signal
possible or open/short circuit to positive
Reduced output
Black exhaust possible
when accelerating from
low revs
Open/short
circuit to earth
17552
-G70 faulty
Open circuit in wiring or
short circuit to earth
17553
-G70 faulty
Open circuit in wiring or
short circuit to positive
Supply voltage
17554
00575
17958
------------
------------
Edition 02.99
S00.5111.53.20
Self-Diagnosis
00625
new
Possible effects
Short-circuit to positive
Fault number
16885
Speed signal
Implausible signal
If necessary
Vehicle speed signal
Implausible signal
Vehicle speed signal
Signal too great
00626
17948
18024
Line interruption/short-circuit
to earth
00668
18025
Line interruption
Bulb defective
E45 defective
Line interruption or shortcircuit
Cruise control
system switch
-E45
Edition 09.03
S00.5111.55.20
Rectifying fault
18009
Implausible signal
Undefined
switch status
01
Short-circuit to earth
Onboard voltage,
terminal 30
00671
OCTAVIA
01
OCTAVIA
Self-Diagnosis
Possible effects
Rectifying fault
new
-
00765
Implausible signal
17762
Modulating piston
movement sender
-G149
00777
18039
Voltage supply
18040
Implausible signal
as appropriate
18047
18020
1)
Edition 02.99
S00.5111.53.20
Self-Diagnosis
OCTAVIA
01
01117
Possible effects
- Check wiring
Binder:
Current Flow Diagrams,
Electrical Fault Finding
and Fitting locations
- Check AC generator Repair Group 27; AC generator
- Reading measured value
block, display group 016
page 01-37
Line interruption
new
old
Fault number
Engine preheating is on
- Check wiring
Binder: Current Flow Diagrams, Electrical Fault
Finding and Fitting locations
- Check low heat output repage 01-18, Actualay
tor diagnosis
17911
01180
01193
19460
Short-circuit to
positive
Edition 09.03
S00.5111.55.20
19459
Short-circuit to earth
Short-circuit to positive
Rectifying fault
01
Self-Diagnosis
Readout on V.A.G 1552
OCTAV1A
01194
Rectifying fault
Line interruption
new
Possible effects
old
Fault number
Engine preheating is on
- Check wiring
Binder: Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
- Check high heat output relay page 01-18, Actuator diagnosis
19462
Short-circuit to earth
Short-circuit to
positive
01237
19461
Short-circuit to positive
Reduced performance
Engine stoppage
-N109 defective
Line interruption or shortcircuit to earth
Engine stoppage
Short-circuit to positive
Reduced performance
Charge pressure too low
Short-circuit to earth
Reduced performance
Charge pressure too high
17945
Fuel shut-off
valve -N109
Mechanical fault
or
Malfunction
Line interruption/short-circuit
to earth
01262
17946
17954
Charge pressure
solenoid valve
-N75
Short-circuit to
positive
Short-circuit to
earth
Line interruption/short-circuit
to earth
17955
17957
Line interruption
Solenoid valve defective
Reduced performance
Charge pressure too low
Edition 01.04
S00.5111.56.20
Fault number
01265
01
Self-Diagnosis
OCTAV1A
new
Possible effects
Rectifying fault
17810
Exhaust gas
recirculation valve
-N18
Short-circuit to
positive
Line interruption/short-circuit
to earth
01266
Short-circuit to positive
17849
Line interruption
Solenoid valve defective
No exhaust gas
recirculation
No exhaust gas
recirculation
Short-circuit to earth
Short-circuit to positive
18026
Line interruption/short-circuit
to earth
18027
Line interruption
Relay defective
Short-circuit to earth
01268
17969
Metering adjuster
-N146
Control difference (deviation)
upper limit value
17970
17971
Edition 01.04
S00.5111.56.20
Black smoke
Irregular engine running
01
Self-Diagnosis
Readout on V.A.G 1552
old
Fault number
01269
new
Possible effects
OCTAV1A
Rectifying fault
17659
Commencement
of injection valve
-N108
Short-circuit to
positive
Line interruption/short-circuit
to earth
Short-circuit to positive
