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Service

Workshop Manual
OCTAVIA
1.9-ltr. / 66 kW (TDI) Engine
Fuel Injection and Glow Plug System

Service Department. Technical Information


S00.5111.50.20

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.

Printed in Czech Republic

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

Basic Edition of Workshop Manual

S00.5111.50.20

Supplement to Basic Edition


Modifications for Vehicles 08.97
Modification of Fault Code
Modifications for Vehicles 08.00
Supplement to Repair Group 01 and 23
Supplement to Repair Group 01 and 23

S00.5111.51.20
S00.5111.52.20
S00.5111.53.20
S00.5111.54.20
S00.5111.55.20
S00.5111.56.20

Contents next page.

The Service Manual is intended only for use within the


koda Organisation; it is not permitted to pass it on to
third persons.
2004 KODA AUTO a. s.

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

Actuator diagnosis ......................................................................................................................


- Performing actuator diagnosis .................................................................................................
- Basic setting .............................................................................................................................
- Coding control unit ...................................................................................................................

01-18
01-18
01-21
01-23

Measured value blocks ...............................................................................................................


- Reading measured value block ................................................................................................
- Display nominal values for general vehicle inspection .............................................................
- Display nominal values for injection pump ...............................................................................
- Display nominal values for engine idling ..................................................................................
- Display nominal values for exhaust gas recirculation ..............................................................
- Display nominal values for temperature sensor .......................................................................
- Display nominal values for automotive power ..........................................................................
- Display nominal values for charge pressure control ................................................................

01-28.2
01-28.2
01-29
01-38
01-46
01-49
01-51
01-52
01-58

Readiness code ...........................................................................................................................


- Reading readiness code ...........................................................................................................
- Generate readiness code .........................................................................................................

23

Fuel Formation/Injection

Servicing a diesel direct fuel injection system .........................................................................


- Safety measures ......................................................................................................................
- Rules for cleanliness ................................................................................................................
- Overview of fitting locations 07.97 .......................................................................................
- Overview of fitting locations 08.97 07.00 .............................................................................
- Overview of fitting locations 08.00 .......................................................................................
- Assembly overview of injection pump ......................................................................................
- Assembly overview of fuel filter ................................................................................................
- Assembly overview of throttle mechanism ...............................................................................
- Adjusting sender for accelerator pedal position .......................................................................
- Disassembling and assembling air filter ...................................................................................
- Removing and installing injection pump ...................................................................................
- Dynamically testing and setting commencement of injection ...................................................
- Removing and installing and testing injection nozzles .............................................................
- Wiring and Component Test with Test Box ..............................................................................
- Replacing engine control unit ...................................................................................................
Inspecting the charge air pressure system ..............................................................................
- Inspecting charge air pressure .................................................................................................
- Inspecting charge pressure control solenoid valve (N75) ........................................................
- Inspecting intake manifold temperature sender (G72) .............................................................
- Inspecting intake manifold pressure sender (G71) and altitude sender ...................................
- Hose layout plan for charge pressure control ...........................................................................

Testing injection control .............................................................................................................


- Testing injection timing device control range ............................................................................
- Testing the commencement of injection valve (N108) .............................................................
- Inspecting fuel temperature sender ..........................................................................................

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

Inspecting exhaust gas recirculation system ...........................................................................


- Inspecting exhaust gas recirculation ........................................................................................
- Inspecting exhaust gas recirculation valve (N18) .....................................................................
- Inspecting air mass meter (G70) ..............................................................................................
- Vacuum plan of hose layout plan for the exhaust gas recirculation system .............................

23-32
23-32
23-34
23-35
23-37

Inspecting control units input quantities ..................................................................................


- Testing voltage supply for diesel direct injection system ..........................................................
- Testing engine speed sender (G28) .........................................................................................
- Testing needle lift sender (G80) ...............................................................................................
- Testing coolant temperature sender (G62) ...............................................................................
- Testing brake light switch and brake pedal switch ...................................................................
- Testing modulating piston movement sender (G149) and metering adjuster (N146) .............
- Testing accelerator pedal position sender (G79) ......................................................................

23-38
23-38
23-41
23-42
23-43
23-44
23-45
23-47

Servicing intake manifold 08.97 ............................................................................................


- Inspecting the change-over of the intake manifold flap ............................................................
- Hose layout plan for intake manifold flap operation .................................................................

23-56
23-57
23-59

Testing auxiliary signals .............................................................................................................


- Testing signals from/to the air conditioning system ..................................................................
- Testing clutch pedal switch (F36) .............................................................................................
- Testing speed signal .................................................................................................................
- Testing engine speed signal .....................................................................................................
- Activating or deactivating cruise control system .......................................................................
- Testing cruise control system ...................................................................................................
- Testing CAN-Bus databus ........................................................................................................

28

Glow plug system

Inspecting glow plug system .....................................................................................................


- Inspecting proper operation ......................................................................................................
- Inspecting glow plugs ...............................................................................................................
- Inspecting glow period warning lamp .......................................................................................

------------ 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.

Technical data of self-diagnosis


Interrogating control unit version
The control unit version is displayed when the
vehicle system tester V.A.G 1552 is connected
and the engine electronics control unit is selected page 01-2.

Edition 12.00
S00.5111.54.20

------------ 01-5 -----------01-1

01

OCTAVIA

Self-diagnosis

Functions available when using vehicle system tester V.A.G 1552


Please refer to the table below for the requirements necessary to enable you to select the
desired functions.
Function

Condition
Engine not
running,
ignition on

Engine
idling

yes

yes

yes1)

yes

01 Interrogate control unit


version

02 Interrogate fault memory


03 Final control diagnosis

yes

yes

05 Erase fault memory

yes

yes

07 Code control unit

yes

no

04 Basic setting
06 End output

08 Read measured value


block
1)

no

yes

yes

yes

yes

yes

Only perform when ignition switched on if


engine does not start (operate starter first
of all for at least 6 seconds).

Connecting vehicle system tester


V.A.G 1552 and selecting engine
electronics control unit
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3, 3A, 3B or 3C
Test conditions
l Battery voltage at least 11.5 V
l Fuse 12 o.k.

l Earth connections at gearbox and on left


below battery o.k.

------------ 01-2 ------------

Edition 12.00
S00.5111.54.20




OCTAVIA

01

Self-diagnosis

K-

Connect vehicle system tester V.A.G 1552


with cable V.A.G 1551/3, 3A, 3B or 3C.

After the vehicle system tester has been connected:


-

Depending on the desired function, switch


the ignition on or start the engine page
01-2, table of Available functions.

If the readouts which appear in the display do


not correspond to the description in the procedure, refer to the following notes:
Notes:

Test of vehicle systems


Control unit does not answer

HELP

Test of vehicle systems


Error in establishing communication

HELP

Test of vehicle systems


K wire not switching to earth

HELP

Test of vehicle systems


K wire not switching to positive

HELP

Test of vehicle systems


Enter address word XX

HELP

Edition 12.00
S00.5111.54.20

If Error in data transmission is displayed


because of an input error, disconnect cable
at vehicle system tester, plug it in again and
repeat the steps.

K If one of the following messages appears in


the display, perform fault finding according
to diagnostic cable fault finding programme:
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder, or
Operating Instructions of vehicle system
tester

Note:

Operate the vehicle system tester on the basis


of the readout in the display.

K Readout in display:
-

Enter address word 01 for Engine electronics and confirm the entry with the key Q.

------------

------------

01

OCTAVIA

Self-Diagnosis

038906018BQ 1.9 l R4 EDC G00SG 2112


Coding 00002
WSC 01234

K The control unit identification appears in the display, e.g.:


038906018BQ Part no. of control unit part1)

1.9 l
R4

EDC

Engine displacement

Engine displacement version (4 cyl. in-line engine)


Injection system (Electronic
Diesel Control)

G or no
display

Vehicle with or without


cruise control system

MG
AG

Manual gearbox
Automatic gearbox

00

2112

Control unit mapping

Data status (software version) of control unit

Coding 00002 Coding variant of control unit


WSC 01234

Workshop code from the


vehicle system tester V.A.G
1552 with which the last
coding was performed

List of all control units


Part no. of CU1)

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

For current control unit version - spare parts


catalogue

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

------------ 01-4 -------------

Edition 09.03
S00.5111.55.20

OCTAVIA

01

Self-diagnosis
Storage of non-existent faults in fault memory
Functions not being performed

Reduction in life of automatic gearbox


If the code does not match the corresponding
version in the vehicle:
Test of vehicle systems
Select function XX

HELP

Check coding of engine control unit page


01-23, Coding engine control unit.
Press key.

K Readout in display:
-

For further procedure Repair descriptions.

Interrogating and erasing fault


memory
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3, 3A, 3B or 3C
Interrogating fault memory
-

Connect vehicle system tester V.A.G 1552


with cable and select engine electronics control unit (address word 01). Engine should
be idling for this step.
(Connecting vehicle system tester and selecting engine electronics control unit page
01-2).

Only if the engine does not start:


Test of vehicle systems
Select function XX

HELP

Switch ignition on.

K Readout in display:
-

Enter 02 for the function Interrogate fault


memory and confirm the entry with the key
Q.

K The number of stored faults or No fault recognized! appears in the 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:
-

Enter 06 for the function End output and


confirm entry with the key Q.

------------ 01-9 -----------01-5

01

Self-Diagnosis

OCTAV1A

If one or several faults are stored:


Fault number: 00542
Needle lift sender -G80
Short-circuit to earth

K Read-out of fault number on display, e.g.:


-

Press key.

Press key.

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


-

Press key.

The stored faults are displayed in sequence.


Vehicle system test
Select function XX

HELP

Press key.

K Read-out on display:
-

Enter 06 for the function end output and


confim entry with key Q.

Rectify fault by referring to the fault table


page 01-8.

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.

Erasing fault memory


Test condition
l Rectifying fault
Note:

After fault elimination the fault memory must


again as described be interrogated and subsequently erased.
For vehicles 08.03

Whenever the fault memory is erased, it is necessary to generate a readiness code page
01-26.
-

------------ 01-6 -------------

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

Test of vehicle systems


Select function XX

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.

K The number of stored faults appears in the display.


If one or several faults are stored:
The stored faults are displayed one after the
other.

Test of vehicle systems


Select function XX

HELP

K After the stored faults have been displayed, the


following readout appears:
-

Test of vehicle systems


Fault memory is erased

Press the keys 0 and 5 for the function Erase


fault memory and confirm the entry with the
key Q.

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.
-

Press the keys 0 and 6 for the function End


output and confirm the entry with the key Q.

Edition 02.99
S00.5111.53.20

Press the key.

Carry out a road test. During the road test,


once again interrogate the fault memory. No
further faults should be displayed.

------------ 01-7 ------------

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.

Explanations concerning the types of faults


(e.g. Interruption or short-circuit to earth):
Readout on V.A.G 1552
old

Fault number

00513

new

Possible cause of fault

16705

Engine speed
sender -G28
Implausible signal

No signal

00519

16706

17563

Line interruption/short-circuit
to earth
Supply voltage

17564
17565
17566

------------ 01-8 -------------

If components are output as faulty:


First check all cables and connectors to these
components as well as the earth connections
according to the Current Flow Diagram. Replace the component only if this test does
not reveal any fault. This applies in particular for faults that are output as sporadically
occurred (SP) faults.

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

Operating instructions for vehicle system


tester

Bent or loose sensor


washer
Distance to speed sender/
sensor rotor too great
Metallic swarf on engine
speed sender -G28
Line interruption of
screening
-G28 defective
-G28 defective
Line interruption or shortcircuit
Line interruption of
screening.

Line interruption or shortcircuit to earth


-G71 defective
Line interruption or shortcircuit

Line interruption or shortcircuit

OCTAVIA

Rectifying fault

- Remove noise insulation


and check sensor washer
- Check engine speed sensor
page 23-41

- Check intake manifold


pressure
page 23-26

- Check sender -G71


- Check intake system for
leaks
page 23-27

Edition 09.03
S00.5111.55.20

OCTAVIA

01

Self-Diagnosis

Readout on V.A.G 1552


Fault number

Possible cause of fault

old

Rectifying fault

Black exhaust when starting


Engine preheater does not
operate
Preglowing always operates for about 20 seconds

- Test coolant temperature


sender page 23-43

Engine preheater does not


operate

- Test intake manifold temperature sender


page 23-25

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

Intake manifold temperature sender -G72


Short circuit to
earth
Open/short
circuit to positive
00532

-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

Open circuit in wiring or


short circuit

Voltage supply tml.


15
Voltage too low

Voltage not present when


ignition on (terminal 15)

Diesel direct injection system control unit -J248


faulty
Voltage supply relay terminal 30 (J322) faulty

Edition 02.99
S00.5111.53.20

- Erase fault memory and


continue checking vehicle
Engine does not start
Engine stops

- Test voltage supply of diesel direct injection system


control unit page 23-38
- Test voltage supply of terminal 15
Current Flow Diagrams,
Electrical Fault Finding
and Fitting Locations
binder
- Replace control unit
page 23-20
- Test voltage supply of diesel direct injection system
control unit page 23-38

------------

Implausible signal

------------

01

OCTAVIA

Self-Diagnosis

Readout on V.A.G 1552


Fault number

Possible cause of fault

old

Rectifying fault

new

00539

Possible effects

17570

Fuel temperature
sender -G81
-G81 faulty
Cable has short circuit to
earth

Several faults stored


Engine stops

- Check plug connection for


injection pump

-G80 faulty
Open circuit in wiring or
short circuit

Glow indicator lamp


flashes
Rough engine running
Reduced output

- Test needle lift sender


page 23-42

Fuel supply (was) interrupted: tank has run


empty, feed line or filter
blocked, system drawing
in air

Fault 00550 Commencement of injection control


possible
Misfiring, jerking

- Check fuel system

Engine stops
Misfiring

- Check cable connection


and plug connection at injection pump

Sender plate of engine


speed sender bent or
loose

Misfiring at exactly
3000 rpm

- Take off oil pan and inspect sender plate

-G80 faulty

Misfiring, jerking (particularly at high revs)

- Replace needle lift sender

Injection pump faulty

00542

17571

- Test fuel temperature


sender page 23-30

(Sporadic) open circuit in


wiring to fuel cut-off valve

Open/short
circuit to positive

Reduced output

Connector for injection


pump separated

Short circuit to
earth

Fault 01268 quantity adjuster control difference


stored
Irregular engine running,
misfiring
No throttle response after
overrun

- Replace injection pump

-G80 faulty
Sporadic open circuit in
wiring (cable break)

Glow indicator lamp


flashes
Misfiring, jerking
Reduced output

- Test needle lift sender


page 23-42

-G81 faulty
Open circuit in wiring or
short circuit to positive

17653

Needle lift sender


-G80
Short circuit to
earth

Implausible signal

Open/short
circuit to positive

------------ 01-10 ------------

17654

17655

Edition 02.99
S00.5111.53.20

OCTAVIA

01

Self-Diagnosis

Readout on V.A.G 1552


Fault number
old
00545

Possible cause of fault

Possible effects

Rectifying fault

new
-

Engine/gearbox electrical connection 1)


Open circuit in wiring or
short circuit

- Test signals from/to automatic gearbox


A - Signal for gearshift

Commencement of delivery not o.k.

Poor performance at
higher revs
Engine difficult to start

- Test and set commencement of injection


page 23-13

Adjustment travel of injection pump blocked (dirt,


swarf)

00550

Hard gearshifts

Poor performance at
higher revs

- Test injection timing control range page 23-28

17656

Commencement of
injection control
Control difference

Engine was stalled (within


the last 50 starts)

- Erase fault memory, continue checking vehicle

Fuel feed (was) interrupted: tank has run


empty, feed line or filter
blocked, system drawing
in air

Fault 00542 Needle lift


sender implausible signal
may be stored

- Check fuel system

Open circuit in wiring to


commencement of injection valve -N108

Engine clatters when idling as commencement of


injection constantly advanced

- Test commencement of
injection valve
page 23-29

Several faults may be


stored

- Test fuse

No constant commencement of injection possible


at Basic setting (display
block 2 varies over more
than 10 readouts)
Irregular engine running,
poor performance

- Replace commencement
of injection valve

Commencement of injection valve -N108 worn

1)

Not available at present.

Edition 02.99
S00.5111.53.20

------------ 01-11 ------------

01

OCTAVIA

Self-Diagnosis

Readout on V.A.G 1552


Fault number

Possible cause of fault

old

Rectifying fault

new

00553

Possible effects

16485

Air mass meter -G70


Implausible signal

Engine was stalled (within


the last 50 starts)

- Erase fault memory, continue checking vehicle

Battery weak

Poor performance
Air mass constantly indicated in measured value
block

- Test battery

Sporadic open circuit in


wiring (cable break) to
needle lift sender -G80

Misfiring, jerking
Fault 00542 Needle lift
sender implausible signal
possible or open/short circuit to positive

- Test needle lift sender


page 23-42

Air filter blocked


Vacuum hoses of exhaust
gas recirculation incorrectly connected or mechanical EGR valve constantly open

Irregular idling, poor performance

- Inspect intake system


- Inspect vacuum hoses
page 23-37

Air mass meter faulty

Poor performance, jerking

- Test air mass meter


page 23-35

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

Short circuit to positive

17553

-G70 faulty
Open circuit in wiring or
short circuit to positive

Supply voltage

17554

Open circuit in wiring or


short circuit

00575

17958

Intake manifold pressure


Control difference
if appropriate
Charge pressure
Control difference

Sudden drop in power


Reduced output

------------

Hoses wrongly connected,


not fitted on, blocked,
leaking
Turbocharger vacuum unit
faulty
Charge pressure control
solenoid valve -N75 faulty

------------

- Test charge pressure


page 23-22
- Inspect charge pressure
hoses page 23-27

Edition 02.99
S00.5111.53.20

Self-Diagnosis

Readout on V.A.G 1552


old

00625

new

Possible cause of fault

Possible effects

Line interruption between


speedometer sender -G22
and dash panel insert
-G22 defective
Speedometer -G21 defective
Line interruption between
dash panel insert and engine control unit

CCS not operational


Air conditioning not operational
Possible load alteration
shock

Short-circuit to positive

Fault number

Glow period warning lamp


not operational

16885

Speed signal
Implausible signal
If necessary
Vehicle speed signal
Implausible signal
Vehicle speed signal
Signal too great

00626

17948
18024

Glow period warning lamp -K29


Short-circuit to
positive

Line interruption/short-circuit
to earth

00668

18025

Line interruption
Bulb defective

Glow period warning lamp


not operational

- Check speed signal


page 23-52
- Check speedometer
sender
Electrical System; Repair
Group 90

- Check glow period warning lamp


page 28-2

Diesel direct injection system relay -J322 jams

Engine does not start


(safety deactivation)

- Test voltage supply for diesel direct injection system


page 23-38

E45 defective
Line interruption or shortcircuit

Cruise control system not


operational

- Check cruise control system


page 23-55
- Reading measured value
block 6
page 01-35

Cruise control
system switch
-E45

Edition 09.03
S00.5111.55.20

Rectifying fault

Glow period warning lamp


lights up constantly

18009

Implausible signal

Undefined
switch status

01

Short-circuit to earth

Onboard voltage,
terminal 30

00671

OCTAVIA

------------ 01-13 -------------

01

OCTAVIA

Self-Diagnosis

Readout on V.A.G 1552


Fault number
old
00741

Possible cause of fault

Possible effects

Rectifying fault

new
-

Brake pedal monitoring


Switch incorrectly set
Open circuit in wiring
-F or -F47 faulty
Fuse faulty
Both brake lights faulty

00765

Preglow indicator lamp


flashes

- Test -F and -F47 and set


page 23-44

Fuse or brake light faulty

- Test fuse and brake light

10-pin connector for injection pump separated


Injection pump faulty
Open circuit in wiring or
short circuit

Several faults stored


Engine stops
Drivability problems
Engine stops

- Inspect plug connection


of injection pump
- Test modulating piston
movement sender
page 23-45

Open circuit in wiring


-G79 faulty (idling switch)

Implausible signal

Speed governed to approx.


1100 rpm as safety measure
No throttle response
Preglow indicator light
flashes
Fast idling speed

- Test accelerator pedal position sender


page 23-47

Preglow indicator light


flashes

- Code control unit


page 01-23

17762

Modulating piston
movement sender
-G149

00777

18039

Accelerator pedal position sender -G79


Signal too large

Voltage supply

18040

Open circuit in wiring or


short circuit

Implausible signal
as appropriate

18047

Open circuit in wiring


-G79 faulty (idling switch)

Accelerator pedal position sender 1/2


-G79+-G185 1)
Implausible signal
Short circuit to positive
01044

Short circuit to positive


-G79 faulty

18020

Engine control unit


incorrectly coded
Invalid control unit coding

1)

Incorrect fault text readout. The correct readout is:


Accelerator pedal position sender -G79

------------ 01-14 ------------

Edition 02.99
S00.5111.53.20

Self-Diagnosis

Readout on V.A.G 1552

OCTAVIA

01

01117

Possible effects

Line interruption between


AC generator and diesel
direct injection system
control unit -J248 AC generator defective
Voltage regulator on AC
generator defective

Auxiliary heater not operational

- 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

Short-circuit in the wiring

Reduced vehicle acceleration, when the air conditioning system is switched on

- Testing signals from/to the


air conditioning system
page 23-49.

Line interruption

new

Possible cause of fault

Engine preheating not operational

Low heat output relay


-J359 defective

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

Load signal for


generator tml. DF
Implausible signal

01180

Engine/air conditioning compressor electrical connection


Short-circuit to
positive

01193

19460

Low heat output


relay -J359
Line interruption
or short-circuit
to earth

Short-circuit to
positive

Edition 09.03
S00.5111.55.20

19459

Short-circuit to earth

Short-circuit to positive

Engine preheating not operational

Rectifying fault

------------ 01-15 -------------

01

Self-Diagnosis
Readout on V.A.G 1552

OCTAV1A

01194

Rectifying fault

Line interruption

new

Possible effects

Engine preheating not operational

High heat output relay


-J360 defective

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

Possible cause of fault

19462

High heat output


relay -J360
Line interruption
or short-circuit
to earth

Short-circuit to earth
Short-circuit to
positive

01237

19461

Short-circuit to positive

Engine preheating not operational

-N109 defective, leaking


or jammed

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

- Check -N109 page


01-18, Actuator diagnosis
- Check wiring
Binder: Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations

Charge pressure
solenoid valve
-N75
Short-circuit to
positive
Short-circuit to
earth

Line interruption/short-circuit
to earth

------------ 01-16 -------------

17955
17957

Line interruption
Solenoid valve defective

- Check charge pressure


solenoid valve page
23-24

Reduced performance
Charge pressure too low

Edition 01.04
S00.5111.56.20

Readout on V.A.G 1552


old

Fault number

01265

01

Self-Diagnosis

OCTAV1A

new

Possible cause of fault

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

Too much exhaust gas


recirculation
Reduced performance,
black smoke

Short-circuit to positive

Glow plug system not operational

18026

- Check exhaust gas recirculation valve -N18


page 23-24

Glow plug relay


-J52
Short-circuit to
positive

Line interruption/short-circuit
to earth

18027

Line interruption
Relay defective

Glow plug system not operational

Short-circuit to earth

01268

Glow plug system not operational

Injection pump defective,


leaking
Line interruption or shortcircuit

Incorrect driving behaviour


Engine stoppage

17969

- Check glow plug relay


-J52

Binder: Current Flow Diagrams, Electrical Fault


Finding and Fitting Locations

Metering adjuster
-N146
Control difference (deviation)
upper limit value

17970

lower limit value

17971

Edition 01.04
S00.5111.56.20

Metering mechanism adjusted


Metering mechanism adjusted

Jerking, poor performance

- Check metering adjuster


-N146 page 23-45
- Replace injection pump
page 23-8

Black smoke
Irregular engine running

------------ 01-17 -------------

01

Self-Diagnosis
Readout on V.A.G 1552

old

Fault number

01269

new

Possible cause of fault

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

Line interruption (fuse)


Short-circuit to earth

For vehicles
08.97

19561

Engine jerks when idling


because commencement
of injection is constantly
adjusted to advance.

Engine jerks when idling


because commencement
of injection is constantly
adjusted to advance.

- Check commencement of
injection valve
page 23-29

Possible that several faults


are stored

- Check fuse

Poor performance because commencement of


injection is constantly adjusted to late

- Check commencement of
injection valve
page 23-29

Hard engine knock

- Check Variable intake manifold flap change-over


valve -N239 page 23-57

01282

Variable intake
manifold flap
change-over
valve -N239
Line interruption/short-circuit
to earth
Short-circuit to
positive

------------ 01-17.1 -------------

19560

Line interruption
Variable intake manifold
flap change-over valve
defective
Short-circuit to positive

Edition 01.04
S00.5111.56.20

Readout on V.A.G 1552


old

new

Possible cause of fault

Possible effects

Rectifying fault

Sender for coolant temperature -G62 supplies


implausible signal caused
by loose contact or corrosion due to humidity in the
connector

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

- Reading measured value


block, display group 007
page 01-51
- Check -G62 page 23-43

Coolant temperature sender -G62


Implausible signal

Signal input in engine


control unit defective
(control unit defective
Coolant regulator defective (thermostat)

16955

- Replacing engine control


unit page 23-20
- Check coolant regulator
1.9 l/66 kW (TDI) Engine,
Mechanical Components;
Repair Group 19

Brake light defective


Brake light does not light
Line interruption or shortup
circuit to positive or earth
Engine speed fluctuations
between brake light switch
during braking
and engine control unit

- Check brake light switch


and brake pedal switch
page 23-44

Brake light switch


-F
Implausible signal

17811
Exhaust gas
recirculation system
Control deviation

Edition 01.04
S00.5111.56.20

Exhaust gas recirculation


valve -N18- defective

Exhaust gas recirculation


system not operational

- Check exhaust gas


recirculation solenoid
valve page 01-18,
Actuator diagnosis

Exhaust gas recirculation


potentiometer -G212- defective

Mixture adaptation not operational

- Check exhaust gas


recirculation valve
1.9 l/66 kW (TDI) Engine, Mechanical Components; Repair Group 26

------------ 01-17.2 -------------

01

Self-Diagnosis
Readout on V.A.G 1552

old

Fault number

17931

new

Possible cause of fault

Possible effects

OCTAV1A

Rectifying fault

Crash signal of
airbag CU
Implausible signal

17964

Fault in airbag system

Airbag warning light comes - Check airbag


on
Body Work; Repair Group
01

Fault in charge pressure


control
-N75 defective

Incorrect driving behaviour


Reduced performance

- Check charge pressure


control solenoid valve
-N75 page 01-18,
Actuator diagnosis
- Check charge pressure
control
1.9 l/66 kW (TDI) Engine,
Mechanical Components;
Repair Group 21

Fault in charge pressure


control
-N75 defective

Incorrect driving behaviour


Reduced performance

- Check charge pressure


control solenoid valve
-N75 page 01-18,
Actuator diagnosis
- Check charge pressure
control
1.9 l/66 kW (TDI) Engine,
Mechanical Components;
Repair Group 21

Cruise control system


switch defective
Line interruption

Cruise control system not


operational

- Check cruise control system page 23-54


- Reading measured value
block 6 page 01-35

Charge pressure
control
Regulating limit
not reached

17965

Charge pressure
control
Regulating limit
exceeded

17977

Cruise control
system switch
(CCS) -E45
Implausible signal

------------ 01-17.3 -------------

Edition 01.04
S00.5111.56.20

Readout on V.A.G 1552


old

Fault number

17978

01

Self-Diagnosis

OCTAV1A

new

Possible cause of fault

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

Engine starts and stops


immediately

Short-circuit in communication cable


Fault in the immobiliser
system

For vehicles
08.97

- Adapt engine control unit


to immobiliser
Binder: Electrical system;
Repair Group 90

- Check immobiliser
Binder: Electrical system;
Repair Group 90

Immobiliser control unit


defective/missing
Engine control unit
wrongly coded

- Code engine control unit


page 01-23

18034

Data bus drive


Missing message from transmission CU

18044

Databus lines to automatic transmission control


unit interrupted

Poor driveability (jerking


- Check data bus page
when changing gears, load
23-55.3
alteration shock etc.)