17660
Valve defective
For vehicles
08.97
19561
- Check commencement of
injection valve
page 23-29
- Check fuse
- Check commencement of
injection valve
page 23-29
01282
Variable intake
manifold flap
change-over
valve -N239
Line interruption/short-circuit
to earth
Short-circuit to
positive
19560
Line interruption
Variable intake manifold
flap change-over valve
defective
Short-circuit to positive
Edition 01.04
S00.5111.56.20
new
Possible effects
Rectifying fault
Fault number
16500
01
Self-Diagnosis
OCTAV1A
Cold-start difficulties at
very low temperatures
Poor driveability during
warm-up
Increase in fuel consumption
Increased emission levels
16955
17811
Exhaust gas
recirculation system
Control deviation
Edition 01.04
S00.5111.56.20
01
Self-Diagnosis
Readout on V.A.G 1552
old
Fault number
17931
new
Possible effects
OCTAV1A
Rectifying fault
Crash signal of
airbag CU
Implausible signal
17964
Charge pressure
control
Regulating limit
not reached
17965
Charge pressure
control
Regulating limit
exceeded
17977
Cruise control
system switch
(CCS) -E45
Implausible signal
Edition 01.04
S00.5111.56.20
Fault number
17978
01
Self-Diagnosis
OCTAV1A
new
Possible effects
Rectifying fault
Engine control
unit blocked
Manipulation attempt
Start attempt with an
adapted ignition key
Engine control unit not
adapted to immobiliser
control unit
For vehicles
08.97
- Check immobiliser
Binder: Electrical system;
Repair Group 90
18034
18044
Check airbag
Body Work; Repair Group
01
18050
Edition 01.04
S00.5111.56.20
01
Self-Diagnosis
Readout on V.A.G 1552
old
Fault number
18058
new
Possible effects
OCTAV1A
Rectifying fault
18061
Read out fault
memory of ABS
control unit
18062
Reduced performance
18065
Poor driveability
Air conditioning
input/output
Short-circuit to
positive
18090
Edition 01.04
S00.5111.56.20
Fault number
For vehicles
08.97
18259
01
Self-Diagnosis
OCTAV1A
new
Possible effects
Rectifying fault
18057
For vehicles
08.97
18262
18056
Hardware defective
Poor driveability
Engine stoppage
Glow period indicator light
flashes
or
defective
19458
Kick-down switch
F8
Implausible signal
65535
Control unit defective
Edition 01.04
S00.5111.56.20
16989
17795
18048
01
OCTAVIA
Self-Diagnosis
Actuator diagnosis
Performing actuator diagnosis
With the actuator diagnosis the following parts
are activated in the sequence indicated:
1. Commencement of injection valve (N108)
2. Exhaust gas recirculation valve (N18)
3. AC compressor engagement
4. Fuel shut-off valve (N109)
5. Charge pressure control solenoid valve
(N75)
6. Glow plug relay (J52)
7. Glow period warning lamp (K29)
8. Low heat output relay (J359) 1)
9. High heat output relay (J360) 1)
10. Fault lamp 2)
1)
2)
HELP
K Read-out on display:
Edition 09.03
S00.5111.55.20
K Readout in display:
-
01
Self-Diagnosis
OCTAVIA
K Readout in display:
K Readout in display:
Note:
The clicking of the valve cannot be heard because of the engine noise and should therefore
be felt by touching.
If the valve does not click:
Final control diagnosis
AC compressor cut-off
page 23-34.
K Readout in display:
Edition 05.97
S00.5111.51.20
page 23-49.
01
Self-Diagnosis
OCTAVIA
K Readout in display:
The engine should stop.
If the engine does not stop:
-
K Readout in display:
Note:
K Readout in display:
K Readout in display:
------------
------------
Edition 05.97
S00.5111.51.20
OCTAVIA
01
Self-Diagnosis
If the warning lamp does not flash:
-
Actuator diagnosis
Low heat output relay -J359
K Read-out on display:
The relay valve must click.
If the relay does not click:
- Check low heat output relay:
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations.
-
Actuator diagnosis
High heat output relay -J360
Press key.
K Read-out on display:
The relay valve must click.