Databus lines defective


Fault in ABS system

Incorrect driving behaviour

- Check data bus page


23-55.3

Fault in airbag system

Warning light for airbag


comes on

Check airbag
Body Work; Repair Group
01

Fault in the system of the


automatic transmission

- Check automatic transmission control unit


Binder: Automatic transmission

Data bus drive


Missing message from
Airbag CU

18050

Read out fault


memory of airbag
control unit

Edition 01.04
S00.5111.56.20

------------ 01-17.4 -------------

01

Self-Diagnosis
Readout on V.A.G 1552

old

Fault number

18058

new

Possible cause of fault

Possible effects

OCTAV1A

Rectifying fault

Data bus drive


Missing message from instrument cluster

18061
Read out fault
memory of ABS
control unit

18062

No vehicle dynamics control - Check ABS control unit


TCS not operational
Binder: Chassis; Antilock
MSR not operational
Brake System

Oil level/oil temperature


sender -G266 defective

Warning light for oil level


comes on

- Check oil level/oil temperature sender -G266


Binder: Electrical System;
Repair Group 90

Short circuit in wiring

Reduced performance

- Check air conditioning


compressor engagement
page 01-18, Actuator
diagnosis

Read out fault


memory of instrument cluster

18065

Poor driveability

Fault in ABS control unit

Databus lines defective


Incorrect or defective
dash panel insert
Incorrect or defective engine control unit

- Check data bus page


23-55.3

Air conditioning
input/output
Short-circuit to
positive

18090

Data bus drive


Implausible signal from ABS
control unit

Databus lines to ABS con- No vehicle dynamics control unit interrupted


trol
TCS not operational
MSR not operational
Fault in ABS system

------------ 01-17.5 -------------

- Check data bus page


23-55.3
- Check ABS control unit
Binder: Chassis;
Antilock Brake System

Edition 01.04
S00.5111.56.20

Readout on V.A.G 1552


old

Fault number

For vehicles
08.97
18259

01

Self-Diagnosis

OCTAV1A

new

Possible cause of fault

Possible effects

Rectifying fault

18057

Data bus drive


Missing message from ABS CU

For vehicles
08.97
18262

Databus lines to ABS control unit interrupted

Fault in ABS system

No vehicle dynamics control

- Check ABS control unit


Binder: Chassis;
Antilock Brake System

18056

Data bus drive

Databus lines to auto Poor driveability


matic transmission or ABS
(jerking when changing
control unit interrupted
gears, load alteration
shock etc.)

- Check data bus page


23-55.3

Fault in automatic transmission or ABS system

Mixture adaptation not operational

- Check ABS control unit


Binder: Chassis; Antilock
Brake System
- Check automatic transmission control unit
Binder: Automatic transmission

Accelerator pedal position


sender -G79 defective

Hardware defective

Shifting points for automatic gearbox N.O.K.

- Check accelerator pedal


position sender -G79
page 23-47

Engine control unit internally defective

Poor driveability
Engine stoppage
Glow period indicator light
flashes

- Replace engine control


unit
page 23-20

or
defective

19458

- Check data bus page


23-55.3

Kick-down switch
F8
Implausible signal

65535
Control unit defective

Edition 01.04
S00.5111.56.20

16989
17795
18048

------------ 01-17.6 -------------

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)

Only for vehicles with special equipment


For vehicles as of 08.03.

Test preconditions for vehicles with air conditioning


l Vehicle at room temperature
(at least + 15C)
l Air conditioning switched on

l Lowest temperature and highest blower


speed preselected
Special tools, aids and testers required

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Procedure
-

Vehicle system test


Select function XX

------------ 01-18 -------------

HELP

Connect vehicle system tester V.A.G 1552


and select engine electronics control unit
(address word 01). The engine must be running in idle page 01-2).

K Read-out on display:

Edition 09.03
S00.5111.55.20

Test of vehicle systems


03 - Final control diagnosis

Press keys 0 and 3 for the function Final


control diagnosis.

K Readout in display:
-

Final control diagnosis


Start of injection valve -N108

01

Self-Diagnosis

OCTAVIA

Confirm the entry with the key Q.

K Readout in display:

When the valve is actuated, this results in a


clearly audible change in the combustion
noise (diesel noise).

If no change in the combustion noise can be


heard:
Final control diagnosis
EGR valve -N18

Test injection timing device control range


page 23-28.

Press the key.

K Readout in display:

The valve should click.

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

Test EGR valve

page 23-34.

Press the key.

K Readout in display:

What is tested is the AC compressor cutoff.

The test step is also displayed in the case of


vehicles without air conditioning.

The AC compressor should stop within 5


seconds (visual inspection with electric
torch), and then start and stop again approximately every 5 seconds.

If the AC compressor is not switched off:


-

Edition 05.97
S00.5111.51.20

Test AC compressor cut-off

page 23-49.

------------ 01-19 ------------

01

Self-Diagnosis

Final control diagnosis


Fuel cut-off valve -N109

OCTAVIA

Press the key.

K Readout in display:
The engine should stop.
If the engine does not stop:
-

Switch off the ignition.

Unscrew fuel cut-off valve and clean any


metal swarf and dirt.

Repeat final control diagnosis; if the engine


again does not stop, replace fuel cut-off
valve.

Final control diagnosis


Charge pressure control solenoid valve -N75

Press the key.

K Readout in display:

The solenoid valve should click.

Note:

It is very difficult to hear the clicking of the valve


and it should therefore be checked by touching.
If the solenoid valve does not click:
-

Final control diagnosis


Glow plugs relay -J52

Test charge pressure control solenoid valve


page 23-24.

Press the key.

K Readout in display:

The relay should click.

Because of the high power consumption of


the glow plugs, it is also possible to check
that the relay switches on and off by observing how the interior light becomes dimmer
and then brighter.

If the relay does not click:


-

Final control diagnosis


Glow period warning light -K29

Test glow plugs relay


Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder

Press the key.

K Readout in display:

The warning light should flash.

------------

------------

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

Check glow period warning lamp


page 28-2.
Press key.

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
-

Vehicle system test


Select function XX

HELP

Press key.

K Read-out on display:
-

Enter 06 for the function end output and


confim entry with key Q.

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

------------ 01-21 -------------

01

OCTAVIA

Self-Diagnosis

Special tools, aids and testers required

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3A, 3B or 3C.
Procedure
-

Vehicle system test


Select function XX

HELP

Basic setting
Enter display group number XXX

HELP

K Read-out on display:
-

System in Basic setting


1
2
3
4
5

10

Enter 04 for the function Basic setting and


confirm entry with the key Q.

K Read-out on display:
-

Connect vehicle system tester V.A.G 1552


and select engine electronics control unit
(address word 01). The engine must be running in idle.
(Connect vehicle system tester and select
engine electronics control unit page 01-2).

Enter 000 and confirm entry with the key Q.

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

Fuel temperature: at approx. 40 C (if the temperature is not reached at


a low outside temperature, ignore specified value)

Ignore

Coolant temperature: approx. 90 C

Ignore

Ignore

Ignore

Accelerator pedal position: 0

The commencement of injection is dependent on the fuel temperature,


specified values
page 23-13, Dynamically test and set commencement of injection
Idling speed: 41...441)
1)

For vehicles 07.97 = 41...44


For vehicles 08.97 = 42...45
For vehicles 05.99 = 43...46

------------ 01-22 -------------

Edition 09.03
S00.5111.55.20

OCTAVIA

01

Self-diagnosis

Coding control unit


If the code which is displayed does not match
the vehicle, or if the control unit has been replaced, it is then necessary to code the control
unit as follows.
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3, 3A, 3B or 3C
Test procedure
-

Test of vehicle systems


Select function XX

HELP

K Readout in display:
-

Code control unit


Enter code number XXXXX

Q
(0-32000)

Connect vehicle system tester V.A.G 1552


and select engine electronics control unit (address word 01). The ignition must be switched on for this step page 01-2.

Enter 07 for the function Code control unit


and confirm the entry with the key Q.

K Readout in display:
-

Enter the relevant code number for this vehicle and confirm the entry with the key Q.

Coding control units

Code
number
00001
00002

Models 07.97

Models fitted with

Code
number

Automatic gearbox

00001

Models 08.97

Manual gearbox

00002
00003

00005

038906018.. 1.9l R4 EDC G00SG 1822

Coding 00002
WSC 01234

Models fitted with


Automatic gearbox

Manual gearbox with activated CAN


databus (models with ABS)
Manual gearbox for 4x4 models

Manual gearbox without CAN databus


(models without ABS)

K The control unit identification is shown in the


display (example):
-

Switch ignition off and on again.

Notes:
The code entered is activated when the ignition is switched on again

If the ignition is not switched off and on again


after entering the valid code, it is then not
possible to erase the fault 01044 Control unit
incorrectly coded.
-

Edition 12.00
S00.5111.54.20

Press key.

------------ 01-23 ------------

01

Vehicle system test


Select function XX

Self-Diagnosis

HELP

OCTAV1A

K Read-out on display
-

Enter 06 for the function end output and


confirm entry with the key Q.

Readiness code
Valid for vehicles 08.03

Reading readiness code


Function
The readiness codes are two 8-digit numerical
codes which indicate the status of the
emission-relevant diagnoses.
If the diagnosis for a system was successfully
performed (e.g. exhaust gas recirculation system), the relevant position of the numerical code
is set from 1 to 0.
This diagnosis is performed at regular intervals
during normal driving. After repairs have been
carried out to an emission-relevant system, it is
recommended to generate the readiness code
in order to thus ensure that the systems operate properly. If a fault is detected during diagnosis, it is then stored in the
fault memory.
The readiness code is erased through deletion
of the fault memory, that is all relevant points
will be set to 1.
Generation of the readiness code means to activate the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems
etc.
Procedure
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-

------------ 01-24 -------------

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

Reading measured value block


00000000 00000110 10000000

17

00000000

Read function 08 Reading measured value


block and select display group 017.

K Read-out on display

Meaning of 8-digit numerical block for readiness code in display field 2


1

7
1

Ignore

Meaning

Ignore

Ignore
Ignore

Ignore

Diagnosis of other systems

Diagnosis of fuel supply


Ignore

Meaning of 8-digit numerical block for readiness code in display field 4


1

Edition 01.04
S00.5111.56.20

7
0

Ignore

Meaning

Ignore

Ignore
Ignore

Ignore
Ignore

Ignore

Diagnosis of exhaust gas recirculation system

------------ 01-25 -------------

01

Self-Diagnosis

OCTAV1A

If the specified values are not reached, generate readiness code page 01-26.

Press key.

Enter function 06 End output and switch


off ignition.

Generating readiness code


Special tools, aids and testers required
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3CTest conditions
l All electrical consumers such as e.g. light
and rear window heater must be switched
off.
l Intake air temperature below 60 C display group 007, display field 3
l Coolant temperature at least 83 C display group 007, display field 4
Procedure
-

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

Interrogating fault memory

Enter function 02 Interrogating fault memory and confirm entry with key Q.

K The number of stored faults or No fault detected appears in the display.


If a fault is stored:
-

Rectify fault by referring to the fault table


page 01-8.

If no fault is stored:
-

------------ 01-26 -------------

Press.

Edition 01.04
S00.5111.56.20

OCTAV1A

Work step 2:
Vehicle system test
Fault memory is erased

01

Self-Diagnosis

K-

Erasing fault memory

Enter function 05 Erasing fault memory and


confirm entry with key Q.

Note:

Readiness code is erased each time the fault


memory is erased.
If the ignition is switched off during Interrogating fault memory and Erasing Fault memory,
the fault memory is not erased.
-

Press.

Work step 3:
-

Switching off ignition

Wait at least 5 seconds with ignition OFF.

Note:

This point is important, because with certain diagnoses the slowing down of the control unit
must be ended. Otherwise readiness code cannot be generated.
Work step 4:
-

Switching on ignition

Wait at least 10 seconds with ignition OFF.

Charge pressure sender is adapted with atmospheric charge pressure sender.


Work step 5: 1st test of fuel supply and
other systems
Reading measured value block
1
2500/rpm
4.6 mg/h
2.0 CA

94.2 C

Start engine.
Select function Reading measured value
block and display group 001.

K-

For 5 seconds increase the engine speed to


2500 rpm and then run engine at idling
speed.

Work step 6:
culation
Reading measured value block
1
1650/rpm
4.1 mg/h
4.0 CA

93.2 C

K-

1st test of exhaust gas recir-

Increase engine speed to 1600 rpm up to


1700 rpm and maintain it for at least 10 seconds in this range.

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

------------ 01-27 -------------

01

Self-Diagnosis
Work step 7:
-

Switching off ignition

Wait at least 5 seconds with ignition OFF.

Work step 8:
-

OCTAV1A

Switching on ignition

Wait at least 10 seconds with ignition ON.

Work step 9: 2nd test of fuel supply and


other systems
Reading measured value block
1
2500/rpm
4.6 mg/h
2.0 CA

94.2 C

Start engine.
Select function Reading measured value
block and display group 001.

K-

For 5 seconds increase the engine speed to


2500 rpm and then run engine at idling
speed.

Work step 10: 2nd test of exhaust gas recirculation


Reading measured value block
1
1650/rpm
4.1 mg/h
2.0 CA

93.2 C

K-

Increase engine speed to 1600 rpm up to


1700 rpm and maintain it for at least 10 seconds in this range.

Reading measured value block


17
00000000 00000110 10000000

00000000

Press C.
Enter 017 for display group 017 and read
readiness code.

K Specified value in display field 2:


00000110
Specified value in display field 4:
000000000
-

------------ 01-28 -------------

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

Work step 11: Interrogating fault memory


X fault detected!

Enter function 02 Interrogating fault memory and confirm entry with key Q.

K The number of stored faults or No fault detected appears in the display.


If a fault is stored:
-

Rectify fault by referring to the fault table


page 01-8 and re-generate the readiness
code page 01-26.

If no fault is stored:
Reading measured value block
17
00000000
00000110
10000000

Edition 01.04
S00.5111.56.20

00000000

Press.

K Readiness code was successfully generated, if


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

------------ 01-28.1 -------------

01

Self-Diagnosis

OCTAVIA

Measured value blocks


Reading measured value block
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
l No fault in fault memory
Special tools, aids and testers required
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-.
Procedure
-

Vehicle system test


Select function XX

HELP

Reading measured value block


Enter display group number XXX

HELP

Connect vehicle system tester V.A.G 1552


and select engine electronics (address word
01). The engine must be running in idle.

K Read-out on display:
-

Enter 08 for the function Read measured


value block and confirm entry with the key
Q.

K Read-out on display:
-

Enter the desired display group number and


confirm entry with the key Q.

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

------------ 01-28.2 -------------

10
HELP

K Read-out on display, e.g.:


-

Press key.

K Read-out on display:
-

Enter 06 for the function End output and


confirm entry with the key Q.

Edition 09.03
S00.5111.55.20

OCTAVIA

01

Self-diagnosis

Specified readouts for general vehicle check

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

Inducted air mass 70...110 o.k.


if not within tolerance
page 01-49, display group 003

Fuel temperature: no specification

Intake manifold temperature: no specification

Coolant temperature: 80...51 o.k.


> 80: warm up engine

Ambient air pressure: no specification

Charge pressure: ignore

Injected quantity: 10...30 o.k.


if not within tolerance
page 01-38, display group 001

Accelerator pedal position: 0

Commencement of injection: 20...60 o.k.


if not within tolerance
page 01-42, display group 004

Idling speed: 41...44 o.k.


if not within tolerance

Edition 12.00
S00.5111.54.20

page 01-46, display group 002

------------ 01-29 ------------

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01

OCTAVIA

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

201

64

153

K Readout in display

127

83

Inducted air mass

not
tolerance

display

003

Intake

up

air

not

pedal

is

------------

not

not

tolerance

tolerance

measured values apply


in
speed

------------

1
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

Inducted air mass 1) 69...110 o.k.


if not within tolerance
page 01-50, display group 003

Fuel temperature: 91...201

Intake manifold temperature: 190...80

Coolant temperature: 80...35 o.k.


> 80: warm up engine

Ambient air pressure: ignore

Charge pressure: ignore

Injected quantity: 15...45 o.k.


if not within tolerance
page 01-39, display group 001

Accelerator pedal position: 0

Commencement of injection: 12...75 o.k.


if not within tolerance
page 01-45, display group 004

Idling speed: 43...46 o.k.


if not within tolerance
1)

page 01-46, display group 002

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

------------ 01-31 ------------

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:

Accelerate the vehicle at full throttle for the test.

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

Inducted air mass: > 210 o.k.


< 210
page 01-55, display group 010

Fuel temperature: no specification

Intake manifold temperature: no specification

Coolant temperature: 80...51 o.k.


> 80: warm up engine

Ambient air pressure: ignore

Charge pressure: 171...191 o.k.


if not within tolerance
page 01-58, display group 011

Injected quantity: 170...195 (full load injected quantity) o.k.


125: emergency injected quantity, system fault detected

Accelerator pedal: 255 (depressed fully)

page 01-5, Interrogating fault memory

Commencement of injection: 180...245 (dependent on engine speed)


if not within tolerance
page 01-42, Display group 004

Engine speed: 160...190 (do not exceed 4000 rpm, engine speed is governed)

------------ 01-32 ------------

Edition 12.00
S00.5111.54.20

OCTAVIA

01

Self-diagnosis




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Display group 000 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:

Accelerate the vehicle at full throttle for the test.

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

Inducted air mass: 255

255

temperature:

display

010

Intake manifold temperature:

Coolant temperature:

up
air pressure:

pressure:
if not
tolerance

Injected quantity:
125:

(full load injected quantity)


injected quantity system fault detected

pedal: 255 (depressed fully)

Commencement of injection:
if not
tolerance
speed:

Edition 12.00
S00.5111.54.20

display

(dependent on
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011

fault memory

speed)

------------ 01-33 ------------

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01

OCTAVIA

Self-diagnosis

Display group 000 at full throttle (road test in 3rd or 4th gear, coolant temperature not less than +80

engine

Notes:

Accelerate the vehicle at full throttle for the test.

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

Inducted air mass: 255

255

temperature:

display

010

Intake manifold temperature:

Coolant temperature:

up
air pressure:

pressure:
if not
tolerance

Injected quantity:
125:

(full load injected quantity)


injected quantity system fault detected

pedal: 255 (depressed fully)

Commencement of injection:
if not
tolerance
speed:

------------

------------

display

(dependent on
Display

011

fault memory

speed)

Edition 12.00
S00.5111.54.20

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Edition 12.00
S00.5111.54.20

------------

------------

pedal depressed

pedal depressed
point

operated
to

Cruise

operating state of

pedal depressed

pedal depressed

Display

(CCS)

pedal and brake pedal depressed

pedal depressed

pedal

pedal

pedal

pedal and brake pedal not depressed

Display
2

state of
pedal and
pedal

opened

opened

closed

state of pedal
positions = 1

display

pedal

pedal monitor

Read measured value block

Display group

able

state

ignition

able

state

able

K Readout in display

on

01

Self-diagnosis

OCTAVIA


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01

Self-diagnosis

OCTAVIA

state

0
1

2 5 5

------------

state

Model fitted with CCS - CCS switched off


Model fitted with CCS - CCS switched on

Model without CCS, CCS function is not activated in engine control unit

------------

Edition 12.00
S00.5111.54.20

01

Self-diagnosis

Display group 016, engine idling


Read measured value block
70.0 %

OCTAVIA

10000001

00

16

13.8 V

K Readout in display

Supply voltage of control unit: ignore

Actuation of heating elements

Operating state of auxiliary heater

Generator load: ignore

Analysis: Table 1, operating state of auxiliary heater


Meaning if readout places = 1
x

1
1)

page 01-37, Table 1

Auxiliary heater switched off because:

page 01-37, Table 2

Coolant temperature greater than 70...80 C1) or intake air temperature


greater than 5 C

Alternator faulty

Battery voltage less than 9 V

Models 07.97 - engine speed less than 800 rpm


Models 08.97 04.99 - engine speed less than 875 rpm
Models 05.99 - engine speed less than 861 rpm

Engine start within the last 10 seconds

Coolant temperature sender (G62) or


intake manifold temperature sender (G72) faulty

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.

Analysis: Table 2, actuation of heating elements


x
1

Meaning if display places = 1

x
1

Actuation of heating elements

Low heating capacity relay (J359), switched on

High heating capacity relay (J360), switched on

Edition 12.00
S00.5111.54.20

------------ 01-37 ------------

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Edition 12.00
S00.5111.54.20

o.k.

cold

o.k.

load
cold

o.k.

Read measured value block

o.k.

Display group 001, engine idling (engine warm, coolant temperature not less than +85 C)
for models 07.97

Specified readouts for injection pump


01

Self-diagnosis

OCTAVIA

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S00.5111.54.20

load

------------

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cold

o.k.

load
cold

o.k.

o.k.,

Read measured value block

Display group
for

engine idling

load

not less

cold

o.k.

load
cold

o.k.

o.k.,

Read measured value block

Display group
for

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not less

01

Self-diagnosis

OCTAVIA

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Edition 12.00
S00.5111.54.20
valve

or

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01

block

closed

Self-diagnosis

OCTAVIA

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S00.5111.54.20

resistance in cable connection


control
pump incorrectly set

resistance in cable connection


control
pump incorrectly set
piston movement sender at

------------

------------

replace

piston movement sender at minimum stop

readout

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replace
stop

readout

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resistance in cable connection


control
pump incorrectly set

replace

piston movement sender at minimum stop

resistance in cable connection


control
pump incorrectly set
piston movement sender at

readout

Read measured value block

replace
stop

readout

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01

Self-diagnosis

OCTAVIA

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------------

------------

Edition 12.00
S00.5111.54.20

cold

valve

cold

valve

blocked

valve

Read measured value block

engine idling

not less than +80 C)

valve

cold

valve

blocked

valve

Read measured value block

engine idling

not less than +85 C)

01

Self-diagnosis

OCTAVIA

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Edition 12.00
S00.5111.54.20

------------

------------

o.k.

o.k.

valve

o.k.

block

valve

Read measured value block

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:
for

01

Self-diagnosis

OCTAVIA

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leaks

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valve

valve

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required).
Accelerate the vehicle at full throttle for the test.
Notes:

test in

at

01

not less

Self-diagnosis

+80

engine

OCTAVIA

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------------

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leaks

valve
blocked

block

valve

valve

Read measured value block

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

Specified readouts for engine idling

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 operating state

Engine speed

Table of engine operating state, page 01-46

Accelerator pedal position


0.0 % o.k.
> 0.0 % Accelerator pedal position sender incorrectly set or faulty
page 01-38; display group 001

page 23-47

Analysis: display of engine operating state


x

x
1

Meaning if display places = 1

x
1

Engine operating state

AC signal

switch off air conditioning

v o.k.: (idling speed switch closed)

Idling speed increased:


if AC switched on
switch off air conditioning
test brake
if accelerator and brake detected
pedal switch
if coolant auxiliary heater switched on
warm up
engine

------------ 01-46 ------------

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.

Read measured value block


0.82 mg/H

-0.12 mg/H

0.49 mg/H

13

K Readout in display
No readout

Variation of injected quantity of cylinders 4, 2, 1 to cylinder 3


-1.5 mg/H...+1.5 mg/H o.k.
All display blocks are too large: cylinder 3 strong
All display blocks are too small: cylinder 3 weak
Variation of injected quantity of cylinder 1 to cylinder 3
-1.5 mg/H...+1.5 mg/H o.k.
> +1.5 mg/H: cylinder 1 weak
< -1.5 mg/H: cylinder 1 strong

Variation of injected quantity of cylinder 2 to cylinder 3


-1.5 mg/H...+1.5 mg/H o.k.
> +1.5 mg/H: cylinder 2 weak
< -1.5 mg/H: cylinder 2 strong

Variation of injected quantity of cylinder 4 to cylinder 3


-1.5 mg/H...+1.5 mg/H o.k.
> +1.5 mg/H: cylinder 4 weak
< -1.5 mg/H: cylinder 4 strong

------------

Edition 12.00
S00.5111.54.20

------------

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OCTAVIA

Self-diagnosis

engine idling (engine

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.

- ...

The relevant cylinder has a weaker performance than cylinder

The relevant cylinder is stronger in performance than cylinder

measured value

and is therefore supplied with more fuel.


and is therefore supplied with less fuel.

in display

Idling controller - injected quantity cylinder

o.k.
cylinder weak

cylinder strong

Idling controller - injected quantity cylinder

o.k.

cylinder weak

cylinder strong

Idling controller - injected quantity cylinder

o.k.
cylinder weak

cylinder strong

Idling controller - injected quantity cylinder

o.k.

cylinder weak

cylinder strong

------------

------------

Edition 12.00
S00.5111.54.20

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S00.5111.54.20

speed

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too cold
warm up
quantity too
temperature very

------------

------------

readouts
injection pump
no correction possible

air mass requested by control unit

recirculation
blip
substitute value

air in intake area


inspect intake system
recirculation

ault memory

leaks

air mass
air mass in display block

ratio

900 rpm

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recirculation valve

K Readout in display

engine idling

not less

gas

01

Self-diagnosis

OCTAVIA

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mass meter

Edition 12.00
S00.5111.54.20

readouts
pump
no correction possible

air mass requested by control unit

too cold

blip
recirculation
t
p
substitute value

memory

up

air in intake area


inspect intake system
recirculation

leaks

air mass
air mass in display block

ratio

900 rpm

Read measured value block

models

recirculation valve

K Readout in display

engine idling (engine

not less

01

C)

Self-diagnosis

OCTAVIA

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01

Self-diagnosis

Read measured value block

K Readout in display

readout

temperature
open circuit in

temperature
open circuit in
substitute value

coolant temperature sender


a
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temperature
intake
open circuit in
a constant

temperature sender
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is

as a

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is
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as a substitute value

Notes:

It is not possible to state specifications for the temperatures.

If the engine is cooled down, the temperature readouts for fuel, intake manifold and coolant are by necessity approximately identical with the ambient temperature. If one of the readout differs significantly, it is then necessary to
test the appropriate sensor.

Edition 12.00
S00.5111.54.20

------------

------------

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OCTAVIA

Self-diagnosis

Specified readouts for


for

Notes:

Accelerate the vehicle at full throttle for the test.

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

K Readout in display

rpm

limit on

basis

- detected air mass


recirculation at
control on

basis

detected air mass

test air mass meter


load

speed

speed too
or too
increased as a result
pedal

speed

------------

------------

pedal not
p

accelerator pedal position sender

incorrectly set or

rpm

Edition 12.00
S00.5111.54.20

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Display group

01

Self-diagnosis

at full

(road test in

or

gear

not less

engine

Notes:

Accelerate the vehicle at full throttle for the test.

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

K Readout in display

rpm

limit on

- detected air mass


control on

speed too

pedal

speed

Edition 12.00
S00.5111.54.20

pedal not
p

basis

basis

detected air mass

test air mass meter


recirculation
t
speed

or too

speed

increased as a result

accelerator pedal position sender

incorrectly set or

rpm

------------

------------

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Self-diagnosis

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test in

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engine

Notes:

Accelerate the vehicle at full throttle for the test.

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required).
Read measured value block

K Readout in display

rpm

limit on

- detected air mass


control on

speed too

pedal

speed

------------

------------

pedal not
p

basis

basis

detected air mass

test air mass meter


recirculation
speed

or too

speed

increased as a result

accelerator pedal position sender

incorrectly set or

rpm

Edition 12.00
S00.5111.54.20

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S00.5111.54.20

mass

mass

less

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block

------------

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mbar

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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:
for

07.97

01

Self-diagnosis

OCTAVIA

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Edition 12.00
S00.5111.54.20

value

mass

or

block

mbar

or

mbar

Read measured value block

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

010 at

01

not less

Self-diagnosis

engine

OCTAVIA

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Edition 12.00
S00.5111.54.20

mass

------------

------------

value

mass

or

block

mbar

or

mbar

Read measured value block

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

Display group 010 at full

or

gear coolant t

not less

+80

engine

01

Self-diagnosis

OCTAVIA

01

Self-diagnosis

OCTAVIA

Specified readouts for charge pressure control

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:

Accelerate the vehicle at full throttle for the test.