If the relay does not click:
- Check low high heat output relay:
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations.
-
Actuator diagnosis
Fault lamp
Press key.
K Read-out on display:
The fault lamp must flash.
If the fault lamp does not flash:
- Check fault lamp
Binder: Current Flow Diagrams, Electrical
Fault Finding and Fitting locations
-
HELP
Press key.
K Read-out on display:
-
Basic setting
Test conditions
l Coolant temperature at least 80 C
l Electrical consumers must be disconnected
(the radiator cooling fan must be off during
this test)
l Air conditioning switched off
Edition 09.03
S00.5111.55.20
01
OCTAVIA
Self-Diagnosis
HELP
Basic setting
Enter display group number XXX
HELP
K Read-out on display:
-
10
K Read-out on display:
-
K Read-out on display:
(1... 10 = Display fields)
Display group 000 in idle (warm engine, coolant temperature not below +85 C)
This display group serves as a dynamic test of the commencement of injection. The commencement of injection valve
(N108) is constantly actuated, so that the injection timing device is retarded.
System in Basic setting
42
46
20
0
90
201
64
153 127
K Read-out on display:
83
Ignore
Ignore
Ignore
Ignore
Ignore
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-diagnosis
HELP
K Readout in display:
-
Q
(0-32000)
K Readout in display:
-
Enter the relevant code number for this vehicle and confirm the entry with the key Q.
Code
number
00001
00002
Models 07.97
Code
number
Automatic gearbox
00001
Models 08.97
Manual gearbox
00002
00003
00005
Coding 00002
WSC 01234
Notes:
The code entered is activated when the ignition is switched on again
Edition 12.00
S00.5111.54.20
Press key.
01
Self-Diagnosis
HELP
OCTAV1A
K Read-out on display
-
Readiness code
Valid for vehicles 08.03
Connect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-24.
Edition 01.04
S00.5111.56.20
01
Self-Diagnosis
OCTAV1A
17
00000000
K Read-out on display
7
1
Ignore
Meaning
Ignore
Ignore
Ignore
Ignore
Edition 01.04
S00.5111.56.20
7
0
Ignore
Meaning
Ignore
Ignore
Ignore
Ignore
Ignore
Ignore
01
Self-Diagnosis
OCTAV1A
If the specified values are not reached, generate readiness code page 01-26.
Press key.
Connect vehicle system tester -V.A.G 1552and enter address word 01 Engine electronics, ignition switched on page 01-2.
Note:
Certain steps must be carried out twice, in order to achieve the readiness code.
Work step 1:
X fault detected
Enter function 02 Interrogating fault memory and confirm entry with key Q.
If no fault is stored:
-
Press.
Edition 01.04
S00.5111.56.20
OCTAV1A
Work step 2:
Vehicle system test
Fault memory is erased
01
Self-Diagnosis
K-
Note:
Press.
Work step 3:
-
Note:
This point is important, because with certain diagnoses the slowing down of the control unit
must be ended. Otherwise readiness code cannot be generated.
Work step 4:
-
Switching on ignition
94.2 C
Start engine.
Select function Reading measured value
block and display group 001.
K-
Work step 6:
culation
Reading measured value block
1
1650/rpm
4.1 mg/h
4.0 CA
93.2 C
K-
In this speed range, the exhaust gas recirculation is active and the control difference is
checked. (Condition for readiness code to generate exhaust gas recirculation).
Edition 01.04
S00.5111.56.20
01
Self-Diagnosis
Work step 7:
-
Work step 8:
-
OCTAV1A
Switching on ignition
94.2 C
Start engine.
Select function Reading measured value
block and display group 001.
K-
93.2 C
K-
00000000
Press C.
Enter 017 for display group 017 and read
readiness code.
Press.
If the specified values are not reached, repeat procedure for generating readiness
code page 01-26.
Edition 01.04
S00.5111.56.20
OCTAV1A
01
Self-Diagnosis
Enter function 02 Interrogating fault memory and confirm entry with key Q.
If no fault is stored:
Reading measured value block
17
00000000
00000110
10000000
Edition 01.04
S00.5111.56.20
00000000
Press.
01
Self-Diagnosis
OCTAVIA
HELP
HELP
K Read-out on display:
-
K Read-out on display:
-
Note:
Display group number 000 is an example to represent the sequence.
Reading measured value block
1
2
3
4
5
6
Vehicle system test
Select function XX
10
HELP
Press key.
K Read-out on display:
-
Edition 09.03
S00.5111.55.20
OCTAVIA
01
Self-diagnosis
Display group 000, engine idling (engine warm, coolant temperature not less than +85 C)
for models 07.97
Read measured value block
42
50
20
90
201
64
153
127
83
K Readout in display
Edition 12.00
S00.5111.54.20
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Self-diagnosis
Display group 000, engine idling (engine warm, coolant temperature not less than +80 C)
for models 08.97 04.99
Read measured value block
42
50
20
90
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153
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127
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tolerance
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tolerance
display
display
display
001
004
002
recirculation system is
about 2 minutes; necessary
blip
or
recirculation
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis
Display group 000, engine idling (engine warm, coolant temperature not less than +80 C)
for models 05.99
Read measured value block
43
50
20
90
201
64
153
127
83
K Readout in display
The measured values apply when the exhaust gas recirculation system is switched on. The exhaust gas recirculation
is switched off in the idling speed range after about 2 minutes; if necessary briefly blip throttle or re-start engine.
Edition 12.00
S00.5111.54.20
01
OCTAVIA
Self-diagnosis
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 C)
for models 07.97
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block 0
186
225
255
186
186
201
64
138
175
233
K Readout in display
Engine speed: 160...190 (do not exceed 4000 rpm, engine speed is governed)
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis
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Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block 0
205
255
201
175
255
K Readout in display
255
temperature:
display
010
Coolant temperature:
up
air pressure:
pressure:
if not
tolerance
Injected quantity:
125:
Commencement of injection:
if not
tolerance
speed:
Edition 12.00
S00.5111.54.20
display
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011
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Self-diagnosis
Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80
engine
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block
205
255
201
175
255
K Readout in display
255
temperature:
display
010
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up
air pressure:
pressure:
if not
tolerance
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125:
Commencement of injection:
if not
tolerance
speed:
------------
------------
display
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011
fault memory
speed)
Edition 12.00
S00.5111.54.20
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S00.5111.54.20
------------
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pedal depressed
pedal depressed
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Self-diagnosis
OCTAVIA
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OCTAVIA
state
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Edition 12.00
S00.5111.54.20
01
Self-diagnosis
OCTAVIA
10000001
00
16
13.8 V
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1
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Ignore
Ignore
If the intake air temperature at engine start is 5 C, the auxiliary heater is then switched off once the coolant
temperature reaches 70 C. If the air temperature is -10 C, however, the auxiliary heater is not switched off until the
coolant temperature is 80 C.
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Edition 12.00
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Edition 12.00
S00.5111.54.20
o.k.
cold
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cold
o.k.
o.k.
Display group 001, engine idling (engine warm, coolant temperature not less than +85 C)
for models 07.97
Self-diagnosis
OCTAVIA
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load
------------
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Self-diagnosis
OCTAVIA
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valve
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Self-diagnosis
OCTAVIA
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------------
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S00.5111.54.20
cold
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blocked
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engine idling
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Self-diagnosis
OCTAVIA
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S00.5111.54.20
------------
------------
o.k.
o.k.
valve
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block
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for
01
Self-diagnosis
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Edition 12.00
S00.5111.54.20
leaks
valve
blocked
block
valve
valve
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Accelerate the vehicle at full throttle for the test.
Notes:
test in
at
01
not less
Self-diagnosis
+80
engine
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Edition 12.00
S00.5111.54.20
------------
------------
leaks
valve
blocked
block
valve
valve
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Accelerate the vehicle at full throttle for the test.
Notes:
Display group
test in
at full
or
gear
not less
engine
01
Self-diagnosis
OCTAVIA
01
OCTAVIA
Self-diagnosis
Display group 002, engine idling (engine warm, coolant temperature not less than +85 C)
Read measured value block
900 rpm
0.0 %
010
88.4 C
K Readout in display
Coolant temperature
85...100 C o.k.