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

On/off ratio (actuation) of charge pressure control solenoid valve


-N75

Momentary charge pressure


as specified charge pressure in display block 2 (tolerance 100 mbar) o.k.
insufficient charge pressure:
test, page 23-22
- No charge pressure control
excessive charge pressure:
- Pressure hose of charge pressure control dropped off or blocked, solenoid
test charge pressure, page 23-22
valve -N75 jamming
- Linkage at turbocharger rusted tight, pressure unit faulty
test charge
pressure, page 23-22

Specified charge pressure requested by control unit


1800...2050 mbar o.k.
> 2050 mbar charge pressure increased by tuning

Engine speed 2800...3200 rpm o.k.

------------ 01-58 ------------

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:

Accelerate the vehicle at full throttle for the test.

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

pressure control solenoid valve

display block

pressure control dropped


test
rusted
pressure unit

tol erance

or

test

pressure
by control unit
mbar
mbar
pressure increased by
rpm

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01

OCTAVIA

Self-diagnosis

011 at

test in

not less

+80

engine

Notes:

Accelerate the vehicle at full throttle for the test.

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 control solenoid valve

pressure
mbar
must
mbar
icient
pressure control

ressure
valve
at

o c

display block

tolerance

pressure control dropped o or


test
rusted
pressure unit

solenoid

test

pressure
by control unit
mbar
mbar
pressure increased by
rpm

Edition 12.00
S00.5111.54.20

OCTAVIA

23

Fuel Preparation/Fuel Injection

Servicing diesel direct injection system


Safety precautions
Pay attention to the following precautions in order to avoid injuries to persons and/or damage
to the fuel injection and glow plug system:
Do not disconnect and connect the cables
of the glow plug and fuel injection system also not of test equipment - unless the ignition is switched off.
To operate the engine at starting speed without it actually starting, e.g. for testing the
compression pressure, unplug the connector at the injection pump.
Before disconnecting the battery, determine
the code of radio sets with anti-theft coding.
The ignition should always be switched off
before disconnecting and connecting the
battery otherwise the diesel direct injection
system control unit may be damaged.

Rules for cleanliness


Pay careful attention to the following 5 rules
for cleanliness when carrying out work on the
fuel supply/fuel injection system:
Thoroughly clean connection points and the
surrounding area before disconnecting.
Place removed parts down on a clean surface and cover over. Do not use fluffing
cloths!
Carefully cover over or seal opened components if repairs are not carried out immediately.
Install only clean parts:
Do not remove replacement parts from their
wrapping until just before installing.
Do not use parts which have been stored
unwrapped (e.g. in tool boxes etc.).
If the system is opened:
Avoid working with compressed air, if possible.
Avoid moving the vehicle, if possible.
In addition, ensure that no diesel fuel flows
onto the coolant hoses. If this happens, it is
then necessary to clean the hoses again
without delay. Replace any hoses which have
suffered damage.

Edition 05.97
S00.5111.51.20

------------ 23-1 ------------

23

Fuel Formation / Fuel Injection

OCTAVIA

Summary of fitting locations 07.97

Components A to E are not shown on the summary illustration.


A - Relay for diesel direct injection system (J322)
Electrical centre page 23-2.1, Fig. 1
B - Glow plug relay (J52)
Electrical centre page 23-2.1, Fig. 1

D - Brake light switch (F) and brake pedal


switch (F47)
Combined in a housing
In footwell at brake pedal page
23-2.1, Fig. 1
E - Clutch pedal switch (F36)
In footwell at clutch pedal page
23-2.1, Fig. 1

C - Accelerator pedal position sender


(G79)
In footwell at accelerator pedal
page 23-6
------------ 23-2 ------------

Edition 03.98
S00.5111.52.20

OCTAVIA

1 - Mechanical exhaust gas recirculation


valve
2 - Injection nozzle with needle lift sender
(G80)
3 - Diesel direct injection system control
unit (J248)
With altitude sender (F96)
4 - Electromagnetic EGR valve (N18)
5 - Charge pressure control solenoid
valve (N75)
6 - Air mass meter (G70)
7 - High heating capacity relay (J360)
Only for models with optional equipment
8 - Low heating capacity relay (J359)
Only for models with optional equipment
9 - Coolant temperature sender (G62)
10 - Engine speed sender (G28)

23

Fuel Formation / Fuel Injection


11 - Plug connection
2-pin
For needle lift sender (G80)
12 - Plug connection
3-pin
For engine speed sender (G28)
13 - 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 cut-off valve (N109)
14 - Commencement of injection valve
(N108)
15 - Fuel cut-off valve (N109)
16 - Fuel metering control of injection
pump
With fuel temperature sender
With quantity adjuster (N146)
With modulating piston movement
sender (G149)
17 - Intake manifold pressure sender (G71)
and intake manifold temperature
sender (G72)

K Fig. 1

Components in footwell

1 - Glow plug relay (J52)


2 - Diesel direct injection system relay (J322)
3 - Clutch pedal switch (F36)
4 - Brake light switch (F) and brake pedal
switch (F47)

Edition 03.98
S00.5111.52.20

------------ 23-2.1 ------------

23

Fuel Formation/Fuel Injection

OCTAVIA

Overview of fitting locations 08.97 07.00

Components A to E are not shown in the illustration.


A - Diesel direct injection system relay
(J322)
electrical centre page 23-3, Fig. 2
B - Glow plug relay (J52)
electrical centre page 23-3, Fig. 2

D - Brake light switch (F) and brake pedal


switch (F47)
combined in a housing
in footwell at brake pedal page
23-3, Fig. 2
E - Clutch pedal switch (F36)
in footwell at clutch pedal page
23-3, Fig. 2

C - Accelerator pedal position sender


(G79)
in footwell at accelerator pedal page
23-6
------------ 23-2.2 ------------

Edition 12.00
S00.5111.54.20

OCTAVIA

23

Fuel Formation / Fuel Injection

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)

11 - Engine speed sender (G28)


12 - Plug connection
2-pin
For needle lift sender (G80)
13 - Plug connection
3-pin
For engine speed sender (G28)
14 - 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 cut-off valve (N109)
15 - Commencement of injection valve
(N108)
16 - Fuel cut-off valve (N109)
17 - Fuel metering control of injection
pump
With fuel temperature sender
With quantity adjuster (N146)
With modulating piston movement
sender (G149)
18 - Intake manifold pressure sender (G71)
and intake manifold temperature
sender (G72)

K Fig. 2

Components in footwell

1 - Glow plug relay (J52)


2 - Diesel direct injection system relay (J322)
3 - Clutch pedal switch (F36)
4 - Brake light switch (F) and brake pedal
switch (F47)

Edition 03.98
S00.5111.52.20

------------ 23-3 ------------

23

Fuel Formation/Fuel Injection

OCTAVIA

Overview of fitting locations 08.00

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Components A to E are not shown in the illustration.

light switch
and brake
switch
combined in a housing
in footwell at brake pedal
page 23-3.2, Fig. 3

direct injection

electrical centre page 23-3.2, Fig. 3

electrical centre page 23-3.2, Fig. 3

switch
in footwell at clutch pedal
page 23-3.2, Fig. 3

sender

in footwell at accelerator pedal page


23-6

------------ 23-3.1 ------------

Edition 12.00
S00.5111.54.20

OCTAVIA

23

Fuel Formation/Fuel Injection

1 - Mechanical exhaust gas recirculation


valve
with intake manifold flap

14 - Plug connection
2-pin
for needle lift sender (G80)

2 - Intake manifold flap changeover valve


(N239)

15 - Plug connection
3-pin
for engine speed sender (G28)

3 - Injection nozzle with needle lift sender


(G80)
4 - Heated crankcase ventilation (N79)
only models with optional equipment
5 - Diesel direct injection system control
unit (J248)
with altitude sender (F96)
6 - Electromagnetic exhaust gas recirculation valve (N18)
7 - Charge pressure control solenoid valve (N75)
8 - Air mass meter (G70)
9 - Low heating capacity relay (J359)
only models with optional equipment
10 - High heating capacity relay (J360)
only models with optional equipment
11 - Coolant temperature sender (G62)

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

1 - Glow plug relay (J52)

2 - Diesel direct injection system relay (J322)


3 - Clutch pedal switch (F36)

4 - Brake light switch (F) and brake pedal


switch (F47)

Edition 12.00
S00.5111.54.20

------------ 23-3.2 ------------

23

Fuel Preparation/Fuel Injection

OCTAVIA

Servicing injection pump

Pay attention to safety precautions


page 23-1

Pay attention to rules for cleanliness


page 23-1

Note:

Fuel hoses at the engine must be secured only


with spring-strap clips. It is not permitted to use
clamp-type or screw-type clips.

Removing and installing injection pump


page 23-8

1 - Stretch bolt
Always replace
20 Nm + 1/4 turn (90)

Dynamic test and setting of start of injection


page 23-13

2 - Injection pump gear


3 - Hub nut
On no account slacken

------------

------------

Edition 05.97
S00.5111.51.20

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OCTAVIA

23

Fuel Formation/Fuel Injection

for feed line


28 Nm

13

replace

Fuel
20 Nm

for cylinder 3 with needle lift sender


removing and installing, testing
page 23-16
tighten screw for return-flow line of
cylinder 3 to 10 Nm

for return-flow line


28 Nm

to control valve/fuel filter

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:

Fuel hoses at the engine must be secured only


with spring strap clips. It is not permitted to use
collar-type or screw-type clips.
1

to fuel tank

2 Feed line
from fuel tank

do not mix up, blue ring at top

fitting location: arrow points toward


fuel tank
if filter replaced, remove retaining
clamp and take off control valve with
fuel lines connected
passage to filter opened at temperature below +15 C
passage to filter closed at temperature above +31 C

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

Assembly overview of throttle


mechanism
For vehicles 07.98
1 - Allan screw
10 Nm

2 - Accelerator pedal position sender


(G79)
inspecting page 23-47
setting page 23-7
3 - Pulley

4 - Spring washer
5 - 10 Nm

6 - Thread cage

7 - Pedal bracket

------------ 23-6 ------------

Edition 09.03
S00.5111.55.20

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OCTAVIA

23

Fuel Formation/Fuel Injection

racket

pedal

testing page 23-47


pedal

accelerator pedal

and

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter, e.g. V.A.G 1526A
Test box V.A.G 1598/22

If the sender has been removed:

K-

Install cable pulley in position shown.

Edition 12.00
S00.5111.54.20

Install sender with preassembled cable pulley.

Connect vehicle system tester V.A.G 1552


page 01-2.

------------

------------

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Edition 12.00
S00.5111.54.20

(G79)

00

100.0

000

2
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010

010

2
C

23

Fuel Formation/Fuel Injection

OCTAVIA

OCTAV1A

Fuel Formation/Injection

23

Disassembling and assembling air filter

1 - Air mass meter -G70


inspecting page 23-35.
2 - Gasket ring
3 - Air filter top part
4 - 6 Nm
5 - Air guide
in air filter top part guide

Edition 01.04
S00.5111.56.20

6 - Filter element
7 - 10 Nm
8 - Air filter bottom part
9 - Air guide
10 - 6 Nm

------------ 23-7.2 ------------

23

OCTAV1A

Fuel Formation/Injection

Removing and installing injection


pump
Special tools, aids and testers required
Adjusting straightedge MP 1-312
Adjusting device for TDC MP 1-313
Rig pin 3359
Counterholder MP 1-216
Key for the timing belt tensioner (e.g. Matra
V159, Hazet 2587, Stahlwille 127-17)
Connection fitting e.g. V.A.G 1318/10
Vacuum pump (e.g. V.A.G 1390)
Torque
Ring spanner for injection lines (e.g. 3035)
Puller T40001 with hooks T40001/2 and
T40001/3
Feeler gauges
If necessary steel straightedge (tear-off tool)
Transparent plastic line
Removing
-

Remove right headlight Electrical System;


Repair Group 94

Remove engine cover.

Remove all the fuel lines from the injection


pump.

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.

------------ 23-8 ------------

Cover the openings with a clean cloth.

Remove air guide pipe between charge air


cooler and intake pipe.

Edition 01.04
S00.5111.56.20

OCTAVIA

23

Fuel Formation / Fuel Injection

Remove the top toothed belt guard, the


vacuum pump and the cylinder head cover.

Remove sound-absorbing pan and air guide


pipe between intercooler and turbocharger.

Engine installed
K-

Take off cover at inspection opening.


Position the crankshaft to TDC of cylinder 1
-arrow-.

Engine placed down on floor


K-

Screw in setting device for TDC point (MP


1-313, as shown in the illustration.

Set setting device to 96 mm -arrow- (the left


notch of the vernier -arrow A- is the reference point).

Rotate crankshaft until TDC marking -arrow


B- on the flywheel is aligned with the edge of
the setting device.

Engine attached to engine holder MP 1-202

Edition 03.98
S00.5111.52.20

Position flexible steel ruler (marking tool)


against the circumference of the flywheel.
Measure exactly 100 mm from the TDC
marking -arrow A- and make a mark -arrow
B- as an aid with marking tool.

------------

K-

------------

23

Fuel Formation / Fuel Injection

OCTAVIA

K-

Screw in adjusting device for TDC MP 1-313


as shown in illustration.

Set adjusting device to 91.4 mm (the lefthand notch of the vernier -arrow A- is the
reference point).

Rotate crankshaft until the help marking on


the flywheel is aligned with the edge of the
adjusting device -arrow B-.

For all cases


K-

Lock the camshaft with the adjusting


straightedge MP 1-312.

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-

Slacken the bolts -1- attaching the injection


pump sprocket.

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.

If it is not possible to lock the injection pump


sprocket with the locking pin, rotate the
crankshaft so that the holes for the locking
pin are aligned. Then, slacken the bolts of
the injection pump sprocket and, only now,
position the crankshaft to TDC.
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.

------------

------------

Edition 03.98
S00.5111.52.20

OCTAVIA

23

Fuel Formation / Fuel Injection

Unscrew the nut of the tensioning pulley.