< 85 C:
warm up engine
Engine speed
page 23-47
x
1
x
1
AC signal
Edition 12.00
S00.5111.54.20
OCTAVIA
01
Self-diagnosis
Display group 013, engine idling (engine warm, coolant temperature not less than +85 C)
for models 07.97
The fuel injection system features a smooth idling control. It is able to detect differences in performance between the
individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective
metering of the quantity of fuel injected in the idling speed range.
Such differences are detected in the idling speed range on the basis of the signal supplied by the engine speed
sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the
same rhythm, all the cylinders are performing the same work. If one cylinder has a weaker performance, the crankshaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger performance accelerates the crankshaft to such an extent that it requires a shorter time.
If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser
injected quantity until the engine is again running smoothly.
What is shown in the measured value block is the variation of the injected quantity of the individual cylinders in
comparison to cylinder 3, which is necessary to achieve smooth engine idling.
+... mg/H: The relevant cylinder has a weaker performance than cylinder 3 and is therefore supplied with more fuel.
- ... mg/H: The relevant cylinder is stronger in performance than cylinder 3 and is therefore supplied with less fuel.
-0.12 mg/H
0.49 mg/H
13
K Readout in display
No readout
------------
Edition 12.00
S00.5111.54.20
------------
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OCTAVIA
Self-diagnosis
models
not less
C)
The fuel injection system features a smooth idling control. It is able to detect differences in performance between the
individual cylinders (parts tolerances, injector flow, compression, etc.) and to compensate for these by selective
metering of the quantity of fuel injected in the idling speed range.
Such differences are detected in the idling speed range on the basis of the signal supplied by the engine speed
sender, which supplies four signals for each crankshaft revolution to the control unit. If the signals are received in the
same rhythm, all the cylinders are performing the same work. If one cylinder has a weaker performance, the crankshaft requires a longer time for the next half crankshaft revolution. In contrast, a cylinder with a stronger performance accelerates the crankshaft to such an extent that it requires a shorter time.
If the control unit has detected a variation, the cylinder in question is immediately supplied with a greater or lesser
injected quantity until the engine is again running smoothly.
- ...
measured value
in display
o.k.
cylinder weak
cylinder strong
o.k.
cylinder weak
cylinder strong
o.k.
cylinder weak
cylinder strong
o.k.
cylinder weak
cylinder strong
------------
------------
Edition 12.00
S00.5111.54.20
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Edition 12.00
S00.5111.54.20
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mass
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Edition 12.00
S00.5111.54.20
value
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Edition 12.00
S00.5111.54.20
mass
------------
------------
value
mass
or
block
mbar
or
mbar
mbar
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Accelerate the vehicle at full throttle for the test.
Notes:
test in
or
gear coolant t
not less
+80
engine
01
Self-diagnosis
OCTAVIA
01
Self-diagnosis
OCTAVIA
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +85 C)
for models 07.97
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block
3340 rpm
1830 mbar
1850 mbar
11
68 %
K Readout in display
Edition 12.00
S00.5111.54.20
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OCTAVIA
01
Self-diagnosis
Display group 011 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80 C, engine
speed 2900...3100 rpm) for models 08.97 04.99
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block
rpm
mbar
11
mbar
K Readout in display
ratio
pressure
mbar
must
mbar
icient
pressure control
solenoid valve
at
speed
Edition 12.00
S00.5111.54.20
display block
tol erance
or
test
pressure
by control unit
mbar
mbar
pressure increased by
rpm
------------
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OCTAVIA
Self-diagnosis
011 at
test in
not less
+80
engine
Notes:
Read off or print out the measured values once an engine speed of 3000 rpm has been reached (second person
required).