Take the toothed belt off the toothed belt


sprockets of the camshaft and injection
pump.

Unplug the connector for the electrical connections of the injection pump.

K-

Unscrew the securing bolts -1- at the mounting bracket.

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-

Then, unscrew the securing bolts from the


rear support -arrow-.
Take off the injection pump.

Installing
-

Insert the front securing bolts and tighten the


bolts to 25 Nm.

Loosely secure the injection pump sprocket


at the hub with new securing bolts (do not
rotate injection pump sprocket).

------------

Edition 03.98
S00.5111.52.20

Insert the injection pump into the mounting


bracket and first of all attach the bolt at the
rear support with the tapered nut.

------------

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------------

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Edition 12.00
S00.5111.54.20

The adjusting straightedge must not be used as


a counterholder when slackening and tightening the camshaft sprocket. Counterhold camshaft sprocket with special tool MP 1-216.
Note:
S

23

Fuel Formation/Fuel Injection

OCTAVIA

OCTAVIA

23

Fuel Formation / Fuel Injection

Note:
K Ensure the retaining claw is correctly positioned.
-

Tighten the securing nut to 20 Nm.

Once again, check the TDC marking at the


flywheel.

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.
-

Tighten the bolt for attaching the camshaft


sprocket to 45 Nm (counterhold with MP
1-216).

Remove the locking pin 3359.

Remove the adjusting straightedge MP 1-312


from the camshaft.

Rotate the crankshaft two revolutions in direction of rotation of engine until the crankshaft is again positioned at TDC of cylinder
1.

Check whether the injection pump sprocket


can be locked with locking pin 3359.

If it is not possible to lock the injection pump


sprocket:
-

Rotate the crankshaft sufficiently until the


holes for the locking pin are aligned and lock
the injection pump sprocket with locking pin
3359.

Slacken the bolts attaching the injection


pump sprocket.

Rotate crankshaft until the help marking on


the flywheel is aligned with the edge of the
adjusting device.

If it is possible to lock the injection pump


sprocket:
-

Edition 03.98
S00.5111.52.20

Tighten the bolts attaching the injection pump


sprocket to 20 Nm + turn (90).
Remove locking pin 3359.

------------

------------

23

Fuel Formation / Fuel Injection

OCTAVIA

Connect the injection lines, fuel feed line and


electric cables.

K-

Fill the injection pump with clean diesel fuel


as follows:
-

Screw the connection fitting V.A.G 1318/


10 into the return flow opening of the injection pump.

Connect the vacuum pump (e.g. V.A.G


1390) to the return-flow opening with a
transparent fuel line about 1 m long.

Operate the vacuum pump until fuel flows


out of the return-flow opening. Do not
draw fuel into the vacuum pump.

Install top toothed belt guard, vacuum pump


and cylinder head cover.

Install air guide pipe from intercooler with


hose to the intake manifold.

Install connectors at intake manifold pressure sender and intake manifold temperature sender.

Install right headlight Electrical System;


Repair Group 94; Exterior Lights/Bulbs/
Switches.

Install top engine trim panel.

Install sound-absorbing pan and air guide


pipe between intercooler and turbocharger.

Dynamically test and set commencement of


injection page 23-13.

------------

Close the return-flow pipe.

------------

Edition 03.98
S00.5111.52.20

6
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OCTAVIA

23

Fuel Formation/Fuel Injection

t
commencement

and
injection

Notes:

Commencement of injection must always be


checked and set, if necessary, after replacing the toothed belt or also after slackening
the bolted connections at the injection pump
or at the toothed belt sprockets.
Dynamic testing of commencement of injection is only possible in function 04 Basic
setting of engine as, during this function, the
commencement of injection valve is constantly actuated and the injection timing device is thus retarded.
t

and

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C

Torque wrench 5...50 Nm (e.g. V.A.G 1331)


Counterholder MP 1-216
Locking pin 3359

Initiate basic setting


1
2
3
4

0
9

10

Select function Basic setting, display group


001 page 01-21.

K-

Check readout in display block 7 (coolant


temperature).

Specification: less than 73 (equals 85 C)

Do not continue with the test until the coolant


temperature is reached.

Commencement of injection in display block


2 is dependent on the fuel temperature in
display block 9.
Specification: Figure - range C

A - Display block 2, commencement of injection


B - Display block 9, fuel temperature

C - Specified range for commencement of injection

Edition 12.00
S00.5111.54.20

------------

------------


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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

Fuel Formation/Fuel Injection

OCTAVIA

OCTAVIA

23

Fuel Formation / Fuel Injection

Slacken the third bolt attaching the injection


pump sprocket and turn the pump shaft
slightly:
Turning shaft to the left
commencement of injection retarded
Turning shaft to the right
commencement of injection advanced

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.
-

Install top toothed belt guard.

Install air guide pipe from intercooler with


hose to intake manifold.

Plug in connectors at intake manifold pressure sender and intake manifold temperature sender.

Install top engine trim panel.

Install right headlamp Electrical System;


Repair Group 94; Exterior Lights/Bulbs/
Switches.

Once again check commencement of injection for specified value.

If the commencement of injection is not within


the specified range:
Correct the setting at the injection pump
sprocket.

If the commencement of injection is not within


the specified range:
-

Check fuel injection control page 23-28,


replace injection pump if necessary.

Injection pump is o.k.:


-

Edition 03.98
S00.5111.52.20

Replace engine electronics control unit


page 23-20.

------------

------------

23

OCTAVIA

Fuel Preparation/Fuel Injection

Removing and installing and testing injectors


Note:
Faulty injectors cause the following problems:
Loss of power
Excessive black smoke in exhaust
Intensified blue exhaust when starting from
cold
High fuel consumption
Engine overheats
Knocking in one or several cylinders
Misfiring
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3
Injector tester (e.g. V.A.G 1322)
Delivery pipe V.A.G 1322/2
Torque wrench 5...50 Nm (e.g. V.A.G 1331)
Ring wrench for injection pipes (e.g. 3035)
As need be, puller for valve stem seals MP
1-230 and auxiliary tool
Removing
-

Use the ring wrench (e.g. 3035) to detach


the injection pipes.

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.
-

Shop-make the following auxiliary tool for


injectors which are tight:

------------

Unscrew securing bolt, take off tensioning


clamp and remove injector.

------------

Edition 05.97
S00.5111.51.20

OCTAVIA

23

Fuel Formation/Injection
Preparing an auxiliary tool
-

Saw off an injection line (e.g. spare part line)


approx. 5 cm behind the nozzle union nut.

Hard solder an M6 bolt to the sawn off line.

Thoroughly clean the auxiliary tool, the injection nozzle cannot be used if dirty!

K-

Tighten the union nut of the auxiliary tool on


the jammed nozzle and insert the extractor
MP 1-230 on the welded nut.

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.
-

Insert injection nozzles.

Pay attention to correct fitting of the bracket


in the cylinder head.

Insert clamp and tighten fixing screw.

Tightening torques:
Injection lines: 25 Nm
Banjo bolt for return line (cyl. 3): 10 Nm
Screw for clamp: 20 Nm
Testing
-

Reading measured value block


13
0.82 mg/H -0.12 mg/H 0.49 mg/H

Connect vehicle system tester V.A.G 1552


and activate the function Reading measured
value block page 01-28.2.

K-

Reading measured value block, display group


013, engine in idle page 01-47.
Specified value: -1.50 mg/H...+1.50 mg/H
(milligram per stroke)

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).

------------ 23-17 ------------

23

Fuel Preparation/Fuel Injection

OCTAVIA

If the fault moves with the injector, replace


the relevant injector.

If the fault remains at the cylinder, test the


compression.

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.

K Test injectors with injector tester (e.g. V.A.G


1322) and pressure pipe V.A.G 1322/2.

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
-

Slowly press the pump lever down. When


fuel ejection starts, read off the ejection pressure. If the ejection pressure differs from the
specified pressure, replace the injector.
New injectors
Wear limit

19...20 MPa
17 MPa

Testing for leaks


l Pressure gauge switched on
-

------------

------------

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

Wiring and Component Test with


Test Box
Note:

For testing use e.g. the handheld multimeter


-V.A.G 1526 A or B-, also the voltage tester
e.g. -V.A.G 1527 B-.
For connecting measuring equipment (e.g.
voltage tester, handheld multimeter etc.) always use the adapter cable set e.g. -V.A.G
1594 A, B or C-

The contact numbers of the connector of the


control unit and the socket numbers of the
test box are identical.
Attention!

To avoid damaging the electronic components,


switch on the relevant measuring range before connecting the measuring cables and comply with the
test conditions.
Special tools, aids and testers required
Test box -V.A.G 1598/22- or -V.A.G 1598/31Test procedure
-

Switch off ignition.

Unscrew windscreen wiper arms and remove


cover of plenum chamber
Body Work, Repair Group 66.
-

Release the plug locks and unplug the plug


connector of the engine control unit.

For the test box -V.A.G 1598/22K-

Edition 01.04
S00.5111.56.20

Connect test box -V.A.G 1598/22- to connector of wiring loom.


Perform test as described in the relevant repair sequences.

------------ 23-19 ------------

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------------

------------

Edition 12.00
S00.5111.54.20

Notes:

23

Fuel Formation/Fuel Injection

OCTAVIA

Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

------------

OCTAVIA

------------

23

OCTAV1A

Fuel Formation/Injection

Replacing engine control unit


Special tools, aids and testers required
Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B or 3C-

038906018.. 1.9 l R4 EDC G00SG 1002

Coding 00002
WSC 01234

Connect vehicle system tester -V.A.G 1552and select engine electronics control unit
page 01-2.

K The control unit identification appears in the display, e.g.:


-

Part no. of control unit part and write in coding.

End output (function 06).

Removing
-

Switch off ignition.

Unscrew windscreen wiper arms and remove


cover of plenum chamber
Body Work, Repair Group 66.
-

Release the plug locks and remove the control unit plugs.

K-

Use a screwdriver to push the catch of the


fixture to the side and pull the engine control
unit forward.

Installing
The installation occurs in reverse order.
-

Check current coding and code new control


unit page 01-23.

Adjust the engine control unit to the immobilizer control unit


Electrical System Repair Group 96.
-

On vehicles fitted with CCS; activate CCS


page 23-54.

Interrogate the fault memory, erase the fault


memory, if necessary eliminate any faults
which exist page 01-5.

For vehicles 08.03


-

------------ 23-20 ------------

Generate readiness code page 01-26.

Edition 01.04
S00.5111.56.20

Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

------------

OCTAVIA

------------

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------------ 23-22 ------------

Edition 12.00
S00.5111.54.20

11

01

Have a second person operate V.A.G 1552.


Warning!

and

tem

23

Fuel Formation/Fuel Injection

OCTAVIA

OCTAVIA

23

Fuel Formation/Fuel Injection


If the charge pressure measured is too low, the
following faults are possible:
Hose of charge pressure control dropped off,
leaking or blocked.
Charge pressure control solenoid valve (N75)
blocked.
Mechanism (linkage, shaft) of bypass valve
stiff or jammed (bypass valve constantly open).
Pressure unit leaking.
If the charge pressure measured is o.k., repeat
measurement of charge pressure with charge
pressure control:
-

Plug in connector at charge pressure control solenoid valve (N75).

Read measured value block, display group


011, engine idling page 01-58.

Accelerate vehicle in 3rd gear at full throttle


for about 1500 rpm.

At about 3000 rpm check readout in display


block 3 and note.

Models 07.97
Read measured value block
3090 rpm
1866 mbar 1917 mbar

11

62 %

Specification in display block 3:


1800...2050 mbar
Models 08.97 04.99

Read measured value block


3090 rpm
1866 mbar 1917 mbar

11

62 %

Specification in display block 3:


1700...2080 mbar
Models 05.99

Read measured value block


3090 rpm
1866 mbar 1917 mbar

11

62 %

Specification in display block 3:


1850...2250 mbar
Continued for all models
If the charge pressure measured is too low, the
following faults are possible:

Electrical fault in charge pressure control


solenoid valve.

Charge pressure control solenoid valve


(N75) jamming in open position.

If the charge pressure measured is too high,


the following faults are possible:
Charge pressure control solenoid valve (N75)
occasionally jamming in closed position.

Charge pressure increase as a result of tuning.


Edition 12.00
S00.5111.54.20

------------

------------

23

OCTAVIA

Fuel Formation/Fuel Injection

Testing charge pressure control solenoid valve (N75)


Special tools, testers and aids required
Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)
Test box V.A.G 1598/22 or V.A.G 1598/31
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3, 3A, 3B or 3C
Diode test lamp (e.g. V.A.G 1527 B)
Test condition
l Fuses 29 and 34 o.k.
Test procedure
-

Connect vehicle system tester V.A.G 1552


and select engine electronics control unit
page 01-2.

Select final control diagnosis and activate


charge pressure control solenoid valve -N75
page 01-18.

If the valve is not actuated (does not click):


K-

Unplug connector -1- from charge pressure


control solenoid valve (N75) and connect
diode test lamp between contacts of connector.

Diode test lamp must flash.


Diode test lamp flashes.

End final control diagnosis.

Switch ignition off.

Connect multimeter to valve -2- for resistance measurement.

Models 07.00

Specification: 25...45

Models 08.00

Specification: 14...20

Continued for all models

If the specification is not achieved:

------------

------------

Edition 12.00
S00.5111.54.20

OCTAVIA

23

Fuel Formation/Fuel Injection


-

Replace charge pressure control solenoid


valve (N75).

Diode test lamp does not flash:


-

End final control diagnosis.

Switch ignition off.

Connect multimeter for voltage measurement


to contact 1 of connector -1- and to earth.

Switch ignition on.




!























Specification: approx. battery voltage

If the specification is not achieved:


-

Switch ignition off.

Connect test box to wiring loom to engine


control unit page 23-19.

est

K Test the following cable connections for short


circuit to positive and to negative and also for
open circuit (connector -1-).
2-pin connector at wiring
loom, contact

est

2, 28

.
socket
15

Rectify any open circuit or short circuit in the


wiring.

est

K Test the following cable connections for short


circuit to positive and to negative and for open
circuit (connector -1-).
2-pin connector at
wiring loom, contact
1
2

est

.
socket
1, 2
62

Rectify any open circuit or short circuit in the


wiring.

Continued for all models

If no fault is found in the wiring:


-

Edition 12.00
S00.5111.54.20

Replace engine control unit (J248) page


23-20.

------------

------------

23

------------

Fuel Formation/Fuel Injection

------------

OCTAVIA

Edition 12.00
S00.5111.54.20

D
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OCTAVIA

23

Fuel Formation/Fuel Injection

ture sender
t

testers and aids

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)

Test box V.A.G 1598/22 or V.A.G 1598/31

Read measured value block


15.4 C

16.7 C

K-

Read measured value block, display group


007; engine switched off and cooled down
page 01-51.
Observe readout in display block 3.

Note:

If an open circuit exists in the wiring to the sender,


a substitute value of 136.8 C is displayed.
-

End output (function 06) and switch ignition


off.

If an implausible temperature, or a substitute


temperature of 136.8 C is displayed:

K-

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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Test

Edition 12.00
S00.5111.54.20

52

Test

25

Test

Test

50...100

23

Fuel Formation/Fuel Injection

OCTAVIA

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Edition 12.00
S00.5111.54.20

------------

------------

If

OCTAVIA

23

Fuel Formation/Fuel Injection

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S00.5111.54.20

1013

10

testers and aids

Testing
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23

and altitude sender

Fuel Formation/Fuel Injection

OCTAVIA


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OCTAVIA

23

Fuel Formation/Fuel Injection

23

------------

Fuel Formation/Fuel Injection

------------

OCTAVIA

Edition 12.00
S00.5111.54.20

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OCTAVIA

23

Fuel Formation/Fuel Injection

control

control

2
3

connection at

control

unit

acuum

element

valve

3
4

return valve
white connection points toward charge
pressure control solenoid valve -N75
acuum unit

o air

control

unit
for charge pressure control valve
part of turbocharger, cannot be replaced separately

10
11

valve

recirculation

acuum

12

13

Edition 12.00
S00.5111.54.20

return valve

------------

------------

23

OCTAVIA

Fuel Preparation/Fuel Injection

Testing start of injection control


Testing injection timing control
range
Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3
Procedure
Final control diagnosis
Start of injection valve -N108

Initiate final control diagnosis and actuate the


start of injection valve page 01-18.

K Readout in display:
Actuation of the valve is indicated by a clearly
audible change in the combustion noise (diesel combustion noise).
-

Basic setting
42 46 0 20

90

201

64

153

0
127

Initiate the basic setting page 01-21.

K Readout in display, e.g.:

83
-

K-

Set start of injection, if necessary


page 23-13.

Remove the fuse 34 -arrow-.

Basic setting
42 255 0 20

90

201

64

153

0
127

83

Observe the readout in display zone 2.


The readout should increase to 255

Note:

As a result of the interruption to the voltage, the


start of injection valve is closed. The pump internal chamber pressure can no longer be lowered and acts to its full extent on the piston of
the injection control. The injection control is
moved toward the advanced stop.

------------

------------

Edition 05.97
S00.5111.51.20













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S00.5111.54.20

------------

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If the

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If the

OCTAVIA

23

Fuel Formation/Fuel Injection

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Edition 12.00
S00.5111.54.20

10

connector at

14

Test

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connector at

Test

23

Fuel Formation/Fuel Injection

OCTAVIA

Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

------------

OCTAVIA

------------

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------------

------------

Edition 12.00
S00.5111.54.20

1.

Test procedure

testers and aids

Testing

23

temperature sender

Fuel Formation/Fuel Injection

OCTAVIA

23

Fuel Formation/Fuel Injection

0
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OCTAVIA

Specification:

Specification in field A applies to temperature


0...50 C, in field B to a temperature of 50...100
C.
Example:

A temperature of 30 C equals a specification of 1500...2000


A temperature of 80 C equals a specification of 275...375
If the specification is not achieved:
Replace injection pump

page 23-8.

If the specification is achieved:


-

Connect test box to wiring loom to engine


control unit page 23-19.

est

K Test the following cable connections for short


circuit to positive and to negative and also for
open circuit (connector -1-).
10-pin connector at

est

76

.
socket
53

Rectify any open circuit or short circuit in the


wiring.

est

K Test the following cable connections for short


circuit to positive and to negative and for open
circuit (connector -1-).
10-pin connector at
4
7

Edition 12.00
S00.5111.54.20

est

.
socket
103
111

Rectify any open circuit or short circuit in the


wiring.

------------

------------

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Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

OCTAVIA

Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

------------

OCTAVIA

------------

23

OCTAVIA

Fuel Formation / Fuel Injection

Testing exhaust gas


recirculation system
Testing exhaust gas recirculation
Operation of the exhaust gas recirculation system is tested by measuring the inducted air
mass. If exhaust gas is recirculated, the fresh
air portion which is detected by the air mass
meter is less. The greater the quantity of exhaust gas recirculated, the smaller the signal
supplied by the air mass meter.

Special tools, testers and aids required

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3
Procedure for models 07.97
Read measured value block
900 rpm
6.5 mg/H

1.480 V

87.3 C

Read measured value block, display group


001, engine idling page 01-36.

K Readout in display:
-

Check readout in display block 4 (coolant


temperature).
Specification: at least 85 C

Do not continue with the test until the coolant


temperature is reached.
-

Read measured value block


900 rpm
272 mg/H

3
268 mg/H

54 %

Press the key C.

Press the key 0 twice and key 3 for Display


group number 003 and confirm the entry with
the key Q.

K Readout in display:
-

Read measured value block


900 rpm
272 mg/H

3
268 mg/H

54 %

Briefly blip the throttle and then allow the


engine to continue idling.

K-

Check the readout in display block 2 (specified air mass).


Specification: 230...370 mg/H

If the air mass is higher than specified, the cause


may be the following:
Coolant temperature too low

Intake manifold temperature very high


Injected quantity too high

------------ 23-32 ------------

Edition 03.98
S00.5111.52.20

OCTAVIA

23

Fuel Formation / Fuel Injection

Fault in fault memory


Read measured value block
900 rpm
272 mg/H

3
268 mg/H

54 %

K-

Check the readout in display block 3 (actual


air mass).
Specification: should agree with specified air
mass in display block 2
(tolerance 20 mg/H)

If the actual air mass is more than 20 mg/H lower


than the specified air mass, the following faults
are possible:
Unmetered air in intake area
Excessive exhaust gas recirculation
If the actual air mass is more than 20 mg/H
higher than the specified air mass, the following faults are possible:

Engine has been idling for 3 minutes

Insufficient or no exhaust gas recirculation

If the actual air mass is a constant 425 mg/H,


the following faults are possible:
Open circuit in wiring to air mass meter
Implausible air mass detected

If the specifications are not achieved:


-

Final control diagnosis


EGR valve -N18

Start final control diagnosis and operate the


EGR valve page 01-18.

K Readout in display:

The valve should click.

If the valve does not click:


-

Test EGR valve (N18)

page 23-34.

If the valve clicks:


-

Check the vacuum hoses

page 23-37.

If the vacuum hoses are o.k.:


-

Edition 03.98
S00.5111.52.20

Test mechanical exhaust gas recirculation


valve:
1.9-ltr./66 kW Engine, Mechanical Components; Repair Group 26; Exhaust gas
recirculation system

------------ 23-33 ------------


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------------

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Edition 12.00
S00.5111.54.20

If a constant value of 550 mg/H is shown in display block 3, test the air mass meter page
23-35.
Note:

4
4

23

Fuel Formation/Fuel Injection

OCTAVIA

Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

------------

OCTAVIA

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23

OCTAVIA

Fuel Formation/Fuel Injection

Testing electromagnetic
gas recirculation

testers and aids

Hand-held multimeter (e.g. V.A.G 1526 A)


Adapter cable set (e.g. V.A.G 1594 A)

Test box V.A.G 1598/22 or V.A.G 1598/31


Test condition

29 and 34

l
T
-

onnect
tester and select
engine electronics control unit page 01-2.

control diagnosis and


Select
exhaust gas recirculation solenoid
page 01-18.

the

is not actuated (does not

K-

connector -1- to the exhaust gas


recirculation solenoid

onnect multimeter
resistance measurement to the
-2-.
14...20

the

exhaust gas recirculation solenoid

the

ignition on.

the

------------

------------

is

onnect multimeter
measurement to contact 1 o connector -1- and to
earth.

is not

is not

test box to the


loom to the
engine control unit page 23-19.

Edition 12.00
S00.5111.54.20

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OCTAVIA

23

Fuel Formation/Fuel Injection


est

K Test the following cable connections for short


circuit to positive and to negative and also for
open circuit (connector -1-).
2-pin connector at

est

2, 28

.
socket
29

Rectify any open circuit or short circuit in the


wiring.

est

K Test the following cable connections for short


circuit to positive and to negative and for open
circuit (connector -1-).
2-pin connector at
1
2

est

.
socket
1, 2
61

Rectify any open circuit or short circuit in the


wiring.

Continued for all models

If no fault is found in the wiring:


-

Edition 12.00
S00.5111.54.20

Replace engine control unit (J248) page


23-20.

------------

------------

23

------------

Fuel Formation/Fuel Injection

------------

OCTAVIA

Edition 12.00
S00.5111.54.20

(3

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OCTAVIA

23

Fuel Formation/Fuel Injection

air mass meter

The signal from the air mass meter is required


by the control unit for calculating the permissible injected quantity and for controlling the exhaust gas recirculation. The smaller the signal
supplied by the air mass meter, the less fuel
may be injected.
t

testers and aids

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)

Test box V.A.G 1598/22 or V.A.G 1598/31


est condition

l Fuses 29 and 34 o.k.

Read measured value block, display group


010, engine idling page 01-55.

Warning!

Have a second person operate V.A.G 1552.

Read measured value block


mg/H
1030 mbar
1011 mbar

10

0.0 %

K-

Observe readout in display block 1.


Specification: 230...370 mg/H

If the specification is not achieved:


-

Test exhaust gas recirculation page 23-32.

If the specification is achieved:


-

Read measured value block


830 mg/H
1030 mbar 1850 mbar

Edition 12.00
S00.5111.54.20

10

100 %

Accelerate vehicle in 3rd gear at full throttle


from about 1500 rpm.

At about 3000 rpm, check readout in display


block 4 and note.

Specification in display block 4:


100 % (accelerator pedal position)

------------

------------

23

Fuel Formation/ Fuel Injection

OCTAVIA

If the specification is not achieved:


-

Repeat the test and accelerate the vehicle


at full throttle.

Models 07.97

Read measured value block


830 mg/H
1030 mbar 1850 mbar

10
100 %

Specification in display block 3:


1800...2050 mbar (charge pressure)

Read measured value block


830 mg/H
1030 mbar 1850 mbar

10
100 %

Specification in display block 1:


>750 mg/H (inducted air mass)

Models 08.97

Read measured value block


830 mg/H
1030 mbar 1850 mbar

10
100 %

Specification in display block 3:


1700...2080 mbar (charge pressure)

Read measured value block


830 mg/H
1030 mbar 1850 mbar

10
100 %

Specification in display block 1:


>800 mg/H (inducted air mass)

Continued for all models

If the specification is not achieved:


-

Test charge pressure page 23-22.

Replace the air mass meter (G70).

If a constant readout appears in display block 1


(fixed substitute value):
Models 07.97 = 425 mg/H
Models 08.97 = 550 mg/H

------------ 23-36 ------------

Switch off the ignition.

Edition 02.99
S00.5111.53.20

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------------

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OCTAVIA

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52
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OCTAVIA

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OCTAVIA

23

Fuel Formation/Fuel Injection

23

------------

Fuel Formation/Fuel Injection

------------

OCTAVIA

Edition 12.00
S00.5111.54.20

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Edition 12.00
S00.5111.54.20

13

------------

------------

return valve

12
11

10

acuum

valve

recirculation

unit
for charge pressure control valve
part of turbocharger, cannot be replaced separately
control

o air

acuum unit

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white connection points toward charge
pressure control solenoid valve -N75

3
2

valve

acuum

element

models 08.97

valve

models 08.97
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recirculation

OCTAVIA

23

Fuel Formation/Fuel Injection

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Fuel Formation/Fuel Injection

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OCTAVIA

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104
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Edition 12.00
S00.5111.54.20

------------

------------

23

Fuel Formation / Fuel Injection

OCTAVIA

Testing brake light switch and


brake pedal switch
In view of the fact that the fuel injection system
operates with an accelerator pedal sender
(potentiometer), which could develop a fault, the
engine is governed for safety reasons when the
brakes are applied. The control unit requires the
brake light switch signal and, in addition, the
brake pedal switch signal for this purpose. What
this means, therefore, is that, if the brake is operated when the accelerator pedal is constantly
depressed, the engine is immediately governed
down to idling speed. If the switch positions are
not clearly detected, this can result in unintentional governing of the engine speed.

Special tools, testers and aids required

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3
Procedure
Read measured value block
0 km/h
000

6
000000

K Readout in display:
-

Read measured value block


0 km/h
000

6
000000

6
000000

Check readout in display block 2.


Specification: 0 0 0

Read measured value block


0 km/h
011

Read measured value block, display group


006, engine idling page 01-33.

Slowly depress brake.

Specification: 0 1 1
Both readouts should jump from 0 to 1.

Middle readout = brake pedal switch

Right-hand readout = brake light switch


Read measured value block
0 km/h
000

6
000000

Slowly release brake pedal into rest position.


Specification: 0 0 0
Both readouts should switch back again from
1 to 0.

If one of the readouts or both does not switch


from 0 to 1:
-

------------ 23-44 ------------

Test the switches or the cable connections


to the switches.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder

Edition 03.98
S00.5111.52.20

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------------

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OCTAVIA

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S00.5111.54.20

------------

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100.0

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S00.5111.54.20

0
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23

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OCTAVIA

OCTAVIA

23

Fuel Formation/Fuel Injection


Test the wiring between test box and connector
of sender for open circuit according to the current flow diagram:
6-pin connector at
wiring loom, contact

Test box V.A.G 1598/22,


socket

11

24

23

12

6
-

25

Rectify any open circuit or short circuit in the


wiring.