Read measured value block
rpm
mbar
11
mbar
K Readout in display
ratio
speed
------------
------------
pressure
mbar
must
mbar
icient
pressure control
ressure
valve
at
o c
display block
tolerance
solenoid
test
pressure
by control unit
mbar
mbar
pressure increased by
rpm
Edition 12.00
S00.5111.54.20
OCTAVIA
23
Edition 05.97
S00.5111.51.20
23
OCTAVIA
Edition 03.98
S00.5111.52.20
OCTAVIA
23
K Fig. 1
Components in footwell
Edition 03.98
S00.5111.52.20
23
OCTAVIA
Edition 12.00
S00.5111.54.20
OCTAVIA
23
1 - Intake fitting
With mechanical exhaust gas recirculation valve
With intake manifold flap
2 - Intake manifold flap changeover valve
(N239)
3 - Injection nozzle with needle lift sender
(G80)
4 - Diesel direct injection system control
unit (J248)
With altitude sender (F96)
5 - Electromagnetic EGR valve (N18)
6 - Charge pressure control solenoid
valve (N75)
7 - Air mass meter (G70)
8 - High heating capacity relay (J360)
Only for models with optional equipment
9 - Low heating capacity relay (J359)
Only for models with optional equipment
10 - Coolant temperature sender (G62)
K Fig. 2
Components in footwell
Edition 03.98
S00.5111.52.20
23
OCTAVIA
)
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light switch
and brake
switch
combined in a housing
in footwell at brake pedal
page 23-3.2, Fig. 3
direct injection
switch
in footwell at clutch pedal
page 23-3.2, Fig. 3
sender
Edition 12.00
S00.5111.54.20
OCTAVIA
23
14 - Plug connection
2-pin
for needle lift sender (G80)
15 - Plug connection
3-pin
for engine speed sender (G28)
16 - Plug connection
10-pin
for fuel temperature sender (G81)
for quantity adjuster (N146)
for modulating piston movement sender (G149)
for commencement of injection valve
(N108)
for fuel shut-off valve (N109)
17 - Commencement of injection valve
(N108)
18 - Fuel shut-off valve (N109)
19 - Fuel metering control of injection pump
with fuel temperature sender (G81)
with quantity adjuster (N146)
with modulating piston movement
sender (G149)
20 - Intake manifold pressure sender (G71)
and intake manifold temperature sender (G72)
12 - Vacuum unit
13 - Engine speed sender (G28)
K Fig. 3
Components in footwell
Edition 12.00
S00.5111.54.20
23
OCTAVIA
Note:
1 - Stretch bolt
Always replace
20 Nm + 1/4 turn (90)
------------
------------
Edition 05.97
S00.5111.51.20
W
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OCTAVIA
23
13
replace
Fuel
20 Nm
10 Injection
tighten to 25 Nm
use ring wrench, e.g. 3035, for removing injection lines
always remove complete set of lines
11
45 Nm
12
20
21
22
23
2
2
Note:
to fuel tank
2 Feed line
from fuel tank
Edition 12.00
S00.5111.54.20
------------
------------
23
OCTAVIA
Fuel Formation/Injection
1 - Retaining clip
2 - Return line
from injection pump
3 - Feed line
to injection pump
4 - Fuel filter
the direction of flow is marked by arrows
for removing loosen clamping screw
at bracket
do not mix up connections
replace if damaged
fill up with diesel fuel before installing
5 - Gasket
replace if damaged
6 - Drain plug
to ventilate remove the retaining clip
of the preheating valve and remove
preheating valve with the fuel lines
connected, loosen clamping screw
and pull the filter upwards
release and drain approx. 0.1 litre fluid
4 - Spring washer
5 - 10 Nm
6 - Thread cage
7 - Pedal bracket
Edition 09.03
S00.5111.55.20
E
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OCTAVIA
23
racket
pedal
accelerator pedal
and
K-
Edition 12.00
S00.5111.54.20
------------
------------
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Edition 12.00
S00.5111.54.20
(G79)
00
100.0
000
2
C
010
010
2
C
23
OCTAVIA
OCTAV1A
Fuel Formation/Injection
23
Edition 01.04
S00.5111.56.20
6 - Filter element
7 - 10 Nm
8 - Air filter bottom part
9 - Air guide
10 - 6 Nm
23
OCTAV1A
Fuel Formation/Injection
Note:
Use the open ring spanner e.g. 3035 for removing high pressure lines.
-
Remove plug from the intake manifold pressure sender and the intake temperature
sender.
Edition 01.04
S00.5111.56.20
OCTAVIA
23
Engine installed
K-
Edition 03.98
S00.5111.52.20
------------
K-
------------
23
OCTAVIA
K-
Set adjusting device to 91.4 mm (the lefthand notch of the vernier -arrow A- is the
reference point).
The adjusting straightedge should be centred as follows: Rotate the locked camshaft
until one end of the adjusting straightedge
makes contact with the cylinder head. Use a
feeler gauge to measure the clearance produced at the other end of the adjusting
straightedge. Insert a feeler gauge equal to
half the clearance measured, between adjusting straightedge and cylinder head. Now,
rotate the camshaft until the adjusting
straightedge touches the feeler gauge. Insert a second feeler gauge with the same
thickness at the other end between adjusting straightedge and cylinder head.
K-
Notes:
Use the locking pin 3359 for counterholding
the injection pump sprocket page 23-12,
Fig. A13-0052.
Always moisten the locking pin with oil. Use
a mirror to make it easier to insert the pin.
------------
------------
Edition 03.98
S00.5111.52.20
OCTAVIA
23
Unplug the connector for the electrical connections of the injection pump.
K-
Note:
On no account, slacken the central nut -2- of
the injection pump sprocket otherwise the basic setting of the injection pump will be altered
and can no longer be set with workshop tools.
K-
Installing
-
------------
Edition 03.98
S00.5111.52.20
------------
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------------
------------
Edition 12.00
S00.5111.54.20
23
OCTAVIA
OCTAVIA
23
Note:
K Ensure the retaining claw is correctly positioned.
-
Tighten the new bolts for attaching the injection pump sprocket to 20 Nm.
Note:
The bolts for attaching the sprocket must only
be used once as these are stretch bolts.
-
Rotate the crankshaft two revolutions in direction of rotation of engine until the crankshaft is again positioned at TDC of cylinder
1.
Edition 03.98
S00.5111.52.20
------------
------------
23
OCTAVIA
K-
Install connectors at intake manifold pressure sender and intake manifold temperature sender.
------------
------------
Edition 03.98
S00.5111.52.20
6
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OCTAVIA
23
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Notes:
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Edition 12.00
S00.5111.54.20
------------
------------
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------------
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Edition 12.00
S00.5111.54.20
13
Provided the check reveals that the commencement of injection is within the specified range
-C-, it is not necessary to carry out any new setting. After replacing the injection pump and the
engine control unit, the commencement of injection should be set to the mean value.
Note:
23
OCTAVIA
OCTAVIA
23
Note:
On no account should you slacken the nuts -2for the hub otherwise the basic setting of the
injection pump will be altered and cannot be set
with workshop tools.
-
Tighten the new bolts for attaching the injection pump sprocket to 20 Nm + 1/4 turn (90)
(counterhold with locking pin 3359).
Note:
The bolts for attaching the sprocket must only
be used once as these are stretch bolts.
-
Plug in connectors at intake manifold pressure sender and intake manifold temperature sender.
Edition 03.98
S00.5111.52.20
------------
------------
23
OCTAVIA
If necessary, unscrew banjo bolt for returnflow pipe (injector of cyl. 3).
Note:
Always remove all of the injection pipes. Do not
alter the shape.
-
------------
------------
Edition 05.97
S00.5111.51.20
OCTAVIA
23
Fuel Formation/Injection
Preparing an auxiliary tool
-
Thoroughly clean the auxiliary tool, the injection nozzle cannot be used if dirty!
K-
Note:
Store the auxiliary tool with dust protection for
future use.
Installing
Note:
Always replace the copper seal and O-ring between the cylinder head and injection nozzles.
-
Tightening torques:
Injection lines: 25 Nm
Banjo bolt for return line (cyl. 3): 10 Nm
Screw for clamp: 20 Nm
Testing
-
K-
Edition 09.03
S00.5111.55.20
If one or several specified values are outside the tolerance, interchange the injection
nozzles (except for the nozzle of cylinder 3).
23
OCTAVIA
If the compression is o.k., replace the relevant delivery valve together with seal
page 23-4, Servicing injection pump.
Notes:
Always use a soft object (plastic, wood) to
remove the seal from the pump otherwise
the sealing surface may be scratched.