If no fault is found in the wiring:


-

Replace engine control unit (J248) page


23-20.

Models 08.98

- Remove bottom part of dash panel


Body Fitting Work; Repair Group 68.
-

Unplug 6-pin connector for accelerator pedal


position sender (G79).

K-

Test resistance of accelerator pedal position


sender:
Accelerator

Contacts

not depressed

2+3

not depressed
not depressed
depressed

depressed

not depressed

4+3
5+6

1+6

If the specification is not achieved:


-

Edition 12.00
S00.5111.54.20

Specification
0.6...1.4 k
0.6...1.4 k
0.6...1.4 k

0.6...1.4 k

Replace accelerator pedal position sender


(G79).

------------ 23-48.1 ------------

23

OCTAVIA

Fuel Formation/Fuel Injection


If the specification is achieved:
K-

Test voltage supply of accelerator pedal position sender:


6-pin connector at
wiring loom, contact

Specification

2+3

approx. 5 V

2 + earth

approx. 5 V

1 + earth

approx. 5 V

1+6

approx. 5 V

If the specification is not achieved:


-

Connect test box to the wiring loom to the


engine control unit page 23-19.

Test box V.A.G 1598/22


K Test the wiring between test box and connector
of sender for open circuit according to the current flow diagram:
6-pin connector at
wiring loom, contact

Test box V.A.G 1598/22,


socket

11

23

12

4
6
-

------------ 23-48.2 ------------

24
25

Rectify any open circuit or short circuit in the


wiring.

Edition 12.00
S00.5111.54.20

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Fuel Formation/Fuel Injection


.

K Test the wiring between test box and connector


of sender for open circuit according to the current flow diagram:
wiring loom, contact

open circuit or short circuit in the

no fault is found in the wiring:

Edition 12.00
S00.5111.54.20

engine control unit

page

------------ 23-48.3 ------------

23

------------ 23-48.4 ------------

Fuel Formation/Fuel Injection

OCTAVIA

Edition 12.00
S00.5111.54.20

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additional

and to air

The AC compressor is switched off by the engine control unit in the following situations:
when accelerating from a low speed (recognised by change in angle and accelerator
pedal position sender and from the vehicle
speed signal)
in the emergency programme (emergency
mode)
if the coolant is hotter than 120 C

for about 6 seconds each time the engine is


started

l Air conditioning o.k.

l Air conditioning switched on


l No fault in fault memory
t

and

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)

Test box V.A.G 1598/22 or V.A.G 1598/31


Hand lamp

Final control diagnosis


AC compressor control

K-

Initiate final control diagnosis and actuate AC


compressor control page 01-18.

AC compressor must stop within 5 seconds


(visual check with hand lamp), and then run for
5seconds and stop again.
If the AC compressor does not switch off:

Edition 12.00
S00.5111.54.20

------------

------------


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Edition 12.00
S00.5111.54.20

contact

16

contact

23

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OCTAVIA

Read measured value block


900 rpm
0.0 %

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OCTAVIA

23

Fuel Formation/Fuel Injection

111

2
18.4 C

Specification in display block 3: X X 1 (AC


signal)

If the specification is not achieved:


-

Connect test box to the wiring loom to the


engine control unit page 23-19.
.

Test the wiring for short circuit to positive and to


negative and also for open circuit.
.

48

contact

Current Flow Diagrams,


Electrical Fault Finding,
Fitting Locations binder

Rectify any open circuit or short circuit in the


wiring.
.

Test the wiring for short circuit to positive and to


negative and also for open circuit.
.

49

Edition 12.00
S00.5111.54.20

contact

Current Flow Diagrams,


Electrical Fault Finding,
Fitting Locations binder

Rectify any open circuit or short circuit in the


wiring.

------------

------------

23

------------

Fuel Formation/Fuel Injection

------------

OCTAVIA

Edition 12.00
S00.5111.54.20

@
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OCTAVIA

23

Fuel Formation/Fuel Injection

This signal is used to avoid overrevving and load


change jolts when the clutch is released, and is
required for the cruise control system.
t

and

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)

Test box V.A.G 1598/22 or V.A.G 1598/31


condition

l Fuses o.k.

Read measured value block


0 km/h
000

000000

Read measured value block


0 km/h
100

000000

Read measured value block, display group


006; engine switched off page 01-35.
Specification in display block 2: 0 X X

Depress clutch.

Specification: 1 X X

If the specification is not achieved:


-

End output (function 06) and switch the ignition off.

Unplug the connector of the clutch pedal


switch page 23-2, Overview of fitting locations.

K-

Connect the multimeter for resistance measurement between the contacts of the switch.

Specification:
Clutch not depressed: max. 10
Clutch depressed:

If the specification is not achieved:


-

Replace clutch pedal switch (F36).

If the specification is achieved:

Edition 12.00
S00.5111.54.20

------------

------------

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S00.5111.54.20

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23

Fuel Formation/Fuel Injection

OCTAVIA

Edition 12.00
S00.5111.54.20

23

Fuel Formation/Fuel Injection

------------

OCTAVIA

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Edition 12.00
S00.5111.54.20

000

000000

Have a second person operate V.A.G 1552.


Warning!

and

condition

23

Fuel Formation/Fuel Injection

OCTAVIA

23

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Fuel Formation/Fuel Injection


-

Diode test lamp must flash (about 4x for each


revolution of wheel).

Note:

Ensure that the right front wheel does not rotate.


If the diode test lamp does not flash:

Test the following cable connections for short


circuit to positive and to negative and also for
open circuit.
.

51

contact

Rectify any open circuit or short circuit in the


wiring.
.

Connect diode test lamp between socket 1


(earth) and socket 20 (vehicle speed signal).

Switch ignition on and rotate front left wheel


by hand.

Diode test lamp must flash (about 4x for each


revolution of wheel).

Note:

Ensure that the right front wheel does not rotate.


If the diode test lamp does not flash:

Test the following cable connections for short


circuit to positive and to negative and also for
open circuit.
.

20

contact

Rectify any open circuit or short circuit in the


wiring.

If no fault is found in the wiring:


-

Edition 12.00
S00.5111.54.20

Determine all the users of the vehicle speed


signal (e.g. radio, air conditioning, etc.), separate the connection to the dash panel insert
one after the other and repeat the test until
the cause is determined.

------------

------------

23

------------

Fuel Formation/Fuel Injection

------------

OCTAVIA

Edition 12.00
S00.5111.54.20

E
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OCTAVIA

23

Fuel Formation/Fuel Injection

and

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Test box V.A.G 1598/22 or V.A.G 1598/31

The engine speed signal is required for the rev


counter and for the air conditioning. If an automatic gearbox is fitted, it is also required for
calculating the shift points.
The signal shape which is generated by the
engine speed sender (G28), cannot be analysed
however and it is therefore first of all processed
in the engine control unit.
The engine speed is determined as follows:

Read measured value block


rpm
5.6 mg/H
1.480 V

1
87.3 C

Read measured value block, display group


001; engine idling page 01-38.

Briefly operate full throttle.

Specification in display block 1:


The current engine speed must be displayed
(evenly over entire range). This engine speed
display must agree with the revs indicated
on the right counter.

If the specification is not achieved:


-

Connect test box to the wiring loom to the


engine control unit page 23-19.
.

Test cable connection from rev counter to


contact 6 of test box for open circuit
Current Flow Diagrams, Electrical Fault
Finding, Fitting Locations binder.
.

Test cable connection from rev counter to


contact 27 of test box for open circuit
Current Flow Diagrams, Electrical Fault
Finding, Fitting Locations binder.

Edition 12.00
S00.5111.54.20

------------

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Edition 12.00
S00.5111.54.20

1552

condition

and

control

23

01

Fuel Formation/Fuel Injection

OCTAVIA

OCTAVIA

23

Fuel Formation/Fuel Injection

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Readout in display (example):

038906012F 1.9l
Coding 00001

R4 EDC G000AG 2813


WSC 01234

K If G000AG is displayed, cruise control system


is activated.

038906012F 1.9l
Coding 00001

R4 EDC 0000AG 2813


WSC 01234

K If 000AG is displayed, cruise control system is


deactivated.

Test of vehicle systems


Select function XX

HELP

K Readout in display:
-

Enter 11 for the function Login procedure


and confirm entry with the key Q.

Enter code number as specified in the table


below and confirm entry with the key Q.
Activate CCS

11463

Deactivate CCS

16167

End output (function 06).

Conduct a road test.

cruise control

With the exception of an operating switch, the


CCS does not have any separate components.
All the functions are performed by the engine
control unit. The minimum vehicle speed for the
cruise control function is 30 km/h.
t

testers and aids

Vehicle system tester V.A.G 1552 with cable


V.A.G 1551/3, 3A, 3B or 3C
Hand-held multimeter (e.g. V.A.G 1526 A)
Adapter cable set (e.g. V.A.G 1594 A)
Test box V.A.G 1598/31
Test condition
l Fuses o.k.
T
-

Edition 12.00
S00.5111.54.20

Read measured value block, display group


006; engine idling page 01-35.

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------------

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Edition 12.00
S00.5111.54.20

readout

not

condition

and

1552

23

Fuel Formation/Fuel Injection

OCTAVIA

&
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A
E
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Edition 12.00
S00.5111.54.20

------------

23

Fuel Formation / Fuel Injection

OCTAVIA

Servicing intake manifold flap 08.97

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

Testing intake manifold flap changeover page


23-57.

------------ 23-56 ------------

Edition 03.98
S00.5111.52.20

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OCTAVIA

23

Fuel Formation/Fuel Injection

and

Hand vacuum pump (e.g. V.A.G 1390)

Test box V.A.G 1598/22 or V.A.G 1598/31

Hand-held multimeter (e.g. V.A.G 1526 A)


Adapter cable set (e.g. V.A.G 1594 A)
Current flow diagram
condition

l Fuses 29 and 34 o.k.

Start engine and run at idling speed for about


5 seconds.

Switch ignition off.

Observe positioning lever at intake manifold


flap (2nd person required).

After the ignition is switched off, the intake


manifold flap must close for about 3 seconds,
then move back into its original position.

If the intake manifold flap does not switch over,


perform the following inspections:
-

Inspect switchover mechanism of intake


manifold flap by operating the linkage by
hand. It must be possible to easily move the
intake manifold flap.

Ensure the vacuum hoses are correctly attached and connected as specified in the
hose diagram page 23-59.

Detach vacuum hose at vacuum positioning


element for intake manifold flap.

Connect hand vacuum pump to vacuum positioning element.

Operate hand vacuum pump.

Intake manifold flap must close.

Edition 12.00
S00.5111.54.20

------------

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Fuel Formation/Fuel Injection

OCTAVIA

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------------

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OCTAVIA

23

Fuel Formation/Fuel Injection

23

------------

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------------

OCTAVIA

Edition 12.00
S00.5111.54.20

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Edition 12.00
S00.5111.54.20

------------

------------

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

white connection points toward charge


pressure control solenoid valve -N75

3
2

1 Vacuum

element

models 08.97

models 08.97
Vacuum

element

Vacuum
o

o air

recirculation

OCTAVIA

23

Fuel Formation/Fuel Injection

OCTAVIA

28

Glow Plug System

Testing glow plug system


Testing operation
Special tools, testers and aids required
Hand-held multimeter (e.g. V.A.G 1526)
Current flow diagram
Test conditions
l Battery voltage at least 11.5 V
l Diesel direct injection system control unit
(J248) o.k.
l Strip fuse for glow plugs (S 132) o.k.

Test procedure
K-

Switch off the ignition.


Unplug connector -1- at the coolant temperature sender (G62) -2-.

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.
-

Unplug the glow plug connectors from the


glow plugs.

Connect the multimeter for voltage measurement to a glow plug connector and to engine
earth.

Switch on the ignition.


approx. battery voltage
should be displayed for about 20 seconds.

If no voltage is present:
-

Rectify any open circuit in the wiring or short


circuit.
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations binder
During the simulated glow plug heating operation, the glow period warning lamp (K29) should
come on.

Edition 03.98
S00.5111.52.20

------------ 28-1 ------------

28

OCTAVIA

Glow Plug System


If the warning light does not come on:
-

Test glow period warning light page 28-2.

Testing glow plugs


Special tools, testers and aids required
Diode test lamp (e.g. V.A.G 1527 B)
Hinged wrench for glow plugs (e.g. 3220)
Test condition
l Battery voltage at least 11.5 V
Test procedure
-

Switch ignition off.

Unplug glow plug connectors from the glow


plugs.

Connect cable of diode test lamp to battery


positive (+).

Switch ignition on.

K-

Connect test prod of diode test lamp to each


glow plug one after the other.
LED comes on: glow plug o.k.
LED does not come on: replace glow plug.

Use hinged wrench, e.g. 3220, for removing


and installing the glow plugs.
Tightening torque: 15 Nm

Testing glow period warning light


Special tools, testers and aids required
Vehicle system tester V.A.G 1552 with cable
V.A.G 1551/3, 3A, 3B or 3C
Test box V.A.G 1598/22 or V.A.G 1598/31
Adapter cable set (e.g. V.A.G 1594 A)
Test condition
l Fuse 29 o.k.

------------ 28-2 ------------

Edition 12.00
S00.5111.54.20

OCTAVIA

Glow Plug System


-

Final control diagnosis


Glow period warning light -K29

28

Initiate final control diagnosis and operate


glow period warning light page 01-18.

K Readout in display:

The warning light must flash.

If the warning light does not flash:


-

Connect test box to the wiring loom to the


engine control unit page 23-19.

Test box V.A.G 1598/22


-

Use an adapter cable to connect sockets 1


and 41 of the test box.

Test box V.A.G 1598/31


-

Use an adapter cable to connect sockets 1


and 42 of the test box.

Continued for all models


-

Switch ignition on.


Warning light must come on.

If the warning light does not come on:


-

Rectify any open circuit or short circuit in the


wiring
Current Flow Diagrams, Fault Finding,
Fitting Locations binder.
If the warning light now comes on, but not during
final control diagnosis:
-

Edition 12.00
S00.5111.54.20

Replace engine control unit (J248) page


23-20.

------------ 28-3 ------------