If the car has covered more than 15000 km,
always replace the set of delivery valves.
This engine is equipped with 2-spring injectors.
The quantity of fuel is injected in this case in 2
stages.
If there is any problem with these injectors, it is
only possible to replace them as it is neither
possible to set the pressure nor to repair the
injector.
Important!
When testing injectors, ensure that the fuel spray
does not strike your hands otherwise the fuel will
penetrate into the skin as a result of the high pressure and may cause severe injuries.
l Pressure gauge switched on
-
19...20 MPa
17 MPa
------------
------------
Slowly press the pump lever down and maintain the pressure at about 15 MPa for 10
seconds. During this time, no fuel should drip
out of the injector opening.
If a leak exists, replace injector.
Edition 05.97
S00.5111.51.20
OCTAV1A
23
Fuel Formation/Injection
Edition 01.04
S00.5111.56.20
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S00.5111.54.20
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23
OCTAVIA
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
------------
23
OCTAV1A
Fuel Formation/Injection
Coding 00002
WSC 01234
Connect vehicle system tester -V.A.G 1552and select engine electronics control unit
page 01-2.
Removing
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Release the plug locks and remove the control unit plugs.
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Installing
The installation occurs in reverse order.
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Edition 01.04
S00.5111.56.20
Edition 12.00
S00.5111.54.20
23
------------
OCTAVIA
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S00.5111.54.20
11
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23
OCTAVIA
OCTAVIA
23
Models 07.97
Read measured value block
3090 rpm
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------------
------------
23
OCTAVIA
Models 07.00
Specification: 25...45
Models 08.00
Specification: 14...20
------------
------------
Edition 12.00
S00.5111.54.20
OCTAVIA
23
!
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Edition 12.00
S00.5111.54.20
------------
------------
23
------------
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OCTAVIA
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Edition 12.00
S00.5111.54.20
Unplug connector -1- from the intake manifold temperature sender -2-.
Connect multimeter for resistance measurement to contacts 1 and 2 of the intake manifold temperature sender -2-.
------------
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S00.5111.54.20
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S00.5111.54.20
1013
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part of turbocharger, cannot be replaced separately
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Edition 12.00
S00.5111.54.20
return valve
------------
------------
23
OCTAVIA
K Readout in display:
Actuation of the valve is indicated by a clearly
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------------
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Edition 05.97
S00.5111.51.20
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S00.5111.54.20
Specification
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23
OCTAVIA
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pedal position sender and from the vehicle
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Edition 12.00
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S00.5111.54.20
------------
23
OCTAVIA
1 - Intake manifold
2 - 10 Nm
3 - O-ring
Replace
4 - Intake connection
With exhaust gas recirculation valve
and intake manifold flap
5 - 10 Nm
6 - Gasket
Replace
7 - Connection pipe
To exhaust manifold
8 - 25 Nm
9 - Vacuum positioning element for intake
manifold flap
10 - Intake manifold flap changeover valve
-N239
Testing page 23-57
The intake manifold flap is closed for about 3
seconds when the engine is switched off and
then opens again. This reduces the engine stop
jolt.
11 - Vacuum supply
From vacuum pump
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OCTAVIA
Edition 12.00
S00.5111.54.20
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Edition 12.00
S00.5111.54.20
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13
12
11 Vacuum
10
recirculation
Pressure unit
for charge pressure control valve
part of turbocharger, cannot be replaced separately
control solenoid
o air
Vacuum unit
3
2
1 Vacuum
element
models 08.97
models 08.97
Vacuum
element
Vacuum
o
o air
recirculation
OCTAVIA
23
OCTAVIA
28
Test procedure
K-
Note:
When the connector is unplugged from the
sender, the cold engine state is simulated and
appropriate glow plug heating operation is carried out when the ignition is switched on.
-
Connect the multimeter for voltage measurement to a glow plug connector and to engine
earth.
If no voltage is present:
-
Edition 03.98
S00.5111.52.20
28
OCTAVIA
K-
Edition 12.00
S00.5111.54.20
OCTAVIA
28
K Readout in display:
Edition 12.00
S00.5111.54.20